EP4080685A1 - Prefabricated electrical cable and connector assembly - Google Patents

Abstract

The invention relates to a ready-made electrical cable (2) for an electrical plug connector (3), having an electrical conductor (8) which is designed as a strand made up of several individual wires and which has at least one end section (10) compacted in the form of a plate. The ready-made electrical cable (2) has an elongated contact element (11) with at least one side surface that forms a first connecting surface (12) that is connected to the compacted end section (10) of the electrical conductor (8). , and with at least one further side surface facing away from the first connecting surface (12), which forms a first contact surface (13) for contacting a counter-contact surface (14) of a counter-contact element (7) of a counter-connector (5).

Description

The invention relates to a ready-made electrical cable for an electrical plug connector, having an electrical conductor which is designed as a stranded wire made up of several individual wires, according to the preamble of claim 1.

The invention also relates to a connector arrangement, having a ready-made electrical cable and an electrical connector.

When cables are assembled, their ends, in particular the ends of their inner conductors, are prepared for assembly in an electrical connector. During this process, the electrical conductors are often cut to length, stripped and provided with one or more contact elements. For example, as part of the cable assembly, a contact element of the subsequent connector can be electrically and mechanically connected to an electrical conductor routed within a cable sheath and later mounted in a connector housing of the connector. The fully assembled contact element can then be used within the plug connector for contacting with a mating contact element of a mating connector.

Various electrical connectors are known from electrical engineering. As is known, electrical plug connectors are used to transmit electrical supply signals and/or data signals to the corresponding mating plug connector. Within the scope of the invention, a plug connector or mating plug connector can be a plug, a built-in plug, a socket, a coupling or an adapter. The term "connector" or "mating connector" used in the context of the invention is representative of all variants.

In particular, connectors and electrical cables for the automotive industry and for vehicles are subject to high demands on their robustness and the safety of the plug connections. Above all, electromobility is provided by the automotive industry and their suppliers face great challenges, since high electrical power has to be transmitted in the vehicles via the cables or plug connections. The thermal load and the resulting waste heat, which is associated with the high current flow, is considerable. Accordingly, in order to reduce the heat loss, the contact resistance between the electrical conductor of the cable and the contact element and between the contact element of the connector and the mating contact element of the mating connector should be as low as possible.

High-voltage connectors are used in the vehicle sector, especially in electric and/or hybrid vehicles, to supply a vehicle battery with charging current, to extract the stored energy from the battery and feed it to an electrical consumer, or to connect several batteries or battery modules to one another.

In addition to safe and preferably low-impedance electrical connections within the connector and at the transition to the mating connector, a high-voltage connector must also be easy and inexpensive to produce due to the mass suitability of the connector. In addition, the plug connection, in particular a high-voltage plug connection or a plug connection for transmitting safety-relevant control signals, should be mechanically robust and reliably secured against unintentional opening.

The contact between a high-voltage cable and a high-voltage plug connector is typically made via a contact sword, which is mechanically connected to the electrical conductor of the electrical cable. The attachment of the contact blade to the electrical conductor is, however, comparatively complex and expensive. Furthermore, the resulting contact resistance is often not ideal.

As an alternative to a welded-on contact blade, it is also known to make contact in a contact area with a mating contact element of a mating connector in the form of a plate with an electrical conductor designed as a stranded wire made up of several individual wires. The electrical conductor itself can thus serve as a contact element. The compacting of the stranded wire is, however, comparatively susceptible to tolerances and therefore generally leads to a more or less uneven contact surface, as a result of which the electrical and mechanical connection with the mating contact element of the mating connector can be affected. In addition, in the case of a contact element designed as a compacted stranded wire, it is complex to provide suitable latching means for latching with the connector housing.

In view of the known state of the art, the object of the present invention is to provide a ready-made electrical cable which is preferably suitable for transmitting high electrical currents with low contact resistance, and which is particularly suitable for mass production but can nevertheless be produced with great precision.

Finally, it is also the object of the invention to provide a connector arrangement whose electrical connector is preferably suitable for the transmission of high electrical currents with low contact resistance, and which is particularly suitable for mass production but can nevertheless be manufactured with great precision.

The object is achieved for the assembled electrical cable with the features listed in claim 1. With regard to the connector arrangement, the object is achieved by the features of claim 15. The dependent claims and the features described below relate to advantageous embodiments and variants of the invention.

A ready-made electrical cable for an electrical plug connector is provided. The assembled electrical cable has an electrical conductor which is in the form of a strand made up of a number of individual wires and which has at least one end section which is compacted in the form of a plate.

The thickness of the plate-like compacted end portion can be much smaller than the width and the length of the plate-like compacted end portion.

The electrical cable can in particular be a high-voltage cable or a high-voltage line for vehicle technology for the transmission of high currents, for example with voltages of 1,500 volts or more. The assembled electrical cable according to the invention can be used particularly advantageously in electrically driven vehicles, for example in electric vehicles or hybrid vehicles.

The assembled electrical cable can have a cable sheath encasing the electrical conductor. In this case, the electrical conductor can be exposed (stripped) from the cable sheath in the region of its end section.

In principle, the assembled cable can have any number of electrical conductors, for example one inner conductor, two inner conductors or more inner conductors, three inner conductors or more inner conductors, four inner conductors or more inner conductors, five inner conductors or more inner conductors. Optionally, an outer conductor can also be provided. The invention is described below essentially using a ready-made electrical cable that has exactly one inner conductor. However, this is not to be understood as limiting. The inner conductor or inner conductors can be arranged coaxially to the central axis of the cable. However, the inner conductor or conductors can also be distributed uniformly around the central axis of the cable.

The assembled electrical cable preferably has exactly one inner conductor that runs inside the cable sheath. Optionally, shielding can be provided, for example a braided cable shield that is spaced apart from the inner conductor by means of a dielectric material and/or a cable foil.

According to the invention, the assembled electrical cable has an elongate contact element (the length of the contact element can therefore be greater than the width along a longitudinal axis), with at least one side surface that forms a first connecting surface that is connected to the compacted end section of the electrical conductor, as well as with at least one further side surface facing away from the first connecting surface, which forms a first contact surface for contacting a mating contact surface of a mating contact element of a mating connector.

Because the stranded wire is compacted in the form of a plate, a particularly good electrical connection to the contact element can result, in particular since the contacting surface between the electrical conductor and the contact element is particularly large. The contact element can be produced with high precision, for example with a precisely defined size and geometry of the contact surface, which can have a significantly better surface quality in comparison with the corresponding side surface of the plate-shaped compacted end section. Furthermore, it can Cover protruding individual wires that have not been sufficiently compacted in the contact element. The combination proposed according to the invention of a compacted end section of a stranded wire with a contact element attached thereto combines the advantages of the high current transferability associated with the compacting of the stranded wire with the advantages of a contact surface that can be produced particularly precisely by a separate contact element.

The connection between the contact area and the electrical conductor can be robust and low-impedance and consequently suitable for the transmission of particularly high currents.

The contact surface and/or the counter-contact surface can preferably each be a completely contiguous surface. However, several individual contact surfaces and/or mating contact surfaces can also be provided.

In an advantageous development of the invention, it can be provided that the contact element is designed as a contact plate. The thickness of the contact sheet can be, for example, 0.1 mm to 2.0 mm, preferably 0.3 mm to 1.0 mm, particularly preferably 0.4 mm to 0.6 mm.

In particular, the use of a contact plate can represent a particularly economical solution. Due to the plate-shaped compaction of the electrical conductor on the one hand and the use of a contact sheet on the other hand, maximum material savings can be made possible with extremely precise manufacture and sufficient dimensional stability at the same time.

In addition, the space required for the contact area of the assembled electrical cable can advantageously be reduced.

The contact element can also be designed as a contact plate. In particular, the use of a plurality of small contact plates, which are arranged distributed over the plate-shaped compacted end section, can also be provided.

In principle, an arbitrarily designed contact element can be provided. However, the contact element is particularly preferably not designed as a contact sleeve. The contact element, in particular the contact plate, can be designed in one piece, for example as a stamped and bent part. However, the contact sheet can also be deep-drawn or produced in some other way. However, the contact plate is preferably produced as a stamped and bent part.

According to a development of the invention, it can be provided that the contact element and the individual wires of the electrical conductor are made of the same material.

The contact element and/or the individual wires of the electrical conductor are preferably made of aluminum or copper. In principle, however, any material that is suitable for transmitting high currents can be provided.

According to a development of the invention, it can be provided that the contact element has a coating. A silver coating is preferably provided. The contact element can preferably be coated by strip electroplating.

The contact resistance can be further improved by a coating. If the contact element is made of aluminum, for example, this can sometimes tend to oxidize in the area of the contact surface. This can be avoided by the coating, for example the silver coating.

The contact surface is preferably a planar, flat surface. However, the first contact surface can also be curved or round. A curved first contact surface can be suitable in particular for contacting the contact lamellae mentioned below or for forming the contact lamellae.

In a further development of the invention it can be provided that further side surfaces of the contact element form respective further connecting surfaces, the contact element preferably having a total of two to five connecting surfaces which are each connected to the compacted end section of the electrical conductor.

For example, in addition to the first connecting surface, a second connecting surface, a third connecting surface, a fourth connecting surface and/or a fifth connecting surface can be provided. Preferably, each of the connecting surfaces with connected to another corresponding side face of the compacted end portion.

Insofar as two connecting surfaces (eg the first connecting surface and the second connecting surface) are provided, the contact element can preferably be folded over an edge of the plate-shaped compacted end section.

Insofar as three connecting surfaces (eg the first connecting surface, the second connecting surface and the third connecting surface) are provided, the contact element can be folded over two edges of the compacted end section, in particular be U-shaped.

Insofar as four connecting surfaces (eg the first connecting surface, the second connecting surface, the third connecting surface and the fourth connecting surface) are provided, the contact element can be folded over three edges of the compacted end section, for example.

It can also be provided that a connecting surface of the contact element is connected to an end face of the plate-shaped compacted end section or is wrapped around an edge of the end face.

By using several connecting surfaces, the contacting possibilities can be increased, for example further contact surfaces for contacting one or more mating contact elements can be provided and/or an improved covering of the compacted end section can be provided, for example to cover protruding individual wires.

In a development of the invention, it can be provided that the at least one connecting surface is aligned parallel to a corresponding side surface of the compacted end section, to which the connecting surface is connected.

The at least one connecting surface is preferably connected to the corresponding side surface of the compacted end section over its entire surface.

A parallel alignment of the connecting surface to the corresponding side surface, in particular a full-surface connection, can further reduce the contact resistance and enable the transmission of even higher currents.

The contact surfaces are preferably each arranged parallel to their corresponding connecting surfaces.

In an advantageous development of the invention, it can be provided that the at least one connecting surface is materially connected to the compacted end section.

A material connection between the connection surface and the compacted end section can enable a particularly low transition resistance. In addition, the compacted end section and the contact element can be connected to one another in a particularly robust manner in this way. Corrosion of the transition region between the contact element and the electrical conductor can also possibly be avoided, in particular if the material connection is a gas-tight material connection.

A screw connection, rivet connection or crimp connection between the electrical conductor and the contact element can preferably be dispensed with within the scope of the invention.

The electrical conductor can preferably be non-detachably connected to the contact element, as a result of which the electrical conductor can no longer be removed from the contact element without being destroyed. In particular, the gas-tight connection already mentioned can be provided between the connecting surface of the contact element and the corresponding side surface of the plate-shaped compacted end section.

In a development of the invention, it can be provided that the at least one connecting surface completely covers a corresponding side surface of the compacted end section to which the connecting surface is connected.

In this way, the contact surface for contacting the counter-contact surface of the counter-contact element can be enlarged. In addition, protruding individual wires can be covered comprehensively.

In an advantageous development of the invention, it can be provided that a further side surface of the contact element forms a second contact surface for contacting a mating contact surface of a mating contact element of a mating connector.

In principle, further contact surfaces can also be provided, for example a third contact surface, a fourth contact surface and/or a fifth contact surface.

In particular, the use of two contact surfaces, which are arranged on opposite sides of the compacted end section when the contact element is in the connected state with the plate-shaped compacted end section, can be advantageous for contacting with the mating connector, for example to enable pliers-like contacting on both sides.

In an advantageous development of the invention, it can be provided that the at least one contact surface of the contact element is designed as a primarily flat surface for surface contacting with the counter-contact surface.

In this way, a contact element can be designed in the manner of a contact sword, in combination with the advantages according to the invention.

In an advantageous development of the invention, it can also be provided that the at least one contact surface of the contact element has one or more contact lamellae, which are at least partially elastic in the contacting direction, for contacting the counter-contact surface.

The use of contact lamellae can increase the contact force to the mating contact element and thus improve the power transmission. As an alternative to using contact lamellae, the contact surface can in principle have any rigid and/or elastic projections on the contact surface (e.g. ribs). In the simplest In this case, however, planar contacting can be provided, ie the contact area can be completely planar or even.

The contact lamellae can be punched out of the contact surface of the contact element, for example. However, the contact lamellae can also be fastened individually or in groups on the contact surface of the contact element. The use of a separate contact lamellar element, which is introduced between the contact surface and the mating contact surface and is optionally fixed in the connector, on the assembled cable, in the mating connector or on the mating contact element, can also be advantageous.

In an advantageous development of the invention, it can be provided that at least one of the contact surfaces or that the at least one contact surface has at least one first latching means for latching with a corresponding second latching means of the connector or connector housing in order to ensure mutual latching between the assembled cable and the Provide connectors or connector housing when the assembled cable is mounted in the connector or connector housing.

The holding force of the assembled, assembled cable in the plug connector can be increased by the latching means and primary and/or secondary latching can be provided in an advantageous manner.

In principle, any number of first latching means and corresponding second latching means can be provided.

In a further development it can be provided that the first latching means is designed as a spring clip punched out of the contact surface. The plug connector, in particular the plug connector housing of the plug connector, can have a corresponding latching recess or a corresponding latching lug, into which or behind which the spring shackles can latch in the assembled state of the assembled cable.

In a development, it can alternatively or additionally also be provided that the first latching means is a latching lug or latching hook formed on the contact surface is trained. The plug connector, in particular the plug connector housing of the plug connector, can have an elastic spring clip which is able to snap in behind the latching lug or behind the latching hook when the assembled cable is in the assembled state.

In a further development, it can alternatively or additionally also be provided that the first latching means is designed as a latching recess within the contact surface. The plug connector, in particular the plug connector housing of the plug connector, can have an elastic spring clip which is able to snap in behind the latching lug or behind the latching hook when the assembled cable is in the assembled state.

The configurations and combinations of the latching means mentioned above are only to be understood as examples. In principle, any latching means can be provided which, in combination, enable a suitable latching between the assembled electrical cable and the connector or the connector housing.

Optionally, but not preferred, the contact element can also have latching elements for latching with the mating contact element and/or mating connector. However, the connector housing can be latched to a mating connector housing of the mating connector.

In one embodiment of the invention it can be provided that the contact element has further functional elements. For example, the at least one contact surface can have at least one coding element, for example a coding element punched out of the contact surface, in order to provide mechanical coding between the contact element and a counter-coding element of the connector or connector housing. In this way it can be ensured that only a contact element approved for connection to the connector or a ready-made electrical cable can be installed in the connector or connector housing, and/or that the installation takes place with correct alignment and positioning.

According to a development of the invention, it can be provided that the electrical conductor has a conductor cross-section greater than 10 mm ² , preferably greater than 30 mm ² , particularly preferably greater than 60 mm ² , for example greater than 90 mm ² or also greater than 200 mm ² . In particular, a conductor cross-section can be provided which is suitable for electrical energy transmission in high-voltage technology, i.e. for the transmission of high electrical currents (e.g. 100 A to 2 kA) with AC voltages of 30 V to 1 kV or more or DC voltages of 60 V to 1 5 kV or more, especially in automotive engineering.

In an advantageous development of the invention, it can be provided that the individual wires of the electrical conductor are welded to one another in order to form the plate-shaped, compacted end section

Preferably, the strands may be pressure welded, resistance welded, or fusion welded together. In principle, however, any material connection techniques are possible.

The invention also relates to a connector arrangement, having a ready-made electrical cable according to the statements above and below and the electrical connector.

The plate-shaped compacted end section can be accommodated within the connector, preferably within a connector housing of the connector. The connector housing can in particular be a plastic housing, preferably made of a stiff plastic or hard plastic. The connector housing can preferably be produced by means of an injection molding process or a deep-drawing process. Provision can be made for the connector housing to be designed in one piece or preferably in multiple pieces. The connector housing can be designed to provide protection against accidental contact for the conductive components of the connector.

The proposed electrical connector is particularly advantageous as a high-voltage connector, especially for use in electric mobility. A cell module connector interface for connecting battery cell modules, for example, can advantageously be provided by the electrical plug connector, with a particularly advantageous configuration of the contacting.

The assembled electrical cable can advantageously be used as a busbar replacement. By compacting the stranded wire in combination with applying the contact element, in particular a contact plate, a particularly economical and at the same time high-quality contacting option can be provided. The contact element can have a smooth contact surface that can be produced precisely, with the contact resistance between the electrical conductor and the contact element being able to be particularly low due to the compaction of the stranded wire. In this way, the contact can also be particularly robust and able to absorb high cable tensile forces, for example tensile forces greater than 100 N.

Provision can be made for the plug connector to have one or more spring elements which are designed and arranged in order to generate contact pressure between at least the first contact surface and the corresponding mating contact surface of the mating contact element when the plug connector is connected to the mating connector.

• Plattenförmiges Kompaktieren eines als Litze aus mehreren Einzeldrähten ausgebildeten elektrischen Leiters in einem Endabschnitt des elektrischen Leiters; und
• Verbinden eines länglichen Kontaktelements mit dem plattenförmig kompaktierten Endabschnitt, indem zumindest eine von einer ersten Kontaktfläche abgewandte Seitenfläche des Kontaktelements, die eine erste Verbindungsfläche ausbildet, mit dem kompaktierten Endabschnitt des elektrischen Leiters verbunden wird.

The invention also relates to a method for assembling an electrical cable, having at least the following method steps:

• Plate-shaped compacting of an electrical conductor designed as a strand of several individual wires in an end section of the electrical conductor; and
• Connecting an elongate contact element to the plate-shaped compacted end section by connecting at least one side surface of the contact element, which faces away from a first contact surface and forms a first connecting surface, to the compacted end section of the electrical conductor.

The invention also relates to a device for assembling an electrical cable for carrying out the above-mentioned method.

Features that have been described in connection with one of the objects of the invention, namely given by the inventive assembled electrical cable, the connector arrangement and the method and the device for assembly, can also be advantageously implemented for the other objects of the invention. Likewise, advantages that were mentioned in connection with one of the objects of the invention can also be understood in relation to the other objects of the invention.

In addition, it should be pointed out that terms such as "comprising", "having" or "with" do not exclude any other features or steps. Furthermore, terms such as "a" or "that" which indicate a singular number of steps or features do not exclude a plurality of features or steps - and vice versa.

In a puristic embodiment of the invention, however, it can also be provided that the features introduced in the invention with the terms “comprising”, “having” or “with” are listed exhaustively. Accordingly, one or more listings of features may be considered complete within the scope of the invention, e.g. considered for each claim. The invention can consist exclusively of the features mentioned in claim 1, for example.

It should be mentioned that designations such as "first" or "second" etc. are primarily used for reasons of distinguishing between respective device or method features and are not necessarily intended to indicate that features are mutually dependent or related to one another.

Furthermore, it should be emphasized that the values and parameters described here are deviations or fluctuations of ±10% or less, preferably ±5% or less, more preferably ±1% or less, and very particularly preferably ±0.1% or less of the respectively named Include value or parameter, provided that these deviations are not excluded in the implementation of the invention in practice. The specification of ranges by means of initial and final values also includes all those values and fractions that are enclosed by the range specified in each case, in particular the initial and final values and a respective mean value.

Exemplary embodiments of the invention are described in more detail below with reference to the drawings.

The figures each show preferred exemplary embodiments in which individual features of the present invention are shown in combination with one another. Features of an embodiment can also be implemented independently of the other features of the same embodiment and can accordingly be Those skilled in the art can easily be connected to other meaningful combinations and sub-combinations with features of other exemplary embodiments.

Elements with the same function are provided with the same reference symbols in the figures.

Figur 1

eine erfindungsgemäße Steckverbinderanordnung aus einem konfektionierten elektrischen Kabel und einem elektrischen Steckverbinder, in einer seitlichen Schnittdarstellung;

Figur 2

ein erfindungsgemäßes konfektioniertes elektrischen Kabel in einer stirnseitigen Darstellung, gemäß einem ersten Ausführungsbeispiel;

Figur 3

das konfektionierte elektrische Kabel der Figur 2 in einer Seitenansicht;

Figur 4

ein erfindungsgemäßes konfektioniertes elektrischen Kabel in einer stirnseitigen Darstellung, gemäß einem zweiten Ausführungsbeispiel;

Figur 5

ein erfindungsgemäßes konfektioniertes elektrischen Kabel in einer perspektivischen Darstellung, gemäß einem dritten Ausführungsbeispiel;

Figur 6

das konfektionierte elektrische Kabel der Figur 5 in einer stirnseitigen Darstellung;

Figur 7

ein erfindungsgemäßes konfektioniertes elektrischen Kabel in einer stirnseitigen Darstellung, gemäß einem vierten Ausführungsbeispiel;

Figur 8

ein Kontaktelement zur Verwendung mit einem erfindungsgemäß konfektionierten elektrischen Kabel gemäß einem fünften Ausführungsbeispiel, mit verschiedenen Ausgestaltungen von ersten Rastmitteln in einer perspektivischen Darstellung;

Figur 9

ein weiteres Kontaktelement zur Verwendung mit einem erfindungsgemäß konfektionierten elektrischen Kabel mit einem als Rastnase ausgebildeten ersten Rastmittel in einer Seitenansicht;

Figur 10

eine weitere erfindungsgemäße Steckverbinderanordnung aus einem konfektionierten elektrischen Kabel und einem elektrischen Steckverbinder, in einer stirnseitigen Schnittdarstellung;

Figur 11

eine weitere erfindungsgemäße Steckverbinderanordnung aus einem konfektionierten elektrischen Kabel und einem elektrischen Steckverbinder, in einer seitlichen Schnittdarstellung; und

Figur 12

eine weitere erfindungsgemäße Steckverbinderanordnung aus einem konfektionierten elektrischen Kabel und einem elektrischen Steckverbinder, in einer seitlichen Schnittdarstellung.

They show schematically:

figure 1

a connector assembly according to the invention from a ready-made electrical cable and an electrical connector, in a lateral sectional view;

figure 2

an inventive assembled electrical cable in an end view, according to a first embodiment;

figure 3

the assembled electrical cable figure 2 in a side view;

figure 4

an inventive assembled electrical cable in an end view, according to a second embodiment;

figure 5

an inventive assembled electrical cable in a perspective view, according to a third embodiment;

figure 6

the assembled electrical cable figure 5 in an end view;

figure 7

an inventive assembled electrical cable in an end view, according to a fourth embodiment;

figure 8

a contact element for use with an inventively assembled electrical cable according to a fifth embodiment, with different configurations of first latching means in a perspective view;

figure 9

a further contact element for use with an electrical cable assembled according to the invention with a first latching means designed as a latching lug in a side view;

figure 10

another connector assembly according to the invention from a ready-made electrical cable and an electrical connector, in a front sectional view;

figure 11

another connector assembly according to the invention from a ready-made electrical cable and an electrical connector, in a lateral sectional view; and

figure 12

another connector assembly according to the invention from a ready-made electrical cable and an electrical connector, in a lateral sectional view.

figure 1 shows a connector arrangement 1, having an inventive assembled electrical cable 2 and an electrical connector 3. The electrical connector 3 has a connector housing 4, in which the assembled electrical cable 2 is accommodated with at least one end. For this purpose, the cable 2 can preferably be inserted into the connector housing 4 along a mounting direction M.

In the exemplary embodiment, the connection to a corresponding mating connector 5 takes place along a plug-in direction S, which runs orthogonally to the mounting direction M, which, however, is not to be understood as limiting. An example is a mating connector housing 6 of mating connector 5 in figure 1 shown in dashed lines and also a mating contact element 7 of the mating connector 5 is shown. The invention is particularly suitable for use in high-voltage technology in vehicles, for example for the electrical connection between individual batteries, battery modules and/or electrical loads such as electric motors.

The assembled electrical cable 2 , which is only to be understood as an example, extends along a longitudinal axis L and has a single electrical conductor 8 which is routed within a cable sheath 9 . However, a cable jacket 9 is not absolutely necessary. For suitability in high-voltage technology, in particular for the transmission of high electrical currents greater than 10 amperes and more, the electrical conductor 8 preferably has a conductor cross-section greater than 10 mm ² , in particular greater than 30 mm ² , particularly preferably greater than 60 mm ² , for example also larger than 90 mm ² . In principle, however, other conductor cross sections can also be provided. Provision can also be made for the electrical cable 2 to have more than one electrical conductor 8 .

The electrical conductor 8 is in the form of a stranded wire made up of several individual wires and is compacted in the form of a plate in an end section 10, cf Figures 2 and 3 . In order to form the end section 10 which is compacted in the form of a plate, the individual wires of the electrical conductor 8 are preferably welded to one another, for example pressure-welded, resistance-welded or fusion-welded.

The proposed assembled electrical cable 2 has an elongate contact element. In the exemplary embodiments, the contact elements are each designed as contact plates 11, preferably with a thickness between 0.3 mm and 1.0 mm, particularly preferably with a thickness between 0.4 mm and 0.6 mm. In principle, however, any desired contact element can be provided, for example a plate-shaped contact element. The contact element or contact plate 11 and the individual wires of the electrical conductor 8 can be made of the same material, for example aluminum or copper. To improve the contact resistance, the contact element or contact sheet 11 can also have a coating, preferably a silver coating (not shown).

the Figures 2 and 3 show a first exemplary embodiment of the assembled electrical cable 2. The contact plate 11 has a side surface which forms a first connecting surface 12 which is connected to the compacted end section 10 or to a corresponding side surface of the compacted end section 10 of the electrical conductor 8. The contact plate 11 also has a side surface facing away from the first connecting surface 12, which has a first contact surface 13 for contacting a counter-contact surface 14 (cf., for example, figure 10 ) of the mating contact element 7 of the mating connector 5 is formed.

Due to the plate-shaped compaction of the end section 10 of the stranded wire, a particularly low-impedance electrical connection between the electrical conductor 8 and the contact element or contact plate 11 can be provided via the first connecting surface 12 on the one hand, and a particularly smooth, flat first contact surface 13 for contacting with the mating contact element 7 on the other will.

In the Figures 4 to 8 some variants of the contact element designed as a contact plate 11 are shown to make it clear that other side surfaces of the contact element or contact plate 11 can also form additional connection surfaces 15, 17, 18, 19, for example a total of two to five connection surfaces 15, 17, 18, 19, which are connected to the compacted end portion 10 of the electrical conductor 8, respectively.

According to the embodiment of figure 4 it is provided, for example, that the contact sheet 11 has the first connecting surface 12 and a further, second connecting surface 15, the contact sheet 11 being folded over an edge of the plate-shaped compacted end section 10 of the electrical conductor 8. This edge can preferably be the edge of the contact plate 11 facing the mating contact element 7 during the plugging process. In this way it can be avoided that protruding individual wires negatively influence the plugging process.

Provision can be made for a contact surface to be formed on the side surface of the contact element or contact plate 11 facing away from the respective connecting surface 12 , 15 , 17 , 18 , 19 . However, the number of contact surfaces does not necessarily have to correspond to the number of connection surfaces 12 , 15 , 17 , 18 , 19 . The first contact surface 13 and only optionally a second contact surface 16 are preferably provided (for example if a pincer-like contact with the counter-contact element 7 or a contact with a plurality of counter-contact elements 7 is provided). The contact surfaces 13, 16 are generally arranged along the main surfaces of the plate-shaped compacted end sections 10 (see, for example, figures 2 and 7 ).

In the Figures 5 and 6 a further exemplary embodiment is shown as an example, according to which, in addition to the first connecting surface 12 and the second connecting surface 15 a third connecting surface 17 is also provided in order to form a U-shaped contact sheet 11 which is folded over two edges of the end section 10 which is compacted in the form of a plate.

A fourth connecting surface 18 (cf. figure 7 ) can be provided. The example in figure 7 The contact sheet 11 shown or the assembled electrical cable 2 can thus advantageously be contacted from both sides and/or used modularly and independently of the orientation.

At this point it should be mentioned that the contact plate 11 can in principle be produced in any way, but is preferably produced as a stamped and bent part. In particular (but not exclusively) when using four connecting surfaces 12, 15, 17, 18, as in figure 7 shown, but a deep-drawn contact element 11 can also be suitable. Insofar as the contact element 11 is deep-drawn, it can be advantageous during deep-drawing to ensure that connecting surfaces facing away from one another (in Figure 7, the first connecting surface 12 and the fourth connecting surface 18, as well as the second connecting surface 15 and the third connecting surface 17) are as parallel as possible keep each other. Insofar as the contact sheet 11 is produced as a stamped and bent part and is to have four connecting surfaces 12, 15, 17, 18, it can optionally be provided that any adjoining edges between two connecting surfaces 12, 15, 17, 18 or within a connecting surface 12, 15, 17, 18 to be connected to one another with a material fit, ie to close any production-related gap between or within the connecting surfaces 12, 15, 17, 18, for example by means of a laser welding process.

An end face connection of the contact plate 11 to an end face of the plate-shaped compacted end section 10 can also be provided. An example of this is in figure 8 a fifth connecting surface 19 is provided.

In the exemplary embodiments, the respective connecting surfaces 12, 15, 17, 18, 19 run parallel to the corresponding side surfaces of the compacted end section 10 and are connected to the corresponding side surfaces of the compacted end section 10 over their entire surface. The connection is preferably materially bonded, very particularly preferably gas-tight.

As shown in the exemplary embodiments, it can be provided that the connecting surfaces 12, 15, 17, 18, 19 completely cover the respective corresponding side surface of the compacted end section 10. The axial length L _K of the connecting surface 12, 15, 17, 18, 19 can thus correspond to the axial length of the compacted end section 10 (cf. figure 3 ). However, the connecting surfaces 12, 15, 17, 18, 19 and/or the entire contact element or contact plate 11 can also have a shorter axial length L _K and thus only extend over a partial area of the axial length of the compacted end section 10. In principle, several contact elements or contact sheets 11 or connecting surfaces 12, 15, 17, 18, 19 can also be connected to the same corresponding side surface of the compacted end section 10.

In order to mount the assembled electrical cable 2 in the context of assembly in the connector 3 or in the connector housing 4 of the connector 3, it can be provided that the at least one contact surface 13, 16 has at least one first latching means for latching with a corresponding second latching means of the Connector housing 4 has to provide mutual locking when the assembled electrical cable 2 is fully inserted into the connector 3. In the Figures 8, 9 and 11 exemplary locking means are shown.

For example, the first latching means can be designed as a spring clip 20 punched out in the contact surface 13, 16 (cf. figures 8 and 11 ), which is located behind a lug or other edge of the connector housing 4 (cf. figure 11 ) is able to engage in order to secure the assembled electrical cable 2 against being pulled out against the mounting direction M.

Alternatively or additionally, latching recesses 22 can also be formed in the contact surface 13, 16 (cf. figures 8 and 12 ), In the corresponding second locking means of the connector housing 4, such as locking lugs and / or spring tabs, are able to snap (not shown).

It can also be provided (cf. figure 9 ) that on the contact surface 13, 16 corresponding latching lugs 21 are formed, behind which spring tabs (not shown) of the connector housing 4 are able to engage, complementary to the in figure 11 shown variant.

In principle, the contact surface 13, 16 of the contact element or of the contact plate 11 can also have other functional elements. A mechanical coding between the assembled electrical cable 2 and the connector housing 4 is indicated in FIG. 12 as an example. For this purpose, the contact surface 13, 16 can have coding elements 23, for example punched-out coding elements 23, which can only be inserted into counter-coding elements 24 of the connector housing 4 in a predefined positioning and/or orientation. Furthermore, it can be ensured in this way that only suitable or permissible electrical cables 2 can be accommodated in the connector housing 4 .

As already in the context of figure 1 mentioned above, the contacting between counter-contact element 7 and contact element or contact plate 11 preferably takes place orthogonally to the mounting direction M of the assembled electrical cable 2. For this purpose, full-surface contacting can be provided, as in figure 1 indicated, after which the contact surface 13, 16 of the contact element or contact sheet 11 is designed as a primarily flat surface for surface contact with the counter-contact surface 14. However, the contact surface 13, 16 and/or the counter-contact surface 14 preferably has an orthogonal directional component for mutual contact, for example contact lamellae 25.

Contacting by means of contact lamellae 25 is shown in an example in figure 10 shown. Provision can be made for one or more contact lamellae 25, which are at least partially elastic in the contacting direction, to be formed from the contact surface 13, 16 itself, for example punched out. Alternatively, separate contact lamellae 25 can be applied to the contact surface 13, 16. In addition, it is possible to use a separate contact lamella element 26 with several contact lamellas 25 (cf. figure 11 ) between the contact surface 13, 16 and the mating contact surface 14 to be introduced, in particular to be mounted captively in the connector housing 4. Through the use of contact lamellae 25, the contact pressure between the contact element or contact plate 11 and counter-contact element 7 can be increased and the contact can thus be improved.

In all cases of contacting between the contact element or contact plate 11 and counter-contact element 7, it can be advantageous to use one or more Provide spring elements 27 in the connector housing 4 and/or mating connector housing 6 in order to press the contact surface 13, 16 against the mating contact surface 14. Corresponding spring elements 27 are exemplified in the Figures 10 and 11 implied.

Claims (15)

Ready-made electrical cable (2) for an electrical plug connector (3), having an electrical conductor (8) which is designed as a strand made up of several individual wires and which has at least one end section (10) compacted in the form of a plate,
marked by
an elongate contact element (11) having at least one side surface which forms a first connection surface (12) which is connected to the compacted end section (10) of the electrical conductor (8), and at least one other side surface which is separated from the first connection surface (12) side surface facing away, which forms a first contact surface (13) for contacting a counter-contact surface (14) of a counter-contact element (7) of a counter-connector (5). Assembled electrical cable (2) according to claim 1,
characterized in that
the contact element is designed as a contact plate (11), preferably with a thickness between 0.3 mm and 1.0 mm, particularly preferably with a thickness between 0.4 mm and 0.6 mm. Ready-made electrical cable (2) according to claim 1 or 2,
characterized in that
the contact element (11) and the individual wires of the electrical conductor (8) are made of the same material, preferably aluminum or copper. Ready-made electrical cable (2) according to one of Claims 1 to 3,
characterized in that
the contact element (11) has a coating, preferably a silver coating. Ready-made electrical cable (2) according to one of Claims 1 to 4,
characterized in that
further side surfaces of the contact element (11) form respective further connecting surfaces (15, 17, 18, 19), the contact element (11) preferably having a total of two to five connecting surfaces (12, 15, 17, 18, 19) which are connected to the compacted End portion (10) of the electrical conductor (8) are each connected. Ready-made electrical cable (2) according to one of Claims 1 to 5,
characterized in that
the at least one connecting surface (12, 15, 17, 18, 19) is aligned parallel to a corresponding side surface of the compacted end section (10) to which the connecting surface (12, 15, 17, 18, 19) is connected, and preferably over the entire surface connected to the corresponding side face of the compacted end portion (10). Ready-made electrical cable (2) according to one of Claims 1 to 6,
characterized in that
the at least one connecting surface (12, 15, 17, 18, 19) is materially connected to the compacted end section (10). Ready-made electrical cable (2) according to one of Claims 1 to 7,
characterized in that
the at least one connecting surface (12, 15, 17, 18, 19) completely covers a corresponding side surface of the compacted end section (10) to which the connecting surface (12, 15, 17, 18, 19) is connected. Ready-made electrical cable (2) according to one of Claims 1 to 8,
characterized in that
a further side surface of the contact element (11) forms a second contact surface (16) for contacting a mating contact surface (14) of a mating contact element (7) of a mating connector (5). Ready-made electrical cable (2) according to one of Claims 1 to 9,
characterized in that
the at least one contact surface (13, 16) of the contact element (11) a) is designed as a primarily flat surface for surface contacting with the counter-contact surface (14); or b) has one or more contact lamellae (25), which are at least partially elastic in the contacting direction, for contacting with the counter-contact surface (14). Ready-made electrical cable (2) according to one of Claims 1 to 10,
characterized in that
the at least one contact surface (13, 16) each has at least one first latching means (20, 21, 22) for latching with a corresponding second latching means of the connector (3) in order to ensure mutual latching between the assembled cable (2) and the connector ( 3) to be provided when the assembled cable (2) is mounted in the connector (3). Assembled electrical cable (2) according to claim 11,
characterized in that
the first latching means is designed as a spring clip (20) punched out of the contact surface (13, 16), as a latching lug (21) formed on the contact surface (13, 16) and/or as a latching recess (22) within the contact surface (13, 16). . Ready-made electrical cable (2) according to one of Claims 1 to 12,
characterized in that
the electrical conductor (8) has a conductor cross-section greater than 10 mm ² , preferably greater than 30 mm ² , particularly preferably greater than 60 mm ² , for example greater than 90 mm ² . Ready-made electrical cable (2) according to one of Claims 1 to 13,
characterized in that
the individual wires of the electrical conductor (8) are welded together to form the plate-shaped compacted end section (10), preferably pressure welded, resistance welded or fusion welded together. Connector arrangement (1), comprising a ready-made electrical cable (2) according to any one of claims 1 to 14 and the electrical Connector (3), wherein the plate-shaped compacted end section (10) is accommodated within a connector housing (4) of the electrical connector (3).

Images