EP3396781A1 - Electrical coupling part and method of manufacturing the coupling part - Google Patents

Abstract

It is proposed a two-part electrical coupling part (1) for attachment to an electrical line (2). The coupling part comprises an outer housing (3), in which a contact carrier is inserted, which is provided with through holes for receiving electrical contact parts, which are electrically connected in the mounting position with one electrical conductor of the line. In addition, the coupling part has a molded protective body (4). A sealing disk (14) is provided which prevents spray material from penetrating into the through holes of the contact carrier, into mounting openings or gaps between the contact carrier and the outer housing (3) during the injection molding of the protective body (4) and impairs the functioning of the coupling part. In addition, a method for producing the coupling part is proposed.

Description

area

The invention relates to a two-part electrical coupling part for attachment to an electrical line and to a method for producing the coupling part.

Background of the invention

Electric coupling parts of the generic type are used for example in the automotive sector to connect electrical units and components together. For example, it is necessary to electrically connect ABS sensors in each wheel of a vehicle with a corresponding ABS control unit. The electrical coupling parts are exposed to harsh operating conditions, including mechanical shock, dirt, and spray. Nevertheless, it is required that the electrical connections in question function reliably over a long service life.

Currently come for the application mentioned two-piece plug used, which are protected with a mountable cap on the line side against harmful environmental influences.

From the EP 2 099 099B1 In addition, a one-piece plug with an electrical line is known, in which on a contact body, a clamping body is attached to which a protective body is molded, which surrounds the electrical line. In addition, sealing elements are arranged in through holes of the contact body, through which the electrical conductors of the electrical line are guided and which seal the through holes.

On this basis, it is an object of the present invention to provide an improved two-part coupling part and a method for producing such a coupling part.

Summary of the invention

For the purposes of the present application, the term "coupling part" designates both a plug with plug pins and a socket with can contacts. Accordingly, "contact parts" or "contact elements" so either the connector pins or the can contacts.

According to a first aspect of the present invention, an electric coupling member for mounting to an electric wire is proposed. The conduit has a plurality of electrical conductors surrounded by insulation, which are surrounded by a common jacket of insulating material. The coupling part further comprises a contact carrier, which is provided with through holes for receiving electrical contact parts, which are electrically connected in the mounting position with one electrical conductor of the line. In addition, the coupling part has a molded protective body and is characterized in that the coupling part comprises an outer housing, in which the contact carrier is inserted, that on the line facing end face of the coupling part, which is formed by contact carrier and outer housing together, a sealing washer is arranged close fitting, and that the gasket has through holes for passing through the surrounded by an insulation electrical conductor of the line, which are dimensioned so that the gasket in the mounting position rests close to the insulation. The sealing washer can also be designed in several parts.

The sealing disk prevents spray material from penetrating into the through-holes of the contact carrier, into mounting openings or gaps between the contact carrier and the outer housing during the injection-molding of the protective body, and to the functionality of the coupling part can affect. The molded protection body is resistant to mechanical stress, splash water and dirt.

In one embodiment, the through holes are arranged in the contact carrier in two mutually parallel rows and the sealing disc is formed in three parts. In a further development, the sealing washer has two outer legs and a center leg, which are connected via film bridges, which simplifies the handling of the sealing washer in production compared to a situation in which the outer and middle legs are three completely separate parts.

It has proved to be advantageous if the sealing disc forms a labyrinth seal on the end face facing the conduit, which is formed jointly by contact carrier and outer housing. The labyrinth seal provides a reliable seal of the contact carrier against the ingress of liquid spray material.

In one embodiment, the sealing washer has sealing pins which close the mounting slots arranged between the outer housing and the contact carrier. This measure also serves to prevent the penetration of spray material into the contact carrier.

In a development according to the invention, each electrical line is provided with a single seal, which is arranged on the insulation of the electrical line in the through hole, in which the respective electrical line is connected to a contact part, and which seals the through hole. The single seals are an additional measure to prevent spray material from entering the contact carrier.

• einsetzen eines Kontaktträgers in ein Außengehäuse;
  • anschließen von mehreren elektrischen Leiter einer elektrischen Leitung an Kontaktelemente;
  • einsetzen der Kontaktelemente in den Kontaktträger;
  • aufsetzen einer Dichtungsscheibe auf der der Leitung zugewandten Stirnfläche des Kupplungsteils, die von Kontaktträger und Außengehäuse gemeinsam gebildet wird, wobei Durchgangsöffnungen in der Dichtungsscheibe in Montageposition dicht an der Isolierung anliegen; und
  • umspritzen des Kupplungsteils an der Leitungsseite mit einem Schutzkörper.

According to a second aspect of the present invention, a method for producing a coupling part according to the invention is proposed. The method comprises the following steps:

• inserting a contact carrier into an outer housing;
  • connecting a plurality of electrical conductors of an electrical line to contact elements;
  • inserting the contact elements in the contact carrier;
  • placing a sealing washer on the line facing end face of the coupling part, which is formed by the contact carrier and the outer housing together, wherein passage openings in the sealing disc in the mounting position bear tightly against the insulation; and
  • overmoulding the coupling part on the line side with a protective body.

Short description of the drawing

• Fig. 1 eine perspektivische Ansicht des erfindungsgemäßen Kupplungsteils;
• Fig. 2A bis 2F eine Veranschaulichung des Aufbaus des Kupplungsteils aus Fig. 1;
• Fig. 3A und 3B eine Dichtungsscheibe in Werkzeuglage;
• Fig. 4A und 4B eine Dichtungsscheibe in Einbaulage; und
• Fig. 5 ein Flussdiagramm des erfindungsgemäßen Herstellungsverfahrens.

The invention will be explained in more detail below by way of example with reference to embodiments with reference to the accompanying drawings. Show it

• Fig. 1 a perspective view of the coupling part according to the invention;
• Figs. 2A to 2F an illustration of the structure of the coupling part Fig. 1 ;
• FIGS. 3A and 3B a sealing washer in the tool position;
• FIGS. 4A and 4B a sealing washer in installation position; and
• Fig. 5 a flow chart of the manufacturing method according to the invention.

The same or similar elements are provided in the figures with the same or similar reference numerals.

embodiment

Fig. 1 shows an inventive two-part coupling part 1 in a perspective view with a multicore line connected thereto 2. The coupling part 1 has an outer housing 3, to which a protective body 4 is molded. The molded protection body 4 is more resistant to environmental influences and mechanical damage than a patch cap known in the art.

Regarding Fig. 2 the structure of the coupling part 1 will be explained in more detail below.

Fig. 2A shows an inner housing, which forms a contact carrier 6 for the coupling part 1. The contact carrier is made of mechanically stable insulating material, such as polyamide (PA) or polybutylene terephthalate (PBT). In the contact carrier 6 through holes 7 are provided, in which contact elements (not shown) are used. The through holes 7 are arranged in two parallel rows. The contact carrier 6 has only one example and the invention is not limited to a certain number of through holes or in a certain manner as the through holes are arranged in the contact carrier 6. In other embodiments, more or fewer through holes may be provided. In addition, 7 contact elements are not necessarily used in all through holes. The number of contact elements depends rather on the requirements of the particular application. A production technical advantage here is that numerous applications can be covered with only a contact carrier 6 with a relatively large number of through holes, which require a different number of contacts.

Fig. 2B shows the outer housing 3 of the coupling part 1, in which the contact carrier 6 is used and where it locks in the installed position. In the outer housing 3 mounting slots 8 and locking elements (not shown) are provided. The outer housing 3 is also provided with a bracket 9, with which the coupling part is locked on its counterpart when it is plugged onto the counterpart. The counterpart can be a plug or a socket depending on the application.

Fig. 2C shown the contact carrier 6 used in the outer housing 3.

The contact elements are formed from sheet metal strips and are equipped with a locking element, by which they are secured after insertion into the contact carrier 6 against axial displacement. At the in Fig. 2D In the example of application shown, the line 2 to be connected to the coupling part 1 has five wires 11, each formed by an electrical conductor surrounded by insulation. The contact elements are each crimped onto a stripped end of a wire 11 and inserted into a through hole 7 of the contact carrier 6, where the contact elements engage.

The extent described and in Fig. 2 the coupling part 1 shown is not yet suitable for use, because neither the contact elements are protected from environmental influences nor a strain relief for the line 2 is present. This purpose is fulfilled in Fig. 1 shown protective body 4, which is molded onto the outer housing 3. It should be noted that the through holes 7 and the contact elements must be protected from the spray material of a protective body produced by injection molding, so that the contact elements are not covered by spray material and lose their functionality. In addition, without countermeasures there is also the danger that the spray material through holes partially or completely closes and the coupling part is no longer pluggable.

In the coupling part according to the invention therefore a seal plate 14 is placed on a line-side end face 12 which is formed by the contact carrier 6 and the outer housing 3, as seen from Fig. 2E is apparent. The gasket 14 is seated with a press fit on the end face 12 in order to ensure a good seal. The sealing washer 14 is formed in three parts and in the FIGS. 3A and 3B shown in greater detail.

Fig. 2F the coupling part 1 according to the invention with molded protective body 4 partially in a cross-sectional view, in which it can be seen that the protective body 4, the upper portion of the outer housing. 3 engages and thus has a secure hold on the outer housing 3 and at the same time seals the outer housing 3 against environmental influences. The protective body 4 is made of, for example, PA or PBT and is produced by injection molding in a corresponding injection mold. In order to improve the connection between the outer housing 3 and the protective body 4, the outer housing 3 may also have grooves or be grooved in its upper area. In addition, it can be seen how the gasket protects the contact carrier 6 against the ingress of spray material.

Fig. 3A shows the three-piece gasket 14, which has two outer legs 16, 17 and a middle leg 18, which are connected to each other via two film bridges 20, 21. In the middle leg 18 and the outer legs 16, 17 semicircular recess 22 are provided, which are opposite to each other in pairs. The sealing disc 14 has on the outer legs 16, 17 in each case two lugs 23, which are arranged opposite corresponding recesses 24.

In Fig. 3B is the gasket 14 off Fig. 3 A shown again in a perspective view in which the film bridges 20, 21 are more visible. The FIGS. 3A and 3B show the gasket 14 after its production as an injection molded part, which is also referred to as "tool position".

The FIGS. 4A and 4B are corresponding representations showing the gasket 14 in the installed position. In Fig. 4A It can be seen that in the installed position, the lugs 23 of the outer legs 16, 17 are received in the recesses 24 in the middle leg 18. The recesses 22 of the outer legs 16, 17 and the center leg 18 fit together to round openings whose diameter is dimensioned so that the edge of the openings, the insulation of the wires 11 tightly encloses.

Fig. 4B shows the in Fig. 4A illustrated installation position of the sealing washer 14 in a perspective view.

The underside of the sealing disc is designed so that it forms a labyrinth seal with the end face 12, which is formed by the contact carrier 6 and the outer housing 3. When installing the sealing washer, seal the seal on the underside of the sealing washer The sealing disk also covers the dividing edges between the contact carrier 6 and the outer housing 3. Overall, it is achieved by these measures that the coupling part is sealed on the line side.

The installation of the sealing washer 14 on the in Fig. 2D shown coupling part 1 is effected in that the sealing disc 14 is laterally pushed onto the coupling part 1, that the outer legs 16, 17, the wires 11 of the line 2 engage around from the outside, while the middle leg 18 comes to rest between the wires 11. The sealing washer 14 rests on the end face 12. After the recesses 22 are aligned with the wires 11, or vice versa, the outer legs 16, 17 are pressed toward the center leg 18 and the sealing disc is locked on the end face 12. The gasket is seated with a press fit on the end face 12. Thereafter, the protective body 4 is molded on the line side of the coupling part 1. The sealing disc 14 ensures that no spray material penetrates into the contact carrier 6 and disturbs the operation of the contact carrier.

In an alternative embodiment, the gasket 14 is a one-piece. During assembly of the one-piece sealing washer 14, the individual wires 11 of the conduit 2 are inserted through openings in the sealing washer and the sealing washer is to a certain extent "parked" on the wires. Then the contact elements are connected to the stripped ends of the wires 11 and inserted into the contact carrier 6 and locked. Thereafter, the sealing disc is pressed down on the end face 12 on which the sealing disc is pressed against, whereby the sealing disc 14 prevents the penetration of spray material into the contact carrier 6.

Fig. 5 shows a flowchart with the individual steps for producing a coupling part according to the invention 1. First, the contact carrier 6 is inserted into the outer housing 3 in step S1. In step S2, contact elements are connected to the wires 11 of the line 2. The connected contact elements are then in step S3 in the Contact carrier 6 is inserted. Then, in step S4, the sealing washer 14 is placed and finally molded in step S5 of the protective body 4.

In the claims, the words "comprising" and "comprising" do not exclude other elements or steps, and the indefinite article "a" does not exclude a plurality.

The fact that individual functions and elements are listed in different dependent claims does not mean that a combination of these functions and elements could not be used to advantage.

LIST OF REFERENCE NUMBERS

1

coupling part

2

management

3

outer casing

4

protective body

6

contact support

7

Through holes

8th

mounting slots

9

hanger

11

Wires of the line 2

12

face

14

sealing washer

16.17

outer leg

18

middle leg

20.21

movie bridges

22

recess

23

nose

24

pronunciations

S1-S5

steps

Claims (8)

An electrical coupling member (1) for attachment to an electrical lead (2) comprising a plurality of insulated electrical conductors surrounded by a common jacket of insulating material, comprising a contact support (6) having through holes (7) for receiving is provided by electrical contact parts, which are electrically connected in the mounting position, each with an electrical conductor of the line and with a molded protective body (4), characterized - That the coupling part (1) comprises an outer housing (3), in which the contact carrier (6) is inserted, - That on the line (2) facing end face (12) of the coupling part (1), which is formed by contact carrier (6) and outer housing (3) together, a sealing disc (14) is arranged tightly fitting, and - That the gasket (14) through openings for passing through the surrounded by an insulation electrical conductor of the line (2), which are dimensioned so that the sealing disc (14) in the mounting position rests close to the insulation. Electrical coupling part according to claim 1, characterized in that the sealing disc (14) is designed in several parts. Electrical coupling part according to claim 2, characterized in that the through holes (7) in the contact carrier (6) are arranged in two mutually parallel rows and that the sealing disc (14) is formed in three parts. Electrical coupling part according to claim 3, characterized in that the sealing disc on two outer legs (16, 17) and a center leg (18) which are connected on one side via film bridges (20, 21). Electrical coupling part according to one of the preceding claims, characterized in that the sealing disc (14) on the line (2) facing the end face (12), which is formed by the contact carrier (6) and outer housing (3) together forms a labyrinth seal. Electrical coupling part according to one of the preceding claims, characterized in that the sealing disc (14) has sealing pins which close between the outer housing (3) and the contact carrier (6) arranged mounting slots (8). Electrical coupling part according to one of the preceding claims, characterized in that each electrical line is provided with a single seal, which is arranged on the insulation of the electrical line in the through hole (7), in which the respective electrical line is connected to a contact element, and which seals the through hole (7). A method for producing a coupling part according to any one of the preceding claims, wherein the method comprises the following steps: - Insert a contact carrier (6) in an outer housing (3); - connecting several electrical conductors of an electrical line (2) to contact elements; - Insert the contact elements in the contact carrier (6); - Place a sealing washer (14) on the line (2) facing the end face (12) of the coupling part (1), which is formed by the contact carrier (6) and outer housing (3) together, wherein passage openings in the sealing disc in the mounting position close to the insulation; and - Overmolding the coupling part (1) on the line side with a protective body (4).

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