Assembled electric cable and plug connector arrangement

Abstract

The invention relates to a pre-assembled electrical cable (2) for an electrical connector (3), comprising an electrical conductor (8) designed as a stranded wire consisting of several individual wires, and having at least one plate-shaped compacted end section (10). The pre-assembled electrical cable (2) is provided to have an elongated contact element (11) with at least one side surface forming a first connecting surface (12) connected to the compacted end section (10) of the electrical conductor (8), and with at least one further side surface facing away from the first connecting surface (12) forming a first contact surface (13) for contacting a mating contact surface (14) of a mating contact element (7) of a mating connector (5).

Description

[0001] The invention relates to a prefabricated electrical cable for an electrical connector, comprising an electrical conductor which is designed as a stranded wire comprising several individual wires, according to the preamble of claim 1.

[0002] The invention also relates to a connector assembly comprising a pre-assembled electrical cable and an electrical connector.

[0003] During cable assembly, the ends, particularly the ends of their inner conductors, are prepared for installation in an electrical connector. During this process, the electrical conductors are often cut to a defined length, stripped, and provided with one or more contact elements. For example, during cable assembly, a contact element of the subsequent connector can be electrically and mechanically connected to an electrical conductor routed within a cable sheath and later mounted in a connector housing of the connector. The fully assembled contact element can then be used within the connector to contact a mating contact element of a mating connector.

[0004] Various electrical connectors are known in electrical engineering. Electrical connectors are known to transmit electrical supply signals and / or data signals to the corresponding mating connectors. Within the scope of the invention, a connector or mating connector can be a plug, a panel connector, a socket, a coupling, or an adapter. The terms "connector" and "mating connector" used within the scope of the invention represent all variants.

[0005] Connectors and electrical cables for the automotive industry and vehicles, in particular, are subject to stringent requirements regarding their robustness and the reliability of their connections. Electromobility, in particular, poses major challenges for the automotive industry and its suppliers, as high electrical power must be transmitted via the cables and connectors in vehicles. The thermal load and the resulting waste heat associated with the high current flow are significant. Therefore, to reduce heat loss, the contact resistance between the electrical conductor of the cable and the contact element, as well as between the contact element of the connector and the mating contact element of the mating connector, should be as low as possible.

[0006] High-voltage connectors are used in the automotive sector, primarily in electric and / or hybrid vehicles, to supply a vehicle battery with charging current, to extract the stored energy from the battery and supply it to an electrical consumer, or to connect several batteries or battery modules to each other.

[0007] In addition to secure and preferably low-resistance electrical connections within the connector and at the transition to the mating connector, a high-voltage connector must also be easy and cost-effective to manufacture due to its mass production capability. Furthermore, the connector, especially a high-voltage connector or a connector for transmitting safety-relevant control signals, should be mechanically robust and reliably protected against accidental opening.

[0008] The connection between a high-voltage cable and a high-voltage connector is typically made via a contact blade, which is mechanically connected to the electrical conductor of the electrical cable. However, attaching the contact blade to the electrical conductor is comparatively complex and costly. Furthermore, the resulting contact resistance is often not ideal.

[0009] As an alternative to a welded contact blade, it is also known to form a plate-shaped contact with an electrical conductor formed as a stranded wire composed of several individual wires in a contact area for contacting a mating contact element of a mating connector. The electrical conductor can thus itself serve as a contact element. However, the compaction of the stranded wire is comparatively susceptible to tolerances and therefore generally leads to a more or less uneven contact surface, which can impair the electrical and mechanical connection with the mating contact element of the mating connector. Furthermore, with a contact element formed as a compacted stranded wire, it is complex to provide suitable locking means for locking it to the connector housing.

[0010] In view of the known state of the art, the object of the present invention is to provide a prefabricated electrical cable which is preferably suitable for transmitting high electrical currents with low contact resistance and which is particularly suitable for mass production but can nevertheless be produced with high precision.

[0011] Finally, it is also an object of the invention to provide a connector arrangement whose electrical connector is preferably suitable for transmitting high electrical currents with low contact resistance, and which is particularly suitable for mass production but can nevertheless be manufactured with high precision.

[0012] The object is achieved for the prefabricated electrical cable with the features listed in claim 1. With regard to the connector assembly, the object is achieved by the features of claim 15. The dependent claims and the features described below relate to advantageous embodiments and variants of the invention.

[0013] A pre-assembled electrical cable for an electrical connector is provided. The pre-assembled electrical cable comprises an electrical conductor formed as a stranded wire composed of several individual wires and having at least one plate-shaped compacted end section.

[0014] The thickness of the plate-shaped compacted end section can be much smaller than the width and length of the plate-shaped compacted end section.

[0015] The electrical cable can, in particular, be a high-voltage cable or a high-voltage line for automotive technology for transmitting high currents, for example, with voltages of 1,500 volts or more. The prefabricated electrical cable according to the invention can be used particularly advantageously in electrically powered vehicles, for example, in electric vehicles or hybrid vehicles.

[0016] The pre-assembled electrical cable may have a cable sheath enclosing the electrical conductor. In this case, the electrical conductor may be exposed (stripped) from the cable sheath in the region of its end section.

[0017] In principle, the pre-assembled cable can have any number of electrical conductors, for example one inner conductor, two or more inner conductors, three or more inner conductors, four or more inner conductors, five or more inner conductors. Optionally, an outer conductor can also be provided. The invention is described below essentially with reference to a pre-assembled electrical cable that has exactly one inner conductor. However, this is not to be understood as limiting. The inner conductor(s) can be arranged coaxially to the central axis of the cable. However, the inner conductor(s) can also be arranged evenly distributed around the central axis of the cable.

[0018] Preferably, the prefabricated electrical cable has exactly one inner conductor that runs within the cable sheath. Shielding can optionally be provided, for example, a cable shield braid and / or a cable foil spaced from the inner conductor by a dielectric material.

[0019] According to the invention, the prefabricated electrical cable has an elongated contact element (the length of the contact element can therefore be greater than the width along a longitudinal axis), with at least one side surface which forms a first connection surface which is connected to the compacted end section of the electrical conductor, and with at least one further side surface facing away from the first connection surface, which forms a first contact surface for contacting a mating contact surface of a mating contact element of a mating connector.

[0020] Because the stranded wire is compacted in a plate-like manner, a particularly good electrical connection to the contact element can be achieved, especially since the contact surface between the electrical conductor and the contact element is particularly large. The contact element can be manufactured with high precision, for example, with a precisely defined size and geometry of the contact surface, which can have a significantly better surface quality compared to the corresponding side surface of the plate-like compacted end section. Furthermore, the contact element can cover protruding individual wires that have not been sufficiently compacted.The combination of a compacted end section of a stranded wire with a contact element attached thereto proposed according to the invention combines the advantages of the high current transferability associated with the compaction of the stranded wire with the advantages of a contact surface that can be produced with particular precision by means of a separate contact element.

[0021] The connection between the contact area and the electrical conductor can be robust and low-resistance and therefore suitable for transmitting particularly high currents.

[0022] The contact surface and / or the counter-contact surface can preferably each be a completely continuous surface. However, several individual contact surfaces and / or counter-contact surfaces can also be provided.

[0023] In an advantageous development of the invention, the contact element can be designed as a contact plate. The thickness of the contact plate can be, for example, 0.1 mm to 2.0 mm, preferably 0.3 mm to 1.0 mm, particularly preferably 0.4 mm to 0.6 mm.

[0024] In particular, the use of a contact plate can represent a particularly cost-effective solution. The plate-like compaction of the electrical conductor, on the one hand, and the use of a contact plate, on the other, enable maximum material savings while simultaneously achieving extremely precise manufacturing and sufficient dimensional stability.

[0025] In an advantageous manner, the installation space requirement for the contact area of ​​the prefabricated electrical cable can also be reduced.

[0026] The contact element can also be designed as a contact plate. In particular, the use of several contact plates distributed over the plate-shaped, compacted end section can also be provided.

[0027] In principle, any contact element can be designed. However, it is particularly preferred that the contact element not be designed as a contact sleeve.

[0028] The contact element, in particular the contact plate, can be formed as a single piece, for example, as a stamped and bent part. However, the contact plate can also be deep-drawn or manufactured in some other way. Preferably, however, the contact plate is manufactured as a stamped and bent part.

[0029] According to a further development of the invention, it can be provided that the contact element and the individual wires of the electrical conductor are made of the same material.

[0030] Preferably, the contact element and / or the individual wires of the electrical conductor are made of aluminum or copper. In principle, however, any material suitable for transmitting high currents can be used.

[0031] According to a further development of the invention, the contact element can be provided with a coating. Preferably, a silver coating is provided. The contact element can preferably be coated by strip electroplating.

[0032] A coating can further improve the contact resistance. For example, if the contact element is made of aluminum, this can sometimes be prone to oxidation in the area of ​​the contact surface. This can be prevented by a coating, such as silver.

[0033] The contact surface is preferably a planar, flat surface. However, the first contact surface can also be curved or round. A curved first contact surface can be particularly suitable for contacting the contact lamellae mentioned below or for forming the contact lamellae.

[0034] In a further development of the invention, it can be provided that further side surfaces of the contact element form respective further connecting surfaces, wherein the contact element preferably has a total of two to five connecting surfaces which are each connected to the compacted end section of the electrical conductor.

[0035] For example, in addition to the first connecting surface, a second connecting surface, a third connecting surface, a fourth connecting surface, and / or a fifth connecting surface may be provided. Preferably, each of the connecting surfaces is connected to a different corresponding side surface of the compacted end section.

[0036] Insofar as two connecting surfaces (e.g. the first connecting surface and the second connecting surface) are provided, the contact element can preferably be folded over an edge of the plate-shaped compacted end section.

[0037] Insofar as three connecting surfaces (e.g. the first connecting surface, the second connecting surface and the third connecting surface) are provided, the contact element can be folded over two edges of the compacted end section, in particular be U-shaped.

[0038] Insofar as four connecting surfaces (e.g. the first connecting surface, the second connecting surface, the third connecting surface and the fourth connecting surface) are provided, the contact element can, for example, be folded over three edges of the compacted end section.

[0039] It can also be provided that a connecting surface of the contact element is connected to an end face of the plate-shaped compacted end section or is folded over an edge of the end face.

[0040] By using multiple connecting surfaces, the contacting options can be increased, for example, additional contact surfaces can be provided for contacting one or more mating contact elements and / or an improved sheathing of the compacted end section can be provided, for example to cover protruding individual wires.

[0041] In a further development of the invention, it can be provided that the at least one connecting surface is aligned parallel to a corresponding side surface of the compacted end section to which the connecting surface is connected.

[0042] Preferably, the at least one connecting surface is fully connected to the corresponding side surface of the compacted end section.

[0043] A parallel alignment of the connection surface to the corresponding side surface, in particular a full-surface connection, can further reduce the contact resistance and enable the transmission of even higher currents.

[0044] Preferably, the contact surfaces are arranged parallel to their corresponding connecting surfaces.

[0045] In an advantageous development of the invention, it can be provided that the at least one connecting surface is materially connected to the compacted end section.

[0046] A bonded connection between the connecting surface and the compacted end section can enable particularly low contact resistance. Furthermore, the compacted end section and the contact element can be connected particularly robustly in this way. Corrosion of the transition area between the contact element and the electrical conductor can also be prevented, especially if the bonded connection is a gas-tight bonded connection.

[0047] A screw connection, rivet connection or crimp connection between the electrical conductor and the contact element can preferably be dispensed with within the scope of the invention.

[0048] The electrical conductor can preferably be permanently connected to the contact element, whereby the electrical conductor can no longer be removed from the contact element without causing damage. In particular, the aforementioned gas-tight connection can be provided between the connecting surface of the contact element and the corresponding side surface of the plate-shaped, compacted end section.

[0049] In a further development of the invention, it can be provided that the at least one connecting surface completely covers a corresponding side surface of the compacted end section to which the connecting surface is connected.

[0050] In this way, the contact area for contacting the mating contact surface of the mating contact element can be enlarged. Furthermore, protruding individual wires can be fully covered.

[0051] In an advantageous development of the invention, it can be provided that a further side surface of the contact element forms a second contact surface for contacting a mating contact surface of a mating contact element of a mating connector.

[0052] In principle, further contact surfaces can also be provided, for example a third contact surface, a fourth contact surface and / or a fifth contact surface.

[0053] In particular, the use of two contact surfaces, which in the case of the connected state of the contact element with the plate-shaped compacted end section are arranged on opposite sides of the compacted end section, can be advantageous for contacting with the mating connector, for example in order to enable a two-sided, pincer-like contact.

[0054] In an advantageous development of the invention, it can be provided that the at least one contact surface of the contact element is designed as a primarily flat surface for surface contact with the counter contact surface.

[0055] In this way, a contact element can be designed in the manner of a contact blade, in combination with the advantages according to the invention.

[0056] In an advantageous development of the invention, it can also be provided that the at least one contact surface of the contact element has one or more contact lamellas which are at least partially elastic in the contacting direction for contacting the counter contact surface.

[0057] The use of contact lamellas can increase the contact force with the mating contact element and thus improve current transfer. As an alternative to the use of contact lamellas, the contact surface can, in principle, have any rigid and / or elastic projections on the contact surface (e.g., ribs). In the simplest case, however, a flat contact can be provided, i.e., the contact surface can be completely flat or level.

[0058] The contact blades can, for example, be punched out of the contact surface of the contact element. However, the contact blades can also be attached individually or in groups to the contact surface of the contact element. The use of a separate contact blade element, which is inserted between the contact surface and the mating contact surface and is optionally fixed in the connector, on the pre-assembled cable, in the mating connector, or on the mating contact element, can also be advantageous.

[0059] In an advantageous development of the invention, it can be provided that at least one of the contact surfaces or that the at least one contact surface each has at least one first locking means for locking with a corresponding second locking means of the plug connector or plug connector housing in order to provide a mutual locking between the pre-assembled cable and the plug connector or plug connector housing when the pre-assembled cable is mounted in the plug connector or plug connector housing.

[0060] The locking means can increase the holding force of the assembled pre-assembled cable in the connector and advantageously provide primary and / or secondary locking.

[0061] In principle, any number of first locking means and corresponding second locking means can be provided.

[0062] In a further development, the first locking means can be designed as a spring tab punched out of the contact surface. The connector, in particular the connector housing of the connector, can have a corresponding locking recess or a corresponding locking lug into or behind which the spring tabs can engage when the assembled cable is in the assembled state.

[0063] In a further development, alternatively or additionally, the first locking means can be designed as a locking lug or locking hook formed on the contact surface. The connector, in particular the connector housing of the connector, can have an elastic spring tab that can lock behind the locking lug or locking hook when the assembled cable is in place.

[0064] In a further development, alternatively or additionally, the first locking means can be designed as a locking recess within the contact surface. The connector, in particular the connector housing of the connector, can have an elastic spring tab that can lock behind the locking lug or behind the locking hook when the assembled cable is in the assembled state.

[0065] The aforementioned configurations and combinations of locking means are merely examples. In principle, any locking means can be provided that, in combination, enable suitable locking between the pre-assembled electrical cable and the connector or connector housing.

[0066] Optionally, but not preferred, the contact element can also have locking elements for locking with the mating contact element and / or mating connector. However, the connector housing can be lockable with a mating connector housing of the mating connector.

[0067] In one embodiment of the invention, it can be provided that the contact element has additional functional elements. For example, the at least one contact surface can have at least one coding element, for example a coding element punched out of the contact surface, to provide mechanical coding between the contact element and a counter-coding element of the connector or connector housing. In this way, it can be ensured that only a contact element or pre-assembled electrical cable approved for connection to the connector can be mounted in the connector or connector housing, and / or that the mounting is carried out with correct alignment and positioning.

[0068] According to a further development of the invention, it can be provided that the electrical conductor has a conductor cross-section greater than 10 mm 2<, preferably greater than 30 mm 2<, particularly preferably greater than 60 mm 2<, for example greater than 90 mm 2< or even greater than 200 mm 2<. In particular, a conductor cross-section can be provided which is suitable for electrical energy transmission in high-voltage technology, i.e. for transmitting high electrical currents (for example 100 A to 2 kA) at alternating voltages of 30 V to 1 kV or more or direct voltages of 60 V to 1.5 kV or more, in particular in automotive technology.

[0069] In an advantageous development of the invention, it can be provided that the individual wires of the electrical conductor are welded together in order to form the plate-shaped compacted end section

[0070] Preferably, the individual wires can be pressure-welded, resistance-welded, or fusion-welded. However, any material-bonded joining technique is possible.

[0071] The invention also relates to a connector assembly comprising a prefabricated electrical cable according to the above and following embodiments and the electrical connector.

[0072] The plate-shaped, compacted end section can be accommodated within the connector, preferably within a connector housing of the connector. The connector housing can, in particular, be a plastic housing, preferably made of a rigid plastic or hard plastic. The connector housing can preferably be manufactured by means of an injection molding process or a deep-drawing process. The connector housing can be provided as a single-piece or, preferably, as a multi-piece. The connector housing can be designed to provide contact protection for the conductive components of the connector.

[0073] The proposed electrical connector is particularly advantageously suited as a high-voltage connector, especially for use in electromobility. The electrical connector can advantageously provide, for example, a cell module connector interface for connecting battery cell modules, with a particularly advantageous contact design.

[0074] The prefabricated electrical cable can advantageously be used as a busbar replacement. By compacting the stranded wire in combination with the application of the contact element, in particular a contact plate, a particularly economical yet high-quality contacting option can be provided. The contact element can have a smooth, precisely manufactured contact surface, whereby the contact resistance between the electrical conductor and the contact element can be particularly low due to the compaction of the stranded wire. In this way, the contact can also be particularly robust and can absorb high cable tensile forces, for example, tensile forces greater than 100 N.

[0075] It can be provided that the connector has one or more spring elements which are designed and arranged to generate a contact pressure between at least the first contact surface and the corresponding mating contact surface of the mating contact element when the connector is connected to the mating connector.

[0076] The invention also relates to a method for assembling an electrical cable, comprising at least the following method steps: Plate-shaped compaction of an electrical conductor formed as a stranded wire comprising a plurality of individual wires in an end portion of the electrical conductor; and connecting an elongated contact element to the plate-shaped compacted end portion by connecting at least one side surface of the contact element facing away from a first contact surface, which forms a first connecting surface, to the compacted end portion of the electrical conductor.

[0077] Furthermore, the invention relates to a device for assembling an electrical cable for carrying out the above-mentioned method.

[0078] Features described in connection with one of the subject matters of the invention, specifically the prefabricated electrical cable, the connector assembly, and the method and device for assembly according to the invention, can also be advantageously implemented for the other subject matters of the invention. Likewise, advantages mentioned in connection with one of the subject matters of the invention can also be understood to apply to the other subject matters of the invention.

[0079] It should also be noted that terms such as "comprising," "having," or "with" do not exclude other features or steps. Furthermore, terms such as "a" or "the," which indicate a singular number of steps or features, do not exclude a plurality of features or steps—and vice versa.

[0080] In a purist embodiment of the invention, however, it may also be provided that the features introduced in the invention with the terms "comprising," "having," or "with" are listed exhaustively. Accordingly, one or more lists of features may be considered complete within the scope of the invention, for example, for each claim. The invention may, for example, consist exclusively of the features mentioned in claim 1.

[0081] It should be noted that terms such as "first" or "second" etc. are used primarily for reasons of distinguishing between respective device or process features and are not necessarily intended to indicate that features are mutually dependent or related to one another.

[0082] 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 specified value or parameter, provided that these 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 enclosed by the respective specified range, in particular the initial and final values ​​and a respective mean value.

[0083] The applicant explicitly reserves the right to claim one or more of the following subject-matter separately and / or in combination with the features mentioned above and below in the present description: 1. Assembled electrical cable (2) for an electrical connector (3), comprising an electrical conductor (8) which is designed as a stranded wire made up of several individual wires and which has at least one plate-shaped compacted end section (10), characterized by an elongated contact element (11) having at least one side surface forming a first connecting surface (12) connected to the compacted end portion (10) of the electrical conductor (8), and at least one further side surface facing away from the first connecting surface (12) forming a first contact surface (13) for contacting a mating contact surface (14) of a mating contact element (7) of a mating connector (5). 2. Assembled electrical cable (2) according to item 1, characterized bythat the contact element is designed as a contact plate (11), preferably with a thickness between 0.3 mm and 1.0 mm, particularly preferably with a thickness between 0.4 mm and 0.6 mm. 3. Assembled electrical cable (2) according to item 1 or 2, characterized by that the contact element (11) and the individual wires of the electrical conductor (8) are made of the same material, preferably aluminum or copper. 4. Assembled electrical cable (2) according to one of the items 1 to 3, characterized by that the contact element (11) has a coating, preferably a silver coating. 5. Assembled electrical cable (2) according to one of the items 1 to 4, characterized bythat further side surfaces of the contact element (11) form respective further connecting surfaces (15, 17, 18, 19), wherein the contact element (11) preferably has a total of two to five connecting surfaces (12, 15, 17, 18, 19), which are each connected to the compacted end section (10) of the electrical conductor (8). 6. Assembled electrical cable (2) according to one of the items 1 to 5, characterized by that the at least one connecting surface (12, 15, 17, 18, 19) is aligned parallel to a corresponding side surface of the compacted end section (10), to which the connecting surface (12, 15, 17, 18, 19) is connected, and is preferably fully connected to the corresponding side surface of the compacted end section (10). 7. Assembled electrical cable (2) according to one of the items 1 to 6, characterized bythat the at least one connecting surface (12, 15, 17, 18, 19) is integrally connected to the compacted end section (10). 8. Assembled electrical cable (2) according to one of the items 1 to 7, characterized by that the at least one connecting surface (12, 15, 17, 18, 19) completely covers a corresponding side surface of the compacted end section (10) to which the connecting surface (12, 15, 17, 18, 19) is connected. 9. Assembled electrical cable (2) according to one of the items 1 to 8, characterized by that a further side surface of the contact element (11) forms a second contact surface (16) for contacting a mating contact surface (14) of a mating contact element (7) of a mating connector (5). 10. Assembled electrical cable (2) according to one of the items 1 to 9, characterized bythat the at least one contact surface (13, 16) of the contact element (11) a) is designed as a predominantly flat surface for surface contact with the mating contact surface (14); or b) has one or more contact blades (25) designed to be at least partially elastic in the contacting direction for contacting the mating contact surface (14). 11. Assembled electrical cable (2) according to one of the items 1 to 10, characterized by that the at least one contact surface (13, 16) each has at least one first locking means (20, 21, 22) for locking with a corresponding second locking means of the connector (3) in order to provide mutual locking between the pre-assembled cable (2) and the connector (3) when the pre-assembled cable (2) is mounted in the connector (3). 12. Pre-assembled electrical cable (2) according to item 11, characterized bythat the first locking means is designed as a spring tab (20) punched out of the contact surface (13, 16), as a locking lug (21) formed on the contact surface (13, 16), and / or as a locking recess (22) within the contact surface (13, 16). 13. Assembled electrical cable (2) according to one of the items 1 to 12, characterized by that the electrical conductor (8) has a conductor cross-section greater than 10 mm 2<, preferably greater than 30 mm 2<, particularly preferably greater than 60 mm 2<, for example greater than 90 mm 2<. 14. Assembled electrical cable (2) according to one of the items 1 to 13, characterized byin that the individual wires of the electrical conductor (8) are welded together to form the plate-shaped, compacted end section (10), preferably by pressure welding, resistance welding, or fusion welding. 15. A connector arrangement (1) comprising a prefabricated electrical cable (2) according to one of the objects 1 to 14 and the electrical connector (3), wherein the plate-shaped, compacted end section (10) is accommodated within a connector housing (4) of the electrical connector (3).

[0084] In the following, embodiments of the invention are described in more detail with reference to the drawings.

[0085] The figures each show preferred embodiments in which individual features of the present invention are illustrated in combination with one another. Features of one 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 useful combinations and subcombinations with features of other embodiments.

[0086] In the figures, functionally identical elements are provided with the same reference numerals.

[0087] They show schematically: Figure 1 shows a connector arrangement according to the invention comprising a pre-assembled electrical cable and an electrical connector, in a side sectional view; Figure 2 shows a pre-assembled electrical cable according to the invention in a front view, according to a first embodiment; Figure 3 shows the pre-assembled electrical cable of the Figure 2 in a side view; Figure 4 shows a pre-assembled electrical cable according to the invention in a front view, according to a second exemplary embodiment; Figure 5 shows a pre-assembled electrical cable according to the invention in a perspective view, according to a third exemplary embodiment; Figure 6 shows the pre-assembled electrical cable of the Figure 5in a frontal view; Figure 7 shows a pre-assembled electrical cable according to the invention in a frontal view, according to a fourth exemplary embodiment; Figure 8 shows a contact element for use with an electrical cable pre-assembled according to the invention according to a fifth exemplary embodiment, with various configurations of first locking means in a perspective view; Figure 9 shows a further contact element for use with an electrical cable pre-assembled according to the invention with a first locking means designed as a locking lug in a side view; Figure 10 shows a further plug connector arrangement according to the invention comprising a pre-assembled electrical cable and an electrical plug connector, in a frontal sectional view; Figure 11 shows a further plug connector arrangement according to the invention comprising a pre-assembled electrical cable and an electrical plug connector, in a side sectional view;and Figure 12 shows a further connector arrangement according to the invention comprising a prefabricated electrical cable and an electrical connector, in a side sectional view. ;

[0088] Figure 1 shows a connector assembly 1 comprising a prefabricated electrical cable 2 according to the invention and an electrical connector 3. The electrical connector 3 has a connector housing 4 in which the prefabricated electrical cable 2 is received at least one end. For this purpose, the cable 2 can preferably be inserted into the connector housing 4 along an assembly direction M.

[0089] The connection with a corresponding mating connector 5 is made in the exemplary embodiment along a plug-in direction S, which is orthogonal to the mounting direction M, which, however, is not to be understood as limiting. By way of example, a mating connector housing 6 of the mating connector 5 is shown in Figure 1 shown in dashed lines, and also a mating contact element 7 of the mating connector 5 is shown. The invention is particularly suitable for use in high-voltage technology in vehicles, for example for the electrical connection between individual batteries, battery modules, and / or electrical consumers, such as electric motors.

[0090] The prefabricated electrical cable 2, which is only to be understood as an example, extends along a longitudinal axis L and has a single electrical conductor 8 which is guided within a cable sheath 9. However, a cable sheath 9 is not absolutely necessary. To be suitable for high-voltage technology, in particular for transmitting high electrical currents greater than 10 amperes and more, the electrical conductor 8 preferably has a conductor cross-section greater than 10 mm 2<, in particular greater than 30 mm 2<, particularly preferably greater than 60 mm 2<, for example also greater than 90 mm 2<. In principle, however, other conductor cross-sections can also be provided. It can also be provided that the electrical cable 2 has more than one electrical conductor 8.

[0091] The electrical conductor 8 is designed as a stranded wire made of several individual wires and is compacted in a plate-like manner in an end section 10, see for example also the Figures 2 and 3To form the plate-shaped compacted end section 10, the individual wires of the electrical conductor 8 are preferably welded together, for example, pressure welded, resistance welded or fusion welded.

[0092] The proposed prefabricated electrical cable 2 has an elongated contact element. In the exemplary embodiments, the contact elements are each designed as contact plates 11, preferably with a thickness between 0.3 mm and 1.0 mm, particularly preferably with a thickness between 0.4 mm and 0.6 mm. In principle, however, any desired contact element can be provided, for example, even a plate-shaped contact element. The contact element or contact plate 11 and the individual wires of the electrical conductor 8 can be made of the same material, for example, aluminum or copper. To improve the contact resistance, the contact element or contact plate 11 can also have a coating, preferably a silver coating (not shown).

[0093] The Figures 2 and 3show a first embodiment of the prefabricated electrical cable 2. The contact plate 11 has a side surface which forms a first connecting surface 12, which is connected to the compacted end section 10 or to a corresponding side surface of the compacted end section 10 of the electrical conductor 8. The contact plate 11 also has a side surface facing away from the first connecting surface 12, which has a first contact surface 13 for contacting a mating contact surface 14 (cf. for example Figure 10 ) of the mating contact element 7 of the mating connector 5.

[0094] Due to the plate-shaped compaction of the end section 10 of the stranded wire, a particularly low-resistance electrical connection between the electrical conductor 8 and the contact element or contact plate 11 can be provided via the first connecting surface 12, on the one hand, and a particularly smooth, flat first contact surface 13 for contacting with the mating contact element 7, on the other hand.

[0095] In the Figures 4 to 8 Some variants of the contact element designed as a contact plate 11 are shown to illustrate that further side surfaces of the contact element or contact plate 11 can also form further connecting surfaces 15, 17, 18, 19, for example a total of two to five connecting surfaces 15, 17, 18, 19, which are each connected to the compacted end section 10 of the electrical conductor 8.

[0096] According to the embodiment of the Figure 4For example, it is provided that the contact plate 11 has the first connecting surface 12 and a further, second connecting surface 15, wherein the contact plate 11 is folded over an edge of the plate-shaped, compacted end section 10 of the electrical conductor 8. This edge can preferably be the edge of the contact plate 11 facing the mating contact element 7 during the plugging process. In this way, it can be avoided that protruding individual wires negatively influence the plugging process.

[0097] It can be provided that a contact surface is formed on each side surface of the contact element or contact plate 11 facing away from the respective connecting surface 12, 15, 17, 18, 19. However, the number of contact surfaces does not necessarily have to correspond to the number of connecting surfaces 12, 15, 17, 18, 19. Preferably, the first contact surface 13 and only optionally a second contact surface 16 are provided (for example, if a pincer-like contact with the mating contact element 7 or a contact with several mating contact elements 7 is provided). The contact surfaces 13, 16 are generally arranged along the main surfaces of the plate-shaped compacted end sections 10 (cf., for example, Figures 2 and 7 ).

[0098] In the Figures 5 and 6a further exemplary embodiment is shown, according to which, in addition to the first connecting surface 12 and the second connecting surface 15, a third connecting surface 17 is provided in order to form a U-shaped contact plate 11 which is folded over two edges of the plate-shaped compacted end section 10.

[0099] A fourth connecting surface 18 (cf. Figure 7 ) may be provided. The example shown in Figure 7 The contact plate 11 shown or the prefabricated electrical cable 2 can thus advantageously be contactable from both sides and / or be used modularly and independently of the orientation.

[0100] At this point, it should be mentioned that the contact plate 11 can, in principle, be manufactured in any way, but is preferably manufactured as a stamped and bent part. In particular (but not exclusively) when using four connecting surfaces 12, 15, 17, 18, as shown in Figure 7shown, however, a deep-drawn contact element 11 may also be suitable. If the contact element 11 is deep-drawn, it may be advantageous to ensure during deep-drawing that connecting surfaces facing away from one another (in Figure 7 the first connecting surface 12 and the fourth connecting surface 18, as well as the second connecting surface 15 and the third connecting surface 17) retain their parallelism to one another as far as possible. If the contact sheet 11 is manufactured as a stamped and bent part and is to have four connecting surfaces 12, 15, 17, 18, it can optionally be provided to connect any adjacent edges between two connecting surfaces 12, 15, 17, 18 or within a connecting surface 12, 15, 17, 18 in a material-to-material manner, i.e. to close any manufacturing-related gap between or within the connecting surfaces 12, 15, 17, 18, for example by means of a laser welding process.

[0101] It is also possible to provide a frontal connection of the contact plate 11 with a front side of the plate-shaped compacted end section 10. For example, Figure 8 a fifth connecting surface 19 is provided.

[0102] In the exemplary embodiments, the respective connecting surfaces 12, 15, 17, 18, 19 run parallel to the corresponding side surfaces of the compacted end section 10 and are fully connected to the corresponding side surfaces of the compacted end section 10. The connection is preferably materially bonded, most preferably gas-tight.

[0103] As shown in the exemplary embodiments, it can be provided that the connecting surfaces 12, 15, 17, 18, 19 completely cover the respective corresponding side surface of the compacted end section 10. The axial length LK of the connecting surfaces 12, 15, 17, 18, 19 can thus correspond to the axial length of the compacted end section 10 (cf. Figure 3 ). However, the connecting surfaces 12, 15, 17, 18, 19 and / or the entire contact element or contact plate 11 can also have a shorter axial length LK and thus extend only over a portion of the axial length of the compacted end section 10. In principle, several contact elements or contact plates 11 or connecting surfaces 12, 15, 17, 18, 19 can also be connected to the same corresponding side surface of the compacted end section 10.

[0104] In order to mount the pre-assembled electrical cable 2 in the connector 3 or in the connector housing 4 of the connector 3 during assembly, it can be provided that the at least one contact surface 13, 16 has at least one first locking means for locking with a corresponding second locking means of the connector housing 4 in order to provide mutual locking when the pre-assembled electrical cable 2 is fully inserted into the connector 3. In the Figures 8, 9 and 11 Examples of locking devices are shown.

[0105] For example, the first locking means can be designed as a spring tab 20 punched out in the contact surface 13, 16 (cf. Figures 8 and 11 ), which is located behind a locking lug or other edge of the connector housing 4 (see Figure 11 ) in order to secure the prefabricated electrical cable 2 against withdrawal against the mounting direction M.

[0106] Alternatively or additionally, locking recesses 22 can also be formed in the contact surface 13, 16 (cf. Figures 8 and 12 ), into which the corresponding second locking means of the connector housing 4, for example locking lugs and / or spring tabs, can engage (not shown).

[0107] It may also be provided (cf. Figure 9 ) that corresponding locking lugs 21 are formed on the contact surface 13, 16, behind which spring tabs (not shown) of the connector housing 4 can engage, complementary to the Figure 11 shown variant.

[0108] In principle, the contact surface 13, 16 of the contact element or contact plate 11 can also have additional functional elements. Figure 12 shows an example of a mechanical coding between the pre-assembled electrical cable 2 and the connector housing 4. For this purpose, the contact surface 13, 16 can have coding elements 23, for example, punched coding elements 23, which can be inserted into counter-coding elements 24 of the connector housing 4 only in a predefined position and / or orientation. Furthermore, this can ensure that only suitable or permissible electrical cables 2 can be accommodated in the connector housing 4.

[0109] As already discussed in the context of Figure 1As mentioned, the contact between the counter contact element 7 and the contact element or contact plate 11 is preferably orthogonal to the mounting direction M of the prefabricated electrical cable 2. For this purpose, a full-surface contact can be provided, as in Figure 1 , according to which the contact surface 13, 16 of the contact element or contact plate 11 is designed as a primarily flat surface for surface contact with the mating contact surface 14. However, the contact surface 13, 16 and / or the mating contact surface 14 preferably have an orthogonal directional component for mutual contact, for example, contact blades 25.

[0110] The contacting by means of contact blades 25 is shown as an example in Figure 10shown. It can be provided that one or more contact blades 25, which are at least partially elastic in the contacting direction, are formed from the contact surface 13, 16 itself, for example, by being punched out. Alternatively, separate contact blades 25 can also be applied to the contact surface 13, 16. Furthermore, it is possible to have a separate contact blade element 26 with several contact blades 25 (cf. Figure 11 ) between the contact surface 13, 16 and the mating contact surface 14, in particular to mount it captively in the connector housing 4. By using contact blades 25, the contact pressure between the contact element or contact plate 11 and the mating contact element 7 can be increased and thus the contact can be improved.

[0111] In all cases of contact between contact element or contact plate 11 and mating contact element 7, it may be advantageous to provide one or more spring elements 27 in the connector housing 4 and / or mating connector housing 6 in order to press the contact surface 13, 16 against the mating contact surface 14. Corresponding spring elements 27 are shown by way of example in the Figures 10 and 11 indicated.

Claims

1. Assembled electrical cable (2) for an electrical connector (3), comprising an electrical conductor (8) which is designed as a stranded wire comprising a plurality of individual wires and which has at least one plate-shaped compacted end section (10), and further comprising an elongated contact element (11) having at least one side surface which forms a first connecting surface (12) which is connected to the compacted end section (10) of the electrical conductor (8), and at least one further side surface facing away from the first connecting surface (12) which forms a first contact surface (13) for contacting a mating contact surface (14) of a mating contact element (7) of a mating connector (5), characterized in thatthe at least one contact surface (13, 16) of the contact element (11) has one or more contact lamellae (25) which are at least partially elastic in the contacting direction for contacting the counter-contact surface (14).

2. Assembled electrical cable (2) according to claim 1, characterized in that the contact element is designed as a contact plate (11), preferably with a thickness between 0.3 mm and 1.0 mm, particularly preferably with a thickness between 0.4 mm and 0.6 mm.

3. Assembled electrical cable (2) according to claim 1 or 2, characterized in that the contact element (11) and the individual wires of the electrical conductor (8) are made of the same material, preferably aluminum or copper.

4. Assembled electrical cable (2) according to one of claims 1 to 3, characterized in that the contact element (11) has a coating, preferably a silver coating.

5. Assembled electrical cable (2) according to one of claims 1 to 4, characterized in that further side surfaces of the contact element (11) form respective further connecting surfaces (15, 17, 18, 19), wherein the contact element (11) preferably has a total of two to five connecting surfaces (12, 15, 17, 18, 19) which are each connected to the compacted end section (10) of the electrical conductor (8).

6. Assembled electrical cable (2) according to one of claims 1 to 5, characterized in that the at least one connecting surface (12, 15, 17, 18, 19) is aligned parallel to a corresponding side surface of the compacted end section (10), to which the connecting surface (12, 15, 17, 18, 19) is connected, and is preferably connected over its entire surface to the corresponding side surface of the compacted end section (10).

7. Assembled electrical cable (2) according to one of claims 1 to 6, characterized in thatthe at least one connecting surface (12, 15, 17, 18, 19) is integrally connected to the compacted end section (10).

8. Assembled electrical cable (2) according to one of claims 1 to 7, characterized in that the at least one connecting surface (12, 15, 17, 18, 19) completely covers a corresponding side surface of the compacted end section (10) to which the connecting surface (12, 15, 17, 18, 19) is connected.

9. Assembled electrical cable (2) according to one of claims 1 to 8, characterized in that a further side surface of the contact element (11) forms a second contact surface (16) for contacting a mating contact surface (14) of a mating contact element (7) of a mating connector (5).

10. Assembled electrical cable (2) according to one of claims 1 to 9, characterized in thatthe contact blades (25) are punched out of the contact surface (13, 16) of the contact element (11) or are attached individually or in groups to the contact surface (13, 16) of the contact element (11).

11. Assembled electrical cable (2) according to one of claims 1 to 10, characterized in that the at least one contact surface (13, 16) each has at least one first locking means (20, 21, 22) for locking with a corresponding second locking means of the plug connector (3) in order to provide mutual locking between the pre-assembled cable (2) and the plug connector (3) when the pre-assembled cable (2) is mounted in the plug connector (3).

12. Assembled electrical cable (2) according to claim 11, characterized in thatthe first locking means is designed as a spring tab (20) punched out of the contact surface (13, 16), as a locking lug (21) formed on the contact surface (13, 16) and / or as a locking recess (22) within the contact surface (13, 16).

13. Assembled electrical cable (2) according to one of claims 1 to 12, characterized in that the electrical conductor (8) has a conductor cross-section greater than 10 mm 2 preferably larger than 30 mm 2 , particularly preferably larger than 60 mm 2 , for example larger than 90 mm 2 .

14. Assembled electrical cable (2) according to one of claims 1 to 13, characterized in that the individual wires of the electrical conductor (8) are welded together to form the plate-shaped compacted end section (10), preferably pressure-welded, resistance-welded or fusion-welded.

15. Connector assembly (1) comprising a prefabricated electrical cable (2) according to one of claims 1 to 14 and the electrical connector (3), wherein the plate-shaped compacted end portion (10) is accommodated within a connector housing (4) of the electrical connector (3).

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