Method for bundling multi-core cables and corresponding bundled cables

Abstract

The present invention describes a method for bundling multi-core cables and a correspondingly bundled cable. The cable comprises at least a first core wire conductively connected to a first contact element and a second core wire conductively connected to a second contact element. The method comprises: arranging the first and second contact elements in a contact carrier having a contact side and a cable side; sealing the first longitudinal channel and the first through-opening in a liquid-tight manner by introducing two first seals into the first through-opening; sealing the second longitudinal channel and the second through-opening in a liquid-tight manner by introducing two second seals into the second through-opening; and forming a connector connecting the contact carrier to the outer cover of the cable by injection molding at least one rear section of the contact carrier surrounding the first and second through-openings and a section of the cable extending at the cable side.

Description

Technical Field

[0001] The present invention relates to a method for bundling multi-core cables and a cable bundled in the method. Background Art

[0002] Cables are used to connect electrical components to one another in an electrically conductive manner. In addition, cables can be used to transmit electrical signals with low electrical power within the scope of symmetrical or asymmetrical signal transmission. Such signals can be exchanged, for example, between components such as control units, sensors or actuators in a motor vehicle. However, cables can also be used within the scope of energy supply to transmit high electrical power.

[0003] In the context of bundling, the cables are adapted according to their intended use. In this case, the cables can be brought to the desired length and appropriately processed at the cable ends of the cables. In particular, a support structure can be arranged at the cable ends in order to locally support or reinforce the cables. In addition, a plug connector unit can be arranged at the cable ends so that the cable can be connected to other cables or electrical components. The plug connector unit can include one or more electrical contact elements, such as sockets or contact pins, which can be held in place, for example, by suitable contact carriers and can be electrically insulated from each other. The support structure can be used, for example, to support the contact carrier at the cable.

[0004] For example, DE 10 2005 042 027 A1 describes a method for producing a plug connector, in which a contact is injection-molded over in a central region to form a front housing section of the plug connector, and a cable connection end of the contact is injection-molded over to form a rear housing section of the plug connector.

[0005] EP 2 545 616 B1 describes a plug connector having a molded-on supporting structure.

[0006] US 2005 / 0014417 A1 shows another example of a plug connector produced by an injection molding method. Summary of the invention

[0007] There may be a need for a method for bundling multicore cables, by which the cable ends of the multicore cables can be provided with plug connectors that are robust against bending and tensile loads in a simple, reliable and / or cost-effective manner. In addition, a corresponding bundling cable may also be required.

[0008] This need can be met by the content of the independent claim. Advantageous embodiments are set forth in the dependent claims, the following description and the drawings.

[0009] A first aspect of the present invention relates to a method for bundling a multi-core cable. In this case, the cable has at least one first core and a second core and an outer cover that at least partially surrounds the first core and the second core. In addition, an end section of the inner conductor of the first core is electrically conductively connected to a first contact element, while an end section of the inner conductor of the second core is electrically conductively connected to a second contact element. The method comprises at least the following steps, which can preferably be performed in a given order: (i) arranging the first contact element and the second contact element in a contact carrier having a contact side and a cable side, wherein the contact carrier has a first longitudinal channel connecting the contact side to the cable side, a second longitudinal channel connecting the contact side to the cable side, a first through opening intersecting the first longitudinal channel, and a second through opening intersecting the second longitudinal channel, wherein at least one section of the first contact element is arranged in a front portion of the first longitudinal channel extending between the contact side and the first through opening, and at least one of the second contact elements The section is arranged in a front part of the second longitudinal channel extending between the contact side and the second through-opening; (ii) the first longitudinal channel and the first through-opening are liquid-tightly sealed by introducing two first seals into the first through-opening; (iii) the second longitudinal channel and the second through-opening are liquid-tightly sealed by introducing two second seals into the second through-opening; and (iv) a connecting piece connecting the contact carrier to the outer cover of the cable is formed by injection molding at least one rear section of the contact carrier surrounding the first through-opening and the second through-opening and a section of the cable extending on the cable side.

[0010] A second aspect of the invention relates to a cable, such as can be manufactured in a method according to an embodiment of the first aspect of the invention. The cable comprises: at least one first core and a second core; an outer cover, which at least partially surrounds the first core and the second core; a contact carrier, which has a contact side, a cable side, a first longitudinal channel connecting the contact side with the cable side, a second longitudinal channel connecting the contact side with the cable side, a first through-opening intersecting the first longitudinal channel, and a second through-opening intersecting the second longitudinal channel; a first contact element, which is electrically connected to an end section of an inner conductor of the first core and is at least partially arranged in a front portion of the first longitudinal channel extending between the contact side and the first through-opening; a second contact element, which is electrically connected to an end section of the inner conductor of the second core and is at least partially arranged in a front portion of the second longitudinal channel extending between the contact side and the second through-opening; and a connector, which connects the contact carrier to the outer cover and is molded by injection molding at least one rear section of the contact carrier surrounding the first through-opening and the second through-opening and a section of the cable extending on the cable side.

[0011] The cable can include an electrically conductive inner conductor, for example, in the form of a single wire or a stranded wire (a stranded wire is a braid consisting of a plurality of single wires) and a core sheath consisting of an electrically insulating material (for example, a plastic, in particular a polymer) which at least partially surrounds the inner conductor. The outer sheath of the cable can also be made of an electrically insulating material. The core wires can be deinsulated, for example, at their core wire ends. The contact elements can be respectively arranged at these deinsulated core wire ends and thus be electrically conductively connected, i.e. connected by welding, soldering and / or crimping.

[0012] For example, the first core can be a working signal core for transmitting a working signal, and the second core can be a reference signal core for transmitting a suitable reference signal. In other words, the cable can be used to transmit a differential signal, for example via Ethernet or low voltage differential signaling (LVDS). By forming a difference between the working signal and the reference signal, undesirable interference signals in the two cores, for example caused by induced voltages or impressed currents, can be almost completely eliminated.

[0013] The first or second contact element can be an elongated, pin-shaped and / or socket-shaped plug connector element made of an electrically conductive material such as a metal sheet. The contact element can, for example, have a front section in the form of a socket for receiving a corresponding pin-shaped plug part or in the form of a pin for introduction into a corresponding socket-shaped plug part, while the rear section of the contact element can be electrically conductively connected to the corresponding core. For example, the contact element can be implemented as a (sheet metal) stamped part and / or a bent part.

[0014] The contact carrier can generally be understood as a housing for accommodating contact elements or as an inner part of a housing or a plug housing. The contact carrier can be shaped so that the contact elements are positioned and / or fastened relative to each other. In addition, as mentioned above, the contact carrier can be shaped as a support structure in order to limit the mechanical load on the core wire when plugging and unplugging the core wire. The contact carrier can be made of an electrically insulating material. In particular, the contact carrier can be a plastic molded part, for example. The contact carrier can be made in one piece, for example by injection molding, or can also be composed of a plurality of individual parts, for example of two half shells.

[0015] The contact carrier can have a plurality of openings, channels or recesses. In addition, the contact carrier can have a longitudinal channel for each contact element, and in the case of two contact elements, a first longitudinal channel and a second longitudinal channel respectively. Such a first or second longitudinal channel can, for example, be a connecting channel extending substantially in a straight line between the contact side of the contact carrier and the cable side opposite to the contact side. The two longitudinal channels can be aligned substantially parallel to each other here. For example, when bundling cables, the contact element can be introduced into the corresponding longitudinal channel from the cable side until it is moved to the end position in the direction of the contact side and is fastened, for example, locked in the end position. It is feasible that the contact element is completely arranged within the corresponding longitudinal channel in the corresponding end position of the contact element. However, it is also feasible that the (e.g. pin-shaped) front section of the contact element extends from the contact carrier at the contact side in the corresponding end position of the contact element.

[0016] Furthermore, each longitudinal channel is penetrated by at least one through-opening. Such a through-opening can be, for example, a transverse channel extending transversely to the respective longitudinal channel, which, for example, connects the upper side and the lower side or the front side and the rear side of the contact carrier to one another. The first and second through-openings can be separate, i.e., not connected to one another, openings in the contact carrier. Alternatively, the first and second through-openings can be different regions of a single, larger through-opening in the contact carrier, which intersects the first longitudinal channel and the second longitudinal channel.

[0017] The two through openings are mainly used to achieve the sealing of the contact carrier for the subsequent injection molding of the contact carrier. For this purpose, the correspondingly molded seals are introduced into the two through openings before the injection molding. Such seals can be in particular sealing tools, i.e. parts that are removed from the cable again after the contact carrier is injection molded. Alternatively, the seal can be an integral component of the bundled cable. For example, the seal can be introduced from the sides opposite to each other and gathered into the corresponding through openings until the seal reaches the end position. The seal can be molded so that the seal not only seals the corresponding through opening at the two ends of the through opening in a liquid-tight manner, i.e., for example, at the upper and lower sides or the front and rear sides of the contact carrier in a liquid-tight manner in the corresponding end position of the seal, but also seals the corresponding longitudinal channel toward the cable side of the contact carrier in a liquid-tight manner. For example, it is feasible that one of the two first or second seals is used as an anvil, while the other of the two first or second seals is used as a punch. The seal can be formed in such a way that it fills the corresponding region of the through-opening in which it is introduced in a sealing manner. The seal acting as anvil and the seal acting as a punch can sealably surround the corresponding wire extending between the seals. This prevents liquid injection molding material, which is usually injected into the injection molding tool at very high pressures of up to several hundred bars, from penetrating from the cable side into the front part of the first or second longitudinal channel and into the corresponding contact element during the subsequent injection molding coating, which could impair the function of the contact element.

[0018] The sealing of the contact carrier can be carried out, for example, by means of one or more sealing forks, wherein the seal can be implemented as a special shaped section of such a sealing fork. For example, it is possible to combine each of the first seals and each of the second seals to form each sealing fork. Alternatively, the seal can also be implemented as a separate component or in another form familiar to the person skilled in the art. For example, the seal can also be part of an injection molding tool.

[0019] The molding of the connector can be carried out by means of an injection molding tool, which in a closed state surrounds the section of the contact carrier and the section of the cable protruding from the contact carrier, that is, it is enclosed in a female mold that forms the connector to be molded. The section of the contact carrier to be injection molded can be a rear section of the contact carrier facing the cable side, in which the first through-opening and the second through-opening are also arranged. On the contrary, during the injection molding, the front section of the contact carrier facing the contact side can be located outside the injection molding tool or at least outside the female mold. Therefore, it is prevented that the liquid injection molding material penetrates from the contact side into the longitudinal channel and penetrates into the contact element located therein. However, it is also feasible to completely injection mold the contact carrier (see below). The protruding section of the cable to be injection molded can include an exposed section of the first core wire and the second core wire, that is, the outer cover is removed in this section and the corresponding core wire covers of the two core wires are exposed accordingly. The exposed section can extend between the cable side and the outer cover along the longitudinal direction of the cable. In addition, the end sections of the outer cover can be injection molded. The above-mentioned exposed sections of the cores can be stabilized, fixed relative to each other and electrically insulated from each other by the connecting piece. In addition, the gap between two cores can be filled with injection molding material (see below). The tensile loads acting on the individual cores can also be limited by the connecting piece.

[0020] Depending on the requirements, the connecting piece can be shaped in such a way that, for example, different functional sections are present on its outer surface. Such a functional section can be, for example, a single-sided or double-sided cutout arranged relative to the through-opening, which allows a (possibly automated) visual inspection of the wire section extending in the contact carrier. Thus, installation errors can be detected early, for example within the scope of a camera inspection. Another example of such a functional section is a specially shaped contour element, such as a locking flange, a locking groove, etc., which can be used to lock a separate plug housing to the connecting piece. Such a contour element has the advantage that the plug housing can be easily mounted and disassembled.

[0021] For molding the connecting piece, for example, glass fiber reinforced plastic or other suitable fiber plastic composites can be used as injection molding material. However, according to the purpose of use, other injection molding materials can also be used to mold the connecting piece.

[0022] In summary, this method allows for simple, rapid and reliable bundling of multi-core cables. In particular, by molding the connector by injection molding, it is possible to dispense with the use of complex components, such as additional plastic half shells, additional sealing elements for sealing the contact carrier or additional, for example wedge-shaped, spacers for widening the cable cores. It has been shown that the method described here allows for simple, rapid and reliable bundling of twisted pairs of conductors with (for example unshielded) two-wire plug connectors, such as are also used for data transmission in motor vehicles.

[0023] Cables bundled in this way are particularly robust against bending and tensile loads, especially in the transition area between the contact carrier and the outer jacket of the cable. In other words, the injection-molded connector ensures that sufficient pulling forces can be applied without damaging the cable, such as tearing or breaking individual wires or cores.

[0024] Without limiting the scope of the invention in any way, the idea and enabling features of the embodiments of the invention can also be considered to be based on the ideas and cognitions described below.

[0025] According to one embodiment, the method comprises removing the first seal and the second seal after the connector has been formed. As described above, the seal can be a detachable sealing tool. The seal can be designed, for example, so that after the seal is introduced into the contact carrier up to the end position, the seal protrudes from the contact carrier. For example, a protruding section of the seal can prevent the through-opening from being covered with the injection molding material during the injection molding. By removing the seal after the connector has been formed, that is, after the injection molding material has hardened, a corresponding recess is obtained in the connector, which is opposite to the corresponding through-opening of the contact carrier or transitions into the through-opening in an aligned manner. Thus, for example in the context of a (possibly camera-assisted) quality inspection, the core wire in the contact carrier can still be touched or observed after the injection molding.

[0026] According to one embodiment, in order to seal the first longitudinal channel in a liquid-tight manner, the section of the wire cover of the first wire that extends into the first through-opening is clamped between the first seal. Additionally or alternatively, in order to seal the second longitudinal channel in a liquid-tight manner, the section of the wire cover of the second wire that extends into the second through-opening can be clamped between the second seal. For example, for this purpose, the seal can have a correspondingly shaped, for example a correspondingly circular, recess at the end of the seal facing the wire. It is important that the seal surrounds the respective wire cover in a liquid-tight manner in the clamped state, i.e., forms a surrounding liquid-tight sealing edge together with the respective wire cover. As a result, it is possible to prevent liquid injection molding material from penetrating between the seal and the respective wire cover.

[0027] According to one embodiment, the contact carrier also has a third through-opening that intersects the front part of the first longitudinal channel. Accordingly, the method also includes closing the third through-opening in a liquid-tight manner by introducing two third seals into the third through-opening. Here, in order to mold the connector, the section of the contact carrier that surrounds the third through-opening is also injection-molded. For example, the third through-opening can be used to lock the first contact element in the first longitudinal channel. For example, to this end, the first contact element can have one or more locking flanges or locking springs. In order to prevent liquid injection molding material from reaching the front part of the first longitudinal channel via the third through-opening and then penetrating into the first contact element, the third through-opening can be correspondingly sealed on both sides by means of a third seal. For example, the third seal can be removed again after the connector is molded.

[0028] According to one embodiment, the contact carrier also has a fourth through-opening that intersects the front part of the second longitudinal channel. Accordingly, the method also includes closing the fourth through-opening in a liquid-tight manner by introducing two fourth seals into the fourth through-opening. Here, in order to mold the connector, the section of the contact carrier that surrounds the fourth through-opening is also injection molded. The fourth through-opening can be used, for example, to lock the second contact element in the second longitudinal channel. For example, to this end, the second contact element can have one or more locking flanges or locking springs. In order to prevent the liquid injection molding material from reaching the front part of the second longitudinal channel via the fourth through-opening and then penetrating into the second contact element, the fourth through-opening can be correspondingly sealed on both sides by means of a fourth seal. For example, the fourth seal can be removed again after the connector is molded.

[0029] Similar to as mentioned above in conjunction with the first and second through openings, the third and fourth through openings can be separate openings in the contact carrier, or can be different regions of a single larger through opening in the contact carrier that intersects the front portion of the first longitudinal channel and intersects the front portion of the second longitudinal channel.

[0030] According to one embodiment, the gap between the section of the first core extending from the cable side and the section of the second core extending from the cable side is filled with injection molding material by an injection molding method. Thus, on the one hand, fluctuations in the spacing between the two cores on the cable side can be prevented, which fluctuations are caused, for example, by bending loads or tensile loads or mechanical vibrations. On the other hand, the electrical insulation or dielectric insulation between the two cores can be improved, because compared with air, the injection molding material usually has a significantly higher relative dielectric constant, for example, at least twice as high. Finally, this embodiment can ensure that the two cores have almost the same coupling impedance or output impedance, such as this is necessary for the transmission of differential signals. In order to ensure the lowest possible interference emission and robustness with respect to interference radiation, the protruding sections of the two cores can also be completely embedded in the injection molding material, so that the two cores can be fastened at a defined spacing between each other. The contact carrier can have a wedge, which extends at least partially into the gap to ensure that, for example, during the injection molding coating, the first core and the second core are not pressed out of the preset position of the core by the injection molding material. Furthermore, before the step of forming the connecting element, a retaining element can be positioned in the region of the gap between the cores and / or at the core outside the gap in order to hold the cores in their position during the injection molding. In this regard, it is particularly advantageous to arrange two retaining elements outside the gap outside the first core and the second core so that the first core and the second core extend side by side outside the gap between the two retaining elements. After the forming step, the retaining elements can be removed from the first core and the second core.

[0031] According to one embodiment, the connecting piece is left open at a location opposite the first through-opening and the second through-opening. In other words, the first through-opening or the second through-opening can pass through both the contact carrier and the connecting piece. For example, the first through-opening or the second through-opening can connect the top and bottom side or the front and rear side of the connecting piece to each other. As a result, the wire section extending in the contact carrier can be touched and / or seen from the outside, which simplifies quality inspection, for example.

[0032] According to one embodiment, the housing has a shaped end section for producing a form fit in the longitudinal direction of the cable. Here, in order to shape the connector, the shaped end section of the housing is injection molded. The end section of the housing to be injection molded can be shaped, for example, with one or more grooves, which can extend at least partially in the circumferential direction of the cable. The groove can be introduced into the housing, for example, using a rotating tool. Subsequently, a form fit can be produced by filling the groove(s) with injection molding material. As a result, the connector can be connected to the housing in a material-fitting and form-fitting manner, which improves the robustness of the bundled cables with respect to tensile loads.

[0033] According to one embodiment, the cable further comprises a plug housing for accommodating the plug. Here, the contact carrier is at least partially arranged in the plug housing. The plug housing can be used, on the one hand, to protect the components arranged therein from environmental influences, and on the other hand, to mechanically couple the contact carrier or the contact element with the corresponding plug. For example, when viewed in the longitudinal direction of the contact carrier, the plug housing can extend out of the contact carrier on one side or on both sides and / or partially or completely surround the contact carrier in the circumferential direction of the contact carrier. Here, the plug housing can be opened at least toward the contact side. In addition to the contact carrier, at least one section of the connector and / or a section of the cable extending from the connector can be arranged in the plug housing.

[0034] According to one embodiment, the plug housing is fastened to the connection piece. This has the effect that when plugging in or unplugging, the forces acting on the plug housing are mainly introduced into the relatively stable connection piece. Thus, for example, damage to the core wire or the contact carrier can be avoided.

[0035] According to one embodiment, the connecting piece has a locking section in which the plug housing is locked. The locking section can include a suitable contour or structure for connecting the plug housing to the connecting section in a form-fitting and / or force-fitting manner. As indicated above, the locking section can be a locking flange, a locking groove, etc. As a result, the plug housing can be positioned and fastened to the connecting piece with little manufacturing effort. This embodiment also allows for simple disassembly of the plug housing.

[0036] According to one embodiment, the connector has a cup-shaped section for accommodating the plug. The cup-shaped section of the connector can, for example, extend beyond the contact side of the contact carrier and thus form a plug socket for accommodating the plug together with the contact carrier. This can further simplify the bundling of cables. In particular, it is possible to dispense with placing a separate plug socket on the contact carrier.

[0037] It should be noted that the feasible features and advantages of the embodiments of the present invention are described in part with reference to the method for bundling multi-core cables and in part with reference to the corresponding bundled cables. Those skilled in the art recognize that the features described for each embodiment can be transferred to, adapted to, and / or exchanged with other embodiments in a similar and appropriate manner to achieve other embodiments of the present invention and possible synergistic effects. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Advantageous embodiments of the present invention are explained in further detail below with reference to the drawings, wherein neither the drawings nor the explanations are to be interpreted as limiting the present invention in any way.

[0039] Figure 1The cable is schematically shown before being injection molded in a method according to one exemplary embodiment of the present invention.

[0040] Figure 2 Schematic diagram of the process after injection molding Figure 1 cables.

[0041] Figures 3 to 7 The cables in various steps of the method according to one embodiment of the present invention are schematically shown.

[0042] Figure 8 Schematically showing the Figure 4 Longitudinal section of the contact carrier in FIG.

[0043] Fig. 9 Schematically showing the section line AA through Figure 8 Cross-sectional view of the contact carrier in FIG.

[0044] Fig.10 A flow chart is shown for explaining a method according to one exemplary embodiment of the present invention.

[0045] The accompanying drawings are schematic and not drawn to scale. In the various drawings, the same reference numerals indicate the same or similarly functioning features. DETAILED DESCRIPTION

[0046] Figure 1 A section of a cable 100 is schematically shown, comprising a first core 102a and a second core 102b. The two cores 102a, 102b are partially surrounded by an outer casing 104 of the cable 100. Furthermore, the cable 100 comprises a first contact element 106a and a second contact element 106b, wherein the first contact element 106a is electrically conductively connected to an end section of an inner conductor 108a of the first core 102a, and the second contact element 106b is electrically conductively connected to an end section of an inner conductor 108b of the second core 102b. The contact elements 106a, 106b can be connected to the corresponding inner conductor 108a or 108b, for example, by crimping, welding and / or soldering. The contact elements 106a, 106b are also shaped so as to accommodate a corresponding mating contact element 110a or 110b of a plug 112, with which the cable 100 can be connected. For example, as Figure 1 As shown, the contact elements 106 a , 106 b can each have a socket-shaped section for receiving a corresponding pin-shaped section of the mating contact element 110 a or 110 b (or vice versa).

[0047] The cable 100 further comprises a contact carrier 114, which has a first longitudinal channel 116a, a second longitudinal channel 116b, a first through opening 118a intersecting the first longitudinal channel 116a, and a second through opening 118b intersecting the second longitudinal channel 116b. The contact carrier 114 has a contact side 120 and a cable side 122 opposite to the contact side 120. The longitudinal channels 116a and 116b connect the contact side 120 and the cable side 122, respectively. The two through openings 118a and 118b can respectively connect the front side (at the bottom of the cable side) of the contact carrier 114. Figure 1 , the side facing the observer) and the rear side of the contact carrier 114 (in Figure 1 The through openings 118a, 118b essentially allow the contact carrier 114 to be sealed by means of suitable seals, which will be described in detail below.

[0048] The first contact element 106a is arranged in a front part of the first longitudinal channel 116a facing the contact side 120, wherein the first core 102a protrudes from the first longitudinal channel 116a for a section at the cable side 122. The second contact element 106b is arranged in a front part of the second longitudinal channel 116b facing the contact side 120, wherein the second core 102b protrudes from the second longitudinal channel 116b for a section at the cable side 122. The contact elements 106a, 106b can be as follows Figure 1 completely as shown Figure 7 In addition, the contact elements 106a, 106b can be fastened in a determined position in the corresponding longitudinal channels 116a or 116b of the contact elements, for example by means of spring force and / or locking means, such as Figure 8 shown.

[0049] The contact elements 106a, 106b can be positioned in the corresponding longitudinal channels 116a or 116b of the contact elements so that the core cover 124a of the first core 102a extends into the intersection area between the first longitudinal channel 116a and the first through-opening 118a, or the core cover 124b of the second core 102b extends into the intersection area between the second longitudinal channel 116b and the second through-opening 118b. Figure 1 As shown, the core wire covers 124a, 124b can also extend through the corresponding intersection area.

[0050] The through-openings 118a, 118b can be, for example, wider than the longitudinal channels 116a or 116b intersecting the through-openings and undercut the respective longitudinal channels 116a or 116b on both sides. Figure 1The through openings 118a, 118b in the embodiment are respectively formed as slots with rectangular cross sections. However, the through openings 118a, 118b can also be formed to have other suitable cross sections, such as circular or trapezoidal cross sections.

[0051] like Figure 2 As shown, the cable 100 further includes a connector 200 that supports the contact carrier 114 on the housing 104 and reduces bending and tensile loads of the core wires 102 a , 102 b , for example, when the plug 112 is inserted or removed.

[0052] The connecting piece 200 is a molded part, which is formed by injection molding a rear section 202 of the contact carrier 114 facing the cable side 122 and having two through-openings 118a, 118b and a section 204 of the cable 100 protruding at the cable side 122 using a suitable injection molding material. In this case, the connecting piece 200 can surround an end section 205 of the housing 104.

[0053] The injection molding material can be, for example, a polyamide-glass fiber composite material. However, other injection molding materials are also possible.

[0054] In order to connect the connecting piece 200 to the housing 104 not only in a materially bonded manner but also in a form-fitting manner, the end section 205 of the housing 104 can be correspondingly profiled. For example, the end section 205 can be profiled with at least one groove 206. The groove 206 can completely or only partially surround the housing 104 in the circumferential direction of the housing. The groove 206 can be cut into the housing 104, for example, by means of a suitable cutting tool. Finally, by filling the groove 206 with injection molding material, a form fit that acts in the longitudinal direction of the cable 100 is produced.

[0055] The connecting piece 200 can be left open at a location opposite to the through openings 118a, 118b, so that the wire shields 124a, 124b extending in the contact carrier 114 can be seen and / or contacted from the outside through the connecting piece 200. In this case, the connecting piece 200 can be opened on one side or on the other side. Figure 2 Leave the sides blank as shown.

[0056] For example, in order to be able to transmit differential signals via the cores 102a, 102b, it is important that the cores 102a, 102b are spaced apart from each other at a defined distance (at Figure 1 and Figure 2 In other words, the two cores 102a, 102b should be separated from each other by a gap 208 with a defined width in this area. In order to fasten the cores 102a, 102b relative to each other, the gap 208 can be filled with injection molding material during the injection molding (see Figure 2 ). This prevents the width of the gap 208 from changing, i.e. the cores 102a, 102b from significantly moving laterally relative to one another. The injection molding material filling the gap 208 also serves as a dielectric between the cores 102a, 102b. Thus, for example, even in the event of bending loads, the resulting dielectric constant between the cores 102a, 102b can remain largely constant. The cores 102a, 102b can also be completely embedded in the injection molding material between the cable side 122 and the housing 104, such as Figure 2 shown.

[0057] Below, based on Figures 3 to 10 The various steps of the method for bundling cables 100 are described in more detail. The basic sequence of the method is Fig.10 In the description.

[0058] Figure 3 The end section of the cable 100 is shown in an initial state before the contact carrier 114 is placed. Each contact element 106a, 106b can, for example, have one or more locking springs 300 (see below) for fastening in the contact carrier 114. By way of example, the contact elements 106a, 106b are implemented here as bent sheet metal stampings. However, other embodiments of the contact elements 106a, 106b are also possible.

[0059] In step S10, the contact carrier 114 is placed on the cable 100. As has been described above according to Figure 1 As described, in this case the contact elements 106 a , 106 b connected to the respective wire 102 a , 102 b are introduced into the contact carrier 114 and secured there by means of the locking spring 300 .

[0060] Figure 4 A possible embodiment of a suitable contact carrier 114 is shown after being attached to the cable 100 in step S10. Figure 1 Differently, here, the contact carrier 114 additionally has a third through-opening 400a intersecting the front part of the first longitudinal channel 116a and a fourth through-opening 400b intersecting the front part of the second longitudinal channel 116b. The locking spring 300 of the contact element 106a, 106b is hooked into the corresponding through-opening 400a or 400b, thereby preventing the corresponding contact element 106a or 106b from slipping out in the corresponding longitudinal channel 116a or 116b.

[0061] In order to prevent the injection molding material from reaching the front part of the longitudinal channels 116a, 116b that accommodates the contact elements 106a, 106b during the subsequent injection molding, the corresponding seals are introduced into the four through-openings 118a, 118b, 400a, 400b in step S20. Here, two first seals 900a, 900b are introduced into the first through-opening 118a and two second seals 902a, 902b are introduced into the second through-opening 118b. A cross-sectional view of the contact carrier 114 with the introduced seals 900a, 900b, 902a, 902b is shown in FIG. Figure 8 and Fig. 9 The four seals 900a, 900b, 902a, 902b ensure that liquid injection molding material neither penetrates through the through-openings 118a, 118b nor penetrates from the cable side 122 into the longitudinal channels 116a, 116b.

[0062] Additionally, depending on the length of the connecting part 200 to be molded, two third seals (not shown) can be introduced into the third through-opening 400a, and two fourth seals (not shown) can be introduced into the fourth through-opening 400b, so that the injection molding material cannot penetrate into the corresponding longitudinal channel 116a or 116b through the through-openings 400a, 400b.

[0063] exist Fig. 9 It is shown that the cores 102a, 102b can be clamped, for example, between the corresponding seals 900a, 900b or 902a, 902b in order to close the corresponding longitudinal channel 116a or 116b in a liquid-tight manner. To this end, the seals 900a, 900b or 902a, 902b can be introduced from the sides opposite to each other into the corresponding through-opening 118a or 118b and brought together, for example, until a stop.

[0064] The ends of the respective seals 900a, 900b or 902a, 902b facing the cores 102a, 102b can be designed in a suitable manner, in particular such that the cores 102a, 102b are surrounded fluid-tightly by the respective seals 900a, 900b or 902a, 902b in the clamped state.

[0065] The seal can be conveniently designed to be conical in the respective longitudinal direction of the seal, thereby enabling a reliable sealing of the respective through-opening to be achieved.

[0066] After the contact carrier 114 is sealed in step S20, the connector 200 is molded in step S30. For this purpose, the section of the contact carrier 114 to be injection molded is arranged together with the section of the cable 100 to be injection molded in a suitable injection molding tool, the injection molding tool is closed, and the cavity bounded by the injection molding tool is filled with injection molding material. For example, the section to be injection molded can already be arranged in the injection molding tool in step S20. It is also possible to achieve a liquid-tight sealing of the contact carrier 114 in the injection molding tool by means of a seal.

[0067] Figure 5 A possible embodiment of a suitable connector 200 after the injection molding in step S30 is shown. In this example, the injection-molded section 202 of the contact carrier 114 only includes the first through-opening 118a and the second through-opening 118b. The third through-opening 400a and the fourth through-opening 400b are not injection-molded here. However, it is possible that the contact carrier 114 is completely injection-molded, as shown in the example. Figure 7 In this case, it is necessary to additionally close the third through-opening 400a and the fourth through-opening 400b in a liquid-tight manner in step S20 by means of a third or fourth seal.

[0068] like Figure 5 As shown in FIG. 2 , the connector 200 can have a specially shaped locking section 500 for locking the plug housing 600 (see FIG. 2 ). Figure 6 ). The locking section 500 can, for example, include a surrounding locking groove 502 and / or a stopper 504. The stopper 504 can be used to limit the displacement stroke of the plug housing 600 in the longitudinal direction of the cable 100. For example, the stopper 504 can be adjacent to the edge of the locking groove 502. However, the locking section 500 can also be formed in other suitable ways.

[0069] In addition, as mentioned above based on Figure 2 As described, the connecting piece 200 can have a slot-shaped recess 506 on one side or on both sides relative to the first through-opening 118a and the second through-opening 118b. The recess 506 can therefore also be used as a kind of observation window for visual inspection of the core wire section extending in the contact carrier 114 (for example, in a camera-assisted manner).

[0070] Optionally, the plug housing 600 can be fastened to the connector 200 in step S40, for example by locking the plug housing 600 in a locking section 500 of the connector 200. The plug housing 600 can be partially or completely fixed to the connector 200. Figure 6As shown, the contact carrier 114 is completely surrounded together with the molded connection part 200. The plug housing 600 can be used, for example, as a plug socket for accommodating and / or locking the plug 112 (see Figure 1 ).

[0071] As already explained, the contact carrier 114 can also be completely embedded in the connecting part 200, as in Figure 7 . In this case, the connecting piece 200 can extend beyond the contact side 120 of the contact carrier 114. In particular, the section 700 of the connecting piece 200 that extends beyond the contact carrier 114 at the contact side 120 can be, for example, cup-shaped and together with the contact carrier 114 form a socket for accommodating the plug 112. In this case, the contact elements 116a, 116b can, for example, each have a pin-shaped front section 702a or 702b that can extend from the contact carrier 114 at the contact side 120 or can extend into the cup-shaped section 700 of the connecting piece 200.

[0072] Finally, it should be pointed out that terms such as "having", "comprising" etc. do not exclude other elements or steps, and terms such as "a" or "an" do not exclude a plurality. It is further pointed out that features or steps that have been described with reference to one of the above embodiments can also be used in combination with other features or steps of other embodiments described above. Reference numerals in the claims are not to be regarded as limitations.

[0073] Reference numerals list

[0074] 100 Cables

[0075] 102a First core line

[0076] 102b Second core wire

[0077] 104 Cover

[0078] 106a First contact element

[0079] 106b Second contact element

[0080] 108a Inner conductor of the first core wire

[0081] 108b Inner conductor of the second core wire

[0082] 110a First mating contact element

[0083] 110b Second mating contact element

[0084] 112 Plug

[0085] 114 Contact bearing

[0086] 116a First longitudinal channel

[0087] 116b Second longitudinal channel

[0088] 118a First through opening

[0089] 118b Second through opening

[0090] 120 Contact side

[0091] 122 Cable side

[0092] 124a Core cover of the first core

[0093] 124b Core cover for the second core

[0094] 200 Connectors

[0095] 202 Rear section of contact carrier

[0096] 204 Extended section of cable

[0097] 205 End section of core shield

[0098] 206 slots

[0099] 208 Gap

[0100] 300 Locking spring

[0101] 400a Third through opening

[0102] 400b Fourth through opening

[0103] 500 Locking section

[0104] 502 Locking slot

[0105] 504 Stopper

[0106] 506 Blank

[0107] 600 Plug Housing

[0108] 700 Cup-shaped section of connecting piece

[0109] 702a Front section of the first contact element

[0110] 702b Front section of the second contact element

[0111] 900a First seal

[0112] 900b First seal

[0113] 902a Second seal

[0114] 902b Second seal

Claims

1. A method for bundling multi-core cables (100), wherein: The cable (100) comprises at least one first core wire (102a) and a second core wire (102b) and an outer cover (104), wherein the outer cover at least partially surrounds the first core wire (102a) and the second core wire (102b), wherein an end section of an inner conductor (108a) of the first core wire (102a) is electrically conductively connected to a first contact element (106a), and an end section of an inner conductor (108b) of the second core wire (102b) is electrically conductively connected to a second contact element (106b), wherein the method comprises: The first contact element (106a) and the second contact element (106b) are arranged in a contact carrier (114) having a contact side (120) and a cable side (122), wherein the contact carrier (114) has a first longitudinal channel (116a) connecting the contact side (120) to the cable side (122), a second longitudinal channel (116b) connecting the contact side (120) to the cable side (122), a first through-opening (118a) intersecting the first longitudinal channel (116a), and a second through-opening (118b) intersecting the second longitudinal channel (116b), wherein at least one section of the first contact element (106a) is arranged in a front portion of the first longitudinal channel (116a) extending between the contact side (120) and the first through-opening (118a), and at least one section of the second contact element (106b) is arranged in a front portion of the second longitudinal channel (116b) extending between the contact side (120) and the second through-opening (118b); By introducing two first sealing members (900a, 900b) into the first through-opening (118a), the first longitudinal channel (116a) and the first through-opening (118a) are closed in a liquid-tight manner; By introducing two second sealing members (902a, 902b) into the second through-opening (118b), the second longitudinal channel (116b) and the second through-opening (118b) are closed liquid-tightly; and A connector (200) is formed by injection molding at least one rear section (202) of the contact carrier (114) surrounding the first through-opening (118a) and the second through-opening (118b) and a section (204) of the cable (100) extending at the cable side (122).

2. The method according to claim 1, further comprising: After the connector (200) is formed, the first seal (900a, 900b) and the second seal (902a, 902b) are removed.

3. The method according to any one of the preceding claims, in, In order to seal the first longitudinal channel (116a) in a liquid-tight manner, a section of the wire cover (124a) of the first wire (102a) extending into the first through-opening (118a) is clamped between the first seals (900a, 900b); and / or In order to seal the second longitudinal channel (116b) in a liquid-tight manner, a section of the wire shield (124b) of the second wire (102b) extending into the second through-opening (118b) is clamped between the second seals (902a, 902b).

4. The method according to any one of the preceding claims, in, The contact carrier (114) also has a third through opening (400a) intersecting the front portion of the first longitudinal channel (116a); Wherein, the method further comprises: By introducing two third sealing members into the third through-opening (400a), the third through-opening (400a) is closed liquid-tightly; In order to mold the connecting piece (200), a section of the contact carrier (114) surrounding the third through-opening (400a) is also injection-molded.

5. The method according to any one of the preceding claims, in, The contact carrier (114) also has a fourth through opening (400b) intersecting the front portion of the second longitudinal channel (116b); Wherein, the method further comprises: By introducing two fourth sealing members into the fourth through-opening (400b), the fourth through-opening (400b) is closed liquid-tightly; In order to mold the connecting piece (200), a section of the contact carrier (114) surrounding the fourth through-opening (400b) is also injection-molded.

6. The method according to any one of the preceding claims, in, A gap (208) between a section of the first core (102a) extending from the cable side (122) and a section of the second core (102b) extending from the cable side (122) is filled with an injection molding material by an injection molding method.

7. The method according to any one of the preceding claims, in, The outer cover (104) has a shaped end section (205) for producing a form fit in the longitudinal direction of the cable (100); In order to form the connecting piece (200), the profiled end section (205) of the outer cover (104) is injection molded over.

8. A cable (100), comprising: at least one first core wire (102a) and a second core wire (102b); An outer cover (104) at least partially surrounding the first core wire (102a) and the second core wire (102b); A contact carrier (114) having a contact side (120), a cable side (122), a first longitudinal channel (116a) connecting the contact side (120) with the cable side (122), a second longitudinal channel (116b) connecting the contact side (120) with the cable side (122), a first through-opening (118a) intersecting the first longitudinal channel (116a), and a second through-opening (118b) intersecting the second longitudinal channel (116b); a first contact element (106a) which is electrically conductively connected to an end section of an inner conductor (108a) of the first core (102a) and is at least partially arranged in a front portion of the first longitudinal channel (116a) extending between the contact side (120) and the first through-opening (118a); a second contact element (106b) which is electrically conductively connected to an end section of an inner conductor (108b) of the second core (102b) and is at least partially arranged in a front portion of the second longitudinal channel (116b) extending between the contact side (120) and the second through-opening (118b); and A connecting piece (200) connects the contact carrier (114) to the outer cover (104) and is formed by injection molding at least one rear section (202) of the contact carrier (114) surrounding the first through-opening (118a) and the second through-opening (118b) and a section (204) of the cable (100) extending at the cable side (122).

9. The cable (100) according to claim 8, in, The connecting piece (200) is recessed at locations opposite to the first through-opening (118a) and the second through-opening (118b).

10. The cable (100) according to claim 8 or 9, further comprising: A plug housing (600) for accommodating the plug (112); Therein, the contact carrier (114) is at least partially arranged in the plug housing (600).

11. The cable (100) according to claim 10, in, The plug housing (600) is fastened to the connecting piece (200).

12. The cable (100) according to claim 11, in, The connecting piece (200) has a locking section (500), and the plug housing (600) is locked in the locking section (500).

13. The cable (100) according to any one of claims 8 to 12, in, The connecting piece (200) has a cup-shaped section (700) for receiving a plug (112).

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