Contact element and method for manufacturing same

Patent metadata

Field	Value
Publication number	US-9627781-B2
Application number	US-201214004628-A
Country	US
Kind code	B2
Filing date	Feb 9, 2012
Priority date	Mar 16, 2011
Publication date	Apr 18, 2017
Grant date	Apr 18, 2017

Abstract

A contact element for contacting a contact point formed on a body includes: an element section on the contact point side for a force-locking connection to the contact point, an element section on the connection side for connection to an electrical connection conductor, and an intermediate section which connects the two element sections to one another for compensating for thermal expansions. At least the element sections on the contact point side and on the connection side are made of different integrally bonded materials having material properties which are adapted to the functionality of the corresponding element section.

First claim

What is claimed is:

1. A contact element for contacting an electrical contact point formed on a body, comprising:
a first element section on a contact point side for forming a force-locking contact with the electrical contact point;
a second element section on a connection side for connection to an electrical connecting conductor; and
an intermediate section connecting the first and second element sections to one another for equalizing thermal expansions;
wherein at least the first element section on the contact point side and the second element section on the connection side are made of different integrally bonded materials having material properties which are adapted to the respective functionalities of the first and second element sections; and
wherein the first element section on the contact point side is made of a heat-resisting material.

2. The contact element as recited in claim 1 , wherein the heat-resisting material used to make the first element section on the contact point side is a heat-resisting alloy according to DIN 10269.

3. The contact element as recited in claim 2 , wherein the second element section on the connection side is made of a corrosion-resistant steel of the 1.43xx family according to DIN 10088.

4. The contact element as recited in claim 3 , wherein the corrosion-resistant steel is in a solution-annealed state.

5. The contact element as recited in claim 3 , wherein the intermediate section is made of a cold-worked corrosion-resistant steel of the 1.43xx family according to DIN 10088.

6. The contact element as recited in claim 1 , wherein the intermediate section is made of the same material as at least one of the first end section on the contact point side and the second end section on the connection side.

7. The contact element as recited in claim 6 , wherein the first element section on the contact point side and the second element section on the connection side are formed in separate element parts, and wherein at least a portion of the intermediate section is configured as a part of a unitary piece also including at least one of the first and second element sections, and wherein the first and second element parts are joined and integrally bonded in an area of the intermediate section to form a preassembled unit.

8. A method for manufacturing a contact element for contacting an electrical contact point formed on a body, the contact element having: a first element section on a contact point side for forming a force-locking contact with the electrical contact point; a second element section on a connection side for connection to an electrical connecting conductor; and an intermediate section connecting the first and second element sections to one another for equalizing thermal expansions; wherein at least the first element section on the contact point side and the second element section on the connection side are made of different integrally bonded materials having material properties which are adapted to the respective functionalities of the first and second element sections, and wherein the first element section on the contact point side and the second element section on the connection side are formed in separate element parts, the method comprising:
forming a first unitary piece by punching and bending, wherein the first unitary piece includes the first element section on the contact point side and a portion of the intermediate section;
forming a second unitary piece by punching and bending, wherein the second unitary piece includes the second element section on the connection side and a portion of the intermediate section; and
joining and integrally bonding the first and second unitary pieces in an area of the intermediate section.

9. A method for manufacturing a contact element for contacting an electrical contact point formed on a body, the contact element having: a first element section on a contact point side for forming a force-locking contact with the electrical contact point; a second element section on a connection side for connection to an electrical connecting conductor; and an intermediate section connecting the first and second element sections to one another for equalizing thermal expansions; wherein at least the first element section on the contact point side and the second element section on the connection side are made of different integrally bonded materials having material properties which are adapted to the respective functionalities of the first and second element sections, the method comprising:
integrally bonding a first metal band and a second metal band side-by-side at an abutting edge to form a bimetal band, wherein the first metal band is made of the materials of the first element section on the contact point side and the second metal band is made of the materials of the second element section on the connection side; and
punching out a punched part having a length extending laterally across the abutting edge of the bimetal band, wherein the first element section on the contact point side emerges from the first metal band portion of the punched part, and wherein the second element section on the connection side and the intermediate section emerge from the second metal band portion of the punched part.

10. A method for manufacturing a contact element for contacting an electrical contact point formed on a body, the contact element having: a first element section on a contact point side for forming a force-locking contact with the electrical contact point; a second element section on a connection side for connection to an electrical connecting conductor; and an intermediate section connecting the first and second element sections to one another for equalizing thermal expansions; wherein at least the first element section on the contact point side and the second element section on the connection side are made of different integrally bonded materials having material properties which are adapted to the respective functionalities of the first and second element sections, the method comprising:
integrally bonding (i) a first metal band to a first abutting edge of a second metal band and (ii) a third metal band to a second abutting edge of the second metal band to form a multi-metal band, wherein the first metal band is made of the materials of the first element section on the contact point side, the second metal band is made of materials of the intermediate section, and the third metal band is made of the materials of the second element section on the connection side; and
punching out a punched part having a length extending laterally across the first and second abutting edges of the multi-metal band, wherein the first element section on the contact point side emerges from the first metal band portion of the punched part, the intermediate section emerges from the second metal band portion of the punched part, and the second element section on the connection side emerges from third metal band portion of the punched part.

Assignees

• Winkler Peter
• Maier Rainer
• Jaehnig Gregor
• Buchholz Bastian
• Rattay Bernd
• Schneider Jens
• Soyez Guido
• Stier Joachim
• Russ Sebastian
• Klett Sascha
• Bosch Gmbh Robert

Inventors

• Winkler Peter
• Maier Rainer
• Jaehnig Gregor
• Buchholz Bastian
• Rattay Bernd
• Schneider Jens
• Soyez Guido
• Stier Joachim
• Russ Sebastian
• Klett Sascha

Classifications

• H01R13/03 Primary

  characterised by the material, e.g. plating, or coating materials · CPC title

• H01R43/16

  for manufacturing contact members, e.g. by punching and by bending · CPC title

• H01R4/625

  Soldered or welded connections · CPC title

• H01R4/18 Primary

  by crimping {(H01R4/01, H01R4/2495 take precedence; for coaxial cables H01R9/0518)} · CPC title

• H01R43/0207

  Ultrasonic-, H.F.-, cold- or impact welding · CPC title