DE102017208884A1 - Electrical connection unit and method for its production - Google Patents

Abstract

The invention relates to an electrical connection unit (1), comprising a plurality of components, which are at least partially enveloped by a common plastic shell, wherein as components at least two electrical connection lines (7) are provided and are additionally provided as components:
an Ethernet wire pair (8) comprising two Ethernet wires (9),
or
- At least one required for an Ethernet communication electronic component.
Furthermore, the invention relates to a method for producing an electrical connection unit (1).

Description

The invention relates to an electrical connection unit and a method for the production thereof.

Transmission control devices for vehicles are generally known from the prior art. These transmission control units must be tight and resistant to high temperatures. For electrical connection plug and line systems are provided which produce the electrical connection from the plug contact to the circuit board in the transmission control unit over distances of more than 15 mm. This connector and line systems have trained as a punched grid connectors on which long metallic strip lines that serve as electrical lines are injected into plastic. One end of the lines is connected to the circuit carrier, the other end is equipped with connector contacts or other electrically conductive elements.

The invention has for its object to provide an improved over the prior art electrical connection unit and an improved over the prior art method for producing an electrical connection unit.

The object is achieved by an electrical connection unit with the features of claim 1 and a method for producing an electrical connection unit with the features of claim 10.

Advantageous embodiments of the invention are the subject of the dependent claims.

An electrical connection unit according to the invention, for example a plug or a socket, comprises a plurality of components, which are at least partially enveloped by a common plastic cover. As components, at least two electrical connection lines are provided. In addition, as components, an Ethernet pair of wires, comprising two Ethernet wires, or at least one required for an Ethernet communication electronic component is provided. The Ethernet cores are electrical lines which in particular enable Ethernet data communication, i. H. are suitable for such Ethernet data communication. They are thus suitable for transmitting electrical communication signals, in particular data communication signals. They expediently fulfill an Ethernet specification.

In a method according to the invention for producing such an electrical connection unit, the plurality of components are thus enveloped at least in sections by the common plastic shell, wherein as components, as already mentioned above, at least two electrical connection lines are provided and additionally as components the Ethernet pair, comprising the Both Ethernet wires are provided or additionally as a component which is provided at least one required for the Ethernet communication electronic component.

The at least one electronic component required for the Ethernet communication is, for example, an electronic circuit, for example an integrated electronic circuit. It can also be provided several such electronic components. This electronic component is suitable for carrying out electrical data communication and is required for such an implementation.

The electrical connection unit is provided in particular for electronic units, for example for control units, which require an Ethernet data line, for example for a control unit for a vehicle, in particular for a transmission control unit. In particular, a media tightness of the electrical connection unit and the housing and a high temperature resistance can be ensured by the solution according to the invention. In such electrical connection units, in particular when the components are poured into the plastic shell, d. H. the plastic shell is produced in a casting process, in particular in an injection molding process, no Ethernet data lines have been provided so far, since a cable routing within such an electrical connection unit usually over a length of more than 15 mm is required. However, in the case of Ethernet cable pairs, untwisted and unshielded cable routing over more than 15 mm is difficult, since it is associated with electromagnetic interference, so that signal transmission could then be disturbed or no longer possible.

For such particular trained as a gearbox electronic units, which are particularly tight and high temperature resistant, there are already designed as a connector and line systems electrical connection units that produce the electrical connection of a plug contact to a circuit board over distances of more than 15 mm. There are connectors, especially punched grid, where long metallic strip lines, which serve as electrical lines, are injected in plastic. One end of the leads is connected to the circuit carrier, the other end is typically equipped with connector contacts or other electrically conductive elements. In the state of Technology is an integration of an Ethernet pair of wires not provided due to the above problems.

Therefore, there are so far provided separate automotive Ethernet data lines, the cable typically consists of a closely adjacent twisted pair, possibly shielded. In plug-in and transition areas, the twist must be resolved as short as possible, in particular smaller than 15 mm. On this short, untwisted line route the functionality of the signal transmission is maintained. With longer untwisted pipelines, the risk of loss of signal transmission functionality increases. Similarly, the risk increases due to interference.

In the lead frame of the previously described electrical connection unit described above, the punched strip lines can not be realized as a twisted wire. Even a complete shielding is expensive. A possible unequal length of the lead frame lines, a possible strong bending of the line course and a comparatively high distance of the adjacent lines makes the use as an Ethernet pair impossible.

In the solution according to the invention, the Ethernet pair of wires in the electrical connection unit, in particular for mechatronic systems such as transmission control units, usually much longer than 15 mm. In this case, the signal transmission is ensured by the inventive solution even with such a length. A distance of the closely adjacent wire pair is less than 500 μm in the solution according to the invention. The Ethernet pair of wires is passed in the inventive solution through a sealed housing. The media density is ensured. The electrical connection unit according to the invention is advantageously designed with high temperature stability, in particular it holds over a period of 3000 hours a temperature of 150 ° C and / or stood over a period of 240 hours a temperature of 175 ° C. The components of the electrical connection unit are advantageously designed such that they also survive a hot injection-molding process of producing the plastic cover. Advantageously, the Ethernet pair meets the specification for automotive Ethernet cables LV213 supplement sheet OABR 100 BASET1.

In the alternative, which provides at least one required for the Ethernet communication electronic component or a plurality of such components in the electronic connection unit, these are one or more components of the circuit board in the housing of, for example, as a control unit, in particular transmission control unit, formed electronic unit in the electrical connection unit so that no cable routing of the Ethernet wire pair through the electrical connection unit through to the usually arranged on the circuit board in the housing required for the Ethernet communication electronic components is required. As a result, a length of the Ethernet pair of wires, which is then still required for contacting these electronic components for the Ethernet communication in the electrical connection unit, for example, to the uncritical length of less than 15 mm or 15 mm maximum shortened.

The Ethernet pair is designed, for example, as an Ethernet cable, or the Ethernet wires are formed as enamel wires and twisted together to form the Ethernet pair or the Ethernet wires are formed as stamped wire lines or the Ethernet wires are on at least one circuit board educated. As a result, a configuration of the Ethernet wire pair adapted to the respective requirements of the electrical connection unit can be selected. In the method of manufacture, the Ethernet pair of wires is formed accordingly.

In an advantageous embodiment, the Ethernet cores formed as punched grid lines are twisted together to form the Ethernet wire pair. In the corresponding embodiment of the method for production, they are twisted together accordingly. Twisting reduces the susceptibility to electromagnetic interference and thus ensures signal transmission.

If the Ethernet cores are formed on at least one printed circuit board, then the printed circuit board is advantageously designed as a flexible printed circuit board or formed in a regionally bendable manner via a thin milling. As a result, the laying of the Ethernet wire pair in the electrical connection unit is made possible according to respective requirements.

A further possibility for laying the Ethernet wire pair according to the respective requirements is achieved, for example, by the fact that the Ethernet cores are formed across at least two interconnected printed circuit boards which are angled away from one another by means of at least one connecting element. This also makes an angled laying of the Ethernet wire pair possible. It is also possible to provide a plurality of such printed circuit boards over the course of the wires, in which case two of these printed circuit boards are connected to one another by means of at least one such connecting element. This allows a multiple angled laying.

The common plastic shell is advantageously made of a thermoplastic material or of a thermosetting plastic, in particular as a casting, preferably as an injection molded part. In the process of preparation, the plastic shell is formed accordingly, d. H. the components are expediently inserted into a casting mold and at least partially encapsulated with the plastic. This is done for example with a thermosetting plastic, for example an epoxy resin, and is then also referred to as Ummolden, or for example with a thermoplastic material by injection molding.

Conveniently, an electrical contact element is arranged at least at one end of at least one of the electrical connection lines and / or at least one of the Ethernet wires. In the process of preparation, it is arranged accordingly. Advantageously, it is partially encapsulated with the plastic of the plastic shell, d. H. partly cast in sections. This ensures the media tightness. For example, electrical contact elements are respectively arranged on the ends facing the electronics unit, which are each designed, for example, as a solder contact. These are connected in the process of manufacture, for example by welding or crimping with the respective end. The connection to the circuit carrier can then be done, for example, by soldering. At the other ends, for example, electrical contact elements are arranged, which are designed as so-called crimp contacts. These have a blind hole for insertion of the end and are connected by crimping with the end. For example, these electrical contact elements are designed as round contacts to allow a plug connection.

Advantageously, the Ethernet cores are surrounded by at least one shield, in particular both Ethernet cores from a common shielding. However, alternatively or additionally, it can also be provided that both Ethernet cores each have a shielding. The shielding reduces electromagnetic susceptibility.

The shield is formed, for example, as a Drahtgeflechtumhüllung or as an electrically insulating plastic or as an enveloping metallization on a plastic sheath of the Ethernet wires or as an electrically conductive and / or metal fiber-filled plastic on a plastic sheath of the Ethernet wires.

Embodiments of the invention will be explained in more detail below with reference to a drawing.

• 1 eine schematische Darstellung einer elektrischen Verbindungseinheit.

Showing:

• 1 a schematic representation of an electrical connection unit.

1 shows a schematic representation of an electrical connection unit 1 for example, as a control unit, in particular as a transmission control unit for a vehicle, trained electronic unit 2 , The electronics unit 2 points to a circuit carrier 3 arranged electronic components 4 . 5 on, which via the electrical connection unit 1 to contact. One of these electronic components 5 is an electronic component required for Ethernet communication 5 ,

The electrical connection unit 1 has a punched grid in the example shown 6 on, in which two electrical connection lines 7 are designed as strip lines. Furthermore, in this stamped grid 6 an Ethernet wire pair 8th inserted, which two twisted together Ethernet wires 9 that has a common sheath 10 are provided. This sheath 10 or at least a part of this sheath 10 is advantageously as a shield 11 formed, whereby the Ethernet wire pair 8th shielded against electromagnetic interference.

The Ethernet pair 8th in the embodiment shown here or in the other embodiments described below is, for example, as a common insert 12 formed, which in the stamped grid 6 and with this together in a mold can be inserted or directly into the mold can be inserted, as described in more detail below.

At each one outer end of the electrical connection lines 7 is in each case a trained as a plug contact electrical contact element 13 arranged. Similarly, at each one outer end of the Ethernet wires 9 each designed as a plug contact electrical contact element 13 arranged. These electrical contact elements 13 at the respective outer end are, at least with the Ethernet wires 9 , For example, each designed as a so-called crimp contact, ie, for example, as a round contact element, in its respective blind hole, the Ethernet core 9 plugged in and crimped.

At each one the circuit carrier 3 facing inner end of the electrical connection lines 7 is in each case a trained as a transition element electrical contact element 13 arranged to form a transition from the form of stripline electrical connection line 7 to the circuit carrier 3 manufacture. Likewise, at each one the circuit carrier 3 facing inner end of the Ethernet wires 9 in each case a trained as a transition element electrical contact element 13 arranged to make a transition from the respective Ethernet wire 9 to the circuit carrier 3 manufacture. These electrical contact elements 13 at the respective inner end are, at least with the Ethernet wires 9 , For example, each designed as a so-called Einlötkontakt and, for example, with the respective Ethernet core 9 connected by welding or crimping. To ensure a sufficient distance between the electrical contact elements 13 at the outer ends and between the electrical contact elements 13 at the inner ends of the Ethernet wire pair 8th ensure are the ethernet wires 9 not twisted together in the respective end, ie they are in this end an untwisted Ethernet wire pair 8th , as in 1 shown.

The punched grid 6 with the inserted Ethernet wire pair 8th is, not shown here, at least partially wrapped by a plastic cover. This plastic sheath expediently extends to the electrical connection contacts 13 , wherein in particular the electrical connection contacts 13 At the outer ends are partially wrapped by the plastic cover. As a result, a media tightness of the electrical connection unit 1 reached. Media density means in particular liquid-tight and advantageously also gas-tight.

The plastic sheath is formed for example of a thermoplastic material, for example of polyamide, or of a thermosetting plastic, for example of an epoxy resin. Advantageously, the stamped grid to form the plastic shell 6 with the inserted Ethernet wire pair 8th or expediently with the entire the Ethernet wire pair 8th comprehensive insert 12 placed in a mold and encapsulated with the plastic accordingly. In the case of a thermoplastic, this is expediently carried out in a plastic injection molding tool and by means of a plastic injection molding process.

The Ethernet pair 8th is, for example, as a high temperature suitable for automotive applications, i. h designed for vehicle applications, suitable Ethernet cable that withstands temperatures of 150 ° C for a period of 3000 hours. This Ethernet cable is also suitable for plastic injection molding, ie it can in the stamped grid 6 inserted and molded with a thermoplastic material, such as polyamide, in the manner described above to form the plastic shell.

The two twisted together Ethernet wires 9 Comprehensive Ethernet cables basically have the same cable characteristics as an exposed, outgoing Ethernet cable. The Ethernet cable can be single-sheathed or double-sheathed and, for example, additionally longitudinally sealed within the sheath 10 or the sheathing 10 be.

Alternatively, the Ethernet wire pair 8th be formed and / or shielded in another way, in which case it advantageously has the same line properties.

In the described and in 1 schematically illustrated embodiment of the electrical connection unit 1 can advantageously a previously used training, in particular external form, the electrical connection unit 1 and the punched grid 6 remain as used. Advantageously, instead of a further pair of conventional punched-strip lines, not shown here, the plastic-castable, in particular suitable for injection molding, high-temperature suitable and suitable for Ethernet applications Ethernet pair of wires 8th , which is advantageously designed as a twisted Ethernet cable, inserted.

The electrical connection unit 1 and their punched grid 6 thus advantageously have the same properties as before, for example, only reduced by the further punched lattice strip line pair and extended to the function of the Ethernet data line by means of the integrated Ethernet pair of wires 8th for the secure operation of an Ethernet communication interface of the mechatronic system, ie the electronic unit designed, for example, as a control unit, in particular a transmission control unit for a vehicle 2 ,

Alternatively to the above and in 1 illustrated embodiment of the Ethernet wire pair 8th Ethernet cables can be Ethernet cables 9 be formed as enamel wires, which are twisted together, in the stamped grid 6 inserted and wrapped in the manner described above with the plastic to form the plastic shell. Alternatively, the Ethernet wires 9 of the Ethernet wire pair 8th be designed as stamped wire lines, for example, as impedance-controlled strip lines, which are then wrapped in the manner described above with the plastic to form the plastic shell. Alternatively, in particular by means of the stamped grid 6 or by means of another stamped grid, a twisted Stripline be formed by the Ethernet wires 9 as punched grid lines, in particular punched grid strip lines, are formed and twisted together. These are then inserted, for example, in the stamped grid shown above 6 and thus inserted into a casting tool or directly inserted into a casting tool and wrapped in the manner described above with the plastic to form the plastic shell, for example, overmoulded.

Alternatively, the Ethernet wires 9 be formed on at least one circuit board. For example, a plurality of printed circuit board pieces are provided, which are bendable via a thin milling or connected to each other via additional connecting elements and are angled to each other. The Ethernet wires 9 are advantageously impedance-controlled.

Alternatively, the printed circuit board is designed, for example, as a flexible printed circuit board, also referred to as a flexible printed circuit board. Such flexible circuit boards are already known from the prior art and have electrical lines which are externally electrically isolated and as Ethernet cores 9 can be used. Such flexible printed circuit boards can be bent and laid essentially as desired. Also these Ethernet wires 9 are advantageously impedance-controlled. The printed circuit board or printed circuit boards or PCB pieces are then also in the stamped grid 6 and inserted with this in the casting tool or directly into the casting tool and wrapped in the manner described above with the plastic to form the plastic shell, for example, overmoulded.

In an alternative embodiment, not shown, the required for the Ethernet communication electronic component 5 not on the circuit carrier 3 but as required for the Ethernet communication component in the electrical connection unit 1 integrated. Then the insertion of the Ethernet wire pair 8th not required or it is at least a much shorter Ethernet wire pair 8th required.

Preferably, the electrical connection unit 1 and their components resistant to high temperatures, in particular, they withstand a temperature of 150 ° C and / or stand for a temperature of 175 ° C for 3,000 hours.

The electrical connection unit 1 is advantageously externally resistant to water and oils and other motor vehicle typical media, ie it is formed media-dense. Advantageously, the electrical connection unit 1 furthermore gastight, for example up to 500 mbar vacuum. Advantageously, at least the Ethernet wire pair can be 8th and all associated therewith in the respective training components, ie advantageously the entire insert 12 , bend at least in some areas, one for each of the electrical connection unit 1 to achieve the required shape.

The Ethernet pair 8th In all embodiments, advantageously comprises two Ethernet wires 9 which can be twisted together.

The Ethernet wires 9 are advantageously already externally electrically isolated or in the manufacturing process for producing the electrical connection unit 1 wrapped with an electrically insulating material.

The electrical properties of the Ethernet wire pair 8th Suitably meet the applicable automotive Ethernet requirements under OABR (Open Alliance BroadRreach Ethernet).

The Ethernet cable pair designed as a cable line, ie as an Ethernet cable 8th Conveniently complies with the LV 213 (Cable) Supplement OABR BASE T1.

The entire system of electrical connection unit 1 and, for example, as a control unit, in particular transmission control unit, trained electronic unit 2 Conveniently meets the applicable OABR Ethernet requirements.

The Ethernet pair 8th in its respective embodiment described above, ie advantageously the entire insert 12 , And advantageously also the other of the plastic shell enveloped components of the electrical connection unit 1 can be advantageously in the plastic injection molding process with a thermoplastic, for example polyamide, in the manner described above at least partially wrap or encase in a Ummoldingprozess with a thermoset, for example, with a filled epoxy resin, at least in sections.

Advantageously, in the process for producing the electrical connection unit 1 at the respective end of the respective Ethernet wire 9 and / or at the respective end of the respective electrical connection line 7 a respective electrical contact element 13 attached, as already described above, for example, a circular contact, a rectangular contact, a solder contact, a so-called jumper or other electrical contact element 13 , The attachment can be done for example by welding, crimping, clipping, soldering or otherwise.

Advantageously, the trained in the manner described above Ethernet wire pair 8th including the attached electrical contact elements 13 ie the entire insert 12 , by customizing the plastic cover so integrate into the plastic shell that the electrical connection unit 1 between the electrical contact elements 13 Media-tight is formed.

The Ethernet pair 8th is advantageously of at least one shield 11 surround. This shielding 11 For example, it can be formed by means of a in the stamped grid 6 and / or in the casting tool inserted wire mesh sheath, by means of an applied in a first Vorumspritzung electrically insulating plastic, by means of an applied enveloping metallization on a example produced by a first pre-injection and already thinly applied plastic insulation around the Ethernet pair of wires 8th and / or by means of a further pre-extrusion of an electrically conductive plastic or a metal fiber-filled plastic, which is applied to the first shell of the electrically insulating plastic produced by the first pre-extrusion.

LIST OF REFERENCE NUMBERS

1

connecting unit

2

electronics unit

3

circuit support

4, 5

component

6

lead frame

7

connecting line

8th

Ethernet twisted pair

9

Ethernet wire

10

jacket

11

shielding

12

insert

13

contact element

Claims (10)

Electrical connection unit (1), comprising a plurality of components, which are at least partially enveloped by a common plastic shell, wherein at least two electrical connection lines (7) are provided as components and are additionally provided as components: an Ethernet wire pair (8) comprising two Ethernet wires (9), or - At least one required for an Ethernet communication electronic component. Electrical connection unit (1) according to Claim 1 in which - the Ethernet wire pair (8) is designed as an Ethernet cable, or - the Ethernet wires (9) are formed as enamel wires and are twisted together to form the Ethernet wire pair (8), or - the Ethernet Cores (9) are formed as punched grid lines, or - the Ethernet wires (9) are formed on at least one printed circuit board. Electrical connection unit (1) according to Claim 2 , wherein the formed as a punched grid lines Ethernet wires (9) to form the Ethernet pair of wires (8) are twisted together. Electrical connection unit (1) according to Claim 2 , wherein the circuit board is formed as a flexible printed circuit board or formed by a thin milling region partially bendable. Electrical connection unit (1) according to Claim 2 , Wherein the Ethernet cores (9) are formed over their cores course on at least two angled by at least one connecting element interconnected circuit boards. Electrical connection unit (1) according to one of the preceding claims, wherein the common plastic sheath is formed from a thermoplastic material or from a thermosetting plastic, in particular as a casting, preferably as an injection molded part. Electrical connection unit (1) according to one of the preceding claims, wherein at least at one end of at least one of the electrical connection lines (7) and / or at least one of the Ethernet cores (9) an electrical contact element (13) is arranged. Electrical connection unit (1) according to one of the preceding claims, wherein the Ethernet wires (9) of at least one shield (11) are surrounded. Electrical connection unit (1) according to Claim 8 wherein the shield (11) is formed - as a wire mesh sheath, or - as an electrically insulating plastic, or - as an enveloping metallization on a plastic sheath of the Ethernet wires (9), or - as an electrically conductive and / or metal fiber-filled plastic on a plastic sheath. Method for producing an electrical connection unit (1) according to one of the Claims 1 to 9 , wherein a plurality of components are at least partially enveloped by a common plastic shell, wherein at least two electrical connecting lines (7) are provided as components and are additionally provided as components: - an Ethernet pair of wires (8) comprising two Ethernet cores (9 ), or - at least one electronic component required for Ethernet communication.

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