EP2945227A1 - Device for the connection of an electrical component with at least one electrical conductor and method for producing such a device - Google Patents

Abstract

The invention relates to a device for connecting an electrical component (30, 32, 34) or an assembly (40) to at least one electrical conductor (21, 22, 23, 24, 25), with a carrier component (10) into which at least an electrically conductive connecting element (17; 18; 30) is integrated. According to the invention, at least one fixing (12, 13) of the at least one electrical conductor (21, 22, 23, 24, 25) is integrated on the carrier component (10), via which the at least one electrical conductor (21, 22, 23, 24, 25 ) is brought into a conductive connection with the connecting element (17; 18; 30). The invention also relates to a method for producing such a device.

Description

The invention relates to a device for connecting an electrical component with at least one electrical conductor according to the preamble of claim 1. The invention further relates to a method for producing such a device according to the preamble of claim 9.

From the DE 10 2008 057 478 A1 a carrier element for electrical components is known, in which a wire, which serves to produce an electrical connection, is embedded in a plastic material of the carrier element.

The object of the invention is to provide an improved device for connecting an electrical component with at least one electrical conductor and a method for producing such a device.

This object is achieved with regard to the device by the features of claim 1. An improved method is specified in claim 9. Advantageous embodiments of the invention are specified in the respective dependent claims.

The inventive solution provides that at least one support member made of plastic connects to at least one strand of a cable as an electrical conductor and the other at least one connecting element for coupling an electrical component or an electrical assembly.

The carrier component ensures a simple, process-reliable, permanently sealed connection between the electrical conductor and the electrical component. The carrier component with the strands fixed thereto replaces a three-dimensional 3D circuit carrier (MID) in a cost-effective manner, in which the electrical connections are in the form of copper conductor tracks. The elimination of previously used stamped grid, the tool costs are reduced significantly. The connection points for wired components can be made very flexible. For the fixation of the strands cheap joining techniques can be used and freely combined, such as splicing, crimping, soldering or welding.

Preferably, the support member is formed of a molded plastic by injection molding. As an alternative to conventional overmolding, it is also possible to use a macromelt process or a hotmelt process in the form of thermoplastic or reactive (PUR) hotmelts. The casting materials of the macromelt process are thermoplastic hot melt adhesives based on polyamide. By means of these methods, an "encapsulation" in the sense of this invention can likewise be produced.

According to a further alternative, the carrier component can also be formed by at least one already prefabricated plastic molded part. This can optionally be additionally encapsulated after fixing the electrical conductors and the connecting elements with a plastic material. According to a further alternative, after fixing the electrical conductors and the connecting elements, a first prefabricated plastic molded part can also be surrounded by a second prefabricated plastic molded part or can be completed to a closed whole.

Preferably, the fixation surrounds at least partially a plastic insulation of the at least one electrical conductor. The fixation can be formed for example as a groove, in which the plastic insulation of the at least one electrical conductor is pressed and clamped there. Likewise, the connecting elements, in turn, for example, as wires, as a connector or may be formed as sockets, be embedded in correspondingly shaped recesses on the support member. The fixation of the electrical conductors can also be done in other ways, for example, by splicing, crimping, soldering or welding.

It is also advantageous if the support member has at least one recess, are guided over the spaced-apart stripped portions of the electrical conductors. The stripping can also be done later after positioning and fixing the electrical conductor over this recess, the recess access to the tool - for example a Fensterabisoliervorrichtung - facilitates stripping.

It is particularly advantageous if the carrier component additionally has holders for electronic components. This additionally increases the usefulness of the carrier component.

These holders for the electronic components are preferably provided on correspondingly shaped projections of the carrier component. The projections may be integrally formed on the support member, but also be formed as a separate component and, for example, by a positive connection (clips, locking) or a cohesive connection (molding, plastic welding) are connected to the support member.

It is also advantageous if the carrier component comprises a cable receptacle for receiving a cable sheath of a cable having a plurality of electrical conductors. The integration of a cable receptacle on the support member allows a well protected from dirt and moisture introduction of the electrical conductors in the support member.

1. a) Einlegen des zumindest teilweise abisolierten Endes wenigstens eines elektrischen Leiters in eine Fixierung,
2. b) Einlegen zumindest eines elektrisch leitenden Verbindungselements und optional weiterer elektronischer Bauteile in eine Form,
3. c) Umspritzen des zumindest einen teilweise abisolierten Endes des wenigstens einen elektrischen Leiters sowie des elektrisch leitenden Verbindungselements und der optionalen weiteren elektronischen Bauteile in der Form mit einem nichtleitenden Kunststoff.

A method for producing a device according to the invention is characterized by the following method steps:

1. a) inserting the at least partially stripped end of at least one electrical conductor into a fixation,
2. b) inserting at least one electrically conductive connecting element and optionally further electronic components in a mold,
3. c) encapsulating the at least one partially stripped end of the at least one electrical conductor and the electrically conductive connecting element and the optional further electronic components in the mold with a non-conductive plastic.

In an alternative method it is provided that the fixation is formed on an already prefabricated plastic molded part, which is placed for example in a mold and encapsulated by a non-conductive plastic.

• Fig. 1 eine schematische Ansicht einer elektrischen Baugruppe, die mittels eines
• Trägerbauteils kontaktiert wird;
• Fig. 2 eine schematische Ansicht der noch nicht zusammengefügten Teile einer erfindungsgemäßen Vorrichtung,
• Fig. 3 eine schematische Seitenansicht eines erfindungsgemäßen Trägerbauteils,
• Fig. 4 eine schematische Ansicht aller für die Kontaktierung notwendigen Bauteile unter Weglassung des Trägerbauteils,
• Fig. 5 eine schematische Ansicht aller für die Kontaktierung notwendigen, am Trägerbauteil angeordneten Bauteile, und
• Fig. 6 eine schematische Ansicht einer Alternative zur Figur 4 mit am Trägerbauteil angeordneten Splice-Verbindungen.

An exemplary embodiment of a device according to the invention and of a method particularly suitable for its production will be explained in more detail below with reference to the drawings. The same reference numerals in the various figures denote the same elements. It shows:

• Fig. 1 a schematic view of an electrical assembly, by means of a
• Carrier component is contacted;
• Fig. 2 a schematic view of the not yet assembled parts of a device according to the invention,
• Fig. 3 a schematic side view of a carrier component according to the invention,
• Fig. 4 a schematic view of all components necessary for the contacting, omitting the carrier component,
• Fig. 5 a schematic view of all necessary for contacting, arranged on the support member components, and
• Fig. 6 a schematic view of an alternative to FIG. 4 with arranged on the support member splice connections.

In FIG. 1 is an electronic assembly 40 electrically contacted with a cable 20 via a support member 10. A projection 16 on the carrier component 10 serves to hold further electronic components.

In FIG. 2 is the support member 10 and all other components required for the contacting are shown as an exploded view in not yet assembled state. This includes on the one hand a cable 20 which is surrounded by a cable sheath 26 and in the embodiment comprises five stranded wires 21, 22, 23, 24 and 25. The five stranded wires 21, 22, 23, 24 and 25 have a stripped portion 28 just before their end.

The carrier component 10 has a cable receptacle 11 on the side of the cable 20. The carrier component 10 furthermore has a strand holder 12 on which a plurality of fixations 13 are formed for the ends of the stranded conductors 21, 22, 23, 24 and 25. Fixations 13 are also provided at the other end of the support member 10. These serve to fix electrical conductors 17 or 18 or connectors 30. The support member 10 has in its central region between the fixings 13 a recess 14 which is large enough that a tool for stripping the arranged within the recess 14 areas of Litz wires 21, 22, 23, 24 and 25 has access to the insulations of the stranded wires 21, 22, 23, 24 and 25 in order to partially remove them to produce the desired contact.

The conductors 17 are used in the embodiment shown for contacting a Hall IC or Hall sensor 32. The lines 18 serve for contacting a capacitor 34. The Hall IC 32 and the capacitor 34 are arranged as well as a magnet 36 on a projection 16 which either formed as an integral part of the support member 10 on an extension 15 thereof or which is connected as a separate prefabricated member 16 with the support member 10. The projection 16 has a plurality of receptacles 161, 162 for mounting the electronic components (Hall sensor 32, capacitor 34, magnet 36), in which these are preferably held or locked in a form-fitting manner. The holder 162 for the Hall sensor 32 is preferably designed so that the Hall sensor 32 is held in relation to the oppositely arranged magnet 36 under a defined bias voltage.

The support member 10 is preferably after fixing the in FIG. 2 shown stranded lines 21, 22, 23, 24 and 25, the lines 17 and 18 and the connector 30 and the additional electronic components 32, 34 and 36 of a further plastic component 19 sheathed or surrounded. The further plastic component 19 can be produced as encapsulation in a mold; Alternatively, however, it can also be pushed over the carrier component 10 as a prefabricated hollow component and latched, welded or glued thereto. Due to the further plastic component 19, which forms a component of the carrier component 10 after application, a secure and permanent protection of the electrical connections from mechanical stresses and all weather influences arises in each case.

In FIG. 6 the connection between the stranded conductors 21, 22, 23, 24 and 25 and the conductors 17 and the connectors 30 is produced by splice connections 31. Splicing is a tried-and-tested process for reliable connections in the field of connection technology for printed circuit boards with strands.

In the embodiment shown (see in particular Fig. 4 ) serve the middle three stranded wires 22, 23 and 24 of the contacting with the lines 17 of the Hall sensor 32. The two wire leads 23 and 24 are additionally connected to the conductors 18 of the capacitor 34. The two outer Litzenleitungen 21 and 25 are conductively connected to the connectors 30 and can be connected, for example, in a simple manner with the ends of the assembly 40 belonging, not shown in detail coil.

The connectors 30 are preferably formed as Preci-dip contacts. These provide a particularly secure connection by a multi-point support by several lamellar contacts.

LIST OF REFERENCE NUMBERS

10

support component

11

cable storage

12

heald

13

fixation

14

recess

15

extension

16

head Start

161

Bracket (on 16)

162

Bracket (on 16)

17

ladder

18

ladder

19

Plastic component (encapsulation)

20

electric wire

21

stranded

22

stranded

23

stranded

24

stranded

25

stranded

26

cable sheath

28

(stripped) section (from 21-25)

30

Connectors

31

Splice connections

32

Hall sensor

34

capacitor

36

magnet

40

module

Claims (10)

Device for connecting an electrical component (30, 32, 34) or an assembly (40) with at least one electrical conductor (21, 22, 23, 24, 25), with a carrier component (10), into which at least one electrically conductive connecting element (17; 18; 30) is integrated, characterized in that on the support member (10) at least one fixation (12; 13) of the at least one electrical conductor (21, 22, 23, 24, 25) is integrated over which the at least an electrical conductor (21, 22, 23, 24, 25) is brought into conductive connection with the connecting element (17; 18; 30). Apparatus according to claim 1, characterized in that the carrier component (10) is formed by at least one plastic molded part. Apparatus according to claim 1 or 2, characterized in that the fixation (13) surrounds a plastic insulation of the at least one electrical conductor (21, 22, 23, 24, 25). Device according to one of the preceding claims, characterized in that the carrier component (10) has at least one recess (14) over which spaced-apart stripped sections (28) of the electrical conductors (21, 22, 23, 24, 25) are guided. Device according to one of the preceding claims, characterized in that the carrier component (10) has holders (161, 162) for electronic components (32, 34, 36). Apparatus according to claim 5, characterized in that the holders (161, 162) are provided on correspondingly shaped projections (16) of the carrier component (10). Device according to one of the preceding claims, characterized in that the carrier component (10) has a cable receptacle (11) for receiving a cable sheath (26) of a plurality of electrical conductors (21, 22, 23, 24, 25) comprising cable (20). Device according to one of the preceding claims, characterized in that the carrier component (10) is formed from two parts, of which at least one is formed as a plastic injection molded part (19) Method for producing a device according to one of Claims 1 to 8, characterized by the following method steps: a) inserting the at least partially stripped end of at least one electrical conductor (21, 22, 23, 24, 25) into a fixation (13), b) inserting at least one electrically conductive connecting element (17; 18; 30) and optionally further electronic components (32; 34; 36) into a mold, c) encapsulating the at least one partially stripped end of the at least one electrical conductor (21, 22, 23, 24, 25), the electrically conductive connecting element (17, 18, 30) and the optional further electronic components (32, 34, 36) in the mold with a non-conductive plastic for producing a carrier component (10; 19). A method according to claim 9, characterized in that the fixing (13) on a plastic molded part (10) is formed, which is encapsulated by the non-conductive plastic (19).

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