CONTACT ASSEMBLY FOR CONNECTING AN ELECTRICAL CONDUCTOR AND CONDUCTOR CONNECTION TERMINAL WITH SUCH A CONTACT ASSEMBLY

A contact assembly for connecting an electrical conductor via a spring-loaded clamping. A conductor rail component is made of a conductor rail material and designed as a profile component angled parallel to the conductor insertion direction of an electrical conductor into the contact assembly, at least in sections. A spring component with a clamping spring is made of a spring material and is mechanically connected to the conductor rail component and is set up for clamping an electrical conductor via the clamping spring at a clamping point on the conductor rail component. A conductor insertion opening and a conductor insertion channel are connected to the conductor insertion opening, through which an electrical conductor inserted at the conductor insertion opening can be routed to the clamping point. The conductor insertion channel is formed from at least one first wall, a second wall, and a third wall.

This nonprovisional application claims priority under 35 U.S.C. § 119 (a) to German Patent Application No. 20 2023 101 521.2, which was filed in Germany on Mar. 27, 2023, and which is herein incorporated by reference.

BACKGROUND OF THE INVENTION

Field of the Invention

The invention relates to a contact assembly for connecting an electrical conductor via a spring-loaded clamping, comprising: a conductor rail component that is made of a conductor rail material, wherein the conductor rail component is designed as a profile component angled parallel to the conductor insertion direction of an electrical conductor into the contact assembly, at least in sections; a spring component with a clamping spring, wherein the spring component is made of a spring material, is mechanically connected to the conductor rail component and is set up for clamping an electrical conductor via the clamping spring at a clamping point on the conductor rail component; a conductor insertion opening and a conductor insertion channel connected to the conductor insertion opening, through which an electrical conductor inserted at the conductor insertion opening can be routed to the clamping point, wherein the conductor insertion channel is formed by at least a first wall, a second wall, and a third wall, wherein the first wall is substantially parallel to the second wall, and the third wall extends at least from the first wall to the second wall, and wherein the electrical conductor is insertable into the contact assembly in the space formed between the first wall, the second wall, and the third wall. The invention also relates to a conductor connection terminal having at least one such contact assembly.

Description of the Background Art

A generic type of contact assembly is known from DE 20 2014 101 856 U1. The contact assembly, also known as a quick connect terminal, is used for direct soldering onto an electrical circuit board.

SUMMARY OF THE INVENTION

It is therefore an object of the invention to further optimize a contact assembly, in particular for an application as a contact insert in a conductor connection terminal.

This object is achieved in an example with a contact assembly in that at least one wall of the conductor insertion channel, in particular the third wall, is formed partly from the conductor rail component and partly from the spring component. As a result, the contact assembly can be miniaturized in terms of size, wherein this design allows for the spring component to be mechanically connected to the conductor rail component in a particularly favorable way and the smoothest possible outer contour of the overall assembly to be realized. Such a smooth outer contour is in turn advantageous if the contact assembly is to be used as a contact insert of a conductor connection terminal and is accordingly to be used in a recess of a housing of the conductor connection terminal. In addition to the third wall, one or more further walls of the conductor insertion channel can also be formed partly from the conductor rail component and partly from the spring component.

As mentioned, the conductor rail component can be designed as an angled profile component, at least in sections. It can also be designed as an angled profile component throughout. The conductor rail component can be arranged in at least one section overlapping with the spring component, e.g., in the area of the third wall. The angled area of the conductor rail component extends at least in some areas in a section of the overlap of the conductor rail component and the spring component.

Advantageously, the conductor insertion channel can thus be formed partly from the conductor rail component and partly from the spring component starting from the conductor insertion opening. The conductor rail component can be made of a particularly conductive conductor rail material, such as copper or a copper alloy. The spring component can be made of a particularly good resilient material, in particular a material other than the conductor rail material. For example, a spring-hard steel material can be used.

The contact assembly can be made up of only these two components, i.e., the conductor rail component and the spring component.

The clamping point can be formed on the first wall. In this case, it is advantageous for the conductor rail component to form at least part of the first wall.

One wall of the first and second walls can be completely or at least partially formed from a section of the conductor rail component and the other wall of the first and second walls is formed completely or at least partly from a section of the spring component. Thus, the formation of the conductor insertion channel is divided between the two components, namely the conductor rail component and the spring component.

The third, which is partly formed from the conductor rail component and partly from the spring component, can have successive sections of the spring component and the conductor rail component in the conductor guide direction and/or orthogonal to the conductor insertion direction. If one or more further walls are formed partly from the conductor rail component and partly from the spring component, these can each have successive sections of spring component and conductor rail component in the conductor guide direction and/or orthogonal to the conductor insertion direction. In this way, the conductor rail component and the spring component can be nested together in a particularly cost-effective manner and can be connected to each other in a form-fit via nesting without additional complex fastening measures. In this case, the sections of the spring component and the conductor rail component, which follow one another in the conductor insertion direction and/or orthogonal to the conductor insertion direction, can be arranged aligned with each other, i.e., at the same height, so that essentially a smooth surface is obtained. If the material thickness of the conductor rail component and the spring component is essentially the same, it is particularly possible that an essentially step-free smooth surface is formed on both the outside and the inside of the conductor insertion channel.

The spring component can have a U-shaped curved section which forms at least part of the conductor insertion channel. In this way, a significant part of the conductor insertion channel can be formed from the spring component. In addition, such a U-shaped curved section can advantageously be coupled positively with an equally U-shaped curved section of the conductor rail component. Accordingly, in an example of the invention, the conductor rail component may also have a U-shaped curved section that forms at least part of the conductor insertion channel, whereby this ensures, for example, that an electrical conductor can be inserted in the conductor insertion channel without obstruction by snagging or the like.

The U-shaped curved section of the spring component can extend, for example, to the conductor insertion opening. The side legs of the U-shaped curved section can form parts of the third and a fourth wall; the connecting section between the side legs of the U-shaped section can form part of the second wall.

The conductor insertion channel can be U-shaped from the first wall, the second wall and the third wall or additionally has a fourth wall that closes the U-shape upwards and is opposite the third wall. In the first variant, the conductor insertion channel is thus open on one side where there is no fourth wall. This is particularly space-saving and advantageous when using the contact assembly as a contact insert in a conductor connection terminal housing, as a housing wall can then close off the conductor insertion channel to the open side.

The fourth wall can be formed partly from the conductor rail component and partly from the spring component. This has the advantage that the conductor rail component can be connected to the spring component even more easily and reliably via positive coupling. The fourth wall can have consecutive sections of the spring component and conductor rail component in the conductor insertion direction and/or orthogonal to the conductor insertion direction.

The second wall and the fourth wall, which are opposite each other, have consecutive sections of spring component and conductor rail component in the conductor insertion direction and/or orthogonal to the conductor insertion direction.

The spring component can be attached to the conductor rail component via form-fit and/or material-fit fastening. This allows for simple and reliable coupling of the spring component to the conductor rail component in terms of production technology. In the case of positive coupling, for example, a corresponding coupling contour may be disposed on the conductor rail component, e.g., in the form of a puzzle piece, and a coupling contour designed as a negative for this can be present on the spring component. In the case of material-fit fastening, this can be done, for example, by welding, soldering or clinching.

The spring component, formed as a clamping spring, can have a one-sided leaf spring, which can be designed as a spring tongue inclined towards the conductor insertion direction, which is arranged at an angle towards the conductor rail component and has a clamping edge at the free end, wherein the clamping point for clamping the electrical conductor is formed between the conductor rail component and the clamping edge. This allows for reliable and easy clamping of an electrical conductor with a comparatively simple design of the contact assembly. In particular, it is not necessary for symmetrical clamping to be achieved via two counter-rotating spring tongues. Due to the one-sided clamping by the inclined spring tongue, the electrical conductor can be reliably clamped to the clamping point on the conductor rail component and electrically contacted.

The spring tongue can be designed as a material tongue that is flared and bent away from the material of the spring component. This minimizes the number of components in the contact assembly and simplifies manufacturing and assembly.

The spring tongue can have a protruding actuating tab for actuating the spring tongue. This allows for simple and reliable mechanical actuating and, accordingly, a deflection of the spring tongue via an actuating element, such as an actuating lever, which will be explained below. For example, the actuating tab can be molded in one piece with the spring tongue. The actuating tab may protrude from the spring tongue in a direction leading away from the third wall.

The contact assembly can be designed as part of an electrical connector, wherein the contact assembly has at least one electrical contact molded to the conductor rail component on the side facing away from the conductor insertion opening. In this way, a miniaturized connector with advantageous spring pressure connection technology for the electrical conductors can be realized. In particular, it is possible to realize connectors with such contact assemblies with a pitch of only 2.5 mm.

The contact assembly can be designed as a contact insert of a conductor connection terminal. Accordingly, the contact assembly can be placed in the housing of such a conductor connection terminal. In particular, the contact assembly can be designed without solder terminal contacts, especially without SMD terminal contacts.

The above-mentioned object is also achieved by a conductor connection terminal with a housing and a contact assembly of the type described above arranged in the housing, or several contact assemblies of the type described above arranged next to each other in the housing in a stringing direction. Here, too, the advantages explained above can be realized. The housing can be designed as an insulating material housing.

The conductor connection terminal can be designed as an electrical connector, wherein the contact assembly or the contact assemblies each have at least one plug contact. In this way, a miniaturized connector with spring pressure connection technology can be provided with the contact assembly according to the invention.

The contact assembly or contact assemblies may each have an assigned, swiveling actuating lever, wherein one actuating lever is each set up to open the clamping point of an assigned contact assembly. This has the advantage that the user can easily open the clamping point by operating the actuating lever. There is no need for an additional actuating tool that is not part of the conductor connection terminal. As an alternative to an actuating lever, there may also be an actuating pusher or an actuating slider.

The spring tongue or its clamping edge of the clamping spring of the assigned contact assembly can be moved away from the conductor rail component by manual actuating of the respective swiveling actuating lever. By such manual actuating, the clamping point can be opened. When the clamping point is open, an electrical conductor can be placed at the clamping point or removed from the conductor connection terminal without significant effort.

The actuating lever can have a tangential lateral actuating surface arranged on its first or second long side for actuating the spring tongue. This has the advantage that the actuating lever can also be miniaturized well and thus enables the realization of a miniaturized conductor connection terminal with a plurality of contact assemblies. In addition, such tangential actuating of the clamping spring minimizes the required manual actuating force to operate the actuating lever.

DETAILED DESCRIPTION

FIGS.1and2show a contact assembly9for connecting an electrical conductor via spring-loaded clamping. The contact assembly9has a conductor rail component3, which is formed of a conductor rail material, and a spring component4, which is made of a spring material. The spring component4has a clamping spring in the form of a one-sided leaf spring, which is formed as a spring tongue43and is made from the material of the spring component4and bent off. An electrical conductor can be inserted in the contact assembly9in a conductor insertion direction L through a conductor insertion opening11and can be routed to a clamping point10, where the electrical conductor can be pressed against the conductor rail component3via the spring force of the spring tongue43and can thus be mechanically fixed and at the same time electrically contacted. The spring tongue43is inclined towards the conductor insertion direction L and points in the direction of the conductor rail component3. The spring tongue43can have a clamping edge44at its free end.

On the spring tongue43there is also an actuating tab45protruding from the spring tongue43, which can be used to actuate the spring tongue via an actuating element, e.g., an actuating lever described below. The actuating tab45may be slightly inclined with respect to the spring tongue43.

As can be seen, the conductor rail component3can be designed as a profile component angled parallel to the conductor insertion direction L, at least in sections. In the example shown above, the conductor rail component in the drawing view has a vertical section30and a horizontal section31, which is essentially arranged at right angles.

The spring component4can also be designed as a profile component angled parallel to the conductor insertion direction L, at least in sections. In the illustrated example, the spring component4has a vertical section40and a horizontal section41, which is essentially arranged at right angles. The sections31,41are arranged overlapping each other.

The contact assembly9has a conductor insertion channel connected to the conductor insertion opening11, through which an electrical conductor inserted at the conductor insertion opening11is routed to the clamping point10. The conductor insertion channel is formed from at least one first wall W1, a second wall W2and a third wall W3. The first wall W1is essentially parallel to the second wall W2. The third wall W3extends at least from the first wall W1to the second wall W2. In the illustrated example, the first wall W1is formed from the section30of the conductor rail component, the second wall W2is formed from the section40of the spring component4. The third wall W3is formed partly from the conductor rail component3and partly from the spring component4, namely from the section31of the conductor rail component3and the section41of the spring component4, which overlaps at least partially with the section31. The section41extends in the conductor insertion direction L only over the length of the conductor insertion channel, i.e., up to the point where the inclined spring tongue43begins.

FIG.3shows an example of a contact assembly9, which in turn, like the contact assembly already explained inFIGS.1and2, has a conductor rail component3and a spring component4. There is also a conductor insertion channel with the first wall W1, the second wall W2and the third wall W3. In contrast to the example ofFIGS.1and2, inFIG.3the third wall W3is formed exclusively from a section31of the conductor rail component3. In this case, the spring tongue43has a window-like area made of the material of the spring component4and surrounded on all sides from the material of the spring component4. Viewed in the conductor insertion direction L behind the clamping point10, the spring component4has an end section49, which is arranged overlapping with a leg39of a U-shaped area of the conductor rail component3on the end side. Via the end section49, the spring component4can be fixed to the conductor rail component3.

FIG.4shows an example of a contact assembly9which is designed in a similar way to the example ofFIG.3, wherein, in contrast toFIG.3, the spring tongue43is similar to that in the example ofFIGS.1and2, i.e., it does not have a window-like opening of the spring component4, but from a recess open on one side. The spring tongue43also has an actuating tab45located on the spring tongue43, protruding from it.

In the example ofFIG.5, the spring tongue43is similar to the example ofFIG.4. The conductor insertion channel is in turn formed from a first wall W1, a second wall W2and a third wall W3. The first wall W1is formed from a section30of the conductor rail component3, the second wall W2from a section40of the spring component4. The third wall, W3, is formed from a section31of the conductor rail component and additionally from an adjoining section41of the spring component4. The sections31and41may be arranged at least substantially at the same level, i.e., the section31essentially merges into the section41without steps. For example, if the material thicknesses of the spring material and the conductor rail material are somewhat uneven, a slight heel may be formed on the outside of the conductor insertion channel, and on the inside, the transition can be made essentially without a heel. The sections31,41essentially form the third wall W3in a direction orthogonal to the conductor insertion direction L, i.e., in a transverse direction, from successive sections of spring component4and conductor rail component3.

It can also be seen inFIG.5that in the conductor insertion direction L, behind the section41and well before the clamping point10, a further section38of the conductor rail component3is arranged, which also forms a part of the conductor insertion channel or the third wall W3. In this way, the third wall W3in this area is formed from successive sections of spring component4and conductor rail component3in the conductor insertion direction L, namely from the section41and the following section38.

On the other side, i.e., at the end facing away from the conductor insertion opening11, the contact assembly9can be designed in a similar way as in the conductor insertion channel, wherein at the end facing away from the conductor insertion opening11, the contact assembly9can be mirror-symmetrical to the conductor insertion channel.

FIG.6shows an example of a contact assembly9in which the conductor insertion channel is formed from four walls, namely a first wall W1, a second wall W2, a third wall W3and a fourth wall W4. The first, second and third walls are arranged in a similar way to the examples described above, i.e., in a U-shape that is open at the top. In the example ofFIG.6, this U-shape is closed at the top, namely by the fourth wall W4, which is opposite the third wall W3and is essentially parallel to it. This creates a conductor insertion channel that is closed on all sides around the circumference.

In the example ofFIG.6, the conductor rail component3forms the first wall W1via section30. Sections31,32of the conductor rail component3protrude from section30, which are essentially bent at right angles to it. The spring component4has a U-shaped curved section via which the second wall W2and parts of the third wall W3and the fourth wall W4are formed. The side legs of the U-shape, i.e., sections41,42of the spring component4, have respective recesses to form a positive connection with the conductor rail component3, which have an undercut in relation to the conductor rail component3, e.g., a recess in the form of a puzzle piece. The conductor rail component3also has puzzle piece-shaped sections on its sections31,32, which form parts of the third wall W3and the fourth wall W4, which are designed as a counterpart to the recesses in the sections41,42. Due to the puzzle-piece-shaped areas, a form-fitting coupling of the spring component4to the conductor rail component3is realized. In addition, both the third wall W3and the fourth wall W4are formed in the conductor insertion direction and additionally transversely to the conductor insertion direction from successive sections of spring component4and conductor rail component3, namely in the area of the third wall W3from sections31,41and in the area of the fourth wall W4from sections32,42.

FIG.7shows an example of a contact assembly9, which is formed with a comparable form-fitting coupling between the conductor rail component3and the spring component4, i.e., again with puzzle-shaped sections in the area of the third wall W3and the fourth wall W4. In contrast to the example ofFIG.6, in the example ofFIG.7, the conductor rail component3has a U-shaped curved area, which is formed from sections30,31,32. In the example ofFIG.7, the puzzle-piece-shaped recesses are formed in sections31,32of the conductor rail component3. On the spring component4, the contours engaging in the recesses of sections31,32and formed as a counterpart are formed on sections41,42bent away from the section40. Due to the puzzle-piece-shaped areas, a form-fitting coupling of the spring component4to the conductor rail component3is realized. In addition, both the third wall W3and the fourth wall W4are formed in the conductor insertion direction and additionally transversely to the conductor insertion direction from successive sections of spring component4and conductor rail component3, namely in the area of the third wall W3from sections31,41and in the area of the fourth wall W4from sections32,42.

FIG.7also shows an example of the contact assembly9in which an electrical plug contact7is formed on the conductor rail component3in the conductor insertion direction L behind the clamping point10, e.g., by one-piece molding from the material of the conductor rail component3. The plug contact7can, for example, be designed as a fork contact or other socket contact, as shown, the plug contact7can also be designed differently, e.g., as a knife or pin contact. This allows for the contact assembly to be used as part of an electrical connector.

The example with the electrical plug contact7described above inFIG.7can also be combined with all other examples of the contact assembly9, even if this is not explicitly shown in the drawings.

FIG.8shows an example of a contact assembly9in which the conductor rail component3is in turn coupled to the spring component4via a positive connection, wherein, similar to the examples ofFIGS.6and7, the conductor rail component3is nested with the spring component4in the area of the third and fourth walls W3, W4. In the example ofFIG.8, the spring component4has a U-shaped curved section in the area of the conductor insertion channel, which begins at the conductor insertion opening11. In addition, the conductor rail component3also has a U-shaped area behind the U-shaped area of the spring component4in the conductor insertion direction L. The first wall W1is formed from section30of the conductor rail component3, the second wall W2from section40of the spring component4. The third wall W3is formed in the conductor insertion direction and additionally transversely to the conductor insertion direction from successive sections41,31of the spring component4and the conductor rail component3, the fourth wall W4is formed in the conductor insertion direction and additionally transversely to the conductor insertion direction from successive sections42,32of the spring component4and the conductor rail component3. Sections31,32of the conductor rail component3each have a recess with an undercut, in which an area of the respective section41,42of the spring component4projecting in the conductor insertion direction engages.

FIG.9shows a contact assembly9, which is similar in design to that shown inFIG.8and also has a plug contact7molded to the conductor rail component3. Furthermore, according toFIG.9, the contact assembly has a support tab33on the conductor rail component, which extends to the plane of section30and is arranged at the marginal edge of section30facing away from the third wall W3. The support tab33is arranged in the conductor insertion direction L behind the conductor insertion channel and extends advantageously in the conductor insertion direction L beyond the clamping point10. The support tab33is used to support the actuating lever, which is explained in more detail below. Advantageously, the support tab33can have a chamfer34facing the fourth wall W4at the marginal edge facing away from the third wall W3.

FIG.10shows the contact assembly9as shown inFIG.9with a swiveling actuating lever5attached to it. The actuating lever5has a manual actuating section50where it can be operated manually. The actuating lever5is swiveled about an axis51. The actuating lever5also has a tangential lateral actuating surface52located on one of its long sides for actuating the spring tongue43.FIG.10shows the arrangement of the contact assembly9and the actuating lever5in the unactuated state of the actuating lever5. When the actuating lever5is not actuated, the clamping point is closed, i.e., the spring tongue43rests against the conductor rail component3if no electrical conductor is inserted there or presses the electrical conductor against the conductor rail component3. It can also be seen that the actuating lever5rests with a contact side opposite the tangential lateral actuating surface52against the support surface33of the conductor rail component3.

FIG.11shows the arrangement according toFIG.10with the actuating lever5in an actuated position. The actuating lever is now swiveled by a certain angle. Due to the actuating surface52, which interacts with the actuating tab45, the spring tongue43has now been deflected and thus moved away from its contact surface on the conductor rail component3. In this state, the clamping point is open. Here, too, it can be seen that the actuating lever5rests with a contact side opposite the tangential lateral actuating surface52(which is not visible in the figure) on the support surface33of the conductor rail component3. The force of the spring tongue43acting on the actuating lever5is thus absorbed by the support surface33, so that a self-supporting contact assembly can be created in which no or only small forces are transferred to an insulating material housing surrounding the contact assembly.

FIG.12shows a conductor connection terminal1in the form of an electrical connector. The conductor connection terminal1has a housing2in which several contact assemblies9of the type described above are arranged next to each other in a stringing direction A. The housing2has a conductor insertion opening20for each contact assembly9, through which an electrical conductor can be routed to the conductor insertion opening11and the conductor insertion channel of the contact assembly9.

It can also be seen that for each contact assembly arranged in the housing2, there is an actuating lever5for actuating the spring tongue43. On the side diametrically opposed to the conductor insertion opening20, the housing2has a mating area21, with which the conductor connection terminal1or the electrical connector formed with it can be plugged together with a mating connector. Within the mating area21the respective plug contacts7of the contact assemblies9are arranged.