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EP0566969A2 - Procédé de la fabrication d'un peigne de câbles - Google Patents

Procédé de la fabrication d'un peigne de câbles Download PDF

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Publication number
EP0566969A2
EP0566969A2 EP93106017A EP93106017A EP0566969A2 EP 0566969 A2 EP0566969 A2 EP 0566969A2 EP 93106017 A EP93106017 A EP 93106017A EP 93106017 A EP93106017 A EP 93106017A EP 0566969 A2 EP0566969 A2 EP 0566969A2
Authority
EP
European Patent Office
Prior art keywords
wiring harness
lines
casing
harness according
contact elements
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP93106017A
Other languages
German (de)
English (en)
Other versions
EP0566969A3 (fr
Inventor
Gerhard Reichinger
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Leoni AG
Original Assignee
Leonische Drahtwerke AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Leonische Drahtwerke AG filed Critical Leonische Drahtwerke AG
Publication of EP0566969A2 publication Critical patent/EP0566969A2/fr
Publication of EP0566969A3 publication Critical patent/EP0566969A3/fr
Withdrawn legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/0045—Cable-harnesses
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/20—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for assembling or disassembling contact members with insulating base, case or sleeve
    • H01R43/24—Assembling by moulding on contact members
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/28—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26

Definitions

  • the invention relates to a method for producing a wire harness with the method steps according to the preamble of claim 1.
  • the subject of a further invention is an inventive wire harness according to the preamble of independent claim 6.
  • the cable harnesses mentioned at the outset are preferably installed as cable sets in automobiles. However, there are also many other possible uses for cable harnesses, for example installation in water and aircraft and use in plant construction.
  • a particularly advantageous embodiment of a wire harness is in the EP-B-0 288 752 described.
  • This known cable harness has several cables bundled in the cable harness and enclosed by a molded body.
  • the peculiarity of the cable harness described there is that the molded body enclosing the lines consists of several sub-areas with different materials with regard to their elasticity.
  • the great advantage of this selection of materials is that the molded body has both areas with high elasticity and areas with low elasticity.
  • the areas with high elasticity are desired at so-called predetermined bending points of the molded body, while the areas with low elasticity are preferably used in the so-called prefabricated assembly area. It is favorable in terms of production technology that the lines can be extrusion-coated or foamed with the various molded body materials. It is also advantageous that this known wiring harness can be packaged in a very space-saving manner and, because of its ease of installation, can be assembled very inexpensively.
  • the cable harnesses known from EP-B-0 288 752 like other known cable harnesses, essentially consist of the cables mentioned, bundled in the cable harness, of contact elements at the cable ends and of coupling parts for connection to further cable harnesses and / or for connection to a supplier and / or consumer.
  • the production of known cable harnesses essentially includes the following manufacturing steps: First, cable sections are cut from practically endlessly wound cable reels with preferably single-core cables. These cable sections form the cables in the cable harness and have the desired cable length after being cut to length. Each cable is usually assigned its own insulation sleeve. This insulation cover corresponds to the known cable insulation on the cable reel. The insulation sleeve serves both for insulation against undesired mechanical influences and for insulation against undesired electrical influences.
  • the lines cut to the desired length are pre-contacted in a next process step.
  • the cables are stripped at their ends.
  • the stripped ends are then connected in contacting manner with contact elements. This striking of the contact elements on the lines can for example by soldering, crimping, clamping, welding or the like. respectively.
  • coupling parts are usually designed either as a plug or as a socket. Different manufacturing methods are known for manufacturing such coupling parts designed as plugs or sockets. In addition, various embodiments with different technical structures of coupling parts and in particular plugs and sockets are also known.
  • the coupling parts are always manufactured in a separate manufacturing step. Only when the pre-contacted lines are connected to the coupling parts are the various cable bundles pre-assembled, i.e. they are brought into their desired final relative position to each other. If the individual line strands are arranged in their nominal position relative to one another, the molded body enclosing the individual line strands is sprayed or foamed in the known production processes.
  • the object of the first-mentioned invention is to simplify the manufacturing method described in order to make wire harnesses simpler and less expensive to be able to manufacture. This object is achieved by saving one method step in accordance with the overall combination of the method steps according to claim 1.
  • the inventive simplification of the manufacturing process consists in the fact that the lines are still pre-contacted with contact elements and the lines are pre-assembled. It is possible to first provide the lines with the contact elements and then prefabricate them, or first to prefabricate the lines in their final relative position to one another and then to provide them with the contact elements.
  • the invention consists in the summary of the process step connector production with the process step application of the molded body.
  • the pre-contacted and pre-assembled cables are provided with an integral jacket.
  • This integral casing is also effective as a coupling part in the area of the contact elements. Both the coupling parts and the molded bodies are therefore formed by the casing and this casing is produced in a single process step. The cost savings due to the elimination of a procedural step is evident.
  • claim 2 it is advantageous to first insert the pre-connected and pre-assembled lines in a mold and to cast the integral casing in the last process step.
  • the entire wiring harness is cast around the ends of the contact elements.
  • the molding tool has the necessary mounting elements for secure positioning of the individual lines and in particular their ends provided with the contact elements.
  • claim 3 relates to a manufacturing process for the sheathing by foaming the lines.
  • foam material is shot into the molding tool with a single shot to foam around the lines and the contact elements.
  • the coupling parts designed as plugs, sockets, plug sleeves or plug sockets must be positioned and aligned in a stationary manner in such a way that quick and contact-safe assembly, and increasingly also robot assembly, is ensured.
  • a certain stiffness of the coupling parts is required for this.
  • the coupling parts of the supplier or consumer and of the cable harness are preferably designed to be complementary to one another according to the lock and key principle at the connection points. This means that there is, for example, a plug on the wiring harness and a socket on the consumer or vice versa.
  • both coupling parts must be designed so stiff that they each have complementary designed and interacting guide surfaces.
  • fixing plates For example, it is possible to insert so-called fixing plates into the casing.
  • three-dimensional, housing-shaped fixing elements into the casing.
  • the geometry of these fixing elements can in turn correspond to that of a conventional connector housing.
  • the manufacturing method according to the invention can also be modified in such a way that the fixing elements are only subsequently attached to the finished integral casing of the wiring harness.
  • the manufacturing method is expediently expandable in that the pre-assembled lines are provided with reinforcement-like stiffening bodies. These reinforcement-like stiffening bodies are then effective as reinforcement in the finished cable harness provided with the sheathing. It is essential and important in the inventive manufacturing process that the entire sheathing of the wire harness up to the contacting points of the lines is integrally cast or foamed in a single manufacturing process.
  • This wiring harness essentially has the lines provided with contact elements and coupling parts, which are arranged in a defined relative position to one another, the integral sheathing being effective both as a molded body for the wiring harness and as a coupling part.
  • the guidance of the sheathing material in the immediate vicinity of the contact elements has the further advantage that the coupling parts have a smaller construction volume and thus on the one hand the material consumption is effectively reduced and on the other hand space-saving constructions are made possible. In particular, it also saves installation space on the vehicle, ie on the assembly object. In addition, the smaller construction volume makes it easier to assemble the wiring harness and ultimately also saves weight, which in turn has an effect on the overall weight balance of the assembly object, for example the motor vehicle.
  • the subject of claim 7 is a casing made of molded PU material.
  • a casing consisting of a foam material is provided.
  • the advantage of this sheathing made of a foam material is the higher internal elasticity of the wiring harness. This is advantageous from an assembly point of view if, for example, contact pins protruding from a plug are to be axially pivotable for easier assembly.
  • Claims 11 to 16 relate partly to inventive and partly advantageously expedient training and further developments of fixing elements in the area of the coupling parts. Also in EP-B 0 288 752, installation situations are described in which a high degree of flexibility or bendability of the coupling part jacket or of the cladding jacket region of the wiring harness directly adjacent to the coupling part jacket is desired in the area of the coupling parts. This requirement can go so far that the positioning stability of the complementary coupling parts designed according to the lock and key principle is not sufficiently guaranteed. To solve this problem, it is proposed in claim 12 to place a fixing plate in front of the connector body integrated in the casing of the cable harness. This fixing plate is provided with bores which form through openings for the contact pins of a plug.
  • the bores can serve as through openings for receptacles or receptacles of sockets.
  • the passage openings can be dimensioned so that the contact pins penetrate the passage openings at a radial distance from the passage opening edges, so that the resulting gap between the contact pins and the passage opening edges can be filled by the interposition of parts of the integral casing.
  • the sheathing material can be unstable, i.e. elastic be to allow a certain deflection of the contact pins in the radial direction.
  • the fixing elements can either be part of the integral component enclosed by the integral casing or, alternatively, can be adapted subsequently to the wiring harness according to claim 15.
  • the fixing elements can either be part of the integral component enclosed by the integral casing or, alternatively, can be adapted subsequently to the wiring harness according to claim 15.
  • a fixing plate can advantageously be attached to the wiring harness by gluing or clipping.
  • claim 17 relates to a further measure to increase moisture tightness.
  • materials for the sheathing on the one hand and for the insulation sheaths of the individual lines on the other hand which react chemically with one another in such a way that they form a material connection in the final assembly state
  • the inventive idea of the integral construction of the wiring harness can be further perfected.
  • This integral connection of the integral sheathing with the insulating sleeves of the lines leads to a monolithic overall structure of the overall sheathing.
  • Fig. 1 shows a coupling part designed as a socket 1.
  • the socket 1 consists essentially of foam or solid or compact material existing integral casing 2.
  • the passage openings 5 serve as receptacles for the contact pins 6 of the plug 7 shown in FIG. 2.
  • the central longitudinal axes 8 of the passage openings 5 likewise run in the axial direction 4.
  • the radial direction 9 runs at right angles to the axial direction 4.
  • a line bundle consisting of five lines 10 runs into the socket 1.
  • the lines 10 are each provided with a schematically indicated insulator covering 11. At their ends facing the through openings 5, the lines 10 are connected to the contact elements 12 which act as plug-in sockets.
  • Fig. 1 shows a special embodiment of a wire harness for the following special application. After assembly, this wiring harness is located in areas where no moisture can enter, even in the worst case. In such cases, it would be a waste of material to provide the entire wiring harness with the moisture-resistant sheathing. In such cases, the casing is led from the areas at risk of moisture into the areas which are completely at risk of moisture, so that the area at risk of moisture and the casing overlap over a certain distance. This is the hatched area to the right of the auxiliary line 13 in FIGS. 1 and 2. The casing 2 is provided with a flange-like closure 14 in these areas which are not at risk of moisture.
  • the lines 10 are either only covered by their insulating sheath 11 in the moisture-endangered area or are provided with an auxiliary sheath 15. In such cases, it is therefore possible to have the sheathing end before the line ends on the dry side, so that the individual lines can then either be guided individually in the moisture-free dry areas or without any sheath 2 or can be guided in bundles by means of the auxiliary sheath 5.
  • Fig. 2 shows the recognizable complementary to the socket 1 plug 7.
  • the plug 7 can be inserted in the axial direction 4 in the socket 1 such that the contact pins 6 engage according to the lock and key principle in the contact sockets in the through openings 5. While at the Socket 1 according to FIG. 1, the contact sockets form the contact elements 12, the contact pins 6 form the contact elements in the connector 7 according to FIG. 2.
  • the contact pins 6 protrude from the active surface 16 in the axial direction 4.
  • the active surface 16 is delimited on the edge by the border 17, which also projects in the axial direction 4.
  • the inner surfaces 18 of the border 17 are designed as guide surfaces.
  • the socket 1 has a step 19 in the region of its insertion end 3.
  • the area between the step 19 and the insertion end 3 is designed here as a sliding surface 20 such that the sliding surface 20 of the socket 1 and the inner surfaces 18 of the border 17 on the plug 7 slide together when plug connector 7 and socket 1 in the manner of a sliding guide.
  • the sliding surface 20 of the socket 1 and the inner surfaces 18 of the border 17 of the plug 7 are thus effective as an assembly aid when joining the plug 7 and socket 1.
  • Both the area of the socket 1 with the sliding surface 20 and the border 17 on the plug 7 can be stiffened by additional fixing elements in the integral casing 2.
  • the individual wiring harness branches 21, 21a, 21b, 21c, 21d have different cross-sectional shapes in accordance with the sections A-A, B-B and C-C.
  • the wire harness branch 21 corresponds to the main strand of the wire harness.
  • the integral sheathing 2 is divided into the three sub-areas 22, 22a and 22b.
  • the partial areas 22, 22a and 22b each have materials with different elasticity.
  • the left section 22 is made of a material of normal elasticity.
  • the middle tel area 22a has a very high elasticity and is additionally provided with a bending perforation 23.
  • the right section 22b is finally effective as a distribution switch 24.
  • the distribution switch 24 consists of rigid material.
  • the cable branch 21a with the socket 1 according to FIG. 1 goes from the distribution switch 24.
  • the cable branch 21 a here has an oval cross-sectional shape according to section A-A.
  • the distribution switch 24 leads to the cable branch 21d, which carries the plug 7 according to FIG. 2 at its end.
  • the cable branch 21 c with terminal cube socket 25 also goes off from the distribution switch 24.
  • the cube socket 25 has four through openings 5 which act as plug-in sockets 5.
  • the cube socket 25 is complementary to the coupling part 26 shown in FIG. 4.
  • the integral sheathing 2 of the wiring harness branch 21d carrying the plug 7, like the integral sheathing 2 of the wiring harness branch 21c carrying the cube socket 25, corresponds to the design of the integral sheathing 2 in the region of the partial region 22 of the wiring harness branch 21 shown on the left in FIG. 3 according to the circular cross section BB.
  • the line 10 which has only an insulating sheath 11 and at its free end carries a cable eyelet 27 which acts as a contact element.
  • This line 10 carrying the cable sleeve 27 is provided for the above-described laying in a dry area.
  • the integral casing 2 consists of a soft and thus flexible foam or solid material over the entire area shown in FIG. 4.
  • a fixing plate 29 which is comparatively hard compared to the casing material is placed on the end face 28 of the coupling part 26 formed from the material of the integral casing 2.
  • the fixing plate 29 has at least one molded projection (not shown) on its side facing the end face 28 of the coupling part 26, which is encapsulated by the material of the casing.
  • the fixing plate 29 also has four through openings 5 for the four contact pins 6.
  • the diameter of the passage openings 5 of the fixing plate 29 running in the radial direction 9 is in this case significantly larger than the diameter in the radial direction 9 of the contact pins 6.
  • the contact pins 6 thus penetrate the passage openings 5 in the fixing plate 29 with an insulating radial distance. This radial distance enables the sheath material of the integral casing 2 to penetrate into the ring region created by the radial distance between the passage opening edges on the one hand and the contact pins 6 on the other hand. In this way, the live contact pins 6 are simply electrically isolated from the fixing plate 29.
  • the high elasticity of the material of the integral casing in the ring areas does not endanger the positioning accuracy of the contact pins 6, because this ring thickness of the ring surrounding the contact pins 6 made of the material of the integral casing 2 is relatively small, so that the stabilizing Effect of the fixing plate 29 is almost completely retained.
  • the inner circumference of the hole surrounds the casing material in the surrounding area in a corset-like manner, which causes the contact elements, in the exemplary embodiment of the contact pins 6, to be held concentrically.
  • a certain residual radial mobility, in particular pivotability, of the contact pins 6 is indicated by the auxiliary arrows 30.
  • This relatively low mobility serves to compensate for any manufacturing tolerances that may occur on the side of the circular plug-like coupling part 26 on the one hand and the cube socket 25 complementary thereto.
  • the circular connector-like coupling part 26 shown in FIG. 4 and the cube socket 25 shown in FIG. 3 in turn work together according to the key-lock principle.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Insulated Conductors (AREA)
  • Details Of Connecting Devices For Male And Female Coupling (AREA)
EP93106017A 1992-04-16 1993-04-14 Procédé de la fabrication d'un peigne de câbles. Withdrawn EP0566969A3 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE9205489U 1992-04-16
DE9205489 1992-04-16

Publications (2)

Publication Number Publication Date
EP0566969A2 true EP0566969A2 (fr) 1993-10-27
EP0566969A3 EP0566969A3 (fr) 1995-06-28

Family

ID=6878751

Family Applications (1)

Application Number Title Priority Date Filing Date
EP93106017A Withdrawn EP0566969A3 (fr) 1992-04-16 1993-04-14 Procédé de la fabrication d'un peigne de câbles.

Country Status (2)

Country Link
EP (1) EP0566969A3 (fr)
ES (1) ES2044811T1 (fr)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0709252A1 (fr) * 1994-10-26 1996-05-01 Leonische Drahtwerke AG Faisceau de câbles en particulier pour le montage dans une carosserie de voiture
DE19537724A1 (de) * 1995-10-10 1997-04-17 Gore W L & Ass Gmbh Konfektioniertes Kabel, Herstellungsverfahren dafür sowie mit konfektioniertem Kabel versehenes Hörgerät
US6120327A (en) * 1997-07-22 2000-09-19 Lear Automotive Dearborn, Inc. Foam wire harness with shape memory
EP1262999A1 (fr) * 2001-06-01 2002-12-04 Siemens Aktiengesellschaft Faisceau de câbles, en particulier pour connexion avec des bornes électriques
WO2012169158A1 (fr) * 2011-06-07 2012-12-13 Yazaki Corporation Faisceau de câblage et système de fabrication de faisceau de câblage
CN104282364A (zh) * 2014-10-24 2015-01-14 安徽电信器材贸易工业有限责任公司 可拆分的连体电缆
DE102023115453A1 (de) * 2023-06-14 2024-12-19 Unger Kabel-Konfektionstechnik GmbH Kabelbaum zur Innenverkabelung eines Elektrogerätes sowie Verfahren zum optimierten Herstellen einer Innenverkabelung

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3048008A1 (de) * 1980-12-19 1982-07-15 Kabel- und Metallwerke Gutehoffnungshütte AG, 3000 Hannover "kabelbaum"
EP0288752A1 (fr) * 1987-03-31 1988-11-02 Leonische Drahtwerke AG Faisceau de câblage, en particulier pour véhicules

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3048008A1 (de) * 1980-12-19 1982-07-15 Kabel- und Metallwerke Gutehoffnungshütte AG, 3000 Hannover "kabelbaum"
EP0288752A1 (fr) * 1987-03-31 1988-11-02 Leonische Drahtwerke AG Faisceau de câblage, en particulier pour véhicules

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0709252A1 (fr) * 1994-10-26 1996-05-01 Leonische Drahtwerke AG Faisceau de câbles en particulier pour le montage dans une carosserie de voiture
DE19537724A1 (de) * 1995-10-10 1997-04-17 Gore W L & Ass Gmbh Konfektioniertes Kabel, Herstellungsverfahren dafür sowie mit konfektioniertem Kabel versehenes Hörgerät
US6120327A (en) * 1997-07-22 2000-09-19 Lear Automotive Dearborn, Inc. Foam wire harness with shape memory
EP1262999A1 (fr) * 2001-06-01 2002-12-04 Siemens Aktiengesellschaft Faisceau de câbles, en particulier pour connexion avec des bornes électriques
WO2012169158A1 (fr) * 2011-06-07 2012-12-13 Yazaki Corporation Faisceau de câblage et système de fabrication de faisceau de câblage
CN104282364A (zh) * 2014-10-24 2015-01-14 安徽电信器材贸易工业有限责任公司 可拆分的连体电缆
DE102023115453A1 (de) * 2023-06-14 2024-12-19 Unger Kabel-Konfektionstechnik GmbH Kabelbaum zur Innenverkabelung eines Elektrogerätes sowie Verfahren zum optimierten Herstellen einer Innenverkabelung

Also Published As

Publication number Publication date
ES2044811T1 (es) 1994-01-16
EP0566969A3 (fr) 1995-06-28

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