Prefabricated cables, plug connector assemblies, methods and equipment for manufacturing cables

Abstract

This invention relates to a prefabricated cable (1). It also relates to a plug connector assembly (100). Finally, it relates to a method and apparatus for manufacturing the cable (1). The prefabricated cable (1) includes an outer conductor shield (5) and an insulating element (4). The insulating element (4) has a first longitudinal section (L1) and a second longitudinal section (L2), in which the insulating element (4) is exposed from the outer conductor shield (5), and the second longitudinal section is adjacent to the first longitudinal section and enclosed by the outer conductor shield (5) in the second longitudinal section. The cross-sectional area of ​​the insulating element (4) in the first longitudinal section (L1) varies with the cross-sectional area in the second longitudinal section (L2) such that the first longitudinal section (L1) of the insulating element (4) can be inserted into the first longitudinal section (S1) of the outer conductor contact element (14) of an electrical plug connector (15), and the insulating element (4) is oriented to the outer conductor contact element (14) in the first longitudinal section (L1).

Description

Technical Field

[0001] This invention relates to prefabricated cables, plug connector assemblies, and methods and apparatus for manufacturing cables. Background Technology

[0002] Plug connectors are used to connect cables to other cables or printed circuit boards. The plug connectors are used to electrically and mechanically attach the cables during the cable manufacturing process.

[0003] In the manufacture of cables, particularly high-frequency cables, the inner conductor is exposed from the insulating element, the insulating element is exposed from the outer conductor shield, and the outer conductor shield is exposed from the cable sheath. Subsequently, a support sleeve may be optionally crimped onto the exposed outer conductor shield or the cable sheath, and the outer conductor shield may be folded onto the support sleeve. Finally, the cable, prefabricated in this manner, is inserted into and crimped onto the outer conductor contact element of the plug connector.

[0004] For high-frequency signal transmission, the transition between the cable and the plug connector is optimized in terms of impedance characteristic curves. Here, the impedance of the plug connector, and the impedance characteristic curve in the transition between the cable and the plug connector, is ideally matched to the reference impedance of the cable, for example, 50 ohms. Alternatively, appropriate measures are taken in the plug connector for anti-compensation for mismatches. In both cases, reflections of the high-frequency signal along the signal transmission path are minimized.

[0005] In this process, the geometry of the various components of the plug connection (i.e., the outer conductor shield, optional support sleeve, insulating element, inner conductor contact element, and outer conductor contact element) must be ideally matched with each other under ideally small manufacturing tolerances. Furthermore, each manufacturing step must be performed with the best possible manufacturing precision.

[0006] Depending on the technical requirements of different application areas, especially in the automotive industry, the various components of a cable—namely, the inner conductor, insulation elements, outer conductor shielding, and cable sheath—are made of specific materials and have specific geometric dimensions.

[0007] Here, the outer diameter of the insulating element is primarily important for the manufacturing process because, for impedance matching purposes, this outer diameter should correspond to the inner diameter of the outer conductor contact element. In this way, a corresponding outer conductor contact element with a matching inner diameter will be manufactured for each cable with a corresponding outer diameter of the insulating element. This requires various designs, tools, manufacturing plans, and machine procedures. Overall, this makes manufacturing more complex and thus adversely increases manufacturing costs significantly.

[0008] Retaining outer conductor contact elements with different inner diameters also significantly increases storage costs.

[0009] This is a situation that needs improvement. Summary of the Invention

[0010] In this context, the objective of this invention is to define a prefabricated cable that can significantly reduce the aforementioned manufacturing and storage costs.

[0011] Additionally, a plug connector assembly and a method and apparatus for manufacturing cables should be specified, which can also significantly minimize the aforementioned manufacturing and storage costs in various situations.

[0012] Accordingly, the following are provided:

[0013] A prefabricated cable (hereafter occasionally referred to simply as "cable"), having

[0014] -Outer conductor shielding, and

[0015] -Insulating components,

[0016] - Wherein, the insulating element has a first longitudinal portion, in which the insulating element is exposed from the outer conductor shield, and

[0017] - A second longitudinal portion, adjacent to the first longitudinal portion, wherein the insulating element in the second longitudinal portion is encapsulated by an outer conductor shield.

[0018] - wherein the cross-sectional area of ​​the insulating element in the first longitudinal portion is modified relative to the cross-sectional area of ​​the insulating element in the second longitudinal portion such that the first longitudinal portion can be inserted into the first plug connector portion of the outer conductor contact element of the plug connector, and the insulating element is calibrated to the outer conductor contact element in the first longitudinal portion.

[0019] A plug connector assembly, comprising:

[0020] - Cables, and

[0021] - Plug connector, the plug connector is connected to at least one end of the cable.

[0022] -The cable has an outer conductor shield, and

[0023] -Insulating components,

[0024] - Wherein, the insulating element has a first longitudinal portion, in which the insulating element is exposed from the outer conductor shield, and

[0025] - It has a second longitudinal portion adjacent to the first longitudinal portion, and wherein the insulating element is encapsulated by an outer conductor shield.

[0026] - wherein the cross-sectional area of ​​the insulating element in the first longitudinal portion is modified relative to the cross-sectional area of ​​the insulating element in the second longitudinal portion such that the first longitudinal portion of the insulating element is inserted into the first plug connector portion of the outer conductor contact element of the plug connector, and the insulating element is calibrated to the outer conductor contact element in the first longitudinal portion.

[0027] A method for manufacturing cables,

[0028] -In the first longitudinal section, the insulating element is exposed from the outer conductor shield.

[0029] -The cross-sectional area of ​​the insulating element in the first longitudinal portion is modified relative to the cross-sectional area of ​​the insulating element in the second longitudinal portion adjacent to the first longitudinal portion.

[0030] -The cable is inserted into the outer conductor contact element of the plug connector and connected to, preferably crimped to, the outer conductor contact element.

[0031] - wherein the cross-sectional area of ​​the first longitudinal portion is modified relative to the cross-sectional area of ​​the second longitudinal portion, such that the first longitudinal portion of the insulating element can be inserted into the first plug connector portion of the outer conductor contact element of the plug connector, and the first longitudinal portion of the insulating element is calibrated to the outer conductor contact element.

[0032] An apparatus for manufacturing cables, having

[0033] - A processing device for modifying the cross-sectional area of ​​the cable's insulation elements exposed from the outer conductor shield in the first longitudinal portion, and

[0034] - A connecting device for inserting a cable into the outer conductor contact element of a plug connector.

[0035] -The processing device is configured such that the processing device modifies the cross-sectional area of ​​the first longitudinal portion so that the first longitudinal portion can be inserted into the first plug connector portion of the outer conductor contact element, and the first longitudinal portion of the insulating element is aligned with the outer conductor contact element.

[0036] A specific advantage of the present invention is that the identical outer conductor contact element of the plug connector with a specific inner diameter can be used for cables with different geometries, particularly cables with different outer diameters and insulating elements.

[0037] If the outer diameter of the insulating element corresponds to the inner diameter of the outer conductor contact element, then the cable's insulating element abuts against the outer conductor contact element of the plug connector after the connection process, and the cable's insulating element is calibrated to the outer conductor contact element of the plug connector. In this context, calibration means that, in the first longitudinal portion, the cross-section of the insulating element, particularly the outer diameter of the insulating element, is adapted to the cross-section of the outer conductor contact element, particularly the inner diameter of the outer conductor contact element. The first longitudinal portion of the insulating element is preferably inserted into the outer conductor contact element of the plug connector without inserting an air layer.

[0038] Conversely, if the outer diameter of the insulating element differs from the inner diameter of the outer conductor contact element, the cross-sectional area of ​​the longitudinal portion of the insulating element exposed from the outer conductor shield, hereinafter referred to as the first longitudinal portion, can be modified according to the invention relative to the cross-sectional area of ​​the longitudinal portion of the insulating element enclosed by the outer conductor shield (hereinafter referred to as the second longitudinal portion). Here, the cross-sectional area of ​​the first longitudinal portion can be modified such that the first longitudinal portion of the insulating element can be inserted into the longitudinal portion of the outer conductor contact element, and the insulating element is marked to the outer conductor contact element in the first longitudinal portion. A commonly used longitudinal portion of the outer conductor contact element, hereinafter referred to as the first plug connector portion, in which the first longitudinal portion of the insulating element is inserted, and wherein the first longitudinal portion is marked to the outer conductor contact element.

[0039] In an additional manufacturing step prior to the process of connecting the cable to the plug connector, it is preferably performed to modify the cross-sectional area of ​​the first longitudinal portion to correspond to the cross-sectional area of ​​the second longitudinal portion of the insulating element. Alternatively, this additional manufacturing step can also be performed when pressing the support sleeve onto the outer conductor shield.

[0040] The prefabricated cable according to the invention is configured such that the cross-sectional area of ​​the insulating element in the first longitudinal portion is exposed from the outer conductor shield, and the cross-sectional area of ​​the insulating element relative to the second longitudinal portion enclosed by the outer conductor shield can be modified such that the first longitudinal portion of the insulating element can be inserted into the first plug connector portion of the outer conductor contact element, and the first longitudinal portion of the insulating element is marked to the outer conductor contact element.

[0041] The cross-sectional areas of the insulating element in the first and second longitudinal sections are respectively the cross-sectional areas whose surface normal vectors are oriented parallel to the longitudinal axis of the cable. Here and below, the surface normal vector is understood to be a vector oriented perpendicular to the cross-sectional area.

[0042] By using the universally applicable outer conductor contact element, manufacturing and storage costs can be significantly reduced when manufacturing cables with plug connectors, although additional manufacturing steps are required.

[0043] The cable is preferably a high-frequency cable, i.e., a cable used for transmitting high-frequency signals. Here, high-frequency signals are understood to be electrical signals in the frequency range of 5MHz-5THz, which is essentially within the frequency range of electromagnetic waves. This frequency range is suitable for transmission at data transmission rates of preferably at least 50Gbit / s, particularly preferably at least 100Gbit / s, most particularly preferably at least 200Gbit / s, further preferably at least 500Gbit / s, and even more preferably at least 1000Gbit / s.

[0044] This type of high-frequency cable preferably has an inner conductor, an insulating element enclosing the inner conductor, an outer conductor shield enclosing the insulating element, and a cable sheath enclosing the outer conductor shield. High-frequency cables configured in this way and having only a single inner conductor are also called coaxial cables. Furthermore, high-frequency cables can also have multiple inner conductors or cable cores, such as two, three, four, or even more inner conductors. These inner conductors are electrically and mechanically isolated from each other and from the outer conductor shield by a common insulating element.

[0045] In the case of multiple inner conductors, these inner conductors can be twisted together in the cable as “twisted pair” cables, or laid in parallel as “parallel strand” cables, for example.

[0046] The outer conductor shield can specifically be a braided outer conductor shield consisting of individual interlaced wires.

[0047] It should be understood that the features mentioned above and still described below can be used not only in the corresponding combinations stated, but also in other combinations or individually, without departing from the scope of the invention.

[0048] The second longitudinal portion of the insulating element preferably remains in its original state in terms of its cross-sectional area and is therefore not modified. In this way, the prefabricated cable according to the invention is preferably configured such that the outer diameter of the second longitudinal portion in the insulating element is different from the inner diameter of the first plug connector portion in the outer conductor contact element. Therefore, inserting the insulating element of the prefabricated cable into the outer conductor contact element of the plug connector can be limited to the first longitudinal portion of the insulating element, the outer diameter of which is adapted to the inner diameter of the outer conductor contact element.

[0049] In a first preferred improvement of the invention, the cross-sectional area of ​​the first longitudinal portion of the insulating element relative to the second longitudinal portion is modified such that the insulating element in the first longitudinal portion and the second longitudinal portion have different outer diameters. The outer diameter in the first longitudinal portion of the insulating element here corresponds to the preferably constant inner diameter in the first plug connector portion of the outer conductor contact element.

[0050] The insulating elements along the entire first longitudinal portion and the entire second longitudinal portion preferably have a constant outer diameter in various cases, and these outer diameters differ from each other. In this way, the prefabricated cable can be inserted into the first plug connector portion of the outer conductor contact element in a relatively simple and simultaneously calibrated manner through the first longitudinal portion of its insulating element, which also preferably has a constant inner diameter. In this way, the outer wall of the first longitudinal portion of the insulating element is supported circumferentially on the inner wall of the first plug connector portion of the outer conductor contact element.

[0051] This modification of the cross-sectional area in the first longitudinal portion of the insulating element advantageously represents the simplest form of the insulating element in terms of manufacture within the context of the present invention.

[0052] In a first embodiment of the prefabricated cable according to the invention, the outer diameter of the insulating element is configured to be larger than the inner diameter of the first plug connector portion of the outer conductor contact element. The outer diameter of the insulating element in the entire first longitudinal portion is reduced relative to the outer diameter in the second longitudinal portion by a forging or cutting process, so that the outer diameter of the insulating element in the first longitudinal portion can be adapted to the inner diameter of the first plug connector portion of the outer conductor contact element.

[0053] Therefore, the outer diameter of the insulating element in the first longitudinal portion is preferably reduced by a forming process, i.e., by radial stamping using a stamping device. The stamping device includes a stamping punch and a stamping die, both having semi-cylindrical recesses, which are in various cases positioned opposite each other. The stamping punch typically moves along the direction of the fixed stamping die until the two semi-cylindrical recesses form a common full-cylindrical recess. The diameter of the first longitudinal portion of the insulating element, which is radially inserted into the recesses of the stamping punch and the stamping die, is forged to the diameter of the closed full-cylindrical recess of the stamping punch and the stamping die.

[0054] Alternatively, the forming process can be carried out by hot stamping, using temperature-controlled semi-cylindrical stamping punches and temperature-controlled semi-cylindrical stamping dies.

[0055] It is also possible to modify the cross-sectional area using separation tools, particularly those described in more detail below.

[0056] On the one hand, the insulating element can be made of a porous dielectric insulating material. The porosity of this type of dielectric insulating material is preferably between 20% and 75% by volume, and particularly preferably between 50% and 75% by volume. For example, foamed polyethylene or foamed polypropylene are porous dielectric insulating materials. In the case of porous dielectric insulating materials, radial compression of the insulating element in the first longitudinal section by stamping or hot stamping does not cause any significant displacement of the insulating material in the axial direction from the first longitudinal section.

[0057] However, if the insulating material is non-porous or only microporous, the porosity is therefore less than 20% by volume, or significantly less than 20% by volume, respectively. For example, non-foamed polytetrafluoroethylene or non-foamed polypropylene are non-porous or only microporous insulating materials. In the case of non-porous or only microporous insulating materials, in both molding processes, the insulating material is displaced axially from the first longitudinal portion due to the radial compression of the insulating element.

[0058] To prevent any undesirable displacement of the insulating material in the direction of the second longitudinal portion of the insulating element, while the insulating element is radially stamped in the transition region between the first and second longitudinal portions, a web with sharp edges (which in various cases is preferably arranged in a full circumferential manner on the stamping punch and the stamping die) is cut into the insulating element. The groove thus arranged in the insulating element in a preferably full circumferential manner, and which holds the web with sharp edges within it during the stamping process, has a depth of appropriate dimensions. The groove depth is set as a function of the diameter variation in the first longitudinal portion.

[0059] As a result of the radial stamping process, the insulating material or insulating layer is axially displaced in the direction near the cable end, and if necessary, the insulating material or insulating layer can be separated from the first longitudinal portion of the insulating element in a further manufacturing step using a separation tool via a cutting process described below. Conventional cutting equipment can be used for the cutting process.

[0060] Besides reducing the outer diameter of the first longitudinal portion of the insulating element by stamping or hot stamping, the outer diameter of the first longitudinal portion can also be reduced by a separation process. The separation process preferably occurs via a precisely positioned laser beam, photon beam, electron beam, ion beam, or water jet, utilizing the filamentation work involved in machining the outer diameter of the insulating element. In this process, the prefabricated cable moves relative to the radiation source through its insulating element, or the radiation source moves relative to the insulating element of the prefabricated cable.

[0061] However, alternatively, a subtractive machining method having subtractive machining tools configured to produce filaments accordingly is also conceivable.

[0062] However, besides reducing the outer diameter along the first longitudinal portion of the insulating element, other modifications to the cross-sectional area in the first longitudinal portion relative to the cross-sectional area in the second longitudinal portion are also possible in the second embodiment of the cable according to the invention, without any modification to the outer diameter. Here, the cross-sectional area in the first longitudinal portion of the insulating element is configured such that the insulating material of the insulating element in the first longitudinal portion completely fills the intermediate region between the prefabricated cable inner conductor and the outer conductor contact element in its first plug connector portion. The outer wall of the first longitudinal portion of the insulating element is thus supported circumferentially on the inner wall of the first plug connector portion of the outer conductor contact element. Furthermore, in the first longitudinal portion of the insulating element, there is preferably no cavitation in the intermediate region between the prefabricated cable inner conductor and the outer conductor contact element of the plug connector.

[0063] For this purpose, at least one recess, preferably extending in the shape of a groove or slot along the entire first longitudinal portion, is preferably molded onto the surface of the insulating element by a suitably configured stamping device. To achieve a suitable coaxial arrangement between the inner and outer conductor contact elements of the cable, a plurality of recesses are provided, preferably configured as grooves or slots, and these recesses are evenly distributed along the perimeter of the first longitudinal portion. These groove- or slot-shaped recesses in the first longitudinal portion are preferably closed upon insertion into the outer conductor contact element.

[0064] Alternatively, these recesses, which preferably extend in the shape of grooves or slots on the surface of the first longitudinal portion, can also be produced by a suitable separation method.

[0065] These individual recesses, in the shape of grooves or slots, preferably extend in a straight and parallel manner on the surface of the first longitudinal portion of the insulating element. However, other suitable profiles for these individual recesses in the shape of grooves or slots, such as serrated profiles, are also conceivable. Finally, individual recessed portions offset from each other, such as individual (slot-shaped) holes along the first longitudinal portion of the insulating element, are also conceivable.

[0066] Finally, it is conceivable that multiple holes are evenly distributed across the cross-sectional area of ​​the insulating element and, in various cases, extend along the entire first longitudinal portion. For example, these holes can be produced, in various cases, by drilling or stamping devices introduced axially into the insulating element. To achieve a single displacement of the insulating material guided towards the proximal plug end of the power cable, the first longitudinal portion of the insulating element can be enclosed by a suitably sized punch and associated stamping die. Furthermore, in the transition between the first and second longitudinal portions, a web with sharp edges (which, in various cases, is disposed on the punch and the stamping die) can be cut into a groove, preferably a full circumference, within the insulating element.

[0067] However, the outer diameter of the insulating element can also be configured to be smaller than the inner diameter in the first plug connector portion of the outer conductor contact element.

[0068] In a third embodiment of the prefabricated cable according to the invention, the outer diameter of the first longitudinal portion of the insulating element is increased relative to the outer diameter of the second longitudinal portion of the insulating element by a compression process, such that the first longitudinal portion of the insulating element can be inserted and positioned in a calibrated manner into the first plug connector portion of the outer conductor contact element.

[0069] For this purpose, the first longitudinal portion of the insulating element is compressed in the axial direction by a suitably configured stamping punch, which moves axially along the direction of the second longitudinal portion on the end side of the first longitudinal portion. In addition to the axially movable stamping punch, the stamping device has another stamping punch that is radially movable relative to a typically stationary stamping die.

[0070] The movement of the axially movable stamping punch occurs only when the radially movable stamping punch and the stamping die combine to form a common enclosed, fully cylindrical recess, in which the first longitudinal portion of the insulating element is concentrically positioned. The diameter of the common enclosed, fully cylindrical recess of the radially movable stamping punch and the stamping die is determined such that the first longitudinal portion of the insulating element abuts the inner wall of the closed recess after the compression process and is thus given an increased outer diameter.

[0071] In order to limit the compression process to the first longitudinal portion of the insulating element, the web with sharp edges can be cut into a groove that is preferably full-circumference in the transition between the first and second longitudinal portions. The web with sharp edges is configured on a radially movable punch and a punch die in various cases.

[0072] The length of the first longitudinal portion of the insulating element (whose cross-sectional area is modified relative to the cross-sectional area of ​​the second longitudinal portion of the insulating element) preferably corresponds to at least the length of the first plug connector portion of the outer conductor contact element, or preferably corresponds to the length of the first plug connector portion of the outer conductor contact element.

[0073] The length of the first longitudinal portion in this type of insulating element is achieved by the appropriate size of the deformation tool (e.g., a stamping punch and a stamping die), by a precisely executed deformation process, and optionally by an additional cutting process that has the effect of precisely lengthening the first longitudinal portion.

[0074] To simplify the insertion of the first longitudinal portion of the insulating element into the first plug connector portion of the outer conductor contact element, in a preferred improvement of the prefabricated cable according to the invention, a chamfer is provided at one end of the first longitudinal portion in the direction near the plug end of the cable. This is particularly advantageous in the case of the first longitudinal portion of the insulating element, wherein the reduction in the cross-sectional area of ​​the prefabricated cable according to the invention, according to the second embodiment, is not achieved by a reduction in the outer diameter, and the outer diameter of the first longitudinal portion is therefore increased relative to the inner diameter of the first plug connector portion of the outer conductor contact element.

[0075] The cross-sectional area of ​​the first longitudinal portion of the insulating element is reduced by more than 0.5 times, particularly preferably by more than 0.7 times, and most particularly preferably by more than 0.8 times, relative to the cross-sectional area of ​​the second longitudinal portion of the insulating element. Similarly, the cross-sectional area of ​​the first longitudinal portion of the insulating element is preferably increased by less than 2 times, particularly preferably by less than 1.5 times, and most particularly preferably by less than 1.2 times, relative to the cross-sectional area of ​​the second longitudinal portion of the insulating element.

[0076] The present invention also relates to a plug connector assembly having a cable and a plug connector connected to at least one end of the cable.

[0077] The cable has an outer conductor shield and an insulating element. The insulating element has a first longitudinal portion and a second longitudinal portion. The insulating element is exposed from the outer conductor shield in the first longitudinal portion, and the second longitudinal portion is adjacent to the first longitudinal portion. The insulating element is enclosed by the outer conductor shield in the second longitudinal portion.

[0078] According to the invention, the cross-sectional area of ​​the insulating element in the first longitudinal portion is modified relative to the cross-sectional area of ​​the insulating element in the second longitudinal portion, such that the first longitudinal portion of the insulating element is inserted into the first plug connector portion of the outer conductor contact element of the plug connector in a calibrated manner, and the insulating element is calibrated to the outer conductor contact element in the first longitudinal portion. The cross-sectional areas of the first and second longitudinal portions of the insulating element are here oriented such that the associated surface normal vector extends parallel to the longitudinal axis of the plug connector assembly.

[0079] The plug connector is not limited to a specific type of plug connector, but the present invention is particularly suitable for plug connectors and plug connections in the high-frequency field. Specifically, these can be plug connectors or plug connections of the PL, BNC, TNC, SMBA (FAKRA), SMA, SMB, SMS, SMC, SMP, BMS, HFM (FAKRA-Mini), H-MTD, BMK, Mini-Coax, or Makax types. The plug connector is particularly preferably configured as an H-MTD plug connector.

[0080] The plug connector according to the invention can be used particularly advantageously in vehicles, especially motor vehicles. Potential applications include autonomous driving, driver assistance systems, navigation systems, infotainment systems, rear-view entertainment systems, internet connectivity, and gigabit wireless (IEEE 802.11ad standard). Potential applications also involve high-resolution cameras, such as 4K and 8K cameras, sensors, in-vehicle computers, high-resolution displays, high-resolution dashboards, 3D navigation devices, and mobile transceivers.

[0081] The term “vehicle” here describes any means of transport, particularly land vehicles, sea vehicles, or aircraft, including spacecraft.

[0082] In a preferred embodiment, the plug connector according to the invention has a second plug connector portion adjacent to the first plug connector portion. The second plug connector portion, located within the outer conductor contact element, contains at least one dielectric material. On one hand, electrical isolation between the outer conductor contact element and the inner conductor contact element is achieved through at least one dielectric material. On the other hand, a signaling portion exhibiting capacitive or inductive transmission behavior can be achieved by appropriately selecting a material and by appropriately shaping at least one dielectric material. This signaling portion compensates for discontinuities in inductance or capacitance caused by the abrupt change in cross-sectional area in the transition between the first and second longitudinal portions of the insulating element contained in the cable.

[0083] When the cross-sectional area in the transition from the second longitudinal portion to the first longitudinal portion of the insulating element contained in the cable is reduced, i.e. in the case of capacitive discontinuity, a signaling portion having higher inductive transmission behavior than in the case of no capacitive discontinuity can be implemented for compensation.

[0084] Therefore, an insulating element is preferably used in the second plug connector portion within the outer conductor contact element of the plug connector. This insulating element has at least one recess extending into the second plug connector portion. The at least one air-filled recess gives the signaling portion an effective dielectric constant that is lower than the effective dielectric constant of the dielectric material of the insulating element in the second plug connector portion without the recess. In this way, a signaling portion with higher inductive transmission characteristics than the signaling portion without the recess is achieved.

[0085] When the cross-sectional area in the transition from the second longitudinal portion to the first longitudinal portion of the insulating element contained in the cable is increased, i.e. in the case of inductive discontinuity, a signaling portion having higher capacitance transmission behavior than in the case where there is no capacitance discontinuity can be implemented for compensation.

[0086] Therefore, an insulating element is used in the second plug connector portion within the outer conductor contact element of the plug connector. The insulating element is made of a dielectric material with a higher dielectric constant than in the case where there is no compensation for inductive discontinuity.

[0087] Finally, the present invention also relates to a method for manufacturing cables.

[0088] In the method for manufacturing a cable according to the invention, the insulation element of the cable is exposed from the outer conductor shield of the cable in a first longitudinal portion, unless the insulation element has been exposed in any other way prior to it. Subsequently, the cross-sectional area of ​​the insulation element in the first longitudinal portion is modified relative to the cross-sectional area of ​​the insulation element in a second longitudinal portion adjacent to the first longitudinal portion. Finally, the cable can be inserted into and connected (preferably crimped) to the outer conductor contact element of the plug connector (this can occur within the context of the method according to the invention, or independently of the method according to the invention). According to the invention, the cross-sectional area of ​​the first longitudinal portion is modified relative to the cross-sectional area of ​​the second longitudinal portion such that the first longitudinal portion of the insulation element can be inserted into the first plug connector portion of the outer conductor contact element of the plug connector in a calibrated manner, and the insulation element is calibrated to the outer conductor contact element in the first longitudinal portion.

[0089] The configuration of cross-sectional area modification and the associated processing procedures discussed above in the context of the prefabricated cable according to the present invention can be applied in a similar manner to the deformation of the cross-sectional area of ​​the first longitudinal portion of the insulating element relative to the cross-sectional area of ​​the second longitudinal portion.

[0090] It should be noted that the prefabricated cable is inserted into and positioned within the outer conductor contact element of the plug connector, such that the first longitudinal portion of the insulating element preferably extends within the first plug connector portion of the outer conductor contact element without any axial offset.

[0091] The positioning of the prefabricated cable within the outer conductor contact element of the plug connector can be determined by a sensor device, preferably a measuring probe. The measuring probe contacts the end of the inner conductor contact element, which is pressed against the inner conductor of the cable.

[0092] In addition to the method steps mentioned, the method for manufacturing a cable according to the present invention may also include additional method steps performed before or after the mentioned method steps. For example, the manufacturing process typically includes exposing an outer conductor shield from the cable sheath, or exposing an inner conductor from the insulation element, and subsequently crimping an inner conductor contact element onto the exposed inner conductor.

[0093] According to a particularly preferred improvement, the cross-sectional area in the first longitudinal portion is modified such that the insulating element is scribing in the radial direction by a separating tool, whereby the separating tool is subsequently moved axially relative to the insulating element in its radial cut position in the insulating element toward the cable end (also referred to above as the "front cable end") in order to peel off the insulating layer to be removed from the insulating element.

[0094] As a result of the processing procedure using the aforementioned separation tools, the cross-sectional area can be removed using technically simple equipment, while still ensuring a high level of process reliability and precision. The insulating layer typically has a hollow cylindrical design, and can be scraped and / or torn off, either from the remaining insulating element or from the insulating layer held on the inner conductor.

[0095] The relative axial movement of the separation tool can be caused by the movement of the separation tool itself and / or by the movement of the cable.

[0096] What can be provided is that the cable and / or separating tool rotates during the scribing process and / or rotates once scribing is complete (e.g., during axial movement of the separating tool and the insulating element). As a result, the cutting procedure can be further improved.

[0097] What can be provided is a zero cut in the area at or exactly at the end of the cable to cut the insulation layer to be cut through a straight cut edge.

[0098] The insulating element is preferably scribbled in a partially circumferential manner using a separation tool, but more preferably in a completely circumferential manner, wherein, optionally, one or more webs may be maintained between different partially circumferential scratches.

[0099] Preferably, two separation tools are provided, particularly two separation tools that can be actuated toward each other and are preferably arranged exactly opposite each other. However, alternatively, more than two separation tools may also be provided. In principle, a single separation tool may also be provided, particularly when the separation tool and / or the cable rotate during scribing, and / or when the separation tool is configured as a forming cutter having a shape that at least partially adapts to the contour of the insulating element.

[0100] According to one improvement, the separating tool may have exactly one forming tool adapted to the provided cross-sectional area of ​​the first longitudinal portion. However, preferably, exactly two or more forming tools adapted to the provided cross-sectional area of ​​the first longitudinal portion and used for combining radial scratches are provided, and these forming tools are actuated toward each other. The use of precisely arranged forming tools opposite to each other has proven particularly suitable.

[0101] According to one improvement, it may be advantageous to heat the insulating element at least in the first longitudinal portion before and / or during the modification of its cross-sectional area. In this way, the insulating element can become softer, which facilitates its machinability, particularly by means of the aforementioned separating tool. For example, it can be provided that the tool (e.g., a stamping device, a part of the stamping device, a separating tool, or a cutting device) is heated accordingly to induce a corresponding heat input into the insulating element. However, heat can also be supplied in another manner, such as by a hot gas flow.

[0102] The insulating element is preferably heated only to below its melting temperature so as to soften it rather than melt it. In particular, it can be heated to just below its melting temperature.

[0103] However, in principle, it is also possible to heat the insulating element to or above its melting temperature (e.g., to just above the melting temperature or optionally significantly above the melting temperature).

[0104] One improvement that can be specifically provided is that the separation tool is heated, preferably to an operating temperature between 50°C and 250°C, particularly preferably to an operating temperature between 170°C and 200°C.

[0105] It has been shown that heated separating tools with two forming cutters are particularly suitable for peeling the insulation layer in the first longitudinal portion as the separating tool moves axially relative to the insulating element. In this case, the separating tool or the forming cutter can be pushed along the excess material or insulation layer to be removed, respectively.

[0106] The invention also includes an apparatus for manufacturing cables. The apparatus for manufacturing cables according to the invention comprises a processing device and a connecting device. The processing device is used to modify the cross-sectional area of ​​a first longitudinal portion of the cable's insulation element exposed from the outer conductor shield, and the connecting device is used to insert the cable into the outer conductor contact element of a plug connector. The processing device according to the invention is configured such that it modifies the cross-sectional area of ​​the first longitudinal portion of the insulation element so that the first longitudinal portion can be inserted into the first plug connector portion of the outer conductor contact element in a form-fit and calibrated manner.

[0107] This processing apparatus is typically an actuating tool that enables a predefined and adjustable modification of the cross-sectional area in the first longitudinal portion of an insulating element. In the case of stamping or hot stamping, the actuating tool is a stamping device. The stamping device has a positionable stamping punch and an associated stationary stamping die. After setting a predetermined position target value, the positionable stamping punch can be actuated according to conventional physical active principles, i.e., electrical, hydraulic, pneumatic, etc.

[0108] In the case of a separation method, the processing apparatus or actuating tool can alternatively be a laser, photon, electron, ion, or water source, configured to measure the intensity of the corresponding beam / jet and to position the beam / jet within the first longitudinal portion of the insulating element. Finally, a subtractive machining apparatus with subtractive machining tools can also be used in a separation method.

[0109] According to a particularly preferred design embodiment, the processing device can also be a separating tool for radially scribing the insulating element. The separating tool and / or cable transport device can be configured to axially move the separating tool in the direction toward the cable end while it is scribing the insulating element. In this way, any excess insulation layer can be peeled (particularly scraped off) from the cable. The separating tool preferably has two forming cutters that can actuate toward each other, as described above. The separating tool can be heated.

[0110] The coupling device is preferably a positionable clamping arm that properly clamps the cable and inserts it into the outer conductor contact element of the plug connector, positioning the cable within that element. The coupling device here will preferably use sensor information from the aforementioned sensor device to identify the current position of the cable during the coupling process.

[0111] The present invention also relates to a computer program product having a program code device that, when the program is executed on a control device for an apparatus for manufacturing cables (specifically according to the above and below embodiments), executes a method for manufacturing cables (specifically according to the above and below embodiments).

[0112] The present invention also relates to a separate method for manufacturing cables, wherein an outer insulation layer is peeled from the electrical insulator of the cable, wherein the insulating element is radially etched downward to a defined depth using a separating tool, wherein the radial cutting position of the separating tool in the insulating element is then axially moved relative to the insulating element in a direction toward the cable end, so as to peel the insulation layer from the insulating element. The embodiments described above and below may represent alternative modifications to the method.

[0113] Where convenient, the above design embodiments and modifications can be combined with each other in any arbitrary manner. Further possible design embodiments, modifications, and implementations of the invention also include combinations of features of the invention described above or below with respect to exemplary embodiments that are not expressly mentioned. Specifically, those skilled in the art will also add several individual aspects as improvements or additions to the corresponding basic form of the invention. Attached Figure Description

[0114] The invention will now be described in more detail by way of exemplary embodiments illustrated in the accompanying drawings, in which:

[0115] Figures 1A-1G An isometric view of a first embodiment of a cable to be manufactured in each manufacturing step is shown;

[0116] Figures 2A-2E A cross-sectional view of a first embodiment of a cable to be manufactured according to the various manufacturing steps is shown;

[0117] Figure 3A , Figure 3B An isometric view of a second embodiment of a cable to be manufactured in each manufacturing step is shown;

[0118] Figure 4A , Figure 4B A cross-sectional view of a second embodiment of a cable to be manufactured according to the various manufacturing steps is shown;

[0119] Figures 5A-5E An isometric view of a third embodiment of a cable to be manufactured in each manufacturing step is shown;

[0120] Figure 6A , Figure 6B A cross-sectional view of a third embodiment of a cable to be manufactured according to the various manufacturing steps is shown;

[0121] Figure 7A A side view of the plug connector assembly is shown;

[0122] Figure 7B A cross-sectional view of the plug connector assembly is shown; and

[0123] Figures 8A-8C An isometric view of a fourth embodiment of a cable to be manufactured according to the various manufacturing steps is shown.

[0124] The accompanying drawings are intended to provide a deeper understanding of embodiments of the invention. The drawings visualize the embodiments and, in conjunction with the description, illustrate the basic principles and concepts of the invention. Other embodiments and numerous advantages mentioned become apparent from the drawings. Elements in the drawings are not necessarily shown to scale.

[0125] Unless otherwise stated, the same functionally equivalent elements, features and parts having the same action in the accompanying drawings are provided with the same reference numerals in various cases.

[0126] The accompanying figures are described below in a way that is interconnected and generalized. Detailed Implementation

[0127] It is possible Figure 1AThe cable 1 (especially the high-frequency cable) has undergone several manufacturing steps near the plug end 2 of the cable 1.

[0128] Cable 1 (representing a high-frequency cable) preferably includes an inner conductor 3 enclosed by an insulating element 4. Instead of the inner conductor 3, cable 1 may also have paired inner conductors for transmitting differential signals. Here, the two inner conductors in the pair are spaced apart from each other and electrically isolated from each other by the insulating element 4. Finally, cable 1 may also have multiple pairs of inner conductors, which in various cases are arranged parallel or intersecting each other, spaced apart from each other, and electrically isolated from each other by the insulating element 4.

[0129] The insulating element 4 may optionally be encapsulated by an electrically insulating cable membrane (not shown). Either the insulating element 4 or the cable membrane is ultimately encapsulated by an outer conductor shield 5, which is typically composed of braided individual conductive wires. Finally, the outer conductor shield 5 is encapsulated by an electrically insulating cable sheath 6.

[0130] As from Figure 1A Therefore, preferably in the first manufacturing step, the outer conductor shield 5 is exposed from the cable sheath 6 in the near plug region 2 of the cable 1.

[0131] like Figure 1A The isometric diagram in the figure indicates and in Figure 2A As can be seen more clearly in the cross-sectional view, in another manufacturing step, a support sleeve 7 is applied to the near-plug end of the high-frequency cable 1 on the outer conductor shield 5 exposed from the cable sheath 6. The support sleeve 7 is preferably crimped to the outer conductor shield 5. The outer conductor shield 5 is folded back near the support sleeve 7.

[0132] Because the outer conductor shield 5 is folded back near the support sleeve 7, there is an area on the near plug end 2 of the high-frequency cable 1 where the insulating element 4 is exposed from the outer conductor shield 5.

[0133] Up to this point, in this method, the cable manufacturing of cable 1 is known according to the prior art.

[0134] In accordance with the present invention and according to Figure 1B In another method step of cable manufacturing, relative to the second longitudinal portion L2 (refer to...) Figure 2A The cross-sectional area of ​​the insulating element 4 in the first longitudinal section L1 (refer to) is reduced by using a suitable stamping device 8. Figure 2A The cross-sectional area is defined as the cross-sectional area of ​​the insulating element 4, whose surface normal vector is oriented parallel to the longitudinal axis 9 of the cable 1. Therefore, the cross-sectional area represents the cross-sectional area of ​​the insulating element 4, which is oriented transversely to the longitudinal axis 9 of the high-frequency cable 1.

[0135] The first longitudinal portion L1 preferably extends across the entire longitudinal range of the cable 1, wherein the insulating element 4 is exposed from the outer conductor shield 5. Therefore, the second longitudinal portion L2 of the insulating element 4 extends across the entire longitudinal range of the cable 1, wherein the insulating element 4 is enclosed by the outer conductor shield 5. This constitutes the remaining longitudinal range of the cable 1.

[0136] Alternatively, the first longitudinal portion L1 having a reduced cross-sectional area of ​​the insulating element 4 may extend only within a sub-region of the longitudinal range of the insulating element 4 where it is exposed from the outer conductor shield 5.

[0137] The reduction in cross-sectional area in the first longitudinal portion L1 of the insulating element 4 is preferably configured to be constant along the entire first longitudinal portion L1.

[0138] In a first embodiment of the prefabricated cable 1 according to the present invention, the reduction of the cross-sectional area in the first longitudinal portion L1 of the insulating element 4 is achieved by forging the outer diameter of the insulating element 4.

[0139] The processing device 21 that performs the forging of the outer diameter in the first longitudinal portion L1 of the insulating element 4 is preferably a stamping device 8.

[0140] The stamping device 8 typically includes a stamping punch 81 and a stamping die 82, the stamping punch being radially movable relative to the insulating element 4, and the stamping die being radially positioned relative to the insulating element 4. The stamping punch 81 and the stamping die 82 each have a cross-sectional profile with a semi-cylindrical recess. The diameter of the semi-cylindrical recess of the stamping punch 81 and the stamping die 82 corresponds to the reduced outer diameter in the first longitudinal portion L1 of the insulating element 4 to be achieved by the stamping process. When the stamping punch 81 and the stamping die 82 are in operation according to… Figure 1C When the two parts converge during the stamping process, their semi-cylindrical recesses form a common fully cylindrical recess, and the first longitudinal portion L1 of the insulating element 4 is axially mounted in the fully cylindrical recess. Therefore, the outer diameter of the first longitudinal portion L1 of the insulating element 4 corresponds to the reduced inner diameter of the common fully cylindrical recess of the stamping punch 81 and the stamping die 82.

[0141] Web plate 10 with sharp edges (see details) Figure 2A In various cases, the web 10 is positioned near the cable end of the semi-cylindrical recess in the stamping punch 81 and stamping die 82. The web acts like a knife and scribes a preferably full-circumference groove 11 in the transition between the first longitudinal portion L1 and the second longitudinal portion L2 within the insulating element 4. This preferably full-circumference groove 11 prevents undesirable displacement of the insulating material from the first longitudinal portion L1 into the second longitudinal portion L2 during the stamping process.

[0142] When according to Figure 1D When the stamping punch 81 and stamping die 82 are forked, a cable 1 with an insulating element 4 is produced. The insulating element 4 has an outer diameter that is reduced relative to its outer diameter in the second longitudinal portion L2 in its first longitudinal portion L1 and near the plug end 2. The insulating material that is displaced from the first longitudinal portion L1 due to the reduced outer diameter moves axially in the direction near the plug end 2 of the cable 1.

[0143] In accordance with Figure 1E In another manufacturing step, the near-plug end region 12 of the insulating element 4 is removed using cutting equipment 13. (As from...) Figure 1F As a result, the inner conductor 3 is exposed from the insulating element 4 near the plug end of the high-frequency cable 1. Here, the inner conductor 3 is also exposed from the insulating material that has been axially displaced from the first longitudinal portion L1 by a stamping process.

[0144] As an alternative to mechanical stamping, hot stamping can also be used. In the latter, the stamping punch 81 and stamping die 82 are heated to a suitable temperature. The increased temperature of the stamping punch 81 and stamping die 82 during the stamping process causes the insulating material to melt in adjacent (preferably sleeve-shaped) regions within the first longitudinal portion L1 of the insulating element 4. The molten solar material is then axially or radially drawn away from the first longitudinal portion L1 by a suitably configured suction device.

[0145] In the next manufacturing step, based on... Figure 2B In the connection process of the connection device 20, a cable is prefabricated in this manner and inserted into the outer conductor contact element 14 of the plug connector 15.

[0146] The assembly consisting of cable 1 and plug connector 15 is currently referred to as plug connector assembly 100.

[0147] The connecting device 20 is typically an axially positionable clamping arm that clamps the cable 1 in the second longitudinal portion L1 of the insulating element 4, on the cable sheath 6, and positions the cable 1 axially. Specifically, the first longitudinal portion L1 of the insulating element 4 is positioned in the first plug connector portion S1 of the outer conductor contact element 14 of the plug connector 15, such that the first longitudinal portion L1 preferably lies exactly within the first plug connector portion S1 in the axial direction. Therefore, the longitudinal range of the first longitudinal portion L1 preferably corresponds to the longitudinal range of the first plug connector portion S1.

[0148] According to the present invention, the first longitudinal portion L1 of the insulating element 4 is inserted into the first plug connector portion S1 of the outer conductor contact element 14 and is calibrated to the outer conductor contact element 14. In this manner, the outer diameter of the insulating element 4 in the first longitudinal portion L1 preferably corresponds to the inner diameter of the first plug connector portion S1 of the outer conductor contact element 14. Therefore, in the manufacturing method according to the present invention, the original outer diameter of the insulating element 4, which remains in the first longitudinal portion L1 in the second longitudinal portion L2 of the insulating element 4, is adapted to the inner diameter S1 of the first plug connector portion of the outer conductor contact element 14.

[0149] This adaptation of the outer diameter of the insulating element 4 to the inner diameter of the outer conductor contact element 14 is also called calibration. In this case, the outer diameter profile of the insulating element 4 associated with the cable 1 is adapted to the inner diameter profile of the outer conductor contact element 14 in the plug connector 15.

[0150] For the sake of completeness, Figure 2B The diagram shows the inner conductor contact element 16 of the plug connector 15, which is preferably connected to the inner conductor 3 of the high-frequency cable by crimping. An appropriately configured insulating element 17 for electrical isolation and spacing is inserted within the plug connector 15 between the inner conductor contact element 16 and the outer conductor contact element 14.

[0151] exist Figure 2C , Figure 2D and Figure 2E In each manufacturing step, the cross-sectional outlines of the main components of the first embodiment of the prefabricated cable 1 according to the invention are shown schematically (i.e., not to scale) in various cases.

[0152] Before modifying the cross-sectional area in the first longitudinal portion L1 of the insulating element 4 according to the invention, the cross-sectional profile of the main components of the cable 1 is from... Figure 2C The insulating element 4, spanning the entire longitudinal range of cable 1, has a substantially constant outer diameter D1. (As from...) Figure 2E As a result, the outer diameter D1 of the insulating element 4 is increased relative to the inner diameter D2 in the first plug connector portion S1 of the outer conductor contact element 14. Therefore, according to Figure 2C The prefabricated cable 1 cannot be inserted into the outer conductor contact element 14 of the plug connector 15.

[0153] In accordance with Figure 2D When the outer diameter of the first longitudinal portion L1 of the insulating element 4 is reduced from the larger outer diameter D1 to the smaller outer diameter D2, the cross-sectional area of ​​the first longitudinal portion L1 of the insulating element 4 is reduced, so that it can be adjusted according to... Figure 2E The first longitudinal portion L1 of the insulating element 4 is inserted into the first plug connector portion S1 of the outer conductor contact element 14 in a calibrated manner.

[0154] In a second embodiment of the prefabricated cable 1 according to the invention, the original outer diameter of the insulating element 4 is also increased relative to the inner diameter of the outer connector contact element 14. Similarly, in this case, it is impossible to insert the prefabricated cable 1, particularly the first longitudinal portion L1 of the insulating element 4, into the first plug connector portion S1 of the outer conductor contact element 14. According to the invention, the cross-sectional area of ​​the insulating element 4 within the first longitudinal portion L1 is also reduced relative to the cross-sectional area within the second longitudinal portion L2.

[0155] Therefore, according to Figure 3A and Figure 3B In the stamping process, a plurality of recesses 18 are formed in the first longitudinal portion L1 of the insulating element 4. These recesses are distributed on the periphery of the first longitudinal portion L1 and extend in the longitudinal direction. These recesses 18 are preferably configured as slots in various cases, particularly according to… Figure 4A The V-shaped notch 18 can also be used. Alternatively, a U-shaped notch or a notch with a different cross-sectional profile can be used. The stamping punch 81 and the stamping die 82 each have a semi-cylindrical recess, the diameter of which corresponds to the original outer diameter in the first longitudinal portion L1 of the insulating element 4. To accommodate the notch-shaped recess 18, webs 19 extending longitudinally are disposed on the inner perimeter of the semi-cylindrical recesses of the stamping punch 81 and the stamping die 82. These webs 19 each have a cross-sectional profile corresponding to the cross-sectional profile of the notch-shaped recess 18.

[0156] The web 10 with sharp edges is also configured in various cases near the cable end of the semi-cylindrical recess of the stamping punch 81 and the stamping die 82. The web 10 is etched with a preferably full-circumference groove 11 in the transition between the first longitudinal portion L1 and the second longitudinal portion L2 during the stamping process. The web 10 with sharp edges prevents undesirable displacement of the insulating material from the slotted recess 18 formed in the first longitudinal portion L1 along the direction of the second longitudinal portion L2 of the insulating element 4 during the stamping process.

[0157] In the stamping process, the insulating material displaced from the slot-shaped recess 18 in the first longitudinal portion L1 of the insulating element 4 is displaced in the actual direction toward the plug end of the prefabricated cable 1. Similar to the first embodiment of the prefabricated cable 1, in the cutting process, by... Figure 1E and 1F The cutting device 13 removes the insulating material that has shifted in the axial direction.

[0158] In another manufacturing step, cable 1 is inserted into plug connector 15. The slot-shaped recess 18 in the first longitudinal portion L1 of insulating element 4 is compressed when inserted into the first plug connector portion S1 of outer conductor contact element 14, such that the original outer diameter of the first longitudinal portion L1 of insulating element 4 in the inserted state is adapted to the smaller inner diameter D2 of outer conductor contact element 14. This reduction in the outer diameter of the first longitudinal portion L1 of insulating element 4 is achieved by closing the slot-shaped recess 18.

[0159] exist Figure 4A and 4B In each manufacturing step, the cross-sectional outlines of the main components of the second embodiment of the prefabricated cable 1 according to the invention are shown schematically (i.e., not to scale) in various cases.

[0160] It is possible Figure 4A The cross-sectional profile of the second embodiment of the prefabricated cable 1 is shown, wherein a plurality of slotted recesses 18 are configured to be distributed on the periphery of the first longitudinal portion after the stamping process. The outer diameter D1 of the insulating element 4 in the first longitudinal portion L1 after the stamping process corresponds to the outer diameter D1 before the stamping process, and is unmodified relative to the outer diameter in the second longitudinal portion L2 of the insulating element 4.

[0161] exist Figure 4B The cross-sectional profile of the cable 1 inserted into the outer conductor contact element 14 can be seen. The outer diameter D1 of the first longitudinal portion L1 of the insulating element 4 corresponds to the reduced inner diameter D1 of the outer conductor contact element 14. Due to the reduction in the outer diameter of the first longitudinal portion L1 of the insulating element 4, each slot-shaped recess 18 is closed. Figure 4B This is schematically shown in the diagram by the dashed lines placed at the corresponding positions of the insulating element 4.

[0162] In a third embodiment of the prefabricated cable 1 according to the invention, the outer diameter of the insulating element 4 is reduced relative to the inner diameter of the outer conductor contact element 14 in the first plug connector portion S1. In this case, it is possible to insert the prefabricated cable 1 into the outer conductor contact element 14 of the plug connector 15. However, an air layer is located between the first longitudinal portion L1 of the insulating element 4 and the first plug connector portion S1 of the outer conductor contact element 14. The radial range of the cable 4 is not respectively adapted to or calibrated to the radial inner range of the plug connector 15.

[0163] For calibration purposes, according to the present invention, the cross-sectional area of ​​the insulating element 4 in the first longitudinal portion L1 is increased relative to the cross-sectional area in the second longitudinal portion L2.

[0164] Therefore, the first longitudinal portion L1 of the insulation element 4 in the prefabricated cable 1 is deformed in terms of its cross-sectional area during the stamping process using the stamping device 8. In this case, according to Figure 5A The stamping device 8 includes a stamping punch 81, a stamping die 82, and a stamping punch 83. The stamping punch 81 and the stamping die 82 are arranged radially or movable relative to the first longitudinal portion L1 of the insulating element 4 in various cases, and the stamping punch 83 is axially movable relative to the first longitudinal portion L1 of the insulating element 4.

[0165] The radially movable stamping punch 81 and stamping die 82 each have a semi-cylindrical recess, which are arranged opposite each other in various cases and according to... Figure 5B During the stamping process, a common cylindrical recess is formed, and the first longitudinal portion L1 of the insulating element 4 is inserted into the cylindrical recess. The inner diameters of the two semi-cylindrical recesses or the common cylindrical recess are larger than the original outer diameter of the first longitudinal portion L1 of the insulating element 4 before the stamping process, such as... Figure 5B As shown. According to Figure 5D and 5E After the stamping process, the inner diameter of the semi-cylindrical recess of the radially movable stamping punch 81 and stamping die 82 corresponds to the outer diameter of the first longitudinal portion L1 of the insulating element 4.

[0166] The web 10 with sharp edges is also configured in various cases near the cable end of the semi-cylindrical recess of the radially movable stamping punch 81 and stamping die 82. During the stamping process, the web 10 is etched with a preferably full-circumference groove 11 in the transition between the first longitudinal portion L1 and the second longitudinal portion L2. The web 10 with sharp edges prevents undesirable displacement of the insulating material from the first longitudinal portion L1 along the direction of the second longitudinal portion L2 of the insulating element 4 during the stamping process.

[0167] In the first step of the stamping process, according to Figure 5B The radially movable stamping punch 81 and stamping die 82 converge and, in various cases, form a common fully cylindrical recess through their two semi-cylindrical recesses. The first longitudinal portion L1 of the insulating element 4 is concentrically inserted and positioned within this fully cylindrical recess of the stamping device 8. The concentric positioning of the first longitudinal portion L1 of the insulating element 4 within the common fully cylindrical recess of the radially movable stamping punch 81 and stamping die 82 is a substantial prerequisite for the concentricity between the inner conductor 3 and the fully stamped first longitudinal portion L1 of the insulating element 4.

[0168] In accordance with Figure 5CIn the second step of the stamping process, the axially movable stamping punch 83 is pressed against the end face of the first longitudinal portion L1 of the insulating element 4. Due to this axial compression of the insulating element 4, the first longitudinal portion L1 of the insulating element 4 is compressed, and the outer diameter of the first longitudinal portion L1 increases in this way. In the second step of the stamping process, the outer diameter of the first longitudinal portion L1 increases to the size of the inner diameter of the common cylindrical recess of the radially movable stamping punch 81 and the stamping die 82.

[0169] from Figure 5D As can be seen, the first longitudinal portion L1 of the insulating element 4 and the inner conductor 3 encapsulated therein thus fill the entire interior of the cylindrical recess of the stamping device 8. From Figure 5E As can be seen, at the end of the stamping process, the outer diameter of the first longitudinal portion L1 of the insulating element 4 increases relative to the outer diameter of the second longitudinal portion L2 of the insulating element 4. At the end of the stamping process, the outer diameter of the first longitudinal portion L1 of the insulating element 4 corresponds to the inner diameter of the first plug connector portion S1 of the outer conductor contact element 14.

[0170] exist Figure 6A and 6B In each manufacturing step, the cross-sectional outlines of the main components of the prefabricated cable 1 according to the invention are shown schematically (i.e., not to scale) in various cases.

[0171] from Figure 6A The cross-sectional profile of the prefabricated cable 1 before the stamping process is obtained. The original outer diameter D1 of the first longitudinal portion L1 of the insulating element 4 corresponds to the outer diameter D1 of the second longitudinal portion L2 of the insulating element 4, and is smaller than the inner diameter D2 of the first plug connector portion S1 of the outer conductor contact element 14. Due to... Figure 6B The stamping process compresses the diameter of the first longitudinal portion L1 of the insulating element 4 from a smaller diameter D1 to a larger diameter D2, thereby enabling the first longitudinal portion L1 of the insulating element 4 to be inserted into the first plug connector portion S1 of the outer conductor contact element 14 in a calibrated manner.

[0172] exist Figure 7A and 7B The plug connector assembly 100 is shown in the side view and sectional view:

[0173] The sectional view is located at the second plug connector portion S2 of the plug connector 15 (see...). Figure 2B In the first plug connector S1, the second plug connector portion is preferably adjacent to the first plug connector portion S2. In the second plug connector portion S2, the insulating element 4 is inserted into the outer conductor contact element 14, and the insulating element 4 does not completely fill the area between the outer conductor contact element 14 and the inner conductor contact element 16.

[0174] Therefore, the insulating element 4 spanning the entire range of the second plug connector portion S2 has at least one recess 22 in various cases. Figure 7B (There are a total of two recesses 22 in the figure). At least one recess 22 is designed in various cases near the perimeter of the sheath of the insulating element 4, thereby forming a cavity between the outer conductor contact element 14 and the inner conductor contact element 16, which is filled with air. As is known, the dielectric constant of air is 1, while the dielectric constant of the dielectric material of the insulating element 4 is typically greater than 1. This results in an effective dielectric constant of the combination of the two dielectric materials in the second plug connector portion S2 being less than the dielectric constant of the insulating element 4 that completely fills the intermediate space between the outer conductor contact element 14 and the inner conductor contact element 16. In this way, when the insulating element 4 is designed to have at least one recess 22, the longitudinal portion L4 has more inductive transmission characteristics than a fully cylindrical design of the insulating element 4 that completely fills the intermediate region between the outer conductor contact element 14 and the inner conductor contact element 16. Therefore, the capacitive discontinuity in the cable 1 with the insulating element 4 designed in this way can be compensated by abruptly reducing the cross-sectional area, and an impedance-adapted signal transmission distance can be achieved over the entire longitudinal range of the plug connector assembly 100.

[0175] Finally, through Figures 8A to 8C Another, particularly preferred method for reducing the cross-sectional area in the first longitudinal portion L1 of the insulating element 4 is described. Figure 8A The insulating element 4, which has not yet been machined, is shown; Figure 8B The machining of insulating element 4 is shown; and Figure 8C The machined insulating element 4 is shown.

[0176] The processing apparatus 21 may have the shown separating tool 23, which preferably has two forming cutters 24 adapted to the cross-sectional area provided by the first longitudinal portion L1. The forming cutters 24 are arranged opposite to each other and actuable toward each other (see...). Figure 8A (The arrow in the image) is used to scribble the insulating element 4 downwards in the radial direction to the provided depth.

[0177] While the separating tool 23 remains within the insulating element 4, relative axial movement between the separating tool 23 and the cable 1 can then begin, for example, through linear displacement of the separating tool 23, such as... Figure 8BAs shown in the diagram. Thus, excess insulation layer 25 to be removed can be peeled or scraped off from the remaining insulation element 4. Here, the excess insulation layer 25 can initially be pushed in a bead-like manner in front of the forming cutter 24 until the bead reaches the end of the cable. The process can be advantageously facilitated by heating the insulation element 4, particularly when the separating tool 23 or its forming cutter 24 is heated. Therefore, the insulation layer 25 can become softer and thus easier to peel off.

[0178] If necessary, the insulating layer 25, which is displaced by the separating tool 23 in a manner similar to that of the first embodiment, can be removed during the cutting process by means of a cutting device.

[0179] exist Figures 8A to 8C The exemplary embodiments of the invention described herein can, in principle, be combined in any manner with the exemplary embodiments, variations, and modifications of the invention already described above. For example, in the case of a corresponding design embodiment of the blade of the forming tool 24, as an alternative or supplement to removing the sleeve-shaped insulating layer 25, it may also be provided that the groove 11 and / or recess 18 are formed in the insulating element 4 by the forming tool 24.

[0180] Although the invention has been fully described above with reference to several preferred exemplary embodiments, the invention is not limited thereto and may be modified in different ways.

Claims

1. A plug connector assembly (100) comprising a prefabricated cable (1) and a plug connector (15) connected to at least one cable end of the prefabricated cable (1), the prefabricated cable having an outer conductor shield (5) and an insulating element (4), wherein, The insulating element (4) has a first longitudinal portion (L1) and a second longitudinal portion (L2), in which the insulating element (4) is exposed from the outer conductor shield (5), the second longitudinal portion (L2) is adjacent to the first longitudinal portion (L1), and in the second longitudinal portion (L2) the insulating element (4) is enclosed by the outer conductor shield (5), wherein the cross-sectional area of ​​the insulating element (4) in the first longitudinal portion (L1) is modified relative to the cross-sectional area of ​​the insulating element (4) in the second longitudinal portion (L2) such that the first longitudinal portion (L1) can be inserted into the first plug connector portion (S1) of the outer conductor contact element (14) of the plug connector (15), and in the first longitudinal portion (L1), the insulating element (4) is tagged to the outer conductor contact element (14), wherein the first longitudinal portion (L1) of the insulating element (4) is inserted into the first plug connector portion (S1); Its features are, Within the outer conductor contact element (14) of the plug connector (15), at least one dielectric material for compensating for impedance changes between the first longitudinal portion (L1) and the second longitudinal portion (L2) is located in the second plug connector portion (S2), which is adjacent to the first plug connector portion (S1).

2. The plug connector assembly (100) according to claim 1, Its features are, The prefabricated cable (1) is configured such that the outer diameter of the second longitudinal portion (L2) of the insulating element (4) is different from the inner diameter of the first plug connector portion (S1) of the outer conductor contact element (14).

3. The plug connector assembly (100) according to claim 1 or 2, Its features are, The prefabricated cable (1) is configured such that the insulating element (4) completely fills the area between the outer conductor contact element (14) and the inner conductor (3) of the prefabricated cable (1) within the first longitudinal portion (L1) and the first plug connector portion (S1).

4. The plug connector assembly (100) according to claim 1 or 2, Its features are, A groove (11) is provided in the transition between the first longitudinal portion (L1) and the second longitudinal portion (L2) in the insulating element (4).

5. The plug connector assembly (100) according to claim 4, Its features are, The groove (11) is a full-circumference groove.

6. The plug connector assembly (100) according to claim 1 or 2, Its features are, The cross-sectional area of ​​the insulating element (4) is constant throughout the first longitudinal portion (L1), and is dimensionally smaller than the cross-sectional area of ​​the insulating element (4) in the second longitudinal portion (L2).

7. The plug connector assembly (100) according to claim 1 or 2, Its features are, The outer diameter of the insulating element (4) is constant throughout the first longitudinal portion (L1), and is dimensionally smaller relative to the outer diameter of the insulating element (4) in the second longitudinal portion (L2).

8. The plug connector assembly (100) according to claim 1 or 2, Its features are, At least one recess (18) is disposed on the periphery of the insulating element (4), the recess (18) extending in the longitudinal direction across the entire first longitudinal portion (L1) in various cases.

9. The plug connector assembly (100) according to claim 1 or 2, Its features are, Multiple recesses (18) are disposed on the periphery of the insulating element (4), and the recesses (18) extend in the longitudinal direction across the entire first longitudinal portion (L1) in various cases.

10. The plug connector assembly (100) according to claim 1 or 2, Its features are, The outer diameter of the insulating element (4) is constant throughout the first longitudinal portion (L1), and is dimensionally larger relative to the outer diameter of the insulating element (4) in the second longitudinal portion (L2).

11. The plug connector assembly (100) according to claim 1 or 2, Its features are, The insulating element (4) has a chamfer on the plug end of the first longitudinal portion (L1).

12. A method for manufacturing a cable (1), wherein a plug connector (15) is electrically and mechanically attached to said cable (1), wherein, In the first longitudinal portion (L1), the insulating element (4) is exposed from the outer conductor shield (5), wherein the cross-sectional area of ​​the insulating element (4) in the first longitudinal portion (L1) is modified relative to the cross-sectional area of ​​the insulating element (4) in the second longitudinal portion (L2), the second longitudinal portion (L2) is adjacent to the first longitudinal portion (L1), wherein the cable (1) is inserted into and connected to the outer conductor contact element (14) of the plug connector (15), wherein the cross-sectional area of ​​the first longitudinal portion (L1) is modified relative to the cross-sectional area of ​​the second longitudinal portion (L2) such that the first longitudinal portion (L1) can be inserted into the first plug connector portion (S1) of the outer conductor contact element (14) of the plug connector (15), and the insulating element (4) is tagged to the outer conductor contact element (14) in the first longitudinal portion (L1); Its features are, Within the outer conductor contact element (14) of the plug connector (15), at least one dielectric material for compensating for impedance changes between the first longitudinal portion (L1) and the second longitudinal portion (L2) is located in the second plug connector portion (S2), which is adjacent to the first plug connector portion (S1).

13. The method according to claim 12, Its features are, The cross-sectional area in the first longitudinal portion (L1) is modified by compressing the first longitudinal portion (L1).

14. The method according to claim 12, Its features are, The cross-sectional area of ​​the first longitudinal portion (L1) is modified by forging the first longitudinal portion (L1) in the forming process.

15. The method according to claim 14, Its features are, The cross-sectional area of ​​the first longitudinal portion (L1) is modified by forging the first longitudinal portion (L1) in a stamping or hot stamping process.

16. The method according to claim 12, Its features are, The modification of the cross-sectional area in the first longitudinal portion (L1) is achieved by the following steps: the insulating element (4) is scribbled in the radial direction by a separating tool (23), so that the separating tool (23) located in the insulating element (4) at its radial cutting position moves axially relative to the insulating element (4) in the direction toward the cable end in order to peel off the insulating layer (25) to be removed from the insulating element (4).

17. The method according to claim 16, Its features are, The separating tool (23) has at least one forming cutter (24) adapted to the shape of the cross-sectional area provided by the first longitudinal portion (L1) and capable of being actuated toward the first longitudinal portion (L1).

18. The method according to claim 17, Its features are, The separation tool (23) has two forming cutters (24) that are capable of actuating toward each other.

19. The method according to any one of claims 12 to 18, Its features are, The insulating element (4) is heated at least in the first longitudinal portion (L1) before and / or during the modification of the cross-sectional area.

20. The method according to any one of claims 16 to 18, Its features are, The separation tool (23) is heated to an operating temperature between 50°C and 250°C.

21. The method according to claim 20, Its features are, The separation tool (23) is heated to an operating temperature between 170°C and 200°C.

22. The method according to any one of claims 12 to 18, Its features are, The cross-sectional area is modified parallel to the first longitudinal portion (L1), and the web plate (10) with sharp edges of the stamping device (8) is grooved (11) in the insulating element (4) in the transition between the first longitudinal portion (L1) and the second longitudinal portion (L2).

23. The method according to claim 22, Its features are, The groove (11) is a full-circumference groove.

24. The method according to any one of claims 12 to 18, Its features are, The modification of the cross-sectional area in the first longitudinal portion (L1) is achieved through a separation process, which is generated by a laser beam, photon beam, electron beam or ion beam, or water jet.

25. An apparatus for manufacturing a cable (1), wherein a plug connector (15) is electrically and mechanically attached to said cable (1), having - Processing device (21), the processing device (21) is used to modify the cross-sectional area of ​​the insulation element (4) of the cable (1) that has been exposed from the outer conductor shield (5) in the first longitudinal portion (L1); as well as - A connecting device (20) for inserting the cable (1) into the outer conductor contact element (14) of the plug connector (15), Its features are, The processing device (21) is configured such that the processing device (21) modifies the cross-sectional area in the first longitudinal portion (L1) so that the first longitudinal portion (L1) can be inserted into the first plug connector portion (S1) of the outer conductor contact element (14), and the insulating element (4) is marked to the outer conductor contact element (14) in the first longitudinal portion (L1). In the outer conductor contact element (14) of the plug connector (15), at least one dielectric material for compensating for the impedance change between the first longitudinal portion (L1) and the second longitudinal portion (L2) of the insulating element (4) is located in the second plug connector portion (S2), which is adjacent to the first plug connector portion (S1).

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