EP2913898A1 - Electrical plug-in connector and method for its mounting - Google Patents

Abstract

The invention relates to an electrical connector comprising a housing (22) having a front end and a rear end, which are connected to one another via a housing interior (221) which is open on both sides and whose wall is provided with first latching means (222, 223), - One in the housing interior (221) arranged latching body (20) whose wall is equipped with second locking means (203) which interact with the first latching means (222, 223) such that the latching body (20) axially fixed in the housing interior (221) is and - One in the locking body (20) fixed and axially passing through this contact unit (18) comprising a front end of the housing (22) facing, rigid Polstiftabschnitt (16) and an electrically and mechanically connected thereto, the rear end of the housing ( 22) passing through cable (14). The invention is characterized in that the latching body (20) is formed as an embossing body firmly embedding the contact unit (18) in the connection region of the cable (14) with the pole pin section (16).

Description

Field of the invention

• ein Gehäuse mit einem vorderen Ende und einem hinteren Ende, die über einen beidseitig offenen Gehäuseinnenraum, dessen Wandung mit ersten Rastmitteln ausgestattet ist, miteinander verbunden sind,
• einen im Gehäuseinnenraum angeordneten Rastkörper, dessen Wandung mit zweiten Rastmitteln ausgestattet ist, welche derart mit den ersten Rastmitteln wechselwirken, dass der Rastkörper im Gehäuseinnenraum axial fixiert ist, und
• eine in dem Rastkörper fixierte und diesen axial durchsetzende Kontakteinheit, umfassend einen zum vorderen Ende des Gehäuses weisenden, steifen Polstiftabschnitt und ein elektrisch und mechanisch mit diesem verbundenes, das hintere Ende des Gehäuses durchsetzendes Kabel.

The invention relates to an electrical connector comprising

• a housing with a front end and a rear end, which are connected to each other via a housing interior open on both sides, the wall of which is equipped with first latching means,
• a latching body arranged in the housing interior, the wall of which is equipped with second latching means which interact with the first latching means such that the latching body is axially fixed in the housing interior, and
• a fixed in the locking body and axially passing through this contact unit, comprising a pointing to the front end of the housing, rigid Polstiftabschnitt and an electrically and mechanically connected thereto, the rear end of the housing by passing cable.

The invention further relates to a method for mounting such a connector.

State of the art

Generic connectors are known from the DE 197 00 048 B4 ,

Electrical connectors, especially in the automotive sector, are exposed to considerable stresses, for example due to vibrations, spray water, temperature fluctuations, etc. They must be made of high quality. On the other hand, requires the large amount of required connectors alone in the Motor vehicle area a mass suitable and cheap production. The installation effort is essential in the cost of a connector.

The above-mentioned generic document discloses a substantially three-piece connector. A housing serves for external protection and defines a mechanical interface with a corresponding plug-in element. The required for the electrical function of the connector electrical contact unit in turn consists of two subunits, namely a Polstiftabschnitt, which may be formed in particular as a stamped and folded sheet metal part, and a cable which is connected to the Polstiftabschnitt both electrically and mechanically. The connection between the cable and Polstiftabschnitt is typically done by crimping, but can also be produced by soldering, welding or otherwise. For fixing the contact unit in the housing, a latching body is provided, which serves as an adapter between the contact unit and housing. The locking body is provided on its outside with locking means which are arranged in corresponding locking means on the inside of the axially continuous housing interior. The interior of the locking body itself is also formed as an axially continuous cavity whose inner wall has latching means which interact with corresponding latching means of the contact unit. The fixation of the contact unit in the housing thus takes place via a two-stage latching connection: the contact unit is latched in the latching body; the locking body is locked in the housing.

This concept raises several disadvantages. On the one hand, each locking connection is necessarily subject to play, so that the overall play of the pole pin to the housing is large and the precision of the connector correspondingly low. Next, an axial portion of the contact unit for the arrangement of the corresponding locking means is required for the latching connection between the contact unit and the latching body. The known connector therefore builds accordingly long. Ultimately, the low tightness against longitudinal water must be considered disadvantageous. Each of the two locking means interfaces leads to the formation of axially extending gaps, which develop a capillary action, with which penetrating water is passed on in the axial direction and can cause damage in a downstream electronics.

From the DE 20 2006 012 240 U1 a connector is known in which between the connector housing and insulation, an elastic spout is arranged to avoid gaps in which due to capillary moisture could penetrate.

From the CA 2 576 626 A1 a connector is known in which the conductor channel is produced through the insulation with the aid of two casting cores, which partially overlap. The cores are placed inside the mold and can be removed after injection of the casting material in axially opposite directions. In this case, the casting cores are designed such that there are corresponding latching means at both ends of the conductor channel.

From the US 2003/0 224 660 A1 a connector is known in which both connector halves are surrounded by an outer shell, wherein the second connector half and the outer shell are equipped with corresponding locking means and all three are formed so that upon engagement of the locking means between the second connector half and the outer shell, the first and the second connector half are firmly connected.

From the DE 197 00 048 B4 a connector is known in which a connector block is provided with solid side walls with a resilient locking tongue and in addition with an externally accessible retaining element.

task

It is the object of the present invention to further develop a generic connector such that an improved mechanical precision, reduced Axialbauraumbedarf and improved longitudinal water tightness can be achieved.

Presentation of the invention

This object is achieved in conjunction with the features of the preamble of claim 1, characterized in that the detent body is formed as a contact body in the connecting region of the cable with the Polstiftabschnitt firmly embedding Umspritzungskörper.

• Bereitstellen eines Gehäuses mit einem vorderen Ende und einem hinteren Ende, die über einen beidseitig offenen Gehäuseinnenraum, dessen Wandung mit ersten Rastmitteln ausgestattet ist, miteinander verbunden sind,
• Bereitstellen eines wenigstens ein freies Ende aufweisenden, elektrisch leitfähigen Kabels,
• Bereitstellen eines steifen Polstiftabschnitts mit wenigstens einem Polstift und einem einstückig mit diesem ausgebildeten Koppelbereich,
• axiales Durchführen des Kabels durch den Gehäuseinnenraum, sodass dessen freies Ende über das vordere Ende des Gehäuses hinausragt,
• mechanisches Verbinden, unter Ausbildung einer elektrischen Verbindung, des freien Endes des Kabels mit dem Koppelbereich des Polstiftabschnitts zu einer Kontakteinheit,
• Umspritzen der Kontakteinheit im Bereich des Koppelbereichs des Polstiftabschnitts mit einem spritzbaren, elektrisch isolierenden Kunststoff unter Ausbildung eines zu den ersten Rastmitteln korrespondierende zweite Rastmittel aufweisenden Rastkörpers und
• Einschieben des Rastkörpers samt der von ihm eingebetteten Kontakteinheit in das Gehäuse bis zur axialen Fixierung des Rastkörpers im Gehäuseinnenraum durch Wechselwirkung der ersten Rastmittel mit den zweiten Rastmitteln.

Another object of the invention is a method for mounting an electrical connector, comprising the steps:

• Providing a housing having a front end and a rear end, which are connected to one another via a housing interior open on both sides, the wall of which is equipped with first latching means,
• Providing an electrically conductive cable having at least one free end,
• Providing a rigid pole pin section with at least one pole pin and an integrally formed with this coupling region,
• axial passage of the cable through the housing interior, so that its free end protrudes beyond the front end of the housing,
• mechanically connecting, forming an electrical connection, the free end of the cable with the coupling region of the pole pin section to a contact unit,
• Injection of the contact unit in the region of the coupling region of the Polstiftabschnitts with a sprayable, electrically insulating plastic to form a corresponding to the first locking means second locking means detent body and
• Insertion of the detent body together with the contact unit embedded by it in the housing until the axial fixation of the detent body in the housing interior by interaction of the first detent means with the second detent means.

Preferred embodiments of the invention are the subject of the dependent claims.

The basic idea of the present invention is to optimize the connection between the contact unit and the latching body with regard to mechanical precision, axial space requirement and longitudinal water-tightness. This is achieved by an immediate encapsulation of the contact unit to form a precisely shaped Umspritzungskörpers, so that the contact unit is firmly embedded in Umspritzungskörper and the Umspritzungskörper can be locked in a basically known manner with the housing. This eliminates a locking interface, whereby the resulting total game between Polstift and housing is reduced accordingly. Also, the fixed embedding of the contact unit in the injection-molded body significantly reduces the gap acting as a capillary. Especially Advantageous choice of material, as explained below, a gap formation between contact unit and Umspritzungskörper completely prevented. Finally, the firm embedding of the contact unit in Umspritzungskörper also ensures that even small projections in the surface of the contact unit lead to a positive locking of the contact unit in Umspritzungskörper in the axial direction. On separate locking means can be dispensed with, so that the space required for this purpose in the prior art axial space can be saved.

Typically, the cable has an electrically conductive sheath sheathed with an electrically insulating sheath. The use of naked, i. Although not insulated cable is also conceivable, in practice, however, will find little application. When using a typical, sheathed cable is provided in a preferred embodiment of the invention that the jacket is materially connected to the locking body. As provided in a preferred development, this material bond can be realized, in particular in the context of the encapsulation process, when the jacket and the ratchet body have the same material consistency in the material bond region. For example, it can be provided that the jacket and the plastic material of the extrusion-coated body have similar or identical melting points, so that the jacket is melted on the surface during the extrusion-coating process and combines with the extrusion-coating material. The term material uniformity in the present context does not necessarily mean that the jacket and encapsulation material must necessarily be identical. The uniformity of the material can also be subsequently produced by, for example, in the case of the above-described case of the melting of the mantle surface, a boundary region consisting of a material mixture which can not be unambiguously assigned to either the mantle or the overmold body. In this boundary region, which can be assigned to both elements, both elements are material-uniform in the sense of the local description.

As an alternative to the above-described thermal connection, the material integrity can also be provoked by chemical agents, which are applied to the cable sheath, for example, immediately before the encapsulation process.

The formation of such material integrity requires, as the skilled person will recognize, always suitable in individual cases combination of materials. However, there are application-relevant cases in which no such combination of materials of jacket and Umspritzungskörper can be found. For example, cable sheaths made of PTFE or PTFE coating are often used. PTFE is known to be thermally very stable and chemically inert. In particular, to cover such or similar cases may be provided in a development of the invention that the cable carries in its contact region to the detent body a closed-pored porous elastomeric sleeve. Due to the inherent elasticity of the elastomeric sleeve, it rests sealingly against the cable (in the case that the sleeve does not surround only the cable but the cable and coupling region of the pole section, the elastomeric sleeve seals against these two). The porosity of the elastomeric sleeve leads to an open outer surface into which the encapsulation material can penetrate and thus form a positive connection. However, a closed pore porous material should be chosen, i. a material in which the pores are not interconnected so that capillary channels form over longer distances. This would be contrary to the desired sealing effect against longitudinal water. By contrast, a closed-pore porous material already offers a good seal due to the above-described positive connection between encapsulation material and sleeve, in combination with the elasticity of the sleeve material, without opening up an alternative longitudinal water path via its pores.

For the design of the interacting first and second locking means no fundamental restriction can be seen. However, it has proven particularly advantageous if the first latching means have radially inwardly directed projections which engage in corresponding recesses in the surface of the latching body. The locking body can thereby obtain a very simple geometric outer shape, which is particularly advantageous in the context of the encapsulation process in terms of the cost of tool making.

Specifically, it is recommended that the first locking means have two axially aligned, with their free ends to the front end of the housing facing arms, each with a radially inwardly directed nose, the nose having a front, flatter and a rear, steeper slope. Such a configuration requires insertion the locking body during assembly from the front end of the housing forth. This is the typical mounting direction for the present invention, as opposed to the prior art, as inserting from behind into the housing would require a larger housing interior.

As an additional sealing measure, it has proven to be advantageous if the cable is gripped in a lying between the first locking means and the rear end of the housing sealing region of a tightly against him lamellar seal, which bears radially on the outside tight against the wall of the housing interior. In order to prevent an unintentional axial displacement of the lamellar seal during operation, it is provided in a preferred development that the wall of the housing interior for axially delimiting the sealing region immediately before and / or behind this has a radially inwardly projecting collar on which the lamellar seal axially is applied. The lamellar seal is thus assigned its own chamber in the housing interior, in which it can be locked due to their usual inherent elasticity.

Further features and advantages of the invention will become apparent from the following specific description and the drawings.

Brief description of the drawings

Figur 1:

einen ersten Verfahrensschritt zur Montage eines erfindungsgemäßen Steckverbinders,

Figur 2:

einen zweiten Verfahrensschritt zur Montage eines erfindungsgemäßen Steckverbinders,

Figur 3:

einen dritten Verfahrensschritt zur Montage eines erfindungsgemäßen Steckverbinders,

Figur 4:

einen vierten Verfahrensschritt zur Montage eines erfindungsgemäßen Steckverbinders,

Figur 5:

eine teilweise geschnittene Darstellung des resultierenden Steckverbinders,

Figur 6:

Kontakteinheit, Rastkörper und Lamellendichtungen einer alternativen Ausführungsform eines erfindungsgemäßen Steckverbinders,

Figur 7:

eine alternative Ausbildung einer Lamellendichtung für einen zweipoligen Steckverbinder.

Show it:

FIG. 1:

a first method step for mounting a connector according to the invention,

FIG. 2:

a second method step for mounting a connector according to the invention,

FIG. 3:

a third method step for mounting a connector according to the invention,

FIG. 4:

a fourth method step for mounting a connector according to the invention,

FIG. 5:

a partially sectioned view of the resulting connector,

FIG. 6:

Contact unit, latching body and plate seals of an alternative embodiment of a connector according to the invention,

FIG. 7:

an alternative embodiment of a lamellar seal for a two-pin connector.

Detailed description of preferred embodiments

FIG. 1 shows a first method step for mounting a connector 10 according to the invention (as in FIG. 4 shown), wherein a lamellar seal 12 is pushed onto a cable 14 with a free end 141. The crank comprises an electrically conductive core 143 and an insulating jacket 142. In the illustrated embodiment, the lamellar seal 12 has three annular disk-like lamellae 121, which are connected to each other with axially compressible webs 122. The central opening 123 of the lamellae 121 and the webs 122 is dimensioned such that it engages around the cable 14 in a force-fitting manner, the adhesion being ensured by the shape and material elasticity of the lamellar seal 12. As a result, a longitudinal water-tightness between the plate seal 12 and cable 14 is achieved.

FIG. 2 shows a second method step, wherein the according to FIG. 1 prefabricated cable 14 is provided at its free end 141 with a Polstiftabschnitt 16. The Polstiftabschnitt 16 is formed as a stamped and folded sheet metal part and has the actual pole pin 161 and a coupling region 162. The coupling region 162 comprises two crimping points 163, 164. With the marginal crimping point 163 it is crimped with the sheath 142 of the cable 14; with the other crimping point 164 it is crimped with the stripped soul 143 of the cable 14 here. In this way, a mechanical and simultaneously electrical connection between the cable 14 and the Polstiftabschnitt 16, so that both together form the contact unit 18 is formed.

FIG. 3 shows the result of a third process step in which the entire coupling region 162 of the Polstiftabschnitts 16 is encapsulated in a Umspritzungsprozess with a locking body 20. The latching body 20 consists of a solid plastic material, which embeds the coupling region 162 of the Polstiftabschnitts 16 fixed. He has a comparatively simple outer structure, namely the shape of a two-sided flattened cylinder 201 with an approximately square face plate 202. The pole pin 161 protrudes from the face plate 202 out. In the region of the flattened sides of the cylinder body 201, a detent recess 203 is arranged in each case, whose significance will be discussed in more detail below.

FIG. 4 shows the final assembly step, namely the insertion of the latching body 20 provided with the contact unit 18 in a housing 22. The housing 22 has an axially continuous, channel-like housing interior 221, in which the contact unit 18 is inserted according to the Montagerichtungspfeil 24. The contact unit 18 is inserted so deeply until the latching lugs 223 of two latching arms 222, which extend in the housing interior 221 in the direction of its front end, engage in the latching recesses 203 and fix the contact unit 18 in the housing 2. The lamellar seal 12 comes to lie in the area behind the latching arms 222 and lies with the outer peripheries of their fins 121 sealingly against the wall of the housing interior 221.

FIG. 5 shows a corresponding connector in the final assembly position.

Note that the assembly order, as in the FIGS. 1 to 4 shown only when the cables 14 are single-stranded and each have two free ends, so that they can be threaded through the housing cavity 221 even after creation of the locking body 20. In many cases, however, this is not the case, for example, when two pole pins 161 of a connector 10 are connected to the two ends of a looped cable 14 to a loop. In this case, it is necessary that the housing 22 is already threaded onto the cable 14 before the creation of the detent body 20, preferably even before the assembly of the contact unit 18 according to FIG FIG. 2 , Particularly preferably even before the sliding of the plate seal 12 according to FIG. 1 ,

FIG. 6 shows an alternative embodiment of a detent body 20 '. In this embodiment, two according to FIG. 2 prefabricated contact units 18 together with a locking body 20 'overmolded. The two cylinder body 201 'are integrally connected to a connecting them, rectangular face plate 202'. In the embodiment shown, each of the cylinder bodies 201 'has a latching recess 203'; It would also be conceivable to have a single, common recess in the area of the end plate 202 '. In FIG. 6 For example, the louver seals 12 for each cable 14 are configured as described in connection with FIG FIG. 1 described.

FIG. 7 shows an alternative embodiment of a lamellar seal 12 ', in which the cable receptacles are not concentric with the outer diameter of the lamella 121' and the webs 122 'are formed. Instead, the lamellar seal 12 'has two parallel channels 124'.

Of course, the embodiments discussed in the specific description and shown in the figures represent only illustrative embodiments of the present invention. A broad range of possible variations will be apparent to those skilled in the art in light of the disclosure herein. In particular, the shape of the plug housing and the pole pins and their number can be varied according to the requirements of the individual case by those skilled in the art.

LIST OF REFERENCE NUMBERS

10

Connectors

12, 12 '

lamellar seal

121, 121 '

lamella

122, 122 '

web

123, 123 '

Cabel Canal

14

electric wire

141

free end of 14

142

coat

143

soul

16

Polstiftabschnitt

161

pole pin

162

coupling region

163

crimping

164

crimping

18

Contact unit

20, 20 '

Catch body, encapsulation body

201, 201 '

cylinder body

202, 202 '

faceplate

203, 203 '

recess

22

casing

221

Housing interior

222

detent arm

223

locking lug

24

Installation direction arrow

Claims (10)

Electrical connector, comprising a housing (22) having a front end and a rear end, which are connected to one another via a housing interior (221) which is open on both sides and whose wall is provided with first latching means (222, 223), - One in the housing interior (221) arranged latching body (20) whose wall is equipped with second locking means (203) which interact with the first latching means (222, 223) such that the latching body (20) axially fixed in the housing interior (221) is and - One in the locking body (20) fixed and axially passing through this contact unit (18) comprising a front end of the housing (22) facing, rigid Polstiftabschnitt (16) and an electrically and mechanically connected thereto, the rear end of the housing ( 22) passing through cable (14), characterized,
in that the latching body (20) is designed as an extrusion-coating body firmly embedding the contact unit (18) in the connection region of the cable (14) with the pole pin section (16). Connector according to claim 1,
characterized,
that the cable (14) with an electrically insulating sheath (142) coated, having electrically conductive core (143) and the jacket (142) material fit with the locking body (20) is connected. Connector according to claim 2,
characterized,
that the jacket (142) and the latching body (20) are of the same material in the material connection region. Plug connector (10) according to one of the preceding claims,
characterized,
in that the cable (14) carries in its contact area to the latching body (20) a closed-pore porous elastomeric sleeve. Connector according to one of the preceding claims,
characterized,
in that the first latching means (222, 223) have radially inwardly directed projections (223) which engage in corresponding recesses (203) in the surface of the latching body (20). Connector according to claim 5,
characterized,
in that the first latching means (222, 223) have two axially aligned arms (222) with their free ends facing the front end of the housing (22), each with a radially inwardly directed lug (223), wherein the lug (223) has a front, flatter and has a rear, steeper slope. Connector according to one of the preceding claims,
characterized,
in that the cable (14) is encompassed in a sealing region lying between the first latching means (222, 223) and the rear end of the housing (22) by a lamellar seal (12, 12 ') lying close to it and sealing radially on the outside Wall of the housing interior (221) is applied. Connector according to claim 7,
characterized,
comprises that the wall of the housing interior (221) for axial limitation of the sealing area immediately before and / or behind a radially inward projecting collar, on which the lamellar seal (12, 12 ') bears axially. Method for assembling an electrical connector, comprising the steps: Providing a housing (22) having a front end and a rear end, which are connected to one another via a housing interior (221) which is open on both sides and whose wall is provided with first latching means (222, 223), Providing an electrically conductive cable (14) having at least one free end (141), Providing a rigid pole pin section (16) with at least one pole pin (161) and an integrally formed with this coupling region (162), axially passing the cable (14) through the housing interior (221) so that its free end (141) projects beyond the front end of the housing (22), - mechanically connecting, forming an electrical connection, the free end (141) of the cable (14) with the coupling region (161) of the pole pin portion (16) to a contact unit (18), - Overmolding of the contact unit (18) in the region of the coupling region (161) of the Polstiftabschnitts (16) with a sprayable, electrically insulating plastic to form a to the first locking means (222, 223) corresponding second latching means (203) having detent body (20) and - Insertion of the locking body (20) together with the embedded contact unit (18) in the housing (22) to the axial fixation of the locking body (20) in the housing interior (221) by interaction of the first locking means (222, 223) with the second locking means (203). Method according to claim 9,
characterized,
in that the cable is provided with a closed-pore porous elastomer sleeve before the encapsulation step in its length to be extrusion-coated.

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