EP3262725B1 - Shielded electric connector - Google Patents

Shielded electric connector Download PDF

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Publication number
EP3262725B1
EP3262725B1 EP16708622.2A EP16708622A EP3262725B1 EP 3262725 B1 EP3262725 B1 EP 3262725B1 EP 16708622 A EP16708622 A EP 16708622A EP 3262725 B1 EP3262725 B1 EP 3262725B1
Authority
EP
European Patent Office
Prior art keywords
shielding
connector
shielded
housing
plug
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
EP16708622.2A
Other languages
German (de)
French (fr)
Other versions
EP3262725A1 (en
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 PL16708622T priority Critical patent/PL3262725T3/en
Priority to EP19212454.3A priority patent/EP3641072B1/en
Priority to PL19212454T priority patent/PL3641072T3/en
Priority to DK19212454.3T priority patent/DK3641072T3/en
Publication of EP3262725A1 publication Critical patent/EP3262725A1/en
Application granted granted Critical
Publication of EP3262725B1 publication Critical patent/EP3262725B1/en
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
    • H01R13/648—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
    • 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
    • H01R13/46—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  
    • 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 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 each other 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 manufacture 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 angular 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 a 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 to 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.
  • 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 plug connector for a shielded cable in which an insulating body is encapsulated by injection molding with an electrically conductive composite material to form a shielding element.
  • the DE 10 2012 009 790 A1 relates to the injection molding of a liquid metal component by means of a nozzle into the cavity of a tool or a mold. It is possible to inject the metal component onto a prefabricated component.
  • 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 of the shielding involved 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 which 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 has a plurality of shielding shells with one another, or at least one shielding shell with at least one shielding housing, or connects several shielding housings with one another, or 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 the multiple shielding housings and provides an anchoring there with low electrical contact resistance and a complete, in particular causes complete 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 is cast directly onto the connector, in particular onto and around the connector, during assembly or in the manufacturing 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.
  • the contact resistance between the shielding sheaths of cables and / or the shielding housings of plug connectors to that in situ is made of liquid metal molded and the shielding sheaths and / or the shielding housing interconnecting the shield housing 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. A 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 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 a suitable 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 are from a Line insulation should be surrounded, it can be advantageous to better protect the line elements with an additional intermediate insulating body against the hot molten metal flow when casting 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 connecting part is encapsulated by the shielding housing, so that a good electrical connection to the shielding housing of the Connector is given what constitutes 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 / mK.
  • PET polyethylene terephthalate
  • PUR compact polyurethane
  • PEI polytherimide
  • PTFE polytetrafluoroethylene
  • PVC polyvinyl chloride
  • polyamide e.g. nylon ® or Perlon ®
  • 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 onto 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. In the case of heavy loads and great heat development in the power connector, good heat dissipation can thus still take place with a simple structure 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 with several connection points for line elements is provided, which either one or more lines, or one or more 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 shielding 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 cables 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 between 120 ° and 420 ° C, for example.
  • 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, for example tin-plating of the shielding sheaths or shielding housings, and with it during in situ casting these merge, 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, depending on the material, by injection molding the intermediate insulating body in situ, 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 sleeves and the line elements are at the end of the two Lines made free, 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.
  • the contact elements of the connector are attached to the end of the line elements of the shielded line and through Inserting into the insulating connector housing, the contact elements are isolated from one another.
  • 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 isolated, for example by overmolding with temperature-resistant plastic.
  • a plastic is preferably used which has a temperature resistance in the range from about 180 ° C to 230 ° C.
  • the intermediate insulating body and the are free Made shielding sheath of the cable 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.
  • the line elements are then connected to a distributor 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 cover 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 shell can be created by partial melting on the shielding shell concerned. Such 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, 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 to one another.
  • an intermediate insulating body 32 made of temperature-resistant insulating Injection-molded plastic so that the line insulation of the two coaxial cables meet at roughly 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 sleeves 10, 20 consist, for example, of a metal wire mesh, so that good anchoring and good electrical contact with the shielding housing 30 is obtained when casting around.
  • 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 which is hereby incorporated by reference.
  • Fig. 4 the coaxial cable connector is usable per se. Usually, however, 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 connects a shielded line 1 to contact elements 34 of the connector.
  • the shielded line 1 as a cable comprises one or more Line elements 11, 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 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 region 101 which is axially limited 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 screen housing 30 is formed by casting around the intermediate insulating body 32 and the shielding sleeve 10 in the ring area 101 made of liquid metal.
  • 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 jacket 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 connecting part 41, which is attached to the rear end of the Connector head protrudes 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 region 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 according to 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. After cooling, 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.
  • a metal casting tool 6 Fig. 17
  • any sprues 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.
  • 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 against 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. Then 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, whereby the protective jacket 33 surrounding the shielded housing 30 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, provides the shielding on the entire connector head represents.
  • the shielding on the connector 4 is accomplished by the shielded housing 30, which is made by 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 junction 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 fins 302 in order to dissipate heat from the interior of the power connector even better to the outside.
  • a data connector is produced accordingly, it being possible to use a plastic for the intermediate insulating body 32 which has a low thermal conductivity, since less heat needs to be dissipated during operation. In return, this has the advantage that when the screen housing 30 is cast in situ, the line elements 11 are even better protected from the effects of heat.
  • 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 at associated connection points 83 or 84 connected to the distributor body 8 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.
  • a shielding housing 30 ( Fig. 26 ) cast, i.e.
  • the shielding housing 30 surrounds the intermediate insulating body 32 without any gaps 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 sleeve 10, 20 of the respectively connected line 1, 2 is established. Then - if desired - the protective jacket 33 is attached.
  • Various low-melting metals and metal alloys, particularly metal solders, are useful for the purposes of the invention.
  • All lead-containing tin solders, all lead-free tin solders, including Sn-Bi solders with a melting point of around 130 ° C and silver solders can be used.
  • 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 shielded housing 30, especially if it consists of tin solder so that it fuses with the shielded 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 individual plug 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 a way other 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 shield 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 encapsulating 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.

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Description

Gebiet der ErfindungField of invention

Die Erfindung betrifft einen geschirmten elektrischen Verbinder zur Verbindung von geschirmten elektrischen Leitungen oder Steckverbindern untereinander sowie auf Verfahren zur Herstellung des geschirmten elektrischen Verbinders.The invention relates to a shielded electrical connector for connecting shielded electrical lines or connectors to one another and to methods for producing the shielded electrical connector.

Ein solcher geschirmter elektrischer Verbinder kann die Gestalt der Verbindung zwischen zwei Koaxialkabeln, oder von mehreren geschirmten Kabeln untereinander als Verteiler annehmen, oder die Verbindung kann zwischen einem geschirmten Kabel und einem Steckverbinder existieren, oder kann die Form eines geschirmten Mehrfachverteilers annehmen, der mehrere geschirmte Steckverbinder oder geschirmte Kabel miteinander verbindet.Such a shielded electrical connector can take the form of the connection between two coaxial cables, or of several shielded cables among each other 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.

Hintergrund der ErfindungBackground of the invention

Aus der DE 196 13 228 B4 ist ein elektrischer Steckverbinder mit Anschlusskabel bekannt mit einer metallischen Kupplungseinrichtung mit Überwurfmutter oder mit Schraube und mit einem einwärts gerichteten Kragen, der mit einer gecrimpten Hülse in Kontakt steht und die Verbindung zwischen der Kupplungseinrichtung und der Abschirmung des Abschlusskabels herstellt. Die Herstellung eines geschirmten Steckverbinders mit gecrimpter Schirmhülse ist aufwändig, es werden viele Einzelteile benötigt und die Vorbereitung des anzuschließenden Kabels wird von Hand durchgeführt, ebenso wie die Montage der vielen Einzelteile. Im Falle von Steckverbindern in Winkelform ist die Herstellung noch schwieriger zu bewältigen. Die elektrische Verbindung durch Crimpen von Teilen ist ferner nicht immer sicher, insbesondere kann sich der Übergangswiderstand an der Crimpverbindung bei Temperaturwechsel und bei Alterung ändern, was die Abschirmqualität des Steckverbinders herabsetzt.From the DE 196 13 228 B4 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 manufacture 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 angular 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.

Aus dem US-Patent 5,906,513 ist ein geschirmter gespritzter elektrischer Verbinder bekannt, bei dem ein hülsenförmiges metallisches Gehäuse kabelseitig mit Schlitzen zur Bildung von Laschen vorgesehen ist, die auf die Metallgeflecht-Abschirmung des Kabels gepresst werden, wonach das hülsenförmige Metallgehäuse hinter der metallischen Verbinderkupplung, die freigelegte Metallgeflecht-Abschirmung und das Kabelende mit thermoplastischem Material umspritzt werden. Das thermoplastische Material enthält Litzen aus dünnem Metalldraht, die während des Spritzvorganges gegen das hülsenförmige Metallgehäuse gepresst werden, um gute elektrische Kontinuität zwischen Kabel und Verbinder oder zu den hülsenartigen Gehäusen von Steckverbindern herzustellen. Auch hier kann der Übergangswiderstand zwischen den Abschirmteilen sich bei Temperaturwechsel und bei Alterung verschlechtern.From the U.S. Patent 5,906,513 a shielded injection-molded electrical connector is known in which a sleeve-shaped metallic housing is provided on the cable side with slots to form tabs which are pressed onto the metal braid shielding of the cable, after which the sleeve-shaped metal housing behind the metallic connector coupling, the exposed metal braid shielding and the cable end can be overmolded with thermoplastic material. The 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. Here, too, the contact resistance between the shielding parts can deteriorate with temperature changes and with aging.

Aus der DE 10 2008 018 403 A1 und der WO 2011/151373 A1 sowie der EP 2 109 194 A2 ist ein Steckverbinder mit einem daran angeschlossenen geschirmten Kabel bekannt, bei dem eine gespritzte Schirmhülse aus elektrisch leitendem Material, insbesondere einem elektrisch leitendem Kunststoff, die Kabelabschirmung mit der Kupplungsmutter des Steckverbinders elektrisch verbindet. Unter elektrisch leitendem Kunststoff wird allgemein ein mit Metallfasern gefüllter Kunststoff verstanden. Solches elektrisch leitfähiges Material kann spritzgussfähig sein (vgl. DIN 24450). Im Einzelnen werden die elektrischen Leiterenden des Kabels im Steckergehäuse angeschlossen, an dem eine Metallhülse angeordnet wird. Im Anschluss daran wird ein isolierender Träger spritzgegossen, der sich vom Leiterschirm bis in das Gehäuse hinein erstreckt. Um die isolierenden Träger wird ein elektrisch leitendes Hülsenteil spritzgegossen, das den Leiterschirm mit der Metallhülse und damit mit dem Gehäuseschirm des elektrischen Verbinders verbindet. Jedoch macht elektrisch leitender Kunststoff nur schwache Kontakte zu metallischen Oberflächen des Steckverbinders oder des Kabels, so dass der Übergangswiderstand an den Übergangsflächen zwischen dem elektrisch leitenden Kunststoffmaterial und den metallischen Flächen am Steckverbinder bzw. an der Kabelabschirmung erhöhte Werte aufweist, die sich zudem noch verschlechtern können, wenn sich in Folge des Schrumpfens oder Schmelzens des Kunststoffs Spalte oder Risse an den Übergangsflächen auftun. Ferner weisen leitfähige Kunststoffe in nachteiliger Weise eine geringere Schirmdämpfung als Metall auf.From the DE 10 2008 018 403 A1 and the WO 2011/151373 A1 as well as the EP 2 109 194 A2 a connector with a shielded cable connected to it is known, in which a 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). In detail, the electrical conductor ends of the cable are connected in the connector housing to 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. However, 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. Furthermore, conductive plastics disadvantageously have a lower shielding attenuation than metal.

Aus DE 10 2011 012 763 A1 ist ein Steckerverbinder für ein abgeschirmtes Kabel bekannt, bei dem ein Isolierkörper mit einem elektrisch leitenden Verbundmaterial zur Bildung eines Schirmelementes spritzgusstechnisch umgossen ist. Die DE 10 2012 009 790 A1 betrifft das Spritzgießen einer flüssigen Metallkomponenten mittels einer Düse in die Kavität eines Werkzeuges oder einer Form. Dabei ist es möglich, die Metallkomponente an ein vorgefertigtes Bauteil anzuspritzen.Out DE 10 2011 012 763 A1 a plug connector for a shielded cable is known in which an insulating body is encapsulated by injection molding with an electrically conductive composite material to form a shielding element. the DE 10 2012 009 790 A1 relates to the injection molding of a liquid metal component by means of a nozzle into the cavity of a tool or a mold. It is possible to inject the metal component onto a prefabricated component.

Allgemeine Beschreibung der ErfindungGeneral description of the invention

Der Erfindung liegt die Aufgabe zugrunde, einen geschirmten elektrischen Verbinder mit guter Schirmverbindung zwischen geschirmten elektrischen Leitungen und/oder geschirmten Steckverbindern zu schaffen.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.

Ein weiterer Aspekt der Aufgabe ist es, einen langlebigen geschirmten elektrischen Verbinder zu schaffen, bei welchem die Übergangswiderstände zwischen den beteiligten Komponenten der Schirmung während der Lebensdauer des Verbinders gering bleiben.Another aspect of the task is to create a durable, shielded electrical connector in which the contact resistance between the components of the shielding involved remains low during the life of the connector.

Ein weiterer Aspekt der Aufgabe ist es, einen geschirmten elektrischen Verbinder zu schaffen, welcher einfach und weitestgehend maschinell herstellbar ist und möglichst wenige Einzelteile aufweist.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.

Die Aufgabe der Erfindung wird durch den Gegenstand der unabhängigen Ansprüche gelöst. Vorteilhafte Weiterbildungen der Erfindung sind in den Unteransprüchen definiert.The object of the invention is achieved by the subject matter of the independent claims. Advantageous further developments of the invention are defined in the subclaims.

Im Einzelnen enthält der geschirmte elektrische Verbinder ein oder mehrere Leitungselemente, die wenigstens einer Leitung oder wenigstens einem Steckverbinder angehören. Im Falle von mehreren Leitungen können diese wenigstens teilweise miteinander verbunden sein, um einen Verteiler zu bilden. Die Leitungselemente können beispielsweise als Leitungsadern eines elektrischen Kabels oder als Fortsetzungen von Steckerkontaktelementen eines Steckverbinders ausgebildet sein. Der Verbinder umfasst ferner eine oder mehrere Abschirmhüllen und/oder ein oder mehrere Abschirmgehäuse, die als Kabelabschirmung wenigstens einer Leitung bzw. als Gehäuseabschirmelemente wenigstens einem Steckverbinder angehören. Die Erfindung umfasst ferner ein Schirmgehäuse, das entweder mehrere Abschirmhüllen untereinander, oder wenigstens eine Abschirmhülle mit wenigstens einem Abschirmgehäuse, oder mehrere Abschirmgehäuse untereinander verbindet, oder einen Teil des Abschirmgehäuses bildet. Das Schirmgehäuse besteht aus einem gegossenen Metallkörper, der in situ auf Ringbereiche sowohl der einen Abschirmhülle oder der mehreren Abschirmhüllen, als auch auf Ringbereiche des einen Abschirmgehäuses oder der mehreren Abschirmgehäuse gegossen worden ist und dort eine Verankerung mit geringem elektrischem Übergangswiderstand ergibt und eine vollständige, insbesondere lückenlose Schirmung des Verbinders bewirkt. Das Schirmgehäuse kann sich auch zwischen zwei miteinander zu verbindenden, geschirmten Kabeln oder Kabelgruppen erstrecken.In detail, the shielded electrical connector contains one or more line elements which 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 has a plurality of shielding shells with one another, or at least one shielding shell with at least one shielding housing, or connects several shielding housings with one another, or 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 the multiple shielding housings and provides an anchoring there with low electrical contact resistance and a complete, in particular causes complete shielding of the connector. The shielded housing can also extend between two shielded cables or cable groups to be connected to one another.

Mit anderen Worten besteht das Schirmgehäuse vorzugsweise nicht aus vorgefertigten Schalen- oder Hülsenteilen, sondern es wird beim Zusammenbau bzw. im Konfektionsprozess des Verbinders unmittelbar an den Verbinder, insbesondere an aus Kunststoff bestehende Bestandteile des Verbinders und darum herum angegossen. Es wird demnach flüssiges Metall bzw. eine flüssige Metalllegierung direkt an aus Kunststoff bestehende Bestandteile des Verbinders und darum herum gegossen. Das Schirmgehäuse wird demnach aus flüssigem Metall in situ an den bereits teilgefertigten Verbinder angegossen bzw. um Bestandteile des teilgefertigten Verbinders in situ herum gegossen.In other words, the screen housing preferably does not consist of prefabricated shell or sleeve parts, but is cast directly onto the connector, in particular onto and around the connector, during assembly or in the manufacturing 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.

Damit kann Lückenbildung vermieden werden, welche z.B. auftreten kann, wenn eine Hülse auf die Abschirmhülle eines Kabels gecrimpt wird, oder die Abschirmung zwei gecrimpte Hülsen umfasst. Ferner ist der Übergangswiderstand zwischen den Abschirmhüllen von Kabeln und/oder den Abschirmgehäusen von Steckverbindern zu dem in situ aus flüssigem Metall angegossenen und die Abschirmhüllen und/oder die Abschirmgehäuse miteinander verbindenden Schirmgehäuse gering. Die von dem in situ angegossenen Schirmgehäuse hergestellten elektrischen Verbindungen sind ferner langlebig und unterliegen nur in geringem Maße Alterungsprozessen. Da bei der Erfindung nicht mit vorgefertigten aufzumontierenden Schirmhülsen gearbeitet wird, ist die Herstellung des Verbinders vereinfacht. Eine besonders große Vereinfachung und Qualitätsverbesserung ergibt sich ersichtlich bei Winkelverbindern.This avoids the formation of gaps, which can occur, for example, when a sleeve is crimped onto the shielding sleeve of a cable, or the shielding comprises two crimped sleeves. Furthermore, the contact resistance between the shielding sheaths of cables and / or the shielding housings of plug connectors to that in situ is made of liquid metal molded and the shielding sheaths and / or the shielding housing interconnecting the shield housing 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. A particularly great simplification and quality improvement can be seen in the case of angle connectors.

Bei der Herstellung des Schirmgehäuses durch Metallguss direkt an die Abschirmhüllen und/oder Abschirmgehäuse ergibt sich eine gute Verankerung und innige Verbindung zwischen den angrenzenden Teilen der Schirmung, was zu einem geringen Übergangswiderstand zwischen den Teilen der Abschirmung führt. Bei entsprechender Wahl der Materialien der miteinander zu verbindenden Teile kann es sogar zu einer metallurgischen Verbindung kommen. Eine solche Verbindung ist besonders dauerhaft und von gleichbleibender Qualität.When the shield housing is manufactured by casting 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 a suitable 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.

Nach einer Ausgestaltung der Erfindung ist das Schirmgehäuse wenigstens teilweise auf und um einen Zwischenisolierkörper aus temperaturfestem elektrisch isolierendem Material gegossen, der die Leitungselemente beim Gießvorgang des Schirmgehäuses schützt. Zur Handhabung der Leitungselemente beim Zusammenbau des Verbinders werden die Enden der Leitungselemente, beispielsweise die Leitungsadern eines Kabels, von der Abschirmhülle frei gemacht, die typischerweise aus einem Metallgeflecht besteht. Auch wenn die Leitungselemente von einer Leitungsisolierung umgeben sein sollten, kann es vorteilhaft sein, die Leitungselemente mit einem zusätzlichen Zwischenisolierkörper besser gegen den heißen Metallschmelzfluss beim Gießen des Schirmgehäuses zu schützen. Der Zwischenisolierkörper kann aus wärmeresistentem elektrisch isolierendem Material bestehen und genügend dick gemacht werden, um den Anforderungen beim Gießen des Schirmgehäuses zu genügen.According to one embodiment of the invention, 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. In order to handle the line elements when assembling the connector, 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 are from a Line insulation should be surrounded, it can be advantageous to better protect the line elements with an additional intermediate insulating body against the hot molten metal flow when casting 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.

Im Falle eines Steckverbinders zum paarenden Verbinden mit einem Gegensteckverbinder werden die rückwärtigen Fortsetzungen der Kontaktelemente des Steckverbinders als die Leitungselemente genutzt. Die Kontaktelemente oder Leitungselemente werden zweckmäßig von einem elektrisch isolierenden Verbindergehäuse beherbergt. Um dieses Verbindergehäuse, welches die Kontaktelemente oder Leitungselemente hält, ist eine Kupplungshälfte des Steckverbinders, die mit der anderen Kupplungshälfte des Gegensteckverbinders zusammen arbeiten soll, herum gebaut, die als eine elektrische Abschirmverbindung zu dem Gegensteckverbinder wirksam ist. Dies stellt einen einfachen und sicheren Aufbau eines geschirmten Steckverbinders dar.In the case of a connector for paired connection with a mating connector, 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. To this connector housing, which holds the contact elements or line elements, 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.

Das Abschirmgehäuse des Steckverbinders kann ein metallisches Verbindungsteil und metallische Halbschalen umfassen, die auf dem isolierenden Verbindergehäuse mithilfe eines Überwurfrings befestigt sind und Teil der Kupplungshälfte des Steckverbinders bilden. Ein rückwärtiges Randteil des metallischen Verbindungsteils ist von dem Schirmgehäuse umgossen, so dass eine gute elektrische Verbindung zu dem Abschirmgehäuse des Steckverbinders gegeben ist, was die Abschirmgüte des Steckverbinders ausmacht.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 connecting part is encapsulated by the shielding housing, so that a good electrical connection to the shielding housing of the Connector is given what constitutes the shielding quality of the connector.

Wenn der Steckverbinder für eine Datenleitung ausgebildet und vorzugsweise mehrere Leitungselemente aufweist, werden diese von einem Zwischenisolierkörper aus elektrisch isolierendem und thermisch schlecht leitendem Material geschützt. Die thermische Leitfähigkeit des Materials des Zwischenisolierkörpers liegt in diesem Fall vorzugsweise zwischen 0,01 und 10 W/m-K. In Betracht kommen z.B. Polyethylenterephtalat (PET), Polyurethan kompakt (PUR), Polyimid (z.B. Kapton®), Polytherimid (PEI), Polytetrafluorethylen (PTFE), Polyvinylchlorid (PVC), Polyamid (z.B. Nylon® oder Perlon®), Polypropylen (PP), Polycarbonat (z.B. Makrolon®), Epoxydharz, Polymethylmetacrylat (PMMA), Polyethylen (PE), Polystyrol (PS), Polysiloxan (Silikon) und Polybutylenterephthalat (PBT). Ggf. besteht der Zwischenisolierkörper aus einem geschäumten Kunststoff, mit welchem eine thermische Leitfähigkeit zwischen 0,01 und 0,1 W/m-K, vorzugsweise um 0,02 W/m-K, erreicht werden kann. Hierdurch wird ein guter Schutz empfindlicher Drahtisolierungen beim Gießen des Schirmgehäuses erzielt.If 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. In this case, the thermal conductivity of the material of the intermediate insulating body is preferably between 0.01 and 10 W / mK. For example, polyethylene terephthalate (PET), compact polyurethane (PUR), polyimide (e.g. Kapton ® ), polytherimide (PEI), polytetrafluoroethylene (PTFE), polyvinyl chloride (PVC), polyamide (e.g. nylon ® or Perlon ® ), polypropylene (PP ), Polycarbonate (e.g. Makrolon ® ), epoxy resin, polymethyl methacrylate (PMMA), polyethylene (PE), polystyrene (PS), polysiloxane (silicone) and polybutylene terephthalate (PBT). If necessary, 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.

Wenn eines der Leitungselemente des Steckverbinders die Schutzerde führt (PE-Leiter), wird das Abschirmgehäuse vorzugsweise mit einer gegossenen Abzweigung unmittelbar an die Schutzerde angegossen. Dies stellt eine einfache und sichere Verbindung zwischen der äußeren Abschirmung und der innen verlaufenden Schutzerde (PE-Leiter) dar, welche insgesamt die Konstruktion des Steckverbinders vereinfacht.If one of the line elements of the connector leads to the protective earth (PE conductor), 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.

Im Falle eines Leistungssteckverbinders wird der Zwischenisolierkörper aus einem elektrisch isolierenden und thermisch gut leitenden Material hergestellt. Vorzugsweise ist das Schirmgehäuse mit Kühlrippen versehen und wird insbesondere einschließlich der Kühlrippen auf den thermisch gut leitenden Zwischenisolierkörper in situ aus Metall gegossen. Die thermische Leitfähigkeit des Materials des Zwischenisolierkörpers liegt in diesem Fall vorzugsweise zwischen 0,2 und 10 W/m-K. In Betracht kommen z.B. LATICONTHER® oder ein vorgefertigter Zwischenisolierkörpers aus Keramik. Bei starker Belastung und großer Wärmeentwicklung beim Leistungssteckverbinder kann somit bei einem einfachen Aufbau des Leistungssteckverbinders trotzdem eine gute Wärmeabfuhr erfolgen.In the case of a power connector, 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 onto the thermally highly conductive intermediate insulating body. In this case, 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. In the case of heavy loads and great heat development in the power connector, good heat dissipation can thus still take place with a simple structure of the power connector.

Der Zwischenisolierkörper kann sowohl beim Datenverbinder als auch beim Leistungsverbinder entweder als vorgefertigter Zwischenisolierkörper eingesetzt werden oder, wenn ein thermoplastischer Kunststoff verwendet wird, in situ spritzgegossen werden, bevor das Schirmgehäuse gegossen wird, was einen effizienten Herstellungsprozess erlaubt.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.

Der erfindungsgemäße Verbinder kann auch als Mehrfachverteiler für eine oder mehrere geschirmte Leitungen und/oder einen oder mehrere geschirmte Steckverbinder ausgestaltet sein. Es wird ein Verteilkörper mit mehreren Anschlussstellen für Leitungselemente vorgesehen, die entweder einer oder mehreren Leitungen, oder einem oder mehreren Steckverbindern angehören. Dieser Verteilkörper und angrenzende Leitungselemente werden bei der Herstellung des Schirmgehäuses und auch später während des Betriebs des Mehrfachverteilers geschützt. Das Schirmgehäuse umgibt den Zwischenisolierkörper unmittelbar und ist je nach Verbindungs- und Verteilpartner entweder an Ringbereiche von Abschirmhüllen der geschirmten Leitungen und/oder an Endbereiche von Abschirmgehäusen der Steckverbinder in situ gegossen und somit innig angeschlossen. Die Konstruktion des Verteilers ermöglicht somit eine Vielzahl von unterschiedlichen Mehrfachverteilern, bei denen ein oder mehrere Steckverbinderanschlüsse oder ein oder mehrere unmittelbare Leitungsanschlüsse auch gemischt angewendet werden können.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 with several connection points for line elements is provided, which either one or more lines, or one or more 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 shielding 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 cables 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.

Um der erfindungsgemäßen Erfindung ein gefälliges Aussehen zu geben und das Schirmgehäuse elektrisch zu isolieren, wie es handelsüblich ist, wird das Schirmgehäuse vorzugsweise von einem isolierenden Schutzmantel aus Kunststoff umgeben.In order to give the invention according to the invention a pleasing appearance and to electrically isolate the shield housing, as is customary in the trade, the shield housing is preferably surrounded by an insulating protective jacket made of plastic.

Das aus Metallguss bestehende Schirmgehäuse kann z.B. aus einer niedrig schmelzenden Metalllegierung bestehen. Die Solidustemperatur liegt dabei z.B. zwischen 120° und 420°C. Insbesondere kann die Metalllegierung ein Metalllot, z.B. ein Zinn-Lot sein. Z.B. haben sich bei Verwendung von Zinn-Lot (Schmelztemperatur etwa 230°C) keine Schädigungen der umgossenen Kunststoffteile, wie Leitungsisolierungen und Zwischenisolierkörper gezeigt. Insbesondere bei der Verwendung von Metalllot kann das Schirmgehäuse beim in situ Gießen Bestandteile, z.B. eine Verzinnung der Abschirmhüllen oder Abschirmgehäuse anschmelzen und mit dieser verschmelzen, was eine besonders niederohmige Schirm-Verbindung ermöglicht.The screen housing made of cast metal can for example consist of a low-melting metal alloy. The solidus temperature is between 120 ° and 420 ° C, for example. In particular, the metal alloy can be a metal solder, for example a tin solder. For example, when using tin solder (melting temperature approx. 230 ° C.), no damage to the encapsulated plastic parts, such as line insulation and intermediate insulating bodies, has been shown. In particular when using metal solder, the shielding housing can melt components, for example tin-plating of the shielding sheaths or shielding housings, and with it during in situ casting these merge, which enables a particularly low-resistance shield connection.

Die Erfindung betrifft auch Verfahren zur Herstellung des geschirmten elektrischen Verbinders in seinen verschiedenen Ausführungsformen.The invention also relates to methods of making the shielded electrical connector in its various embodiments.

Das Verfahren zur Herstellung des geschirmten elektrischen Verbinders wird demnach in seiner allgemeinen Form wie folgt durchgeführt:

  1. a) Verbinden der freien Enden der Leitungselemente miteinander;
  2. b) Optional Aufbringen des Zwischenisolierkörpers auf den freien Enden der miteinander verbundenen Leitungselemente;
  3. c) Umgießen der einen oder mehreren freigemachten Abschirmhüllen und/oder der einen oder mehreren Abschirmgehäuse und gegebenenfalls des Zwischenisolierkörpers mit flüssigem Metall zur Bildung des Schirmgehäuses.
The process for manufacturing the shielded electrical connector is therefore carried out in its general form as follows:
  1. a) connecting the free ends of the line elements to one another;
  2. b) optionally applying the intermediate insulating body to the free ends of the interconnected line elements;
  3. c) Casting around the one or more exposed shielding shells and / or the one or more shielding housings and optionally the intermediate insulating body with liquid metal to form the shielding housing.

Das Aufbringen des optionalen Zwischenisolierkörper kann dabei materialabhängig durch Spritzgießen des Zwischenisolierkörpers in situ erfolgen oder der Zwischenisolierkörper kann als vorgefertigtes Teil eingesetzt werden.The optional intermediate insulating body can be applied, depending on the material, by injection molding the intermediate insulating body in situ, or the intermediate insulating body can be used as a prefabricated part.

Wenn der geschirmte elektrische Verbinder zwei geschirmte Leitungen miteinander verbinden soll, werden die Abschirmhüllen und die Leitungselemente am Ende der beiden Leitungen frei gemacht, die freien Enden der Leitungselemente werden miteinander verbunden und der Zwischenisolierkörper wird auf den freien Enden der miteinander verbundenen Leitungselemente aufgebracht. Anschließend wird der Zwischenisolierkörper und die freigemachten Abschirmhüllen mit flüssigem Metall zur Bildung des Schirmgehäuses umgossen. Auf diese Weise entsteht ein Verbinder mit niedrigem elektrischem Übergangswiderstand zwischen den Abschirmhüllen der miteinander zu verbindenden Leitungen und dem Schirmgehäuse des Verbinders. Dieser niedrige elektrische Übergangswiderstand verspricht dauerhaft niedrig zu bleiben, auch bei robustem Umgang mit dem Verbinder.If the shielded electrical connector is to connect two shielded lines to one another, the shielding sleeves and the line elements are at the end of the two Lines made free, 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. This creates a connector with a low electrical contact resistance 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 low over the long term, even with robust handling of the connector.

Bei der Herstellung eines elektrisch geschirmten Steckverbinders, bei dem Leitungselemente einer geschirmten Leitung an Kontaktelemente des Verbinders angeschlossen werden, werden die Abschirmhülle und die Leitungselemente am Ende der geschirmten Leitung frei gemacht, die Kontaktelemente des Steckverbinders werden am Ende der Leitungselemente der geschirmten Leitung angebracht und durch Einfügen in das isolierende Verbindergehäuse werden die Kontaktelemente voneinander isoliert. Zwischen dem isolierenden Verbindergehäuse und der Stelle, an der die Leitungselemente von dem gemeinsamen Isoliermantel befreit worden sind, also auf frei verbleibenden oder einzeln isolierten Leitungselementen, wird der Zwischenisolierkörper, z.B. durch Umspritzen mit temperaturfestem Kunststoff, aufgebracht. Vorzugsweise wird ein Kunststoff verwendet, welcher eine Temperaturfestigkeit bis in den Bereich von etwa 180°C bis 230°C aufweist. Anschließend werden der Zwischenisolierkörper und die frei gemachte Abschirmhülle der Leitung mit flüssigem Metall zur Bildung des Schirmgehäuses umgossen. Auf diese Weise kann ein Steckverbinder mit einfachem, robustem Aufbau hergestellt werden, bei dem der elektrische Übergangswiderstand zwischen Abschirmhülle der Zuführungsleitung und dem Abschirmgehäuse des Steckverbinders niedrig ist und während der Lebensdauer des Steckverbinders niedrig zu bleiben verspricht.When producing an electrically shielded connector, in which line elements of a shielded line are connected to contact elements of the connector, the shielding sleeve and the line elements at the end of the shielded line are exposed, the contact elements of the connector are attached to the end of the line elements of the shielded line and through Inserting into the insulating connector housing, the contact elements are isolated from one another. 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 isolated, for example by overmolding with temperature-resistant plastic. A plastic is preferably used which has a temperature resistance in the range from about 180 ° C to 230 ° C. Then the intermediate insulating body and the are free Made shielding sheath of the cable encased with liquid metal to form the shielded housing. In this way, 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.

Bei einer Ausgestaltung des Verbinders als Mehrfachverteiler werden je nachdem, ob der Mehrfachverteiler mit einer oder mehreren Leitungen unmittelbar zu verbinden ist, oder ob der Mehrfachverteiler mit einem oder mehreren einzelnen Steckverbindern zu versehen ist, die Abschirmhülle und die Leitungselemente am Ende der anzuschließenden Leitung oder Leitungen frei gemacht und/oder es werden Steckverbinder mit jeweiligem Abschirmgehäuse und jeweiligen Leitungselementen bereit gestellt. Anschließend werden die Leitungselemente mit einem Verteilkörper verbunden. Daraufhin wird der Zwischenisolierkörper auf den frei gemachten Leitungselementen und um den Verteilkörper herum aufgebracht, z.B. durch Umspritzen mit Kunststoff hergestellt. Anschließend wird der Zwischenisolierkörper und jede frei gemachte Abschirmhülle umgossen und/oder die Randzone des Abschirmgehäuses im Falle eines Steckverbinders wird mit flüssigem Metall zur Bildung des Schirmgehäuses umgossen. Die Erfindung ermöglicht somit eine große Variabilität im Aufbau von elektrisch geschirmten Mehrfachverteilern.If 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. The line elements are then connected to a distributor 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 cover 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.

Bei dem erfindungsgemäßen Verfahren können Lötverbindungen zwischen Schirmgehäuse und Abschirmhülle durch teilweises Aufschmelzen an der betroffenen Abschirmhülle geschaffen werden. Solche Lötverbindungen entstehen bei dem Metallgießen des Schirmgehäuses, wenn entsprechende Vorbereitungen an der jeweiligen Abschirmhülle getroffen werden, beispielsweise wenn verzinnte Drahtgeflechte als Abschirmhülle eingesetzt werden.In the method according to the invention, soldered connections between the shielding housing and the shielding shell can be created by partial melting on the shielding shell concerned. Such 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.

Im Folgenden wird die Erfindung anhand von Ausführungsbeispielen und unter Bezugnahme auf die Figuren näher erläutert, wobei gleiche und ähnliche Elemente teilweise mit gleichen Bezugszeichen versehen sind und die Merkmale der verschiedenen Ausführungsbeispiele miteinander kombiniert werden können.The invention is explained in more detail below using exemplary embodiments and with reference to the figures, with identical and similar elements in some cases being provided with the same reference numerals and the features of the various exemplary embodiments being able to be combined with one another.

Kurzbeschreibung der Figuren:Brief description of the figures:

Ausführungsbeispiele der Erfindung werden anhand der Zeichnungen beschrieben. Dabei zeigt:

Fig. 1
zwei Koaxialkabel mit sich gegenüberstehenden abisolierten Innenleitern und mit freigemachten Enden der Abschirmhüllen,
Fig. 2
die Innenleiter mit einer Kupplungshülse verbunden,
Fig. 3
die Kupplungshülse mit einem Zwischenisolierkörper versehen,
Fig. 4
die Abschirmhüllen der beiden Koaxialkabel über ein Schirmgehäuse verbunden,
Fig. 5
den Koaxialkabel-Verbinder nach Fig. 4 mit einem Schutzmantel versehen,
Fig. 6
einen Längsschnitt durch den Koaxialkabel-Verbinder der Fig. 5,
Fig. 7
ein abgeschirmtes Kabel mit an den abisolierten Ader-Enden angecrimpten Kontaktelementen,
Fig. 8
die Kontaktelemente in ein Verbindergehäuse gesteckt,
Fig. 9
die Adern außerhalb des Verbindergehäuses mit einer Zwischenisolierung umspritzt,
Fig. 10
das Kabelende mit einem metallischen Schirmgehäuse umgossen, das einen Ringflansch aufweist,
Fig. 11
den geschirmten Steckverbinder,
Fig. 12
den Steckverbinder nach Fig. 11 von einem Schutzmantel umgeben,
Fig. 13
einen Längsschnitt durch den Steckverbinder nach Fig. 12,
Fig. 14
ein vorbereitetes Kabelende an einen Steckverbinderkopf angeschlossen
Fig. 15
das Kabelende mit Steckverbinderkopf in ein Spritzgusswerkzeug eingelegt,
Fig. 16
das Kabelende nahe dem Steckverbinderkopf mit einem Zwischenisolierkörper umspritzt,
Fig. 17
den Steckverbinderkopf mit umspritztem Kabelende in ein Metallgusswerkzeug eingelegt,
Fig. 18
den Steckverbinder mit einem metallischen Schirmgehäuse umgossen,
Fig. 19
den Steckverbinder nach Fig. 18 mit einem Schutzmantel versehen,
Fig. 20
einen Längsschnitt durch einen Leistungssteckverbinder mit Schutzerde-Anbindung,
Fig. 21
einen vergrößerten Längsschnitt durch den Kopf des Leistungssteckverbinders in gedrehter Schnittebene,
Fig. 22
eine perspektivische Darstellung eines Leistungssteckverbinders,
Fig. 23
einen Leistungssteckverbinder in Winkelform,
Fig. 24
einen Verteilkörper eines Mehrfachverteilers,
Fig. 25
den Verteilkörper mit umspritztem Zwischenisolierkörper,
Fig. 26
den Mehrfachverteiler mit Schirmgehäuse,
Fig. 27
den Mehrfachverteiler nach Fig. 26 mit Schutzmantel und
Fig. 28
einen Längsschnitt durch den Mehrfachverteiler nach Fig. 27.
Embodiments of the invention are described with reference to the drawings. It shows:
Fig. 1
two coaxial cables with stripped inner conductors facing each other and with exposed ends of the shielding sleeves,
Fig. 2
the inner conductor connected with a coupling sleeve,
Fig. 3
provide the coupling sleeve with an intermediate insulating body,
Fig. 4
the shielding sheaths of the two coaxial cables are connected via a shielded housing,
Fig. 5
the coaxial cable connector Fig. 4 provided with a protective jacket,
Fig. 6
a longitudinal section through the coaxial cable connector of Fig. 5 ,
Fig. 7
a shielded cable with contact elements crimped onto the stripped wire ends,
Fig. 8
the contact elements are plugged into a connector housing,
Fig. 9
the wires outside the connector housing are coated with intermediate insulation,
Fig. 10
the end of the cable is encased in a metallic shielded housing with an annular flange,
Fig. 11
the shielded connector,
Fig. 12
the connector Fig. 11 surrounded by a protective sheath,
Fig. 13
a longitudinal section through the connector Fig. 12 ,
Fig. 14
a prepared cable end is connected to a connector head
Fig. 15
the cable end with the connector head is placed in an injection molding tool,
Fig. 16
the cable end near the connector head is coated with an intermediate insulating body,
Fig. 17
the connector head with the molded cable end is placed in a metal casting tool,
Fig. 18
the connector is encased in a metallic shielded housing,
Fig. 19
the connector Fig. 18 provided with a protective jacket,
Fig. 20
a longitudinal section through a power connector with protective earth connection,
Fig. 21
an enlarged longitudinal section through the head of the power connector in a rotated sectional plane,
Fig. 22
a perspective view of a power connector,
Fig. 23
an angled power connector,
Fig. 24
a distributor body of a multiple distributor,
Fig. 25
the distribution body with overmolded intermediate insulating body,
Fig. 26
the multiple distributor with shielded housing,
Fig. 27
the multiple distributor Fig. 26 with protective sheath and
Fig. 28
a longitudinal section through the multiple distributor Fig. 27 .

Detaillierte Beschreibung der ErfindungDetailed description of the invention

Die Fig. 1 - 6 zeigen die Entstehung eines Koaxialkabel-Verbinders. Die Koaxialkabel bilden eine erste geschirmte Leitung 1 und eine zweite geschirmte Leitung 2. Jede Leitung umfasst ein Leitungselement 11 bzw. 21, eine Leitungsisolierung 12 bzw. 22, eine Abschirmhülle 10 bzw. 20 und einen Isoliermantel 13 bzw. 23. Um die Leitungselemente 11, 21 miteinander zu verbinden, wird eine metallische Kupplungshülse 31 benutzt, welche die beiden blanken Enden der Leitungselemente 11 und 21 elektrisch miteinander verbindet. In den Raum zwischen den Leitungsisolierungen 12 und 22 wird ein Zwischenisolierkörper 32 aus temperaturfestem isolierendem Kunststoff spritzgegossen, so dass sich die Leitungsisolierungen der beiden Koaxialkabel etwa auf gleichem Durchmesser begegnen. Die Lücke zwischen den beiden freigelegten Isoliermänteln 13 und 23 wird durch ein Schirmgehäuse 30 geschlossen, das die Abschirmhüllen 10 und 20 elektrisch miteinander verbindet. Die Abschirmhüllen 10, 20 bestehen beispielsweise aus einem Metalldrahtgeflecht, so dass sich beim Umgießen eine gute Verankerung und ein guter elektrischer Kontakt mit dem Schirmgehäuse 30 ergibt.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, line insulation 12 or 22, a shielding sleeve 10 or 20 and an insulating jacket 13 or 23 To connect 21 to one another, a metallic coupling sleeve 31 is used, which electrically connects the two bare ends of the line elements 11 and 21 to one another. In the space between the line insulation 12 and 22, an intermediate insulating body 32 made of temperature-resistant insulating Injection-molded plastic so that the line insulation of the two coaxial cables meet at roughly 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 sleeves 10, 20 consist, for example, of a metal wire mesh, so that good anchoring and good electrical contact with the shielding housing 30 is obtained when casting around.

Dies führt zu einem geringen elektrischen Übergangswiderstand zwischen den Abschirmhüllen 10, 20 einerseits und dem Schirmgehäuse 30 andererseits. Das Schirmgehäuse 30 besteht somit aus einem in situ gegossenen Metallkörper, der mittels eines Metallgusswerkzeugs erzeugt wird. Ein entsprechendes Metallgusswerkzeug ist in Fig. 17 dargestellt. Ggf. wird das in situ gegossene Schirmgehäuse 30 mit Heißkanaltechnik angusslos erzeugt, wie z.B. in der DE 10 2012 009 790 beschrieben ist, die hiermit durch Referenz inkorporiert wird.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 which is hereby incorporated by reference.

In der Form nach Fig. 4 ist der Koaxialkabel-Verbinder an sich gebrauchsfähig. Üblicherweise wird jedoch noch ein Schutzmantel 33 um das Schirmgehäuse 30 und die benachbarten Enden der Leitungen 1 und 2 gelegt. Damit wird die handelsübliche Form eines Verbinders 3 erhalten. Die geschirmte Verbindung zwischen den beiden Leitungen 1 und 2 ist damit vollständig.In the shape of Fig. 4 the coaxial cable connector is usable per se. Usually, however, 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.

Die Fig. 7 - 13 zeigen die Entstehung eines Steckverbinders, der eine geschirmte Leitung 1 an Kontaktelemente 34 des Steckverbinders anschließt. Die geschirmte Leitung 1 als Kabel umfasst ein oder mehrere Leitungselemente 11, eine Leitungsisolierung 12, eine Abschirmhülle 10 und einen Isoliermantel 13 rundherum. Wie aus Fig. 7 ersichtlich, ist das vordere Ende der Leitung 1 abisoliert, so dass die blanken Enden der Leitungselemente 11, auf welche die Kontaktelemente 34 aufgecrimpt werden, aus der Leitungsisolierung 12 vorstehen und auch die Abschirmhülle 10 und der Isoliermantel 13 sind am vorderen Ende der Leitung 1 durch einen Schnitt bei 14 gekürzt worden. Ferner wurde der Isoliermantel 13 durch einen Schnitt bei 15 bis zum Erreichen der Abschirmhülle 10 eingeschnitten und ein Isoliermantel-Randteil 16 wurde nach vorne in Richtung des Leitungsendes geschoben, um einen axial beidseits begrenzten Abschirmringbereich 101 frei zu legen. Ferner ist eine Überwurfmutter 351 als Teil einer Kupplungshälfte 35 auf das Ende der Leitung 1 bis zum Erreichen des unversehrten Isoliermantels 13 geschoben.the Fig. 7-13 show the creation of a connector that connects a shielded line 1 to contact elements 34 of the connector. The shielded line 1 as a cable comprises one or more Line elements 11, 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 the front end of the line 1 a cut at 14 has been shortened. Furthermore, 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 region 101 which is axially limited 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.

Die Enden der Leitungselemente 11 werden nunmehr mit den angecrimpten Kontaktelementen 34 in Bohrungen eines isolierenden Verbindergehäuses 36 geschoben, wonach der in Fig. 8 dargestellte Zustand entsteht. Wie ersichtlich, gibt es einen freibleibenden Bereich 17 zwischen dem Verbindergehäuse 36 und dem Isoliermantel-Randteil 16, in welchem sich die einzelnen mit Leitungsisolierung 12 versehenen Leitungselemente 11 befinden, wie in Fig. 8 dargestellt. Dieser frei verbleibende Bereich 17 wird durch Spritzgießen mit isolierendem Kunststoff, z.B. Macromelt zur Bildung eines Zwischenisolierkörpers 32 geschlossen, wie in Fig. 9 dargestellt.The ends of the line elements 11 are now pushed with the crimped contact elements 34 into bores of an insulating connector housing 36, after which the in Fig. 8 shown condition arises. As can be seen, there is a free area 17 between the connector housing 36 and the insulating jacket edge part 16, in which the individual line elements 11 provided with line insulation 12 are located, as in FIG Fig. 8 shown. This remaining free area 17 is closed by injection molding with insulating plastic, for example Macromelt, to form an intermediate insulating body 32, as in FIG Fig. 9 shown.

Ausgehend von dem in Fig. 9 dargestellten Zustand, wird ein Schirmgehäuse 30 durch Umgießen des Zwischenisolierkörpers 32 und der Abschirmhülle 10 im Ringbereich 101 aus flüssigem Metall hergestellt. Das so in situ gegossene Schirmgehäuse 30 reicht auch teilweise um das isolierende Verbindergehäuse 36 herum und bildet dort einen Ringflansch 301. Die gefangene Überwurfmutter 351 kann nunmehr über das Schirmgehäuse 30 hinweg bis zur Anlage an den Ringflansch 301 vorgeschoben werden, wie in Fig. 11 dargestellt. Dies stellt den gebrauchfähigen Zustand des Steckverbinders dar. Um zur handelsüblichen Ausführungsform zu gelangen, wird noch ein Schutzmantel 33 über das Schirmgehäuse 30 spritzgegossen, wobei der Verbinder das Aussehen gemäß Fig. 12 und 13 annimmt.Based on the in Fig. 9 State shown, a screen housing 30 is formed by casting around the intermediate insulating body 32 and the shielding sleeve 10 in the ring area 101 made of 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. To get to the commercially available embodiment, a protective jacket 33 is injection molded over the screen housing 30, the connector having the appearance Fig. 12 and 13th accepts.

Die Herstellung eines weiteren Steckverbinders 4 wird gemäß Fig. 14 - 19 erläutert. Zunächst wird ein Kopf des Steckverbinders 4 an das Ende der Leitungselemente 11 der Leitung 1 angeschlossen. Zu diesem Zweck sind die Leitungselemente 11 und die Abschirmhülle 10 im Abschirmringbereich 101 frei gemacht worden, wie dies anhand der Fig. 7 beschrieben worden ist.The production of a further connector 4 is carried out according to Figures 14-19 explained. First, a head of the connector 4 is connected to the end of the line elements 11 of the line 1. For this purpose, the line elements 11 and the shielding sleeve 10 have been made free in the shielding ring area 101, as shown on the basis of FIG Fig. 7 has been described.

Der Kopf des Steckverbinders 4 weist eine Überwurfmutter 451 auf, die Teil der Kupplungshälfte ist, welche mit einem (nicht dargestellten) Gegensteckverbinder zusammen arbeitet, um den Steckverbinder 4 mit dem Gegensteckverbinder paarend zu verbinden. Von der Überwurfmutter 451 verdeckt ist das vordere Ende eines elektrisch isolierenden Verbindergehäuses 46 zu sehen, in welchem die Kontaktelemente angeordnet sind, die mit den blanken Enden der Leitungselemente 11 verbunden sind. Der Kopf des Steckverbinders 4 umfasst noch ein metallisches Verbindungsteil 41, das am hinteren Endes des Steckverbinderkopfes vorsteht und nach vorne und um das elektrisch isolierende Verbindergehäuse 46 herum reicht, um bei Kupplung mit einem Gegensteckverbinder die Schirmung zu diesem zu gewährleisten.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 connecting part 41, which is attached to the rear end of the Connector head protrudes 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.

Mit Fig. 15 ist ein offenes Spritzgusswerkzeug 5 dargestellt, das einen Hohlraum zur Aufnahme des Verbundes aus dem Kopf des Steckverbinders 4 und der Leitung 1 aufweist. Das metallische Verbindungsteil 41 weist einen ersten Abdichtringbereich 411 auf, der zusammen mit dem Isoliermantel-Randteil 16 einen Gießhohlraum 50 begrenzt. Zu diesem Gießhohlraum 50 führt ein Spritzgießkanal 51, über welchen ein elektrisch isolierender Kunststoff gespritzt wird, der die Leitungselemente 11 einhüllt. Nach Erkalten bildet sich ein Zwischenisolierkörper 32, wie in Fig. 16 dargestellt.With 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 region 411 which, together with the insulating jacket edge part 16, delimits a casting cavity 50. An injection molding channel 51, over which an electrically insulating plastic is injected, which envelops the line elements 11, leads to this casting cavity 50. After cooling, an intermediate insulating body 32 is formed, as in FIG Fig. 16 shown.

Der Roh-Steckverbinder nach Fig. 16 wird in den Hohlraum eines Metall-Gusswerkzeuges 6 eingelegt (Fig. 17), wobei ein Gießhohlraum 60 zwischen dem Isoliermantel 13 der Leitung 1 und einem zweiten Abdicht-Ringbereich 412 abgegrenzt wird. In diesen Gießhohlraum 60 führen Gießkanäle 61 und 62 hinein, durch welche flüssiges Metall einer Metalllegierung, z.B. Zinnlot, eingegossen wird. Nach Erkalten bildet sich aus der erstarrten Metalllegierung das Schirmgehäuse 30, das den Zwischenisolierkörper 32, den Isoliermantel-Randteil 16 und die Abschirmhülle 10 im Abschirmringbereich 101 umschließt. Wenn nicht ansatzlos gegossen worden ist, werden eventuell noch entstandene Angussstutzen entfernt, wonach ein an sich gebrauchsfähiger Steckverbinder erhalten wird, wie er in Fig. 18 dargestellt ist. Handelsübliche, geschirmte Steckverbinder weisen jedoch noch einen Schutzmantel 33 um das Schirmgehäuse 30 herum auf, wie dies in Fig. 19 und 20 dargestellt ist.The raw connector according to 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. After cooling, 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. If the casting has not been carried out seamlessly, any sprues 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.

Um einen solchen handelsüblichen Steckverbinder herzustellen, wird der an sich gebrauchsfähige Steckverbinder in einen Gießhohlraum eines weiteren, nicht dargestellten Spritzgießwerkzeuges so eingelegt, dass das Spritzwerkzeug an dem Abdichtringbereich 412 einerseits und an einem unbetroffenen Bereich des Isoliermantels 13 jenseits des Schirmgehäuses 30 andererseits abdichtet. Danach wird der Steckverbinder der Fig. 18 zwischen dem Abdichtringbereich 412 und dem unbetroffenen Bereich des Isoliermantels 13 mit isolierendem Kunststoff umspritzt, wodurch der das Schirmgehäuse 30 umgebende Schutzmantel 33 entsteht und ein handelsüblicher Steckverbinder gemäß Fig. 19 erhalten wird.To produce such a commercially available connector, 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 against 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. Then 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, whereby the protective jacket 33 surrounding the shielded housing 30 and a commercially available connector according to FIG Fig. 19 is obtained.

Die beschriebenen Arbeiten können vollautomatisiert durchgeführt werden. Durch die Aufteilung in einzelne Schritte und Durchführung dieser Schritte entlang einer Fertigungsstraße, die auch als Rundteller ausgeführt sein kann, ist eine rasche Fertigung möglich. Die gesamte Zykluszeit kann dabei geringer sein, als wenn der Steckverbinder mit einer einzelnen, aber dann dickwandigeren Umspritzung hergestellt werden würde. Wenn die Umspritzungen mit isolierendem Kunststoff und das Umgießen mit flüssigem Metall für drei aufeinander folgende Steckverbinder gleichzeitig ausgeführt werden, wird die Durchlaufzeit pro Stück Steckverbinder von der längsten Zykluszeit in dem Herstellungsprozess bestimmt. Es sei bemerkt, dass das Umgießen mit Metall eine sehr kurze Zykluszeit aufweist.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.

Die Fig. 20, 21 zeigen einen Längsschnitt durch einen Leistungssteckverbinder mit Schutzerde-Anbindung (PE-Anbindung) des Schirmgehäuses 30. Wie daraus hervorgeht, werden die blanken Enden 110 der Leitungselemente 11 mit Kontaktelementen 44 mechanisch und damit auch elektrisch verbunden, beispielsweise durch Verlöten, Verquetschen oder Crimpen. Der Kopf des Steckverbinders 4 weist ein elektrisch isoliertes Verbindergehäuse 46 auf, durch dessen axiale Bohrungen die vorderen Enden der Kontaktelemente 44 gesteckt sind. Um das Verbindergehäuse 46 erstreckt sich ein rohrförmiges metallisches Verbindungsteil 41, das mit Eingriffsvorsprüngen 413 versehen ist, um metallische Halbschalen 42 zu halten, die mit Verschraubungen 420 Teil der Kupplungshälfte 45 des Steckverbinders 4 bilden. Die Halbschalen 42, von denen es beispielsweise zwei gibt, werden durch einen Überwurfring 43 auf dem metallischen Verbindungsteil 41 und dem isolierenden Verbindergehäuse 46 durch Presskraft gehalten. Das metallische Verbindungsteil 41 und die Halbschalen 42 bilden um den betreffenden Verbinder 4 ein Abschirmgehäuse 40, das einen hinteren Ringbereich 401 aufweist, an dem es mit dem Schirmgehäuse 30 aufgrund des in situ Metallgießens des Schirmgehäuses 30 innig verbunden ist.the Fig. 20 , 21 show a longitudinal section through a power connector with protective earth connection (PE connection) of the shielded housing 30. As can be seen from this, 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.

Der Leistungssteckverbinder gemäß Fig. 20 und 21 wird ähnlich hergestellt, wie mit Fig. 14 - 19 beschrieben worden ist. Das Ende der Leitung 1 wird mit einem Abschirmringbereich 101 zur Freilegung der Abschirmhülle 10 versehen und am Kopf des Steckverbinders 4 findet sich das metallische Verbindungsteil 41, welches zusammen mit den Halbschalen 42 die Schirmung am gesamten Steckverbinderkopf darstellt. Die Schirmung am Steckverbinder 4 wird durch das Schirmgehäuse 30 bewerkstelligt, das durch in situ Metallgießen in der mit Fig. 14 - 19 beschriebenen Weise erzeugt wird.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, provides the shielding on the entire connector head represents. The shielding on the connector 4 is accomplished by the shielded housing 30, which is made by in situ metal casting in the with Figures 14-19 described manner is generated.

Ein Kontaktelement 440 (Fig. 20) führt Schutzerde (PE) und ist über eine direkt mitgegossene Abzweigung 303 mit dem in situ gegossenen Schirmgehäuse 30 verbunden. Der Zwischenisolierkörper 32 besteht in diesem Bespiel aus elektrisch isolierendem und thermisch schlecht leitendem Material, um die Leitungselemente 11 bei der Herstellung des Schirmgehäuses 30 durch das Metallgießen gegen die von der Metallschmelze einwirkende Hitze zu schützen.A contact element 440 ( Fig. 20 ) carries protective earth (PE) and is connected to the in situ cast shielded housing 30 via a junction 303 cast directly at the same time. In this example, 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.

Die Fig. 22 und 23 stellen einen Leistungssteckverbinder dar, der im Inneren ähnlich aufgebaut sein kann wie der Steckverbinder nach Fig. 20 und 21, jedoch besteht der Zwischenisolierkörper 32 aus elektrisch isolierendem, aber gut thermisch leitendem Material, um im Betrieb die Abwärme des Leistungssteckverbinders besser abführen zu können. Mit gefüllten Kunststoffen kann eine Wärmeleitfähigkeit von 0,2 W/mK bis nahezu 10 W/mK bei guter elektrischer Isolierung erreicht werden. Der Zwischenisolierkörper 32 kann aber auch aus einem vorgefertigten Keramikbauteil bestehen, welches eine noch höhere Wärmeleitfähigkeit aufweisen kann. Die Schirmhülse 30 ist hier ferner mit Kühlrippen 302 versehen, um Wärme vom Inneren des Leistungssteckverbinders noch besser nach außen abzuführen.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 fins 302 in order to dissipate heat from the interior of the power connector even better to the outside.

Am Beispiel des Leistungssteckverbinders der Fig. 23 wird gezeigt, dass ein solcher auch als Winkelsteckverbinder gebaut werden kann. Dies trifft allerdings auch auf die anderen beschriebenen Bauformen zu. Man benötigt im Wesentlichen lediglich angepasste Spritzgießwerkzeuge bzw. Metallgusswerkzeuge in Winkelform für den Gießhohlraum.Using the example of the power connector of the Fig. 23 it is shown that such a connector can also be used as an angle connector can be built. However, this also applies to the other designs described. Essentially, all that is required is adapted injection molding tools or metal casting tools in an angular shape for the casting cavity.

Ein Datensteckverbinder wird entsprechend hergestellt, wobei für den Zwischenisolierkörper 32 ein Kunststoff verwendet werden kann, welcher eine geringe Wärmeleitfähigkeit aufweist, da im Betrieb weniger Wärme abgeführt zu werden braucht. Dies hat im Gegenzug den Vorteil, dass beim in situ Gießen des Schirmgehäuses 30 die Leitungselemente 11 noch besser vor der Hitzeeinwirkung geschützt sind.A data connector is produced accordingly, it being possible to use a plastic for the intermediate insulating body 32 which has a low thermal conductivity, since less heat needs to be dissipated during operation. In return, this has the advantage that when the screen housing 30 is cast in situ, the line elements 11 are even better protected from the effects of heat.

Die Fig. 24 bis 28 zeigen einen geschirmten Mehrfachverteiler, der einen Verbinder zur Verbindung mehrerer geschirmter Steckverbinder 7 miteinander darstellt. Die Verbindung der einzelnen Steckverbinder 7 erfolgt über einen Verteilkörper 8. Dieser Verteilkörper 8 enthält zwei Leiterplatten 81 und 82 mit Verteilleitungen zwischen Anschlussstellen 83, 84 und 85. Die Anschlussstellen 85 sind über Querverbindungsleitungen 86 miteinander verbunden.the Figures 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.

Die Steckverbinder 7 umfassen ein metallisches Verbindungsteil, das ein äußeres Abschirmgehäuse 70 (Fig. 28) bildet und der Kupplung zu einem komplementären Gegensteckverbinder dient. Im Inneren des Abschirmgehäuses 70 ist ein elektrisch isolierendes Verbindergehäuse 76 untergebracht, um die Kontaktelemente 74 zu halten. Die Kontaktelemente 74 sind an zugehörigen Anschlussstellen 83 oder 84 an den Verteilkörper 8 angeschlossen und weisen Verlängerungen auf, die Leitungselemente 71 bilden. Ausgehend vom Zustand der Fig. 24 wird ein Zwischenisolierkörper 32 um die Leitungselemente 71 und den Verteilkörper 8 spritzgegossen, so dass der Zustand gemäß Fig. 25 erzielt wird. Um den Zwischenisolierkörper 32 wird anschließend ein Schirmgehäuse 30 (Fig. 26) gegossen, also als in situ gegossener Metallkörper hergestellt, der mit den Abschirmgehäusen 70 der Steckverbinder 7 verzahnt (Fig. 28) ist und dadurch einen äußerst geringen Übergangswiderstand zwischen den Teilen 70 und 30 bewirkt. Das Schirmgehäuse 30 umgibt den Zwischenisolierkörper 32 lückenlos und bietet so eine gute Schirmung des Gesamtverbinders auch im Bereich des Verteilkörpers 8.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 at associated connection points 83 or 84 connected to the distributor body 8 and have extensions which form line elements 71. Based on the state of the Fig. 24 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. A shielding housing 30 ( Fig. 26 ) cast, i.e. manufactured as a metal body cast in situ, which interlocks with the shielding housings 70 of the connector 7 ( Fig. 28 ) and thereby causes an extremely low contact resistance between parts 70 and 30. The shielding housing 30 surrounds the intermediate insulating body 32 without any gaps and thus offers good shielding of the overall connector also in the area of the distributor body 8.

Um dem Verbinder ein handelsübliches Aussehen zu verleihen, wird noch ein Schutzmantel 33 um das Schirmgehäuse 30 durch Spritzgießen gelegt. Der so komplettierte Steckverbinder ist in Fig. 27 dargestellt.In order to give the connector a commercial appearance, 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.

Der als Mehrfachverteiler ausgebildete Verbinder der Fig. 27 kann auch dahingehend abgewandelt werden, dass er eine oder mehrere geschirmte Leitungen ohne sämtliche Steckverbinder 7 umfasst. Mit anderen Worten, einer, einige oder sämtliche Steckverbinder 7 können durch direkt angeschlossene geschirmte Leitungen 1 oder 2 ersetzt werden. In diesem Fall werden die Leitungselemente 11, 21 der betreffenden Leitungen im Sinne der Leitungselemente 71 an den Verteilkörper 8 angeschlossen. Danach wird der Zwischenisolierkörper 32 durch Spritzgießen erzeugt und der Zwischenisolierkörper 32 wird mit dem Schirmgehäuse 30 aus Metall umgossen und gleichzeitig wird die elektrische Verbindung zu der Abschirmhülle 10, 20 der jeweils angeschlossenen Leitung 1, 2 hergestellt. Danach wird - falls gewünscht - der Schutzmantel 33 angebracht.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. In other words, one, some or all of the plug connectors 7 can be replaced by directly connected shielded lines 1 or 2. In this case, the line elements 11, 21 of the relevant lines are connected to the distributor body 8 in the sense of the line elements 71. Thereafter, 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 sleeve 10, 20 of the respectively connected line 1, 2 is established. Then - if desired - the protective jacket 33 is attached.

Zum Zwecke der Erfindung sind verschiedene niedrigschmelzende Metalle und Metalllegierungen, insbesondere Metalllote brauchbar. Es kommen alle bleihaltigen Zinnlote, alle bleifreien Zinnlote, auch Sn-Bi-Lote mit Schmelzpunkt um 130°C sowie Silberlote in Betracht. Die Abschirmhülle 10 der betreffenden Leitungen oder das Verbindungsteil 41 eines entsprechend ausgebildeten Verbinders können verzinnt sein, was der Verbindung mit dem Schirmgehäuse 30 förderlich ist, insbesondere wenn diese aus einem Zinnlot besteht, so dass dieses mit dem Schirmgehäuse 30 verschmilzt. Auch die Vernickelung der angesprochenen Teile ist möglich. Die angesprochenen Teile können aber auch aus blankem Edelstahl bestehen. Abschirmhüllen können auch als Schirmgeflecht mit blanken Kupferdrähten ausgeführt sein.Various low-melting metals and metal alloys, particularly metal solders, are useful for the purposes of the invention. All lead-containing tin solders, all lead-free tin solders, including Sn-Bi solders with a melting point of around 130 ° C and silver solders can be used. 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 shielded housing 30, especially if it consists of tin solder so that it fuses with the shielded 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.

Für die Stabilität der Verbindung zwischen dem Verbindungsteil 41 einerseits und dem Schirmgehäuse 30 andererseits, bzw. zwischen der Abschirmhülle 10 und dem Schirmgehäuse 30, ist es günstig, wenn es dünne Rippen und dünne Schirmdrähte gibt, die sich bei der Metallumgießung stark erwärmen können, so dass, wenn diese dünnen Teile verzinnt sind, die Oberfläche dieser dünnen Teile lokal gut anschmilzt und dort eine gute Verlötung stattfindet. Dadurch ergibt sich ein besonders niedriger elektrischer Übergangswiderstand.For the stability of the connection between the connecting part 41 on the one hand and the shield housing 30 on the other hand, or between the shielding sleeve 10 and the shield housing 30, it is advantageous if there are thin ribs and thin shield wires that can heat up strongly when the metal is encapsulated that when these thin parts are tinned, the surface of these thin parts melts well locally and a good soldering takes place there. This results in a particularly low electrical contact resistance.

Bei durchgeführten Tests hat der erfindungsgemäße Steckverbinder einen Übergangswiderstand im Milliohmbereich ergeben. Dieser sehr geringe Übergangswiderstand war auch nach durchgeführten großen Temperaturwechseln unverändert geblieben.When tests were carried out, 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.

Eine weitere bemerkenswerte Eigenschaft des erfindungsgemäßen Verbinders ist die Ausbildung der Schirmgehäuses 30 als vollständig geschlossene Einheit, abgesehen von den axialen Öffnungen für die Zuleitungen oder für die Einzelsteckverbinder. An diesen Öffnungen ist die Schirmung der jeweils angeschlossenen Leitung bzw. des Steckverbinderkopfes angeschlossen und komplettiert die Rundum-Abschirmung um 360°. Mit anderen Worten ist das Schirmgehäuse 30 demnach vorzugsweise im Bereich der Leitungsverbindungen radial vollständig und lückenlos geschlossen. Das Schirmgehäuse 30 bildet demnach insbesondere eine um den gesamten Umfang der Schirmverbindung geschlossene Metallhülle.Another remarkable property of 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 individual plug connectors. The shielding of the connected cable or the connector head is connected to these openings and completes the all-round shielding by 360 °. In other words, 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.

Weitere mögliche AbwandlungenFurther possible modifications

Der Zwischenisolierkörper 32 dient dem Schutz und/oder zur Isolation der Leitungselemente (Leitungsader im Falle eines Kabels oder rückwärtige Enden der Kontaktelemente im Falle eines Steckverbinders) und kann in anderer Weise als durch Umspritzen der Leitungselemente mit isolierendem Kunststoff hergestellt werden. Man kann Dichtungen, Schrumpfschläuche, Kunststoffgehäuse und Klebemassen oder vorgefertigte Einsatzteile vorsehen, um die Leitungselemente gegen das flüssige Metall zu schützen, wenn das Schirmgehäuse 30 hergestellt wird.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 a way other 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 shield housing 30 is produced.

Bei mancher Ausführungsform des Zwischenisolierkörpers 32 kann man die Abschirmhülle 10 über die Schnittfläche 14 hinaus vorstehen lassen, um das Schirmgehäuse 30 an diesem vorstehenden Ende der Abschirmhülle 10 elektrisch durch Umgießen mit flüssigem Metall anzuschließen.In some embodiments of the intermediate insulating body 32, 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 encapsulating liquid metal.

Die Herstellung des Zwischenisolierkörpers 32 kann auch im Niederdruck-Verfahren erfolgen, was ein Abdichten direkt auf den Leitungselementen 11 oder an der Abschirmhülle 10 ermöglicht.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.

Der Schutzmantel 33 muss nicht unbedingt durch Umspritzen mit Kunststoff hergestellt werden. Es kann auch ein vorgefertigtes Bauteil, etwa eine Tülle, als Schutzmantel 33 verwendet werden.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.

Es ist dem Fachmann ersichtlich, dass die vorstehend beschriebenen Ausführungsformen beispielhaft zu verstehen sind und die Erfindung nicht auf diese beschränkt ist, sondern in vielfältiger Weise variiert werden kann, ohne den Schutzbereich der Ansprüche zu verlassen. Ferner ist ersichtlich, dass die Merkmale unabhängig davon, ob sie in der Beschreibung, den Ansprüchen, den Figuren oder anderweitig offenbart sind, auch einzeln wesentliche Bestandteile der Erfindung definieren, selbst wenn sie zusammen mit anderen Merkmalen gemeinsam beschrieben sind.It is evident to the person skilled in the art that the embodiments described above are to be understood as examples and that the invention is not restricted to these, but rather can be varied in many ways without departing from the scope of protection of the claims. Furthermore, it can be seen that the features, regardless of whether they are disclosed in the description, the claims, the figures or otherwise, also individually define essential components of the invention, even if they are described together with other features.

Claims (15)

  1. A shielded electrical connector for connecting shielded electrical lines or plug-in connectors to one another, comprising:
    - one or more conductor elements (11, 21, 71) belonging to at least one line (1,2) or at least one plug-in connector (4, 7);
    - one or more shielding sleeves (10, 20) or shielding casings (40, 70) belonging to at least one line (1, 2) or at least one electrical plug-in connector (4, 7);
    - a shielding housing (30) either connecting a plurality of shielding sleeves (10, 20) with one another, or connecting at least one shielding sleeve (10) to at least one shielding casing (40), or connecting a plurality of shielding casings (70) with one another, or forming part of the shielding casing; and
    - an intermediate insulating body (32) made of temperature-resistant, electrically insulating material;
    characterised in that
    the shielding housing (30) consists of a cast metal body that has been cast in situ from liquid metal or liquid metal alloy on and around annular portions (101, 201, 401, 701) of the one or more shielding sleeves (10, 20) or the one or more shielding casings (40, 70), where it establishes an anchoring means having a low electrical contact resistance and provides complete shielding of the electrical connector; and that the shielding housing (30) has been cast in situ at least partially onto the intermediate insulating body (32), and wherein the intermediate insulating body (32) protects the one or more conductor elements (11) during the casting process of the shielding housing (30).
  2. The shielded electrical connector according to claim 1, in the form of a plug-in connector (4) for being mated with a complementary plug-in connector, wherein the terminal elements (34, 44) of the plug-in connector (4) are the conductor elements thereof, and wherein an electrically insulating connector housing (36, 46) is provided which supports the terminal elements, wherein furthermore a coupling half (45) is defined on the plug-in connector (4), which is effective as an electrical shielding connection to the complementary plug-in connector.
  3. The shielded electrical connector according to claim 2, wherein the shielding casing (40) comprises a metallic coupling part (41) and metallic half shells (42) mounted on the insulating connector housing (46) by means of a sleeve ring (43) and define a portion of the coupling half (45).
  4. The shielded electrical connector according to any one of claims 1 to 3,
    wherein one of the conductor elements (110) is on protective earth (PE) and the shielding casing (40) is electrically connected to the protective earth (PE) through a cast branching (303).
  5. The shielded electrical connector according to any one of claims 1 to 4,
    wherein the plug-in connector (4) is implemented as a data connector and comprises a plurality of conductor elements (11) which are surrounded by the intermediate insulating body (32) that comprises electrically insulating material of low thermal conductivity.
  6. The shielded electrical connector according to any one of claims 1 to 4,
    wherein the plug-in connector (4) implemented as a power connector and comprises a plurality of conductor elements, which are surrounded by the intermediate insulating body (32) that comprises electrically insulating material of good thermal conductivity and has been cast in situ on and around the shielding housing (30) including cooling fins (302).
  7. The shielded electrical connector according to any one of claims 1 to 4,
    configured as a multiway terminal block for one or more shielded lines and/or for one or more shielded plug-in connectors (7), comprising:
    - a distributing body (8) having a plurality of connection points (83, 84) for the conductor elements (11, 21, 71) belonging to either one or more lines, or to one or more plug-in connectors (7);
    - an intermediate insulating body (32) surrounding the distributing body (8) and adjacent conductor elements (11, 21, 71);
    wherein the shielding housing (30) surrounds the intermediate insulating body (32) and has been cast in situ either on and around the annular portions of shielding sleeves of the shielded lines and/or onto peripheral portions (701) of shielding casings (70) of the plug-in connectors (7).
  8. The shielded electrical connector according to any one of claims 1 to 7,
    wherein the shielding housing (30) is enclosed by an electrically insulating protective jacket (33).
  9. The shielded electrical connector according to any one of claims 1 to 8,
    wherein the shielding housing (30) is made of a low-melting metal alloy.
  10. The shielded electrical connector according to claim 9, wherein the metal alloy is a tin solder.
  11. A method for producing a shielded electrical connector according to any one of the preceding claims, comprising the steps of:
    a) connecting the stripped ends of the conductor elements (11, 21) with one another;
    b) applying the intermediate insulating body (32) onto the stripped ends of the interconnected conductor elements (11, 21);
    c) overcasting the one or more stripped shielding sleeves (10, 20) and/or the one or more shielding casings (40, 70) and the intermediate insulating body (32) with liquid metal or liquid metal alloy to form the shielding housing (30), wherein the intermediate insulating body (32) protects the one or more conductor elements (11) during the casting process of the shielding housing (30).
  12. The method for producing a shielded electrical connector according to claim 11, wherein for producing a coaxial cable connector which connects a first shielded line (1) to a second shielded line (2), the shielding sleeves (10, 20) and the conductor elements (11, 21) are stripped at the ends of the first and the second lines (1, 2) prior to step a); and wherein in step c) the intermediate insulating body (32) and the stripped shielding sleeves (10, 20) are overcast with liquid metal to form the shielding housing (30).
  13. The method for producing a shielded electrical connector according to claim 11, wherein for producing a plug-in connector (4) according to claim 2, which connects conductor elements (11) of a shielded line (1) to terminal elements (34, 44) of the plug-in connector (4), step a) is performed comprising
    - stripping the shielding sleeve (10) and the conductor elements (11) at the end of the shielded line (1);
    - mounting the terminal elements (34, 44) at the ends of the conductor elements (11) and insulating the terminal elements from each other by the insulating connector housing (36, 46);
    and in step c), overcasting the intermediate insulating body (32) and the stripped shielding sleeve (10) with liquid metal to form the shielding housing (30).
  14. The method for producing a shielded electrical connector according to claim 11, wherein for producing a multiway terminal block according to claim 7, which connects one or more shielded lines and/or one or more shielded electrical plug-in connectors (7) to one another, the method comprises, prior to step a),
    stripping the shielding sleeve (10) and the conductor elements (11) at the ends of the one or more line(s) to be connected, and/or providing the one or more shielded electrical plug-in connector(s) (7) with a respective shielding casing (70) and respective conductor elements (71); and applying the intermediate insulating body (32) onto the stripped conductor elements (71) and around the distributing body (8);
    and step c) comprises overcasting the intermediate insulating body (32) and the stripped shielding sleeve in the case of a shielded line to be connected, and/or the peripheral portion (701) of the shielding casing (70) in the case of a shielded electrical plug-in connector (7) with liquid metal to form the shielding housing (30).
  15. The method according to any one of claims 11 to 14, as far as shielded lines (1, 2) are concerned, wherein a respective solder connection is established between the shielding housing (30) and the one or more shielding sleeves (10, 20) of the shielded lines (1, 2) by partially melting metal at the concerned shielding sleeve (10, 20).
EP16708622.2A 2015-02-25 2016-02-24 Shielded electric connector Active EP3262725B1 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
PL16708622T PL3262725T3 (en) 2015-02-25 2016-02-24 Shielded electric connector
EP19212454.3A EP3641072B1 (en) 2015-02-25 2016-02-24 Shielded electric connector
PL19212454T PL3641072T3 (en) 2015-02-25 2016-02-24 Shielded electric connector
DK19212454.3T DK3641072T3 (en) 2015-02-25 2016-02-24 SHIELDED ELECTRICAL CONNECTOR

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102015102703.8A DE102015102703B4 (en) 2015-02-25 2015-02-25 Shielded electrical connector and manufacturing process
PCT/EP2016/053817 WO2016135170A1 (en) 2015-02-25 2016-02-24 Shielded electric connector

Related Child Applications (3)

Application Number Title Priority Date Filing Date
EP19212454.3A Division EP3641072B1 (en) 2015-02-25 2016-02-24 Shielded electric connector
EP19212454.3A Division-Into EP3641072B1 (en) 2015-02-25 2016-02-24 Shielded electric connector
EP19216712.0 Division-Into 2019-12-16

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EP3262725A1 EP3262725A1 (en) 2018-01-03
EP3262725B1 true EP3262725B1 (en) 2022-01-05

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EP19212454.3A Active EP3641072B1 (en) 2015-02-25 2016-02-24 Shielded electric connector

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US (2) US10374363B2 (en)
EP (2) EP3262725B1 (en)
JP (1) JP6781160B2 (en)
CN (1) CN107258039B (en)
CZ (1) CZ33674U1 (en)
DE (2) DE102015102703B4 (en)
DK (3) DK3262725T3 (en)
ES (1) ES2903426T3 (en)
HU (1) HUE057700T2 (en)
PL (2) PL3641072T3 (en)
WO (1) WO2016135170A1 (en)

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Also Published As

Publication number Publication date
EP3641072A1 (en) 2020-04-22
EP3641072B1 (en) 2021-09-22
DK3641072T3 (en) 2021-11-22
HUE057700T2 (en) 2022-05-28
ES2903426T3 (en) 2022-04-01
WO2016135170A1 (en) 2016-09-01
CN107258039A (en) 2017-10-17
EP3262725A1 (en) 2018-01-03
CN107258039B (en) 2019-07-16
PL3641072T3 (en) 2022-01-03
US20190312387A1 (en) 2019-10-10
DE102015102703B4 (en) 2020-06-25
DE202016008811U1 (en) 2019-11-11
DE102015102703A1 (en) 2016-08-25
DK201900112Y3 (en) 2020-02-18
PL3262725T3 (en) 2022-03-07
US10916892B2 (en) 2021-02-09
US20180054026A1 (en) 2018-02-22
US10374363B2 (en) 2019-08-06
CZ33674U1 (en) 2020-02-04
JP2018510462A (en) 2018-04-12
JP6781160B2 (en) 2020-11-04
DK3262725T3 (en) 2022-01-31
DK201900112U1 (en) 2020-01-09

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