Prefabricated electric cable, plug connector assembly, and method and apparatus for manufacturing an electric cable

Abstract

The invention relates to a prefabricated electric cable (3) comprising an outer conductor shield (2) and a support sleeve (1) which is fastened to the outer conductor shield (2) and which has an end (4) closer to the plug and an end (5) closer to the cable. According to the invention, in an end portion (6) closer to the cable, the support sleeve (1) tapers towards the end (5) closer to the cable.

Description

[0001] The invention relates to a pre-assembled electrical cable comprising an outer conductor shield and a support sleeve attached to the outer conductor shield, according to the preamble of claim 1.

[0002] The invention further relates to a connector arrangement comprising an electrical cable and an electrical connector connected to at least one cable end.

[0003] The invention also relates to a method for assembling an electrical cable, wherein a support sleeve having a plug-side end and a cable-side end is attached to an outer conductor shield of an electrical cable, according to the preamble of claim 10.

[0004] When assembling cables, their conductors are typically connected to a connector to enable subsequent electrical connections with other cables or conductors that have corresponding connectors or mating connectors. A connector or mating connector can be a plug, a panel-mount plug, a socket, a coupling, or an adapter. The terms "connector" and "mother connector," as used in this invention, are representative of all variants.

[0005] In cable assembly, a mechanically and electrically optimized connection must be achieved between the electrical cable pre-assembled with a support sleeve and an electrical connector.

[0006] Especially for connectors used in the automotive industry and in vehicles, high demands are placed on their robustness and the safety of the connections. A connector must withstand sometimes high stresses, such as mechanical loads, and remain reliably closed so that the electrical connection is not unintentionally interrupted, for example, during vehicle operation. Ensuring safety is paramount, particularly for autonomous vehicle operation and driver assistance systems.

[0007] From a mechanical perspective, a stable and vibration-resistant connection between the electrical cable and the electrical connector, especially without any "wobbling," must be achieved. This requires a suitable connection between the support sleeve and an outer conductor section of the electrical connector (hereinafter referred to as the "outer conductor element" or "outer conductor assembly") that is attached to the support sleeve.

[0008] During autonomous vehicle operation or when using driver assistance systems, large amounts of data from multiple cameras, various sensors, and navigation sources must be combined and transmitted, usually in real time. Operating numerous devices, screens, and cameras therefore requires a high-performance infrastructure within the vehicle's electronics. Consequently, the demands placed on connectors and cable connections within a vehicle, particularly regarding the required data rate, are now very high. At the same time, to save space and weight, it is crucial to design the connectors to be as compact as possible.

[0009] From an electrical perspective, particular attention must therefore be paid to an impedance-matched transition between the electrical cable and the electrical connector (or between the support sleeve and the outer conductor element of the electrical connector). In particular, geometric discontinuities must be avoided.

[0010] To meet the requirements, it is generally necessary to position the pre-assembled electrical cable, with the support sleeve attached to the cable, precisely in the axial direction relative to the outer conductor contact or outer conductor element of the connector. This is currently not satisfactorily resolved, or only possible to a limited extent or with great difficulty, particularly in the assembly of cables for use in high-frequency technology.

[0011] For further background information, reference should also be made to the following publications. US 2003 / 003805 A1 proposes, for an XSR audio connector, mounting an insulating clamping sleeve on the braided shield of a cable and folding the braided shield over the clamping sleeve to contact an outer conductor element of the connector. EP 2 456 013 A2 relates to a method for producing a crimp connection between a coaxial cable and a coaxial connector having an outer conductor section. US 4,990,105 A relates to arranging a central socket contact in a coaxial plug connector. Furthermore, DE 10 2016 122 728 A1 discloses a device for processing cable ends, comprising an image processing system configured to capture an image of the cable end for cable processing and to determine the position of the cable end based on this image.EP 3 429 029 A1 relates to a connector arrangement with a connector and a cable connected to the connector, wherein the connector arrangement has an outer conductor contact extending from the connector to the sheath of the cable and having a radial indentation at the location of an annular groove.

[0012] EP 3 242 359 A1 relates to a cable with a plug-in connector comprising an inner conductor, insulation, a shield, a sleeve, a jacket, and a support sleeve. The outer conductor of the plug-in connector has a radial constriction created by crimping. The support sleeve has a substantially hollow cylindrical section and three ribs at the cable end. As a result of the crimping process, the ribs are bent radially inwards and have an oblique radial inward orientation, so that the ribs are pressed into the wire braid of the cable.

[0013] In view of the prior art, the object of the present invention is to provide a pre-assembled electrical cable and a connector arrangement in which the fastening of an outer conductor element to a support sleeve attached to the cable is improved in mechanical and electrical terms.

[0014] Finally, it is also an object of the invention to provide a method for the assembly of an electrical cable in which the mounting of an outer conductor element on a support sleeve attached to the cable is improved.

[0015] The problem is solved for the pre-assembled electrical cable with the features listed in claim 1 and for the connector arrangement with the features listed in claim 9. With regard to the method, the problem is further solved with the features listed in claim 10.

[0016] The dependent claims and the features described below relate to advantageous embodiments and variants of the invention.

[0017] A pre-assembled electrical cable is provided, comprising an outer conductor shield and a support sleeve attached to the outer conductor shield, the support sleeve having a plug-side end and a cable-side end.

[0018] In principle, any electrical cable with any number of inner conductors or cable cores can be provided within the scope of the invention. For example, an electrical cable within the scope of the invention can have one inner conductor, two inner conductors, three inner conductors, four inner conductors, or even more inner conductors. Preferably, an electrical cable with two inner conductors is provided.

[0019] If an electrical cable has only one conductor, it can be a coaxial cable. If an electrical cable has more than one conductor, the conductors can be twisted together, like a twisted-pair cable; however, the conductors can also be parallel, as in a parallel-pair cable.

[0020] The outer conductor shield can, in particular, be an outer conductor shield braid made of interwoven individual wires.

[0021] In the context of the invention, the connector-side end of the support sleeve refers to the axial end of the support sleeve that faces the free cable end to be processed during assembly. The connector-side end of the support sleeve preferably faces an opening in the electrical connector, which is to be attached to the electrical cable during cable assembly, and which is provided for the insertion of a subsequent mating connector.

[0022] The cable-side end is the end of the support sleeve that faces away from the connector-side end in the axial direction. The support sleeve thus extends axially between the connector-side end and the cable-side end along its longitudinal axis or central axis.

[0023] According to the invention, the support sleeve is designed to taper in a cable-side end section towards the cable-side end.

[0024] The cable-side end section preferably extends in the axial direction and borders directly on the cable-side end.

[0025] Preferably, the tapered section extends directly to the cable-side end of the support sleeve. The diameter of the support sleeve can thus increase directly from the cable-side end towards the connector-side end along the cable-side end section (for example, linearly, conically, or even curvedly).

[0026] Preferably, no axial section with a constant diameter is provided immediately starting from the cable-side end.

[0027] It can preferably be provided that the support sleeve tapers along the entire cable-side end section (and not only along an axial sub-area of ​​the cable-side end section), preferably continuously.

[0028] Preferably, the tapering in the cable-side end section is not a chamfer, a transition radius or a beveled edge of the support sleeve.

[0029] Preferably, the support sleeve has, in addition to the cable-side end section, further sections, in particular a connector-side end section that extends axially from the connector-side end of the support sleeve. Optionally, a central section running between the connector-side end section and the cable-side end section may also be provided. However, the connector-side end section can also be directly adjacent to the cable-side end section.

[0030] The support sleeve can preferably consist solely of the cable-side end section. The support sleeve can also consist solely of the cable-side end section and the middle section. The support sleeve can also consist solely of the cable-side end section and the connector-side end section. The support sleeve can also consist solely of the cable-side end section, the middle section, and the connector-side end section.

[0031] According to the invention, the cable-side end section tapers conically towards the cable-side end.

[0032] The tapered design of the support sleeve in the cable-side end section according to the invention can particularly improve the axial positioning of the support sleeve on the electrical cable and / or the axial positioning of the support sleeve within a component or assembly of an electrical connector to be applied during assembly, for example, the outer conductor element described below. This allows for reliable axial positioning of the support sleeve.

[0033] The use of a tapered cable-side end section according to the invention can improve the mechanical and electrical connection between the support sleeve and the electrical cable and / or the subsequent connector. In particular, assembly-related tolerances of components or assemblies can be compensated for.

[0034] According to the invention, the cable-side end section of the support sleeve is designed in such a way that it can be deformed by a deformation process, preferably a crimping process, so that the cable-side end section tapers towards the cable-side end.

[0035] Preferably, the tapering of the cable-side end section can be created or reinforced during the forming (in particular, pressing or crimping) of the support sleeve on the electrical cable and / or during the crimping of a component or assembly of the subsequent electrical connector onto the support sleeve. In particular, the tapering can be partially or completely created during the crimping or pressing of the outer conductor element, described below, onto the support sleeve.

[0036] To form the tapered cable-side end section, at least one recess (free recess), preferably two recesses, can be provided in the area of ​​the cable-side end section.

[0037] The recess(s) can be notch-shaped. Slot-shaped recesses, similar to those in a spring basket, are also possible.

[0038] According to the invention, the cable-side end section of the support sleeve has a cut, preferably two cuts or more cuts, which extend axially through the cable-side end section starting from the cable-side end.

[0039] Preferably, groups of opposing incisions can be provided along the circumference of the support sleeve.

[0040] Preferably, notches in the form of notches can be provided.

[0041] For example, by using one or more incisions, the tapering in the cable-side end section can be created during the fastening of the support sleeve to the cable or during the fastening of another component of the electrical connector to the support sleeve by a deformation process, in particular by a crimping process.

[0042] According to a further development of the invention, it can be provided that the cable-side end section of the support sleeve is designed as a deformation area, in particular a crimp area, for fastening the support sleeve to the outer conductor shield.

[0043] It may also be provided that the cable-side end section of the support sleeve is designed as a deformation area, in particular a crimping area, for fastening a component or assembly of an electrical connector, for example the outer conductor element, to the support sleeve.

[0044] In a further development of the invention, it can be provided that the cable-side end section of the support sleeve, in particular the tapered axial area of ​​the cable-side end section, extends over an axial length that corresponds to at least 5% of the total length of the support sleeve, preferably at least 10% of the total length of the support sleeve, particularly preferably at least 20% of the total length of the support sleeve, most preferably at least 40% of the total length of the support sleeve, more preferably at least 50% of the total length of the support sleeve, and even more preferably at least 60% of the total length of the support sleeve.

[0045] Preferably, the cable-side end section, which tapers towards the cable-side end, is not a chamfered surface of an edge of the support sleeve or a bevel.

[0046] According to the invention, the cable-side end section of the support sleeve tapers towards the cable-side end in such a way that the cable-side end has an oval or elliptical profile.

[0047] In an advantageous embodiment of the invention, it can be provided that the support sleeve forms at least one end face adjacent to the plug-side end which can be used as a stop.

[0048] The at least one end face can be designed in particular as a stop for the support sleeve in another component of the electrical connector, in particular the outer conductor element of the electrical connector described below.

[0049] The use of a stop can improve the axial positioning of the support sleeve on the electrical cable and / or in a component or assembly, for example the outer conductor element of the electrical connector.

[0050] In a preferred embodiment of the invention, the support sleeve is designed to form a positive-locking connection with an outer conductor element of an electrical connector. The following measures can be provided to achieve this positive lock: 1. the support sleeve is supported axially with its plug-side end face, which can be used as a stop, against a radially inwardly directed stop area formed on the inner wall of the outer conductor element; and 2. the cable-side end section of the support sleeve is supported in a constriction of the outer conductor element of the connector formed by a crimping process.

[0051] In particular, this allows for a backlash-free axial fixation with optimized electrical properties between the stop area of ​​the outer conductor element and the support sleeve.

[0052] In a further development of the invention, it can be provided that the support sleeve tapers in a plug-side end section towards the plug-side end.

[0053] The preceding and following characteristics relating to the cable-side end section can also be understood as referring to the plug-side end section - and vice versa.

[0054] In particular, the tapering can extend directly to the connector-side end of the support sleeve. The diameter of the support sleeve can thus increase directly from the connector-side end towards the cable-side end along the connector-side end section (for example, linearly, conically, or even curvedly).

[0055] Preferably, no axial section with a constant diameter is provided immediately starting from the end on the plug side.

[0056] It can preferably be provided that the support sleeve tapers along the entire connector-side end section (and not only along an axial sub-area of ​​the connector-side end section), preferably continuously.

[0057] Preferably, the tapering in the plug-side end section is not a chamfer, a transition radius or a beveled edge of the support sleeve.

[0058] The use of a connector-side end section that tapers towards the connector-side end, in addition to the tapered cable-side end section, can be advantageous to further improve the axial positioning of the support sleeve on the electrical cable and / or in a component or assembly, for example the outer conductor element of an electrical connector.

[0059] A connector-side end section that tapers towards the end on the plug side can preferably be provided as an alternative to a stop of the support sleeve adjacent to the end on the plug side - but possibly also in addition to this.

[0060] In an advantageous embodiment of the invention, it can be provided that the outer conductor shield is folded back over the support sleeve.

[0061] In particular, a section of the outer conductor shield protruding from the connector-side end of the support sleeve towards the front, free end of the cable can be folded back over the support sleeve. Preferably, the folded-back shield or outer conductor shield extends axially over the length of the support sleeve or beyond the cable-side end of the support sleeve.

[0062] According to the invention, the tapered cable-side end section improves adhesion and thus strain relief and electrical connection of the outer conductor shield between the support sleeve and a component or assembly pushed onto the support sleeve, in particular the outer conductor element of the connector.

[0063] In an advantageous embodiment of the invention, the support sleeve may have two support areas. A first support area may be provided adjacent to the connector-side end and comprise two U-shaped half-shells with their openings positioned opposite each other. Furthermore, a second support area may be provided adjacent to the cable-side end and have a round or oval cross-section.

[0064] A support sleeve with two support areas can be particularly advantageous when an electrical cable with multiple conductors, for example, two inner conductors, is used. The contour of the first support area can thus be adapted to the contour or cross-section of the adjacent inner conductors of the electrical cable, thereby improving the mechanical holding force. Conversely, to improve the mechanical and electrical connection between the support sleeve and a component or assembly, especially the outer conductor element of the connector, which typically has a round cross-section, a second support area with a preferably (essentially) round cross-section can be advantageous.

[0065] The first support area and the second support area can preferably be connected to each other by one, and especially preferably by two, axially extending webs.

[0066] According to the invention, the pre-assembled electrical cable has an outer conductor element of an electrical connector which is attached to the support sleeve, preferably crimped.

[0067] The external conductor element can be a single piece or a multi-piece assembly. It can also be referred to as an external conductor assembly, particularly if it is a multi-piece assembly.

[0068] The improved support sleeve according to the invention is particularly suitable for fastening in an outer conductor element or in an outer conductor assembly of the subsequent connector.

[0069] It may be provided that the support sleeve, the outer conductor shield, and / or the outer conductor element or assembly are crimped or pressed together in the first support area and / or in the second support area. Preferably, only the support sleeve and the outer conductor shield are crimped or pressed together in the first support area. Preferably, the support sleeve, outer conductor shield, and outer conductor element or assembly are crimped or pressed together in the second support area.

[0070] In a further development of the invention, it can be provided that the outer conductor element forms at least one stop area for the at least one end-face stop of the support sleeve, preferably an internal shoulder or at least a web projecting into the interior of the outer conductor element.

[0071] The support sleeve can therefore be advantageously inserted into the outer conductor element in the axial direction until the stop area is reached.

[0072] According to the invention, it is further provided that the outer conductor element has at least one deformation area, in particular a crimp area, in order to press or crimp the outer conductor element with the cable-side end section of the support sleeve (and optionally also with the connector-side end section).

[0073] In particular, pressing or crimping the outer conductor element in an axial area, which (in the case of a support sleeve inserted axially into the outer conductor element to its end position) is located in the area of ​​the cable-side end section or the plug-side end section of the support sleeve, can lead to a mechanically and electrically stable and impedance-matched connection.

[0074] The interaction of the outer conductor element with the tapered cable-side end section of the support sleeve during the crimping or pressing of the components ultimately results in an axially play-free fixation of the support sleeve within the outer conductor element. The support sleeve can be axially supported both at the stop area and in the tapered section.

[0075] Due to the conical or tapered shape of the cable-side end section in conjunction with the deformation area of ​​the outer conductor element, it is possible for the support sleeve to move axially further towards the stop area or the inner shoulder of the outer conductor element during the deformation process, thus enabling even better crimping.

[0076] It may be provided that the support sleeve, particularly in the second support area, has a recess which is formed in the axial direction following the contour of the outer conductor shield.

[0077] The invention also relates to a connector arrangement comprising an electrical cable and an electrical connector connected to at least one cable end. The connector arrangement (in particular the electrical connector) has a support sleeve attached to an outer conductor shield of the electrical cable, with a connector-side end and a cable-side end, and an outer conductor element attached to the support sleeve. The support sleeve is designed to taper in a cable-side end section towards the cable-side end.

[0078] Preferably, the outer conductor shield is folded back over the support sleeve and preferably clamped between the constriction of the outer conductor element and at least the cable-side end section of the support sleeve.

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

[0080] The connector according to the invention can be used particularly advantageously within a vehicle, especially a motor vehicle. Possible areas of application include autonomous driving, driver assistance systems, navigation systems, infotainment systems, rear-seat entertainment systems, internet connections, and Wireless Gigabit (IEEE 802.11ad standard). Potential applications include high-resolution cameras, for example, 4K and 8K cameras, sensors, onboard computers, high-resolution displays, high-resolution dashboards, 3D navigation devices, and mobile communication devices.

[0081] The term "vehicle" describes any means of transportation, in particular vehicles on land, water or in the air, including spacecraft.

[0082] However, the connector according to the invention is suitable for any application within the entire field of electrical engineering and is not limited to use in automotive engineering.

[0083] Due to the tapering in the cable-side end section, play between the support sleeve and an outer conductor element of an electrical connector can be avoided.

[0084] Particularly preferably, the stamped and bent part pre-formed for the support sleeve can be used for assembling an electrical cable with a connector for use in high-frequency technology.

[0085] The invention further relates to a method for assembling an electrical cable, wherein a support sleeve having a connector-side end and a cable-side end is attached to an outer conductor shield of an electrical cable, wherein the outer conductor shield is folded back over the support sleeve, and wherein an outer conductor element or an outer conductor assembly of an electrical connector is axially slid over the support sleeve and pressed or crimped onto the support sleeve. It is provided that the outer conductor element has at least one deformation area where it is pressed or crimped to the support sleeve, at least in the area of ​​a cable-side end section that tapers towards the cable-side end of the support sleeve.

[0086] Preferably, the support sleeve is inserted into the outer conductor element in such a way that air inclusions and the resulting electrical disturbances are reduced.

[0087] The cable can be inserted axially into the outer conductor element until the support sleeve hits a stop area and then pressed or crimped to the outer conductor element in the area of ​​the tapered cable-side end section.

[0088] The maximum deformation force (or crimp force) can preferably be applied in the area of ​​the cable-side end section of the support sleeve by a deformation tool (in particular a crimping tool) which is to be aligned accordingly with the position of the cable-side end section.

[0089] In the method according to the invention, it is provided that the tapered cable-side end section is formed from an originally sleeve-shaped support sleeve by conically deforming the support sleeve during the crimping of the outer conductor element on the support sleeve in such a way that the cable-side end has an oval or elliptical profile.

[0090] The support sleeve can be manufactured from a stamped and bent part as part of the process.

[0091] The stamped and bent part can be pre-formed to the support sleeve before being attached to the outer conductor of the electrical cable.

[0092] In the method according to the invention, it is provided that the stamped and bent part is provided with a cut, preferably two cuts or more cuts, which extend axially from the later cable-side end of the support sleeve through the cable-side end section of the later support sleeve.

[0093] Within the framework of the inventive method, any further process steps for the assembly of the electrical cable can be provided, which can be carried out before, between or after the process steps already mentioned.

[0094] For example, it may be provided that first the cable sheath of the electrical cable is stripped in the area of ​​the cable end to be processed and the detached section of the cable sheath is pulled off the electrical cable. Subsequently, the support sleeve according to the invention can be attached to the exposed outer conductor shield of the electrical cable, preferably by crimping or pressing.

[0095] After the outer conductor shield has been folded over the support sleeve, any existing cable foil and any optional dielectric filler material can be stripped and removed from the electrical cable to expose the individual inner conductors or cable cores, which at this point are usually still separately insulated.

[0096] The cable insulation can then be stripped, exposing the ends of the cable conductors. Subsequently, one inner conductor of the connector can be connected to the cable conductors, preferably by crimping or pressing.

[0097] Subsequently, the cable can be inserted into the outer conductor element up to a predetermined axial end position as part of the further cable assembly process. This predetermined end position can be defined, for example, by a stop area within the outer conductor element, such as an internal shoulder or at least a rib projecting into the interior of the outer conductor element. A tapered section within the outer conductor element can also be provided, corresponding to a tapered end section of the support sleeve on the connector or cable side.

[0098] If necessary, the axial position of the support sleeve within the outer conductor element can additionally be detected by means of a sensor device in order to determine the position of a deformation tool (in particular crimping tool) for fastening the outer conductor element to the support sleeve.

[0099] After the outer conductor element has been attached, preferably by crimping or pressing, to the support sleeve, the electrical cable, pre-assembled up to this point, can be inserted into the plastic housing of the electrical connector until the outer conductor element reaches a predetermined axial end position within the plastic housing and, for example, engages in a primary locking mechanism. A secondary locking mechanism can then optionally be engaged.

[0100] The above procedure is merely an example. The order of the individual steps may differ or be supplemented.

[0101] The axial position of the support sleeve within the outer conductor element can be determined by the sensor device, taking into account the axial position of the outer conductor element. In particular, if the outer conductor element has a stop area for the support sleeve, the relative axial position of the support sleeve within the outer conductor element may be known in advance. The absolute axial position, for example within a device for assembling an electrical cable, can then be easily calculated by the sensor device, if necessary.

[0102] The sensor device may also include one or more sensors to detect the axial position of the support sleeve within the outer conductor element.

[0103] Furthermore, it should be mentioned that features described in connection with the pre-assembled electrical cable can, of course, also be advantageously implemented for the connector arrangement and method according to the invention – and vice versa. Furthermore, advantages already mentioned in connection with the pre-assembled electrical cable can also be understood as relating to the connector arrangement and method according to the invention – and vice versa.

[0104] It should also be noted that terms such as "comprehensive," "exhibiting," or "with" do not exclude other characteristics or steps. Furthermore, terms such as "a" or "the," which indicate a singular number of steps or characteristics, do not exclude a plurality of characteristics or steps—and vice versa.

[0105] In a purist embodiment of the invention, however, it may also be provided that the features introduced in the invention with the terms "comprising," "comprising," or "with" are exhaustively listed. Accordingly, one or more lists within the scope of the invention may be considered complete, for example, one for each patent claim. The invention may, for instance, consist exclusively of the features mentioned in patent claim 1.

[0106] Furthermore, it should be emphasized that the values ​​and parameters described herein include deviations or fluctuations of ±10% or less, preferably ±5% or less, more preferably ±1% or less, and most preferably ±0.1% or less of the respective named value or parameter, provided that such deviations are not excluded in the practical implementation of the invention. The specification of ranges by initial and final values ​​also includes all those values ​​and fractions that are encompassed by the respective named range, in particular the initial and final values ​​and a respective mean value.

[0107] Exemplary embodiments of the invention are described in more detail below with reference to the drawing.

[0108] The figures each show preferred embodiments in which individual features of the present invention are combined with one another. Features of an embodiment can also be implemented independently of the other features of the same embodiment and can therefore be readily combined by a person skilled in the art to form further meaningful combinations and subcombinations with features of other embodiments.

[0109] In the figures, functionally identical elements are provided with the same reference symbols.

[0110] They show schematically: Figure 1: A stamped and bent part preformed into a support sleeve with two support areas, shown in perspective; Figure 2: The support sleeve of the Figure 1 after a crimping process in the area of ​​the cable end in perspective view; Figure 3 the support sleeve of the Figure 2in a top view of the cable end; Figure 4 a pre-assembled electrical cable with the support sleeve attached to an outer conductor shield according to Figure 2 and an outer conductor element of an electrical connector attached to the support sleeve in a perspective longitudinal section; Figure 5 the pre-assembled electrical cable of the Figure 4 in perspective view with a partially cut-out outer conductor element; Figure 6 the pre-assembled electrical cable of the Figure 4 in perspective view; Figure 7 the pre-assembled electrical cable of the Figure 4 in a top view of the plug-side end of the support sleeve; Figure 8 the support sleeve and the outer conductor element of the Figure 4 in a lateral sectional view without the electrical cable; Figure 9 the support sleeve and the outer conductor element of the Figure 8in perspective sectional view; Figure 10 a support sleeve according to a second embodiment of the invention with only one support area in perspective view; Figure 11 the support sleeve of the Figure 10 Figure 12 shows a support sleeve according to a third embodiment of the invention with two conical end sections in a side view; Figure 13 shows a connector arrangement according to the invention; Figure 14 shows a method according to the invention for assembling an electrical cable; and Figure 15 shows a device for assembling an electrical cable.

[0111] Figure 1 shows a stamped and bent part pre-formed to form a support sleeve 1 for attachment to an outer conductor shield 2 (see, for example, Figure 5 ) of an electrical cable 3. The support sleeve 1 has a plug-side end 4 and a cable-side end 5.

[0112] The support sleeve 1 has a cable-side end section 6 which is designed such that it is formed by a deformation process, exemplified below by a crimping process (indicated by arrows in Figure 1 (as indicated) is deformable in such a way that the cable-side end section 6 tapers towards the cable-side end 5 after the crimping process, as shown in Figure 2 is shown. Figure 3 Figure 1 shows a top view of the cable-side end 5 of the support sleeve 1. The crimping process mentioned can be provided in particular within the framework of the cable assembly described below, preferably for attaching the support sleeve 1 to the outer conductor shield 2 of the electrical cable 3 and / or within the framework of attaching an outer conductor element 7, which will be described below, to the support sleeve 1.

[0113] To create the taper towards the cable-side end 5, the cable-side end section 6 of the support sleeve 1 has two notches 8 extending axially (along the central axis or longitudinal axis L) from the cable-side end 5 through the cable-side end section 6. In principle, any number of notches 8 can be provided, including one or more than two, for example, three, four, five, or even more. The cable-side end section 6 of the support sleeve 1 can also be designed in the form of a spring-loaded cage.

[0114] The cable-side end section 6 of the support sleeve 1 extends over an axial length that corresponds to at least 5% of the total length of the support sleeve 1, preferably at least 10% of the total length of the support sleeve 1, particularly preferably at least 20% of the total length of the support sleeve 1, most preferably at least 40% of the total length of the support sleeve 1, further preferably at least 50% of the total length of the support sleeve 1, and even more preferably at least 60% of the total length of the support sleeve 1.

[0115] The cable-side end section 6 of the support sleeve 1 tapers towards the cable-side end 5 such that the cable-side end 5 has an oval or elliptical cross-section, as shown in the exemplary embodiment (see in particular Figure 3 ).

[0116] The examples in the Figures 1 to 9The support sleeve 1 shown has two support areas 9, 11. A first support area 9 is provided, which is arranged adjacent to the plug-side end 4 and has two U-shaped half-shells 10 in cross-section, the openings of which are arranged opposite each other (see in particular the Figures 5 and 7 A second support area 11 is formed adjacent to the cable-side end 5 and has a round or oval cross-section. The first support area 9 is connected to the second support area 11 by means of two axial webs 30. In principle, the first support area 9 can also be omitted, as shown in the embodiments of Figures 10 and 11 is shown.

[0117] The Figures 4 to 9 Figure 1 shows a pre-assembled electrical cable 3. The electrical cable 3 has, by way of example, two inner conductors 12 or cable cores (see in particular the figure 1). Figures 5 to 7), each of which is encased in a dielectric 13 and preferably runs in a twisted axial direction through the electrical cable 3. Optionally, the inner conductors 12, each individually provided with the dielectrics 13, can be guided together in an insulating material 14 (also referred to as "filler"). The inner conductors 12, insulated with their respective dielectrics 13, are surrounded by a cable foil (also referred to as "shielding foil"), around which the outer conductor shield 2 is arranged. The cable jacket 15 is arranged around the outer conductor shield 2 (see figure). Figure 13 ). The illustrated pre-assembled electrical cable 3 is partially stripped at the cable end to be processed in order to allow access to the inner conductors 12 and the outer conductor shield 2 for cable assembly.

[0118] The pre-assembled electrical cable 3 has a support sleeve 1 attached to the outer conductor shield 2. The outer conductor shield 2 is preferably folded back over the support sleeve 1. The routing of the outer conductor shield 2 is shown by way of example in Figure 8 indicated, with electrical cable 3 hidden for simplicity.

[0119] The pre-assembled electrical cable 3 also includes an outer conductor element 7 of an electrical connector 16 (see figure). Figure 13 ) which is attached to the support sleeve 1, preferably crimped. As is particularly well done in the Figures 8 and 9As can be seen, the outer conductor element 7 has at least one stop area for at least one end-face stop 17 of the support sleeve 1. In the exemplary embodiment, the stop area is designed as an internal shoulder 18. Several shoulders 18 for several stops 17 of the support sleeve 1 can also be provided, as shown. In principle, at least one web projecting into the interior of the outer conductor element 7 can also be provided to form the at least one stop area. The support sleeve 1 can thus abut positively against the shoulders 18 or against the stop area of ​​the outer conductor element 7.

[0120] Furthermore, the outer conductor element 7 has a crimp area (indicated by two arrows in Figure 8(indicated), to crimp the outer conductor element 7 to the cable-side end section 6 of the support sleeve 1. The outer conductor shield 2 can be squeezed between the support sleeve 1 and the outer conductor element 7. The cable-side end section 6 of the support sleeve 1 is preferably designed as a crimp area for attaching the support sleeve 1 to the outer conductor shield 2 and / or for attaching the outer conductor element 7 to the support sleeve 1.

[0121] Due to the tapered design of the cable-side end section 6 of the support sleeve 1, a sufficiently stable and electrically suitable connection between the outer conductor element 7 and the support sleeve 1 can be achieved even if the crimping tool is positioned inaccurately (e.g. due to tolerances).

[0122] Due to the advantageous combination of the inner shoulder(s) 18 of the outer conductor element 7 and the tapered cable-side end section 6 of the support sleeve 1, which advantageously interacts with the crimp area of ​​the outer conductor element 7, a positive-locking connection can be formed between the support sleeve 1 and the outer conductor element 7. This advantageously avoids air inclusions and allows the outer conductor shield 2 to run advantageously between the outer conductor element 7 and the support sleeve 1. According to the invention, a particularly good mechanical connection and an optimized electrical connection, especially without impedance discontinuities, can be provided.

[0123] As especially in the Figures 4 to 6As can be seen, the first support area 9 of the support sleeve 1 is particularly well suited for crimping to the two inner conductors 12 of the electrical cable 3, which have an elongated or oval / elliptical cross-section. The second support area 11, on the other hand, is advantageously suited for connection to the predominantly round outer conductor element 7.

[0124] In the Figures 10 and 11 An alternative support sleeve 1 is shown in which a first support area 9 is omitted. The invention is also advantageously suitable for use with a support sleeve 1 having only one support area 11. An exemplary routing of the outer conductor shield 2 is indicated in Figure 11.

[0125] Another embodiment of a support sleeve 1 according to the invention is described in Figure 12 depicted. The in Figure 12The support sleeve 1 shown has a connector-side end section 19 that tapers towards the connector-side end 4 of the support sleeve 1. A central section 20 runs between the connector-side end section 19 and the cable-side end section 6. However, the two end sections 4 and 19 can also be arranged adjacent to each other. A corresponding outer conductor element 7 can preferably have two crimp areas for crimping to the cable-side end section 6 and / or to the connector-side end section 19 of the support sleeve 1. In this way, a suitable positive connection between the outer conductor element 7 and the support sleeve 1 can also be created.

[0126] Figure 13Figure 1 shows a connector assembly 21 comprising the electrical cable 3 and an electrical connector 16 to be connected to the cable end shown. The electrical connector 16 has a plastic housing 22 (shown only as an example) into which the previously described outer conductor element 7 can be inserted and locked. For this purpose, a primary locking mechanism (not shown) and optionally a secondary locking mechanism 23 for locking the primary locking mechanism can be provided. The plastic housing can have locking means 24 for locking with a complementary mating connector (not shown). The inner conductor(s) 12 of the electrical cable 3 are connected to inner conductor contacts 25 of the connector 16, in particular by crimping. The previously described support sleeve 1 is attached to the outer conductor shield 2 of the electrical cable 3.The outer conductor shield 2 is further folded back over the support sleeve 1 (only partially shown for better illustration).

[0127] A method for assembling an electrical cable 3 according to the present invention is described in Figure 14 As indicated, in a first process step S1, a support sleeve 1 having a connector-side end 4 and a cable-side end 5 is attached to the outer conductor shield 2 of an electrical cable 3. In a second process step S2, the outer conductor shield 2 is then folded back over the support sleeve 1.

[0128] According to a third process step S3, an outer conductor element 7 of an electrical connector 16 is then pushed axially over the support sleeve 1 and crimped onto the support sleeve 1. .

[0129] Of course, further process steps not shown may also be included in the assembly of the electrical cable 3.

[0130] The method can be implemented as a computer program product using program code means on a control device 26 of a device 27 for the assembly of an electrical cable 3.

[0131] A device 27 for assembling an electrical cable 3, which is only to be understood as an example and in a highly schematic form, is shown in Figure 15 The device 27 has a sensor device 28 for detecting the axial position of the support sleeve 1 arranged within the outer conductor element 7 of the electrical connector 16 and attached to the outer conductor shield 2 of the electrical cable 3.

[0132] The device 27 further comprises an axially positionable deformation tool (hereinafter referred to as a crimping tool 29) and the control device 26 for determining a predetermined axial crimp position for the crimping tool 29. The control device 26 is preferably configured to determine the crimp position based on the axial position of the support sleeve 1 detected by means of the sensor device 28, such that the outer conductor element 7 can be crimped on the support sleeve 1 by means of the crimping tool 29, at least in the area of ​​a cable-side end section 6 that tapers towards the cable-side end 5 of the support sleeve 1.

Claims

1. A prefabricated electric cable (3), having an outer conductor shield (2), a support sleeve (1), attached to the outer conductor shield (2), and an outer conductor element (7) of an electrical connector (16), which is attached to the support sleeve (1), wherein the support sleeve (1) has a connector-side end (4) and a cable-side end (5), and wherein the support sleeve (1), in a cable-side end portion (6), tapers conically in the direction of the cable-side end (5), wherein the outer conductor element (7) has at least one deformation region for swaging the outer conductor element (7) to the cable-side end portion (6) of the support sleeve (1), and wherein the cable-side end portion (6) of the support sleeve (1) is deformed by a deforming process in such a way that the cable-side end portion (6) tapers conically in the direction of the cable-side end (5) in such a way that the cable-side end (5) has an oval or elliptical profile, and wherein the cable-side end portion (6) of the support sleeve (1) has an incision (8), preferably two incisions (8) or more incisions (8) which, starting from the cable-side end (5), extend in the axial direction through the cable-side end portion (6).

2. The prefabricated electric cable (3) as claimed in claim 1, characterized in that the cable-side end portion (6) of the support sleeve (1) is designed as a deformation region for attaching the support sleeve (1) to the outer conductor shield (2).

3. The prefabricated electric cable (3) as claimed in claim 1 or 2, characterized in that the cable-side end portion (6) of the support sleeve (1) extends over an axial length which corresponds to at least 5 % of the total length of the support sleeve (1), preferably corresponds to at least 10 % of the total length of the support sleeve (1), particularly preferably corresponds to at least 20 % of the total length of the support sleeve (1), especially preferably corresponds to at least 40 % of the total length of the support sleeve (1), further preferably corresponds to at least 50 % of the total length of the support sleeve (1) and even further preferably corresponds to at least 60 % of the total length of the support sleeve (1).

4. The prefabricated electric cable (3) as claimed in one of claims 1 to 3, characterized in that the support sleeve (1), adjacent to the connector-side end (4), forms at least one end face which can be used as a stop (17).

5. The prefabricated electric cable (3) as claimed in one of claims 1 to 4, characterized in that the support sleeve (1), in a connector-side end portion (19), tapers in the direction of the connector-side end (4).

6. The prefabricated electric cable (3) as claimed in one of claims 1 to 5, characterized in that the outer conductor shield (2) is folded back over the support sleeve (1).

7. The prefabricated electric cable (3) as claimed in one of claims 1 to 6, characterized in that the support sleeve (1) has two support regions (9, 11); a first support region (9), which is arranged adjacent to the connector-side end (4) and has two half shells (10), which are substantially U-shaped in cross-section and are arranged with their openings opposite one another; and a second support region (11), which is formed adjacent to the cable-side end (5) and has a circular or oval cross-section.

8. The prefabricated electric cable (3) as claimed in in one of claims 4 to 7, characterized in that the outer conductor element (7) forms at least one stop region for the at least one end-face stop (17) of the support sleeve (1), preferably an internal shoulder (18) or at least one web projecting into the interior of the outer conductor element (7).

9. A connector arrangement (21), comprising a prefabricated electric cable (3) according to one of claims 1 to 8 and a connector (16) connected to at least one cable end.

10. A method for fabricating an electric cable (3), according to which a support sleeve (1) having a connector-side end (4) and a cable-side end (5) is attached to an outer conductor shield (2) of an electric cable (3), according to which the outer conductor shield (2) is folded back over the support sleeve (1), and according to which an outer conductor element (7) of an electrical connector (16) is pushed axially over the support sleeve (1) and swaged to the support sleeve (1), wherein the outer conductor element (7) has at least one deformation region at which it is swaged to the support sleeve (1), at least in the region of a cable-side end portion (6) which tapers in the direction of the cable-side end (5) of the support sleeve (1), wherein the tapering cable-side end portion (6) is formed from an originally sleeve-shaped support sleeve (1) in that the support sleeve (1) is conically deformed during the crimping of the outer conductor element (7) to the support sleeve (1) in such a way that the cable-side end (5) has an oval or elliptical profile, and wherein the cable-side end portion (6) of the support sleeve (1) has an incision (8), preferably two incisions (8) or more incisions (8) which, starting from the cable-side end (5), extend in the axial direction through the cable-side end portion (6).

11. The method as claimed in claim 10, characterized in that the support sleeve (1) is made from a punched and bent part.

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