EP1085603B1 - Connector with cable, replacing process for a connector with cable and the appropriate tool - Google Patents

Description

The invention relates to a connector with cable, a method of making the connector with cable, and a tool for making a cable connector.

The increasing variety of electrically or electronically controlled devices requires the use of cables that include a plurality of conductors. It is essential that the conductors are still well insulated from each other, to avoid crosstalk. When using such cables in automobiles, a further problem is to achieve a precise connection of the cables with connectors, which is stable against mechanical vibrations and vibrations. Such connectors are known in a variety, while the connectors are designed for receiving flat cables containing a plurality of conductor strips. The connectors often include two types of connections, one of which serves to electrically connect the connector to a conductor of the cable and the second connection is a mechanical connection. This mechanical connection is essentially the train protection and causes even the smallest movements of the contact against the conductor can be avoided or can be completely ruled out. Such mechanical connections can be achieved, for example, by bonding the jacket made of an insulating material of the cable to the dielectric housing of the connector. It is also known to weld the jacket of a cable to a connector housing. In addition, there are also punched joints, where one not penetrated by a conductor part of the cable is connected to the housing of the connector. For example, a rivet is knocked into the connector housing by the cable. All of the mentioned types of connection of connectors, in particular connector housings and cables require due to the achievable precision of the electrically conductive connection of the conductor to the contact also a high degree of accuracy in the manufacture of the connector and in the generation of the cable end, with the Connector to be connected. The manufacture of the connector and the production of the cable end to be used for connection is carried out under high quality standards with largely automated machines. As a result, a high quality of the connection of plug and cable can be achieved. The connectors are often used in widely branched cable connections, where they are used both in central cable strands and in branched side arms. The connectors are preferably designed as a connector, so that the corresponding cable branches are easily connected to each other or can be branched off from a main strand.

Connectors are used in the automotive industry, for example, to connect the components of the electronically controlled ignition system with each other or to control the security elements such as airbags electrically. Furthermore, they find use in the entire electrical system, and in particular in the controlled by the battery of the automobile and the alternator of the automobile lighting system. All arranged on the steering column elements are substantially electrically connected to the parts driven by them. The array density in the steering column, which is typically a cable harness containing numerous cables, makes it difficult to make a necessary repair perform. In order not to have to replace the entire wire harness, which is very costly, the cables are cut in case of failure of a cable or a connector damage and locally replaced the faulty spot either by bypass lines or a new connector attached. Here, there is the problem that these repairs can be carried out essentially only manually in poorly accessible places.

From the published patent application DE 197 47 116 A1 a connection arrangement for connecting a flat cable with connections is known. In the connection arrangement, the conductors of the flat cable are held by a lower layer of the flat cable and the conductors are connected to terminals of an external component. As a rule, several conductors are connected to a plurality of terminals of the external component. In this case, miniaturized conductors and connections can be interconnected. In the connection arrangement, pre-positioning accuracy is achieved by mutually locking cutouts attached to the flat cable and protrusions on the external component. The relative positions of the conductors of the flat cable and the terminals of the external component are thus exactly predetermined. The electrically conductive connection of the conductors of the flat cable and the terminals of the external component can thus be achieved by ultrasonic welding. The connection arrangement thus allows the replacement of a defective flat cable or a no longer functional component without a manual connect, such as a manual soldering process. Also in this connection arrangement, the difficulty is that they can be used only at the points for connecting flat cables and a defective and thus to be replaced connector or component, which are accessible to the necessary welding device. At Inaccessible positions in the engine compartment of an automobile, for example, the use of such a connection arrangement thus provides no advantages.

In the field of data processing, it is known (US-A 5 314 346) to adapt connector cables to the needs of subscribers by inserting a repair patch having a circuit with pads at the broken point of the cable and passing the repaired spot through Enclosed protective housing.

In the case of a flat cable, it is known (US Pat. No. 5,389,741) to insert intermediate layers which can be removed at periodically repeating points between the insulation formed by covering films and the conductors, so that the flat cable has periodic thickening points. At these thickening points, the flat cable can be severed, there to solve the cover sheets together with the intermediate layers of the conductors and repulse the loosened areas. The exposed on the top and bottom conductors of the flat cable can be connected via connection terminals as a bridge member with the exposed conductors of another cable, after which the connection point and the recoiled cover film parts are enclosed by a protective housing. It is also possible, instead of the connection with another cable, to rivet or caulk the uncovered ends of the conductors with connection pins, with the turned-back ends of the cover films serving as reinforcing underlay. A direct connection of the conductor of the first cable and another cable is not provided.

The invention has for its object to provide a connector with cable, which can be easily connected for repair purposes with another cable and then forms an electrically and mechanically reliable connection between the two cable pieces involved.

The invention is defined by the claims.

The invention has the advantage that a connector or a flat cable can be connected together in an electrical unit so that the connection corresponds to the standard in the factory first connection of both parts. Another advantage of the invention is to be considered that the replacement of a connector and / or a cable in an electrical unit can be done quickly and easily and thus cost. A particular further advantage of the invention is that the replacement of one of the two parts is also possible in places that are not easily accessible.

Further advantageous features of the invention will become apparent from the dependent claims.

The cable connector according to the invention comprises a dielectric connector housing which holds at least one electrical contact terminal and one connected to the at least one electrical contact terminal Head of cable surrounded by insulating material. In this case, the cable has a first, from the insulating material free or exposable body. The first free or exposable position of the conductor is also electrically conductively connected to another conductor of another cable.

In the inventive method of replacing a cable connector, the connector maintains at least one electrical contact in a connector housing. In this case, the terminal contact with a conductor of a cable is electrically connected. In addition, the conductor is at least partially surrounded by an insulating material. According to the invention, the cable is severed and on the cable remaining on the connector at least one location of the insulating material is exposed to form a portion for electrical connection of the conductor to another conductor of another cable, the conductor being connected to the portion of the other conductor of the cable another cable is connected.

In a further embodiment of the invention, the cable has at least one second location at which the conductor is free or exposable by the insulating material. In a preferred embodiment of the invention, the at least one second location is located between the free or exposed location and the connector housing. In a particularly preferred embodiment of the invention, the first and second free or exposable position with respect to the longitudinal axis of the cable are mounted at different positions. By providing a first and a second free or exposable position of the conductor on the cable, there is the particular advantage that, according to the invention, the connector can be replaced as often as desired or connected to a cable.

In the connector according to the invention or the method according to the invention, at least one of the free or exposable points is provided with an insulating cover piece. The invention also includes a connector for replacing a cable connector in which the cover piece partially surrounds the cable. It is also within the scope of the invention that the cover piece is formed as an electrically insulating adhesive strip and is glued laterally outstanding on the insulating material.

In another embodiment, the insulating material is partially removable at the first and second locations, such that the cable and the further cable are connectable to each other at the first and / or second location. In this case, the cable can be connected to the rotated by 180 ° about its longitudinal axis further cable.

It is also provided that the cable and the further cable are glued together at the first and / or second location with an adhesive. In a particularly preferred embodiment of the invention, the adhesive is attached to an inner wall of the cable and / or the further cable. The adhesive may also be a hot melt adhesive which is thermoplastically deformable and / or curable by infrared radiation.

In the connector according to the invention and the method according to the invention, the conductor is etched free of the insulating material at the first and / or at least a second location. Likewise, the other conductor may be electrically connected to the conductor by a solder joint. It is also provided to electrically connect the further conductor to the conductor by means of an inductive solder connection. It is also conceivable that the further conductor with the conductor of the connector by a laser-induced Solder connection is connected. In another embodiment of the invention, the further conductor is connected to the conductor of the connector by an electrically conductive adhesive.

In a preferred embodiment of the present invention, the cable and / or the further cable is in each case a flat cable. In a particularly preferred embodiment of the invention, the flat cable contains a flexible foil conductor. In an equally preferred embodiment, the conductor and / or the further conductor is formed as a flexible printed circuit board.

According to the invention, the conductor and / or the further conductor are surrounded by a cover foil and a base foil. The cover and / or the base film may also be polyester films as well as polyimide films.

The invention also includes a tool that can be used to replace a cable connector and to provide an electrically conductive connection of the conductor of the cable provided on the connector to a conductor of another cable, and means for electrically conductive connection the first exposed or exposable position of the conductor with a further conductor of another cable. In this case, the means for electrically conductive connection may be formed as a soldering device. As a soldering an inductive or laser-induced soldering is conceivable.

According to the invention means are provided in the tool, which allow a mutual connection of insulating material of the connector located on the cable with insulating material of the other cable. In this case, a heat source can be used, which is also used to generate the electrical connection. However, it can also be an additional heat source which can be used especially for producing the tensile mechanical connection, for example in the form of a Infrared lamp be provided.

Likewise, the electrical connection can be carried out by means of a welding device. It can be designed as a resistance or laser or ultrasonic welding device. Also conceivable is a bonding device for producing the electrically conductive connection. Likewise, the invention covers a crimping device for electrically conductive connection. A further embodiment of the tool according to the invention also comprises according to the invention a means for exposing a first location of the cable from the insulating material. The tool according to the invention proves to be particularly advantageous in that it enables a connection which corresponds to a standard corresponding to the first connection.

The invention will be explained in more detail with reference to the accompanying drawings of an embodiment.

Fig. 1

eine perspektivische Darstellung eines erfindungsgemäßen Verbinders;

Fig. 2

die Vorderansicht des Verbinders nach Fig. 1;

Fig. 3

die Draufsicht auf den erfindungsgemäßen Verbinder nach Fig. 1;

Fig. 4

einen Schnitt gemäß der Linie IV-IV in Fig. 3 in vergrößerter Darstellung;

Fig. 5

eine perspektivische Darstellung eines weiteren erfindungsgemäßen Verbinders;

Fig. 6

den mit A gekennzeichneten Ausschnitt der Fig. 4 in vergrößerter Darstellung;

Fig. 7

den mit B gekennzeichneten Ausschnitt der Fig. 4 in vergrößerter Darstellung;

Fig. 8

ein zur Verbindung mit einem erfindungsgemäßen Verbinder vorbereitetes Kabel;

Fig. 9

einen in einer elektrischen Einheit befindlichen zu ersetzenden Verbinder; und

Fig. 10

den in Fig. 9 mit C gekennzeichneten Ausschnitt in vergrößerter Darstellung.

Fig. 11

einen Schnitt durch ein erfindungsgemäßes Werkzeug zur Verbindung eines Verbinders mit einem Kabel;

Show it:

Fig. 1

a perspective view of a connector according to the invention;

Fig. 2

the front view of the connector of FIG. 1;

Fig. 3

the top view of the connector according to the invention of FIG. 1;

Fig. 4

a section along the line IV-IV in Figure 3 in an enlarged view.

Fig. 5

a perspective view of another connector according to the invention;

Fig. 6

the section marked A of Figure 4 in an enlarged view.

Fig. 7

the section marked with B of Figure 4 in an enlarged view.

Fig. 8

a cable prepared for connection to a connector according to the invention;

Fig. 9

one in an electrical unit located to replacing connector; and

Fig. 10

the section marked C in FIG. 9 in an enlarged view.

Fig. 11

a section through an inventive tool for connecting a connector with a cable;

1 shows a connector 1 according to the invention with a cable 2 preferably designed as a flat cable. A connector housing 3 is made of a dielectric material and, according to FIG. 2, has a rectangular cross-section. At the bottom 4 longitudinal walls 5 and 6 are arranged at right angles and also meet at right angles to a ceiling 7 of the connector housing 3. At an end face 8 pass through passages 9 each with square openings 10. The passages 9 pass through an end face 8 opposite end face 11 of the connector housing 3 with square openings 12, which are surrounded by a skirt 13. In a preferred embodiment of the invention, the ceiling 7 of the connector housing 3 is indicated at 15 and 16, over the entire width of the connector housing 3 extending sections and divided into three bridge-like sections 7a to 7c.

According to Fig. 1 and 2, the flat cable 2 leads three conductor strips 2a, 2b and 2c, wherein in the figures for the sake of clarity, only the conductor strip 2a is connected to a contact 17 of the connector 1. The electrically conductive connection is formed in this preferred embodiment as at 18 reference number of Fig. 4 mounted solder joint, wherein according to Fig. 4, the conductor strip 2a and the contact 17 is electrically conductive connected to each other. The flat cable 2 usually includes a plurality of conductor strips 2a to 2c. Likewise, the connector usually contains a plurality of contacts 17 whose electrically conductive connection with the corresponding conductor strips of the illustrated connection of conductor strips 2a and contact 17 corresponds.

In a preferred connector, the flat cable 2 has at least one flexible film conductor 2a to 2c, which is surrounded electrically insulated by a cover film 19 and a base film 20 according to FIGS. 6, 7. The base film 20 and the cover film 19 are preferably glued together so that they are impermeable to dust and moisture and isolate the flexible film conductor 2a to 2c from the environment.

In each case, an adhesive is applied to one side of the films 19, 20, and the films 19, 20 are brought with their adhesive sides on or under the conductor strips 2a-2c and at the conductor strip-free sections 21, 22 - see FIG. 3 - mutually bonded.

The cover and base sheets 19, 20 are preferably sheets of the same material and thickness, which in a particularly preferred embodiment of the present invention are transparent to visible and / or infrared light, and consist of, for example, polyester or polyimide. In a particularly preferred embodiment of the present invention, the flat cable 2 may be formed as a flexible, printed circuit board covered with a base sheet 20 and a cover sheet 19.

According to FIG. 4, the opening 12 runs out with a substantially pyramidal receiving collar 23 attached to it on the end face 11 of the connector housing 3. The skirt 13, the opening 12 and the receiving collar 23 are appropriate made of a dielectric material. The preferably obelisk-like enclosure 13 abuts, according to FIG. 4, with its larger base surface 13a against an end face 17a of the contact 17. 1, 2 inserted through the opening 10 in the passage 9 contact 17 is secured with a resilient support arm 24 on a parallel to the end face 11 extending wall 25 of the bridge-like ceiling portion 7b against movement in the direction of the arrow v . According to the invention, the contact consists of a material of high electrical conductivity, preferably of copper or of a copper alloy. The holding arm 24 is made of a high-strength material, such as a metal or a metallic alloy, preferably made of stainless steel.

The openings 10 are arranged on the front side 8 between the bridge-like ceiling section 7 c and the bottom 4. The arranged in the middle of the end face 8 opening 11 is bounded laterally by the support walls 26. The from the center of the end face 8 from the longitudinal walls 5, 6 facing openings 10 are bounded laterally by the respective longitudinal wall 5, 6 and one of the support walls 26. The support walls 26 are spaced from the bottom 4 of the connector housing 3 by a parallel to the bottom 4 opening slot 27 (Fig. 4), in which the flat cable 2 is inserted.

According to the invention, the conductor strips 2 a, 2 b and 2 c in the connector housing 3 of Kontaktierungsbügeln, of which in the figures only the contacting of the conductor strip 2 a serving Kontaktierungsbügel 29 is shown, contacted. The Kontaktierungsbügel 29, which consists of an electrically conductive material, preferably copper, has an angled tab 30 at its end facing away from the end face 11 of the connector housing 3 end.

According to Fig. 4, the flat cable 2 is inserted into the opening slot 27 so that it is between bottom 4 and Contacting clip 29 is located. Of the inserted into the opening slot 27 part of the flat cable 2, the cover sheet 19 has been removed. An illustrated in Fig. 4 at 31, the strain relief of the flat cable 2 serving mechanical attachment of the flat cable 2 to the connector housing 3 is designed in one embodiment of the connector as an adhesive bond. Preferably, the mechanical connection is provided by an adhesive layer 31, which is mounted between a ceiling 7 facing surface 32a of a support portion 32 and the base film 20 of the flat cable 2. In a particularly preferred embodiment of the present invention, the adhesive layer 31 is made of a curable by irradiation with UV light adhesive. The adhesive layer 31 is attached between the base film 20 and the support portion 32 perpendicular to the longitudinal axis of the flat cable 2 between the conductor strips 2a to 2c of the flat cable 2, respectively. However, the adhesive layer can also preferably be applied over the entire width of a receiving section 39 according to FIG. 5.

The adhesive layer 31 may preferably be mounted on the support section 32 and / or also on an underside 20 a of a portion of the base film 20 which corresponds to the position shown in FIG. 4 when the flat cable 2 is inserted.

4, the flat cable 2 is inserted into the opening slot 27 between the Kontaktierungsbügel 29, wherein on the end face 11 facing the end of the flat cable 2, the cover sheet 19 is removed. In a particularly preferred embodiment of the present invention, the cover film 19 can also be detached by using a laser, preferably a CO ₂ laser.

The exposed conductor strip 2a is at an electrical connection portion shown at 18 electrically conductive, preferably via a solder joint, connected to the Kontaktierungsbügel 29. The solder is preferably applied to the conductor strip 2a and pressed the Kontaktierungsbügel 29 with its longitudinal wall 29a on the solder.

The solder joint is preferably made by inductive soldering. For this purpose, the connector housing 3 is held therein with flat cable 2 and contact 17 in an induction coil, that the solder is liquefied. The liquefaction of the solder and thus the electrical connection can also be generated according to the invention by irradiation of visible light, preferably of laser light, provided that the connector housing 3, e.g. at its bridge-like ceiling portion 7c is transparent thereto, or via the conductor strips 2a to 2c windows or openings 34a-34c corresponding to FIG. 5 are present, which allow access to the flat cable 2. Furthermore, in such an embodiment, a likewise optically transparent cover film 19 is used. In this case, in the context of the invention, the light can also be focused on the solder.

According to the invention, in a connector housing 3 according to FIG. 1, the flat cable 2 can also be connected outside of the connector housing 3 to the contacting bracket 29 of the contact 17 by laser-induced soldering and thereafter inserted into the connector housing.

In the case of a window-like interrupted ceiling section 7c (FIG. 5), the soldered connection can also be produced by placing a conventional soldering iron on a side 29b of the contacting clip 29 facing away from the solder shown in FIG. Upon solidification of the solder then the conductor strip 2a and the Kontaktierungsbügel 29 are electrically connected to each other and with a certain mechanical strength. The chosen temperature of a soldering tip is adjusted according to the invention the nature of the related solder. When using a conventional soldering tin, the temperature will be approximately in the temperature range of 150 ° C to 250 ° C. The solder joint can preferably also be produced by ironing. According to the invention, the flat cable 2 and the connector 1 can be used together in the connector housing 3. In this case, the flat cable 2 is inserted through the opening slot 27 and the contact 17 through the opening 10 in the connector housing 3 in a direction indicated by the arrow w in FIG.

In a connector according to FIG. 5, the bridge-like ceiling section 7c is interrupted by the openings 34a -34c into two sections 35 and 36 which are connected to the longitudinal wall 5 by a web 37. Right angles to the longitudinal walls 5, 6, the opening 34 a of the web 37 and the support wall 26 is limited. The opening 34 b is bounded at right angles to the longitudinal walls 5 and 6 of the support walls 26 and the opening 34 c of the longitudinal wall 6 of the connector housing 3 and the support wall 26.

The openings 34a-34c allow access in the direction of the ceiling 7 of the connector housing 3 on the bottom 4 of the connector housing 3 on a flat cable 2 inserted on a receiving portion 39, which is shown in the figures only with its connection area.

The electrically conductive connection is formed in this preferred embodiment of the invention as Krimpverbindung, in which the conductor strip 2a and the contact 17 are electrically conductively connected to each other by preferably three Krimspülsen 40a-40c. The Crimpers 40a-40c are, for example, with the aid of a Krimpzange formed with their cutting edges sleeve lugs 41, 42, the cover sheet 19 piercing the Conductor strip 2a connected.

In the embodiment of the present invention shown in Fig. 4, the two indicated at 18, 30 compounds along the longitudinal axis of the flat cable 2 are provided at a matching position. However, the electrical connection 18 and the strain relief serving mechanical connection 30 along a transverse side of the flat cable 2 are offset from each other, wherein the electrical connection 18 respectively at positions corresponding to the conductor strip 2a-c, and the mechanical connection 30 to the non Conductor strips 2a-c interspersed areas of the flat cable 2 are attached.

According to the invention, however, the electrical connection illustrated at 18 and the mechanical connection indicated at 31 may also be attached at different positions along the longitudinal axis of the flat cable 2.

In a particularly preferred embodiment of the invention, the bridge-like ceiling section 7c is interrupted with windows or openings, corresponding to that shown at 34a to 34c in FIG. 5, which are exactly above the sections 21, 22 of the flat cable 2 which are not interspersed with conductor strips 2a-2c are arranged. Here, in the mechanical connection, an adhesive 31 is chemically crosslinked by irradiation of collimated electrons, and a connection of the connector housing 3 and the base sheet 20 is generated at the atomic junction level. According to the invention, a final value of the tensile strength of the connection of the connector housing 3 and the flat cable 2 is generated by the intensity and the duration of the radiation.

In a particularly preferred embodiment of the present invention, the strain relief mechanical connection of flat cable 2 and connector housing 3 is given over a light radiation curable adhesive. In this case, the connector 1 has the openings 34a, b, c shown in FIG. 5 in the region of the bridge-like ceiling section 7c. In this case, an adhesive, preferably a polymerized material is applied to the support portion 32 of the connector housing 3. The flat cable 2 is slightly pressed with the outward-facing side 20 a of the base film 20 on the adhesive to achieve a weak fixation of the flat cable 2 to the connector housing 3. In the manufacturing process of the connector according to the invention, which usually takes place on an industrial scale on a large scale on an automated machine, light, preferably UV light, is additionally radiated onto the flat cable 2. The UV light is filtered from a broadband emitter and focused focused on the splice. Within the scope of the invention, however, it is also included to use the UV lines contained in the spectrum of a gas ion laser, for example an Ar ⁺ laser. Likewise, it is also possible to use an EXCIMER laser radiating in the UV region of the spectrum. According to the invention, the laser radiation can either be focused or unfocussed to produce the mechanical connection 31. According to the invention, the mechanical connection 31 is arranged on the base film 20 over the width of the flat cable 2 on the sections 21, 22 not penetrated by the conductor strips 2a-2c. According to the invention, the base and / or cover sheets 20, 19 used in the flat cable 2 are transparent to visible and ultraviolet light.

At one of the free end of the flat cable 2 associated section 43 of FIG. 1 and Fig. 7, the cover sheet 19 is removed. Corresponding sections of the conductor strips 2 a to 2 c are according to the invention at least unilaterally free and are only on their underside of the base film 20th surround. Between the section 43 and the connector housing 3, the flat cable 2 is provided at a further section 44 with a cover piece 45. The cover piece 45 is preferably made of an insulating material and is formed in a particularly preferred embodiment of the present invention as an adhesive strip. According to Fig. 6, the cover sheet 19 is removed in the section 44. The conductor strips 2a to 2c are exposed in the section 44 on one side and are surrounded only by the insulating base film 20 on the other side. The adhesive strip 45 projects beyond the longitudinal section of the flat cable 2 on both sides of the partial layer 44 of the flat cable 2 which has been exposed from the cover layer. The adhesive strip 45 is adhesively bonded to the upper side 19b of the cover film 19 at its underside 45a provided with an adhesive with its adhesive side. The adhesive is preferably the same adhesive as applied to the flat cable 2 on sides 19a and 20b of the cover sheet 19, 20 facing the conductive strips 2a to 2c. The adhesive is preferably an adhesive applied to commercially available polyimide or polyester films on one side. The removal of the cover sheet 19 at the sections 44 and 43 can be done by the methods described above. In the production of the flat cable but the cover sheet 19 in the sections 43, 44 may already be omitted.

The connection of the connector according to the invention and its cable with another cable or the method according to the invention for replacing a cable-provided connector is carried out essentially as follows and described with reference to the following figures.

At the portion 43 of the flat cable 2 is or the cover sheet 19 is removed. The conductor strips 2a to 2c are preferably exposed by removing the cover sheet 19 with a cutting tool, but the cover sheet 19 can also be removed with the aid of a laser, preferably a CO ₂ laser.

After the flat cable 2 located on the connector according to the invention has been freed from the cover foil 19 at its section 43, it can be connected to a similar flat cable. Such a flat cable 46 is shown in FIG. The flat cable 46 also preferably has three conductor strips 46a to 46c. In the flat cable 46 shown in sections in FIG. 8, the conductor strips 46a to 46c are likewise exposed in a subsection 47 by removal of a cover film 48 and are surrounded by a base film 49 in an electrically insulating manner on only one side. A side 49b of the base film 49 facing the conductor strips 46a to 46c is provided with adhesive in sections 50 and 51 which lie between the conductor strips.

The flat cable 46 is now connected to the flat cable 2 that the side 49b of the base film 49 rests on the uncovered in the section 43 side 20b of the base film 20 of the flat cable 2. In this case, the portion 43 of the flat cable 2 is substantially congruent so under the portion 47 of the flat cable 46 that the conductor strips 2a-c of the flat cable 2 and the conductor strips 46a-c of the flat cable 46 lie on one another. By a pressure exerted on both sides by outer sides of the flat cable, the two base films 20 and 49 are glued together in a mechanically stable connection. The adhesive effect is applied by the adhesive which is exposed in each case between the conductor strips. In addition, the compound can by a softening of the adhesive and thus better Distribution of the adhesive leading to heating can be improved. If the connector 1 with its flat cable 2 is separated from the further flat cable 46, then the adhesive strip 45 is pulled off the flat cable 2 and the flat cable 2 is cut transversely to the longitudinal direction in the section 44 along the line 52 according to FIG. The position of the cut 52 is selected such that a further section 53 exposed by the cut and facing the partial section 43 can be used on the flat cable 2 as a new connection point. In this case, the subsection 53 is provided with the function of the subsections 43 and / or 47 in the connection of connector 1 and flat cable 2 to the flat cable 46. As described above, a further connector according to the invention provided with a cable can now be electrically conductively connected to the section 53 as described above. The electrically conductive connection of the conductor strips 2a-c, 46a-c is produced according to the invention by a solder connection, preferably a laser-induced or inductively produced solder connection. The electrically conductive connection can also be generated by welding.

In the inventive method for replacing a cable provided with a connector, the cable is disconnected so that the connection of a spare connector with cable is possible. In this case, a separation point may already be present on the cable. However, such a separation point can also be attached during the process. FIG. 9 schematically shows an electrical unit with a central element 54 and further electrical connectors or switching elements 54a to 54c connected thereto. The central element 54 is connected to a connector 56 via a cable 55, which is preferably formed as a flat cable. Preferably, a portion 57 is on the flat cable 55 provided on which a cover sheet 58 of the flat cable 55 is removed and on both sides of the remote location overlapping with a preferably formed as an adhesive strip cover piece 59 is covered. In case of malfunction of the connector 56, this can then be replaced as follows.

First, the adhesive strip 59 is pulled off the flat cable 55 and the flat cable along the line X-X of FIG. 10 is severed. In this case, the portion 57a remaining on the flat cable 55 connected to the central element 54, which has been removed from the cover film 58, corresponds to the section 43 according to FIG. 1. A connector with a cable as shown in FIG. 1 can then be connected to the section 57a in that the side 20b of the base film is pressed onto conductor strips 55a to 55c of the flat cable 55 and one side 60b of the base film 60. The connection of flat cable 55 and connector 1 may be performed with an adhesive provided on sides 20b and 60b. However, it is also possible to additionally apply an adhesive to the sections of the base film side 58b between the conductor strips 55a to 55c. When applying the connector 1 can be transferred by pressure on the film 20 of the connector 1 but also adhesive and a connection can be made.

The connection of the cable of the connector according to the invention with another cable can be carried out with the tool 61 according to the invention shown in FIG. 11. In this case, according to the invention, the mechanical connection of the cable and the electrical connection from the head of the cable with another conductor of the other cable, as explained with reference to the aforementioned figures made. For connecting a replacement connector 62 to a cable 63, the cable 64 attached to the connector is located with its portion exposed from the cover sheet (see FIG. 43 in Fig. 1 - in a slot 65, the upper part of a 66th and a lower part 67 of the tool 61 is limited. The cable 63 provided for connection to the replacement connector 62 is also in the slot 65 as shown in FIG. 12. The cables 63, 64 can be inserted into the slot 65 by folding the upper or lower part 66, 67 away from one another. The cables 63, 64 are placed so that their cover film-free sections are on top of each other. The electrically conductive connection of the conductor and further conductor is generated according to the invention via a soldering device mounted in the lower part 67 and / or the upper part 66. In this case, in the lower 67 and / or upper part 66, a laser be mounted, the emitted radiation is directed to the position of exposed conductor points. But lower and upper part 67, 66 of the tool 61 may also be penetrated by an induction coil, which is used for soldering the two conductors. In this case, an insertion of the cable by only partially unfolding of the lower and upper part 67, 66 is achieved. In a further embodiment of the present invention, it is provided to perform the soldering by a soldering iron.

The electrical connection of the conductor according to the invention can also be achieved by welding, wherein a resistance and / or laser and / or ultrasonic welding device can be used. In this case, corresponding modifications of the tool 61 are included in the invention. The bonding of the insulating films from the cable 63 and the cable 64 attached to the replacement connector 62 is accomplished as described above by heating the adhesive applied to insides of the insulating films. In this case, a softening achieved by the heating and a mechanical pressing of the cables 63, 64 against each other. The pressing can be accomplished by pressure surfaces, which are provided in the tool. These can either be operated from the outside or are after insertion of the cable 63,64 in the tool 61 already on the cables. As a heat source, the means used to produce the electrical connection can be used. However, it is also possible to provide further means provided merely for generating the mechanical connection, for example in the form of a laser and / or an infrared lamp. In addition, it is understood that the tool 61 is provided with the necessary supplies such as a power supply and the like.

The invention is not limited to the described embodiments, which can be modified in many ways. Thus, in the method for replacing a cable connector as illustrated in Figs. 9 and 10, other than the predetermined portion 57 for attaching and connecting the connector to cable may be selected. At any point of the flat cable 55, the cover sheet 58 can be separated approximately by means of a knife, whereby the conductor strips 55a to 55c are exposed. It is only to be noted that the portion where the cover sheet has been removed corresponds in size to the exposed portion located on a cable connected to a spare connector. It is understood that the conductor and / or the further conductor are exposed by removing the base film instead of the cover sheet or can be.

In the context of the present invention, the uncovered sections of the cables to be connected can also be mechanically connected to one another with additionally applied adhesive. Such an adhesive may be a thermosetting adhesive. However, it is also conceivable to apply an adhesive, which is irradiated by light, from the visible or the ultraviolet spectral range, can be cured to a mechanically stable and tensile strength compound. The adhesive can be applied to only one and / or on both of the uncovered exposed positions of the respective cable.

In the context of the invention, the base and cover sheets 20, 19 may be made of different materials. They can be glued against each other as well as welded together at the edges. The flat cable 2 provided according to the invention on the connector can also be constructed of conductor strips of different dimensions, which can then be connected to the respectively provided contacts of the connector, depending on their dimension with the above-described electrical connection method.

The invention also includes connectors 1 which are provided with a flat cable 2 on which more than two cable sections 43, 44 freed from the cover sheet 19 are provided. It is understood that the method according to the invention can also be used to make a connector of an electrical unit, e.g. the main wiring harness in a motor vehicle, according to the steps described above, and after a repair that is performed for example in a workshop, using the provided on the cable free or exposable points 44, 47 can be reconnected to the electrical unit. It is understood that according to the invention, a cable which is connected to the cable provided on the connector can be exchanged for another cable. For this purpose, the subsections 43 are used according to the invention for disconnecting the cable from the provided on the connector cable and 44 for attaching a replacement cable.

Also it is possible on a cable or flat cable an electrical unit to replace a connector according to the invention using the free or exposable points 43, 44 as often as desired on the flat cable 2 connected to it. At the time of first connection of the connector to the flat cable of the electrical unit, a first vacant space is used on the flat cable 2 provided on the connector 1, as shown at 43 in Fig. 1. At replacement of the connector 1, the connector 1 to be replaced becomes along the line 52 (Fig. 1) separated from the flat cable 2. A replacement connector 1 'with flat cable 2' is then connected to a corresponding section 43 'of its flat cable 2' to the section 44 of FIG. 1 with the flat cable 2 of the replaced connector 1. Due to the presence of two free or exposable locations on the sections 43, 44 (43 ', 44'), this can be repeated as often as desired with a new replacement connector 1 '.

With the connector according to the invention and / or with a connector intended for replacement in the method according to the invention, the production and execution of the electrical and mechanical connection is not limited to the above-described types of connection. The mechanical connection can also be made by laser-induced welding. In this case, the base film of a flat cable is mechanically stable connected to the connector housing. However, it should be noted in all types of connection production that the mechanical connection has a corresponding tensile strength which can withstand a tensile force of at least up to 90N. The electrical connection of conductor strips and contact can also be made by ironing or by resistance welding. These methods can take place both inside the connector housing 3, if the corresponding access possibilities are provided, but they can also be done outside the connector housing.

According to the invention, a separating device can also be present in the tool 61 with which the connector 56 to be replaced is separated from the electrical unit. Also, a means for stripping or exposing the conductors may be present in the tool 61. Conceivable are conventional knives or cutting tools or wire strippers.

Finally, it is understood that the individual features of the invention may also be used in combinations other than those illustrated and described.

Claims (36)

1. Connector with cable, comprising:

   a dielectrical connector housing (3) with one or more electrical connection contacts (17) held by said connector housing (3),

   a first cable (2) with one or more first conductors (2a, 2b, 2c) and with insulating material (19, 20, 21, 22) around the first conductor(s) (2a, 2b, 2c),
   wherein the first conductor(s) (2a, 2b, 2c) is / are connected to a respective connection contact (17),
   characterised by the following features:

   the first cable (2) is prepared for connection to a further cable (46) of the same type which comprises one or more further conductors (46a, 46b, 46c) and insulating material (48, 49, 50, 51) around the further conductor(s) and indeed is prepared in such a manner that the insulating material (19, 20, 21, 22; 48, 49, 50, 51) of the first and the further cable (2; 46) respectively contains a covering film (19, 48) which can be removed on one portion (43; 47) in order to expose a respective surface of the conductor(s) (2a, 2b, 2c; 46a, 46b, 46c),

   the exposed surfaces of the first and the further conductors can be laid one on top of the other and be securely electrically and mechanically connected to each other.
2. Connector according to claim 1,
   wherein the first cable (2) comprises at least a second point (44) at which the first conductor(s) (2a - 2c) is /are free of, or can be made free of, insulating material (19, 20).
3. Connector according to claim 2,
   wherein the at least one second point (44) is disposed between the removable portion (43) of the first cable (2) and the connector housing (3).
4. Connector according to claim 2 or 3,
   wherein at least one of the exposed or exposable second points (44) is provided with an insulating covering element (45) and / or the covering element (45) partially surrounds the first cable (2).
5. Connector according to claim 4,
   wherein the covering element (45) is formed as an electrically insulating adhesive strip (45) and is stuck on the insulating material (19, 20) in a laterally projecting way.
6. Connector according to one of the claims 2 to 5,
   wherein the insulating material (19, 20) can be partially removed on the portion (43) and at the second point (44) in such a manner that the first cable (2) and the further cable (46) can be accurately connected to each other on the portion (43) and / or at the second point (44).
7. Connector according to claim 6,
   wherein the cable (2) can be connected to the further cable (46) rotated by 180° about its longitudinal axis.
8. Connector according to claim 7,
   wherein the first cable (2) and the further cable (46) are stuck together with an adhesive on their portion (43, 47) and / or at the second point (44).
9. Connector according to claim 8,
   wherein the adhesive is applied to an inner wall (19a, 48a, 20b, 49b) of the first cable (2) and / or of the further cable (46) and can be a thermal adhesive which can be thermoplastically moulded and / or hardened by means of infrared radiation.
10. Connector according to claim 9,
    wherein the further conductor(s) (46a - 46c) of the further cable (46) is / are electrically conductively connected to the conductor(s) (2a - 2c) of the first cable (2) by a respective solder joint (18) and indeed as an inductive solder joint and / or a laser-induced solder joint.
11. Connector according to claim 10,
    wherein the further conductor(s) (46a - 46c) of the further cable (46) is / are connected to the conductor(s) (2a - 2c) of the first cable by an electrically conductive adhesive.
12. Connector according to one of the claims 1 to 11,
    wherein the first cable (2, 64) and / or the further cable (46, 55, 63) is / are (a) flat cable(s).
13. Connector according to claim 12,
    wherein the flat cable (2, 46, 55, 63, 64) contains a flexible sheet conductor.
14. Connector according to claim 13,
    wherein the conductor(s) (2a - 2c) of the first cable (2) and / or the further conductor(s) (46a - 46c) of the further cable (46) is / are formed as (a) printed circuit board(s).
15. Connector according to claim 13 or 14,
    wherein the conductor(s) (2a - 2c) of the first cable (2) and / or the further conductor (46a - 46c) of the further cable (46) is / are surrounded by a covering film (19, 48) and a base film (20, 49).
16. Connector according to claim 15,
    wherein the covering (19, 48) and / or the base film (20, 29) are polyester and / or polyimide films.
17. Method for producing a connector provided with cable according to one of the claims 1 to 16,
    characterised by the following steps:

    a) the first cable (2) is cut through;

    b) a covering film (19) is removed on the first cable (2) remaining on the connector (1) in order to form a portion (43) wherein the surface of the conductor(s) (2a - 2c) of the first cable is exposed;

    c) steps a) and b) are carried out accordingly in respect of the further cable (46);

    d) the exposed conductor(s) (46a - 46c) of the further cable (46) and the exposed conductor(s) (2a - 2c) of the first cable (2) are securely electrically and mechanically connected to each other on the portion (43).
18. Method according to claim 17,
    wherein at least one second point (44) is arranged on the first cable (2) wherein the insulating material (19, 20) is removed from the conductor(s) (2a - 2c).
19. Method according to claim 18,
    wherein the insulating material (19, 20) has been removed on the portion (43) and the at least one second point (44) in order to expose the conductor(s) (2a - 2c) of the first cable (2).
20. Method according to claim 17 or 18,
    wherein the second point (44) is arranged between the portion (43) and the connector housing (3).
21. Method according to claim 20,
    wherein the second point (44) is provided with an insulating covering element (45) and / or the covering element (45) partially surrounds the first cable (2).
22. Method according to claim 21,
    wherein an electrically insulating adhesive strip (45) as a covering element is (45) is stuck onto the insulating material (19, 20) in a projecting way on the second point (44).
23. Method according to one of the claims 18 to 22,
    wherein the insulating material (19, 20) is partially removed on the portion (43) and the second point (44) in such a manner that the first cable (2) and the further cable (46) are accurately connected together at the portion (43) and / or the second point (44).
24. Method according to claim 23,
    wherein the first cable (2) is connected to the further cable (46) rotated about 180° relative to its longitudinal axis.
25. Method according to claim 23 or 24,
    wherein the first cable (2) and / or the further cable (46) are stuck together with an adhesive at the portion (43, 47) and / or the second point (44).
26. Method according to claim 25,
    wherein the adhesive is applied to an inner wall (20b, 19a, 49b, 48a) of the first cable (2) and / or the further cable (46) and / or can be thermoplastically moulded and / or hardened by infrared radiation.
27. Method according to claim 26,
    wherein the conductor(s) (2a, 2b, 2c) is / are electrically conductively connected at the portion (43) to the conductor(s) (46a - 46c) of the further cable by a solder joint (18) which is implemented as an inductive solder joint and / or laser-induced solder joint.
28. Method according to claim 27,
    wherein the conductor(s) (2a - 2c) of the first cable (2) are connected to the further conductor(s) (46a - 46c) of the further cable (46) by a conductive adhesive.
29. Method according to one of the claims 17 to 28,
    wherein a flat cable is worked on as a first cable (2) and / or as a further cable (46).
30. Tool for producing a connector provided with cable according to one of the claims 1 to 16,
    characterised by
    means of electrically conductively connecting the first conductor(s) (2a, 2b, 2c) of the first cable (2) on an exposed portion (43) to the further conductor(s) of the further cable (46) and
    means of producing a mechanical connection of the first cable (2) to the further cable (46).
31. Tool according to claim 30,
    wherein the means of electrically conductive connection are implemented as a soldering device, thereby constituting an inductive or laser-induced soldering device.
32. Tool according to claim 30,
    wherein the means of electrically conductive connection are implemented as a welding device, thereby constituting a resistance or laser or ultrasound welding device.
33. Tool according to claim 30,
    wherein the means of electrically conductive connection are implemented as a crimping device.
34. Tool according to one of the claims 30 to 33,
    characterised in that it is designed to free the portion (43) of the first cable (2) of the insulating material.
35. Tool according to one of the claims 30 to 34,
    characterised in that the means of producing a mechanical connection are implemented as a heat source which can be implemented as an infrared lamp and / or resistance heating or as a laser.
36. Tool for carrying out the method according to one of the claims 17 to 29.

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