DE102011077886B4 - Method of cable assembly - Google Patents

Abstract

A method of wiring, comprising the steps of providing a contacting sleeve (10) with a radially inwardly facing cutting edge (12), wherein the contacting sleeve (10) continues to a contact element (20) comprising a core (21) and one of the contacting sleeve (10) partially surrounded mounting portion (22), providing a cable (1) with an external insulation (7), one of the insulation (7) surrounded shield (8) with the inwardly facing side of the insulation (7 ) is in contact and an inner insulation (5) surrounding a strand bundle (3), wherein the shield (8) between the inner insulation (5) and the insulation (7) is arranged; Applying the contacting sleeve (10) on the cable (1), so that the core (21) between the strands (4) of the strand bundle (3) is arranged and the contacting sleeve (10) the strand bundle (3) with the introduced core (21 ) surrounds; Magnet forming of the applied contacting sleeve (10), wherein the contacting sleeve (10) is pressed onto the insulation (7), whereby the cutting edge (12) completely penetrates the insulation (7) and at least contacts the shield (8), the contacting sleeve (10). is connected to the outer surface of the mounting portion (22) and the core (21) is electrically connected to the strand bundle (3).

Description

The present invention relates to a method for cable assembly of a line, which is designed in particular for use in vehicles, in particular in motor vehicles. Under cable assembly in this regard is to be understood in particular the production of ready-to-connect cables, cable bundles and entire wiring harnesses with plugs, contacts or wire end ferrules. The cables can be used primarily for the electrical supply of electrical consumers. Likewise, however, the use for the grounding of electrical systems is conceivable.

In the prior art, cables with cables comprising an external insulation, which can also be referred to as a protective jacket, and a conductive element surrounded by the insulation are known. The conductive element may be, for example, the conductor, for. B. in the form of a strand bundle of multiple strands, or to act a conductor shield. 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. In a cohesive connection, such as soldering, however, the contacting is difficult, since the arranged under the shield inner insulation surrounding the conductor or the strand bundle, can be damaged, with the result of increased rejects.

Therefore, a so-called crimping method is often used in the prior art as an alternative to cohesive connection, in which a force is applied by a pressing tool on a sleeve-like element to produce sufficient contact of the sleeve with the shield or the conductor or conductor bundle. In this case, however, it has proven to be problematic that only an asymmetrical force acting on the sleeve can be achieved as a rule, so that even in this alternative, the layers located 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.

Furthermore, from the WO 02/060012 A1 a method of cable assembly is known in which a contacting sleeve is applied with a radially inwardly facing cutting edge on a cable with an external insulation and a conductive element surrounded by the insulation. By reshaping the applied contacting sleeve, the cutting edge completely penetrates the insulation and contacts the conductive element.

From the WO 2008/104668 A1 It is also known to press a sleeve power contact element by magnet forming on a strand bundle. Further prior art, which relates to the magnetic forming of Kontaktierungshülsen, is also the WO 2008/104980 A2 and the DE 103 57 048 A1 ,

The US 6,705,884 B1 further describes a Kontaktierungshülse for a coaxial cable with a core for contacting the central conductor of the coaxial cable.

Finally, the reveals US 5,362,251 A a coaxial connector consisting of two parts, a housing part connected to the coaxial cable and a connector part cooperating therewith via a threaded connection.

In view of the above, the object of the present invention is to provide a method of cable assembly, which makes it possible to connect a contacting sleeve with the shield without damaging the remaining parts of the cable and thereby produce less waste.

This object is achieved by a method having the features of claim 1. Advantageous developments of the present invention can be found in the subclaims.

The basic idea of the present invention is to provide the contacting sleeve with a cutting edge facing the insulation and to press the sleeve onto the insulation by means of magnet forming, whereby the cutting edge penetrates the insulation and at least contacts the shield as a conductive element. In this case, the magnetic forming allows a repeatable, symmetrical force distribution over the circumference of the Kontaktierungshülse to plastically deform. Thus, a defined deformation path of the sleeve can be adjusted and the way that the cutting edge penetrates into the cable to be set exactly. This ensures that the shielding and / or the underlying layers are not damaged by the contacting of the contacting sleeve with the shield and the associated deformation.

A line or a prefabricated line, especially in use in vehicles and preferably motor vehicles is used, comprises a cable, in which it 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, surrounding the conductor inner insulation, a surrounding the inner insulation shield and the insulation or the protective jacket, which in turn surrounds the shield constructed. The contacting sleeve may be part of a coaxial connector, namely the part which is connected to the shield.

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 tapered in cross-section to allow a preferably easy penetration into the insulation. The contacting sleeve is by means of magnetic forming, d. H. contactless, deformed and pressed against the insulation, wherein the cutting edge completely penetrates the insulation and is at least in contact with the shield. Advantageously, the cutting edge is at least slightly, d. H. partially, penetrate the shield to ensure reliable contact. Magnetic Forming is an electrodynamic high energy conversion process for cold working of electrically conductive materials by means of electromagnetic pulse technology (EMPT). In this case, the semifinished product, here the Kontaktierungshülse, positioned within a coil optionally with intervening field transducer and formed without contact by the force of a pulsed magnetic field of very high intensity, d. H. unlike crimping without mechanical contact to the tool. In this case, by the Magnetumformverfahren a uniform and symmetrical force distribution along the circumference of the Kontaktierungshülse be applied to this, so that a uniform along the circumference deformation of the Kontaktierungshülse results and the Kontaktierungshülse has no mechanical stresses on its outer surface. Thereby, the penetration depth of the cutting edge can be adjusted optimally and repeatably in an exact manner and along the entire circumference, so that damage to the shield 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 sources of error and thus the reject rates of a suitably assembled line are minimized, since, for example, a folded shield layer around a support sleeve is no longer required.

The cable has a conductor and an inner insulation or dielectric surrounding the conductor, and the shield is arranged between the inner insulation or the dielectric and the insulation. In order to connect the cable with a coaxial plug in a simple manner and inexpensive to produce at low cycle times, the Kontaktierungshülse continues to a contact element, which is in communication with the conductor. The contact element has a core, which is arranged between the strands of a strand bundle as a conductor of the cable and a partially surrounded by the contacting sleeve mounting portion, wherein the contacting sleeve is additionally connected by magnet forming the contacting sleeve with the outer surface of the mounting portion.

According to the invention, the contacting sleeve also surrounds the strand bundle with the introduced core and at least the core is connected to the strand bundle by magnetic deformation of the contacting sleeve. This makes it possible by only one process step, namely to contact the magnet forming the Kontaktierungshülse with the shield and to secure the contact element on the core on the conductor or strand bundle and the contacting sleeve on the contact element, namely its attachment area.

In order to prevent contact between the part of the contact element connected to the conductor and the contacting sleeve, it may be preferable to contact the inside of the contacting sleeve or the outside of the contacting sleeve in the area in which it is in contact with the strand bundle and / or the attachment portion is in contact to provide insulation. Alternatively or additionally, it is of course also possible to provide insulation on the fastening section. In a further alternative, the core with the connector connected thereto can be formed separately from the fastening section and insulation can be provided between the fastening section and the core.

Preferably, however, the core is formed integrally with the attachment portion and continues from this.

In addition, according to a preferred embodiment, the core and / or the attachment portion are 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 portion are frusto-conical. This leads to the advantage that a secure hold of the contact element between the strands or in the sleeve against tensile stress on the contact element or cable is ensured by positive locking.

In addition, it may be necessary to protect the line from water ingress. For this purpose, at least a first and a second sealing element are advantageously provided on opposite sides of the cutting edge on the radially inner side of the contacting sleeve. These may be separate sealing elements z. As sealing rings or a coating of sealing material. By pressing the contacting sleeve against the insulation by the magnetic deformation, the sealing elements are pressed into sealing contact with the insulation and thus seal along the circumference on both sides of the cut produced by the cutting edge by the insulation, so that a water inlet over the cut in the insulation to the shield can be reliably and easily avoided without an additional process step would be required.

In the method for cable assembly according to the invention, a contacting sleeve with a radially inwardly facing cutting edge on a cable with an external insulation and a shield surrounded by the insulation, z. B. on a coaxial cable, postponed. Thereafter, the applied contacting sleeve is magnetically deformed to press the sleeve onto the insulation, the cutting edge completely penetrating the insulation and at least contacting the shield. As mentioned above, the cutting edge penetrates at least partially into the shield in order to produce a reliable contact.

As a rule, contact elements, to which the contacting sleeve can be counted, have a housing of non-conductive material in order to protect the connection point. 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 magnet forming is then advantageously carried out by applying a magnetic field through the housing to the sleeve. This allows pre-assembly of the plug. It is also conceivable, at the same time, together with the above-mentioned sealing elements, to achieve a sealing of the housing in the longitudinal direction of the cable.

With the method according to the invention, compared with the conventional method, in particular the removal of an outer insulation, pushing on a support sleeve, covering the shield and pressing, fewer steps are required for line assembly, namely only the pressing on of 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. H. by hand, is performed. Thus, the manufacturing process can be carried out in a shorter time.

Further advantages and features of the present invention, which may be implemented alone 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. This is done with reference to the accompanying drawings, in which:

1 shows a longitudinal section through a conduit according to a first embodiment not according to the invention;

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

3 a longitudinal section through a conduit according to a second embodiment shows.

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

In the following, the method of the present invention is explained with reference to a contacting sleeve, which is connected to the shield of a coaxial cable, wherein the 1 and 2 show a non-inventive first embodiment.

The administration 1 has a cable 2 which is a coaxial cable in the illustrated embodiment. The coaxial cable 2 has a leader or a soul 3 on, consisting of a strand bundle or conductor bundle consisting of several individual conductors or strands 4 is formed. The leader 3 is of an internal insulation or a dielectric 5 surrounded protectively. Between an external insulation 7 or the protective jacket and the internal insulation 5 or the dielectric is a shield 8th shown, which is usually a metal mesh.

How it continues 1 it can be seen is a contacting sleeve 10 made of an electrically conductive material around the outer insulation 7 arranged. The contacting sleeve 10 has a substantially cylindrically shaped contacting portion 11 on. In this contacting section 11 is a cutting edge 12 provided, extending from the radially inner side 14 the contacting sleeve 10 extends radially inward. The cutting edge 12 is preferably integral with the contacting sleeve 10 educated. Furthermore, the cutting edge runs 12 for an improved cutting action preferably radially inwardly pointed. The cutting edge penetrates 12 the outside insulation 7 completely and contacted the shield 8th ie it comes in contact with the shield 8th , However, it is also conceivable that the cutting edge 12 at least slightly in the shield 8th penetrates to ensure a reliable contact. However, the penetration depth should preferably be below 50% of the radial strength of the shield 8th , preferably below 30% and most preferably below 15% of the thickness of the shield in the radial direction.

The contacting sleeve 10 this is at least in Kontaktierungsabschnitt 11 deformed by magnet forming so that it plastically deformed on the outside insulation 7 is pressed on. This is done as described with reference to 2 is explained by a Magnetumformverfahren.

In Magnetumformverfahren the contacting sleeve 10 with the cutting edge 12 first on a cable, as it relates to 1 has been explained, postponed to the position at which the contact is to be made. In this position, by the magnetic forming process, a force F at least in the contacting section 11 along the circumference of the contacting sleeve 10 exercised, so that the contacting sleeve 10 plastically deformed in this area, reshaped and against the outer surface of the external insulation 7 is pressed. During this process, the cutting edge penetrates 12 along the circumference in the outer insulation 7 penetrates them and comes with the shield 8th in contact or partially penetrates into this, as described above.

As a rule, the forming sleeve is formed by the deformation 10 springing forces of the line 1 so that the shielding 8th and under the shield 8th lying layers and the conductor core or the strands 4 the line against the contacting sleeve 10 to press. The contacting sleeve 10 is thus with the outside insulation 7 or with the shield 8th positively connected.

The penetration of the cutting edge 12 in the external insulation 7 and their partial displacement can, for example, by scoring the outer 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 the contacting sleeve and the outer surface 15 the external insulation 7 can be achieved, it can, according to a preferred embodiment and as shown 2 it can be seen to make sense a first and second sealing element 16 respectively. 17 between the inside 14 the contacting sleeve 10 and the outer surface 15 the isolation 7 provided. These sealing elements 16 . 17 be when the contact sleeve 10 by means of the magnetic field during the magnetic forming process and the application of the force F against the outer surface 15 the isolation 7 pressed and come in sealing contact with the insulation. In 1 are the sealing elements 16 and 17 not shown, however, would be crimped left and right hand on opposite sides of the cutting edge 12 lie and thus reliably seal the generated section in the longitudinal direction of the cable L. For this purpose, it may be more advantageous, annular sealing elements 16 . 17 , z. B. similar to an O-ring to use. Alternatively, pasty sealing elements 16 . 17 be used. In the contacting sleeve 10 may be provided corresponding annular recess grooves, in which the sealing elements 16 . 17 are included. However, it is also just an intermediate, as it is in 2 is apparent, conceivable. With appropriate grooves, however, the seals could be reliably held in position when pushed onto the cable, ie in the contacting sleeve 10 be pre-assembled.

In addition, it is also conceivable to apply the force F to the sleeve by means of a magnetic field through an electrically non-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 contact takes place in the preassembled state. For simplicity, however, has been dispensed with a representation of the housing in the figures. In any case, the case would be in 2 but at least in the area of Kontaktierungsabschnitts 11 the contacting sleeve 10 completely surrounded.

The second embodiment of the invention in 3 forms the lead 1 from the 1 and 2 such further that the contacting sleeve 10 to a contact element 20 continues. The contact element comprises a core 21 that is integral with a mounting section 22 is designed. Furthermore, a kind of plug or pin 23 integral with the attachment portion 22 intended. The core 21 is advantageously the attachment portion 22 tapered out. The attachment section 22 is advantageously designed in the same direction tapered. The core 21 is located in relation to the attachment section opposite the pin 23 , Both the core 21 as well as the attachment section 22 are frustoconical in the illustrated embodiment.

To form a coaxial plug, the contacting sleeve extends 10 advantageously until over the attachment portion 22 out and 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 23 ,

Advantageously, the contacting of the contact element takes place in particular in the case of a stranded conductor made of aluminum 20 with the conductor 3 by the strands or individual conductors 4 of the conductor through the core 21 be pushed apart. In other words, the core becomes 21 between the individual leaders 4 or strands introduced. The contacting sleeve 10 extends such that it into a second contacting area 30 the strands 4 of the leader 3 into the core 21 was introduced, surrounds. By applying a magnetic field directly to the contacting sleeve 10 in the second contacting area 30 or alternatively through a housing, the contacting sleeve 10 also in the contact area 30 plastically deformed (formed), causing the strands 4 against the core acting as an abutment 21 be pressed and contacting the strands 4 with the core 21 and thus the contact element 20 or the plug 23 he follows. In particular, by providing the core 21 and / or the tapered formation of the attachment portion 22 and the core 21 a welding of the strands 4 with the core 21 and thus with the contact element 20 take place, which is particularly true when using aluminum as a stranded material and / or as a material of the contact element 20 is advantageous. In addition, the contacting sleeve extends 10 also in such a way over the contact element 20 that they are the attachment section 22 surrounds. Here is a mounting section 31 arranged in the magnet forming the Kontaktierungshülse 10 such against the attachment portion 22 of the contact element 20 is pressed, that a firm connection of the contact element 20 done in the sleeve. By magnet forming in the sections 11 . 30 and 31 Preferably, at the same time, the contacting of the contacting sleeve 10 with the shield 8th , contacting the core 21 , ie the contact element 20 , with the single wires 4 and the attachment of the contacting sleeve 10 at the attachment portion 22 of the contact element 20 or vice versa done in a process step. To an electrical connection between the contact element 20 and the contacting sleeve 10 To prevent is preferably between the inside 14 the contacting sleeve 10 in the field of strands 4 and / or the attachment portion 22 , preferably between both an electrical insulation 26 interposed. Also in the area of the attachment section 22 can, as in terms of 2 be explained, a sealing element are arranged (not shown) to a longitudinal water-tightness also at the junction between the mounting portion 22 and the inside 14 the contacting sleeve 10 to realize. By this embodiment in 3 In the simplest way, a coaxial connector is connected 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 embodiments and various modifications and modifications are conceivable. It is also possible individual aspects of the various embodiments in the 1 . 2 and 3 to combine with each other, unless the individual aspects contradict each other.

Claims (7)

Method for cable assembly comprising the steps of: providing a contacting sleeve ( 10 ) with a radially inwardly facing cutting edge ( 12 ), wherein the contacting sleeve ( 10 ) to a contact element ( 20 ), which has a core ( 21 ) and one of the contacting sleeve ( 10 ) partially surrounded mounting portion ( 22 ), providing a cable ( 1 ) with an external insulation ( 7 ), one of the isolation ( 7 ) shielding ( 8th ) with the inward side of the insulation ( 7 ) and one a strand bundle ( 3 ) surrounding inner insulation ( 5 ), wherein the shield ( 8th ) between the inner insulation ( 5 ) and isolation ( 7 ) is arranged; Applying the contacting sleeve ( 10 ) on the cable ( 1 ), so the core ( 21 ) between the strands ( 4 ) of the strand bundle ( 3 ) is arranged and the contacting sleeve ( 10 ) the strand bundle ( 3 ) with the introduced core ( 21 ) surrounds; Magnetic forming of the applied contacting sleeve ( 10 ), wherein the contacting sleeve ( 10 ) on the isolation ( 7 ) is pressed, causing the Cutting edge ( 12 ) the isolation ( 7 ) completely penetrates and the shield ( 8th ) at least contacted, the contacting sleeve ( 10 ) with the outer surface of the attachment area ( 22 ) and the core ( 21 ) with the strand bundle ( 3 ) is electrically connected. Method according to Claim 1, in which the cutting edge ( 12 ) in the magnet forming partially in the shield ( 8th ) penetrates. Method according to one of claims 1 or 2, wherein the contacting sleeve ( 10 ) is received 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 ) he follows. Method according to one of the preceding claims, wherein on the inside ( 14 ) of the contacting sleeve ( 10 ) in the area in which they are connected to the strand bundle ( 3 ) is in contact and / or with the attachment portion ( 22 ), an insulation ( 25 . 26 ) is provided. Method according to one of the preceding claims, in which the core ( 21 ) in one piece from the attachment section ( 22 ) continues. Method according to one of the preceding claims, in which the core ( 21 ) and / or the attachment section ( 22 ), in particular in a direction starting from the end of the conductive element ( 8th ) to the contact element ( 20 ) is tapered towards / are. Method according to one of the preceding claims, comprising at least a first and a second sealing element ( 16 . 17 ) located on opposite sides of the cutting edge ( 12 ) and on the inside ( 14 ) of the contacting sleeve ( 10 ) and after magnet forming with the insulation ( 7 ) are in sealing contact.

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