DE102021001478A1 - Electrical connector and method for assembling an electrical connection line for such a connector - Google Patents

Abstract

Describes an electrical connector with a receptacle housing that has at least one receiving chamber, with a collective seal that has at least one through hole, with at least one electrical plug contact that is arranged in the at least one receiving chamber and is electrically connected to an electrical connecting line, wherein each connection line has an insulated section with an insulating sleeve, which is guided through a through-hole of the collective seal, the insulating sleeves each having at least one projection with an increased cross-sectional width at the level of the through-holes of the collective seal. In addition, a method for assembling the electrical connection lines for such a connector is proposed.

Description

The invention relates to an electrical plug connector with a socket housing that has at least one receiving chamber, with a collective seal that has at least one through hole, with at least one electrical plug contact that is arranged in the at least one receiving chamber and is electrically connected to an electrical connecting line, each lead wire having an insulated portion with an insulating sheath that is passed through a through hole of the common seal. The invention also relates to a method for assembling an electrical connection line for such a connector.

Such a connector is from the German Offenlegungsschrift DE10 2018 209 354 A1 known. This document also describes that a plug-in contact can easily damage a common seal when it is inserted, which leads to the system leaking.

To remedy this deficiency, it is proposed to provide the plug contact to be used with a protective cover as an assembly aid. The disadvantage here is that this results in disposable items and additional work steps are required.

The object was to create a generic plug connector in a simple and cost-effective manner that achieves very good sealing on the side of the connection line and in which the risk of damage to the collective seal during assembly is as low as possible.

This object is achieved according to the invention in that the insulating sleeves each have at least one molded-on part with an enlarged cross-sectional width at the height of the through-holes of the collective seal.

In addition, there was the task of creating an advantageous method for assembling the electrical connection lines for such a connector.

This object is solved by the features of claim 14.

According to the invention, the cross-sectional width of the insulating sleeves of the connection lines is increased in some areas at one or more points by molding. The term molding should be understood in a broad sense in accordance with the following description.

At least one area with an increased cross-sectional width is at the height of the through-holes of the collective seal in the case of a finally assembled connection line. The diameters of the through-holes can thus be designed for the cross-sectional widths of the molded-on insulating sleeves, instead of the normal cross-sectional widths of the insulating sleeves.

Since the diameters of the through-holes of the collective seal are all larger than in the case of conventionally designed connection lines, the collective seal is very much less susceptible to damage when the plug-in contacts are passed through these larger through-holes.

Another advantage is that the collective seal can be designed very simply and inexpensively. In particular, the through-holes of the collective seal can be designed as smooth through-holes that do not require sealing lips, since the tightness can be achieved through the contours of the moldings on the insulating sleeves.

It is also very advantageous that identically designed through-holes can be equipped with very different line diameters if connecting lines are processed with molded parts that are adapted to the diameter of the through-holes.

The at least one molding on each connection line can be produced in a simple and advantageous manner using a heated mold. These areas can be shaped particularly advantageously by a tool that also strips the connecting lines of insulation.

Further advantageous refinements and developments emerge from the dependent claims and the following description of the figures.

• 1 erfindungsgemäßen Steckverbinder,
• 2 einen Steckverbinder nach dem Stand der Technik,
• 3 mehrere Ausführungsvarianten von Anformungen an einer Isolierhülle,
• 4 eine weitere Ausführungsvariante einer Anformung an einer Isolierhülle, eingesetzt in eine Sammeldichtung,
• 5 eine zweite Ausführung eines erfindungsgemäßen Steckverbinders,
• 6 eine dritte Ausführung eines erfindungsgemäßen Steckverbinders,
• 7 Verfahrensschritte zum Konfektionieren einer Anschlussleitung.

The invention will be illustrated and explained in more detail below with reference to the drawing. In a sectional view, the

• 1 connector according to the invention,
• 2 a connector according to the state of the art,
• 3 several design variants of moldings on an insulating sleeve,
• 4 a further design variant of a molding on an insulating sleeve, used in a collective seal,
• 5 a second embodiment of a connector according to the invention,
• 6 a third embodiment of a connector according to the invention,
• 7 Process steps for assembling a connecting cable.

In all of the connector embodiments shown below, the same components and those with the same effect have been provided with the same reference symbols.

the 2 shows a prior art connector. The plug connector has a socket housing 1, which has at least one and preferably several receiving chambers 2, in which a plug contact 5 is inserted when the plug connector is fully assembled. The plug contact 5 has a latching spring 11 by which it is fixed in the receiving chamber 2 .

The stripped solid or stranded wire of a single-wire electrical connection line 6 is connected to each plug contact 5 . The mechanical and electrical connection between the plug contact 5 and the connecting line 6 can be established in a known manner, such as by crimping, soldering or welding.

Outside of its connection area with the plug contact 5, the electrical connection line 6 leading out of the socket housing 1 is provided with an insulating sleeve 7 made of a thermoplastic material.

In the case of a finally assembled plug connector, each connection line 6 is routed through a common collective seal 3 . The collective seal 3 is fixed in the receptacle housing 1 by a hold-down device 10 which is snapped into place in the receptacle housing 1 after the collective seal 3 has been inserted. The hold-down device 10 has one or more bushings 17 through which all connecting lines 6 are also passed.

Known designs of collective seals 3 usually have the form of a rubber mat, which provides a mostly circular through-hole 4 for each connecting line 6, through which the connecting line 6 is threaded. The one in the 2 Collective seal 3 shown in section also has at least one circumferential sealing lip 12 on the inner edges of each through hole 4 , which rests tightly against insulating sleeve 7 of connecting line 6 .

In order to achieve efficient assembly, it is necessary and therefore also customary to push the connection lines 6 through the through-holes 4 of the collective seal 3 with the plug contacts 5 already attached. Otherwise, many and sometimes long prefabricated connection lines 6 would have to be pulled almost completely through the through-holes 4 of the collective seal 3, which would be cumbersome, time-consuming and expensive.

The problem arises here that a typical plug contact 5 has, at least in sections, a larger cross section than the insulating sleeve 7 of the connection line 6, and can also be shaped unevenly and with sharp edges. However, since the width of the through holes 4 or the width of the sealing lips 12 of the collective seal 3 is designed for the cross-sectional width of the insulating sleeve 7 in order to be able to lie tightly against it, there is a risk that the collective seal made of a soft plastic material (rubber mat). 3 and in particular whose sealing lips 12 are damaged when a plug contact 5 passes through the plug contact body by tearing or cutting.

It should be emphasized here that even a single damage to a collective seal 3 makes it leaky and thus unusable, so that a considerable and therefore cost-relevant reject rate can arise as a result, particularly in the case of multi-pin plug connectors.

In order to prevent damage, it would therefore be desirable for the through-holes 4 of a collective seal 3 to be as large as possible. However, this possibility is limited by the fact that the edges of the through holes 4 or the sealing lips 12 of the collective seal 3 must lie tightly against the insulating sleeves 7 of the connection lines 6 after the installation is complete in order to fulfill their intended purpose.

The inventive solution to this problem is in the 1 shown. The through holes 4 of the collective seal 3 are here, unlike in the 2 , executed without sealing lips. As a result, the through holes 4 in the collective seal 3 are significantly larger here than in the exemplary embodiment of FIG 2 . In order to compensate for this, several projections 8 are attached to the section of the connection line 6 that is routed through the collective seal 3 on the insulating sleeve 7, which enlarge the cross-sectional width of the insulating sleeve 7 in sections. Through the projections 8, the through-holes 4 of the collective seal 3 are also filled and sealed here along their entire cross-sectional areas.

The projections 8, which increase the cross-sectional width at one or more points of the insulating sleeve 7, can be produced in a variety of ways. There are possibilities, to form the projections 8 either by using the original material of the insulating sleeve 7 itself or by applying an additional material in some areas to the insulating sleeve 7 .

With regard to the first possibility, it can be specifically provided that the at least one projection 8 is produced by heating and compressing the insulating sleeve 7 in sections.

If the material of the insulating sleeve 7 is suitably selected, the projections 8 can also be created by cold treatment or chemical treatment of the insulating sleeve 7, which causes the material of the insulating sleeve 7 to swell.

A regional enlargement of the cross-section of the insulating sleeve 7 through an additionally introduced material can also take place in different ways. For example, a plastic overmoulding can be applied to the areas of the insulating sleeve 7 that are to be enlarged.

Alternatively, the at least one molding 8 can be vulcanized onto the insulating sleeve 7 .

Cross-section-enlarging formations 8 on the insulating sleeve 7 can also be formed by an applied shrink tube. Or by a metal or plastic sleeve attached to the insulating sleeve 7, which is attached to the insulating sleeve 7 by gluing. As an alternative to this, also by a metal sleeve that is pressed onto the insulating sleeve 7 .

1. a) Fixieren einer isolierten elektrischen Anschlussleitung 6 in einem Fixierblock 16. Hierbei wird eine vorzugsweise als Endlosleitung ausgeführte Anschlussleitung 6 an vorbestimmter Leitungslänge mit einer Kraft F in einem Fixierblock 16 fixiert.
2. b) Ansetzen eines zwei- oder mehrteiligen Abisolierformgebungswerkzeugs 13, welches die vorgesehene Form der mindestens einen Anformung 8 als eine Hohlform 14 ausbildet und an einem Endabschnitt ein Abisoliermesser 15 ausbildet, an die Anschlussleitung 6.
3. c) Zusammenfahren und Erhitzen der Teile des Abisolierformgebungswerkzeugs 13, oder alternativ Zusammenfahren des vorab erhitzten Abisolierformgebungswerkzeugs 13.
4. d) Abisolieren der Anschlussleitung 6 durch Verfahren des Abisolierformgebungswerkzeugs 13 relativ zum Fixierblock 16 um eine vorgegebenen Weg s in axialer Richtung der Anschlussleitung 6. Das geschlossene Abisolierformgebungswerkzeug 13 fährt dabei den Weg s, bis das noch freie Volumen in der Hohlform 14 des Abisolierformgebungswerkzeugs 13 mit weich gewordener Isolationsmasse 20 von der Isolierhülle 7 der Anschlussleitung 6 gefüllt ist und damit die gewünschte Form auf der Isolierhülle 7 entstanden ist.
5. e) Trennen und optional Kürzen der freigelegten Seele 18 der Anschlussleitung 6.
6. f) Entnehmen der Anschlussleitung 6 aus dem Abisolierformgebungswerkzeugs 13 und
7. g) Verbinden eines Steckkontakts 5 mit der Seele 18 der Anschlussleitung 6.

Dieser Schritt kann beispielsweise durch Crimpen erfolgen.A preferred method for assembling a connection line 6 is in 7 sketchily illustrated. The process steps a) to g) belonging to the process are as follows:

1. a) Fixing an insulated electrical connecting line 6 in a fixing block 16. Here, a connecting line 6, preferably designed as an endless line, is fixed in a fixing block 16 with a force F at a predetermined line length.
2. b) Attaching a two-part or multi-part stripping shaping tool 13, which forms the intended shape of the at least one projection 8 as a hollow mold 14 and forms a stripping blade 15 on one end section, to the connection line 6.
3. c) Bringing together and heating the parts of the stripping die 13, or alternatively bringing the previously heated stripping die 13 together.
4. d) Stripping the connecting line 6 by moving the stripping shaping tool 13 relative to the fixing block 16 by a predetermined path s in the axial direction of the connecting line 6. The closed stripping shaping tool 13 travels the path s until the volume that is still free in the hollow mold 14 of the stripping shaping tool 13 softened insulating compound 20 is filled by the insulating sleeve 7 of the connection line 6 and thus the desired shape on the insulating sleeve 7 is created.
5. e) Separating and optionally shortening the exposed core 18 of the connection line 6.
6. f) removing the connecting lead 6 from the stripping shaping tool 13 and
7. g) Connecting a plug contact 5 to the core 18 of the connection line 6.

This step can be done by crimping, for example.

the 3 FIG. 13 shows three examples of shapes that can be created by the stripping shaping tool 13, respectively. Of course, many other forms are also conceivable and realizable.

In the 3a) a projection 8 has an approximately double-conical shape, with the equatorial area forming a narrow sealing ring 19 all around. 3b) shows an ellipsoidal bead 8 'around the connecting line 6. In the 3c) has the connection line 6 two consecutive projections 8, of the type as already in the 3a) shown. This also corresponds to the execution of a connecting line 6, as in the connector in the 1 is shown.

the 4 represents a connecting line 6 with a further embodiment of an extension 8 ", which essentially has a smooth cylindrical shape. In order to achieve a good seal with such a widened insulating sleeve cross section, it is expedient that the collective seal 3, as shown here, in the through holes 4 circumferential sealing lips 12 which rest against the cylindrical projection 8".

This is at the in the 3 illustrated embodiments of moldings 8, 8 'are not required, since these practically each form a sealing ring themselves through their annular bulges.

In all cases, there is a problem if the projections 8, 8', 8" tilt within the collective seal 3 as a result of external tensile forces FZ acting laterally on the connecting lines 6. This puts pressure on the projections 8, 8', 8", while the opposite lying side is relieved. In the case of unfavorable tolerance positions, leakage can occur there.

Two variants of connectors that solve this problem are in the 5 and 6 shown.

A further projection 9 is attached to the insulating sleeve 7 of the connection line 6 here, which fits into the hold-down device 10 of the socket housing 1 with suction, or whose shape corresponds to the shape of the passages in the hold-down device. The connecting lines 6 are also held centrally in the hold-down device 10 via the additional molding 9 . This results, even in the case of an external tensile force FZ acting laterally on the connecting line 6, as in FIG 6 indicated, no excessive deformation of the collective seal 3.

The kinking of connection lines 6, which are bundled under a deflection cap (not shown here), does not have a damaging effect on the tightness in the passage through the collective seal 3.

A higher vibration resistance of the plug contacts 5 in the receptacle housing 1 is also achieved.

A further advantage of this is that the presence of a protective cap, something to protect against splashing water, is no longer necessary since the surface of the passage 17 in the hold-down device 10 can be almost completely filled. In addition (but not shown here), a further bead can even be formed onto the insulating sleeve 7 of the connection line 6, which then sits above the hold-down device 10 and covers the bushing 17.

Reference List

1

receptacle housing

2

recording chamber

3

collective seal

4

through hole

5

plug contact

6

connecting cable

7

insulating sleeve

8, 8', 8"

molding

9

further shaping

10

hold-down

11

detent spring

12

sealing lip

13

stripping shaping tool

14

hollow mold

15

stripping knife

16

fixing block

17

execution

18

Soul

19

sealing ring

20

insulation mass

f

power

car

traction

s

path

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• DE 102018209354 A1 [0002]

Claims (14)

Electrical plug connector with a socket housing (1) which has at least one receiving chamber (2), with a collective seal (3) which has at least one through hole (4), with at least one electrical plug contact (5) which is in the at least one receiving chamber ( 2) and which is electrically connected to an electrical connecting line (6), each connecting line (6) having an insulated section with an insulating sleeve (7) which is passed through a through hole (4) of the collecting seal (3), thereby characterized in that the insulating sleeves (7) each have at least one projection (8) with an increased cross-sectional width at the height of the through-holes of the collective seal (3). Electrical connector after claim 1 , characterized in that the insulating sleeves (7) each additionally have a further projection (9) with an enlarged cross-sectional width, which is located at the level of a hold-down device (10) fastening the collective seal (3). Electrical connector after claim 1 or 2 , characterized in that the projection (8) and / or the further projection (9) is cylindrical. Electrical connector after claim 1 or 2 , characterized in that the projection (8) and/or the further projection (9) is double-cone-shaped or multi-double-cone-shaped. Electrical connector according to one of the preceding claims, characterized in that the projection (8) and/or the further projection (9) is produced by heating and compressing the insulating sleeve (7) in sections. Electrical connector according to any of Claims 1 until 4 , characterized in that the molding (8) and/or the further molding (9) is applied to the insulating sleeve (7) by a plastic extrusion coating. Electrical connector according to any of Claims 1 until 4 , characterized in that the projection (8) and/or the further projection (9) is vulcanized onto the insulating sleeve (7). Electrical connector according to any of Claims 1 until 4 , characterized in that the projection (8) and/or the further projection (9) is applied to the insulating sleeve (7) as a shrink tube. Electrical connector according to any of Claims 1 until 4 , characterized in that the projection (8) and/or the further projection (9) is applied to the insulating sleeve (7) as a metal or plastic sleeve. Electrical connector after claim 9 , characterized in that a metal or plastic sleeve is glued to the insulating sleeve (7). Electrical connector after claim 9 , characterized in that a metal sleeve is pressed onto the insulating sleeve (7). Electrical connector according to any of Claims 1 until 4 , characterized in that the molding (8) and / or the other molding (9) is produced by a heat or cold treatment of the insulating sleeve (7). Electrical connector according to any of Claims 1 until 4 , characterized in that the molding (8) and / or the further molding (9) is produced by a chemical treatment of the insulating sleeve (7). Method for assembling an electrical connecting cable for a connector claim 1 , with the following method steps: a) Fixing an insulated electrical connection line (6) in a fixing block (16), b) Attaching a stripping shaping tool (13), which has the intended shape of the at least one projection (8) and/or a further projection (9 ) as a hollow mold (14) and forms a stripping knife (15) on an end section, to the connection line (6), c) moving together and heating the stripping shaping tool (13), or alternatively moving together the previously heated stripping shaping tool (13), d) stripping the connecting line by moving the stripping shaping tool (13) relative to the fixing block (16) by a predetermined path (s) in the axial direction of the connecting line (6), e) separating and optionally shortening the exposed core (18) of the connecting line (6), f) removing the connection line (6) from the stripping shaping tool (13) and g) connecting a plug contact (5) to the core of the connection line ng (6).

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