DE102022210844A1 - Connector and method for producing a connector - Google Patents

Abstract

The invention relates to a plug (1) for an electrical connection, wherein the plug (1) comprises at least one plug housing (2) and a number of contact pins (4), and wherein the number of contact pins (4) is at least partially encased in a media-tight manner by means of a first potting material (6) and prefabricated to form a pre-potting body (8), and wherein a first free pin end (4.1) of the at least one contact pin (4) protrudes at a first front end (8.2) of the pre-potting body (8) and a second free pin end (4.2) protrudes at an opposite second front end (4.2) into an inner chamber (8.1) of the pre-potting body (8).

Description

The invention relates to a connector, in particular a connector for a vehicle, and a method for producing a connector.

Plugs or plug modules, particularly for vehicles, have electrical and/or electronic components, such as contact pins and plug boards, which can be exposed to influences such as corrosion, aggressive substances, mechanical stress and/or other external influences. At least some plugs are therefore embedded in plastic so that the electrical and/or electronic components are better protected. In at least some plugs, the plastic is applied to the components and/or the components are encased in it using an injection molding technique - occasionally also called "injection molding", "overmolding", "casting", "sealing" or "molding". With the previous injection molding technique, gaps and leaks often occur during the sealing process when the plugs are manufactured, so that the electronic components, such as the contact pins and the plug board, are not adequately protected.

It is therefore an object of the invention to provide a plug with an improved seal and an improved method for producing a plug.

With regard to the plug, the object is achieved by the features of patent claim 1. With regard to the method, the object is achieved according to the invention by the features of patent claim 9.

Further developments of the invention are the subject of the dependent patent claims.

The plug according to the invention for an electrical connection comprises at least one plug housing and a number of, in particular rotationally symmetrical, contact pins, wherein the number of contact pins is encased, in particular cast or molded, in a media-tight manner at least in regions by means of a first casting material and is prefabricated to form a pre-cast body, and wherein at least a first free pin end of the contact pin protrudes at a first front end of the pre-cast body and a second free pin end protrudes at an opposite end of the pre-cast body into an inner chamber of the pre-cast body. The inner chamber of the pre-cast body is understood to mean in particular an internal and outwardly open recess in the pre-cast body.

The advantages achieved with the invention are in particular that a connector with such a prefabricated pre-cast body (also called pre-molded part) with media-tight cast or molded contact pins and an inner chamber with free pin ends can be additionally sealed media-tight within the inner chamber after connection to another electronic component, such as a connector board. Media-tight encapsulation, in particular cast or molded, is understood in particular to mean gap-free encapsulation, for example by casting or molding, of the contact pin or pins. The contact pins are electrical and/or electronic contact pins. The contact pins are designed to be rotationally symmetrical, for example. The contact pins can be sealed tightly against media, in particular aggressive media, by means of the separate pre-cast body. For example, the contact pins can be cast or molded without a gap using the first encapsulation material, in particular a thermosetting material.

In other words: The inner chamber in the pre-cast body can be additionally cast using a second casting material in a second injection molding process and sealed in a media-tight manner. For example, the first casting material and the second casting material can be identical, for example a thermosetting material. In the hot, uncrosslinked state, the thermosetting material is as fluid as water. When it cools and crosslinks, it contracts slightly and thus wraps around soldering points and contacts without leaving a gap. Alternatively, the first casting material of the pre-cast body can be made of a material with a higher melting temperature than the second casting material for the inner chamber. For example, the first casting material of the pre-cast body is a thermosetting material. The second casting material of the inner chamber is made of a two-component material, for example. This ensures that the inner chamber and the pre-cast body do not become soft and leaky during the second injection molding process. In other words: The pre-cast body and the inner chamber are designed to be dimensionally stable, even during the second injection molding process. In addition, such a connector is designed to be particularly strong and rigid. A highly protected connector is formed by a double seal - a first seal of the contact pins using the pre-molded body and a second seal of the contact pins in the inner chamber. In addition, the solid inner chamber itself can form a sufficiently solid mold chamber for the second seal of the contact pins within the chamber.

The inner chamber is used in particular to seal the soldering points of the contact pins in a later operation.

The plug is intended, for example, for the electrical and/or mechanical connection between components, for example between electrical and/or electronic components of a vehicle. The vehicle can be, for example, a motor vehicle, such as a car, bus or truck, or also a rail vehicle, a ship, an aircraft, such as a helicopter or airplane, or, for example, a motorcycle.

The pre-cast body can comprise at least one positioning pin in the area of the inner chamber. For example, the positioning pin can have larger dimensions than the contact pin. In particular, the positioning pin can have a larger diameter than the contact pin. The contact pin and the positioning pin are arranged at a distance from one another. If there are several contact pins, these can be arranged distributed around the positioning pin.

The contact pin(s) can have at least one undercut. Such an undercut enables an even better connection between the potting material and the contact pin. The undercut enables, in particular, a better connection between the contact pin and the first potting material of the pre-potting body and/or the contact pin and the second potting material in the inner chamber.

An inner wall of the inner chamber can have at least one wall undercut. These wall undercuts also enable a better connection of the inner chamber with the second casting material.

The pre-potting body and a connector board are preferably inserted into one another and connected to one another, with at least one free pin end protruding into the inner chamber engaging in a corresponding connector opening in the connector board. The free pin ends can each be provided with at least one undercut. The inner chamber and, in some areas, the connector board and the free pin ends can be overmolded in a media-tight manner with a further potting material, in particular the second potting material.

In addition, the pre-potting body can be arranged in the connector housing in such a way that its inner chamber is flush with an open housing end. The connector board preferably covers the open housing end.

• - Bereitstellen eines Steckergehäuses,
• - Bereitstellen eines offenen Vorverguss-Werkzeugs mit einer Vergusskavität,
• - Bereitstellen einer Anzahl von Kontaktstiften,
• - Bereitstellen eines Verschlusselements zum Abdichten des oder der Kontaktstifte außerhalb der Vergusskavität (Versehen des oder der Kontaktstifte bereichsweise mit einem Verschlusselement (Quetschverbindung, Schneidring oder Stahlring)),
• - Einlegen einer Anzahl von Kontaktstiften in das offene Vorverguss-Werkzeug derart, dass der oder die Kontaktstifte an einem Übergang in die Vergusskavität mittels des Verschlusselements abdichtbar ist oder sind,
• - Schließen des Vorverguss-Werkzeugs,
• - Einbringen eines Vergussmaterials in die Vergusskavität,
• - Formen eines Vorvergusskörpers, insbesondere Ummanteln, zum Beispiel umlaufendes Umgießen oder Umspritzen der Kontaktstifte in der Vergusskavität und Formen des Vorvergusskörpers, derart, dass ein erstes freies Stiftende der Kontaktstifte an einem ersten stirnseitigen Ende des Vorvergusskörpers herausragt und ein zweites freies Stiftende an einem gegenüberliegenden zweiten stirnseitigen Ende in eine innere Kammer des Vorvergusskörpers hineinragt,
• - Öffnen des Vorverguss-Werkzeugs,
• - Entnahme des Vorvergusskörpers aus dem geöffneten Vorverguss-Werkzeug und
• - Einbau des Vorvergusskörpers mit einer vormontierten Steckerplatine oder ohne eine vormontierte Steckerplatine in das Steckergehäuse.

The method according to the invention for producing a plug is characterized by the following steps:

• - Providing a connector housing,
• - Providing an open pre-potting tool with a potting cavity,
• - Providing a number of contact pins,
• - Providing a closure element for sealing the contact pin(s) outside the potting cavity (providing the contact pin(s) with a closure element (crimp connection, cutting ring or steel ring) in some areas),
• - Inserting a number of contact pins into the open pre-potting tool in such a way that the contact pin(s) can be sealed at a transition into the potting cavity by means of the closure element,
• - Closing the pre-casting tool,
• - Introducing a potting material into the potting cavity,
• - forming a pre-cast body, in particular encasing, for example circumferentially casting or overmolding the contact pins in the casting cavity and forming the pre-cast body in such a way that a first free pin end of the contact pins protrudes at a first front end of the pre-cast body and a second free pin end protrudes at an opposite second front end into an inner chamber of the pre-cast body,
• - Opening the pre-casting tool,
• - Removal of the pre-cast body from the opened pre-cast tool and
• - Installation of the pre-cast body with a pre-assembled connector board or without a pre-assembled connector board into the connector housing.

When the pre-potting tool is subsequently closed before the potting material is introduced, the closure element then engages the contact pins in a media-tight manner, for example by deforming, cutting or digging. Alternatively, the closure element can engage the contact pins in a media-tight manner, for example by means of a press fit.

For further clarification, the invention is described using embodiments shown in the figures. These embodiments are only intended as examples, but not as limitation. Like reference symbols designate like or similar elements.

• 1 schematisch eine Explosionsdarstellung eines Steckers mit Steckergehäuse und Vorvergusskörper,
• 2 schematisch in perspektivischer Darstellung einen Vorvergusskörper,
• 3 schematisch in einer weiteren perspektivischen Darstellung den Vorvergusskörper nach 2,
• 4 schematisch in Schnittdarstellung ein Vorverguss-Werkzeug,
• 5 schematisch eine vergrößerte Darstellung der Schnittdarstellung gemäß 4 im Bereich eines Übergangs in eine Vergusskavität,
• 6 schematisch in Schnittdarstellung einen Kontaktstift,
• 7 schematisch eine teilweise Schnittdarstellung des Vorverguss-Werkzeugs mit Verschlusselementen,
• 8 schematisch in Schnittdarstellung ein Verschlusselement,
• 9 schematisch in perspektivischer Darstellung das Verschlusselement,
• 10 schematisch in Explosionsdarstellung ein alternatives Verschlusselement und teilweise einen Kontaktstift,
• 11 schematisch in Schnittdarstellung das alternative Verschlusselement und den Kontaktstift im zusammengesetzten Zustand,
• 12 schematisch in Schnittdarstellung ein weiteres alternatives Verschlusselement und den Kontaktstift im zusammengesetzten Zustand,
• 13 schematisch in Schnittdarstellung einen Vorvergusskörper und eine Steckerplatine im gesteckten Zustand,
• 14 schematisch in Schnittdarstellung den Vorvergusskörper und die Steckerplatine gemäß 13 teilweise umspritzt,
• 15 schematisch in Schnittdarstellung die Steckerplatine und den Vorvergusskörper mit Hinterschnitten für Dichtelemente,
• 16 schematisch in Schnittdarstellung ein Steckergehäuse mit eingesetztem Vorvergusskörper und Steckerplatine,
• 17 schematisch in Schnittdarstellung ein Steckergehäuse mit eingesetztem Vorvergusskörper und befestigter Steckerplatine,
• 18 schematisch in Explosionsdarstellung einen Stecker mit Steckergehäuse, Vorvergusskörper, Steckerplatine und Dichtelementen,
• 19 schematisch in einer weiteren Explosionsdarstellung den Stecker gemäß 18,
• 20 schematisch in Schnittdarstellung den Stecker gemäß 18 im zusammengesetzten Zustand,
• 21 schematisch eine vergrößerte Darstellung der Schnittdarstellung des Steckers gemäß 20 im Bereich der Verbindung von Kontaktstift und Steckerplatine,
• 22 schematisch eine Schnittdarstellung eines Steckers,
• 23 schematisch eine Explosionsdarstellung des Steckers mit einer alternativen Befestigung der Steckerplatine,
• 24 schematisch eine weitere Explosionsdarstellung des Steckers gemäß 23, und
• 25 schematisch eine Schnittdarstellung des Steckers im zusammengesetzten Zustand.

Showing:

• 1 schematically an exploded view of a connector with connector housing and pre-cast body,
• 2 schematically in perspective view a pre-cast body,
• 3 schematically in another perspective view the pre-cast body according to 2 ,
• 4 schematic sectional view of a pre-casting tool,
• 5 schematically an enlarged view of the sectional view according to 4 in the area of a transition to a casting cavity,
• 6 schematic sectional view of a contact pin,
• 7 schematically a partial sectional view of the pre-casting tool with closure elements,
• 8th schematic sectional view of a closure element,
• 9 schematic perspective view of the closure element,
• 10 schematically in exploded view an alternative closure element and partially a contact pin,
• 11 schematic sectional view of the alternative locking element and the contact pin in the assembled state,
• 12 schematic sectional view of another alternative closure element and the contact pin in the assembled state,
• 13 schematic sectional view of a pre-cast body and a connector board in the plugged state,
• 14 schematic sectional view of the pre-cast body and the connector board according to 13 partially overmolded,
• 15 schematic sectional view of the connector board and the pre-cast body with undercuts for sealing elements,
• 16 schematic sectional view of a connector housing with inserted pre-cast body and connector board,
• 17 schematic sectional view of a connector housing with inserted pre-cast body and attached connector board,
• 18 schematic exploded view of a connector with connector housing, pre-cast body, connector board and sealing elements,
• 19 schematically in another exploded view the plug according to 18 ,
• 20 schematic sectional view of the plug according to 18 in the assembled state,
• 21 schematically an enlarged view of the sectional view of the plug according to 20 in the area of the connection between contact pin and connector board,
• 22 schematically a sectional view of a plug,
• 23 schematically an exploded view of the connector with an alternative fastening of the connector board,
• 24 schematically another exploded view of the connector according to 23 , and
• 25 schematic sectional view of the plug in the assembled state.

1 shows schematically an exploded view of a plug 1 with a plug housing 2 and a number of contact pins 4.

The Indian 1 The schematically illustrated plug 1 is described below using three spatial directions that run perpendicular to one another. A longitudinal direction x runs largely horizontally and preferably parallel to a plug longitudinal direction. A transverse direction y that runs perpendicular to the longitudinal direction x is aligned horizontally. A vertical direction z runs perpendicular to the longitudinal direction x and perpendicular to the transverse direction y. In the plug 1, the vertical direction z preferably runs parallel to a plug vertical axis.

The plug 1 serves for an electrical connection, in particular for the electrical connection of electronic and/or electrical components of a vehicle.

The plug 1 comprises as a plug housing 2 in particular a hollow cylindrical body 2.0 with a receiving opening 2.01.

The number of contact pins 4 is at least partially encapsulated in a media-tight manner by means of a first encapsulation material 6, in particular overmolded, and pre-cast to form a pre-encapsulation body 8. The pre-cast body 8 comprises an inner chamber 8.1.

At least a first free pin end 4.1 of the respective contact pin 4 protrudes at a first front end 8.2 of the pre-potting body 8. A second free pin end 4.2 of the respective contact pin 4 protrudes at an opposite second front end 8.3 into the inner chamber 8.1 of the pre-potting body 8.

The contact pins 4 are sealed without gaps by means of the pre-potting body 8 (also called pre-molded part). In other words: the contact pins 4 are themselves partially encased by means of the first potting material 6, in particular cast or molded around, so that the contact pins 4 are sealed against media in this cast area.

The contact pins 4 are each designed as rotationally symmetrical contacts. The contact pins 4 are made of a conductive material, in particular of a metal.

The pre-cast body 8 can comprise at least one positioning pin 8.4 for positioning in the area of the inner chamber 8.1. The positioning pin 8.4 is formed from the first casting material 6. The positioning pin 8.4 is formed simultaneously during the molding of the pre-cast body 8, as described in more detail below.

In addition, the connector housing 2 can comprise a fastening flange 2.3. The fastening flange 2.3 can be provided with extensions 2.2, in particular vertically protruding extensions 2.2. The extensions 2.2 are designed, for example, as positioning pins 2.7 (also referred to as alignment pins) and/or as connecting pins 2.8 (also referred to as fastening pins).

For example, the respective positioning pin 8.4 and/or 2.7 can have larger dimensions than the respective contact pin 4 or the connecting pin 2.8. In particular, the positioning pin 8.4 or 2.7 can have a larger diameter than the contact pin 4 or the connecting pin 2.8.

The positioning pins 2.7 and the connecting pins 2.8 are arranged on the fastening flange 2.3 of the connector housing 2, for example in a circle around the receiving opening 2.01 (also referred to as the housing opening).

The contact pin 4 and the positioning pin 8.4 are arranged at a distance from one another. If there are several contact pins 4, these can be arranged distributed around the positioning pin(s) 8.4.

2 shows schematically in perspective the pre-potting body 8 with the contact pins 4 molded by means of the first potting material 6 and the positioning pin 8.4.

The inner chamber 8.1 is formed only at one end, in particular at the second front end 8.3, of the pre-cast body 8. The inner chamber 8.1 serves for further later sealing.

An inner wall 8.1.1 of the inner chamber 8.1 can have at least one wall undercut 8.1.2. These wall undercuts 8.1.2 enable a better connection of the inner chamber 8.1 with a second seal of the contact pins 4 and the inner chamber 8.1, as described in more detail below.

The respective contact pins 4 can have one or more undercuts 4.3. The undercuts 4.3 enable a better connection during the second sealing.

3 shows schematically in a further perspective view the pre-cast body 8 according to 2 .

An outer wall 8.5 of the pre-cast body 8 comprises at least one circumferential step 8.5.1 or one shoulder.

The pre-potting body 8 can further comprise one or more cylindrical base regions 8.6 for centering the pre-potting body 8 in the connector housing 2.

4 shows schematically in section a pre-potting tool 9 for prefabrication of the pre-potting body 8 with the contact pins 4 (shown in 1 to 3 ).

The pre-potting tool 9 comprises two tool halves 9.1, 9.2. 4 shows the pre-potting tool 9 in the closed state. A potting cavity 9.3 is formed between the two tool halves 9.1, 9.2. In other words: the potting cavity 9.3 is still empty and unfilled.

Before the casting cavity 9.3 is cast, at least one contact pin 4 is arranged in the pre-casting tool 9. The free pin ends 4.1, 4.2 are arranged in hollow bores 9.4 of the pre-casting tool 9. A pin area 4.4 located between the two free pin ends 4.1 and 4.2, which is sealed, in particular encased, for example The part to be cast or molded is located in the area of the casting cavity 9.3.

In the example shown, the contact pin 4 is provided with two closure elements 11 for the gap-free and media-tight encapsulation of the pin area 4.4 to be encased. The closure elements 11 are arranged at the transitions from the middle pin area 4.4 to the free pin ends 4.1, 4.2. In particular, the respective closure element 11 borders on the middle pin area 4.4 and extends away from it in the direction of the associated free pin end 4.1 or 4.2.

The closure elements 11 are designed, for example, as a cutting ring or a cutting sleeve.

5 shows schematically an enlarged view of the sectional view according to 4 in the area of a transition from the middle pin area 4.4 to the free end 4.1 of the contact pin 4 in the tool half 9.2.

The closure element 11, for example designed as a cutting sleeve or cutting ring, digs into the undercut 4.3 of the contact pin 4 at a front-side shoulder 4.4.1 of the contact pin 4 when the tool halves 9.1, 9.2 are closed, and thereby seals the free end 4.1 of the contact pin 4 against an injection pressure when the first potting material 6 is introduced into the potting cavity 9.3.

As the first potting material 6, a thermosetting material is introduced into the potting cavity 9.3. A thermosetting material is particularly fluid in the hot, molten state, similar to water.

6 shows a schematic sectional view of an embodiment of a contact pin 4.

The contact pin 4 can comprise several undercuts 4.3 in the pin area 4.4 to be coated for better connection when sealing it with the first potting material 6.

In the transition area between the respective pin end 4.1 or 4.2 and the pin area 4.4, a front-side shoulder 4.4.1 is formed. The front-side shoulder 4.4.1, in particular in the form of the undercut 4.3, serves for the engagement of the closure element 11 for sealing during the sealing of the pin area 4.4.

7 shows a schematic partial sectional view of the pre-potting tool 9 with two closure elements 11. A first closure element 11.1 is arranged at an upper transition to the potting cavity 9.3 in the hollow bore 9.4 of the first tool half 9.1. A second closure element 11.2 is arranged at a lower transition to the potting cavity 9.3 in the hollow bore 9.4 of the second tool half 9.2.

A closure element 11 is therefore provided for each free pin end 4.1, 4.2. The respective closure element 11 digs deep into the frontal shoulder 4.4.1 of the pin area 4.4 to be coated and thus seals the free pin ends 4.1, 4.2 against the casting cavity 9.3 in the pre-casting tool 9 (as in 4 and 6 shown).

8th shows a schematic sectional view of an example of the closure element 11. The closure element 11 is designed as a cutting sleeve or a cutting ring. The closure element 11 comprises a hollow cylindrical region 11.3. At an end 11.4 facing the front shoulder 4.4.1, the closure element 11 comprises a cutting edge 11.5. The cutting edge 11.5 is designed to be circumferential. The cutting edge 11.5 is a cutting ring. The cutting edge 11.5 protrudes from the front end 11.4 of the closure element 11. For example, the cutting edge 11.5 has a height 11.6 in the millimeter range. The cutting edge 11.5 can also have a cutting wedge with an angle 11.7 between 20° and 60°.

9 shows a schematic perspective view of the closure element 11 with the circumferential cutting edge 11.5 at the end 11.4. At the end 11.4, the closure element 11 can be provided with internal insertion bevels 11.8 (also called a bore). The insertion bevels 11.8 serve to better thread the associated contact pin 4.

10 shows a schematic exploded view of an alternative closure element 11' and partially a contact pin 4 with a modified front-side shoulder 4.4.1. The contact pin 4 has a circumferential bead 4.4.2 above the front-side shoulder 4.4.1 in the direction of the free end 4.1 or 4.2.

The alternative closure element 11' is designed as a steel ring insert with an insertion bevel 11.8 and a circumferential and inwardly rounded edge 11.9.

11 shows a schematic sectional view of the alternative closure element 11' and the contact pin 4 in the assembled state.

When the alternative closure element 11' and the contact pin 4 are fitted together, a press fit and a Sealing the respective free end 4.1 or 4.2 against the casting cavity 9.3.

12 shows a schematic sectional view of another alternative closure element 11" and a contact pin 4 with a modified front-side shoulder 4.4.1 in the assembled state. The front-side shoulder 4.4.1 can additionally comprise an annular dome 4.4.3, in particular all around.

The alternative closure element 11" is designed, for example, as a simple sleeve with insertion bevels 11.8.

13 shows a schematic sectional view of an example of a pre-cast body 8 made of the first casting material 6 that encases a contact pin 4. The second free end 4.2 of the contact pin 4 that extends into the inner chamber 8.1 is inserted into a connector board 12. The connector board 12 comprises, for example, a corresponding connector opening 12.1. In addition, the connector board 12 can have at least one filling opening 12.4 for filling the inner chamber 8.1 with a second casting material 14 (shown in 14 ). The filling opening 12.4, for example, has a larger diameter than the plug opening 12.1.

The positioning pin 8.4 serves to position the pre-cast body 8 to the connector board 12. The connector board 12 comprises, for example, a corresponding positioning receptacle 12.2.

The connector board 12 is positioned on the pre-cast body 8 in such a way that this connector board 12 at least partially covers or covers the inner chamber 8.1.

The contact pin 4 inserted into the plug opening 12.1 can be integrally connected, in particular soldered, to the plug board 12. To seal these soldering points, the inner chamber 8.1, the plug board 12 and/or the free end 4.2 of the contact pin 4 can be sealed or filled, for example cast or injected, with a second potting material 14, in particular an identical or similar thermosetting material or a 2-component material, as in 14 shown. For example, the first potting material 6 and the second potting material 14 can be identical, for example a thermosetting material. Thermosetting material is particularly suitable due to its thin liquid when warm, so that it can form an extremely tight seal around soldering points and contacts and harden.

14 shows schematically in section the pre-cast body 8 and the connector board 12 according to 13 which is additionally sealed, in particular partially encased, for example overmolded, in the area of the inner chamber 8.1 by means of the second potting material 14. The second potting material 14 can be introduced into the inner chamber 8.1, for example, through the at least one filling opening 12.4 in the connector board 12 from the underside of the connector board 12 opposite the pre-potting body 8.

For this purpose, the connector board 12 is pressed against the pre-potting body 8 in particular in such a way that leakage of the second potting material 14 between the connector board 12 and the front end of the pre-potting body 8 is prevented.

15 shows a schematic sectional view of the pre-cast body 8 and the connector board 12 with the undercuts or recesses 8.5.1 on the outer wall 8.5 for sealing elements 16. The sealing elements 16 are, for example, ring seals. Alternatively, the sealing elements 16 can be omitted if the connector housing 2 comprises molded-on sealing rings.

16 shows a schematic sectional view of the connector housing 2 with an inserted pre-potting body 8 formed from the first potting material 6 and a mounted connector board 12 sealed by means of the second potting material 14. The sealing elements 16 are pressed here via internal bevels 2.1 in the connector housing 2 against the shoulders 8.5.1 of the pre-potting body 8.

The connector housing 2 can be placed on the pre-cast body 8, in particular on its first front end 8.2 (shown in 1 ) or plugged on. Alternatively, the pre-potting body 8 can be arranged in the connector housing 2 such that the inner chamber 8.1 of the pre-potting body 8 is flush with an open housing end 2.6 of the connector housing 2.

In addition to the connector opening(s) 12.1 and the positioning receptacle(s) 12.2, the connector board 12 can comprise further positioning receptacles 12.2 for positioning pins 2.7 of the connector housing 2 and fastening openings 12.3 for the connecting pins 2.8 of the connector housing 2. Connecting pins 2.8 (also called fastening and forming pins or bolts) of the connector housing 2 designed as protruding extensions 2.2 can be inserted into the fastening openings 12.3. The positioning pins 2.7 of the connector housing 2 designed as extensions 2.2 can be inserted into the further positioning receptacles 12.2. The extensions 2.2 of the connector housing 2 serve to position the Connector housing 2 relative to connector board 12 and in particular the fastening of connector housing 2 to connector board 12.

17 shows a schematic sectional view of the connector housing 2 with the pre-cast body 8 inserted and the connector board 12 attached. The positioning pins 2.7 are inserted into the additional positioning receptacles 12.2. To attach the connector housing 2 to the connector board 12, the connecting pins 2.8 designed as extensions 2.2 can be connected, in particular caulked, to the plug-in board 12 in the fastening openings 12.3 by means of a thermal connection process, such as a hot caulking process or an ultrasonic caulking process. In 17 the connecting pins 2.8 are already caulked to the connector board 12.

18 shows a schematic exploded view of an example of the connector 1 with the connector housing 2 with positioning pins 2.7 and connecting pins 2.8 protruding from the fastening flange 2.3, the pre-cast body 8 with contact pins 4 and with the separate connector board 12 and with the separate sealing elements 16.

The connector housing 2 comprises the fastening flange 2.3, from which the positioning pins 2.7 and connecting pins 2.8 designed as extensions 2.2 protrude for the alignment and positioning of the connector housing 2 to the connector board 12 or for fastening to the connector board 12.

19 shows schematically in a further exploded view the connector 1 according to 18 . The connector board 12 comprises the connector openings 12.1 for the contact pins 4, the positioning receptacles 12.2 for the positioning pins 8.4 and 2.7 and the fastening openings 12.3 for the connecting pins 2.8.

20 shows schematically in section the connector 1 according to 18 in the assembled state.

21 shows schematically an enlarged view of the sectional view of the plug 1 according to 20 in the area of the connection between contact pin 4 and connector board 12. In the area of the free end 4.2 of the contact pin 4 sealed by means of the second potting material 14, the latter can be provided with undercuts 4.3 for a better connection to the second potting material 14.

In the area of the connector opening 12.1, the free end 4.2 is soldered to the connector board 12. The connector board 12 is preferably sealed on both sides of the soldering point with the second potting material 14. In other words: the connector board 12 is sealed on the top and bottom with the second potting material 14, in particular encased, for example cast or molded.

22 to 25 show a further development of the connector 1, which provides additional fastening means 18 for connecting the pre-cast body 8 to the connector board 12.

22 shows a schematic sectional view of the plug 1, wherein an anchor pin was cast as a first fastening means 18.1 when sealing the plug board 12 using the second casting material 14. The first fastening means 18.1 is thus additionally anchored in the pre-cast body 8. For this purpose, an anchor receptacle 8.7 is formed in the pre-cast body 8 when the pre-cast body 8 is formed. The anchor receptacle 8.7 can be designed, for example, as a chamber or a hollow opening.

23 shows a schematic exploded view of the plug 1 with a second fastening means 18.2. The second fastening means 18.2 is designed, for example, as a clip ring which can be provided in addition to or as an alternative to the hot-stamped extensions 2.2. During assembly with the plug housing 2, locking hooks 18.2.1 lock into corresponding locking openings 2.4. The locking hooks 18.2.1 can also be protected by ribs 2.5, in particular longitudinal ribs, on the plug housing 2.

24 shows schematically a further exploded view of the connector 1 according to 23 and 25 shows schematically a sectional view of the connector 1 according to 23 and 24 in the assembled state.

The fastening flange 2.3 of the connector housing 2 has only the vertically protruding positioning pins 2.7. The locking hooks 18.2.1 can additionally be protected by the ribs 2.5, in particular longitudinal ribs, on the connector housing 2.

• - Bereitstellen eines Steckergehäuses 2,
• - Bereitstellen des Vorverguss-Werkzeugs 9, insbesondere eines offenen Vorverguss-Werkzeugs 9, mit einer Vergusskavität 9.3,
• - Bereitstellen einer Anzahl von Kontaktstiften 4,
• - Bereitstellen mindestens eines Verschlusselements 11, bevorzugt von mindestens zwei Verschlusselementen 11, zum Abdichten des oder der Kontaktstifte 4 außerhalb der Vergusskavität 9.3 in dem Vorverguss-Werkzeug 9, zum Beispiel werden freie Enden 4.1, 4.2 der Kontaktstifte 4 bereichsweise jeweils mit einem Verschlusselement 11, zum Beispiel einen Schneidring, einen Stahlring,
• - Einlegen der Kontaktstiften 4 in das offene Vorverguss-Werkzeug 9 derart, dass die Kontaktstifte 4 an einem Übergang in die Vergusskavität 9.3 mittels des oder der Verschlusselements/e 11 abdichtbar sind,
• - Schließen des Vorverguss-Werkzeugs 9,
• - Einbringen eines ersten Vergussmaterials 6 in die Vergusskavität 9.3, insbesondere Ummanteln, zum Beispiel Umspritzen oder Umgießen der Kontaktstifte 4 in der Vergusskavität 9.3, und Formen eines Vorvergusskörpers 8 derart, dass erste freie Stiftenden 4.1 der Kontaktstifte 4 an einem ersten stirnseitigen Ende 8.2 des Vorvergusskörpers 8 herausragen und zweite freie Stiftenden 4.2 an einem gegenüberliegenden zweiten stirnseitigen Ende 8.3 in eine innere Kammer 8.1 des Vorvergusskörpers 8 hineinragen,
• - Öffnen des Vorverguss-Werkzeugs 9, und
• - Entnahme des Vorvergusskörpers 8 mit den eingegossenen Kontaktstiften 4 aus dem geöffneten Vorverguss-Werkzeug 9 und
• - Einbau des Vorvergusskörpers 8 mit einer vormontierten Steckerplatine 12 oder ohne eine vormontierte Steckerplatine 12 in das Steckergehäuse 2.

The connector 1 described above can be manufactured by the following procedure with the following steps:

• - Providing a connector housing 2,
• - Providing the pre-potting tool 9, in particular an open pre-potting tool 9, with a potting cavity 9.3,
• - Providing a number of contact pins 4,
• - Providing at least one closure element 11, preferably at least two closure elements 11, for sealing the or of the contact pins 4 outside the casting cavity 9.3 in the pre-casting tool 9, for example, free ends 4.1, 4.2 of the contact pins 4 are each partially sealed with a closure element 11, for example a cutting ring, a steel ring,
• - Inserting the contact pins 4 into the open pre-potting tool 9 such that the contact pins 4 can be sealed at a transition into the potting cavity 9.3 by means of the closure element(s) 11,
• - Closing the pre-casting tool 9,
• - introducing a first potting material 6 into the potting cavity 9.3, in particular encasing, for example overmolding or casting the contact pins 4 in the potting cavity 9.3, and forming a pre-potting body 8 such that first free pin ends 4.1 of the contact pins 4 protrude at a first front end 8.2 of the pre-potting body 8 and second free pin ends 4.2 protrude at an opposite second front end 8.3 into an inner chamber 8.1 of the pre-potting body 8,
• - Opening the pre-casting tool 9, and
• - Removal of the pre-cast body 8 with the cast-in contact pins 4 from the opened pre-cast tool 9 and
• - Installation of the pre-cast body 8 with a pre-assembled connector board 12 or without a pre-assembled connector board 12 into the connector housing 2.

When the pre-potting tool 9 is closed and before the first potting material 6 is introduced, the respective closure element 11 engages the associated contact pin 4 in a media-tight manner and seals the associated free end 4.1 or 4.2 against the potting cavity 9.3. Alternatively, such a closure element 11 can be provided that closes the free ends 4.1 or 4.2 in a media-tight manner by means of a press fit with the contact pin 4.

List of reference symbols

1

Plug

2

Connector housing

2.0

hollow cylindrical body

2.01

Receiving opening

2.1

Inside slope

2.2

renewal

2.3

Mounting flange

2.4

Latching opening

2.5

rib

2.6

open housing end

2.7

Positioning pin

2.8

Connecting pin

4

Contact pin

4.1

first free donor

4.2

second free pin end

4.3

Undercut

4.4

Pen area

4.4.1

frontal heel

4.4.2

bead

4.4.3

Ring dome

6

first casting material

8th

Pre-cast body

8.1

inner chamber

8.1.1

Interior wall

8.1.2

Wall undercut

8.2

first front end

8.3

second front end

8.4

Positioning pin

8.5

Exterior wall

8.5.1

Paragraph

8.6

cylindrical base area

8.7

Anchor holder

9

Pre-casting tool

9.1, 9.2

Tool half

9.3

Casting cavity

9.4

Hollow bore

11, 11', 11"

Locking element

11.1

first closure element

11.2

second locking element

11.3

hollow cylindrical area

11.4

End

11.5

Cutting edge

11.6

Height

11.7

angle

11.8

Insertion bevel

11.9

rounded edge

12

Connector board

12.1

Plug opening

12.2

Positioning recording

12.3

Mounting opening

12.4

Filling opening

14

second casting material

16

Sealing element

18

Fasteners

18.1

first fastener

18.2

second fastening device

18.2.1

Latching hook

x

Longitudinal direction

y

Transverse direction

z

Vertical direction

Claims (10)

Plug (1) for an electrical connection, which plug (1) comprises at least: - a plug housing (2) and - a number of contact pins (4), characterized in that the number of contact pins (4) are at least partially encased in a media-tight manner by means of a first potting material (6) and are prefabricated to form a pre-potting body (8), wherein a first free pin end (4.1) of the at least one contact pin (4) protrudes at a first front end (8.2) of the pre-potting body (8) and a second free pin end (4.2) protrudes at an opposite second front end (4.2) into an inner chamber (8.1) of the pre-potting body (8). Plug (1) to Claim 1 , characterized in that the pre-cast body (8) comprises at least one positioning pin (8.4) in the region of the inner chamber (8.1). Plug (1) to Claim 1 or 2 , characterized in that the contact pin or pins (4) has or have at least one undercut (4.3). Plug (1) according to one of the preceding claims, characterized in that an inner wall (8.1.1) of the inner chamber (8.1) has at least one wall undercut (8.1.2). Plug (1) according to one of the preceding claims, characterized in that the pre-cast body (8) and a plug board (12) are inserted into one another and connected to one another, wherein the at least one second free pin end (4.2) protruding into the inner chamber (8.1) engages in a corresponding plug opening (12.1) in the plug board (12). Plug (1) to Claim 5 , characterized in that the inner chamber (8.1) and partially the connector board (12) and the second free pin ends (4.2) are encased in a media-tight manner with a second potting material (14). Plug (1) according to one of the preceding claims, characterized in that the pre-cast body (8) is arranged in the plug housing (2) in such a way that its inner chamber (8.1) is flush with an open housing end (2.6). Plug (1) to Claim 7 , characterized in that the connector board (12) covers the open housing end (2.6). Method for producing a plug (1), characterized by the following steps: providing a plug housing (2), providing an open pre-potting tool (9) with a potting cavity (9.3), providing a number of contact pins (4), providing a closure element (11) for sealing the contact pin(s) (4) outside the potting cavity (9.3), inserting a number of contact pins (4) into the open pre-potting tool (9) such that the contact pin(s) (4) can be sealed at a transition into the potting cavity (9.3) by means of the closure element (11), closing the pre-potting tool (9), introducing a first potting material (6) into the potting cavity (9.3) and forming a pre-potting body (8) such that a first free pin end (4.1) of the contact pins (4) protrudes at a first front end (8.2) of the pre-potting body (8). and a second free pin end (4.2) at an opposite second front end (8.3) projects into an inner chamber (8.1) of the pre-potting body (8), opening the pre-potting tool (9), removing the pre-potting body (8) from the opened pre-potting tool (9) and installing the pre-potting body (8) with a pre-assembled connector board (12) or without a pre-assembled connector board (12) into the connector housing (2). Procedure according to Claim 9 , characterized in that when closing the pre-potting tool (9) before introducing the first potting material (6), the closure element (11) engages in the associated contact pin (4) in a media-tight manner or engages the contact pin (4) in a media-tight manner.

Images