WO2012175443A1

WO2012175443A1 - Conductor and method for assembling a conductor

Info

Publication number: WO2012175443A1
Application number: PCT/EP2012/061567
Authority: WO
Inventors: Lutz Lehmann; Wolfgang Wimmer
Original assignee: Lisa Dräxlmaier GmbH
Priority date: 2011-06-21
Filing date: 2012-06-18
Publication date: 2012-12-27
Also published as: DE102011077886B4; DE102011077886A1

Abstract

The invention relates to a conductor, in particular for use in vehicles, comprising a cable which has insulation (7) located on the outside and a conducting element (8) surrounded by the insulation and a contacting sleeve (10), which is made of electrically conductive material and surrounds the insulation and which has at least one cutting edge (12) facing the insulation, wherein the contacting sleeve is pressed onto the insulation (7) by means of magnetic forming in order to establish contact between the conducting element (8) and the contacting sleeve (10) and the cutting edge (12) completely penetrates the insulation (7) and at least contacts the conducting element (8). The invention further relates to a method for assembling such a conductor.

Description

LINE AND METHOD FOR CONDUCTING CONDUCTIVITY

The present invention relates to a conduit which

is designed in particular for use in vehicles, in particular in motor vehicles and a method for cable assembly. In this context, the production of cable assemblies in particular is the production of

ready-to-connect cables, bundles of cables and the whole

To understand cable harnesses with plugs, contacts or even wire ends. The cables can be used especially for

electrical supply of electrical consumers

be used. Likewise, however, the use for the grounding of electrical systems is conceivable.

In the prior art are cables with cables comprising an external insulation, which also serves as a protective jacket

can be designated and a known surrounded by the insulating conductive element. The conductive element may be, for example, the conductor, for. B. in form of

Strand bundles of several strands, or one

Conductor shielding act. In particular, the invention is used in coaxial cables or shielded cables use.

For coaxial cables or shielded cables it is necessary to contact the shielding. For this purpose, the shield can be connected to a contact element. At a

Cohesive connection, such as soldering, I made the contacting j edoch difficult because the arranged under the shield inner insulation surrounding the conductor or the strand bundle, can be damaged, with the result of an increased committee.

Therefore, in the prior art as an alternative to

cohesive connection vielfac a so-called crimping method used in which a force through a

Pressing tool is applied to a sleeve-like element to a sufficient contact of the sleeve with the Shield or the conductor or conductor bundle produce. Here, however, it has proven to be problematic that only an unbalanced force acting on the sleeve can be achieved in the rule, so that even in this

Alternative the layers under the shield, in particular an insulating layer over the conductor,

claimed and possibly damaged.

Furthermore, in conventional methods, a support sleeve is necessary, around which, for example, the shield is folded over and finally pressed with an outer sleeve.

In view of the above, the object of the present invention is to develop an initially mentioned line in such a way or a method for

To create cable assembly, the or it

allows a Kontaktierungshülse with the conductive element of the cable, z. B. to the conductor or the shield

connect without damaging the remaining parts of the cable, thereby producing less waste.

This object is achieved by a line with the features of claim 1 and a method with the features of

Claim 10 solved. Advantageous developments of

present invention can be found in the subclaims.

The basic idea of the present invention is the contacting sleeve with one facing the insulation

To provide cutting edge and the sleeve by means

Pressing magnet forming on the insulation, whereby the cutting edge penetrates the insulation and the conductive

Element, e.g. B. the shield or the conductor or the

Strand bundles, at least contacted. Magnetic forming allows a repeatable, symmetrical

Force distribution over the circumference of the Kontaktierungshülse to plastically deform. Thus, a defined deformation of the sleeve can be adjusted and the way that the cutting edge penetrates into the cable, set exactly become . This ensures that the conductive element and / or the underlying layers through the

Contacting the contacting sleeve with the conductive element and the associated deformation are not damaged.

Accordingly, the present invention defines a conduit that is particularly used in vehicles and preferably motor vehicles. It includes a cable, which is z. B. may be a coaxial cable or a shielded cable. Such a coaxial cable is usually from an inner conductor, the z. B. may be formed by a strand bundle, an inner surrounding the conductor

Insulation, a shield surrounding the inner insulation and the insulation or the protective jacket, which in turn surrounds the shield constructed. However, the present invention is also applicable to cables which are only two or more than four-layered. At a

two-layer cable, the conductive element would be defined by the conductor itself or the strand bundle forming the conductor and the sheath surrounding the conductor would in this case be the external insulation. At a

Coaxial cable, however, according to the invention hereinafter as a conductive element, the shield, which is surrounded by the external insulation or the protective jacket understood. The Kontaktierungshülse, for example, for a coaxial cable, it may be a part of a coaxial connector, namely the part that with the

Shield is connected.

The contacting sleeve surrounds the insulation according to the invention and is formed of electrically conductive material. It is provided with at least one insulation facing the cutting edge, which projects radially from the inner surface of the usually cylindrical contacting sleeve. Preferably, the cutting edge is designed tapering in cross-section to a preferably light penetration, in the isolation too

allow. The contacting sleeve is by means

Magnetic forming, d. H . contactless, deformed and pressed against the insulation, wherein the cutting edge completely penetrates the insulation and with the conductive element, for. B. the shield, at least in contact.

Advantageously, the cutting edge is at least

slightly, d. H . partially in the conductive element

penetrate to make a reliable contact

guarantee . In this case, the Schneidkan e already be formed in the manufacture of Kontaktierungshülse with. For this purpose, it is preferable to design the sleeve as an open sleeve and to punch out of a flat material, wherein the cutting edge can be produced during the punching process. Subsequently, the stamped flat material is rolled to the sleeve. The magnetic reforming is an electrodynamic high-energy deformation experienced for the Kaitumformung

electrically conductive materials by means

electromagnetic pulse technology (magnetic pulse, EMPT), the semifinished product, here the Kontaktierungshülse, positioned within a coil optionally with intervening field transducer and formed without contact by the action of force of a pulsed magnetic field of very high intensity, d. H . unlike crimping without mechanical contact to the tool. It can by the

Magnetumformverfahren a uniform and symmetrical force distribution along the Utnfangs Kontaktierungshü1se be applied to this, so that a along the

Initially uniform shaping of the contacting sleeve results and the contacting sleeve has no mechanical stresses on its outer surface. As a result, in an exact manner and along the entire circumference

Penetration depth of the cutting edge can be set optimally and repeatable, so that damage to the conductive element itself or any underlying layers can be prevented. At the same time a simple and uncomplicated structure is maintained. With the contacting sleeve according to the invention fewer components for contacting a conductor are necessary, at the same time a simplified structure of a prefabricated line is provided. In addition, the s

Sources of error and thus the reject rates of a correspondingly assembled line minimized since

For example, a folded shield layer around a

Support sleeve is no longer required.

Preferably, the present invention is included

Coaxial cables used and the conductive element is by a standing in contact with the inwardly facing side of the insulation shield, for example a

Metal mesh, formed.

As a rule, the cable has a conductor and an inner insulation or a dielectric surrounding the conductor, and the shield is arranged between the inner insulation or the dielectric and the insulation. Around

Advantageously, the cable with a coaxial plug in a simple manner and cost at low

To connect cycle times to produce, it is preferred that the contacting sleeve to a contact element

which communicates with the conductor. The latter can be advantageous when using a

Litzenbündels be realized as a conductor, characterized in that the contact element has a core which between the strands of the

Litz bundle is arranged and one of the

Surrounding contacting sleeve partially

Fastening portion, wherein the contacting sleeve is additionally connected by magnet forming the contacting sleeve with the outer surface of the mounting portion.

Advantageously, the contacting sleeve also surrounds the strand bundle with the introduced core and at least the core is by magnet forming the contacting sleeve with connected to the strand bundle. This makes it possible by only one process step, namely the magnetic forming contact ierungshülse contact with the shield and the contact element via the core on the conductor or.

Litzenbündel and the contacting sleeve on the

Contact element, namely its mounting area to

fasten.

To contact between the part of the contact element connected to the conductor and the contacting sleeve

Prevent, it may be preferred on the inside of the contacting sleeve or the outside of the

Kontak ierungshülse in the area where they with the

Strand bundle is in contact and / or with the

Attachment section is in contact to provide insulation. Alternatively or additionally

Of course, be provided on the mounting portion insulation. In a further alternative, the core with the connector connected thereto can be formed separately from the fastening section and between

Fixing section and core insulation provided v / earth.

Preferably, however, the core is integral with the core

Fastening portion is formed and continues from this.

In addition, according to a preferred embodiment, the shape of the core and / or the attachment portion is designed to be tapered. Here, the core and / or rejuvenate

Attachment portion preferably in a direction from the end of the conductive element, starting from the contact element.

According to one embodiment, the core and / or

Attachment section formed frustoconical. This leads to the advantage that a secure hold of the

Contact element between the strands or. in the sleeve against Tensile load on the contact element or cable through

Positive locking is guaranteed.

In addition, it may be necessary to lead before

Protect water ingress. For this purpose, advantageously at least a first and a second sealing element on opposite Sei en the cutting edge on the radially inner side of the contacting sleeve vorgesehe. These may be separate sealing elements z. As sealing rings or a BeSchichtung of sealing material. By the contacting sleeve is pressed by the magnetic deformation against the insulation, the sealing elements in

sealing contact with the insulation pressed and sealed so along the perimeter on both sides of the through

Cutting edge produced Schnit s through the insulation, so that a water inlet over the cut in the insulation to the conductive element, for. B. the shielding, reliable and easy way can be avoided without an additional process step would be required.

In addition to the above-mentioned line, the present invention also proposes a method of line packaging comprising the following steps. First, a contacting sleeve with a radially inwardly facing cutting edge on a cable with an external

Isolation and a surrounding of the insulation conductive element, for. B. on a coaxial cable, postponed. in the

Connection is the applied contacting sleeve

magnet-formed to press the sleeve on the insulation, wherein the cutting edge completely penetrates the insulation and the conductive element z. B. contacted the shield at least. As mentioned above, the cutting edge penetrates at least partially into the conductive element in order to produce a reliable contact.

In general, contact elements, which include the

Contact sleeve can be counted, a housing non-conductive material to protect the joint. According to an advantageous embodiment, the contacting sleeve is received or preassembled in such a housing made of non-conductive material. This is advantageously applied or pushed onto the cable together with the contacting sleeve. The

Magnetummformung then takes place advantageously by applying a magnetic field through the housing on the sleeve. This will premount the connector

allows. Also, it is possible along with the above

mentioned sealing elements simultaneously to achieve a seal of the housing in the longitudinal direction of the cable.

With the method according to the invention are compared to the usual method, in particular the removal of an outer insulation, sliding a support sleeve, covering the shield and the pressing fewer steps

Cable assembly necessary, namely only the

Pressing on a contact sleeve. In addition, a higher degree of automation is possible, since a support sleeve of the prior art and the folding of the shield only

manually, d. , by hand, is performed. Thus, the Herste11 experienced can perform in less time.

In addition, it is preferable that the insulation before

Magnetic forming and possibly before the complete

Applying the contacting sleeve in the area in which the cutting edge is to penetrate the insulation, vorzuschwächen. This can be achieved for example by scoring or perforating the insulation in this area. As a result, an easier penetration of the cutting edge can be made possible. Furthermore, the cutting edge can be made duller, so that an impression or. Shearing off layers of the cable, for example, the shielding can be prevented. It also reduces energy consumption

Magnetic forming needed to cut the cutting edge into the insulation to press and the penetration of the cutting edge

ensured.

Further advantages and features of the present invention, which may be practiced or in combination with one or more of the above features insofar as they do not conflict with each other, can be found in the following

Description of preferred embodiments of the present invention again. This is done with reference to the accompanying drawings, in which:

Figure 1 shows a longitudinal section through a conduit according to the present invention according to a first embodiment of the present invention;

Figure 2 shows the longitudinal section of Figure 1 before the magnet forming in the sleeve; and

Figure 3 shows a longitudinal section through a conduit according to a second embodiment of the present invention.

In the drawings, like reference characters designate the same or similar elements. In addition, a repeated description of these elements is usually omitted. However, it should be understood that the description of an element of one embodiment is also applicable to the description of the element or similar element in the other embodiment, insofar as no

Contradictions result.

I Next, the present invention will be explained with reference to a Kontaktierungshülse, which is connected to the shield of a coaxial cable.

The cable 1 has a cable 2, which is a coaxial cable in the illustrated embodiment. The coaxial cable 2 has a conductor or a core 3, which is formed from a strand bundle or conductor bundle consisting of a plurality of individual conductors or strands 4. The conductor 3 is surrounded by an inner insulation or a dielectric 5 protective. Between a outer insulation 7 and the protective jacket and the inner insulation 5 and the dielectric, a shield 8 is shown, which is usually a metal mesh.

As can be further seen from Figure 1, is a

Contacting sleeve 10 made of an electrically conductive

Material arranged around the outer insulation 7. The

Contacting sleeve 10 has a substantially

cylindrically shaped contacting portion 11. I this contacting portion 11, a cutting edge 12 is provided which extends from the radially inner side 14 of the contacting sleeve 10 radially inwardly. The cutting edge 12 is preferably integral with the

Contacting sleeve 10 is formed. Furthermore, the running

Cutting edge 12 for improved cutting action

preferably pointed radially inward toward. In this case, the cutting edge 12 penetrates the outer insulation 7 completely and contacts the shield 8, d. H. it comes into contact with the Absc irmung 8. It is also conceivable, however, that the cutting edge 12 at least

slightly penetrates into the shield 8 to a

to ensure reliable contact. The penetration depth should, however, preferably be less than 50% of the radial strength of the shield 8, preferably less than 30% and most preferably less than 15% of the thickness of the shielding in FIG

Radial direction lie.

The contacting sleeve 10 is for this purpose at least in

Contacting section 11 by magnetic forming so

transformed, that it is plastically deformed on the external insulation 7 is pressed. This is done, as explained with reference to Figure 2, by a

Magnetic forming process. When Magnetumformverfahren the Kontaktierungshülse 10 with the cutting edge 12 is first pushed onto a cable, as explained with reference to Figure 1, to the position at which the contact should be made. In this position, a force F is exerted at least in the contacting section 11 along the circumference of the contacting sleeve 10 by the magnetic forming process, so that the

Contacting sleeve 10 plastically deformed in this area, deformed and pressed against the outer surface of the outer insulation 7. During this process, the cutting edge 12 penetrates along the circumference in the outer insulation 7, penetrates it and comes with the

Shield 8 in contact or partially penetrates into this, as described above.

As a rule, the forming of the

Kontaktierungshülse 10 spring-back forces of the line 1, so that the shield 8 and the layers lying under the shield 8 and the conductor core or strands 4 de line press against the contacting sleeve 10. The

Contacting sleeve 10 is thus with the external insulation 7 and. connected to the shield 8 non-positively.

The penetration of the cutting edge 12 in the outer insulation 7 and their partial displacement can

for example, by scoring the outside

Insulation 7 z. B. be facilitated or favored with a paring knife. This processing can be carried out automatically in a pretreatment step.

If a longitudinal water seal between the radially inner side 14 of the contacting sleeve and the

Outer surface 15 of the external insulation 7 can be achieved, it can, according to a preferred embodiment and as shown in Figure 2, be useful a first and second sealing element 16 and 17 between the inner side 14 of the contacting sleeve 10 and the outer surface 15 of

Isolation 7 provide. These sealing elements 16, 17 are pressed in the loading of Kontak ierungshülse 10 by means of the magnetic field during Magnetumformverfahren and applying the force F against the outer surface 15 of the insulation 7 and come into sealing contact with the insulation. In Figure 1, the sealing elements 16 and 17 are not shown, but j edoch pressed left and right hands on

lie opposite sides of the cutting edge 12 and thus the generated section in the longitudinal direction of the cable L.

seal reliably. For this purpose, it may be more advantageous annular sealing elements 16, 17, z. B. similar to an O-ring. Alternatively, too pasty

Be used sealing elements 16, 17. In the

Contacting sleeve 10 can corresponding annular

Be provided recess grooves in which the sealing elements 16, 17 are added. It is, however, also only an intermediate, as can be seen in Figure 2, conceivable. However, with appropriate grooves, the seals could still be reliably held in position when pushed onto the cable, i. H. be pre-assembled in the contacting sleeve 10.

Moreover, it is also conceivable the force F on the sleeve by means of a magnetic field by an electrically not

apply conductive housing on the contacting sleeve. This would have the advantage that the contacting sleeve 10 could already be pre-assembled in the housing and the

Contacting in the preassembled state takes place. Of the

For the sake of simplicity, however, an illustration of the housing in the figures has been dispensed with. In any case, however, the housing in FIG. 2 would be at least in the region of

Contacting portion 11 completely surround the contacting sleeve 10.

The second embodiment in Figure 3 forms the line 1 of Figures 1 and 2 such that the Contacting sleeve 10 continues to a contact element 20. The contact element comprises a core 21, which is designed in one piece with a fastening portion 22. Furthermore, a kind of plug or pin 23 is integral with the

Attachment section 22 is provided. The core 21 is

advantageously to the attachment portion 22 back

designed rejuvenating. The attachment portion 22 is advantageously designed to taper in the same direction. The core 21 is located in relation to

Attachment portion opposite to the pin 23. Both the core 21 and the attachment portion 22 are formed in the illustrated embodiment frusto-conical.

To form a coaxial connector, the contacting sleeve 10 advantageously extends beyond the

Attachment section 22 also forms at its end facing away from the cable 18, the coaxial outer part 24 of the coaxial connector. The coaxial inner part is the plug or pin 23rd

Advantageously, in particular in a

Stranded conductor made of aluminum the contacting of the

Contact element 20 with the conductor 3 by the strands or individual conductors 4 of the conductor are pushed apart by the core 21. In other words, the core 21 is inserted between the individual conductors 4 or strands. The

Contacting sleeve 10 extends such that in a second contacting region 30, the strands 4 of the

Conductor 3, in which the core 21 has been introduced surrounds.

By applying a magnetic field directly to the contacting sleeve 10 in the second contacting region 30 or alternatively through a housing, the

Kontaktierungshü1se 10 plastically deformed (deformed) in the contacting region 30, whereby the strands 4 are pressed against the acting as an abutment core 21 and a contacting of the strands 4 with the core 21 and thus the contact element 20 and the plug 23 takes place. Especially can be done by the provision of the core 21 and / 'or the tapered design of the mounting portion 22 and the core 21, a welding of the strands 4 with the core 21 and thus mi the contact element 20, which zenmaterial especially when using aluminum as Li and / or as material of the contact element 20 is advantageous. In addition, the Kontaktierungshü1se 10 also extends over the contact member 20 so that it surrounds the attachment portion 22. Here, a fixing portion 31 is arranged, which is pressed against the mounting portion 22 of the contact element 20 in the magnetic deformation of the contacting sleeve 10 such that a firm connection of the Kontaktelernents 20 takes place in the sleeve. By magnet forming in the sections 11, 30 and 31 preferably takes place simultaneously, the contacting of the contacting sleeve 10 with the shield 8, the contacting of the core 21, d. H . the Kontaktelernents 20, with the individual wires 4 and the

Attachment of the contacting sleeve 10 to the

Attachment section 22 of the contact element 20 or

conversely done in one process step. In order to prevent an electrical connection between the Kontaktele ent 20 and the Kontaktierungshülse 10, preferably between the inner side 14 of the contacting sleeve 10 in the region of the strands 4 and / or 3efestigungsabschnitts 22, preferably between the two an electrical insulation 26 interposed. Also in the area of

Fixing portion 22 may, as explained with reference to Figure 2, a sealing element are arranged (not shown) to realize a longitudinal water-tightness also at the Verbindungsste11e between the mounting portion 22 and the inner side 14 of the contacting sleeve 10. By means of this embodiment in FIG. 3, a coaxial connector is connected in the simplest way to a coaxial cable. Advantageously, the sleeve can even be preassembled in a housing and the magnet forming take place through the housing. It is understood that the present invention has been explained by way of example only with reference to the above embodiment and various modifications and modes fiction ions are conceivable. It is also possible individual aspects of the various forms of execution in Figures 1, 2 and 3 to combine with each other, except that the individual aspects

contradict.

Claims

PATENTA SPEECHES

1. line, in particular for use in vehicles, comprising

a cable 1 with external insulation (7) and a conductive element (8) surrounded by the insulation; and a surrounding the insulation Kontak ierungshülse (10) made of electrically conductive material mi at least one of the insulation facing cutting edge (12), wherein the

Contacting sleeve for contacting the conductive element (8) with the contacting sleeve (10) by means of magnetic deformation on the insulation (7) is pressed and the cutting edge (12) completely penetrates the insulation (7) and the conductive element (8) at least contacted.

2. Line according to claim 1, wherein the cutting edge (12) partially penetrates into the conductive element (8).

A lead according to claim 1 or 2, wherein the conductive element (8) is a shield (8) in contact with the inwardly facing side of the insulation (7).

4. Lei ung according to claim 3, wherein the cable has a strand bundle (3) surrounding inner insulation (5) and the shield (8) between the inner insulation (5) and the insulation (7) is arranged, wherein the

Contacting sleeve (10) continues to a contact element (20) having a core (21) which is arranged between the strands (4) of the strand bundle (3), and one of the contacting sleeve (10) partially surrounded

Attachment portion (22), wherein the

Contacting sleeve (10) by Magnetummformung the

Contacting sleeve (10) with the outer surface of the

Attachment area (22) is connected.

5. Line according to claim 4, wherein the contacting sleeve (10) the strand bundle (3) with the introduced core (21). surrounds and the core (21) by agnetumformung the

Contacting sleeve (10) is electrically connected to the strand bundle (3).

6. Cable according to one of claims 4 or 5, wherein on the inside (14) of the contacting sleeve (10) in the region in which it is in contact with the strand bundle (3) and / or with the attachment portion (22) in contact , one

Insulation (25, 26) is provided.

7. A conduit according to any one of claims 4 to 6, wherein the core (21) continues in one piece from the attachment portion (22).

8. Line according to one of claims 4 to 7, wherein the core (21) and / or the attachment portion (22), in particular in a direction from the end of the conductive element (8) to the contact element (20) out,

Rejuvenate, in particular frusto-conical are formed.

A conduit according to any preceding claim, comprising at least first and second sealing members (16, 17) disposed on opposite sides of the cutting edge (12) and on the inside (14) of the contacting sleeve (10).

are provided and with the cable, preferably the insulation (7), are in sealing contact.

10. Method for cable assembly comprising the steps:

Applying a contact sleeve (10) with a radially inwardly facing cutting edge (12) to a cable (1) having an external insulation (7) and a conductive element (8) surrounded by the insulation (7);

Magnetic forming of the applied

Contacting sleeve (10) for pressing the contacting sleeve (10) onto the insulation (7), wherein the cutting edge (12) completely penetrates the insulation (7) and the conductive one

At least contacted element (8).

11. The method of claim 10, wherein the cutting edge

(12) partially penetrates into the conductive element (8) during the magnet forming.

12. The method according to any one of claims 10 or 11, wherein the contacting sleeve (10) is accommodated in a housing made of non-conductive material and the magnet forming by applying a magnetic field through the housing on the contacting sleeve (10).

13. The method according to any one of claims 10 to 12, wherein the insulation (7) before the magnetic forming in the region in which the cutting edge (12) penetrates the insulation

is premeditated.