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EP4080685B1 - Câble électrique confectionné et agencement de connecteur enfichable - Google Patents

Câble électrique confectionné et agencement de connecteur enfichable Download PDF

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Publication number
EP4080685B1
EP4080685B1 EP21169672.9A EP21169672A EP4080685B1 EP 4080685 B1 EP4080685 B1 EP 4080685B1 EP 21169672 A EP21169672 A EP 21169672A EP 4080685 B1 EP4080685 B1 EP 4080685B1
Authority
EP
European Patent Office
Prior art keywords
contact
electrical cable
prefabricated
contact element
end section
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
EP21169672.9A
Other languages
German (de)
English (en)
Other versions
EP4080685C0 (fr
EP4080685A1 (fr
Inventor
Willem Blakborn
Maximilian Metzenleitner
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.)
Rosenberger Hochfrequenztechnik GmbH and Co KG
Original Assignee
Rosenberger Hochfrequenztechnik 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 Rosenberger Hochfrequenztechnik GmbH and Co KG filed Critical Rosenberger Hochfrequenztechnik GmbH and Co KG
Priority to EP21169672.9A priority Critical patent/EP4080685B1/fr
Priority to EP24220897.3A priority patent/EP4503344B1/fr
Priority to PCT/EP2022/060406 priority patent/WO2022223608A1/fr
Publication of EP4080685A1 publication Critical patent/EP4080685A1/fr
Application granted granted Critical
Publication of EP4080685B1 publication Critical patent/EP4080685B1/fr
Publication of EP4080685C0 publication Critical patent/EP4080685C0/fr
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
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/025—Contact members formed by the conductors of a cable end
    • 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
    • H01R13/02—Contact members
    • H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
    • 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
    • H01R13/40—Securing contact members in or to a base or case; Insulating of contact members
    • H01R13/42—Securing in a demountable manner
    • H01R13/422—Securing in resilient one-piece base or case, e.g. by friction; One-piece base or case formed with resilient locking means
    • H01R13/4223—Securing in resilient one-piece base or case, e.g. by friction; One-piece base or case formed with resilient locking means comprising integral flexible contact retaining fingers
    • H01R13/4226—Securing in resilient one-piece base or case, e.g. by friction; One-piece base or case formed with resilient locking means comprising integral flexible contact retaining fingers comprising two or more integral flexible retaining fingers acting on a single contact
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H01R4/029—Welded 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
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0207—Ultrasonic-, H.F.-, cold- or impact welding
    • 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
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0214—Resistance welding

Definitions

  • the invention relates to a prefabricated electrical cable for an electrical connector, comprising an electrical conductor which is designed as a stranded wire made up of several individual wires, according to the preamble of claim 1.
  • the invention also relates to a connector arrangement comprising a prefabricated electrical cable and an electrical connector.
  • cables When cables are assembled, their ends, especially the ends of their inner conductors, are prepared for installation in an electrical connector. During this process, the electrical conductors are often cut to a defined length, stripped and provided with one or more contact elements.
  • a contact element of the subsequent connector can be electrically and mechanically connected to an electrical conductor guided within a cable sheath and later mounted in a connector housing of the connector. The fully assembled contact element can then be used within the connector to contact a mating contact element of a mating connector.
  • Various electrical connectors are known from electrical engineering. Electrical connectors are known to be used to transmit electrical supply signals and/or data signals to the corresponding mating connectors.
  • a connector or mating connector can be a plug, a built-in connector, a socket, a coupling or an adapter.
  • the term "connector” or “mating connector” used in the context of the invention represents all variants.
  • connectors and electrical cables for the automotive industry and for vehicles are subject to high demands in terms of their robustness and the safety of the connectors.
  • Electromobility in particular is placing great demands on the automotive industry and their suppliers face major challenges, as high levels of electrical power must be transmitted in vehicles via cables and plug connections.
  • the thermal load and the resulting waste heat associated with the high current flow are significant.
  • the contact resistance between the cable's electrical conductor and the contact element, as well as between the contact element of the plug connector and the mating contact element of the mating connector should be as low as possible.
  • High-voltage connectors are used in the automotive sector, especially in electric and/or hybrid vehicles, to supply a vehicle battery with charging current, to extract the stored energy from the battery and supply it to an electrical consumer, or to connect several batteries or battery modules to each other.
  • a high-voltage connector In addition to safe and preferably low-resistance electrical connections within the connector and at the transition to the mating connector, a high-voltage connector must also be easy and cost-effective to manufacture due to the mass suitability of the connector.
  • the connector especially a high-voltage connector or a connector for transmitting safety-relevant control signals, should be mechanically robust and reliably secured against unintentional opening.
  • the contact between a high-voltage cable and a high-voltage connector is typically made via a contact blade, which is mechanically connected to the electrical conductor of the electrical cable.
  • attaching the contact blade to the electrical conductor is comparatively complex and costly.
  • the resulting contact resistance is often not ideal.
  • a welded contact blade As an alternative to a welded contact blade, it is also known to contact an electrical conductor formed as a stranded wire made of several individual wires in a plate-shaped contact area for contacting a mating contact element of a mating connector.
  • the electrical conductor can thus itself serve as a contact element.
  • the compaction of the stranded wire is relatively susceptible to tolerances and therefore usually leads to a more or less uneven contact surface, which makes the electrical and mechanical connection with the mating contact element of the mating connector.
  • US 2015/075863 A1 refers to an electrical conductor fitted with a connector.
  • the US 2020/169052 A1 refers to a technique for ultrasonically welding an electrical conductor to an electrical terminal.
  • the DE 10 2017 106 742 B3 relates to a connection of a connecting line with a stranded line, in which a connecting part has a first metallic surface made of a first metallic material and a second metallic surface made of a second metallic material different from the first metallic material, the stranded line is formed from a metallic material, the connecting part is placed around the stranded line, encasing the stranded line with the first metallic surface adjacent to the stranded line, and the connecting part is connected to the stranded line at least in a form-fitting manner.
  • the US 2020/350708 A1 concerns an electrical cable with attached connector and a wiring harness and the JP 2011 081918 A a water stop structure for an electrical cable.
  • the US 2015/060135 A1 refers to a cuboid-shaped compacted strand that is crimped to a socket contact.
  • the WO 2012/136433 A1 relates to a connector for an electrical line and a plug connection comprising the connector.
  • the EP 2 012 392 A1 relates to a contact for receiving a mating contact as well as a method for producing such a contact and its attachment to a cable.
  • the object of the present invention is to provide a prefabricated electrical cable which is preferably suitable for transmitting high electrical currents with low contact resistance and which is particularly suitable for mass production but can nevertheless be produced with high precision.
  • a prefabricated electrical cable is provided for an electrical connector.
  • the prefabricated electrical cable has an electrical conductor which is designed as a stranded wire made up of several individual wires and which has at least one plate-shaped compacted end section.
  • the thickness of the plate-shaped compacted end section can be much smaller than the width and length of the plate-shaped compacted end section.
  • the electrical cable can in particular be a high-voltage cable or a high-voltage line for vehicle technology for transmitting high currents, for example with voltages of 1,500 volts or more.
  • the prefabricated electrical cable according to the invention can be used particularly advantageously in electrically powered vehicles, for example in electric vehicles or hybrid vehicles.
  • the prefabricated electrical cable can have a cable sheath that envelops the electrical conductor.
  • the electrical conductor can be exposed (stripped) from the cable sheath in the area of its end section.
  • the prefabricated cable can have any number of electrical conductors, for example one inner conductor, two inner conductors or more inner conductors, three inner conductors or more inner conductors, four inner conductors or more inner conductors, five inner conductors or more inner conductors.
  • an outer conductor can also be provided.
  • the invention is described below essentially with reference to a prefabricated electrical cable that has exactly one inner conductor. However, this is not to be understood as limiting.
  • the inner conductor(s) can be coaxial to the central axis of the cable.
  • the inner conductor(s) can also be evenly distributed around the central axis of the cable.
  • the prefabricated electrical cable has exactly one inner conductor that runs inside the cable sheath.
  • Shielding can optionally be provided, for example a cable shield braid spaced from the inner conductor by means of a dielectric material and/or a cable foil.
  • the prefabricated electrical cable has an elongated contact element (the length of the contact element can therefore be greater than the width along a longitudinal axis), with at least one side surface which forms a first connection surface which is connected to a corresponding side surface of the compacted end section of the electrical conductor, and with at least one further side surface facing away from the first connection surface which forms a first contact surface for contacting a mating contact surface of a mating contact element of a mating connector.
  • the contact element can be manufactured with high precision, for example with a precisely defined size and geometry of the contact surface, which can have a significantly better surface quality compared to the corresponding side surface of the plate-shaped compacted end section. Furthermore, the contact element can cover protruding individual wires that have not been sufficiently compacted.
  • the combination of a compacted end section of a strand with a contact element attached to it proposed according to the invention combines the advantages of the high current transferability associated with the compaction of the strand with the advantages of a contact surface that can be manufactured particularly precisely using a separate contact element.
  • connection between the contact area and the electrical conductor can be robust and low-resistance and therefore suitable for transmitting particularly high currents.
  • the contact surface and/or the counter-contact surface can preferably each be a completely continuous surface. However, several individual contact surfaces and/or counter-contact surfaces can also be provided.
  • the contact element is designed as a contact plate.
  • the thickness of the contact plate can be, for example, 0.1 mm to 2.0 mm, preferably 0.3 mm to 1.0 mm, particularly preferably 0.4 mm to 0.6 mm.
  • the use of a contact plate can represent a particularly economical solution.
  • the plate-shaped compaction of the electrical conductor on the one hand and the use of a contact plate on the other hand enable maximum material savings while at the same time ensuring extremely precise manufacturing and sufficient dimensional stability.
  • the contact element can also be designed as a contact plate.
  • the use of several contact plates, which are distributed over the plate-shaped compacted end section, can also be provided.
  • any contact element can be designed. However, it is particularly preferred that the contact element is not designed as a contact sleeve.
  • the contact element in particular the contact sheet, can be made in one piece, for example as a stamped and bent part.
  • the contact sheet can also be deep-drawn or manufactured in some other way.
  • the contact sheet is manufactured as a stamped and bent part.
  • the contact element and the individual wires of the electrical conductor are made of the same material.
  • the contact element and/or the individual wires of the electrical conductor are made of aluminum or copper. In principle, however, any material suitable for transmitting high currents can be used.
  • the contact element can have a coating.
  • a silver coating is provided.
  • the contact element can preferably be coated by means of strip electroplating.
  • the contact resistance can be further improved by a coating. If the contact element is made of aluminum, for example, this can sometimes tend to oxidize in the area of the contact surface. This can be avoided by a coating, for example a silver coating.
  • the contact surface is preferably a planar, flat surface.
  • the first contact surface can also be curved or round.
  • a curved first contact surface can be particularly suitable for contacting the contact lamellae mentioned below or for forming the contact lamellae.
  • further side surfaces of the contact element form respective further connection surfaces, wherein the contact element preferably has a total of two to five connection surfaces, which are each connected to the compacted end section of the electrical conductor.
  • each of the connecting surfaces is connected to a different corresponding side surface of the compacted end section.
  • the contact element can preferably be folded over an edge of the plate-shaped compacted end portion.
  • the The contact element must be folded over two edges of the compacted end section, in particular it must be U-shaped.
  • the contact element can, for example, be folded over three edges of the compacted end section.
  • a connecting surface of the contact element is connected to an end face of the plate-shaped compacted end section or is folded over an edge of the end face.
  • the contacting options can be increased, for example, additional contact surfaces can be provided for contacting one or more mating contact elements and/or an improved covering of the compacted end section can be provided, for example to cover protruding individual wires.
  • the at least one connecting surface is aligned parallel to a corresponding side surface of the compacted end section to which the connecting surface is connected.
  • the at least one connecting surface is fully connected to the corresponding side surface of the compacted end section.
  • connection surface to the corresponding side surface in particular a full-surface connection, can further reduce the contact resistance and enable the transmission of even higher currents.
  • the contact surfaces are each arranged parallel to their corresponding connecting surfaces.
  • the at least one connecting surface is materially connected to the compacted end section.
  • a material-locking connection between the connection surface and the compacted end section can enable a particularly low transition resistance.
  • the compacted end section and the contact element can be connected to one another particularly robustly in this way. Corrosion of the transition area between the contact element and the electrical conductor can also be avoided, especially if the material-locking connection is a gas-tight material-locking connection.
  • a screw connection, rivet connection or crimp connection between the electrical conductor and the contact element can preferably be dispensed with within the scope of the invention.
  • the electrical conductor can preferably be permanently connected to the contact element, whereby the electrical conductor can no longer be removed from the contact element without causing damage.
  • the previously mentioned gas-tight connection can be provided between the connecting surface of the contact element and the corresponding side surface of the plate-shaped compacted end section.
  • the at least one connecting surface completely covers a corresponding side surface of the compacted end section to which the connecting surface is connected.
  • the contact area for contacting the counter contact area of the counter contact element can be enlarged.
  • protruding individual wires can be completely covered.
  • a further side surface of the contact element forms a second contact surface for contacting a mating contact surface of a mating contact element of a mating connector.
  • further contact surfaces can also be provided, for example a third contact surface, a fourth contact surface and/or a fifth contact surface.
  • the use of two contact surfaces, which are arranged on opposite sides of the compacted end section in the case of the connected state of the contact element with the plate-shaped compacted end section, can be advantageous for contacting with the mating connector, for example in order to enable a two-sided, pincer-like contact.
  • the at least one contact surface of the contact element is designed as a primarily flat surface for surface contact with the counter contact surface.
  • a contact element can be designed in the manner of a contact blade, in combination with the advantages according to the invention.
  • the first locking means is designed as a spring tab punched out of the contact surface.
  • the connector in particular the connector housing of the connector, can have a corresponding locking recess or a corresponding locking lug into or behind which the spring tabs can lock in the assembled state of the prefabricated cable.
  • the first locking means is designed as a locking recess within the contact surface.
  • the connector in particular the connector housing of the connector, can have an elastic spring tab that can lock behind the locking lug or behind the locking hook when the assembled cable is in the assembled state.
  • any locking means can be provided which, in combination, enable suitable locking between the assembled electrical cable and the connector or the connector housing.
  • the contact element can also have locking elements for locking with the mating contact element and/or mating connector.
  • the connector housing can be lockable with a mating connector housing of the mating connector.
  • the electrical conductor has a conductor cross-section greater than 10 mm 2 , preferably greater than 30 mm 2 , particularly preferably greater than 60 mm 2 , for example greater than 90 mm 2 or even greater than 200 mm 2 .
  • a conductor cross-section can be provided which is suitable for electrical energy transmission in high-voltage technology, i.e. for transmitting high electrical currents (for example 100 A to 2 kA) at alternating voltages of 30 V to 1 kV or more or direct voltages of 60 V to 1.5 kV or more, in particular in automotive technology.
  • the individual wires of the electrical conductor are welded together in order to form the plate-shaped compacted end section
  • the individual wires can be press-welded, resistance-welded or fusion-welded together.
  • any material-bonded connection technique is possible.
  • the invention also relates to a connector arrangement comprising a prefabricated electrical cable according to the above and following embodiments and the electrical connector.
  • the plate-shaped compacted end section can be accommodated within the connector, preferably within a connector housing of the connector.
  • the connector housing can in particular be a plastic housing, preferably made of a rigid plastic or hard plastic.
  • the connector housing can preferably be manufactured by means of an injection molding process or a deep-drawing process. It can be provided that the connector housing is designed in one piece or preferably in several parts.
  • the connector housing can be designed to provide contact protection for the conductive components of the connector.
  • the proposed electrical connector is particularly suitable as a high-voltage connector, in particular for use in electromobility.
  • the electrical connector can advantageously provide, for example, a cell module connector interface for connecting battery cell modules, with a particularly advantageous design of the contact.
  • the prefabricated electrical cable can advantageously be used as a busbar replacement.
  • a particularly economical and at the same time high-quality contacting option can be provided.
  • the contact element can have a smooth, precisely manufactured contact surface, whereby the contact resistance between the electrical conductor and the contact element can be particularly low due to the compaction of the stranded wire.
  • the contact can also be particularly robust and can absorb high cable tensile forces, for example tensile forces greater than 100 N.
  • the invention relates to a device for assembling an electrical cable for carrying out the above-mentioned method.
  • the values and parameters described here include deviations or fluctuations of ⁇ 10% or less, preferably ⁇ 5% or less, more preferably ⁇ 1% or less, and most preferably ⁇ 0.1% or less of the respective specified value or parameter, provided that these deviations are not excluded in the implementation of the invention in practice.
  • the indication of ranges by initial and final values also includes all those values and fractions that are included in the respective specified range, in particular the initial and final values and a respective mean value.
  • Figure 1 shows a connector arrangement 1, comprising a prefabricated electrical cable 2 according to the invention and an electrical connector 3.
  • the electrical connector 3 has a connector housing 4 in which the prefabricated electrical cable 2 is received with at least one end.
  • the cable 2 can preferably be introduced into the connector housing 4 along an assembly direction M.
  • connection with a corresponding mating connector 5 is made along a plug-in direction S that runs orthogonally to the mounting direction M, although this is not to be understood as limiting.
  • a mating connector housing 6 of the mating connector 5 is shown in Figure 1 shown in dashed lines and also a mating contact element 7 of the mating connector 5 is shown.
  • the invention is particularly suitable for use in high-voltage technology in vehicles, for example for the electrical connection between individual batteries, battery modules and/or electrical consumers, such as electric motors.
  • the prefabricated electrical cable 2 which is only to be understood as an example, extends along a longitudinal axis L and has a single electrical conductor 8, which is guided within a cable sheath 9.
  • a cable sheath 9 is not absolutely necessary, however.
  • the electrical conductor 8 preferably has a conductor cross-section greater than 10 mm 2 , in particular greater than 30 mm 2 , particularly preferably greater than 60 mm 2 , for example also greater than 90 mm 2 . In principle, however, other conductor cross-sections can also be provided. It can also be provided that the electrical cable 2 has more than one electrical conductor 8.
  • the electrical conductor 8 is designed as a stranded wire made of several individual wires and is compacted in a plate-shaped end section 10, see for example also the Figures 2 and 3
  • the Individual wires of the electrical conductor 8 are preferably welded together, for example pressure welded, resistance welded or fusion welded.
  • the proposed prefabricated electrical cable 2 has an elongated contact element.
  • the contact elements are each designed as contact plates 11, preferably with a thickness of between 0.3 mm and 1.0 mm, particularly preferably with a thickness of between 0.4 mm and 0.6 mm.
  • any contact element can be provided, for example a plate-shaped contact element.
  • the contact element or contact plate 11 and the individual wires of the electrical conductor 8 can be made of the same material, for example aluminum or copper.
  • the contact element or contact plate 11 can also have a coating, preferably a silver coating (not shown).
  • the Figures 2 and 3 show a first embodiment of the assembled electrical cable 2.
  • the contact plate 11 has a side surface which forms a first connection surface 12 which is connected to the compacted end section 10 or to a corresponding side surface of the compacted end section 10 of the electrical conductor 8.
  • the contact plate 11 also has a side surface facing away from the first connection surface 12 which has a first contact surface 13 for contacting a counter contact surface 14 (cf. for example Figure 10 ) of the mating contact element 7 of the mating connector 5.
  • a particularly low-resistance electrical connection between the electrical conductor 8 and the contact element or contact plate 11 can be provided via the first connection surface 12 on the one hand and a particularly smooth, flat first contact surface 13 for contacting the mating contact element 7 on the other.
  • FIG. 4 to 8 some variants of the contact element designed as a contact plate 11 are shown in order to illustrate that further side surfaces of the contact element or contact plate 11 can also form further connection surfaces 15, 17, 18, 19, for example a total of two to five connection surfaces 15, 17, 18, 19, which are each connected to the compacted end section 10 of the electrical conductor 8.
  • the contact plate 11 has the first connecting surface 12 and a further, second connecting surface 15, wherein the contact plate 11 is folded over an edge of the plate-shaped compacted end section 10 of the electrical conductor 8.
  • This edge can preferably be the edge of the contact plate 11 facing the counter-contact element 7 during the plugging process. In this way, it can be avoided that protruding individual wires have a negative influence on the plugging process.
  • a contact surface is formed on the side surface of the contact element or contact plate 11 facing away from the respective connection surface 12, 15, 17, 18, 19.
  • the number of contact surfaces does not necessarily have to correspond to the number of connection surfaces 12, 15, 17, 18, 19.
  • the first contact surface 13 and only optionally a second contact surface 16 are provided (for example, if a pliers-like contact with the counter-contact element 7 or a contact with several counter-contact elements 7 is provided).
  • the contact surfaces 13, 16 are generally arranged along the main surfaces of the plate-shaped compacted end sections 10 (see, for example, Figures 2 and 7 ).
  • a further embodiment is shown by way of example, according to which, in addition to the first connecting surface 12 and the second connecting surface 15, a third connecting surface 17 is provided in order to form a U-shaped contact plate 11 which is folded over two edges of the plate-shaped compacted end section 10.
  • a fourth connecting surface 18 (cf. Figure 7 ) can be provided.
  • the example in Figure 7 The contact plate 11 shown or the prefabricated electrical cable 2 can thus advantageously be contactable from both sides and/or be modular and usable regardless of the orientation.
  • the contact sheet 11 is manufactured as a stamped and bent part and is to have four connecting surfaces 12, 15, 17, 18, it can optionally be provided to connect any adjacent edges between two connecting surfaces 12, 15, 17, 18 or within a connecting surface 12, 15, 17, 18 in a material-locking manner, i.e. to close any manufacturing-related gap between or within the connecting surfaces 12, 15, 17, 18, for example by means of a laser welding process.
  • the at least one contact surface 13, 16 has at least one first latching means for latching with a corresponding second latching means of the connector housing 4 in order to provide mutual latching when the prefabricated electrical cable 2 is completely inserted into the connector 3.
  • first latching means for latching with a corresponding second latching means of the connector housing 4 in order to provide mutual latching when the prefabricated electrical cable 2 is completely inserted into the connector 3.
  • the contact between the counter-contact element 7 and the contact element or contact plate 11 is preferably made orthogonally to the mounting direction M of the assembled electrical cable 2.
  • a full-surface contact can be provided, as in Figure 1 indicated, according to which the contact surface 13, 16 of the contact element or contact plate 11 is designed as a primarily flat surface for surface contact with the counter contact surface 14.
  • the contact surface 13, 16 and/or the counter contact surface 14 has an orthogonal directional component for mutual contact, for example contact lamellae 25.
  • contact blades 25 The contacting by means of contact blades 25 is exemplified in Figure 10 It can be provided that one or more contact lamellae 25, which are at least partially elastic in the contact direction, are formed from the contact surface 13, 16 itself, for example, are punched out. Alternatively, separate contact lamellae 25 can also be applied to the contact surface 13, 16. It is also possible to have a separate contact lamellae element 26 with several contact lamellae 25 (cf. Figure 11 ) between the contact surface 13, 16 and the mating contact surface 14, in particular to mount it captively in the connector housing 4. By using contact blades 25, the contact pressure between the contact element or contact plate 11 and the mating contact element 7 can be increased and thus the contact can be improved.

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  • Details Of Connecting Devices For Male And Female Coupling (AREA)
  • Connector Housings Or Holding Contact Members (AREA)
  • Coupling Device And Connection With Printed Circuit (AREA)

Claims (14)

  1. Câble électrique confectionné (2) pour un connecteur électrique enfichable (3), comprenant un conducteur électrique (8), formé en toron à partir de plusieurs fils individuels, et présentant au moins une section d'extrémité compactée en forme de plaquette (10) et un élément de contact (11) allongé, comprenant au moins une surface latérale formant une première surface de liaison (12) reliée à une surface latérale correspondante de la section d'extrémité compactée (10) du conducteur électrique (8), ainsi qu'au moins une autre surface latérale opposée à la première surface de liaison (12) formant une première surface de contact (13) pour l'établissement d'un contact avec une surface de contact opposée (14) d'un élément de contact homologue (7) d'un connecteur enfichable homologue (5), dans lequel chacune desdites au moins une surface de contact (13, 16) comporte au moins un premier moyen d'encliquetage (20, 21, 22) pour l'encliquetage avec un second moyen d'encliquetage correspondant du connecteur enfichable (3) pour fournir un encliquetage réciproque entre le câble confectionné (2) et le connecteur enfichable (3) lorsque le câble confectionné (2) est monté dans le connecteur enfichable (3).
  2. Câble électrique confectionné (2) selon la revendication 1,
    caractérisé en ce que,
    l'élément de contact est réalisé sous la forme d'une tôle de contact (11), de préférence avec une épaisseur entre 0,3 mm et 1,0 mm, de manière particulièrement préférée avec une épaisseur entre 0,4 mm et 0,6 mm.
  3. Câble électrique confectionné (2) selon la revendication 1 ou 2, caractérisé en ce que,
    l'élément de contact (11) et les fils individuels du conducteur électrique (8) sont réalisés dans la même matière, de préférence en aluminium ou en cuivre.
  4. Câble électrique confectionné (2) selon l'une des revendications 1 à 3, caractérisé en ce que,
    l'élément de contact (11) est pourvu d'un revêtement, de préférence un revêtement en argent.
  5. Câble électrique confectionné (2) selon l'une des revendications 1 à 4, caractérisé en ce que,
    d'autres surfaces latérales de l'élément de contact (11) forment d'autres surfaces de liaison (15, 17, 18, 19) respectives, dans lequel l'élément de contact (11) possède de préférence deux à cinq surfaces de liaison (12, 15, 17, 18, 19) en tout, reliées toutes avec la section d'extrémité compactée (10) du conducteur électrique (8).
  6. Câble électrique confectionné (2) selon l'une des revendications 1 à 5, caractérisé en ce que,
    ladite au moins une surface de liaison (12, 15, 17, 18, 19) est orientée parallèlement à la surface latérale correspondante de la section d'extrémité compactée (10), avec laquelle la surface de liaison (12, 15, 17, 18, 19) est reliée, et est reliée de préférence sur toute sa surface avec la surface latérale correspondante de la section d'extrémité compactée (10).
  7. Câble électrique confectionné (2) selon l'une des revendications 1 à 6, caractérisé en ce que,
    ladite au moins une surface de liaison (12, 15, 17, 18, 19) est reliée par liaison de matière à matière avec la section d'extrémité compactée (10).
  8. Câble électrique confectionné (2) selon l'une des revendications 1 à 7, caractérisé en ce que,
    ladite au moins une surface de liaison (12, 15, 17, 18, 19) recouvre entièrement une surface latérale correspondante de la section d'extrémité compactée (10), avec laquelle la surface de liaison (12, 15, 17, 18, 19) est reliée.
  9. Câble électrique confectionné (2) selon l'une des revendications 1 à 8, caractérisé en ce que,
    une autre surface latérale de l'élément de contact (11) forme une seconde surface de contact (16) pour l'établissement d'un contact avec une surface de contact opposée (14) d'un élément de contact homologue (7) d'un connecteur enfichable homologue (5).
  10. Câble électrique confectionné (2) selon l'une des revendications 1 à 9, caractérisé en ce que,
    ladite au moins une surface de contact (13, 16) de l'élément de contact (11)
    a) est formée sous la forme d'une surface essentiellement plate pour l'établissement d'un contact sur toute la surface avec la surface de contact opposée (14) ; ou
    b) présente une ou plusieurs lamelles de contact (25) réalisées, dans la direction de l'établissement du contact, de manière au moins partiellement élastique, pour l'établissement du contact avec la surface de contact opposée (14).
  11. Câble électrique confectionné (2) selon l'une des revendications 1 à 10, caractérisé en ce que,
    le premier moyen d'encliquetage est réalisé sous la forme d'une patte élastique (20) découpée dans la surface de contact (13, 16), d'un nez d'encliquetage (21) ménagé sur la surface de contact (13, 16) et/ou d'une ouverture d'encliquetage (22) dans la surface de contact (13, 16).
  12. Câble électrique confectionné (2) selon l'une des revendications 1 à 11,
    caractérisé en ce que,
    le conducteur électrique (8) a une section de conducteur supérieure à 10 mm2, de préférence supérieure à 30 mm2, de manière particulièrement préférée supérieure à 60 mm2, par exemple supérieure à 90 mm2.
  13. Câble électrique confectionné (2) selon l'une des revendications 1 à 12, caractérisé en ce que,
    les fils individuels du conducteur électrique (8) sont soudés les uns aux autres pour former la section d'extrémité compactée en forme de plaquette (10), de préférence par pression, par résistance ou par fusion.
  14. Disposition de connecteur enfichable (1), comprenant un câble électrique confectionné (2) selon l'une des revendications 1 à 13 et le connecteur électrique enfichable (3), dans lequel la section d'extrémité compactée en forme de plaquette (10) est logée à l'intérieur d'un corps de connecteur enfichable (4) du connecteur électrique enfichable (3).
EP21169672.9A 2021-04-21 2021-04-21 Câble électrique confectionné et agencement de connecteur enfichable Active EP4080685B1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
EP21169672.9A EP4080685B1 (fr) 2021-04-21 2021-04-21 Câble électrique confectionné et agencement de connecteur enfichable
EP24220897.3A EP4503344B1 (fr) 2021-04-21 2021-04-21 Câble électrique confectionné et ensemble connecteur
PCT/EP2022/060406 WO2022223608A1 (fr) 2021-04-21 2022-04-20 Câble électrique assemblé et ensemble connecteur

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP21169672.9A EP4080685B1 (fr) 2021-04-21 2021-04-21 Câble électrique confectionné et agencement de connecteur enfichable

Related Child Applications (2)

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EP24220897.3A Division-Into EP4503344B1 (fr) 2021-04-21 2021-04-21 Câble électrique confectionné et ensemble connecteur

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DE102022109737A1 (de) 2022-04-22 2023-10-26 Kromberg & Schubert Automotive Gmbh & Co. Kg Elektrisches Kabel oder elektrische Leitung ausgebildet mit einer Steckkontur zum direkten Einstecken in einen Gegenstecker
DE102023000391B3 (de) 2023-02-08 2024-02-22 Sew-Eurodrive Gmbh & Co Kg Anschlussvorrichtung für einen elektrischen Leiter und Kontaktierungseinheit
DE102024200182A1 (de) * 2024-01-09 2025-07-10 Robert Bosch Gesellschaft mit beschränkter Haftung Kontaktelement, Steckverbinder mit Kontaktelement und Steckverbinderanordnung mit Steckverbinder

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EP4503344A3 (fr) 2025-04-23
EP4503344C0 (fr) 2025-12-17
EP4080685C0 (fr) 2025-01-22
WO2022223608A1 (fr) 2022-10-27
EP4503344A2 (fr) 2025-02-05
EP4080685A1 (fr) 2022-10-26
EP4503344B1 (fr) 2025-12-17

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