EP0580053B1 - A method of producing plugs or sockets for electrical coupling devices - Google Patents

A method of producing plugs or sockets for electrical coupling devices Download PDF

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Publication number
EP0580053B1
EP0580053B1 EP93111119A EP93111119A EP0580053B1 EP 0580053 B1 EP0580053 B1 EP 0580053B1 EP 93111119 A EP93111119 A EP 93111119A EP 93111119 A EP93111119 A EP 93111119A EP 0580053 B1 EP0580053 B1 EP 0580053B1
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EP
European Patent Office
Prior art keywords
flat strips
flat
lead end
end zone
welding
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
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EP93111119A
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German (de)
French (fr)
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EP0580053A1 (en
Inventor
Gerhard Reichinger
Hans Köttgen
Original Assignee
Reichinger Gerhard Dipl-Ing
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Publication of EP0580053A1 publication Critical patent/EP0580053A1/en
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/20—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for assembling or disassembling contact members with insulating base, case or sleeve
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/502—Bases; Cases composed of different pieces
    • H01R13/504—Bases; Cases composed of different pieces different pieces being moulded, cemented, welded, e.g. ultrasonic, or swaged together
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/20—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for assembling or disassembling contact members with insulating base, case or sleeve
    • H01R43/24—Assembling by moulding on contact members

Definitions

  • the invention relates to a method for producing a plug or a coupling socket for electrical plug devices with the features of the preamble of claim 1 and a device for performing the method.
  • plugs or coupling sockets connected to the pipe with a material fit are used wherever plug devices are subject to increased moisture and moisture attack, e.g. in automotive engineering.
  • the disadvantage of the spraying process is the use of complex spraying machines and devices for the external shaping of the plug or the coupling socket.
  • the known device contains a fixed and a movable die, the pressure surfaces of which are interrupted by recesses for the insertion and fixing of the cable lugs.
  • Another flat band is arranged approximately congruently above a first flat band.
  • the cable lugs are arranged in the space between the two flat strips.
  • the movable die is moved against the fixed die.
  • the shape recesses of the fixed and the movable die correspond to each other and, when the two dies are closed, form a cavity for receiving the cable lug and the flat band areas surrounding it.
  • the pressure surface areas of the matrices form heating surfaces for a material connection between the two flat strips. In the closed state of the two dies, the pressure surfaces corresponding to one another lie against one another with the interposition of the flat strips.
  • a cable lug encased by both flat strips lies in each case in the form recesses.
  • the movable die is structurally very complex.
  • the movable die with its heating surfaces is moved against the corresponding heating surfaces of the stationary die.
  • the flat band areas clamped in between the corresponding heating surfaces are first heated up and are thus cohesively connected to one another.
  • the two matrices acting against each other remain in this position after the heating process, so that the cohesively connected flat strip areas can cool down.
  • a blade plate as part of the movable die is moved against the two pressure tools that remain in their closed position. Blades running perpendicular to the flat strips are fixed to the blade plate. When the blade plate is lowered, the blades separate the composite parts from the flat strips.
  • the movable die for carrying out the known method must be constructed from components which are movable relative to one another.
  • the overall structurally very complex design of the device causes unnecessarily high acquisition and maintenance costs.
  • Another disadvantage is that the individual process steps for producing the composite part in a chronologically separate sequence be carried out and the manufacturing time of the composite parts is very long. This in turn increases the cost of manufacturing the individual composite part.
  • the invention is based on the object of simplifying the production of such plugs and coupling sockets in terms of production technology and of making them more cost-effective.
  • Manufacturing time is saved by combining the material connection and separating it into a single work step. This saving is particularly important when it comes to the production of bulk items - as is the case with the manufacture of plugs or coupling sockets. Here, savings can also be felt in the sum of seconds between individual work steps. As a result, the production costs of the individual composite part can be reduced.
  • the preforming of the flat strips with a negative relief according to claim 1 causes a reduced degree of deformation in the material connection of the two flat strips. This improves the material security.
  • the pre-embossed flat strips allow simple positive pre-fixing of the line end area between the two flat strips and the material connection by means of an adhesive.
  • the re-cooling which has not yet taken place completely during the material connection of the flat strip material and its separation, is advantageously used in accordance with claim 2 to carry out the shaping of the composite part which is common in many cases with low mechanical energy of the production means used.
  • the shape embossing can be both the outline shape of the composite part and engravings, lettering or the like. act on the outer surfaces of the composite part.
  • the thermal energy required to produce the flat strips for further process steps e.g. used for embossing or for material connection. This saves energy and thereby lowers the manufacturing costs of the composite part.
  • the manufacturing time is reduced because the warm-up process for the welded or adhesive connection is at least partially eliminated.
  • Claim 5 relates to a preferred embodiment of the flat strips in order to facilitate production and to act as insulation of the line end area to protect against electrical hazards.
  • Claim 7 relates to a device for performing the method according to claim 1.
  • Claim 13 enables the exact manufacture of the composite part with the desired outline shape and the desired cross section in a simple manner. For this purpose, the flat band regions inserted within the cavity formed by two corresponding shaped recesses are heated. The softened flat strip material penetrates the entire cavity of the mold recesses due to the compression of the printing tools. Any plug or coupling socket shape can thus be achieved solely by appropriate design and arrangement of the heating surfaces and the side walls of the recesses. Claim 13 also uses in advantageously the double function of the heating surface, namely on the one hand as part of the mold recess and on the other hand as a means for the material connection.
  • the manufacturing effort of the printing tools and thus the entire device for performing the method is thus reduced. Furthermore, the double function of the heating surface ensures that there is not only a material connection between the two flat strips themselves, but also between the flat strips and the line end area. This leads to a strain relief of the line against the contact elements. This increases the service life of the plug or coupling socket.
  • the heating surfaces are preferably heated by electric current and at the same time support the compression of the two flat band areas by their mechanical pressure effect and by their simultaneous softening the complete filling of the cavity formed by two corresponding recesses.
  • Claim 8 relates to an advantageous embodiment of the printing tools for producing the composite part in a cycle production.
  • Claim 9 relates to the combination of the clock production with a weld to produce the material connection.
  • the work cycles for producing a certain number of composite parts are reduced. As a result, the production system is exposed to less wear. More composite parts are produced per unit of time, which makes the production system more cost-effective.
  • Claims 11 and 12 relate to measures for producing the composite parts in a flow production. As a result, the manufacturing system works even more cost-effectively. According to claim 12, the flow production is combined with a weld to produce the material connection. The flat strips are fed continuously to the printing tools.
  • Claim 14 avoids any waste of the ribbon material. This makes it possible to dispense with complex recycling processes for processing the waste material as a reusable flat belt.
  • the cutting edges according to claim 13 and 14 also fulfill a double function. They are part of the form recesses and at the same time ensure the separation of the composite part. The component expenditure of the device for carrying out the method is thereby further reduced.
  • Claim 15 relates to a measure to ensure the standardized position and the standardized distance between the contact elements.
  • a fixing bridge designed according to claim 16 additionally supports the measures according to claim 15. The contact elements remain fixed in place during the implementation of the method.
  • the design of the fixing bridge according to claim 17 facilitates its integration as part of the connector or coupling socket housing.
  • the connector remains as a moisture-tight unit.
  • the fixing bridge and flat strips are deformed in the same way, so that no additional weak points for possible damage or breaks occur in the finished composite part.
  • the production of the material connection itself is facilitated due to the same material of the fixing bridge and flat strips.
  • the individual supply of a line end area between the two flat strips is superfluous.
  • complex feeding and holding devices for the line end areas can be dispensed with.
  • Such end-to-end line areas favor the mass and flow production of the plug or the coupling socket.
  • the automated manufacture of the plug or the coupling socket is facilitated.
  • Such an alignment of the contact elements and line feeds also saves space when dimensioning the entire production system.
  • the lining up of the line end areas according to claim 19 is thereby facilitated.
  • the supply of the line end regions to the flat strips is additionally improved according to claim 21, the supply of the line end regions to the flat strips without special holding devices.
  • the lined up Line end areas remain reliably in their mutual relative position during the implementation of the method. This supports a trouble-free production process.
  • a particularly space-saving arrangement of line end areas is created during production. This means that a larger number of plugs or coupling sockets can be produced per unit of time. Since the flat strips are preformed according to claim 7 in accordance with the surface shape of the line end regions, the waste or waste of the flat strips is reduced in this way.
  • the arrangement of the fixing bridges according to claim 23 has the effect that the production of the material connection between the flat strips and the line end area is not hindered.
  • the fixing bridges thus have a double function as a holding and fixing means on the one hand and as an integral part of the plug or coupling socket housing on the other.
  • FIG. 1 The process implementation is essentially described with reference to FIG. 1.
  • the illustration in FIG. 1 is limited to the essential functional parts of a manufacturing system for producing a connector.
  • the procedure is explained using a two-pin flat connector 1 (Euro connector).
  • Euro connector two-pin flat connector 1
  • other types of plugs can also be produced, eg multi-pole round or angled plugs with possibly several protective contacts (eg BEN plugs).
  • Coupling sockets can also be manufactured in this way.
  • a line end region 2 (FIG. 3) of a pre-assembled two-wire line 3 is connected to two flat strips 4 in a materially bonded manner.
  • the flat strips 4 extend essentially in a longitudinal direction 5. All rubber-like plastics known for the one-piece connector housing production are suitable as the material for the flat strips 4. After extrusion from an extruder 6, which is only indicated schematically, the flat strips 4 are advanced in the longitudinal direction 5. The two flat belts 4 arranged parallel to one another are temporarily stored in a buffer memory 7, which is also only indicated schematically. The flat strips 4 can also be additionally processed, for example cleaned or coated, in the buffer store 7. After leaving the buffer store, the flat strips 4 each pass into the space between a pressure stamp 8 and an embossing stamp 9. The octagonal stamp 9 has eight stamping surfaces 10. The mutually facing inner sides of the flat strips 4, which act as contact sides 11, in FIG.
  • the pressure stamp 8 is moved in a height direction 12 running perpendicular to the longitudinal direction 5 to the outside 13 of the flat strip 4 opposite the contact side 11.
  • the pressure stamp 8 pressurized with a flat pressure surface 14, the outside 13 of the flat strip 4 in the area of the stamp 9.
  • the stamp 8 and the stamp 9 act on the flat strip 4 in the manner of two clamping jaws.
  • the embossing surfaces 10 are designed in such a way that the contact sides 11 of the flat strips 4 are embossed with a negative relief to the surface shape of the part of the line end region 2 (FIG. 3) to be accommodated by them.
  • the pre-stamped flat strips 4 are moved in the longitudinal direction 5 in the direction of the space between two welding punches 16.
  • the welding stamps 16 face each other with their welding surfaces 17.
  • the welding surfaces 17 are arranged parallel to the flat strips 4.
  • the distance between the two flat strips 4 in the area of the welding stamps 16 is less than during the pre-embossing of the contact sides 11.
  • the line end area is introduced into a space 18 between the two flat strips 4.
  • a total of four line end areas 2 are introduced into the space 18.
  • alternatively effective plug pins 19 and a feed side 20 can be seen as contact elements of the flat plug 1.
  • the longitudinal direction of the line end regions 2 runs essentially perpendicular to the plane of the drawing in FIG. 1.
  • the welding stamps 16, like the pressure stamps 8, are moved in the height direction 12.
  • the flat strips 4 pressurized by the welding punches 16 reduce their mutual distance and embed the line end regions 2 in a form-fitting manner between them due to the pre-embossed contact sides 11.
  • the two welding punches 16 clamp the two flat strips 4 and the line end area 2 between them in the manner of a vice.
  • the welding is then carried out in order to produce a material connection between the flat strips 4 and the line end region 2.
  • the sandwich-like composite part consisting of the layer sequence of flat strip 4 - line end region 2 - flat strip 4 is separated from the remaining region of the flat strips 4 after the welding.
  • the welding surfaces 17 additionally have cutting tools. The cut is made in the vertical direction 12. After the composite part has been separated, the one-piece tab connector 1 is completed.
  • stamping surfaces 10 of two stamping dies 9 can be seen.
  • the embossing surfaces 10 have a rectangular outer contour and are arranged in a plane spanned by the longitudinal direction 5 and a longitudinal line direction 21.
  • the two stamping dies 9 are moved along a lifting direction 22 by holding and lifting devices (not shown).
  • the stroke direction 22 corresponds to the height direction 12 (FIG. 1).
  • the two flat strips 4 are pre-embossed in the direction of the outer sides 13 by a lifting movement of the pressure stamps 8
  • the flat strips 4 in FIG. 2 are embossed in the direction of the contact sides 11 by a lifting movement.
  • pressure parts for generating a counter pressure with respect to the movable embossing dies 9 rest on the outer sides 13 of the flat strips 4, not shown here.
  • the flat strips 4 have a rectangular cross section along the stroke direction 22 and are already pre-embossed as negative reliefs 29 in accordance with the elevations of the embossing surfaces 10. Exactly one half of the volume of the line end region 2 is inserted into the negative reliefs 29 of the flat strips 4 before the welding.
  • the elevations of the embossing surfaces 10 are designed as an image of a volume half of the line end area 2.
  • the two stamping surfaces 10 are constructed identically.
  • the elevations of the two embossing surfaces 10 face away from one another in the stroke direction 22.
  • Each embossing surface has as elevations two volume halves of the line end area 2 lying next to one another in the longitudinal direction 5.
  • the pin reliefs 23 assigned to the connector pins 19 of one volume half and the supply relief 24 assigned to the feed side 20 are the other volume half arranged in the longitudinal direction 5 adjacent. This results in a point-symmetrical structure of the embossing surface 10 in the viewing direction of the stroke direction 22. This configuration of the embossing surfaces 10 reduces the waste of the flat strips 4 and is particularly suitable for symmetrically constructed connectors.
  • the material connection of line end area 2 and flat strips 4 results in strain relief for line 3.
  • the strain relief is further improved by a curved line guide in the area of the feed side 20.
  • the elevations of the embossing surfaces 10 in the area of a strain relief relief 25 are curved.
  • the lines 3 extend essentially along the line longitudinal direction 21. It is arranged perpendicular to the longitudinal direction 5.
  • the line end regions 2 lie in a plane spanned by the longitudinal direction 5 and the line longitudinal direction 21. In the viewing direction of the height direction 12, their arrangement corresponds to the configuration of the embossing surfaces 10 in FIG. 2.
  • Each line end area 2 contains two conductors 26 corresponding to the two-pole flat plug 1.
  • a plug pin 19 is fastened to the ends of each conductor 26 in an electrically contacting manner.
  • the connector pins 19 are arranged in the longitudinal direction 21 of the line.
  • the line 3 is stripped in the area of the feed side 20 up to the ends of the conductors 26.
  • the standardized distance can be established between the two connector pins 19 of a line end region 2.
  • the plug pins 19 are positively locked into a fixing bridge 27.
  • the fixing bridge 27 has rectangular outer contours and extends in the longitudinal direction 5.
  • the fixing bridge 27 is pierced by two cutouts in the longitudinal direction 21 of the cable so that it can form-fit around the outer surface of the plug pins 19.
  • the two fixing bridges 27 in FIG. 3 limit the extension of the line end region 2 in the longitudinal direction 21 of the line.
  • FIG. 4 A total of four lines 3 can be seen in FIG. 4.
  • the alternating arrangement of the line end regions 2 known from FIG. 3 is retained in FIG. 4.
  • the fixing bridge 27 also has rectangular outer contours in FIG. 4, but is lengthened in the longitudinal direction 5 compared to the embodiment in FIG. 3.
  • All plug pins 19 and feed sides 20 are arranged parallel to one another in the longitudinal direction 21 of the line.
  • the notches 28 can facilitate the positive locking of the plug pins 19 and the feed sides 20 into the fixing bridge 27.
  • Each line end area 2 is held by two fixing bridges 27 of the same type.
  • the two fixing bridges 27 are arranged parallel to one another. Their parallel spacing corresponds approximately to the longitudinal plugging of the cable end regions 2 in the longitudinal direction 21 of the cable.
  • each cable end region 2 is held in the region of the plug pins 19 and in the region of the feed side 20 by a fixing bridge 27.
  • the fixing bridges 27 are preferably made of dimensionally stable plastic so that the relative position of the connector pins 19 and the feed side 20 relative to one another is preserved before the welding.
  • FIG. 5 shows an arrangement for establishing a material connection between line end regions 2 and flat strips 4 by means of two welding punches 16.
  • the arrangement of the two line end regions 2 shown in FIG. 5 corresponds to the description in FIG. 3.
  • the contact side 11 visible in FIG. 5 is embossed with four negative reliefs 29. Their design and arrangement correspond to the description in FIG. 2.
  • the two fixing bridges 27 are preferably made of the extruded flat strip material. After welding, they form a material unit with the flat belts 4. For the flat strips 4, such materials are advantageous which have a relatively large surface hardness at ambient temperature, for example after externally protruding conductors 26 are bent in the direction of the plug pins 19 when the welding punches 16 move together and before the molding process associated with softening or liquefying the connector housing material. This prevents such conductors 26 from being able to protrude from the finished plug housing into its circumferential area.
  • the welding surfaces 17 have four shaped recesses 30 corresponding to the surface shape of the finished flat connector housing. Their arrangement corresponds to the arrangement of the four negative reliefs 29.
  • the side walls of the mold recesses 30 running in the longitudinal direction 21 of the line are designed and effective as cutting edges 31.
  • the boundary walls of the form recesses 30, which run in the longitudinal direction 5, are cut out approximately semicircularly, viewed in the longitudinal direction 21 of the line, in order to be able to insert the plug pins 19 or the feed side 20 into the welding punches 16 in a form-fitting manner during the welding.
  • the two welding stamps 16 are moved towards one another in the height direction 12. You clamp the flat strips 4 and the cable end areas 2 between them in the manner of the jaws of a vice. The flat strips 4 are then welded over their entire area to the associated line end regions 2. Any known welding method, for example ultrasonic welding method, is conceivable for this purpose. Full-surface gluing is also possible.
  • the cutting edges 31 separate the finished plug housing from the remaining flat strip material.
  • the outer sides 13 of the flat strips 4 are embossed by the shape recesses 30.
  • the shaped recesses 30 in the exemplary embodiment each have three groove-like embossing depressions 32 which extend in the longitudinal direction 5 and are arranged parallel to one another.
  • the material connection of the flat strips 4 to the line end area 2, the separation of the finished, sandwich-like composite part and the embossing of the outer sides 13 take place in one work step.
  • the parting line between the two flat strips 4 forms the plug pin level.
  • the connector pins 19 or sockets and possibly protective contacts are not necessarily in a common one Level arranged.
  • three or more flat strips 4 are used for carrying out the method. In each case two flat strips 4 then fix at least one plug pin 19 or a socket between them and thus enable the sandwich-like housing structure of a plug or a coupling socket.
  • the two flat strips 4 have a cut surface 33 which extends approximately in the longitudinal direction 21 of the line.
  • the course of the direction of the cut surface 33 corresponds approximately to the course of a side edge of the flat connector 1 in the longitudinal direction 21 of the line.
  • the cut surfaces 33 arise due to the separation of the finished composite parts by the cutting edges 31 during the previous work cycle.
  • Fig. 1 and Fig. 5 it can be seen that the tab 1 is made in a cycle.
  • the use of welding punches 16 with a large number of shaped recesses 30 is advantageous here in order to produce a large number of flat plugs 1 in one work cycle.
  • FIG. 6 shows the manufacture of the tab connector 1 in a continuous production. There is therefore no flow stoppage due to a welding cycle.
  • a plurality of line end areas is arranged in the manner described in FIG. 4 by means of two fixing bridges 27 and is fed in the longitudinal direction 5 to the space between the two flat strips 4.
  • the two flat strips 4 are extruded from two separate, opposing extruders 6 and are first advanced in the height direction 12.
  • Each ribbon 4 is pre-embossed by a pressure roller 34 and an embossing roller 35.
  • Printing roller 34 and embossing roller 35 are each shown in a circle in FIG. 6. While the outer surface of the pressure roller 34 abuts the outer side 13, the outer surface of the embossing roller 35 acts on the contact side 11.
  • Both rollers rotate in the feed direction of the flat strip 4 and can support the movement of the flat strip 4 to the line end regions 2.
  • the outer surface of the embossing roller 35 acts in the manner of the embossing surface 10 (FIG. 1, FIG. 2) and has a large number of relief-like elevations over its circumference.
  • the outer surface of the pressure roller 34 acts in the manner of the pressure surface 14 (FIG. 1).
  • the flat strips 4 are bent approximately in a quarter circle and are then aligned approximately in the longitudinal direction 5. In this area, the flat strips 4 receive the line end area 2 in a form-fitting manner between them.
  • two welding rollers 36 shown in a circle in FIG. 6, act with their outer surfaces on the outer sides 13 of the flat belts 4.
  • the two welding rollers 36 rotate in the longitudinal direction 5.
  • the outer surfaces of the welding rollers 36 have the same function as the welding surfaces 17 (FIG. 5).
  • a plurality of shape recesses 30 and cutting edges 31 are therefore arranged over the circumference of the welding rollers 36.
  • the flat strips 4 are preferably made of transparent material. Damage to the manufacture or use of the flat connector 1, for example wire breaks, can thereby be recognized from the outside.
  • the extruded flat strips 4 can be fed to the line end regions 2 continuously in an endless length. This facilitates the automated manufacture of the tab connector 1.
  • the feed movement of the flat belts 4 only has to be interrupted during the work cycle in a cycle production. This can be done, for example, by the buffer memory 7 (FIG. 1).

Description

Die Erfindung betrifft ein Verfahren zur Herstellung eines Steckers oder einer Kupplungsdose für elektrische Steckvorrichtungen mit den Merkmalen des Oberbegriffs des Anspruches 1 und eine Vorrichtung zur Verfahrensdurchführung.The invention relates to a method for producing a plug or a coupling socket for electrical plug devices with the features of the preamble of claim 1 and a device for performing the method.

Es ist bekannt, elektrische Leitungen vorzukonfektionieren und sodann den Leitungsendbereich der Leitung mit isolierendem Werkstoff, insbesondere Kunststoff, zur Ausbildung des Steckers oder der Kupplungsdose zu umspritzen. Die Leitung ist durch elektrisch leitende Verbindung der einzelnen Leiter mit Kontaktelementen wie Steckerstiften, Buchsen und gegebenenfalls Schutzkontakten sowie durch deren Stellung und Abstand zueinander vorkonfektioniert. Nach dem Umspritzen des mit den Kontaktelementen versehenen Leitungsendbereiches und nach dem Erkalten des Werkstoffes ist der Stecker oder die Kupplungsdose gebrauchsfertig. Die durch den Spritzvorgang entstandene stoffliche Verbindung bewirkt eine feuchtigkeitsdichte Einheit zwischen der Leitung und dem Gehäusewerkstoff des Steckers bzw. der Kupplungsdose. In dieser Weise werden z.B. die Eurostecker gefertigt. Mit der Leitung stoffschlüssig verbundene Stecker bzw. Kupplungsdosen werden überall dort verwendet, wo Steckvorrichtungen einem erhöhten Nässe- und Feuchtigkeitsangriff unterliegen, z.B. im Automobilbau.It is known to prefabricate electrical lines and then to extrusion-coat the line end region of the line with insulating material, in particular plastic, to form the plug or the coupling socket. The cable is pre-assembled by an electrically conductive connection of the individual conductors with contact elements such as plug pins, sockets and, if applicable, protective contacts, and by their position and distance from one another. After the overmolding of the cable end area provided with the contact elements and after the material has cooled, the plug or the coupling socket is ready for use. The material connection created by the spraying process creates a moisture-tight unit between the line and the housing material of the plug or the coupling socket. In this way e.g. the Eurostecker manufactured. Plugs or coupling sockets connected to the pipe with a material fit are used wherever plug devices are subject to increased moisture and moisture attack, e.g. in automotive engineering.

Nachteilig an dem Spritzvorgang ist die Verwendung aufwendiger Spritzmaschinen und Vorrichtungen zur äußeren Formgebung des Steckers oder der Kupplungsdose.The disadvantage of the spraying process is the use of complex spraying machines and devices for the external shaping of the plug or the coupling socket.

Aus US-A-3 392 070 ist eine Vorrichtung zur Massenfertigung kupplungsdosenartiger elektrischer Anschlüsse bekannt. Die elektrischen Kontaktelemente sind durch zwei nebeneinanderliegende Kabelschuhe gebildet. Es handelt sich dort also um eine 2-polige Kupplungsdose. An jedem Kabelschuh ist in bekannter Weise eine Anschlußleitung fixiert. Jeweils zwei Kabelschuhe sind durch eine stoffschlüssige Verbindung zweier Flachbänder zu einer Einheit zusammengefaßt.From US-A-3 392 070 a device for the mass production of coupling socket-like electrical connections is known. The electrical contact elements are formed by two adjacent cable lugs. So it is a 2-pin socket. A connecting cable is fixed to each cable lug in a known manner. There are two cable lugs each combined by a material connection of two flat strips to form a unit.

Die bekannte Vorrichtung enthält eine feststehende und eine bewegliche Matrize, deren Druckflächen durch Formausnehmungen für die Einlage und Fixierung der Kabelschuhe unterbrochen sind. Oberhalb eines ersten Flachbandes ist etwa deckungsgleich ein weiteres Flachband angeordnet. In dem Zwischenraum der beiden Flachbänder sind die Kabelschuhe angeordnet. Zur Herstellung des im wesentlichen aus zwei Kabelschuhen sowie den sie umgebenden Flachbandbereichen bestehenden Verbundteiles wird die bewegliche Matrize gegen die feststehende Matrize verfahren. Die Formausnehmungen der feststehenden und der beweglichen Matrize korrespondieren miteinander und bilden im geschlossenen Zustand der beiden Matrizen einen Hohlraum für die Aufnahme des Kabelschuhs sowie der ihn umgebenden Flachbandbereiche. Die Druckflächenbereiche der Matrizen bilden Heizflächen für eine Stoffschluß-Verbindung der beiden Flachbänder. Im geschlossenen Zustand der beiden Matrizen liegen die miteinander korrespondierenden Druckflächen unter Zwischenlage der Flachbänder aneinander an. In den Formausnehmungen liegt jeweils ein von beiden Flachbändern umhüllter Kabelschuh ein.The known device contains a fixed and a movable die, the pressure surfaces of which are interrupted by recesses for the insertion and fixing of the cable lugs. Another flat band is arranged approximately congruently above a first flat band. The cable lugs are arranged in the space between the two flat strips. In order to produce the composite part consisting essentially of two cable lugs and the flat band areas surrounding them, the movable die is moved against the fixed die. The shape recesses of the fixed and the movable die correspond to each other and, when the two dies are closed, form a cavity for receiving the cable lug and the flat band areas surrounding it. The pressure surface areas of the matrices form heating surfaces for a material connection between the two flat strips. In the closed state of the two dies, the pressure surfaces corresponding to one another lie against one another with the interposition of the flat strips. A cable lug encased by both flat strips lies in each case in the form recesses.

Zur Durchführung der einzelnen Verfahrensschritte ist die bewegliche Matrize konstruktiv sehr aufwendig gestaltet. Zunächst wird die bewegliche Matrize mit ihren Heizflächen gegen die korrespondierenden Heizflächen der feststehenden Matrize verfahren. Die zwischen den korrespondierenden Heizflächen eingeklemmten Flachbandbereiche werden zunächst aufgeheizt und dadurch stoffschlüssig miteinander verbunden. Die beiden gegeneinanderwirkenden Matrizen verbleiben nach dem Heizvorgang in dieser Stellung, damit sich die stoffschlüssig verbundenen Flachbandbereiche abkühlen können. In einem nächsten Arbeitsschritt wird eine Klingenplatte als Bestandteil der beweglichen Matrize gegen die beiden in ihrer geschlossenen Stellung verharrenden Druckwerkzeuge verfahren. An der Klingenplatte sind lotrecht zu den Flachbändern verlaufende Klingen fixiert. Beim Herabfahren der Klingenplatte trennen die Klingen die Verbundteile von den Flachbändern. Demzufolge muß die bewegliche Matrize zur Durchführung des bekannten Verfahrens aus relativ zueinander beweglichen Bestandteilen aufgebaut sein. Die insgesamt konstruktiv sehr aufwendige Gestaltung der Vorrichtung verursacht unnötig hohe Anschaffungs- und Wartungskosten. Weiterhin nachteilig ist, daß die einzelnen Verfahrensschritte zur Herstellung des Verbundteiles in zeitlich getrennter Aufeinanderfolge durchgeführt werden und dadurch die Fertigungszeit der Verbundteile sehr groß ist. Dies wiederum verteuert die Herstellungskosten des einzelnen Verbundteiles.To carry out the individual process steps, the movable die is structurally very complex. First, the movable die with its heating surfaces is moved against the corresponding heating surfaces of the stationary die. The flat band areas clamped in between the corresponding heating surfaces are first heated up and are thus cohesively connected to one another. The two matrices acting against each other remain in this position after the heating process, so that the cohesively connected flat strip areas can cool down. In a next step, a blade plate as part of the movable die is moved against the two pressure tools that remain in their closed position. Blades running perpendicular to the flat strips are fixed to the blade plate. When the blade plate is lowered, the blades separate the composite parts from the flat strips. Accordingly, the movable die for carrying out the known method must be constructed from components which are movable relative to one another. The overall structurally very complex design of the device causes unnecessarily high acquisition and maintenance costs. Another disadvantage is that the individual process steps for producing the composite part in a chronologically separate sequence be carried out and the manufacturing time of the composite parts is very long. This in turn increases the cost of manufacturing the individual composite part.

Ausgehend von den geschilderten Nachteilen liegt der Erfindung die Aufgabe zugrunde, die Herstellung derartiger Stecker und Kupplungsdosen fertigungstechnisch zu vereinfachen und kostengünstiger zu gestalten.Starting from the disadvantages described, the invention is based on the object of simplifying the production of such plugs and coupling sockets in terms of production technology and of making them more cost-effective.

Diese Aufgabe wird durch die Merkmalskombinationen der Ansprüche 1 und 7 gelöst.This object is achieved by the combinations of features of claims 1 and 7.

Durch die Zusammenfassung der Stoffschluß-Verbindung und der Abtrennung zu einem einzigen Arbeitsschritt wird Fertigungszeit eingespart. Diese Einsparung ist vor allem dann wichtig, wenn es sich um die Herstellung von Massenartikeln - wie dies bei der Fertigung von Steckern oder Kupplungsdosen der Fall ist - handelt. Hier machen sich Einsparungen auch im Sekunden-Bereich zwischen einzelnen Arbeitsschritten in der Summe stark bemerkbar. Die Produktionskosten des einzelnen Verbundteiles können dadurch gesenkt werden.Manufacturing time is saved by combining the material connection and separating it into a single work step. This saving is particularly important when it comes to the production of bulk items - as is the case with the manufacture of plugs or coupling sockets. Here, savings can also be felt in the sum of seconds between individual work steps. As a result, the production costs of the individual composite part can be reduced.

Zusätzliche Fertigungsmittel zur Abtrennung der Verbundteile entfallen. Die Fertigung insgesamt ist vereinfacht, da die verwendeten Mittel gleichzeitig für die Stoffschluß-Verbindung und für die Abtrennung verwendet werden. Die gleichzeitige Verwendung einzelner Bauteile für mehrere Arbeitsschritte reduziert auch den Bauteileaufwand der Vorrichtung zur Durchführung des Verfahrens. Dadurch können die Herstellungskosten des Verbundteiles weiter gesenkt werden.Additional manufacturing means for separating the composite parts are eliminated. The production as a whole is simplified since the means used are used simultaneously for the material connection and for the separation. The simultaneous use of individual components for several work steps also reduces the component expenditure of the device for carrying out the method. As a result, the manufacturing costs of the composite part can be reduced further.

Die Vorformung der Flachbänder mit einem Negativ-Relief gemäß Anspruch 1 bewirkt einen reduzierten Verformungsgrad bei der Stoffschluß-Verbindung der beiden Flachbänder. Dadurch ist die Stoffschluß-Sicherheit verbessert. Außerdem ermöglichen die vorgeprägten Flachbänder in einfacher Weise eine formschlüssige Vorfixierung des Leitungsendbereiches zwischen den beiden Flachbändern und die Stoffschluß-Verbindung mittels einer Klebung.The preforming of the flat strips with a negative relief according to claim 1 causes a reduced degree of deformation in the material connection of the two flat strips. This improves the material security. In addition, the pre-embossed flat strips allow simple positive pre-fixing of the line end area between the two flat strips and the material connection by means of an adhesive.

Gemäß Anspruch 2 wird weitere Produktionszeit während der Verfahrensdurchführung eingespart. Die Anzahl der notwendigen Fertigungsmaschinen und -vorrichtungen ist nochmals reduziert.According to claim 2, further production time is saved during the implementation of the method. The number of necessary manufacturing machines and devices is reduced again.

Die während der Stoffschluß-Verbindung des Flachbandmaterials und seiner Abtrennung noch nicht vollständig erfolgte Wiedererkaltung wird gemäß Anspruch 2 vorteilhaft dazu genutzt, mit geringer mechanischer Energie der verwendeten Fertigungsmittel die in vielen Fällen übliche Formprägung des Verbundteiles vorzunehmen. Bei der Formprägung kann es sich sowohl um die Umrißform des Verbundteiles als auch um Gravuren, Schriftzüge o.dgl. auf den Außenflächen des Verbundteiles handeln.The re-cooling, which has not yet taken place completely during the material connection of the flat strip material and its separation, is advantageously used in accordance with claim 2 to carry out the shaping of the composite part which is common in many cases with low mechanical energy of the production means used. The shape embossing can be both the outline shape of the composite part and engravings, lettering or the like. act on the outer surfaces of the composite part.

Nach Anspruch 4 wird die erforderliche Wärmenergie zur Herstellung der Flachbänder für weitere Verfahrensschritte, z.B. zur Prägung oder zur Stoffschluß-Verbindung, ausgenutzt. Dies wirkt energiesparend und senkt dadurch die Herstellungskosten des Verbundteiles. Außerdem wird die Herstellungszeit verringert, da der Aufwärmevorgang für die Schweiß- oder Klebeverbindung zumindest teilweise entfällt.According to claim 4, the thermal energy required to produce the flat strips for further process steps, e.g. used for embossing or for material connection. This saves energy and thereby lowers the manufacturing costs of the composite part. In addition, the manufacturing time is reduced because the warm-up process for the welded or adhesive connection is at least partially eliminated.

Anspruch 5 betrifft eine bevorzugte Ausführungsform der Flach bänder, um die Herstellung zu erleichtern und um als Isolierung des Leitungsendbereiches zum Schutz vor elektrischen Gefahren zu wirken.Claim 5 relates to a preferred embodiment of the flat strips in order to facilitate production and to act as insulation of the line end area to protect against electrical hazards.

Gemäß Anspruch 6 ausgestaltete Flachbänder ermöglichen, daß Beschädigungen oder Brüche von Leitung, Leiter oder Kontaktelementen im Bereich des Leitungsendbereiches erkennbar sind. Dadurch ist ein an die Steckvorrichtung angeschlossenes elektrisches Gerät zusätzlich vor elektrischen Gefahren geschützt. Auch die Ursachenanalyse für eine Bedienerperson im Falle eines elektrischen Defekts ist dadurch erleichtert.Flat strips designed according to claim 6 enable damage or breaks in the line, conductor or contact elements in the region of the End of the line are recognizable. As a result, an electrical device connected to the plug device is additionally protected against electrical dangers. This also simplifies the cause analysis for an operator in the event of an electrical defect.

Anspruch 7 betrifft eine Vorrichtung zum Durchführen des Verfahrens gemäß Anspruch 1. Anspruch 13 ermöglicht in einfacher Weise die exakte Herstellung des Verbundteiles mit der erwünschten Umrißform und dem erwünschten Querschnitt. Hierzu werden die innerhalb des durch zwei korrespondierende Formausnehmungen gebildeten Hohlraumes eingelegten Flachbandbereiche erhitzt. Das erweichte Flachbandmaterial durchsetzt aufgrund des Zusammenpressens der Druckwerkzeuge den gesamten Hohlraum der Formausnehmungen. Jede beliebige Stecker- bzw. Kupplungsdosenform ist somit allein durch entsprechende konstruktive Ausgestaltung und Anordnung der Heizflächen und der Seitenwände der Formausnehmungen erzielbar. Anspruch 13 nutzt auch in vorteilhafter Weise die Doppelfunktion der Heizfläche, nämlich zum einen als Bestandteil der Formausnehmung und zum anderen als Mittel für die Stoffschluß-Verbindung. Der Fertigungsaufwand der Druckwerkzeuge und somit der gesamten Vorrichtung zur Durchführung des Verfahrens ist damit reduziert. Weiterhin gewährleistet die Doppelfunktion der Heizfläche, daß nicht nur eine Stoffschluß-Verbindung zwischen den beiden Flachbändern selbst, sondern auch zwischen den Flachbändern und dem Leitungsendbereich entsteht. Dies bewirkt eine Zugentlastung der Leitung gegenüber den Kontaktelementen. Die Lebensdauer des Steckers bzw. der Kupplungsdose ist dadurch erhöht.Claim 7 relates to a device for performing the method according to claim 1. Claim 13 enables the exact manufacture of the composite part with the desired outline shape and the desired cross section in a simple manner. For this purpose, the flat band regions inserted within the cavity formed by two corresponding shaped recesses are heated. The softened flat strip material penetrates the entire cavity of the mold recesses due to the compression of the printing tools. Any plug or coupling socket shape can thus be achieved solely by appropriate design and arrangement of the heating surfaces and the side walls of the recesses. Claim 13 also uses in advantageously the double function of the heating surface, namely on the one hand as part of the mold recess and on the other hand as a means for the material connection. The manufacturing effort of the printing tools and thus the entire device for performing the method is thus reduced. Furthermore, the double function of the heating surface ensures that there is not only a material connection between the two flat strips themselves, but also between the flat strips and the line end area. This leads to a strain relief of the line against the contact elements. This increases the service life of the plug or coupling socket.

Die Heizflächen werden vorzugsweise durch elektrischen Strom erhitzt und unterstützen gleichzeitig durch ihre mechanische Druckwirkung das Zusammenpressen der beiden Flachbandbereiche und durch deren gleichzeitiges Erweichen die vollständige Ausfüllung des von zwei korrespondierenden Formausnehmungen gebildeten Hohlraums.The heating surfaces are preferably heated by electric current and at the same time support the compression of the two flat band areas by their mechanical pressure effect and by their simultaneous softening the complete filling of the cavity formed by two corresponding recesses.

Anspruch 8 betrifft eine vorteilhafte Ausführungsform der Druckwerkzeuge zur Herstellung des Verbundteiles in einer Taktfertigung.Claim 8 relates to an advantageous embodiment of the printing tools for producing the composite part in a cycle production.

Anspruch 9 betrifft die Kombination der Taktfertigung mit einer Schweißung zur Herstellung der Stoffschluß-Verbindung.Claim 9 relates to the combination of the clock production with a weld to produce the material connection.

Gemäß Anspruch 10 sind die Arbeitstakte zur Herstellung einer bestimmten Anzahl von Verbundteilen reduziert. Die Fertigungsanlage ist dadurch geringerem Verschleiß ausgesetzt. Pro Zeiteinheit werden mehr Verbundteile hergestellt, wodurch die Fertigungsanlage kostengünstiger arbeitet.According to claim 10, the work cycles for producing a certain number of composite parts are reduced. As a result, the production system is exposed to less wear. More composite parts are produced per unit of time, which makes the production system more cost-effective.

Anspruch 11 und 12 betreffen Maßnahmen zur Herstellung der Verbundteile in einer Fließfertigung. Dadurch arbeitet die Fertigungsanlage noch kostengünstiger. Gemäß Anspruch 12 ist die Fließfertigung mit einer Schweißung zur Herstellung der Stoffschluß-Verbindung kombiniert. Hierbei werden die Flachbänder den Druckwerkzeugen kontinuierlich zugeführt.Claims 11 and 12 relate to measures for producing the composite parts in a flow production. As a result, the manufacturing system works even more cost-effectively. According to claim 12, the flow production is combined with a weld to produce the material connection. The flat strips are fed continuously to the printing tools.

Anspruch 14 vermeidet jeglich anfallenden Verschnitt des Flachbandmaterials. Dies ermöglicht den Wegfall aufwendiger Recycling-Verfahren zur Aufbereitung des Verschnittmaterials als wiederverwertbares Flachband.Claim 14 avoids any waste of the ribbon material. This makes it possible to dispense with complex recycling processes for processing the waste material as a reusable flat belt.

Die Schneiden nach Anspruch 13 und 14 erfüllen ebenfalls eine Doppelfunktion. Sie sind Bestandteil der Formausnehmungen und gewährleisten gleichzeitig die Abtrennung des Verbundteiles. Der Bauteileaufwand der Vorrichtung zur Durchführung des Verfahrens ist dadurch weiter reduziert.The cutting edges according to claim 13 and 14 also fulfill a double function. They are part of the form recesses and at the same time ensure the separation of the composite part. The component expenditure of the device for carrying out the method is thereby further reduced.

Anspruch 15 betrifft eine Maßnahme zur Gewährleistung der genormten Stellung und des genormten Abstandes der Kontaktelemente zueinander.Claim 15 relates to a measure to ensure the standardized position and the standardized distance between the contact elements.

Eine nach Anspruch 16 ausgestaltete Fixierbrücke unterstützt die Maßnahmen gemäß Anspruch 15 zusätzlich. Die Kontaktelemente bleiben während der Verfahrensdurchführung ortsfest fixiert.A fixing bridge designed according to claim 16 additionally supports the measures according to claim 15. The contact elements remain fixed in place during the implementation of the method.

Die Ausgestaltung der Fixierbrücke nach Anspruch 17 erleichtert dessen Integration als Teil des Stecker- oder Kupplungsdosengehäuses. Die Steckvorrichtung bleibt als feuchtigkeitsdichte Einheit bestehen. Während der Herstellung der Stoffschluß-Verbindung werden Fixierbrücke und Flach bänder in gleicher Weise verformt, so daß bei dem fertigen Verbundteil keine zusätzlichen Schwachstellen für evtl. Beschädigungen oder Brüche auftreten. Außerdem ist die Herstellung der Stoffschluß-Verbindung selbst aufgrund des selben Materials von Fixierbrücke und Flachbändern erleichtert.The design of the fixing bridge according to claim 17 facilitates its integration as part of the connector or coupling socket housing. The connector remains as a moisture-tight unit. During the manufacture of the material connection, the fixing bridge and flat strips are deformed in the same way, so that no additional weak points for possible damage or breaks occur in the finished composite part. In addition, the production of the material connection itself is facilitated due to the same material of the fixing bridge and flat strips.

Gemäß Anspruch 18 ist eine fehlerlose, der Norm entsprechende Herstellung von Stecker und Kupplungsdose gewährleistet.According to claim 18, an error-free, standard-compliant manufacture of plug and coupling socket is guaranteed.

Nach Anspruch 19 ist die einzelne Zuführung eines Leitungsendbereiches zwischen die beiden Flachbänder überflüssig. Ebenso können dadurch aufwendige Zuführungs- und Halteeinrichtungen für die Leitungsendbereiche entfallen. Derartig aneinandergereihte Leitungsendbereiche begünstigen die Massen- und Fließfertigung des Steckers bzw. der Kupplungsdose.According to claim 19, the individual supply of a line end area between the two flat strips is superfluous. Likewise, complex feeding and holding devices for the line end areas can be dispensed with. Such end-to-end line areas favor the mass and flow production of the plug or the coupling socket.

Nach Anspruch 20 ist die automatisierte Fertigung des Steckers bzw. der Kupplungsdose erleichtert. Eine derartige Ausrichtung der Kontaktelemente und Leitungszuführungen wirkt außerdem platzsparend bei der Dimensionierung der gesamten Fertigungsanlage. Die Aneinanderreihung der Leitungsendbereiche nach Anspruch 19 ist dadurch erleichtert.According to claim 20, the automated manufacture of the plug or the coupling socket is facilitated. Such an alignment of the contact elements and line feeds also saves space when dimensioning the entire production system. The lining up of the line end areas according to claim 19 is thereby facilitated.

Gemäß Anspruch 21 ist die Zuführung der Leitungsendbereiche zu den FlachGemäß Anspruch 21 ist die Zuführung der Leitungsendbereiche zu den Flachbändern ohne besondere Halteeinrichtungen zusätzlich verbessert. Die aneinandergereihten Leitungsendbereiche verbleiben während der Verfahrensdurchführung zuverlässig in ihrer gegenseitigen Relativlage. Dies unterstützt einen störungslosen Fertigungsablauf.According to claim 21, the supply of the line end regions to the flat strips is additionally improved according to claim 21, the supply of the line end regions to the flat strips without special holding devices. The lined up Line end areas remain reliably in their mutual relative position during the implementation of the method. This supports a trouble-free production process.

Nach Anspruch 22 entsteht während der Fertigung eine besonders platzsparende Aneinanderreihung von Leitungsendbereichen. Dadurch läßt sich pro Zeiteinheit eine größere Stückzahl an Steckern bzw. Kupplungsdosen produzieren. Da die Flachbänder nach Anspruch 7 entsprechend der Oberflächengestalt der Leitungsendbereiche vorgeformt werden, ist auf diese Weise der Verschnitt bzw. Abfall der Flachbänder reduziert.According to claim 22, a particularly space-saving arrangement of line end areas is created during production. This means that a larger number of plugs or coupling sockets can be produced per unit of time. Since the flat strips are preformed according to claim 7 in accordance with the surface shape of the line end regions, the waste or waste of the flat strips is reduced in this way.

Die Anordnung der Fixierbrücken nach Anspruch 23 bewirkt, daß die Herstellung der Stoffschluß-Verbindung zwischen Flachbändern und Leitungsendbereich nicht behindert wird.The arrangement of the fixing bridges according to claim 23 has the effect that the production of the material connection between the flat strips and the line end area is not hindered.

Nach Anspruch 24 sind evtl. Arbeitsschritte zur Entfernung der Fixierbrücken während des Fertigungsablaufs unnötig. Die Fixierbrücken haben somit eine Doppelfunktion als Halte- und Fixiermittel einerseits sowie als einstückiger Bestandteil des Stecker- bzw. Kupplungsdosengehäuses andererseits.According to claim 24, steps for removing the fixing bridges during the manufacturing process may be unnecessary. The fixing bridges thus have a double function as a holding and fixing means on the one hand and as an integral part of the plug or coupling socket housing on the other.

Der Erfindungsgegenstand wird anhand von in den Figuren dargestellten Ausführungsbeispielen näher erläutert. Es zeigen:

Fig. 1
eine schematische Darstellung der Herstellung eines Flachsteckers in einer Taktfertigung,
Fig. 2
eine perspektivische Darstellung zweier vorgeprägter Flachbänder mit den dazugehörigen Prägestempeln,
Fig. 3
eine perspektivische Teildarstellung zweier alternierend nebeneinanderliegender Leitungen, wobei die Kontaktelemente jeweils eines Leitungsendbereiches durch eine Fixierbrücke gehalten sind,
Fig. 4
die perspektivische Darstellung von vier alternierend nebeneinanderliegender Leitungen und zwei Fixierbrücken, wobei die beiden Fixierbrücken jeweils in ihrer Längsrichtung hintereinander alternierend die Leitungszuführung und die Kontaktelemente der vier Leitungen halten,
Fig. 5
die perspektivische Darstellung zweier Leitungen ensprechend Fig. 3, jedoch im Zwischenraum zwischen zwei vorgeprägten Flachbändern vor Vollzug der Stoffschluß-Verbindung mittels zweier ebenfalls dargestellter Schweißstempel,
Fig. 6
eine schematische Darstellung der Herstellung des Flachsteckers in einer Fließfertigung.
The subject matter of the invention is explained in more detail with reference to exemplary embodiments shown in the figures. Show it:
Fig. 1
1 shows a schematic representation of the manufacture of a flat connector in a cycle production,
Fig. 2
2 shows a perspective illustration of two pre-embossed flat strips with the associated embossing stamps,
Fig. 3
2 shows a perspective partial illustration of two lines lying next to one another in alternation, the contact elements of each line end area being held by a fixing bridge,
Fig. 4
the perspective representation of four alternately adjacent lines and two fixing bridges, the two fixing bridges alternately holding the line feed and the contact elements of the four lines one behind the other in their longitudinal direction,
Fig. 5
the perspective view of two lines corresponding to Fig. 3, but in the space between two pre-stamped flat strips before completion of the material connection by means of two welding stamps, also shown,
Fig. 6
is a schematic representation of the manufacture of the tab connector in a flow production.

Die Verfahrensdurchführung wird im wesentlichen anhand von Fig. 1 beschrieben. Die Darstellung in Fig. 1 beschränkt sich auf die wesentlichen Funktionsteile einer Fertigungsanlage zur Herstellung eines Steckers. In den Zeichnungen wird die Verfahrensdurchführung anhand eines zweipoligen Flachsteckers 1 (Eurostecker) erläutert.
In prinzipiell gleicher Weise sind jedoch auch andere Steckerarten, z.B. mehrpolige Rund- oder Winkelstecker mit gegebenenfalls mehreren Schutzkontakten (z.B. BEN-Stecker) herstellbar.
Auch Kupplungsdosen lassen sich auf diese Weise fertigen.The process implementation is essentially described with reference to FIG. 1. The illustration in FIG. 1 is limited to the essential functional parts of a manufacturing system for producing a connector. In the drawings, the procedure is explained using a two-pin flat connector 1 (Euro connector).
In principle, however, other types of plugs can also be produced, eg multi-pole round or angled plugs with possibly several protective contacts (eg BEN plugs).
Coupling sockets can also be manufactured in this way.

Zur Herstellung des Flachsteckers 1 wird ein Leitungsendbereich 2 (Fig. 3) einer vorkonfektionierten zweiadrigen Leitung 3 mit zwei Flachbändern 4 stoffschlüssig verbunden.To manufacture the flat connector 1, a line end region 2 (FIG. 3) of a pre-assembled two-wire line 3 is connected to two flat strips 4 in a materially bonded manner.

Die Flachbänder 4 erstrecken sich im wesentlichen in einer Längsrichtung 5. Als Werkstoff für die Flachbänder 4 sind sämtliche für die einteilige Steckergehäusefertigung bekannten, gummiartigen Kunststoffe geeignet.
Nach der Extrusion aus einem lediglich schematisch angedeuteten Extruder 6 werden die Flachbänder 4 in Längsrichtung 5 vorgeschoben. Die beiden parallel zueinander angeordneten Flachbänder 4 werden in einem ebenfalls nur schematisch angedeuteten Pufferspeicher 7 zwischengelagert. In dem Pufferspeicher 7 können die Flachbänder 4 auch noch zusätzlich bearbeitet, z.B. gereinigt oder beschichtet werden.
Nach dem Verlassen des Pufferspeichers gelangen die Flachbänder 4 jeweils in den Zwischenraum zwischen einem Druckstempel 8 und einem Prägestempel 9.
Der achteckige Prägestempel 9 weist acht Prägeflächen 10 auf. Die einander zugewandten, als Kontaktseiten 11 wirksamen Innenseiten der Flachbänder 4 liegen in Fig. 1 im Bereich des Prägestempels 9 unmittelbar jeweils an einer Prägefläche 10 an. Sobald das Flachband 4 an der Prägefläche 10 anliegt, wird der Druckstempel 8 in einer senkrecht zur Längsrichtung 5 verlaufenden Höhenrichtung 12 auf die der Kontaktseite 11 gegenüberliegende Außenseite 13 des Flachbandes 4 zubewegt. Der Druckstempel 8 druckbeaufschlagt mit einer ebenen Druckfläche 14 die Außenseite 13 des Flachbandes 4 im Bereich des Prägestempels 9. Druckstempel 8 und Prägestempel 9 wirken nach Art zweier Klemmbacken auf das Flachband 4 ein. Die Prägeflächen 10 sind derart ausgestaltet, daß die Kontaktseiten 11 der Flachbänder 4 mit einem Negativ-Relief zur Oberflächengestalt des von ihnen aufzunehmenden Teiles des Leitungsendbereiches 2 (Fig. 3) vorgeprägt werden.The flat strips 4 extend essentially in a longitudinal direction 5. All rubber-like plastics known for the one-piece connector housing production are suitable as the material for the flat strips 4.
After extrusion from an extruder 6, which is only indicated schematically, the flat strips 4 are advanced in the longitudinal direction 5. The two flat belts 4 arranged parallel to one another are temporarily stored in a buffer memory 7, which is also only indicated schematically. The flat strips 4 can also be additionally processed, for example cleaned or coated, in the buffer store 7.
After leaving the buffer store, the flat strips 4 each pass into the space between a pressure stamp 8 and an embossing stamp 9.
The octagonal stamp 9 has eight stamping surfaces 10. The mutually facing inner sides of the flat strips 4, which act as contact sides 11, in FIG. 1 lie directly against an embossing surface 10 in the area of the stamp 9. As soon as the flat strip 4 lies against the embossing surface 10, the pressure stamp 8 is moved in a height direction 12 running perpendicular to the longitudinal direction 5 to the outside 13 of the flat strip 4 opposite the contact side 11. The pressure stamp 8 pressurized with a flat pressure surface 14, the outside 13 of the flat strip 4 in the area of the stamp 9. The stamp 8 and the stamp 9 act on the flat strip 4 in the manner of two clamping jaws. The embossing surfaces 10 are designed in such a way that the contact sides 11 of the flat strips 4 are embossed with a negative relief to the surface shape of the part of the line end region 2 (FIG. 3) to be accommodated by them.

Nach erfolgter Vorprägung der Kontaktseiten 11 werden die Druckstempel 8 entgegen der Höhenrichtung 12 zurückbewegt.After pre-embossing of the contact sides 11, the pressure stamps 8 are moved back against the height direction 12.

Die vorgeprägten Flachbänder 4 werden in Längsrichtung 5 in Richtung des Zwischenraumes zwischen zwei Schweißstempeln 16 bewegt. Die Schweißstempel 16 sind mit ihren Schweißflächen 17 einander zugewandt. Die Schweißflächen 17 sind parallel zu den Flachbändern 4 angeordnet. Der Abstand zwischen beiden Flachbändern 4 im Bereich der Schweißstempel 16 ist geringer als während der Vorprägung der Kontaktseiten 11. Im Bereich der Schweißstempel 16 wird der Leitungsendbereich in einen Zwischenraum 18 zwischen den beiden Flachbändern 4 eingebracht.The pre-stamped flat strips 4 are moved in the longitudinal direction 5 in the direction of the space between two welding punches 16. The welding stamps 16 face each other with their welding surfaces 17. The welding surfaces 17 are arranged parallel to the flat strips 4. The distance between the two flat strips 4 in the area of the welding stamps 16 is less than during the pre-embossing of the contact sides 11. In the area of the welding stamps 16, the line end area is introduced into a space 18 between the two flat strips 4.

In Fig. 1 sind in den Zwischenraum 18 insgesamt vier Leitungsendbereiche 2 eingebracht. Von den Leitungsendbereichen 2 sind in Längsrichtung 5 betrachtet alternierend als Kontaktelemente des Flachsteckers 1 wirksame Stekkerstifte 19 und eine Zuführungsseite 20 erkennbar. Die Längsrichtung der Leitungsendbereiche 2 verläuft im wesentlichen lotrecht zur Zeichnungsebene in Fig. 1.In Fig. 1, a total of four line end areas 2 are introduced into the space 18. When viewed in the longitudinal direction 5 of the line end regions 2, alternatively effective plug pins 19 and a feed side 20 can be seen as contact elements of the flat plug 1. The longitudinal direction of the line end regions 2 runs essentially perpendicular to the plane of the drawing in FIG. 1.

Die Schweißstempel 16 werden ebenso wie die Druckstempel 8 in Höhenrichtung 12 verfahren. Die von den Schweißstempeln 16 druckbeaufschlagten Flachbänder 4 verringern ihren gegenseitigen Abstand und betten aufgrund der vorgeprägten Kontaktseiten 11 die Leitungsendbereiche 2 formschlüssig zwischen sich ein. Die beiden Schweißstempel 16 klemmen die beiden Flachbänder 4 und den Leitungsendbereich 2 nach Art eines Schraubstockes zwischen sich ein. Sodann erfolgt die Verschweißung, um eine Stoffschluß-Verbindung zwischen den Flachbändern 4 und dem Leitungsendbereich 2 herzustellen. Das aus der Schichtenfolge Flachband 4 - Leitungsendbereich 2 - Flachband 4 bestehende sandwichartige Verbundteil wird nach der Verschweißung vom übrigen Bereich der Flachbänder 4 abgetrennt. Hierzuweisen die Schweißflächen 17 zusätzlich Schneidwerkzeuge auf. Der Schnitt erfolgt in Höhenrichtung 12. Nach der Abtrennung des Verbundteiles ist der einteilige Flachstecker 1 fertiggestellt.The welding stamps 16, like the pressure stamps 8, are moved in the height direction 12. The flat strips 4 pressurized by the welding punches 16 reduce their mutual distance and embed the line end regions 2 in a form-fitting manner between them due to the pre-embossed contact sides 11. The two welding punches 16 clamp the two flat strips 4 and the line end area 2 between them in the manner of a vice. The welding is then carried out in order to produce a material connection between the flat strips 4 and the line end region 2. The sandwich-like composite part consisting of the layer sequence of flat strip 4 - line end region 2 - flat strip 4 is separated from the remaining region of the flat strips 4 after the welding. For this purpose, the welding surfaces 17 additionally have cutting tools. The cut is made in the vertical direction 12. After the composite part has been separated, the one-piece tab connector 1 is completed.

In Fig. 2 sind Prägeflächen 10 zweier Prägestempel 9 erkennbar. Die Prägeflächen 10 besitzen eine rechteckige Außenkontur und sind in einer durch die Längsrichtung 5 und eine Leitungslängsrichtung 21 aufgespannten Ebene angeordnet. Die beiden Prägestempel 9 werden durch nicht dargestellte Halte- und Hubvorrichtungen entlang einer Hubrichtung 22 bewegt. Die Hubrichtung 22 entspricht der Höhenrichtung 12 (Fig. 1).2, stamping surfaces 10 of two stamping dies 9 can be seen. The embossing surfaces 10 have a rectangular outer contour and are arranged in a plane spanned by the longitudinal direction 5 and a longitudinal line direction 21. The two stamping dies 9 are moved along a lifting direction 22 by holding and lifting devices (not shown). The stroke direction 22 corresponds to the height direction 12 (FIG. 1).

In Blickrichtung der Hubrichtung 22 sind die Außenkonturen der beiden Prägestempel 9 deckungsgleich.In the direction of the stroke direction 22, the outer contours of the two dies 9 are congruent.

Während in Fig. 1 die beiden Flachbänder 4 durch eine Hubbewegung der Druckstempel 8 in Richtung der Außenseiten 13 vorgeprägt werden, werden die Flachbänder 4 in Fig. 2 durch eine Hubbewegung der Prägestempel 9 in Richtung der Kontaktseiten 11 vorgeprägt. Bei dieser Art der Vorprägung liegen an den Außenseiten 13 der Flachbänder 4 hier nicht dargestellte Ebene Druckteile zur Erzeugung eines Gegendrucks gegenüber den beweglichen Prägestempeln 9 an.1, the two flat strips 4 are pre-embossed in the direction of the outer sides 13 by a lifting movement of the pressure stamps 8, the flat strips 4 in FIG. 2 are embossed in the direction of the contact sides 11 by a lifting movement. With this type of pre-embossing, pressure parts for generating a counter pressure with respect to the movable embossing dies 9 rest on the outer sides 13 of the flat strips 4, not shown here.

Die Flachbänder 4 weisen entlang der Hubrichtung 22 einen rechteckigen Querschnitt auf und sind entsprechend den Erhebungen der Prägeflächen 10 als Negativ-Reliefs 29 bereits vorgeprägt.
In die Negativ-Reliefs 29 der Flachbänder 4 wird jeweils genau eine Volumenhälfte des Leitungsendbereiches 2 vor der Verschweißung eingelegt. Zu diesem Zweck sind die Erhebungen der Prägeflächen 10 als Abbild einer Volumenhälfte des Leitungsendbereiches 2 ausgestaltet.
Die beiden Prägeflächen 10 sind identisch aufgebaut. Die Erhebungen der beiden Prägeflächen 10 sind in Hubrichtung 22 einander abgewandt. Jeweils eine Prägefläche weist als Erhebungen zwei in Längsrichtung 5 nebeneinanderliegende Volumenhälften des Leitungsendbereiches 2 auf. Dabei sind die den Steckerstiften 19 zugeordneten Stiftreliefs 23 der einen Volumenhälfte und das der Zuführungsseite 20 zugeordnete Zuführungsrelief 24 der anderen Volumenhälfte in Längsrichtung 5 benachbart angeordnet. Dadurch ergibt sich in Blickrichtung der Hubrichtung 22 ein punktsymmetrischer Aufbau der Prägefläche 10. Diese Ausgestaltung der Prägeflächen 10 reduziert den Verschnitt der Flachbänder 4 und ist besonders für symmetrisch aufgebaute Stecker geeignet.The flat strips 4 have a rectangular cross section along the stroke direction 22 and are already pre-embossed as negative reliefs 29 in accordance with the elevations of the embossing surfaces 10.
Exactly one half of the volume of the line end region 2 is inserted into the negative reliefs 29 of the flat strips 4 before the welding. For this purpose, the elevations of the embossing surfaces 10 are designed as an image of a volume half of the line end area 2.
The two stamping surfaces 10 are constructed identically. The elevations of the two embossing surfaces 10 face away from one another in the stroke direction 22. Each embossing surface has as elevations two volume halves of the line end area 2 lying next to one another in the longitudinal direction 5. The pin reliefs 23 assigned to the connector pins 19 of one volume half and the supply relief 24 assigned to the feed side 20 are the other volume half arranged in the longitudinal direction 5 adjacent. This results in a point-symmetrical structure of the embossing surface 10 in the viewing direction of the stroke direction 22. This configuration of the embossing surfaces 10 reduces the waste of the flat strips 4 and is particularly suitable for symmetrically constructed connectors.

Die Stoffschluß-Verbindung von Leitungsendbereich 2 und Flachbändern 4 bewirkt eine Zugentlastung der Leitung 3. Die Zugentlastung wird durch eine gebogene Leitungsführung im Bereich der Zuführungsseite 20 noch verbessert. Zu diesem Zweck sind die Erhebungen der Prägeflächen 10 im Bereich eines Zugentlastungsreliefs 25 gewölbt ausgestaltet. Dadurch wird beim Einsetzen des Leitungsendbereiches 2 in die Vorprägungen der Flachbänder 4 ein gebogener Leitungsverlauf im Bereich der Zuführungsseite 20 erzwungen.The material connection of line end area 2 and flat strips 4 results in strain relief for line 3. The strain relief is further improved by a curved line guide in the area of the feed side 20. For this purpose, the elevations of the embossing surfaces 10 in the area of a strain relief relief 25 are curved. As a result, when the line end area 2 is inserted into the pre-embossments of the flat strips 4, a curved line course is forced in the area of the feed side 20.

In Fig. 3 sind zwei in Längsrichtung 5 nebeneinanderliegende Leitungsendbereiche 2 erkennbar. Die Leitungen 3 erstrecken sich im wesentlichen entlang der Leitungslängsrichtung 21. Sie ist senkrecht zur Längsrichtung 5 angeordnet.
Die Leitungsendbereiche 2 liegen in einer durch die Längsrichtung 5 und die Leitungslängsrichtung 21 aufgespannten Ebene ein. In Blickrichtung der Hö-henrichtung 12 entspricht ihre Anordnung der Ausgestaltung der Prägeflächen 10 in Fig. 2.3 two line end regions 2 lying side by side in the longitudinal direction 5 can be seen. The lines 3 extend essentially along the line longitudinal direction 21. It is arranged perpendicular to the longitudinal direction 5.
The line end regions 2 lie in a plane spanned by the longitudinal direction 5 and the line longitudinal direction 21. In the viewing direction of the height direction 12, their arrangement corresponds to the configuration of the embossing surfaces 10 in FIG. 2.

Jeder Leitungsendbereich 2 enthält entsprechend dem zweipoligen Flachstekker 1 zwei Leiter 26. An die Enden der Leiter 26 ist jeweils ein Steckerstift 19 elektrisch kontaktierend befestigt. Die Steckerstifte 19 sind in Leitungslängsrichtung 21 angeordnet.
Die Leitung 3 ist im Bereich der Zuführungsseite 20 bis zu den Enden der Leiter 26 abisoliert. Dadurch sind die Leiter 26 im Leitungsendbereich 2 frei beweglich. Zwischen den beiden Steckerstiften 19 eines Leitungsendbereichs 2 kann der genormte Abstand hergestellt werden. Zu diesem Zweck werden die Stekkerstifte 19 formschlüssig in eine Fixierbrücke 27 eingerastet. Die Fixierbrücke 27 weist rechteckige Außenkonturen auf und erstreckt sich in Längsrichtung 5. Die Fixierbrücke 27 ist in Leitungslängsrichtung 21 von zwei Aussparungen durchbrochen, damit sie die Mantelfläche der Steckerstifte 19 formschlüssig umfassen kann. Die beiden Fixierbrücken 27 in Fig. 3 begrenzen die Ausdehnung des Leitungsendbereiches 2 in Leitungslängsrichtung 21.Each line end area 2 contains two conductors 26 corresponding to the two-pole flat plug 1. A plug pin 19 is fastened to the ends of each conductor 26 in an electrically contacting manner. The connector pins 19 are arranged in the longitudinal direction 21 of the line.
The line 3 is stripped in the area of the feed side 20 up to the ends of the conductors 26. As a result, the conductors 26 are freely movable in the line end region 2. The standardized distance can be established between the two connector pins 19 of a line end region 2. For this purpose, the plug pins 19 are positively locked into a fixing bridge 27. The fixing bridge 27 has rectangular outer contours and extends in the longitudinal direction 5. The fixing bridge 27 is pierced by two cutouts in the longitudinal direction 21 of the cable so that it can form-fit around the outer surface of the plug pins 19. The two fixing bridges 27 in FIG. 3 limit the extension of the line end region 2 in the longitudinal direction 21 of the line.

In Fig. 4 sind insgesamt vier Leitungen 3 erkennbar. Die aus Fig. 3 bekannte alternierende Anordnung der Leitungsendbereiche 2 bleibt in Fig. 4 erhalten. Die Fixierbrücke 27 hat in Fig. 4 ebenfalls rechteckige Außenkonturen, ist jedoch in Längsrichtung 5 gegenüber der Ausführungsform in Fig. 3 verlängert. Dadurch rasten die beiden Steckerstifte 19 und die Zuführungsseite 20 benachbarter Leitungsendbereiche 2 formschlüssig in entsprechende Aussparungen ein und derselben Fixierbrücke 27 ein. Sämtliche Steckerstifte 19 und Zuführungsseiten 20 sind parallel zueinander in Leitungslängsrichtung 21 angeordnet.
Entlang der Längsrichtung 5 betrachtet befinden sich an der Fixierbrücke 27 eine Mehrzahl von rechteckigen Einkerbungen 28. Die Einkerbungen 28 können das formschlüssige Einrasten der Steckerstifte 19 und der Zuführungsseiten 20 in die Fixierbrücke 27 erleichtern. Sie können außerdem als Fixiermittel für Zuführungsvorrichtungen bei der Zuführung der Leitungsendbereiche 2 in den Zwischenraum 18 (Fig. 1) dienen.
Jeder Leitungsendbereich 2 wird durch zwei gleichartige Fixierbrücken 27 gehalten. Die beiden Fixierbrücken 27 sind parallel zueinander angeordnet. Ihr Parallelabstand entspricht etwa der Längsersteckung der Leitungsendbereiche 2 in Leitungslängsrichtung 21. Somit ist jeder Leitungsendbereich 2 im Bereich der Steckerstifte 19 und im Bereich der Zuführungsseite 20 von einer Fixierbrücke 27 gehalten.
Die Fixierbrücken 27 sind vorzugsweise aus formstabilem Kunststoff hergestellt, damit die Relativlage der Steckerstifte 19 und der Zuführungsseite 20 zueinander vor der Verschweißung erhalten bleibt.A total of four lines 3 can be seen in FIG. 4. The alternating arrangement of the line end regions 2 known from FIG. 3 is retained in FIG. 4. The fixing bridge 27 also has rectangular outer contours in FIG. 4, but is lengthened in the longitudinal direction 5 compared to the embodiment in FIG. 3. As a result, the two connector pins 19 and the feed side 20 of adjacent line end regions 2 snap into corresponding recesses in one and the same fixing bridge 27. All plug pins 19 and feed sides 20 are arranged parallel to one another in the longitudinal direction 21 of the line.
Viewed along the longitudinal direction 5, there are a plurality of rectangular notches 28 on the fixing bridge 27. The notches 28 can facilitate the positive locking of the plug pins 19 and the feed sides 20 into the fixing bridge 27. They can also serve as fixing means for feed devices when feeding the line end regions 2 into the intermediate space 18 (FIG. 1).
Each line end area 2 is held by two fixing bridges 27 of the same type. The two fixing bridges 27 are arranged parallel to one another. Their parallel spacing corresponds approximately to the longitudinal plugging of the cable end regions 2 in the longitudinal direction 21 of the cable. Thus, each cable end region 2 is held in the region of the plug pins 19 and in the region of the feed side 20 by a fixing bridge 27.
The fixing bridges 27 are preferably made of dimensionally stable plastic so that the relative position of the connector pins 19 and the feed side 20 relative to one another is preserved before the welding.

In Fig. 5 ist eine Anordnung zur Herstellung einer Stoffschluß-Verbindung zwischen Leitungsendbereichen 2 und Flachbändern 4 mittels zweier Schweißstempel 16 erkennbar.
Die Anordnung der beiden in Fig. 5 dargestellten Leitungsendbereiche 2 entspricht der Beschreibung in Fig. 3. Die in Fig. 5 sichtbare Kontaktseite 11 ist mit vier Negativ-Reliefs 29 vorgeprägt. Deren Ausgestaltung und Anordnung entsprechen der Beschreibung in Fig. 2.5 shows an arrangement for establishing a material connection between line end regions 2 and flat strips 4 by means of two welding punches 16.
The arrangement of the two line end regions 2 shown in FIG. 5 corresponds to the description in FIG. 3. The contact side 11 visible in FIG. 5 is embossed with four negative reliefs 29. Their design and arrangement correspond to the description in FIG. 2.

Die beiden Fixierbrücken 27 bestehen vorzugsweise aus dem extrudierten Flachbandwerkstoff. Nach dem Verschweißen bilden sie eine stoffliche Einheit mit den Flachbändem 4.
Für die Flachbänder 4 sind solche Werkstoffe vorteilhaft, die bei Umgebungstemperatur eine relativ große Oberflächenhärte aufweisen, damit etwa nach außen abstehende Leiter 26 beim Zusammenfahren der Schweißstempel 16 und vor dem mit einer Erweichung oder Verflüssigung des Steckergehäusewerkstoffes verbundenen Formvorgang in Richtung auf die Steckerstifte 19 umgebogen werden. Dadurch wird verhindert, daß solche Leiter 26 am fertigen Steckergehäuse bis in dessen Umfangsbereich abstehen können.
Die Schweißflächen 17 weisen vier der Oberflächengestalt des fertigen Flachsteckergehäuses entsprechende Formausnehmungen 30 auf. Deren Anordnung entspricht der Anordnung der vier Negativ-Reliefs 29. Die in Leitungslängsrichtung 21 verlaufenden Seitenwände der Formausnehmungen 30 sind als Schneiden 31 ausgebildet und wirksam.
Die in Längsrichtung 5 verlaufenden Begrenzungswände der Formausnehmungen 30 sind in Leitungslängsrichtung 21 betrachtet etwa halbkreisförmig ausgespart, um die Steckerstifte 19 bzw. die Zuführungsseite 20 während des Verschweißens formschlüssig in die Schweißstempel 16 einlegen zu können.The two fixing bridges 27 are preferably made of the extruded flat strip material. After welding, they form a material unit with the flat belts 4.
For the flat strips 4, such materials are advantageous which have a relatively large surface hardness at ambient temperature, for example after externally protruding conductors 26 are bent in the direction of the plug pins 19 when the welding punches 16 move together and before the molding process associated with softening or liquefying the connector housing material. This prevents such conductors 26 from being able to protrude from the finished plug housing into its circumferential area.
The welding surfaces 17 have four shaped recesses 30 corresponding to the surface shape of the finished flat connector housing. Their arrangement corresponds to the arrangement of the four negative reliefs 29. The side walls of the mold recesses 30 running in the longitudinal direction 21 of the line are designed and effective as cutting edges 31.
The boundary walls of the form recesses 30, which run in the longitudinal direction 5, are cut out approximately semicircularly, viewed in the longitudinal direction 21 of the line, in order to be able to insert the plug pins 19 or the feed side 20 into the welding punches 16 in a form-fitting manner during the welding.

Vor dem Schweißvorgang werden die beiden Schweißstempel 16 in Höhenrichtung 12 aufeinander zubewegt. Sie klemmen die Flachbänder 4 und die Leitungsendbereiche 2 zwischen sich nach Art der Backen eines Schraubstockes ein. Sodann werden die Flachbänder 4 mit den zugehörigen Leitungsendbereichen 2 vollflächig verschweißt. Hierzu ist jedes bekannte Schweißverfahren, z.B. Ultraschweißverfahren, denkbar. Auch ein vollflächiges Verkleben ist möglich.
Während des vollständigen Zusammenfahrens der beiden Schweißstempel 16 in Höhenrichtung 12 trennen die Schneiden 31 das fertige Steckergehäuse von dem restlichen Flachbandwerkstoff ab.
Während des Schweißvorganges werden die Außenseiten 13 der Flachbänder 4 durch die Formausnehmungen 30 geprägt. Zu diesem Zweck weisen die Formausnehmungen 30 in dem Ausführungsbeispiel jeweils drei rillenartige, sich in Längsrichtung 5 erstreckende und parallel zueinander angeordnete Prägevertiefungen 32 auf.
Die Stoffschluß-Verbindung der Flachbänder 4 mit dem Leitungsendbereich 2, die Abtrennung des fertigen, sandwichartigen Verbundteiles und die Prägung der Außenseiten 13 erfolgen in einem Arbeitsschritt.Before the welding process, the two welding stamps 16 are moved towards one another in the height direction 12. You clamp the flat strips 4 and the cable end areas 2 between them in the manner of the jaws of a vice. The flat strips 4 are then welded over their entire area to the associated line end regions 2. Any known welding method, for example ultrasonic welding method, is conceivable for this purpose. Full-surface gluing is also possible.
During the complete movement of the two welding punches 16 in the vertical direction 12, the cutting edges 31 separate the finished plug housing from the remaining flat strip material.
During the welding process, the outer sides 13 of the flat strips 4 are embossed by the shape recesses 30. For this purpose, the shaped recesses 30 in the exemplary embodiment each have three groove-like embossing depressions 32 which extend in the longitudinal direction 5 and are arranged parallel to one another.
The material connection of the flat strips 4 to the line end area 2, the separation of the finished, sandwich-like composite part and the embossing of the outer sides 13 take place in one work step.

Die Teilfuge zwischen den beiden Flachbändern 4 bildet die Steckerstiftebene. Bei anderen Steckerarten als dem Flachstecker 1 sind die Steckerstifte 19 oder Buchsen und gegebenenfalls Schutzkontakte nicht unbedingt in einer gemeinsamen Ebene angeordnet. Bei solchen Steckern ist denkbar, daß für die Verfahrensdurchführung drei oder mehr Flachbänder 4 verwendet werden. Jeweils zwei Flachbänder 4 fixieren dann zwischen sich mindestens einen Steckerstift 19 oder eine Buchse und ermöglichen damit den sandwichartigen Gehäuseaufbau eines Steckers oder einer Kupplungsdose.The parting line between the two flat strips 4 forms the plug pin level. With connector types other than the flat connector 1, the connector pins 19 or sockets and possibly protective contacts are not necessarily in a common one Level arranged. With such plugs, it is conceivable that three or more flat strips 4 are used for carrying out the method. In each case two flat strips 4 then fix at least one plug pin 19 or a socket between them and thus enable the sandwich-like housing structure of a plug or a coupling socket.

In Fig. 5 weisen die beiden Flachbänder 4 eine etwa in Leitungslängsrichtung 21 verlaufende Schnittfläche 33 auf. Der Richtungsverlauf der Schnittfläche 33 entspricht etwa dem Verlauf einer Seitenkante des Flachsteckers 1 in Leitungslängsrichtung 21.
Die Schnittflächen 33 entstehen aufgrund der Abtrennung der fertigen Verbundteile durch die Schneiden 31 während des vorhergehenden Arbeitstaktes.5, the two flat strips 4 have a cut surface 33 which extends approximately in the longitudinal direction 21 of the line. The course of the direction of the cut surface 33 corresponds approximately to the course of a side edge of the flat connector 1 in the longitudinal direction 21 of the line.
The cut surfaces 33 arise due to the separation of the finished composite parts by the cutting edges 31 during the previous work cycle.

In Fig. 1 und Fig. 5 ist erkennbar, daß der Flachstecker 1 in einer Taktfertigung hergestellt wird. Hierbei ist der Einsatz von Schweißstempeln 16 mit einer Vielzahl von Formausnehmungen 30 von Vorteil, um in einem Arbeitstakt eine Vielzahl von Flachsteckern 1 zu fertigen.In Fig. 1 and Fig. 5 it can be seen that the tab 1 is made in a cycle. The use of welding punches 16 with a large number of shaped recesses 30 is advantageous here in order to produce a large number of flat plugs 1 in one work cycle.

In Fig. 6 ist die Herstellung des Flachsteckers 1 in einer Fließfertigung erkennbar. Somit tritt kein Fließ-Stillstand durch etwa einen Schweißtakt auf.
Eine Mehrzahl von Leitungsendbereichen ist in der in Fig. 4 beschriebenen Weise mittels zweier Fixierbrücken 27 angeordnet und wird in Längsrichtung 5 dem Zwischenraum zwischen den beiden Flachbändern 4 zugeführt.
Die beiden Flachbänder 4 werden aus zwei separaten, sich gegenüberliegenden Extrudern 6 extrudiert und werden zunächst in Höhenrichtung 12 vorgeschoben.
Jedes Flachband 4 wird durch eine Druckwalze 34 und eine Prägewalze 35 vorgeprägt. Druckwalze 34 und Prägewalze 35 sind in Fig. 6 jeweils kreisförmig dargestellt. Während die Mantelfläche der Druckwalze 34 an der Außenseite 13 anliegt, beaufschlagt die Mantelfläche der Prägewalze 35 die Kontaktseite 11. Beide Walzen rotieren in Vorschubrichtung des Flachbandes 4 und können die Bewegung des Flachbandes 4 zu den Leitungsendbereichen 2 unterstützen. Die Mantelfläche der Prägewalze 35 wirkt nach Art der Prägefläche 10 (Fig. 1, Fig. 2) und weist über seinen Umfang eine Vielzahl der reliefartigen Erhebungen auf.
Die Mantelfläche der Druckwalze 34 wirkt nach Art der Druckfläche 14 (Fig. 1).6 shows the manufacture of the tab connector 1 in a continuous production. There is therefore no flow stoppage due to a welding cycle.
A plurality of line end areas is arranged in the manner described in FIG. 4 by means of two fixing bridges 27 and is fed in the longitudinal direction 5 to the space between the two flat strips 4.
The two flat strips 4 are extruded from two separate, opposing extruders 6 and are first advanced in the height direction 12.
Each ribbon 4 is pre-embossed by a pressure roller 34 and an embossing roller 35. Printing roller 34 and embossing roller 35 are each shown in a circle in FIG. 6. While the outer surface of the pressure roller 34 abuts the outer side 13, the outer surface of the embossing roller 35 acts on the contact side 11. Both rollers rotate in the feed direction of the flat strip 4 and can support the movement of the flat strip 4 to the line end regions 2. The outer surface of the embossing roller 35 acts in the manner of the embossing surface 10 (FIG. 1, FIG. 2) and has a large number of relief-like elevations over its circumference.
The outer surface of the pressure roller 34 acts in the manner of the pressure surface 14 (FIG. 1).

Nach der Vorprägung verlaufen die Flachbänder 4 etwa viertelkreisförmig gebogen und sind dann etwa in Längsrichtung 5 ausgerichtet. In diesem Bereich nehmen die Flachbänder 4 den Leitungsendbereich 2 formschlüssig zwischen sich auf. Daraufhin wirken zwei in Fig. 6 kreisförmig dargestellte Schweißwalzen 36 mit ihren Mantelflächen auf die Außenseiten 13 der Flachbänder 4 ein. Die beiden Schweißwalzen 36 rotieren in Längsrichtung 5. Die Mantelflächen der Schweißwalzen 36 haben dieselbe Funktion wie die Schweißflächen 17 (Fig. 5). Über den Umfang der Schweißwalzen 36 sind deshalb eine Vielzahl von Formausnehmungen 30 und Schneiden 31 angeordnet.After the embossing, the flat strips 4 are bent approximately in a quarter circle and are then aligned approximately in the longitudinal direction 5. In this area, the flat strips 4 receive the line end area 2 in a form-fitting manner between them. Thereupon two welding rollers 36, shown in a circle in FIG. 6, act with their outer surfaces on the outer sides 13 of the flat belts 4. The two welding rollers 36 rotate in the longitudinal direction 5. The outer surfaces of the welding rollers 36 have the same function as the welding surfaces 17 (FIG. 5). A plurality of shape recesses 30 and cutting edges 31 are therefore arranged over the circumference of the welding rollers 36.

Die Flachbänder 4 bestehen vorzugsweise aus transparentem Werkstoff. Dadurch sind Beschädigungen bei der Herstellung oder beim Gebrauch des Flachsteckers 1, z.B. Leiterbrüche, von außen erkennbar.
Die extrudierten Flachbänder 4 können den Leitungsendbereichen 2 kontinuierlich in einer Endloslänge zugeführt werden. Dies erleichtert die automatisierte Fertigung des Flachsteckers 1.
Lediglich während des Arbeitstaktes in einer Taktfertigung muß die Vorschubbewegung der Flachbänder 4 unterbrochen werden. Dies kann beispielsweise durch den Pufferspeicher 7 (Fig. 1) geschehen.The flat strips 4 are preferably made of transparent material. Damage to the manufacture or use of the flat connector 1, for example wire breaks, can thereby be recognized from the outside.
The extruded flat strips 4 can be fed to the line end regions 2 continuously in an endless length. This facilitates the automated manufacture of the tab connector 1.
The feed movement of the flat belts 4 only has to be interrupted during the work cycle in a cycle production. This can be done, for example, by the buffer memory 7 (FIG. 1).

Der symmetrische Aufbau der Fertigungsanlagen (Fig. 1, Fig. 6) und die im wesentlichen parallel bzw. senkrecht zueinander angeordneten Bewegungsrichtungen begünstigen ebenfalls die automatisierte Fertigung des Flachstekkers 1.The symmetrical structure of the production plants (FIG. 1, FIG. 6) and the movement directions arranged essentially parallel or perpendicular to one another likewise favor the automated production of the flat connector 1.

Claims (24)

  1. A method for manufacturing a plug (1 ) or a coupler socket for electrical plug devices, with a lead (3) comprising at least one conductor (26), whose lead end zone (2) containing at least one contact element (19) is surrounded by a casing consisting of a castable or extrudable insulating material with the following method steps;
    - the lead end zone (2) is brought into the gap (18) between two approximately congruently aligned flat strips (4) of the casing material, in which arrangement the lead (3) and its contact elements (19) extend substantially at right angles to the longitudinal direction (5) of the flat strips (4),
    - the flat strips (4) are joined to each other in a material bond with the interposition of the lead end zone (2) and
    - the sandwich-type composite part formed by the lead end zone (2) with the flat strip zones surrounding it is cut off by a cut extending transversely to the longitudinal direction (5) of the flat strips (4), whereby
    - the material bonding of the flat strips (4) and the cutting off of the finished composite part are effected in one working step,
       characterized in that
    at least the contact sides (11) of the flat strips (4) facing each other are prestamped with a negative relief (29) to the surface shape of the lead end zone (2) to be received by them.
  2. A method according to claim 1,
       characterized in that
    - the material bonding of the flat strips (4).
    - the cutting off of the finished composite part and
    - the form stamping of the composite part are effected in one working step.
  3. A method according to claim 1 or 2,
       characterized by
    ultrasonic welding as the material bonding.
  4. A method according to one of the preceding claims,
       characterized in that
    it is effected by using the extrusion heat as the welding heat for the joint welding or for accelerating the setting of a bonded joint without any substantial delay following the extrusion of the flat strips (4) from an extruder (6).
  5. A method according to one of the preceding claims,
       characterized in that
    the flat strips (4) consist of a synthetic material.
  6. A method according to claim 5,
       characterized by
    transparency of the synthetic material.
  7. Apparatus for manufacturing a plug (1 ) or a coupler socket for electrical plug devices, with a lead (3) comprising at least one conductor (26), whose lead end zone (2) containing at least one contact element (19) is brought between two approximately congruently aligned flat strips (4) of insulating material, which face each other with their contact sides (11), whereby
    - a material bonding between the flat strips (4) with the interposition of the lead end zone (2) and
    - a separation of the composite part, formed by the lead end zone (2) and the flat strip zones surrounding it, from the flat strips (4) and, if applicable,
    - a form stamping of the composite part are effected by pressure tools (8,9,16,34,35,36) that act towards each other,
       characterized by
    a stamping tool (9,35) for prestamping the contact side (11) of the flat strip (4) with a negative relief (29).
  8. Apparatus according to claim 7,
       characterized in that
    the pressure tools are dies (8,9,16) acting on the flat strips (4) in a timed sequence
  9. Apparatus according to claim 8,
       characterized in that
    the dies are welding dies (16)
  10. Apparatus according to claim 8,
       characterized in that
    the pressure tools (8,9,16) produce several adjoining composite parts in one operating stage
  11. Apparatus according to claim 7,
       characterized by
    pressure rollers (34,35,36) as the pressure tools for producing the plug (1 ) or the coupler socket in continuous line production.
  12. Apparatus according to claim 11,
       characterized in that
    the rollers are rotational welding tools (36).
  13. Apparatus according to one of the claims 7-12,
       characterized in that the pressure faces of the pressure tools (16) facing each other contain at least one shaped recess (30) for receiving the lead end zone (2) and the flat strip zones surrounding it, in which arrangement, the shaped recess (30) consists
    - of a bottom as the heating surface (17) for the material bonding and
    - of side walls formed as cutters (31) for the cutting off.
  14. Apparatus according to claim 13,
       characterized in that
    two adjoining shaped recesses (30) lie directly side by side and are separated from each other by their common side wall formed as a cutter (31).
  15. Apparatus according to one of the claims 7 - 14.
       characterized in that
    in the execution of the method, several contact elements (19) of the lead end zone lying side by side are held by a fixing bridge (27) at a desired interspacing and in a desired alignment.
  16. Apparatus according to claim 15,
       characterized in that
    the fixing bridge (27) consists of a synthetic material that is stable in shape.
  17. Apparatus according to claim 15 or 16,
       characterized in that
    the fixing bridge (27) consists of the same material as the flat strips (4).
  18. Apparatus according to one of claims 15 - 17,
       characterized in that
    the contact elements (19) are engaged with a form fit in recesses of the fixing bridge (27).
  19. Apparatus according to one of claims 15 - 18,
       characterized in that
    a fixing bridge (27) grips the lead end zones (2) of several leads (3) and lines them up side by side in the manner of a cartridge belt.
  20. Apparatus according to claim 19,
       characterized by
    a parallel alignment of the contact elements (19) and the lead supplies (20) of leads (3) held side by side at the fixing bridge (27).
  21. Apparatus according to claim 19 or 20,
       characterized in that
    the lead end zones (2) are held by two fixing bridges (27) which are arranged at an interspacing with respect to each other and are approximately parallel.
  22. Apparatus according to claim 21,
       characterized in that
    the fixing bridges (27) hold the lead supplies (20) and the contact elements (19) of respectively one lead end zone (2) one after the other in their longitudinal direction (5) on an alternating basis.
  23. Apparatus according to claim 21 or 22,
       characterized in that
    the interspacing of the two fixing bridges (27) corresponds approximately to the width of the flat strips (4).
  24. Apparatus according to one of the claims 15 - 23,
       characterized in that
    the fixing bridges (27) are connected to the flat strips (4) in a material bond.
EP93111119A 1992-07-18 1993-07-12 A method of producing plugs or sockets for electrical coupling devices Expired - Lifetime EP0580053B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE4223725A DE4223725A1 (en) 1992-07-18 1992-07-18 Process for the production of plugs or coupling sockets for electrical plug devices
DE4223725 1992-07-18

Publications (2)

Publication Number Publication Date
EP0580053A1 EP0580053A1 (en) 1994-01-26
EP0580053B1 true EP0580053B1 (en) 1997-11-26

Family

ID=6463558

Family Applications (1)

Application Number Title Priority Date Filing Date
EP93111119A Expired - Lifetime EP0580053B1 (en) 1992-07-18 1993-07-12 A method of producing plugs or sockets for electrical coupling devices

Country Status (3)

Country Link
EP (1) EP0580053B1 (en)
DE (2) DE4223725A1 (en)
ES (1) ES2048701T1 (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19527123A1 (en) * 1995-07-25 1997-01-30 Bosch Gmbh Robert Method for the electrical connection of two electrical components to one another
US6120327A (en) * 1997-07-22 2000-09-19 Lear Automotive Dearborn, Inc. Foam wire harness with shape memory

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3392070A (en) * 1964-03-05 1968-07-09 Berg Electronics Inc Method and apparatus for sheathing terminals
CA980000A (en) * 1972-05-22 1975-12-16 James Pritulsky Insulating housings for electrical devices
DE2440264C3 (en) * 1974-08-22 1982-02-04 Kabel- und Metallwerke Gutehoffnungshütte AG, 3000 Hannover Procedure for molding a connector onto an electrical line

Also Published As

Publication number Publication date
DE4223725A1 (en) 1994-01-20
EP0580053A1 (en) 1994-01-26
DE59307729D1 (en) 1998-01-08
ES2048701T1 (en) 1994-04-01

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