Intermediate product and method for crimping electrical conductors

Abstract

The invention relates to an intermediate product (1) for crimping, comprising an electrical conductor (2), in particular a network cable (4), having a shielding braid (6) and extending along a longitudinal axis (L), and having an insulation (8) at least partially surrounding the shielding braid (6), wherein the shielding braid (6) has a radially compressed core in a region (10) along the longitudinal axis (L) compared to the immediately adjacent surrounding parts along the longitudinal axis (L). In addition, the invention relates to a method for crimping an electrical conductor (2), wherein before crimping, a region (10) of the electrical conductor (2) extending along the longitudinal axis (L) is compacted. Due to the pre-compacting, the electrical conductor (2) can be compressed in the region (10) to a predetermined diameter (12), thereby improving the quality of the compression process and avoiding manufacturing errors.

Description

Technical Field

[0001] The invention relates to an intermediate product for crimping and a method for crimping electrical conductors. Background Art

[0002] In order to terminate an electrical conductor, a contact with a crimping connection, for example a crimping sleeve, is placed around the electrical conductor and compressed by the crimping connection. As a result, a mechanically and electrically stable connection is produced between the contact and the conductor. The electrical conductors are manufactured with certain tolerances, which leads to irregularities in the diameter of the conductor. In addition, electrical conductors with slightly different diameters can be found on the market. In particular in the case of crimping, this can in fact lead to waste, for example if individual strands of the shielding braid protrude radially from the crimping seams of, for example, a slotted, open crimping sleeve, so that this leads to excessive waste during the production of the crimped conductor.

[0003] The problem underlying the present invention is therefore to provide an intermediate product for crimping which reduces the risk of manufacturing errors during crimping. Summary of the invention

[0004] The problem is solved by an intermediate product for crimping, having an electrical conductor, in particular a network cable, extending along a longitudinal axis, having a shielding braid and having an insulation surrounding the shielding braid, wherein the electrical conductor has a radially compressed core in a region along the longitudinal axis compared to an immediately surrounding portion along the longitudinal axis.

[0005] In addition, the problem is solved by a method for crimping an electrical conductor, in particular a network cable, which extends along a longitudinal axis and has a shielding braid and an insulation surrounding the electrical conductor, the method comprising the following steps: before crimping, in a radial direction, compacting a region of the electrical conductor extending along the longitudinal axis.

[0006] A region with a radially compressed core is formed by compaction. The compressed core can have a predetermined diameter, wherein irregularities in the diameter of the wire are eliminated in the region with the radially compressed core. As a result, a crimping sleeve can be placed around this region and crimped with the conductor without the individual strands protruding radially from the crimping seam. Thus, the generation of scrap due to incorrect crimping is reduced or even prevented. In addition, different electrical conductors with slightly different diameters can be standardized at least in this region so that crimping sleeves of identical construction can be attached in the region of different conductors. As a result, the variety of components is reduced, thereby further saving costs. Small necessities for special wires may be crimped together with existing components, in particular crimping sleeves.

[0007] In the following, further refinements are specified which can be combined with one another independently of one another as required and each of which is advantageous per se.

[0008] Thus, for example, the region with the radially compressed core can be arranged at the free end of the electrical conductor.As a result, the crimping sleeve in the region with the radially compressed core can be pushed slightly upwards and crimped with this region.

[0009] The region with the radially compressed core can be spaced apart from the free end of the electrical conductor along the longitudinal axis, preferably by at most the length of a crimping sleeve which is standardized, in particular for network cables of standardized diameter. As a result, the portion of the shielding braid between the region with the radially compressed core and the free end can be bent back on the crimping sleeve without the shielding braid protruding away from the region along the longitudinal axis.

[0010] According to another advantageous configuration, the length of the region with the radially compressed core can correspond at least to the length of a crimping sleeve standardized for the conductor diameter. Thus, the region with the radially compressed core provides a seat for the crimping sleeve, wherein in this region the diameter of the electrical conductor is predetermined by the compaction.

[0011] In particular, the region of the core with radial compression may be arranged at a distance of about 2 mm to about 4 mm from the free end in the longitudinal axis.

[0012] In another advantageous configuration, the region with the compressed core can taper conically at one end of the region along the longitudinal axis. As a result, for example, a buildup of insulation material at the end of the region along the longitudinal axis can be prevented.

[0013] Preferably, the region with the compressed core may taper conically at both ends of the region along the longitudinal axis, so that a build-up of insulation material at both ends of the region, for example due to a stepwise reduction in the diameter of the electrical conductor, may be prevented.

[0014] According to another advantageous configuration, the electrical conductor can be free of insulation at least in the region with the radially compressed core.Thus, in this region, the crimping sleeve can be applied to the electrical conductor, in particular to the shielding braid, and crimped therewith.

[0015] The shielding braid can be in particular the outer conductor and can be made of stranded wires, for example, wherein by compacting the individual wires can be compressed to the most precise and fully monitored final dimensions. As a result, the processed electrical conductor does not have any protruding strands or any burrs, and the crimping sleeve can be crimped around the area of ​​the core with radial compression.

[0016] After stripping, the region with the radially compressed core can be compacted. As a result, it can be prevented that parts of the insulator are caught by the shielding braid during stripping. However, the region with the radially compressed core is preferably compacted first before being stripped. Thus, the insulator can act as a protective sheath during compaction and damage to individual strands of the shielding braid can be prevented.

[0017] For example, the area of ​​the core with radial compression can be compacted by ultrasonic welding. In particular during ultrasonic welding, an inherently uniform core with the lowest possible contact resistance can be formed. As an alternative, the core can also be compressed by radial compression to a specified diameter.

[0018] According to another advantageous configuration, after crimping the crimping sleeve in the radial compression area, the shielding braid can be bent back around the free end of the electrical conductor protruding along the longitudinal axis, wherein the bent back portion does not protrude from the shielding braid along the longitudinal axis at the end of the crimping sleeve facing away from the free end of the electrical conductor.

[0019] The crimping sleeve may in particular be a supporting sleeve, wherein a predetermined portion from the shielding braid is turned over on the supporting sleeve so that the shielding braid at least partially radially surrounds the supporting sleeve from the outside. The portion may be crimped between the outer sleeve and the supporting sleeve by the outer sleeve. Preferably, the inner conductor may be free before crimping the outer sleeve and may be crimped with the inner conductor sleeve. The outer sleeve may be configured such that it extends along the longitudinal axis over the inner conductor sleeve and radially surrounds it. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In the following, the invention is described in more detail by using exemplary embodiments with reference to the drawings. In the drawings, elements which correspond to one another in design and / or function have the same reference numerals.

[0021] The combination of features shown and described with the various exemplary embodiments is for explanation purposes only. According to the above statements, if its technical effect is not important in a specific application, a feature of the exemplary embodiment can be omitted. Conversely, according to the above statements, if its technical effect is beneficial or necessary for a specific application, another feature can be added to the exemplary embodiment.

[0022] In the attached picture:

[0023] Figure 1 shows a schematic perspective view of an intermediate product according to the invention;

[0024] Figure 2 Shows the crimped Figure 1 A schematic cross-sectional view of an intermediate product is shown.

[0025] Reference numerals

[0026] 1 Intermediate products

[0027] 2 Electrical conductors

[0028] 4 Network cables

[0029] 6 Shielding braid

[0030] 8 Insulator

[0031] 10 Regions

[0032] 12 Predetermined diameter

[0033] 13 Length of region

[0034] 14 Crimp sleeve

[0035] 15 Support sleeve

[0036] 16 Outer conductor

[0037] 17 Length of crimping sleeve

[0038] 18 standard wire

[0039] 20 Inner conductor

[0040] 22 Dielectric

[0041] 24 Free end

[0042] 26 Terminal DETAILED DESCRIPTION

[0043] First, refer to Figure 1 An exemplary configuration of the intermediate product for crimping 1 according to the present invention is explained in more detail.

[0044] The intermediate product 1 comprises an electrical conductor 2, which extends along a longitudinal axis L. The electrical conductor 2 may preferably be a standardized network cable 4. The electrical conductor 2 has a shielding braid 6 and an insulation 8 radially surrounding the shielding braid 6. In a region 10 along the longitudinal axis L, the electrical conductor 2 is radially compressed to a predetermined diameter 12, so that a crimping sleeve 14 can be placed on the electrical conductor 2 in this region 10 and can be crimped therewith. By compacting the electrical conductor 2 in the region 10, the conductor can be reduced to a predetermined diameter and in particular uniform, so that during crimping, individual strands of the shielding braid 6 do not radially protrude from the crimping sleeve 14.

[0045] Preferably, at least the region 10 with radial compression may be free of the insulator 8, e.g. Figure 2As shown, the crimping sleeve 14 can be placed directly on the shielding braid 6. In particular, the insulator 8 can be removed from the area 10 after compaction, so that the insulator 8 acts as a sheath during compaction and the individual strands of the shielding braid 6 are not damaged.

[0046] In particular, the shielding braid 6 may be compressed to a predetermined diameter 12 because the crimping sleeve 14 is placed around and crimped to the shielding braid 6 during crimping.

[0047] The region 10 can be compressed, for example, by ultrasonic welding. As an alternative or in addition to this, the region 10 can also be radially reduced to a predetermined diameter 12 by compressing the individual strands.

[0048] The shielding braid 6 may be an outer conductor 16, which is formed by a twisted wire 18. During the manufacture of the electrical conductor 2, adjustment to the predetermined diameter 12 is made more difficult, in particular due to the shielding braid 6. In the case of the shielding braid 6, irregularities and high tolerances often occur during production, which lead to problems during crimping, however, since individual wire strands, in particular the twisted wire cores, protrude radially from the crimping sleeve 14.

[0049] The electrical conductor 2 may preferably have at least one inner conductor 20, which may be arranged centrally in the electrical conductor 2 and radially surrounded by a dielectric 22. A shielding foil 24 may be arranged between the dielectric 22 and the shielding braid 6 to protect the inner conductor 20 from electrostatic magnets and / or magnetic alternating fields.

[0050] The region 10 may be arranged at the free end 24 of the electrical conductor 2 along the longitudinal axis L. Preferably, the region 10 may be spaced apart from the terminal 26 at the free end 24 of the electrical conductor 2 along the longitudinal axis L. The region 10 may be spaced apart from the terminal 26 along the longitudinal axis L, preferably by at most the length of the crimping sleeve 14, in particular the support sleeve 15, which is standardized for network cables. As a result, when the shielding braid 6 is turned over on the side of the crimping sleeve 14 facing away from the terminal 26, the shielding braid 6 may be prevented from protruding from the crimping sleeve 14.

[0051] The length 13 of the region 10 along the longitudinal length L may preferably correspond at least to the length 17 of a standardized crimping sleeve 14 for network cables. Due to the radial compression in the region 10, a seat may be formed for the crimping sleeve 14, which prevents the crimping sleeve 14 from sliding relative to the region 10 along the longitudinal axis L. This leads to a further simplification of the crimping process.

[0052] Preferably, the region 10 may taper conically along the longitudinal axis L at at least one end of the region 10, in particular at both ends of the region 10. As a result, accumulation of material at the respective ends of the region 10 during stripping may be prevented. The insulator 8 may be stripped more easily, and no step-like intersections may be formed that could get the insulator 8 stuck.

[0053] The free inner conductor 20 can be crimped with the inner conductor sleeve, and then the outer sleeve is crimped with the support sleeve 15, and the portion of the shielding braid 6 turned over on the support sleeve 15 is sandwiched between the support sleeve 15 and the outer sleeve.

[0054] As a result of the intermediate product according to the invention and the method according to the invention, errors during the production of the crimped electrical conductor 2 can be reduced or even prevented. The electrical conductor 2, in particular the shielding braid 6, can be compressed in the region 10 to a substantially uniform and predetermined diameter 12 by pre-compacting, wherein the diameter 12 can be adapted to the respective requirements of the crimping sleeve 14. Furthermore, as a result of the solution according to the invention, various electrical conductors 2 with small diameter differences can be standardized at least in the region 10, so that different electrical conductors 2 can be connected to components of the same structure, such as the crimping sleeve 14. This makes it possible to reduce different components, resulting in further cost savings.

Claims

1. An intermediate product (1) for crimping, comprising an electrical conductor (2), the electrical conductor (2) being a network cable (4), extending along a longitudinal axis (L), having a shielding braid (6) and having an insulation (8) at least partially surrounding the shielding braid (6), wherein: The electrical conductor (2) has a radially compressed core in a region (10) along the longitudinal axis (L) compared to the immediately surrounding portions along the longitudinal axis (L), and a radially compressed core spaced apart from a terminal end (26) of the electrical conductor (2) along the longitudinal axis (L); wherein the radially compressed core of the electrical conductor (2) is crimped to the support sleeve (15); and wherein a predetermined portion from the shielding braid (6) is turned over on the support sleeve (15) so that the shielding braid (6) at least partially radially surrounds the support sleeve (15) from the outside; And wherein the outer sleeve is crimped to the supporting sleeve (15), and the portion of the shielding braid (6) turned over on the supporting sleeve (15) is clamped between the supporting sleeve (15) and the outer sleeve.

2. The intermediate product (1) according to claim 1, wherein The region (10) having the radially compressed core tapers conically along the longitudinal axis (L) at both ends of the region (10).

3. The intermediate product (1) according to claim 1 or 2, wherein: The shielding braid (6) is free of the insulation (8) at least in the region (10) having the radially compressed core.

4. The intermediate product (1) according to claim 1 or 2, wherein: The length of the region (10) with the radially compressed core corresponds at least to the length of a support sleeve (15) along the longitudinal axis (L), the support sleeve (15) being standardized for an electrical conductor (2) of a predetermined diameter.

5. A method for crimping an electrical conductor (2), the electrical conductor (2) being a network cable (4) having a shielding braid (6), extending along a longitudinal axis (L) and having an insulation (8) surrounding the shielding braid (6), the method comprising the following steps: spacing the electrical conductor (2) along the longitudinal axis (L) from a terminal end (26) of the electrical conductor (2); and compacting the region (10) in radial direction before crimping to form a radially compressed core; wherein the radially compressed core of the electrical conductor (2) is crimped to the support sleeve (15); and wherein a predetermined portion from the shielding braid (6) is turned over on the support sleeve (15) so that the shielding braid (6) at least partially radially surrounds the support sleeve (15) from the outside; And wherein the outer sleeve is crimped to the supporting sleeve (15), and the portion of the shielding braid (6) turned over on the supporting sleeve (15) is clamped between the supporting sleeve (15) and the outer sleeve.

6. The method of claim 5, wherein: After the compacting, at least the region (10) is stripped.

7. The method according to claim 5 or 6, wherein: The region (10) is compacted by ultrasonic welding.

8. The method according to claim 5 or 6, wherein: The region (10) is compacted by pressing.

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