DEVICES, TOOLS, AND METHODS FOR FORMING SUCH DEVICES - Patent application

Abstract

To avoid a mechanical damage to an electric conductor, and prevent a crimp barrel from receiving a non-uniform mechanical load which may cause a possibility of opening the crimp barrel due to damage.SOLUTION: An apparatus 10 includes: contact means 15; and an electric cable 20 having a first electric conductor 25. The contact means includes: a crimp barrel 60; and a contact element 65 mechanically and electrically connected to the crimp barrel. The crimp barrel includes a first inner peripheral surface 75 and a first external peripheral surface 85, in which a first in-press 115 and a second in-press 120 deviated to a circumferential direction to an axis from the first in-press are formed by die pressing in a first lower part 110 of at least the crimp barrel, the first inner peripheral surface is pressed to a second external surface 109 of the first electric conductor, the first and second in-presses form the first inner peripheral surface so as to be electrically contacted to the second external surface, and the first inner peripheral surface is tightly fitted to the second external surface.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a device according to claim 1, a tool according to claim 8 and a method for forming such a device according to claim 13. [Background technology]

[0002] Numerous designs of contact means are known which are connected to the electrical conductors of an electrical cable by crimp contact, where the crimp contact is achieved by pressing a portion of the contact means onto the electrical cable, and in the process the electrical conductors can be displaced or damaged by the shaped portion of the contact means. Summary of the Invention [Problem to be solved by the invention]

[0003] It is an object of the present invention to provide an improved apparatus, an improved tool, and an improved method of forming such an apparatus. [Means for solving the problem]

[0004] This object is achieved by an apparatus according to claim 1, a tool according to claim 8 and a method according to claim 13. Advantageous embodiments are specified in the dependent claims.

[0005] It has been discovered that an improved device can be provided, since it includes a contact means and an electrical cable having a first electrical conductor. The contact means includes a crimping barrel and a contact element mechanically and electrically connected to the crimping barrel. The crimping barrel extends along an axis. The crimping barrel has a first inner circumferential surface and a first outer circumferential surface. A first impression and a second impression, offset circumferentially from the first impression relative to the axis, are formed within at least a first lower portion of the crimping barrel. The first inner circumferential surface is formed by the first impression and the second impression such that the first inner circumferential surface presses against the second outer circumferential surface of the first electrical conductor and electrically contacts the second outer circumferential surface. The first inner circumferential surface fits closely to the second outer circumferential surface.

[0006] When the first inner peripheral surface is pressed against the first electrical conductor, the radial length of the first inner peripheral surface can be reduced while substantially maintaining its basic shape. This has the advantage that mechanical damage to the electrical conductor is avoided. In addition, this prevents the crimping barrel from being subjected to uneven mechanical loads that could cause the crimping barrel to break open. This ensures a particularly good electrical and mechanical connection between the contact means and the electrical conductor, making the device particularly reliable and particularly durable, even in the presence of large vibrations.

[0007] Since the first inner peripheral surface is substantially maintained relative to the basic shape of the crimped barrel, i.e., before the crimped barrel is crimped or before the first inner peripheral surface is concentrically reduced, the crimped barrel has a particularly large contact surface with the first electrical conductor.

[0008] Additionally, the close fit to the first inner circumferential surface avoids damage, such as shearing or cutting, to the individual wires of the first electrical conductor.

[0009] In another embodiment, the first inner peripheral surface is substantially shaped to have a circular cross section relative to the axis, so that the crimped barrel is particularly mechanically stable and is not mechanically damaged by the crimping process.

[0010] In a further embodiment, a protrusion is formed circumferentially on the first outer peripheral surface between the first and second impresses, and the crimping barrel has a maximum material thickness radially at this protrusion that is greater than the maximum material thickness at the first and / or second impresses. This design has the advantage that the maximum material thickness is substantially constant radially inside the first and / or second impresses.

[0011] In another embodiment, the electrical cable includes an electrically insulating intermediate layer and a second electrical conductor, the intermediate layer circumferentially covering the second electrical conductor and electrically insulating it from the first electrical conductor. The first electrical conductor is disposed outside the intermediate layer and covers the intermediate layer. The contact element has an opening through which the intermediate layer and the second electrical conductor pass. In this design, the first electrical conductor, for example, can be realized as a shield and contacted by the contact means. The second electrical conductor can be electrically contacted by another contact means.

[0012] In another embodiment, the contact element has a connecting portion and a contact portion, and the connecting portion is electrically and mechanically connected to the contact portion. The connecting portion and the contact portion are preferably formed integrally and from the same material. The connecting portion is realized as a hollow cylinder. An annular gap is realized between the first inner peripheral surface of the crimping barrel and the connecting portion, and the first electrical conductor is arranged in this annular gap. This design is particularly preferred when the first electrical conductor is designed as a shield for contacting the first electrical conductor, and it is ensured that the shielding effect of the electrical conductor is maintained by the crimping barrel and the connecting portion.

[0013] In another embodiment, a third impress is stamped into the crimp barrel to create a convex shape on the first inner peripheral surface, which forms a fourth impress on the connecting portion, which engages with the fourth impress to create a push-fit connection, by which the crimp barrel is connected to the connecting portion.

[0014] In another embodiment, the crimp barrel is circumferentially solid about the axis.

[0015] A tool can be provided that is particularly suitable for forming the above-mentioned device, the tool having a guide means, at least one first pressing jaw and a second pressing jaw circumferentially spaced from the first pressing jaw, the first pressing jaw and the second pressing jaw being arranged by the guide means to be radially movable between a radially outer first position and a radially inner second position.

[0016] The first pressure jaw has a radially inner first pressure surface, and the second pressure jaw has a radially inner second pressure surface, the first and second pressure surfaces together delimiting the crimp barrel and the tool receiving portion for receiving the first electrical conductor, and the guide means is designed to introduce a radially inward pressing force into the first pressure jaw and the second pressure jaw, respectively, such that in each case the first pressure jaw impresses a first impression on the crimped portion, and the second pressure jaw impresses a second impression on the crimped portion, pressing the first inner peripheral surface against the second outer peripheral surface.

[0017] This design has the advantage that the tool uniformly deforms the crimp barrel without forcing the crimp barrel material onto the electrical conductors.

[0018] In another embodiment, the guide means is designed to move the first and second pressure jaws synchronously between a first radially outer position and a second radially inner position. The simultaneous movement of the two pressure jaws ensures that the crimping barrel is pressed particularly uniformly against the electrical conductor.

[0019] In another embodiment, the first pressing surface and the second pressing surface are realized both in a radially outer first position and in a radially inner second position, in each case extending together in a common circular path around the axis of the tool receiving part.

[0020] It is particularly advantageous if a gap is located between the first and second pressing jaws in the circumferential direction relative to the axis, the gap having a gap width in the circumferential direction. The first pressing surface has a first length in the circumferential direction, the gap width being smaller than the first length. The ratio of the first length to the gap width is at least in the range of 1.5 to 10, preferably in the range of 2 to 9, in particular in the range of 3 to 8.

[0021] In another embodiment, the tool has at least one further first pressing jaw, the first pressing jaw and the second pressing jaw being arranged circumferentially offset from one another in a predefined pattern, in particular at a regular distance. The further first pressing jaw is coupled to the guide means and is movable between a first radially outer position and a second radially inner position. Alternatively, the further first pressing jaw is arranged stationary.

[0022] In the case of a stationary design, it is particularly advantageous that the electrical cable can be placed in a first, stationary pressing jaw, and that when the impress is pressed, the pressing jaw advances the cable, thereby not moving the cable.

[0023] It is particularly advantageous if the above-described tool is used to form the above-described device, and a tool, an electrical cable, and contact means are provided. A first electrical conductor is pressed into the crimping barrel. The crimping barrel, together with the first electrical conductor, is inserted into the tool receiving portion. The first and second pressing jaws are moved radially inward from a first radially outer position to a second radially inner position. The first pressing jaw presses the first impress against the crimping barrel, and the second pressing jaw presses the second impress against the crimping barrel, and the first pressing jaw and the second pressing jaw press the first inner peripheral surface against the second outer peripheral surface so that the first inner peripheral surface closely fits the second outer peripheral surface.

[0024] Therefore, the first inner peripheral surface has a reduced radial length while maintaining its basic shape. In other words, the first inner peripheral surface before the first and second impresses and the first inner peripheral surface after the first and second impresses are concentric with each other.

[0025] In this case, it is particularly advantageous if the first pressure jaw and the second pressure jaw are moved synchronously radially inwards towards the axis.

[0026] The present invention will be described in more detail below with reference to the accompanying drawings. [Brief explanation of the drawings]

[0027] [Figure 1] 1 is a perspective view of an apparatus according to a first embodiment; [Figure 2] 2 is a perspective view of a contact element of the contact means of the device shown in FIG. 1; FIG. [Figure 3] FIG. 3 is a longitudinal cross-sectional view of the contact element shown in FIG. 2. [Figure 4] 2 is a cross-sectional view of the device shown in FIG. 1 taken along section AA shown in FIG. 1. [Figure 5] FIG. 2 is a longitudinal cross-sectional view of the device shown in FIG. [Figure 6] FIG. 6 is a perspective view of a tool for forming the device shown in FIGS. 1 to 5. [Figure 7] FIG. 7 is a top view of the tool shown in FIG. 6. [Figure 8] 8 is a flow diagram of a method for forming the device shown in FIGS. 1-5 by the tool shown in FIG. 7. [Figure 9] FIG. 10 shows the crimping barrel during the third step of the method. [Figure 10] FIG. 10 is a perspective view of an apparatus according to a second embodiment. [Figure 11] 11 is a cross-sectional view of the device shown in FIG. 10 taken along section BB shown in FIG. 10. [Figure 12] FIG. 8 is a top view of a development of the tool shown in FIGS. 6 and 7; [Figure 13]FIG. 10 is a perspective view of an apparatus according to a third embodiment. [Figure 14] FIG. 14 is a longitudinal cross-sectional view of the device shown in FIG. [Figure 15] FIG. 8 is a perspective view of a development of the tool shown in FIGS. 6 and 7; DETAILED DESCRIPTION OF THE INVENTION

[0028] FIG. 1 shows a detailed perspective view of a device 10 according to a first embodiment.

[0029] The device 10 includes a contact means 15 and an electric cable 20. The electric cable 20 is illustratively realized as a shielded cable. The electric cable 20 includes a first electric conductor 25. The first electric conductor 25 can be realized as a shield or an outer conductor. The first electric conductor 25 extends along an axis 30. In this case, the first electric conductor 25 is realized as a hollow cylinder approximately parallel to the axis 30. In this case, the first electric conductor 25 can include a wire braid of fine or ultra-fine wires. The wire braid can be woven or constructed from individual wires extending parallel to the axis 30.

[0030] For ease of understanding, the apparatus 10 will be described below in terms of a cylindrical coordinate system relative to axis 30.

[0031] The first electrical conductor 25 is radially outwardly coated with a coating 35. The first coating 35 is formed from a first electrically insulating material and electrically insulates the first electrical conductor 25 from the environment 40. The coating 35 preferably completely surrounds the circumference of the first electrical conductor 25.

[0032] The electrical cable 20 has, radially inward, for example, an electrically insulating intermediate layer 45. In this embodiment, the electrically insulating intermediate layer 45 is circumferentially surrounded by the first electrical conductor 25. The electrical cable 20 has, radially inward of the intermediate layer 45, for example, a second electrical conductor 50.

[0033] The second electrical conductor 50 can be formed from a single wire. The second electrical conductor 50 can also be formed from a bundle of wires, for example, fine or ultra-fine wires. The second electrical conductor 50 can also be called an inner conductor. The second electrical conductor 50 can be used, for example, to transmit data signals. In this case, the transmitted current is less than 1 A. The second electrical conductor 50 can also be designed for the transmission of electrical energy, for example, to supply power to an electric motor. Preferably, for this purpose, the second electrical conductor 50 has a diameter of at least 2 mm. 2 , preferably 5 mm 2 , especially at least 10 mm 2 , preferably at least 25 mm 2 The second electrical conductor 50 has a cross-sectional area of, for example, 200 mm 2 Below, 100mm 2 Below, 50mm 2 It can be designed to be as follows:

[0034] The first electrical conductor 25 and / or the second electrical conductor 50 are made of a conductive second material, preferably copper and / or aluminum and / or gold and / or silver. The first electrical conductor 25 and the second electrical conductor 50 can be made of the same material or different materials.

[0035] Intermediate layer 45 electrically insulates second electrical conductor 50 from first electrical conductor 25. In this embodiment, first electrical conductor 25 is designed to electromagnetically shield second electrical conductor 50 from environment 40. In particular, first electrical conductor 25 is intended to prevent large currents (e.g., 100 A) carried by second electrical conductor 50 from generating electromagnetic fields that interfere with other electrical devices in the vicinity of electrical cable 20. Thus, first electrical conductor 25 improves the electromagnetic compatibility of apparatus 10.

[0036] The contact means 15 comprises a crimp barrel 60 and a contact element 65 connected to the crimp barrel 60. The crimp barrel 60 and the contact element 65 are arranged directly adjacent to each other with respect to the axis 30. In its basic shape, the crimp barrel 60 is realized, for example, as a hollow cylinder with respect to the axis 30 and extends along the axis 30. The crimp barrel 60 is made of a third material, which is electrically conductive. The contact element 65 may likewise be made of a third material. The contact element 65 is also electrically conductive and serves to make an electrical contact to another contact means 70 (shown in dashed lines in FIG. 1 ).

[0037] By means of the first inner peripheral surface 75, the crimp barrel 60 delimits internally the crimp receiving portion 80. In this embodiment, the crimp barrel 60 is of continuous design, and in particular is gapless, meaning that in this embodiment, over its entire length along the axis 30, the crimp barrel 60 does not have any slits or gaps extending radially outward from the first inner peripheral surface 75 to the first outer peripheral surface 85 of the crimp barrel 60.

[0038] The crimp barrel 60 additionally has a first face 90 and a second face 95, with the first face 90 arranged on the side of the crimp barrel 60 facing towards the contact element 65 and the second face 95 arranged on the side of the crimp barrel 60 facing away from the contact element 65. The first end face 90 and the second end face 95 are substantially perpendicular to the axis 30 and have a substantially annular basic shape in plan view. In this case, the first face 90 is offset from the second face 95 in the direction of the axis 30. The electrical cable 20 has a covering portion 100 and a stripped portion 105, within which the electrical cable 20 is realized as described above. In the stripped portion 105, the covering 35 has been removed from the first electrical conductor 25, so that the first electrical conductor 25 is electrically accessible on the radially outer side and is not protected by the first covering 35. The first electrical conductor 25 has a second outer circumferential surface 109 that is freely accessible within the stripped portion 105 .

[0039] When the contact means 15 is attached to the electrical cable 20, the crimping barrel 60 has at least one first impress 115 in the first lower portion 110 and one second impress 120 circumferentially offset from the first impress 115. The first lower portion 110 is adjacent to the second end face 95, for example in the direction of the axis 30. The first lower portion 110 can also be spaced apart from the second end face 95.

[0040] The first impress 115 and the second impress 120 have substantially the same length not only in the circumferential direction but also in the direction of the axis 30. In Figure 1, for example, the first impress and / or the second impress extend substantially over the entire maximum length of the crimp barrel 60 in a direction parallel to the axis.

[0041] A protrusion 130, realized in the form of a rib, extends between the first impress 115 and the second impress 120. The protrusion 130 projects radially outward beyond the first impress 115 and the second impress 120. The protrusion 130 is significantly thinner in the circumferential direction than the first impress 115 and / or the second impress 120.

[0042] FIG. 2 shows a perspective view of the contact element 65 of the contact means 15 shown in FIG.

[0043] The contact element 65 has a connecting portion 135 and a contact portion 140, the connecting portion 135 being adjacent to the contact portion 140 in the direction of the axis 30. The contact portion 140 has, on the side facing the connecting portion 135, a third end face 145 aligned perpendicular to the axis 30. In this case, the contact portion 140 extends radially outward as an edge on the connecting portion 135 and can protrude radially beyond the connecting portion 135.

[0044] The connecting portion 135 is realized, for example, as a hollow cylinder. The contact element 65 has an opening 150 on the inside, which extends through the entire contact element 65 along the axis 30. In this case, the axis 30 is positioned centrally with respect to the opening 150.

[0045] The contact portion 140 is for example realized in the shape of a disk relative to the axis 30. The contact portion 140 is only symbolically represented in Figure 2 and serves to provide contact to the further contact means 70. The contact portion 140 can for example be of a different design than that shown in Figure 3.

[0046] The connecting portion 135 and the contact portion 140 are mechanically and electrically connected to one another and are preferably integrally formed from the same material.

[0047] FIG. 3 shows a longitudinal cross-sectional view of the contact element 65 shown in FIG.

[0048] The contact element 65 is, for example, rotationally symmetrical with respect to the axis 30. The connecting portion 135 is preferably formed integrally with the contact portion 140 from the same material. The connecting portion 135 has, radially outwardly, a third outer peripheral surface 155, for example realized in the form of a cylinder around the axis 30. The connecting portion 135 is longer than the crimping barrel 60 in a direction parallel to the axis.

[0049] FIG. 4 shows a cross-sectional view of the device 10 shown in FIG. 1 taken along section AA shown in FIG.

[0050] Preferably, a plurality of first and second impresses 115, 120 are stamped into the crimping barrel 60 at the first outer peripheral surface 85. In this case, it is particularly advantageous if the first and / or second impresses 115, 120 each extend over a respective angular section of approximately 20 to 60°, preferably 30 to 45°. The protrusions 130 are significantly thinner in the circumferential direction than the first and / or second impresses 115, 120. In the circumferential direction relative to the axis 30, the protrusions 130 can extend over an angular section of approximately 0.5° to 2°, in particular 0.7° to 1.5°.

[0051] In this embodiment, a plurality of first and second impresses 115, 120 are provided in the circumferential direction of the crimping barrel 60. The first and second impresses 115, 120 are substantially identical to one another and have substantially the same distance from one another in the circumferential direction.

[0052] The intermediate layer 45 is radially spaced from a second inner circumferential surface 160 of the contact element 65. In this case, the second inner circumferential surface 160 radially bounds the opening 150.

[0053] FIG. 5 shows a half-longitudinal cross-section of the device 10 shown in FIG.

[0054] The crimping barrel 60 defines an annular gap 210 with its first inner circumferential surface 75 and third outer circumferential surface 155, and the first electrical conductor 25 is disposed in the annular gap 210. As a result, the first electrical conductor 25 is enlarged compared to the jacket portion 100 of the cable 20. The first inner circumferential surface 75 fits closely against the second outer circumferential surface 109 of the first electrical conductor 25.

[0055] When assembled, by implementing the first impress 115 and the second impress 120, the crimp barrel 60 is pressed or crimped onto the first electrical conductor 25 such that the first inner peripheral surface 75 fits closely against the second outer peripheral surface 109, substantially flush against the second outer peripheral surface 109. As a result of pressing the first inner peripheral surface 75 against the second outer peripheral surface 109, the crimp barrel 60 is in electrical contact with the first electrical conductor 25. Additionally, the first inner peripheral surface 75 forms a frictional connection with the second outer peripheral surface 109. As a result of pressing the crimp barrel 60 onto the first electrical conductor 25, the first inner peripheral surface 75 is pressed against the second outer peripheral surface 109 with a pressing force F. C The force is applied from the radially outer side to the radially inner side in the direction of the axis 30 by the force. In this case, the pressure F C The pressure F presses the first electrical conductor 25 radially inward against the third outer peripheral surface 155 of the connecting portion 135. The connecting portion 135 is designed to have pressure stability in the radial direction, and the pressure F C The reaction force F corresponding to G provides a reaction force F G is the pressing force F CThe reaction force F acts from the inside to the outside in the radial direction against the G supports the first electrical conductor 25 radially inward. C and reaction force F G As a result, the first electrical conductor 25 forms a frictional connection radially inward with the connecting portion 135 of the crimp barrel 60 and a frictional connection radially outward with the first inner circumferential surface 75. The frictional connection causes both the crimp barrel 60 and the first electrical conductor 25 to be frictionally connected to the connecting portion 135.

[0056] Intermediate layer 45 and second electrical conductor 50 are routed through opening 150. Connection portion 135 protects intermediate layer 45 and second electrical conductor 50 from compression.

[0057] FIG. 6 shows a perspective view of the tool 165.

[0058] The tool 165 is designed as a crimping tool and has at least one first pressing jaw 170 and at least one second pressing jaw 175 arranged circumferentially relative to the first pressing jaw 170. Preferably, the tool 165 has a plurality of pressing jaws 170, 175 arranged at a distance from each other in the circumferential direction. In addition, the tool 165 can have at least one guide means 180, which is only symbolically represented in Figure 6. The guide means 180 is connected to each of the pressing jaws 170, 175.

[0059] The first pressure jaw 170 has a first pressure surface 185 that is located radially inward of the first pressure jaw 170 and extends a cylindrical segment about the axis 30. The second pressure jaw 175 has a second pressure surface 190 that extends another cylindrical segment relative to the axis 30.

[0060] In this embodiment, the tool 165 has, for example, six pressing jaws 170, 175, which are, for example, identical to one another in design. In this case, the pressing jaws 170, 175 each extend over an equal angular section relative to the axis 30. The pressing jaws 170, 175 can also differ from one another in design. In this embodiment, the pressing jaws 170, 175 are spaced apart from one another in the circumferential direction, with a respective gap 191 extending between the first pressing jaw 170 and the second pressing jaw 175, the gap 191 extending from the radially inner to the radially outer direction from the pressing surfaces 185, 190. In this case, the pressing jaws 170, 175 are, for example, realized such that the gaps 191 have substantially the same gap width in the circumferential direction and increase in radial distance from the axis 30. The gap width of gap 191 may also increase with increasing distance from axis 30 .

[0061] The first pressing surface 185 and / or the second pressing surface 190 have a first length in the circumferential direction, and the gap width of the gap 191 is smaller than the first length. The ratio of the first length to the gap width is preferably at least in the range of 1.5 to 10, preferably in the range of 2 to 9, in particular in the range of 3 to 8.

[0062] FIG. 7 shows a top view of the tool 165.

[0063] The guide means 180 are designed to move the pressure jaws 170, 175 between a first radially outer position and a second radially inner position.

[0064] 7, the solid lines show the pressure jaws 170, 175 in a first radially outer position. The pressure surfaces 185, 190 are arranged in a common first circular path 195 at the first radially outer position. The pressure surfaces 185, 190 radially delimit the tool receiving portion 205.

[0065] The guide means 180 (not shown in FIG. 7 for reasons of clarity) can simultaneously and synchronously move the pressing jaws 170, 175 between a first radially outer position and a second radially inner position. The guide means 180 can, for example, comprise a link guide. The guide means 180 can also include hydraulically actuated elements and actuators designed to move the pressing jaws 170, 175 between the first radially outer position and the second radially inner position.

[0066] 7, the first pressing surface 185 and the second pressing surface 190 are arranged together in a common second circular path 200 about the axis 30. The first circular path 195 and the second circular path 200 are concentric with the axis 30.

[0067] When the pressure jaws 170, 175 are in the second radially inner position, the gap 191 is circumferentially narrower than when the pressure jaws 170, 175 are in the first radially outer position.

[0068] Figure 8 shows a flow diagram of a method for forming the device 10 shown in Figures 1-6. Figure 9 shows a perspective view of the crimp barrel 60 during the third method step 310.

[0069] In a first method step 300, the pressure jaws 170, 175 are moved to a radially outward first position.

[0070] The first method step 300 is followed in a second method step 305 by cutting the electric cable 20, for example coming from a reel, and immediately after cutting, removing the coating 35 from the first electric conductor 25, to achieve a stripped portion 105.

[0071] In a third method step 310, the crimp barrel 60 and contact element 65 are provided in an uncrimped state.

[0072] In the uncrimped state (see FIG. 9), the crimped barrel 60 is realized as a substantially hollow cylinder. In this case, the crimped barrel 60 has a substantially constant material thickness b in the radial direction relative to the axis 30. UThe crimp barrel 60 may be formed from a thin-walled material, such as, for example, sheet metal. In this embodiment, the inner diameter d of the crimp barrel 60 is greater than the length 1, for example, along the axis 30. In this embodiment, the inner diameter d is greater than the maximum outer diameter d of the connecting portion 135. MAX is selected to be larger.

[0073] The third method step 310 is followed by a fourth method step 315 in which the crimp barrel 60 is threaded over the electrical cable 20 or the electrical cable 20 is inserted into the crimp barrel 60 .

[0074] The fourth method step 315 is followed by a fifth method step 320 in which the first electrical conductor 25 is, for example, expanded outwards, which can be done, for example, by means of a mandrel.

[0075] In addition, the intermediate layer 45 and the second electrical conductor 50 are inserted into the opening 150 so that the second electrical conductor 50 and the intermediate layer 45 protrude toward the side of the contact element 65 facing away from the connection portion 135.

[0076] In this case, the contact element 65 is positioned so that the connecting portion 135 is radially engaged between the intermediate layer 45 and the first electrical conductor 25. The first electrical conductor 25 radially surrounds the connecting portion 135 and abuts the third outer peripheral surface 155.

[0077] In a sixth method step 325 following the fifth method step 320, the crimping barrel 60 is pressed against the connection portion 135 and the first electrical conductor 25 arranged in the connection portion 135. In this case, the crimping barrel 60 forms an annular gap 210 having a third outer peripheral surface 155 (see FIG. 5 ), and the expanded first electrical conductor 25 is arranged in the annular gap 210.

[0078] In a seventh method step 330, which follows the sixth method step 325, the device 10 is positioned in the tool receiver 205 such that the pressing surfaces 185, 190 are positioned in radial overlap with the crimping barrel 60. In this case, radial overlap is understood to mean that two components, e.g., the pressing jaws 170, 175 and the crimping barrel 60, overlap when projected radially in the plane in which the axis 30 extends. Likewise, the pressing jaws 170, 175 have a radial overlap with the connection portion 135 and the expanded first electrical conductor 25 in the stripping portion 105.

[0079] In this embodiment, the crimping barrel 60 and the pressure jaws 170, 175 have the same length along the axis 30. In this case, the pressure jaws 170, 175 and the crimping barrel 60 are positioned to have a complete radial overlap.

[0080] In an eighth method step 335 following the seventh method step 330, the guide means 180 in each case applies a radially inward pressing force F C into the pressure jaws 170, 175. Additionally, the guide means 180 moves the pressure jaws 170, 175 from a first radially outer position to a second radially inner position. The pressure jaws 170, 175 each tightly contact the second outer peripheral surface 109 of the crimping barrel 60 with their respective pressure surfaces 185, 190.

[0081] The connecting portion 135 is stiffer than the crimp barrel 60. This is achieved in that the additional wall thickness of the connecting portion 135 is significantly greater than the wall thickness d of the crimp barrel 60 (preferably by a factor of 1.5 to 10).

[0082] Pressing force F C is applied, the connecting portion 135 is subjected to a reaction force F acting radially outward. G Provides a pressing force F Cis introduced into the crimping barrel 60, causing the crimping barrel 60 to press against the first electrical conductor 25, such that the first inner peripheral surface 75 closely fits against and substantially flush with the first outer peripheral surface 85 of the first electrical conductor 25. The geometric design of the first pressing surface 185 and the first pressing jaw 170 allows the first impress 115 to apply a pressing force F C 7 , the first inner circumferential surface 75 of the first electrical conductor 25 fits closely to the first outer circumferential surface 85 of the first electrical conductor 25, thereby substantially maintaining a circular shape.

[0083] Upon stamping, some of the material of the crimp barrel 60 flows into each gap 191 to form the respective protrusions 130. As a result, the crimp barrel 60 has a different material thickness d in the circumferential direction, and thus the material thickness d on the radially inner side of the first impress 115 and the second impress 120 W is smaller than the protrusion 130. The imprinting of the first impress 115 and the second impress 120 also has the advantage of stiffening the crimp barrel 60 and thus preventing undesired widening of the crimp barrel 60 after removal of the pressing jaws 170, 175. In addition, the crimp barrel 60 presses the first electrical conductor 25 against the connection portion 135, which thus frictionally secures the first electrical conductor 25 together with the crimp barrel 60.

[0084] Due to the embossing of the first and second impresses 115, 120 and the resulting reduction in the inner diameter d of the crimping barrel 60, in a ninth method step 340 following the eighth method step 335, the crimping barrel 60 remains under the pressure F even after the removal of the pressure jaws 170, 175. Cat least partially maintains the frictional connection between the crimping barrel 60 and the first electrical conductor 25 or between the first electrical conductor 25 and the connecting portion 135, thereby pressing the first electrical conductor 25 radially inward against the third outer peripheral surface 155, and thus still maintaining a frictional connection between the crimping barrel 60 and the first electrical conductor 25 or between the first electrical conductor 25 and the connecting portion 135.

[0085] The close fit of the first inner peripheral surface 75 against the first electrical conductor 25 prevents portions of the crimp barrel 60 from penetrating into the first electrical conductor 25 when the first and second impresses 115, 120 are stamped. Conversely, after the first and second impresses 115, 120 are stamped, the crimp barrel 60 still has a substantially cylindrical shape at the first inner peripheral surface 75, but now has a reduced inner diameter d.

[0086] This design has the advantage that damage to the first electrical conductor 25 due to stamping of the crimping barrel 60 is avoided. On the one hand, this ensures a particularly good electrical contact between the first electrical conductor 25 and the connection portion 135, and on the other hand, it ensures a particularly good mechanical connection between the first electrical conductor 25 and the contact means 15.

[0087] The ninth method step 340 is followed by a tenth method step 345 in which the second electrical conductor 50 can be electrically contacted, for example by an additional further contact means 70 .

[0088] FIG. 10 shows a perspective view of the device 10 according to the second embodiment.

[0089] The apparatus 10 is substantially identical to the apparatus 10 described in Figures 1 to 9. Only the differences between the apparatus 10 shown in Figure 10 and the apparatus 10 described in Figures 1 to 9 will be discussed below.

[0090] The device 10 shown in FIG. 10 further comprises at least one third impress 215 in the crimping barrel 60. The third impress 215 is, for example, thinner along the axis 30 than the first impress 115 or the second impress 120. In this case, the third impress 215 can also be stamped into the first impress 115 and / or the second impress 120. The third impress 215 is, for example, realized to be deeper in the radial direction than the first impress 115 and / or the second impress 120. In addition, the third impress 215 is thinner in the circumferential direction than the first impress 115 and / or the second impress 120. In this case, the third impress 215 can be elongated.

[0091] In this embodiment, by way of example, two third impresses 215 are provided which are offset from one another in the circumferential direction, for example by 180°. It is also possible to provide a different number of third impresses 215. When positioning the third impresses 215, it is particularly advantageous if the third impresses 215 are offset from the protrusion 130 in the circumferential direction.

[0092] FIG. 11 shows a cross-sectional view of device 10 taken along section line BB shown in FIG.

[0093] The third impress 215 is illustratively shaped such that the third impress 215 forms a convexity 220 on the first inner circumferential surface 75. The convexity 220 is tangent to the third outer circumferential surface 155 and protrudes through the annular gap 210. When the third impress 215 is pressed into the crimp barrel 60, the convexity 220 displaces the first electrical conductor 25 in a circumferential direction (symbolically represented by an arrow in FIG. 11 ).

[0094] It is particularly advantageous if, when the third impress 215 is stamped into the crimping barrel 60, the convexity 220 stamps a fourth impress 225 (shown by a dashed line in FIG. 11 ) into the connecting portion 135, the convexity 220 engages with the fourth impress 225, and thus, in addition to the frictional connection between the convexity 220 and the third outer peripheral surface 155, the crimping barrel 60 achieves a press-fit connection by the engagement of the convexity 220 in the fourth impress 225.

[0095] FIG. 12 shows a side view of a first pressure jaw 170 of a tool 165 in a further development of the tool shown in FIGS.

[0096] The tool 165 is designed to realize the device 10 shown in Figures 10 and 11. The second pressing jaw 175 is essentially identical to the second pressing jaw 175 shown in Figures 6 and 7. Hereinafter, only the differences between the first pressing jaw 170 shown in Figure 12 and the first pressing jaw 170 shown in Figures 6 and 7 will be discussed.

[0097] The first pressing jaw 170 has a formation 230 on the first pressing surface 185 that projects radially inwardly above the first pressing surface 185 and, in this embodiment, extends in a circular path 195, 200 about the axis 30. The formation 230 can be, for example, elongated in a direction parallel to the axis 30 and can extend substantially along the axis 30 in its main length direction.

[0098] The mold 230 is designed to accommodate the third impress 215. Thus, the mold 230 is shorter than the first pressing jaw 170 in the direction parallel to the axis 30.

[0099] The method of forming the device 10 is implemented to be substantially identical to the method described in Figure 8. Additionally, in an eighth method step 335, simultaneously with the first pressing surface 185 impressing the first impress 115, a third impress 215 is also impressed into the crimp barrel 60, thereby forming or impressing the convex shape 220. In this case, the mold 230 can project radially inward to a length such that the mold 230 similarly forms / impresses a fourth impress 225 into the connecting portion 135, impressing and securing the crimp barrel 60 to the connecting portion 135.

[0100] FIG. 13 shows a perspective view of the device 10 according to the third embodiment.

[0101] The apparatus 10 is substantially identical to the apparatus 10 shown in Figures 1 to 12. Only the differences between the apparatus 10 shown in Figure 13 and the apparatus 10 shown in Figures 1 to 9 will be discussed below.

[0102] 1 to 9, for example, the electric cable 20 is realized only by the first electric conductor 25. The first electric conductor 25 serves, for example, to transmit electric energy between two components. In this case, the first electric conductor 25 serves to transmit power, i.e., the current transmitted by the first electric conductor 25 is at least 1 A, preferably at least 5 A, at least 10 A, at least 20 A, at least 50 A, at least 100 A, and less than 200 A, 400 A, or 500 A. The transmitted current is transmitted via the first electric conductor 25 for at least 5 seconds.

[0103] The first electrical conductor 25 is disposed, for example, along the axis 30 and is preferably at least 5 mm 2 , preferably at least 10 mm 2 , preferably at least 25 mm 2 , preferably at least 50 mm 2 , and 200mm 2The first electrical conductor 25 has a cross-sectional area of ​​less than 1 / 4 inch. In this case, the first electrical conductor 25 can be realized by a single wire or by fine or ultra-fine wires, with several individual wires combined to form a bundle of wires. The individual wires, for example, run parallel to one another or are twisted together. The first electrical conductor 25 is electrically insulated from the environment 40 by a coating 35.

[0104] FIG. 14 shows a longitudinal cross-sectional view of the device 10 shown in FIG.

[0105] In this embodiment, the connecting portion 135 is omitted and the crimping barrel 60 of Figures 13 and 14 is realized integrally and from the same material as the contact portion 140. The contact portion 140 is realized, for example, in the form of a disk and the opening 150 in the contact element 65 is omitted.

[0106] To form the device 10 shown in Figures 13 and 14, the formation method described in Figure 8 is carried out in substantially the same manner, and only the differences compared to the method described in Figure 8 will be discussed below.

[0107] In a third method step 310, the crimp barrel 60 and contact element 65 are provided integrally from the same material in an uncrimped state.

[0108] In a fourth method step 315 , the first electrical conductor 25 is inserted into the contact element 65 to a length that abuts the contact portion 140 at the end face or is spaced a predefined distance from the contact portion 140 .

[0109] The fifth method step 320 and the sixth method step 325 are omitted and the seventh method step 330 is performed in the fourth method step 315 so that the tools 165 overlap radially.

[0110] In an eighth method step 335 following the seventh method step 330, the guide means 180 in each case applies a radially inward pressing force F Cinto the pressure jaws 170, 175. Additionally, the guide means 180 moves the pressure jaws 170, 175 from a first radially outer position to a second radially inner position. The pressure jaws 170, 175 each tightly contact the second outer peripheral surface 109 of the crimping barrel 60 with their respective pressure surfaces 185, 190.

[0111] F C A pressing force is introduced into the crimping barrel 60, resulting in the crimping barrel 60 being pressed against the first electrical conductor 25, such that the first inner peripheral surface 75 closely fits against and substantially flush against the first outer peripheral surface 85 of the first electrical conductor 25. The geometric design of the first pressing surface 185 and the first pressing jaw 170 allows the first impress 115 to apply a pressing force F C The second pressing jaw 175 presses the second impress 120 into the first outer peripheral surface 85 with a second pressing surface 190.

[0112] In addition, the pressure F C The close fit of the first inner peripheral surface 75 and the first electrical conductor 25 presses the individual wires of the first electrical conductor 25 together until the crimp barrel 60 and the first electrical conductor 25 are fully compressed. G is provided by the first electrical conductor 25.

[0113] FIG. 15 shows a perspective view of a further development of the device 10 shown in FIGS. 1 to 9 and the tool 165 shown in FIGS.

[0114] The tool 165 is substantially identical to the tool 165 shown in FIG. 6. Unlike the tool 165 shown in FIG. 6, the guide means 180 is realized in such a way that all the pressing jaws 170, 175 can be moved between a first radially outer position and a second radially inner position, except for the first pressing jaw 170 located below. The first pressing jaw 170 located below is fixed to the guide means 180 but is not connected to the guide means 180. In this case, the guide means 180 is designed to move the other pressing jaws 170, 175 between the first radially outer position and the second radially inner position, so that the fixed first pressing jaw 170, together with the first pressing surface 185, is maintained in each case on a first circular path 195 and a second circular path 200, as shown in FIG. 6. As a result, when the pressure jaws 170, 175 are moved between the first radially outer position and the second radially inner position, the axis 30 is moved relative to the first, non-movable first pressure jaw 170 in a direction perpendicular to the axis 30.

[0115] This design has the advantage that the components for realizing the device 10, namely the contact means 15 and the electrical cable 20, can be arranged in the immovable first pressing jaw 170, thus preventing undesired movement during stamping of the impresses 115, 120. [Explanation of symbols]

[0116] 10 equipment 15 Contact Methods 20 Electrical Cables 25 First Electrical Conductor 30 axes 35 Covering 40 Environment 45 Middle Class 50 Second Electrical Conductor 60 Crimping Barrel 65 Contact Elements 70 Further contact methods 75 first inner surface 80 Crimp receiving part 85 First outer surface 90 First end face 95 Second end face 100 (cable) covering 105 (cable) peeled part 109 Second outer surface 110 First Subdivision 115 First Impress 120 The Second Impress 125 Second Subdivision 130 Protrusion 135 Connection part 140 Contact part 145 Third End Face 150 aperture 155 Third outer surface 160 second inner surface 165 Tools 170 First pressing jaw 175 Second pressing jaw 180 Guidance means 185 First pressing surface 190 Second pressing surface 191 Gap 195 First Circular Path 200 Second circular path 205 Tool receiving section 210 Annular Gap 215 The Third Impress 220 Convex 225 The Fourth Impression 230 Molding 300 first method step 305 Second Method Step 310 Third Method Step 315 Fourth Method Step 320 Fifth Method Step 325 Sixth Method Step 330 Seventh Method Step 335 Eighth Method Step 340 9th method step 345 Tenth Method Step

Claims

1. an electrical cable (20) having contact means (15) and a first electrical conductor (25); The contact means (15) comprises a crimp barrel (60) and a contact element (65) mechanically and electrically connected to the crimp barrel (60); The crimping barrel (60) extends along an axis (30); The crimping barrel (60) has a first inner circumferential surface (75) and a first outer circumferential surface (85); a first impress (115) and a second impress (120) circumferentially offset from the first impress (115) relative to the axis (30) are imprinted in at least a first lower portion (110) of the crimping barrel (60); the first inner peripheral surface (75) is formed by the first impress (115) and the second impress (120) such that the first inner peripheral surface (75) is pressed against the second outer peripheral surface (109) of the first electrical conductor (25) and the first inner peripheral surface (75) is in electrical contact with the second outer peripheral surface (109); said first inner peripheral surface (75) closely fits said second outer peripheral surface (109); The contact element (65) is realized as a hollow cylinder and has a connecting portion (135) and a contact portion (140) electrically and mechanically connected to each other, the contact portion (140) having a larger outer diameter than the connecting portion (135); The crimping barrel (60) has the first inner peripheral surface (75) pressed against the second outer peripheral surface (109) of the hollow cylindrical first electrical conductor (25) at the connection portion (135), When the first and second impressions (115, 120) are molded into at least the first lower portion (110) of the crimping barrel (60), the first inner peripheral surface (75) is substantially shaped to have a circular cross section relative to the axis (30). Apparatus (10).

2. A protrusion (130) is formed between the first impress (115) and the second impress (120) in the circumferential direction; the crimping barrel (60) has a maximum material thickness in the radial direction at the projection (130) that is greater than the first impress (115) and / or the second impress (120); 2. The device (10) of claim 1.

3. The electrical cable (20) has an electrically insulating intermediate layer (45) and a second electrical conductor (50); the intermediate layer (45) circumferentially covers the second electrical conductor (50) and electrically insulates the second electrical conductor (50) from the first electrical conductor (25); The first electrical conductor (25) is disposed outside the intermediate layer (45) and covers the intermediate layer (45); The contact element (65) has an opening, and the intermediate layer (45) and the second electrical conductor (50) pass through the opening (150).

3. An apparatus (10) according to claim 1 or 2.

4. the connecting portion (135) and the contact portion (140) are integrally formed from the same material; An annular gap (210) is formed between the first inner peripheral surface (75) of the crimping barrel (60) and the connecting portion (135); The first electrical conductor (25) is disposed in the annular gap (210). An apparatus (10) according to any one of claims 1 to 3.

5. The crimping barrel (60) has no gap in the circumferential direction relative to the shaft (30). An apparatus (10) according to any one of claims 1 to 4.

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