EP1786074A1

EP1786074A1 - Header for electrical appartus, method for the manufacture thereof and electrical appartus.

Info

Publication number: EP1786074A1
Application number: EP06291746A
Authority: EP
Inventors: Stéphane Gallerand
Original assignee: Tyco Electronics France SAS
Current assignee: Tyco Electronics France SAS
Priority date: 2005-11-10
Filing date: 2006-11-09
Publication date: 2007-05-16

Abstract

A header (10) for mounting to an electrical apparatus (40) for connecting the latter to a connector, of the kind comprising several electrical contact tabs (31) each extending in the same general direction of extension, arranged side-by-side and each comprising, at one of its longitudinal ends, a contact zone (32, 32a, 32b) adapted to be electrically connected to the electrical apparatus, and, at the other of its longitudinal ends, a coupling zone (33) for coupling with a complementary contact means of the connector, the contact zones (32, 32a, 32b) together forming a comb for electrical connection to the connector, characterized in that the contact zones and the coupling zones of each of the contact tabs are connected to each other by a transition zone (34) twisted about its general direction of extension such that the plane of electrical contact of the contact zone (32, 32a, 32b) of each of the contact tabs is differently oriented to the plane of electrical contact of the coupling zone (33) of that contact tab.

Description

The present invention relates to a connecting header for electrical apparatus. More precisely, the present invention relates to a header for electrical apparatus allowing electrical connection of the latter to an electrical connector.
The invention also relates to a method for the manufacture of such a header.
Headers of this type are used at the interface between the internal electrical elements of electrical apparatus and a connector which is to be connected to this electrical apparatus. They are used, for example, in electrical systems, in particular, in end effector members, where they form the interface between the internal electrical contact zones of the end effector members and the connectors serving to supply them with power.
In practice, industrial applications frequently impose electrical connectors of standardized dimensions corresponding to a defined type of electrical apparatus.
The design of the apparatus and in particular the internal geometry of their electrical connections vary in accordance with the application. Headers for electrical apparatus are therefore transition elements allowing the electrical connection of electrical apparatus whose geometry varies depending on the application with connectors having a predetermined standard geometry.
The headers are generally elements of the casing of the electrical apparatus designed to be mounted thereon to form a closed assembly.
The problem is therefore to provide a header for electrical connection between, on the one hand, an electrical apparatus and, on the other hand, an electrical connector designed to cooperate with this apparatus.
Generally, such a header comprises a certain number of substantially flat electrical coupling zones, forming electrical contacts and designed to cooperate with the same number of coupling zones on a connector provided for connection to the header.
Each of the contacts is connected in turn to one or more flat electrical contact zones designed to be connected to internal elements of the electrical apparatus.
In practice, the relative angular orientation of the coupling and contact zones of one and the same header is frequently substantially different.
The role of the header is therefore to ensure electrical connection between the internal elements of the apparatus and the electrical contacts of the connector together with geometric transition between the corresponding contact and coupling zones.
A complementary role of the header is to ensure, in certain cases, that a plurality of internal elements of the apparatus designed to be connected to a single contact of the connector are brought to the same electrical potential.
Furthermore, the amperages which have to be transmitted by the header are generally high, which means that the electrical connections in the headers have to be of a large section.
At present, as is visible in Figure 1, these electrical connections are produced by means of contact tabs 1 cut from a metallic sheet and then folded along a plurality of lines in order to arrive at the desired geometric shape, allowing the angular geometric transition mentioned above. The section of the contact tabs 1 is selected as a function of the amperage to be transmitted. The contact tabs 1 thus prepared are then overmolded with a body (not shown in Figure 1) having a geometry allowing, on the one hand, the connection of a connector as mentioned above and, on the other hand, mounting to the casing of the electrical apparatus, preferably closing the latter.
This solution involves the cutting of bent contact tabs following a profile which corresponds to the relative angular orientation desired for the electrical contacts. Thus, as is visible in Figure 1, to provide a relative orientation of 90° between the two ends forming electrical contact zones of one and the same contact tab, it is necessary to cut a contact tab following a profile 2 in the form of an "L" and then to fold it in order to obtain the desired orientation.
The drawbacks of such a solution are numerous. Cutting bent portions of sheet metal is fiddly, and causes material waste. The geometric complexity of the various folds to be performed involves complicated folding processes. When it is necessary to bring internal elements of the electrical apparatus to the same potential, this technique involves the use of double tabs 3 which are particularly complicated to manufacture.
Furthermore, since the contact tabs 1 intended for the header are prepared individually, they have to be positioned individually one relative to the other prior to overmolding. These drawbacks make the cost of manufacturing such a header high.
The object of the present invention is to remedy these drawbacks by proposing a header for mounting to an electrical apparatus for connecting the latter to a connector, of the kind comprising several electrical contact tabs each extending in the same general direction of extension, arranged side-by-side and each comprising, at one of its longitudinal ends, a contact zone adapted to be electrically connected to the electrical apparatus, and, at the other of its longitudinal ends, a coupling zone for coupling with a complementary contact means of the connector, the contact zones together forming a comb for electrical connection to the connector, characterized in that the contact zones and the coupling zones of each of the contact tabs are connected to each other by a transition zone twisted about its general direction of extension such that the plane of electrical contact of the contact zone of each of the contact tabs is differently oriented to the plane of electrical contact of the coupling zone of that contact tab.
Advantageously, according to the preferred teaching of the invention, optionally in combination:

the coupling zones are oriented at an angle between 0 and 90° with respect to their direction of alignment;
the coupling zones each extend in a plane perpendicular to their direction of alignment;
the contact zones extend in two parallel horizontal planes;
a body comprising means for fixing to the electrical apparatus is overmolded on the contact tabs.

The overmolded body preferably presents, on its face designed to bear the coupling zones, a geometry complementary to that of the connector designed to be connected thereto and, on the face designed to be in contact with the casing of the electrical apparatus, means of fixing the header thereon.
These fixing means may for example be holes for fastening screws, or a geometry allowing the header to be force-fitted on the casing.
The invention also provides an electrical apparatus preferably taking the form of an end effector member and making use of such a header.
The invention also relates to a method for the manufacture of a header such as described above, comprising the following steps:

cutting from a metallic sheet, for example by stamping, of a flat piece, in the overall form of comb, comprising a certain number of substantially parallel and coplanar contact tabs, each of the contact tabs having a terminal zone designed to form a coupling zone and, at its opposite end, a terminal zone designed to form a contact zone, the contact tabs remaining connected together by substantially aligned bridges forming a base between said two zones,
shaping of the contact tabs by twisting, for example by using a tool adapted to impart twist at the end of each of the contact tabs, about their general direction of extension such that the electrical contact plane of the contact zone of each of the contact tabs is oriented differently relative to the electrical contact plane of the coupling zone of said contact tab.

Advantageously, according to preferred features, the method additionally comprises the following steps, optionally in combination:

shaping of the contact tabs by swaging so as to form, at the end of each of the contact tabs forming a contact zone, contact zones which extend in parallel planes,
overmolding of a body of insulating material over the previously shaped component in such a way as to leave free the bridges and the contact and coupling zones,
removal of all or some of the bridges, for example by cutting.

According to the selected mode of manufacture, the steps involving shaping of the contact tabs by twisting and/or by swaging may take place after the overmolding step. Furthermore, the steps involving shaping by swaging and removal of the bridges are optional.
Features and advantages of the invention will be revealed by the following description of an example of embodiment and use of a header according to the invention, made by way of illustrative, non-limiting example with reference to the appended drawings, in which:

Figure 1 is a view of a set of tabs for a header of a prior art solution;
Figure 2 is a view of a set of tabs for a header according to the invention;
Figure 3 is a view of the same set of tabs for a header according to the invention, overmolded with a body;
Figure 4 is a view of the same set during manufacture, prior to removal of the bridges;
Figure 5 is a view of a header according to the invention, connected to an electrical apparatus, here an end effector member.

A header 10 according to the invention comprises a set 30 of electrical contact tabs 31 (Fig. 2) disposed so as to be parallel overall and held by overmolding in a body 20 (Fig. 3), the header 10 being designed to be mounted to an end 42 of a casing 41 of an electrical apparatus 40 (Fig. 5) to form at this point a termination closing said casing 41.
Each of the contact tabs 31 exhibits, at one of its longitudinal ends, at least one flat contact zone 32 adapted to be connected electrically to the electrical apparatus 40 and, at an opposite end, a flat coupling zone 33 for coupling to a complementary connector (not shown).
Unlike in the known solution shown in Figure 1, the contact tabs 31 of the header 10 according to the invention have a twisted transition zone 34 between the coupling zones 33 and the contact zones 32 of each of the contact tabs 31, thus enabling them to extend respectively in a differently oriented plane in the longitudinal direction of the contact tabs 31. In a preferred embodiment of the invention described herein, the contact zone 32 and the coupling zone 33 of each of the contact tabs 31 are connected to one another by the transition zone 34, which is twisted such that each of the coupling zones 33 and the contact zones 32 are oriented differently relative to the vertical, in the general direction of extension of each of the contact tabs 31.
In the preferred embodiment shown in particular in Figure 2, the contact tab 31 takes the form of an L whose shorter branch forms two adjacent contact zones 32a and 32b extending in two horizontal parallel planes, thus allowing two different internal elements of the electrical apparatus 40, which would respectively be in electrical contact with the contact zones 32a and 32b, to be brought to the same potential. The planes of the contact zones 32, 32a, 32b are parallel to one another.
The electrical contact between the contact zones 32, 32a and 32b and the internal elements of the electrical apparatus 40 may be achieved by welding.
In this preferred embodiment, one of the contact tabs 31 visible in Figure 2 exhibits the contact zones 32 and the coupling zones 33 connected by a bridge.
In this embodiment, the planes of the coupling zones 33 are all oriented at 90° to their direction of alignment A visible in Figure 2.
As is visible in particular in Figure 3, the set 30 of the contact tabs 31 is held in the body 20, which is overmolded on the contact tabs 31, so as to leave free the contact zones 32 and the coupling zones 33.
The body 20 has at sides thereof two holding lugs 22, each provided with an aperture 23 for the passage of a screw for fastening the connector (not shown) on the header 10.
On the face designed to cooperate with the connector (not shown), the body 20 has an extension 21 configured to protect the electrical coupling zones 33 (not visible in Figure 3). The shape of the extension 21 and its position relative to the coupling zones 33 are determined in such a way that it can cooperate with the connector (not shown), which is designed for connection to the header 10.
On the face designed to cooperate with the casing 41 of the electrical apparatus 40, the body 20 has guides 24, dimensioned so as to provide a force fit with an opening (not visible in the Figures) provided for this purpose in the casing 41 of the electrical apparatus 40. The guides 24 thus participate in holding the header 10 on the casing 41 of the electrical apparatus 40.
In a preferred embodiment, the contact tabs 31 are obtained from a single piece, visible in Figure 4. The unworked piece in the form of a comb is cut, for example by stamping, from a sheet of conductive metal. The various chamfers at the ends of said piece, visible in particular in Figure 4, may advantageously be formed during the same operation.
Advantageously, the comb-like design makes it possible to optimize utilization of the sheet metal serving in manufacture of a base 36 so as to reduce material waste.
The contact tabs 31 are connected together at a center thereof by substantially aligned bridges 35 forming the base 36. The contact zones 32, 32a and 32b are shaped so as to extend in planes parallel to the plane formed by the base 36. This shaping may be effected by swaging, for example. This swaging may be combined with the initial cutting stage effected by stamping.
The contact tabs 31 are then twisted by 90° about their direction of longitudinal extension in such a way that the contact zone 32 and the coupling zones 33 of each of the contact tabs 31 extend respectively in planes oriented differently relative to the vertical, in the longitudinal direction, to correspond with the connector (not shown) used.
This twist may be applied for example by a tool adapted to impart a twist to the contact tab 31 and applied thereto in the coupling zone 33. The twist is imparted to each of the contact tabs 31 along their longitudinal axis and results in plastic deformation of the transition zone 34. Unlike the technical solution presented in Figure 1, and using appropriate tools, angular shaping of the contact tabs 31 may take place in parallel on one and the same comb, which represents a gain in productivity.
In a preferred mode of manufacture, the body 20, made of insulating material, is overmolded on the semi-finished part visible in Figure 4 using a conventional overmolding method. Removal of the bridges 35 follows, for example by cutting, so as to eliminate short-circuits between the contact tabs 31.
In an alternative mode of manufacture, removal of the bridges 35 may be effected prior to overmolding. However, it is advantageous to preserve the bridges 35 until overmolding, insofar as the base 36 makes individual relative positioning of the contact tabs 31 prior to overmolding superfluous, which represents a definite gain in productivity.
Furthermore, depending on the needs of the designers, it is possible to modify cutting of the bridges 35, and thus to preserve or eliminate short-circuits between various contact tabs 31 and therefore between various internal elements of the electrical apparatus 40, this being possible for one and the same type of connector.
As is visible in Figure 5, the finished header 10 is mounted to the end 42 of the casing 41 of the electrical apparatus 40 to form a termination therefor. Thus, after assembly, the contact zones 32, the coupling zones 33 of the header 10, and those of the connector (not shown) are aligned substantially along parallel straight lines.
The electrical apparatus 40 is here an end effector member of an electrical system.
In practice, in the example of application illustrated in Figure 5, the header 10 according to the invention closes the casing 41 of the electrical apparatus 40, while forming a termination allowing connection of the electrical apparatus 40 to a corresponding electrical connector (not shown). The guides 24 of the body 20 effect a force fit with the end 42 of the casing 41. In an alternative embodiment, it is possible, for example, to equip the guides 24 and the end 42 with snap means which improve the hold of the header 10 on the casing 41.
Once the header 10 has been mounted on the casing 41, the contact zones 32, 32a, 32b of the header 10 are welded to contact zones 43 of electrical elements 44 of the electrical apparatus 40. Advantageously, the parallel horizontal planes of the contact zones 32, 32a and 32b correspond respectively to the planes of the contact zones 43 of the electrical apparatus 40 in such a way that the contact zones 32, 32a, 32b of the header 10 and the contact zones 43 of the electrical apparatus 40 are closely superposed once the header 10 has been mounted on the casing 41, thus facilitating welding of the contact zones 32, 32a, 32b, 43. Electrical spot welding may advantageously be used.
Although the invention has been described in particular with reference to a preferred embodiment and mode of manufacture, modifications with regard to shape and details of embodiment may be effected by the person skilled in the art without departing from the spirit of the invention.

Claims

A header (10) for mounting to an electrical apparatus (40) for connecting the latter to a connector, of the kind comprising several electrical contact tabs (31) each extending in the same general direction of extension, arranged side-by-side and each comprising, at one of its longitudinal ends, a contact zone (32, 32a, 32b) adapted to be electrically connected to the electrical apparatus 40, and, at the other of its longitudinal ends, a coupling zone (33) for coupling with a complementary contact means of the connector, the contact zones (32, 32a, 32b) together forming a comb for electrical connection to the connector, characterized in that the contact zones (32, 32a, 32b)and the coupling zones (33) of each of the contact tabs (31) are connected to each other by a transition zone (34) twisted about its general direction of extension such that the plane of electrical contact of the contact zone (32, 32a, 32b) of each of the contact tabs (31) is differently oriented to the plane of electrical contact of the coupling zone (33) of that contact tab (31).
A header according to claim 1, characterized in that the coupling zones (33) are oriented at an angle between 0 and 90° with respect to their direction of alignment.
A header according to claim 2, characterized in that the coupling zones (33) each extend in a plane perpendicular to their direction of alignment.
A header according to any one of the preceding claims, characterized in that the contact zones (32, 32a, 32b) extend in two parallel horizontal planes.
A header according to any one of the preceding claims, characterized in that a body (20) comprising means for fixing to the electrical apparatus (40) is overmolded on the contact tabs (31).
A method for the manufacture of a header, in particular according to any one of claims 1 to 5, characterised in that it comprises the following steps:
- cutting from a metallic sheet of a flat piece, in the overall form of comb, comprising a certain number of substantially parallel and coplanar contact tabs, each of the contact tabs having a terminal zone designed to form a coupling zone and, at its opposite end, a terminal zone designed to form a contact zone, the contact tabs being connected together by substantially aligned bridges forming a base between said two zones,

- shaping of the contact tabs by twisting about their general direction of extension such that the electrical contact plane of the contact zone (32, 32a, 32b) of each of the contact tabs is oriented differently relative to the electrical contact plane of the coupling zone (33) of said contact tab.
A method for the manufacture of a header according to claim 6, characterised in that it additionally comprises the following step:
- shaping of the contact tabs by swaging so as to form, at the end of each of the contact tabs, contact zones which extend in parallel planes.
A method for the manufacture of a header according to either one of claims 6 and 7, characterised in that it additionally comprises the following step:
- overmolding of a body of insulating material over the previously shaped component in such a way as to leave free the bridges and the contact and coupling zones.
A method for the manufacture of a header according to any one of claims 6 to 8, characterised in that it additionally comprises the following step: removal of all or some of the bridges.