EP3364507B1 - Electrical connector for a multi-core electric cable - Google Patents

Description

The invention relates to an electrical connector for a multi-core electrical cable according to the preamble of claim 1.

Such an electrical connector comprises at least two electrical contact elements on the input or cable side, for example in the form of contact plates to which one wire of the associated electrical cable is connected (via a suitable connection point), and furthermore at least two electrical contact elements on the output side, for example in the form of contact plates, each of which has an electrical connector element, for example in the form of an electrically conductive pin, in order to be able to establish an electrical connection with a mating connector. At least one inductive electrical component - e.g., between the cable-side (input-side) electrical contact elements of the connector and its output-side electrical contact elements comprising a plurality of turns integrally formed thereon to form a coil - which can be integrally formed, for example, on the cable-side contact elements and / or the output-side contact elements and via which the cable-side and the output-side contact elements are electrically connected to one another.

This is an electrical connector for multi-core electrical cables, to which an electrical cable is connected on the input side and which is provided with electrical connector elements on the output side in order to be able to bring the electrical cable into electrical connection via the connector and in particular its connector elements with a mating connector . Such connectors are for example from the JP 2001 160463 A and the WO 2006/062629 A1 known.

In the WO 97/47083 describes an electrical connector with a common mode filter, which has a choke section and an insulating section with at least two core elements, each core element comprising two legs, and wherein the Throttle section and the insulating section are each assigned axially extending coils.

For the technical background of the invention, furthermore, the WO 2005/069445 A1 referred. When transmitting signals via electrical cables, signal conditioning is of great importance, for which purpose suitable electrical components are placed in the signal path. This leads to an increased space requirement when accommodating such components.

The invention is based on the problem of improving an electrical connector of the type mentioned at the outset with regard to the requirements described above.

This problem is solved according to the invention by creating an electrical connector with the features of claim 1.

According to this, in the case of an electrical connector of the generic type it is further provided that the turns of the inductive electrical component run spirally along a plane and that an (internal) electrical connection part is formed in one piece from the electrical component, which bridges a section of the electrical component and integrally connects it to the output-side contact elements or the cable-side contact elements (in particular as a separate part from the corresponding contact element) is fixed. The inductive electrical component can furthermore be at least partially enclosed by a jacket made of a plastic mixed with ferromagnetic material (in the ferritic phase).

The solution according to the invention allows the direct one-piece integration of at least one inductive electrical component on the input side of a connector, namely between the cable-side and the output-side contact elements of the connector, so that despite the additional range of functions associated with the inductive electrical component, no additional, separate components are required will.

According to a further development of the invention, the inductive electrical component is an integrally formed component of a carrier body, from which two support sections extend in such a way that they form an annular circumferential structure.

The electrical component can e.g. on the one hand (partially) encapsulated by the associated ferrite jacket; on the other hand, the jacket can be placed on the electrical component, e.g. by putting together individual jacket parts.

Specifically, an inductive electrical component can be arranged between the cable-side contact elements and the output-side contact elements, which comprises two electrical coils, each of which is integrally formed in the manner according to the invention on a cable-side contact element and / or an output-side contact element, such that via a respective electrical coil one cable-side and one output-side contact element (in pairs) are electrically connected to each other.

By means of support sections, the carrier body can be specifically designed to reliably absorb forces, such as torsional forces, and it can serve as a stop and locking means for other components, such as for an outer conductor of the connector.

The two support sections can each run in an arc shape. Furthermore, the two support sections can each have a free end (spaced from the respective connecting section of the carrier region) and can be shaped in such a way that the free ends of the two support sections face one another and lie opposite one another (and, if appropriate, abut against one another).

The carrier body can be formed in one piece in such a way that its support sections can be positioned by bending in such a way that they form an annular (in particular bow-shaped) contour together with the carrier region of the carrier body.

The inductive electrical component and the cable-side and output-side contact elements can be surrounded together by an encapsulation made of an electrically insulating material, in particular plastic. The extrusion coating can have an opening through which the associated ferrite jacket can be applied to the inductive electrical component.

If the components of the connector, such as the cable-side and output-side contact elements as well as the inductive electrical component - and, if applicable, the associated sheath, the carrier body and / or the encapsulation - are enclosed by an outer conductor (e.g. an electrically conductive outer tube), the carrier body can be included be connected to the outer conductor, in particular in a form-fitting and / or material-fitting manner.

The carrier body is e.g. partially arranged within the space surrounded by the outer conductor, in particular in such a way that the inductive component also lies within the space surrounded by the outer conductor. At the same time, the carrier body can be led out in sections from the outer conductor, for example through slots in the outer conductor.

Specifically, the carrier body can be arranged in such a way that its support sections lead out of the outer conductor. The support sections of the carrier body can enclose the outer conductor in sections on the outside.

The support sections of the support body are advantageously only bent over after the support body has been arranged within the space enclosed by the outer conductor and the support sections of the support body have been led out of the outer conductor, for example through slots in the outer conductor.

According to a development of the invention, the input-side (cable-side) and the output-side electrical contact elements and furthermore the inductive electrical component - and optionally the carrier body - are manufactured as components of a single, integrally shaped component, for example in the form of a lead frame, and integrated into the connector been. The lead frame is then divided into separate components if necessary.

Further details and advantages of the invention will become clear in the following description of exemplary embodiments with reference to the figures.

Figur 1A

einen grundsätzlichen Aufbau eines elektrischen Steckverbinders für ein mehradriges elektrisches Kabel mit einem steckerseitig angeordneten elektrischen Bauelement, jedoch ohne den zugehörigen Außenleiter und teilweise durchscheinend dargestellt;

Figur 1B

den elektrischen Steckverbinder aus Figur 1A zusammen mit dem zugehörigen Außenleiter;

Figur 2A

einen Querschnitt durch das an den Steckverbinder aus Figur 1A angeschlossene elektrische Kabel;

Figur 2B

eine schematische Darstellung eines Kabelschirms des elektrischen Kabels;

Figur 3A

einen Längsschnitt durch den Steckverbinder gemäß den Figuren 1A und 1B;

Figur 3B

einen Querschnitt durch den Steckverbinder gemäß den Figuren 1A und 1B;

Figur 4A

eine Explosionsdarstellung der Anordnung aus Figur 1A und 1B vor dem Umbiegen von Stützabschnitten des Trägerkörpers, jedoch ohne explizite Darstellung des elektrischen Bauelementes;

Figur 4B

die Explosionsdarstellung gemäß Figur 4A nach dem Umbiegen der Stützabschnitte;

Figur 5A

eine konkrete Ausgestaltung des (induktiven) elektrischen Bauelementes zur Integration in einen Steckverbinder gemäß den Figuren 1A und 1B, zusammen mit zugehörigen eingangsseitigen und ausgangsseitigen elektrischen Kontaktelementen;

Figur 5B

ein elektrisches Kabel zum Anschluss an den Steckverbinder;

Figur 5C

einen Außenleiter für den Steckverbinder;

Figur 5D

eine Stützhülse für den Steckverbinder.

Figur 5E

das elektrische Kabel aus Figur 5B und die Stützhülse aus Figur 5D im zusammengefügten Zustand;

Figur 6A

einen ersten Schritt beim Herstellen eines Steckverbinders aus den Komponenten der Figuren 5A bis 5E;

Figur 6B

einen zweiten Schritt beim Herstellen eines Steckverbinders aus den Komponenten der Figuren 5A bis 5E.

Figur 6C

einen dritten Schritt beim Herstellen eines Steckverbinders aus den Komponenten der Figuren 5A bis 5E;

Figur 6D

einen vierten Schritt beim Herstellen eines Steckverbinders aus den Komponenten der Figuren 5A bis 5E.

Figur 6E

einen fünften Schritt beim Herstellen eines Steckverbinders aus den Komponenten der Figuren 5A bis 5E;

Figur 6F

einen sechsten Schritt beim Herstellen eines Steckverbinders aus den Komponenten der Figuren 5A bis 5E.

Figur 6G

einen siebten Schritt beim Herstellen eines Steckverbinders aus den Komponenten der Figuren 5A bis 5E;

Figur 7A

einen ersten Schritt beim Herstellen des elektrischen Bauelementes aus Figur 5A;

Figur 7B

einen zweiten Schritt beim Herstellen des elektrischen Bauelementes aus Figur 5A;

Figur 7C

einen dritten Schritt beim Herstellen des elektrischen Bauelementes aus Figur 5A;

Figur 7D

das abschließende Konfigurieren des elektrischen Bauelementes;

Figur 8

eine Einrichtung zum Ausführen der Konfiguration nach Figur 7D.

Show it:

Figure 1A

a basic structure of an electrical connector for a multi-core electrical cable with a plug-side electrical component, but without the associated outer conductor and shown partially translucent;

Figure 1B

the electrical connector Figure 1A together with the associated outer conductor;

Figure 2A

a cross section through to the connector Figure 1A connected electrical cables;

Figure 2B

a schematic representation of a cable shield of the electrical cable;

Figure 3A

a longitudinal section through the connector according to the Figures 1A and 1B ;

Figure 3B

a cross section through the connector according to the Figures 1A and 1B ;

Figure 4A

an exploded view of the arrangement Figure 1A and 1B before bending over support sections of the carrier body, but without explicit representation of the electrical component;

Figure 4B

the exploded view according to Figure 4A after bending the support sections;

Figure 5A

a specific embodiment of the (inductive) electrical component for integration into a connector according to Figures 1A and 1B , together with associated input and output electrical contact elements;

Figure 5B

an electrical cable for connection to the connector;

Figure 5C

an outer conductor for the connector;

Figure 5D

a support sleeve for the connector.

Figure 5E

the electrical cable Figure 5B and the support sleeve Figure 5D in the assembled state;

Figure 6A

a first step in making a connector from the components of the Figures 5A to 5E ;

Figure 6B

a second step in making a connector from the components of the Figures 5A to 5E .

Figure 6C

a third step in making a connector from the components of the Figures 5A to 5E ;

Figure 6D

a fourth step in making a connector from the components of the Figures 5A to 5E .

Figure 6E

a fifth step in making a connector from the components of the Figures 5A to 5E ;

Figure 6F

a sixth step in making a connector from the components of the Figures 5A to 5E .

Figure 6G

a seventh step in making a connector from the components of the Figures 5A to 5E ;

Figure 7A

a first step in the manufacture of the electrical component Figure 5A ;

Figure 7B

a second step in the manufacture of the electrical component Figure 5A ;

Figure 7C

a third step in the manufacture of the electrical component Figure 5A ;

Figure 7D

the final configuration of the electrical component;

Figure 8

a facility to run the configuration after Figure 7D .

The figures Figure 1A and 1B show an electrical connector, on the input side in - Figure 2A Multicore electrical cable 1 shown in cross section is connected and has electrical connector elements 73, 74 on the output side for establishing an electrical connection with a mating connector. In the exemplary embodiment, the electrical cable 1 is designed as a two-wire electrical cable. The two wires 11, 12 of the cable 1 run alongside one another along the longitudinal direction L of the cable; they form parallel veins. These are each formed by an electrical line 11a, 12a, for example made of copper, and an insulating sheath 11b, 12b surrounding the respective line.

The cores 11, 12 of the cable 1 are arranged together in a cable interior defined by a cable sheath 15 running in the longitudinal direction L of the cable and surrounded by it in cross section. The cable jacket 15 consists of an electrically insulating material.

Between the serving for receiving the wires 11, 12 cable interior and the cable jacket 15 is a (in Figure 1A and 1B not visible) arranged cable shield 14. The cable shield 14 can be formed, for example, by a screen braid or also by a film or by a screen braid in combination with a film. The cable shield 14 serves to shield the cable interior and for this purpose consists of a metallic material, such as aluminum. For example, a cable shield 14 in the form of a foil can be an aluminum foil. Alternatively, a plastic film can be used for this purpose, which is coated with an electrically conductive material, such as aluminum, in particular on the inside facing the cable interior.

Shield braids are used in particular for shielding at comparatively low frequencies and cable shields in the form of foils for shielding at comparatively high frequencies (1 MHz to 10 GHz).

Figure 2B schematically shows a possible specific embodiment of a cable shield 14. According to this, the cable shield 14 is placed in the form of a film around the interior of the cable such that the two connecting sections 141, 142 of the film overlap in the circumferential direction. In the resulting overlap area, the cable shield 14 can be opened in a targeted manner if, for example when the cable is being assembled, the interior of the cable is to be accessed.

The cable shield 14 can be combined with the cable jacket 15 to form a structural unit, e.g. by the cable shield 14 being connected to the cable sheath 15 on its outer surface facing away from the cable interior, for example via an adhesive.

In addition to the wires 11, 12, drain strands 21, 22 are arranged in the interior of the cable, each of which extends together with the wires 11, 12 along the longitudinal direction L of the cable. The drain wires 21, 22 are electrically conductive and not insulated, and they are in electrical contact with the cable shield 14. Such filler strands 21, 22 serve to place the cable shield 14 in a defined manner at ground potential, and advantageously also when the cable shield 14 is locally damaged, for example in the case of a film, is torn in sections. Furthermore, the filler strands 21, 22 can additionally contribute to shielding the interior of the cable.

For assembling the cable Figure 2A to the cable as in the Figures 1A and 1B shown to be provided with an electrical connector 1, the drain wires 21, 22 had to be separated from the wires 11, 12 in order to be able to feed a respective cable component to the connector area provided for this purpose. To facilitate such assembly work, a respective drain wire 21, 22 can contain a magnetic, in particular a ferromagnetic material. This can be an alloy (based on iron, nickel, cobalt), in particular steel.

According to a variant, a respective drain wire 21, 22 consists entirely of an electrically conductive ferromagnetic material. According to another variant, a respective drain wire 21, 22 has at least one core made of a ferromagnetic material, which is surrounded by an electrically conductive material. This embodiment enables optimization of the core of the respective one Drain wire 21, 22 with a view to the magnetic properties and the optimization of the outer conductive area of a respective drain wire 21, 22 with a view to the electrical properties (also with a view to the skin effect at high frequencies). A respective drain wire 21, 22 can be formed, for example, by a steel core which is coated with copper. The coating can be done, for example, by electroplating.

Both a respective wire 11, 12 and a respective drain wire 21, 22 of the electrical cable 1 from the Figures 1A , 1B and 2A regularly consists of a plurality of individual wires.

For assembling the electrical cable 1 Figure 2A , for example, in accordance with the Figures 1A and 1B To connect to an electrical connector, a (connector side) connecting section of the cable 1 is freed from the cable jacket 15. The separation of the drain wires 21, 22 from the wires 11, 12 of the cable, for example around those cable components 11, 12; 21, 22 separate the associated connection points on the plug connector Figure 1A To be able to supply, takes place in the exemplary embodiment through the use of magnetic forces. As with Figure 2A Recognizable, a magnet M is approximated for this purpose - after the cable sheath 15 has been cut open at the plug-side cable end - of a respective drain wire 21, 22 at the corresponding cable end. This generates a magnetic field F, which has the tendency to move the corresponding drain wire 21, 22 - because of the ferromagnetic material contained therein - out of the cable interior, as shown in FIG Figure 1A shown configured state of the cable 1 becomes clear. As a result, the drain wires 21, 22 can be separated from the wires 11, 12 of the cable in a simple manner without having to work with tools on the wires 11, 12 and / or drain wires 21, 22.

It is decisive for the described method that a respective drain wire 21, 22 contains a material with such magnetic properties that the drain wire 21, 22 can be separated from the wires 11, 12 of the cable 1 under the influence of magnetic forces. This means that the magnetic properties of the drain wire 21, 22 must differ from those of a respective wire 11, 12.

By lifting a respective drain wire 21, 22 out of the interior of the cable under the influence of magnetic forces, a foil can be used in FIG Figure 2B shown type formed cable shield 14 are automatically opened. Because it is only necessary for this that the ends 141, 142 of the cable shield 14 move away from one another under the action of the outwardly moving drain strands 21, 22.

At the plug end of the cable 1 there is a support crimp 16, i.e. a support sleeve fastened by crimping, which can (optionally) be surrounded by a potting 18, for example in the form of a ferrite-core filter extrusion coating. Such a cable-side (ferrite core) filter acts here as a sheath wave filter, in particular for suppressing sheath waves in the form of high-frequency common mode interference, which e.g. are caused by electrical devices and which spread along the cable 1. That filter thus serves to eliminate or reduce common-mode interference which occurs in phase on the two parallel wires 11, 12 or the electrical lines 11a, 12a and which in the present example are caused in particular by jacket waves.

The connector connected to the end of the cable 1 on the plug side comprises an outer conductor 8, in the exemplary embodiment in the form of an outer tube, which consists of an electrically conductive material and which surrounds the plug in a ring shape in cross section or, in the exemplary embodiment, in a concrete ring shape. The outer conductor 8 extends along a longitudinal direction (cable longitudinal direction L), i.e. axially, from a first, cable-side end 8a to a second, output-side end 8b. It can be connected to the support crimp 16, e.g. cohesive (by welding).

The outer conductor 8 has a pair of first slots 81 and a pair of second slots 82. The slots 81 and 82, respectively, of a respective pair of slots are arranged opposite each other on the outer conductor 8 in the present case. In addition, the slots 81 of the first pair of slots are each offset by 90 ° relative to slots 82 of the second pair of slots in the exemplary embodiment along the circumferential direction of the outer conductor 8.

The slots 81 and 82 extend in the axial direction a of the connector (and thus also along the cable longitudinal direction L) each up to the cable-side axial end of the outer conductor 8 (and form an open end of the respective slot there).

The components of the connector arranged within the interior of the connector enclosed by the outer conductor 8 comprise first, on the input side (ie, on the cable side), electrical contact elements 31, 32 on the cable side, in the present case in the form of contact plates. A connection point in the form of a receptacle 33, 34 for an (stripped) electrical line 11a or 12a of the wires 11, 12 of the electrical cable 1 is integrally formed thereon. By defining the electrical line 11a, 12a (core) of a respective wire 11, 12 of the cable 1 in the respectively assigned receptacle 33, 34, there is over that (electrically conductive) receptacle 33 or 34 makes an electrical contact to a respectively assigned cable-side electrical contact element 31, 32.

On the output side (and at a distance from the cable-side contact elements 31, 32 in the axial direction a), the plug connector (in the interior enclosed by the outer conductor 8) has second, output-side contact elements 71, 72, each of which has a plug element 73 and 74, respectively, in FIG Form of a connector pin is formed, via which the connector can be electrically connected to a mating connector. In the exemplary embodiment, the plug elements 73, 74 project in the axial direction a from the associated contact element 71 or 72 on the output side.

In the present case, a carrier body 4 and an electrical component 5, for example in the form of an electrical filter element, are arranged between the cable-side contact elements 31, 32 and the output-side contact elements 71, 72, the carrier body 4 representing an optional addition to the arrangement. The term "electrical component" is expressly intended to include electronic components and in particular semiconducting components; still active electrical components as well as passive electrical components. In particular, the electrical component can be a passive electrical filter, such as e.g. a common mode filter.

The electrical component 5 has (as an inductive component) two coils 51, 52. On the one hand, it is formed in one piece with the cable-side contact elements 31, 32 and, on the other hand, it is also electrically connected to the output-side contact elements 71, 72 via connecting parts 53, 54. This means that the wires 11, 12 of the electrical cable 1 are each electrically connected to the plug elements 73, 74 of the plug connector via the electrical component 5. Electrical signals which are fed to the plug connector via the wires 11, 12 of the cable 1 thus pass through the electrical component 5 before they are output via the plug elements 73, 74 to a mating connector and thus to an electrical assembly assigned to the mating connector.

In particular, the cable-side (input-side) contact elements 31, 32 on the one hand can be electrically connected in pairs to the output-side contact elements 71, 72 via the electrical component 5. That is, each of the cable-side contact elements 31, 32 is connected via the electrical component 5 to exactly one of the output-side contact elements 71, 72, as follows based on FIG Figures 4A and 4B will be explained in more detail. In the case of an electrical component 5 designed as a common mode filter, common mode interference can occur with such a configuration are eliminated or reduced, which occur (simultaneously) on the two parallel wires 11, 12 and the electrical lines 11a, 12a.

The (optional) carrier body 4 is designed here as a carrier bracket. A support section 43 or 44 of the support body 4 extends from connection sections 41, 42 of the support body 4. This runs curved (arc-shaped) in the circumferential direction along the outer conductor 8. The two support sections 43, 44 of the carrier body 4 form an annular contour.

In the area of the first and second connecting sections 41, 42, the carrier body 4 penetrates one of the first slots 81 of the outer conductor 8 in the radial direction. The electrical component 5 combined in the exemplary embodiment with the carrier body 4 to form a one-piece assembly, like parts of the carrier body 4, is arranged in the interior of the outer conductor 8 and is therefore surrounded by the latter. In the region of its connecting sections 41, 42, however, the carrier body 4 is led radially (in each case through one of the first slots 81) out of the interior of the outer conductor 8.

The supporting sections 43, 44 of the carrier body 4 extending from the connecting sections 41, 42 accordingly extend outside the space enclosed by the outer conductor 8. In the exemplary embodiment, the support sections 43, 44 each run arcuately in the circumferential direction along the outer wall of the outer conductor 8. Together, the two support sections 43, 44 encompass the outer conductor 8 in the circumferential direction at an angle of approximately 180 °.

The support sections 43, 44 of the carrier body 4 each have a free end 43a, 44a, which faces away from the connecting section 41 and 42, at which the respective support section 43 and 44 extends from the carrier body 4. The free ends 43a, 44a of the support sections 43, 44 face one another and lie opposite one another in order to form the described annular contour. In the exemplary embodiment, the free ends 43a, 44a are (slightly) spaced from one another. In another embodiment, these can also be in contact with one another.

In the second slots 82 of the outer conductor 8, the drain wires 21, 22 extending from the electrical cable 1 are arranged with their respective free end sections 21a and 22a, so that the second slots 82 are partially closed by the drain wires 21, 22. The drain wires 21, 22 can be within the respective second Slot 82 cohesively, for example by soldering or welding. More information on this is given below using the Figures 3A and 3B are explained.

The space between the outer conductor 8 and the components 31-34, 4, 5, 61-64 and 71-74 of the plug connector arranged therein is partially covered by a potting compound 85 (potting compound), e.g. in the form of an injection molded part, filled. In the present case, this lies on the inside of the outer conductor 8 facing the inside of the plug and, together with the outer conductor 8, encloses the said components 31-34, 4, 5, 61-64 and 71-74 of the plug connector. The encapsulation 85 has channels 86 in which the free end sections 21a, 22a of the drainage strands 21, 22 are received and guided.

In addition to the functions already described as a holder for the electrical component 5, the carrier body 4 - as a (multi) function bracket - can also perform a number of other functions on the plug connector.

In this case, the carrier body 4 serves as a positioning means for positioning the outer conductor 8 on the plug connector. The positioning of the outer conductor 8 relative to the carrier body 4 takes place concretely in such a way that the outer conductor 8 with its first slots 81, which are open on the cable side (i.e. at the respective end 81a facing the electrical cable 1), is pushed over the carrier body 4, more precisely over the Connecting portions 41, 42 of the carrier body 4 until the closed end 81b of the respective slot 81 opposite the open cable-side end 81a engages with the carrier body 4, as in FIG Figure 1B shown. That is, the closed ends 81b of the slots 81 serve as stops for positioning the outer conductor 8 on the carrier body 4 (along the longitudinal direction L of the cable).

At the same time, the outer conductor 8 (via the first slots 81) is arranged in a form-fitting manner on the carrier body 4. The outer conductor 8 can also be cohesive, e.g. be connected to the carrier body 4 by welding.

At its open, cable-side end 81a, a respective first slot 81 of the outer conductor 8 can be provided with an insertion phase in order to avoid damage to the outer conductor 8 when it is pushed onto the carrier body 4.

According to a development of the invention, the carrier body 4 can each have axially extended extensions 46 which cover the first slots 81 (in sections), cf. Figure 1B , if the carrier body 4 and the outer conductor 8 to each other as intended are aligned and positioned. Such extensions 46 can also serve as guide means for guiding the outer conductor 8 when it is pushed onto the carrier body 4. Furthermore, the extensions can act as an EMC labyrinth, ie not only reduce the free line of sight, but also counteract the penetration of electromagnetic waves into the space within the outer conductor 8.

In the exemplary embodiment, further functions of the carrier body 4 lie in the tension and pressure relief of the components 31-34, 4, 5, 71-74 of the plug connector arranged in the interior of the outer conductor 8 with the action of forces / torques on the outer conductor 8 and in the train. and pressure relief of the drainage strands 21, 22, in particular under the action of torsional forces (along the circumferential direction of the outer conductor 8). This prevents shear off of the filler strands 21, 22.

A coding housing can also be positioned and locked onto the carrier body 4. Furthermore, for AC decoupling (by means of a capacitor) between the carrier body 4 and the contact elements 31, 32; 71, 72 a capacitor can be arranged.

The Figures 3A and 3B show a longitudinal section ( Figure 3A ) and a cross section ( Figure 3B ) through the electrical connector from the Figures 1A and 1B . In this way, in particular the arrangement of axially extending extensions 46 of the carrier body 4 in the first slots 81 of the outer conductor 8 on the one hand and the arrangement of the filler strands 21, 22 in the second slots 82 of the outer conductor 8 on the other hand are illustrated.

Mostly based on Figure 3B it is also shown how torsional forces T1 acting on the outer conductor 8 or on the encapsulation 85 are introduced into the carrier body 4, which in the cross-sectional illustration of FIG Figure 3B is exemplified by the extensions 46. It also shows how torsional forces T2 acting on the filler strands 21, 22 are introduced into the outer conductor 8 (from which they can in turn be released into the carrier body 4). In this way, pressure and strain relief of the filler strands 21, 22 can be achieved under the action of torsional forces, which in particular prevents the fillet strands from shearing off.

Furthermore, the point of view already described further above is clarified again, according to which the carrier body 4, here represented in particular by the axially extended lateral extensions 46 (in two spatial levels), can serve as a guiding aid when pushing on and positioning the outer conductor 8.

At the same time, it becomes clear how an EMC labyrinth is formed by covering the first slots 81 of the outer conductor 8 by means of the extensions 46 of the carrier body 4, in particular because of the flanged design of the extensions 46 (which are mushroom-shaped in cross section) in order to prevent the penetration of electromagnetic waves into to prevent the space surrounded by the outer conductor 8.

Specifically in Figure 3A those points of the second slots 82, namely in the exemplary embodiment end sections 82a in the form of beveled areas, can also be seen, in the vicinity of which a respective drain wire 21, 22 (with its respective free end section 21a, 22a) is fixed to the outer conductor 8, for example cohesively by welding, soldering, gluing, etc. on a support (plateau 82b) formed by the respective end section 82a. This further ensures that the ground connection of the cable shield via the drainage strands 21, 22 to the outer conductor 8 remains stable over the long term and, in particular, the contact resistance is constant over time. The bevelled end sections 82a and the supports 82b formed thereby continue to serve for the transmission of torsional forces. In addition, the beveled end sections 82a and the supports 82b form additional guide aids when the outer conductor 8 is pushed onto the potting compound 85.

Figure 4A shows an exploded view of the electrical connector from the Figures 1A and 1B together with the components directly adjoining it on the cable side, specifically before the bending of the support sections 43, 44 of the carrier body 4 Figures 1A and 1B ). The carrier body 4 can with the electrical component, which in Figure 4A For reasons of clarity, it is not shown in detail, can be combined to form a one-piece assembly, as will be explained below with reference to FIG Figures 5A to 8 will be explained in more detail.

The cable side is in Figure 4A the electrical cable 1 with the wires 11, 12 and their respective core (electrical line 11a or 12a) as well as with the drain wires 21, 22 and with the cable jacket 15. The end of the electrical cable 1 facing the electrical connector is to be provided with the support crimp 16 already described, to which in turn a potting 18 is applied.

On the outside, the plug connector is surrounded by the outer conductor 8 with the first and second slots 81 and 82, the space between the carrier body 4 - with the exception of the support sections 43, 44 leading to the outside - and the outer conductor 8 being filled by a potting compound 85.

Based on the exploded view of the Figure 4A The assembly of the connector, including the connection of the electrical cable 1, can be described as follows:
First, the electrical cable 1 is provided and provided with the supporting crimp 16 at its free end to which it is to be connected to the associated electrical connector. On the electrical cable 1, its drain wires 21, 22 have already been separated, as shown in FIG Figures 2A and 2B described.

The lead frame is then provided, from which the carrier body 4 and the cable-side and output-side contact elements 31, 32; 71, 72 together with the further components 33, 34; 73, 74 are formed. The stripped free ends of the wires 11, 12 of the electrical cable 1, at each of which the associated core is exposed in the form of an electrical line 11a, 12a, are each in contact with a cable-side contact element 31, 32 via its receptacle 33, 34 Intervention. An additional connection is preferably made in a materially bonded manner at the respective contact or engagement area, for example by soldering or welding.

The components defining the interior of the electrical connector, namely the carrier body 4 and the contact elements 31, 32; 71, 72 with the further associated components 33, 34; 73, 74 and the electrical component 5 arranged on the carrier body 4, including the associated wires, are then provided with the insulating encapsulation 85 by injection molding to form the channels 86.

Now the outer conductor 8 is pushed (by means of the first slots 81) over the aforementioned components of the electrical connector, the outer conductor 8 being guided through the carrier body 4. Then the filler strands 21, 22 are compared with their free end sections 21a, 22a Figures 3A and 3B , are introduced into the second slots 82 of the outer conductor 8 provided for this purpose and are fixed there in a materially integral manner, for example by soldering, welding or gluing. And there are the support portions 43, 44 of the carrier body 4 to form the annular configuration from the Figures 1A and 1B bent over as in Figure 4B shown, and optionally also cohesively, for example by welding, fixed to the outer conductor 8.

Finally, the transition between the electrical cable 1 and the connector is provided with the encapsulation 18, which in particular encloses the support crimp 16.

The Figures 5A to 5E show the essential components of an electrical connector of the above based on the Figures 1A to 4B described type, in particular the design of the electrical component 5 is shown in detail.

The specific design of the following based on the Figures 5A to 8 The electrical connector to be described manifests itself in particular in the Figure 5A Inductive electrical component 5 shown as well as - optionally - in the configuration of the carrier body 4 adapted to it. The electrical cable 1, as in Figure 5B shown, the outer conductor 8, as in Figure 1C shown, the support sleeve 16 (support crimp), as in Figure 5D shown, and the assembly of the electrical cable 1 with the support crimp 16, as in Figure 5E are, in contrast, essentially unchanged from that further above on the basis of the Figures 1A to 4B described arrangement, so that reference is made to those description passages belonging to these figures with respect to those components.

This in Figure 5A Electrical component 5 shown is designed as an inductive electrical component. This has windings in the form of electrical coils 51, 52, which are made in one piece with the cable-side contact elements 31, 32, ie, are integrally formed thereon. Specifically, in the exemplary embodiment, the inductive electrical component 5 comprises Figure 5A two coils 51 and 52 each formed by a plurality of windings, each of which is integrally formed on one of the cable-side contact elements 31, 32. The coils 51, 52 each run along a (common) plane and are spiral (wound). In addition, the two coils 51, 52 in the exemplary embodiment have two coil sections 51a, 52a which face one another and thereby run side by side.

The windings of the coils 51, 52 can, for example, each have been produced by laser cutting from a base element formed on the cable-side contact elements 31, 32, as will be explained below with reference to FIG Figures 7A to 7C will be described.

Each coil 51, 52 also has an (inner) connecting part 53 or 54 (in the form of a contact tongue), via which an electrical connection to the output-side contact elements 71, 72 can be established. Specifically, exactly one electrical connection between a coil 51 or 52 and an associated output-side contact element 71 or 72 is to be established in the exemplary embodiment by means of each of the two connection parts 53, 54. As a result, according to the exemplary embodiment, a cable-side electrical contact element 31 or 32 is in electrical connection with exactly one output-side electrical contact element 71, 72 via a coil 51 or 52. In other words, the cable-side and output-side contact elements 31, 32; 71, 72 connected to each other in pairs via a coil 51 or 52.

As already with the Figures 1A to 4B explained, are each formed on the cable-side electrical contact elements 31, 32 connection points 33, 34 in the form of a receptacle; and plug elements 73, 74 in the form of plug pins are molded onto the output-side electrical contact elements 71, 72.

The inductive electrical component 5 and the cable-side electrical contact elements 31, 32 and the output-side electrical contact elements 71, 72 (in the exemplary embodiment in each case with the associated connection points 33, 34 or plug elements 73, 74) in the present case form part of a one-piece stamped grid. The lead frame comprises a plurality of separation points S, in the exemplary embodiment in the form of webs, at which the material of the lead frame can be severed in accordance with the intended purpose in order to use it to initially separate components of the lead frame from one another. At which points the lead frame is cut to separate the components connected via it depends on which circuit diagram is to be produced with the lead frame in individual cases. If, for example, the coils 51, 52 are to be in electrical contact with the output-side contact elements 71, 72 only via the connection parts 53, 54 provided for this purpose, then the connections of the output-side connection elements 71, 72 with the other components of the lead frame can be connected to the corresponding separation points S are cut.

According to Figure 5A shows the arrangement shown in addition to the inductive electrical component 5 and the associated cable-side and output-side contact elements 31, 32; 71, 72 furthermore have a carrier body 4, which in one piece together with the electrical component 5 and the cable-side and output-side contact elements 31, 32; 71, 72 is shaped.

As already described further above, the carrier body 4 comprises in particular support sections 43, 44 which are bent over in order to produce their final configuration. The support sections 43, 44 are in the embodiment of the Figure 5A via a connecting section 41 or 42 in one piece on the cable side Contact elements 31, 32 formed. Axial extensions 46 of the carrier body 4 (with lateral bends 46a) are also integrally formed thereon. By separating at the web-like separating points S provided for this purpose, the carrier body 4 can optionally be separated from the electrical component 5 and the cable-side and output-side electrical contact elements 31, 32; 41, 42 are separated.

The electrical component 5 and the cable-side and output-side electrical contact elements 31, 32; 71, 72 consist of an electrically conductive material. This can therefore also apply to the lead frame as a whole or to its other components, such as in particular the carrier body 4.

To manufacture the electrical connector is according to Figure 6A first the electrical cable 1 is connected to the cable-side contact elements 31, 32. Specifically, for this purpose the insulated free end of a respective electrical line 11a, 12a of the wires 11, 12 of the cable 1 is applied to the associated connection point 33, 34 of the cable 1 and fixed there, for example by welding. The drain wires 21, 22 of the electrical cable 1 are initially still exposed.

Subsequently, the internal connection part 53, 54 of a respective coil 51, 52 is bent over in such a way that it bridges a section of the corresponding coil 51, 52 and electrically contacts the respectively assigned output-side contact element 71, 72, compare Figure 6B . A respective connection part 53, 54 can in turn be fixed to the associated output-side contact element 71 or 72, in particular by welding.

In a further step, after Figure 6C the assembly formed by the inductive electrical component 5, by the cable-side electrical contact elements 31, 32 (with the connection points 33, 34) and by the output-side contact elements 71, 72 (with the plug elements 73, 74) and optionally by the carrier body 4 at least partially encapsulated with an (electrically) insulating material to form a potting 85. The potting 85, including its channels 86, essentially corresponds to that already based on Figure 1B explained potting; however, he points out Figure 6C additionally opening areas 87 over which, as in Figure 6D shown, a ferrite jacket 9 can be introduced, which partially encompasses or encloses the two coils 51, 52 of the electrical component 5. Specifically, in the exemplary embodiment, the ferrite sheath 9 encloses the mutually facing sections 51a, 52a of the two coils 51, 52 (tubular).

In the exemplary embodiment, the ferrite jacket 9 is formed by a plastic mixed with ferromagnetic material (in the ferritic phase).

The ferrite jacket 9 can be produced on the one hand by overmolding the adjacent sections of the coils 51, 52; or individual parts of the ferrite jacket 9, for example two jacket halves, are inserted through the opening regions 87 and plugged together in such a way that they encompass the corresponding sections 51a, 52a of the coils 51, 52.

The next step is according to Figure 6E a (tubular) outer conductor 8 pushed over the arrangement until it comes to a stop with the carrier body 4, as described above with reference to FIG Figures 4A and 4B has been described in detail. Then the filler wires 21, 22 are inserted into the associated second slots 82 of the outer conductor 8; and the support sections 43, 44 of the carrier body 4 are further bent in such a way that they encompass the outer conductor 8 on its outer circumference, compare Figure 6F . The filler strands 21, 22 and / or the support sections 43, 44 can also be attached to the outer conductor 8, for example by (simultaneous) welding.

Furthermore, according to Figure 6G a ferrite can be injected onto the outer conductor 8 and / or onto exposed line sections.

The Figures 7A to 7D illustrate the production of the coils 51, 52, starting from a lead frame, which first has a (plate-like, one-piece, each with a cable-side contact element 31 or 32) base element 5a or 5b, as in FIG Figure 7A shown. According to the Figures 7B and 7C a respective coil 51, 52 is produced from the corresponding base element 5a or 5b by laser cutting, an electrical connection part 53 or 54 also being formed in the central opening of a respective coil 51, 52.

The defined flipping of the connection parts 53, 54 so that they each contact exactly one associated output-side contact element 73 or 74 is based on the Figures 7D and 8th shown in more detail. Thereafter, a holder H (with clamping action) and two bending punches B1, B2 are used to bend the connecting part 53, 54 of a respective coil 51, 52, of which one, first bending punch B1 acts transversely to the direction of extension of the connecting part 53, 54, around this from the plane of the respective coil 51, 52 press, and of which the other, second bending punch B2 acts parallel to the plane of the respective coil 51, 52 on the associated connecting part 53 or 54 in order to move it in the direction of the associated output-side contact element 71 or 72. In addition, a bending jaw B3 is used to ensure, during the action of the bending punches B1, B2, that the connecting part 53, 54 bridges the section of the respective coil 51, 52 to be bridged without touching it. The connecting part (for example 53) is then pressed against the assigned output-side contact element (73) by means of a welding mechanism M and welded to it.

Claims (11)

1. Electrical plug-in connector for a multicore electric cable, comprising

   - at least two cable-side electrical contact elements (31, 32) with associated electrical connection points (33, 34), to each of which a core (11, 12) of the electric cable (1) is to be connected, and

   - at least two output-side electrical contact elements (71, 72), from each of which an electrical plug element (73, 74) protrudes, it being possible to establish an electrical connection with a mating plug by means of the said electrical plug element,
   wherein an inductive electrical component (5) is arranged between the cable-side contact elements (31, 32) and the output-side contact elements (71, 72), which inductive electrical component is integrally formed on the cable-side contact elements (31, 32) and/or the output-side contact elements (71, 72) and by means of which inductive electrical component the cable-side and the output-side contact elements (31, 32; 71, 72) are electrically connected to one another, wherein the electrical component (5) comprises at least one coil (51, 52) with a plurality of integrally formed turns,
   characterized
   in that the turns of a respective coil (51, 52) run in a helical manner along one plane, and in that an internal connection part (53, 54) is integrally shaped from a respective coil (51, 52) and bent over in such a way that it respectively bridges a section of the corresponding coil (51, 52), wherein the connection part (53, 54) is further cohesively fixed to the output-side contact elements (71, 72) or the cable-side contact elements (31, 32) .
2. Electrical plug-in connector according to Claim 1, characterized in that the electrical component (5) is at least partially enclosed by a casing (9) composed of a plastic admixed with ferromagnetic material.
3. Electrical plug-in connector according to Claim 2, characterized in that the electrical component (5) is an integrally formed constituent part of a carrier body (4) from which two supporting sections (43, 44) lead away in such a way that the two supporting sections (43, 44) form an annularly encircling structure.
4. Electrical plug-in connector according to either of Claims 2 and 3, characterized in that the electrical component (5) is at least partially encapsulated by injection moulding by the casing (9).
5. Electrical plug-in connector according to either of Claims 2 and 3, characterized in that the casing (9) is fitted onto the electrical component (5).
6. Electrical plug-in connector according to one of the preceding claims, characterized in that the electrical component (5) which is arranged between the cable-side contact elements (31, 32) and the output-side contact elements (71, 72) comprises two coils (51, 52) which are each integrally formed on a cable-side contact element (31, 32) and/or an output-side contact element (71, 72) in such a way that in each case one cable-side and one output-side contact element (31, 32; 71, 72) are electrically connected to one another by means of a respective coil (51, 52) of the electrical component (5).
7. Electrical plug-in connector according to one of the preceding claims, characterized in that the electrical component (5) and also the cable-side and output-side contact elements (31, 32; 71, 72) are jointly surrounded by an injection-moulding encapsulation (85) composed of an insulating material.
8. Electrical plug-in connector according to one of Claims 2 to 6 and Claim 7, characterized in that the injection-moulding encapsulation (85) has at least one opening (87) through which the casing (9) can be placed onto the electrical component (5).
9. Electrical plug-in connector according to one of the preceding claims, characterized in that the plug-in connector has an interior which is enclosed by an external conductor (8) and in which the electrical component (5) and also the cable-side and output-side contact elements (31, 32; 71, 72) are arranged at least in sections.
10. Electrical plug-in connector according to Claims 3 and 9, characterized in that the external conductor (8) is fixed to the carrier body (4).
11. Electrical plug-in connector according to one of the preceding claims, characterized in that the cable-side and the output-side electrical contact elements (31, 32; 71, 72) and also the electrical component (5) are produced as constituent parts of an individual, integrally formed structural part, in particular in the form of a leadframe.

Images