DE102019127427A1 - Method of manufacturing a connecting element - Google Patents

Abstract

The present invention relates to a method for producing a connecting element for the electrically conductive connection of a power source with at least one consumer connected to the connector and / or between individual consumers, comprising the steps of: providing a connector housing which has a first housing within which at least one The connector holder is arranged or formed by the housing itself, the connector housing having a second housing which is opposite the first housing along an insertion direction, an electrical conductor being guided along the insertion direction through the second housing into the first housing, Conductor end of the electrical conductor in the plug-in holder, so that the conductor end terminates, preferably flush, with an end of the plug-in holder that can be seen from the outside, in particular freely, - introduction of a liquid, viscous en or pasty adhesive in the second housing, curing of the adhesive, so that the electrical conductor is firmly anchored in the housing by the adhesive, the first housing essentially remaining free of the adhesive.

Description

The present invention relates to a method for producing a connecting element for the electrically conductive connection of a power source to at least one consumer connected to the connector and / or between individual consumers.

For example, the connecting element can be a plug-in element of a charging cable or some other cable which is to be connected to a socket or another electrical conductor.

The method proposed here for producing a connecting element is also distinguished in particular by the fact that, in contrast to the methods known from the prior art for producing a connecting element, it is not only inexpensive but also easy to carry out.

The method discussed here comprises a first step by which a connector housing is provided which has a first housing, within which at least one connector holder is arranged or is formed by the housing itself, the connector housing having a second housing which, along an insertion direction, corresponds to the first Housing opposite.

The first housing and the second housing are preferably permanently connected to one another, so that they cannot be separated from one another in a non-destructive manner. For example, the connector housing is an integrally molded plastic part which, in its one-piece form, forms the first and second housings. The connector housing can therefore be free of screws, eyes, interruptions or other two-part formations. In particular, a connector housing can be such a housing which was produced in a single plastic molding step.

In a further step, an electrical conductor is guided along the insertion direction through the second housing into the first housing.

The insertion direction can form an axis of symmetry so that the connector housing is at least partially rotationally symmetrical about the insertion direction. In any case, the second housing and the first housing are arranged one behind the other along the insertion direction.

In a further step, a conductor end of the electrical conductor is positioned in the plug-in holder so that the conductor end terminates, preferably flush, with an end of the plug-in holder that can be seen from the outside, in particular free.

In other words, the electrical conductor is guided into the first housing from behind, that is to say via the second housing, so that after this step the end of the conductor positioned in the first housing can be contacted from the outside.

In a further step, a liquid, viscous or pasty adhesive is inserted into the second housing, with this adhesive being cured in a subsequent step so that the electrical conductor is firmly anchored in the housing by the adhesive, the first housing essentially remains free of the adhesive. Preferably, therefore, only the second housing is at least partially, but preferably completely filled with the adhesive.

After the curing step, the end of the electrical conductor is firmly positioned at least along the insertion direction and can therefore no longer be detached from the connector housing without being destroyed.

GF:

Glasfasern

GB:

Glaskugeln

MF:

Mineralfasern

MX:

nicht spezifizierte Mineralfüllung

GX:

nicht spezifizierte Glasfüllung

CD:

Kohlenstoffmehl

P:

nicht spezifiziertes Füllmehl

In principle, the following materials, which are not listed exhaustively, come into question as materials for the connector housing: Material group modification SHORE D SECTION 75-93 ABS + 30 mass% GF 62-68 ABS / TPE 46 ABS / TPU 58-68 ASA 75 ETFE 60-78 EVA 17-45 PA 11 PA 11 + 23 mass% GF 70 PA 12 PA 12 (normal moist) 75-78 PA 12 + 30 mass% GF (normal moist) 75 PA 612 73 PA 6 PA 6 (normal moist) 52-77 PA 6 + 30 mass% GF 48-80 PA 6 + 30 mass% GF (dry) 84 PA 66 PA 66 + 30 mass% GF 77-82 PA 66 + 30 mass% GB 81 PA 66 + 30 mass% MX 75-82 PAEK 86-90 PAEK + 30 mass% GF 90 PBI 99 PBT 79-86 PBT + 30 mass% GF 53 - 85 PBT + 30 mass% GX 54 Pc 51-85 PC + 30 mass% GF 65-72 PC + 30 mass% GX 70 PCTFE 76 - 80 PE-HD 56-69 PE-LD 39 - 83 PE-LLD 38-60 PE-MD 45 - 60 PE-UHMW 60-65 PEEK 83-88 PEI 88-90 PEK 87 PEK + 30 mass% GF 90 PET PET + 30 mass% GF 63-65 PMMA 52 - 85 PMMA + 30 mass% GF 55 POM 52 - 83 PP 59-77 PP + 30 mass% GF 62-80 PP + 30 mass% CD 74-75 PP + 30 mass% MF 60-74 PP + 30 mass% P 65 PP + 30 mass% CaCO ₃ 55-70 PP / EPDM 40 PS 78-80 PTFE 50-90 PURE 20-84 PVC-U 74-94 PVC-U / NBR 58-74 PVC-P 42-77 PVC-C 82 PVDF 46 - 79 SAN 45-85 SMMA 72-82 TPC 28-82 TPE 48-78 TPE / PTFE 56 TPE-E TPE-E + 30 mass% GF 55 TPO 16-70 TPS 60 TPU TPU + 30 mass% GF 74-80 TPV 40-51 where:

GF:

Fiberglass

GB:

Glass balls

MF:

Mineral fibers

MX:

unspecified mineral filling

GX:

unspecified glass filling

CD:

Carbon flour

P:

unspecified filling flour

The connector housing can also be manufactured with the following 3D printing processes, which are not listed and listed in an exhaustive manner.

The FDM process (Fused Deposition Modeling)

Alternative names: Fused Filament Fabrication (FFF), Fused Layer Modeling (FLM)

The process refers to the application of layers (extrusion) of a material through a hot nozzle. The consumables are in the form of a long wire (so-called filament) on a roll and are pushed into a print head by the conveyor unit, where they are melted and placed on a print bed applied. The print head and / or print bed can be moved in 3 directions. In this way, layers of plastic can be applied one on top of the other.

The SLS process (selective laser sintering)

In contrast to the sintering process, in which substances are bonded together in powder form under the action of heat, in the SLS process this is done selectively by a laser (alternatively also electron beam or infrared beam). So only a certain part of the powder is melted together. For this purpose, a thin layer of powder is always applied to the printing bed by the coating unit. The laser (or other energy source) is now aimed precisely at individual points of the powder layer in order to form the first layer of the print data. The powder is melted or melted and then solidifies again by cooling it slightly. The unmelted powder remains around the sintered areas and serves as a support material. After a layer has solidified, the print bed lowers by a fraction of a millimeter. The coating unit now moves over the print bed and applies the next layer of powder. The second layer of the print data is then sintered by the laser (or other energy source). This creates a three-dimensional object in layers.

Three-Dimensional Printing (3DP)

The 3DP process works very similarly to selective laser sintering, but instead of a directed energy source, a print head moves over the powder. This releases tiny droplets of binding agent onto the underlying powder layers, which are thus bonded together. Otherwise this procedure is the same as the SLS procedure.

Stereolithography (SLA)

Instead of a plastic wire or printing material in powder form, liquid resins, so-called photopolymers, are used in the stereolithography process. They are hardened in layers by UV radiation and thus create three-dimensional objects. To do this, the construction platform in the Harz Basin is gradually lowered. There are also variants (the so-called Polyjet process) without an entire tank with liquid resin. For this, an epoxy resin is applied drop by drop from a nozzle and cured immediately by a UV laser.

Laminated Object Manufacturing (LOM)

Alternative designation: Layer Laminated Manufacturing (LLM)

The process is based neither on chemical reactions nor on a thermal process. A separating tool (e.g. a knife or carbon dioxide laser) is used to cut a film or plate (e.g. paper) along the contour and glue it on top of each other in layers. By lowering the construction platform, a layered object is created from glued, overlapping foils.

As an alternative or in addition, the connector housing or other plastic parts can also be produced by means of a plastic free-form process.

Such a free-form process is based on CAD data. The underlying technology has similarities with injection molding and can be assigned to additive manufacturing or 3D printing.

In such a device (also known as: Freeformer), standard plastic granulate is first melted in a plasticizing cylinder, as is the case with injection molding. In contrast to injection molding, however, molds and tools (machine tools) are no longer used.

Instead, a nozzle closure with piezo technology, which opens and closes up to three hundred times per second, generates tiny plastic droplets (see Fused Deposition Modeling (FDM), in which plastic strands are heated and extruded). The Freeformer builds the components layer by layer from the droplets.

The actual "free-forming" of parts is made possible by a component carrier that is movable in three axes. Complex geometries and undercuts can be created with the Freeformer without, as is the case with some other 3D printing technologies - e.g. B. in stereolithography - for overhanging areas Needing support body. If the machine is equipped with a second discharge unit, two-component parts, e.g. B. hard-soft compounds or different colors can be produced

• • Mehr Möglichkeiten bei der Materialauswahl,
• • Bauteileigenschaften nahezu wie im Serienprozess (Verformung, Wärmeleitung, Brandschutz),
• • Frei in der Gestaltung des Verbindungselements.

Such a process therefore leads to the following advantages, among others:

• • More options in the choice of materials,
• • Component properties almost as in the series process (deformation, heat conduction, fire protection),
• • Free in the design of the connecting element.

This method and the entire process can also be used to react to any required geometry, even if small quantities have to be produced. This means that plugs with all the required properties can be supplied.

The device described above does not consist of filaments either, but rather individual drops.

According to at least one embodiment, the method for producing a connecting element for the electrically conductive connection of a power source with at least one consumer connected to the connector and / or between individual consumers comprises a first step, during which a connector housing is provided which has a first housing, within which at least a connector holder is arranged and / or formed by the housing itself, the connector housing having a second housing which lies opposite the first housing along an insertion direction, an electrical conductor being guided along the insertion direction through the second housing into the first housing, with In a next step, a conductor end of the electrical conductor is positioned in the plug holder so that the conductor end is preferably flush with an end of the plug that is visible from the outside, in particular a free end bracket completes.

In a further step, a liquid, viscous or pasty adhesive is inserted into the second housing, with the adhesive being cured in a subsequent step so that the electrical conductor is firmly anchored in the housing by the adhesive, the first housing being essentially free of the adhesive remains.

According to at least one embodiment, the conductor end is stripped of insulation before the conductor end is positioned in the plug-in holder, a connecting plug with its fixing region being pushed onto an end of the conductor end that is then exposed.

“Stripped” is understood to mean, in particular, at least partial removal of the plastic sheathing of the electrical partial line, for example a wire of the electrical conductor. For example, the stripping length can be 5 mm, 7 mm or more mm.

The connecting plug can initially be any plug element which comprises at least one fixing area, so that the connecting plug can be arranged on the conductor end in a mechanically fixed, preferably non-detachable manner via the fixing area. A fixing area can be understood to mean an area which is designed in such a way that the then exposed conductor end, i. H. the wire itself is pushed into the fixing area and the fixing area therefore forms a kind of clamp. However, it is also possible that the fixing area is also an area to which an additional adhesive element has to be attached in order to be able to fix the exposed end of the conductor end to the fixing area. The exposed end of the conductor end is preferably releasable and, in particular, releasable again from the fixing area without being destroyed.

However, a permanent connection is also conceivable. For this purpose, it is possible for the exposed end to be soldered to the fixing area or otherwise connected using a connection method.

According to at least one embodiment, the connecting plug is inserted flush into the plug-in holder along the insertion direction.

One end of the plug-in holder, which closes off the first housing or is arranged within the first housing, is therefore in this case preferably arranged in length with the connecting plug. This flush arrangement in particular prevents the conductor end, in particular the connector, from protruding from the first housing. Rather, through the flush arrangement can be achieved, at least along the insertion direction, that the connector is firmly positioned in the first housing.

According to at least one embodiment, the connector has, viewed along the insertion direction, a base area and two eyelet areas bordering the base area in the transverse direction, so that a contact area that is open on one side is created in order to connect the connector to a power source or a consumer in an electrically conductive manner, whereby the end of the conductor is attached in the fixing area of the connector so that an electrically conductive connection to the electrical conductor and a power source or a consumer can be established via the connector.

According to at least one embodiment, the plug-in holder, viewed along the insertion direction, has at least one bulge in the direction away from the insertion direction, the connecting plug being inserted into the plug-in holder in such a way that the contact area open to one side points towards the bulge, so that the bulge has a Positioning marking for the alignment of the connecting plug relative to the housing, and in particular within the first housing, is used.

This refinement therefore avoids unwanted rotation of the connector plug relative to the housing, so that the connector plug is always correctly positioned within the housing.

According to at least one embodiment, before the liquid, viscous or pasty adhesive is introduced into the second housing, a positioning aid, preferably detachable, is introduced and / or pushed back into the first housing, the positioning aid being designed in such a way that by pushing the positioning aid into the first housing, the electrical conductor and / or the connector is inserted flush into the connector, in particular if an end of the electrical conductor, i.e. a conductor end and / or the connector, has protruded from the connector before the positioning aid was inserted. In this respect, the end of the electrical conductor and / or connector is pushed back into the plug holder, preferably solely by the pressure of the positioning aid.

According to at least one embodiment, the positioning aid has at least one pressure surface with which the end of the electrical conductor and / or connector is pushed back flush into the plug holder and / or is positioned there, the pressure surface as a recess or as a highlight along an otherwise preferably flat base surface is designed so that a mechanical contact between the positioning aid and the end of the electrical conductor and / or the connector is preferably only established via the pressure surface.

For example, the positioning aid is a disc-shaped, flat, preferably round part, which, viewed from above, has a recess or a prominence on at least one side as the pressure surface claimed above. For example, the positioning aid is made from a hard rubber or a metal, in particular in a one-piece manner.

According to at least one embodiment, the positioning aid remains positioned in the first housing during the introduction of a liquid, viscous or pasty adhesive into the second housing, and is only removed from the (first) housing, in particular non-destructively from the first housing, after the at least partial hardening of the adhesive removed again.

According to at least one embodiment, the electrical conductor is a multi-core electrical conductor, each end of a core of the electrical conductor being provided with the connecting plug, and a separate plug-in holder being formed in the housing for each core.

According to at least one embodiment, viewed around an axis of symmetry of the housing from the direction of the insertion direction, the at least two, preferably three, plug-in holders are arranged in the circumferential direction, preferably equidistant from one another.

For example, viewed from the axis of symmetry, the plug-in brackets are arranged at an angle of 120 degrees to one another.

The invention described here is described below with reference to several figures.

In particular is the 1A to 1H a manufacturing process for the manufacture of a connecting element, as shown above, is shown.

Identical or identically acting components in the figures are provided with the same reference symbols, even if some elements may be shown in an exaggerated manner.

From the 1A can in a side view an embodiment of a connector housing described here 10 can be recognized, the connector housing 10 a first housing 10A (covered) and a second housing 10B having, within the first housing 10A the connector holders 10AA are arranged. An electrical conductor 20th is through the second housing 10B through along an insertion direction E1 in the first housing 10A guided. It is also an orientation aid 70 recognizable, which in the form of an outer haptically perceptible housing tooth 71 is shown. There is also a second housing tooth 72 shown, with both housing teeth facing each other. This makes it easier to identify and position the individual wires within the housing 10 .

As also from the 1A can be recognized, has the connector housing 10 inside a partition 80 between the two housings 10A and 10B three around the direction of insertion E1 radially evenly spaced apart openings 91 on, through which, as in the 1B shown, individual cores of an electrical conductor 20th are passed through.

It can be seen that the electrical conductor 20th along the direction of insertion E1 through the second housing 10B through into the first housing 10A (shown on the reverse and from the 1A and 1B not recognizable), whereby as from the 1C can be recognized, a ladder end 20A of the electrical conductor 20th in the plug-in bracket in three each for the respective wires 20A to 20C of the electrical conductor 20th provided plug-in brackets 10AA is positioned so that each of the conductor ends 21A of the individual wires preferably flush (in the 1C not shown flush, here the individual conductor ends must be in the first housing 10A can still be pushed back) with an end of the plug-in bracket that can be seen from the outside, in particular freely 10AA concludes (see 1E) .

In the 1F is a positioning aid shown in this invention, which is not mandatory but is advantageously conceived 50 recognizable.

In particular, namely from the 1 it can be recognized that before the end of the conductor is positioned in the connector, the end of the conductor 20A or, the individual wires are stripped of the insulation, with one end then exposed 200A each end of the ladder 20A each wire has a connector 30th with its fixing area F10 is postponed.

Again 1E is removed, therefore becomes the connector 30th along the direction of insertion E1 flush in each of the plug-in brackets 10AA introduced.

The 1E it can also be seen that each of the connecting plugs 30th along the direction of insertion E1 a floor area E10 as well as two the floor area E10 in the transverse direction Q1 edging eyelet areas E11 has, so that a contact area open to one side K10 is generated to the connector 30th to be connected to a power source or a consumer in an electrically conductive manner, the respective end of the conductor 20A into the fuser area F10 of the connector is attached so that the connector 30th an electrically conductive connection with the electrical conductor 20th and a power source or a consumer can be produced.

For correct orientation, see the 1E still recognizable that the respective plug-in bracket 10AA along the direction of insertion E1 seen at least one bulge A10 in the direction away from the insertion direction E1 having, wherein the connector 30th in the respective plug-in brackets 10AA is introduced that the contact area open to one side K10 to the bulge A10 points out so that the bulge A10 a positioning mark for the alignment of the connector 30th relative to the housing 10A is.

The positioning aid 50 each has 3 printing areas 50A on, with which the individual ends of the electrically conductive wires of the electrical conductor 20th are pressurized so that the positioning aid 50 as a kind of detachable cap closure in the first housing 10A is introduced and inserted there. The individual ends of the individual wires are therefore automatically correct in the three plug-in holders 10AA positioned.

In the 1G is shown in a side view how at least partially the positioning aid 50 in the first housing 10A is pressed in to create the flush finish as shown above.

In the 1H is shown how curing of the adhesive in a further step 3 is shown so that the electrical conductor 20th through the adhesive 3 in the case 10A and also in the housing 10B is anchored, the first housing 10A remains essentially free of the adhesive. “Essentially” in this context means that a volume of the first housing is occupied by less than 10%, preferably less than 5%, with the adhesive, so that the adhesive is preferably essentially only located in the second housing and not through openings in it the partition wall can flow through into the first housing.

In the 1I is the positioning aid 50 removed again so that the free electrical wires of the electrical conductor shown there 20th are at least partially encapsulated together with the connection housing with a plastic encapsulation, so that a then finished connection element 1 arises in which the connector housing 10 is completely, preferably positively sealed to the outside and thus over the second housing 10B no liquid to the adhesive 3 can arrive.

The invention is not restricted on the basis of the exemplary embodiment, but rather fits into every design and every invention that cannot be clearly found in the registration documents, but can emerge from the registration documents.

List of reference symbols

1

Connecting element

3

Adhesive

10

Connector housing

10A

first housing

10B

second housing

10AA

Connector holder

20th

electrical conductor

20A

End of ladder

21A

End of ladder

200A

exposed end

30th

Connector

50

Positioning aid

50A

Printing area

50B

Base surface

70

Guidance

71

first housing tooth

72

second housing tooth

80

partition wall

91

opening

E1

Insertion direction

E10

Floor area

E11

Eyelet area

F10

Fusing area

K10

Contact area

Q1

Transverse direction

A10

bulge

Claims (10)

Method for producing a connecting element (1) for the electrically conductive connection of a power source to at least one consumer connected to the connector and / or between individual consumers, characterized by the following steps: - Providing a connector housing (10) which has a first housing (10A) has, within which at least one connector holder (10AA) is arranged or is formed by the housing (10A) itself, the connector housing (10) having a second housing (10B) which lies opposite the first housing (10A) along an insertion direction (E1) - An electrical conductor (20) is guided along the insertion direction (E1) through the second housing (10B) into the first housing (10A), - Positioning of a conductor end (20A) of the electrical conductor (20) in the plug-in holder ( 10AA), so that the conductor end (20A), preferably flush, with an externally, in particular free, one hable end of the plug-in holder (10AA), - introduction of a liquid, viscous or pasty adhesive (3) into the second housing (10B), - curing of the adhesive (3) so that the electrical conductor (20) through the adhesive (3) is firmly anchored in the housing (10B), the first housing (10A) remaining essentially free of the adhesive (3). Procedure according to Claim 1 , characterized in that prior to the positioning of the conductor end (20A) in the connector holder (10AA), the conductor end (20A) is stripped, a connecting plug (30) with its then exposed end (200A) of the conductor end (20A) Fusing area (F10) is pushed open. Procedure according to Claim 2 , characterized in that the connecting plug (30) is inserted flush into the plug-in holder (10AA) along the insertion direction (E1). Method according to at least one of the preceding claims, characterized in that the connecting plug (30), viewed along the insertion direction (E1), has a base area (E10) and two eyelet areas (E11) which border the base area (E10) in a transverse direction (Q1). so that a contact area (K10) open to one side is generated in order to connect the connector plug (30) to a power source or a consumer in an electrically conductive manner, the conductor end (20A) being attached to the fixing area (F10) of the connector plug (30) is, so that an electrically conductive connection to the electrical conductor (20) and a power source or a consumer can be established via the connector (30). Method according to at least one of the preceding claims, characterized in that the plug-in holder (10AA), seen along the insertion direction (E1), has at least one bulge (A10) in the direction away from the insertion direction (E1), the connecting plug (30) in such a way the plug holder (10AA) is inserted so that the contact area (K10), which is open on one side, points towards the bulge (A10) so that the bulge (A10) is a positioning mark for the alignment of the connecting plug (30) relative to the housing (10A ) is. Method according to at least one of the preceding claims, characterized in that before the introduction of the liquid, viscous or pasty adhesive (3) into the second housing (10B), a positioning aid (50) is introduced into the first housing (10A), the Positioning aid (50) is designed in such a way that by pushing the positioning aid (50) into the first housing (10A), the electrical conductor (20) and / or the connecting plug (30) is inserted and / or pushed back flush in the plug-in holder (10AA) , in particular if one end of the electrical conductor (20) and / or the connecting plug (30) protruded from the plug-in holder (10AA) before the positioning aid (50) was inserted. Procedure according to Claim 6 , characterized in that the positioning aid (50) has at least one pressure surface with which the end of the electrical conductor (20A) and / or connector (30) is pushed back flush into the plug-in holder (10AA), the pressure surface as a recess or as a highlight in is formed along an otherwise flat base surface (50B), so that a mechanical Contact between the positioning aid (50) and the end of the electrical conductor (20A) and / or the connecting plug (30), preferably only, is established via the pressure surface. Procedure according to Claim 6 or 7th , characterized in that the positioning aid (50) remains positioned in the first housing (10A) during the introduction of a liquid, viscous or pasty adhesive (3) into the second housing (10B), and only after the adhesive has at least partially hardened ( 3) the positioning aid (50) is removed from the housing (10A). Method according to at least one of the preceding claims, characterized in that the electrical conductor (20) is a multi-core electrical conductor, each end of a core being provided with the connecting plug (30), and a separate plug holder (10AA) in the for each core Housing is formed. Procedure according to Claim 9 , characterized in that, seen around an axis of symmetry of the housing from the direction of the insertion direction (E1), the at least two, preferably three, plug-in holders (10AA) are preferably equidistant in the circumferential direction.

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