Cable housing

Abstract

The invention relates to a cable housing. A cable housing (1), in particular a joint protector, for accommodating at least two cables (20, 21). The cable housing (1) comprises at least one cable mounting slot (2, 3, 4) in at least one wall (5) of the cable housing (1). The at least one slot (2, 3, 4) comprises a cable insertion portion (10) adapted to receive at least one cable (20). The cable insertion portion (10) includes a first width (6). The at least one slot (2, 3, 4) further comprises a cable retaining portion (15) adapted to retain the at least one cable (20) by force fit and / or form fit. In addition, the cable holding portion (15) includes a second width (7) smaller than the first width (6).

Description

Technical Field

[0001] The present invention relates to a cable housing, a cable housing system and a method for assembling a cable housing system. Background Art

[0002] The transmission of power and signals is becoming increasingly important in modern vehicles. This applies especially to hybrid and electric vehicles, whose functions are highly dependent on a stable supply of electrical energy.

[0003] In order to transmit power and / or signals to different parts of the vehicle, it is usually necessary to splice cables. For example, it may be necessary to splice cables to provide power to an electric motor attached to the left wheel of the vehicle and an electric motor attached to the right wheel of the vehicle.

[0004] In order to provide one or more splices in a single assembly, splice protectors, which may also be referred to as splice protector connectors and / or splice protector housings, are used. Figure 1 An example of a joint protector currently used in the field is illustrated. The joint protector 4000 is configured to receive a metal bus bar 1000 configured to connect all cables 3000 to be installed. In addition, all terminals 3000 belonging to the joint protector 4000 should be installed to a housing 2000, to which the metal bus bar 1000 is also connected.

[0005] First, the aspect that all the terminals 3000 belonging to the splice protector 4000 should be mounted to one terminal 2000 often leads to production difficulties and complicated automation and / or a risk of poor connection that may not withstand the requirements in the automotive industry.

[0006] Second, the need for an intermediate element, namely, the metal bus bar 1000, in order to establish an electrical connection between the terminals 3000 often results in poor connection and / or increased resistance.

[0007] Third, providing busbar 1000 requires additional manufacturing and processing steps as well as additional material aspects.

[0008] Therefore, an object of the present disclosure is to provide a cable housing, a cable housing system and a method for assembling a cable housing system which at least partially overcome the above-mentioned disadvantages. Summary of the invention

[0009] The objects of the present invention are achieved at least in part by a cable housing, in particular a splice protector, for housing at least two cables according to one aspect of the present invention.

[0010] The cable housing comprises at least one cable installation slot in at least one wall of the housing. It will be appreciated that the at least one cable installation slot may be an elongated and narrow opening. Furthermore, the at least one cable installation slot may preferably extend through the cable housing wall in a substantially straight manner.

[0011] Thereby, the at least one slot comprises a cable insertion portion adapted to receive at least one cable, wherein the cable insertion portion comprises a first width.

[0012] Furthermore, the at least one slot comprises a cable holding portion adapted to hold the at least one cable by force fit and / or form fit, wherein the cable holding portion comprises a second width which is smaller than the first width.

[0013] It should be understood that when the diameter of the at least one cable is smaller than the first width, the at least one cable can be easily inserted into the cable insertion portion. In addition, it should be understood that when the diameter of the at least one cable is larger than the second width, the at least one cable can be easily retained in the cable retaining portion by force fit and / or form fit.

[0014] By means of the cable insertion portion and the cable retaining portion, an easy insertion and subsequent retention of the at least one cable in the cable housing can be achieved without having to carry out extensive fixing operations and / or provide additional fixing elements.

[0015] The at least two cables that the cable housing should accommodate, i.e. also the at least one cable mentioned above, may include a conductor material. The conductor material may include at least one of the following: copper, aluminum, a copper-based alloy and / or an aluminum-based alloy. In addition, the conductor material may include brass. The at least two cables may be rigid and / or flexible. In addition, the at least two cables may be at least partially surrounded by a separator. Therefore, preferably, the separator is removed or removable from a portion of each of the at least two cables. In particular, the portion may be prepared so that ultrasonic welding can be performed to connect the at least two cables.

[0016] Furthermore, the splice protector, which may also be referred to as a splice protector connector and / or a splice protector housing, may be adapted to provide one or more splices within a single assembly.

[0017] The cable housing may include a fixing device that can be switched between an open state and a closed state. The open state may refer to a state in which the at least one cable can be inserted and / or removed from the cable housing. The closed state may refer to a state in which the at least one cable cannot be inserted and / or removed from the cable housing. Therefore, the fixing device can be suitable for at least partially closing the cable insertion portion when in the closed state. In addition, the fixing device is preferably suitable for extending into the cable holding portion when in the closed state. When in the closed state, by extending into the cable holding portion, the fixing device can apply pressure to the cable arranged inside the cable holding portion. Thereby, the fixing of the cable inside the cable housing can be improved.

[0018] Even further preferably, the fixing device comprises a living hinge. The living hinge may also be referred to as a film hinge. A living hinge is defined as a thin flexible hinge made of the same material as the two rigid parts to which it is connected. A living hinge allows minimal friction and / or very little wear. In addition, it has the characteristics of low cost and / or ease of manufacture. The living hinge may be integrally formed with the cable housing and the fixing element movable relative to the cable housing. Exemplarily, the living hinge may be integrally formed with the cable housing and the fixing element by injection molding. In particular, injection molding allows very fast and / or precise manufacturing. It should be understood that, when in the closed state, the fixing element may be adapted to at least partially close the cable insertion portion. In addition, it should be understood that the fixing element is preferably adapted to extend into the cable retaining portion when in the closed state.

[0019] The fixing device may be adapted to press the at least one cable against one end of the at least one slot. Thus, the end is preferably located on the end of the slot opposite to the cable insertion portion. By pressing the at least one cable against one end of the at least one slot, the at least one cable may be securely held within the cable housing. Furthermore, movement of the at least one cable within the at least one slot may be avoided. Thus, wear on the at least one cable and / or the cable housing may be avoided.

[0020] The cable retaining portion may comprise at least one blade, the at least one blade being suitable for retaining the at least one cable by force fit and / or form fit, wherein preferably the at least one blade is suitable for pressing into and / or cutting into the at least one cable. The at least one blade may comprise a polymer and / or a metal material. Therefore, polymers may be preferred due to their excellent insulating properties and / or ease of manufacture. In particular, the at least one blade may be suitable for pressing into and / or cutting into a separator of the at least one cable. Therefore, the at least one blade may not contact the conductor within the at least one cable. Therefore, the electrical conductivity may be maintained at a high level. Preferably, the blade is formed integrally with the connector housing.

[0021] The cable holding portion may comprise at least two blades, the at least two blades being suitable for holding the at least one cable by force fit and / or form fit, wherein preferably, the at least two blades are substantially parallel and / or define the second width, wherein further preferably, the at least two blades are suitable for pressing into and / or cutting into the at least one cable. The at least two blades may comprise a polymer and / or a metal material. Therefore, polymers may be preferred due to their excellent insulating properties and / or ease of manufacture, for example by injection molding. In particular, the at least two blades may be suitable for pressing into and / or cutting into the separator of the at least one cable. Therefore, the at least one blade may not contact the conductor in the at least one cable. Therefore, the electrical conductivity may be kept at a high level.

[0022] Preferably, the blade is integrally formed with the connector housing.

[0023] The fixing device may be adapted to press the at least one cable towards the at least one blade or between the at least two blades. Thus, a force fit and / or a form fit may be achieved between the at least one cable and the at least one blade or the at least two blades. Thus, the fixing of the at least one cable within the cable housing may be further improved and / or movements of the at least one cable may be avoided or at least reduced.

[0024] The at least one blade or the at least two blades can extend along the at least one slot. Thus, for example, the at least one cable that is inserted into the cable insertion portion and pressed into the cable retaining portion by means of the fixing device can slide along the at least one blade or the at least two blades. Thus, the at least one cable is fixed in the cable housing when entering the cable retaining portion without the need for other means. Furthermore, in the above-described configuration, in which the at least one blade or the at least two blades extend along the at least one slot, it is particularly preferred when at least two cables are assumed to be inserted into the at least one slot. This is because the cables can then be kept in a row and supported against each other by a simple configuration.

[0025] The cable housing may comprise at least two slots, preferably at least three slots. Thus, the cable housing may allow sufficient space for a plurality of cables required in a vehicle project. Furthermore, the fixing device may fix at least one cable in each of the slots. Therefore, two slots and three slots have proven to be particularly preferred with regard to the interaction with the fixing device.

[0026] Furthermore, at least one of the at least one slot is configured to receive at least two cables, preferably at least three cables.A slot configured to receive at least two cables provides the advantage that the inserted cables may be supported against each other.

[0027] The object of the present invention is also at least partially achieved by a cable housing system comprising the cable housing as described above and at least two cables accommodated in the housing. Since the cable housing system comprises the cable housing as described above, it should be understood that the above advantages also apply to the cable housing system. In addition, the above aspects about the cable used for the cable housing also apply to the cable housing system.

[0028] The object of the present invention is also at least partially achieved by a method according to another aspect of the present invention. Specifically, a method for assembling a cable housing system comprises the following steps:

[0029] a) providing a cable housing according to the above description;

[0030] b) providing at least two cables;

[0031] c) inserting the cable through a slotted cable insertion portion;

[0032] d) transferring the cable into a cable retaining portion of the slot; and

[0033] e) Repeat steps c) and d) with the other cable.

[0034] Step c) can be performed in such a way that a gripper of an automatic harness assembly machine inserts the cable through a cable insertion portion of a slot, the cable preferably being cut and stripped in pre-processing.

[0035] Step d) can be performed in such a way that, after the clamp has been inserted into the cable, the clamp installs the cable in the slot by moving the cable into the cable holding portion. The cable can thereby be connected to the cable housing and optionally slightly clamped by the at least one blade or the at least two blades. The clamp can then open its jaws and release the cable. The cable is fixed and cannot fall out.

[0036] Therefore, the method may further comprise the following step after step b), preferably after step e): ultrasonically welding parts of the at least two cables together, wherein preferably, the parts of the at least two cables to be welded together are each inserted through the cable housing. Thus, the at least two cables can be welded into the joint and electrically and mechanically connected together.

[0037] Furthermore, the method may further comprise the step of closing the cable housing by switching the fixing device from the open state to the closed state. Thus, the fixing device may at least partially close the cable insertion portion. Thus, no cable may fall out of the cable housing. Furthermore, the fixing device may then extend into the cable holding portion. When in the closed state, by extending into the cable holding portion, the fixing device may apply pressure to the cable arranged inside the cable holding portion. Thus, the fixing of the cable inside the cable housing may be improved.

[0038] Preferably, in all embodiments disclosed herein, the housing or housing system does not comprise a metal busbar. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Below, the drawings are briefly described:

[0040] Figure 1 A cable housing known in the prior art is shown;

[0041] Figure 2 shows a perspective front view of an exemplary cable housing according to the present invention;

[0042] Figure 3 shows a perspective rear view of an exemplary cable housing according to the present invention;

[0043] Figure 4 shows a front view of an exemplary cable housing according to the present invention;

[0044] Figure 5 A cable insertion portion for inserting a first cable through a slot of a cable housing according to the present invention is illustrated;

[0045] Figure 6 illustrating transferring a first cable into a cable retaining portion of the slot;

[0046] Figure 7 illustrates interference between a first cable inserted into a slot and two blades in the slot;

[0047] Figure 8 illustrates closing the cable housing by switching the securing device from an open state to a closed state;

[0048] Fig. 9 illustrating ultrasonically welding together portions of a cable disposed in a cable housing; and

[0049] Fig.10 An exemplary method according to the present invention is shown.

[0050] Reference numerals list

[0051] 1 Cable housing

[0052] 2 slots

[0053] 3 slots

[0054] 4 slots

[0055] 5 Wall of cable housing

[0056] 6First Width

[0057] 7 Second Width

[0058] 10 Cable insertion part

[0059] 15 Cable fixing part

[0060] 16 The First Blade

[0061] 17 The Second Blade

[0062] 20, 21 Cable

[0063] 30 Fixtures

[0064] 50 Cable Enclosure System

[0065] 100 for assembling cable housing systems

[0066] 110 Provide cable housing

[0067] 120 Provide at least two cables

[0068] 130 Insert the cable through the cable insertion portion

[0069] 140 Transfer the cable to the cable holding portion

[0070] 150 Repeat steps 130 and 140 with another cable

[0071] 160 Close the cable housing

[0072] 170 Ultrasonic welding DETAILED DESCRIPTION

[0073] Figure 1 A cable housing 4000 known in the prior art, ie, a splice protector, is shown, wherein a metal bus bar 1000 is configured to be connected to a terminal 3000 to be installed.

[0074] Figures 2 to 9 The exemplary inventive cable housing shown in FIG. 1 is a splice protector for accommodating seven cables. The cable housing 1 comprises three cable mounting slots 2 , 3 , 4 in a wall 5 of the cable housing 1 .

[0075] Thus, each of the slots 2, 3, 4 comprises a cable insertion portion adapted to receive at least one cable and a cable retaining portion adapted to retain at least one cable by force fit and / or form fit.

[0076] exist Figures 2 to 9 2, in particular, slot 2 is provided with reference numerals to describe a specific configuration. However, it can be understood from the figure that slots 3, 4 include the same configuration, except that slot 4 is configured to receive only one cable. Slot 2 includes a cable insertion portion 10 adapted to receive at least one cable 20, wherein the cable insertion portion 10 includes a first width 6 (see Figure 4 The slot 2 further comprises a cable holding portion 15 adapted to hold at least one cable 20 by force fit and / or form fit, wherein the cable holding portion 15 comprises a second width 7 which is smaller than the first width 6. The first width 6 and the second width 7 are Figure 4 and Figure 7 Example in.

[0077] like Figure 2 and Figure 3 As shown in FIG. 1 , the cable housing 1 comprises a fixing device 30 which can be switched between an open state and a closed state. Figure 8 The switching of the fixing device 30 from the open state to the closed state is shown in FIG. Figure 8It can be further seen that the fixing device 30 is adapted to at least partially close the cable insertion portion 10 when in the closed state. The fixing device 30 of the exemplary cable housing 1 comprises a movable hinge 31. The movable hinge 31 is integrally formed with the cable housing 1 and a fixing element that is movable relative to the cable housing 1. Figure 3 It can be seen in particular that the fixing device 30 , ie the fixing element formed integrally with the living hinge 31 , comprises means allowing for a form fit between the fixing device 30 and an orifice provided in the cable housing.

[0078] like Figure 4 As shown in FIG, the cable holding portion 15 of the cable housing 1 comprises two blades 16, 17, which are suitable for holding cables 20, 21 by force fit and / or form fit. Therefore, the two blades 16, 17 are parallel and define a second width 7. In addition, as shown in FIG. Figure 7 As shown in the detail of FIG. 1 , the two blades 16, 17 are suitable for pressing and / or cutting into the cables 20, 21. Figure 4 It can be further seen in FIG. 2 that two cutting edges 16, 17 extend along the slot 2. It is therefore obvious that in the other slots 3, 4, cutting edges like those in the slot 2 are also arranged.

[0079] Figures 5 to 9 Illustrated is an automated assembly process of a cable housing system 50 comprising a cable housing 1 and seven cables accommodated in the final cable housing 1. For the sake of clarity, only two cables 20, 21 are provided with reference numerals.

[0080] Figure 5 The cable 20 is provided by a clamp and a cable housing 1. The cable 20 includes a separator, which is however removed (stripped) at one end of the cable to be inserted into the cable housing 1. The clamp is preferably an automatic clamp. Figure 5 In FIG. 1 , the insertion 130 of the cable 20 through the cable insertion portion 10 through the slot 2 is illustrated by two bold arrows.

[0081] Figure 6 The cable 20 is transferred into the cable holding portion 15 of the slot 2. Therefore, it can be understood that in the two left figures, the cable 20 is still located in the cable insertion portion 10. In the right figure, the cable 20 has been pressed between at least two blades 16, 17 of the cable holding portion 15 of the slot 2 by means of a clamp.

[0082] exist Figure 7 , a state is illustrated when the cable 20 has moved to one end of the slot 2, wherein the end is opposite to the cable insertion portion 10. Figure 6 The final state of the transfer process is shown in the right figure of . Figure 7In FIG. 1 , a detailed cross section of the slot 2 is provided, wherein the plane of the cross section is in one plane with the blades 16, 17. Thus, the interaction between the cable 20, i.e. the spacer of the cable 20, and the two blades 16, 17 can be observed. The interaction can be based on force fit and / or form fit. The force fit can be caused by the spacer pressing into the cable 20. The form fit can be caused by the spacer cutting into the cable 20. A combination is also possible.

[0083] exist Figure 8 , the switching of the fixture 30 from the open state to the closed state is shown. A cross section of the cable housing system 50 is provided, which illustrates the interaction of seven cables with the fixture 30. In particular, the interaction between the cables in contact with the fixture 30 is emphasized by thin arrows. The interaction can be based on force fit and / or form fit. In addition, the interaction can cause the fixture 30 to press the cables against the ends of the slots 2, 3, 4 opposite to the cable insertion portion 10 and the fixture 30. As a result, the fixture 30 also presses the cables 20, 21 between the two blades 16, 17.

[0084] Fig. 9 The step of ultrasonically welding 170 parts of the cables 20, 21 together is illustrated. Thus, the parts of the cables 20, 21 that are welded together are each inserted through the cable casing 1 .

[0085] Fig.10 A schematic diagram of an exemplary method 100 for assembling a cable enclosure system 50 is depicted, the method comprising the following steps:

[0086] a) providing 110 cable housing 1;

[0087] b) providing 120 at least two cables 20, 21;

[0088] c) inserting 130 a cable 20 through the cable insertion portion 10 of a slot 2;

[0089] d) transferring 140 the cable 20 into the cable holding portion 15 of the slot 2;

[0090] e) Repeat steps c) and d) 150 times with the other cable;

[0091] f) closing 160 the cable housing 1 by switching the fixing device 30 from an open state to a closed state, and

[0092] g) Ultrasonic welding 170 at least parts of two cables 20, 21 together.

Claims

1. A cable housing (1) for accommodating at least two cables (20, 21), in particular a splice protector, the cable housing (1) comprising: At least one cable mounting slot (2, 3, 4) located in at least one wall (5) of the cable housing (1), wherein the at least one slot (2, 3, 4) comprises: A cable insertion portion (10) adapted to receive at least one cable (20), wherein the cable insertion portion (10) comprises a first width (6), and A cable holding portion (15) is adapted to hold the at least one cable (20) by force fit and / or form fit, wherein the cable holding portion (15) comprises a second width (7) which is smaller than the first width (6).

2. The cable housing (1) according to claim 1, wherein: The cable housing (1) comprises a fixing device (30) which can be switched between an open state and a closed state, wherein the fixing device (30) is suitable for at least partially closing the cable insertion portion (10) when in the closed state, wherein the fixing device (30) is preferably suitable for extending into the cable holding portion (15) when in the closed state, wherein further preferably, the fixing device (30) comprises a movable hinge (31).

3. The cable housing (1) according to claim 2, wherein: The fixing device (30) is suitable for pressing the at least one cable (20) against one end of the at least one slot (2, 3, 4).

4. The cable housing (1) according to any one of the preceding claims, wherein The cable holding portion (15) comprises at least one blade (16) which is suitable for holding the at least one cable (20) by force fit and / or form fit, wherein preferably the at least one blade (16) is suitable for pressing and / or cutting into the at least one cable (20).

5. The cable housing (1) according to any one of the preceding claims, wherein The cable holding portion (15) comprises at least two blades (16, 17), which are suitable for holding the at least one cable (20) by force fit and / or form fit, wherein preferably, the at least two blades (16, 17) are substantially parallel and / or define the second width (7), wherein further preferably, the at least two blades (16, 17) are suitable for pressing and / or cutting into the at least one cable (20).

6. The cable housing (1) according to any one of claims 2 or 3 and any one of claims 4 or 5, wherein: The fixing device (30) is suitable for pressing the at least one cable (20) toward the at least one blade (16) or for pressing the at least one cable (20) between the at least two blades (16, 17).

7. The cable housing (1) according to any one of claims 4 to 6, wherein: The at least one cutting edge (16) or the at least two cutting edges (16, 17) extend along the at least one slot (2, 3, 4).

8. The cable housing (1) according to any one of the preceding claims, wherein The cable housing (1) comprises at least two slots (2, 3, 4), preferably at least three slots (2, 3, 4).

9. The cable housing (1) according to any one of the preceding claims, wherein At least one of the at least one slot (2, 3, 4) is configured to receive at least two cables (20, 21), preferably at least three cables.

10. A cable housing system (50), comprising: The cable housing (1) according to any one of the preceding claims; and At least two cables (20, 21) are accommodated in the cable housing (1).

11. A method (100) for assembling a cable housing system (50), the method comprising the steps of: a) providing (110) a cable housing (1) according to any one of claims 1 to 10; b) providing (120) at least two cables (20, 21); c) inserting (130) a cable (20) through a cable insertion portion (10) of a slot (2); d) transferring (140) the cable (20) into the cable holding portion (15) of the slot (2); and e) Repeat (150) steps c) and d) with another cable.

12. The method (100) according to claim 11, wherein: The method (100) further comprises the following steps after step b), preferably after step e): Portions of the at least two cables (20, 21) are ultrasonically welded (170) together, wherein preferably, the portions of the at least two cables (20, 21) that are welded together are each inserted through the cable housing (1).

13. The method (100) according to any one of claims 11 or 12 in combination with claim 2, wherein: The method (100) further comprises the following steps: The cable housing (1) is closed (160) by switching the fixing device (30) from the open state to the closed state.

14. The method (100) according to any one of claims 11 to 13, wherein: The method (100) further comprises the following steps: A portion of the insertion end of the cable is stripped away.

Images