EP1122840B1 - Process for manufacturing a socket connector and socket connector - Google Patents

Abstract

The method involves applying the edges of two mold halves (9,10) to the crimpings of plug sockets where the sockets protrude at the front of a hollow volume (12) formed by the two mold halves so as to seal the hollow volume, whereby the edges (13,14) of the two halves have recesses corresponding to the plug sockets. A front housing part can be joined to the rear housing part, preferably by a latching closure. Independent claims are also included for the following: a plug holder part.

Description

The invention relates to a method for producing a connector of a waterproof Plug connection, which one or more via a crimp connection comprising plug elements connected to an electrical lead, the can be plugged together with plug elements mounted in a mating connector are, and which in its rear, the connector elements facing away Area one of one the electrical lines waterproof enclosing Encapsulation formed housing part, wherein for the preparation of this Encapsulation the connector elements are inserted into a mold whose Mold cavity under conditioning of the edges of the two mold halves to the respective Crimping of the connector elements is sealed, the edges of the two mold halves the crimps of the connector elements corresponding recesses exhibit. The invention further relates to a plug connector of a waterproof connector, which one or more via a crimp connection comprising plug elements connected to an electrical line, which can be plugged together with plug elements mounted in a mating connector are, and which in its rear, the connector elements facing away Area one of one the electrical lines waterproof enclosing Encapsulation has formed housing part, said encapsulation directly adjacent to the respective crimps of the connector elements, preferably this surrounds.

For watertight plug connections is when inserting a plug part in a plug receiving part, a waterproof connection of conventional manner manufactured by the fact that the plug receiving part with a to the housing is equipped with circumferential seal and the plug part a the seal of the Plug receiving part in the assembled state cross-extension having a closed lateral surface, wherein the seal is close to the inside this extension rests. Furthermore, the plug receiving part and the plug part sealed against ingress of water along the lines become. For this purpose, it is known, pushed onto the lines of sealing rings to use in hollow cylindrical recesses in the housing the plug receiving part or the plug part in the areas where the electrical wires from the corresponding housing, sealing between Housing and line are pressed. A disadvantage of this type of seal between housing and lines is the space required for the sealing rings, whereby, in particular in the case of a plurality of contact pins or contact sockets and thus multiple lines, the size of the connector is essential is enlarged.

It is also known to seal the electrical lines with a To provide encapsulation. In the case of a plug part, this encapsulation from the electrical wire to the back of the connector pin, so that in this case substantially the entire housing of the male part can be formed by such extrusion coating. In a connector receiving part it is necessary, however, the socket when encapsulating against to protect penetration of the plastic melt. This is usually a Housing part used, which pushed over the line before overmolding and to which the mold halves are applied. This is so close to the Line, that between the line and this housing part no plastic melt can pass through. The encapsulation of the line is on the of the Plug socket facing away from this housing part.

An electrical connector of the type mentioned or a method of the aforementioned type is known from US 5,749,656 A. This connector has contact pins as plug-in elements and thus forms the plug part the electrical connector. The electrical cables are crimped connected to the connector pins, wherein a housing part of the connector is formed by an encapsulation surrounding the crimps. in this connection The correspondingly shaped edges of the mold halves to the crimps created.

The object of the invention is a plug receiving part of a waterproof Provide connector that reliably against ingress of Water is sealed along the electrical lines, doing one as possible has small size and can be produced in a simple manner. According to the invention this is achieved by a method having the features of patent claim 1 or by a connector having the features of claim 8.

Sockets with crimp connections are known, for example from the mentioned US 5,749,656 A, also in connection with those already described known waterproof connectors. A crimp connection is going through a formed on the socket, formed usually U-shaped sheet metal part, in which the electrical conductor to be connected is inserted. In the As a result, the cheeks of the sheet metal part are compressed and thereby becomes the inserted electrical conductor fixed. The crimp connection becomes a created mechanical connection between the conductor and the socket and also the electrical transition contact. In connection with crimp contacts usually ladders formed from a plurality of strands are used, but also waveguides are suitable for crimping. Sockets with crimp connections can also with electrical conductors in the form of Folienleitem get connected. These are fixed on an insulating support layer Conductors provided.

A basic idea of the method according to the invention or of a method according to the invention Plug receiving part is now that the crimp so reproduce exactly that provided with corresponding recesses Rims of the two mold halves are applied to this crimp can to seal the mold cavity. It can do the edges of the Mold halves in the areas where the seals against the crimping areas to be produced, not provided with elastic seals because these do not have sufficient wear resistance to the injection molding process would have. The seal is thus made directly from metal to metal. Furthermore, may by this seal on the respective crimping and the subsequent injection molding of the crimp not unfavorable to be influenced. A common crimping requirement, which ensures is to be that by crimping a sufficiently good mechanical and electrical connection has been created, is that the Compound is gas-tight. This essential for the reliability of crimping Gas-tightness is allowed by the sealing of the mold cavity in the crimping area not lost during encapsulation. Also as a stranded wire or too as a conductor of a film conductor trained electrical conductor may not be damaged become. Since the injection molding process pressures in the amount of 800 to 1000 occur bar and exerted a corresponding locking force on the Formhätften must be, it is quite surprising that the sealing of the mold cavity in Crimpbereich, as it has been shown, no damage to the Crimping leads.

Fig. 1

einen schematischen Längsschnitt durch ein Steckeraufnahmeteil entsprechend dem Stand der Technik;

Fig. 2

eine perspektivische Darstellung der Steckerbuchsen für ein Steckeraufnahmeteil;

Fig. 3

einen schematischen Längsschnitt durch eine Form, in die die in ein Gehäusevorderteil eingesteckten Steckerbuchsen eingelegt sind, entsprechend einer ersten Ausführungsform der Erfindung;

die Fig.

4 und 5 perspektivische Darstellungen des in Fig. 3 schematisch dargestellten Gehäusevorderteils, in welches die Steckerbuchsen eingeschoben werden;

Fig. 6

eine perspektivische Darstellung entsprechend der Fig. 4 des fertiggestellten Steckeraufnahmeteils gemäß der ersten Ausführungsform der Erfindung;

Fig. 7

einen schematischen Längsschnitt durch eine Form, in welche die in ein Gehäusevorderteil eingeschobenen Steckerbuchsen angeordnet sind, entsprechend einer zweiten Ausführungsform der Erfindung;

die Fig. 8 und 9

perspektivische Darstellungen des in Fig. 7 schematisch dargestellten Gehäusevorderteils;

Fig. 10

eine perspektivische Darstellung des fertiggestellten Steckeraufnahmeteils entsprechend der zweiten Ausführungsform der Erfindung;

Fig. 11

eine perspektivische Darstellung der mit Leiterbahnen eines Folienleiters über Crimpkontakte verbundenen Steckerbuchsen für ein Steckeraufnahmeteil entsprechend einer dritten Ausführungsform der Erfindung;

Fig. 12

einen Crimpkontakt einer Steckerbuchse mit einem Folienleiter;

Fig. 13

einen schematischen Längsschnitt durch eine Form, in die die in ein Gehäusevorderteil eingesteckten Steckerbuchsen eingelegt sind, entsprechend der dritten Ausführungsform der Erfindung;

Fig. 14

eine perspektivische Darstellung des fertiggestellten Steckeraufnahmeteils entsprechend der dritten Ausführungsform der Erfindung;

die Fig. 15 bis 18

ein viertes Ausführungsbeispiel der Erfindung, wobei die Fig. 15 die Steckerbuchsen, Fig. 16 das Gehäusevorderteil, in das die Steckerbuchsen eingeschoben sind, Fig. 17 einen Längsschnitt durch die geschlossene Form mit eingelegtem Gehäusevorderteil und Fig. 18 das fertiggestellte Steckeraufnahmeteil zeigt;

Fig. 19

die Steckerbuchsen für ein Steckeraufnahmeteil entsprechend einer fünften Ausführungsform der Erfindung und

Fig. 20

einen schematischen Längsschnitt durch eine Form, in die die in ein Gehäusevorderteil eingesteckten Steckerbuchsen eingelegt sind, entsprechend der fünften Ausführungsform der Erfindung.

Further advantages and details of the invention are explained below with reference to the accompanying drawings. In this show:

Fig. 1

a schematic longitudinal section through a plug receiving part according to the prior art;

Fig. 2

a perspective view of the sockets for a connector receiving part;

Fig. 3

a schematic longitudinal section through a mold, in which the plugged into a housing front part sockets are inserted, according to a first embodiment of the invention;

the Fig.

Figures 4 and 5 are perspective views of the housing front part shown schematically in Figure 3, in which the sockets are inserted.

Fig. 6

a perspective view corresponding to Figure 4 of the finished connector receiving part according to the first embodiment of the invention.

Fig. 7

a schematic longitudinal section through a mold, in which the inserted into a housing front part sockets are arranged, according to a second embodiment of the invention;

FIGS. 8 and 9

perspective views of the housing front part shown schematically in Figure 7;

Fig. 10

a perspective view of the finished connector receiving part according to the second embodiment of the invention;

Fig. 11

a perspective view of the connected to conductor tracks of a film conductor via crimp contacts sockets for a connector receiving part according to a third embodiment of the invention;

Fig. 12

a crimp contact of a female connector with a foil conductor;

Fig. 13

a schematic longitudinal section through a mold, in which the plugged into a housing front part sockets are inserted, according to the third embodiment of the invention;

Fig. 14

a perspective view of the finished connector receiving part according to the third embodiment of the invention;

FIGS. 15 to 18

a fourth embodiment of the invention, wherein Fig. 15, the sockets, Fig. 16 shows the front housing part into which the sockets are inserted, Fig. 17 shows a longitudinal section through the closed mold with inserted front housing part and Fig. 18 shows the finished plug receiving part.

Fig. 19

the sockets for a connector receiving part according to a fifth embodiment of the invention and

Fig. 20

a schematic longitudinal section through a form in which the plugged into a housing front connector sockets are inserted, according to the fifth embodiment of the invention.

The cross section shown schematically in Fig. 1 by a plug receiving part according to the prior art shows a socket 1, which in a Housing front part 2 is inserted. About the electrical connection line 3 is a further housing part 4 is pushed, which with the housing front part. 2 For example, via a (not shown in FIG. 1) locking closure connected is. The housing part 4 has in the area in which it surrounds the conduit 3, a Seal 5 on. As a result, the partially completed plug receiving part placed in a mold cavity and provided with an encapsulation 6, which the electrical wires 3 encloses watertight. From the encapsulation 6 and the housing part 4 is further a groove 7 for receiving a in Fig. 1 not formed seal formed. This serves as a watertight seal between the plug receiving part and a plugged into the plug receiving part Plug part, which faces at its the plug receiving part Front side a projection for engaging over the groove 7 lying seal having. For sealing the plastic melt when attaching the encapsulation 6 with respect to the socket 1 here is the housing part 4 and whose the lines 3 surrounding seals. 5

Fig. 2 shows a perspective view of four sockets 1, to the above Crimping 8 electrical lines 3 are connected. Under use These sockets 1, a connector receiving part to be made.

An embodiment of the invention will be described below with reference to FIGS. 3 to 6 explained. The sockets 1 are prior to insertion into the mold cavity 12 in a front part of the plug receiving part forming the housing part 25th inserted. The springs 22 of the sockets 1 rest in windows 26th on. The housing part 25 with the inserted and latched sockets 1 is in the episode with its insertion opening 27 via the edge 14 of lower mold half 10 laid. Subsequently, the upper mold half 9 is closed, wherein its edge 13 through the insertion opening 28 in the housing part 25th protrudes. The insertion openings 27, 28 are below and above the crimping areas 8 of the sockets 1, wherein the edges 13, 14 of the mold halves 9, 10 in closed state of the mold rest on the crimping 8 to the Seal mold cavity 12.

To complete the plug receptacle plastic is in the mold cavity 12 injected. To prevent the penetration of liquid molten plastic in the back Area of the housing part 25 to facilitate, are at the top and bottom the housing part openings 29, 30 are provided. It gets a relatively softer Injected plastic, which is suitable for forming a seal. To has the mold cavity 12 further circulating, the trainees sealing beads corresponding recesses 31. The finished plug receiving part is shown in Fig. 6. Through the insertion openings 27, 28 are parts of Crimping 8 visible. The housing part 32 formed by the encapsulation is with the housing part 25 firmly connected and the circumferential seal 19 is part this formed of a soft plastic housing part 32 is formed.

A second embodiment of the invention is shown in FIGS. 7 to 10. The sockets 1 are inserted here in a housing part 33 and with its springs 22 in windows 34 in the housing part 33 is locked, which at its Front again insertion openings 35 for the connector pins of a connector part having. This housing part 33 extends with its rear end 36 not on the crimping of the inserted into the chambers 37 of the housing part 33 Sockets 1, but ends before these. On the housing part 33 are arms 38, 39 formed on both sides, extending beyond the rear end 36 of the Housing part 33 extend backwards and inwardly directed lugs 40, 41 have. These lugs are used for anchoring the housing part 33 at the edge 14 of the mold half 10, when the housing part 33 together with the inserted Sockets 1 is inserted into the lower mold half 10. In the episode will in turn closed the upper mold half 9, wherein the edges 13, 14 to the Crimping 8 of the sockets 1 abut. By injecting plastic in the mold cavity 12 is the rear, with the front housing part 33rd connected housing part 42 of the connector receiving part and formed the plug receiving part completed by pushing the seal 19.

By the housing parts 25, 33 corresponding to those described above Embodiments of the invention are used, the introduction of the Sockets 1 in the form easier.

With reference to the figures 11 to 14 explained in the following third embodiment the invention, the sockets 1 via crimp contacts, which Crimp 8 have, connected to electrical lines 3, as on an insulating carrier layer 43 defined conductor tracks of a film conductor 44 are formed. Like such a crimp contact of a socket with a Foil conductor can be formed in principle, is shown in Fig. 12. At the respective Socket is on the side facing away from the insertion rear a web 46 is disposed on the upwardly directed cheeks 45 arranged are, so that an overall U-shaped sheet metal part is formed. At the front, the sockets 1 facing the end of the film conductor 44 are between punched out the conductor tracks areas of the carrier layer. The free ends of the electrical wires 3 are inserted between the cheeks 45. Furthermore, between the cheeks 45, a pressure part 47 of an electric inserted conductive material having a central cavity 48. As a result, the cheeks 45 are pressed against the pressure member 47 to the Make crimp contact. The pressure member 47 serves to provide a reliable, form a gas-tight crimp contact. This printing part 47 could also be in be formed other form, for example as a piece of a stranded wire.

In an analogous manner as in the first embodiment of the invention, the Socket 1 inserted in the sequence in a front housing part 16, the in the fixed mold half 10 is inserted, whereupon the mold half 9 is closed becomes. The edge 13 of the mold half 9 protrudes through an insertion 28th in the housing front part 16. After demolding, a seal 19 is still on a groove in the formed by the encapsulation housing part 32 applied.

In the fourth embodiment of the invention, hereinafter with reference to FIGS 15 to 17 are explained, are two superimposed rows of sockets 1 provided, the respective crimping 8 with the electrical Lines 3 are connected, which are arranged on two flexible Folienleitem 44 are. The sockets are first turn into a front housing part 16 is inserted, as shown in Fig. 16. This housing front part is inserted into the fixed mold half 10, wherein the edge 14 through the Plug-in opening 27 protrudes. The housing front part also has a lateral insertion opening 49 on that in the space between the two rows of crimps 8 leads. Through this insertion opening 49, a slider 50 of the fixed Mold half 10 introduced. Preferably, the insertion opening 49 as formed through opening so that the slider 50 on the other (in Fig. 16 not visible) side of the housing front part 16 again from this can escape and is supported in the tool. As a result, the mold is closed, wherein the edge 13 of the movable mold half 9 through the insertion 28 sticks out. The crimps 8 are thus between the edges 13, 14, the crimpings 8 of the sockets 1 corresponding recesses have, and the slider 50 is clamped. For sealing the mold cavity 12 were again the edges of the two halves of the form on the Crimping created. Another slider 51 is used to limit the mold cavity on the opposite side between the two foil conductors 44 inserted. After injection of plastic into the mold cavity 12 and the demolding of the connector receiving part is to complete the connector receiving part in turn, a seal 19 in an annular groove of the encapsulation formed housing part 32 is inserted.

A fifth embodiment of the invention is shown in Figures 19 and 20. The sockets 1 are here on crimping 8 with electrical lines 3, which have stranded wires. Again, there are two superimposed ones Row of sockets 1 and electrical lines 3 intended. The sockets are inserted into a front housing part 16, which is then inserted into the mold half 10. This mold half 10 has in contrast to the fourth embodiment described above the Invention only a slide 50, which is inserted between the crimping 8 becomes. On the opposite back of the form are the electric ones Lines 3 merged and pass through recesses in the edges of the two mold halves 9, 10 from the mold cavity 12.

Instead of inserting the slider 50 between the crimps 8 before Closing of the mold could also be provided, first the two mold halves 9, 10 and subsequently the slider 50 (and possibly the Slide 51). At its front end, the slider 50 would be in to provide this case advantageously with wedge surfaces through which the cross section of the slider 50 tapers in the region of its front end. Thereby could the slider 50 be inserted between the crimps 8, wherein these are pressed against the edges 13, 14 of the mold halves 9, 10.

Legend to the reference numbers:

1

socket

2

Front housing

3

management

4

housing part

5

poetry

6

encapsulation

7

groove

8th

crimping

9

mold

10

mold

12

mold cavity

13

edge

14

edge

16

Front housing

19

poetry

22

feather

25

housing part

26

window

27

insertion

28

insertion

29

opening

30

opening

31

deepening

32

housing part

33

housing part

34

window

35

insertion

36

rear end

37

chamber

38

poor

39

poor

40

nose

41

nose

42

housing part

43

backing

44

foil conductor

45

cheek

46

web

47

pressure part

48

cavity

49

insertion

50

pusher

51

pusher

Claims (12)

1. A method of producing a plug-and-socket connector of a watertight plug-and-socket connexion, which connector comprises one or more plug elements which are connected by way of a crimp attachment to an electrical line (3) and which can be plugged in together with plug elements mounted in a mating connector, and the rear region - remote from the plug elements - of which connector comprises a housing part (32, 42) formed by an injection-moulded portion surrounding the electrical lines (3) in a watertight manner, wherein the plug elements are inserted into a mould in order to produce the said surrounding injection-moulded portion, the cavity (1) of the mould being sealed off in that the edges (13, 14) of the two mould halves (9, 10) abut against the respective crimps (8) of the plug elements, wherein the edges (13, 14) of the two mould halves (9, 10) have recesses corresponding to the crimps (8) of the plug elements, characterized in that the plug-and-socket connector is constructed as a plug-receiving part comprising plug elements in the form of female connectors (1), wherein plug pins of the mating connector constructed in the form of a plug part can be inserted into the insertion openings in the female connectors (1), in the state where the female connectors (1) are inserted into the mould the lines (3) project from the latter on a first side and the front regions of the female connectors project with the insertion openings of the female connectors on an opposite second side on which the edges (13, 14) of the mould halves (9, 10) abut against the crimps (8), and before insertion into the mould the female connectors (1) are inserted into a housing part (25, 33) which forms the front part of the plug-receiving part.
2. A method according to Claim 1, characterized in that the rear region of the housing part (25) extends over the crimps (8) of the female connectors (1), wherein insertion openings (27, 28) for the edges (13, 14) of the mould halves (9, 10) are provided above and below the crimps (8) of the female connectors (1) inserted into the housing in order to place the edges (13, 14) of the mould halves (9, 10) on the crimps (8) of the female connectors (1).
3. A method according to Claim 2, characterized in that the rear end (36) of the housing part (33) terminates in front of the crimps (8) of the female connectors (1) inserted into the housing part (33), wherein lateral arms (38, 39) extending towards the rear are preferably formed on the housing part (33).
4. A method according to one of Claims 1 to 3, characterized in that the housing part (42) formed by the surrounding injection-moulded portion has a groove which extends around the housing part (42) and into which a seal (19) can be inserted.
5. A method according to one of Claims 1 to 4, characterized in that the housing part (32) formed by the surrounding injection-moulded portion is formed from a soft plastics-material component, wherein the housing part (32) has one or more continuous beads on its surface for forming a seal (19).
6. A method according to one of Claims 1 to 5, characterized in that the electrical lines (3) are conductor tracks - fastened to an insulating carrier layer (43) - of a foil conductor (44).
7. A method according to one of Claims 1 to 6, characterized in that two rows of female connectors (1) arranged one above the other and having respective crimp attachments are provided, wherein the mould comprises a slide (50) which is inserted in the closed state between the crimps (8) of the two rows of the female connectors (1).
8. A plug-and-socket connector of a watertight plug-and-socket connexion, which connector comprises one or more plug elements which are connected by way of a crimp attachment to an electrical line (3) and which can be plugged in together with plug elements mounted in a mating connector, and the rear region - remote from the plug elements - of which connector comprises a housing part (32, 42) formed by an injection-moulded portion surrounding the electrical lines (3) in a watertight manner, wherein the said surrounding injection-moulded portion directly adjoins the respective crimps (8) of the plug elements, and preferably surrounds them, characterized in that the plug-and-socket connector is constructed as a plug-receiving part comprising plug elements in the form of female connectors (1), wherein plug pins of the mating connector constructed in the form of a plug part can be inserted into the insertion openings in the female connectors (1), and a housing part (25) forming the front part of the plug-receiving part extends in its rear region over the crimps (8) of the female connectors (1), wherein insertion openings (27, 28) for the edges (13, 14) of mould halves (9, 10) of a device for injection-moulding around the female connectors are provided above and below the crimps (8) of the female connectors (1) in order to place the edges of the mould halves on the crimps (8) of the female connectors (1).
9. A plug-receiving part according to Claim 8, characterized in that the housing part (33) formed by the surrounding injection-moulded portion has a groove which extends around the housing part and into which a seal (19) can be inserted.
10. A plug-receiving part according to Claim 8 or Claim 9, characterized in that the housing part (25) formed by the surrounding injection-moulded portion comprises a soft plastics-material component, wherein the housing part (25) has one or more continuous beads on its surface for forming a seal (19).
11. A plug-receiving part according to one of Claims 8 to 10, characterized in that the electrical lines (3) are conductor tracks - fastened to an insulating carrier layer (43) - of a foil conductor (44).
12. A plug-receiving part according to one of Claims 8 to 11, characterized in that two rows of female connectors (1) arranged one above the other and having respective crimp attachments are provided, wherein the mould comprises a slide (50) which is inserted in the closed state between the crimps (8) of the two rows of the female connectors (1).

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