High-voltage connector

Abstract

A method for manufacturing a connector for a high-voltage cable (100) with an electrically effective shield is proposed. The proposed method enables the manufacture of a high-voltage cable connector in an automatable process because all work steps are performed from the same end of the high-voltage cable and all components are assembled from the same end. Furthermore, in this method, the shield of the high-voltage cable is not shortened but folded over. This prevents individual loose wire strands from the shield braid, which would otherwise occur if the braid were shortened, from ending up in places where they could cause short circuits. After an insulating tube is slid over a contact piece and a shielding plate onto the folded-over shield, the shielding plate is mechanically and electrically connected to the shield.Finally, two housing halves, between which a seal is inserted, are mounted over the shielding plate so that the seal also provides strain relief for the cable.

Description

Area

[0001] The invention relates to a method for manufacturing a connector for a shielded high-voltage cable and a connector with a high-voltage cable that has a shield. background

[0002] Shielded single-core electrical cables are used, for example, in the automotive sector to connect electrical assemblies and components. To save material and weight, there is a general trend towards increasingly higher operating voltages, which allow for smaller conductor cross-sections. This is particularly true for vehicles with purely electric or hybrid drives. In such vehicles, devices and consumers are increasingly supplied from higher-voltage power sources. These power sources can be designed for voltages of up to 1000 V. Consumers in electric vehicles include, for example, the drive motor and heating units. Due to the high operating voltages, single-core cables with an electrically effective shield are frequently used to connect consumers to a battery.Appropriate connectors are required to connect the described cables. Previously used methods for mounting connectors onto a shielded high-voltage cable generally require manual work, which incurs high production costs. Furthermore, known methods often necessitate shortening the shield of the high-voltage cable. If the shield is made of a wire mesh, this results in short pieces of wire which, if not carefully removed, can lead to unwanted short circuits.

[0003] Starting from this, the present invention has the objective of providing a method for manufacturing a plug for a high-voltage cable and a high-voltage cable with a plug in order to overcome or at least improve one or more of the problems mentioned above. Description of the invention

[0004] To solve this problem, the invention proposes, according to a first aspect, a method for manufacturing a connector for a high-voltage cable with an electrically effective shield. The method comprises the following steps: - Removing a section of predetermined length from the outer sheath of the high-voltage cable to expose the shield; - Attaching an undercrimp sleeve to the exposed shield such that the undercrimp sleeve is mechanically and electrically connected to the shield, wherein the undercrimp sleeve is shorter in the axial direction than the length of the removed section of the outer sheath and a circumferential edge of the undercrimp sleeve abuts an edge of the outer sheath, - Folding over an area of ​​the shield that is not under the undercrimp sleeve to the outside of the undercrimp sleeve, without shortening the folded-over area of ​​the shield, - Removing a section of predetermined length from the inner sheath of the high-voltage cable to expose the conductor of the high-voltage cable, - Striking a contact piece against the exposed conductor, - Sliding an electrically insulating insulator tube over the contact piece, - Sliding an electrically conductive shielding plate over the folded-over shield and the insulator tube, - Attaching the shielding plate to the folded-over shade in order to mechanically and electrically connect the shielding plate to the folded-over shade, - Inserting a seal between two housing halves and - Mounting the two housing halves over the shielding plate by snapping the two housing halves together, which presses the seal and forms a strain relief for the cable.

[0005] The proposed method enables the automated production of a connector for a high-voltage cable. A key aspect of the method is that all work steps are performed from the same side of the high-voltage cable, and all components are assembled from the same side. Therefore, the work steps can be carried out by a robot without manual intervention. Another advantage of the proposed method is that the high-voltage cable shield is not shortened but folded over. This prevents individual loose strands of the shield braid, which would otherwise be created by shortening the braid, from ending up in places where they could cause short circuits. The seal provides strain relief for the connector.

[0006] In an advantageous embodiment, the undercrimp sleeve is attached to the exposed shield by crimping. Crimping is a mature technology that can be easily automated.

[0007] It is advantageous to also attach the shielding plate to the folded-over shield by crimping.

[0008] According to a second aspect of the invention, a high-voltage cable with a connector is proposed, comprising a conductor, an inner and outer sheath, and an electrically effective shield between the inner and outer sheath. The connector further comprises an undercrimp sleeve that is crimped onto the electrically effective shield of the high-voltage cable and on the outside of which an uncut section of the shield is folded over, a contact piece that is attached to the conductor of the high-voltage line, an insulating tube that is pushed over the contact piece, a shielding plate that is attached to the folded-over umbrella and a housing which surrounds the shielding plate, consisting of two interlocking housing halves between which a seal is arranged, whereby the seal is pressed and forms a strain relief for the cable.

[0009] The strain relief ensures that the plug 120 does not detach from the high-voltage line when tensile forces are exerted on the high-voltage line 100.

[0010] In an advantageous embodiment, the housing parts are identical. The use of identical parts reduces production costs for the housing parts and simplifies the manufacturing of the connector, at least from the perspective of simplified logistics and warehousing.

[0011] In an advantageous embodiment, the shielding plate can be made of an electrically conductive plastic. Electrically conductive plastics are, for example, more cost-effective than brass or copper. Brief description of the drawing

[0012] The invention is explained in more detail below using one embodiment as an example, with reference to the accompanying figures. All figures are purely schematic and not to scale. They show: Fig. 1A-L schematically shows individual manufacturing steps for the production of a connector for a high-voltage cable, and Fig. 2 a top view of a connector according to the invention with an open housing.

[0013] Identical or similar elements in the figures are marked with the same or similar reference symbols. Description of exemplary embodiment

[0014] Fig. Figure 1A shows a high-voltage line 100 in a side view, looking at an outer sheath 101 of the high-voltage line 100. The outer diameter of the outer sheath 101 is d1.

[0015] In Fig. Figure 1B shows a longitudinal section of one end of the high-voltage line 100, with individual components of the high-voltage line 100 shown at different lengths for clarity. Beneath the outer sheath 101 lies a shield 102, which is made, for example, of a wire mesh and surrounds an inner sheath 103. The inner sheath 103 encloses a conductor 104. Fig. Figure 1B is purely schematic, so the thicknesses of components 101-104 do not correspond to the actual proportions. For example, the shield 102 is significantly thinner than the inner sheath 103 or the outer sheath 101.

[0016] In Fig. 1C shows the high-voltage line 100 schematically in cross-section. As for Fig. 1B also applies to Fig. 1C, that the thicknesses of components 101-104 do not reflect the actual proportions.

[0017] Fig. Figure 1D shows the high-voltage line 100 from Fig. 1, in which the outer sheath 101 is set off over a length L1. The screen 102, which consists, for example, of a wire mesh, is visible under the outer sheath 101.

[0018] In Fig. 1E is a sub-crimp sleeve 106 pushed onto and crimped onto the shield 102, which in Fig. Figure 1E is illustrated with a slanted line 107. The undercrimp sleeve 106 has an axial length L2, which is less than the length L1, so that the shield 102 is exposed over a section 108 with a length L3, where L1 = L2 + L3. The undercrimp sleeve 106 is pushed over the shield 102 until an edge of the undercrimp sleeve 106 abuts an edge of the cut-off outer sheath 101. The undercrimp sleeve 106 has an outer surface 109.

[0019] In Fig. 1F the exposed section 108 of the shield 102 is folded over the undercrimp sleeve 106, so that the inner sheath 103 is visible over the length L3.

[0020] In Fig. 1G the inner sheath 103 is set back over a length L4, so that the conductor 104 is exposed over a length L4.

[0021] In Fig. 1H is a contact piece 110 attached to the conductor 104, for example by crimping a tubular extension 111 to the conductor 104. The contact piece 110 can be designed in various ways. In particular, the contact piece can be a male or female connector.

[0022] In Fig. In 1I, an insulator tube 112 is pushed over the contact piece 110. The insulator tube is made, for example, of an insulating plastic material. The outer diameter of the insulator tube 112 corresponds essentially to the diameter d2 of the shield 102 folded over the lower crimp sleeve 106. In comparison, the diameter d1 of the outer sheath 101 is smaller.

[0023] In Fig. 1J is a shielding plate 113 slid over the insulator tube 112 and the folded-over shield 102 until the shielding plate 113 completely covers the insulator tube 112 and the folded-over shield 102. Ideally, the shielding plate 113 protrudes a few millimeters beyond the folded-over shield 102.

[0024] In Fig. 1K the shielding plate 113 is crimped onto the folded-over shield 102, which in Fig. 1K is symbolized by a horizontal crimp line 114. In this way, the shielding plate 113 is mechanically fastened and electrically connected to the shield 102.

[0025] In Fig. In 1L, two housing halves 116a, 116b are joined together, enclosing the shielding plate 113. The housing halves 116a, 116b together form a housing 116. The housing halves 116a, 116b are connected to each other by means of a combination of snap openings 117 and snap projections 118. The two housing halves 116a, 116b are identical in construction as identical parts, thus offering cost advantages in the manufacture of the housing parts 116a, 116b and in the production of the connector. With the fully assembled housing 116, a connector 120 according to the invention for a high-voltage cable is produced.

[0026] Fig. Figure 2 shows a top view of the connector 120 with the housing 116 open, revealing a seal 121 inserted between the housing halves 116a and 116b. The seal 121 is elastic and is compressed when the housing halves 116a and 116b are locked together. This provides strain relief for the conductor 100. Reference symbol list 100 high-voltage line 101 outer coat 102 umbrella 103 inner mantle 104 leaders 106 Undercrimp sleeve 107 Diagonal line Section 108 109 Outside of the lower crimp sleeve 110 contact pieces 111 tubular attachment 112 Insulator tube 113 Shielding plate 114 Horizontal line 116 cases 116a,b Housing halves 117 resting openings 118 resting projections 120 plugs 121 Seal

Claims

[1] Method for manufacturing a connector (120) for a high-voltage line (100) with an electrically effective shield (102), the method comprising the following steps - Removing a section of predetermined length (L1) of an outer sheath (101) of the high-voltage line (100) to expose the shield (102); - Attaching an undercrimp sleeve (106) to the exposed screen (102) such that the undercrimp sleeve (106) is mechanically and electrically connected to the screen (102), wherein the undercrimp sleeve (106) is shorter in the axial direction than the length (L1) of the removed section of the outer sheath (101) and a circumferential edge of the undercrimp sleeve (106) borders an edge of the outer sheath (101), - Folding over a portion of the shield (102) that is not under the undercrimp sleeve (106) to an outside (109) of the undercrimp sleeve, without shortening the folded portion of the shield, - Removing a section of predetermined length (L4) of an inner sheath (103) of the high-voltage line (100) to expose the conductor (104) of the high-voltage line (100), - Striking a contact piece (110) against the exposed conductor (104), - Sliding an electrically insulating insulator tube (112) over the contact piece (110), - Sliding an electrically conductive shielding plate (113) over the folded-over shield (102) and the insulator tube (112), - Attaching the shielding plate (113) to the folded-over shade (102) in order to mechanically and electrically connect the shielding plate (113) to the folded-over shade (102), - Inserting a seal (121) between two housing halves (116a,b), and - Mounting the two housing halves (116a,b) over the shielding plate (113) by snapping the two housing halves together, thereby pressing the seal (121) and forming a strain relief for the cable (100). [2] Method according to claim 1, wherein the fastening of the undercrimp sleeve (106) to the exposed shield (102) is carried out by crimping. [3] Method according to claim 1, wherein the fastening of the shielding sheet (113) to the folded-over shield (102) is carried out by crimping. [4] High-voltage cable with a plug (120) comprising a conductor (104), an inner (103) and outer sheath (101) and an electrically effective shield (102) between the inner and outer sheath (103, 102), wherein the plug (120) further comprises a sub-crimp sleeve (106) which is crimped onto the electrically effective shield (102) of the high-voltage line (100) and on the outside (109) of which an unshortened section of the shield (102) is folded over, a contact piece (110) which is attached to the conductor (104) of the high-voltage line (100), an insulating insulator tube (112) which is pushed over the contact piece (110), a shield plate (113) which is attached to the folded-over shield (102) and a housing (116) which surrounds the shielding plate (113), consisting of two interlocked housing halves (116a,b) between which a seal (121) is arranged, whereby the seal (121) is pressed and forms a strain relief for the line (100). [5] Plug according to claim 4, characterized by , that the housing parts (116a,b) are identical parts. [6] Connector according to one of claims 4 or 5, characterized by, that the shielding sheet (113) is made of an electrically conductive plastic.

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