DE102012221048B4 - Method for mechanically connecting cables to one another and wiring harness - Google Patents

Abstract

A method (100) for mechanically connecting cables (165) to one another, the method (100) comprising the following steps: - placing (115) the cables (165) in a mold (155), so that sections of the cables (165) are in the mold (155); - pouring (135) or foaming of the mold (155) by means of a compound (175) in the region of the cables (165) and demolding (140) the mechanically interconnected cables (165) from the mold; - characterized in that a film (155) is provided between the mold (155) and the cables (165) for easier demolding of the cables (165); - wherein the film (155) is attached to the mass (140) during demolding (140) 175) remains; - the film (155) being provided with a label even before the mold (155) is poured or filled with foam.

Description

The present invention relates to a technique for potting or foaming a wire harness. In particular, the invention relates to demolding the cable harness from a mold for potting or foaming.

A cable harness, in particular for use in a motor vehicle, comprises a multiplicity of cables which are shaped and arranged in order to connect electrical components to one another on board a motor vehicle. Several cables run close to one another on sections, often parallel or wound around one another. The cables should be mechanically connected to one another at predetermined points on the cable harness in order to ensure mechanical stability or impermeability of the cable harness to liquids.

The cables can be connected to one another by means of a compound, in particular a potting compound or foaming compound. For this purpose, the cables are placed in a mold in such a way that sections of the cables run within the mold. Then the mold is provided with the compound, so that the compound is placed on and preferably also between the cables. After a curing or setting process, the cables connected to one another can be removed from the mold, that is to say removed from the mold. In order to facilitate demolding or to enable it in the first place, it is usually ensured that an inner surface of the mold is sufficiently smooth. Often the form is made of metal. In addition, a release agent can be used, which is applied to the inner surface of the mold before foaming or pouring. Release agents are usually liquid or spreadable or can be applied, for example, as an aerosol by means of a spraying process. A common release agent is beeswax. It is also possible to use a release agent which is permanently bonded to the surface of the mold, for example by coating the inside of the mold, for example with polytetrafluoroethylene (PTFE; known under the brand name Teflon).

To build up a simple shape, however, a material should often be used which, due to its nature or the surface smoothness that can be achieved, is not suitable for the procedures described. For example, wood has sufficient rigidity, but also relatively large pores on its surface, so that foaming or potting compound can penetrate the pores and bond with the wooden mold so firmly that demolding is difficult or impossible. Common spreadable or liquid release agents can only have a limited effect here.

EP 0 470 396 A2 shows a mold for producing a sheathing for a bundle of lines.

U.S. 3,187,069 A relates to a method for making foamed articles.

DE 10 2008 005 778 A1 relates to a method for producing a molded part blank for laminated molded parts.

EP 0 249 363 A2 relates to a method for producing molded plastic bodies.

The invention is therefore based on the object of specifying a method for mechanically connecting cables to one another which allows the use of inexpensive materials for a foam or potting mold. The invention solves this problem by means of a method with the features of claim 1 and a cable harness with the features of claim 9. Subclaims reproduce preferred embodiments.

A method according to the invention for mechanically connecting cables to one another comprises steps of laying the cables in a mold so that sections of the cables run in the mold, pouring or foaming the mold and removing the mechanically connected cables from the mold. A film is provided between the mold and the cables for easier removal of the cables from the mold.

This makes it possible to produce the mold from a material that can have almost any surface structure and, in particular, also large porosity. The film reliably separates the foaming or potting compound from the mold, so that the mold can be reused. In particular, a simple shape or a prototype for a shape can thus be produced and used with little effort.

Furthermore, the film remains on the mass during demolding. The film can form a permanent bond with the mass. Surface properties of the mass, for example a surface roughness or adhesive properties, can be kept away from an environment by the film. In addition, the film is provided with an identification before it is poured or foamed, for example by means of an imprint, so that the identification is permanently attached to the cables that are mechanically connected to one another.

In one embodiment, the mold is closed before pouring or foaming. Closing can be done completely, leaving a defined, closed volume inside the form exists. The closing can, however, also take place partially, with predetermined points, which for example can be let into the mold as windows, are not closed. As a result, the shape of the encapsulated or foamed area of the cables can be better controlled.

The mass can be a multicomponent agent which expands after being poured into the mold. Due to the expansion of the mass, the space between the mold and the cables can be filled in an improved manner. By using a multi-component compound, expansion can only take place after it has been poured into the mold. In addition, a degree of hardness of the set or hardened mass can be adjusted by a mixing ratio of its components. Mechanical properties of the cables in the area of the ground can thus be influenced in a targeted manner.

In a particularly preferred embodiment, the mass comprises a casting or foaming agent, in particular a polyurethane (PU). Polyurethane can be easily produced in different densities and with different expansion ratios. In addition, polyurethane can be used at a low cost.

In a particularly preferred embodiment, the shape in the area of the cables comprises a negative shape of a grommet, so that a grommet is formed from the compound on the cables. As a result, the cables can be prepared for a passage through a recess, wherein the passage by means of the grommet can be made stable, vibration-damping and moisture-proof. A previous threading or leading through a sleeve body, for example made of rubber or plastic, is not necessary. In particular when the cables are part of a cable harness, the provision of the grommet can simplify a production process for a cable harness and thus contribute to reducing manufacturing costs.

In a preferred embodiment, the film comprises polyethylene (PE). As a result, the film can be elastic so that it can cling to the shape in an improved manner. Alternatively, the film can also consist of a different material, for example polypropylene (PP).

In another embodiment, the film is applied flat to the mold and remains in the mold after removal from the mold.

For this purpose, the film can be glued to the surface of the mold, for example. In a variant, the film can nevertheless be removed from the surface of the mold, for example under the influence of heat, in order to be able to replace the film from time to time.

During pouring or foaming, the film can be fixed to the mold by means of air pressure. For this purpose, a vacuum can be created between the film and the mold. This ensures that the compound lines the mold well.

In another embodiment, the film can be fixed to the mold by means of electrostatics during pouring or foaming. For this purpose, an inner surface of the mold can be statically charged, for example by friction or by means of a high-voltage generator.

A device for mechanically connecting cables to one another comprises a mold for receiving the cables in such a way that sections of the cables run in the mold and a feed device for a film to place the film between the mold and the cables before the mold is in the area of the Cable is foamed or poured out.

The feed device can, for example, comprise a roll or cylinder on which a supply of the film is wound. The device can thus be simple to set up and use.

• 1 Verfahrensschritte eines Verfahrens zum mechanischen Verbinden von Kabeln aneinander;
• 2 einen Abschnitt eines Kabelbaums mit Kabeln, die mittels des Verfahrens von 1 mechanisch aneinander verbunden sind;
• 3 einen Abschnitt eines Kabelbaums nach 2 mit einer an die Kabel angegossenen oder angeschäumten Tülle; und
• 4 eine Form zum Verguss oder zur Verschäumung von Kabeln entsprechend der Ausführungsform von 3

darstellt.The invention will now be described in more detail with reference to the accompanying figures, in which:

• 1 Method steps of a method for mechanically connecting cables to one another;
• 2 a section of a wire harness with cables made by the method of 1 are mechanically connected to each other;
• 3 a section of a wire harness 2 with a grommet cast or foamed onto the cable; and
• 4th a mold for potting or foaming cables according to the embodiment of FIG 3

represents.

1 shows process steps 105 until 145 of a procedure 100 for mechanical connection of cables to each other. The procedural steps shown 105 until 145 are to be understood symbolically and as examples. Not all procedural steps 105 until 145 are in all embodiments of the method 100 required and some of the procedural steps 105 until 145 can be performed in a different order.

In a first step 105 becomes a shape 150 provided, which delimits a space in which foaming or potting is to take place in the following. Usually the form includes 150 two opposite, open ends and is open on one long side between these ends, so that a section of any length of cable can be inserted. In the in 1 embodiment shown is the shape 150 open at the top. However, other embodiments are also possible, for example a shape 155 that is only open at one end to accept one end of a wire harness.

The material of the form 150 is essentially arbitrary, for example the shape 150 be made of wood or a plastic. Form 150 can also consist of several elements of different materials.

A texture of the surface of the form 150 , for example a surface roughness, moisture or greasiness of the surface, can be achieved through the use of the film 155 be negligible. Preferably has the shape 150 sufficient rigidity to withstand the forces and pressures of the subsequent process steps without being deformed.

In step 110 becomes a slide 155 in the form 150 inserted so that the interior of the shape 150 with the foil 155 is designed. The foil 155 can for example be made of polyethylene (PE), polypropylene (PP) or another plastic. The film preferably overlaps 155 Limitations of form 150 in several directions. In one embodiment there is a feed device 160 provided from which the slide 155 removed and put into the mold 150 can be performed. In the embodiment shown, the feed device comprises 160 a roll or platen on which a supply of foil 155 is wound up. The foil 155 can be unwound from the roll by removing the foil 155 in sufficient measure over the form opened at the top 150 pulled and then dropped or attached to the shape 150 is snuggled into. Optionally, the film can be used before or after it is placed in the mold 150 also from the role 160 be separated.

In step 115 become cables 165 that are to be mechanically connected to each other, so in the form 150 inserted that sections of cable 165 in the shape 150 come to rest. This is where the foil is 155 between the cables 165 and the shape 150 so that the cables 165 no direct contact 150 to have.

In an optional step 120 becomes another slide 155 on the cables 165 hung up. Alternatively, a free end of the first film 155 also fold down to the lines 165 to enclose transversely to their direction of extension.

In another optional step 125 becomes the shape 150 by means of a lid 170 locked. The lid is there 170 preferably on the other side of the further film 155 so that the further slide 155 the cables 165 from the lid 170 isolated. In one embodiment, the shape is 150 by means of the lid 170 across the direction of propagation of the cables 165 completely closed. In another embodiment, the form 150 or the lid 170 Include recesses so that the interior of the mold 150 in which the cables 165 are not fully completed.

In the optional step 130 becomes at least one of the foils 155 to the shape 150 or the lid 170 pressed on. The form 150 or the lid 170 have channels through which air is sucked out, which is located between the film 155 and the shape 150 or the lid 170 is located. Due to the vacuum created in this way, the film can 155 on all sides to the interior of the form 150 be pressed.

In another embodiment, the shape 150 or the lid 170 be provided on their inner surfaces with a layer that is statically charged, so that they the film 155 attracts. The static charge can take place, for example, by means of friction or by means of a high-voltage generator. The step 130 can also be run at an earlier point in time. In particular, the static charge can take place before the film 155 in step 110 in the form 150 is inserted.

In step 135 become the cables 165 in the shape 150 potted or foamed. To do this becomes a mass 175 , which can in particular comprise a potting compound or foaming compound, into the mold 150 in the area of cables 165 introduced so that the mass 175 between the cables 165 and the slide 155 lies or the foil 155 form 150 from the cables 165 and the crowd 175 separates. Preferably the mass is 165 formed from several components, with properties of the mass 175 can be influenced by a mixing ratio of the components.

In one embodiment, a potting or foaming agent is used as a mass 175 used that after pouring into the mold 150 between the cables 165 and the slides 155 expands. An expansion factor of the mass 175 , also called climbing behavior, indicates the factor by which the volume of the mass 175 during a reaction phase after the mass increases 175 was brought into a room. In one embodiment are Expansion factors in the range from approx. 1: 2 to 1:12 are possible. Another material property that can be influenced can be the density of the mass 175 after the end of the reaction phase. The density can for example be 500 to 1000 g / l, preferably about 800 g / l. Other material properties that can be influenced can be porosity or elasticity of the mass 175 include. In a preferred embodiment, the encapsulation or foaming compound comprises 175 Polyurethane (PU).

Is the crowd 175 set or hardened, so it is in the crotch 140 out of form 150 demolded. The foil guarantees 155 easy demoulding of the hardened or set mass 175 out of form 150 or from the lid 170 . The foil 155 either does not adhere to the surface of the mold 155 or the lid 170 or not on the surface of the earth 175 or on any of the surfaces. In the embodiment shown, the film adheres 155 at least to a lesser degree in shape 150 or the lid 170 than on the hardened or set mass 175 so that the slide 155 still on the surface of the mass after demolding 175 adheres.

In another embodiment, the film 155 also stronger on the surface of the form 150 or the lid 170 stick so that the cables 165 along with the crowd 175 out of form 150 can be removed while the slide 155 in the shape 150 or on the lid 170 remains. In one embodiment the surface is the mold 150 or the lid 170 with the foil 155 coated, for example by gluing.

The foil remains 155 during demolding in step 140 in the crowd 175 , so it can remain there in one embodiment. In this case, the slide can 155 be provided with a label, which, for example, the cables 165 indicates. In a preferred embodiment, the film 155 marked before stepping in 110 in the form 150 is inserted. After demolding in the crotch 140 there may be protruding sections of the film 155 from the crowd 175 be separated.

Alternatively, in the optional step 145 the foil 155 from the crowd 175 removed. So that is the procedure 100 finished and the cables 165 are mechanically connected or fastened to one another.

2 shows a section 205 a wire harness with cables 165 that by means of the procedure 100 from 1 are mechanically connected to each other. The cables 165 extend essentially parallel to one another and are on a length 1 along their direction of extension with the mass 175 connected to each other. In a preferred embodiment, the length 1 is above approx. 100 mm.

The illustrated embodiment is suitable for the section 205 to prepare the wiring harness for installation in a cable duct. Through the crowd 175 becomes the section 205 made rigid so that it can be more easily secured in the cable duct. It also protects the crowd 175 the cables 165 , for example in front of pressure and chafing points. In other embodiments, the mass 175 also in the area of a bend, a branch or an end of the section 205 of the wiring harness.

3 shows a section 305 of a wire harness in a representation similar to that in 2 , being the mass 175 a spout 310 which forms the cables 165 surrounds in the radial direction. The spout 310 is in particular to carry out the section 305 set up by a recess, for example by a splash guard wall of a motor vehicle. By forming the grommet 310 at the same time as the potting or foaming process as part of the process 100 does not require the section 305 to be carried out before potting or foaming through a separate sleeve element, which can be made of rubber or plastic, for example.

4th shows a shape 400 according to the shape 150 with the lid 170 the end 1 for potting or foaming cables 165 according to the in 3 embodiment shown. Form 400 comprises a first form element 405 and a second shape element 410 which are essentially the functions of the form 150 or the lid 170 im above related to 1 Take shown embodiment. The form elements 405 and 410 in 4th can be separated from one another in the vertical direction. The form elements that are joined together define it 405 and 410 a negative form 415 the spout 310 the end 3 .

The negative form shown 415 is like the shape of the spout 310 in 3 , purely exemplary. In other embodiments, a different negative shape can also be used 415 to form another spout 310 in the form elements 405 and 410 be shaped. In particular, the negative form 415 also only in one of the form elements 405 , 410 be provided so that the other shaped element 410 , 405 may have another shape, for example that of the lid 170 in 1 .

List of reference symbols

100

procedure

105

Deploy form

110

Insert foil

115

Inserting cables

120

if necessary, apply additional film

125

if necessary, closing the mold

130

if necessary, pressing the film against the mold

135

Foam or encapsulation of the cables

140

Demolding the cables

145

remove the foil if necessary

150

shape

155

foil

160

Feeding device

165

cable

170

lid

175

Potting or foaming compound

205

Section of a wire harness

305

Section of a wire harness

310

grommet

400

shape

405

first form element

410

second form element

415

negative form

Claims (9)

A method (100) for mechanically connecting cables (165) to one another, the method (100) comprising the following steps: - placing (115) the cables (165) in a mold (155) so that sections of the cables (165) are in run the mold (155); - Pouring (135) or foaming the mold (155) by means of a compound (175) in the region of the cables (165) and - Removing (140) the mechanically interconnected cables (165) from the mold; - characterized in that a film (155) is provided between the mold (155) and the cables (165) to facilitate removal of the cables (165) from the mold; - wherein the film (155) remains on the mass (175) during demolding (140); - the film (155) being provided with an identification even before the mold (155) is poured or filled with foam. Method (100) according to Claim 1 , whereby the film is provided with an imprint for identification. Method (100) according to Claim 1 or 2 wherein the mold (155) is closed (125) before pouring or foaming (135). The method (100) according to any one of the preceding claims, wherein the mass (175) is a multicomponent agent which expands after being poured into the mold (155). The method (100) according to any one of the preceding claims, wherein the shape (155) in the region of the cables (165) comprises a negative shape (415) of a grommet (310), so that a grommet (310) on the cables (165) from the Mass (175) is formed. The method (100) according to any one of the preceding claims, wherein the film (155) is peeled off (145) from the mass (175) after demolding (140). Method (100) according to one of the preceding claims, wherein the film (155) is fixed (130) to the mold by means of air pressure during the pouring or foaming (135). Method (100) according to one of the preceding claims, wherein the film (155) is fixed (130) to the mold by means of electrostatics during the pouring or foaming (140). Cable harness produced by a method according to one of the Claims 1 until 8th .

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