PLUG CONNECTOR

Abstract

 The present invention relates to contact bushings and to a plug connector (35) with a contact bushing (2) and a contact plug (26), wherein the contact bushing (2) has a connecting element (60) for an electrical conductor, wherein the contact bushing (62) has a contact opening (61), wherein the contact opening (61) is delimited by an inner circumferential contact surface (63) delimiting the contact opening (61), wherein the circumferential contact surface (63) has at least two corners (84), wherein the contact opening (61) is provided for inserting the contact plug (26).

Description

[0001] The invention relates to a plug connector according to Claim 1 and a contact bushing according to Claim 21 and a contact bushing according to Claim 22.

[0002] An angled plug connector is known from WO 2012/023041 A1, wherein a contact bushing is provided which has a circular cross-section, wherein an electrical contact, with a sleeve-shaped circular section, is inserted into the contact bushing, and wherein the sleeve-shaped section is connected to the cylindrical contact bushing in a mechanical and electrically conductive manner.

[0003] The problem of the proposed plug connector or proposed contact bushing consists in providing, with simple mounting and low mounting forces, a large pressing force and thus a great current conductivity between the contact bushing and the contact plug.

[0004] The problem of the invention is solved by the plug connector according to Claim 1 and by the contact bushing according to Claims 21 and 22.

[0005] Further advantageous embodiments are specified in the dependent claims.

[0006] An advantage of the described plug connector or contact bushing consists in that the contact force between the contact bushing and the contact plug is increased at low mounting forces. This is achieved in that the contact surface of the contact bushing is not configured in a circle, but rather has at least two corners or recesses so that insertion of the contact plug is facilitated. By providing the corners or recesses, it is possible to displace material of the contact bushing to a greater extent and thus to achieve an increase in the contact surface and an increase in the contact force of the press contact between the contact bushing and the contact plug.

[0007] In one embodiment, several corners or recesses, which are in particular distributed uniformly around the contact opening, are produced in the contact surface. In this manner, a uniform increase of the contact force is achieved around the periphery of the contact plug.

[0008] In a further embodiment, the recesses substantially have the shape of a corner in cross-section parallel to the contact opening. The corner is formed by side surfaces which are adjacent one another in the corner. This shape can be produced in the contact bushing with the aid of a punching method, for example. In addition, tests have shown that, with the aid of this shape, a high pressing force is achieved with low mounting forces. In addition, the current conductivity between the contact bushing and the contact plug is improved when this shape of the recesses is used.

[0009] In a further embodiment, the contact surface is formed by at least three side surfaces which are adjacent one another in predetermined corner regions at fixed angles.
In a further embodiment, the corner of the recess is disposed symmetrical to the circular line of the contact opening. As a result of this, the mounting forces are reduced too and in addition an increased pressing force and an increased current conductivity are achieved.

[0010] Depending on the embodiment selected, the contact opening is produced with the aid of a punching process. In addition, the contact plug can also be manufactured in the form of a punched part. In this way, cost-effective production is made possible.

[0011] In a further embodiment, the contact bushing substantially has the shape of a plate, wherein adjacent to the contact opening there is configured a collar which represents at least a part of the contact surface. In this manner, the contact surface is enlarged using simple means, without having to use a thicker plate overall. As a result, material, construction space and weight are saved.

[0012] Depending on the embodiment selected, the collar can have further recesses. As a result, the flexibility of the collar sections can be adjusted.

[0013] In a further embodiment, the contact plug has a slot at least in a first contact section, which is inserted into the contact opening. The slot is disposed along a longitudinal axis of the contact plug. In this manner, the flexibility of the contact plug for the pressing of the contact plug into the contact opening can be reduced. For example, the slot can have a width perpendicular to the longitudinal axis of the contact plug, which can be in the region of 0.1 to 3 mm or greater.

[0014] In a further embodiment, the housing of the plug connector is configured in several parts, so that a simple mounting of the housing is possible. In addition, the individual housing parts can be configured from different materials. The material can thus be optimally matched to the function of the housing part.

[0015] Depending on the embodiment selected, the further contact opening can, in cross-section, have the shape of a polygon. For example, the contact opening in cross-section can have the shape of a triangle, quadrilateral, decagon or hexadecagon.

[0016] In addition, depending on the selected design, the plug connector can have a circular or a polygonal, in particular a rectangular or square outer profile.

[0017] In a further design, the contact bushing is manufactured by a folded plate, in particular a punched part. This therefore enables cost-effective manufacturing.

[0018] In a further design, the contact plug has a first contact section and a second contact section, wherein the first contact section is provided for introduction into the contact opening of the contact bushing, wherein the first contact section in cross-section perpendicular to the longitudinal extension of the contact plug has a polygonal shape which is rounded in corner regions, in particular a rectangular shape, and wherein the second contact section has a cylindrical interior. As a result, an advantageous shape is supplied for the contacting of the contact bushing and for the contacting of a further contact by the second contact section.

[0019] In a further design, the plug connector is designed in the shape of a sleeve and has a continuous interior with an open front end, wherein the contact bushing has a contact surface, wherein the front end of the contact plug faces the contact surface, wherein the contact plug in particular has at least one side recess. It is possible to insert through the open front end a tool which acts on the contact surface and which can pull the contact plug off of the contact bushing.

[0020] In a further design, the contact plug is manufactured from a punched part which is punched out of a plate and which has been bent into an appropriate shape, wherein side edges of the punched part abut one another at a contact line, the contact line in particular being configured perpendicular to a longitudinal extension of the sleeve-shaped contact plug. In this manner, a stable contact plug is supplied with the aid of a folded punched part.

[0021] In a first design, the contact bushing has a connecting element for an electrical conductor, wherein the contact bushing has a contact opening, wherein the contact opening is delimited by a circumferential contact surface, wherein the contact surface has at least two corners, wherein the contact opening is provided for inserting the contact plug.

[0022] In addition, in a second design, the contact bushing has a connecting element for an electrical conductor, wherein the contact bushing has a contact opening, wherein the contact opening has an inner contact surface delimiting the contact opening (61), wherein at least two recesses are produced in the circumferential contact surface, wherein the contact opening is provided for inserting the contact plug in order to configure a force-fitting connection between the contact plug and the contact surface of the contact bushing.

[0023] The invention is explained in greater detail below on the basis of the figures. In the figures:

Fig. 1 shows a punched part for configuring the contact bushing,

Fig. 2 shows the contact bushing in a first view,

Fig. 3 shows the contact bushing in a second view,

Fig. 4 shows the contact bushing in a third view,

Fig. 5 shows the contact plug in a first perspective view,

Fig. 6 shows the contact plug when being pushed into the contact bushing,

Fig. 7 shows the plug connector, wherein the contact plug is inserted into the contact bushing,

Fig. 8 shows a cross-section through the plug connector of

Fig. 7,

Fig. 9 shows a cross-section through the plug connector of

Fig. 7 with a first tool for releasing the contact plug from the contact bushing,

Fig. 10 shows a cross-section through the plug connector of

Fig. 7 with a second tool for releasing the contact plug from the contact bushing,

Fig. 11 shows a cross-section through the plug connector of

Fig. 7 with a third tool for releasing the contact plug from the contact bushing,

Fig. 12 shows an exploded depiction of a further plug connector;

Fig. 13 shows a mounted plug connector,

Fig. 14 shows a schematic cross-sectional representation through the contact plug and the other contact bushing,

Fig. 15 shows a contact plug which is inserted into the other contact bushing,

Fig. 16 shows a contact bushing as a punched part,

Fig. 17 shows a contact plug as a punched part,

Fig. 18 shows a schematic depiction of contact plugs which are connected with a band,

Figure 19 to 27 show various embodiments of other contact bushings,

Fig. 28 shows a cross-section through a contact plug which is inserted into another contact bushing,

Fig. 29 shows an enlarged cutout of Fig. 28,

Fig. 30 shows a cross-section through a contact plug which is inserted into a further embodiment of a further contact bushing, and

Fig. 31 to 33 show various forms of the contact opening.

[0024] Fig. 1 shows a punched part 1 which is punched out of a plate and which can be folded to make a contact bushing. The punched part 1 is manufactured from an electrically conductive material, for example iron or steel. The punched part 1 has as a connecting element a fixing lug 3 configured substantially rectangularly. The fixing lug 3 is, in a middle section, connected to a first lug 5. The first lug 5 is configured substantially perpendicular to the fixing lug 3. The first lug 5 has a first connecting section 4 which is connected to the fixing lug 3. The first connecting section 4 merges into a first section 6. The first section 6 is configured substantially rectangularly and merges into a second section 7. The second section 7 has one bearing surface 8, 9 each at opposing longitudinal sides. The bearing surfaces 8, 9 project laterally beyond the width of the second section 7. The first and second bearing surface 8, 9 extend by a fixed distance perpendicular to the centre axis 15 beyond the normal width. The second section 7 merges into a third section 10. The third section 10 has one connecting lug 11, 12 each at opposing longitudinal sides. The connecting lugs 11, 12 project laterally beyond the width of the third section 10.

[0025] The first section 6 has a second and third lug 13, 14 respectively at opposing longitudinal sides. The first lug 5 is configured to be mirror-symmetrical relative to a centre axis 15. The second and third lugs 13, 14 are likewise configured to be mirror-symmetrical relative to the centre axis 15. The second lug 13 protrudes, by an intermediate section 16, out of a side surface of the first section 6. The intermediate section 16 merges into a rectangular side section 17. The side section 17 has a recess 18 in an end section.
The side section 17 has a greater width, i.e. a greater longitudinal extension parallel to the centre axis 15, than the intermediate section 16.

[0026] Fig. 2 shows the contact bushing 2 with the fixing lug 3. The fixing lug 3 is formed in a U shape and serves to contact an electrical conductor, wherein the ends of the fixing lug 3 are securely crimped onto the electrical conductor.

[0027] A centre section 19 of the fixing lug 3 defines a first plane. The first lug 5 is, starting from the centre axis 19, bent upwards perpendicularly in the region of the first connecting section 4. The first section 6 is disposed perpendicular to the centre section 19 and is configured substantially plate-shaped in the form of a planar surface. The second section 7 is disposed substantially perpendicular to the first section 6. In addition, the second and third lugs 13, 14 are disposed so as to be bent in the same direction perpendicular to the first section 6. The second and third lugs 13, 14 are oriented to be substantially parallel to one another. The bearing surfaces 8, 9 of the second section 7 bear on side surfaces 20, 21 of the second and third lugs 13, 14 respectively.

[0028] The third section 10 is disposed between the second and third lugs 13, 14 and is oriented substantially parallel to the first section 6. The first connecting lug 11 engages in the recess 18 of the second lug 13. The second connecting lug engages in the recess of the third lug 14. A cage-type contact bushing 2 substantially constructed of three lugs 5, 13, 14 is thus configured. End sections of the second and third lugs 13, 14 are connected to side surfaces of the third section 10 in a form-fitting manner.

[0029] Depending on the embodiment selected, a force-fitting connection or a welded connection, instead of a form-fitting connection, can be provided between the second and third lugs 13, 14 and the third section 10. In this embodiment, it is possible to dispense with the recess 18 and the connecting lugs 11, 12. In this embodiment, the side edges of the third section 10, for example, are welded onto the inner sides of the second and third lugs 13, 14 respectively. In contrast to a force-fitting connection, the form-fitting connection offers the advantage that a sufficient elasticity can be supplied in the event of a high prestressing force within the contact region of the contact bushing in order to guarantee a press fitting of a contact plug with high contact pressure.

[0030] Fig. 3 shows the contact bushing 2 with a view onto a contact opening 22. The contact opening 22 has, perpendicular to an insertion direction, a rectangular cross-section with four corners. The contact opening 22 is delimited on four sides by plate-shaped surfaces which are disposed in pairs perpendicular to one another. The delimiting surfaces are represented by the lugs 13, 14 which are disposed in parallel, and the first and third sections 6, 10 which are disposed in parallel. Furthermore, the contact opening 22 has a floor 23 which is formed by the second section 7 of the first lug 5. The second and third lugs 13, 14 have, at an inner rim 24, a bevel 25 which facilitates an insertion of a contact plug. The bevel 25 is configured tapering towards the floor 23, so that the distance between the second and the third lugs 13, 14 is reduced towards the floor 23. Depending on the embodiment selected, it is possible to dispense with the bevels 25.

[0031] Fig. 4 shows another perspective view of the contact bushing 2. In this case, it can be clearly recognised that a free end 51 of the third section 10 is flush with side surfaces of the second and third lugs 13, 14 in a form-fitting manner.

[0032] Fig. 5 shows, in a perspective depiction, a contact plug 26. The contact plug 26 has a first contact section 27 and a second contact section 28. The first contact section 27 is provided to be introduced into the contact opening 22 of the contact bushing 2. The contact plug 25 is manufactured from an electrically conductive material, for example metal. In the depicted exemplary embodiment, the contact plug 26 is manufactured from a punched part which is punched out of a plate and which has been bent into an appropriate shape, wherein side edges of the punched part abut one another at a contact line 29. The contact line is preferably configured perpendicular to the longitudinal extension of the sleeve-shaped contact plug 26.

[0033] In the depicted embodiment, the first contact section 27 in cross-section perpendicular to the longitudinal extension of the contact plug 26 has a rectangular shape, in particular a square shape which is rounded in the corners. Depending on the design selected, the first contact section 27 in cross-section can also have the shape of a polygon, in particular the shape of a uniform polygon with sides of equal length. In addition, in a further embodiment, the first contact section can also have a circular outer profile, i.e. a round outer profile, and be formed as a hollow cylinder, for example. The outer profile of the contact plug 26 tapers towards a contact end 30. As a result, insertion into the contact opening 22 is facilitated. In addition, the contact end 30 is configured open in the form of an annular profile. The contact plug 26 has an open front end. In the depicted embodiment, the cross-section widens from the first contact section 27 to the second contact section 28, with the outer profile of the contact plug 26 also changing. In a further embodiment, the outer diameter of the first contact section can also be configured to be constant over the length. In addition, the first and second contact sections can also have the same diameters. In the depicted exemplary embodiment, the second contact section 28 substantially has a cylindrical outer profile. Furthermore, the outer diameter of the second contact section 28 is larger than the outer diameter of the first contact section 27. In addition, the contact plug 26 has a first and a second recess 31, 32 respectively at opposing sides.

[0034] Fig. 6 shows the contact bushing 2 and the contact plug 26 during the mounting process in which the contact plug 26 is inserted into the contact opening 22. In the depicted embodiment, in which the first contact section 27 of the contact plug 26 has a rounded rectangular shape, the planar side surfaces of the first contact section 27 are oriented parallel to the planar side surfaces of the contact opening 22. Furthermore, the contact plug 26 is designed in the shape of a sleeve and has a continuous interior 33, in which there is provided a contact sleeve 34 in the region of the second contact section 28. The contact plug 26 is open at both ends. In the first contact section, the interior 33 has the same cross-sectional shape as the outer profile of the first contact section. The second contact section 28 has a cylindrical interior 33, in which the cylindrical contact sleeve 34 is received. The contact sleeve 34 is configured to manufacture an electrically conductive contact to an inserted conductor.

[0035] Fig. 7 shows the plug connector 35 in the mounted state.

[0036] Fig. 8 shows a cross-section through the plug connector 35, with the contact plug 26 being inserted at the front end into the contact opening 22 with the first contact section 27 up to the second section 7. The contact plug 26 is inserted into the contact bushing 2 with a high pressing force. By bearing on the second section 7, a defined mounting position is set. In this manner, the contact plug 26 can be inserted into the end position, i.e. into the bearing on the second section 7 into the contact opening 22, with a high insertion force. Figures 9 to 11 show various tools with which the contact plug 26 can be pulled out from the contact bushing 2. All of these tools 55, 36, 37 function according to the corkscrew principle.

[0037] Fig. 9 shows a first tool 55 which is inserted into the interior 33 of the contact plug 26. The first tool 55 has a pin 38 which rests against the second section 7 by a front end 39. In addition, the first tool 55 has a tightening element 40 which is tightened against the second contact section 28. The tightening element 40 is squeezed outwards by a tightening section 41 of the pin 38 against the inner wall of the interior 33. A pressing connection is thus manufactured between the first tool 35 and the contact plug 26. In addition, the tightening section 41 of the pin 38 has a thread with which the pin 38 can be screwed in along a longitudinal axis of the contact plug 26 deeper into the interior 33 towards the second section 7 by turning an engaging element 48. In this manner, a front end of the pin 38 is prestressed against the second section 7, as a result of which the pin 38 is supported with the thread relative to the tightening element 40. The tightening element 40 is connected to the second contact section 28 via a prestressing. Thus, the contact plug 26 is pulled out of the contact opening 22.

[0038] Fig. 10 shows an embodiment of a second tool 36 which is also provided for pulling the contact plug 26 away from the contact bushing 2. In this embodiment, the pin 38 has lever elements 42 which are pivotably borne at a screw sleeve 46. The screw sleeve 46 is borne on the pin 38 via a thread. After the second tool 36 is inserted into the interior 33, the lever elements 42 project into the recesses 31, 32. The lever elements 42 are configured in the form of angled lever arms pivotably configured on a screw sleeve 44. In addition, the lever elements 42 are connected to the pin 38 via the screw sleeve 46 in such a manner that the screw sleeve 46 and the lever elements 42 are pulled in the direction of the second end 43 of the pin 38 when the pin is turned. The front end 39 of the pin 38 is supported against the second section 7, so that, as a result of the pin 38 turning, the lever elements 42 are removed from the front end 39 and thereby pull the contact plug 26 out of the contact opening 22.

[0039] Fig. 11 shows a further embodiment of a third tool 37, in which the pin 38 has a threaded section 45. A screw sleeve 46 is provided on the threaded section. The screw sleeve 46 has pivotably borne arms 47, which are connected to the screw sleeve 46 in an opposite manner relative to a centre axis of the pin 38. After the third tool 37 is pushed into the interior 33, the arms 47 swing outwards into the first and second recesses 31, 32 respectively. At the second end 43, the pin 38 has an engaging element 48 with which the pin 38 can be made to rotate. When the pin turns, the arms 47 engage in the recesses 31, 32, which means that the turning of the screw sleeve 46 is inhibited. Since the screw sleeve 46 is connected to the threaded section 48 via a thread 48, the screw sleeve 46 is moved in the direction of the second end 43 of the pin 38 through the turning of the pin 38. A pull-away force is thus exerted on the contact plug 26, which means that the contact plug 26 is pulled out of the contact opening 22 by the turning of the pin 38.

[0040] In an angle region 49, the arms 47 are pivotably borne on the screw sleeve, rotatable around an axis of rotation 50. The angle region 49 stretches from an orientation parallel to the centre axis of the pin 38, the arms 47 thereby being directed away from the front end 39, up to a 90° angle with respect to the longitudinal axis of the pin 38, as is depicted in Fig. 11. The arms 47 can thus be oriented parallel to the pin 38 when the pin 38 is inserted, and then tip, for example by gravity, into a 90° angle to the centre axis of the pin 38 when the recesses 31, 32 are reached.

[0041] Depending on the design selected, the recesses 31, 32 can be configured only on the inner wall of the interior 32 or as continuous openings, as depicted in the figures.

[0042] Fig. 12 shows, in an exploded view, a further embodiment of a plug connector. In this embodiment, a further contact bushing 62 is configured in the form of a plate in which another contact opening 61 is produced. The further contact bushing 62 is connected to an electrical conductor, which is not visible and which is encased with an isolation layer 75, via a connecting element, for example in the form of a connecting lug 60. Any other type of connecting element can also be used instead of a connecting lug. The further contact opening 61 has an inner contact surface 63, which delimits the contact opening, the contact surface 63 being configured substantially circularly in cross-section. In the depicted embodiment, several recesses 64 are produced in the contact surface 64. The additional contact opening 61 is provided in order to receive the contact plug 26 in a force-fitting manner. Furthermore, a first housing part 65 is depicted which has an insertion opening 66 for inserting the further contact bushing 62. In addition, the first housing part 65 has a second insertion opening 67. In the depicted exemplary embodiment, the second insertion opening 67 is disposed at a 90° angle to the first insertion opening 66. The first housing part 65 is otherwise configured closed, in order to represent a mechanical and electrical protection for the further contact bushing 62.

[0043] Furthermore, a second housing part 68 is provided which is configured substantially in the shape of a sleeve and which has fixing lugs 69, 70, 71. The fixing lugs 69, 70, 71 are configured to latch into fixing notches in the first housing part 65. In this manner it is possible for the second housing part 68 to be releasably connected to the first housing part 65. The second housing part 68 has a cylindrical interior into which the contact plug 26 is inserted upon mounting. Furthermore, a third housing 72 is provided which substantially has a cylinder shape. The diameter of the third housing part 72 is configured such that the third housing part 72 can be pushed over the second housing part 68 and is able to be releasably connected to the second housing part 68 with the aid of connecting means 73 configured in the form of notches or lugs, for example.

[0044] Fig. 13 shows a mounted state of the plug connector. In this case, three housing parts 65, 68, 72 are connected to one another, and the further contact bushing 62 is inserted into the first housing part 65. The contact plug 26 is disposed in the second housing part 68 and projects into the first housing part 65. In addition, a contact section of the contact plug 26 is inserted into the further contact opening 61.

[0045] Fig. 14 shows a schematic depiction of the contact plug 26 and of the further contact bushing 62 and of the electrical conductor 74. The contact plug 26 has a cylindrical shape, wherein, for example, a contact sleeve 34 can be disposed in a cylindrical interior 33 of the contact plug 26. The contact sleeve 34 can have inwardly projecting spring elements which are oriented parallel to the longitudinal extension of the contact plug 26 and which are bound by a first end to an upper ring and by a second end to a lower ring. The contact sleeve 34 is provided in order to improve an electrical contact between the contact plug 26 and a further contact of a further plug or of a further plug connector. Depending on the embodiment selected, it is also possible to dispense with the contact sleeve 34. In addition, instead of the contact sleeve 34 it is possible to provide a different contact element in order to improve the electrical contact between the contact plug 26 and the further contact. At the upper end, the contact plug 26 has a first contact section 27, which upon mounting is inserted in and through the further contact opening 61. The ring-shaped contact surface 63 can be clearly seen in the depicted cross-sectional depiction of the further contact bushing 62. Recesses 64 are produced on the ring-shaped contact surface 63. The recesses 64 serve to facilitate a press fit when the contact plug 26 is inserted. For example, the recesses 64 extend in the insertion direction of the contact plug over the entire width of the contact surface 63. In addition it can be seen that the further contact bushing 62 substantially has the shape of a plate 76, with a ring-shaped collar 77 being configured on an upper side of the plate 76, with the collar surrounding the further contact opening 61 and forming at least a part of the contact surface 63. In this manner, the width, configured in the insertion direction of the contact plug 26, of the contact surface 63 is enlarged. Depending on the embodiment selected, it is also possible to dispense with the collar 77. In the exemplary embodiment depicted, the recesses 64 are disposed distributed uniformly around the radius of the contact surface 63. Depending on the embodiment selected, the recesses 64 can also have other cross-sections, shapes and/or sizes.

[0046] In a schematic perspective depiction, Fig. 15 shows the contact plug 26 which is inserted into the other contact bushing 62. Thus the mounted state according to Fig. 13 is depicted.

[0047] In a schematic depiction, Fig. 16 shows the further contact bushing 62 which is configured in the form of a punched part and which is connected to a punched strip 78. The punched strip 78 and the further contact bushing 62 are configured as one piece. Several undepicted further contact bushings 62 are connected to the punched strip, so that the contact bushings 62 can be supplied in a manner which is practical for a production line.

[0048] Fig. 17 shows the contact bushing 26 which is also configured in the form of a punched part and which is connected to a second punched strip 79. Several undepicted contact plugs 26 are configured with the second punched strip 79. The contact plugs can thus also be made available for manufacture in the form of a rolled-up punched strip.

[0049] Fig. 18 shows a corresponding schematic depiction of a second punched strip 79 with several contact plugs 26 which are supplied as a rolled-up punched strip for manufacture with the aid of an automated method.

[0050] Figures 19 to 26 show various embodiments of a further contact bushing 62.

[0051] Fig. 19 shows a simple embodiment of a further contact bushing 62 substantially configured as a plate 76. The further contact opening 61 is produced in the plate 76. By way of example, both the panel 76 and the further contact opening 61 are produced in the form of a punching process from a plate-shaped, electrically conductive material, in particular sheet metal. In this design, the contact surface 63 is configured as a polygon formed by several planar side surfaces 91,92,93,94, wherein the side surfaces 91,92,93,94 are adjacent to one another in corner regions and form recesses 64 in the corner regions. In this manner, 16 recesses 64 are configured uniformly distributed in a circumferential contact surface 63 which laterally surrounds the further contact opening 61. In a further embodiment, the recesses 64 can be produced for example in the form of slots in a circularly circumferential contact surface 63, which for example have in the plane of the contact surface 63 a cross-section in the form of a corner which tapers at a fixed angle.

[0052] Fig. 20 shows a further embodiment of the further contact bushing 62. In this case, the further contact bushing 62 has the form of a plate 76 in which the further contact opening 61 is produced. Furthermore, a collar 77 is configured adjacent to the further contact opening 61. In this embodiment, the collar 77 consists of four part-ring-shaped collar sections disposed spaced apart from one another. One recess 82 respectively is disposed between two collar sections 88, 89, 80, 81 respectively. In this embodiment, the contact surface 63 is formed by an inner surface in the region of the plate and by inner surfaces of the collar sections 88, 89, 80, 81. Depending on the embodiment selected, recesses 64 can also be provided both in the region of the plate 76 in the contact surface 63 and on the inner surfaces of the collar sections 88, 89, 80, 81.

[0053] Fig. 21 shows a further embodiment configured in accordance with the embodiment of Fig. 19, but additionally has a collar 77. The collar 77 likewise has several preferably planar side surfaces 91,92,93,94 adjacent to one another in corner regions. The corner regions form the recess 64. An inner side of the collar forms part of the contact surface 63. In a further embodiment, the recesses 64 can be produced for example in the form of slots in a circularly circumferential contact surface 63.

[0054] Fig. 22 shows a further embodiment configured substantially in accordance with the embodiment of Fig. 21. In this design, the contact surface 63 is configured as a polygon formed by several planar side surfaces 91,92,93,94, wherein the side surfaces 91,92,93,94 are adjacent to one another in corner regions and form the recesses 64 in the corner regions. In this manner, 10 recesses 64 are configured uniformly distributed in the depicted exemplary embodiment in a circumferential contact surface 63 which laterally surrounds the further contact opening 61. In Fig. 22, it is also possible to see a preferred embodiment of the recesses 64 which is also configured in the form of adjacent side surfaces 91,92,93,94, in particular in the form of planar side surfaces. In a further embodiment, the recesses 64 can be produced for example in the form of slots in a circularly circumferential contact surface 63.

[0055] Fig. 23 shows the underside of the further contact bushing 62 from Fig. 22. In this embodiment, a rounded area is configured in the entry region 83 of the further contact opening 61, with the diameter of the contact opening tapering in the insertion direction of the contact plug 26. For example, this can also be generated by a punching process which is used to introduce the further contact opening 61. Thus the entry region 83 tapers in the direction of the further contact opening 61 starting from a surface of the plate 76. The insertion of the contact plug 26 is improved as a result.

[0056] Fig. 24 shows a further embodiment of the further contact bushing 62 which has a further contact opening 61, wherein in addition a collar 77 in the form of four collar sections 88, 89, 80, 81 is configured. In this embodiment, in contrast to the embodiment of Fig. 20, the spacing between the collar sections 88, 89, 80, 81 is configured to be larger. The further recesses 82 between the collar sections are thus selected to be larger. In addition, recesses 64 are introduced into the contact surface 63 between the collar sections 88, 89, 80, 81. Therefore, the contact surface is substantially formed only by the inner surfaces of the collar sections 88, 89, 80, 81 and of the surface regions of the plate 76 which are situated on the same axis.

[0057] Fig. 25 shows a rear side of the further contact bushing 62 from Fig. 24. In this embodiment too, a conically tapering entry region 83 can be configured on the further contact opening 61.

[0058] Fig. 26 shows a further embodiment of a further contact bushing 62 which substantially corresponds to the embodiment of Fig. 19, wherein however only 10 recesses 64 are disposed in the contact surface 63 instead of 16 recesses 64 in Fig. 19. In this design, the contact surface 63 is configured as a polygon formed by several side surfaces 91,92,93,94,95 wherein the side surfaces 91,92,93,94,95 are adjacent to one another in corner regions and form the recesses 64 in the corner regions. In this manner, 10 recesses 64 are configured uniformly distributed in a circumferential contact surface 63 which laterally surrounds the further contact opening 61. In a further embodiment, the recesses 64 can be produced for example in the form of slots in a circularly circumferential contact surface 63.

[0059] Fig. 27 shows a plan view onto the further contact bushing 62 from Fig. 26. The shape of the recesses 64 can be clearly seen here. In the depicted exemplary embodiment, the recesses 64 are configured in the form of straight side surfaces which converge in a corner region 84. Depending on the embodiment selected, it is also possible for bent, in particular convex, surfaces to be used instead of straight surfaces 91,92,93,94,95. In addition, a rounded region can also be provided instead of a corner region 84.

[0060] By way of example, the further contact opening 61 can, in particular in the embodiments from figures 19 to 27, in cross-section, have the shape of a regular polygon. In this case, the recesses 64 are formed by the corners of the polygon. For example, the further contact opening 61 in cross-section can have the shape of a triangle, quadrilateral, decagon or hexadecagon. The greater the number of corners, the smaller the free space for receiving material, but the free spaces are all the more equally distributed on the contact surface 63.

[0061] In a schematic depiction, Fig. 28 shows a partial cutout of a contact plug 26 which is inserted into a further contact bushing 62. The further contact bushing 62 substantially has the form from Fig. 21. In this case, free spaces 85 are depicted in the region of the recesses 64 of the contact surface 63 between the contact surface 63 and the outer surface of the contact plug 26. In this design, the contact surface 63 can be configured as a polygon formed by several side surfaces 91,92,93,94,95 wherein the side surfaces 91,92,93,94,95 are adjacent one another in corner regions and form the recesses 64 in the corner regions. In this manner, recesses 64 are introduced uniformly distributed in a circumferential contact surface 63 which laterally surrounds the further contact opening 61. In a further embodiment, the recesses 64 can be produced for example in the form of slots in a circularly circumferential contact surface 63.

[0062] Fig. 29 shows an enlarged cutout depiction from Fig. 28. The free spaces 85 are configured in different sizes depending on the matching of the outer diameter of the contact plug 26 to the inner diameter of the further contact opening 61. The free spaces serve to enable a significant press fit with low mounting forces. As a result, the surface contact between the contact surface 63 and the contact plug 26 is improved. As a result, higher currents can be transmitted.

[0063] In a schematic depiction, Fig. 30 shows a partial cutout of a further contact bushing 62, which depicts a collar 77 with collar sections 88, 89, 80, 81 and further recesses 82 configured between them. The further contact bushing 62 substantially corresponds to the embodiment of Fig. 20. In the case of this embodiment, the further recesses 82 enable an easier outward bending of the collar sections 88, 89, 80, 81 in contrast to a collar 77 without further recesses.

[0064] For a suitably high press fit, the outer diameter of the contact plug 26 is selected to be larger than the inner diameter of the further contact opening 61.

[0065] Depending on the embodiment selected, the contact plug 26 has a slot at least in the first contact section 27, which is inserted into the further contact opening 61. Depending on the embodiment selected, the slot 86 can extend over the entire length of the contact plug 26, as depicted in Fig. 12. By way of example, the slot 86 can have a slot width of 1 to 5 mm. By providing the slot 86 it is possible to achieve an easier deformation of the outer periphery of the contact plug 26 when it is inserted into the further contact opening 61.

[0066] Fig. 31 shows a schematic partial cutout of a contact bushing 2 with a contact opening 61 which in cross-section has the shape of a triangle delimited by three planar side surfaces 91,92,93, wherein the three side surfaces 91,92,93 merge into one another in three corner regions 84 with the same angles. In addition, the three side surfaces are of equal length. Depending on the design selected, the side surfaces can also be configured to be convexly bent in the image plane. Perpendicular to the image plane, side surfaces can be disposed at a 90° angle to the image plane.

[0067] Fig. 32 shows a schematic partial cutout of a contact bushing 2 with a contact opening 61 which in cross-section has the shape of a square delimited by four planar side surfaces 91,92,93,94 wherein the four side surfaces 91,92,93,94 merge into one another in four corner regions 84 at a 90° angle respectively. In addition, the side surfaces are of equal length. Depending on the design selected, the side surfaces can also be configured to be convexly bent in the image plane. Perpendicular to the image plane, the side surfaces can be disposed at a 90° angle to the image plane.

[0068] Fig. 33 shows a schematic partial cutout of a contact bushing 2 with a contact opening 61 which in cross-section has the shape of a pentagon delimited by five planar side surfaces 91, 92, 93, 94, 95 wherein the side surfaces 91, 92, 93, 94, 95 merge into one another in five corner regions 84 with the same angles. In addition, the side surfaces are of equal length. Furthermore, the contact opening 61 can be configured with a cross-section surface in the form of any polygon, and in particular with side surfaces of equal length and with identical corner angles. Depending on the design selected, the side surfaces can also be configured to be convexly bent in the image plane. Perpendicular to the image plane, side surfaces can be disposed at a 90° angle to the image plane.

[0069] Depending on the embodiment selected, the shape of the cross-section of the first contact section of the contact plug can be adapted to the shape of the cross-section of the contact opening of the contact bushing, and in particular can be identical. In addition, the shape of the cross-section of the contact opening and the shape of the cross-section of the first contact section may also differ.

List of reference numbers

[0070] 

1

punched part

2

contact bushing

3

fixing lug

4

first connecting section

5

first lug

6

first section

7

second section

8

first bearing surface

9

second bearing surface

10

third section

11

first connecting lug

12

second connecting lug

13

second lug

14

third lug

15

centre axis

16

intermediate section

17

side section

18

recess

19

centre section

20

first side surface

21

second side surface

22

contact opening

23

floor

24

inner rim

25

bevel

26

contact plug

27

first contact section

28

second contact section

29

contact line

30

contact end

31

first recess

32

second recess

33

interior

34

contact sleeve

35

plug connector

36

second tool

37

third tool

38

pin

39

front end

40

tightening element

41

tightening section

42

lever element

43

second end

45

threaded section

46

screw sleeve

47

arms

48

engaging element

49

angle region

50

axis of rotation

51

free end

55

first tool

60

connecting lug

61

further contact opening

62

further contact bushing

63

contact surface

64

recess

65

first housing part

66

insertion opening

67

second insertion opening

68

second housing part

69

first fixing lug

70

second fixing lug

71

third fixing lug

72

third housing part

73

connecting means

74

electrical conductor

75

isolation

76

plate

77

collar

78

punched strip

79

second punched strip

80

third collar section

81

fourth collar section

82

further recess

83

entry region

84

corner region

85

free space

86

slot

88

first collar section

89

second collar section

91

1st side surface

92

2nd side surface

93

3rd side surface

94

4th side surface

95

5th side surface

Claims

1. A plug connector (35) with a contact bushing (2, 62) and a contact plug (26), wherein the contact bushing (2, 62) has a connecting element (3,60) for an electrical conductor, wherein the contact bushing (2,62) has a contact opening (22,61), wherein the contact opening (22,61) is delimited by a contact surface (6,10,13,14,63), wherein the contact surface (6,10,13,14,63) has at least two corners (84), wherein the contact opening (22,61) is provided for inserting the contact plug (26),
the contact plug (26) being inserted into the contact opening (22,61), and a force-fitting connection being configured between the contact plug (26) with the contact surface (6,10,13,14,63) of the contact bushing (62).

2. The plug connector according to Claim 1, wherein the corners (84) are produced in the contact surface (63) in the form of recesses (64), wherein in particular several recesses (64) are produced in the contact surface (63), and wherein the recesses (64) are distributed uniformly around the contact opening (61).

3. The plug connector according to Claim 2, wherein the corner is formed by two side surfaces (91,92,93,94,95) which are adjacent one another in the corner (84).

4. The plug connector according to any one of the preceding claims, wherein the contact surface (63) is formed by at least three side surfaces (91,92,93) which in predetermined corners (84) are adjacent to one another at fixed angles.

5. The plug connector according to any one of the preceding claims, wherein the contact opening (61) is produced via a punching process.

6. The plug connector according to any one of the preceding claims, wherein the contact opening (61) is produced in a plate (76), wherein a collar (77), which projects away from the plate (76) at a fixed angle, in particular at a right angle from the plate (76), is configured around the contact opening (61), wherein the contact surface (63) with the corners (84) extends into an inside of the collar (77).

7. The plug connector according to Claim 6, wherein the collar (77) has recesses (64) and in particular the contact surface (63) has recesses (64).

8. The plug connector according to Claim 6, wherein recesses (64) are produced only in the collar (77).

9. The plug connector according to Claim 7, wherein the recesses (64) extend through an entire thickness of the plate (76), and wherein in particular the recesses (64) extend through a total width of the collar (77).

10. The plug connector according to any one of the preceding claims, wherein the contact plug (26) is configured in the shape of a sleeve and in particular has an open front end (30).

11. The plug connector according to Claim 10, wherein the contact plug (26), at least in one connection section, which plugs into the contact bushing (62), has a slot (86) which is disposed along a longitudinal axis of the contact plug (26).

12. The plug connector according to Claim 10 or 11, wherein the contact plug (26) is manufactured from a punched part.

13. The plug connector according to any one of the preceding claims, wherein the contact opening (61) in cross-section has the shape of a polygon, in particular the shape of a regular polygon.

14. The plug connector according to any one of Claims 6 to 13, wherein the collar (77) in cross-section has an inner profile which has the form of a polygon.

15. The plug connector according to any one of the preceding claims, wherein the contact plug (26) has a circular outer profile.

16. The plug connector according to any one of Claims 1 to 14, wherein the contact plug (26) has a polygonal, in particular rectangular or square outer profile.

17. The plug connector according to any one of Claims 1-4, 10-14, or 16, wherein the contact bushing (2) is formed by a folded plate, in particular a folded punched part (1), wherein the contact bushing (2) has four side surfaces (6,10,13,14) and a floor surface (23), wherein side surfaces are adjacent to one another via corners.

18. The plug connector according to any one of Claims 16 to 18, wherein the contact plug (26) has a first contact section (27) and a second contact section (28), wherein the first contact section (27) is provided for introduction into the contact opening (22) of the contact bushing (2), wherein the first contact section (27) in cross-section perpendicular to the longitudinal extension of the contact plug (26) has a polygonal shape which is rounded in corner regions, in particular a rectangular shape, and wherein the second contact section (28) has a cylindrical interior (33).

19. The plug connector according to any one of Claims 15 to 18, wherein the contact plug (26) is designed in the shape of a sleeve and has a continuous interior (33) with an open front end, wherein the contact bushing (2) has a contact surface (7,23), wherein the front end (39) of the contact plug (26) faces the contact surface (7,23), and wherein the contact plug (26) in particular has at least one side recess (31,32).

20. The plug connector according to any one of Claims 15 to 19, wherein the contact plug (26) is manufactured from a punched part which is punched out of a plate and which has been bent into an appropriate shape, wherein side edges of the punched part abut one another at a contact line (29), the contact line in particular being configured perpendicular to a longitudinal extension of the sleeve-shaped contact plug (26).

21. A contact bushing (2,62) for a contact plug (26), wherein the contact bushing (2,62) has a connecting element (3, 60) for an electrical conductor, wherein the contact bushing (2,62) has a contact opening (22,61), wherein the contact opening (22,61) is delimited by a circumferential contact surface (63), wherein the contact surface (2,63) has at least two corners (84), wherein the contact opening (61) is provided for inserting the contact plug (26).

22. A contact bushing (62) for a contact plug (26), wherein the contact bushing (62) has a connecting element (60) for an electrical conductor, wherein the contact bushing (62) has a contact opening (61), wherein the contact opening (61) has an inner contact surface (63) delimiting the contact opening (61), wherein at least two recesses (64) are produced in the circumferential contact surface (63), wherein the contact opening (61) is provided for inserting the contact plug (26) in order to configure a force-fitting connection between the contact plug (26) and the contact surface (63) of the contact bushing (62).

Drawing