EP3477777B1 - Electrical conductor with screen conductor - Google Patents

Description

area

The invention relates to an electrical line which has an electrical shield which is in contact with an additional line and which forms a shield outlet.

background

Electrical lines of the type mentioned at the beginning are used, for example, in the automotive sector to connect electrical units and components to one another. In order to save material and weight, a general tendency towards ever higher operating voltages can be observed, which allow smaller cable cross-sections. This applies in particular to vehicles with a purely electric drive or with a hybrid drive. In such vehicles, devices and consumers are therefore increasingly being supplied with increased voltage from power sources. The power sources used can be designed for voltages of up to 1000 V. Consumers are, for example, air conditioning compressors and, particularly in the case of electric vehicles, a drive motor and existing heating devices. An active device is, for example, the charger for charging a battery. For the connection of consumers and devices with a corresponding battery or with control electronics connected to the same, electrical lines provided with an electrically effective shield are used. In many cases, it is necessary with such lines to connect the shield of the electrical lines to ground. When the cables are used in vehicles, they are exposed to harsh operating conditions, in particular mechanical vibrations, dirt and splash water. Nevertheless, it is required that the relevant electrical lines and their connections function reliably over a long period of use.

From the DE 33 21 936 A1 a coaxial cable connector is known which is designed to connect a ground line to the shield of a coaxial line to connect. To do this, the shield of the coaxial line is connected to a ground line and then plugged into a connector housing. The connector housing has a cavity which allows the cavity and in particular the connection area where the ground line is connected to the screen to be closed with a potting compound. The disadvantage is that this type of sealing is complex and, in the case of silicone sheathed cables, is only suitable for temperature ranges of a maximum of 90-100 ° C.

In the document DE 197 41 572 A1 a device for connecting two shielded insulated electrical conductors is described according to the preamble of claim 1. The inner core of the first conductor is connected to the inner core of the second conductor and the screen of the first conductor is connected to the screen of the second conductor. For use in an explosive environment, an insulated sleeve unit is provided that surrounds the connection point.

Proceeding from this, the present invention has the object of creating an electrical line with a shield exit that is easier to manufacture.

Summary of the invention

To solve this problem, the invention proposes an electrical line with at least one insulated conductor which is surrounded by an electrical screen which is contacted at a contact point with an additional conductor which forms a screen exit. A tightly sealing housing is mounted on the electrical line around the contact point.

In one embodiment, the electrical lead can include multiple insulated conductors.

The proposed solution is designed in such a way that single-core and multi-core cables, for example HV silicone sheathed cables, can be used in temperature ranges up to 180 ° C. The contact area between the electrical shield of the line and the shield outlet is reliably protected from environmental influences and, in particular, from corrosion by the housing. The assembled housing is also with Cables can be used whose outer jacket material, such as silicone, for example, a waterproof encapsulation solution, as is known from the prior art, cannot be implemented.

According to the invention, a first seal and a second seal are inserted into the housing, which seal the housing to the outside. Each of the seals in addition still be profiled on their outer circumference, in particular have circumferential beads in order to improve the sealing effect even further.

According to the invention, the second seal has several through openings for the at least one insulated conductor and the additional conductor.

Each seal is advantageously held in the housing by means of a retaining cap fastened on the housing. The retaining cap also has the advantage that the seal is protected from mechanical influences that could impair the sealing effect. Latching means can be provided on the housing and the retaining cap, which ensure simple assembly and, at the same time, a secure fit of the retaining cap.

According to the invention, a holding element is provided which fixes the contact point in the housing. This prevents the contact point from moving back and forth in the housing, which in the worst case could damage the contact point or even break a line.

In an expedient development, a contact element establishes electrical contact between the electrical shield and the further conductor. The contact element enables the contact between the additional line and the electrical shield to be established quickly and easily. The contact element can in particular be a cable lug.

A support sleeve is advantageously provided, which is arranged under the electrical screen. The support sleeve protects the underlying inner sheath of the cable and the wires embedded in the inner sheath from mechanical damage caused by a subsequent crimping process.

In an advantageous development, a crimp sleeve tightly encloses the contact element, as a result of which the electrical shield is clamped between the support sleeve and the annular cable lug. The contact to the electrical Shield is thus achieved through a simple standard crimping process.

In an advantageous development of the invention, the retaining cap, through which one or more insulated lines and the additional conductor pass, has markings that visibly identify the individual conductors. For example, when assembling the lines in an automobile, the simple identification of the wires in the line can bring advantages in production.

Brief description of the drawing

Fig. 1A

eine perspektivische Ansicht einer erfindungsgemäßen Leitung im zusammengebauten Zustand;

Fig. 1B

einen Querschnitt einer geschirmten Leitung mit zwei Adern;

Fig. 1C

eine Explosionsdarstellung der Leitung aus Figur 1A;

Fig. 2A

ein Kabelschuh mit einer angeschlossenen zusätzlichen Leitung;

Fig. 2B

einen Kabelschuh in einer vergrößerten perspektivischen Darstellung;

Fig. 3A-3C

Zwischenzustände bei der Herstellung der Leitung aus Figur 1A; und

Fig. 4A-4B

eine teilweise zusammengebaute Leitung in zwei unterschiedlichen perspektivischen Ansichten.

In the following, the invention is explained in more detail using an embodiment example with reference to the accompanying figures. All figures are purely schematic and not to scale. Show it:

Figure 1A

a perspective view of a line according to the invention in the assembled state;

Figure 1B

a cross section of a shielded cable with two wires;

Figure 1C

an exploded view of the line Figure 1A ;

Figure 2A

a cable lug with a connected additional line;

Figure 2B

a cable lug in an enlarged perspective view;

Figures 3A-3C

Intermediate states in the production of the line Figure 1A ; and

Figures 4A-4B

a partially assembled line in two different perspective views.

The same or similar elements are provided with the same or similar reference symbols in the figures.

Embodiment

Figure 1A shows a line according to the invention, which is designated as a whole by the reference numeral 100. The line 100 comprises a shielded line 101 and a cylindrical housing 102 for a shield exit. The shielded line 101 enters the housing 102 at a first end face 103. Two wires 106, 107 of the line 101 and an additional line 108 emerge from the housing 102 on an opposite, second end face 104. The additional line 108 is provided with an electrical shield 109 ( Figure 1B ) of the line 101 and forms the shield exit. The electrical shield is formed in particular from a wire mesh made of copper wires.

Figure 1B shows a cross section through the line 101, which has two wires 106, 107. The wires 106, 107 each include an electrical conductor 111 which is surrounded by insulation 112. The two wires 106, 107 are enclosed by an inner jacket 113 which is surrounded by the electrical screen 109. Finally, the line 101 has an insulating outer jacket 116. The outer jacket is made of silicone, for example. In Figure 1B For the sake of clarity, a distance 114 is shown between the outer jacket 116 and the screen 109, which in reality is not present.

In Figure 1C the structure of the lines 100 is shown in an exploded view in greater detail. In addition to those already in the Figures 1A and 1B Elements shown are shown further components, the function of which will be described in more detail below. These further components include a support sleeve 117 and a cable lug 118. Reference number 119 shows the electrical shield 109 in an expanded state because, in the assembled state of the line 100, the support sleeve 117 is arranged under the electrical shield 109 at this point. A crimp barrel 121 is also shown. A first seal 122 and a first retaining cap 123 are attached to the first end face 103 of the housing 102 is provided. The seal 122 has a central through opening 124 which lies tightly against the outer jacket of the line 101. The first retaining cap 123 has a through opening 126 which enables the line 101 to pass through the retaining cap 123. On the opposite second end face 104, where the wires 106, 107 and the line 108 exit from the housing 102, a hold-down device 127, a second seal 128 and a second retaining cap 129 are provided. The second seal 128 has three through openings 131 for the wires 106, 107 and the additional line 108. The through openings 131 close off tightly with the respective insulation of the wires or the additional line. Corresponding passages are provided in the second retaining cap 129, which allow the wires 106, 107 and the additional line 108 to pass through, as shown in FIG Figure 1A can be seen. The seals 123 and 128 have a profiled circumferential surface in order to improve the sealing effect with respect to the housing 102. The seals 123 and 128 are thus set up and suitable for sealing off the interior of the housing 102 against environmental influences, in particular against moisture and dirt

In Figure 2A the cable lug 118 is shown in an enlarged perspective view. The cable lug 118 has a cylindrical connection area 201 which encloses the support sleeve 117 in the assembled position. The cylindrical connection area 201 is provided with a longitudinal slot 202. In one embodiment, the inner diameter of the connection area 201 is selected to be slightly smaller than the outer diameter of the support sleeve 117, so that the cable lug has a resilient seat on the support sleeve 117. This is advantageous when assembling the line 100 because the cable lug 118 can be placed on the support sleeve 117, but does not simply fall off the support sleeve 117 again. The connection area 201 merges into an elongated assembly section 203 which is provided with two pairs of clamping tabs 204 and 206. During the assembly of the additional line 108, the clamping tabs 204 are pressed onto a conductor of the line 108 in order to produce an electrical contact. The Clamping flaps 206 are pressed onto the insulation of the line 108 and thus hold the line 108 firmly and form a strain relief.

Figure 2B shows the cable lug 118 with the additional line 108 mounted.

The line 100 described so far is produced as follows:
As in Figure 3A is shown, in a first step the outer sheath 116, the electrical shield 109 and the inner sheath 113 are removed from a line 101 in a first section 301 in order to expose the wires 106, 107. In a second section 302, the wire mesh forming the electrical shield 109 is expanded, so that a collar 303 protruding from the line 101 in the radial direction is formed. Then the support sleeve 117 is placed on the inner casing 113 exposed in the second section 302.

Out Figure 3B it can be seen that the cable lug 118, to which the additional line 108 is connected, is placed on the support sleeve 117. The expanded wire mesh of the electrical shield 109 is placed over the cable lug 118.

With the crimp barrel 121, which in Figure 3C is pushed from the left over the electrical shield 109, the cable lug and the support sleeve 117, the electrical shield 109 is pressed or crimped onto the cable lug 118, whereby an electrical connection between the cable lug 118 and the electrical shield 109 is established. This creates an in Figure 3C Contact point V, marked with a circle, for the shield outlet 108. During crimping, the support sleeve 117 prevents mechanical pressure from being exerted on the inner jacket 113 and the wires 106, 107 embedded therein in order to effectively protect the elements mentioned from mechanical damage.

Figure 4A shows how the prepared line 101 is inserted into the housing 102. In Figure 4A from the left is the first seal 122 on the line 101 pushed on and inserted into the housing 102, where the seal seals the line 101 on one side and the housing 102 on the other. The seal 121 is fixed in the housing 102 with the first retaining cap 123. For this purpose, the retaining cap 123 is latched onto the housing 102, with latching lugs 401 requested on the housing engaging in corresponding latching openings 402 in the covering cap 123. The hold-down device 127 is then pushed into the side of the housing 102 that is still open. The hold-down device 127 has a cylindrical jacket 403 which, however, extends only over part of an imaginary circumferential line, as a result of which a recess 404 is created in the jacket 403. On one end face, the jacket 403 is provided with a flange 406 which has rectangular grooves 407. The hold-down device 127 is inserted into the housing 102 in such a way that the assembly section 203 of the cable lug 118 comes to lie in the recess 404, while the grooves 407 engage in corresponding guide ribs 408 which are formed on the inside of the housing 102. The guide ribs 408 end in front of the front edge 409 of the housing 102 so that the second seal 128 has a smooth, circular bearing surface.

Figure 4B shows the housing 102 with the inserted hold-down device in a side view, still without the second seal 128, which is only then inserted into the housing 102.

Again referring to Figure 4A the through opening in 131 in the second seal 128 can be seen. The second seal 128 seals the wires 106, 107 and the additional line 108 and the housing 102. In the installed state, the second seal 128 rests on the hold-down device 127. Finally, the second retaining cap 129 is placed and latched onto the housing 102, resulting in the fully assembled line 100, which is shown in FIG Figure 1A is shown. In this assembled state, the hold-down device 127 presses on the connection area 201 of the cable lug 118, as a result of which the line 101 is fixed in the housing.

In an advantageous embodiment, identifications visible to the outside are provided on the second retaining cap 129, with which the two wires 106, 107 or the additional line 108 can be easily identified.

In the claims, the words "comprising" and "comprising" do not exclude other elements or steps, and the indefinite article "a" does not exclude a plurality.

A single unit or device can perform the functions of several elements set out in the claims. The fact that individual functions and elements are listed in different dependent claims does not mean that a combination of these functions and elements cannot also be used to advantage. <u> List of reference symbols </u> 100 management 201 Connection area 101 shielded cable 202 Longitudinal slot 102 casing 203 Assembly section 103.104 Front sides of the housing 204 Clamp flaps 206 Clamp flaps 106.107 Cores of line 101 108 additional line 301 first section 109 electric screen 302 Second part. 303 Collar (visor) 111 electrical conductor 112 insulation 401 Locking lugs 113 inner coat 402 Locking openings 114 distance 403 404 Sheath recess 116 insulating outer sheath 117 Support sleeve 406 flange 118 Cable lug 407 Groove 119 flared electrical shield 408 Guide ribs 409 frontal edge 121 Crimp barrel 122 first seal 123 first retaining cap 124 Through opening 126 passage 127 Hold-down 128 second seal 129 second retaining cap 131 Through opening

Claims (8)

1. An electrical line with at least one insulated conductor (106, 107), which is surrounded by an electrical shield (109), which is contacted at a contact point (V) with an additional conductor (108), and with a housing tightly closing around the contact point (V), which is mounted on the electrical line, wherein a first seal (122) and a second seal (128) are in inserted into the housing (102), which seal the housing to the outside, characterized in that the additional conductor (108) forms a shield discharge line, in that the second seal (128) has several through-openings (131) for the at least one insulated conductor (106, 107) and the additional conductor (108) and in that a retaining element (127) fixes the contact point (V) in the housing (102).
2. The electrical line according to claim 1, characterized in that the electrical line has several insulated conductors (106, 107).
3. The electrical line according to claim 1 or 2, characterized in that each seal (122, 128) is held in the housing (102) by means of a retaining cap (123, 129) fastened on the housing.
4. The electrical line according to any one of the preceding claims, characterized in that a contact element (118) establishes an electrical contact between the electrical shield (109) and the additional conductor (108).
5. The electrical line according to claim 4, characterized in that the contact element is a cable lug (118).
6. The electrical line according to any one of the preceding claims, characterized in that a support sleeve (117) is provided, which is arranged under the electrical shield (109).
7. The electrical line according to claim 6, characterized in that a crimp sleeve (121) firmly encloses the contact element (118), whereby the electrical shield (109) is firmly clamped between the support sleeve (117) and the cable lug.
8. The electrical line according to any one of claims 3 to 7, characterized in that the retaining cap (123, 129), through which one or several insulated lines (106, 107) and the additional conductor (108) pass, has markings, which visibly identify the individual conductors (106, 107, 108).

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