Cable sealing housing and method for producing such a housing

Abstract

The invention relates to a cable-sealing arrangement having an at least two-part housing with an upper part and a lower part, and at least one opening formed as a cable-entry point in the housing, wherein the upper part and the lower part each form one part of the openings, characterized in that, when the housing is in the joined state, abutting joining surfaces of the upper part and lower part have been laser-welded to one another.

Description

[0001] Cable sealing housing and method for producing such a housing

[0002] Housing

[0003] The subject matter relates to a cable sealing housing and a method for producing such a housing

[0004] In the automotive industry, electrical wiring is safety-relevant. Since vehicles are generally exposed to changing environmental conditions, such as rain, splashing water, road salt, strong temperature fluctuations, and the like, electrical connections are always sources of error, particularly with regard to leakage currents, short circuits, and / or corrosion. Especially with battery cables, which may also be permanently connected to the battery positive potential,

[0005] Contact corrosion can be promoted by the voltage applied to the cable.

[0006] Connections between two electrical cables are usually made using a cable lug and / or appropriate screw connections. It is important that the connection point is protected against moisture penetration. Today, this is usually achieved using a heat-shrink tube with an internal adhesive, which is pulled over the connection point and then shrunk. However, such a heat-shrink tube, especially in conjunction with silicone-sheathed cables, is problematic due to longitudinal water seeping between the heat-shrink tube and the cable insulation. Complete sealing is almost impossible to achieve.

[0007] Particularly for battery cables or other high-voltage applications in the automotive industry, the so-called fording depth is also a relevant criterion. Vehicles can only be submerged in water to a certain depth. This depth is called the fording depth. Laying battery cables underground may result in the cables being below the vehicle's fording depth. In particular, there is a risk that submerging underground electrical cables in water could cause permanent damage.

[0008] Underfloor and / or outdoor installations are always problematic due to moisture penetration. However, with the electrification of the powertrain, underfloor and / or outdoor installations, particularly outside the passenger compartment, are increasingly being used. In this case, and especially in high-voltage applications, especially at voltages above 48V and above 300V, the connection between the cables must be specially protected against moisture penetration.

[0009] In particular, it must be prevented that longitudinal water causes leakage currents or short circuits.

[0010] In particular, sealing center taps, where a branch cable branches off in the middle of a main cable, requires insulation with an expensive Y-shaped heat-shrink tube, and the manufacturing effort required to thread the cables through such a tube is enormous. Furthermore, the sealing effect is sometimes inadequate, especially with silicone-sheathed cables, depending on the cable insulation material. The permissible ambient temperature for the use of such systems is also limited by the melting temperature of the internal adhesive.

[0011] In addition to expensive heat-shrink tubing, it's possible to protect the connection from water using a housing. Sealing the housing, however, is always problematic.

[0012] The object of the invention was therefore to protect the connection between at least two electrical cables within a motor vehicle against moisture. This object is achieved by a cable sealing housing according to claim 1. A cable sealing housing can also be referred to as a sealing housing, casing, enclosure, or the like.

[0013] First, a two-part housing is proposed. Such a housing is formed from at least one upper part and at least one lower part. The terms "top" and "bottom" describe the relationship between the two parts. An upper part can also be referred to as a first part, and a lower part can be referred to as a second part. An upper part can also be referred to as a second part, and a lower part can be referred to as a first part.

[0014] The upper and lower parts can each be shell-shaped and form the housing when joined. When joined, the connection between two cables or a cable and a connecting bolt or another connecting part is formed within the housing. A cable can be a connecting cable or a main cable or vice versa. Main and branch cables are terms used to linguistically differentiate between these two cables. The cables themselves can be essentially the same, identical or similar in structure. When a branch cable is mentioned, this always also includes a connecting part, connecting bolt, connecting piece, connecting lug, connecting part or the like. What these parts have in common is that they can be electrically connected to the main cable and at least one electrically conductive part, preferably encased in an insulating material, leads out of the housing.Whenever a main cable is mentioned, this always includes a connector, terminal bolt, connector piece, terminal lug, connecting piece, or the like. What these parts have in common is that they can be electrically connected to the connecting cable at a center tap and that at least two electrically conductive parts, preferably encased in an insulating material, are led out of the housing.

[0015] The two-part design of the housing, in particular the upper and lower parts, has the advantage that at any point along the cable harness, even in the area of ​​a

[0016] Center tap, the housing can be arranged. A center tap can be implemented at any point along the main cable and sealed by the housing in question.

[0017] The previous and following statements regarding the seam and gap primarily refer to the cable entry area of ​​the housing. Therefore, the following features apply, particularly to the seam and gap in the cable entry area, also referred to as the opening. However, the features can also refer to other areas, in particular all areas of the seam and the gap between the housing parts.

[0018] Another advantage of the two-part housing is that after joining the main cable and the branch cable, this connection can be inserted into the lower / upper part, then the second part of the housing is placed on top, and the closed housing is sealed. The laborious process of threading the connection into a Y-shaped heat-shrink tube is eliminated.

[0019] A fully assembled cable with main cable and branch cable can simply be inserted into one of the two sections of the enclosure. The enclosure can then be sealed by joining this one section to the other, and the two parts can then be welded together. It is particularly important that the seam between the two enclosure parts is sealed. It is also particularly important that longitudinal water does not penetrate into the enclosure along the seam between the two enclosure parts in the cable entry area.

[0020] The housing has at least one opening formed as a cable entry, also referred to as a cable entry. The opening is used to insert the cable into the housing. The opening is preferably formed in an area between the upper part and the lower part. When the housing is joined, the opening can be partly in the upper part and partly in the lower part. If, for example, the upper part is placed on the lower part, the side walls of the upper and lower parts rest against one another. In an area of ​​a wall, the upper part and the lower part each have a recess which forms part of the opening when the housing is joined. The cable is led out of or into the housing in the area of ​​this opening.

[0021] The seam between the two housing parts is of particular importance in the area of ​​the inner surface of the cable entry. The cables and their insulation lie directly against the sealing element or the inner surface of the housing. If a sealing element is present, it lies against the inner surface of the housing. Moisture could penetrate into the housing via a gap running lengthwise along the cable / sealing element in the area of ​​the seam. It is therefore necessary to prevent such a gap. This is achieved by filling the gap with material melted during welding, particularly in the area of ​​this inner surface. To ensure that the gap is completely closed, it is preferable for a bead of melted material to protrude beyond the gap into the interior of the cable entry.

[0022] To seal the housing, it is now proposed that the joining edges of the upper and lower parts be welded together when the housing is assembled. The upper and lower parts are welded in a particularly moisture-tight, but preferably also gas-tight, manner. The upper and lower parts are directly adjacent to each other with their joining edges when joined. Using laser welding, the materials of the upper and lower parts can be melted and thus joined together. The materials are, in particular, plastics, especially thermoplastics. PA6 or PA6.6 with an optional glass fiber content of between 15-30% by weight or volume is preferred.

[0023] The cable seal in question is particularly suitable for a cable branch at a center tap of a main cable. A main cable can be stripped at a center tap. The main cable extends on both sides of this stripped area with an insulating sheath. The material of the insulating sheath of the main cable and / or the branch cable can be silicone. The material of the insulating sheath can also be PVC. For joining the two housing parts, these have mutually facing joining surfaces. It has been found to be advantageous if a first joining surface is a flat surface and the second joining surface has a rib. The first joining surface can be formed by an end face of an edge of one of the housing parts. The first joining surface preferably runs perpendicular to an outer wall and / or an inner wall of the housing.

[0024] The second joining surface is initially arranged corresponding to the first joining surface on the other housing part. Unlike the first joining surface, however, the second joining surface is not flat, but rather has a rib. The rib is a projection on the joining surface. The rib preferably has a rectangular cross-section. The rib can also have a conical cross-section, in particular, tapering conically from the root toward the end wall.

[0025] In a cross-section, the first joining surface has a greater width than the end face of the rib. The rib rests against the first joining surface with its end face. The first joining surface extends laterally to the side walls of the rib in a planar area. On the inner side wall of the rib, the first joining surface preferably extends completely flat as far as the inner wall of the housing; on the outer side wall of the rib, the first joining surface also preferably extends completely flat as far as the outer wall of the housing. However, it is also possible for the first joining surface to offset towards the second joining surface in the manner of a fold or a collar.

[0026] Starting from the second joining surface, the rib has two opposing side walls and an end wall. The side walls preferably run parallel to each other. The end wall preferably runs perpendicular to at least one side wall. The end wall of the rib faces the first joining surface during joining. The end wall of the rib runs parallel to the first joining surface during joining. The rib has a height of less than 1 cm, preferably less than 2-5 mm. The rib preferably has a height of 1 mm. The width of the rib, i.e. the distance between the side walls of the rib, is preferably equal to the height of the rib.

[0027] The rib creates a gap between the two joining surfaces. The rib acts as a spacer between the joining surfaces. When the first joining surface rests on the rib, the root (base) of the rib is spaced from the adjacent surface by the gap. This gap must be closed. For this reason, it is proposed that laser welding be carried out until an area of ​​the rib facing the first surface is melted, and that molten material from the rib at least partially fills the gap between the facing joining surfaces. The material of the rib is preferably heated and melted by the laser. The temperature of the molten material subsequently causes the material of the first joining surface to melt in the area of ​​the rib. Material from the first and second parts therefore melts preferentially, filling the gap.Furthermore, the melting of the material on both joining surfaces means that after cooling, the two housing parts are welded together.

[0028] During laser welding, the laser is preferably guided through the material of the first part. In particular, the laser beam runs through the material of the first part, exits the first joining surface and strikes the rib, in particular the end face of the rib. The laser is preferably guided along the longitudinal direction of the rib. The laser is preferably guided several times with a spatial offset in a radial direction (i.e. from the inside to the outside or from the outside to the inside of the housing) along the longitudinal direction of the rib. The laser is guided over the rib with the offset in a sufficiently short time that it melts the material of the end face of the rib across the surface. The laser irradiates the surface virtually simultaneously, so that this is referred to as quasi-simultaneous welding.

[0029] The material of the first part is preferably different from the material of the second part. It is also preferred that the melting point of the material of the first part is the same as the melting point of the material of the second part. It is also possible for the material of the rib to be different from the material of the first joining part. It is also possible for the material of the rib to be different from the material of the second joining part. The rib and the second joining part are preferably one piece and / or made of the same material. The material of the first part and / or the rib differs from the material of the second part, in particular with regard to its optical properties. In particular, the material of the second part and / or the rib absorbs the radiation energy of the laser more than the material of the first part.According to one embodiment, it is proposed that a region of the first surface directly adjacent to the rib is melted by laser welding, and molten material at least partially fills the gap between the mutually facing joining surfaces. The laser beam is adjusted so that it impinges on the surface of the second joining surface in the region of the rib, in particular on the end face of the rib. The material of the rib and / or the second part is such that the radiation energy of the laser beam is sufficient to heat the material above its melting point / melting temperature at atmospheric pressure. The melting temperature is preferably reached after less than 2 seconds, preferably less than 1 second of laser irradiation. The material melts and liquefies. The molten material flows into the gap caused by the rib between the first and second joining surfaces.It is understood that after welding, the gap is at least partially closed by the molten and resolidified material. The molten material is located in the gap after welding. As a contact force presses the two parts together during welding, the molten material is forced into the gap. The gap narrows in width due to the melting of the rib material and the contact force.

[0030] According to one embodiment, it is proposed that the molten material of the first surface and the molten material of the rib bond together, at least partially closing the gap between the facing joining surfaces. The laser's energy input onto the second joining surface heats it. The temperature can be sufficient to also reach the melting point of the material of the first joining part adjacent to the rib. The material of the first part and the second part is thus melted in the region of the joining surface, and the molten materials combine to form a melt. This melt flows, as described above, into the gap.

[0031] After the joining surface is no longer exposed to the laser beam, the melt cools and solidifies and the first part is bonded to the second part via the melt.

[0032] According to one embodiment, it is proposed that the molten material fills the gap between the mutually facing joining surfaces substantially only in the region of an inner wall of the housing. The geometry of the two joining surfaces and the arrangement of the rib is preferably such that the melt fills the gap between the mutually facing joining surfaces only in the region of an inner wall of the housing. The rib lies within the second joining surface with its side walls at a respective distance from an inner wall and an outer wall of the housing as well as from the first and second parts. The arrangement is such that the molten material (the melt) flows preferentially and / or initially into the region of the gap between the two parts that lies inside the housing. As a result, this gap is preferably initially closed.Particularly in the region of the opening, the gap extends in the longitudinal direction of the opening, starting from the outer wall to the inner wall of the housing, parallel to the rib. Water can penetrate longitudinally into the interior of the housing through this gap. The described preferred filling of the gap in the inner region ensures that this region of the gap is securely closed. Preferably, such an amount of material of the rib and / or the first part is melted that the volume of the melt is at least equal to, and preferably greater than, the volume of the gap between the inner side wall of the rib and the inner wall of the housing.

[0033] According to one embodiment, it is proposed that a settlement path of the rib caused by the laser welding is greater than 0.1 mm, preferably greater than 0.2 mm and less than 0.5 mm, preferably less than 0.4 mm. As already explained, the material of at least the rib is melted by the laser welding. During laser welding, the first part is pressed against the second part with a force. The force is applied at an angle to the joining surfaces, in particular at right angles. Due to the force on the melting, the rib settles by a settlement path. It is preferred if the settlement path is set as described. As a result, on the one hand, sufficient material is melted to sufficiently fill the gap, and on the other hand, part of the rib remains unmelted.This ensures that the melt flows into the gap in the desired manner. According to one exemplary embodiment, it is proposed that in a cross-section through the second joining surface the rib is arranged off-center, in particular offset in the direction of an inner wall of the housing, in particular that a distance of an inner side wall of the rib to an inner wall of the housing is smaller than a distance of an outer side wall of the rib to an outer wall of the housing. The fact that the rib is closer to the inner wall of the housing than to the outer wall ensures that the material melted by the rib completely closes the gap between the rib and the inner wall of the housing.

[0034] The described arrangement is preferred in the area of ​​the cable entry.

[0035] Preferably, the rib is located centrally in the area outside the cable entry or even in the surrounding collar of the second joining surface. This improves accessibility for the laser.

[0036] It is preferred if the rib is arranged off-center in the region of the cable entry, offset inwards. Furthermore, it is preferred if the rib is also arranged off-center in the region of the remaining housing, i.e. in the region not related to the cable entry, but differently than the region of the cable entry. In particular, the rib can be offset outwards there. In the region of the cable entry, the arrangement towards the center is advantageous in order to seal the longitudinal gap. In the region away from the cable entry, the arrangement is offset outwards in order to close an external gap.

[0037] The laser preferably hits the end face of the fin off-center. In particular, the laser hits the end face of the fin further away from the inner wall of the housing. The fin thus initially melts in this inner area, and the melt is directed toward the inner wall of the housing.

[0038] The laser is preferably passed over the entire end face of the rib in short time sequences. In particular, the laser is passed quasi-simultaneously along the end face of the rib. The laser is passed over the end face in a radially offset manner in the shortest possible time sequence, allowing the entire end face to melt.

[0039] According to one embodiment, it is proposed that the material melted by laser welding completely fills the gap between the housing parts, starting from the rib towards an inner wall of the housing, in particular that the molten material has a bead pointing into the interior of the housing. As already described, the area of ​​the gap between the rib and the inner wall of the housing is critical with regard to longitudinal watertightness. It is therefore proposed to melt a volume such that the gap is completely filled, at least in this area. In particular, more material is melted so that an inwardly projecting bead forms on the inner wall of the housing, in particular in the area of ​​the opening. However, the bead is only so small that the sealing ring described below ensures adequate sealing.

[0040] The sealing ring should preferably be made of a particularly soft and temperature-resistant material. Silicone or rubber are preferred. The insulation, however, can vary. Typical materials are silicone, PVC, or PUR. EPDM, XLPE / XLPO, and PA11 / PA12 are also conceivable. When using a silicone insulation jacket, the sealing ring is preferably also made of silicone.

[0041] In the stripped area, the bare metal of the cable core is mechanically and electrically connected to a branch cable, preferably to its bare metal at a likewise stripped end. Connection can be force-fitting, form-fitting, and / or bonded. Connection can include crimping, soldering, and / or welding. The branch cable can be formed, in particular, as a splice.

[0042] The two cable ends of the main cable, extending from the stripped center tap, protrude from two openings in the housing, and the end of at least one branch cable, extending from the center tap, protrudes from at least a third opening in the housing. More than two cables can also be welded together to form a "star." This could be necessary, for example, if different insulation materials are used in a single cable harness. This allows for a modular design that meets specific requirements.

[0043] Main cables and branch cables can be connected to each other in a first process step. For example, an area in the center of the main cable can be stripped first. One end of a branch cable can also be stripped. A stripped end of a branch cable can be placed on the bare metal of the main cable exposed after stripping. Main and branch cables can be connected to each other with their metallic strands. This is possible, for example, using ultrasonic welding, laser welding, resistance welding, friction welding, or similar processes.

[0044] Main cables and branch cables can be formed as stranded conductors with a large number of strands or as solid conductors with only one strand made of solid material.

[0045] In particular, the main cable can also be designed as a flat conductor rail from which the branch cable branches off. The main cable can also have a round or, in the case of a flat conductor rail, a square conductor cross-section. The branch cable can preferably have a round conductor cross-section.

[0046] After joining the cables, they can be inserted into the upper or lower section, and the cable harnesses can be inserted into the recesses provided in the side panels. The corresponding upper / lower section can then be attached and positioned over the cable harnesses with the recesses aligned. The openings formed by the upper and lower sections enclose the cable harnesses all the way around, particularly the cable insulation.

[0047] According to one embodiment, it is proposed that the cables be arranged in an insulated manner in the region of a respective opening on the housing. Insulation is achieved by placing a sealing ring between the insulation jacket of the cable and the housing. An inner almond surface of the sealing ring rests against the insulation jacket of the cable, and an outer surface of the sealing ring rests against the inner wall of the housing in the region of the opening.

[0048] It is advisable to first pull two sealing rings onto the main cable and position them on either side of the center tap. The insulation of the center tap can be removed before or after this. Another sealing ring can be pushed onto the also stripped end of the branch cable. This can also be done before or after stripping. When removing the insulation, the insulation jacket can be cut open, for example, using a laser or a knife. The sealing ring is preferably made of a plastic that is softer than the housing material and can be referred to as a soft component. The sealing ring is particularly made of an elastomer, EPDM, silicone, or rubber.

[0049] The sealing ring can, for example, consist of a core made of a hard component and outer surfaces made of the soft component. The soft component can enclose the core all the way around. It is also possible for the sealing ring to be formed from a hard component and a soft component along its longitudinal axis. However, the sealing ring can also preferably be formed only from the soft component.

[0050] According to one embodiment, the hard component can be glued or welded to the housing. This creates a sealed, material-to-material joining zone between the inner surface of the opening and the hard component.

[0051] Preferably, however, the soft component rests circumferentially against the cable insulation and circumferentially against an inner surface of the opening. Due to the elastic deformation of the sealing ring, it acts as a seal against longitudinal water.

[0052] The cable is movably mounted in the opening. In order to prevent leaks from occurring due to axial movements of the cable, it is proposed that the sealing ring be formed in a lamellar manner on at least the inner circumferential surface, but preferably also on the outer circumferential surface. In this case, at least two, but preferably more, axially spaced-apart, radially protruding, preferably completely circumferential lamellae can be provided. A lamella on an outer circumferential surface is formed from a region that projects further radially outwards and a region that projects less radially outwards. A lamella on an inner circumferential surface is formed from a region that projects further radially inwards and a region that projects less radially inwards. The lamellae on the outer circumferential surface are preferably suitable for sealing the bead formed by welding.It is preferred if the radial extent of the lamellae relative to the opening is greater than the radial extent of the bead. The radial extent of the lamellae is preferably greater than the radial extent of the bead by a factor of at least 2, preferably at least 5 or at least 10, preferably between 2 and 10, preferably at most 10.

[0053] In a longitudinal section, the lamellae can be triangular, truncated conical, curved, or similar. Here, areas that extend radially further outward can alternate with areas that extend radially further inward.

[0054] According to one embodiment, it is proposed that the sealing ring be bellows-shaped. This allows the sealing ring to compensate for movements along the longitudinal axis of the cable while maintaining its tightness.

[0055] According to one embodiment, it is proposed that the sealing ring has an oversize relative to the opening. Thus, in the joined state, the sealing ring between the housing and the cable is elastically compressed in the radial direction. The inner diameter of the sealing ring is preferably smaller than the outer diameter of the cable with insulation jacket. The outer diameter of the sealing ring is preferably larger than the inner diameter of the opening in the joined state of the housing. The sealing ring is thus pushed onto the cable and elastically stretched in the process. When inserting the sealing ring into the opening and closing the housing, the sealing ring is preferably elastically compressed. As a result, the sealing ring is elastically compressed in the joined state.

[0056] The first joining surface can be flat and the second joining surface can have the rib. The end face of the rib can be flat and lie flat against the first joining surface. Welding can then be carried out particularly in the area of ​​the mutually assigned

[0057] At these contacting joining surfaces, the

[0058] Welding process initiated.

[0059] In this context, it is particularly preferred if the materials of the upper and lower parts (first and second parts) have different optical properties, in particular opacities, from one another. It is particularly preferred if the housing part having the first joining surface has a lower opacity than the housing part having the second joining surface with the rib or only the rib. A laser can then shine through the first part to the joining surface of the second part, heating the materials at this transition between the two housing parts and welding them together.

[0060] To completely seal the housing, we propose that the rib be completely circumferential, with the exception of at least one opening, and then the two housing parts are completely welded together in the manner described. The opening is sealed by the described gasket.

[0061] The opening extends in an axial direction from the interior of the housing outward. The opening preferably protrudes axially outward from the housing. The rib can run along the axial extent of the opening, in particular parallel to it.

[0062] The material of the first and second part is chosen so that their melts combine and are moisture-proof after solidification

[0063] According to one embodiment, it is proposed that the sealing ring is mounted between two axially spaced-apart, at least partially circumferential stops arranged on the inner surface of the housing. One stop can be formed by a projection pointing radially inward in the region of the opening. The projection can be at least partially circumferential. Two axially spaced-apart stops can mount the sealing ring axially in the opening. The stops form a clear width that is smaller than the outer circumference of the sealing ring. It is preferred if a stop is arranged in both the upper part and the lower part, wherein these respective stops form a partially circumferential stop in the joined state. In the joined state, the sealing ring cannot slip axially beyond one of the at least partially circumferential stops.The sealing ring is preferably mounted in an axially compressed manner between the stops. The axial extent of the sealing ring is preferably at least partially greater than the axial distance between the at least partially circumferential stops from one another, so that when the sealing ring is inserted between the stops, it is axially compressed.

[0064] According to one embodiment, the hard component is radially surrounded on both sides by the soft component. In the axial direction, the hard component protrudes beyond the soft component. In the joined state, this hard component protrudes outward beyond the opening. In the protruding region, the hard component encompasses a projection forming the opening on an outer surface. This encompassing region of the hard component can engage with locking means on the outer circumference of the projection forming the opening, particularly relative to the axial direction.

[0065] An axial direction is defined by the direction in which the cable is inserted into the opening. An axial direction can thus be understood, in particular, as a direction that runs transversely, preferably substantially perpendicularly, to the outer surface in which the opening is formed. The axial direction is, in particular, parallel to the surface normal of the surface in which the opening is formed in the assembled state of the housing.

[0066] A radial direction runs perpendicular to the axial direction. The radial direction is preferably the direction of extension of the opening. The radial direction preferably extends outward from a center point of the opening. The opening can be oval, rectangular, round, or the like. The opening is particularly adapted to the cable cross-section, which can be rectangular for a flat cable or round for a round cable.

[0067] A further aspect is a method according to claim 24.

[0068] Laser welding is preferably performed using a diode laser. Due to the selected plastics, the radiation output is such that a diode laser is sufficient. Diode lasers are particularly suitable for industrial production due to their longevity and low power consumption.

[0069] According to one embodiment, during laser welding, a laser beam strikes the joining surfaces at an angle, in particular, the laser strikes the joining surfaces substantially parallel to a surface normal of the first and / or second joining surface. The laser is preferably guided through the first part, exits the first joining surface, and strikes the second joining surface.

[0070] According to one embodiment, during laser welding, the laser is directed through the first joining surface to the rib of the second joining surface. This initially melts the material of the rib.

[0071] According to one embodiment, during laser welding, the laser is focused in such a way that the surface of the rib facing the first joining surface is melted first. This ensures that the laser's radiation power acts preferentially on the end face of the rib, melting it first.

[0072] According to one embodiment, it is proposed that the joining surfaces be pressed against each other during laser welding with a contact force, wherein the contact force runs essentially parallel to a surface normal of the first and / or second joining surface. Pressing together ensures that, when the rib melts, the two parts move toward each other perpendicular to their joining surfaces along the rib's settling path. The contact force ensures that the melt fills the gap and that the two parts of the housing are joined upon cooling.

[0073] According to one embodiment, it is proposed that the contact force be more than 1000 N, preferably more than 2000 N, in particular 3000 N, and / or that the contact force be less than 5000 N, in particular less than 4000 N. It has been shown that this contact force ensures that the melt flows correctly in the gap and that, after cooling, the gap is sealed by the cooled melt. The contact force is preferably adjusted depending on the width of the rib, so that sufficient contact pressure is ensured.

[0074] According to one embodiment, it is proposed that the joining surfaces be exposed to the laser during laser welding for a duration of more than 2 seconds, preferably between 3 seconds and 3.5 seconds, and / or that the joining surfaces be exposed to the laser during laser welding for a duration of less than 5 seconds, preferably less than 4 seconds. This duration ensures, on the one hand, that sufficient material of the rib and the first joining surface melts, and, on the other hand, that the rib is still present after welding.

[0075] The subject matter is explained in more detail below using a drawing showing exemplary embodiments. The drawing shows:

[0076] Fig. 1 a center tap as a splice;

[0077] Fig. 2a-d various embodiments of sealing rings;

[0078] Fig. 3 shows the arrangement of a sealing ring in a cable housing according to one embodiment; Fig. 4 shows the arrangement of a sealing ring in a housing according to one embodiment;

[0079] Fig. 5 shows the arrangement of a sealing ring in a housing according to an embodiment;

[0080] Fig. 6a a cross-section through the two housing parts before laser welding;

[0081] Fig. 6b a cross-section through the two housing parts during laser welding;

[0082] Fig. 6c a cross-section through the two housing parts after laser welding;

[0083] Fig. 7a-c views of a housing according to an embodiment;

[0084] Fig. 8 is a view of a housing according to an embodiment.

[0085] Fig. 1 shows a connection between two cables. A main cable 2 is connected to a branch cable 4. The two cables 2, 4 are formed from a cable core 2a, 4a and an insulation sheath 2b, 4b.

[0086] The cable cores 2a, 4a are made of a metallic material, in particular copper or a copper alloy, and aluminum or an aluminum alloy. The main cable 2 is stripped in a central region 6, i.e. the insulation sheath 2b is removed from the cable core 2a. This can be done in particular by removing the insulation sheath 2b using a laser, in particular by cutting open the insulation sheath 2b using a laser. Starting from the region 6, the cable 2b extends with two cable ends. The cable core 4a of the branch cable 4 is connected to the cable core 2a in the region 6. In particular, there is a material connection. In this case, soldering or welding is particularly possible. However, it is also possible to provide a clamping connection, in particular in the form of a crimp.The connection is preferably formed by welding, in particular by friction welding, preferably by ultrasonic welding or by resistance welding. The cable cores 2a, 4a are thus mechanically and / or electrically connected to one another.

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

[0088] A sealing ring 8 can be provided on the cable 2 at each of the two cable ends, spaced apart from the region 6. A sealing ring 8 can be provided on the cable 4 at a distance from the region 6. The sealing ring 8 will be described in more detail below.

[0089] During production, two sealing rings 8 can be pushed onto the main cable 2 at a distance from the area 6. Before or after this, the insulation sheath 2b in the area 6 can be removed. Subsequently, a stripped cable end of the branch cable 4 is connected in the area 6 with its cable core 4a to the cable core 2a in the manner described above. Before or after this, a sealing ring 8 can be pushed onto the branch cable 4. A connection is formed between a main cable 2 and a branch cable 4, with a sealing ring 8 being pushed onto the respective insulation sheaths 2b, 4b at a distance from the connection at the outgoing cable ends. Such a connection between two cables can be protected against moisture, as will be described below. A sealing ring 8 to be pushed onto the insulation sheaths 2b, 4b is shown as an example in Figures 2a-d.A cross-section and a longitudinal section through a sealing ring 8 are shown.

[0090] In Fig. 2a, the cross-section shows that the sealing ring 8 has an outer circumference 8a and an inner clear width 8b. The inner clear width 8b is geometrically similar, particularly in its profile, to the cross-sectional profile of the respective cable 2, 4, and is preferably round or rectangular.

[0091] A longitudinal section through the sealing ring 8 shows that it has lamellae 12 spaced apart along the axial axis 10 in the region of its inner surface. The lamellae 12 are formed by regions that project radially further inward and regions that project radially less far inward. Radial is a direction perpendicular to the longitudinal axis 10. The lamellae 12 are preferably circumferential to a central axis that runs along the longitudinal axis 10.

[0092] When the sealing ring 8 is pushed on, the lamellae 12 rest on the insulation jacket 2b with their radially inwardly projecting areas.

[0093] For sealing against the housing, it is preferred that, in addition to the lamellae 12, lamellae 14 are also provided on the outer circumference 8a, as shown in Fig. 2b. The lamellae 14 can be formed in a similar manner to the lamellae 12 and have regions that project radially further outward and regions that project radially less outward. The regions that project radially further outward rest against the inner wall surfaces of the housing opening when installed.

[0094] Fig. 2c shows a sealing ring 8 made of a soft component 8' and a hard component 8". The sealing rings 8 according to Figures 2a and b, which are formed only from the soft component 8', are additionally supplemented by a hard component 8" according to Figures 2c and d. According to Fig. 2c, the hard component 8" is provided on the outer circumference of the sealing ring 8. In the longitudinal section according to Fig. 2c, it can be seen that the lamellae 12, as previously described, are provided on an inner circumference.

[0095] A ring made of a hard component 8" is circumferentially located on the outer circumference 8a of the sealing ring 8. A circumferential projection in the manner of a welding lug can be provided on this ring. This projection can, in the joined state, rest against the inner circumferential surface of the housing and be welded there in a manner described above for the joining surfaces. The hard component 8" is preferably made of the same material as an upper or lower side of a housing.

[0096] Fig. 2d shows a further embodiment of a sealing ring 8. In this sealing ring, the hard component 8" extends out of an axial end face of the sealing ring 8. The hard component 8" preferably surrounds the soft component 8" on the outer circumference 8a of the sealing ring 8. The lamellae 12, 14 are provided according to Fig. 2b.

[0097] The part of the hard component 8" which has a U-shaped cross section engages around the outer housing wall when joined, in order to fix the sealing ring 8 in the housing.

[0098] Fig. 7a shows a lower part 16 and an upper part 18 of a housing. It can be seen that the lower part 16 and the upper part 18 are half-shell-shaped. Recesses into which a cable can be inserted are provided in the housing parts 16, 18. The recesses open into openings 20, which are only partially formed by the upper part 18 and the lower part 16 in the unjoined state and only combine to form a complete opening 20 in the joined state.

[0099] A connection according to Fig. 1 can be inserted into a lower part 16, as shown in Fig. 7b. The sealing rings 8 are positioned directly in the area of ​​the openings 20. The upper part 18 is then placed onto the lower part 16.

[0100] Fig. 7c shows how the upper part 18 and lower part 16 are joined to form a housing 22. The upper part 18 and lower part 16 are integrally connected along a weld seam 24. The cable ends of the cables 2, 4 protrude from the openings 20. The openings 20 are shaped such that, together with the sealing ring 8, they form a seal, as will be shown below. Fig. 3 shows a plan view of a lower part 16, whereby the description can also apply, at least in part, to the upper part 18.

[0101] Firstly, it can be seen that the lower part 16 is bowl-shaped and a sealing ring 8 is inserted in the area of ​​each opening 20. The sealing ring 8 rests with its lamellae 14 against the inner surface of the lower part 16. A hard component 8" is provided on the sealing ring 8, projecting beyond an end face. In longitudinal section, the hard component 8" is U-shaped so that it encompasses the outer surface of the lower part 16. In the joined state, the upper part 18 is placed onto the lower part 16. The lamellae 14 are compressed radially inwards. The hard component 8" is then pushed onto the opening so that it encompasses both the upper and lower parts in the area of ​​the opening 20 and fixes them to one another. The cables are not shown in Fig. 3, but rest with their insulation sheaths 2b, 4b against the inner lamellae 12 and elastically deform them radially outwards.

[0102] The sealing ring 8 is compressed in the joined state and seals the opening 20 both on the inside of the housing and the cable sheath.

[0103] A joining surface 24 is provided on the lower part 16. A complementary joining surface 24 is provided on the upper part 18. Fig. 6a shows the two housing parts as upper part 18 and lower part 16 in a cross-section. A cross-section, including the cross-section generally described above, through the housing parts, i.e., also through the joining surfaces, preferably runs perpendicular to a longitudinal extension of the rib.

[0104] The upper part 18 has a joining surface 24a. The surface normal of the joining surface 24a is perpendicular to the surface normal of the cross-sectional area shown, thus perpendicular to an axis extending into the plane of the drawing and parallel to a longitudinal extension of the upper part 18.

[0105] The lower part 16 has a joining surface 24b. The surface normal of the joining surface 24b is perpendicular to the surface normal of the cross-sectional area shown, thus perpendicular to an axis extending into the plane of the drawing and parallel to a longitudinal extension of the lower part 16.

[0106] A rib 26 is arranged on the joining surface 24b. The rib 26 extends longitudinally parallel to the surface normal of the cross-sectional area shown, parallel and perpendicular to the axis extending into the plane of the drawing.

[0107] The rib has two side walls 27a, 27b. Side wall 27a faces the interior of the housing. Side wall 27b faces the exterior of the housing. Furthermore, the rib 26 has an end face 27c. The end face 27c runs parallel to the joining surface 24a.

[0108] As can be seen, the rib 26 is located off-center on the joining surface 24b. The rib 26 is offset toward the interior of the housing. However, it is also possible that the rib 26 is offset toward the exterior of the housing.

[0109] It can also be seen that the joining surfaces 24a, b lie on outwardly projecting collars 44 of the two housing parts. The lower collar 44 on the part with the rib 26 makes it possible to apply a counterholder or stop. A hold-down device can then press against this counterholder with the contact force on the collar 44 of the upper part. The lower collar thus serves as a support surface for the counterholder. A further advantage is that the laser only has to penetrate less material of the first part due to the upper collar in order to strike the end face 27c of the rib 26.

[0110] To join the upper part 18 and the lower part 16, the joining surface 24a faces the joining surface 24b and is placed on the end face 27c of the rib 26, as shown in Fig. 6b. The upper part is then pressed against the lower part 16 with a holding-down device with a contact force in the direction 32. The holding-down device can be pressed against the collar 44. The rib 26 forms a gap 34 between the upper part 18 and the lower part 16.

[0111] The upper part 18 is formed from a material that has a lower opacity than the material of the lower part 16 and / or the material of the rib 26. This allows a laser beam 30 to be guided through the material of the upper part 18 to the joining surface 24. The laser beam 30 radiates through the upper part 18 and heats the materials of the lower part 16 and upper part 18 at the joining surfaces 24a and 24b, in particular the rib 26, and here the end face 27c, so that they melt. The melting area is shown in black.

[0112] During welding, the two housing halves 16, 18 are moved toward each other under pressure, so that they bond when the materials melt. As the materials melt, the melt flows into the gap 34, as shown in Fig. 6c.

[0113] Fig. 6c shows how molten material 36 has flowed into the gap 34. Due to the off-center arrangement of the rib 26, the material 36 flows preferentially towards the inner wall of the housing. It can be seen that a bead 38 is formed on the inner surface of the housing. Material 36 also flows towards the outer wall of the housing. It is shown that the gap 34 between the joining surfaces 24a, b between the side wall 27a and the inner wall of the housing is completely filled with material 36. The gap 34 between the joining surfaces 24a, b can be partially (shown) or completely filled with material 36 between the side wall 27b and the outer wall of the housing.

[0114] The material 36 is formed by melted material from both the rib 26 and the upper part 18. After cooling, the melted material 36 solidifies, and the upper part 18 and lower part 16 are joined together. Through the melting and pressing, the rib 26 is compressed along a set path 42 toward the joining surface 24b. The bead 38 is completely enclosed by the lamellae 14, thus sealing the opening.

[0115] Fig. 4 shows a further embodiment in which the sealing ring 8 is axially fixed in the lower shell 16 at the opening 20 by two stops 40a, 40b. The sealing ring 8 can also be axially compressed by the stops 40a, b. Here, too, the sealing ring 8 provides a seal on the inner surface of the housing and on the insulation jackets in the manner described.

[0116] Fig. 5 shows a further embodiment in which a sealing ring 8 according to Fig. 2c is used. In contrast to the previous embodiments, the sealing of the sealing ring 8 on the inside of the housing is realized via the radially outwardly projecting welding lug. Here, the welding lug can be welded to the inner surface of the lower shell 16 and upper shell 18. In particular, a laser beam is directed to the welding surface, and the weld melts the materials so that they are bonded together after cooling.

[0117] The embodiments according to Figs. 3-5 differ only in the type of sealing rings 8. However, the insertion of the cables and the connection of the upper part 18 and lower part 16 to one another in the manner shown in Figs. 6a and b, as well as in the manners generally described for this purpose, do not differ. Fig. 8 shows a further embodiment. It can be seen that the upper part 18 and lower part 16 each have a collar 44 in the region of their outer edges. The collar 44 on the upper part forms the first joining surface 24a. This is preferably flat. The collar 44 on the lower part 16 forms the second joining surface 24b. The rib 26 runs along the joining surface 24b. The rib 26 extends along the side edge of the lower part 16.

[0118] It can be seen that the radial position of the rib 26 on the joining surface 24b is variable.

[0119] Preferably, the radial position of the rib 26 on the joining surface 24b is variable such that it is differently off-centered at different positions along the longitudinal axis of the joining surface 24b. In particular, the position of the rib 26 in the region of the opening is offset inwardly, off-center, as shown. As the rib continues further, away from the opening 22, the position of the rib 26 on the joining surface 24b shifts. In particular, the position of the rib 26 in the region remote from the opening 18 is offset outwardly, off-center, as shown. In this region, the rib 26 preferably lies on the collar 44 of the lower part 16 and below the collar 44 of the upper part 18.

[0120] Also shown is the trajectory of the laser 30: The laser 30 moves several times radially offset along the longitudinal axis of the rib 26, as shown in dashed lines.

[0121] The laser 30 moves along this trajectory within a very short time, e.g., less than 10 seconds, preferably less than 5 seconds, preferably less than 1s. In particular, the laser moves along this trajectory in such a time that material of the rib 26 that has already melted no longer solidifies. This allows the entire surface of the rib 26 to be melted, and the upper part 18 can be welded along the rib 26 by pressing it onto the lower part 16. In particular, the entire rib 26 is melted in this way. The laser irradiates the surface of the rib 26 quasi-simultaneously by tracing and irradiating the longitudinal axis of the rib 26 several times in a radially offset manner. This takes place within a time span in which the molten material cannot solidify, so that a full-surface join can be created between the joining surface 24a and the end face of the rib 26.

[0122] List of reference symbols

[0123] 2 main cables

[0124] 4 branch cables

[0125] 2a, 4a cable core

[0126] 2, 4b Insulation jacket

[0127] 6 Area

[0128] 8 Seal

[0129] 8' soft component

[0130] 8" hard component

[0131] 8a Outer circumference

[0132] 8b clear width

[0133] 10 Longitudinal axis

[0134] 12, 14 slats

[0135] 16 Lower part

[0136] 18 top

[0137] 20 Opening

[0138] 22 housings

[0139] 24a, b joining surfaces

[0140] 26 rib

[0141] 27a,b side wall

[0142] 27c frontal surface

[0143] 30 laser beam

[0144] 32 direction

[0145] 34 gap

[0146] 36 Materials

[0147] 38 bulge

[0148] 40a, b stop

[0149] 42 setting path

[0150] 44 collar

Claims

Patent claims 1. Cable sealing housing with an at least two-part housing with an upper part and a lower part, at least one opening formed as a cable entry in the housing, wherein the upper part and the lower part each form part of the openings, wherein in the joined state of the housing, mutually facing joining surfaces of the upper part and lower part are laser-welded to one another, characterized in that a first of the mutually facing joining surfaces is a substantially flat surface and that a second of the mutually facing joining surfaces has a rib protruding in the direction of the surface normal of this joining surface and that by the laser welding a region of the rib facing the first surface is melted and molten material of the rib at least partially fills a gap between the mutually facing joining surfaces.2 Cable sealing housing according to claim 1, characterized in that by laser welding a directly adjacent to the rib. region of the first surface is melted and molten material at least partially fills the gap between the mutually facing joining surfaces. . Cable sealing housing according to claim 2, characterized in that the molten material of the first surface and the molten material of the rib bond together and the gap between the facing joining surfaces disappears at least partially.

4. Cable sealing housing according to one of the preceding claims, characterized in that the molten material fills the gap between the mutually facing joining surfaces in the region of an inner wall of the housing.

5. Cable sealing housing according to one of the preceding claims, characterized in that a setting path of the rib caused by the laser welding is greater than 0.1 mm, preferably greater than 0.2 mm and less than 0.5 mm, preferably less than 0.4 mm.

6. Cable sealing housing according to one of the preceding claims, characterized in that in a cross-section through the second joining surface, the rib is arranged off-center, in particular offset towards an inner wall of the housing, in particular that a distance of an inner side wall of the rib to an inner wall of the housing is less than a distance of an outer side wall of the rib to an outer wall of the housing, or that in a cross-section through the second joining surface, the rib is arranged off-center, in particular offset towards an outer wall of the housing, in particular that a distance of an outer side wall of the rib to an outer wall of the housing is less than a distance of an inner side wall of the rib to an inner wall of the housing. . Cable sealing housing according to one of the preceding claims, characterized in that the material melted by the laser welding completely fills the gap between the housing parts, starting from the rib towards an inner wall of the housing, in particular that the melted material has a bead pointing into the interior of the housing.

8. Cable sealing housing according to one of the preceding claims, characterized in that at least one branch cable, in particular as a splice, is connected to a stripped center tap of a main cable within the housing and that the cable ends of the main cable leading from the center tap are led out of the housing through two openings and that the at least one branch cable is led out of the housing through at least a third opening.

9. Cable sealing housing according to one of the preceding claims, characterized in that the cables are insulated in the region of a respective opening.

10. Cable sealing housing according to one of the preceding claims, characterized in that at least one of the openings has a sealing ring formed from at least one soft component that rests circumferentially on the insulation of the respective cable and circumferentially on an inner surface of the respective opening.

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

12. Cable sealing housing according to one of the preceding claims, characterized in that the sealing ring is bellows-shaped.

13. Cable sealing housing according to one of the preceding claims, characterized in that the upper part and the lower part are formed from plastics with different opacities.

14. Cable sealing housing according to one of the preceding claims, characterized in that the rib is formed from a less opaque material than the material of the joining surface adjacent to the rib. •15. Cable sealing housing according to one of the preceding claims, characterized in that the rib is arranged on the upper part and the flat joining surface on the lower part or that the rib is arranged on the lower part and the flat joining surface on the upper part.

16. Cable sealing housing according to one of the preceding claims, characterized in that the rib is completely circumferential with the exception of at least one opening.

17. Cable sealing housing according to one of the preceding claims, characterized in that the rib is arranged in the region of the opening.

18. Cable sealing housing according to one of the preceding claims, characterized in that the rib is welded to the flat surface in such a way that the molten material seals the gap in a moisture-tight manner.

19. Cable sealing housing according to one of the preceding claims, characterized in that in the joined state the sealing ring between the housing and the cable is compressed in the radial direction.

20. Cable sealing housing according to one of the preceding claims, characterized in that the sealing ring is mounted between two axially spaced-apart stops arranged on the inner circumferential surface of the housing and extending at least partially around the opening.

1. Cable sealing housing according to one of the preceding claims, characterized in that the sealing ring is formed from a soft component and a hard component.

2. Cable sealing housing according to one of the preceding claims, characterized in that the hard component is formed on an outer circumference of the sealing ring with a radially outward-pointing projection, and the projection is welded to the upper part and the lower part.

3. Cable sealing housing according to one of the preceding claims, characterized in that the hard component extends in the axial direction beyond the opening into a sealing section. A method for producing a cable sealing housing according to any one of the preceding claims, comprising: Providing a first part and a second part of a housing with at least one opening formed as a cable entry in the housing, wherein the first part and the second part form an upper part and a lower part of the housing, Applying the two parts with mutually facing joining surfaces, wherein a first of the mutually facing joining surfaces is a flat surface and a second of the mutually facing joining surfaces has a rib protruding from a surface in the direction of the surface normal of this surface and laser welding the first part to the second part along the mutually abutting joining surfaces, wherein during laser welding a region of the rib facing the flat surface is melted and the melted material of the rib partially fills a gap between the mutually facing joining surfaces. Method according to claim 24, characterized in that the joining surfaces are welded with a diode laser. Method according to claim 24 or 25, characterized in that during laser welding a laser beam is directed at an angle to the Joining surfaces, in particular, the laser strikes the joining surfaces essentially parallel to a surface normal of the first and / or second joining surface. Method according to one of claims 24 to 26, characterized in that during laser welding, the laser strikes the rib of the second joining surface through the first joining surface. Method according to one of claims 24 to 27, characterized in that during laser welding, the laser is focused such that the surface of the rib facing the first joining surface is melted first. Method according to one of claims 24 to 28, characterized in that during laser welding, the joining surfaces are pressed against one another with a contact force, wherein the contact force runs essentially parallel to a surface normal of the first and / or second joining surface. Method according to one of claims 24 to 29, characterized in that the contact force is more than 1000 N, preferably more than 2000 N, in particular 3000 N, and / or that the contact force is less than 5000 N, in particular less than 4000 N.Method according to one of claims 24 to 30, characterized in that the joining surfaces are exposed to the laser for a duration of more than 2 s, preferably between 3 s and 3.5 s, during laser welding, and / or that the joining surfaces are exposed to the laser for a duration of less than 5 s, preferably less than 4 s, during laser welding.

Images