Cable sealing shell and manufacturing method thereof

Abstract

The invention relates to a cable seal having an at least two-part housing having an upper part and a lower part on which at least one opening is formed as a cable inlet, where the upper part and the lower part each form part of the opening, characterized in that when the housing is in an engaged state, the upper part and the lower part form part of the opening. The abutting joint surfaces of the upper and lower portions have been laser welded to each other.

Description

Technical Field

[0001] The invention relates to a cable sealing housing and a manufacturing method thereof. Background Art

[0002] In the automotive industry, electrical wiring is closely related to safety. As vehicles are often exposed to changing environmental conditions such as rain, water spray, snow-melting salt, strong temperature fluctuations, etc., electrical connections are always a source of failures, especially leakage currents, short circuits and / or corrosion. Especially for battery cables, which may be permanently connected to the positive potential of the battery, the voltage applied to the cable promotes contact corrosion.

[0003] The connection between two cables is usually made using cable clamps and / or corresponding threaded sleeve joints. The main point here is that the connection point is protected from moisture ingress. Today, this is usually achieved using heat shrink tubing with an internal adhesive, which is pulled over the connection point and then shrunk. However, this type of heat shrink tubing, especially when connected to silicone-sheathed cables, has the problem of longitudinal water leakage between the heat shrink tubing and the cable insulation. In this case, it is almost impossible to achieve a complete seal.

[0004] Especially for battery cables or other high-voltage applications in the automotive industry, the so-called wading depth is also an important criterion. The vehicle can only be immersed in water to a certain depth. This depth is known as the wading depth. Laying the battery cable on the bottom means that the cable can be below the wading depth of the vehicle. In particular, there is the risk that cables laid on the bottom can be permanently damaged if immersed in water.

[0005] Due to the laying on the bottom and / or laying on the outside, there are always problems with moisture ingress. However, due to the electrification of the powertrain, the laying on the bottom and / or on the outside is increasingly common, especially outside the cabin. In this case, especially in the case of high-voltage applications, especially when the voltage is greater than 48V, especially when the voltage exceeds 300V, the connections between the cables must be particularly secured against moisture ingress. In particular, longitudinal water leakage currents or short circuits must be prevented.

[0006] In particular, the sealing of the center tap, where the branch cable forks in the middle of the main cable, can only be done with expensive Y-type heat shrink tubing, which is very expensive to manufacture to thread the cable through. In addition, the sealing effect depends in particular on the insulation material of the cable, which is sometimes less than ideal, especially for silicone sheathed cables. The permissible ambient temperature for using such systems is also limited by the melting temperature of the internal adhesive.

[0007] In addition to expensive heat shrink tubing, it is also possible to use a housing to waterproof the connection. However, there are always problems with the sealing of the housing. Summary of the invention

[0008] Therefore, the primary object of the present invention is to protect the connection between at least two cables in a vehicle from moisture. This object can be solved by the cable sealing housing according to claim 1.

[0009] The cable gland may also be referred to as a gland, housing, casing or similar component.

[0010] Initially, it was recommended to use a two-part housing. This housing consists of at least one upper part and at least one lower part. The concepts of upper part and lower part describe the relationship between the two parts. The upper part can also be called the first part and the lower part can be called the second part. The upper part can also be called the second part and the lower part can be called the first part.

[0011] The upper part and the lower part can be respectively bowl-shaped and form a housing in the joined state. In the joined state, a connection between two cables, or a connection between a cable and a connecting bolt or another connecting piece is formed in the housing. The cable can be a connecting cable or a main cable, and vice versa. The concepts of main cable and branch cable are used to distinguish the two cables linguistically. The structure of the cable itself can be basically the same, completely consistent or similar. The branch cable mentioned is also generally referred to as a connector, a connecting bolt, a connecting part, a terminal lug, a connector or a similar part. What these parts have in common is that they can be electrically connected to the main cable, and at least one conductive part (preferably covered with an insulating material) passes through the housing. The main cable mentioned is also generally referred to as a connector, a connecting bolt, a connecting part, a terminal lug, a connector or a similar part. What these parts have in common is that they can be electrically connected to the connecting cable at the intermediate tap, and at least two conductive parts (preferably covered with an insulating material) pass through the housing.

[0012] The housing is designed in two sections, specifically consisting of an upper part and a lower part, which has the advantage that the housing can be arranged at any position on the cable bundle, such as in the area of ​​a center tap. The center tap can be realized at any position on the main cable and sealed with this housing.

[0013] The description of seams and gaps in the preceding and following texts mainly relates to the cable entry region of the housing. In this regard, the following features are particularly applicable to seams and gaps in the cable entry region (also referred to as opening). However, these features can also be applied to other regions, in particular all seams and gaps between housing parts.

[0014] The two-part housing also has the advantage that after connecting the main cable to the drop cable, the connection can be inserted into the lower / upper part and the second part of the housing can be placed, and the closed housing is sealed in this way. No time-consuming threading of the connection through a Y-shaped heat shrink tubing is required.

[0015] The assembled cables (including the main cable and the drop cable) are simply inserted into one of the two parts of the housing, which is then connected to the other part of the housing, thereby closing the housing and welding the two parts together. It is particularly noteworthy that a seam between the two housing parts is sealed. In addition, it is particularly noteworthy that in the cable entry area, longitudinal water does not penetrate into the housing along the seam between the two housing parts.

[0016] At least one opening is provided in the housing as a cable entry, also referred to as a cable entry. The opening is used to introduce the cable into the housing. Preferably, the opening is formed in the region between the upper part and the lower part. When the housing is in the engaged state, the opening can be located partially in the upper part and partially in the lower part. For example, if the upper part is placed on the lower part, the side walls of the upper part and the lower part will abut against each other. The upper part and the lower part each have a groove in a region of the side wall, which forms a part of the opening when the housing is in the engaged state. The cable protrudes from or is introduced into the housing at the opening.

[0017] The seam between the two housing parts is particularly important in the area of ​​the inner side of the cable entry. The insulation of the cable is in direct contact with the sealing element or the inner side of the housing; if there is a sealing element, it is in contact with the inner side of the housing. Moisture can penetrate into the housing through gaps extending longitudinally along the cable / sealing element in the area of ​​the seam. It is therefore necessary to avoid such gaps. To achieve this, the gaps need to be filled with molten material during welding, especially in the area of ​​the inner side. To ensure that the gap is completely closed, a projection of molten material preferably extends from the gap into the interior of the cable entry.

[0018] In order to seal the housing, it is now proposed that the abutting surfaces of the upper part and the lower part are already laser welded to one another when the housing is in the joined state. The upper part and the lower part are welded together in a particularly moisture-tight and preferably gas-tight manner. The connecting edges of the upper part and the lower part directly abut against one another in the joined state. Laser welding can be used to melt the materials of the upper part and the lower part and to join them together. These materials are mainly plastics, in particular thermoplastics. Preferably PA6 or PA6.6, whose glass fiber content is optionally between 15 and 30% by weight or vol%.

[0019] This cable sealing method is particularly suitable for cable branches on the center tap of the main cable. The main cable can be stripped at the center tap. The main cable with insulating sheath extends on both sides of the stripping area. The insulating sheath material of the main cable and / or the branch cable can be silicone. The material of the insulating sheath can also be polyvinyl chloride.

[0020] In order to join the two housing parts, their joining surfaces face each other. It has proven to be more advantageous if the first joining surface is a plane and the second joining surface has ribs. The first joining surface can be formed by an edge end surface of one of the housing parts. Preferably, the first joining surface is perpendicular to the outer wall and / or the inner wall of the housing.

[0021] The second joint surface is first arranged on the other housing part in the same way as the first joint surface. However, unlike the first joint surface, the second joint surface is not planar but has ribs. The ribs are protrusions on the joint surface. Preferably, the ribs have a rectangular cross section. The ribs can also have a conical cross section, in particular tapering from the bottom to the front wall.

[0022] In cross section, the width of the first joint surface is greater than the width of the end surface of the fin. The end surface of the fin abuts the first joint surface. On the side of the side wall of the fin, the first joint surface extends in the corresponding plane area. On the inner side wall of the fin, the first joint surface preferably extends completely flat to the inner wall of the shell. On the outer side wall of the fin, the first joint surface also preferably extends completely flat to the outer wall of the shell. However, the first joint surface may also protrude in the direction of the second joint surface in the form of a folded edge or a flange.

[0023] The fin starts from the second joint surface and has two opposite side walls and a front wall. Preferably, the two side walls extend parallel to each other. Preferably, the front wall is perpendicular to at least one of the side walls. When engaged, the front wall of the fin faces the first joint surface. When engaged, the front wall of the fin is parallel to the first joint surface. The height of the fin is less than 1 cm, preferably less than 2-5 mm. The height of the fin is preferably 1 mm. The width of the fin, i.e. the distance between the side walls of the fin, is preferably equal to the height of the fin.

[0024] The ribs form a gap between the two joint surfaces. The ribs are a kind of spacer between the joint surfaces. If the first joint surface is in contact with the ribs, the root (bottom) of the ribs is separated from the adjacent surface by the gap. This gap must be closed. It is therefore recommended to melt the area of ​​the ribs facing the first surface by laser welding, and the molten material of the ribs will at least partially fill the gap between the oppositely positioned joint surfaces. Preferably, the material of the ribs is heated and melted by laser. The temperature of the molten material will then melt the material of the first joint surface in the rib area. In this way, the material of the first part and the second part will preferentially melt and fill the gap. Further, by melting the material of the two joint surfaces, the two shell parts will be welded together after cooling.

[0025] In laser welding, the laser is preferably guided through the material of the first part. In particular, the laser beam passes through the material of the first part, is emitted from the first joint surface, and irradiates the fin, especially the end face of the fin. The laser is preferably guided along the longitudinal direction of the fin. The laser is preferably guided to be spatially offset multiple times along the longitudinal direction of the fin in the radial direction (i.e. from the inside to the outside of the shell or from the outside to the inside). The laser is offset on the fin in a sufficiently short time, so that the material of the end face of the fin is melted over a large area. The laser irradiates the surface quasi-synchronously, so it is called quasi-synchronous welding.

[0026] The material of the first part is preferably different from the material of the second part. Preferably, the melting point of the material of the first part is the same as the melting point of the material of the second part. In addition, the material of the ribs may also be different from the material of the first joining part. In addition, the material of the ribs may also be different from the material of the second joining part. Preferably, the ribs and the second joining part are integrally formed and / or made of the same material. The material of the first part and / or the ribs is different from the material of the second part, especially in terms of optical properties. In particular, the material of the second part and / or the ribs has a higher absorption rate of laser radiation energy than the material of the first part.

[0027] According to one embodiment, it is suggested to melt the first surface area directly against the fin by laser welding, and the molten material of the fin will at least partially fill the gap between the opposite joint surfaces. The laser beam is adjusted accordingly so that it irradiates the second joint surface surface of the fin area, in particular the end face of the fin. The material of the fin and / or the second part should ensure that the radiation energy of the laser beam is sufficient to heat the material to above the melting point / melting temperature at normal pressure. Preferably, the melting temperature is reached after laser irradiation for less than 2 seconds, more preferably less than 1 second. The material melts and liquefies. The molten material flows into the gap between the first and second joint surfaces caused by the fin. It goes without saying that after welding, the melted and resolidified material at least partially closes the gap. After welding, the gap contains molten material. During the welding process, the pressing force pushes the two parts towards each other, thereby forcing the molten material into the gap. Due to the melting of the material of the fin and the pressing force, the width of the gap is reduced.

[0028] According to one embodiment, it is suggested that the molten material of the first surface and the molten material of the fins are connected together in a material-locked manner and at least partially fill the gap between the oppositely positioned joint surfaces. The energy input by the laser heats the second joint surface. This temperature is sufficient to reach the melting point of the material of the first joint part that is in contact with the fin. In this way, the materials of the first part and the second part melt in the area of ​​the joint surface, and the molten materials combine to form a melt. The melt flows into the gap as described above. After the joint surface is no longer exposed to the laser beam, the melt cools and solidifies, and the first part is connected to the second part in a material-locked manner through the melt.

[0029] According to one embodiment, it is suggested that the molten material fills the gap between the opposing joint surfaces substantially only in the inner wall area of ​​the shell. The geometry of the two joint surfaces and the arrangement of the fins preferably allow the melt to fill the gap between the opposing joint surfaces only in the inner wall area of ​​the shell. The fin is located in the second joint surface, and its side walls are spaced a certain distance from the inner wall and outer wall of the shell and the first and second parts. This arrangement allows the molten material (melt) to flow preferably and / or initially into the gap area between the two parts located inside the shell. Thus, this gap is preferably closed at the beginning. In particular, in the opening area, the gap extends from the outer wall of the shell to the inner wall along the longitudinal direction of the opening, parallel to the fins. Longitudinal water can penetrate into the shell through this gap. By preferentially filling the gap in the inner area as described above, it is ensured that the gap area is firmly closed. Preferably, a certain amount of the material of the fins and / or the first part is melted so that the volume of the melt is at least equal to, preferably greater than, the volume of the gap between the inner side wall of the fin and the inner wall of the shell.

[0030] According to one embodiment, it is recommended that the sinking path of the fins caused by laser welding is greater than 0.1 mm, preferably greater than 0.2 mm, less than 0.5 mm, and more preferably less than 0.4 mm. As mentioned above, by laser welding, at least the material at the fins will melt. During the laser welding process, the first part is pressed toward the second part by force. The force is at a certain angle to the joint surface, especially a right angle. Due to the force on the melt, the fins will sink a certain sinking path. The sinking path is preferably set as described above. On the one hand, this can melt enough material to fill the gap, and on the other hand, some fins are still not melted. This ensures that the melt flows into the gap in an ideal way.

[0031] According to one embodiment, it is suggested that the fin is arranged off-center on the cross section through the second joint surface, in particular, offset in the direction of the inner wall of the housing; in particular, the distance between the inner side wall of the fin and the inner wall of the housing is smaller than the distance between the outer side wall of the fin and the outer wall of the housing. Since the fin is closer to the inner wall of the housing than to the outer wall, it is ensured that the melted material of the fin can completely close the gap between the fin and the inner wall of the housing.

[0032] The arrangement is preferably located in the area of ​​the cable entry.

[0033] The ribs are preferably located in the central area outside the cable entry or even on the flange surrounding the second joint surface. This improves the accessibility of the laser.

[0034] The ribs are preferably arranged eccentrically and offset inwards at the cable entry. Further preferably, the ribs are also arranged eccentrically in the area of ​​the rest of the housing (i.e. an area that does not affect the cable entry), but different from the area of ​​the cable entry. In particular, the ribs can be offset outwards. In the area of ​​the cable entry, the arrangement towards the center is advantageous for sealing the longitudinal gap. In the area away from the cable entry, the arrangement is offset outwards to close the outer gap.

[0035] The laser preferably irradiates the end face in a manner deviating from the center of the fin end face. In particular, the laser irradiates the fin end face closer to the inner wall of the shell. Therefore, the fin first melts in this inner area, and the molten material flows to the inner wall of the shell.

[0036] The laser preferably passes through the entire end face of the fin in a very short time. In particular, the laser is guided along the end face of the fin quasi-synchronously. The laser passes through the end face in a radially offset manner in the shortest time, thereby melting the entire end face.

[0037] According to one embodiment, it is proposed that the material melted by laser welding completely fills the gap between the housing parts from the rib to the inner wall of the housing, in particular the molten material has a projection towards the inside of the housing. As mentioned above, the gap area between the rib and the inner wall of the housing is crucial for the longitudinal water tightness. It is therefore proposed to melt a corresponding volume so that the gap is completely filled at least in this area. In particular, more material is melted so that a projection protruding inwards is formed on the inner wall of the housing, in particular in the opening area. However, this projection is very small and can only ensure that the sealing ring described below has sufficient tightness.

[0038] The sealing ring is preferably made of a particularly soft and temperature-resistant material. Silicone or rubber is preferably used here. On the other hand, the insulating material may also vary. Silicone, PVC or PUR are typically used here. EPDM, XLPE / XLPO, PA11 / PA12 and other materials may also be considered. When a silicone insulating sheath is used, the sealing ring is preferably also made of silicone.

[0039] In the stripping area, the bare metal of the cable core is mechanically and electrically connected to the tap cable, and the bare metal end of the tap cable is preferably also stripped. In particular, the connection can be force-locked, form-locked and / or material-locked. In particular, the connection can include crimping, soldering and / or welding. In particular, the tap cable can be formed as a joint.

[0040] The two cable ends of the main cable extending from the stripped center tap extend from two openings of the housing, while the end of at least one branch cable extending from the center tap extends from at least a third opening of the housing. It is also possible to weld more than 2 cables together to form a "star shape", for example against the background of using different insulation materials in the wiring harness. This allows a modular structure that meets the requirements.

[0041] The main cable and the drop cable can be connected to each other in a first process step. For example, a central section of the main cable can be stripped first. One end of the drop cable can also be stripped. The stripped end of the drop cable can be placed on the bare metal of the main cable that is exposed after stripping. The main cable and the drop cable can be connected to each other via their metal cords.

[0042] For example, ultrasonic welding, laser welding, resistance welding, friction welding and the like may be used.

[0043] The main cable and the drop cable can consist of a stranded conductor comprising multiple strands or a solid conductor comprising only one strand of a solid material. In particular, the main cable can also be constructed as a flat conductor rail from which the drop cables branch. The conductor cross section of the main cable can also be round or, in the case of a flat conductor rail, square. The drop cable preferably has a round conductor cross section.

[0044] After the cables have been connected, they can be inserted into the upper or lower part and the cable bundle can be inserted into the groove in the side wall designed for this purpose. The corresponding upper / lower part can then be placed and each is arranged with the groove above the cable bundle. The opening formed by the upper and lower parts surrounds the cable bundle, in particular the insulating sheath of the cable.

[0045] According to one embodiment, it is proposed to arrange the cables in an insulated manner in the region of the respective openings in the housing. Here, the insulation is established by placing a sealing ring between the insulating sheath of the cable and the housing. The inner side of the sealing ring abuts against the insulating sheath of the cable, and the outer side of the sealing ring abuts against the inner wall of the housing in the region of the openings.

[0046] It is recommended to first install two sealing rings on the main cable and arrange them on both sides of the center tap. The insulation of the center tap can be removed before or after this. Push another sealing ring onto the end of the tap cable, which is also stripped. This can also be done before or after stripping. When removing the insulation, you can use a tool such as a laser or a knife to cut through the insulating sheath.

[0047] The sealing ring is preferably made of a plastic material that is softer than the shell material, which can be referred to as a soft component. The sealing ring is mainly made of elastomer, EPDM, silicone resin or rubber.

[0048] For example, the sealing ring can have an inner core made of a hard component and an outer side made of a soft component. The soft component can surround the inner core. The sealing ring can also be formed by a hard component and a soft component along its longitudinal axis. However, preferably, the sealing ring can also be composed only of the soft component.

[0049] According to one embodiment, the hard component can be bonded or welded to the housing so that a sealed, material-locked annular joint area can be formed between the inner surface of the opening and the hard component.

[0050] However, the soft component is preferably in circumferential contact with the insulation layer of the cable and in circumferential contact with the inner side of the opening. The sealing of longitudinal water is achieved by the elastic deformation of the sealing ring.

[0051] The cable is arranged at the opening in a movable manner. In order to prevent leakage caused by axial movement of the cable, it is recommended that the sealing ring is in the form of a sheet at least on the inner side, and preferably also on the outer side. Here, at least two, but preferably more axially spaced, radially protruding, preferably completely surrounding thin sheets can be designed. The thin sheet on the outer side consists of an area that protrudes more radially outward and an area that protrudes less radially outward. The thin sheet on the inner side consists of an area that protrudes more radially inward and an area that protrudes less radially inward. The thin sheet on the outer side is preferably suitable for sealing the protrusion formed by welding. Among them, it is preferred if the radial extension of the thin sheet relative to the opening is greater than the radial extension of the protrusion. Preferably, the radial extension of the thin sheet is at least 2 times larger than the radial extension of the protrusion, preferably at least 5 times or at least 10 times, preferably between 2 and 10 times, and preferably a maximum of 10 times.

[0052] The longitudinal section of the slice can be triangular, conical, arc-shaped or similar. Here, the areas protruding radially outwards can alternate with the areas protruding radially inwards.

[0053] According to one embodiment, it is proposed that the sealing ring is in the form of a bellows, so that the sealing ring can compensate for movements along the longitudinal axis of the cable while maintaining its sealing properties.

[0054] According to one embodiment, it is proposed that the size of the sealing ring is larger than the size of the opening. In this way, the sealing ring between the housing and the cable is elastically compressed in the radial direction in the engaged state. The inner diameter of the sealing ring is preferably smaller than the outer diameter of the cable with the insulating sheath. The outer diameter of the sealing ring is preferably larger than the inner diameter of the opening of the housing in the engaged state. In this way, the sealing ring is pushed onto the cable and elastically stretched in the process. When the sealing ring is inserted into the opening and closes the housing, the sealing ring is preferably elastically compressed. In this way, the sealing ring is elastically compressed in the engaged state.

[0055] The first joint surface can be a plane, and the second joint surface can be provided with ribs. The end surface of the ribs can be a plane and lie flat on the first joint surface.

[0056] Subsequently, welding is performed, in particular in the region of the mutually associated joint surfaces. The welding process takes place on these mutually contacting joint surfaces.

[0057] In this case, it is preferred if the materials of the upper and lower parts (first and second parts) have different optical properties, in particular opacity. At the same time, it is particularly preferred if the shell part with the first joint surface has a lower opacity than the shell part with the second joint surface and ribs or only ribs. The laser can then be irradiated through the first part to the joint surface of the second part, heating the material at the transition between the two shell parts and welding them together.

[0058] In order to completely close the housing, we propose that the ribs completely surround the housing, except for at least one opening, and that the two housing parts are then completely welded together in the manner described. The opening is sealed by the seal described.

[0059] The opening extends axially from the inside of the housing to the outside. The opening preferably protrudes axially outward from the housing. The ribs may extend along the axial extension direction of the opening, in particular parallel thereto.

[0060] The materials of the first and second parts are selected accordingly so that their melts bond together after solidification and are moisture resistant.

[0061] According to one embodiment, it is suggested that the sealing ring is installed between two axially spaced, at least partially surrounding blocks arranged on the inner side of the housing. The block can be formed by a radially inward projection in the opening area. Wherein, the projection can at least partially surround. The two axially spaced blocks can axially support the sealing ring in the opening. In this case, the net width formed by the blocks is smaller than the outer circumference of the sealing ring. Preferably, the blocks are arranged in the upper part and the lower part respectively, wherein each block forms a partially surrounding block in the engaged state. In the engaged state, the sealing ring cannot slide axially outside one of the at least partially surrounding blocks. Preferably, the sealing ring is axially compressed between the blocks. The axial extension of the sealing ring is preferably at least partially greater than the axial distance between the at least partially surrounding blocks, so that when the sealing ring is inserted between the blocks, it is axially compressed.

[0062] According to one embodiment, the hard component is surrounded by the soft component on both radial sides. In the axial direction, the hard component protrudes beyond the soft component. In the engaged state, these hard components protrude outwards at the opening. In the protruding area, the hard component surrounds the projection forming the opening on the outer side. This surrounding area of ​​the hard component can be locked with a locking device on the outer circumference of the projection forming the opening, especially with respect to the axial direction.

[0063] The axial direction is determined by the direction in which the cable is inserted into the opening. The axial direction is therefore particularly understood to extend transversely, preferably substantially perpendicularly, to the outer surface in which the opening is formed. In particular, the axial direction is parallel to the surface normal of the surface in which the opening is formed when the housing is in the engaged state.

[0064] The radial direction extends at right angles to the axial direction. The radial direction is preferably the extension direction of the opening. The radial direction preferably extends outwards from the center point of the opening. The opening can be oval, oblong, rectangular, circular or similar. In particular, the opening is adapted to the cross section of the cable, in particular the cross section of a flat cable can be rectangular and the cross section of a round cable can be circular.

[0065] Another aspect is a method according to claim 24.

[0066] Laser welding is preferably carried out using a diode laser. Due to the choice of plastic material, the radiation power of the diode laser is sufficient. Diode lasers have a long service life and low power consumption, making them particularly suitable for industrial production.

[0067] According to one embodiment, it is suggested that during the laser welding process, the laser beam irradiates the joint surface at a certain angle, in particular the laser irradiates the joint surface substantially parallel to the surface normal of the first and / or second joint surface. The laser is preferably guided through the first part, emitted from the first joint surface and irradiates the second joint surface.

[0068] According to one embodiment, it is suggested that during the laser welding process, the laser passes through the first joint surface and irradiates the ribs of the second joint surface, thereby firstly melting the material of the ribs.

[0069] According to one embodiment, it is suggested to focus the laser accordingly during the laser welding process so as to first melt the fin surface facing the first joint surface, so as to ensure that the radiation power of the laser acts preferentially on the end surface of the fin and melts it.

[0070] According to one embodiment, it is proposed to press the joint surfaces against each other with a pressing force during laser welding, wherein the pressing force is substantially parallel to the surface normal of the first and / or second joint surface. The pressing ensures that the two parts move relative to each other perpendicularly to their joint surfaces along the sinking path of the fins when the fins melt. The pressing force ensures that the melt fills the gap and that the two parts of the housing are joined together after cooling.

[0071] According to one embodiment, it is recommended that the pressing force is greater than 1000 N, preferably greater than 2000 N, in particular 3000 N, and / or the pressing force is less than 5000 N, in particular less than 4000 N. It has been shown that this pressing force ensures a correct flow of the melt in the gap and ensures sealing of the gap with the cooled melt. The pressing force is preferably set depending on the width of the ribs in order to provide a sufficient pressing force.

[0072] According to one embodiment, it is suggested that during the laser welding process, the joint surface is exposed to the laser for more than 2 seconds, preferably between 3 seconds and 3.5 seconds, and / or during the laser welding process, the joint surface is exposed to the laser for less than 5 seconds, preferably less than 4 seconds. This duration can ensure that sufficient material of the fin and the first joint surface is melted on the one hand, and on the other hand, it can ensure that the fin still exists after welding. BRIEF DESCRIPTION OF THE DRAWINGS

[0073] The present invention will be explained in more detail below with reference to the accompanying drawings which illustrate embodiments.

[0074] Figure 1 As the center tap of the junction;

[0075] Figure 2a to Figure 2d Various embodiments of sealing rings;

[0076] Figure 3 Arrangement of a sealing ring in a cable housing according to one embodiment;

[0077] Figure 4 Arrangement of the sealing ring in the housing according to one embodiment;

[0078] Figure 5 Arrangement of the sealing ring in the housing according to one embodiment;

[0079] Figure 6a Cross-section of the two housing parts before laser welding;

[0080] Figure 6b Cross-section of two housing parts during laser welding;

[0081] Figure 6c Cross-section of the two housing parts after laser welding;

[0082] Figures 7a to 7c A view of a housing according to one embodiment;

[0083] Figure 8 A view of a housing according to one embodiment. DETAILED DESCRIPTION

[0084] Figure 1 A connection between two cables is shown. A main cable 2 is connected to a drop cable 4. The two cables 2, 4 consist of a cable core 2a, 4a and an insulating sheath 2b, 4b.

[0085] The cable cores 2a, 4a are made of a metal material, in particular copper or a copper alloy and aluminum or an aluminum alloy. The main cable 2 is stripped in a central region 6, i.e. the insulating sheath 2b is removed from the cable core 2a. This is achieved in particular by removing the insulating sheath 2b with a laser, in particular by cutting the insulating sheath 2b with a laser. The two cable ends of the cable 2b extend from the region 6.

[0086] The cable core 4a of the tap cable 4 is connected to the cable core 2a in the area 6. In particular, the two are connected in a material-locked manner. Soldering or welding can be achieved here. However, it can also be designed as a clamping connection, in particular in the form of a crimp. The connection is preferably formed by welding in a material-locked manner, in particular by friction welding, preferably by ultrasonic welding or by resistance welding. As a result, the cable cores 2a, 4a are mechanically and / or electrically connected to each other.

[0087] The cable core 4a is exposed at one cable end on the drop cable 4. The other end of the cable 4 extends from the area 6. The connection between the main cable 2 and the drop cable 4 shown here can also be called a junction.

[0088] On the cable 2, sealing rings 8 may be provided at two ends of the cable at a certain distance from the area 6. On the cable 4, sealing rings 8 may be provided at a certain distance from the area 6. The sealing rings 8 will be described in detail below.

[0089] During the manufacturing process, two sealing rings 8 can be pushed onto the main cable 2 at a distance from the area 6. Before or after this, the insulating jacket 2b can be removed in the area 6. Then, in the area 6, the stripped cable end with the cable core 4a of the drop cable 4 is connected to the cable core 2a in the above-described manner. Before or after this, the sealing rings 8 can be pushed onto the drop cable 4. A connection is formed between the main cable 2 and the drop cable 4, wherein the sealing rings 8 are pushed onto the outlet cable ends on the respective insulating jackets 2b and 4b at a distance from the connection. As described below, this connection between the two cables can be moisture-proof.

[0090] Figure 2a to Figure 2d The sealing ring 8 pushed onto the insulating sheaths 2b and 4b is shown by way of example. A cross section and a longitudinal section of the sealing ring 8 are shown in each case.

[0091] Figure 2a In the figure, the cross section shows that the sealing ring 8 has an outer circumference 8a and an inner clear width 8b. The inner clear width 8b is similar in geometry to the cross-sectional profile of each cable 2, 4, especially in profile, and is preferably circular or rectangular.

[0092] The longitudinal section of the sealing ring 8 shows that in the region of its inner side, the sealing ring 8 has lamellae 12 spaced apart from each other in the axial direction 10. The lamellae 12 consist of regions protruding more radially inwards and regions protruding less radially inwards. The radial direction is a direction perpendicular to the longitudinal axis 10. The lamellae 12 preferably surround a central axis extending along the longitudinal axis 10.

[0093] When the sealing ring 8 is pushed on, the region of the lamella 12 protruding radially inwards abuts against the insulating sheath 2 b.

[0094] like Figure 2b As shown, in order to achieve sealing relative to the housing, in addition to the thin sheet 12, a thin sheet 14 is preferably arranged on the outer circumference 8a. The thin sheet 14 can be formed in the same way as the thin sheet 12 and has a region protruding more radially outward and a region protruding less radially outward. In the assembled state, the region protruding radially outward abuts against the inner wall surface of the housing opening.

[0095] Figure 2c The sealing ring 8 is shown to be composed of a soft component 8' and a hard component 8". Figure 2a The sealing ring 8 shown in FIG. 1 and FIG. 2 is composed only of a soft component 8'. Figure 2c and d, the hard component 8" is additionally supplemented. Figure 2c , the hard component 8" is arranged on the outer circumference of the sealing ring 8. Figure 2c The longitudinal section shown shows that the lamellae 12 are arranged on the inner circumference as described above.

[0096] Around the outer circumference 8a of the sealing ring 8, a circular ring made of a hard component 8" is in contact. An annular projection in the form of a welding piece can be provided on the circular ring. In the joined state, the projection can be in contact with the inner side of the housing and welded together in the manner described above for the joint surfaces. The hard component 8" is preferably made of the same material as the upper part or the lower part of the housing.

[0097] Figure 2d Another embodiment of the sealing ring 8 is shown. In this sealing ring, the hard component 8" is led out from the axial end face of the sealing ring 8. The hard component 8" preferably surrounds the soft component 8' on the outer circumference 8a of the sealing ring 8. The thin sheets 12, 14 are arranged according to Figure 2b set up.

[0098] In the joined state, the U-shaped cross section of the hard component 8" partially surrounds the outer wall of the housing, so as to fix the sealing ring 8 in the housing.

[0099] Figure 7aThe lower part 16 and the upper part 18 of the housing are shown. It can be seen that the lower part 16 and the upper part 18 are designed in the form of half shells. A groove is provided in the housing parts 16, 18, into which the cable can be introduced. The groove leads to an opening 20, and in the unengaged state, the upper part 18 and the lower part 16 only form a part of the opening 20, and in the engaged state, they are joined to form the complete opening 20.

[0100] like Figure 7b As shown, according to Figure 1 The connection can be inserted into the lower part 16. At the same time, the sealing ring 8 is positioned directly in the area of ​​the opening 20. The upper part 18 is then placed on the lower part 16.

[0101] Figure 7c It is shown how the upper part 18 and the lower part 16 are joined to form a housing 22. The upper part 18 and the lower part 16 are connected to each other in a materially bonded manner along a weld seam 24. The cables 2, 4 protrude through the opening 20 through the cable end. The opening 20 is shaped so that it can be sealed with the sealing ring 8 as shown below.

[0102] Figure 3 A plan view of the lower part 16 is shown, wherein what has been described also applies at least partially to the upper part 18 .

[0103] First, it can be seen that the lower part 16 is bowl-shaped and that the sealing ring 8 is installed in the area of ​​the opening 20. The thin sheet 14 of the sealing ring 8 is against the inner side of the lower part 16. The sealing ring 8 is designed with a hard component 8", which protrudes from the end face. In the longitudinal section, the hard component 8" is U-shaped and surrounds the outer side of the lower part 16. In the joined state, the upper part 18 is placed on the lower part 16. At the same time, the thin sheet 14 is pressed radially inward. The hard component 8" is then pushed to the opening so that it surrounds the upper part and the lower part at the same time in the area of ​​the opening 20 and fixes them to each other. Figure 3 The cable is not shown in the figure, but its insulating sheaths 2b, 4b are in contact with the inner sheet 12 and elastically deform it radially outward.

[0104] The sealing ring 8 is compressed in the engaged state, thereby sealing the opening 20 at the inside of the housing and at the cable sheath.

[0105] The lower portion 16 is provided with an engagement surface 24. The upper portion 18 is provided with a corresponding complementary engagement surface 24.

[0106] Figure 6a Cross sections are shown of two housing parts as upper part 18 and lower part 16. Cross sections through the housing parts (including the cross sections generally described above), ie cross sections through the joint surfaces, preferably extend perpendicularly to the longitudinal extension direction of the ribs.

[0107] The upper part 18 has a contact surface 24 a , the surface normal of which is perpendicular to the surface normal of the cross section shown and thus perpendicular to an axis extending in the plane of the drawing and parallel to the longitudinal extension of the upper part 18 .

[0108] The lower part 16 has a joining surface 24 b , the surface normal of which is perpendicular to the surface normal of the cross section shown and thus perpendicular to an axis extending in the plane of the drawing and parallel to the longitudinal extension of the lower part 16 .

[0109] Arranged on the joining surface 24b are ribs 26. The ribs 26 extend in their longitudinal extension parallel to the surface normal of the cross section shown and parallel to an axis extending perpendicularly to the plane of the drawing.

[0110] The rib 26 has two side walls 27a, b. The side wall 27a faces the inside of the housing. The side wall 27b faces the outside of the housing. In addition, the rib 26 has an end face 27c. The end face 27c extends parallel to the joint surface 24a.

[0111] As can be seen, the rib 26 is eccentrically located on the engagement surface 24b. Wherein, the rib 26 is offset to the inner side of the shell. However, the rib 26 may also be offset to the outer side of the shell.

[0112] It can also be seen that the joining surfaces 24a, b are located on the flanges 44 of the two housing parts that protrude outwards. A top plate or a stop can be mounted via the lower flange 44 located on the part with the ribs 26. In this way, the holding device can press the top plate with the pressing force of the flange 44 of the upper part. The lower flange can thus serve as a support surface for the top plate. There is also a further advantage here, that the laser only needs to penetrate the less material of the first part via the upper flange to irradiate the end face 27c of the rib 26.

[0113] like Figure 6b As shown, in order to make the upper part 18 and the lower part 16 engage, the engagement surface 24a is directed toward the engagement surface 24b and is placed on the end surface 27c of the rib 26. Then, the upper part is pressed against the lower part 16 by a pressing device with a pressing force in the direction 32. The pressing device can be pressed against the flange 44. A gap 34 is formed between the upper part 18 and the lower part 16 by the rib 26.

[0114] The upper portion 18 is made of a material having a lower opacity than the material of the lower portion 16 and / or the material of the fins 26. Thus, the laser beam 30 can pass through the material of the upper portion 18 and reach the joint surface 24. The laser beam 30 passes through the upper portion 18 and heats the materials of the lower portion 16 and the upper portion 18, in particular the fins 26 and the end surface 27c, at the joint surfaces 24a and 24b, thereby melting them. The melted area is shown in black.

[0115] During the welding process, the two housing parts 16, 18 are moved relative to each other under pressure so as to join together when the materials melt. Figure 6c As shown, the material will flow into the gap 34 after melting.

[0116] Figure 6c It is shown how the molten material 36 flows into the gap 34. Due to the eccentric arrangement of the fins 26, the material 36 preferably flows in the direction of the inner wall of the housing. It can be seen that a projection 38 is formed on the inner side of the housing. In addition, the material 36 also flows in the direction of the outer wall of the housing. As shown in the figure, the gap 34 between the joint surfaces 24a, b between the side wall 27a and the inner wall of the housing is completely filled with material 36. The gap 34 between the joint surfaces 24a, b between the side wall 27b and the outer wall of the housing can be partially (as shown) or completely filled with material 36.

[0117] The material 36 is formed by the molten material of the fin 26 and the upper portion 18. After cooling, the molten material 36 solidifies, and the upper portion 18 and the lower portion 16 are joined together. Due to melting and pressing, the fin 26 is compressed toward the joining surface 24b on the sinking path 42. The protrusion 38 is completely surrounded by the thin sheet 14, thereby sealing the opening.

[0118] Figure 4 Another embodiment is shown, in which the sealing ring 8 is axially fixed at the opening 20 in the lower half shell 16 by two stops 40a, 40b. The sealing ring 8 can also be compressed axially by the stops 40a, b. Here, the sealing ring 8 also seals the inner surface of the housing on the one hand and the insulating sheath on the other hand in the above-mentioned manner.

[0119] Figure 5 Another embodiment is shown, in which the Figure 2c The sealing ring 8 is provided. Unlike the previous embodiment, the sealing of the sealing ring 8 on the inner side of the housing is achieved by a welding piece protruding radially outward. Here, the welding piece can be welded to the inner surface of the lower half shell 16 and the upper half shell 18. In particular, a laser beam is irradiated to the welding surface and the molten material is welded so that the materials are connected to each other in a material-locking manner after cooling.

[0120] Figures 3 to 5 The only difference between the illustrated embodiments is the type of sealing ring 8. Figure 6a The insertion of the cable and the interconnection of the upper part 18 and the lower part 16 do not differ in the manner shown in , b and in the manner generally described therefor.

[0121] Figure 8Another embodiment is shown. It can be seen that the upper part 18 and the lower part 16 each have a flange 44 in their outer edge areas. The flange 44 on the upper part forms a first engagement surface 24a. The engagement surface is preferably a plane. The flange 44 on the lower part 16 forms a second engagement surface 24b. The rib 26 extends along the engagement surface 24b. The rib 26 extends along the side of the lower part 16.

[0122] It can be seen that the radial position of the rib 26 on the engagement surface 24b is variable.

[0123] The radial position of the rib 26 on the engagement surface 24b is preferably variable, so that it has different eccentricities at different positions along the longitudinal axis of the engagement surface 24b. In particular, as shown in the figure, the position of the rib 26 in the opening area is eccentric inwards. As the rib moves further away from the opening 22, the position of the rib 26 on the engagement surface 24b changes. In particular, as shown in the figure, in the area away from the opening 18, the position of the rib 26 is eccentric outwards. In this area, the rib 26 is preferably located on the flange 44 of the lower part 16 and under the flange 44 of the upper part 18.

[0124] Also shown is the trajectory of the laser 30. The laser 30 is radially offset several times along the longitudinal axis of the fin 26, as shown by the dashed lines.

[0125] The laser 30 travels this trajectory in the shortest possible time, for example less than 10 seconds, preferably less than 5 seconds, and more preferably less than 1 second. In particular, the melted material of the fin 26 no longer solidifies while the laser passes through this trajectory. In this way, the entire surface of the fin 26 can be melted and welded together along the fin 26 by pressing the upper part 18 onto the lower part 16. In particular, the entire fin 26 is melted in this way. The laser passes and irradiates the longitudinal axis of the fin 26 multiple times in a radially offset manner, so that the surface of the fin 26 is quasi-synchronously irradiated. During this time, the molten material cannot solidify, so that a full-surface joint can be formed between the joint surface 24a and the end face of the fin 26.

[0126] Description of Reference Numerals

[0127] 2 Main cables

[0128] 4 Breakout Cables

[0129] 2a, 4a cable core

[0130] 2b, 4b insulation sheath

[0131] 6 Regions

[0132] 8 Sealing ring

[0133] 8' Soft component

[0134] 8" Rigid Component

[0135] 8a Outer circumference

[0136] 8b Clear width

[0137] 10 Vertical axis

[0138] 12, 14 thin slices

[0139] 16 Lower part

[0140] 18 Upper part

[0141] 20 Opening

[0142] 22 Housing

[0143] 24a, b Joint surface

[0144] 26 ribs

[0145] 27a, b Side wall

[0146] 27c End face

[0147] 30 Laser Beam

[0148] 32 Direction

[0149] 34 Gap

[0150] 36 Materials

[0151] 38 raised part

[0152] 40a, b Stopper

[0153] 42 Sinking Path

[0154] 44 Flange

Claims

1. A cable sealing housing, the cable sealing housing having - an at least two-part housing having an upper part and a lower part, - the housing has at least one opening formed as a cable entry, -in, The upper portion and the lower portion each constitute a portion of an opening, wherein - when the housing is in the joined state, the joint surfaces of the upper part and the lower part facing each other are welded together by laser, It is characterized in that - of the opposing joint surfaces, the first joint surface is a substantially flat surface, and of the opposing joint surfaces, the second joint surface has ribs protruding in the direction of the surface normal of the joint surfaces, and The region of the fin facing the first surface is melted by laser welding, and the molten material of the fin at least partially fills the gap between the opposing joint surfaces.

2. The cable sealing housing according to claim 1, It is characterized in that - By laser welding, the first surface area directly in contact with the fin is melted, and the molten material of the fin at least partially fills the gap between the opposing joint surfaces.

3. The cable sealing housing according to claim 2, It is characterized in that The molten material of the first surface and the molten material of the fins are connected together in a material-locked manner and at least partially fill the gap between the opposing joint surfaces.

4. The cable gland according to any one of the preceding claims, It is characterized in that The molten material fills the gap between the opposing joint surfaces in the region of the inner wall of the housing.

5. The cable gland according to any one of the preceding claims, It is characterized in that The fin sinking path caused by laser welding is greater than 0.1 mm, preferably greater than 0.2 mm, and less than 0.5 mm, preferably less than 0.4 mm.

6. Cable sealing housing according to any one of the preceding claims, It is characterized in that - in a cross section through the second joint surface, the fin is arranged off-center, in particular offset in the direction of the inner wall of the housing; in particular, the distance between the inner side wall of the fin and the inner wall of the housing is smaller than the distance between the outer side wall of the fin and the outer wall of the housing, or - In the cross section through the second joint surface, the rib is arranged off-center, in particular offset toward the outer wall of the housing; in particular, the distance between the outer wall of the rib and the outer wall of the housing is smaller than the distance between the inner wall of the rib and the inner wall of the housing.

7. Cable sealing housing according to any one of the preceding claims, It is characterized in that The material melted by the laser welding completely fills the gap between the housing parts starting from the ribs to the inner wall of the housing, in particular the molten material has a projection towards the interior of the housing.

8. Cable sealing housing according to any one of the preceding claims, It is characterized in that - At least one branch cable is connected to the stripped center tap of the main cable in the housing, in particular as a junction, the cable ends of the main cable extending from the center tap being led out of the housing through two openings, and at least one branch cable being led out of the housing through at least a third opening.

9. The cable gland according to any one of the preceding claims, It is characterized in that - The cables are insulated in the area of ​​their respective openings.

10. The cable gland according to any one of the preceding claims, It is characterized in that The sealing ring formed by at least one soft component is in circumferential contact with the insulation layer of each cable and, at at least one opening, in circumferential contact with the inner side surface of each opening.

11. Cable sealing housing according to any one of the preceding claims, It is characterized in that The sealing ring has at least two axially spaced circumferential lamellae on the inner side and / or the outer side at the opening.

12. The cable gland according to any one of the preceding claims, It is characterized in that -The sealing ring is in the form of a bellows.

13. The cable gland according to any one of the preceding claims, It is characterized in that - The upper part and the lower part are made of plastics having different opacities from each other.

14. The cable gland according to any one of the preceding claims, It is characterized in that The material of the fins is less opaque than the material of the joining surface against the fins.

15. Cable sealing housing according to any one of the preceding claims, It is characterized in that - ribs are arranged in the upper part and the flat joint surface is arranged in the lower part, or The ribs are arranged in the lower part and the planar joint surface is arranged in the upper part.

16. Cable sealing housing according to any one of the preceding claims, It is characterized in that - The fin is completely surrounding except for at least one opening.

17. The cable gland according to any one of the preceding claims, It is characterized in that - The fins are arranged in the area of ​​the opening.

18. Cable sealing housing according to any one of the preceding claims, It is characterized in that - The fins are welded accordingly to the flat surface so that the molten material seals the gap moisture-tight.

19. The cable gland according to any one of the preceding claims, It is characterized in that - In the engaged state, the sealing ring between the housing and the cable is compressed in the radial direction.

20. The cable gland according to any one of the preceding claims, It is characterized in that The sealing ring is mounted between two axially spaced-apart stops arranged on the inner side of the housing and extending at least partially around the opening.

21. The cable gland according to any one of the preceding claims, It is characterized in that -The sealing ring consists of a soft component and a hard component.

22. A cable gland according to any one of the preceding claims, It is characterized in that The hard component forms a radially outward projection on the outer circumference of the sealing ring, and the projection is welded to the upper part and the lower part.

23. The cable gland according to any one of the preceding claims, It is characterized in that The hard component extends axially beyond the opening toward the sealing section.

24. A method for manufacturing a cable sealing housing according to any one of the preceding claims, comprising: - preparing a first part and a second part of a housing, the housing having at least one opening formed as a cable entry, wherein the first part and the second part form an upper part and a lower part of the housing, - mutually opposing joint surfaces are arranged on the two parts, wherein of the opposing joint surfaces, a first joint surface is a plane, and of the opposing joint surfaces, a second joint surface has ribs protruding from the surface along the surface normal direction of the surface, and - laser welding the joint surface of the first part and the second part, wherein - During the laser welding process, the area of ​​the fin facing the plane surface is melted and the molten material of the fin partially fills the gap between the opposing joint surfaces.

25. The method according to claim 24, It is characterized in that - Welding of joint surfaces using diode laser.

26. The method according to claim 24 or 25, It is characterized in that During the laser welding process, the laser beam irradiates the joining surfaces at a certain angle, in particular the laser beam irradiates the joining surfaces substantially parallel to the surface normal of the first and / or second joining surfaces.

27. The method according to any one of claims 24 to 26, It is characterized in that - During the laser welding process, the laser passes through the first joint surface and irradiates the ribs of the second joint surface.

28. The method according to any one of claims 24 to 27, It is characterized in that During the laser welding process, the laser is focused accordingly so that the rib surface facing the first joining surface is melted first.

29. The method according to any one of claims 24 to 28, It is characterized in that During laser welding, the joining surfaces are pressed against one another with a pressing force, wherein the pressing force is substantially parallel to a surface normal of the first and / or second joining surface.

30. The method according to any one of claims 24 to 29, It is characterized in that - the pressing force is greater than 1000N, preferably greater than 2000N, in particular 3000N, and / or the pressing force is less than 5000N, in particular less than 4000N 31. The method according to any one of claims 24 to 30, It is characterized in that - During laser welding, the joint surface is exposed to the laser for more than 2 seconds, preferably between 3 seconds and 3.5 seconds, and / or during laser welding, the joint surface is exposed to the laser for less than 5 seconds, preferably less than 4 seconds.

Images