HK1180838A - Method for producing an electric interface and interface - Google Patents

Description

Method for producing an electrical interface and interface

Technical Field

The invention relates to a method for producing an electrical interface, in particular a plug-in connection, preferably a multipolar shielded electrical interface, preferably a plug, a socket, a Y-part, a T-part or the like, comprising at least one cable (connected to the interface) with a shielding (shield) which surrounds the conductors and is guided from the cable to and/or into the interface, the interface comprising electrical contacts.

Furthermore, the invention relates to a shielded electrical interface, in particular a plug-in connection, preferably a plug, a socket, a Y-part, a T-part, etc., comprising at least one cable with a shielding layer, which is connected to the interface, the interface comprising electrical contacts, the cable comprising wires/bundled conductors (bunchedconconductors) to be connected, the shielding layer surrounding the wires, in particular to an interface, which is produced according to the method of the invention.

The term "electrical interface" should be understood in the broadest sense of the word. Here, it may represent, for example, a single-pole or multi-pole shielded plug connection or a so-called Y-connection or T-connection and/or suitable connecting means. In order to achieve shielding as good as possible, a 360 ° shielded enclosure is usually required, for example a bundled wire with shielding.

Background

Generally speaking, different solutions have been proposed to provide adequate shielding for a variety of distinct interfaces and/or plug connections. In particular to provide shielding for plugs having complex geometries. For example, in angled plug T-connectors and Y-splitters, achieving 360 ° shielding from the cable to the interface is extremely cumbersome and therefore results in an interface that is expensive to produce and complete.

In practice, most different interfaces are known, for example in the form of plugs. Here, reference is made, merely by way of example, to WO 2008/061572a2 or DE 202007005264U 1. WO2006/005398A1 shows how bunched wires can be fed into a plug connection, which is a very complicated process. The same is true of EP 0412412a 1.

It is known from DE 10350763a1 analysis to produce coaxial cables with angled plug connections, wherein the cable connected to the actual plug connection is inserted into an injection-molded cavity forming a 90 ° arc and is surrounded by a heat-shrinkable material during the injection molding process. Before this, any kind of shield must be inserted into the actual plug-in connection and fixed in a conventional manner. This process is expensive.

Half shells are typically provided to form the plug housing, with the actual cable tray being injection molded over at least a portion of the housing. Shield contact is typically achieved by crimping, clamping, or welding the exposed braided wire shield to the housing and/or a separate shield sleeve.

The electrical and shielding contacts are usually realized via stamped or bent parts, for example using integrally formed crimping claws, which are bent through 90 ° to obtain a bent plug. It is often necessary to weld the seams of the respective housing parts formed in order to achieve a sufficiently conductive connection and at the same time sufficient stability.

It is known from practice to wrap a shield layer with a shrink wrap with a metal layer. In addition, an adhesive copper tape is used, which is then injection molded (the coating is applied by means of injection molding).

The main problem of the interfaces of the prior art, in particular of the plug-in connection, is in terms of production, since the process of shielding the wires leading into the interface and completing and/or assembling the assembly in a suitable manner is extremely expensive and complicated. The production method is cumbersome and thus expensive, especially when the interface is made as a mini interface in the form of a mini plug-in connection.

Disclosure of Invention

The object of the invention is to provide a method for producing an electrical interface, preferably a multi-pole shielded electrical interface, in particular a plug-in connection, preferably a plug, a socket, a Y-part, a T-part or the like, according to which the corresponding interface can be produced in a simple manner and cost-effectively. Furthermore, a correspondingly generated interface will be provided.

The above object is achieved in accordance with a method having the features of claim 1. Thus, according to the method of the invention, for forming the shielding element, which may be spaced from the electrical contacts or may be insulated by embedding an insulator, the coating of the contact with injection molding and the use of an insert part with an insert contact may be employed by injection molding, coating the shielding layer of one or more electrical cables and at least one region adjacent to said shielding layer surrounding the electrical contacts with an electrically conductive composite material.

With regard to the interface of the invention, the above object is achieved by the independent claim 15. The interface is thus characterized in that the shielding element is formed by coating the shielding layer of the cable and at least one region surrounding the electrical contact adjacent to said shielding layer with an electrically conductive composite material by means of injection moulding, said shielding element being spaced from the electrical contact or being insulated by embedding an insulator, see the description of the previous paragraph.

According to the invention it has been realized that the shielding in the cable can easily be guided into the electrical interface, e.g. into a plug, into a socket, etc., i.e. such that the shielding element is formed by injection moulding applying an electrically conductive composite material on the shielding of one wire or possibly several wires and at least one area surrounding the electrical contacts adjacent to the shielding. Here, care must be taken that the shielding element is separated from the electrical contacts or insulated by using an insulator.

According to the invention, the connection to the shielding of the conductor has to be realized by injection molding techniques, although the thermoplastic materials commonly used for injection molding exhibit virtually non-conductive properties. Thus, the composite material used herein is electrically conductive and suitable for injection molding. Thus, injection molding is used on the one hand for the electrical contacting of the shielding layer and on the other hand for molding, so that it is not necessary to bend the shielding layer, the solder here the shielding ring, or other electrically conductive housing parts of the interface or electrically conductive components of the interface in any other way.

The composite material used for injection moulding and thus for producing the shielding element can be injection moulded and comprises a metal component, where it is necessary that after injection moulding the conductive surface, the metal matrix, or the metal dispersant is conductive, i.e. diffuses the compound. Composite materials with low-melting metals are suitable here, preferably with a melting point below 200 ℃. A eutectic or peritectic structure with a low melting point is particularly suitable here.

Furthermore, preferably, the composite material should comprise a thermoplastic material which ultimately forms the matrix. The processing temperature, i.e. the temperature range of the injection moulding process, should be from 250 ℃ to 300 ℃. The composite material may also comprise electrically conductive particles, in particular metal fibers and/or metal particles, improving the electrical conductivity of the composite material and thereby enhancing the suitability of the composite material for producing shielding elements by injection molding.

According to the invention, the composite material is used for coating and contacting the shielding layer of the cable by injection molding, thereby avoiding the need for conventional contacts and/or connections to the interface housing. Therefore, the production is technically easier.

With regard to the composite materials used, it should be noted that the thermoplastic material may have a specific gravity of 10 to 25% by weight, the low-melting metal may have a specific gravity of 10 to 40% by weight, and the other "additives" may have a specific gravity of 30 to 75% by weight, wherein the materials included as "additives" (in particular steel or copper fibers or corresponding particles) promote the formation of the electrically conductive structure. By this combination, up to 10 can be produced after the injection molding process⁶Specific electrical conductivity of S/m and thermal conductivity greater than 10W/mK. The shielding element obtained by suitable production and/or injection moulding is thus particularly suitable for forming the shielding layer of a cable at the various components of a conventional interface.

Within the scope of the method according to the invention, the cable is first manufactured in a conventional manner, and then the conductor (in particular the stranded wire comprised in the conductor) and the shield are exposed at both ends, wherein an electrical insulation is maintained between the stranded glue line and the shield.

To form the electrical contact, the wire and/or a stranded glue line of the wire is crimped (crimp). The conductive material may also be applied to the stranded wire by injection molding. This can be of the same material as the shielding element produced by injection moulding and thus form the cable here. Compared with the conventional common manual method, the invention can automatically produce complex wiring and connection, thereby greatly simplifying the production process and reducing the production cost.

The cable is manufactured in the same way as in the prior art, by inserting the cable into an injection moulding tool. The strand contacts are also part of the multi-component injection molding process, which will be discussed in more detail below. The insertion or connection and/or contact of the bridges, side bars and other connections can be made in an injection-molded manner. In any case, the contact pins are produced directly on the strands by injection molding, where contacts of complex geometry and shape can be produced. A stylus of arbitrary profile can be obtained. Here, no special bending or welding process is required, since the electrical contacts are already produced on the strands during the injection molding process.

When electrical contacts have been produced, whatever the form they are, said electrical contacts are at least partially embedded in an insulator made of plastic, for example an insert part, but this is not mandatory. In embodiments where such an insulator is technically injection molded, the insulator forms one type of interface body, such as a plug/jack body, which is the first formation of the interface. The interface body must comprise insulating plastic and must be connected to the cable which is integral with the electrical contacts in a technical injection molding process. The free end of the cable and the previously formed contact are (at least partially) embedded in the insulator and positioned according to the contact required for operation.

Furthermore, it is advantageous if functional elements, such as self-locking cams, springs, etc., are integrated in the interface body during the injection molding of the interface body. The self-locking cam can be produced from the same material as the interface body, i.e. it is moulded and/or integrated in the technical injection moulding process, e.g. it protrudes inwards. It is also possible to insert a separate spring element into the injection mold and to apply a coating thereon, wherein the positioning of the spring element can be arbitrary here.

In a further step, an interface body comprising an electrically isolating material (plastic) may be formed according to the above explanations, the above-mentioned at least partial shielding element being formed by injection molding from the electrically conductive composite material. In particular, the cable and the interface body produced at the end can be inserted again into the injection molding tool, so that at least the shield layer projection of the cable insulation and/or the shield mesh forming the shield layer and the interface body are coated by injection molding. By this measure, a shielding element is obtained, i.e. the shielding layer of the cable is fully inserted into the interface, which shielding layer, depending on the extent of the interface body, comprises a non-conductive plastic, which is coated with a conductive composite material by injection molding.

If desired, the cable in the front and/or in the region of the shielding element and in the front and/or in the region of a part of the shielding layer formed according to the above explanations can be coated with an electrically insulating plastic in an injection molding process, forming the outer shape of the interface and/or plug-in connection, i.e. forming the housing. The plastic may surround the area of one end of the cable and a part of or the entire shielding element, wherein the interface body is located below the shielding element. By this measure, the outer shape of the interface body is finally defined, for example a straight or angled plug. For example, the housing may be injection molded into any shape, such as for an angled plug, the housing comprising a portion of a cable to complete the production of the interface to which the cable is connected. The housing may be a flanged housing, i.e. a counterpart of a coupling plug.

At the free end, i.e. the open face of the produced interface, any components can be inserted and/or inserted or screwed and/or screwed into a screw ring, for example made of metal. Any coupling means (connector, etc.) may be used with the interface.

The interface produced according to the above explanation can be produced in injection moulding processes, which can be carried out independently of each other in separate tools. In addition, at least two different interface regions adjacent to each other may be produced simultaneously in a single injection molding tool (e.g., during overmolding). It is also possible to produce several different areas simultaneously by injection moulding, and according to the invention the electrical contacting and at least the shielding and the actual moulding have to be carried out in a single processing step of the injection moulding technique. Expensive assembly and/or completion, which in the prior art is mainly performed manually, is no longer necessary in the method according to the invention.

It should be mentioned here that the method according to the invention involves applying the coating by injection moulding and the plug body as an insert part.

Independent claim 15 claims a shielded electrical interface, which is preferably produced according to the method of the present invention. For this interface, the shielding element must be formed via injection molding by applying a conductive composite material on the shielding layer of the cable and at least one area adjacent to the shielding layer surrounding the electrical contacts. The shielding element is spaced from the electrical contacts or is isolated by embedding an insulator, although this is not mandatory.

As already explained for the method according to the invention, the composite material comprises a metal binder as composite material and, after injection molding, a metal surface, a metal framework and/or a metal dispersion, i.e. a penetrable structure, is realized. The composite material may comprise a low melting metal, preferably having a melting point below 200 ℃, and preferably a thermoplastic material having a processing temperature (injection molding temperature) in the range of from 250 ℃ to 300 ℃. Additional conductive components (e.g., metal fibers and/or small metal particles) enhance the conductivity and shielding desired characteristics.

In the interface according to the invention, the contacts can be at least partially embedded by injection molding in an insulating body which forms the interface body, in particular the plug/socket body. Functional elements such as self-locking cams, springs, etc. can be integrated in the interface body. Threads (threads) and other coupling mechanisms for connection may also be integrated.

The coating is applied at least partially on the interface body by injection molding and forming the shielding element, wherein the non-conductive plastic is applied by injection molding on the shielding element and the cable in the front and/or in the region of at least a part of the shielding element when forming the outer shape of the interface and/or plug-in connection. The housing may be molded in any shape, such as an angled plug or an angled socket.

Drawings

There are numerous ways of implementing and further extending the teachings of the present invention in an advantageous manner. To this end, reference is made, on the one hand, to the claims depending on claims 1 and 15 and, on the other hand, to the following description of preferred exemplary embodiments of the invention on the basis of the figures. The general preferred embodiments and further developments of the teaching are also explained in connection with preferred exemplary embodiments of the invention on the basis of the figures. The figures show:

fig. 1a is a schematic cross-sectional view of an exemplary embodiment of an interface in the form of a plug according to the present invention, in which a spiral ring is provided at the end, the contact is coated by injection molding to create a spacer,

fig. 1b is a schematic partial cross-sectional view of another exemplary embodiment of an interface in the form of a plug according to the present invention, in which a toroid is provided at the end, an embedded spacer is used as an insert,

fig. 2 is a schematic cross-sectional view of another exemplary embodiment of an interface according to the invention in the form of a plug, wherein self-locking cams and shielding elements are provided on the outside and on the inside,

fig. 3 is a schematic cross-sectional view of another exemplary embodiment of an interface in the form of a plug according to the present invention, in which a snap lock is embedded internally by injection molding,

fig. 4a is a schematic cross-sectional view of another exemplary embodiment of a mouthpiece according to the present invention, which is made in the form of an angled plug with a screw cap as a dispenser,

fig. 4b is a schematic cross-sectional view of another exemplary embodiment of an interface according to the present invention, which is made in the form of an angle plug as a distributor, wherein the angle plug has a directly formed conductive lock element and/or a directly injection molded shielding element,

fig. 4c is a schematic cross-sectional view of another exemplary embodiment of an interface according to the invention, which is made in the form of an angle plug as a distributor and in which the metal insertion parts (self-locking cams, shielding elements for 360 ° shielding) are coated by injection molding, and

fig. 5 is a schematic cross-sectional view of another exemplary embodiment of an interface according to the present invention in the form of a Y-part with three cables embedded therein.

Detailed Description

Fig. 1a shows an exemplary embodiment of an interface in the form of a plug produced according to the method of the invention, wherein the shielding 1 of the cable 2 is guided in the interface. Fig. 1 clearly shows that the front area of the shielding layer 1 is isolated so that direct contact is possible.

The electrically isolated conductor 3 projects further into the interface and/or plug and is connected at its two ends to the contacts 4 by crimping, welding or the like, or the conductor 3 is coated with a coating by injection molding.

In order to receive the electrical contacts 4 and to embed them in the plug, an insulating body 5 comprising plastic has been produced by injection molding, wherein the electrical contacts 4 are integrated in the insulating body 5 by a crimped connection. The spacer 5 ultimately forms the interface body, based on which additional functional area can be produced by injection molding.

The insulator 5 is molded in the manner according to the invention to form a shielding element 6 with an electrically conductive composite material, also by injection molding, the shielding element 6 produced in this way being in electrical contact with the shielding layer 1 and guiding the shielding layer 1 via the insulator 5 into the interface and/or guiding the shielding layer 1 along the interface.

The insulating body 7 as a further component can also be produced by injection molding from electrically insulating plastic. The housing 7 is embedded in the cable insulation 8 and tightly sealed with respect to the cable insulation 8. The jacket 7 extends from the cable insulation 8 and at least partially beyond the shielding element 6, and may form a stop for the end-side assembly of a spiral 9 or the like. The housing 7 produced by injection moulding techniques may also extend across the entire shielding element 6 up to the front end of the shielding element 6, thus covering the entire shielding element 6. Any other embodiments and forms are also possible.

Fig. 1b shows a further exemplary embodiment of an interface produced according to the invention in the form of a plug, in contrast to the embodiment according to fig. 1a, in which an insulating body 5 is inserted as an insert part, i.e. as an "external" insulating body. The spacer 5 provided here is equivalent to the insertion body meaning the insertion member. In particular, a conventionally produced insertion body is equipped with electrical contacts 4. The wire 3 is soldered. An isolation is provided in the cable cavity. The shield element 6 is injection moulded, the outer contour determining the shape.

Fig. 2 shows another embodiment of an interface according to the invention in the form of a plug, where the shielding element 6 is made longer and thus extends further, well beyond the insulating body 5, than the embodiment of fig. 1a and 1 b. In order to achieve a secure coupling, the self-locking cam 10 is formed in the manner according to fig. 2, i.e. by injection molding. It is also possible to incorporate a conductive self-locking unit via a self-locking hook. Alternatively, one or more resilient radially arranged contact cams in the form of injection moulded shield elements can be integrated, their return force pressing against the flange housing, thereby achieving circumferential shielding inside the interface. Additional elastic rings may be provided, which may also be embedded by injection moulding.

According to the above explanation, the number of transfer resistances (transfer resistances) is greatly reduced.

Fig. 3 shows another exemplary embodiment of an interface according to the invention in the form of a plug, in contrast to the embodiment shown in fig. 2, in which a spring 11 is provided in the extended shielding element 6 by injection molding. Here, it should be mentioned that the electrical contact of the above-mentioned functional element can be realized by coating the metal insert part using injection molding for shielding and/or guiding the current. It is also advantageous when the elastic element, for example a spring, is provided with a wear-resistant surface to allow to achieve a return force that is maintained for a long time on one side, and to obtain as low a flow resistance as possible on the other side. The long lasting return force can be achieved by suitable spring materials exhibiting corresponding mechanical characteristics. As low a flow resistance as possible can be achieved by, for example, further suitable surfaces.

Fig. 4a shows a schematic view of another exemplary embodiment of an interface according to the present invention, wherein the interface is in the form of an angle plug. Fig. 4a clearly shows that by designing the injection-molded housing 7, an angular plug is obtained, in which design the entire shape of the injection-molded housing 7 is embedded in the shielding element 6.

Fig. 4b shows a schematic view of another exemplary embodiment of an interface according to the invention in the form of an angle plug with an electrically conductive self-locking unit in the form of a self-locking cam 10 and a directly injection molded shielding element 6.

Fig. 4c shows another exemplary embodiment of an interface according to the invention, which is made in the form of an angle plug as a distributor, wherein the metal insert part 13 acts as a self-locking hook. The metal insert part 13 is embedded in the injection-molded shielding element 6.

Finally, fig. 5 shows a schematic view of a distributor made in the form of a Y-piece, in which a total of three cables 2 are electrically connected to each other. The interface comprises different functional elements in the form of bridges 12, which bridges 12 are placed on the insulating body 5 produced by injection moulding and are electrically isolated from each other. The free end of the cable 2 is embedded in the insulator 5, forming an interface body.

The entire insulation 5 is surrounded by an injection-molded shielding element 6, which shielding element 6 contacts the respective shielding layer 1 of the cable 2 and thus embeds the cable 2.

The outer shape is achieved by injection moulding the housing 7, i.e. from an electrically isolating physical material. The form of the interface and/or Y-part is thus defined by the injection moulding technique, i.e. by the housing 7.

It should be mentioned that the exemplary embodiments discussed above are only intended to illustrate the claimed teachings by way of example, but that the teachings are not limited to the description herein.

List of reference numerals

1 Shielding layer

2 electric cable

3 conductor (conductor of cable)

4 electric contact

5 spacer, interface body

6 Shielding element

7 outer cover

8 Cable isolation

9 Spiro ring

10-locking (self-locking) cam

11 spring

12 bridge

13 metal insert parts.

Claims (18)

1. Method for producing an electrical interface, in particular a plug-in connection, preferably a multi-pole shielded, preferably a plug, a socket, a Y-part, a T-part or the like, comprising at least one cable (2) to which a shielding layer (1) is connected, the interface comprising electrical contacts (4), the cable (2) comprising wires (3) to be connected to the electrical contacts (4), the shielding layer (1) surrounding the wires (3) and being guided from the cable (2) to and/or into the interface,

characterized in that, in order to form a shielding element (6), the shielding layer (1) of the cable (2) or cables (2) and at least one region surrounding the electrical contact (4) adjacent to the shielding layer (1) are provided with an electrically conductive composite material by injection molding, the shielding element (6) being separated from the electrical contact (4) or by an embedded insulating body (5).

2. The method of claim 1, wherein the composite material comprises a metal component and, after the injection molding, comprises a metal matrix or a penetrable metal dispersant, i.e., a penetrable structure.

3. A method according to claim 1 or 2, wherein the composite material comprises a low melting point metal, the melting point of which is preferably below 200 ℃.

4. A method according to any of claims 1-3, wherein the composite material preferably comprises a thermoplastic material and the processing temperature thereof is in the range of from 250 ℃ to 300 ℃.

5. The method according to any of claims 1-4, wherein the composite material comprises electrically conductive particles, in particular metal fibers and/or metal small particles.

6. The method according to any of claims 1-5, characterized in that the cable (2) is made of a conductor (3), in particular a multi-stranded wire comprised in the conductor (3) and the shield (1) are exposed at both ends.

7. Method according to any of claims 1-6, characterized in that the glue strands are crimped to form the electrical contact (4) or that an electrically conductive material is applied to the glue strands by injection moulding.

8. Method according to any of claims 1-7, characterized in that the contact (4) is at least partially embedded by injection moulding in a possible external insulating body (5) made of plastic, which insulating body (5) forms an interface body, such as a plug/socket body.

9. Method according to claim 8, characterized in that functional elements, such as self-locking cams, springs or the like, are integrated in the interface body during the shaping thereof.

10. Method according to claim 8 or 9, characterized in that the electrically conductive composite material is applied on at least part of the interface body (5) by injection moulding when forming the shielding element (1).

11. Method according to any of claims 1-10, characterized in that the cable (2) is coated with an electrically isolating plastic by injection moulding in front of and/or in the area of the shielding element (6) and at least a part of the shielding layer (1) when forming the outer shape of the interface and/or the plug-in connection, i.e. when forming the housing (7).

12. Method according to claim 11, characterized in that the housing (7) is injection moulded in any shape, for example in the form of an angled plug embedding a part of the cable (2).

13. Method according to any of claims 1-12, characterized in that the zones are injection moulded in succession.

14. Method according to any of claims 1-12, wherein at least two different areas are injection moulded simultaneously, for example in an overmoulding process.

15. A shielded electrical interface, in particular a plug-in connection, preferably a plug, a socket, a Y-part, a T-part or the like, comprising at least one cable (2) with a shielding (1), the interface comprising an electrical contact (4), the cable (2) comprising a wire/stranded wire (3) to be connected to the electrical contact (4), the shielding (1) surrounding the wire (3), the interface being in particular produced according to the method of claims 1-14, characterized in that,

-forming a shielding element (6) by injection moulding a conductive composite material on a shielding layer (1) of the cable (2) and on at least one area surrounding the electrical contact (4) adjacent to the shielding layer (1), the shielding element (6) being separated from the electrical contact (4) or by an embedded insulator (5).

16. Interface according to claim 15, characterized in that said composite material comprises a metal component and after said injection moulding a metal matrix or a penetrable metal dispersion, i.e. a penetrable structure, wherein said composite material comprises a low melting metal, preferably a thermoplastic material, having a melting point preferably below 200 ℃, and possibly further electrically conductive components, such as metal fibers and/or metal particles, having a processing temperature in the range of from 250 to 300 ℃.

17. Interface according to claim 15 or 16, characterized in that the contacts are at least partially embedded in an insulating body (5) by means of injection molding techniques, the insulating body (5) forming an interface body, in particular a plug/socket body, into which interface body (5) the functional elements, such as self-locking cams, springs, etc., can be integrated.

18. Interface according to claim 17, characterized in that in the formation of the shielding element (6) a coating is applied on at least part of the interface body (5) by injection moulding, and in the formation of the outer shape of the interface and/or the plug-in connection, i.e. in the formation of the housing (7), the housing (7) can be moulded in any shape by applying an electrically isolating plastic to the cable (2) injection moulded in front of and/or in the area of the shielding element (6) and at least part of the shielding layer (1).