EP1083627B1 - Electrical connector assembly - Google Patents

Description

The invention relates to an electrical Connector assembly with a flat cable and a Strain relief and a method for producing a Combination of connector and flat cable.

Electrical connectors are usually to their appropriate use with a connector assigned Cable provided. Often multipolar connectors are on associated cables with a corresponding number of conductors connected. In the course of an ever stronger integration electrical and electronic components in particular takes also in the automotive industry, the number of electrical connections and Head steadily too, which is why multiple cables often become strands or whole wire harnesses. The strands are common in recent automotive developments stated that individual conductors are arranged side by side and form a multi-core cable, whose individual conductors the respective contacts of the connector in part individually must be connected. This, however, increases the risk from permutations of the individual conductors of a cable to what leads to electrical misallocation and usually corresponding malfunctioning. Furthermore, that is Weight of conventional harnesses, including ribbon cables, consisting of round ladders, which are insulated individually typically proportional to the number of conductors, i. despite merging several conductors into one Multiple conductor cable can hardly save weight be achieved.

From the document US 4,722,692 is such Cable termination assembly with a multi-conductor cable with several electrical conductors in the form of round wires and an insulation as well as electrical contacts to Connection between the conductors of the cable and one further component known. The electrical contacts are formed clamp-like, what the risk of Injuries to the ladder.

As an alternative to cables with wire conductors are becoming increasingly flexible film conductors are used, which are typically made of a base film, a number of flat, in cross-section essentially rectangular metallic conductors and a Cover foil exist. The ladders are next to each other arranged and are located between the two slides. The conductors are typically about 0.5 mm to 4 mm wide and about 0.05 mm thick. The used plastics for the Base and cover sheet of a film conductor, in particular the Frequently used polyesters have a very smooth surface Surface. Therefore, nearly all fail for foil conductors Connection techniques relying on a mechanical hold of the cable in the connector due to stiction, So the usual clamping and Krimpverbindungen. On the On the other hand, foil conductors tend to crack, which is why a piercing of the foil conductor with nail or IDC-like areas of the contacts as well may be disadvantageous, if not additional measures be taken. Such initial violations of Foil conductors usually already form under low Tensile stresses the starting point of cracking, the too a complete destruction of the cable, which in later real use, for example in the Motor vehicle electronics can have devastating consequences.

From DE 197 47 116 A1 a connector is known, in which only the contacts of the connector with the electrical conductors of a flat cable Ultrasonic welding are electrically connected. These electrical connection but has only a very small mechanical tensile strength on, as the electrical conductors themselves are typically very thin. Therefore be at this conventional approach to strain relief of electrical connection holes punched in the cable, in which is a corresponding pin, located on the connector is engaged. But also this type of strain relief often leads to the unwanted initial injury and also to a broadening of the foil conductor because of Space for the punch holes. Likewise, the connector housing be made wider according to the to install a latching pin, which increased an Material requirement and thus an increased weight result Has. In case of stress, in particular tensile load or Vibration expand the punched holes and the Strain relief function is degraded. It is obviously, that kind of strain relief only can act punctually, what an inhomogeneous distribution of Forces in the cable cause cracking favored.

From the document US 4,589,584 is also a electrical connection for polymeric conductive material in which by means of ultrasonic energy two Flat cable fused directly or without connectors become. Disadvantageously, this type of Connection not particularly resilient and moreover not Soluble and therefore for many applications, especially in the Automotive sector unsuitable.

In another connection method according to DE 196 33 933 A1, the connector housing is integrally connected to the Foil conductor injection-molded. This method is with a complicated manufacturing process connected. As well as the one-piece molding of the housing to the smooth Surface no material connection with the Foil conductors can be achieved as well Strain relief pin attached to the connector housing, which in engage the foil conductor, the risk of injury of the Increase film conductor and additional material and Space requirements cause.

In many applications, especially in the Automotive industry, high demands are being made on the Resilience of the compound provided. In the automotive sector typically will have a tensile strength of 80 N per cable required. But also the permanent vibrations, which the Cable and connector already exposed during normal operation , cause in the known bonding techniques in many cases a progressive relaxation of the Joints.

The invention is therefore based on the object, a inexpensive, reliable and permanently tensile electrical connector assembly with a flat cable, especially with a flexible foil conductor available do.

The problem is solved in a surprisingly simple way already by the features of claim 1 or claim 18 .

The invention provides an electrical connector assembly comprising a flat cable having one or more electrical conductors partially surrounded by a dielectric insulating material and a connector having one or more electrical contacts and a dielectric housing. The contacts are electrically connected to the conductors of the flat cable and the flat cable is mechanically non-detachably connected to the strain relief connector substantially. The mechanical connection includes a weld formed connection between the insulation of the flat cable and the housing of the connector. Surprisingly, welding does not lead to a substantial violation of the flat cable and still provides a permanently high-tensile connection. Welding is quick and inexpensive, which enables high production speeds and saves costs. Since both the housing and the cable insulation are preferably made of plastic, a welded connection is easy to produce. The mechanical connection is nevertheless heat resistant.
Typically, high tensile forces arise during assembly of an electrical connector assembly between the flat cable and the connector housing as it is typically attacked on the housing while being pulled on the cable. The mechanical connection of the connector assembly according to the invention advantageously has a high tensile strength there, especially since the insulation of the flat cable and the connector housing itself are designed to be resistant to tensile stress. Such a permanent mechanical connection is also long-term and permanently vibration-resistant. Furthermore, the shape of the region in which is welded, are adapted to the connector geometry, ie this can be carried out, for example, flat. A flat mechanical connection leads to a distribution of the forces occurring, so that the mechanical connection is uniformly loaded. Furthermore, the connector assembly is insensitive to high humidity, a typical requirement in the automotive field is a life of 1000 hours at 85% relative humidity and a temperature of 80 ° C, which is safely maintained by the invention.

It is particularly advantageous to a flat cable use, which comprises a foil conductor, or in is essentially a foil conductor, since flexible foil conductors a significant weight saving over others Allow flat cables. An inventive electrical Connector assembly with a flexible foil conductor is e.g. Resistant to windscreen washer fluid, greases and oils. For find the electrical connector according to the invention preferably foil conductor use, in which the electrical conductor between a dielectric base film and a dielectric cover sheet are arranged. The mechanical connection advantageously comprises a Weld between the base and / or cover sheet with the Casing. The base and the cover foil can do this Polyester exist. Polyester is easy to weld and is particularly stable and long-term resistant. That `s how it is advantageous to use a flexible foil conductor at the electrical conductors as printed conductors are formed, this also allows the use of electrical conductors, not just a direct connection represent between two ends of the film conductor, but e.g. also contain electronic components themselves.

The welding is preferably by means of laser welding executed. Laser welding is in particular with Infrared lasers fast, precise and clean executable. The Laser welding can still be carried out in particular if the contacts and the flat cable already in their Target position are arranged in the connector housing. The Laser welding is particularly suitable for flexible Foil conductors, as the base and cover sheets typically have a relatively high transmission for the laser light. The laser beam is preferably used for welding Area directed between the tracks of the film conductor and thereby substantially heats the dielectric housing through the base and cover foil.

In a further embodiment, the electrical Ladder in a section freed from isolation. This stripped area may already be in the production of the Flat cable can be provided or in the course of Manufacturing process of the electrical connector assembly to be provided. The electrical connection is at Such a prepared flat cable then in the area of made of stripped conductor.

In further advantageous embodiments, the Contacts and the ladder connected by crimping or the contacts comprise an area of which the Flat cable is penetrated. Even from one Insulation penetrating electrical connection goes into advantageously no cracking of the flat cable, since the mechanical connection an effective strain relief, especially the penetrated areas causes.

In a preferred embodiment, the electrical Connection between the contacts of the connector and the Conductors of the flat cable an electrical welded connection, which preferably by resistance welding, Ultrasonic welding or laser welding is made.

In an alternative embodiment, the electrical connection between the contacts of the connector and the conductors of the flat cable caused by soldering Compound, in particular in a stripped area. in the Area of soldering is located between the contacts and the electrical conductors a solder, in particular a Reflow solder to the electrical connection manufacture. The soldering causes a reliable electrical Connection and the soldering process is only a minor thermal stress on the flat cable and the contacts. It is in a highly advantageous manner, the waste heat of the To use the soldering process to weld between the Isolation of the flat cable and the connector housing to achieve what a step in production saves. The reverse production route is also possible in such a way that the waste heat of the welding process for Making the mechanical connection used for soldering becomes. There are different soldering applications, in particular laser brazing, resistance brazing, induction brazing and / or ironing.

It is advantageous to use a connector whose Housing has a window through which the electrical and / or areas to be mechanically connected optically are accessible. Through the window, the electric Connection and / or the mechanical connection through Welding done. This is especially for laser welding, Laser soldering, resistance soldering or ironing advantageous. The Induction soldering, on the other hand, can also be achieved by the dielectric Housing done through.

In a preferred embodiment, the electrical contact an insertion aid for the flat cable. The insertion aid prevents snagging of the flat cable during Insertion into the connector housing. The insertion aid can Also include a spring, which connects the flat cable to the housing expresses what is beneficial if the solder joint is not through a window in the housing is accessible from the outside, e.g. in induction soldering.

A particularly effective strain relief is achieved if the flat cable is not in a straight line between the mechanical and electrical connection, but includes a curvature. This is not under tension standing excess material of the flat cable is important if the flat cable and the connector housing are different Have expansion coefficients. This can be at a different extent or contraction in particular by heating or cooling the electrical Connector assembly mechanical stresses are avoided.

In a preferred embodiment of the electrical Connector assembly has the flat cable outside the Housing an area in which the electrical conductors are freed from isolation to an additional To provide contact zone. The contact zone can already formed during the production of the flat cable or in the manufacture of the connector assembly be provided. If a malfunction of the connector occurs, at the additional contact zone a new one Connector with a prefabricated piece of flat cable, the also has a contact zone, be attached, as it especially with connector assemblies with foil conductors difficult to exchange single defective contacts. In front or after attaching the complete new connector with a prefabricated piece of flat cable to the contact zone can the old, defective connector is removed, e.g. isolated become. This possibility opens a simple and fast Repair of a defective invention Connector assembly, so that not necessarily a completely new Connector assembly must be used, which is a Cost savings in case of repair means. For protection the exposed in the contact zone electrical conductors and to avoid short circuits is the contact zone preferably with a protective film, e.g. self-adhesive can be covered.

It is also beneficial to mechanical welding e.g. from all sides of the flat cable, so that the Connection between the cable and the housing liquid or is fluid-tight.

In a preferred embodiment of the inventive method are first and outside the Housing the contacts with the conductors of the flat cable electrically connected, in particular soldered. In one second step is the flat cable with the contacts in it Target position arranged in the connector housing. In one third step is the insulation of the flat cable preferably through a window in the housing to the housing welded, preferably laser welded. This method has the advantage that for many different connectors one Universal soldering machine can be used and not specific recording devices for different Connectors must be made. Furthermore, the Soldering and the welding process for the production of mechanical connection to two different, be made of specialized production facilities.

In an alternative embodiment of the inventive method, the electrical contacts and the flat cable are first placed in their target position in the connector and then the contacts are electrically connected to the conductors of the flat cable, in particular soldered and the insulation of the flat cable welded to the housing. In this case, the soldering process and / or the welding process for producing the mechanical connection are preferably carried out through a window in the housing of the connector. In addition, it is advantageous to carry out the process of electrical connection and welding for mechanical joining in one step, because this saves time in production.
In particular, when laser-brazed and laser-welded, both can be done by the same laser, thereby reducing machine cost.

In a preferred embodiment, the contacts and the flat cable to your destination position in the connector arranged with a solder between them. Thereafter, a laser beam is applied to a portion of the contact directed, causing the conductor and the contact with each other be soldered. Before or after the soldering process, the laser between the contacts on the insulation of the flat cable, in particular the base or cover foil of a foil conductor directed, creating a weld with the housing is reached. Here, the laser power in each Step independently optimized.

In an alternative embodiment, the Contacts and the flat cable to your destination position in the Arranged connector, wherein a solder in a stripped area between the exposed conductors and is the contact. After that, a laser beam on a Area of the contact, causing the head and the Be soldered together. The soldering becomes like that controls that the insulating material of the flat cable under the solder joint with the housing during soldering resulting heat welded.

Fig. 1

eine perspektivische Ansicht eines ersten Ausführungsbeispiels der Verbinderbaugruppe,

Fig. 2

eine Aufsicht auf die Rückseite der in Fig. 1 dargestellten Verbinderbaugruppe,

Fig. 3

eine Draufsicht auf die in Fig. 1 dargestellte Verbinderbaugruppe von oben,

Fig. 4

einen Schnitt entlang der Achse A-A aus Fig. 3,

Fig. 5

einen Detailschnitt des Bereiches D aus Fig. 4,

Fig. 6

eine perspektivische Ansicht eines zweiten Ausführungsbeispiels der Verbinderbaugruppe,

Fig. 7

eine Aufsicht auf die Rückseite der in Fig. 6 dargestellten Verbinderbaugruppe,

Fig. 8

eine Draufsicht auf die in Fig. 6 dargestellte Verbinderbaugruppe von oben,

Fig. 9

eine Schnittdarstellung entlang der Achse A-A aus Fig. 8,

Fig. 10

einen Detailschnitt des Bereiches E aus Fig. 9,

Fig. 11

eine perspektivische Ansicht eines dritten Ausführungsbeispiels der Verbinderbaugruppe,

Fig. 12

eine Aufsicht auf die Rückseite der in Fig. 11 dargestellten Verbinderbaugruppe,

Fig. 13

eine Draufsicht auf die in Fig. 11 dargestellte Verbinderbaugruppe von oben,

Fig. 14

eine Schnittdarstellung entlang der Achse A-A aus Fig. 13,

Fig. 15

einen Detailschnitt des Bereiches F aus Fig. 14,

Fig. 16

eine Draufsicht auf ein viertes Ausführungsbeispiel der Verbinderbaugruppe von oben,

Fig. 17

einen Schnitt entlang der Achse A-A aus Fig. 16,

Fig. 18

einen Detailschnitt des Bereiches G aus Fig. 17,

Fig. 19

eine Schnittdarstellung durch die in Fig. 6 gezeigte Verbinderbaugruppe,

Fig. 20

einen Detailschnitt des Bereiches H des in Fig. 19 dargestellten Folienleiters,

Fig. 21

eine Detailschnitt des Bereiches K des in Fig. 20 dargestellten Folienleiters,

Fig. 22

eine Schnittzeichnung eines fünften Ausführungsbeispiels der Verbinderbaugruppe,

Fig. 23

eine perspektivische Ansicht eines sechsten Ausführungsbeispiels der Verbinderbaugruppe,

Fig. 24

einen ersten Schritt eines Ausführungsbeispiels des Verfahrens,

Fig. 25

ein Resultat des ersten Verfahrensschritts aus Fig. 24,

Fig. 26

einen zweiten Schritt des Verfahrens aus Fig. 24 und Fig. 25.

In the following the invention will be explained in more detail by means of exemplary embodiments and with reference to the drawings.
Show it:

Fig. 1

a perspective view of a first embodiment of the connector assembly,

Fig. 2

a plan view of the back of the connector assembly shown in Figure 1,

Fig. 3

1 a top view of the connector assembly shown in FIG. 1 from above,

Fig. 4

a section along the axis AA of Fig. 3,

Fig. 5

a detail section of the area D of FIG. 4,

Fig. 6

a perspective view of a second embodiment of the connector assembly,

Fig. 7

a plan view of the back of the connector assembly shown in Fig. 6,

Fig. 8

a top view of the connector assembly shown in Fig. 6 from above,

Fig. 9

a sectional view taken along the axis AA of FIG. 8,

Fig. 10

a detail section of the area E of FIG. 9,

Fig. 11

a perspective view of a third embodiment of the connector assembly,

Fig. 12

a plan view of the back of the connector assembly shown in Fig. 11,

Fig. 13

a top view of the connector assembly shown in Fig. 11 from above,

Fig. 14

a sectional view along the axis AA of FIG. 13,

Fig. 15

a detail section of the region F of FIG. 14,

Fig. 16

a top view of a fourth embodiment of the connector assembly from above,

Fig. 17

a section along the axis AA of FIG. 16,

Fig. 18

a detail section of the region G of FIG. 17,

Fig. 19

a sectional view through the connector assembly shown in Fig. 6,

Fig. 20

a detail section of the region H of the film conductor shown in Fig. 19,

Fig. 21

a detail section of the region K of the film conductor shown in Fig. 20,

Fig. 22

a sectional view of a fifth embodiment of the connector assembly,

Fig. 23

a perspective view of a sixth embodiment of the connector assembly,

Fig. 24

a first step of an embodiment of the method,

Fig. 25

a result of the first method step of FIG. 24,

Fig. 26

a second step of the method of FIG. 24 and FIG. 25.

The invention will be described below with reference to preferred embodiments described in more detail. Fig. 1 to 5 show a first embodiment of a according to the invention connector assembly 1. Fig. 6 to 10 show a second connector assembly 101, Figs. 11 to 15 a third connector assembly 201, Figs. 16 to 18 a fourth Connector assembly 301 and Figs. 19 to 21 Details of the fourth Connector assembly 301. Same or equivalent components bear reference signs, each same or last two digits are the same and, if not otherwise explained the corresponding components with same reference number also a similar or comparable Function.

1 shows a first exemplary embodiment of a connector assembly 1 according to the invention, consisting of a connector 5 and a foil conductor 30.
The connector 5 consists of an integrally molded dielectric housing 10 and a contact inserted into the housing 10. The housing contains three cavities 17 of which the left cavity is equipped with the contact. There is shown a terminal tab 21 of the contact, which has three Krimplaschen 24, two of which run from the left and one from the right arcuately to each other. The Krimplaschen 24 penetrate a conductor 33 of a film conductor 30 and clamp the film conductor 30 mechanically at the contact point. The housing 10 has windows 11 through which the area in which the Crimean patches are located is optically accessible from above. The contact is inserted from the front side 2 in the left cavity 17, the middle and the right cavity 17 are not populated in this illustration, but may also be equipped with appropriate occupancy of the contacts of the connector. The three cavities 17 are separated from one another by partitions 19, which have a trough 18 on each side. A portion of the foil conductor 30 is inserted from the front side 2 in the housing 10 and is located above the terminal lug 21 of the contact 20. The partitions 19 are spaced from a housing bottom 15, so that the foil conductor 30 between the partitions 19 and the housing bottom 15 is inserted is.

In an alternative embodiment, which in Fig. 23, the right partition 19a is integral with the housing bottom 15 is connected. The film conductor points to the right partition 19a between the tracks 33 a slit-shaped recess 40, so that the Foil conductor 30 comb-like in the cavities 17 left and Inserting right around the partition 19a in the housing 10 around. In particular, this asymmetric slitting of the film conductor 30 prevents the foil conductor from being inserted upside down can be.

The foil conductor 30 has three conductor tracks 33 from each of which is associated with a cavity 17. The housing 10 has a housing extension 16 on the front side 2, which supports the foil conductor 30.

The back 3 of the housing 10 is the mating Connection of the contact 20 with a corresponding one Counterpart, which is not shown here.

Fig. 2 shows the electrical connector assembly 1 with the housing 10, the contact 20 and the film conductor 30. The Contact 20 is in the left of the three cavities 17 introduced. The Krimplaschen 24 penetrate the left of the three tracks 33 from the bottom on the outside of the Conductor 33 and bulge in an arc inside. The cavities 17 have on the back of the housing 10 depending an opening 14 through the two unequipped Cavities 17 are visible.

Fig. 3 shows the electrical connector assembly 1 with the housing 10. The cavities 17 extend along a longitudinal axis 4 within the housing. The foil conductor 30 is inserted from the front side 2 into the housing 10. Through the window 11 is the electrical connection, the by the penetration of the left trace of the three Crimean pegs 24 is defined, optically accessible.

Fig. 4 shows the connector assembly 1 with the housing 10. The contact 20 is located in the, along the Axis 4 in Fig. 3 extending cavity 17. The housing 10th has the window 11 and the opening 14 for mating the Contact 20 with the counterpart not shown on the Back 3 on. The contact 20 has an intermediate region 22 on which a body portion 27 of the contact 20 with the Connecting strap 21 connects. The intermediate region 22 extends not parallel to the terminal lug 21, so that a cavity 26th between the terminal lug 21 and the housing bottom 15th arises. The intermediate region 22 provides a spring action in a direction perpendicular to the housing bottom 15. The contact 20 also has a locking tab 23 which in the opening 13 of the housing 10 protrudes. A Rastquerstrebe 12 is located in front of the latching tab 23 to prevent the contact 20 from slipping out from the illustrated target position in the housing 10 to prevent. A portion of the foil conductor 30 is located within the cavity 17 above the terminal tab 21 in Contact with the same. Between the film conductor 30 and the Housing extension 16, which supports the film conductor 30, There is a mechanical connection in the form of a Welded joint 25. The mechanical welded joint 25 is shown voluminously for the sake of clarity, though a welded joint usually a direct connection between the two connected elements, here the Foil conductor 30 and the housing extension 16, forms.

Fig. 5 shows a part of the connector housing 10 with the Window 11 and the partition 19 with the trough 18. Der Cavity 26 is defined by the terminal tab 21 of the contact 20, and the housing bottom 15 defines which connecting strap 21 and housing bottom parallel to each other and spaced apart from each other. The foil conductor 30 consists of a base sheet 31 with adjacent thereto and the base sheet 31 touching conductor tracks 33 and a cover sheet 32 the again touch the tracks from above. The Base film 31 and the housing extension 16 are through the Weld 25 permanently connected mechanically. at this, but also in other possible embodiments the base film 31 and the cover film 32 are preferably made made of polyester, because polyester is well weldable. Of the Foil conductor 30 is in the range of mechanical Welded 25 optically accessible from above, so that the Welding can still be done when the connector assembly 1 already, as shown, is composed in such a way that the contact 20 and the foil conductor 30 in the completely used target position.

Fig. 6 shows the connector assembly 101 consisting of a connector 105 and a foil conductor 30. The connector 105 is composed of a one-piece molded dielectric Housing 10 and a contact inserted into the housing 10 together. The contact has a connection tab 121 with a section 124 which serves as a cable insertion aid. One Section of the foil conductor 30 is located in the housing 10 between the terminal lug 121 and the housing bottom 15th

Fig. 7 shows the connector assembly 101 with the, in the left cavity 17 inserted contact 120. The, as Insertion serving portion 124 of the terminal 121th is partially spaced from the foil conductor 30 and tapers towards the front 2.

Fig. 8 shows the connector assembly 101, with the Connector 105, the left cavity 17 with the contact 120th is equipped. In a region 134 of the in the housing 10th inserted foil conductor 30, the cover foil 32 is removed, so that the tracks 33 are exposed. The stripped Area 134 is located completely in the housing and lies partially below the terminal strap 121 and the Insertion aid 124 of the contact 120. The stripped area and a part of the terminal tab 121 are optically through Window 11 is accessible to solder through the window and / or welding to produce the electrical Make connection. The insertion aid 124 protrudes partially into Direction to the front 2 of the connector over the stripped area 134 addition.

Fig. 9 shows a section through the connector assembly 101. The contact 120 is located in the, along the Axis 4 in Fig. 8 extending cavity 17. The contact 120th has an intermediate region 122, which the body part 27 with the connecting plate 121 connects. The intermediate area 122 does not run parallel to the terminal lug 121. A section the film conductor 30 is located between the Connecting tab 121 and the housing bottom 15. At the Connecting tab 121 is the insertion aid 124, which Insertion aid 124 in the direction of the front side 2 of the housing 10 points. The insertion aid includes an acute angle the housing bottom 15 and points away from it. The Insertion aid 124 prevents hooking of the film conductor 30, when the foil conductor in the housing 10 between the Connecting strap 121 and the housing bottom 15 of the Front 2 is inserted in the direction of the back 3.

Fig. 10 shows a detail section of the connector assembly 101 with the foil conductor 30 and the window 11. The Terminal tab 121 of the contact 120 runs parallel to Caseback 15 and is spaced therefrom. An area the film conductor 30 is located between the Connecting tab 121 and the housing bottom 15. The cover film 32nd of the film conductor 30 is in a region 134 which partially below the terminal strap 121 is removed, so that the Conductors 33 on the, the connecting plate 121 facing Page exposed and contactable. In a part of the stripped area 134 below the terminal strap 121 there is an electrical connection 135. The electrical connection 135 is by soldering or in a alternative embodiment produced by welding. Of the soldered or welded area of the terminal strip is located below the window 11, so that the connecting strap of a location outside the housing is optically accessible and the electrical solder joint, e.g. by Laser soldering, ironing, resistance soldering, laser welding, Ultrasonic welding or resistance welding through the Window 11 is done. The film conductor is through the Housing extension 16 supported. The base film 31 and the Housing extension 16 are by the mechanical Welded connection 125 permanently mechanically together connected. The foil conductor 30 is in the range of mechanical weld joint 125 from above optically accessible, so that the mechanically stable welding still can be done when the connector assembly 101 already, as shown is composed so that the contact 120th and the foil conductor 30 in the fully inserted Target position. The fact that the electrical Connection 135 and the mechanical weld 125 located along the longitudinal axis 4 at different locations, Both compounds can be made independently be. The mechanical weld can e.g. by Laser welding be made.

In an alternative embodiment, which in FIG. 22 is shown, the film conductor 30 between the 125 mechanical welding and electrical Connection 135 three kinks 34, 35 and 36, so that the foil conductor 30 forms a roof-like fold 37. The roof-like fold 37 avoids tension different expansion or contraction of the housing 10th and the foil conductor 30, e.g. when warming the Connector assembly 101.

Fig. 11 shows a connector assembly 201 consisting of a connector 205 and a foil conductor 30. The connector 205 is composed of an integrally formed dielectric Housing 210 and a contact inserted into the housing 210 together. The housing 210 has at the front end 2 a Bottom portion 216 and two side walls 217, which together form a U-shaped housing extension, which opens upwards is. Partitions 219, the cavities 17 from each other have cut-outs 240 above the Housing bottom. One area of the film conductor is of the Floor section 216 supports and extends to a portion below the partitions 219. The end 241 of the recess 240 serves as End stop for the foil conductor during insertion. One Section of the film conductor 30 is located between the Connecting strap 121 and the housing bottom 15 and the Bottom portion 216. An area of the terminal tab 121 is through the upwardly open U-shaped housing extension of optically accessible at the top.

Fig. 12 shows the connector assembly 201 with the, in the left cavity 17 inserted contact 120th

Fig. 13 shows the connector assembly 201. In a Area 134 of introduced into the housing 10 and of the Bottom portion 216 supported foil conductor 30 is the Cover film 32 is removed, so that the conductor tracks 33 are exposed. The stripped region 134 is partially in the U-shaped Housing extension, and is partially under the Connecting tab 121 and under the insertion 124. The stripped area and part of the terminal strap 121 are visually through the opening of the U-shaped housing extension accessible to the electrical connection between the Terminal tab 121 and the conductor 33 to allow, if the foil conductor 30 and the contact 120 in their target position are introduced.

Fig. 14 shows a section through the connector assembly 201. The contact 120 is located in the, along the Axis 4 in Fig. 13 extending cavity 17th

FIG. 15 shows a detail section of the connector 205. The terminal strip 121 of the contact 120 runs parallel to Caseback 215 and is spaced therefrom. An area the film conductor 30 is located between the Terminal tab 121 and the housing bottom 215, wherein a part protrudes into the recess 240 and close to the End stop 241 is enough. The cover sheet 32 of the film conductor 30th is removed in a region 234 of the film conductor 30, so in that the conductor tracks 33 on the side of the connection tab 121 are exposed and contactable. The stripped area 234 is partially between the terminal strap 121st and the housing bottom 215. Between the terminal lug 121 and the conductor 33 is located in the stripped region 234 a solder joint 235, which the conductor 33 with the Connecting plate 121 electrically connects. Under the solder joint 235 is the weld 225, which is the base film 31 of the film conductor 30 with the housing bottom 215 mechanically combines. As the solder joint 235 and the mechanical Welded 225 are on top of each other and the Connecting tab 121 at the soldered point 235 from above is optically accessible, the solder joint may e.g. through a Laser beam are melted when the contact 120th and the foil conductor 30 in the fully inserted Target position. The waste heat of the soldering process generates then also the mechanical weld 225. As in Fig. 13 can also be seen in the area between two Conductors 33 along a vertical line to Longitudinal axis 4 are welded independently of the soldering 235, as well as this area from outside the case visually is accessible.

In a preferred embodiment of the method according to the invention, shown in FIGS. 24 to 26, in a first step (FIG. 24) the laser beam 50, for example of a CO ₂ laser 51, is directed onto the cover film 32 of the film conductor 30. As a result of the irradiation, the cover film 32 partially sublimes, as a result of which the stripped region 234 of the film conductor 30 is formed. The stripped film conductor is shown in FIG. 25. In a second step, after the film conductor is placed in the housing 210 of the connector 205 in its target position, the laser beam 50 is directed onto the terminal strip 121, thereby forming the solder 235 and the mechanical weld 225. This method is particularly advantageous, since only one laser 51 is necessary for the three working steps: stripping, soldering and welding.

Fig. 16 shows a connector assembly 301, in which a Cavity 17 is equipped with a contact 320. Of the Foil conductor 30 is from the front side 2 in a housing 310th used. The case is in the front of one Housing cover 311 closed.

Fig. 17 shows a section through the connector assembly 301. The contact 320 is located in the, along the Axis 4 in Fig. 16 extending cavity 17th

FIG. 18 shows a detail section of the connector 305. The terminal strip 121 of the contact 320 runs parallel to Housing bottom 315 and is spaced therefrom. An area the film conductor 30 is located between the Terminal strip 121 and the housing bottom 315. The base film 31 is mechanically connected to the housing bottom 315 by the Weld 225 connected and the terminal strap 121 is with the conductor 33 in a stripped region 234 of the Foil conductor 30 soldered in area 235. The connecting strap 121 has an insertion aid 324 which is approximately at an angle of 60 ° with the housing bottom 315 and from the Caseback toward the front 2 away. The Insertion aid 324 has at the, the housing bottom farthest End of a Andrücklasche 328, the housing cover 311st touched and parallel to the housing cover 311 runs. The Insertion aid 324 with Andrucklasche 328 is under mechanical tension which ensures that the Connecting strap 121 is pressed onto the film conductor 30. This contact pressure is advantageous to good soldering reach, in particular because the solder joint 235 is not optical is accessible from the outside. A soldering can in particular by induction soldering non-contact from outside through the dielectric housing 310 take place, wherein the waste heat of the Soldering the mechanical weld 225 generates.

Fig. 19 shows the connector assembly 101 with the Foil conductor 30. In area H there is an area in the cover sheet 32 of the film conductor 30 is removed to to define a predefined repair point. Fig. 20 shows the enlarged section H in Fig. 19. The cover sheet 32 is removed in an area 401. The stripped area 401 is complete with a protective film 400, the especially self-adhesive, covered. A section of the Protective film 400 overlaps at both ends of the protective film 400 with the cover sheet 32. A portion of this overlap is in Fig. 21 is shown enlarged.

It should be noted that the invention is not limited to the specific embodiments.

Claims (35)

1. Electrical connector assembly, comprising:

   a flat cable having one or more electrical conductors (33) which are at least partially surrounded by a dielectric insulation material and

   a connector (5) having one or more electrical contacts (20) and a dielectric housing (10),

   the contacts (20) being electrically connected to the conductors (33) of the flat cable and
   the flat cable being mechanically connected to the connector (5) in an essentially non-releasable manner for the purpose of strain relief,
   characterised in that
   the flat cable has a sheet conductor (30) with flat conductors (33),
   the mechanical connection comprising a connection (25) between the insulation material of the sheet conductor and the housing (10) of the connector (5) produced by welding and
   a section of the sheet conductor (30) being located between connecting plates (121) of the contacts (20) and the base of the housing (15) and the conductors (33), on the side facing the connecting plates (121), lying free in a region (134) and electrically contacted with the connecting plates (121).
2. Electrical connector assembly according to Claim 1, in which the mechanical connection is a connection which has been produced by means of laser welding.
3. Electrical connector assembly according to Claim 1 or 2, in which the dielectric insulation material of the sheet conductor (30) contains a base sheet (31) and a covering sheet (32), between which the electrical conductors (33) are arranged.
4. Electrical connector assembly according to Claim 3, in which the mechanical connection comprises a connection between the housing (10) of the connector (5) and the base sheet (31) and / or covering sheet (32) of the sheet conductor (30).
5. Electrical connector assembly according to Claim 3 or 4, in which the electrical connections comprise printed conductor tracks.
6. Electrical connector assembly according to one of the preceding claims, in which the electrical connection between the conductors (33) and the contacts (20) comprises a region in which the flat cable is penetrated by a section of the contact (20).
7. Electrical connector assembly according to one of the preceding claims, in which the electrical conductors (33) are free of the insulation in a first region (134), in which the electrical connection is situated.
8. Electrical connector assembly according to one of the preceding claims, in which the electrical connection between the contacts (20) and the conductors (33) comprises a crimp connection.
9. Electrical connector assembly according to one of the Claims 1 to 7, in which the electrical connection between the contacts (20) and the conductors (33) is a connection (235) which has been produced by soldering, which connection comprises, in particular, a reflow soldering agent.
10. Electrical connector assembly according to one of the Claims 1 to 7, in which the electrical connection between the contacts (20) and the conductors (33) comprises a connection which has been produced by laser soldering, resistance soldering, induction soldering and iron soldering.
11. Electrical connector assembly according to one of the Claims 1 to 7, in which the electrical connection between the contacts (20) and the conductors (33) comprises a connection (135) which has been produced by welding.
12. Electrical connector assembly according to one of the preceding claims, in which the housing (10) comprises a window (11), through which window (11) the regions that are to be electrically and / or mechanically connected are optically accessible from a position outside the housing.
13. Electrical connector assembly according to one of the preceding claims, in which the flat cable comprises a tensile-elastic region (37).
14. Electrical connector assembly according to one of the preceding claims, in which the contact comprises a section which is designed as an insertion aid for the flat cable.
15. Electrical connector assembly according to one of the preceding claims, in which the contact (20) comprises a section which is designed as a press-on spring (324, 328), which presses the flat cable and the housing (10) onto one another.
16. Electrical connector assembly according to one of the preceding claims, in which the electrical conductors (33) are free of the insulation in a second region (401) outside the housing (10).
17. Electrical connector assembly according to Claim 16, in which the second region (401), in which the conductors (33) are free of the insulation, is covered with a protective sheet (400) which is, in particular self-adhesive.
18. Method for producing an electrical connector assembly, comprising:

    the process of electrically connecting electrical contacts (20) of a connector (5) to electrical conductors (33) of a flat cable which are at least partially surrounded by an insulation, and

    the process of mechanically connecting the insulation of the flat cable to the housing (10) of the connector (5) in an essentially non-releasable manner,

    characterised in that
       a section of the flat cable is inserted between connection plates (121) of the contacts (20) and a base (15) of the housing (10),
       the conductors (33) on the side facing the connection plates (121) lie free in a region (134) and are electrically contacted with the connection plates (121), and
       the mechanical connecting process comprises welding.
19. Method according to Claim 18, in which the mechanical connection is produced by laser welding.
20. Method according to Claim 18 or 19, in which a flat cable is used which comprises a flexible sheet conductor (30), in which the insulation contains a dielectric base sheet (31) and a dielectric covering sheet (32).
21. Method according to Claim 20, in which the mechanical connection is produced as a connection between the housing (10) of the connector (5) and the base sheet (31) and / or the covering sheet (32) of the sheet conductor (30).
22. Method according to one of the preceding method claims, in which the electrical conductors (33) are rendered free of the insulation in a first region (134) and an electrical connection is produced in this region.
23. Method according to one of the preceding method claims, in which an electrical connection is produced between the contacts (20) and the conductors (33) by crimping.
24. Method according to one of the Claims 18 to 22, in which an electrical connection is produced between the contacts (20) and the conductors (33) by soldering.
25. Method according to one of the Claims 18 to 22, in which an electrical connection is produced between the contacts (20) and the conductors (33) by laser soldering, resistance soldering, induction soldering or iron soldering.
26. Method according to Claim 24 or 25, in which the welded connection (25) is produced by the heat of the soldering.
27. Method according to Claim 24, in which the soldered connection (235) is produced by the heat of the welding.
28. Method according to one of the Claims 18 to 22, in which an electrical connection between the contacts (20) and the conductors (33) is produced by welding.
29. Method according to one of the Claims 18 to 22, in which an electrical connection is produced between the contacts (20) and the conductors (33) by laser welding, resistance welding or ultrasonic welding.
30. Method according to one of the preceding method claims, in which the electrical and / or mechanical connections between the connector (5) and the flat cable are produced through a window (11) in the housing (10).
31. Method according to one of the Claims 18 to 25 or 28 to 29, in which, outside the housing (10) of the connector (5), the conductors (33) of the flat cable are electrically conductively connected to the contacts (20) of the connector (5), afterwards the contacts (20) and the flat cable are arranged in a target position in the housing (10) and afterwards, through a window (11) in the housing (10), the flat cable is welded to the housing (10).
32. Method according to one of the Claims 18 to 30, in which the contacts (20) and the flat cable are arranged in a target position in the connector (5) and afterwards in the housing (10) of the connector (5), through a window (11), the contacts (20) of the connector (5) are electrically conductively connected to the conductors (33) of the flat cable and the flat cable is welded to the housing (10).
33. Method according to Claim 32, in which the electrical connecting process and the welding process are effected in one work step.
34. Method according one of the Claims 18 to 22, in which, preferably after the contacts (20) and the flat cable have been arranged in a target position in the connector (5), a laser beam (50) is directed at a region (121) of the contact (20) in order to produce laser soldering between the contact (20) and the conductor (33), between which a soldering agent is situated, and the laser beam (50) is directed at a region between the conductors (33) of the flat cable in order to produce laser welding (25).
35. Method according Claim 34, in which, preferably after the contacts (20) and the flat cable have been arranged in a target position in the connector (5), the laser beam (50) is directed at a region (121) of the contact (20) in order to produce laser soldering (235) between the contact (20) and the conductor (33) and the resulting evolution of heat by the contact (20) and / or the conductor (33) welds the insulation of the flat cable to the housing (10), in particular under the laser soldering (235).

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