Method of manufacturing electrical plug connectors for multi-core cables

Abstract

The invention relates to a method for producing an electrical plug connector at the end of a multicore electrical cable (1), the core wires (11, 12) of which are surrounded annularly in cross section by an outer conductor (2) in the end, wherein the outer conductor (2) is extruded in the direction to the core wires (11, 12) in sections radially by means of at least one press tool (P1a, P1b) and is provided with an extrusion sheath (3) in sections in a die casting tool. Here, the at least one press tool (P1a, P1b) remains at the outer conductor (2) after the application of the action on the outer conductor (2) in order to partially delimit and / or seal a mold cavity to be filled with a plasticized molding compound to form the extrusion sheath, wherein, in order to further delimit the mold cavity, at least one tool part (S1, S2) of the die casting tool is guided in the direction to the outer conductor (2) and positioned around the outer conductor.

Description

TECHNICAL FIELD

[0001] The present invention relates to a method for manufacturing an electrical plug connector for a multi-core cable. BACKGROUND

[0002] It is known in the prior art that single-core and / or multi-core cables are equipped at the end with plug connectors in order to enable the cables to be detachably connected to other connections. For this purpose, the component parts of the plug connector are usually fixed at the cable by means of a forming process, such as a stamping process or a bending process. Furthermore, it can be necessary to arrange further component parts, such as injection-moulded parts, at the cable using a forming process. A problem that often arises in practice is that a large number of production machines are required for the manufacture and assembly of the individual component parts of the plug connector for the different processes. This significantly increases the manufacturing outlay and the manufacturing costs.

[0003] DE 102 016 215 686 A1 discloses a plug connector with an insulator and an electrical wire end connected with a plug contact. The insulator is formed from a shot of a uniform insulating material which materially surrounds the plug contact and the wire end. An electrically conductive shielding sleeve is materially embedded at least in sections in the insulating material within the insulator, which electrically shields the plug contact and the wire end.

[0004] JP 2012-22928 A discloses a method for manufacturing an inner conductor contact for a connector with an insulator. An inner conductor of a shielded cable is arranged in a crimping region of the inner conductor contact. An inner clamp die comprising an upper die and a lower die is mounted on an inner clamp. The crimping region is pressed in an extrusion contact manner with the inner conductor of the shielded cable by means of a concave crimping portion of the upper die and a concave cushioning portion of the lower die. A shot chamber is subsequently formed around the inner conductor contact and filled with a resin material to form the insulator.

[0005] DE 102 009 049 132 A1 discloses a shielded plug connector arranged at the end of a shielded cable and a method for manufacturing the same. At least one contact fitting connected with an electrical conductor of the cable is provided in a contact carrier. A sheath composed of an electrically conductive material is provided here, wherein the sheath is arranged on the shielding braid of the cable and is in electrical contact with the shielding braid. Furthermore, the space between the contact carrier and the sheath is filled with an electrically non-conductive plastic. An outer sheath is at least partially superimposed onto the contact carrier, the space and the sheath, wherein the surface of the sheath contacts the inner region of the outer sheath for electrical contact. SUMMARY

[0006] It is an object of the present invention to improve the method of the type mentioned in the opening part with regard to the manufacturing process.

[0007] The invention relates to a method for producing an electrical plug connector for a multi-core cable, the core wires of which are surrounded annularly in cross section by an outer conductor at the end of the cable to which the plug connector is to be fitted. In this method, the outer conductor is extruded in the direction of the core wires of the cable in a segmented manner in the radial direction by means of at least one (first) press die, and the outer conductor is provided with an extrusion sheath in a segmented manner in a die casting tool.

[0008] Subsequently, this method also provides that the at least one (first) press die is positioned or remains positioned at the outer conductor after the outer conductor has been formed, such that the press die (first press die) partially delimits a mold cavity to be filled with plasticized molding compound in order to form the extrusion sheath, and at least one tool part of the die casting tool is guided and positioned in the direction of the outer conductor (2) and around the outer conductor before the plasticized molding compound is subsequently introduced into the mold cavity in order to further delimit the mold cavity.

[0009] The solution according to the invention allows the targeted forming of the outer conductor, for example by means of a punching process and / or a bending process, to be combined with the extrusion sheath of the outer conductor in one work process, which can be carried out inside a tool, wherein at least one (first) press die is arranged at the tool and in particular in the tool.

[0010] Here, the at least one press die is positioned or remains positioned in contact with the outer conductor after the outer conductor has been formed, in order to thereby seal the mold cavity and to keep the plasticized molding compound introduced into the mold cavity from reaching the region of the outer conductor covered by the at least one first press die. In other words, the covered region remains free of plasticized molding compound.

[0011] In particular, the at least one press die can act on the outer conductor in the radial direction in order to reduce the spacing between the core wire and the outer conductor in the radial direction.

[0012] Advantageously, two first press dies respectively form the outer conductor in the radial direction in different directions in order to extrude the outer conductor in the direction of the core wire, wherein the press dies in particular act on the same axial section of the outer conductor. This can mean that the press dies substantially oppose one another in the radial direction.

[0013] In order to delimit the mold cavity in which the outer conductor is provided with the extrusion sheath at least in sections (together with the at least one first press die), at least two tool parts can be positioned around the outer conductor. Here, the respective tool parts can be formed by slides which can be moved relative to the outer conductor in the radial direction in order to delimit or open the mold cavity.

[0014] According to an improvement, the cable comprises a shield in the region of the plug connector (to be produced), which in cross section encloses the core wire of the cable in a ring shape, and the cable can in particular have a shielding braid. It can also be proposed here that at least one further (second) press tool acts on the outer conductor in order to deform the outer conductor such that the outer conductor is in electric contact with the shield of the cable in a defined, permanent manner. In particular, in particular two further second press tools can act on the outer conductor in different directions in order to deform the outer conductor such that the outer conductor is in electric contact with the shield of the cable. The respective further second press tool can be arranged at and in particular in the tool in which the outer conductor of the cable is provided with the extrusion sheath.

[0015] According to an improvement of the method, the shield of the cable can be supported at a support element which encloses the core wire in a ring shape in the region in which the shield is in electric contact with the outer conductor as a result of the deformation of the outer conductor, for example in order to thereby span the support element by the shield of the cable.

[0016] According to an embodiment of the method according to the application, at least one further second press tool is removed from the cable after the outer conductor has been formed, and at least one tool part is positioned at the cable at the location of the outer conductor in order to form a mold cavity in which the outer conductor is provided at least section-wise with the extrusion sheath by injection or injection molding of the molding compound (and which is also sealed and / or delimited by the at least one first press tool). That is to say, by removing the at least one further (second) press tool from the cable, it is now possible to purposefully delimit the mold cavity by means of suitable tool parts of the die casting tool. In other words, by removing the at least one further second press tool from the cable, a space is opened which is subsequently delimited as a mold cavity by means of the at least one tool part.

[0017] The solution according to the application also relates to an electrical plug connector which is produced by means of the method according to the application. BRIEF DESCRIPTION OF DRAWINGS

[0018] Further details and advantages of the application are explained in the following description of embodiments, with reference to the drawings.

[0019] The drawings show:

[0020] Figure 1A An insert for a die casting tool is shown as a starting point for producing an electrical plug connector at a multi-core cable, the insert having a shielding braid and a cable jacket;

[0021] Figure 1B An insert is shown which results from Figure 1A after a first processing step which comprises the application of a support crimp;

[0022] Figure 1C An insert is shown which results fromFigure 1B the insert after a further processing step comprising crimping a shielding braid onto the support crimp;

[0023] Figure 1D the insert after a further processing step comprising applying an outer conductor; Figure 1C the insert after a further processing step comprising applying an outer conductor;

[0024] Figure 2A the insert after a further processing step comprising applying an outer conductor; Figure 1D the insert after a further processing step comprising applying an outer conductor;

[0025] Figure 2B the insert after a further processing step comprising applying an outer conductor; Figure 1D the insert after a further processing step comprising applying an outer conductor; Figure 2A the insert after a further processing step comprising applying an outer conductor; the insert after a further processing step comprising applying an outer conductor;

[0026] the insert after a further processing step comprising applying an outer conductor; Figure 3A the insert after a further processing step comprising applying an outer conductor; Figure 2B the insert after a further processing step comprising applying an outer conductor; the insert after a further processing step comprising applying an outer conductor;

[0027] the insert after a further processing step comprising applying an outer conductor; Figure 3B the insert after a further processing step comprising applying an outer conductor; Figure 2B the insert after a further processing step comprising applying an outer conductor; the insert after a further processing step comprising applying an outer conductor;

[0028] the insert after a further processing step comprising applying an outer conductor; Figure 4 the insert after a further processing step comprising applying an outer conductor; Figure 2A the insert after a further processing step comprising applying an outer conductor; the insert after a further processing step comprising applying an outer conductor;

[0029] the insert after a further processing step comprising applying an outer conductor; Figure 5 the insert after a further processing step comprising applying an outer conductor; Figure 4 the insert after a further processing step comprising applying an outer conductor; the insert after a further processing step comprising applying an outer conductor;

[0030] the insert after a further processing step comprising applying an outer conductor; Figure 6 the insert after a further processing step comprising applying an outer conductor; Figure 2B the insert after a further processing step comprising applying an outer conductor; Figure 4 the insert after a further processing step comprising applying an outer conductor; Figure 5 the insert after a further processing step comprising applying an outer conductor; the insert after a further processing step comprising applying an outer conductor;

[0031] the insert after a further processing step comprising applying an outer conductor; Figure 7 the insert after a further processing step comprising applying an outer conductor; Figure 6 the insert after a further processing step comprising applying an outer conductor. DETAILED DESCRIPTION

[0032] Figure 1A A section of a multi-core cable 1 is shown, which section relates to an axial end of the cable 1 which is to be further processed for forming an electrical plug connector and which is also referred to as an insert. In the present embodiment, the cable 1 is embodied as a two-core cable. Here, two core wires 11, 12 of the cable 1 run alongside one another along a cable longitudinal direction L; they form parallel core wires in the extended cable. The core wires 11, 12 each comprise, for example, an electrical wire and an insulating jacket surrounding the respective electrical wire.

[0033] The core wires 11, 12 of the cable 1 are jointly arranged in a cable interior which is annularly surrounded in cross section by a cable jacket 15 which extends along the cable longitudinal direction L. The cable jacket 15 is composed of an electrically insulating material.

[0034] Between the cable interior for accommodating the core wires 11, 12 and the cable jacket 15 there is also arranged a cable shield 13, 14 which surrounds the core wires 11, 12 and extends along the cable longitudinal direction L. This cable shield can be formed, for example, by a shielding braid or by a film or by a combination of a shielding braid and a film. The last-mentioned variant is shown in Figure 1A , in which a supplementary shielding film is fitted on the inner side of the shielding braid which faces the core wires 11, 12.

[0035] The cable shield 13, 14 serves for electrical shielding of the cable interior and is therefore of a metallic material, for example aluminium. Here, a plastic film can be used as the shielding film which is coated on the inner side facing the cable interior, in particular, with a conductive material, for example aluminium.

[0036] The metallic shielding braid is mainly used for shielding at relatively low frequencies, and the cable shield in the form of a metallic film or a film coated with metal is used for shielding at relatively high frequencies (1 MHz to 10 GHz).

[0037] The cable shield 13, 14 can be combined with the cable jacket 15 as one structural unit, for example by combining the cable shield 13, 14 on its outer surface facing away from the core wires 11, 12 with the cable jacket 15, for example by means of an adhesive connection.

[0038] In the configuration shown in Figure 1A , the cable 1 is partially detached from the cable jacket 15 at its axial end which is to form the plug connector, so that the cable shield 14 or its shielding braid forms the outer surface of the cable there. Furthermore, in this embodiment the cable 1 at its free end is covered by an insulation sheath 18 which is spaced apart from the cable jacket 15 along the cable longitudinal direction L. There is thus a region between the cable jacket 15 and the insulation sheath 18 along the cable longitudinal direction L in which the shielding braid forms the outer surface of the cable 1.

[0039] According to Figure 1B , a support crimp 16 is applied at the cable 1 or more precisely at the axial end (insert) of the cable in such a way that the support crimp 16 adjoins a region of the cable 1 in which the shielding braid is not surrounded by the cable jacket 15 or forms the outer surface of the cable 1. In this embodiment the support crimp 16 is applied partly onto the shielding braid and partly onto the cable jacket 15.

[0040] Then, according to Figure 1C , the cable shield 14 or the shield braid of the cable shield, which in the embodiment is specifically detached, is crimped such that it covers the support crimp 16 on the outside facing away from the core wires 11, 12. This also results in that, on the side for releasing the end of the cable 1 or towards the insulation jacket 18, the exposed core wires 11, 12 of the cable 1 are axially connected to the support crimp 16 covered by the crimped shield braid and on the other side to the cable section surrounded by the cable jacket 15.

[0041] Finally, as shown in Figure 1D , an outer conductor 2 is applied to the axial end of the cable 1, in this embodiment in the form of an outer tube which consists of an electrically conductive material and which in cross section surrounds the end in a ring shape or in this embodiment specifically in a torus shape. The outer conductor 2 extends along the longitudinal direction (cable longitudinal direction L), that is to say axially from a first cable side end 22 to a second output side end 23, both ends being arranged on either side of an intermediate section 21 of the outer conductor 2.

[0042] The outer conductor 2 covers the support crimp 16 as well as the section of the shield braid which is crimped here. In this embodiment, the outer conductor 2 also covers, among other things, the region of the end of the cable 1 in which the core wires 11, 12 are exposed, that is to say not surrounded by other components of the cable 1, the outer conductor covering, if necessary, parts of the cable jacket 15 (connected to the support crimp 16) and / or the (partial) insulation jacket 18.

[0043] The thus prepared end of the cable 1 is radially shaped, or specifically pressed together, in the region of the outer conductor 2 from the outside of the outer conductor 2 using at least one press tool (press tool) P1a, P1b; P2a, P2b. Figure 2A In the embodiment of , the shaping in different directions, in particular in opposite directions, respectively pairs the outer conductor 2 radially using the press tools P1a, P1b; P2a, P2b.

[0044] Specifically, the shaping takes place here at the axial end of the cable 1 or at two axially spaced-apart positions of the outer conductor 2 along the cable longitudinal direction L and is achieved there, among other things, using a pair of press tools P1a, P1b or P2a, P2b, respectively.

[0045] Here, one or more press tools P1a, P1b or P2a, P2b can be provided (as press tools) at or specifically in a press tool into which the axial end of the cable 1 is placed as an insert and which then (segmentally) extrusion encapsulates the axial end.

[0046] After the outer conductor 2 is used as a component part of the cable 1 in a (injection) tool in which the outer conductor 2 is to be equipped with an extruded jacket, the shaping of the outer conductor 2 can be implemented in particular by means of the respective pressing dies P1a, P1b or P2a, P2b.

[0047] The radial shaping of the at least one first pressing die or in particular of the two first pressing dies P1a, P1b takes place at a first axial section of the outer conductor 2 (intermediate section 21) for reducing the radial spacing between the outer conductor 2 and the core wires 11, 12 of the cable 1, by inwardly extruding and deforming the intermediate section 21 of the outer conductor 2, as shown in Figure 2B and Figure 3B The wave resistance can thereby be improved, as shown. As long as the core wires 11, 12 of the cable 1 are exposed in the intermediate section 21 of the outer conductor 2, the core wires are merely and directly surrounded by the outer conductor 2 and not by the cable shield 13, 14 or the support crimp 16.

[0048] The radial shaping of the at least one second pressing die or in particular of the two second pressing dies P2a, P2b takes place at a further second axial section of the outer conductor 2 (cable-side end section 22) for producing a defined electrical connection at the (crimped) shield braid, i.e. for a "measuring connection", and / or for providing a release tension element, by inwardly punching and deforming the intermediate section 21 of the outer conductor 2, as shown in Figure 2B and Figure 3A wherein the intermediate section is radially extruded towards the shield braid and, if necessary, towards the cable jacket 15.

[0049] As shown in Figure 4 and Figure 5 the pressing dies P2a, P2b of the second pressing die pair are subsequently removed from the outer conductor 2 in the radial direction R and at least one slide S1, S2 or in particular a pair of slides S1, S2 of a die-casting tool is brought into the proximity of the outer conductor 2 and positioned around the outer conductor in the radial direction R, so that one of the slides S1, S2 thereby forms a defined die cavity (chamber) which is filled with plasticized molding compound in order to extrude the end section (insert) of the cable 1 or in particular the outer conductor 2 and, if necessary, a section of the cable jacket 15, which is inserted into the die-casting tool, with molding compound, e.g. plasticized plastic, thereby producing a corresponding sectional extruded jacket 32, as shown in Figure 6 .

[0050] The sectional extruded jacket 32 can connect the section of the outer conductor 2 which is extruded towards the support crimp 16 (cable-side end section 22) to the cable jacket 15 and thereby serves as a release tension element for the cable 1 and in particular for the cable jacket 15.

[0051] During the described injection-molding process, at least one first mold or mold pair of first molds remains at the cable 1 or, to be precise, at the outer conductor 2 and can thereby contribute to laterally delimiting and, if appropriate, sealing the mold cavity, so that no plasticized molding compound is present on the thus covered region of the outer conductor 2, as is indicated by the intermediate section of the extruded jacket according to the reference numeral 21 in the outer conductor 2. Figure 6

[0052] As is indicated in the drawing according to Figure 6 It is clearly shown that, on the side of the first mold facing away from the slide plates S1, S2, a further portion of extruded jacket 33 can also be applied to the outer conductor 2, for example to the output-side end 23 of the outer conductor, the first mold again being used to delimit and, if appropriate, seal the corresponding mold cavity laterally during its manufacture. The further extruded jacket 33 can be used, for example, for mounting mechanical elements and, in particular, has molded-in locking elements, such as locking hooks, for securing the plug housing. The extruded jacket 3 of the outer conductor 2 thus results from the plurality of portions of extruded jacket 32, 33.

[0053] As is indicated in the drawing according to Figure 7 Finally, the plug housing 5 is moved to the corresponding prepared axial end of the (+) cable 1 and is secured there, for example by means of locking hooks provided at the axial end of the cable 1.​

Claims

1. A method for manufacturing an electrical plug connector, which is located at an end of a multi-core electrical cable (1), the core wires (11, 12) of which are surrounded annularly in cross section by an outer conductor (2) in the end, wherein, The outer conductor (2) is formed in the direction of the core wire (11, 12) in sections in the radial direction by at least one pressing mold (P1a, P1b), and the outer conductor (2) is provided in sections with an extrusion sheath (3) in a die casting tool, characterized in that At least one pressing mold (P1a, P1b) is positioned at the outer conductor (2) after the forming of the outer conductor in order to partially delimit a mold cavity to be filled with plasticized forming compound for forming the extrusion sheath (3), and in order to further delimit the mold cavity, at least one tool part of the die casting tool is guided and positioned in the direction of the outer conductor (2) and around the outer conductor.

2. The method of claim 1, wherein, At least one pressing mold (P1a, P1b) is positioned at the outer conductor (2) after the forming in order to seal the mold cavity, and the area of the outer conductor (2) covered by at least one pressing mold (P1a, P1b) remains free of plasticized forming compound introduced into the mold cavity.

3. The method according to claim 1 or 2, characterized in that, At least one pressing mold (P1a, P1b) forms the outer conductor (2) in the radial direction in order to reduce the distance between the core wire (11, 12) and the outer conductor (2) in the radial direction (R).

4. The method according to claim 1 or 2, characterized in that, At least one pressing mold (P1a, P1b) is arranged at the die casting tool such that the end of the cable (1) is placed at the die casting tool before the outer conductor (2) is formed by at least one pressing mold (P1a, P1b).

5. The method according to claim 1 or 2, characterized in that, At least two tool parts are positioned around the outer conductor (2) such that the tool parts jointly delimit the mold cavity with at least one pressing mold (P1a, P1b).

6. The method of claim 1 or 2, wherein, The respective tool part is formed by a slide which can be moved relative to the outer conductor (2) in the radial direction (R) in order to delimit the mold cavity or open the mold cavity.

7. The method of claim 1 or 2, wherein, The cable (1) has a shield in the region of a plug connector, the shield surrounds the core wire (11, 12) of the cable, and at least one further pressing mold (P2a, P2b) forms the outer conductor (2) in order to deform the outer conductor (2) such that the outer conductor is in electrical contact with the shield.

8. The method of claim 7, wherein, Two further pressing molds (P2a, P2b) form the outer conductor (2) in different directions in order to deform the outer conductor (2) such that the outer conductor is in electrical contact with the shield of the cable (1).

9. The method of claim 7, wherein, In the region in which the shield is in electrical contact with the outer conductor (2) as a result of the deformation of the outer conductor, the shield of the cable (1) is supported at a support element which surrounds the core wire (11, 12) in a ring and the shield is spanned across the support element.

10. The method of claim 7, wherein, After the shaping of the outer conductor (2) at least one further pressing mold (P2a, P2b) is removed from the cable (1) and at least one tool part is positioned at the cable (1) at the location of the outer conductor to form a mold cavity, which is further sealed and / or delimited by at least one pressing mold (P1a, P1b).

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