assembly of an electric cable with a cable terminal

Abstract

Title of the invention: Assembling an electric cable with a cable terminal Method for crimping a cable terminal (10) onto an electric cable (1), with the following steps: Providing an electric cable (1) having an outer insulation sheath (3) and at least one conductive strand (2), with a sheathed portion (1g), Providing a terminal (10) having hoop wings (15) and providing a seal (11) having a sealing portion (14) and a hoop portion (12), Stripping the electric cable (1) so as to form a stripped portion (1d), Positioning the hoop portion (12) of the seal (11) so as to directly cover the stripped portion (1d) of the cable (1), without the hoop portion (12) covering the sheathed portion (1g) of the cable (1), Fully crimping the hoop wings (15) onto the hoop portion (12) of the seal (11) without the hoop wings (15) covering the sheathed portion (1g) of the cable (1). Abstract figure: Figure 1

Description

Title of the invention: assembly of an electric cable with a cable terminal Technical field of the invention

[0001] The present description relates generally to an electrical cable terminal assembly, for example in the field of connectors and electrical cables in a motor vehicle. State of the art

[0002] In many applications it is necessary to mount electrical cables on terminals or connector housings and to make the connection waterproof against moisture or dust, etc. For this purpose, sealing gaskets are used, which are arranged on the cable sheath and which provide sealing between the cable and the inner walls of the terminal or connector housing.

[0003] There is known in the prior art an assembly with an electric cable terminal, as disclosed in document US5824962.

[0004] The conventional rubber seal comprises a first part having sealing lips that provide a sealing function, and a second part is adapted to be fixed to the sheathed wire. More specifically, an insulating piece of the metal terminal is forcibly deformed to surround the rubber seal around the entire periphery of the sheathed wire, thereby fixing the rubber seal to the sheathed wire. Further provided in this prior art document is an intermediate piece entwined on the peripheral surface of the seal.

[0005] In return, the assembly of the prior art above has the disadvantage of having an interface part which makes the assembly more expensive and more complex to manufacture. In addition, the assembly of the prior art cannot adapt to several cable diameters and does not ensure good fixing of the joint on the electric wire.

[0006] Furthermore, since known seals are made of an elastic material, crimping can lead to severe deformations of the seal. These deformations not only impair the sealing properties, but also have the effect that the minimum tensile force requirements between the seal and the electrical cable are no longer met. Thus, a loosening of the crimped connection between the electrical cable and the seal can occur when handling the cable or when pulling the crimped terminal (e.g. out of a housing).

[0007] Furthermore, document EP2856568B1 discloses a seal. The seal comprises a sealing portion and a hooping portion, with an additional reinforcing element. cooperating with a flange. The reinforcing element improves the crimping, "protects" the joint during crimping and reduces deformation of the relatively flexible joint. However, the reinforcing element is an additional part that increases the cost of the joint and makes its manufacture more complex. Statement of the invention

[0008] An object of the present disclosure is to address the above-mentioned drawbacks of the prior art and to improve cable terminal assemblies and in particular, firstly, to provide an assembly of an electrical cable and a cable terminal, the cable being provided with an outer insulating sheath and at least one conductive strand, and having a sheathed portion and a stripped portion, the assembly further having a seal with a sealing portion and a hooping portion, the terminal having hooping wings, and wherein the sealing portion of the seal is assembled onto the sheathed portion of the cable, and the hooping portion of the seal is assembled directly onto the stripped portion of the cable, and the hooping wings are fully assembled onto the hooping portion of the seal.

[0009] This makes it possible to provide a cable terminal assembly that can adapt to different diameters of electrical cable while ensuring good assembly and good fixing of the terminal on the cable, in particular under traction. In addition, this makes it possible not to damage the cable during assembly, nor to damage the seal, which thus ensures good sealing and good fixing. Furthermore, this makes it possible to reduce the number of parts and to facilitate assembly and manufacturing, which reduces manufacturing costs. The assembly is thus adaptable to different cable diameters.

[0010] The term "sheathed portion" or "insulated portion" means a portion of the cable in which the external insulating sheath partially or completely covers the at least one conductive strand, and the term "bare portion" means a portion of the cable in which the external insulating sheath does not cover the at least one conductive strand.

[0011] A cable terminal is understood to mean a cable connector arranged to be connected to another cable connector, of the same cable or of another cable.

[0012] Preferably, the cable has a plurality of conductive strands.

[0013] Advantageously, the hooping wings are arranged to crimp (or allow crimping of) the seal at the hooping portion, so as to pinch it vigorously (i.e. firmly).

[0014] Advantageously, the hoop wings do not overlap when they are crimped onto the hoop portion of the joint.

[0015] In other words, the hoop wings are not juxtaposed (also called “O” hooping).

[0016] This makes it possible to improve the fixing of the hoop wings on the joint, so that all of the hoop wings are in contact with the joint.

[0017] In a preferred embodiment, the hooping portion has a shoulder arranged to abut the sheathed portion of the cable.

[0018] This ensures precise positioning of the seal on the cable and thus ensures better fixing, while facilitating manufacturing.

[0019] Advantageously, the cable terminal further has a male distal part or a female distal part.

[0020] This allows the cable terminal to be connected to another cable terminal having the compatible distal part, and to connect two cable ends together (i.e. two cables, or the same coiled cable). Thus, a first terminal having a male distal part can be connected to a second terminal having a female distal part.

[0021] The present disclosure also relates to a method of crimping a cable terminal onto an electrical cable, with the following steps:

[0022] - Providing an electrical cable having an outer insulating sheath and at least one strand conductor, with a sheathed portion,

[0023] - Providing a terminal having hoop wings and providing a seal having a portion sealing and a portion of hooping,

[0024] - Strip the electrical cable so as to form a stripped portion,

[0025] - Position the hooping portion of the seal so as to directly cover the portion stripped of the cable, without the hooping portion covering the sheathed portion of the cable,

[0026] - Fully crimp the hoop wings onto the hoop portion of the joint without the hoop wings do not cover the sheathed portion of the cable.

[0027] Advantageously, the stripped portion is increased, that is to say it has a significant length which is greater than the stripped portion of a conventional cable and / or greater than the hooping portion of the joint.

[0028] Advantageously, the step of stripping the electrical cable so as to form a stripped portion can be replaced by the step of providing the electrical cable with the stripped portion.

[0029] This makes it possible to propose a crimping method (or hooping method) that is easy to implement, improving the fixing and holding of the cable terminal on the cable, without damaging either the terminal or the cable, which improves the service life of both. In addition, this makes it possible to adapt the same terminal model to different electrical cables of different diameters. That is to say, this makes it possible to use a known joint and crimp it with the new crimping method described. In other words, this makes it possible to use an existing joint and apply the crimping method of the cable terminal on the electrical cable using an existing joint. This also prevents damage to the binding portion.

[0030] Advantageously, the method further has the following step:

[0031] - Position the sealing portion of the seal at the level of the sheathed portion of the cable without the sealing portion of the gasket covering the stripped portion of the cable.

[0032] This ensures better fixing of the terminal on the cable.

[0033] Advantageously, the method further has the following step:

[0034] - Fully crimp the hoop wings onto the hoop portion of the joint without the hoop wings do not overlap.

[0035] This ensures that the terminal is securely attached to the cable.

[0036] Advantageously, the method further has the following step:

[0037] - Abut a shoulder of the hooping portion of the seal on the sheathed portion of the cable.

[0038] This ensures that the terminal is correctly positioned before crimping. Description of the figures

[0039] Other characteristics and advantages of the present description will appear more clearly on reading the following detailed description of an embodiment given by way of non-limiting example and illustrated by the appended drawings, in which:

[0040] [Fig-1] represents a side view of an assembly of an electrical cable and a cable terminal according to the present description,

[0041] [Fig.2] represents a top view of the assembly according to the present description,

[0042] [Fig.3] shows a schematic representation of an electric cable and the method crimping according to the present description.

[0043] [Fig.4] represents the schematic representation of the process with additional steps comments,

[0044] [Fig.5] represents the schematic representation of the process with further steps additional,

[0045] [Fig.6] represents an assembly according to the prior art,

[0046] [Fig.7] represents a joint according to the prior art.

[0047] Detailed description of the embodiments

[0048] [Fig.l] shows a side view of an assembly of an electrical cable and a cable terminal according to the present description.

[0049] A cable 1 has an outer insulating sheath 3 and a plurality of conductive strands 2 with a sheathed portion 1g of the cable 1 and a stripped portion 1d of the cable 1. The cable 1 has a longitudinal axis XX'. An axis YY' is shown in order to delimit the sheathed portion 1g of the cable 1 and the stripped portion Id of the cable 1. The outer insulation sheath 3 is preferably made of plastic and the conductive strands 2 are preferably made of a conductive material such as copper. In a particular embodiment, the outer diameter of the sheath 3 is 4.8 mm (or between 4 and 5 mm) and the inner diameter of the sheath 3 is 3.2 mm (or between 3 and 4 mm). The conductive strands 2 each have a diameter of 0.32 mm (or between 0.25 mm and 0.35 mm). Note that the conductive strands 2 may each have a different diameter.

[0050] The assembly of the electric cable 1 with an electric cable terminal 10 is shown. The terminal 10 has hoop wings 15. The assembly further has a seal 11 having a sealing portion 14 and a hoop portion 12, wherein the sealing portion 14 of the seal 11 is assembled on the sheathed portion 1g of the cable 1, and the hoop portion 12 of the seal 11 is assembled directly on the stripped portion 1d of the cable 1. The hoop wings 15 are fully assembled on the hoop portion 12 of the seal 11. The seal 11 has rotational symmetry and can easily be manufactured by a two-component molding process.

[0051] In a preferred embodiment, the seal 11 is made of a plastic material, in particular silicone. The sealing portion 14 has waves on its external diameter, which vary between 4.25 mm and 7.2 mm. The hooping portion 12 has a smaller diameter than the sealing portion 14. The hooping portion 12 may have a diameter of 2.3 mm (or between 2 and 3 mm). The hooping portion 12 may have a length of 3.2 mm and the sealing portion may have a length of 4.3 mm.

[0052] The hoop wings 15 are made of metal, preferably steel, and are connected to a second hoop portion 16 directly crimped or clamped onto the conductive strands 2. The second hoop portion 16 is connected to a distal part 17, which may be male or female, so as to connect the terminal 10 to another distal part 17 compatible with another terminal 10. The second hoop portion 16 and the distal part 17 are made of a conductive material, preferably steel. The second hoop portion 16, once crimped onto the conductive strands 2, leaves a short end 2a of the conductive strands 2. Thus an electric current can flow from the conductive strands 2 of the cable 1 to the distal part 17.

[0053] The hooping portion 12 of the joint 11 is positioned on the stripped portion Id of the cable 1, so as to be in direct contact with the conductive strands 2. The hooping wings 15 are then pinched on the hooping portion 12 of the joint 11, and closed on the hooping portion 12, without the hooping wings 15 touching each other. The hooping wings 15, preferably two in number, thus entirely touch the hooping portion 12 of the joint 11, but are not juxtaposed one on the other. A space of 0.2 mm can thus be present between the hooping wings 15 at their distal end, when they are closed.

[0054] Preferably, the seal 11 has an internal shoulder 18 (shown schematically in [Fig.4]) so as to abut on the sheathed portion 1g of the cable 1 when assembling the seal 11 on the cable 1. This ensures the correct positioning of the seal 11 on the cable 1, and the correct alignment of the hooping portion 12 on the stripped portion 1d of the cable 1. Thus, when crimping the hooping wings 15 on the hooping portion 12 of the seal 11, the correct fixing of the terminal 10 on the cable 1 by means of the seal 11 is ensured, and the seal 11 is not damaged (for example by incorrect positioning of the hooping wings 15).

[0055] The shoulder 18 is produced at the change in diameter between the hooping portion 12 and the sealing portion 14 of the seal 11, so as to come opposite the sheathed portion 1g when the seal 11 is introduced into the cable 1 from the stripped portion 1d, along the longitudinal axis XX'. Thus, the shoulder 18 comes into abutment against the sheathed portion 1g at the axis YY'.

[0056] The seal 11 further has a collar 19, so as to guide the hooping wings 15, in particular during crimping and once crimped.

[0057] [Fig.2] represents a top view of the assembly. The reference signs are retained as much as possible, in relation to [Fig.l].

[0058] The space between the hoop wings 15 is thus visible in the top view. The hoop wings 15 thus cover 98% of the hoop portion 12 of the joint 11 in a preferred embodiment. In addition, the crimping of the second hoop portion 16 on the conductive strands 2 is shown, as well as the end 2a of the conductive strands 2.

[0059] [Fig. 3] shows a schematic representation of an electrical cable and the crimping method according to the present description.

[0060] The cable 1 is provided with the stripped portion Id in which the conductive strands 2 are exposed and bare, and the sheathed portion 1g in which the conductive strands 2 are insulated and covered by the outer insulation sheath 3. The stripped portion Id is stripped so as to form a preferably increased stripped portion. In other words, the inner peripheral surface of the hooping portion 12 will be entirely in contact with the stripped portion Id, once assembled.

[0061] [Fig.4] shows the schematic representation of the method with additional steps. The seal 11 is provided and inserted into the end of the cable 1, from the stripped portion Id. The hooping portion 12 of the seal 11 is positioned so that the inner peripheral surface of the hooping portion 12 is directly and fully in contact with the stripped portion Id of the cable 1 without the hooping portion 12 covering the sheathed portion 1g of the cable 1.

[0062] The sealing portion 14 of the seal 11 is thus positioned at the level of the sheathed portion 1g of the cable 1 without the sealing portion 14 of the seal 11 covering the stripped portion Id of cable 1.

[0063] The method may further include the step of abutting the shoulder 18 of the hooping portion 12 of the seal 11 on the sheathed portion 1g of the cable 1g, at the axis YY'. This ensures the correct positioning of the seal 11 of the terminal 10.

[0064] [Fig.5] shows the schematic representation of the process with further additional steps.

[0065] The step of providing the terminal 10 having the hoop wings 15 and providing the seal 11 having the sealing portion 14 and a hoop portion 12 is divided into sub-steps of first providing the seal 11 with the sealing portion 14 and the hoop portion 12, and then providing the hoop wings 15 coming as a single piece with the second hoop portion 16 and the distal piece 17.

[0066] The next step is to completely crimp the hoop wings 15 onto the hoop portion 12 of the joint 11 without the hoop wings 15 covering the sheathed portion 1g of the cable 1. Thus the hoop portion 12 is not damaged at the time of crimping.

[0067] Furthermore, the entire crimping of the hoop wings 15 onto the hoop portion 12 of the joint takes place without the hoop wings 15 overlapping.

[0068] The step of crimping the second hooping portion 16 onto the conductive strands 2 is also carried out.

[0069] It is possible to provide the electric cable 1 directly with the increased stripped portion Id, that is, the step of stripping the electric cable 1 is directly carried out with the correct dimension. In other words, the stripped portion Id is directly with the correct stripped dimension.

[0070] [Fig.6] represents an assembly according to the prior art, as described in document US5824962.

[0071] The conventional rubber seal 50 comprises a first portion having sealing lips 51 which provide a sealing function, and a second portion 55 is adapted to be fixed to the sheathed wire 52. More specifically, an insulating piece 54 of the metal terminal 53 is forcibly deformed to surround the rubber seal around the entire periphery of the sheathed wire 52, thereby fixing the rubber seal to the wire 52. Further provided in this prior art document is an intermediate piece entwined on the peripheral surface of the seal at the fixing.

[0072] [Fig.7] represents a joint according to the prior art, as described in document EP2856568B1.

[0073] The seal comprises a sealing portion 32 and a hooping portion 31, with an additional reinforcing element 34 cooperating with a flange 33. The reinforcing element improves crimping, "protects" the seal during crimping and reduces deformations of the relatively flexible seal.

[0074] It will be understood that various modifications and / or improvements obvious to those skilled in the art can be made to the different embodiments described in the present description. In particular, reference is made to the inversion of the steps provided that this is not incompatible. It is also possible to provide neutral distal parts which can be coupled regardless of the corresponding distal part to be coupled.

Claims

Claims

1. An assembly of an electric cable (10) and a cable terminal (10), the cable (1) being provided with an outer insulating sheath (3) and at least one conductive strand (2), and having a sheathed portion (1g) and a stripped portion (Id), the assembly further having a joint (11) with a sealing portion (14) and a hooping portion (12), the terminal (10) having hooping wings (15), and wherein the sealing portion (14) of the joint (11) is assembled on the sheathed portion (1g) of the cable (1), and characterized in that the hooping portion (12) of the joint (11) is assembled directly on the stripped portion (Id) of the cable (1), and the hooping wings (15) are fully assembled on the hooping portion (12) of the joint (11).

2. An assembly according to claim 1, wherein the hoop wings (15) do not overlap when crimped onto the hoop portion (12) of the joint (11).

3. Assembly according to one of claims 1 to 2, in which the hooping portion (12) has a shoulder (18) arranged to abut on the sheathed portion (1g) of the cable (1).

4. Assembly according to one of claims 1 to 3, further having a male distal part (17) or a female distal part (17).

5. A method of crimping a cable terminal (10) onto an electrical cable (1), with the following steps: • Providing an electrical cable (1) having an outer insulating sheath (3) and at least one conductive strand (2), with a sheathed portion (1g), • Providing a terminal (10) having hoop wings (15) and providing a seal (11) having a sealing portion (14) and a hoop portion (12), • Stripping the electrical cable (1) so as to form a stripped portion (Id), • Positioning the hoop portion (12) of the seal (11) so as to directly cover the stripped portion (Id) of the cable (1), without the hoop portion (12) covering the sheathed portion (1g) of the cable (1), • Fully crimping the hoop wings (15) onto the sealing portion (14) and a hoop portion (12), hooping (12) of the joint (11) without the hooping wings (15) covering the sheathed portion (1g) of the cable (1).

6. Crimping method according to claim 5, further having the following step: • Positioning the sealing portion (14) of the seal (11) at the sheathed portion (1g) of the cable (1) without the sealing portion (14) of the seal (11) covering the stripped portion (1d) of the cable (1).

7. Crimping method according to one of claims 5 to 6, further having the following step: • Fully crimping the hoop wings (15) onto the hoop portion (12) of the joint (11) without the hoop wings (15) overlapping.

8. Crimping method according to one of claims 5 to 7, in which the step: • Stripping the electric cable (1) so as to form a stripped portion (Id), is replaced by the step: • Providing the electric cable (1) with the stripped portion (Id).

9. Crimping method according to one of claims 5 to 8, further having the following step: • Abutting a shoulder (18) of the hooping portion (12) of the joint (11) on the sheathed portion (1g) of the cable (1).

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