EP2978084B1 - Module with a contact element - Google Patents

Description

The invention relates to an assembly with a contact element according to the preamble of patent claim 1.

Such an assembly is for example from the EP 1 255 330 B1 out.

Cassettes with such an assembly are used in a steering wheel or steering system to drive a consumer, e.g. an airbag module to contact with a power supply, wherein the consumer is provided steering wheel fixed, rotates in a revolution of the steering wheel with and thereby adjusted relative to the vehicle-fixed power supply. To contact the consumer with the power supply one or more flat conductor ribbon cables are provided in the cassette.

The EP 1 324 435 B1 shows a cassette with a terminal provided on a stator and provided on a rotatable rotor further terminal, which are electrically connected to each other via a winding extending flat conductor ribbon cable with a plurality of flat conductors. A load and a voltage source are connected to the terminals via connecting cables. At their respective ends, the flat conductor strip line has electrical contact elements, which are each connected to the connection lines. The contact elements can be designed as plug with plug pins for plugging or as a contact carrier for fixed connection of electrical conductors, eg by welding or soldering.

From the DE 10 2006 013 434 A1 goes out a connection device for the transmission of electric current, in which two juxtaposed ribbon cables are connected at their ends to contact points. The ribbon cables each have a flat conductor which is arranged at both ends at a contact point. The two ribbon cables are included corresponding width next to each other. Their flat conductors are each connected directly to a separate contact point without any material removal.

From the above-mentioned EP 1 255 330 B1 is a arranged in a cassette assembly, in which a plurality of parallel juxtaposed flat conductor of a flat conductor ribbon cable are each connected with their ends to a plate-shaped, designed as a contact element contact carrier. The flat conductors of the flat conductor strip line are contacted at a lower end of the contact carrier with contact areas, for example by welding or soldering. The contact areas are insulated from one another, fastened to the contact carrier and extend to an upper end of the contact carrier opposite the lower end, to which respective further connecting leads are attached. The contact areas can also be designed as plug-in elements for connection to further connection lines at the upper end.

The invention has for its object to make the initially described assembly and a method for their preparation so that a simple and secure contact between the contact areas of the contact element and the flat conductors is guaranteed.

This object is achieved according to the characterizing features of claims 1 and 5.

The dependent claims describe advantageous developments.

The contact element of this assembly has at least two contact areas, which are spaced apart in a lateral direction of a band plane. The band plane corresponds to the plane of the flat conductor ribbon conductor and thus the plane in which the individual leads extend; In this case, the at least two contact areas extend in the band plane, since they receive the flat conductors areally. Thus, the contact areas extending in the band plane lie side by side, ie spaced apart in a lateral direction, and not only vertically one above the other.

Thus, in each case a flat conductor can be placed on a contact region, and subsequently a contacting in a contacting direction perpendicular to the band plane, in particular by welding or soldering; These two contacts are thus spaced from one another laterally.

The band level can z. B. a longitudinal direction, which shows in the line direction of the flat conductor ribbon line, and have a transverse direction. The contact areas are preferably spaced apart in the transverse direction. Stripped ends of the flat conductor can z. B. are inserted in the longitudinal direction in the contact elements to lie perpendicular to each contact area.

Thus, it can advantageously be achieved that a plurality of flat conductor ribbon cables with one or more flat conductors, for. B. two flat conductors forming laterally staggered stripped areas, quickly and easily, e.g. can be electrically contacted with the contact element in a welding or soldering in a direction perpendicular to the band plane Kontaktierrichtung.

The contact regions are preferably made of a conductive material, for example metal, in particular bronze, wherein the contact regions are insulated from one another. The contact areas are electrically connected to, for example, designed as pins terminals of the contact element, which can be connected to the terminals connecting lines of a consumer or a power supply.

A contact region and a connection electrically connected thereto can be punched out of a metal sheet, for example, as a one-piece punching element in a punching process, wherein a stamped grid with several such punched elements is punched out simultaneously in a single punching process can be, so that the punching elements below, z. B. after the formation of the individual contact elements, can be separated from each other in a separation process.

The contact elements can thus be formed by encapsulation of the stamped elements of a stamped grid, so that a cost-effective and safe production is possible.

The cassette has at least two flat conductor strip lines, each with a flat conductor, which can be electrically contacted via the contact regions of the contact element with the consumer or the voltage source.

According to a first embodiment, in each case a flat conductor strip line has only one flat conductor, which are each contacted on the contact element on a contact region; According to a further embodiment, the flat conductor strip line in each case two laterally, in particular in the transverse direction, spaced apart flat conductor, so that on the contact element a total of four flat conductors are contacted, preferably two flat conductors can be contacted in each case together with a common contact area and thus the same or switched are redundant, whereby a high security against a failure is achieved, or a higher power can be transmitted.

To form an insulating region between the flat conductors, each flat conductor is preferably surrounded by an insulating material. The contacting takes place in stripped end areas.

In the first embodiment, each having one flat conductor per flat conductor ribbon conductor on each side of the assembly, the end regions are for contacting the two laterally offset contact regions of the contact element the flat conductor preferably also laterally stepped to each other or laterally offset; Thus, the first end region of the flat conductor of the first flat conductor ribbon line is laterally offset from the second end region of the second flat conductor of the second flat conductor ribbon line. As a result of the lateral spacing, the stripped end regions of the flat conductors can be contacted with the two laterally offset contact regions of the contact element without the end regions touching one another and thus creating a short circuit.

According to the second embodiment, each having two laterally spaced apart flat conductors per flat conductor strip line on each side are contacted or contacted for contacting the end portions of both flat conductors of the first flat conductor ribbon laterally to the end regions of the flat conductor of the second flat ribbon conductor, so that two opposite sides can be contacted in each case together with a contact area, wherein the adjacent flat conductors of both flat conductor strip lines do not touch each other.

The contacting of the contact regions of the contact element with the end regions of the flat conductor is preferably carried out by a soldered or welded connection. As a result of the lateral spacing, in each case one end region with a contact region in the soldering or welding direction perpendicular to the strip plane can be soldered or welded without a faulty short circuit formation occurring between the contact regions or the end regions.

In order to protect against slippage of the flat conductor or the laterally offset end portions of the contact element preferably insulating webs are arranged. These preferably delimit the end regions to two sides, so that in particular it can be prevented that the laterally offset end regions of the flat conductors slip in the lateral direction can, for example, during the welding process. Thus, advantageously, a failure of the contact element, for example by a short circuit, can be prevented.

Fig. 1

eine Aufsicht auf eine Kassette mit einer Flachleiter-Bandleitung gemäß einer ersten Ausführung;

Fig. 2

eine Kassette mit einer Flachleiter-Bandleitung gemäß einer zweiten Ausführung;

Fig. 3

ein Kontaktelement mit zwei Kontaktbereichen;

Fig. 4a, b, c,

d eine Baugruppe gemäß einer ersten Ausführungsform mit zwei einadrigen Flachleiter-Bandleitungen und einem Kontaktelement mit jeweils zwei Kontaktbereichen;

Fig. 5a, b, c

eine Baugruppe gemäß einer zweiten Ausführungsform mit zwei zweiadrigen Flachleiter-Bandleitungen (vier Flachleitern) und einem Kontaktelement mit jeweils zwei Kontaktbereichen;

Fig. 6 bis 8

eine Baugruppe gemäß einer dritten Ausführungsform;

Fig. 9 bis 11

Detailansichten eines Kontaktelementes gemäß einer weiteren Ausführung; und

Fig. 12

ein Flussdiagramm zur Herstellung einer Kassette mit einer Flachleiter-Bandleitung.

The invention will be explained below with reference to the accompanying drawings of some embodiments. Show it:

Fig. 1

a plan view of a cassette with a flat conductor strip line according to a first embodiment;

Fig. 2

a cassette with a flat conductor strip line according to a second embodiment;

Fig. 3

a contact element with two contact areas;

Fig. 4a, b, c,

d shows an assembly according to a first embodiment with two single-core flat conductor ribbon conductors and a contact element with two contact regions;

Fig. 5a, b, c

an assembly according to a second embodiment with two two-conductor ribbon conductor lines (four flat conductors) and a contact element with two contact areas;

Fig. 6 to 8

an assembly according to a third embodiment;

Fig. 9 to 11

Detailed views of a contact element according to another embodiment; and

Fig. 12

a flow chart for producing a cassette with a flat conductor ribbon cable.

FIG. 1 shows a cassette 1 with two mutually rotatable, concentric running, circular walls 2 and 3, wherein the solid wall 2 part of a stator and the adjustable wall 3 is part of a rotatable rotor. The cassette 1 is intended in particular for use in a steering wheel and serves to make electrical contact with a power supply 4 with an electronics 5 of a load, eg an airbag module and / or a steering wheel heater, which is adjustable in the steering wheel.

Between a stator located at the fixed terminal 6 and an adjustable end point 7 located on the rotor, a line assembly 8 is provided with two flat conductor ribbon lines 8.1 and 8.2, wherein the line assembly 8 is wound between the terminals 6 and 7 such that the adjustable wall 3 opposite the fixed wall 2 can be rotated; the adjustable terminal 7 is thus rotated in the direction of arrow 15 relative to the fixed terminal 6. The winding of the line assembly 8 or the two flat conductor ribbon lines 8.1 and 8.2 is adapted so that a steering wheel connected to the rotor and thus to the adjustable wall 3, e.g. at least six revolutions without significant effect on the two ribbon conductors 8.1 and 8.2, i. the turns of the two flat conductor ribbon cables 8.1 and 8.2 thereby change only their diameter. Between the fixed terminal 6 and the power supply 4, a first electrical connection line 9 and between the terminal 7 and the electronics 5, a second electrical connection line 10 is further provided.

The FIG. 2 shows an alternative embodiment of the cassette 1, wherein the line assembly 8 is wound in two winding areas 11 and 12 respectively opposite. Here is a reversal point 13 as part of a guide body 14, which reverses the winding direction of the ribbon conductor 8.

In order to provide a conductive transition between the connection lines 9, 10 and the flat conductor ribbon 8 at the terminals 6, 7, a first contact element 16 and at the adjustable end 7 a second contact element 17 is provided at the fixed end 6, in particular Fig. 4d and 5c shown. Since both contact elements 16, 17 can be identical according to this embodiment, reference will first be made in the following to a contact element 16, 17 alone.

According to the in Fig. 3 shown embodiment of the contact element 16, 17 are two flat, z. B. approximately equal contact areas 18.1, 18.2 provided, which are isolated from each other. Both contact areas 18.1, 18.2 extend in a band plane 50, 60, which also represents the plane of the two flat conductor ribbon conductors 8 to be contacted. In this case, the contact regions 18.1, 18.2 are spaced apart in a transverse direction or lateral direction 50, the lateral direction 50 being a direction in the band plane 50, 60, and the band plane 50, 60 continuing through a longitudinal direction 60, that in the line direction of the flat conductors Band 8 shows is fixed.

The contact areas 18.1, 18.2 are made of a conductive metal, such as bronze, and are surrounded by a sheath 19 of an insulating material, such as plastic, partially so that their surfaces are exposed for contacting. The contact regions 18.1, 18.2 can be formed in particular by a single-part or multi-part stamped grid 29. A first contact area 18.1 is further electrically connected to a first terminal 20.1 and a second contact area 18.2 to a second terminal 20.2. The connections 20.1, 20.2 serve here the contacting of the connecting lines 9, 10 of the power supply 4 and the consumer 5 to the two flat conductor ribbon cables 8.1 and 8.2.

According to a first embodiment, which in the FIGS. 4a to 4d is shown, each of the two flat conductor ribbon lines 8.1 and 8.2, a flat conductor 21.1, 21.2, which are each electrically connected to one of the contact areas 18.1, 18.2 of the contact element 16, 17. Each flat conductor 21.1, 21.2 is in each case flat, ie in the transverse and longitudinal direction 50, 60 of the band level expanded, and surrounded by an insulation 22.1, 22.2 of its respective ribbon conductor 8.1 and 8.2, both flat conductor ribbon lines 8.1 and 8.2 flat to each other lie and the insulation 22.1, 22.2 prevents both flat conductors 21.1, 21.2 are short-circuited. According to Fig. 4c are the two single-core flat conductor ribbon cables 8.1 and 8.2 congruent superimposed so that they are separated with respect to the band level in the vertical, ie in the vertical direction 70 from each other and isolated over the insulation 22.1, 22.2 against each other.

At their end regions 23.1, 23.2, the flat conductors 21.1, 21.2 are respectively stripped, ie exposed from the insulation 22.1, 22.2, and lie on the contact areas 18.1, 18.2, whereby they are firmly connected electrically, for example, by a soldering or welding connection. So that the stripped end region 23.1 of the first flat conductor 21.1 does not touch the stripped end region 23.2 of the second flat conductor 21.2 lying thereon, these are arranged offset in the lateral direction 50 relative to one another. For this purpose, the first flat conductor 21.1 in its end region in the lateral direction 50 to one side and the second flat conductor 21.2 according to Fig. 4b offset relative to it in the lateral direction 50 to the other side. The flat conductors 21.1, 21.2 are thus electrically connected according to this embodiment, each with different contact areas 18.1, 18.2 and isolated from each other.

In this way, advantageously, after placing the flat conductors 21.1, 21.2 on the contact areas 18.1, 18.2 parallel in a single soldering or welding process secure contact both contact areas 18.1, 18.2 in the vertical direction, which thus represents the contacting direction 70.

According to Fig. 4d is at both ends of the two flat conductor ribbon cables 8.1 and 8.2 each have a contact element 16, 17 is provided, wherein the connection of the individual leads 21.1, 21.2 to the contact elements 16, 17 takes place at both ends in the same way. For example, the first flat conductor 21.1 may be connected to the positive pole of the voltage supply 4 and the second flat conductor 21.2 to the negative pole or a ground potential.

According to the in Fig. 5a to 5c In the alternative embodiment shown, the two two-conductor ribbon conductor lines 108.1 and 108.2 each have two laterally offset flat conductors 121.1, 121.2, 121.3, 121.4, which are surrounded by an insulation 122.1, 122.2 such that all four conductors 121.1, 121.2, 121.3 , 121.4 are initially isolated from each other. The flat conductors 121.1, 121.2, 121.3, 121.4 are respectively stripped at their end regions such that the two flat conductor strip lines 108.1 and 108.2 each have two stripped end regions 123.1, 123.2, 123.3, 123.4, as in FIG Fig. 5b shown. Furthermore, the stripped end regions 123.1, 123.2, 123.3, 123.4 are offset in the lateral direction as in the first embodiment, so that they do not touch each other and can each be connected directly to the contact regions 18.1, 18.2 in the vertical contacting direction 70.

The stripped regions 123.1 and 123.2 of the first flat conductor ribbon conductor 108.1 with the associated flat conductors 121.1 and 121.2, or the stripped regions 123.3 and 123.4 of the second ribbon conductor 108.2 with the associated flat conductors 121.3 and 121.4, in the flat conductor ribbon cables 108.1 and 108.2 are each directly superimposed, both are electrically connected to the first and the second contact region 18.1, 18.2, respectively, so that a redundancy is achieved; Thus, if, for example, the first flat cable 121.1 fails, an electrical transport via the third flat cable 121.3 continues to take place, which results in increased functional reliability.

According to a third embodiment, in the FIGS. 6 to 8 is shown, the two two-conductor flat conductor strip lines 208.1 and 208.2, as in the second embodiment, two offset in the lateral direction and by an insulation 222.1, 222.2 mutually insulated flat conductor 221.1, 221.2, 221.3, 221.4. However, the stripped regions 223.1, 223.3 or 223.2, 223.4 superimposed flat conductor 221.1, 221.3 or 221.2, 221.4 are not arranged offset to one another according to this embodiment.

In the thus overlying stripped regions 223.1, 223.3 of the first and third flat conductor 221.1, 221.3 or the stripped regions 223.2, 223.4 of the second and fourth flat conductor 221.2, 221.4 additionally laterally offset holes 40 are introduced. These ensure that the stripped areas 223.1, 223.2, 223.3, 223.4 can be selectively pressed directly onto the contact areas 18.1, 18.2 with a corresponding soldering or welding tool or brought into contact therewith, without any further materials intervening therebetween; This results in a direct point of attack for a connection tool.

According to the FIGS. 9 to 11 a further embodiment of the contact elements 116, 117 is shown, in particular, the terminals 120.1, 120.2 are designed as plug pins.

Between the contact areas 18.1, 18.2, a plurality of guide webs 25 are arranged in the casing 19. The webs 25 are used in particular for guiding or positioning the stripped end regions 23.1, 23.2, 123.1, 123.2, 123.3, 123.4, 223.1, 223.2, 223.3, 223.4 when placing the flat conductors 21.1, 21.2, 121.1, 121.2, 121.3, 121.4, 221.1, 221.2, 221.3, 221.4 to the contact areas 18.1, 18.2. The distance between the webs 25 to each other is chosen so that the mutually offset, stripped end portions 23.1, 23.2, 123.1, 123.2, 123.3, 123.4, 223.1, 223.2, 223.3, 223.4 can be placed or pushed fit between the webs 25, without them overlapping. The stripped areas 23.1, 23.2, 123.1, 123.2, 123.3, 123.4, 223.1, 223.2, 223.3, 223.4 can be placed so that this either completely - which is easily recognized by the fitter and by turning the flat conductor 21.1, 21.2, 121.1, 121.2 , 121.3, 121.4, 221.1, 221.2, 221.3, 221.4 - or do not touch at all. Thus, a reverse polarity protection is guaranteed.

To form the cassette 1 is according to Fig. 12 In step St0, it is initially provided to provide stripped conductors 21.1, 21.2, 121.1, 121.2, 121.3, 121.4, 221.1, 221.2, 221.3, 221.4 and two contact elements 16, 17 in the end regions.

Subsequently, in a step St1 of the flat conductor 21.1 according to Fig. 4a or the connected flat conductors 121.1, 121.2 according to Fig. 5a or 221.1, 221.2 according to Fig. 6 with their stripped end portions 23.1, 123.1, 123.2, 223.1, 223.2 flat on the corresponding contact areas 18.1, 18.2 both contact carrier 16, 17 so placed that they can be electrically contacted later with each other and the webs 25, the stripped end portions 23.1, 123.1, 123.2, 223.1, 223.2 limit up and down, and continue the second lead 21.2 according to Fig. 4b or the connected flat conductors 121.3, 121.4 according to Fig. 5b or 221.3, 221.4 according to Fig. 7 With their stripped end portions 23.2, 123.3, 123.4, 223.3, 223.4 areally placed on the corresponding contact areas 18.1, 18.2.

In a subsequent step St2, the stripped end regions are contacted with the contact regions 18.1, 18.2 in the vertical contacting direction, in particular welded or soldered. This can be done successively successively or simultaneously.

Subsequently, according to step St3, the contact elements 16, 17, 116, 117 inserted into a cassette 1 and the terminals 20.1, 20.2 connected to the corresponding wires of the connecting lines 9, 10.

Claims (7)

1. An assembly with a contact element (16, 17, 116, 117) for the electrical connection of at least two flat conductor-ribbon lines (8.1, 8.2, 108.1, 108.2, 208.1, 208.2) which have at least one flat conductor (21.1, 21.2, 121.1, 121.2, 121.3, 121.4, 221.1, 221.2, 221.3, 221.4) each, which is surrounded by an insulation (21.1, 22.2), wherein the contact element has two contact areas (18.1, 18.2), which are insulated from each other and extend in the plane (50, 60) of the ribbon lines, to which in mounting position the flat conductors (21.1, 21.2, 121.1, 121.2, 121.3, 121.4, 221.1, 221.2, 221.3, 221.4) which are bared at their ends (23.1, 23.2) respectively on the one hand as well as two electrically conducting connecting elements (20.1, 20.2, 120.1, 120.2) on the other hand are connected in an electrically conducting manner, characterized in

   - that the two flat conductor-ribbon lines (23.1, 23.2, 123.1, 123.2, 123.3, 123.4, 223.1, 223.2, 223.3, 223.4) in mounting position ly laminar on top of each other and are insulated against each other and

   - that the bared ends (23.1, 23.2) of the flat conductors are graded laterally or staggered to each other such, that each flat conductor is connected only to one of the contact areas (18.1, 18.2) of the contact elements (16, 17, 116, 117), avoiding that the ends (23.1, 23.2) of the flat conductors touch each other.
2. Assembly according to claim 1, characterized in that at least between the contact areas (18.1, 18.2) a guide bar (25) is provided for the guidance of the flat conductors (21.1, 21.2, 121.1, 121.2, 121.3, 121.4, 221.1, 221.2, 221.3, 221.4) which are to the mounted.
3. Assembly according to claim 1 or 2, characterized in that the connecting elements (20.1, 20.2, 120.1, 120.2) with the contact areas (18.1, 18.2) are constructed as a metallic one piece or a multipart piece punching element or punching lattice (29).
4. Assembly according to claim 3, characterized in that the one piece or multipart piece punching element or punching lattice (29) with the contact areas (18.1, 18.2) is surrounded by an insulating sheathing (19, 119).
5. Method for the manufacturing of an assembly according to claim 1 with at least the following steps:

   - providing of at least two flat conductor-ribbon lines (8.1, 8.2, 108.1, 108.2, 208.1, 208.2) which have at least one flat conductor (21.1, 21.2, 121.1, 121.2, 121.3, 121.4, 221.1, 221.2, 221.3, 221.4) each, which is surrounded by an insulation (21.1, 22.2) and extends in a ribbon plane (50, 60), and

   - providing of two contact elements (16, 17) with contact areas (18.1, 18.2), which are graded to each other in the direction (50) of the ribbon plane (50, 60), wherein

   - the end areas (23.1, 23.2, 123.1, 123.2, 123.3, 123.4, 223.1, 223.2, 223.3, 223.4) of the flat conductors (21.1, 21.2, 121.1, 121.2, 121.3, 121.4, 221.1, 221.2, 221.3, 221.4) are bared and are graded laterally or staggered to each other,

   - at least two flat conductor-ribbon lines (8.1, 8.2, 108.1, 108.2, 208.1, 208.2) which are insulated against each other are laid laminar on top of each other,

   - the bared ends (23.1, 23.2, 123.1, 123.2, 123.3, 123.4, 223.1, 223.2, 223.3, 223.4) of the flat conductors are laid on the contact areas (18.1, 18.2) of the contact elements (16.17) and

   - the bared ends (23.1, 23.2, 123.1, 123.2, 123.3, 123.4, 223.1, 223.2, 223.3, 223.4) with the contact areas (18.1, 18.2) are contacted in a contact device (70) perpendicular to the ribbon plane (St3).
6. Method according to claim 5, characterized in that the contacting of the bared ends (23.1, 23.2, 123.1, 123.2, 123.3, 123.4, 223.1, 223.2, 223.3, 223.4) of the two flat conductor-ribbon lines (8.1, 8.2, 108.1, 108.2, 208.1, 208.2) with the contact areas (18.1. 18.2) is made in one working step.
7. Method according to claim 5 or 6, characterized in that the end areas (23.1, 23.2, 123.1, 123.2, 123.3, 123.4, 223.1, 223.2, 223.3, 223.4) of the flat conductors are outlined by a contour method, e. g. by punching, by stamping, by cutting, by piercing and/or use of a laser.

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