Set of lines with plug connector

Abstract

A cable set (10) with a plug connector (6) comprises a cable (1) with at least one core line (2) that is electrically conductively connected to a connecting element (4), wherein the connecting element (4) is arranged in a continuous receptacle (8) in a contact carrier (7) of the plug connector (6). A first connecting section (4a) of the connecting element (4), with which the at least one core line (2) is fastened to the connecting element (4), has a first outer diameter that corresponds to an inner diameter (9) of a connection receptacle (8a) of the continuous receptacle (8) of the contact carrier (7).

Description

[0001] The present invention relates to a cable harness with a connector according to the preamble of claim 1.

[0002] Cable assemblies with connectors are widely used as prefabricated components. Connectors form the electrical connection component between different modules and devices in many electrical and electronic devices as well as industrial production systems.

[0003] Plug-in connections significantly support the simple and rapid interchangeability of various devices and manufacturing modules, as well as the installation of complex and potentially meshed infrastructures. Plug-in connections not only transmit power and signals but also form interfaces for data transmission.

[0004] The existing solutions have proven themselves to be effective. However, there is a constant need for further development, creating greater functionality with increased safety, a compact design, fewer components, and flexibility.

[0005] Solving this problem is the object of the invention. The invention solves this problem through the subject matter of claim 1.

[0006] A cable harness according to the invention with a connector comprises a cable with at least one core line that is electrically connected to a connecting element, wherein the connecting element is arranged in a continuous receptacle in a contact carrier of the connector. A first connecting section of the connecting element, with which the at least one core line is fastened to the connecting element, has a first outer diameter that corresponds to an inner diameter of a connection receptacle of the continuous receptacle of the contact carrier.

[0007] An advantage of this solution is that the design of the first connecting section and the corresponding connection receptacle enables simple sealing that does not require any additional parts.

[0008] Further advantageous embodiments can be found in the remaining subclaims.

[0009] In one embodiment, the contact carrier of the connector is a cylindrical component with a longitudinal axis, a connection side for the at least one wire and a plug side. The contact carrier has a connection section, a plug section, a circumferential collar, an edge section, a first end face of the connection side, a second end face of the plug side, and at least one continuous receptacle for the connecting element. The contact carrier can advantageously be manufactured simply as an injection-molded part from an electrically insulating plastic.

[0010] A further embodiment provides that a seal, at least a spray-through prevention of the overmolding compound, is formed between the first connecting section of the connecting element and the contact carrier by means of a narrow gap or a press fit between the first outer diameter of the first connecting section of the connecting element and the corresponding inner diameter of the connection receptacle of the continuous receptacle of the contact carrier. This seal, as a type of gap seal, is advantageously simple to form and requires no additional sealing components, especially since it is a static application.

[0011] In a further embodiment, it is advantageous if a distance between the outside of the first connecting section and the inside of the connection receptacle is in a range of 0.05 mm excess to 0.1 mm gap, since this enables simple sealing.

[0012] Yet another embodiment provides for a free end of the first connecting section to have a front end formed with a uniform, stable, largely circumferential, accessible mounting edge, with the other end of the first connecting section transitioning into a bent section. The largely circumferential mounting edge does not always have to be closed in its circumference, as this depends on the thickness of the conductor. This provides an advantageously simple way to quickly install the connecting element in the contact carrier. This can be done manually and / or mechanically using an assembly tool.

[0013] In one embodiment, the offset portion of the first connecting portion has a second outer diameter that is smaller than the first outer diameter of the first connecting portion. This allows even stranded wires with a smaller conductor cross-section to be advantageously attached to the connecting element.

[0014] In an alternative embodiment, the offset section of the first connecting section has a second outer diameter that is equal to the first outer diameter of the first connecting section. This advantageously allows the use of single-core cables with a larger conductor cross-section, while the offset section also provides a sealing effect.

[0015] In another embodiment, it is advantageous that a seal to the wire insulation of the wire cables is formed by the offset section of the connecting element towards the inside of the continuous receptacle of the contact carrier of the connector.

[0016] In a further embodiment, a connection section of the contact carrier is surrounded in its end region on the connection side by an end section of an insulating body. The insulating body also surrounds the at least one free conductor of the cable and an end region of the cable and firmly connects the plug connection to the insulating body. This enables an advantageously simple sealing of the contact carrier on the connection side.

[0017] A further embodiment provides for the insulating body to be formed from an overmolding compound. This is advantageous because it allows for different insulating body shapes, particularly for handling and strain relief.

[0018] In a further embodiment, the overmolding compound is in contact with an outer side of the connection section in the first quarter of the contact carrier, with the contact carrier, with the edge section, the mounting edge of the connecting element, and with the at least one wire secured in the first connection section, thus forming a seal of the connecting element to the outside on the connection side of the connector. This results in simple sealing and strain relief of the wire, the connecting element, the continuous receptacle, and the connection section of the contact carrier.

[0019] In one design, the uniform, stable mounting edge, which is accessible almost all the way around, is aligned with the edge section of the contact carrier's connection side. This is advantageous for sealing the contact carrier, the single-core cable, the connecting element, and the continuous mounting of the contact carrier. The largely circumferential mounting edge does not always have to be closed in its circumference, as this depends on the conductor thickness.

[0020] One embodiment provides for the connecting element to be a crimp element, with the first connecting section being an insulation crimp, a second connecting section being a conductor crimp, and a contact section being a receptacle or a pin. Crimp elements are advantageous stamped / bent parts because they are cost-effective and form commercially available components of high quality.

[0021] In an alternative design, the connecting element can be a turned part. This is advantageous for special designs, for example, and increases the range of applications.

[0022] The following advantages arise. a stable, largely circumferentially accessible mounting edge of the connecting element Sealing against overmolding compound at the first connection section Sealing to the inside by a bend on the wire insulation, depending on the insulation diameter by contact and / or pressing Sealing to the contact carrier by always the same outer diameter

[0023] Embodiments of the invention are described below with reference to the accompanying drawings. These embodiments serve merely to illustrate the invention using preferred constructions, but do not represent the invention exhaustively. Therefore, other embodiments, as well as modifications and equivalents of the illustrated embodiment, are also feasible within the scope of the claims.

[0024] They show: Fig. 1 is a schematic perspective view of an embodiment of a cable set according to the invention; Fig. 2 is a schematic perspective view of a connecting element of the embodiment according to Fig. 1 ; Fig. 3 a schematic enlarged perspective view of the area III of the connecting element according to Fig. 2 ; Fig. 4 a schematic enlarged perspective view of the area IV of the embodiment according to Fig. 1; Fig. 5 a schematic enlarged perspective view of a section of a connecting element of a variant of the embodiment according to Fig. 1 ; Fig. 6-8 schematic views of an embodiment of a connector according to the invention of the embodiment according to Fig. 1 ; Fig. 9 a schematic sectional view of the first embodiment of the connector according to the invention according to Fig. 6-8 ; and Fig. 10 a schematic sectional view of a variant of the embodiment of the connector according to the invention according to Fig. 9 .

[0025] Fig. 1 shows a schematic perspective view of an embodiment of a cable harness 10 according to the invention.

[0026] The cable set 10 comprises a cable 1, with at least one core cable 2 and a contact unit KE.

[0027] In the example shown, the cable 1 has four core wires 2. Each core wire 2 is an electrical conductor 3 with insulation. The electrical conductor 3 can be a (single) wire or a stranded conductor.

[0028] The contact unit KE has at least one electrically conductive connecting element 4 for connecting a wire 2 to an electrically conductive pole of a connector (not shown). Such a connector can be a socket element or a plug element. In the illustrated embodiment, each wire 2 of the cable 1 is assigned a connecting element 4.

[0029] Each connecting element 4 is designed with a plug-in sleeve for contacting a contact in a mating connector (e.g. socket or plug) and has a first connecting section 4a and a second connecting section 4b for connection to a respective wire cable 2.

[0030] In this embodiment, the connecting element 4 is designed as a crimp element. Of course, other designs are also possible, such as a turned part.

[0031] In the example of the crimping element shown, the first connecting section 4a is an insulation crimp and the second connecting section 4b is a conductor crimp.

[0032] The first connecting section 4a forms a mechanical fastening of a holding section 2a of the insulated wire cable 2 in the end region of the insulation of the wire cable 2.

[0033] In the second connecting section 4b, a stripped end section of the conductor 3 of the wire cable 2 is mechanically and electrically conductively fastened by a crimping or pressing process.

[0034] The second connecting section 4b is electrically conductively connected in one piece to a contact section 4c, which here forms the plug-in sleeve. Instead of the plug-in sleeve, the connecting element 4 can also be provided with a plug element, e.g., a plug pin, as the contact section 4c.

[0035] The contact unit KE is designed for installation in a contact carrier 7. This is described further below.

[0036] Fig. 2 shows a schematic perspective view of a connecting element 4 of the embodiment according to Fig. 1 .

[0037] In Fig. 3 is a schematic enlarged perspective view of the area III of the connecting element 4 according to Fig. 2 shown.

[0038] In Fig. 2The connecting element 4 is shown prior to assembly. The first connecting section 4a and the second connecting section 4b are connected to each other by a first connecting web 4d. The contact section 4c is attached to the second connecting section 4b via a second connecting web 4e.

[0039] An outwardly projecting projection 4h is formed on the second connecting web 4e. This projection 4h serves to fix the connecting element 4 when inserting or pushing it into the contact carrier 7 and is described below in connection with Fig. 6 explained further.

[0040] A free end of the first connecting section 4a has an end face. The first connecting sections 4a are formed on this end face with a uniform, stable, largely circumferentially accessible mounting edge 4g. The largely circumferential mounting edge does not always have to be closed in its circumference, as this depends on the thickness of the conductor. The other end of the first connecting section 4a transitions into a cranked section 4f, which in turn is connected to the second connecting section 4e.

[0041] Fig. 4 shows a schematic enlarged perspective view of the area IV of the embodiment according to Fig. 1 .

[0042] In this illustration, the core wire 2 of the cable 1 is attached, i.e., fastened, to the connecting element 4. The core wire 2 is mechanically fastened with its holding section 2a in the end region of its insulation in the first connecting section 4a by crimping or pressing the first connecting section 4a and crimping or pressing the offset section 4f.

[0043] A first end region 5 of the first connecting section 4a below the mounting edge 4g has a fixed outer diameter, which is always manufactured with the same outer diameter. This will be explained in more detail below.

[0044] In this exemplary embodiment, a second end region 5a of the first connecting section 4a in the offset section 4f has an outer diameter that is smaller than the outer diameter in the first end region 5 of the first connecting section 4a. This is due to the dimensions of the single-core cable 2, since different conductor cross-sections and insulation thicknesses are possible.

[0045] One end of the holding section 2a with the end of the insulation protrudes from the offset section 4f above the first connecting web 4d to the second connecting section 4c.

[0046] The stripped end portion of the conductor 3 is also connected to the second connecting portion 4c by crimping or pressing.

[0047] Fig. 5 shows a schematic enlarged perspective view of a section of a connecting element 4 of a variant of the embodiment according to Fig. 1 represents.

[0048] In contrast to the connecting element 4 of the embodiment according to Fig. 1 and Fig. 4 the connecting element 4 of the variant is for a single conductor 2 with larger dimensions (conductor cross-section, insulation thickness) than those of the single conductor 2 of the embodiment according to Fig. 1 and Fig. 4 provided.

[0049] The crimping or pressing is in Fig. 5 The outer diameter of the first end region 5 near the mounting edge 4g corresponds to the outer diameter of the first end region 5 of the embodiment according to Fig. 1 and 4 .

[0050] In this variant of the exemplary embodiment, however, the outer diameter of the second end region 5'a of the first connecting section 4a in the offset section 4'f has the same outer diameter as the first end region 5 of the first connecting section 4a. In other words, the first connecting section 4a has the same outer diameter in all regions. The offset section 4'f is designed without an offset and rests against the holding region 2a of the insulation of the core cable 2.

[0051] Fig. 6-8 show schematic views of the embodiment of a connector 6 according to the invention of the embodiment according to Fig. 1 .

[0052] In Fig. 6 a schematic sectional view of the connector 6 with the wire cables 2 of the cable set 10 is shown.

[0053] Fig. 7 shows a perspective view of the connector 6 with the cable set 10 Fig. 6 represents.

[0054] Fig. 8 shows the view of the connector 6 after Fig. 7 with an assembly tool 11.

[0055] The contact unit KE with the connecting elements 4 of the cable set 10 is mounted in a contact carrier 7 of a connector 6 using an assembly tool 11 ( Fig. 8 ) mounted.

[0056] The contact carrier 7 is a cylindrical component with a longitudinal axis 7a, a connection side AN for the conductors 2, and a plug side ST. The contact carrier 7 has a connection section 7b, a plug section 7c, a circumferential collar 7d, an edge section 7e of a first end face of the connection side AN, and a second end face 7f of the plug side ST.

[0057] The contact carrier is made of an insulating material, e.g. plastic.

[0058] Starting at the connection side AN, the connection section 7b extends in the direction of the longitudinal axis 7a and then transitions into the plug-in section 7c. The transition between the connection section 7b and the plug-in section 7c is surrounded by the circumferential, radially outwardly projecting collar 7d.

[0059] In this exemplary embodiment, the contact carrier 7 has four continuous receptacles 8, which run parallel to the longitudinal axis 7a of the contact carrier from a first end face with the edge portion 7e to an opposite second plug-in end face 7f. The continuous receptacles 8 each serve to accommodate the connecting elements 4.

[0060] Each of the continuous receptacles 8 has a connection receptacle 8a in the region of the connection section 7a of the contact carrier 7 and a plug receptacle 8b in the region of the plug-in section 7c of the contact carrier 7. The connection receptacle 8a and the plug receptacle 8b merge into one another in the region of the circumferential collar 7d.

[0061] The connecting elements 4 with the attached conductors 2 of the cable 1 are inserted from the connection side AN into the respective through-holes 8. For this purpose, an assembly tool 11 with a bevelled assembly end with an opening 11a is used ( Fig. 8 ), which exerts pressure on the mounting edge 4g of the connecting element 4 during insertion. The opening 11a is shaped for the wire 2 in order to enclose it and prevent damage.

[0062] The assembly of the connecting elements 4 can be done manually and / or mechanically.

[0063] The continuous receptacles 8 are formed with a circular cross-section in the contact carrier 7 and are designed such that the projection 4h of a respective connecting element 4 engages in a recess 8c in the region of the transition of a respective connection receptacle 8a and the associated connector receptacle 8b and thus fixes the associated connecting element 4 in a fixed position in the respective continuous receptacle 8.

[0064] When the connecting elements 4 are mounted, i.e. inserted and fixed, in the through-hole receptacles 8, the first connecting sections 4a and second connecting sections 4b are each arranged in the terminal receptacle 8a, wherein the contact sections 4c are each arranged in the connector receptacle 8b.

[0065] The first connecting sections 4a of the connecting elements 4 with the respective conductor line 2 attached thereto are positioned with their respective end region 5 in the input region of the respective connection receptacle 8a. The outer diameter of the end regions 5 corresponds to the inner diameter 9 of the respective connection receptacle 8a. This is shown in Fig. 7-8 By means of a narrow gap or a press fit of the outer diameter of the end regions 5 and the corresponding inner diameter 9, a seal is achieved between the first connecting section 4a of the connecting element 4 and the contact carrier 7. The distance between the outer side of the first connecting section 4a and the inner side of the connection receptacle 8a lies in a range of 0.05 mm oversize to 0.1 mm gap. For example, the distance can be approximately 0.05 mm.

[0066] The uniform, stable, largely circumferentially accessible mounting edge 4g, which here is aligned with the edge section 7e of the contact carrier 7, contributes in particular to such a seal.

[0067] In Fig. 9 is a schematic sectional view of the first embodiment of the connector 6 according to the invention according to Fig. 6-8 shown.

[0068] In its end region on the connection side AN, the connection section 7b is surrounded by approximately one-quarter of an end section of an insulating body 12. The insulating body 12 also surrounds the free conductors 2 of the cable 1 and an end section of the cable 1. In this way, the plug connection 6 is firmly connected to the insulating body 12.

[0069] The insulating body 12 is formed from an overmolding compound 12a which surrounds the contact carrier 7 of the connector 6, the wire leads 2 extending from the connection side AN of the connector 6 to the cable 1 and an end region of the insulation of the cable 1.

[0070] The overmolding compound 12a is in contact with the outside of the connection section 7b in the first quarter of the contact carrier 7, with the edge section 7e, the mounting edges 4g of each connecting element 4 and the wire leads 2 fastened in the first connecting sections 4a and thus forms a seal of the connecting elements 4 to the outside on the connection side AN of the connector 6.

[0071] Towards the inside, i.e. towards the inner region of the continuous receptacles 8 of the contact carrier 7 of the connector 6, a seal is achieved by the wire insulation of the holding sections 2a of the wire cables 2 through the respective offset section 4f of the associated connecting element 4. This is achieved, depending on the insulation diameter of the holding section 2a of the wire cables 2, by contacting or pressing the respective offset section 4f.

[0072] Fig. 10 shows a schematic sectional view of a variant of the embodiment of the connector 6 according to the invention according to Fig. 9 , wherein an outer diameter of the wire insulation of the holding sections 2a of the wire lines 2 is larger here than in the embodiment according to Fig. 9is formed. The outer diameters of the first connecting sections 4a and the offset sections 4f are of equal size and seal the connecting element 4 against the connection receptacle 8a over the entire length of the first connecting section 4a and the offset section 4f.

[0073] The connecting elements 4 can be so-called identical parts for both the embodiment and the variant.

[0074] The connecting elements 4 can be designed as stamped / bent parts or as turned parts.

[0075] The insulating body 12 provides strain relief for the wire leads 2 and the cable 1 in conjunction with the connector 6.

[0076] The invention is not limited by the embodiments described above, but can be modified within the scope of the claims. List of reference symbols

[0077] Cable 1 Single-core cable 2 holding section 2a Director 3 connecting element 4 connecting section 4a, 4b Contact section 4c connecting bridge 4d, 4e Offset section 4f, 4'f Mounting edge 4g projection 4h End area 5; 5a, 5'a connectors 6 Contact carrier 7 Longitudinal axis 7a Connection section 7b Plug-in section 7c collar 7d edge section 7e Plug-in end face 7f Recording 8 Connection holder 8a Connector holder 8b recess 8c inner diameter 9 cable harness 10 Assembly tool 11 opening 11a Insulating body 12 Overmolding compound 12a Connection side TO Contact unit KE Plug side ST

Claims

1. A cable set (10) with a plug connector (6), comprising a cable (1) with at least one wire (2) which is electrically connected to a connecting element (4), wherein the connecting element (4) is arranged in a continuous receptacle (8) in a contact carrier (7) of the plug connector (6), characterized in that a first connecting section (4a) of the connecting element (4), with which the at least one wire (2) is fastened to the connecting element (4), has a first outer diameter which corresponds to an inner diameter (9) of a connection receptacle (8a) of the continuous receptacle (8) of the contact carrier (7).

2. Cable set (10) according to claim 1, characterized in thatthe contact carrier (7) of the plug connector (6) is a cylindrical component with a longitudinal axis (7a), with a connection side (AN) of the at least one wire cable (2) and a plug side (ST), wherein the contact carrier (7) has a connection section (7b), a plug section (7c), a circumferential collar (7d), an edge section (7e), a first end face of the connection side (AN), a second end face (7f) of the plug side (ST), and the at least one continuous receptacle (8) for the connecting element (4).

3. Cable set (10) according to one of the preceding claims, characterized in that ​by means of a narrow gap or a press fit of the first outer diameter of the first connecting section (4a) of the connecting element (4) and the corresponding inner diameter (9) of the connection receptacle (8a) of the continuous receptacle (8) of the contact carrier (7), a seal, at least an injection-through prevention of the overmolding compound (12a), is formed between the first connecting section (4a) of the connecting element (4) relative to the contact carrier (7).

4. Cable set (10) according to claim 3, characterized in that a distance between the outside of the first connecting section (4a) and the inside of the connection receptacle (8a) is in a range of 0.05 mm oversize up to 0.1 mm gap.

5. Cable set (10) according to one of the preceding claims, characterized in thata free end of the first connecting section (4a) has an end face which is formed with a uniform, stable, largely circumferential, accessible mounting edge (4g), wherein the other end of the first connecting section (4a) merges into a cranked section (4f).

6. Cable set (10) according to claim 5, characterized in that the offset portion (4f) of the first connecting portion (4a) has a second outer diameter which is smaller than the first outer diameter of the first connecting portion (4a).

7. Cable set (10) according to one of claims 1 to 5, characterized in that the offset portion (4f) of the first connecting portion (4a) has a second outer diameter which is equal to the first outer diameter of the first connecting portion (4a).

8. Cable set (10) according to one of claims 5 to 7, characterized in thatinwards towards the inner region of the continuous receptacle (8) of the contact carrier (7) of the connector (6), a seal to the wire insulation of the wire cables (2) is formed by the offset section (4f) of the connecting element (4).

9. Cable set (10) according to one of claims 5 to 8, ​ the connection section (7b) of the contact carrier (7) is surrounded in its end region on the connection side (AN) by an end section of an insulating body (12), wherein the insulating body (12) also surrounds the at least one free wire line (2) of the cable (1) and an end region of the cable (1) and firmly connects the plug connection (6) to the insulating body (12).

10. Cable set (10) according to claim 9, ​ the insulating body (12) is formed from an overmolding compound (12a).

11. Cable set (10) according to claim 10, ​the overmolding compound (12a) is in contact with an outer side of the connection section (7b) in the first quarter of the contact carrier (7), with the edge section (7e), the mounting edge (4g) of the connecting element (4) and the at least one wire (2) fastened in the first connection section (4a), thus forming a seal of the connecting element (4) to the outside on the connection side (AN) of the connector (6).

12. Cable set (10) according to claim 11, ​ the uniform, stable, largely circumferentially accessible mounting edge (4g) is aligned with the edge section (7e) of the connection side (AN) of the contact carrier (7).

13. Cable set (10) according to one of the preceding claims, ​ the connecting element (4) is a crimping element, wherein the first connecting section (4a) is an insulation crimp, a second connecting section (4b) is a conductor crimp and a contact section (4c) is a plug-in sleeve or a plug-in pin.

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