EP2267728B1 - Electric cable and cable assembly - Google Patents

Description

The present invention relates to an electrical line arrangement comprising at least one electrical line, both in particular for the simultaneous transmission of a plurality of different control signals in a motor vehicle.

The increasing importance of electronic functions in modern systems, especially in motor vehicles, necessitates simultaneous transmission of a variety of different signals in these systems. Such simultaneous transmission of multiple signals requires a corresponding plurality of separate electrical signal paths, for example, electrical lines.

Conventional electrical lines, in particular those designed for the transmission of control signals in a motor vehicle, typically consist of a copper conductor, which is surrounded by an insulating cable jacket.

For the simultaneous transmission of different signals, it is necessary to provide a corresponding number of such lines, which brings a considerable material and cost and space requirements.

The DE 22 10 222 A1 discloses a multicore electrical line comprising a plurality of thin wires of electrically conductive material having a resin varnish applied to the surface thereof, and an outer sheath enclosing the thin wires of an electrically insulating material. Several of the thin wires can form a group, with several different colored groups enclosed by a common outer sheath.

An electrical line arrangement with the features of the preamble of claim 1 is known from DE 202 01 726 U1 known. Moreover, that teaches JP 2000-268641 A a wire harness having a plurality of twisted lines, which are connected at both ends in each case with a connector.

An object of the invention is to provide an electrical cable arrangement which makes it possible, with reduced effort, to provide individual cable harnesses with a minimum of unused conductors for individual systems, in particular motor vehicles.

To solve the problem, an electrical line assembly with the features of claim 1 is provided.

The electrical line of the line arrangement comprises a plurality of conductors twisted together and surrounded by a common cable jacket, which are each surrounded by an insulating coating layer to avoid interactions between signals carried in the conductors.

In other words, the invention is based on the general idea to combine a plurality of individual conductors into a line and to isolate the individual conductors from one another by respective lacquer layers so that different electrical signals can be transmitted simultaneously and independently of one another via the line. The particular advantages of the line are in a particularly compact design, a minimal cost of materials and a particularly cost manufacturability.

The twist serves to suppress electromagnetic interactions between signals carried in the twisted conductors and increases the robustness of the signal transmission against external electromagnetic interference. In addition, an improved mechanical flexibility and resistance to breakage of the electrical line is ensured.

Among other things, the compact design is made possible by the fact that the insulating lacquer layer of a conductor can be very thin in comparison to the cross section of the conductor. The cost of materials and space requirements of the electrical line is thereby greatly reduced compared to a corresponding plurality of conventional individual signal lines, each with its own cable jacket.

In addition, the electrical line due to their simple structure in a very simple manner and thus can be produced inexpensively. In particular, existing machine tools can be used for this purpose.

The electrical line is preferably a vehicle line of the type FLY, which in particular satisfies one of the standards DIN EN 13602, DIN 53505 and DIN ISO 6722 class B.

At least one of the conductors may be formed of a metal such as copper or aluminum.

The common cable sheath, in which the conductors are combined and preferably fixed, can be designed in a manner known per se at least substantially tubular or cylindrical and insulate the conductors from the environment. Preferably, the cable jacket comprises a plastic material which is produced by extrusion. It is particularly preferred if the cable jacket comprises at least one material selected from the group consisting of polyvinyl chloride (PVC), Polyethylene (PE), polyphenylene ether (PPE), polyurethane and Teflon.

In the electrical line arrangement according to the invention, the electrical line is connected at both ends in each case with an electrical connector. Such a connector allows a simplified connection of the electrical line assembly to a device having a corresponding mating connector. In this way, a plurality of separate signal paths between devices or the like can be produced in a particularly simple manner.

The number of enamel-insulated conductors within a line and thus the number of signals that can be transmitted simultaneously through the line is in principle not limited. It is therefore easily possible to produce lines with different numbers of enamel-insulated conductors and then to create the necessary signal paths through a corresponding individual combination of several lines with corresponding and possibly different numbers of enamel-insulated conductors in a concrete system. The lines can be summarized in a conventional manner to a cable harness or wiring harness. The invention is thus suitable for use in a modular line system and makes it possible to provide individual cable sets or harnesses with a minimum of unused conductors for individual systems with reduced effort.

Advantageous embodiments of the invention are described in the description, the subclaims and the drawings.

Depending on the type of signals to be transmitted and possible external disturbances as well as the desired mechanical properties of the electrical line, in principle any twisting between the conductors of the electrical line can be provided. Thus, several conductor pairs may be twisted in pairs and / or the lay lengths of several twists may be different. Furthermore, at least one second order twist may be provided, i. a twist consisting of several conductors twisted together is in turn twisted with at least one further twist of conductors. In principle, the twists forming the second-order twist can have identical or different lay lengths. It can also be twisted all conductors of the electrical line in first order with each other.

In principle, all conductors of the electrical line can have substantially the same cross-sectional areas. Alternatively, however, at least two of the conductors may also have different cross-sectional areas. By different cross-sectional areas different resistances of the respective conductors can be realized, which may be useful depending on the particular signals to be transmitted and in particular their frequencies. Depending on the application, it may also be advantageous if different conductors either have different cross-sectional areas and / or different thicknesses of the insulating lacquer layer.

According to a further advantageous embodiment, at least one and in particular each conductor has an over its length at least substantially constant cross-sectional area, which may for example be in the range of a few hundredths of a square millimeter to a few tenths of a square millimeter. A conductor having such a cross-sectional area is common to those used in automotive control applications Signals and line lengths particularly suitable transmission properties. The cable jacket preferably has a wall thickness substantially constant over the length of the conductor in the range of a few tenths of a millimeter, for example in the range between 0.3 and 0.5 millimeters.

It is particularly preferred if at least two conductors and in particular all conductors are optically distinguishable. This facilitates proper connection of different signal sources and sinks to the conductors.

To ensure optical differentiation of the conductors, the conductors may have differently colored insulating lacquer layers. In the case of a transparent insulating lacquer layer, however, the conductors themselves may also have different colors, for example if the conductors consist of different materials. According to the invention, at least two conductors, in particular by special surface textures or textures, can be haptically distinguished.

According to a further embodiment, a strain relief is provided, which may be formed, for example, by a thread extending over the length of the electrical line and / or by a glass fiber extending over the length of the electrical line. Such a strain relief preferably runs in the middle of the ladder. In the case of a twist of conductors, it is advantageous if the conductors are twisted around the strain relief. Alternatively, the strain relief may be part of a twist, so be twisted with at least one conductor.

It is further preferred if an electrical shield surrounding the conductors is provided. Such electrical shielding can for example, consist of an arranged between the conductors and the cable jacket electrically conductive foil.

In principle, the electrical line arrangement according to the invention can have any desired number of electrical lines and of connectors connected to the electrical lines. Depending on the application, it can be advantageous in this case if all conductors of an electrical line are each connected at their one end to a first connector and are connected at their other end to a second connector. In a conduit arrangement with a plurality of electrical lines, it may be advantageous if multiple electrical lines are connected to one and the same connector. Conversely, in principle, the conductors of one and the same electrical line can be connected at one end of the line to different connectors.

If a plurality of conductors of an electrical line or different electrical lines are connected to one and the same connector, at least two conductors can be connected to different connection elements of the connector to form different signal paths. If a signal path with increased conductivity is required, however, two or more conductors can also be connected to the same connection element of a connector. In this way, a signal can be transmitted in parallel via several conductors.

A conductor may be connected in a manner known per se and in particular by a plug-in, clamping, soldering, pressing or riveting connection or by another detachable or non-detachable electrical connection to a connection element of a connector.

According to a further advantageous embodiment, a conductor of an electrical line connected to a connection element of a connector is stripped substantially only in a connection region in which the conductor is in electrical contact with the connection element, i. the conductor has no insulating lacquer layer only in this area. This prevents a short circuit between the conductor and other conductive elements in the environment, as well as adjacent conductors or connectors.

Such a connection region is usually in the region of one end of the conductor. In the context of the invention, however, a connection region of a conductor may also lie in a region of the conductor which is significantly spaced apart from the ends of the conductor, for example by several 10 cm, provided the line jacket of the conductor is removed in this region. In this way, a conductor can be connected not only at its ends but also in a central region to a connection element of a connector.

Fig. 1

eine Querschnittsansicht einer elektrischen Leitung einer erfindungsgemäßen elektrischen Leitungsanordnung;

Fig. 2

eine erfindungsgemäße elektrische Leitungsanordnung;

Fig. 3a-d

einen Teil der Leitungsanordnung von Fig. 2 in unterschiedlichen Fertigungszuständen;

Fig. 4

einen Mittelbereich einer elektrischen Leitung mit einem teilweise entfernten Leitungsmantel; und

Fig. 5

den Mittelbereich der elektrischen Leitung aus Fig. 4 mit einem teilweise entfernten Leitungsmantel und voneinander beabstandeten Leitern.

Hereinafter, the present invention will be described purely by way of example with reference to an advantageous embodiment with reference to the accompanying drawings. Show it:

Fig. 1

a cross-sectional view of an electrical line of an electrical cable assembly according to the invention;

Fig. 2

an electrical line arrangement according to the invention;

Fig. 3a-d

a part of the line arrangement of Fig. 2 in different production states;

Fig. 4

a central portion of an electrical lead having a partially removed conductive sheath; and

Fig. 5

the middle region of the electrical line Fig. 4 with a partially removed cable jacket and spaced conductors.

Fig. 1 shows a cross-sectional view of an electrical line with seven conductors 10 made of, for example, copper, which are each surrounded by an insulating resist layer 14. Characterized in that the conductors 10 are electrically isolated from each other by their insulating coating layer 14, seven separate signal paths are provided by the illustrated line, which make it possible to transmit a maximum of seven different electrical signals simultaneously. It should be noted that the number of seven conductors here is purely exemplary and may vary depending on the application. This means that lines with more or less than seven conductors are also conceivable.

The conductors 10 have substantially similar cross-sectional areas, which may range from a few hundredths of a square millimeter to a few tenths of a square millimeter. The conductors 10 are twisted together and surrounded by a common conductor sheath 16 having an extruded plastic material.

Fig. 2 shows an embodiment of an electrical line arrangement according to the invention. An electrical line 18 with a as in Fig. 1 shown cross section is connected at both ends with a connector 20. The respective end of the electrical line 18 is for this purpose inserted into an opening 22 of the housing 24 of the connector 20. The connectors 20 each have one in the housing 24 used insert 26, which with connection elements 36 (FIG. Fig. 3 ) is provided. Each conductor 10 of the electrical line is connected by means of a solder connection to one of the connecting elements 36. The insert 26 has a plurality of openings 28 through which the connection elements 36 of the connector 20 for complementary connections of a plug connector 20 to the complementary formed socket (not shown) are accessible.

The housing 24 of the connector 20 has two spring elements 30, each with a locking lug 32, which enter a latching connection with corresponding recesses of the socket when inserting the connector 20 into the socket. In addition, a key projection 34 is provided on the housing 24, which together with a complementary to the key projection 34 recess of the socket allows insertion of the connector 20 only in a predetermined orientation.

In Fig. 3a-d is a part of the electrical line arrangement according to the invention Fig. 2 shown with a portion of the electrical line 18 and the associated connector 20 in different manufacturing states.

Fig. 3a shows the electrical lead 18 and the housing 24, the insert 26 and the connection elements 36 of the connector 20 prior to assembly of the connector 20 and establishing the connection between the connector 20 and the electrical line 18th

Each connection element 36 has a soldering surface 44, to which a conductor 10 is soldered and the conductor 10 can thereby be connected to the connection element 36. Alternatively, the conductor 10 can also by means of a Crimpverbindung or in other material and / or non-positive manner to the connection elements 36 are connected.

The insert 26 of the connector 20 has a plurality of slots 42, in each of which a connection element 36 can be inserted.

The cable jacket 16 of the line 18 is removed in a region of the illustrated end of the line 18, so that the individual conductors 10 twisted together are freely accessible. The insert 26 has a latching nose 38, which engages in the inserted state in a recess 40 of the housing 24 and produces a latching connection between the insert 26 and the housing 24.

Fig. 3b shows the conduit arrangement after the conduit 18 has been inserted through the opening 22 in the housing 24.

Fig. 3c shows the line arrangement after the connection elements 36 have been inserted into the corresponding slots 42 of the insert 26 and the conductors 10 have been soldered to the solder pads 42 of the connection elements 36. The conductors 10 are stripped for this purpose in the area in which they rest against the solder surfaces 44.

The inserted connection elements 36 are electrically isolated from each other, and all conductors 10 are connected to different connection elements 36. In this way, each conductor 10 provides its own signal path.

Fig. 3d shows the line arrangement at finished connection between connector 20 and electrical line 18, so after inserting the insert 26 into the housing 24th

Fig. 4 shows a central portion of an electric wire having a like in Fig. 1 has shown cross-section. In the illustrated central region of the cable jacket 16 is partially removed, so that the lacquer-insulated conductor 10 are accessible from the outside.

Fig. 5 shows the central area of the electric line of Fig. 4 , wherein the enamel-insulated conductor 10 in the region in which the cable jacket 10 has been removed, spaced from each other and thus are individually accessible. For example, this spaced apart arrangement can be created simply by twisting the two ends of the central region against the direction of rotation of the twisted conductors 10 and slightly pressing the two ends towards each other.

In the in Fig. 5 In the situation illustrated, it is possible to contact the individual conductors 10 in the illustrated central area by locally stripping the conductors 10 and connecting them to corresponding connectors, thereby providing additional connection possibilities in the central area of the electrical line.

LIST OF REFERENCE NUMBERS

10

ladder

14

insulating varnish layer

16

cable sheath

18

electrical line

20

Connectors

22

opening

24

casing

26

commitment

28

opening

30

spring element

32

locking lug

34

key post

36

connecting element

38

locking lug

40

recess

42

slot

44

soldering

Claims (12)

1. Electrical line arrangement comprising an electrical line (18) which comprises a plurality of conductors (10) which are twisted together and are surrounded by a common line sheath (16) and which electrical line is connected to in each case one electrical plug-in connector (20) at the two ends, wherein at least two conductors (10) are connected to different connection elements (36) of a plug-in connector (20),
   characterized in that
   the conductors (10) are each surrounded by an insulating coating layer (14) in order to avoid interactions between different signals which are carried in the conductors (10), and at least two conductors (10) can be haptically distinguished.
2. Electrical line arrangement according to Claim 1,
   characterized in that
   the conductors (10) all have substantially identical cross-sectional areas, or at least two of the conductors (10) have different cross-sectional areas.
3. Electrical line arrangement according to Claim 1 or 2,
   characterized in that
   at least one, and in particular each, conductor (10) has a cross-sectional area, which is at least substantially constant over its respective length, in the range of a few hundredths of a square millimetre to a few tenths of a square millimetre.
4. Electrical line arrangement according to one of the preceding claims,
   characterized in that
   at least two conductors (10) and in particular all of the conductors can be visually distinguished.
5. Electrical line arrangement according to one of the preceding claims,
   characterized in that
   the line sheath (16) comprises an, in particular extruded, plastic material which is selected, in particular, from the group which comprises polyvinyl chloride, polyethylene, polyphenylene ether, polyurethane and Teflon.
6. Electrical line arrangement according to one of the preceding claims,
   characterized in that
   a strain-relief means is provided which is formed, in particular, by a thread which extends over the entire length of the electrical line and/or by a glass fibre which extends over the entire length of the electrical line.
7. Electrical line arrangement according to one of the preceding claims,
   characterized in that
   an electrical shield which surrounds the conductors (10) is provided.
8. Electrical line arrangement according to one of the preceding claims,
   characterized in that
   at least two conductors (10) of the electrical line (18) are connected to the same connection element (36) of the connector (20).
9. Electrical line arrangement according to one of the preceding claims,
   characterized in that
   a conductor (10) which is connected to a connection element (36) of the connector (20) is stripped of insulation substantially only in a connection region in which the conductor (10) is in electrical contact with the connection element (36).
10. Electrical line arrangement according to Claim 9,
    characterized in that
    the connection region is situated in the region of an end of the conductor (10).
11. Electrical line arrangement according to Claim 9 or 10,
    characterized in that
    the connection region is situated in a region of the conductor which is at a significant distance from the ends of the conductor (10).
12. Use of an electrical line arrangement according to one of Claims 1 to 11 for simultaneously transmitting a plurality of signals in a cable harness of a motor vehicle.

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