Flexible electrical cable, preferably connection and data cable, and method for manufacturing a flexible electrical cable, preferably connection and data cable

Abstract

The invention relates to a flexible electrical cable (1), preferably a connection and data cable, comprising an outer sheath (2) which has an outer sheath surface (3) and includes at least two conductors (4) surrounded by the outer sheath (2) for conducting electrical signals and / or electric current, wherein the at least two conductors (4) form a conductor pattern of the cable (1), wherein the conductor pattern of the cable (1) is not concentric and wherein the cable (1) has a general conductor pattern that is identical at every point along the length of the cable (1).To provide a flexible electrical cable (1) that facilitates easier assembly and wiring, for example with a connector, the sheath (3) shall have at least one detectable marking (13) extending along the length of the cable (1), wherein the marking (13) is arranged along the length of the cable (1) with respect to the general conductor pattern such that it is located at the same position at every point along the length of the cable (1) with respect to the general conductor pattern. The invention also relates to a method for manufacturing a flexible electrical cable (1), preferably a connection and data cable.

Description

[0001] The invention relates to a flexible electrical cable, preferably a connection and data cable, comprising an outer sheath having an outer sheath surface and comprising at least two conductors surrounded by the outer sheath for conducting electrical signals and / or electrical current, wherein the at least two conductors form a conductor pattern (“real” conductor pattern) of the cable, wherein the conductor pattern of the cable is not concentric and wherein the cable has a general conductor pattern that is identical at every point along the length of the cable.

[0002] The wording "the conductor pattern of the line is not concentric" excludes designs of lines in which all conductors of this line are arranged concentrically around one and the same center point in the manner of a target.

[0003] In practice, such cables are connected at each end, for example with a plug or similar device. It can happen that, due to an oversight, the conductors of the cable are not connected to the correct terminal, such as on a plug.

[0004] The object of the invention is to avoid the aforementioned disadvantages and to provide a flexible electrical cable that allows for easier assembly and wiring, for example with a plug.

[0005] This task is solved by providing the outer surface with at least one detectable marking extending over the length of the conductor, wherein the marking, viewed over the length of the conductor, is arranged in such a way that it is provided at the same position at every point along the length of the conductor in relation to the general conductor pattern.

[0006] The general conductor pattern refers to the distribution and arrangement of the conductors within the cable, while the "actual" conductor pattern refers to the actual conductor pattern present at every point. For example, if the cable has four conductors, each consisting of a solid wire, the "actual" conductor pattern corresponds to the general conductor pattern at every point. However, if, for example, a conductor consists of stranded wire with a large number of twisted strands, the "actual" conductor pattern differs from the general conductor pattern. In this case, the general conductor pattern is always such that the marking is located at the same position relative to the general conductor pattern at every point along the length of the cable. However, the "actual" conductor pattern may differ slightly at every point along the length of the cable due to the large number of twisted strands in the stranded wire.The same applies if a conductor is designed, for example, as a wire mesh. In this respect, the "true" conductor pattern deviates from the general conductor pattern, for example, if a conductor is stranded within itself.

[0007] In the simplest case, the marking can be an optical marking, such as an applied line. A magnetic stripe that can be detected is also conceivable as a marking.

[0008] In the embodiment according to the invention, a marking along the entire length of the cable follows a single conductor. Consequently, the user can identify the general conductor pattern at the relevant point on the cable based on the marking. The user can therefore cut the cable at any point and, with respect to the marking in the cut area, will have the same general conductor pattern. This allows the user to insert the end of the cable into, for example, a piercing connector without error. When inserting the cable, the user simply needs to align the end so that the marking on the cable corresponds to a marking on the connector, for example. The cable can then be inserted, and each conductor is automatically inserted into the correct contact. Incorrect assembly is therefore no longer possible.

[0009] In this respect, the marking indicates the position of a specific conductor within the cable. Therefore, the cable, viewed along its entire length, has a consistently identical overall conductor pattern relative to its longitudinal axis with respect to the marking. The marking runs precisely to the position of a specific conductor within the cable, ensuring that the overall conductor pattern of the cable is identical at every point along its longitudinal axis. If the conductors run perfectly straight within the cable, the marking will also run in a correspondingly straight line.

[0010] A marking can be continuous. However, it is also quite possible for a marking to have breaks. Preferably, the breaks are so small that even if the cable is cut in the area of ​​a break, the user can still position the cable correctly in relation to the connector.

[0011] The cross-section of the cable can be, for example, round or rectangular. The conductor cross-section can range from 0.14 mm². 2 and 6.0 mm 2 , preferably between 1.0 mm 2 up to 2.5 mm 2 The conductors can vary in cross-sectional shape and size. Naturally, conductors of different cross-sectional shapes and sizes can be arranged within the cable. The material of a conductor can be copper (single wire) or galvanized, tinned, or silver-plated copper. A conductor can, for example, consist of a solid wire. Of course, a conductor can also be a stranded wire with a multitude of strands. A conductor can also be designed as a wire mesh. In this case, the conductor in question, such as the outer conductor in a coaxial cable, forms a kind of ring.

[0012] The number of conductors in the cable can be up to 25. Preferably, the cable has 3 to 8 conductors.

[0013] The outer sheath forms the casing and is typically extruded from a thermoplastic material. Its primary function is to protect the cable and ensure its suitability for environmental conditions. Suitable materials for the outer sheath include polyvinyl chloride (PVC), thermoplastic materials such as polyethylene (PE) or polypropylene (PP), or a thermoplastic elastomer (TPE), preferably a urethane-based thermoplastic elastomer (TPE-U).

[0014] Multiple markings may be provided. In this case, the markings are unevenly distributed around the circumference of the pipe.

[0015] At least one marking can be designed as a form-defining marking. A form-defining marking proves advantageous insofar as the marking cannot "detach" during use of the cable. Furthermore, the form-defining marking directly serves as a guide.

[0016] At least one defining characteristic can be a groove provided in the outer sheath. The grooved cable thus has at least one groove in its outer sheath. Each groove runs in a position corresponding to a specific conductor in the cable, so that the overall conductor pattern of the cable is identical along its longitudinal axis at every point. The groove can, for example, have a rectangular, semicircular, or triangular cross-section. Other cross-sections are, of course, also possible. For instance, the groove can also be a T-slot. A T-slot has an undercut, as the bottom of the slot is flat and the two sides of the slot form a "T" shape. The groove marks the position of a conductor in the cable and also serves as a guide groove, for example, when inserting the cable into a designated guide in a connector.

[0017] At least one defining characteristic can be a projection extending beyond the outer surface. This projection can, for example, have a rectangular, semicircular, or triangular cross-section. Other cross-sectional shapes are, of course, also possible.

[0018] Several conductors can be provided, preferably arranged in a stranded configuration around a core. In this cable, each marking is precisely aligned with a specific conductor running within the cable, ensuring that the overall conductor pattern along the longitudinal axis is identical at every point along the cable. In a cable with stranded conductors, each marking is present circumferentially and along a distance defined as the lay length. The lay length defines the distance a conductor needs to complete one full circuit around the stranded structure. The stranding imparts flexibility to the cable. Due to the stranding, when the cable is bent, a conductor located on the inside of the bend can be compressed, while a conductor located at the opposite point along the transverse axis can be stretched. The stranding process involves the combined action of a twisting and a pulling motion during manufacturing.Shorter lay lengths are better suited for cables subjected to bending stress. In stranding "with back twist," the individual conductors are twisted without any kinks, i.e., without torsion, whereas in stranding "without back twist," the cable is subject to a twist.

[0019] The conductor can have at least one, preferably copper-free, dummy element running its entire length. The dummy element can, for example, have a round shape. Other cross-sectional shapes are also conceivable. Provided that at least one dummy element is copper-free, it does not serve to conduct current and / or electrical signals. The core of the conductor can be formed by a dummy element.

[0020] At least one of the blanking elements can be hollow along its entire length. This hollow blanking element serves as a guide. For example, the plug into which the end of the cable is to be inserted can have a corresponding pin-like projection that is inserted into the hollow blanking element when the end of the cable is inserted into the plug.

[0021] At least one conductor can have insulation. Suitable materials for insulating a conductor include fluoropolymers, polyethylene (PE), thermoplastic elastomer (TPE), polyvinyl chloride (PVC), or silicone rubber (Si), with polypropylene (PP) being particularly preferred.

[0022] The insulation of at least one conductor may be enclosed by a braid.

[0023] At least one conductor can be enclosed by a banding, and / or the conductors can be enclosed by a common banding. Suitable banding materials include, for example, PE film, nonwoven fabric, or aluminum-laminated film; PP film is particularly preferred.

[0024] An inner sheath can also be provided between the conductors on the one hand and the outer sheath on the other.

[0025] At least one conductor can be designed as a coaxial cable. A coaxial cable is a two-core cable with a concentric cross-section. It consists of an inner conductor surrounded at a constant distance by a hollow cylindrical outer conductor (braid). Insulation is provided between the inner and outer conductors. The outer conductor shields the inner conductor from interference. The outer conductor is enclosed by a sheath.

[0026] The invention also relates to a method for manufacturing a flexible electrical cable, preferably a connection and data cable, comprising an outer sheath having an outer sheath surface and comprising at least two conductors surrounded by the outer sheath for conducting electrical signals and / or electric current, wherein the at least two conductors form a conductor pattern (“real” conductor pattern) of the cable, wherein the conductor pattern of the cable is not concentric and wherein the cable has a general conductor pattern that is identical at every point along the length of the cable.

[0027] The wording "the conductor pattern of the line is not concentric" excludes designs of lines in which all conductors of this line are arranged concentrically around one and the same center point in the manner of a target.

[0028] In practice, such cables are connected at each end, for example with a plug or similar device. It can happen that, due to an oversight, the conductors of the cable are not connected to the correct terminal, such as on a plug.

[0029] The object of the invention is to avoid the aforementioned disadvantages and to provide a method that enables easier assembly and wiring of a flexible electrical cable, for example with a plug.

[0030] This problem is solved by longitudinally extruding the conductors in a defined, permanent position with a thermoplastic coating, and by providing the coating surface, preferably during the extrusion process, with at least one detectable marking extending along the length of the conductor, wherein the marking is arranged along the length of the conductor such that it is located at the same position relative to the overall conductor pattern at every point along the length of the conductor. Preferably, the conductor is then wound onto a spool.

[0031] The general conductor pattern refers to the distribution and arrangement of the conductors within the cable, while the "actual" conductor pattern refers to the actual conductor pattern present at every point. For example, if the cable has four conductors, each consisting of a solid wire, the "actual" conductor pattern corresponds to the general conductor pattern at every point. However, if, for example, a conductor consists of stranded wire with a large number of twisted strands, the "actual" conductor pattern differs from the general conductor pattern. In this case, the general conductor pattern is always such that the marking is located at the same position relative to the general conductor pattern at every point along the length of the cable. However, the "actual" conductor pattern may differ slightly at every point along the length of the cable due to the large number of twisted strands in the stranded wire.The same applies if a conductor is designed, for example, as a wire mesh. In this respect, the "true" conductor pattern deviates from the general conductor pattern, for example, if a conductor is stranded within itself.

[0032] In the simplest case, the marking can be an optical marking, such as an applied line. A magnetic stripe that can be detected is also conceivable as a marking.

[0033] Thus, in a cable manufactured according to the inventive method, a marking along the entire length of the cable follows a single conductor. Consequently, the user can identify the general conductor pattern at any given point on the cable based on the marking. The user can therefore cut the cable at any point and, with respect to the marking in the cut area, will have the same general conductor pattern. This allows the user to insert the end of the cable into, for example, a piercing connector without error. When inserting the cable, the user simply needs to align the end so that the marking on the cable corresponds to a marking on the connector. Then, the cable can be inserted, and each conductor is automatically inserted into the correct contact. Incorrect assembly is therefore no longer possible.

[0034] In this respect, the marking indicates the position of a specific conductor within the cable. Therefore, the cable, viewed along its entire length, has a consistently identical overall conductor pattern relative to its longitudinal axis with respect to the marking. The marking runs precisely to the position of a specific conductor within the cable, ensuring that the overall conductor pattern of the cable is identical at every point along its longitudinal axis. If the conductors run perfectly straight within the cable, the marking will also run in a correspondingly straight line.

[0035] A marking can be continuous. However, it is also quite possible for a marking to have breaks. Preferably, the breaks are so small that even if the cable is cut in the area of ​​a break, the user can still position the cable correctly in relation to the connector.

[0036] Preferably, during the extrusion process, at least one shaping marking, preferably in the form of a groove, can be introduced into the outer shell by means of a shaping nozzle.

[0037] The conductor, which is marked with at least one identifier, can then be twisted. The conductor, preferably already twisted, can then be heated and subsequently cooled to relieve the torsional stress while maintaining the torsional stress. The twisting of the conductor can take place before heating. In this case, the conductor, already twisted, is then heated and subsequently cooled while maintaining the torsional stress to relieve it. Of course, the conductor can also be heated during the twisting process itself.

[0038] The conductor, which is marked with at least one identifier, can then be twisted and wound under tension onto an intermediate coil. The twisted conductor can then be rewound onto a final coil while maintaining the torsional tension. Before being wound onto the final coil, the conductor under torsional tension is first heated and then cooled to relieve the tension. This thermal treatment releases the stresses caused by the twist. The conductor is fixed around its longitudinal axis by the aforementioned thermal treatment of heating and subsequent cooling, without any unwinding or resulting lay length.

[0039] Provided the cable is wound onto a winding spool, the cable, which must be marked with at least one identifier, can be unwound from the spool and twisted in a stranding machine. It is then wound under tension onto an intermediate spool and, while maintaining the torsional tension, rewound onto a final spool. Before being wound onto the final spool, the cable under torsional tension is first heated and then cooled to relieve the tension. The twisting of the conductors results from the combined action of a rotational movement and an unwinding motion from the winding spool. The cable is wound onto the intermediate spool while maintaining tension to prevent the newly introduced twist from unraveling due to torsional stresses within the cable.

[0040] During heating, the cable can be heated up to the thermoplastic phase of the outer sheath's plastic.

[0041] The pipe can be heated by passing it through a hot runner system. Alternatively, the pipe can also be heated using another suitable temperature control device, such as a hot air oven, an infrared oven, or the like.

[0042] The following section explains exemplary embodiments of the invention illustrated in the drawings. The drawings show: Fig. 1 to 16 conductor diagrams of different configurations of a flexible electrical conductor according to the invention and Fig. 17 A perspective side view of a flexible electrical cable with five stranded conductors.

[0043] In all figures, identical reference symbols are used for identical or similar components.

[0044] The Fig. Figures 1 to 16 show different designs of flexible electrical cables 1. These cables 1 can be, for example, connection and data cables used to conduct electrical signals and / or electric current.

[0045] Each electrical conductor 1 has an outer sheath 2, which has an outer sheath surface 3 and comprises several conductors 4 surrounded by the outer sheath 2, the conductors 4 of the conductor 1 forming a conductor pattern. As the Fig. Figures 1 to 16 show that the conductor pattern of each conductor 1 is not concentric. Each conductor 1 exhibits an identical general conductor pattern at every point along its length.

[0046] In the embodiments according to the Fig. Each line 1 to 7 has five conductors 4, each conductor 4 being a stranded wire. Each stranded wire in turn consists of a plurality of strands. In the middle, i.e., in the core, of the line 1 is a dummy element 5.

[0047] In the exemplary embodiment according to Fig. 3. An inner sheath 6 is additionally provided between the conductors 4 on the one hand and the outer sheath 2 on the other.

[0048] While in the Fig. The fact that the five conductors 4 of each conductor 1 are identically formed, as shown in lines 1 to 7, is demonstrated Fig. Figure 8 shows an embodiment in which a conductor 4 is designed as a coaxial cable 7. The coaxial cable 7 consists of an inner conductor 8, which is surrounded at a constant distance by a hollow cylindrical outer conductor (braid) 9. An insulating layer 10 is located between the outer conductor 9 and the inner conductor 8. The outer conductor 9 shields the inner conductor 8 from interference radiation. On its outer side, the outer conductor 9 is again surrounded by an insulating layer 10, designed as a sheath.

[0049] In the design according to Fig. 9 is a leader 4 trained as a pair. Other variations of leader diagrams are in the Fig. Figures 10 to 16 are shown. In the embodiment according to Fig. 13 a braid 11 is provided between the outer sheath 2 and the inner sheath 6, while the conductor 1 in the embodiment according to Fig. 16 has a banding 12 between the outer sheath 2 and the conductors 4.

[0050] In all embodiments of the conductor 1 according to the invention, the outer surface 3 has at least one detectable marking 13. In the illustrated embodiments, each detectable marking 13 is a shape-defining marking that extends continuously over the entire length of the conductor 1. Each marking 13 is arranged along the length of the conductor 1 with respect to the general conductor pattern such that the marking 13 is located at the same position at every point along the length of the conductor 1 with respect to the general conductor pattern.

[0051] In the Fig. For parts 1 to 5 and 8 to 16, the defining characteristic is a groove with a rectangular cross-section. The in Fig. The illustrated conductor 1 also has a shape-defining marking in the form of a groove. However, in the illustrated embodiment, the groove is designed as a T-slot.

[0052] In the exemplary embodiment according to Fig. 6 the shaping marking is designed as a rectangular projection, while Fig. Figure 7 shows an embodiment in which the shaping characteristics are formed as triangularly shaped projections arranged irregularly around the circumference of the line 1.

[0053] In the in the Fig. In the embodiments shown in Figures 1 to 16, at least some or all conductors 4 are designed as stranded wire. In this respect, the "actual" conductor pattern is not the same at every point along the conductor 1, since the strands of a stranded wire are not located in the same position at every point along the conductor 1. Nevertheless, the general conductor pattern is identical for each conductor 1, and the marking 13, i.e., for example, the groove, is arranged along the length of the conductor 1 with respect to the general conductor pattern such that it is located at the same position at every point along the length of the conductor 1.

[0054] In Fig. Figure 2 shows an embodiment in which two grooves are provided which are not evenly distributed around the circumference of the line 1.

[0055] If one of the two ends of a corresponding line 1 is to be connected to a plug, the corresponding plug indicates – for example, when connected to a line 1 – Fig. 1 - five contacts and a rectangular projection. The rectangular projection of the connector is designed to correspond with the groove in the conductor 1. Each contact in the connector can, for example, be designed as a pin. The user simply needs to align the end of the conductor 1 to be inserted into the connector so that the groove of the conductor 1 is in line with the projection on the connector. Then, while maintaining the correct alignment, the end of the conductor 1 is inserted into the connector. This presses each pin of a contact into a conductor 4. In this way, each of the five conductors 4 is inserted into the correct contact on the connector side. The groove serves to align the conductor 1 and simultaneously guide it.

[0056] Fig. 17 indicates line 1 to Fig. 1 in a perspective side view. How Fig. As illustrated in Figure 17, the cable 1 is stranded, meaning the conductors 4 are arranged stranded around the dummy element 5 forming the core. The marking 13, which serves as a form-defining indicator, is positioned in relation to a specific conductor 4 running within the cable 1, ensuring that the overall conductor pattern along the longitudinal axis is identical at every point along the cable 1. The marking 13 encircles the cable 1 over a lay length S. The lay length S defines the distance the conductors 4 require to complete one full circuit around the stranded cable. The user can cut the cable 1 at any point and, after aligning the end, insert it into a connector, for example, as described above, always establishing a connection between the correct conductor 4 and the correct contact.

[0057] At the in Fig. In the depicted conductor 1, the centrally located dummy element 5, which in this case also forms the core of the conductor 1, is hollow along its entire length. This is advantageous if, for example, the connector (not shown), into which the end of the conductor 1 is to be inserted, has a corresponding pin-like projection. When the end of the conductor 1 is inserted into the connector, the projection on the connector side is inserted into the hollow, centrally located dummy element 5. In this respect, the hollow, centrally located dummy element 5 serves as a guide.

Claims

[1] Flexible electrical cable (1), preferably a connection and data cable, comprising an outer sheath (2) having an outer sheath surface (3) and comprising at least two conductors (4) surrounded by the outer sheath (2) for conducting electrical signals and / or electric current, wherein the at least two conductors (4) form a conductor pattern of the cable (1), wherein the conductor pattern of the cable (1) is not concentric and wherein the cable (1) has a general conductor pattern that is identical at every point along the length of the cable (1), characterized by , that the cladding surface (3) has at least one detectable marking (13) extending over the length of the conductor (1), wherein the marking (13) is arranged over the length of the conductor (1) in relation to the general conductor pattern such that it is provided at the same position at every point along the length of the conductor (1) in relation to the general conductor pattern. [2] Flexible electrical conductor (1) according to the preceding claim, characterized by , that several markings (13) are provided and the markings (13) are arranged unevenly distributed over the circumference of the line (1). [3] Flexible electrical conductor (1) according to any one of the preceding claims, characterized by , that at least one marking (13) is designed as a form-giving marking. [4] Flexible electrical conductor (1) according to the preceding claim, characterized by , that at least one shaping marking is formed as a groove provided in the outer shell (2). [5] Flexible electrical conductor (1) according to one of claims 3 or 4, characterized by , that at least one shaping feature is formed as a projection extending beyond the outer shell (2). [6] Flexible electrical conductor (1) according to any one of the preceding claims, characterized by, that several conductors (4) are provided which are preferably arranged stranded around a core. [7] Flexible electrical conductor (1) according to the preceding claim, characterized by , that the line (1) has at least one, preferably copper-free, dummy element (5) which is guided through the entire length of the line (1). [8] Flexible electrical conductor (1) according to the preceding claim, characterized by , that at least one blind element (5) is hollow along its entire length. [9] Flexible electrical conductor (1) according to any one of the preceding claims, characterized by , that at least one conductor (4) has insulation (10). [10] Flexible electrical conductor (1) according to any one of the preceding claims, characterized by , that in at least one conductor (4) the insulation (10) is enclosed by a braid (11). [11] Flexible electrical conductor (1) according to the preceding claim, characterized by, that at least one conductor (4) is enclosed by a banding (12) and / or the conductors (4) are enclosed by a common banding (12). [12] Flexible electrical conductor (1) according to any one of the preceding claims, characterized by , that an inner sheath (6) is provided between the conductors (4) on the one hand and the outer sheath (2) on the other. [13] Flexible electrical conductor (1) according to any one of the preceding claims, characterized by , that at least one conductor (4) is designed as a coax (7). [14] Method for manufacturing a flexible electrical cable (1), preferably a connection and data cable, comprising an outer sheath (2) having an outer sheath surface (3) and comprising at least two conductors (4) surrounded by the outer sheath (2) for conducting electrical signals and / or electric current, wherein the at least two conductors (4) form a conductor pattern of the cable (1), wherein the conductor pattern of the cable (1) is not concentric and wherein the cable (1) has a general conductor pattern that is identical at every point along the length of the cable (1), in particular for manufacturing a flexible electrical cable (1) according to one of the preceding claims, characterized by, that the conductors (4) are coated with a thermoplastic material in a defined, permanent position in an extrusion process in the longitudinal direction and that the coating surface (3) is provided, preferably during the extrusion process, with at least one detectable marking (13) extending over the length of the conductor (1), wherein the marking (13) is arranged over the length of the conductor (1) in relation to the general conductor pattern such that it is provided at the same position at every point along the length of the conductor (1) in relation to the general conductor pattern. [15] Method according to the preceding claim, characterized by , that during the extrusion process at least one shaping marking, preferably in the form of a groove, is introduced into the outer shell (2) by means of a shaping nozzle. [16] Method according to one of claims 14 or 15, characterized by, that the line (1) provided with at least one marking (13) is subsequently twisted and the line (1), preferably already twisted, is first heated and then cooled while maintaining the torsional stress in order to relieve the torsional stress. [17] Method according to any one of claims 14 to 16, characterized by , that the line (1) provided with at least one marking (13) is subsequently twisted and wound onto an intermediate coil under tension, and wherein the twisted line (1) is then rewound onto a final coil while maintaining the torsional tension, wherein the line (1) under torsional tension is first heated and then cooled before being wound onto the final coil to relieve the torsional tension. [18] Method according to one of claims 16 or 17, characterized by , that the conductor (1) is heated up to the thermoplastic phase of the plastic of the outer sheath (2) when heated. [19] Method according to any one of claims 16 to 18, characterized by , that the line (1) is routed through a hot runner for heating.

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