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EP3641072B1 - Geschirmter elektrischer verbinder - Google Patents

Geschirmter elektrischer verbinder Download PDF

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Publication number
EP3641072B1
EP3641072B1 EP19212454.3A EP19212454A EP3641072B1 EP 3641072 B1 EP3641072 B1 EP 3641072B1 EP 19212454 A EP19212454 A EP 19212454A EP 3641072 B1 EP3641072 B1 EP 3641072B1
Authority
EP
European Patent Office
Prior art keywords
shielding
connector
housing
cable
shielded
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.)
Active
Application number
EP19212454.3A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP3641072A1 (de
Inventor
Daniel Nolting
Manuel TÜNKER
Valeri Reimchen
André MÜHLENBERND
Kathrin Dober
Cord Starke
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.)
Phoenix Contact GmbH and Co KG
Original Assignee
Phoenix Contact GmbH and Co KG
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 Phoenix Contact GmbH and Co KG filed Critical Phoenix Contact GmbH and Co KG
Priority to PL19212454T priority Critical patent/PL3641072T3/pl
Publication of EP3641072A1 publication Critical patent/EP3641072A1/de
Application granted granted Critical
Publication of EP3641072B1 publication Critical patent/EP3641072B1/de
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R9/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, e.g. terminal strips or terminal blocks; Terminals or binding posts mounted upon a base or in a case; Bases therefor
    • H01R9/03—Connectors arranged to contact a plurality of the conductors of a multiconductor cable, e.g. tapping connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/648—Protective earth or shield arrangements on coupling devices, e.g. anti-static shielding  
    • H01R13/658—High frequency shielding arrangements, e.g. against EMI [Electro-Magnetic Interference] or EMP [Electro-Magnetic Pulse]
    • H01R13/6591—Specific features or arrangements of connection of shield to conductive 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
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/648—Protective earth or shield arrangements on coupling devices, e.g. anti-static shielding  
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/514—Bases; Cases composed as a modular blocks or assembly, i.e. composed of co-operating parts provided with contact members or holding contact members between them
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/648—Protective earth or shield arrangements on coupling devices, e.g. anti-static shielding  
    • H01R13/658—High frequency shielding arrangements, e.g. against EMI [Electro-Magnetic Interference] or EMP [Electro-Magnetic Pulse]
    • H01R13/6591—Specific features or arrangements of connection of shield to conductive members
    • H01R13/65912—Specific features or arrangements of connection of shield to conductive members for shielded multiconductor cable
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/648—Protective earth or shield arrangements on coupling devices, e.g. anti-static shielding  
    • H01R13/658—High frequency shielding arrangements, e.g. against EMI [Electro-Magnetic Interference] or EMP [Electro-Magnetic Pulse]
    • H01R13/6591—Specific features or arrangements of connection of shield to conductive members
    • H01R13/6592—Specific features or arrangements of connection of shield to conductive members the conductive member being a shielded cable
    • 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
    • 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
    • H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
    • 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
    • H01R2107/00—Four or more poles

Definitions

  • the invention relates to a shielded electrical connector for connecting or distributing shielded electrical lines or connectors to one another and to methods for producing the shielded electrical connector.
  • Such a shielded electrical connector can take the form of the connection between two coaxial cables, or of several shielded cables among themselves as a distributor, or the connection can exist between a shielded cable and a connector, or can take the form of a shielded multiple distributor, the several shielded connectors or connects shielded cables together.
  • an electrical connector with connecting cable is known with a metallic coupling device with a union nut or with a screw and with an inwardly directed collar which is in contact with a crimped sleeve and establishes the connection between the coupling device and the shielding of the terminating cable.
  • the production of a shielded connector with a crimped shield sleeve is complex, many individual parts are required and the preparation of the cable to be connected is carried out by hand, as is the assembly of the many individual parts. In the case of angled connectors, manufacture is even more difficult to manage.
  • the electrical connection by crimping Furthermore, sharing is not always safe, in particular the contact resistance at the crimp connection can change with temperature changes and with aging, which reduces the shielding quality of the connector.
  • thermoplastic material contains strands of thin metal wire which are pressed against the sleeve-shaped metal housing during the injection molding process in order to establish good electrical continuity between the cable and connector or to the sleeve-like housings of connectors.
  • the contact resistance between the shielding parts can deteriorate with temperature changes and with aging.
  • a connector with a shielded cable connected to it in which an injection-molded shield sleeve made of electrically conductive material, in particular an electrically conductive plastic, electrically connects the cable shield to the coupling nut of the connector.
  • Electrically conductive plastic is generally understood to mean a plastic filled with metal fibers. Such electrically conductive material can be injection moldable (see DIN 24450).
  • the electrical conductor ends of the cable are connected in the connector housing, on which a metal sleeve is arranged.
  • An insulating carrier is then injection molded, which extends from the conductor screen into the housing.
  • An electrically conductive sleeve part is injection molded around the insulating carrier, which connects the conductor screen to the metal sleeve and thus to the housing screen of the electrical connector.
  • Another connector which consists of an injection-molded shield element having injectable electrically conductive material, in particular an electrically conductive plastic.
  • electrically conductive plastic only makes weak contacts to metallic surfaces of the connector or the cable, so that the contact resistance at the transition surfaces between the electrically conductive plastic material and the metallic surfaces on the connector or on the cable shield has increased values, which can also deteriorate if gaps or cracks open up at the transition surfaces as a result of the shrinkage or melting of the plastic.
  • conductive plastics disadvantageously have a lower shielding attenuation than metal.
  • a method for producing a shielded electrical interface in which an area around the electrical contacts adjoining the shield is overmolded with an electrically conductive composite material.
  • the composite material should preferably comprise a thermoplastic plastic which ultimately forms a type of matrix.
  • the invention is based on the object of creating a shielded electrical connector with a good shield connection between shielded electrical lines and / or shielded plug connectors.
  • Another aspect of the task is to create a durable, shielded electrical connector in which the contact resistance between the components involved in the shielding remains low during the life of the connector.
  • Another aspect of the task is to create a shielded electrical connector which can be produced simply and largely by machine and has as few individual parts as possible.
  • the shielded electrical connector contains one or more line elements that belong to at least one line or at least one plug connector. In the case of several lines, these can be at least partially connected to one another in order to form a distributor.
  • the line elements can be designed, for example, as line cores of an electrical cable or as continuations of plug contact elements of a plug connector.
  • the connector further comprises one or more shielding sleeves and / or one or more shielding housings which, as cable shielding, belong to at least one line or, as housing shielding elements, belong to at least one plug connector.
  • the invention further comprises a shielding housing which either connects several shielding shells to one another, or at least one shielding shell with at least one shielding housing, or several shielding housings to one another, or which forms part of the shielding housing.
  • the shielding housing consists of a cast metal body which has been cast in situ on ring areas of both the one shielding cover or the multiple shielding covers and on ring areas of the one shielding housing or multiple shielding housings causes complete, in particular seamless, shielding of the connector.
  • the shielded housing can also extend between two shielded cables or cable groups to be connected to one another.
  • the screen housing preferably does not consist of prefabricated shell or sleeve parts, but it is cast directly onto the connector, in particular onto and around the connector, during the assembly or assembly process of the connector. Accordingly, liquid metal or a liquid metal alloy is poured directly onto components of the connector made of plastic and around them. The screen housing is accordingly cast in situ from liquid metal onto the already partially manufactured connector or cast around components of the partially manufactured connector in situ.
  • the shielding comprises two crimped sleeves. Furthermore, the transition resistance between the shielding sheaths of cables and / or the shielding housings of plug connectors to the shielding housing cast in situ from liquid metal and connecting the shielding sheaths and / or the shielding housings to one another is low.
  • the electrical connections made by the screen housing cast in situ are also durable and are only subject to aging processes to a small extent. Since the invention does not work with prefabricated shielding sleeves to be mounted, the manufacture of the connector is simplified. One Particularly great simplification and quality improvement can be seen in the case of angle connectors.
  • the shield housing When the shield housing is manufactured by casting metal directly onto the shielding sheaths and / or shielding housing, there is good anchoring and intimate connection between the adjacent parts of the shielding, which leads to a low contact resistance between the parts of the shielding. With the appropriate choice of materials for the parts to be connected to one another, a metallurgical connection can even occur. Such a connection is particularly durable and of consistent quality.
  • the shield housing is at least partially cast on and around an intermediate insulating body made of temperature-resistant, electrically insulating material, which protects the line elements during the casting process of the shield housing.
  • an intermediate insulating body made of temperature-resistant, electrically insulating material, which protects the line elements during the casting process of the shield housing.
  • the ends of the line elements for example the conductors of a cable, are made free of the shielding sheath, which typically consists of a metal mesh. Even if the line elements should be surrounded by line insulation, it can be advantageous to better protect the line elements with an additional intermediate insulating body against the hot molten metal flow during casting of the shielded housing.
  • the intermediate insulating body can consist of heat-resistant, electrically insulating material and be made sufficiently thick to meet the requirements when casting the screen housing.
  • the rear continuations of the contact elements of the connector are used as the line elements.
  • the contact elements or line elements are expediently accommodated in an electrically insulating connector housing.
  • a coupling half of the connector which is intended to work together with the other coupling half of the mating connector, is built around, which acts as an electrical shielding connection to the mating connector. This represents a simple and safe structure of a shielded connector.
  • the shielding housing of the connector can comprise a metallic connecting part and metallic half-shells which are fastened to the insulating connector housing with the aid of a coupling ring and which form part of the coupling half of the connector.
  • a rear edge part of the metallic connection part is encapsulated by the shielding housing, so that a good electrical connection to the shielding housing of the connector is provided, which determines the shielding quality of the connector.
  • the plug connector is designed for a data line and preferably has a plurality of line elements, these are protected by an intermediate insulating body made of electrically insulating and thermally poorly conductive material.
  • the thermal conductivity of the material of the intermediate insulating body is preferably between 0.01 and 10 W / m ⁇ K.
  • PET Polyethylene terephthalate
  • PUR compact polyurethane
  • PEI polytherimide
  • PTFE polytetrafluoroethylene
  • PVC polyvinyl chloride
  • polyamide e.g. Nylon® or Perlon®
  • PP polypropylene
  • polycarbonate e.g.
  • the intermediate insulating body consists of a foamed plastic with which a thermal conductivity between 0.01 and 0.1 W / mK, preferably around 0.02 W / mK, can be achieved. This provides good protection for sensitive wire insulation when casting the screen housing.
  • the shielding housing is preferably cast directly onto the protective earth with a cast branch. This represents a simple and secure connection between the outer shield and the protective earth (PE conductor) running on the inside, which simplifies the construction of the connector overall.
  • the intermediate insulating body is made from an electrically insulating and thermally highly conductive material.
  • the shielded housing is preferably provided with cooling ribs and, in particular, including the cooling ribs, is cast in situ from metal on the thermally highly conductive intermediate insulating body.
  • the thermal conductivity of the material of the intermediate insulating body is preferably between 0.2 and 10 W / mK. LATICONTHER® or a prefabricated intermediate insulating body made of ceramic come into consideration, for example. With heavy loads and a large amount of heat generated by the power connector, good heat dissipation can thus still take place with a simple construction of the power connector.
  • the intermediate insulating body can either be used as a prefabricated intermediate insulating body for both the data connector and the power connector or, if a thermoplastic is used, it can be injection molded in situ before the shielded housing is cast, which allows an efficient manufacturing process.
  • the connector according to the invention can also be designed as a multiple distributor for one or more shielded lines and / or one or more shielded plug connectors.
  • a distributor body is provided with several connection points for line elements which either belong to one or more lines or to one or more plug connectors. This distributor body and adjacent line elements are protected during the manufacture of the shielded housing and also later during the operation of the multiple distributor.
  • the shielded housing surrounds the intermediate insulating body directly and, depending on the connection and distribution partner, is cast in situ either on ring areas of the shielding sheaths of the shielded lines and / or on end areas of the shielding housings of the connector and is thus intimately connected.
  • the construction of the distributor thus enables a large number of different multiple distributors in which one or more plug connector connections or one or more direct line connections can also be used in a mixed manner.
  • the shield housing is preferably surrounded by an insulating protective jacket made of plastic.
  • the screen housing made of cast metal can, for example, consist of a low-melting metal alloy.
  • the solidus temperature is e.g. between 120 ° and 420 ° C.
  • the metal alloy can be a metal solder, for example a tin solder.
  • tin solder melting temperature approx. 230 ° C
  • the shielding housing can melt components, e.g. tin-plating of the shielding sheaths or shielding housings, and fuse with them during in situ casting, which enables a particularly low-resistance shield connection.
  • the invention also relates to methods of making the shielded electrical connector in its various embodiments.
  • the optional intermediate insulating body can be applied in situ by injection molding the intermediate insulating body, or the intermediate insulating body can be used as a prefabricated part.
  • the shielded electrical connector is to connect two shielded lines to one another, the shielding sheaths and the line elements at the end of the two lines are exposed, the free ends of the line elements are connected to one another and the intermediate insulating body is applied to the free ends of the line elements connected to one another. Then the intermediate insulating body and the exposed shielding sheaths are encased with liquid metal to form the shielded housing. In this way, a connector with low electrical contact resistance is created between the shielding sheaths of the lines to be connected to one another and the shielded housing of the connector. This low electrical contact resistance promises to remain permanently low, even if the connector is handled robustly.
  • the contact elements of the connector are attached to the end of the line elements of the shielded line and the contact elements are isolated from one another by inserting them into the insulating connector housing.
  • the intermediate insulating body is applied between the insulating connector housing and the point at which the line elements have been freed from the common insulating jacket, i.e. on line elements that remain free or individually insulated, for example by overmolding with temperature-resistant plastic.
  • a plastic is preferably used which has a temperature resistance in the range from approximately 180.degree. C. to 230.degree.
  • the intermediate insulating body and the exposed shielding sleeve of the cable are encased with liquid metal to form the shielded housing.
  • a connector with a simple, robust structure can be produced in which the electrical contact resistance between the shielding sleeve of the supply line and the shielding housing of the connector is low and promises to remain low during the life of the connector.
  • the connector is designed as a multiple distributor, depending on whether the multiple distributor is to be connected directly to one or more lines, or whether the multiple distributor is to be provided with one or more individual plug connectors, the shielding sleeve and the line elements at the end of the line or lines to be connected made free and / or connectors with respective shielding housings and respective line elements are provided. Then the line elements are with connected to a distribution body. The intermediate insulating body is then applied to the exposed line elements and around the distributor body, for example produced by overmolding with plastic. Subsequently, the intermediate insulating body and each exposed shielding shell is cast around and / or the edge zone of the shielding housing in the case of a connector is cast around with liquid metal to form the shielding housing.
  • the invention thus enables great variability in the construction of electrically shielded multiple distributors.
  • soldered connections between the shielding housing and the shielding cover can be created by partially melting the affected shielding cover.
  • soldered connections are created during the metal casting of the shielding housing when appropriate preparations are made on the respective shielding cover, for example when tinned wire meshes are used as the shielding cover.
  • the Figs. 1-6 show the creation of a coaxial cable connector.
  • the coaxial cables form a first shielded line 1 and a second shielded line 2.
  • Each line comprises a line element 11 or 21, a line insulation 12 or 22, a shielding sleeve 10 or 20 and an insulating jacket 13 or 23
  • a metallic coupling sleeve 31 is used, which electrically connects the two bare ends of the line elements 11 and 21 connects with each other.
  • An intermediate insulating body 32 made of temperature-resistant insulating plastic is injection molded into the space between the line insulations 12 and 22, so that the line insulations of the two coaxial cables meet at approximately the same diameter.
  • the gap between the two exposed insulating jackets 13 and 23 is closed by a shielded housing 30 which electrically connects the shielding sheaths 10 and 20 to one another.
  • the shielding sheaths 10, 20 consist, for example, of a metal wire mesh, so that good anchoring and good electrical contact with the shielding housing 30 are obtained when casting around. This leads to a low electrical contact resistance between the shielding sleeves 10, 20 on the one hand and the shielding housing 30 on the other hand.
  • the screen housing 30 thus consists of a metal body cast in situ, which is produced by means of a metal casting tool. A corresponding metal casting tool is in Fig. 17 shown. If necessary, the screen housing 30 cast in situ is produced without a sprue using hot runner technology, for example in FIG DE 10 2012 009 790 described.
  • the coaxial cable connector is usable per se.
  • a protective jacket 33 is also placed around the shielded housing 30 and the adjacent ends of the lines 1 and 2.
  • the commercially available form of a connector 3 is thus obtained.
  • the shielded connection between the two lines 1 and 2 is now complete.
  • the Fig. 7-13 show the creation of a connector that uses a shielded cable 1 Contact elements 34 of the connector connects.
  • the shielded line 1 as a cable comprises one or more line elements 11, a line insulation 12, a shielding sleeve 10 and an insulating jacket 13 all around. How out Fig. 7 As can be seen, the front end of the line 1 is stripped so that the bare ends of the line elements 11, onto which the contact elements 34 are crimped, protrude from the line insulation 12 and the shielding sleeve 10 and the insulating jacket 13 are also through at the front end of the line 1 a cut at 14 has been shortened.
  • the insulating jacket 13 was cut through a cut at 15 until it reached the shielding sleeve 10 and an insulating jacket edge part 16 was pushed forward in the direction of the line end in order to expose a shielding ring area 101 which is axially delimited on both sides. Furthermore, a union nut 351, as part of a coupling half 35, is pushed onto the end of the line 1 until the intact insulating jacket 13 is reached.
  • a shielded housing 30 is produced by casting around the intermediate insulating body 32 and the shielding sleeve 10 in the ring area 101 from liquid metal.
  • the screen housing 30 cast in situ in this way also extends partially around the insulating connector housing 36 and forms an annular flange 301 there.
  • the captured union nut 351 can now be pushed over the screen housing 30 until it rests against the annular flange 301, as shown in FIG Fig. 11 shown. This represents the usable state of the connector.
  • a protective sheath 33 is injection molded over the screen housing 30, the connector having the appearance Fig. 12 and 13th accepts.
  • the head of the connector 4 has a union nut 451, which is part of the coupling half, which works together with a mating connector (not shown) in order to connect the connector 4 to the mating connector in a paired manner.
  • the front end of an electrically insulating connector housing 46, in which the contact elements are arranged, which are connected to the bare ends of the line elements 11, can be seen covered by the union nut 451.
  • the head of the connector 4 also includes a metallic one Connecting part 41, which protrudes at the rear end of the connector head and extends to the front and around the electrically insulating connector housing 46, in order to ensure the shielding to this when coupling with a mating connector.
  • FIG. 15 an open injection molding tool 5 is shown, which has a cavity for receiving the composite of the head of the connector 4 and the line 1.
  • the metallic connecting part 41 has a first sealing ring area 411 which, together with the insulating jacket edge part 16, delimits a casting cavity 50.
  • an intermediate insulating body 32 is formed, as in FIG Fig. 16 shown.
  • the raw connector after Fig. 16 is inserted into the cavity of a metal casting tool 6 ( Fig. 17 ), wherein a casting cavity 60 is delimited between the insulating jacket 13 of the line 1 and a second sealing ring area 412.
  • Casting channels 61 and 62 lead into this casting cavity 60 through which liquid metal of a metal alloy, for example tin solder, is poured.
  • the solidified metal alloy forms the shielding housing 30, which encloses the intermediate insulating body 32, the insulating jacket edge part 16 and the shielding sleeve 10 in the shielding ring area 101.
  • any sprue sockets that may still have arisen are removed, after which a plug-in connector that can be used per se is obtained, as shown in FIG Fig. 18 is shown.
  • Commercially available, shielded connectors have however, a protective jacket 33 around the screen housing 30, as shown in FIG Fig. 19 and 20th is shown.
  • the connector which is usable per se, is inserted into a casting cavity of a further injection molding tool, not shown, in such a way that the injection molding tool seals on the sealing ring area 412 on the one hand and on an unaffected area of the insulating jacket 13 on the other side of the screen housing 30 on the other.
  • the connector becomes the Fig. 18 between the sealing ring area 412 and the unaffected area of the insulating jacket 13 is encapsulated with insulating plastic, as a result of which the protective jacket 33 surrounding the shielded housing 30 is produced and a commercially available connector according to FIG Fig. 19 is obtained.
  • the work described can be carried out fully automatically. By dividing them into individual steps and performing these steps along a production line, which can also be designed as a round plate, rapid production is possible.
  • the total cycle time can be shorter than if the connector were manufactured with a single, but then thick-walled overmolding. If the overmoulding with insulating plastic and the overmolding with liquid metal for three consecutive connectors are carried out at the same time, the throughput time per connector piece is determined by the longest cycle time in the manufacturing process. It should be noted that metal overmolding has a very short cycle time.
  • the Fig. 20 , 21 show a longitudinal section through a power connector with protective earth connection (PE connection) of the shielded housing 30.
  • PE connection protective earth connection
  • the bare ends 110 of the line elements 11 are mechanically and thus also electrically connected to contact elements 44, for example by soldering, squeezing or crimping.
  • the head of the plug connector 4 has an electrically insulated connector housing 46, through whose axial bores the front ends of the contact elements 44 are inserted.
  • a tubular metallic connecting part 41 extends around the connector housing 46 and is provided with engagement projections 413 in order to hold metallic half-shells 42 which, with screw connections 420, form part of the coupling half 45 of the plug connector 4.
  • the half-shells 42 of which there are, for example, two, are held by a compression ring 43 on the metallic connecting part 41 and the insulating connector housing 46 by pressing force.
  • the metallic connecting part 41 and the half-shells 42 form a shielding housing 40 around the relevant connector 4, which has a rear ring area 401 at which it is intimately connected to the shielding housing 30 due to the metal casting of the shielding housing 30 in situ.
  • the power connector according to Fig. 20 and 21 is made in a similar way as with Figures 14-19 has been described.
  • the end of the line 1 is provided with a shielding ring area 101 to expose the shielding sleeve 10 and at the head of the connector 4 there is the metallic connecting part 41, which, together with the half-shells 42, represents the shielding of the entire connector head.
  • the shielding on the connector 4 is accomplished by the shielded housing 30, which is in situ Metal casting in the with Figures 14-19 described manner is generated.
  • a contact element 440 ( Fig. 20 ) carries protective earth (PE) and is connected to the in situ cast shielded housing 30 via a branch 303 cast directly at the same time.
  • the intermediate insulating body 32 consists of electrically insulating and thermally poorly conductive material in order to protect the line elements 11 against the heat from the molten metal during the manufacture of the shielded housing 30 by means of the metal casting.
  • the Figures 22 and 23 represent a power connector which can be constructed in a similar way inside as the connector according to Fig. 20 and 21 , however, the intermediate insulating body 32 consists of electrically insulating, but highly thermally conductive material in order to be able to better dissipate the waste heat of the power connector during operation. With filled plastics, a thermal conductivity of 0.2 W / mK to almost 10 W / mK can be achieved with good electrical insulation.
  • the intermediate insulating body 32 can, however, also consist of a prefabricated ceramic component, which can have an even higher thermal conductivity.
  • the shielding sleeve 30 is also provided here with cooling ribs 302 in order to dissipate heat from the interior of the power connector even better to the outside.
  • FIGS. 24 to 28 show a shielded multiple distributor, which represents a connector for connecting several shielded plug connectors 7 to one another.
  • the connection of the individual plug connectors 7 takes place via a distribution body 8.
  • This distribution body 8 contains two circuit boards 81 and 82 with distribution lines between connection points 83, 84 and 85.
  • the connection points 85 are connected to one another via cross connection lines 86.
  • the connectors 7 comprise a metallic connecting part which has an outer shield case 70 ( Fig. 28 ) forms and the coupling is used to form a complementary mating connector.
  • An electrically insulating connector housing 76 is housed in the interior of the shield housing 70 in order to hold the contact elements 74.
  • the contact elements 74 are connected to the distributor body 8 at associated connection points 83 or 84 and have extensions which form line elements 71.
  • an intermediate insulating body 32 is injection molded around the line elements 71 and the distributor body 8, so that the state according to FIG Fig. 25 is achieved.
  • To the intermediate insulating body 32 is then a screen housing 30 ( Fig. 26 ) cast, i.e.
  • the shielding housing 30 completely surrounds the intermediate insulating body 32 and thus offers good shielding of the overall connector also in the area of the distributor body 8.
  • a protective jacket 33 is placed around the shielded housing 30 by injection molding.
  • the connector completed in this way is in Fig. 27 shown.
  • the connector designed as a multiple distributor of the Fig. 27 can also be modified in such a way that it comprises one or more shielded lines without any plug connectors 7.
  • one, some or all of the plug connectors 7 can be replaced by directly connected shielded lines 1 or 2.
  • the line elements 11, 21 of the relevant lines are connected to the distributor body 8 in the sense of the line elements 71.
  • the intermediate insulating body 32 is produced by injection molding and the intermediate insulating body 32 is encapsulated with the shielding housing 30 made of metal and at the same time the electrical connection to the shielding sheath 10, 20 of the respectively connected line 1, 2 is established. Then - if desired - the protective jacket 33 is attached.
  • All leaded tin solders come All lead-free tin solders, also Sn-Bi solders with a melting point of around 130 ° C and silver solders can be considered.
  • the shielding sleeve 10 of the relevant lines or the connecting part 41 of a correspondingly designed connector can be tin-plated, which is beneficial for the connection to the shielding housing 30, especially if it consists of tin solder so that it fuses with the shielding housing 30.
  • Nickel-plating of the parts mentioned is also possible.
  • the parts mentioned can also consist of bare stainless steel. Shielding sleeves can also be designed as braided shields with bare copper wires.
  • the connector according to the invention showed a contact resistance in the milliohm range. This very low contact resistance remained unchanged even after major temperature changes were carried out.
  • the connector according to the invention is the design of the screen housing 30 as a completely closed unit, apart from the axial openings for the supply lines or for the single connectors.
  • the shielding of the connected cable or the connector head is connected to these openings and completes the all-round shielding by 360 °.
  • the shielding housing 30 is therefore preferably closed radially completely and without gaps in the area of the line connections.
  • the shield housing 30 accordingly forms, in particular, a metal shell that is closed around the entire circumference of the shield connection.
  • the intermediate insulating body 32 serves to protect and / or isolate the line elements (line core in the case of a cable or rear ends of the contact elements in the case of a connector) and can be produced in other ways than by overmolding the line elements with insulating plastic. Seals, shrink tubes, plastic housings and adhesives or prefabricated insert parts can be provided in order to protect the line elements against the liquid metal when the shielded housing 30 is produced.
  • the shielding shell 10 can protrude beyond the cut surface 14 in order to electrically connect the shielding housing 30 to this protruding end of the shielding shell 10 by being encapsulated with liquid metal.
  • the intermediate insulating body 32 can also be produced using the low-pressure method, which enables sealing directly on the line elements 11 or on the shielding sleeve 10.
  • the protective jacket 33 does not necessarily have to be produced by insert molding with plastic.
  • a prefabricated component, such as a grommet, can also be used as a protective jacket 33.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Details Of Connecting Devices For Male And Female Coupling (AREA)
  • Connector Housings Or Holding Contact Members (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
EP19212454.3A 2015-02-25 2016-02-24 Geschirmter elektrischer verbinder Active EP3641072B1 (de)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL19212454T PL3641072T3 (pl) 2015-02-25 2016-02-24 Osłonięty łącznik elektryczny

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102015102703.8A DE102015102703B4 (de) 2015-02-25 2015-02-25 Geschirmter elektrischer Steckverbinder und Herstellungsverfahren
EP16708622.2A EP3262725B1 (de) 2015-02-25 2016-02-24 Geschirmter elektrischer verbinder
PCT/EP2016/053817 WO2016135170A1 (de) 2015-02-25 2016-02-24 Geschirmter elektrischer verbinder

Related Parent Applications (2)

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EP16708622.2A Division EP3262725B1 (de) 2015-02-25 2016-02-24 Geschirmter elektrischer verbinder
EP16708622.2A Division-Into EP3262725B1 (de) 2015-02-25 2016-02-24 Geschirmter elektrischer verbinder

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EP3641072A1 EP3641072A1 (de) 2020-04-22
EP3641072B1 true EP3641072B1 (de) 2021-09-22

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EP (2) EP3641072B1 (ja)
JP (1) JP6781160B2 (ja)
CN (1) CN107258039B (ja)
CZ (1) CZ33674U1 (ja)
DE (2) DE102015102703B4 (ja)
DK (3) DK3641072T3 (ja)
ES (1) ES2903426T3 (ja)
HU (1) HUE057700T2 (ja)
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Publication number Publication date
DK3262725T3 (da) 2022-01-31
US10916892B2 (en) 2021-02-09
EP3262725A1 (de) 2018-01-03
JP2018510462A (ja) 2018-04-12
EP3641072A1 (de) 2020-04-22
CN107258039A (zh) 2017-10-17
PL3262725T3 (pl) 2022-03-07
JP6781160B2 (ja) 2020-11-04
PL3641072T3 (pl) 2022-01-03
HUE057700T2 (hu) 2022-05-28
WO2016135170A1 (de) 2016-09-01
DK201900112U1 (da) 2020-01-09
DK3641072T3 (da) 2021-11-22
US20180054026A1 (en) 2018-02-22
DE102015102703A1 (de) 2016-08-25
CN107258039B (zh) 2019-07-16
DK201900112Y3 (da) 2020-02-18
DE202016008811U1 (de) 2019-11-11
US20190312387A1 (en) 2019-10-10
CZ33674U1 (cs) 2020-02-04
EP3262725B1 (de) 2022-01-05
ES2903426T3 (es) 2022-04-01
DE102015102703B4 (de) 2020-06-25
US10374363B2 (en) 2019-08-06

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