Patent Publication Number: US-11050177-B2

Title: Contact assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of the filing date under 35 U.S.C. § 119(a)-(d) of German Patent Application No. 102018214203.3, filed on Aug. 22, 2018. 
     FILED OF THE INVENTION 
     The invention relates to a contact assembly and, more particularly, to a contact assembly for an electrical connector. 
     BACKGROUND 
     Plug and socket connectors generally include contact assemblies to transmit electrical signals, for example. The plug connector includes a contact that is plugged into a plug receiving opening in the plug-in direction and bears on contact surfaces of the socket connector. In this case, the theoretical number of contact surfaces can be too small, as a result of which an insufficient electrical contacting is obtained. An increase in the number of contact surfaces can lead to the plug contact not being able to make uniform contact the contact surfaces of the socket. 
     Therefore, there is a need to provide a solution that enables a stable electrical and mechanical contacting between the plug and socket connector assembly. 
     SUMMARY 
     A contact assembly for an electrical connector is provided and generally includes a plurality of first contact bodies and a plurality of second contact bodies. The plurality of first contact bodies include contact surfaces that provide a first contact plane. The plurality of second contact bodies include contact surfaces that provide a second contact plane that is spaced apart from and projecting beyond the first contact plane by a height. The plurality of second contact bodies are elastically deflectable to the first contact plane. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will now be described by way of example with reference to the accompanying Figures, of which: 
         FIG. 1  shows a perspective view of a socket connector according to the invention; 
         FIG. 2  shows a perspective view of a socket housing of a socket connector according to the invention; 
         FIG. 3  shows a perspective view of a contact assembly according to the invention, with a base plate; and 
         FIG. 4  shows a sectional view of a socket connector having contact assembly a according to the invention, showing a plug connector inserted therein. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     Hereinafter, the invention is described in greater detail by way of example using exemplary embodiments with reference to the attached figures. In the figures, elements which correspond to one another in design and/or function are provided with the same reference symbols. 
     The combination of features shown and described with the individual exemplary embodiments serves solely the purposes of explanation. In accordance with the statements above, it is possible to dispense with a feature from an exemplary embodiment if its technical effect is of no importance in a particular application. Conversely, in accordance with the statements above, a further feature can be added in an exemplary embodiment if its technical effect is meant to be advantageous or necessary to a particular application. 
     Now with reference to  FIGS. 1-4 , a socket connector  1  according to the invention is shown. To aid comprehension, the description uses a Cartesian coordinate system, with a plug-in direction S, a transverse direction Q and a height direction H. The embodiments depicted in the figures are given merely by way of example and serve the purpose of explanation. Thus, a plug contact can also be provided with a contact assembly  3  according to the invention, for example. 
       FIG. 1  shows an exemplary embodiment of the socket connector  1 . The socket connector  1  generally includes a socket housing  2 , which has been formed from a metal sheet by stamping and bending and which is shown in  FIG. 2  in a further schematic perspective view, and a contact assembly  3  according to the invention. 
     The socket housing  2  includes an upper side  4  and a lower side  6  which are spaced apart from one another in the height direction H. The upper side  4  and lower side  6  are connected to one another by side walls  8  which extend in the height direction H. The side walls  8  are formed by springs  10 , which enables the upper side  4  to move relative to the lower side  6  along the height direction H. The socket housing  2  can be widened and/or compressed along the height direction H. The socket housing  2  surrounds a plug connector receiving space  12  which increases in the case of widening in the height direction H and decreases in the case of compression. A part of the plug connector receiving space  12  is formed by a plug receiving opening  14 , into which a plug contact  16 , schematically depicted in  FIG. 1 , can be plugged along the plug-in direction S into the socket housing  2 . In particular, the insertion of the plug contact  16  can lead to the socket housing  2  and the plug receiving opening  14  being widened. A plug connector  15  according to the invention is likewise depicted in  FIG. 1  and includes a plug contact  16  and a socket connector  1  according to the invention. 
       FIG. 1  shows a force-free state  17 , which, in the example shown, is already a first widened position  19 . By inserting the plug contact  16  into the plug receiving opening  14 , the socket housing  2  and the plug receiving opening  14  can be widened further and cross over into a second widened position. By compression, for example by pressing together at the upper side  4  and lower side  6 , the socket housing  2  can be compressed in the height direction H, so that it can be introduced into a housing  18  (not shown in greater detail in  FIG. 1 ). Through compression, the socket housing  2  can cross over into a narrowed position. When the force is removed, the socket housing  2  can automatically cross over into the shown first widened position  19 . 
     In an alternative configuration, the configuration in  FIG. 1  can also correspond to a narrowed position  20  and the socket housing  2  can firstly be transferred into a widened position by plugging in the plug contact  16 . 
     In the shown embodiment, the socket housing  2  has a first catch  22  with a lock  24  positioned along a front region thereof with respect to the plug-in direction S. Through the first catch  22 , the socket housing  2 , in a narrowed position, can be retained in a corresponding housing  18 . The lock  24  may automatically lock in place when the socket housing  2  is inserted and thereby establishes a form-fit (see  FIG. 4 ). 
     Furthermore, in a rear region in the plug-in direction S, the socket housing  2  possesses a second catch  26 . The second catch  26  is configured to establish a form-fit with the housing  18  in a widened position. The second catch  26  is formed by a protrusion  28  which, in the embodiment shown, is attached to the upper side  4  and protrudes in the height direction H in relation to it. 
     The first catch  22  can establish, with the housing  16 , a form-fit which acts in the plug-in direction S, the second catch  26  being able to establish, with the housing  16 , a form-fit which acts counter to the plug-in direction S. The protrusion  28  and/or the lock  24  can be formed from the upper side  4  by stamping or embossing. Alternatively, or also additionally, a lock  24  and/or a protrusion  28  can be present on the lower side  6 . 
     In addition to the socket housing  2  shown in  FIG. 2 , the socket connector  1  may include, by way of example, an embodiment of a contact assembly  3  according to the invention with a base plate  30  which is depicted in a schematic perspective view in  FIG. 3 . The base plate  30  is provided with several contact elements  32  which protrude from a surface  34  of the base plate  30  in the direction of the plug receiving opening  14 . 
     The base plate  30  has a free end which can be plugged into the socket housing  2  against the plug-in direction S up to the stop, so that at least one section of the base plate  30  is placed in the socket housing  2  and the contact elements  32  project into the plug connector receiving space  12 . 
     For this purpose, the socket housing  2  is provided at its end located to the front in the plug-in direction S with a receiving pocket  36  which has a substantially U-shaped cross-section with two legs  38  spaced apart from one another in the height direction H and a base  40  which connects the two legs  38  to one another in a plane parallel to a plane spanned by the plug-in direction S and height direction H. The free end of the base plate  30  can be introduced into the receiving pocket  36  against the plug-in direction S. In this case, the free end of the base plate  30  comes to a stop against the base  40  of the receiving pocket  36  and is encompassed by the legs  38 . The receiving pocket  36  can be formed by bending, for example, one leg  38  being formed by the lower side  6  of the socket housing  2 . The receiving pocket  36  is thus form-fit with the base plate  30  counter to the plug-in direction S. 
     The lower side  6  of the socket  4  projects out beyond the side walls  8  in the plug-in direction S. On the projecting section, the lower side  6  is provided with lugs  42  which can be bent around a protrusion  44  protruding in the height direction. As a result, the base plate  30  can be retained in a more stable manner in the socket housing  2 . The protrusion  44  can have a depression  46  around which the lug  42  can be bent, so that the lug  42  is planked by the protrusion  44 . Thus, a form-fit can be established in and counter to the plug-in direction S by the lug  42  and the base plate  30  can be connected to the socket as rigidly as possible in terms of movement. 
     That end of the base plate  30  is remotely positioned from the socket housing  2  and is, as depicted in  FIG. 1 , attached to a cable  48  with an electrical terminal  50 , for example a cable lug, or an electrical conductor. For example, the base plate  30  can contain a crimp connection region in order to produce an electrical connection between the cable and the plug contact. The base plate can be introduced into the socket in the socket connector and in this case can project out of the socket at the end located to the rear in the plug-in direction, wherein the projecting part can be affixed indirectly or directly to a terminal or an electrical conductor. For example, the base plate  30  can also be welded to an electrical, conductive contact body. 
     In the shown embodiment, the base plate  30  includes an electrical terminal  49  which can be connected to the cable  48 . The base plate  30  can, for example, be connected to the electrical conductor  50  in a materially bonded manner by welding. Electrical signals or electrical power can be transmitted to the plug contact  16  through the socket connector  1 . 
     The base plate  30  is preferably formed from an electrically conductive material, in particular from copper or a copper alloy. 
     A first group of contact elements  32  is formed by a rigid, convexly curved contact body  52 , on the peak  53  of which there is formed a contact surface  54  for contacting an electrically conductive contact  55 , such as a plug contact  16 , for example. The contact surfaces  54  of the contact bodies  52  point in the direction of the plug receiving opening  14 . The contact bodies  52  can in particular be configured in a mechanically robust manner, so that the plug contact  16  can rest stably on the contact surface  54 . The contact surfaces  54  of the contact bodies  52  in this case form a first contact plane  56  which is substantially parallel to a plane spanned by the plug-in direction S and transverse direction Q and which delimits the plug receiving opening  14  in the height direction H. 
     In order to obtain a statically determined system in a simple manner, the first contact plane  56  may be spanned by three contact surfaces  54  which are arranged in a triangle, wherein two contact surfaces are positioned in a row running in the transverse direction Q. When the plug contact  16  is plugged into the plug receiving opening  14 , the plug contact  16  bias mainly on the contact surfaces  54  of the first contact plane  56 . Therefore, the mechanical stability of a plug connector  15  according to the invention can be further improved by the statically determined system. 
     As shown, the contact surfaces  54  can be arranged in a triangle in order to create a statically determined contact plane in a simple manner. In particular, the first contact plane  56  can be spanned by three contact surfaces  54  since, from a mechanical point of view, the plug contact  16  bears mainly on the contact surfaces  54  of the first contact plane  56 . At least of the first contact plane  56 , the mechanical stability of the system can be further improved by the static nature of the contact surfaces  54 . The contact surfaces  54  can be contacted uniformly, and the plug contact  16  can be prevented from swaying. 
     To compensate for tolerances and to improve the electrical and mechanical contacting of the plug contact  16 , the contact assembly  3  and the socket connector  1  have a second contact plane  66  spaced apart from the first contact plane  56  and projecting beyond the first contact plane  56  in the height direction H, this second contact plane  66  being spanned by a plurality of contact surfaces  68  on contact bodies  70  that are elastically deflectable at least up to the first contact plane  56 . 
     The elastically deflectable contact bodies  70  are formed by contact tongues  72 , which extend from the base plate  30  in the height direction H and counter to the plug-in direction S up to a convexly curved free end  74 . Each contact tongue  72  includes a peak  75  of which there are arranged the contact surfaces  68  of the second plane. The second contact plane  66  is likewise designed in a statically determined manner with three contact bodies  70  arranged in a triangle. The contact surfaces  68  of the second contact plane  66  can thus also be contacted uniformly by the plug contact  16 . 
     The elastically deflectable contact bodies  70  of the second contact plane  66  can be formed by the contact tongues  72  that extend obliquely to the plug-in direction, towards a receptacle. In an exemplary embodiment, the contact tongues  72  can in this case be arranged at an angle between approximately 30° and 150° to the plug-in direction, wherein the contact tongues  72  are connected at one end to the base plate  30  and are convexly bent at the free end. The contact surface  68  can be formed at the free end of the contact tongue  72  and be arranged substantially parallel to the contact surface  54  of the first contact plane  56  and the plug-in direction. The contact tongues  72  can extend in the direction of a plug receiving opening  14  situated to the front in the plug-in direction. 
     In a particularly advantageous configuration, the contact tongues  72  can however extend in the direction away from the opening  14 , such that the contact tongues  74  form a run-on slope along which the plug contact  16  can slide as the plug contact  16  is being plugged into the plug receiving opening  14  and in this case the contact tongues  72  push in the direction of the first contact plane  56 . 
     The contact tongues  72  can taper toward the free end. The width transverse to the plug-in direction can decrease towards the free end, as a result of which a trapezoidal configuration of the contact tongues  72  arises and the distribution of stress in a contact tongue  72  is optimized. 
     In particular, the material thickness, particularly in the direction of the receptacle, of the contact tongues  72 , can decrease towards the free end. This can improve the distribution of stress once again. Furthermore, this can lead to a stabilization in the contact surface. The density of the material at the free end can increase in this case, as a result of which the contact surface becomes mechanically more solid. The decrease in the material thickness can be produced by milling, for example. 
     As shown, the second contact plane  66  can likewise be spanned by three contact surfaces  68 , as a result of which it can be ensured that the second contact plane  66  is likewise statically arranged in a simple manner. As a result, six contact surfaces are furthermore constantly in engagement with the plug contact  16 , wherein the contact surfaces  54  of the first contact plane  56  span a contact plane which is fixed compared to the second contact plane  66  and the contact surfaces  68  of the second contact plane  66  span a flexible contact plane which is movable relative to the fixed contact plane. Both contact planes are statically determined, so that the plug contact can bear securely on all contact surfaces. 
     In an exemplary embodiment, as shown, the contact surfaces  68  of the second contact plane  66  can likewise be arranged in a triangle, with the triangle of the first contact plane  56  being arranged opposite the triangle of the second contact plane  66  and with them overlapping and the corners being formed in each case by a contact surface. In particular, one corner of the first triangle can be arranged on a base of the second triangle and conversely one corner of the second triangle can be arranged on a base of the first triangle. Through the arrangement in overlapping triangles, it is possible to achieve a particularly space-saving configuration of the contact assembly  3 , wherein, in a first depth situated in the plug-in direction, two contact surfaces of one contact plane and one contact surface of the other contact plane are contacted and, in a second depth situated in the plug-in direction and spaced apart from the first depth, two contact surfaces of the other contact plane and one contact surface of the one contact plane are contacted. 
     In order to create a particularly contact assembly  3  and/or a socket connector  1  that is compact, it is particularly advantageous if a contact body  52  of the first contact plane  56  is arranged in a first row, arranged in the transverse direction Q, between two contact bodies  70  of the second contact plane  66 , and a contact body of the second contact plane  66  between two contact bodies  52  of the first contact plane  56  is conversely arranged in a second row spaced apart from the first row in the plug-in direction S. 
     The contact tongues  72  taper in the direction of the free end  74 , such that they have a trapezoidal tongue back  76 . As a result, the stress distribution of the stress acting on the contact tongues  72  due to the elastic deflection can be improved. Furthermore a material thickness  78  decreases in the height direction H, as a result of which the distribution of stress is further improved and the solidity of the contact surface  68  can be further reinforced. 
     According to another configuration (not shown), the contact tongues  72  can also extend in the plug-in direction S and height direction H away from the base plate  30 . As a result, the plug contact  16  can slide along the tongue back  76  during plugging-in and deflect the contact tongue  72  in the direction of the first contact plane  56 . 
     The contact surfaces  54 ,  68  of the first and second contact planes  56 ,  66  are formed integrally as a monolithic component  80 . For this purpose, the contact bodies  52 ,  70  can be formed by plastic deformation. For example, the contact bodies  52 ,  70  can be formed by stamping. A contact tongue  72  extends in each case into a contact receiving passageway  82  which passes through the base plate  30 . 
     The contact surfaces  54 ,  68  are configured in an undulating, staggered manner, as a result of which the contacting of the plug contact  16  improves once again. 
     The contact planes  56 ,  66  are spaced apart from one another in the height direction H by the height  84 , wherein the first contact plane  56  delimits the plug receiving opening  14  and the second contact plane  66  is arranged in the plug receiving opening  14 . 
     The rigid contact bodies  52  of the first contact plane  56  can be rigid in particular compared to the contact bodies  70  of the second contact plane  66 . The spring stiffness of the rigid contact bodies  52  can preferably be stiffer than the spring stiffness of the springs  10 . 
     The spring strength of the springs  10  can in particular be stronger than the spring strength of the elastically deflectable contact bodies  70 , so that the contact bodies  70  can be pushed in the direction of the first contact plane  56  when the plug contact  16  is being plugged into the plug receiving opening  14 . In particular, a minimum normal force of the plug connector  15  can deflect the second contact plane  66  so far that the first and second contact planes  56 ,  66  are arranged in a common plane. 
     The socket has a press-on lug  90 , which delimits the plug receiving opening  14  in the height direction H and which is spaced apart from the first contact plane  56 , so that the plug receiving opening  14  extends in the height direction H from the first contact plane  56  to the press-on lug  90 . The second contact plane  66  is arranged between the press-on lug  90  and the first contact plane  56 , such that the press-on lug  90  pushes a plug contact  16  against the contact surfaces  68  of the second contact plane  66  and deflects the contact bodies  70  in the direction of the first contact plane  56  by the height  84 , such that the contact surfaces  54 ,  68  are arranged on a common plane. 
     The elastically deflectable contact bodies  70  of the second contact plane  66  can thus compensate for a tolerance and provide additional electrically conductive contact surfaces  68 , while the rigid contact bodies  52  of the first contact plane  56 , alongside electrical contacting, serves the purpose of mechanical stabilization. From a mechanical point of view, the plug contact  16  bears mainly on the contact surfaces  54  of the first contact plane  56 . 
     Therefore, through the socket connector  1  according to the invention, a mechanical and electrically stable contacting can be achieved with a plurality of contact surfaces  54 ,  68 . 
     As a result of the aforementioned design, the number of electrically conductive contacted contact surfaces  54 ,  68  can be increased in a simple manner, wherein the elastically deflectable contact bodies  70  of the second contact plane  66  can compensate for tolerances. From a mechanical point of view, the plug contact  16  bears mainly on the contact surfaces  54  of the first contact plane  56 , which makes the system mechanically more stable. 
     The foregoing illustrates some of the possibilities for practicing the invention. Many other embodiments are possible within the scope and spirit of the invention. The combination of features shown and described in the individual exemplary embodiments serves solely the purposes of explanation. The disclosed invention utilizes the above identified components, as a system, in order to more efficiently construct an electrical connector for a particular purpose. Therefore, more or less of the aforementioned components can be used to conform to that particular purpose. In addition, according to the above statements, a further feature can be added in an exemplary embodiment if its technical effect is meant to be advantageous or necessary for a particular application. It is, therefore, intended that the foregoing description be regarded as illustrative rather than limiting, and that the scope of the invention is given by the appended claims together with their full range of equivalents.