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WO-2026093286-A1 - CONTACT ELEMENT, PLUG CONNECTOR HAVING A CONTACT ELEMENT, PLUG CONNECTOR ASSEMBLY HAVING A PLUG CONNECTOR, AND ELECTRICAL DEVICE HAVING A PLUG CONNECTOR ASSEMBLY

WO2026093286A1WO 2026093286 A1WO2026093286 A1WO 2026093286A1WO-2026093286-A1

Abstract

The invention relates to a contact element (1) for a plug connector (100), the contact element (1) being configured to be mounted, in particular detachably, on a busbar (301) of a component (300), in particular a component of a vehicle, and to be plugged together with a mating contact element (201) of a mating plug connector (200) in a plug-in direction (Z), the contact element (1) having: --a contact-making portion (2), configured to make contact with the mating contact element (201), at a first end (3); -- a mounting portion (4), configured for mounting on the busbar (301), at a second end (5); -- in particular a fastening portion (6), configured for coupling, in particular detachably, to a plug connector housing (101) of the plug connector (100); and the contact element (1) being produced as an extruded part, in particular in one piece.

Inventors

  • Wallensteiner, Georg
  • Liebing, David
  • KAISER, THOMAS
  • PUBRL, HARALD

Assignees

  • ROBERT BOSCH GMBH

Dates

Publication Date
20260507
Application Date
20251028
Priority Date
20241029

Claims (15)

  1. 1. Contact element (1) for a connector (100), the contact element (1) configured for, in particular detachable, mounting on a busbar (301) of a component (300), in particular a component of a vehicle, and for plugging together along a plugging direction (Z) with a mating contact element (201) of a mating connector (200); the contact element (1) comprising: - a contacting section (2) designed to contact the mating contact element (201) at a first end (3); - a mounting section (4) designed for mounting on the busbar (301) at a second end (5); - in particular a fastening section (6) designed for coupling, in particular detachable coupling, with a connector housing (101) of the connector (100); wherein the contact element (1) is manufactured as an extruded part (40), in particular in one piece.
  2. 2. Contact element (1) according to the preceding claim, wherein the contact element (1) is configured to transmit high power, in particular at least 1 kW or at least 10 kW or at least 50 kW, and/or the contact element (1) is configured to be arranged or mounted in a connector (100) designed as a high-voltage connector or to be operated at high voltages, and/or wherein the component (300) is configured as an HV component, in particular selected from the group: a voltage converter, in particular an inverter (302); an energy storage device, in particular a battery; an electric machine. R. 416213 - 54 -
  3. 3. Contact element (1) according to one of the preceding claims, wherein the contact element (1) is selected from the group consisting of: a knife contact, in particular a flat knife contact (7); a fork contact (8) with at least two contact knives (8a, 8b) spaced apart from each other, in particular parallel to each other.
  4. 4. Contact element (1) according to one of the preceding claims, wherein an opening (9) for inserting or passing through a fastening means (10) is provided in the assembly section (4), in particular a through opening (11) or a blind hole opening (27).
  5. 5. Contact element (1) according to the preceding claim, wherein the opening (9) extends parallel to the insertion direction (Z), or wherein the opening (9) extends parallel to the extrusion direction (SR), or wherein the opening (9) extends perpendicular to the insertion direction (Z), and in particular parallel to a contact plane (KE) of the contacting section (2), or wherein the opening (9) extends perpendicular to the insertion direction (Z), and in particular perpendicular to the contact plane (KE) of the contacting section (2).
  6. 6. Contact element (1) according to one of the preceding claims, wherein the mounting section (4) and the fastening section (6) overlap, in particular viewed in a direction perpendicular to a fastening direction (BR) of the contact element (1) in the connector housing (101).
  7. 7. Contact element (1) according to one of the preceding claims, wherein the contact element (1) has a first wall thickness (D1) in the contacting section (2), wherein the contact element (1) has a second wall thickness (D2) in the mounting section (4), in particular wherein the contact element (1) has a third wall thickness (D3) in the fastening section (6), wherein the first wall thickness (D1) differs, in particular by R. 416213 - 55 - at least 10% or at least 25% of the second wall thickness (D2) and/or especially of the third wall thickness (D3).
  8. 8. Contact element (1) according to one of the preceding claims, wherein a groove (12), in particular open to the outside, is provided in the fastening section (6), and/or wherein a projection (13), in particular directed outwards, is provided in the fastening section (6), and/or wherein a profile (14), in particular for locking and/or interlocking with the connector housing (101), is provided in the fastening section (6), in particular a fir tree profile (15) or a barbed profile.
  9. 9. Contact element (1) according to one of the preceding claims, wherein at least one cooling fin (17) is formed on the contact element (1), in particular on an outer side (18) of the contact element (1).
  10. 10. Contact element (1) according to the preceding claim, wherein the at least one cooling fin (17) is arranged: - in the contacting section (2), in particular on a side facing away from the side contacted by the mating contact element (201), and/or - in the fastening section (6), and/or - in the assembly section (4), in particular on an outside of the assembly section (4).
  11. 11. Contact element (1) according to one of the preceding claims, wherein the contacting section (2) has different wall thicknesses, in particular wherein a contacting section groove (19) and/or a contacting section projection (20) is provided in the contacting section (2), in particular configured as a coding means (21) for the mating contact element (201) and/or as a stop (22) for the mating contact element (201) and/or as a receptacle (34) for a sensor (35) or a control element (36). R. 416213 - 56 -
  12. 12. Contact element (1) according to one of the preceding claims, wherein the contact element (1) has a compensating section (23), in particular wherein the compensating section (23) is provided in the assembly section (4) and/or in the fastening section (6) and/or between the assembly section (4) and the fastening section, wherein in the compensating section (23) a wall (24) of the contact element (1), in particular viewed along the plugging direction (Z), has at least one left-curved section (25) and/or at least one right-curved section (26), in particular both at least one left-curved section (25) and at least one right-curved section (26).
  13. 13. Connector (100) for mating with a mating connector (200) along a mating direction (Z), the connector (100) being particularly designed for mounting on a component (300), the connector (100) comprising: - a connector housing (101); - a contact element (1) according to one of the preceding claims.
  14. 14. Connector arrangement (400), comprising the connector arrangement (400): - a mating connector (200) comprising in particular a mating connector housing (202) and a mating contact element (201), in particular having a compacted end (203) of an electrical conductor (204). - a connector (100) according to the preceding claim.
  15. 15. Electrical device (500), comprising the electrical device (500): - a component (300) with a busbar (301) and in particular with a component housing (303); - a connector (100) according to claim 13. ...

Description

R. 416213 - 1 - Description Title Contact element, connector with a contact element, connector assembly with a connector and electrical device with a connector assembly Field of invention The invention relates to a contact element, a connector with a contact element, a connector arrangement with a connector and an electrical device with a connector arrangement. State of the art Electrical connectors typically consist of a (often insulating) connector housing and at least one contact element. These contact elements are manufactured as stamped and bent parts from readily available, cost-effective standard materials from various manufacturers (sheets of different materials, properties, and/or thicknesses) and are available in many variations, e.g., as socket contacts, contact blades, fork contacts, etc. Depending on the application, desired properties, and dimensions, a suitable sheet can easily be purchased "off the shelf" and formed into the desired contact element through the stamping and bending process. A wide variety of sheets or coiled sheets with different wall thicknesses, materials, and surface properties (e.g., different coatings, roughness, etc.) are readily available. Furthermore, such stamped and bent parts can be manufactured with a high throughput rate using established machines, requiring only the sheet or coiled sheet to be provided. In the field of connectors, especially connectors for vehicles, e.g. electric cars, two-wheelers, three-wheelers, quads, trucks, commercial vehicles, boats, airplanes, helicopters, drones, etc., for the transmission of high power (e.g. at least 1 kW) R. 416213 - 2 - For applications involving high currents (e.g., at least 1 A or at least 10 A) or high voltages (e.g., at least 40 V or at least 100 V), contact elements with a cross-section of at least 10 mm² are typically used to ensure sufficient current-carrying capacity. Such connectors with this type of contact element are mated with mating connectors, which may have a complementary contact element, particularly during vehicle assembly. Such a connector or connector assembly should function reliably even under conditions such as high temperature fluctuations, vibrations, and mechanical shocks. Furthermore, it should be easy to connect and disconnect with minimal manual force. German patent DE 10 2008 045 810 A1 discloses an electrical fork contact, suitable for use in automotive applications, for a stamped grid of a power distribution unit for high electrical currents. The fork contact is manufactured as a stamped and bent part from a stamped sheet. From DE 10 2021 108 916 A1, a contact arrangement for transmitting an electrical voltage and a connection module with a contact arrangement are known. The contact arrangement is suitable, for example, for use in automotive applications, e.g., for an inverter that can be operated with voltages of 48 V or 60 V or higher (e.g., in so-called high-voltage applications). The contact arrangement has at least one fork contact with a first U-shaped, flat end and a second end opposite the first end with a cylindrical contact surface. The fork contact is arranged with its first end outside and its second end inside the housing. The fork contact is designed as a one-piece stamped and bent part, or the fork-shaped part, designed as a stamped sheet metal part, is connected to the cylindrical part, e.g., by a welding or soldering process. From EP 4 089 864 A1, a contact device for a double busbar is known, wherein the double busbar has two busbars stacked on top of each other, wherein the contact device has an even number of connectors per busbar, arranged symmetrically to an axis of symmetry of the contact device, wherein the connectors R. 416213 - 3 - both busbars are aligned in a common connector plane. Flat contacts, designed as stamped and bent parts, are arranged between the busbars of the double busbar and the connectors. Disclosure of the invention The invention is based on the understanding that manufacturing a contact element (particularly for use in or on vehicles) as a stamped and bent part for a connector, especially for a connector for transmitting high power, high currents, and/or for use at high voltages, can be relatively expensive using conventional processes. Manufacturing a contact element as a stamped and bent part requires a progressive die, in which, among other things, the stamping, embossing, bending, and clinching steps must be performed. Changes to the geometry of the stamped and bent part necessitate costly modifications to the die. Furthermore, the invention is based on the understanding that while the sheet metal used can be obtained inexpensively as standard material, a significant proportion of the sheet metal used in the production of such contact elements is generated as waste, which is not particularly sustainable, as this waste must be remelted at considerable energy expense or disposed of. Furthermore, the invention is based on the understand