GB2612852A

GB2612852A - Ferrule with wire crimp for shielded functionality

Info

Publication number: GB2612852A
Application number: GB2116520.4A
Authority: GB
Inventors: Ramaekers Udo; Mazal Tobias; Wishoth Soren
Original assignee: Aptiv Technologies Ltd
Current assignee: Aptiv Technologies Ltd
Priority date: 2021-11-16
Filing date: 2021-11-16
Publication date: 2023-05-17
Also published as: GB202116520D0

Abstract

An electrical connector suitable for a high voltage current cable (1), where the cable comprises a first conductive wire (30), a second conductive wire (19), and a cable shield (figure 4, 50) arranged to electrically shield the first conductive wire (30). The electrical connector comprises a crimp portion (10) configured for crimping the second conductive wire (19), and a ferrule (20) connected to the crimp portion (10) and configured to receive the first conductive wire (30). The ferrule (20) is arranged to fasten the cable shield (figure 4, 50) and electrically connect the cable shield (figure 4, 50) with the second conductive wire (19). The ferrule (20) may be crimped on a portion of the cable shield (figure 4, 50). The ferrule (20) may comprise an inner part (24) and an outer part (23), and wherein the ferrule (20) is arranged to sandwich the portion of the cable shield (figure 4, 50) between the inner part (24) and the outer part (23).

Description

DESCRIPTION

TITLE: Ferrule with wire crimp for shielded functionality

[0001] TECHNICAL FIELD

[0002]The present disclosure relates in general to the field of electrical cables, and in particular to the field of shielded cables for high voltage current. The electrical cables are intended to be used in any kind of industries, in particular automotive industry. [0003]TECHNICAL BACKGROUND [0004] Shielded electrical cables are known. For example, the document KR20180045216A discloses a braided shield having a complex connection. Further, the document US5033982 discloses an electrical connector for high voltage having a plastic shield.

[0005]There is a need for solving the problem of electromagnetic induced current on the shield for high current application, while improving the lifetime of the connection of the shield and providing a simple connection.

[0006] SUMMARY

[0007] One aim of the present disclosure is, in a first aspect, to solve the drawbacks of the prior art and to improve the electrical connectors, in particular those used in combination with electrical cable having a cable shield, or electrical shield, and to propose an electrical connector for a high voltage current cable, the cable having: - a first conductive wire, - a second conductive wire, - a cable shield arranged to electrically shield the first conductive wire, wherein the electrical connector has: - a crimp portion configured for crimping the second conductive wire, - a ferrule connected to the crimp portion and configured to receive the first conductive wire, and the ferrule is arranged to fasten the cable shield and electrically connect the cable shield with the second conductive wire.

[0008]The high voltage current cable may be also called electrical cable or cable. The crimp portion may be also called extended portion.

[0009]The ferrule is arranged to fasten the cable shield and electrically connect the cable shield with the second conductive wire, via the crimp portion.

[0010]This allows to propose a clean, easy and safe assembly and to improve the lifetime connection of the shield. Further, this can be used with different cable sizes and shield -2 -wires, which means this is scalable. Still further, this allows for an easier manufacturing with a safe and repeatable processing, which could be parametric. Still further, this allows for different crimp variants of the ferrule, which is thereby modular and easily adaptable to a wide variety of design. In particular, the crimping may be circular, hexagonal or cat ear crimp, not being limited to theses shapes. Still further, this allows for a free orientation but it can be also used in a specified or defined position. In addition, the usage of these ferrules avoids broken shield strands and the shield strands orientation may be given by the ferrule. Besides, this allows to enhance the electromagnetic compatibility of the electrical cable.

[0011]Advantageously, the ferrule, the crimp portion and the cable shield comprise a conductive material, such as metal (copper, aluminum, steel, not being limited to such materials).

[0012]Advantageously, the ferrule may be crimped on a portion of the cable shield. [0013]Advantageously, the ferrule may have an inner part and an outer part, and the ferrule is arranged to sandwich the portion of the cable shield between the inner part and the outer part.

[0014]Advantageously, the inner part may have a shoulder portion arranged to abut the outer part.

[0015]This allows for a simplified and more robust electrical connection and fastening, while improving the lifetime. Further, this allows to improve the shield strand orientation and to avoid any broken shield strands. Still further, this allows for a simplified and more robust connection of the components of the ferrule, and a more precise manufacturing. [0016]Advantageously, the crimp portion may have at least one first arm arranged to be crimped on a conductive portion of the second conductive wire.

[0017]Advantageously, the crimp portion may have at least one second arm arranged to be crimped on a insulation portion of the second conductive wire.

[0018]Advantageously, the crimp portion may have at least one attachment arm partly arranged in at least one opening of the outer part.

[0019]This allows to provide a simplified and robust connection between the ferrule and the second conductive wire and between the outer part and the crimp portion. [0020]Advantageously, the at least one attachment arm is arranged to surround the portion of the cable shield.

[0021]This allows to provide a simplified and robust connection between the ferrule and cable shield.

[0022]Advantageously, the crimp portion is integral with the outer part. -3 -

[0023]This allows for a simplified construction of the electrical connector and an easier manufacturing of the electrical connector.

[0024]Advantageously, the at least one first arm has at least one recess. [0025]Advantageously, the crimp portion is arranged to be outside the first conductive wire when mounted on the electrical cable, at least partially.

[0026]This allows to divert the induced current in the cable shield outside the first conductive wire, through the conductive portion of the second conductive wire.

[0027] One aim of the present disclosure is, in a second aspect, to solve the drawbacks of the prior art and to improve the electrical cables, in particular those having a cable shield, or electrical shield, and to propose an electrical cable for high voltage current, having: - a first conductive wire, - a cable shield arranged to electrically shield the first conductive wire, characterized in that the electrical cable further has a second conductive wire and a ferrule arranged to fasten and electrically connect the cable shield and the second conductive wire.

[0028]This allows to propose a clean, easy and safe assembly and to improve the lifetime connection of the shield. Further, this can be used with different cable sizes and shield wires, which means this is scalable. Still further, this allows for an easier manufacturing with a safe and repeatable processing, which could be parametric. Still further, this allows for different crimp variants of the ferrule and the electrical connector, which is thereby modular and easily adaptable to a wide variety of design. In particular, the crimping may be circular, hexagonal or cat ear crimp, not being limited to theses shapes. Still further, this allows for a free orientation but it can be also used in a specified or defined position. In addition, the usage of these ferrules avoids broken shield strands and the shield strands orientation may be given by the ferrule. Besides, this allows to enhance the electromagnetic compatibility of the electrical cable.

[0029]Advantageously, the ferrule may be crimped (or pinched or fastened or attached) on a portion of the cable shield.

[0030]Advantageously, the ferrule may be made out of a conductive material, such as metal, copper, steel, stainless steel, or the like.

[0031]Advantageously, the cable shield may have a plurality of strands.

[0032]Advantageously, the ferrule may have an inner part and an outer part, and the portion of the cable shield is sandwiched between the inner part and the outer part. [0033]Advantageously, the inner part may have a shoulder portion arranged to abut the outer part. -4 -

[0034]This allows for a simplified and more robust electrical connection and fastening, while improving the lifetime. Further, this allows to improve the shield strand orientation and to avoid any broken shield strands. Still further, this allows for a simplified and more robust connection of the components of the ferrule, and a more precise manufacturing. [0035]Advantageously, the extended portion may have at least one first arm crimped on a conductive portion of the second conductive wire.

[0036]Advantageously, the extended portion may have at least one second arm crimped on a insulation portion of the second conductive wire.

[0037]Advantageously, the extended portion may have at least one attachment arm (or third arm) partly arranged in at least one opening of the outer part.

[0038]This allows to provide a simplified and robust connection between the ferrule and the second conductive wire and between the outer part and the ferrule. [0039]Advantageously, the portion of the cable shield is surrounded by the at least one attachment arm.

[0040]This allows to provide a simplified and robust connection between the ferrule and cable shield.

[0041]Advantageously, the extended portion is integral with the outer part.

[0042]This allows for a simplified construction of the ferrule and an easier manufacturing of the electrical cable.

[0043]Advantageously, the at least one first arm has at least one recess. [0044]Advantageously, the at least one recess is in a perpendicular direction of the extended portion.

[0045]Advantageously, the extended portion extends in a longitudinal direction of the electrical cable.

[0046]Advantageously, the first conductive wire has at least one conductive portion, and the electrical cable further has an inner insulation and an outer insulation, wherein the inner insulation is arranged to surround the at least one conductive portion, and the cable shield is arranged between the inner insulation and the outer insultation. [0047]Advantageously, the first conductive wire has at least one conductive portion. [0048]Advantageously, the first conductive wire further has an inner insulation and an outer insulation, wherein the inner insulation is arranged to surround the at least one conductive portion, and the cable shield is arranged between the inner insulation and the outer insultation. -5 -

[0049]This allows to provide the electrical cable with an electrical shielding functionality. Thereby, a conductive portion of the second conductive wire is electrically connected with the cable shield.

[0050]Advantageously, the second conductive wire is arranged outside the first conductive wire.

[0051]This allows to divert the induced current in the cable shield outside the first conductive wire, through the conductive portion of the second conductive wire. [0052]Advantageously, the electrical cable has a plurality of second wires. [0053]Advantageously, the electrical connector has a plurality of first arms arranged to crimp conductive portions of the plurality of second wires.

[0054]Advantageously, the plurality of first arms are arranged to crimp the conductive portions of the plurality of second wires together or separately. In other words, one crimp claw may crimp one or more wires.

[0055]Advantageously, the plurality of second wires may be placed on opposite sides of the first conductive wire, or close by, or equally spaced.

[0056]Advantageously, the plurality of first arms are connected to a plurality of intermediate portions or to a common intermediate portion.

[0057]Advantageously, the electrical connector (crimp portion) has a plurality of second arms arranged to be connected to one or more second conductive wires. [0058]Advantageously, the electrical connector (crimp portion) has a plurality of third arms arranged to be connected to one or more second conductive wires.

[0059]This allows to connect the cable shield with several second conductive wires, in order to enhance the diversion of induced current in the cable shield or to ensure the function if a connection is missed.

[0060]A third aspect of the present disclosure relates to a method for manufacturing the electrical cable according to the second aspect and/or the electrical connector according to the first aspect, having the steps consisting of: - providing a first conductive wire with a cable shield, - fastening and electrically connecting a ferrule and a crimp portion with the cable shield and a second conductive wire, respectively [0061]This allows to provide a simplified method for manufacturing an electrical cable having improved shielding functionality while providing a more robust electrical cable, in particular a more robust connection of the cable shield while diverting the induced current in the cable shield. -6 -

[0062]The cable shield may be used to electrically protect the first conductive wire from electric and/or electromagnetic noise.

[0063]Advantageously, the method further have the steps consisting of: - crimping at least one first arm on a conductive portion of the second conductive wire, - inserting at least one attachment arm in an opening of an outer part of the ferrule, - bending the at least one attachment arm on the outer part. [0064]Advantageously, the method further have the steps consisting of: - crimping at least one first arm on a conductive portion of the second conductive wire. [0065]Advantageously, the method further have the steps consisting of: - inserting at least one attachment arm in an opening of an outer part of the ferrule, - bending the at least one attachment arm on the outer part. [0066]Advantageously, the method further have the steps consisting of: - crimping at least one second arm on a insulation portion of the second conductive wire. [0067]This allows to provide a simplified manufacturing of the electrical cable while improving the lifetime and the robustness of the connection.

[0068]Advantageously, the method further has the steps consisting of: - inserting the outer part on the cable shield and abutting the outer part on a inner part of the ferrule.

[0069]This allows to provide a simplified and more precise manufacturing of the electrical cable while improving the lifetime and the robustness of the connection.

[0070]1n other words, the latter aspect relates to a method for manufacturing an electrical cable having the steps consisting of: - providing a first conductive wire with a cable shield, - fastening and electrically connecting the electrical connector of the previous aspect with the cable shield and a second conductive wire. [0071]The method may further have the steps consisting of: - crimping at least one first arm on a conductive portion of the second conductive wire, - inserting at least one attachment arm in an opening of an outer part of the ferrule, - bending the at least one attachment arm on the outer part. [0072]The method may further have the steps consisting of: - inserting the outer part on the cable shield and abutting the outer part on a inner part of the ferrule. [0073] BRIEF DESCRIPTION OF THE DRAWINGS -7 - [0074] Other features and advantages of the present disclosure will appear more clearly from the following detailed description of particular non-limitative examples of the disclosure, illustrated by the appended drawings where: [0075] Figure 1 represents an electrical cable and an electrical connector according to a first embodiment of the present disclosure, wherein the electrical cable has a first conductive wire with a first diameter, [0076] Figure 2 represents the electrical cable and the electrical connector according to a second embodiment of the present disclosure, wherein the first conductive wire has a bigger diameter than in figure 1, [0077] Figure 3 represents the electrical cable and the electrical connector according to a third embodiment of the present disclosure, wherein the first conductive wire has a plurality of wire strands, [0078] Figure 4 represents a detailed view of the electrical connector, the electrical connector being in a three-parts configuration, [0079] Figure 5 represents the electrical cable with the electrical connector in a two-parts configuration, [0080] Figure 6 represents a detailed view of the electrical connector in the two-parts configuration, [0081] Figure 7 represents a method for manufacturing the electrical cable including the electrical connector in the three-parts configuration.

[0082] DETAILLED DESCRIPTION

[0083] Figure 1 represents an electrical cable and an electrical connector according to a first embodiment of the present disclosure, wherein the electrical cable has a first conductive wire with a first diameter.

[0084]An electrical cable 1 for high voltage current has a first conductive wire 30. The first conductive wire 30 has a conductive portion 29 of a first diameter and made out of a conductive material such as metal or copper. The conductive portion 29 is surrounded by an inner insulation 22i and an outer insulation 22o. The electrical cable cross-section (preferably the inner insulation cross section) may be for example from 10 mm2 to 240 mm2, without being limited to such values.

[0085]The electrical cable 1 has a cable shield 50 which is hidden by the ferrule 20 in figure 1 but is visible on figure 4 and figure 6. The cable shield 50 is sandwiched between the inner insulation 22i and the outer insulation 22o. The cable shield 50 is arranged to electrically shield the first conductive wire 30. That is, the cable shield 50 may protect the first -8 -conductive wire 30 from outside electrical or electromagnetic noise or, protect the environment against the electrical or electromagnetic noise of the first conductive wire 30. [0086]The electrical cable 1 further has a ferrule 20 having an inner part 24 and an outer part 23. The cable shield 50 is sandwiched between the inner part 24 and the outer part 23, when the outer insulation 22o is removed on the portion of the electrical cable 1 which will receive the ferrule 20. That is to say, the cable shield 50 surrounds the inner part 24 and is surrounded by the outer part 23. In a preferred embodiment, the inner part 24 is inserted in the cable shield 50 from a first end of the electrical cable 1, while the outer part 23 is inserted onto (or on top) the cable shield 50 from an opposite end of the electrical cable 1. Thereby, the cable shield 50 is fasten by, and electrically connected with, the inner part 24 and the outer part 23. In a preferred embodiment, the ferrule 20 is crimped onto the cable shield 50.

[0087]The cable shield 50 may be braided and made out of conductive material such as aluminium or steel. The inner insulation 22i and/or the outer insulation 22o may be made out of a insulation material, such as a plastic material.

[0088]The inner part 24 and/or the outer part 23 of the ferrule 20 may be made out of a conductive material, such as metal or steel.

[0089] The electrical cable 1 further has a second conductive wire 19, which has a conductive portion 19c made out of a conductive material such as metal or copper and a insulation portion 13 made out of an insulation material such as a plastic material. The conductive portion 19c may have a section of 2.5 mm2 or more, without being limited to theses values. The second conductive wire 19 will conduct the electro-magnetic induced current of the cable shield 50 when the ferrule 20 is installed on the electrical cable 1.

[0090]The electrical connector has the ferrule and an extended portion 10. The extended portion 10, also called crimp portion 10, has two first arms 11, two second arms 12 and two third arms (or attachment arms) 16, the number of arms or of each type of arms being not!imitative. The first arms 11 are represented in figure 1 in an open position, ready to be crimped (or clamped, i.e. in a closed position) onto the conductive portion 19c of the second conductive wire 19. The second arms 12 are represented in an open position, ready to be crimped (or clamped, i.e. in a closed position) onto the insulation portion 13 of the second conductive wire 19. The two third arms 16 are represented in a closed position in two openings 25 of the outer part 23. The third arms 16 may be inserted in the openings 25 and then bend back of an outer surface of the outer part 23.

[0091] In a preferred embodiment, the openings 25 are slots, but they may also be in the shape of holes, apertures or grooves. -9 -

[0092]The outer part 23 may be abutted against a shoulder of the inner part 24, so as to be located more precisely.

[0093]The inner part 24 and the outer part 23 may be cylindrical. In a preferred embodiment, the inner part 24 and the outer part 23 may be conical.

[0094]The extended portion 10 is provided with intermediate portion 14 and 15, linking respectively the first arms 11 and the second arms 12 on one side; and the first arms 11 and the third arms 16 on the other (preferably opposite) side.

[0095] In a preferred embodiment, the electrical cable 1 extends in a longitudinal direction X. The same applies for the electrical connector, in particular the ferrule 20 and the extended portion 10, and the second conductive wire 19.

[0096] In a preferred embodiment, the ferrule 20 is cylindrical, which means that the outer part 23 and the inner part 24 have ring portion or sleeve portion.

[0097] Figure 2 represents the electrical cable 1 and the electrical connector according to a second embodiment wherein the first conductive wire 30 has a bigger diameter than in figure 1.

[0098]The reference numbers are kept as far as possible compared to other figures and embodiments, and generally speaking in the whole description.

[0099]The conductive portion 29 has an other (e.g. bigger) diameter compared to that of figure 1, for an other (e.g. bigger) cross-section. The diameter of the ferrule 20 (inner part 24 and outer part 23) is adapted accordingly [0100] Generally speaking, the ferrule 20 may be adapted to different sizes of electrical cables (e.g. cross section) and also different sizes of cable shield. The same applies for the crimp portion 10.

[0101] Figure 3 represents the electrical cable 1 and the electrical connector according to a third embodiment, wherein the first conductive wire 30 has a plurality of wire strands 29a-29d. Each wire strand acts as a conductive portion.

[0102] Figure 4 represents a detailed view of the electrical connector, the electrical connector being in a three-parts configuration. The electrical connector may be in particular suitable for any one of the mentioned embodiments.

[0103]The ferrule 20 has the inner part 24 and the outer part 23. The extended portion 10 has the first arms 11, the second arms 12 and the third arms 16.

[0104]The third arms 16 may be inserted in the openings 25 of the outer part 23 and bent thereon, on the outer surface of the outer part 23, so as to clamp (or fix or attach or couple) the extended portion 10 with the outer part 23.

-10 - [0105] In a preferred embodiment, the first arms 11 may be provided with at least one recess (for example one, two, three or four recesses, not being limited to that numbers), so as to improve the crimping of the second conductive portion 19c when the first arms 11 are crimped (or pinched) thereto.

[0106] In a preferred embodiment, the cable shield 50 is sandwiched between the outer part 23 and the inner part 24, and may be sandwiched, at least on a portion of the cable shield 50 between an inner (or back) portion of the third arms 16 and the inner part 24. [0107] Figure 5 represents the electrical cable 1 and electrical connector in a two-parts configuration.

[0108] In the two-parts configuration, the ferrule 20 has the outer part 33 which is integral with the extended portion 10. In contrast, in the three-parts configuration as explained above, the outer part 23 and the extended portion 10 are different pieces.

[0109]The two-parts configuration or three-parts configuration are applicable to all kind of diameters of the first conductive wire 30 and all kind of diameters of the second conductive wire 19.

[0110] Figure 6 represents a detailed view of the electrical connector in the two-parts configuration.

[0111]The first arm 11 is represented with the recesses 17 as mentioned above.

[0112]The cable shield 50 is arranged between the outer portion 33 and the inner portion 24.

[0113]The outer portion 33 and the inner portion 24 may be fixed together with any kind of fixation, such as crimping.

[0114] Figure 7 represents a method for manufacturing the electrical cable including the electrical connector in the three-parts configuration.

[0115]The first step, numbered 100, consists of providing the outer part 23 of the ferrule 20 with two openings 25 as explained above.

[0116]Then, the arrow A illustrates the way to the second step, numbered 101, which consists in providing the extended portion 10, having the first arms 11, the second arms 12 and the third arms 16.

[0117]Then, the arrows B illustrates the way to the third step, numbered 102, which consists in inserting the third arms 16 in the openings 25 of the outer part 23.

[0118]Then the arrows C illustrates the way to the fourth step 103, which consists in bending the third arms 16 onto the external surface of the outer part 23, so as to clamp the extended portion 10 with the outer part 23 in order to form an assembly.

-11 - [0119] Then the outer part 23 may be inserted in the electrical cable 1 and the inner part may be inserted in the electrical cable 1 from an opposite end, so that the cable shield can be installed around the inner part 24 and be surrounded by the outer part 23 [0120]The second conductive wire 19 may be crimped with the first arms 11 and the second arms 12, on its conductive portion 19c and insulation portion 13 as explained above. [0121]Thereby, the electrical cable 1 can have an improved shielding functionality.

[0122] It is of course understood that obvious improvements and/or modifications for one skilled in the art may be implemented, still being under the scope of the disclosure as it is defined by the appended claims.

[0123]The embodiments may be combined whenever possible. The steps may be combined and/or inverted whenever possible.

Claims

-12 -CLAIMS 1 An electrical connector for a high voltage current cable, the cable having: - a first conductive wire (30), - a second conductive wire (19), - a cable shield (50) arranged to electrically shield the first conductive wire (30), wherein the electrical connector has: - a crimp portion (10) configured for crimping the second conductive wire (19), - a ferrule (20) connected to the crimp portion (10) and configured to receive the first conductive wire (30), and the ferrule (20) is arranged to fasten the cable shield (50) and electrically connect the cable shield (50) with the second conductive wire (19).
2. The electrical connector according to claim 1, wherein the ferrule (20) is crimped on a portion of the cable shield (50).
3 The electrical connector according to claim 2, wherein the ferrule (20) has an inner part (24) and an outer part (23, 33), and wherein the ferrule (20) is arranged to sandwich the portion of the cable shield (50) between the inner part (24) and the outer part (23, 33).
4. The electrical connector according to claim 3, wherein the inner part (24) has a shoulder portion arranged to abut the outer part (23, 33).
The electrical connector according to any one of claims 1 to 4, wherein the crimp portion (10) has at least one first arm (11) arranged to be crimped on a conductive portion (19c) of the second conductive wire (19).
6 The electrical connector according to claim 5, wherein the crimp portion (10) has at least one second arm (12) arranged to be crimped on a insulation portion (13) of the second conductive wire (19).
-13 - 7 The electrical connector according to any one of claims 5 to 6 in their dependency on claim 3, wherein the crimp portion (10) has at least one attachment arm (16) partly arranged in at least one opening (25) of the outer part (23, 33).
8. The electrical connector according to claim 7, wherein the at least one attachment arm (16) is arranged to surround the portion of the cable shield (50).
9. The electrical connector according to any one of claims 5 to 8 in their dependency to claim 3, wherein the crimp portion (10) is integral with the outer part (23, 33).
10. The electrical connector according to any one of claims 5 to 9, wherein the at least one first arm (11) has at least one recess (17).
11. The electrical connector according to any one of claims 1 to 10, wherein the crimp portion (10) is arranged to be outside the first conductive wire (30)when mounted on the electrical cable (1).
12.A method for manufacturing an electrical cable (1) having the steps consisting of: - providing a first conductive wire (30) with a cable shield (50), - fastening and electrically connecting the electrical connector of any one of claims 1 to 11 with the cable shield (50) and a second conductive wire (19).
13. The method according to claim 12, further having the steps consisting of: - crimping at least one first arm (11) on a conductive portion (19c) of the second conductive wire (19), - inserting at least one attachment arm (16)in an opening (23) of an outer part (23, 33) of the ferrule (20), - bending the at least one attachment arm (16) on the outer part (23).-14 -
14.The method according to claim 13, further having the steps consisting of: -inserting the outer part (23) on the cable shield (50) and abutting the outer part (23) on a inner part (24) of the ferrule (20).