EP3528351A1 - Electrical connector for a multi-core electric cable - Google Patents

Abstract

The invention relates to an electrical connector for a multi-core electrical cable, having at least two cable-side electrical contact elements (31, 32), to each of which a wire (11, 12) of the electrical cable (1) is to be connected, and having at least two output side electrical contact elements (71, 72), of which in each case a plug element (73, 74) goes off, via which an electrical connection with a mating connector can be produced. In this case, between the cable-side contact elements (31, 32) and the output-side contact elements (71, 72) at least one inductive electrical component (5) is arranged, which is integrally formed on the cable-side contact elements (31, 32) and / or the output-side contact elements (71, 72) is integrally formed and via which the cable-side and the output-side contact elements (31, 32; 71, 72) are electrically connected to one another, wherein the electrical component (5) has a plurality of turns integrally formed thereon for forming at least one coil (51, 52). comprising, wherein the electrical component (5) is an integrally molded part of a support body (4) from which two support portions (43, 44) depart such that the two support portions (43, 44) form an annular circumferential structure, and at least partially is enclosed by a jacket (9) made of a plastic mixed with ferromagnetic material.

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 input or cable-side electrical contact elements, for example in the form of contact plates, to each of which a wire of the associated electrical cable (via a suitable connection point) is connected, as well as at least two output-side electrical contact elements, for example in the form of contact plates, of which in each case an electrical plug element, for example in the form of an electrically conductive pin, goes off in order to be able to establish an electrical connection with a mating connector. In this case, between the cable-side (input side) electrical contact elements of the connector on the one hand and its output side electrical contact elements on the other hand at least one inductive electrical component - eg comprising a plurality of integrally formed thereon turns to form a coil - Arranged, for example, can be integrally formed 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 together.

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

In the WO 97/47083 An electrical connector is described with a common mode filter having a choke section and an insulating section with at least two core elements, each core element comprising two legs, and with each axially extending coil associated with the choke section and the insulating section.

To the technical background of the invention is further on the WO 2005/069445 A1 directed. In the transmission of signals via electrical cables, the signal conditioning is regularly of great importance, for which appropriate electrical components are placed in the signal path. This leads to an increased space requirement for accommodating such components.

The invention is based on the problem to improve an electrical connector of the type mentioned in view of the above requirements.

This problem is inventively solved by the provision of an electrical connector with the features of claim 1.

Thereafter, the inductive electrical component is an integrally molded part of a carrier body, depart from the two support portions such that they form an annular circumferential structure, wherein the electrical component at least partially by a jacket made of a ferromagnetic material (in the ferritic phase) offset plastic is enclosed. The inductive electrical component may comprise a plurality of turns integrally formed thereon.

The windings of the inductive electrical component run in this case, for example. spiral along a plane.

The electrical component may e.g. on the one hand (partially) to be 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.

According to one embodiment of the invention, an electrical connection part is integrally formed out of the electrical component, which bridges a section of the electrical component and which is fixed cohesively to the output-side contact elements or the cable-side contact elements (as a separate part from the corresponding contact element).

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

In this case, the carrier body can be designed specifically for the reliable absorption of 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 extend arcuately. Furthermore, the two support sections may each have a free end (spaced from the respective connection section of the support section) and be shaped in such a way that the free ends of the two support sections face each other and face each other (and possibly abut one another).

The carrier body may be integrally formed in such a way that its supporting 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 jointly surrounded by an encapsulation of an electrically insulating material, in particular of plastic. In this case, the encapsulation may 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 and the inductive electrical component - and optionally the associated jacket, the carrier body and / or the overmoulding - are enclosed by an outer conductor (for example an electrically conductive outer tube), e.g. the carrier body to be connected to the outer conductor, in particular form-fitting and / or material fit.

The carrier body is e.g. partially disposed within the space surrounded by the outer conductor, in particular such that the inductive component is located within the space surrounded by the outer conductor. At the same time, the carrier body may be led out in sections from the outer conductor, for example through slots of the outer conductor.

Specifically, the carrier body may be arranged such that it is led out with its support portions of the outer conductor. In this case, the support sections of the carrier body can enclose the outer conductor sections on the outside.

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

According to one embodiment of the invention, the input side (cable side) and the output side electrical contact elements and further the inductive electrical component - and optionally the carrier body - as components of a single, integrally molded component, for example in the form of a punched grid, manufactured and integrated into the connector Service. If necessary, the stamped grid is subdivided into separate components.

Further details and advantages of the invention will become apparent 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 connector side arranged electrical component, but without the associated outer conductor and partially translucent shown;

FIG. 1B

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

FIG. 2A

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

FIG. 2B

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

FIG. 3A

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

FIG. 3B

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

FIG. 4A

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

FIG. 4B

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

FIG. 5A

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

FIG. 5B

an electrical cable for connection to the connector;

FIG. 5C

an outer conductor for the connector;

FIG. 5D

a support sleeve for the connector.

FIG. 5E

the electrical cable off FIG. 5B and the support sleeve FIG. 5D in the assembled state;

FIG. 6A

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

FIG. 6B

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

FIG. 6C

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

FIG. 6D

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

FIG. 6E

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

FIG. 6F

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

FIG. 6G

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

FIG. 7A

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

FIG. 7B

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

FIG. 7C

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

Figure 7D

the final configuration of the electrical component;

FIG. 8

a means for performing the configuration Figure 7D ,

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

The wires 11, 12 of the cable 1 are arranged together in a cable jacket 15 which is defined by a cable jacket 15 running in the cable longitudinal direction L and is surrounded by the cable interior in a ring-shaped manner in cross-section. The cable sheath 15 consists of an electrically insulating material.

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

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

FIG. 2B schematically shows a possible concrete embodiment of a cable shield 14. Hereinafter, the cable shield 14 is wrapped in the form of a film around the cable inside, that the two connecting portions 141, 142 of the film overlap in the circumferential direction. In the overlap region resulting therefrom, the cable shield 14 can be selectively opened if - for example when assembling the cable - the cable interior is to be accessed.

The cable shield 14 may be combined with the cable jacket 15 to form a structural unit, e.g. in that the cable shield 14 is connected to the cable sheath 15 on its outer surface remote from the cable interior, for example via an adhesive.

In addition to the wires 11, 12 in the cable interior Beilauflitzen 21, 22 are arranged, each extending together with the wires 11, 12 along the cable longitudinal direction L. The Beilauflitzen 21, 22 are electrically conductive and not isolated, and they are in electrical contact with the cable shield 14. Such Beilauflitzen 21, 22 serve to define the cable shield 14 defined to ground potential, and advantageously even if the cable shield 14 is locally damaged, is torn in sections in the case of a film. Furthermore, the battens 21, 22 can additionally contribute to the shielding of the cable interior.

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

According to one variant, a respective fillet slit 21, 22 consists entirely of an electrically conductive ferromagnetic material. According to another variant, a respective Beilauflitze 21, 22 at least one consisting of a ferromagnetic material core, which is surrounded by an electrically conductive material. This embodiment makes it possible to optimize, on the one hand, the core of a respective fill-strands 21, 22 with regard to the magnetic properties and the optimization of the outer conductive region of a respective fill-strands 21, 22 with regard to the electrical properties (also with regard to the skin effect at high levels) frequencies). Thus, a respective Beilauflitze 21, 22 may be formed approximately by a core of steel, which is coated with copper. Coating can be done by electroplating, for example.

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

For assembling the electric cable 1 from FIG. 2A , for example, this according to the Figures 1A and 1B To connect to an electrical connector, a (connector-side) connecting portion of the cable 1 is released from the cable sheath 15. Separating the battens 21, 22 from the wires 11, 12 of the cable, about those cable components 11, 12; 21, 22 separated from the respective associated connection points on the connector Figure 1A to be able to perform, takes place in the embodiment by the use of magnetic forces. As based on FIG. 2A recognizable, this is - after cutting the cable sheath 15 at the plug-side cable end - a respective Beilauflitze 21, 22 at the corresponding cable end a magnet M approximated. This generates a magnetic field F, which has the tendency to move the corresponding Beilauflitze 21, 22 - because of the ferromagnetic material contained therein - out of the cable interior, as with reference to the in Figure 1A shown configured state of the cable 1 is clear. As a result, the Beilauflitzen 21, 22 in a simple manner from the wires 11, 12 of the cable separate, without tools with the wires 11, 12 and / or Beilauflitzen 21, 22 would have to be handled.

It is decisive for the method described that a respective fillet slit 21, 22 contains a material with such magnetic properties that the slits 21, 22 can be separated from the strands 11, 12 of the cable 1 under the influence of magnetic forces. That is, the magnetic properties of the fillets 21, 22 must be different from those of a respective wire 11, 12.

By lifting a respective Beilauflitze 21, 22 from the cable interior under the action of magnetic forces can thereby a through a film of in FIG. 2B illustrated type cable shield 14 are opened automatically. Because it is only necessary for this that the ends 141, 142 of the cable shield 14 under the action of moving outward Beilauflitzen 21, 22 from each other.

At the plug-side end of the cable 1, a support crimp 16, ie a support sleeve fastened by crimping, is applied, which (optionally) can be surrounded by a potting 18, for example in the form of a ferrite-core-filter encapsulation. Such a cable-side (ferrite core) filter acts here as a jacket wave filter, in particular for the suppression of sheath waves in the form of high-frequency common mode noise, which are caused for example by electrical equipment and propagate along the cable 1. The filter thus serves to eliminate or reduce common-mode noise which occurs in phase at the two parallel wires 11, 12 or the electrical leads 11a, 12a and which are caused in particular by sheath waves in the present example.

The adjoining the plug-side end of the cable 1 connector comprises an outer conductor 8, in the embodiment in the form of an outer tube, which consists of an electrically conductive material and which surrounds the plug in cross-section annular or concrete in the exemplary embodiment annular. The outer conductor 8 extends along a longitudinal direction (cable longitudinal direction L), that is, axially, from a first, cable-side end 8a to a second, output-side end 8b. It may be connected to the support crimp 16, e.g. cohesively (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 of a respective pair of slots are arranged in the present case in each case opposite one another on the outer conductor 8. In addition, the slots 81 of the first pair of slots are arranged offset relative to slots 82 of the second pair of slots in the embodiment along the circumferential direction of the outer conductor 8 in each case by 90 °.

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

The components of the connector arranged within the interior of the connector enclosed by the outer conductor 8 comprise on the input side (i.e., on the cable side) first, cable-side electrical contact elements 31, 32, in the form of contact plates. To each of these is integrally formed a connection point in the form of a receptacle 33, 34 for a (stripped) electrical line 11a and 12a of the wires 11, 12 of the electric cable 1. By fixing the electrical line 11a, 12a (core) of a respective core 11, 12 of the cable 1 in the respective associated receptacle 33, 34, there is an electrical contact with a respectively assigned cable-side via those (electrically conductive) receptacle 33 or 34 electrical contact element 31, 32nd

On the output side (and spaced from the cable-side contact elements 31, 32 in the axial direction a), the connector (in the space enclosed by the outer conductor 8 interior) second, output-side contact elements 71, 72, to each of which a male member 73 and 74, in this case Form of a plug pin, is formed, via which the connector is electrically connected to a mating connector. The plug elements 73, 74 are in the exemplary embodiment in the axial direction of a from the associated output-side contact element 71 and 72 from.

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 supplement to the arrangement. The term "electrical component" should explicitly include electronic components and in particular semiconducting components; furthermore active electrical components as well as passive electrical components. In particular, the electrical component may be a passive electrical filter, such as e.g. a common mode filter, act.

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

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

The (optional) support body 4 is in the present case designed as a support bracket. Of connecting portions 41, 42 of the support body 4 is in each case a support portion 43 and 44 of the support body 4 from. This extends curved (arcuate) in the circumferential direction along the outer conductor 8. The two support portions 43, 44 of the support body 4 form an annular contour.

In the region of the first and second connecting portion 41, 42, the carrier body 4 penetrates in each case one of the first slots 81 of the outer conductor 8 in the radial direction. In this case, the combined in the embodiment with the support body 4 to a one-piece assembly electrical component 5, as well as parts of the support body 4, arranged in the interior of the outer conductor 8, so it is surrounded by this. In the region of its connecting sections 41, 42, however, the carrier body 4 is led out radially (each through one of the first slots 81) out of the interior of the outer conductor 8.

The outgoing of the connecting portions 41, 42 support portions 43, 44 of the support body 4 accordingly extend outside the space enclosed by the outer conductor 8 space. In the exemplary embodiment, the support sections 43, 44 each extend arcuately in the circumferential direction along the outer wall of the outer conductor 8. Together, the two support sections 43, 44 surround the outer conductor 8 in the circumferential direction over 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 or 42, on which the respective support section 43 or 44 leaves the carrier body 4. The free ends 43a, 44a of the support portions 43, 44 face each other and face each other to form the described annular contour. In the embodiment, the free ends 43a, 44a (slightly) spaced apart. In another embodiment, these may also rest against one another.

In the second slots 82 of the outer conductor 8, the Beilauflitzen 21, 22 departing from the electric cable 1 are arranged with their respective free end portion 21a and 22a, so that the second slots 82 are partially closed by the Beilauflitzen 21, 22. Beilauflitzen 21, 22 may be cohesively, within the respective second slot 82, for example, by soldering or welding, set. Further details will be given below on the basis of FIGS. 3A and 3B be explained.

The space between the outer conductor 8 and the components 31-34, 4, 5, 61-64 and 71-74 of the connector arranged therein is partially filled by a potting 85 (potting compound), for example in the form of an injection-molded part. In the present case, this lies on the inner side of the outer conductor 8 facing the plug interior 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 potting 85 has channels 86 in which the free end portions 21a, 22a of the Beilauflitzen 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 - on the connector still receive a plurality of other functions.

Thus, the carrier body 4 in the present case serves as a positioning means for positioning the outer conductor 8 on the connector. The positioning of the outer conductor 8 relative to the support body 4 takes place concretely in such a way that the outer conductor 8 is pushed with its cable side (ie at the respective end of the electrical cable 1 facing end 81 a) open first slots 81 on the support body 4, more precisely on the Connecting portions 41, 42 of the support body 4 until the closed end 81b of the respective slot 81 opposite to the open cable-side end 81a engages with the support body 4, as in FIG FIG. 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 cable longitudinal direction L).

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

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

According to one embodiment of the invention, the support body 4 each have axially extending extensions 46, which cover the first slots 81 (sections), see. FIG. 1B when the carrier body 4 and the outer conductor 8 are aligned and positioned as intended. Such extensions 46 can also serve as guide means for guiding the outer conductor 8 when pushed onto the carrier body 4. Furthermore, the extensions can act as an EMC labyrinth, so not only reduce the free line of sight, but also counteract the penetration of electromagnetic waves in the space inside the outer conductor 8.

Other functions of the support body 4 are in the embodiment in the tension and pressure relief of the arranged in the interior of the outer conductor 8 components 31-34, 4, 5, 71-74 of the connector in the effect of forces / torques on the outer conductor 8 and in the train - and pressure relief of the Beilauflitzen 21, 22, in particular under the Effect of torsional forces (along the circumferential direction of the outer conductor 8). This makes it possible to prevent shearing of the auxiliary slits 21, 22.

On the support body 4, a coding housing can also be positioned and locked. 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 FIGS. 3A and 3B show a longitudinal section ( FIG. 3A ) and a cross section ( FIG. 3B ) through the electrical connector from the Figures 1A and 1B , In this way, in particular the arrangement of axially extended 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 Beilauflitzen 21, 22 in the second slots 82 of the outer conductor 8 on the other hand illustrated by drawing.

Especially based FIG. 3B In addition, it is shown how torsional forces T1 acting on the outer conductor 8 or on the potting 85 are introduced into the carrier body 4, which in the cross-sectional representation of FIG FIG. 3B is exemplified by the extensions 46. Furthermore, it is shown how torsional forces T2 acting on the follower slits 21, 22 are introduced into the outer conductor 8 (from which they can in turn be discharged into the carrier body 4). As a result, a pressure and strain relief of the Beilauflitzen 21, 22 can be achieved under the action of torsional forces, which in particular prevents shearing the Beilauflitzen.

Furthermore, the point of view already described 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 planes), can serve as guide aid for sliding and positioning the outer conductor 8.

Similarly, it is clear how, by the covering of the first slots 81 of the outer conductor 8 by means of the extensions 46 of the support body 4, in particular because of the flared configuration of the (in cross-section mushroom-shaped) extensions 46, an EMC labyrinth is formed to the penetration of electromagnetic waves in to prevent the space surrounded by the outer conductor 8 space.

Specifically in FIG. 3A are also those locations of the second slots 82, namely in the embodiment end portions 82a in the form of beveled areas, recognizable, in the vicinity of a respective Beilauflitze 21, 22 (with their respective free end portion 21a, 22a) is fixed to the outer conductor 8, for example, materially by welding, soldering, Sticking, etc., on a support formed by the respective end portion 82 a (platform 82 b). This further ensures that the ground connection of the cable shield on the battens 21, 22 to the outer conductor 8 remains stable over time and in particular the contact resistance is constant in time. The tapered end portions 82a and the pads 82b formed thereby continue to serve to transmit torsional forces. In addition, the beveled end portions 82a and the pads 82b form additional guide aids when sliding the outer conductor 8 on the potting 85th

FIG. 4A shows an exploded view of the electrical connector from the Figures 1A and 1B together with the cable side immediately adjoining components, and that before the bending of the support portions 43, 44 of the support body 4. (This is formed as shown in FIG Figures 1A and 1B described.) The carrier body 4 may be connected to the electrical component, which in FIG. 4A for reasons of clarity is not shown in detail, be summarized to form an integrally molded assembly, as further below with reference to FIGS. 5A to 8 will be explained in more detail.

Cable side is in FIG. 4A the electrical cable 1 with the wires 11, 12 and their respective core (electrical line 11a and 12a) and with the Beilauflitzen 21, 22 and with the cable sheath 15 shown. The electrical connector facing the end of the electric cable 1 is provided with the already described Stützcrimp 16, on which in turn a potting 18 is applied.

Externally, the connector of the outer conductor 8 is surrounded with the first and second slots 81 and 82, wherein the space between the support body 4 - with the exception of outwardly guided support portions 43, 44 - and the outer conductor 8 is filled by a potting 85.

Starting from the exploded view of the FIG. 4A the assembly of the connector, including the connection of the electric cable 1, can be described as follows:
First, the electrical cable 1 is provided and provided with the Stützcrimp 16 at its free end, to which it is to be connected to the associated electrical connector. At the electrical cable 1 are already Beilauflitzen 21, 22 have been separated, as based on the FIGS. 2A and 2B described.

Subsequently, the stamped grid is provided, from which the carrier body 4 and the cable-side and output-side contact elements 31, 32; 71, 72 together with the other associated components 33, 34; 73, 74 are formed. The stripped free ends of the wires 11, 12 of the electric cable 1, at each of which the associated core in the form of an electrical line 11a, 12a exposed, are each with a cable-side contact element 31, 32 via the receptacle 33, 34 in contact or in Intervention brought. An additional connection is preferably cohesively on the respective contact or engagement region, 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 other associated components 33, 34; 73, 74 and arranged on the support body 4 electrical component 5 including the associated wires are then provided by encapsulation with the insulating potting 85 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, wherein the outer conductor 8 is guided by the carrier body 4. Then the Beilauflitzen 21, 22 with their free end portions 21a, 22a, compare FIGS. 3A and 3B , Introduced into the provided second slots 82 of the outer conductor 8 and there cohesively, for example by soldering, welding or gluing, set. And there are the support portions 43, 44 of the support body 4 to form the annular configuration of the Figures 1A and 1B bent over, as in FIG. 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 encloses in particular the support crimp 16.

The FIGS. 5A to 5E show the essential components of an electrical connector of the above with reference to the FIGS. 1A to 4B described type, in particular, the formation of the electrical component 5 is shown in detail.

The specific embodiment of the below with reference to FIGS. 5A to 8 to be described electrical connector manifests itself in particular in the FIG. 5A shown inductive electrical component 5 and further - optionally - in the adapted thereto configuration of the support body 4. The electric cable 1, as in FIG. 5B illustrated, the outer conductor 8, as shown in Figure 1C, the support sleeve 16 (Stützcrimp), such as in FIG. 5D shown, as well as the assembly of the electric cable 1 with the Stützcrimp 16, as in FIG. 5E In contrast, in contrast to the above with reference to FIG FIGS. 1A to 4B described arrangement, so reference is made with respect to those components in the description passages belonging to these figures.

This in FIG. 5A illustrated electrical component 5 is formed as an inductive electrical component. This has windings in the form of electrical coils 51, 52, which are designed in one piece with the cable-side contact elements 31, 32, that is, integrally formed thereon. Specifically, the inductive electrical component 5 in the embodiment according to FIG. 5A two each formed by a plurality of windings coils 51 and 52, which are integrally formed on one of the cable-side contact elements 31, 32, respectively. The coils 51, 52 each extend along a (common) plane and are spirally designed (wound). In addition, in the exemplary embodiment, the two coils 51, 52 have two coil sections 51a, 52a facing each other and extending side by side.

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

A respective coil 51, 52 further has an (inner) connection part 53 or 54 (in the form of a respective contact tongue), via which an electrical connection with the output-side contact elements 71, 72 can be produced. Specifically, in the exemplary embodiment, exactly one electrical connection between a coil 51 or 52 and an associated output-side contact element 71 or 72 is to be produced by means of each of the two connection parts 53, 54.

As a result, according to the exemplary embodiment, in each case a cable-side electrical contact element 31 or 32 is electrically connected via a coil 51 or 52 to precisely one output-side electrical contact element 71, 72. In other words, the cable-side and output-side contact elements 31, 32; 71,72 connected via a respective coil 51 and 52 in pairs.

As already on the basis of FIGS. 1A to 4B explained, are respectively formed on the cable-side electrical contact elements 31, 32 connecting points 33, 34 in the form of a receptacle; and at the output side electrical contact elements 71, 72 Steckerlemente 73, 74 are formed in the form of plug pins.

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 embodiment, in each case with the associated connection points 33, 34 or plug elements 73, 74) in this case form part of an integrally formed stamped grid. The stamped grid comprises a plurality of separation points S, in the exemplary embodiment in the form of webs on which the material of the stamped grid can be severed in each case as intended, in order to initially separate interconnected components of the stamped grid from one another. At which points the punched grid is severed in each case in order to separate the components connected thereto depends on which circuit diagram is to be produced in an individual case with the stamped grid. 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 stamped grid can be connected to the latter corresponding separation points S are severed.

According to FIG. 5A has the illustrated arrangement in addition to the inductive electrical component 5 and the associated cable-side and output-side contact elements 31, 32; 71, 72 further comprises a support body 4 integrally formed together with the electrical component 5 and the cable-side and output-side contact elements 31, 32; 71, 72 is formed.

As already described above, the carrier body 4 in particular comprises support sections 43, 44, which are bent over to produce their final configuration. The support portions 43, 44 are in the embodiment of FIG. 5A integrally formed on the cable-side contact elements 31, 32 in each case via a connecting portion 41 and 42, respectively. Furthermore, axial extended extensions 46 of the carrier body 4 (with lateral angled portions 46a) are also integrally formed thereon. By detachment from 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 are made of an electrically conductive material. This can thus also apply to the stamped grid as a whole or to its other components, in particular the carrier body 4.

For the preparation of the electrical connector is according to FIG. 6A First, the electrical cable 1 to the cable-side contact elements 31, 32 connected. Specifically, for this purpose, the isolated 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 there cohesively, for example by welding. The Beilauflitzen 21, 22 of the electric cable 1 are initially still free.

Subsequently, the inner connection part 53, 54 of a respective coil 51, 52 is bent in such a way that it bridges in each case a section of the corresponding coil 51, 52 and electrically contacts the respectively assigned output-side contact element 71, 72 FIG. 6B , The definition of a respective connection part 53, 54 on the associated output-side contact element 71 or 72 can in turn be made materially, in particular by welding.

In a further step is after FIG. 6C the at least partially 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 connector elements 73, 74) and optionally by the support body 4 to form a casting 85 with an (electrically) insulating material encapsulated. The potting 85, including its channels 86, corresponds essentially to that already described FIG. 1B explained potting; he points, however, according to FIG. 6C additionally opening areas 87, over which, as in FIG. 6D a ferrite jacket 9 can be introduced, which surrounds or surrounds the two coils 51, 52 of the electrical component 5 partially. Specifically, in the exemplary embodiment, the ferrite jacket 9 encloses the mutually facing, juxtaposed sections 51a, 52a of the two coils 51, 52 (tube-like).

The ferrite jacket 9 is formed in the embodiment by a ferromagnetic material (in the ferritic phase) offset plastic.

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

In the following step, according to FIG. 6E a (tubular) outer conductor 8 is pushed over the assembly until it comes to the stop with the carrier body 4, as described above with reference to FIG FIGS. 4A and 4B has been described in detail. Then, in the manner already described, the insertion of the auxiliary slits 21, 22 into the associated second slits 82 of the outer conductor 8 takes place; and further, the support portions 43, 44 of the support body 4 are bent such that they surround the outer conductor 8 at its outer periphery, compare FIG. 6F , Beilauflitzen 21, 22 and / or the support portions 43, 44 can also be attached to the outer conductor 8, for example by (simultaneous) welding.

Furthermore, according to FIG. 6G a ferrite are sprayed on the outer conductor 8 and / or on exposed line sections.

The FIGS. 7A to 7D illustrate the preparation of the coils 51, 52, starting from a stamped grid, which in each case at the respective points first one (plate-like, integrally with each cable-side contact element 31 or 32 shaped) base element 5a and 5b, as in FIG. 7A shown. According to the FIGS. 7B and 7C a respective coil 51, 52 is produced from the corresponding base element 5a or 5b by laser cutting, wherein in the central opening of a respective coil 51, 52 also an electrical connection part 53 or 54 is formed.

The defined flipping of the connecting 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, for bending the connecting part 53, 54 of a respective coil 51, 52, a holder H (with clamping effect) and two bending dies B1, B2 are used, of which the one, first bending punch B1 acts transversely to the extension direction of the connecting part 53, 54 on the latter, in order to push this out of the plane of the respective coil 51, 52, and of which the other, second bending punch B2 parallel to the plane of the respective coil 51, 52 acts on the associated connection part 53 or 54, in order to this zugeordente output side contact element 71 or 72 to move. In addition, a bending jaw B3 is used to ensure, during the action of the bending dies B1, B2, that the connecting part 53, 54 bridges the section of the respective coil 51, 52 to be bridged, without touching it. Subsequently, the connection part (eg 53) is pressed by means of a welding mechanism M against the associated output-side contact element (73) and welded thereto.

Claims (15)

Electrical connector for a multi-core electrical cable, with - At least two cable-side electrical contact elements (31, 32) with associated electrical connection points (33, 34), to each of which a wire (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 connector element (73, 74) protrudes, via which an electrical connection with a mating connector can be produced, wherein between the cable-side contact elements (31, 32) and the output-side contact elements (71, 72) an inductive electrical component (5) is arranged, which is integrally formed on the cable-side contact elements (31, 32) and / or the output-side contact elements (71, 72 The electrical component (5) comprises at least one coil (51, 52) with a plurality of turns integrally formed thereon and is at least partially enclosed by a jacket (9) made of a ferromagnetic material offset plastic,
characterized,
in that the electrical component (5) is an integrally formed component of a carrier body (4), from which two support sections (43, 44) depart such that the two support sections (43, 44) form an annular peripheral structure. An electrical connector according to claim 1, characterized in that the turns of a respective coil (51, 52) extend spirally along a plane. Electrical connector according to claim 1 or 2, characterized in that the electrical component (5) of the jacket (9) is at least partially encapsulated. Electrical connector according to claim 1 or 2, characterized in that the jacket (9) is placed on the electrical component (5). Electrical connector according to one of the preceding claims, characterized in that the jacket (9) is formed by a staggered with ferromagnetic material in the ferritic phase plastic. Electrical connector according to one of the preceding claims, characterized in that from the electrical component (5) integrally a connection part (53, 54) is formed, which bridges a portion of the electrical component (5) and the materially connected to the output-side contact elements (71, 72) or the cable-side contact elements (31, 32) is fixed. Electrical connector according to one of the preceding claims, characterized in that between the cable-side contact elements (31, 32) and the output-side contact elements (71, 72) arranged electrical component (5) comprises two coils (51, 52), each in one piece a cable-side contact element (31, 32) and / or an output-side contact element (71, 72) are integrally formed such that via a respective coil (51, 52) of the electrical component (5) each have a cable-side and an output-side contact element (31, 32, 71, 72) are electrically connected to each other. Electrical connector according to claim 7, characterized in that the jacket (9) facing each other, adjacent to each other extending portions (51a, 52a) of the two coils (51, 52) encloses. Electrical connector according to one of the preceding claims, characterized in that the electrical component (5) and the cable-side and output-side contact elements (31, 32; 71, 72) are jointly surrounded by an encapsulation (85) made of an insulating material. Electrical connector according to claim 9, characterized in that the encapsulation (85) has at least one opening (87) through which the jacket (9) can be applied to the electrical component (5). Electrical connector according to claim 4, 8 and 10, characterized in that individual parts of the jacket (9) are inserted through the at least one opening (87) and fitted together so that they the juxtaposed portions (51a, 52a) of the coils (51 , 52). Electrical connector according to one of the preceding claims, characterized in that the connector comprises an outer conductor (8) enclosed interior, in which the electrical component (5) and the cable-side and output-side contact elements (31, 32, 71, 72) at least in sections are arranged. Electrical connector according to claim 12, characterized in that the outer conductor (8) is fixed to the carrier body (4). Electrical connector according to claim 12 or 13, characterized in that first and second connecting portions (41, 42) of the carrier body (4) each penetrate a slot (81) of the outer conductor (8) in the radial direction and that of the connecting portions (41, 42) outgoing support portions (43, 44) of the support body (4) extend outside of the outer conductor (8) enclosed space and extend arcuately in the circumferential direction along the outer wall of the outer conductor (8). Electrical 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 the electrical component (5) as components of a single, integrally molded component, in particular in the form of a stamped grid, are made.

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