EP3639328B1 - Method for producing a socket contact - Google Patents

Description

The invention relates to a method for producing a socket contact, the socket contact consisting of a sleeve and a contact cage.

Various embodiments of socket contacts are already known from the prior art. These are often designed in several parts, with the individual parts being manufactured separately from one another and only being connected to one another in a further assembly process that is independent of the respective manufacturing processes. By spatially separating production and assembly, additional steps are required to prepare for assembly, in which the individual components must first be aligned with one another before they can be connected. In addition, due to the separate production of the components, a sufficient amount of components of different types must be supplied during assembly so that they are available in the appropriate number during assembly. However, this means that a constant supply of individual components must be maintained and updated. Alternatively, the components must be counted each time so that they are available in the required quantity. However, additional feeding processes and storage are expensive and time-consuming. If a manufacturing process of a component of the socket contact is faster than another manufacturing process, the various manufacturing processes either have to be time-consumingly stacked together or throttled, which leads to expensive and inefficient production. Furthermore, different manufacturing methods, machine types or feed speeds can also lead to different production speeds.

Methods for producing socket contacts are, for example, from the publications CN 104525762 A and US 6,656,002 B2 known, with the latter being able to produce a socket contact with a contact cage. Further socket contacts consisting or at least having a sleeve and a contact cage are also from the documents DE 20 2016 100 095 U1 , WO 2012/088968 A1 and DE 20 2016 106 666 U1 known.

The invention is therefore based on the object of overcoming the aforementioned disadvantages and of providing an efficient method for producing socket contacts in which the individual socket contact components do not have to be kept in stock and the socket contact components can be connected to one another quickly and easily. The process should be cheaper and faster than the known conventional processes.

This task is achieved by the combination of features according to claim 1.

According to the invention, a method for producing a socket contact is proposed, in particular a high-current socket contact. The socket contact consists of a sleeve and a contact cage. In the method, the sleeve is made or formed from a first metal strip and the contact cage from a second metal strip. In the method, at least one step for forming the sleeve and one step for forming the contact cage are carried out in a parallel shaping process.

The first and second metal strips each have a longitudinal direction. The method includes at least one step of feeding the first metal strip into a first punching device and the second metal strip into a second punching device.

The method further comprises a step of perforating and punching the first metal strip using a punching tool of the first punching device. The perforation of the first metal strip takes place after a first predetermined length, so that a section of the metal strip is delimited along the longitudinal direction by one perforation to the next, directly adjacent section of the metal strip. The perforation can be formed by a large number of breakthroughs, openings arranged or adjacent to one another or by at least one connecting web between two sleeve blanks of the metal strip. By stamping, which can take place simultaneously with perforating or independently of it, the first metal strip is formed into a sleeve blank with connecting sections. The sleeve blank is connected to a subsequent or preceding sleeve blank through the perforation or the at least one connecting web. As a result, the first metal strip is formed into a large number of sleeve blanks connected to the perforation by perforating and stamping. The sleeve blank forms locking, counter-locking and holding elements by stamping, in which, for example, projections, depressions and locking tabs are provided in order to fix the sleeve resulting from the sleeve blank to the contact cage. Alternatively, the Sleeve can also be fixed to other components by latching, counter-latching and holding elements in order to fix the socket contact. These locking, counter-locking or holding elements can also be bent integrally with the stamping or subsequently. The die-cutting can be formed by punching out, punching in, embossing or a mixture of these. The connecting sections of the sleeve blank are each formed on the edge regions of the sleeve blank in the longitudinal direction of the first metal strip and correspond to one another. The connecting sections serve to connect the sleeve blank to itself and/or align it with one another during forming into a sleeve.

In addition, the method additionally includes at least the step of perforating and punching the second metal strip using a punching tool of the second punching device. The second metal strip is perforated after a second predetermined length, with the second metal strip being formed by stamping into a plurality of contact cage blanks connected to one another by the perforation. This step of perforating and stamping the second metal strip is carried out in particular at the same time or in parallel with the step of perforating and stamping the first metal strip, so that a contact cage blank is formed for each sleeve blank. The contact cage blank is formed with a grid structure and connection sections. The connection sections of the contact cage blanks are each formed on the edge regions of the contact cage blank in the longitudinal direction of the second metal strip and correspond to one another, so that the connection sections can be connected to one another or brought into engagement with one another when the contact cage blank is formed into a contact cage. The grid structure essentially forms the contact area into a contact element of a plug, which is inserted into the socket contact during later use. The lattice structure is formed in particular by a plurality of webs running parallel to one another, so that a first edge region is connected to a second edge region by the plurality of webs and the first and second edge regions, which lie opposite one another in the width direction of the second band on the contact cage blank, each form the connection sections connects with each other. The grid structure is formed from a large number of contact lamellas. Through the perforation, which is formed from a plurality of adjacent or adjacent openings, openings or through at least one connecting web, the contact cage blank is connected to a subsequent contact cage blank, so that the second metal strip is formed into a plurality of contact cage blanks connected to the perforation . The connection sections allow the respective edge regions of the contact cage blank to be inserted The longitudinal direction of the second metal strip can be aligned with one another and/or connected to one another.

In the sense of the invention, it can be said that a respective metal strip is formed into a sleeve or contact cage blank or into a plurality of interconnected sleeve or contact cage blanks during perforation and stamping, as well as that the respective metal strip after perforating and stamping consists or is formed from a large number of interconnected sleeve or contact cage blanks.

The first and second predetermined lengths are related to each other and are each substantially the inner circumference of the tubular sleeve and the tubular contact cage, respectively. The second predetermined length determines the inner diameter of the contact cage and depends on the outer diameter of the contact element of the plug to be accommodated. The first predetermined length determines the inner diameter of the sleeve and is designed so that the sleeve can accommodate the contact cage. Therefore, the first predetermined length essentially corresponds to the second predetermined length plus 2 * π * x and plus a compensation value y, where x is the thickness of the second metal strip and the compensation value y determines the clearance between the sleeve and the contact cage. The unequal first and second predetermined lengths result in different feed speeds for the first and second metal strips during perforation and punching. Since the sleeve blanks are longer than the contact cage blanks, the first metal strip must be fed at a higher speed than the second metal strip to produce the contact cage blanks.

• Zuführen des ersten Metallbandes aus der Vielzahl von Hülsenrohlingen zu einer ersten Trenn- und Umformeinrichtung und des zweiten Metallbandes aus einer Vielzahl von Kontaktkäfigrohlingen zu einer zweiten Trenn- und Umformeinrichtung,
• Trennen und Umformen des ersten Metallbandes aus einer Vielzahl von Hülsenrohlingen in der ersten Trenn- und Umformeinrichtung, wobei jeweils ein Hülsenrohling an der Perforation von dem ersten Metallband getrennt und durch Rollen oder Biegen zu einer Hülse umgeformt wird, wodurch sich eine hohlzylindrische und zu beiden Seiten in Breitenrichtung des ersten Metallbandes geöffnete bzw. rohrförmige Form ergibt,
• Trennen und Umformen des zweiten Metallbandes aus einer Vielzahl von Kontaktkäfigrohlingen in der zweiten Trenn- und Umformeinrichtung, wobei jeweils ein Kontaktkäfigrohling an der Perforation von dem zweiten Metallband getrennt und durch Rollen oder Biegen zu einem Kontaktkäfig umgeformt wird, wodurch sich eine hohlzylindrische und zu beiden Seiten in Breitenrichtung des zweiten Metallbandes geöffnete bzw. rohrförmige Form ergibt.

The procedure also includes the following steps:

• feeding the first metal strip from the plurality of sleeve blanks to a first separating and forming device and the second metal strip from a plurality of contact cage blanks to a second separating and forming device,
• Separating and forming the first metal strip from a plurality of sleeve blanks in the first separating and forming device, with one sleeve blank being separated from the first metal strip at the perforation and formed into a sleeve by rolling or bending, thereby forming a hollow cylindrical sleeve on both sides results in an open or tubular shape in the width direction of the first metal strip,
• Separating and forming the second metal strip from a plurality of contact cage blanks in the second separating and forming device, wherein one contact cage blank is separated from the second metal strip at the perforation and formed into a contact cage by rolling or bending, thereby forming a hollow cylindrical and on both sides Open or tubular shape results in the width direction of the second metal strip.

Separating and/or forming the metal strips can take place in parallel and separately or integrally with one another. The width direction is orthogonal to the respective longitudinal direction of the metal strip. The sleeve and contact body blanks are each bent or rolled about an axis that is orthogonal to the longitudinal direction of the respective metal strip.

In addition, before separating, after forming or between separating and forming the sleeve blanks or the contact cage blanks, a further step can take place in which the sleeve blanks or the contact cage blanks are formed and, for example, numbers are stamped or latching, counter-latching or holding elements are formed.

• Zuführen der Hülse und des Kontaktkäfigs zu einer Montageeinrichtung,
• Montage der Hülse und des Kontaktkäfigs in der Montageeinrichtung zu dem Buchsenkontakt, wobei der Kontaktkäfig in die Hülse eingeschoben und an der Hülse fixiert wird.

To assemble the sleeve blanks and the contact cage blanks together, the method according to the invention further comprises at least the following steps:

• feeding the sleeve and the contact cage to an assembly device,
• Assembly of the sleeve and the contact cage in the assembly device to the socket contact, the contact cage being inserted into the sleeve and fixed to the sleeve.

Because one sleeve blank is formed for each contact cage blank, there can be no supply bottlenecks during assembly. In addition, the sleeve blanks and the contact cage blanks are formed into the sleeves and contact cages directly before assembly and no additional alignment is necessary to align them for assembly, since the sleeves and contact cages are held in the orientation required for assembly.

According to the invention, the first and second punching devices as well as the first and second separating and forming devices are connected to one another at least in terms of control technology or are designed integrally with one another, so that the respective method steps are parallelized. This means that unequal speeds cannot occur when producing the sleeves and contact cages.

Furthermore, in a further advantageous method variant, the first and second punching devices are formed integrally with one another. The first and second punching devices can, for example, have a common control or be driven by a common drive.

Furthermore, in an advantageous development, the first and second punching tools can be formed in one piece with one another. Cutting and forming tools for cutting and forming can also be designed in one piece or integrally with one another.

In a further development of the method, the lattice structure of the second metal strip is formed by punching out cutouts or openings that run parallel to one another. The cutouts are arranged orthogonally relative to the longitudinal direction of the second metal strip or at an angle to the longitudinal direction of the second metal strip. The webs or contact lamellae are formed between the cutouts, which results in a lamella structure. Alternatively, the webs can also have a curved course instead of a straight line.

Advantageously, before the cutting and forming of the second metal strip, the method can have an additional forming step of the second metal strip, in which the second metal strip is compressed in its width which is orthogonal to the longitudinal direction, so that a central region running along the metal strip protrudes bulgingly from the second metal strip. This creates a contact and clamping area in which the contact cage contacts the contact element of the plug when the plug is inserted into the socket contact.

When stamping the first and second metal strips, in an advantageous development of the method, a connecting section is formed on two edge sections opposite each other in the longitudinal direction of the respective metal strip, which engage with one another or lie against one another when the respective metal strip is formed.

A further advantageous method variant provides that when the first and/or the second metal strip is punched into shape, locking, counter-locking and/or holding elements corresponding to one another are punched into the first and second metal strip. The sleeve and the contact cage can be fixed to one another during assembly by means of the locking, counter-locking and/or holding elements. In addition, the sleeve or the contact cage can be connected to the remaining socket into which the socket contact is inserted. The locking elements can be formed by locking tabs and counter-locking elements and the holding elements can be formed by projections and support surfaces.

To form the contact and clamping area on the contact lamellae of the contact cage, an advantageous method variant provides that when the contact cage blank is formed into the contact cage, the contact cage is twisted so that in the width direction of the second metal strip from which the contact cage is formed, it turns more centrally into a Circumferential area constricts. Due to the constriction, a central area of the contact cage protrudes in a bulging manner in the circumferential direction and curves inwards. The torsion can be supported by shaping pressure elements so that the torsion follows a predetermined shape.

When assembling the sleeve with the contact cage, the locking elements are locked with a respective counter-locking element or arranged in such a way that the respective support surfaces or locking elements rest on a holding element in order to fix the contact cage in the sleeve. This can also be implemented through additional shaping, such as bending a tab through a breakout.

In addition, the connection sections of the sleeve and/or the contact cage can be cohesively connected to one another during forming or assembly or afterwards, for example by soldering.

The features disclosed above can be combined in any way, as long as this is technically possible and they do not contradict each other.

Fig. 1

eine schematische Darstellung eines erfindungsgemäßen Verfahrens;

Fig. 2

einen Hülsenrohling;

Fig. 3

einen Kontaktkäfigrohling;

Fig. 4

eine Hülse;

Fig. 5

einen Kontaktkäfig;

Fig. 6

einen Buchsenkontakt;

Fig. 7

eine alternative Ausführung eines Buchsenkontaktes.

Other advantageous developments of the invention are characterized in the subclaims or are shown in more detail below together with the description of the preferred embodiment of the invention with reference to the figures. Show it:

Fig. 1

a schematic representation of a method according to the invention;

Fig. 2

a sleeve blank;

Fig. 3

a contact cage blank;

Fig. 4

a sleeve;

Fig. 5

a contact cage;

Fig. 6

a socket contact;

Fig. 7

an alternative version of a socket contact.

The figures are exemplary schematic. The same reference numbers in the figures indicate the same functional and/or structural features.

Figure 1 shows a method according to the invention. The first and second metal strips 22, 32, each with a longitudinal direction L1, L2, are each fed to the process from a roll (not shown). The metal strips 22, 32 run parallel to one another into the punching device 1, which has two punching tools that are integral with one another and with which the metal strips 22, 32 are each formed by perforating and punching. The first metal band 22 is formed into a plurality of sleeve blanks 21 connected by the perforation 27 and the second metal band 32 is formed into a plurality of contact cage blanks 31 connected by the perforation 37. Sleeve and contact cage blanks 21, 31 run through the perforations 27, 37 respectively connected to a band parallel to each other in the separating and forming device 2, in which the individual sleeve and contact cage blanks 21, 31 are separated and formed at the respective perforation 27, 37. During forming in the separating and forming device 2, the sleeve or contact cage blanks 21, 31 are each rolled so that tubular sleeves 20 or contact cages 30 are formed. During forming, the connection sections 25', 25", 35', 35" formed on the sleeve blanks 21 and on the contact cage blanks 31 are each locked or brought into engagement with the corresponding connection sections, so that the sleeves 20 maintain their shape and cannot spring apart and the contact cages 30 are aligned with one another at their respective connection sections 35'35". The contact cages 30 are according to additionally twisted after rolling by fixing the areas opposite in the width direction of the metal strip and twisting them relative to one another, whereby a constriction is formed in the circumferential area 36. The sleeves 20 and the contact cages 30 are transported from the separating and forming device 2 into the assembly device 3, with a contact cage 30 being formed for each sleeve 20 and transported to the assembly device 3. In the assembly device 3, a contact cage 30 is inserted into a sleeve 20 or a sleeve 20 is pushed onto a contact cage 30. The locking elements 33, 34 are locked with the respective counter-locking elements 24 or brought into contact with the holding elements 23, whereby the contact cage 30 is fixed in the sleeve 20 and the socket contact 10 is formed. Through the dashed line in Figure 1 It is shown schematically that the individual process steps through the punching device 1, the separating and forming device 2 and the assembly device 3 are arranged in one system or spatially in direct succession.

In Figure 2 a sleeve blank 21 is shown. In the punching device 1, the counter-locking elements 24 are punched out and projections are formed on the opposite side of the first metal strip 22 by punching in depressions. The projections serve as holding elements 23. On the edge sections of the first metal strip 22, which are opposite in the longitudinal direction, corresponding connecting sections 25 ', 25" are formed as locking and counter-locking elements, which are locked together in the separating and forming device 2. Before separating the plurality of sleeve blanks 21 are connected to one another through the perforation 27, the perforation in the case of the sleeve blank 21 shown being designed as a web on a connecting section 25′ designed as a locking element, which extends from the connecting section 25′ in the longitudinal direction to the connecting section 25″ designed as a counter-locking element. of a directly adjacent sleeve blank.

A contact cage blank 31 is in Figure 3 shown. A grid structure with contact lamellae is formed on the contact cage blank 31 by means of a large number of mutually parallel cutouts 38. The cutouts 38 run from a first to a second edge region 39 ', 39" in the width direction of the second metal strip 32, from which the contact cage blank 31 is formed, connecting the webs formed by the cutouts 38 and each lying between two cutouts 38 the first edge area 39 'with the second edge area 39". The locking elements 33, 34 are formed in the first and second edge regions 39', 39" during stamping. The locking elements 33, 34 are formed in the second edge region 39". latching elements 34 are designed as latching tabs which are bent out of the plane of the metal strip in order to be able to engage resiliently in the counter-latching elements 24 of the sleeve. On the edge regions in the longitudinal direction of the second metal strip 32 there are corresponding connection sections 35 ', 35', which are formed during stamping. When the contact cage blank 31 is rolled into the contact cage 30 in the separating and forming device 2, the edge regions in the longitudinal direction are formed using the connection sections 35'. , 35 "oriented towards each other by a connection section 35 'trained as a tongue with the connection section 35" trained as a contact area ". a web on a connection section 35', which extends in the longitudinal direction of the second metal strip 32 from the respective connection section 35' to the directly adjacent connection section 35" of the directly adjacent contact cage blank.

Figures 4 and 5 show the sleeve 20 and the contact cage 30 after separation and forming by the separating and forming device 2. The respective connection sections 25 ', 35' are brought into engagement or into contact with the respective corresponding connection sections 25", 35". The locking element 34 designed as a tongue is protected to the outside so that it can engage or snap into the counter-locking element 24 designed as an opening during assembly. In the circumferential region 36 of the contact cage 30, which is arranged centrally in the width direction of the second metal strip 32 from which the contact cage 30 is formed, an inwardly pointing bulge or constriction is formed by torsion.

In Figure 6 the socket contact 10 is shown after assembly, with the locking element 33, which is designed as a groove-shaped recess, resting on the holding element designed as a support surface and the locking element 34 designed as a tongue engages in the counter-locking element 24 designed as an opening. The assembly is carried out by inserting them laterally transversely to the transport direction of the bands 22, 32 of the contact cage 30 into the sleeve 20. The connection sections 35 ', 35" of the contact cage only serve to align the respective edge regions with one another, whereas the connection sections 25', 25" of the Sleeve 20 serves to hold the tubular or hollow cylindrical socket contact 10 together in the circumferential direction.

Figure 7 shows a further embodiment of the socket contact as a socket contact 10 '. The sleeve 20' of the socket contact 10' is extended in the width direction, with a connection section 26' being formed during stamping, cutting and forming. A conductor can be connected directly to the socket contact 10' through the connection section 26'.

The implementation of the invention is not limited to the preferred exemplary embodiments given above. Rather, a number of variants are conceivable, which make use of the solution presented even in fundamentally different designs, provided that they fall within the scope of protection of the claims. For example, the sleeve and contact cage could be brought into an angular tube shape during forming by bending along predetermined bending edges.

Reference symbol list

1

Punching device

2

Separating and forming device

3

Assembly facility

10

Socket contact

10'

Socket contact

20

sleeve

20'

sleeve

21

Sleeve blank

22

first metal band

23

Holding element

24

Counter-locking element

25'

Connection section

25"

Connection section

26'

Connection section

27

perforation

30

contact cage

30'

contact cage

31

Contact cage blank

32

second metal band

33

Locking element

34

Locking element

35'

Connection section

35"

Connection section

36

surrounding area

37

perforation

38

Detail

39'

first edge area

39"

second edge area

L1

Longitudinal direction

L2

Longitudinal direction

Claims (9)

1. Method for producing a socket contact (10) consisting of a sleeve (20) and a contact cage (30), which are formed from a first and a second metal strip (22, 32) each having a longitudinal direction (L1, L2), wherein at least one step for forming the sleeve (20) and one step for forming the contact cage (30) are performed in a parallel shaping and forming process and wherein the method comprises at least the following steps:

   • feeding the first metal strip (22) into a first punching device and feeding the second metal strip (32) into a second punching device;

   • perforating and die-stamping the first metal strip (22) by way of a punching tool of the first punching device, wherein the perforation (27) is carried out in each case after a first predetermined length and the first metal strip (22) is formed by the die-stamping to afford a sleeve blank (21) having connection portions, wherein the sleeve blank (21) is connected by the perforation (27) to a subsequent sleeve blank (21), such that the first metal strip (22) is formed to afford a plurality of sleeve blanks (21) connected at the perforation (27);

   • perforating and die-stamping the second metal strip (32) by way of a punching tool of the second punching device, wherein the perforation (37) is carried out in each case after a second predetermined length and the second metal strip (32) is formed by the die-stamping to afford a contact cage blank (31) having a grating structure and connection portions, wherein the contact cage blank (31) is connected by the perforation (37) to a subsequent contact cage blank (31), such that the second metal strip (32) is formed to afford a plurality of contact cage blanks (31) connected at the perforation (37);

   • feeding the first metal strip (22), consisting of the plurality of sleeve blanks (21), to a first separating and forming device and feeding the second metal strip (32), consisting of a plurality of contact cage blanks (31), to a second separating and forming device;

   • separating and forming the first metal strip (22), consisting of a plurality of sleeve blanks (21), in the first separating and forming device, wherein in each case a sleeve blank is separated from the first metal strip (22) at the perforation (27) and formed by rolling or bending to afford a sleeve (20),

   • separating and forming the second metal strip (32), consisting of a plurality of contact cage blanks (31), in the second separating and forming device, wherein in each case a contact cage blank (31) is separated from the second metal strip (32) at the perforation (37) and formed by rolling or bending to afford a contact cage (30), wherein the method also comprises the following steps:

   • feeding the sleeve (20) and the contact cage (30) to a preferably fully automatic assembly device,

   • assembling the sleeve (20) and the contact cage (30) in the assembly device to afford the socket contact (10), wherein the contact cage (30) is pushed into the sleeve (20) transversely to the transport direction of the strips (22, 32) and fixed to the sleeve (20), wherein the first and the second punching device and the first and the second separating and forming device are connected to one another in terms of control technology, such that the respective method steps are parallelized.
2. Method according to Claim 1, wherein the first and the second punching device are formed integrally with one another.
3. Method according to either of the preceding claims, wherein the first and the second punching tool are formed in one piece with one another.
4. Method according to Claim 1, wherein the grating structure of the second metal strip (32) is formed by punching out cutouts (38) running parallel to one another and running orthogonally with respect to the longitudinal direction (L2) of the second metal strip (32) or at an angle to the longitudinal direction (L2) of the second metal strip (32).
5. Method according to the preceding Claims 1 and 2, wherein, before the separating and forming of the second metal strip (32), the method comprises an additional step of forming the second metal strip (32) in which the second metal strip (32) is compressed in its width, such that a central region running along the metal strip protrudes convexly out from the second metal strip.
6. Method according to one of the preceding claims, wherein, during the die-stamping of the first and the second metal strip (22, 32), a connection portion (25', 25", 35', 35") is formed in each case on two edge portions which are opposite in the longitudinal direction (L1, L2) of the respective metal strip (22, 32), which connection portions engage into one another during the forming of the respective metal strip (22, 32).
7. Method according to one of the preceding claims, wherein, during the die-stamping of the first and/or the second metal strip (22, 32), mutually corresponding latching, counter-latching and/or retaining elements (23, 24, 33, 34) are punched into the first and second metal strips (22, 32).
8. Method according to one of the preceding claims, wherein, during the forming of the contact cage blank (31) to afford the contact cage (30), the contact cage (30) is twisted such that a region (36) that is central in a width direction and runs in an encircling manner in a circumferential direction is constricted.
9. Method according to the preceding Claims 1 and 8, wherein, during the assembly, the latching elements (33, 34) are latched to a respective counter-latching element (24) or bear against a retaining element (23) in order to fix the contact cage (30) in the sleeve (20).

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