ELECTRICAL CONTACT DEVICE AND A METHOD FOR ITS MANUFACTURE

Abstract: The contact device comprises a metal plate (1) with a slit ex­ tending to an edge (7) of the plate which separates two strip-shaped, resilient tongues (13) from each other and serves to take up a wire with an electrically conductive core (31) surrounded by an insulating jacket (33). Starting from the said edge (7) the slit successively com­ prises a lead-in section (17), a scraper section (21) for cutting through the insulating jacket (33), a contact section (23) for making electrical contact with the core (31), and a circular first opening (5). By pressing a pin (25) with a diameter which gradually increases over its length into the first opening (5) the tongues (13) are bent away sideways from each other, so that the contact section (23) is approximately V-shaped. The scraper section (21) is formed by the transition between the widest part of the contact section (23) and a second circular opening (9) which is intersected by the split.

Description: The invention relates to an electrical contact device, comprising a metal plate with a slit extending from an edge of the plate, which slit separates two strip-shaped, resilient tongues from each other and serves to take up a wire with an electrically conductive core surrounded by an insulating jacket which is directed approximately perpendicularly to the plane of the plate, for which purpose the slit successively comprises the following sections: a lead-in section located close to the said edge of the plate, the greatest width of which is larger than the diameter of the insulating jacket, a scraper section, the smallest width of which is at most equal to the diameter of the core, a contact section, the width of which is smaller than the smallest width of the scraper section, and an approximately circular first opening at the dead-end of the slit, the diameter of which is greater than the smallest width of the contact section. The invention also relates to a method for manufacturing a contact device of this kind. A contact device of the kind mentioned in the preamble is known from EP-A-0 177 955. The known contact device is formed by making at least one opening in a metal plate and joining it by a strait slit to the V-shaped cut out lead-in section of the contact device. The slit defines two resilient tongues between which a non-insulated wire may be inserted and pushed down until it is wedged in the opening whose diameter is slightly smaller than the wire diameter. However it often happens that wires which are normally the same, have slightly different diameters as a consequence of manufacturing tolerances. As a result, for wires having a diameter smaller than the nominal value, the contact quality may be very poor. In addition, if the wire is relatively thick, it is difficult to push down the wire into the wedging opening and the resilient tongues may be sheared off due to the stress or the wire may be damaged. Moreover, if the wire is insulated, sharp edges are needed in order to cut into the insulator before the wire core is wedged in the first opening. When the slit becomes narrower in steps at the site of the transition between the lead-in section and the contact section, a sharp edge is formed which constitutes the scraper section, which cuts through the insulating jacket when the wire is pressed into the slit. The shape of the slit is determined by the shape of the punching tool. In practice, it has been found that the angle obtained by punching, which constitutes the scraper section, is often slightly rounded, as a result of which the cutting through of the insulating jacket does not always take place optimally. It is an object of the invention to indicate a contact device of the kind mentioned in the preamble, in which the scraper section is very sharp at all times and in which the contact section is suitable for wires with a core diameter that differs to some extent from the nominal value and, in addition, can be easily adapted to the core diameter of the wire to be used after the slit has been made. For this purpose, the contact device according to the invention is characterised in that the tongues are bent away from each other sideways close to the dead-end of the slit in the plane of the plate, so that the contact section of the slit is approximately V-shaped, and in that the scraper section is formed by the transition between the widest part of the contact section and a second approximately circular opening made in the plate which is intersected by the slit. In this construction of the contact device the width of the contact section can be changed by bending the tongues outwards to a greater or lesser extent. In addition, the width is place-dependent, so that the contact force can be influenced by pressing the wire further or less far into the slit. The scraper section is formed by the transition between the second circular opening and the straight cut-off sides of the contact section. A transition of this kind is always very sharp. The method for manufacturing the contact section according to the invention is characterised in that in a suitable metal plate the first and the second opening are formed, the tongues then being separated from each other by making a straight cut extending from the edge of the plate via the second opening to the first opening, and finally the tongues being bent away from each other sideways in the plane of the plate, as a result of which the plate material near the first opening is plastically deformed and the slit acquires its ultimate shape. A further elaboration of this method is characterised in that the bending away from each other of the tongues is effected by pressing a pin with a diameter which gradually increases over its length into the first opening until the width of the slit at the site of the scraper section has reached a predetermined value. The above-mentioned operation can be carried out shortly before the wire is fitted, if required, when the dimensions of this wire and therefore also the required width of the contact section are known precisely. The invention will now be further explained on the basis of the drawing. Figs. 1 to 3 inclusive show three stages in the manufacture of an electrical contact device according to the invention, Fig. 4 shows a tool that can be used in the manufacture, and Fig. 5 shows an embodiment of a contact device according to the invention with a wire fitted into it. Fig. 1 shows a plate 1 which is obtained by a punching operation from a larger plate or a long strip of metal with resilient properties (for example, phosphor bronze). The plate 1 can be connected via non-punched-out parts of the original plate or strip to other plates of similar shape (not shown), so that a consecutive series of plates is available, which can be transported in a customary manner along a row of successive tools. The plate 1 comprises a relatively narrow section 3 which acts as a connection section of the contact device to be formed and which, in this example, is designed as a flat plug pin. If required, this section can, for example, also be designed as a solder lug. In the part of the plate 1 situated above the connection section 3 in fig. 1 a first opening 5 is made close to the connection section and a second opening 9 close to the top edge 7. These openings are, for example, also formed by means of a punching operation. As shown in fig. 2, a straight cut 11 is made in the plate 1, for example, by a cutting operation. The cut 11 runs from the top edge 7 via the second opening 9 to the first opening 5, where it terminates. By making the cut 11, two tongues 13 are formed in the plate 1 which extend on either side of the cut. Finally, as shown in fig. 3, the tongues 13 are bent away from each other sideways in the direction of the arrows 15, while remaining in the plane of the plate 1. During this operation the material of the plate 1 close to the first opening 5 is plastically deformed and the cut 11 takes on the shape of an approximately V-shaped slit, the widest part of which is located close to the edge 7 and the narrowest part close to the first opening 5. This slit comprises a lead-in section 17 located close to the top edge 7 of the plate 1, the shape of which is partly determined by a V-shaped cut-out 19 (see fig. 1) formed when punching out the plate 1. In addition, the slit successively contains a scraper section 21 and a contact section 23. The slit comes to a dead end in the first opening 5. The scraper section 21 is formed by the transition between the second opening 9 and the widest part of the contact section 23. At the site of this transition, the cut 11 issues into the second opening 9, sharp angles being formed that project into the slit. The tongues 13 can be bent apart, for example, by clamping each of these tongues into a suitable tool and then moving these tools away from each other. Preferably, however, this bending is effected by means of a tool comprising a pin 25, as shown in fig. 4. The pin 25 has a diameter which gradually increases over its length, the smallest diameter at the free end 27 being smaller than, and the largest diameter close to the other end being greater than, the diameter of the first opening 5. As shown in fig. 3, the pin 25 is pressed into the first opening 5, as a result of which the tongues 13 are bent apart. The further the pin 25 is pressed into the first opening 5, the further the tongues 13 are bent apart. In this way, the width of the split, particularly at the site of the scraper section 21, can easily be set very accurately and adapted to the diameter of the core of a wire to be pressed into the slit. Fig. 5 shows an embodiment of a contact device according to the invention, into which a wire is fitted. The contact device is placed in an electrically insulating housing 29 (indicated schematically with dashed lines). The housing 29 may, for example, be a connector housing or a contact strip fitted to the flange of a coil. The wire, shown in cross-section, which is directed perpendicularly to the plane of the contact device (the plane of the plate 1), comprises an electrically conductive core 31, made for example of copper, and an insulating jacket 33, made for example of synthetic material. The wire is pressed into the slit from above, so that it first enters the lead-in section 17. The greatest width of this lead-in section is larger than the diameter of the insulating jacket 33 so that it is sufficient to bring the wire above this lead-in section without great accuracy, after which it is automatically guided to the centre of the slit when being pressed further downwards. Next, the wire reaches the scraper section 21, the smallest width of which is at most equal to the diameter of the core 31, so that the insulating jacket 33 is cut through when passing the sharp angles which form the transition between the second opening 9 and the edges of the contact section 23. When the wire is then pressed further into the contact section 23, the edges of this contact section make electrical contact with the core 31, as a result of which this core is slightly deformed and the tongues 13 are elastically pressed outwards. After the wire has stopped against or close to the housing 29, the resilience of the tongues 13 ensures that a good electrical contact is maintained between the core 31 and the contact device. Thanks to the fact that the contact section is V-shaped, a good electrical contact can be made, even when the diameter of the core displays slight deviations with respect to the nominal value. It is only necessary to press thinner wires slightly further and thicker wires slightly less far into the contact section. When contact has to be made with wires which have a different nominal core diameter, the width of the slit can be adapted to this diameter when the tongues 13 are being bent apart by pushing the pin 25 further or less far into the first opening 5. It is thus possible to carry out the necessary punching and cutting operations in advance and to keep the semi-finished product shown in fig. 2 in stock. When the wire diameter is known precisely, the last operation described on the basis of figures 3 and 4 can be carried out. No separate punching tools are therefore needed in order to produce contact devices for various nominal wire diameters and it is also unnecessary to keep contact devices with various slit widths in stock. It will be clear that this saves costs. By way of example, the dimensions are given below of a contact device according to the invention which proved to be satisfactory in practice for making contact with a wire, the insulating jacket 33 of which had an external diameter of 0.265 mm and the core a diameter of 0.251 mm: Material: phosphor bronze sheet with a thickness of 0.5 mm; Width of the two tongues 13 together before being bent apart: 3.5 mm; Distance from the top edge 7 to the connection section 3: 8 mm; Distance from the centre of the first opening 5 to the top edge 7: 4.9 mm; Diameter of the first opening 5: 0.7 mm; Distance from the centre of the second opening 9 to the top edge 7: 1.07 mm; Diameter of the second opening 9: 0.3 mm; Distance between the tongues 13 half way along the slit: 0.16 mm. Under these conditions a good electrical contact was obtained by positioning the wire half way along the slit (approximately 2.6 mm from the top edge 7).

Claims: An electrical contact device, comprising a metal plate (1) with a slit (11) extending from the edge (17) of the plate (1), which slit separates two strip-shaped, resilient tongues (13) from each other and serves to take up a wire with an electrically conductive core (31) surrounded by an insulating jacket (33) which is directed approximately perpendicularly to the plane of the plate (1), for which purpose the slit (11) successively comprises the following sections: an approximately V-shaped cut out lead-in section (17) located close to the said edge (7) of the plate (1), the greatest width of which is larger than the diameter of the insulating jacket (33), a scraper section (21), the smallest width of which is at most equal to the diameter of the said core (31), a contact section (23), the width of which is smaller than the smallest width of the scraper section (21), and an approximately circular first opening (5) at the dead-end of the slit (11), the diameter of which is greater than the smallest width of the contact section (23), characterised in that the tongues (13) are bent away from each other sideways close to the dead-end of the slit (11) in the plane of the plate (1), so that the contact section (23) of the slit (11) is approximately V-shaped, and in that the scraper section (21) is formed by the transition between the widest part of the contact section (23) and a second approximately circular opening (9) made in the plate (1) which is intersected by the slit (11). A method for manufacturing of a contact device as claimed in claim 1, characterised in that in a suitable metal plate (1) the lead-in section (17), the first (5) and the second opening (9) are formed, the tongues (13) then being separated from each other by making a straight cut extending from the edge (17) of the plate (1) via the second opening (9) to the first opening (5), and finally the tongues (13) being bent away from each other sideways in the plane of the plate (1), as a result of which the plate material near the first opening (5) is plastically deformed and the slit (11) acquires its ultimate shape. A method as claimed in claim 2, characterised in that the bending away from each other of the tongues (13) is effected by pressing a pin (25) with a diameter which gradually increases over its length into the first opening (5) until the width of the slit (11) at the site of the scraper section (21) has reached a predetermined value.

Inventors: HUISKES, GERARDUS BERNARDUS
Applicants: N.V. PHILIPS' GLOEILAMPENFABRIEKEN
Application year: 1987
Main classification: H01R4
IPC codes: H01R4