WO2022223608A1 - Câble électrique assemblé et ensemble connecteur - Google Patents

Câble électrique assemblé et ensemble connecteur Download PDF

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Publication number
WO2022223608A1
WO2022223608A1 PCT/EP2022/060406 EP2022060406W WO2022223608A1 WO 2022223608 A1 WO2022223608 A1 WO 2022223608A1 EP 2022060406 W EP2022060406 W EP 2022060406W WO 2022223608 A1 WO2022223608 A1 WO 2022223608A1
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WO
WIPO (PCT)
Prior art keywords
contact
connector
electrical
contact element
assembled
Prior art date
Application number
PCT/EP2022/060406
Other languages
German (de)
English (en)
Inventor
Willem Blakborn
Maximilian Metzenleitner
Original Assignee
Rosenberger Hochfrequenztechnik Gmbh & Co. Kg
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Rosenberger Hochfrequenztechnik Gmbh & Co. Kg filed Critical Rosenberger Hochfrequenztechnik Gmbh & Co. Kg
Publication of WO2022223608A1 publication Critical patent/WO2022223608A1/fr

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/025—Contact members formed by the conductors of a cable end
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/40—Securing contact members in or to a base or case; Insulating of contact members
    • H01R13/42—Securing in a demountable manner
    • H01R13/422—Securing in resilient one-piece base or case, e.g. by friction; One-piece base or case formed with resilient locking means
    • H01R13/4223—Securing in resilient one-piece base or case, e.g. by friction; One-piece base or case formed with resilient locking means comprising integral flexible contact retaining fingers
    • H01R13/4226—Securing in resilient one-piece base or case, e.g. by friction; One-piece base or case formed with resilient locking means comprising integral flexible contact retaining fingers comprising two or more integral flexible retaining fingers acting on a single contact
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H01R4/029—Welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0207—Ultrasonic-, H.F.-, cold- or impact welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0214—Resistance welding

Definitions

  • the invention relates to a ready-made electrical cable for an electrical 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.
  • cables 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.
  • 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.
  • 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.
  • 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.
  • Electromobility in particular poses major challenges for the automotive industry and its suppliers, since high levels of electrical power have to be transmitted in the vehicles via the cables or plug-in connections.
  • the thermal load and the resulting waste heat, which is associated with the high current flow, is considerable.
  • 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 in order to use the stored energy from the Remove battery and supply an electrical consumer or to connect multiple batteries or battery modules with each other.
  • a high-voltage connector 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.
  • 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.
  • a welded-on contact blade 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 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 impaired.
  • a contact element designed as a compacted stranded wire it is complex to provide suitable latching means for latching with the connector housing.
  • US 2015/075863 A1 relates to an electrical conductor equipped with a connecting piece.
  • US 2020/169052 A1 relates to a technique for ultrasonically welding an electrical conductor to an electrical terminal.
  • DE 10 2017 106 742 B3 relates to a connection of a connecting line with a stranded line, in which a connecting part has a first metallic surface made of a first metal material and a second metallic surface made of a second metal material that is different from the first metal material, the stranded line being formed from a metal material is, the connecting part encasing the stranded line, with the first metallic surface adjoining the stranded line, is laid around the stranded line, and the connecting part is at least positively connected to the stranded line.
  • US 2020/350708 A1 relates to a terminal-attached electric wire and wire harness, and JP 2011 081918 A to a water stop structure for an electric wire.
  • the object of the present invention is to provide a ready-made electrical cable which is preferably used for the transmission of high electrical currents with low contact resistance, and which is particularly suitable for mass production but can still be produced with high precision.
  • 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.
  • the electrical conductor can be exposed (stripped) from the cable sheath in the region of its end section.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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, the contact element can cover protruding individual wires that have not been sufficiently compacted.
  • 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.
  • 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.
  • 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.
  • 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.
  • the use of a plurality of small contact plates, which are arranged distributed over the plate-shaped compacted end section, can also be provided.
  • an arbitrarily designed contact element can be provided.
  • 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.
  • the contact sheet can also be deep-drawn or produced in some other way.
  • the contact plate is preferably produced as a stamped and bent part.
  • 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.
  • 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.
  • 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.
  • 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.
  • a second connecting surface, a third connecting surface, a fourth connecting surface and/or a fifth connecting surface can be provided.
  • each of the connecting surfaces is connected to a different corresponding side surface of the compacted end portion.
  • the contact element can preferably be folded over an edge of the plate-shaped compacted end section.
  • the contact element can be folded over two edges of the compacted end section, in particular be U-shaped.
  • the contact element can be folded over three edges of the compacted end section, for example.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the at least one connecting surface completely covers a corresponding side surface of the compacted end section to which the connecting surface is connected.
  • the contact surface for contacting the counter-contact surface of the counter-contact element can be enlarged.
  • protruding individual wires can be covered comprehensively.
  • 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.
  • further contact surfaces can also be provided, for example a third contact surface, a fourth contact surface and/or a fifth contact surface.
  • 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.
  • 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.
  • a contact element can be designed in the manner of a contact sword, in combination with the advantages according to the invention.
  • 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.
  • contact lamellae can increase the contact force to the mating contact element and thus improve the power transmission.
  • the contact surface can in principle have any rigid and/or elastic projections on the contact surface (e.g. ribs). In the simplest case, however, a planar contact can be provided, i. H. the contact surface can be completely planar or flat.
  • the contact lamellae can be punched out of the contact surface of the contact element, for example.
  • 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.
  • 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 provide the connector 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.
  • first latching means and corresponding second latching means can be provided.
  • the first latching means is designed as a spring clip punched out of the contact surface.
  • the connector in particular the connector housing of the connector, can have a corresponding latching recess or a corresponding latching lug have, in or behind which the spring shackles can engage in the assembled state of the assembled cable.
  • the first latching means is designed as a latching lug or latching hook formed on 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 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.
  • 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.
  • the contact element can also have latching elements for latching with the mating contact element and/or mating connector.
  • the connector housing can be latched to a mating connector housing of the mating connector.
  • the contact element has further functional elements.
  • 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.
  • 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 .
  • 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 (for example 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.
  • the individual wires of the electrical conductor are welded to one another in order to form the plate-shaped, compacted end section
  • the strands may be pressure welded, resistance welded, or fusion welded together.
  • 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.
  • 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.
  • the contact can also be particularly robust and able to absorb high cable tensile forces, for example tensile forces greater than 100 N.
  • the invention also relates to a method for assembling an electrical cable, having at least the following method steps:
  • the invention also relates to a device for assembling an electrical cable for carrying out the above-mentioned method.
  • 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 in the implementation of the invention in practice excluded are.
  • 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.
  • Figure 1 shows a connector assembly according to the invention from a ready-made electrical cable and an electrical connector, in a lateral sectional view;
  • FIG. 2 shows a front view of a ready-made electrical cable according to the invention, according to a first exemplary embodiment
  • FIG. 3 shows the assembled electrical cable of FIG. 2 in a side view
  • FIG. 4 shows a front view of a ready-made electrical cable according to the invention, according to a second exemplary embodiment
  • FIG. 5 shows a perspective view of a ready-made electrical cable according to the invention
  • FIG. 6 shows the assembled electrical cable of FIG. 5 in an end view
  • FIG. 7 shows a front view of a ready-made electrical cable according to the invention, according to a fourth exemplary embodiment
  • FIG. 8 shows a perspective view of a contact element for use with an electrical cable assembled according to the invention according to a fifth exemplary embodiment, with different configurations of first latching means
  • FIG. 9 shows a side view of 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;
  • FIG. 10 shows a further connector arrangement according to the invention made up of a ready-made electrical cable and an electrical connector, in a front-side sectional view;
  • FIG. 11 shows a further connector arrangement according to the invention made up of a ready-made electrical cable and an electrical connector, in a lateral sectional representation
  • FIG. 12 shows a further connector arrangement according to the invention made up of a ready-made electrical cable and an electrical connector, in a lateral sectional view.
  • Figure 1 shows a connector assembly 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.
  • the cable 2 can preferably be inserted into the connector housing 4 along a mounting direction M.
  • 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.
  • a mating connector housing 6 of mating connector 5 is shown in dashed lines in FIG. 1, and a mating contact element 7 of mating connector 5 is also 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 .
  • a cable jacket 9 is not absolutely necessary.
  • 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 .
  • 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 designed as a stranded wire made up of several individual wires and is compacted in a plate-like manner in an end section 10, see also Figures 2 and 3, for example. resistance welded or fusion welded.
  • the proposed assembled electrical cable 2 has an elongate contact element.
  • 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.
  • 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.
  • the contact element or contact sheet 11 can also have a coating, preferably a silver coating (not shown).
  • 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 connected is.
  • the contact plate 11 also has a side surface facing away from the first connecting surface 12, which forms a first contact surface 13 for contacting a mating contact surface 14 (see, for example, FIG. 10) of the mating contact element 7 of the mating connector 5.
  • 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.
  • Figures 4 to 8 show some variants of the contact element designed as a contact plate 11 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 connected to the compacted end portion 10 of the electrical conductor 8, respectively.
  • the contact plate 11 has the first connecting surface 12 and a further, second connecting surface 15, with the contact plate 11 being wrapped around an edge of the plate-shaped, compacted end section 10 of the electrical conductor 8.
  • This edge can preferably be that of the mating contact element 7 act during the plugging process facing edge of the contact plate 11. In this way it can be avoided that protruding individual wires negatively influence the plugging process.
  • the number of contact surfaces does not necessarily have to correspond to the number of connecting 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-like compacted end sections 10 (cf., for example, FIGS. 2 and 7).
  • FIG. 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 plate 11, which wraps around two edges of the plate-shaped compacted end section 10 is turned over.
  • a fourth connecting surface 18 (cf. FIG. 7) can also be provided.
  • the contact plate 11 or assembled electrical cable 2 shown as an example in FIG. 7 can thus advantageously be contacted from both sides and/or be used in a modular manner and independently of the orientation.
  • the contact plate 11 can in principle be produced in any way, but is preferably produced as a stamped and bent part.
  • a deep-drawn contact element 11 can also be suitable.
  • 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.
  • a fifth connecting surface 19 is provided for this purpose in FIG.
  • 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.
  • the connecting surfaces 12, 15, 17, 18, 19 completely cover the respective corresponding side surface of the compacted end section 10.
  • the axial length LK of the connecting surface 12, 15, 17, 18, 19 can thus correspond to the axial length of the compacted end section 10 (cf. FIG. 3).
  • 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 LK and thus only extend over a partial area of the axial length of the compacted end section 10.
  • 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.
  • 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.
  • 9 and 11 exemplary latching means are shown.
  • 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 able to latch behind a latching lug or other edge of the connector housing 4 (cf. Figure 11) in order to secure the assembled electrical cable 2 to be secured against being pulled out in the opposite direction to the mounting direction M.
  • latching recesses 22 can also be formed in the contact surface 13, 16 (see FIGS. 8 and 12) into which the corresponding second latching means of the connector housing 4, for example latching lugs and/or spring tabs, are able to latch (not shown).
  • latching lugs 21 are formed on the contact surface 13, 16, behind which the spring shackles (not shown) of the connector housing 4 are able to latch, complementary to the variant shown in FIG.
  • 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.
  • the contact surface 13, 16 have coding elements 23, for example punched-out coding elements 23, which in counter-coding elements 24 of the connector housing 4 only in one predefined positioning and/or orientation can be inserted. Furthermore, it can be ensured in this way that only suitable or permissible electrical cables 2 can be accommodated in the connector housing 4 .
  • the contact between mating contact element 7 and contact element or contact plate 11 is preferably orthogonal to the mounting direction M of the assembled electrical cable 2.
  • full-surface contact can be provided, as indicated in Figure 1, after which the contact surface 13, 16 of the contact element or contact sheet 11 is designed as a primarily flat surface for surface contacting with the mating contact surface 14.
  • 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.
  • the contacting by means of contact lamellae 25 is shown in FIG. 10 by way of example. 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. It is also possible to introduce a separate contact lamellar element 26 with several contact lamellae 25 (cf. FIG. 11) between the contact surface 13, 16 and the mating contact surface 14, in particular to mount it 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.

Landscapes

  • Details Of Connecting Devices For Male And Female Coupling (AREA)

Abstract

L'invention concerne un câble électrique assemblé (2) pour un connecteur électrique (3), comprenant un conducteur électrique (8), qui se présente sous la forme d'un conducteur toronné composé d'une pluralité de fils individuels et qui a au moins une partie d'extrémité (10) compactée en une forme plate. Selon l'invention, le câble électrique assemblé (2) comporte un élément de contact allongé (11), comprenant au moins une surface latérale formant une première surface de raccordement (12), qui est raccordée à la partie d'extrémité compactée (10) du conducteur électrique (8), et comprenant au moins une surface latérale supplémentaire, qui est opposée à la première surface de raccordement (12) et forme une première surface de contact (13) pour mettre en contact une surface de contact homologue (14) d'un élément de contact homologue (7) d'un connecteur homologue (5). Chacune des au moins une surface de contact (13, 16) présente au moins un premier moyen de verrouillage (20, 21, 22) destiné à être verrouillé sur un second moyen de verrouillage correspondant du connecteur électrique (3), afin de réaliser un verrouillage mutuel entre le câble assemblé (2) et le connecteur électrique (3) lorsque le câble assemblé (2) est installé dans le connecteur (3).
PCT/EP2022/060406 2021-04-21 2022-04-20 Câble électrique assemblé et ensemble connecteur WO2022223608A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP21169672.9A EP4080685A1 (fr) 2021-04-21 2021-04-21 Câble électrique confectionné et agencement de connecteur enfichable
EP21169672.9 2021-04-21

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WO2022223608A1 true WO2022223608A1 (fr) 2022-10-27

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