Abstract:
A resilient conductive contact spring is bent to define at least three tulip-shaped receptacles for receiving conductive devices that are to be electrically connected together by the contact spring. The contact spring can be included in a socket arrangement for connecting an electrical component mounted within a housing with a bus bar power supply system arranged outside the housing.

Description:
REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a national stage application under 35 C.F.R. §371 of the PCT International Application No. PCT/ EP2014/064921 filed Jul. 11, 2014, which claims priority of the German application No. DE 20 2013 103 444.4 filed Jul. 31, 2013. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    A resilient conductive contact spring is bent to define at least three tulip-shaped receptacles for receiving conductive devices that are to be electrically connected together by the contact spring. The contact spring can be included in a socket arrangement for connecting an electrical component mounted within a housing with a bus bar power supply system arranged outside the housing. 
         [0004]    2. Description of Related Art 
         [0005]    The invention relates to a contact element provided for electrically connecting electrical connecting elements of an externally routed bus system, especially bus bars and/or plug connectors. 
         [0006]    Electrical power distribution technology requires bus systems that ensure electrical supply and electrical signals to spatially distributed electrical components. Such electrical components include electrical equipment that ensures electrical supply, e.g., power supply units and line filters, particularly for frequency converters and servo controllers. Other electrical devices may, in principle, be connected to such a bus system. 
         [0007]    To ensure simple installation and quick access to such a bus system, electrical connections, especially in the form of bus bars, are often routed outside of the electrical components. This makes tapping into the electrical supply and electrical signals at preferably any point of the bus system very simple and easy. 
         [0008]    German patent No. DE 20 2013 102 303.5 discloses a row component arrangement with such a bus system. The row component arrangement comprises multiple row components that may be arranged adjacent one another on a mounting base, particularly a support rail. The row components have an electronics housing and an electrical assembly with electrical components, which assembly is preferably arranged on a circuit board and in the electronic housing. Each have a socket structure comprising a contact element in order to connect the electrical assembly to the externally routed bus system. The contact element is designed as a clamping spring and is S-shaped, such that it has a first tulip-shaped receptacle for connecting a bus bar, and a second tulip-shaped receptacle for connecting to the electrical assembly. 
         [0009]    The object of the present invention is to devise an alternative contact element, which will make it possible to connect an electrical device, particularly a row component, to an externally routed bus system, and which, compared with the prior-art contact element, may be used in a more versatile fashion and is better suited for power distribution. Moreover, an electrical device, particularly a row component with such a contact element, is to be devised. 
       SUMMARY OF THE INVENTION 
       [0010]    Accordingly, a primary object of the invention is to provide a resilient conductive contact spring is bent to define at least three tulip-shaped receptacles for receiving conductive devices that are to be electrically connected together by the contact spring. 
         [0011]    Another object of the invention is to provide a socket arrangement including the contact spring for connecting an electrical component mounted within a housing with a bus bar power supply system arranged outside the housing. Hence, a contact element is devised and provided to connect electrical connecting elements of an externally routed bus system, particularly bus bars and/or plug connectors, and having at least three tulip-shaped receptacles for receiving the electrical connecting elements. In this way, two tulip-shaped receptacles for receiving connecting elements, preferably of the bus system, particularly bus bars, become available. Thus, either more connecting elements of the bus system may be connected to the contact element, or else a tulip-shaped receptacle is provided in order to receive a connecting element, particularly one end of a bus bar, such that a large contact surface for contacting the connecting element becomes available, thereby allowing for more contact points and making the contact element especially well-suited for power currents. 
         [0012]    The tulip-shaped receptacles are preferably alternately accessible from a first direction, or a second direction opposite the first direction. In this embodiment, it is preferable that the tulip-shaped receptacles accessible from the first direction are provided for attaching the connecting elements of the bus system, and that the tulip-shaped receptacle accessible from the second direction is provided for connecting an electrical assembly. 
         [0013]    Contact elements with more than three tulip-shaped receptacles are also preferred. It is preferable here that at least two of the tulip-shaped receptacles for connecting the bus system be provided. 
         [0014]    The contact element is preferably made of an electrically highly conductive material, so that it conducts electricity well. It is preferably made as a stamped and bent part, preferably as an integral stamped and bent part. It is especially preferable that the contact element be made of a strip material, e.g., highly conductive sheet metal, preferably of copper. It is likewise preferable that it has good elastic properties, making it flex, when electrical connecting elements are inserted against a restoring force, and act as a clamping spring. This will lock the connection elements arranged in the receptacle spaces in the contact element. 
         [0015]    For this reason, the tulip-shaped receptacles have two longitudinal members, between which the tulip-shaped receptacle is arranged. The longitudinal members are preferably interconnected by transverse members. 
         [0016]    To improve even further the electrical contact and/or the current-carrying capacity, contacting means are preferably provided on the longitudinal members. As contacting means are preferred, e.g., embossments, which are raised in the tulip-shaped receptacle, or perforations, such that the longitudinal members form at least partly in a lamella-like fashion. 
         [0017]    In a first embodiment, the contact element is made in one piece. This embodiment allows the element to be made very inexpensively and quickly and easily mountable, as a single component. 
         [0018]    In a second embodiment, the contact element is made from a plurality of receptacle parts. Here, identically designed receptacle parts are preferably used for the same contact element. In a preferred embodiment, the receptacle parts are each U-shaped. A contact element with three tulip-shaped receptacles is thereby preferably made of three receptacle parts. However, an embodiment, in which the receptacle parts are interconnected by means of receptacle connectors, is likewise preferred. For instance, in this embodiment, a contact element with three tulip-shaped receptacles consisting of two receptacle parts is made with one receptacle connector, while a contact element from five tulip-shaped receptacles consisting of three receptacle parts is made from two receptacle connectors. Thus, for tulip-shaped receptacles, n-1 receptacle parts and n-2 receptacle connectors are always needed. Likewise, the receptacle connectors are preferably U-shaped, but may be made of a less expensive material. Furthermore, a contact element of any size may be made from such receptacle parts. What&#39;s more, the receptacle connector may also be used to join together multiple contact elements with multiple tulip-shaped receptacles. 
         [0019]    In another embodiment, the contact element includes a cover spring, e.g., made of resilient steel. The cover spring is provided in order to exert a clamping force on the contact element, and preferably acting in and against one clamping direction. The clamping direction extends preferably perpendicularly to the first and/or second direction. Thus, the cover spring supports the contact element and respectively the restoring force, which acts on a connecting element arranged in the contact element. It is preferred that the cover spring is roughly U-shaped in the cross section. 
         [0020]    The object is furthermore achieved with a socket structure having a contact element and at least one electrical connecting element provided for electrical connection of the contact element with an electrical assembly. For example, a connector represents such an electrical connection element. 
         [0021]    Preferably, the socket structure also comprises at least two electrical connection elements of an externally routed bus system, particularly two bus bars. The bus bars are preferably arranged in alignment with one another and locked in the same tulip-shaped receptacle. In this arrangement, the tulip-shaped receptacles accessible from the first direction may be used for a bus line. Thus, at least two bus lines may be connected with the same contact element to the electrical assembly, or similarly preferably, the bus bars are each inserted into a tulip-shaped receptacle of the contact element. This will require two tulip-shaped receptacles for the same bus line. However, the contact surface toward the bus bars is greater, so that the arrangement is particularly suitable for power currents. 
         [0022]    The socket structure preferably includes a housing, wherein the contact element is arranged. The housing is provided primarily as contact protection for the operator. 
         [0023]    The object is additionally achieved with an electrical device, particularly a row component. The electrical device preferably includes an electrical assembly, as well as a socket structure provided for electrically connecting the electrical assembly with the externally routed bus system, and which includes a contact element according to the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0024]    Other objects and advantages of the invention will become apparent from a study of the following specification, when viewed in the light of the accompanying drawing, in which: 
           [0025]      FIG. 1 a    is a side elevation view of a first embodiment of the contact spring of the present invention; 
           [0026]      FIG. 1 b    is a detailed side elevation view of a socket connection arrangement according to  FIG. 5 ; 
           [0027]      FIGS. 1 c , 1 d , and 1 e    are side elevation, front perspective, and front exploded perspective views, respectively, of another embodiment of the contact spring of the present invention; 
           [0028]      FIG. 2 a    is a side elevation view of another embodiment of the invention; 
           [0029]      FIG. 2 b    is a perspective view of a modification of the contact spring of  FIG. 1   a;    
           [0030]      FIG. 3 a    is a top perspective view of a first bus bar arrangement using the contact springs of  FIG. 1 a   , and  FIG. 3 b    is a top plan view of the apparatus of  FIG. 3   a;    
           [0031]      FIG. 4 a    is a top perspective view of a second bus bar arrangement using the contact springs of  FIG. 1 a   , and  FIG. 4 b    is a top plan view of the apparatus of  FIG. 4 a   ; and 
           [0032]      FIG. 5  is a front perspective view of a bus bar power distribution system mounted externally on the front a row of electrical box housings. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0033]    Referring first more particularly to  FIG. 1 a   , the electrical contact spring  1  is made of a conductive resilient sheet material, such as steel. It is thereby designed to be resilient and has a restoring force. It is produced as a stamped and bent part in one piece, and is thus very cost effective. 
         [0034]    In one cross-section, the contact spring it generally W-shaped, and has three tulip-shaped receptacles  11 ,  12 ,  13 . A W-shaped or roughly W-shaped contact spring entails that the two tulip-shaped receptacles  11 ,  13  are accessible from a first direction  71 , while the third tulip-shaped receptacle  12  is accessible from a second direction  72 , opposite the first direction  71 . The tulip-shaped receptacle  12 , which is accessible from the opposite direction  72 , is arranged between the two tulip-shaped receptacles  11 ,  13 , which are accessible from the first direction  71 . 
         [0035]    The tulip-shaped receptacles  11 ,  12 ,  13  are arranged between two longitudinal leg portions  18  of contact spring  1 , and are interconnected by the transverse portions  19 . The transverse portions  19  are here roughly arc-shaped. The longitudinal portions  18  may be bent apart against the restoring force against a clamping direction  73 , which extends transversely to the first direction  71 . Electrically conductive contact elements  3 ,  4  inserted in the tulip-shaped receptacles  11 ,  12 ,  13  therefore become locked due to the restoring force in contact element  1 . 
         [0036]    Contact spring  1  has two open ends  16  on two outer longitudinal portions  18 , while two inner longitudinal portion  18  limit two adjacent tulip-shaped receptacles  11 ,  12 ,  13  accessible from the opposite directions  71 ,  72 . Contact protrusions  17  are provided on the inner surfaces of the longitudinal leg portions  18 , and formed here as embossments protruding into the tulip-shaped receptacles  11 ,  12 ,  13 . 
         [0037]    The tulip-shaped receptacles  11 ,  12 ,  13  are provided to receive the electrical contact elements  3 ,  4 . It is desirable here that the two tulip-shaped receptacles  11 ,  13  accessible from the first direction  71  for receiving the bus bars  3  of one or two bus lines  31 ,  32 ,  33 ,  34  of a bus system  30  (see  FIGS. 3 and 4 ). In this embodiment, each of the two bus lines  31 ,  32  and  33 ,  34  carries an identical electrical potential. The tulip-shaped receptacle  12  accessible from the second direction  72  is preferably provided for receiving an electrical connection element  4 , which connects the bus bars  3  to an electrical assembly of an electrical device  101  (see  FIG. 5 ), particularly a row component. This electrical connection element is preferably designed as a plug connector  4  ( FIG. 1 b   ). 
         [0038]    Contact spring  1  is preferably arranged in a housing  106 . In this embodiment, it may be inserted modularly into such an electric device  101  as a socket structure  100 . Such a socket structure  100  is shown schematically in  Figs. 1 b    and  5 . 
         [0039]      FIG. 1 c    shows the contact element  1  with a cover spring  2  made of, e.g., steel. In the cross-section, the cover spring  2  is roughly U-shaped and has two open cover spring ends  22 . In the area of the cover spring ends  22 , a bend  21  is provided at the longitudinal portions  23  of the cover spring, which longitudinal portions  23  are interconnected by transverse portion  2 , so that the cover springs  2  may be bent apart against a restoring force against a clamping direction  73 . The bends  21  are formed precisely such that at the open ends  22  of the cover spring, so that a cross force  25  extends opposite the clamping force  73 . 
         [0040]    As shown in  FIGS. 1 d  and 1 e   , in order for the tulip-shaped receptacle  12 , which is accessible from the second direction  72 , to be accessible also at the cover spring  2  arranged on contact element  1 , the cover spring  2  contains a through opening  26  arranged in the transverse portion  24  of the cover spring, which opening extends partially into the longitudinal leg portions  23  of the cover spring. The transverse portion  24  of the cover spring is therefore divided into two portions  241  of the cover spring. 
         [0041]    In order to insert contact element  1  into the opening  26 , the two transverse members  19  of contact element  1  arranged on side  28  facing the cover spring  2  are designed to have a narrower width than the remainder of contact element  1  (see  FIG. 1 e   ). 
         [0042]    In each of the longitudinal leg portions  23  of the cover spring  2 , a tongue  27  is likewise provided, and is bent at an open extremity of tongue  271 , such that a tongue ridge  272  is formed. One tongue ridge  272  extends inwardly toward, while the other tongue ridge  272  extends outwardly against, the clamping direction  73 . 
         [0043]    Because cover spring  2  is arranged on contact spring  1 , contact spring  1  is compressed by the ridges  25  and the tongue ridges  272  due to the restoring force of the cover spring  2 . Thus, the cover spring  2  supports contact element  1 , as the electrical connection elements  3 ,  4  are being locked in the tulip-shaped receptacles  11 ,  12 ,  13 . 
         [0044]    Referring now to  FIG. 2 a   , a contact spring  1 ′ having five tulip-shaped receptacles  11 - 15  is provided, wherein three receptacles  11 ,  13 ,  15  are accessible from the first direction  71 , and two receptacles  12 ,  14  are accessible from the second direction  72 . This contact spring  1 ′ is likewise made in one piece, having stamped and bent parts. Preference is given to three of the tulip-shaped receptacles  11 ,  13 ,  15 , accessible from the first direction  71 , for receiving bus bars  3 , and two of the tulip-shaped shaped receptacles  12 ,  14 , accessible from the second direction  72 , for receiving the contacts  4  for contacting the electrical assembly. However, a reverse arrangement is also possible. 
         [0045]      FIG. 2 b    shows a modification of the contact spring  1  containing perforations provided on the longitudinal leg portions  18 , whereby the latter are formed at least partially lamellarly. The perforations are formed smaller in the central longitudinal portions  18   a  than in the outermost longitudinal leg portions  18   a , so as to increase the current-carrying capacity of contact spring  1 . 
         [0046]      FIG. 3 a    shows an arrangement of a total of four such contact springs  1  of  FIG. 2 b    and bus bars  3 . The bus bars  3  are arranged in end-to-end alignment with one another, so that in each case, two bus bars  3  end in the same tulip-shaped receptacle  11 ,  13 . Thus, bus bars  3  here form four bus lines  31 ,  32 ,  33 ,  34  of a bus system  30 , whereby in each case, two of the bus lines  31 ,  32  and  33 ,  34  carry the same electrical potential. 
         [0047]    In  FIG. 4 a   , each of the tulip-shaped receptacles  11 ,  13  only receives one bus bar  3 . As a result, a contact area formed between bus bars  3  and the longitudinal leg portions  18  of contact springs  1  is greater, when compared with the way it is used in  FIG. 3 a   . Hence, the four contact springs  1  guide only two bus lines  31 ,  32  of the bus system  30 . This arrangement is especially suitable for power currents. 
         [0048]      FIG. 5  shows an electrical distribution arrangement  10  including two electrical devices  101  formed as row components and arranged adjacent to one another here. In the following, the terms row component and electrical device  101  are used interchangeably. 
         [0049]    The row components  101  each have a socket structure  100  that includes an electrical contact spring  1 , which is enclosed by a housing  106 , which is provided for operator contact protection. The socket structures  100  are each modularly inserted in their row component  101 . 
         [0050]    The row components  101  each have electrical assemblies comprising electrical printed circuit boards  103 . To connect the electrical assemblies electrically with an externally routed bus system  30 , solder connectors  104  are provided, which are soldered to the printed circuit board  103  and have a contact (not shown). 
         [0051]    The solder contacts  104  are provided as connecting elements in order to connect the electric circuit board  103  with contact spring  1 , and contact spring  1  with bus system  30 . They are formed as plugs (not shown) on the sides of contact springe  1 . 
         [0052]    Bus system  30  of the depicted embodiment includes four bus lines  31 - 34 . Each of these are formed by bus bars  3  inserted next to one another by pushing. In this embodiment, the socket structures  100  preferably have two contact springs  1  with three tulip-shaped receptacles  11 ,  12 ,  13  (see  FIG. 1 b   ), such that two bus lines  31 - 34  each carry the same voltage potential. But, in principle, socket structures  100  having a contact spring  1  with seven tulip-shaped receptacles (not shown) are also conceivable, whereby all the bus lines  31 - 34  carry the same voltage potential. 
         [0053]    In order to arrange the row components  101  adjacent one another, wall mounts  105  are provided as fastening means on the housings  102  of both row components  101 . 
         [0054]    While in accordance with the provisions of the Patent Statutes the preferred forms and embodiments of the invention have been illustrated and described, it will be apparent to those skilled in the art that changes may be made without deviating from the invention described above.