Zurichstr. 72, 8306 Briittisellen, Schweiz

Connector, connector assembly, and a tool and method for assembling the connector assembly

The present invention relates to a plug connector for a flexible conductor foil. Moreover, the present invention relates to a plug connector assembly, which has the plug connector, as well as a tool and a method for assembling the plug connector assembly.

Prior Art

Flexible conductor foils with foil-insulated conductors are today used in different areas of entertainment and consumer electronics, but also in vehicle construction. Conductor foils in particular come into use there where a very flexible conductor structure is desired, with the lowest possible weight and restricted spatial requirements. Flexible conductor foils allow an ordered parallel routing of a plurality of separated conductor paths, wherein larger bends are also possible and parts can thus be electrically conductively connected with each other, that are arranged in an only very restricted installation space. In particular in vehicle construction, conductor foils of this type must also be able to withstand large mechanical influences, for example such as vibrations.

Thus, in particular the contacting of the individual foil-insulated conductors gains a particular significance. Particularly in vehicle construction, this contacting has to be configured to be secure and resistant to external mechanical influences, but also to temperature influences and environmental influences of different types.

DE 10 2015 100 401 B4 describes a plug connector for flexible conductor foils having foil- insulated conductors having a plug connector housing in which at least one plug contact element is arranged. In one connection area, blades that are electrically conductively connected with the at least one plug contact element can penetrate and fix at least one foil- insulated conductor during the production of an electric contact. The plug connector housing comprises two housing parts that can slide into each other. The first housing part stores the blades and the at least one plug contact element that is electrically conductively connected with this. The second housing part takes up the flexible conductor foil and stores this. Moreover, the second housing part has at least one blade receiver that is matched to the blades, the boundary faces of which are formed in such a way that at least some of the blades are bent in the direction of the foil-insulated conductor during the pushing-in of the two housing parts. By bending the blades, a pressure is exerted on the contact faces between the blades and conductor foil, so that the electric contact faces are enlarged. Simultaneously, the blades are kept under a certain tension in the plug connector housing. In this way, an electrically good and gas-tight contacting can be achieved in the plug connector.

With the blades being bent at the point at which they protrude from a male connector and thus being angled across their entire length towards the male connector, at the contact point between the conductor foil and blades, a constant mechanical load is however exerted on the conductor foil. Particularly, if the plug connector is continually exposed to vibrations during its use in automotive engineering, this could lead to damage to the conductor foil. The pressure that is exerted on the boundary faces of the second housing part via the bent blades could additionally cause a detachment of the first housing part from the second housing part, due to the impact of vibrations.

It is therefore an object of the present invention to provide a plug connector and a plug connector assembly that creates an electrically outstanding and gas-tight contacting of plug contacts and can thereby also withstand high mechanical loads. A further aim of the present invention is to provide a tool and a method in order to allow an assembling of the plug connector assembly in one work step, so that the assembling can be carried out automatedly. Disclosure of the invention

These objects are solved in a first aspect of the invention by a plug connector for a flexible conductor foil with foil-insulated conductors. This plug connector has a first housing part and a second housing part. The first housing part has at least one plug contact element with which several blades are electrically conductively connected. The second housing part has a receiving area for the conductor foil. The two housing parts are pushed into each other.

At least one first ridge of the second housing part is configured to press a conductor foil that is arranged in the receiving area in the direction of the blades during the pushing-in of the housing parts. This first ridge can also be referred to as the first rib. The first ridge is configured to engage in a tight fit with a blade, if a first area of a first blade is bent in the direction of the first ridge. Especially, the first ridge has a surface curvature. While the first area is intended to be bent, the first blade additionally has a second area, which is intended to not be bent. The first blade can intersect a conductor of the flexible conductor foil so that it comes to rest on the second area of the first blade. It is thereby fixed in this position by the first ridge, so that it can no longer move back in the direction of the first area of the first blade. Since the first area of the first blade is bent in such a way that it lies in a tight fit on the first ridge, the first ridge is also prevented from moving away from the conductor foil so that this could leave its position. Even if the plug connector is exposed to high mechanical loads, the bent area of the first blade securely holds the first ridge in its position and this, in its turn, secures the position of the conductor foil. An occurrence of leaks in the plug connector is thus reliably prevented. Since the second area of the first blade is not bent, no forces act on the contact area between the second area of the first blade and the conductor foil when at rest. Vibrations can thus also be tolerated, without the first blade undesirably carving further into the flexible conductor foil, which could lead to a degradation of the electrical contacting by the end of the vibrations.

It is preferred that the first housing part has at least one first blade and at least one second blade. The first blade is longer than the second blade. While the first blade is intended to be bent in its first area in order to engage in a tight fit with a first ridge, the second blade solely serves to intersect the conductor foil and to electrically contact it. By arranging several first blades and second blades in a row behind each other, a conductor of the conductor foil can be intersected at several places, in order to ensure such a redundant electrical contacting of the conductor with the plug contact element.

More preferably, the arrangement of the blades in a row is thereby effected so that that the row comprises two first blades and at least two second blades. Most preferably, several second blades are arranged between two first blades. By means of the arrangement of the first blades on the two ends of the row, they can achieve an especially consistent mechanical connection between the first housing part and the second housing part. In this case it is furthermore preferred that the first area of every first blade is bent in the direction of a second blade. This allows the bending of the first blade, without creating a need for an additional space along the first row for this. Thus, advantage is taken of the fact that the first blades can be bent over the second blades, since they are longer than the second blades.

In one embodiment of the invention there are two first blades and two second blades in each row. In another embodiment of the invention there are two first blades and three second blades in each row.

Every first ridge is, to this end, preferably arranged between a first blade and a second blade. If the first area of a first blade is then bent in the direction of a second blade, it comes to rest on the first ridge and engages in a tight fit with this. It thereby presses on this from the side of the first ridge that faces the second housing part and thus reliably prevents the first ridge moving away from the first housing part and with it from the conductor foil.

It is furthermore preferred that the second housing part has at least one second ridge, which can also be referred to as the second rib. The second ridge is arranged between two blades. Especially, the second ridge is arranged between two second blades. It is configured to press the conductor foil that is arranged in the receiving area in the direction of the blades during the pushing-in of the housing parts. Thus, every second ridge thereby supports the first ridges to fix the conductor foil in its position.

All first ridges and all potentially available second ridges are preferably configured as sliding surfaces for the blades.

The first area of the first blade preferably has a smaller width than its second area. Due to the change in width of the first blade and the pre-centring in the first area that is connected with this, a lasting, stable contacting of the conductor in the second area can be ensured. Furthermore, this causes a strain relief via the geometry located at the contact, which causes a clamping of the foil conductor in the mounted state of the plug connector. Simultaneously, a bending of the first blade in its first area is simplified by the fact that its width is only small. In principle, a geometry with two different widths can also be provided for the two blades, in order to improve the contacting in the area of the higher width. A bending of the two blades in the narrower area is, however, not provided. The transition from one width to the next width can be carried out both as a step and as a continual transition. In principle, still further areas with a still larger width can also be provided in addition to the first two areas. The width of the areas thus increases steadily from the first area, which faces the second housing part, up to the further areas. Preferably, the second housing part has an opening above every first ridge on its side that faces away from the first housing part. Such an opening can in particular be created as an opening that extends across several ridges. The opening makes it possible to exert a force on the first blades of the first housing part from the side of the second housing part that faces away from the first housing part, by means of a tool, in order to bend these blades.

In a second aspect of the invention, a plug connector assembly is provided which has a plug connector according to the first aspect of the invention as well as a flexible conductor foil with foil-insulated conductors. The width of the conductor foil in particular essentially corresponds to the width of the receiving area. The conductor foil is arranged in the receiving area of the plug connector in such a way that it is intersected by at least one blade. In this case, this is at least one first blade. If, however, the plug connector also has second blades, the conductor foil is also intersected by this. The conductor foil is pressed into the plug connector assembly in the direction of the first housing part by at least one first ridge. If the plug connector has second ridges, then the conductor foil is also pressed in the direction of the first housing part by these. A first blade lies in a tight fit on every first ridge and presses this in the direction of the conductor foil.

The first blade is preferably bent in its first area by at least 80°. Particularly preferably, it is bent by 90° and thus essentially runs parallel to one of the sides of the second housing part that faces the first housing part.

If the plug connector has at least one first blade and at least one second blade, then the end of the bent first blade is in particular positioned over the end of a second blade.

It is furthermore preferred that the first blade is essentially bent in a circular arc in its first area. This embodiment of the plug connector assembly can be achieved by a gentle bending of the first blade by a suitable tool, without the danger hereby existing that the first blade could break. In a third aspect of the invention, a tool for assembling the plug connector assembly is provided. This has at least one concave bending area that is configured to engage in an opening of the plug connector. The bending area in particular protrudes from a main body of the tool. Through the opening, the bending area can come into contact with a first blade of the plug connector. The bending area has a surface curvature that corresponds to a surface curvature of a first ridge of the plug connector. By the bending area bending in such a way, due to pressure on the first blade of its first area, that it assumes the surface curvature of the bending area, a tight fit is produced between the first blade and a first ridge of the plug connector. When there are two first blades in a row behind each other the tips of the first blades point to each other in one embodiment of the invention. In another embodiment of the invention the tips point away from each other. In yet another embodiment of the invention the tips point in the same direction.

Preferably the tip of each bent first blade is arranged above the tip of a second blade.

In principle, it is possible for all first ridges that can be reached through a common opening in the second housing part of the plug connector to provide a single collective concave bending area. However, for every first ridge of the plug connector, a separate concave bending area of the tool is preferably provided, in order to enable an especially precise bending of the first blades.

A fourth aspect of the invention relates to a method for assembling the plug connector assembly. Initially, a first housing part and a second housing part of the plug connector are provided. These are thereby not yet pushed into each other so far that blades of the first housing part would protrude into the receiving area of the second housing part. Further to this, a flexible conductor foil with foil-isolated conductors is inserted into the receiving area of the second housing part. The conductor foil and plug connector should thereby have been selected in such a way that every conductor of the conductor foil exclusively comes to rest over blades which are each electrically connected with exactly one plug contact element. Following this, the housing parts are pushed into each other. At least one first ridge and optionally also two ridges of the plug connector thereby press the conductor foil in the direction of the at least one blade, so that the conductor foil is ultimately intersected by the blade. In order to fix the two housing parts and the conductor foil in this position, a first area of the first blade is bent in the direction of the first ridge, until the first blade engages in a tight fit with the first ridge.

This bending of the first blade can in particular occur by means of the tool according to the second aspect of the invention.

Even if it is principally possible to push the housing parts into each other at first and only then to bend the first areas of all the first blades, it is however preferred that the pushing-in and the bending are carried out simultaneously. The number of method steps is thus decreased, which simplifies an automation of the method. The simultaneous pushing-in and bending can in particular be achieved in that the tool according to the third aspect of the invention is already engaged with the plug connector, before the housing parts are pushed into each other. During the pushing-in, the first blades then first intersect the conductor foil, subsequently meet on the bending area of the tool and are bent until the bending process is stopped by the tight fit between first blade and first ridge. During the bending process, both housing parts continuously move towards each other, so that potentially available second blades, which are shorter than the first blades, can intersect the conductor foil during the bending process.

Brief description of the drawings

Exemplary embodiments of the invention are represented in the drawings and are described in more detail in the following description.

Fig. 1a shows components of a plug connector assembly according to an exemplary embodiment of the invention in a first assembly step in an isometric view.

Fig. 1 b shows components of a plug connector assembly according to an exemplary embodiment of the invention in a first assembly step in a cutaway isometric view.

Fig. 1c shows components of a plug connector assembly according to an exemplary embodiment of the invention in a first assembly step in a cutaway side view.

Fig. 2a shows a plug connector assembly according to an exemplary embodiment of the invention in a second assembly step in an isometric view.

Fig. 2b shows a plug connector assembly according to an exemplary embodiment of the invention in a second assembly step in a cutaway isometric view.

Fig. 2c shows a plug connector assembly according to an exemplary embodiment of the invention in a second assembly step in a cutaway side view.

Fig. 3a shows a plug connector assembly according to an exemplary embodiment of the invention in a third assembly step in an isometric view.

Fig. 3b shows a plug connector assembly according to an exemplary embodiment of the invention in a third assembly step in a cutaway isometric view.

Fig. 3c shows a plug connector assembly according to an exemplary embodiment of the invention in a third assembly step in a cutaway side view.

Fig. 4 shows an exemplary embodiment of a tool according to the invention. Fig. 5 shows another exemplary embodiment of a tool according to the invention.

Fig. 6a shows a tool and a plug connector assembly according to an exemplary embodiment of the invention in a second assembly step in an isometric view.

Fig. 6b shows a tool and a plug connector assembly according to an exemplary embodiment of the invention in a second assembly step in a cutaway isometric view.

Fig 6c shows a tool and a plug connector assembly according to an exemplary embodiment of the invention in a second assembly step in a cutaway side view.

Fig 7a shows a tool and a plug connector assembly according to an exemplary embodiment of the invention in a third assembly step in an isometric view.

Fig. 7b shows a tool and a plug connector assembly according to an exemplary embodiment of the invention in a third assembly step in a cutaway isometric view.

Fig. 7c shows a tool and a plug connector assembly according to an exemplary embodiment of the invention in a cutaway side view.

Fig. 8 shows a plug connector assembly according to another exemplary embodiment of the invention in a second assembly step in a cutaway side view.

Fig. 9 shows a plug connector assembly according to another exemplary embodiment of the invention in a third assembly step in a cutaway side view.

Fig. 10 shows a plug connector assembly according to another exemplary embodiment of the invention in a second assembly step in a cutaway side view.

Fig. 11 shows a plug connector assembly according to another exemplary embodiment of the invention in a third assembly step in a cutaway side view.

Fig. 12 shows a plug connector assembly according to another exemplary embodiment of the invention in a second assembly step in a cutaway side view.

Fig. 13 shows a plug connector assembly according to another exemplary embodiment of the invention in a third assembly step in a cutaway side view. Fig. 14 shows a plug connector assembly according to another exemplary embodiment of the invention in a second assembly step in a cutaway side view.

Fig. 15 shows a plug connector assembly according to another exemplary embodiment of the invention in a third assembly step in a cutaway side view.

Fig. 16 shows a plug connector assembly according to another exemplary embodiment of the invention in a second assembly step in a cutaway side view.

Fig. 17 shows a plug connector assembly according to another exemplary embodiment of the invention in a third assembly step in a cutaway side view.

Exemplary embodiments of the invention

In Figs. 1a to 1c, a first assembly step of a plug connector assembly according to a first exemplary embodiment of the invention is shown. A plug connector 10 and a flat flexible conductor foil 20 with foil-insulated conductors are provided. The plug connector 10 has a first housing part 30 and a second housing part 40. Several plug contact elements 31 , which are configured as spring elements, are arranged in the first housing part 30. Every plug contact element 31 is electrically conductively connected with each two first blades 33 and three second blades 34 that are arranged between the two first blades 33 over a row 32 of blades, which is configured as a cutting edge. The first blades 33 are longer than the second blades 34. Each of the blades 33, 34 respectively has a first area 331, 341, which faces away from the row 32, and a second area 332, 342, that faces towards the row 32. Every first area 331, 341 is narrower than the respective second area 332, 342. The second housing part 40 has a receiving area 41 for the conductor foil 20. This receiving area is widened towards the outside of the plug connector 10 in a funnel shape, in order to facilitate the insertion of the conductor foil 20. Two first ridges 42 are arranged in such a way that they each come to rest between a first blade 33 and a second blade 34 during the pushing-in of the two housing parts 30, 40. On their sides that face away from the first housing part 30, they each have a face, the contour of which is curved in a circular arc from the first blade 33 to the second blade 34. Furthermore, the second housing part 40 has two second ridges 43. These are arranged in such a way that they each come to rest between two second blades 34 during the pushing-in of the housing parts 30, 40. Two openings 44 in the top of the second housing part 40 respectively enable access to a row of first ridges 42, which runs perpendicular to a row 32 of blades 33, 34. Every opening 44 thus also enables access to the first blades 32, which respectively run along the first ridges 42 during the pushing-in of the two housing parts 30, 40. In a second assembly step, which is shown in Figs. 2a to 2c, the conductor foil 20 is pushed into the receiving area 41 of the plug connector 10, so that it is mounted in this. Every conductor of the conductor foil 20 thereby comes to rest over a row 32 of blades 33, 34.

In Figs. 3a to 3c it is shown how the two housing parts 30, 40 are pushed together in a third assembly step. The first ridge 42 and second ridge 43 thereby press the conductor foil 20 onto the blades 33, 34, which firstly intersect the conductor foil with their first areas 331 , 341 and then with their second areas 332, 342. Finally, the ridges 42, 43 fix the conductor foil 20 in its intended final position. The first areas 331 of the first blades 33 are bent in a circular arc by 90° in the direction of their respective first ridge 42, until they come to rest in a tight fit on the curved face of the first ridge 42. The tips of both bent first blades 33 point to each other. It is thus no longer possible to move the two housing parts 30, 40 out of each other. A loosening of the ridges 42, 43 from the conductor foil 20 is thereby prevented, so that the plug connector 10 engages in a lasting, gas-tight connection with the conductor foil 20.

A first exemplary embodiment of a tool 50 for bending the first area 331 of the first blade 33 is shown in Fig. 4. It has two concave bending areas 51 with circular-arc contours, which protrude from the main body of the tool 50. These correspond to the shape in which the first areas 331 of the first blades 33 should be bent, and also match with the surface curvature of the first ridge 42. The tool 50 is designed in such a way that it can be mounted on the second housing part 40. Every bending area 51 thus engages in one of the openings 44. In this way, the tool can exert a force on the first areas 331 of the first blades 33 that protrude over the first ridge 42, and bend these in the direction of the first ridge 42.

A second exemplary embodiment of the tool 50 according to the invention is shown in Fig. 5. This has a separate bending area 51 for every first blade 33 of the plug connector 10. All bending areas 51 which are intended to engage in one of the two openings 44 of the second housing part 40 are designed as concave recesses in a shared support 52, which protrudes from the main body of the tool 50. During placement of the tool 50 on the second housing part 40, every support 52 engages in one of these openings 44.

In one exemplary embodiment of the assembly method, the assembly steps shown in Figs. 1 a to 3c are carried out first, and one of the tools according to the invention is then placed on the second housing part 40, in order to bend the first areas 331 of the first blades 33 in such a way that they take on the shape shown in Figs. 3b and 3c. In a second exemplary embodiment of the assembly method, the tool 50 is already placed on the second housing part 40 in the first assembly step or in the second assembly step. In Figs. 6a to 6c it is shown how the second assembly step proceeds in this case, and in Figs. 7a to 7c it is shown how the third assembly step proceeds in this case. In the third assembly step, the first areas 331 of the first blade 33 thereby first intersect the conductor foil 20. They then meet on the bending area 51 of the tool 50. While the conductor foil 20 is moved further in the direction of the row 32, and is thereby intersected by the two areas 332 of the first blades 33, and is also successively intersected by the first areas 341 and then by the second areas 342 of the second blades 34, the pressure of the tool 50 exerted on the first areas 331 of the first blades 33 deforms the latter in the direction of their respective first ridges 42, so that a tight fit between the first area 331 of every first blade 33 and its respective first ridge 42 is produced. As shown in Fig. 7b, the first area 331 of every first blade 33 is thereby clamped between its first ridge 42 and a bending area 51 of the tool 50. If the tool 50 is ultimately removed, the assembled state of the plug connector assembly occurs that is shown in Figs. 3a to 3c.

According to further embodiments of the invention, the plug connector the first housing part 30 may comprise different rows 32 of blades 33, 34, which are configured as a cutting edge. When using another row 32 of blades, the two first ridges 42 and any second ridges 43 are arranged according to the arrangement of the first blades 33 and second blades 34.

A second embodiment of the plug connector assembly in the second assembly step is shown in Fig. 8. It differs from the plug connector assembly according to the first embodiment in only having two second blades 34 in each row 32. The middle second blade 34 that is neighboured by two further second blades 34 in the first embodiment has been removed. Instead of two second ridges 43 that are each neighboured by two second blades 34 in each row 32 this embodiment comprises one second ridge 43 that is so broad, that it filles the space occupied by the omitted two second ridges 43 and the omitted second blade 34 of the first embodiment, when the two housing parts 30, 40 are pushed together in the third assembly step. This is shown in Fig. 9. As in the first embodiment of the plug connector assembly the first areas 331 of the first blades 33 are bent in a circular arc by 90° in the direction of their respective first ridge 42, until they come to rest in a tight fit on the curved face of the first ridge 42 and the tips of both first blades 33 point to each other.

A third embodiment of the plug connector assembly in the second assembly step is shown in Fig. 10. In each row 32 there are two first blades 33 and three second blades 34. Each first blade 33 is arranged between two second blades 34 so that one second blade 34 is arranged between two first blades 34. When the two housing parts 30, 40 are pushed together in the third assembly step two fist ridges 42 each come to rest between a first blade 33 and one of the outer second blades 34. Two second ridges 43 each come to rest between a first blade 33 and the middle second blade 34 during the pushing-in of the housing parts 30, 40. This is shown in Fig. 11. The first areas 331 of the first blades 33 are bent in a circular arc by 90° in the direction of their respective first ridge 42, until they come to rest in a tight fit on the curved face of the first ridge 42 and the tips of both first blades 33 point away from each other.

Fig. 12 shows a fourth embodiment of the plug connector assembly in the second assembly step. It differs from the plug connector assembly according to the third embodiment in only having two second blades 34 in each row 32. The middle second blade 34 that is arranged between the first blades 33 in the third embodiment has been removed. Instead of two second ridges 43 that are each neighboured by a first blade 33 and a second blade 34 in each row 32 this embodiment comprises one second ridge 43 that is so broad, that it filles the space occupied by the omitted two second ridges 43 and the omitted second blade 34 of the third embodiment, when the two housing parts 30, 40 are pushed together in the third assembly step. Therefore, it comes into rest between the two first blades 33. This is shown in Fig. 13. As in the third embodiment of the plug connector assembly the first areas 331 of the first blades 33 are bent in a circular arc by 90° in the direction of their respective first ridge 42, until they come to rest in a tight fit on the curved face of the first ridge 42 and the tips of both first blades 33 point away from each other.

Fig. 14 shows a fifth embodiment of the plug connector assembly in the second assembly step. In each row 32 a first blade 33 is consecutively followed by two second blades 34, one further first blade 33 and one further second blade 34. When the two housing parts 30, 40 are pushed together in the third assembly step, as shown in Fig. 15 a fist ridge 42 comes to rest between the first blade 33 at the beginning of the row 32 and the consecutive second blade 34. One second ridge 42 is arranged between the two neighboured second blades 34 and a further second ridge is arranged between the further first blade 33 and the second blade in front of it. A further first ridge comes into rest between this further first blade 33 and the second blade 34 at the end of the row 32. In each of the previous four embodiments the first ridges 41 are curved in different direction so that the tips of both first blades 33 point to each other or point away from each other. In contrast, the first ridges 41 of the second housing part 40 of the plug connector assembly according to the fifth embodiment are curved in the same direction so that the tips of both first blades 33 point in the same direction after they have been bent in a circular arc by 90° in the direction of their respective first ridge 42.

A sixth embodiment of the plug connector assembly in the second assembly step is shown in Fig. 16. It differs from the plug connector assembly according to the fifth embodiment in only having on second blade 34 between the first blades 33 in each row 32. Instead of two second ridges 43 this embodiment comprises only one second ridge 43 that is so broad, that it filles the space occupied by the omitted two second ridges 43 and the omitted second blade 34 of the fourth embodiment, when the two housing parts 30, 40 are pushed together in the third assembly step. Therefore, it comes into rest between a first blade 33 and a second blade 34. This is shown in Fig. 17. As in the fifth embodiment of the plug connector assembly the first areas 331 of the first blades 33 are bent in a circular arc by 90° in the direction of their respective first ridge 42, until they come to rest in a tight fit on the curved face of the first ridge 42 and the tips of both first blades 33 point in the same direction.