Electric unit for a motor vehicle with a plug-in connection, plug for a plug-in connection on an electric unit, and method for producing a plug for a plug-in connection on an electric unit

Abstract

An electric unit such as an electric water pump or an electric radiator fan for a motor vehicle with a plug-in connection comprises a region of the connections between contact tongues and stripped ends of the individual wires of the cable of the plug is sealed, and that a sufficient tightness can be ensured in relation to the ingress of moisture along the wires from the surroundings of the water pump through the plug into the housing. A plug and method for producing the plug for a plug-in connection on an electric unit includes a strain relief means, and a seal in the region of the electric contact between the contact tongues and the wire ends of the individual wires.

Claims

1. An electric unit with a plug-in connection for electric attachment to the vehicle electrics, the electric unit comprising a housing, in which an electric machine and electronics for the actuation of the electric machine are received, the electronics being arranged on a printed circuit board and being connected to contact receptacles, and a plug which supplies current supply or energy for the electronics via electric contact between the contact receptacles and contact tongues of the plug, the contact between the contact receptacles and contact tongues taking place in a first end region of a plug housing, the contact tongues making electric contact with individual wires of a supply line of the vehicle electrics and being held in an insulated manner, sealed in a central region of the plug housing, the plug housing comprising, furthermore, a second end region, out of which the individual wires are routed, and the plug being received at least with its first end region and also with its central region in the housing of the electric unit, the plug being arranged in a region of the housing, which region requires a pressure equalization, and, for the purposes of ventilation, the plug having a ventilating duct which, starting from an inlet/outlet opening in the first end region, opens into an inlet/outlet opening in the second end region, and an equalization between the housing interior space and the outer surroundings of the housing therefore being possible.

2. The electric unit for a motor vehicle having a plug-in connection according to claim 1, at least one of the two inlet/outlet openings being closed by way of a membrane, preferably a Gore-Tex membrane.

3. The plug according to claim 1, at least one of the two inlet/outlet openings, preferably the inlet/outlet opening in the first end region, being sealed by way of a membrane, preferably a Gore-Tex membrane.

4. A plug for a plug-in connection on an electric unit, which the plug comprises a plug housing which is produced from a plastic with a first end region, a second end region and a central region, a number of contact tongues being provided which comprise a first end region, a second end region and a central region, and the number of contact tongues being held at least in their central region in a manner which is encapsulated by plastic in the first end region, and a number of individual wires of a multicore cable being routed out of the second end region of the plug housing, the number of individual wires comprising an insulating encapsulation and a stripped end region, and being connected and electrically contacted by way of the stripped end region in the central region of the plug housing to/with the first end region of the contact tongues, and at least the contact points between the number of individual wires and contact tongues in the central region of the plug housing being potted by a sealing mass, preferably a resin, or being held in a manner which is overmolded, sealed or embedded by a thermoplastic material, and the plug comprising, furthermore, a strain relief means for the individual wires, the plug housing comprising a ventilating duct/pressure equalization duct which, starting from an inlet/outlet opening which is arranged in the first end region, opens into an inlet/outlet opening which is arranged in the second end region.

5. The plug according to claim 4, the plug housing being configured from a shaped plastic material as a plate-shaped element, and the central region of the plug housing having a window-like recess, and the window-like recess, in which the contact points/electric contact between contact tongues and individual wires are configured, being filled with the sealing potting compound.

6. The plug according to claim 4, the second end region of the plug housing having a number of through bores, in which the individual wires are held in a led-through manner, and an integrally joined connection for achieving the strain relief means being configured between the insulating encapsulation of the individual wires and the plug housing in the region of the through bores.

7. The plug according to claim 4, the plug housing being formed as a plate-shaped element with the first end region and integrally formed lateral limbs which form a central and second end region, a U-shaped recess being formed between a first end region and the lateral limbs, and an elongate recess being configured in the first end region, in which the elongate recess and the second end regions of the contact tongues are positioned.

8. The plug according to claim 7, the U-shaped recess, with the contact points between the contact tongues and the individual wires, and the side regions of the plug housing which delimit the U-shaped recess, and the elongate recess of the first end region of the plug housing being overmolded by the thermoplastic material in order to achieve the seal by way of a thermoplastic material in such a way that at least the ends of the contact tongues in the first end region remain free for contact with contact receptacles, and the strain relief means being formed by way of the embedding of the individual wires in the thermoplastic material.

9. The plug according to claim 4, the contact between the contact tongues and the individual wires being achieved via a soldered connection.

10. The plug according to claim 4, the contact between the contact tongues and the individual wires being achieved via a crimp connection.

11. A method for producing a plug for a plug-in connection on an electric unit, having the following method steps: a) providing of a number of contact tongues made from an electrically conductive material, the contact tongues having a first end region, a central region and a second end region which preferably comprises ends which are bent away by 90 degrees, b) providing of a mold for producing a plug housing from a plastic material with a first end region, a central region with a window-like recess, and a second end region with through bores for the individual wires, c) inserting of the contact tongues into the mold in such a way that, after the molding method, they are held in the first end region of the plug housing such that they are encapsulated in their central region by the plastic, the second end regions are freely accessible, and the first end regions of the contact tongues are arranged in the window-like section, d) producing of the plug housing with formed contact tongues by way of a plastic shaping method in the mold, preferably by way of a casting method, injection molding method or transfer molding method, e) providing of a multicore supply cable with a number of individual wires, the individual wires comprising an insulating encapsulation and a stripped end region, f) plugging of the individual wires through the through bores in the second end region of the plug housing, g) producing of an electrically conductive connection between the number of individual wires and the first end region of the contact tongues, h) producing of an integrally joined and/or non-positive connection between the encapsulation of the individual wires and the through bores by way of the supply of heat and/or pressure, i) producing of a seal in the window-like recess by way of casting of a sealing potting compound, preferably a resin, into the window-like recess, the plug housing being produced with a ventilating duct which, starting from an inlet/outlet opening in the first end region of the plug housing, opens into an inlet/outlet opening in the second end region of the plug housing.

12. The method for producing a plug according to claim 11, the contact tongues being fed in an automated manner, starting from a reel.

13. The method for producing a plug according to claim 11, the contact tongues being fed in an automated manner, starting from a reel.

14. A method for producing a plug for a plug-in connection on an electric unit, having the following method steps: a) providing of a number of contact tongues made from an electrically conductive material, the contact tongues having a first end region, a central region and a second end region which preferably comprises ends which are angled away by 90 degrees, b) providing of a multicore supply cable with a number of individual wires, the individual wires comprising an insulating encapsulation and a stripped end region, c) producing of an electrically conductive connection between the number of individual wires and the first end region of the contact tongues, d) providing of a mold for producing a plug housing from a plastic material with a first end region which comprises an elongate recess and laterally integrally formed limbs with a central region and a second end region and a U-shaped recess which is configured between the limbs, e) inserting of the contact tongues with connected individual cores into the mold in such a way that, after the molding method, the contact tongues are held in the first end region of the plug housing such that they are encapsulated by the plastic in their central region, and the second end regions are arranged in the elongate recess such that they are freely accessible, and the first end regions of the contact tongues with connected individual cores are arranged in the U-shaped recess, f) producing of the plug housing with formed contact tongues by way of a plastic shaping method in the mold, preferably by way of a casting method, injection molding method or transfer molding method, g) producing of a seal by way of overmolding of the U-shaped recess, with the contact points between the contact tongues and the individual wires, and the side regions of the plug housing which delimit the U-shaped recess, and the elongate recess of the first end region of the plug housing with thermoplastic material in such a way that at least the ends of the second end regions of the contact tongues remain free for contact with contact receptacles, and the strain relief means being formed by way of the embedding of the individual wires in the thermoplastic material, and the second end region of the plug housing being added.

15. The method for producing a plug according to claim 14, the plug housing being produced with a ventilating duct which, starting from an inlet/outlet opening in the first end region of the plug housing, opens into an inlet/outlet opening in the second end region of the plug housing.

16. The method for producing a plug according to claim 15, a seal, preferably a Gore-Tex membrane for sealing against environmental influences, being applied in a further method step to at least one of the inlet/outlet openings, preferably the inlet/outlet opening in the first end region.

17. The method according to claim 16, the application taking place by way of an ultrasonic welding method.

Description

FIGURES

(1) In the following text, the present invention will be described on the basis of exemplary embodiments, reference being made to the appended drawings, in which

(2) FIG. 1 shows an exemplary electric water pump in accordance with the invention,

(3) FIG. 2 shows a cross section of the exemplary electric water pump,

(4) FIG. 3 shows a detail of a housing of the water pump with an attached plug of the plug-in connection in a front view,

(5) FIG. 4 shows a detail of a housing of the water pump with an attached plug of the plug-in connection in a rear view,

(6) FIGS. 5a-5f show method steps for producing a first exemplary embodiment of a plug of the plug-in connection,

(7) FIG. 6 shows the plug according to the invention which is produced according to FIGS. 5a-5f, in a three-dimensional illustration in a view from below,

(8) FIG. 7 shows the plug according to the invention after the method step of FIGS. 5d and 5e, in an illustration from below in a cut-away state,

(9) FIG. 8 shows the plug according to the invention after the method step of FIGS. 5d and 5e, in another rotated perspective view in a sectioned view,

(10) FIGS. 9a-9c show method steps for producing a second exemplary embodiment of a plug of the plug-in connection,

(11) FIG. 10 shows a perspective view of a radiator fan with a plug in accordance with the second exemplary embodiment, and

(12) FIG. 11 shows a view of the interior of a radiator fan with a fan impeller and a mounted plug.

DETAILED DESCRIPTION

(13) FIGS. 1 and 2 show an electric water pump which is known from the prior art. This is driven by an electric machine which comprises a stator 24 and a rotor 26. The rotor 26 is connected to a pump impeller 28 for moving a fluid. The fluid enters into the water pump through an inlet 12 in a volute 10, is brought into contact with the pump impeller 28, and is moved through an outlet 14 in the volute 10. The rotor 26 and the stator 24 of the electric machine are contained in a housing 20 which is connected to the volute 10. The electronics which are required for the actuation of the electric machine are contained on a printed circuit board (PCB) and are connected to contact receptacles. The current supply or energy for the electronics is delivered by means of a plug-in connection between the printed circuit board or the contact receptacles and the contact tongues of a plug 1. The contact tongues are contacted electrically with individual wires of the wiring harness/supply line 46, and are held in the plug 1 in a sealed and insulated manner. During the assembly, the plug 1 is plugged with contact tongues 30 which are arranged on the end side at least partially into the housing of the water pump. Here, the contact tongues are plugged into the contact receptacles on the printed circuit board, and an electric contact is established between the plug 1 and the printed circuit board. The figures do not show the plug-in connection which comprises the plug 1 or the contact tongues and the contact receptacles of the printed circuit board.

(14) FIGS. 1 and 2 show the arrangement of the plug 1, 1′ on the housing 20 of the pump 2 in a merely diagrammatic manner. As has already been mentioned at the outset, in order to form a plug-in connection, the plug 1, 1′ can be contacted electrically with a multiplicity of corresponding plug-in contacts/contact receptacles of an electric unit in a motor vehicle.

(15) FIGS. 3 and 4 show the plug 1 in the mounted situation of the plug-in connection on a housing element 20 of the water pump 2. The printed circuit board with the corresponding plug-in contacts/contact receptacles is not shown. It can be seen from the illustrations that a first end region 30 of the plug 1 is situated within the housing 20 of the water pump 2 in the mounted situation, and the opposite second end region 31 with the supply cable 46 protrudes out of the housing 20 of the water pump 2. The first end region 30 of the plug 1 is preferably arranged in a region of the water pump, which region comprises an air space and requires a pressure equalization. In order to make the pressure equalization possible, the plug 1 is provided with a pressure equalization duct 40; the pressure equalization duct 40 is arranged in such a way that, starting from an inlet or outlet opening 41 which is arranged in the first end region 30 of the plug, it opens into an inlet or outlet opening 42 which is arranged in the second end region 31 of the plug 1. As a result, after the mounting of the plug 1 in the housing 20, a connection is established between the air space in the housing 20 and the surrounding space U of the water pump 2 in the motor vehicle. The inlet/outlet opening 41 which is arranged on the first end region 30 of the plug 1 is covered by way of a membrane 44, preferably a Gore-Tex membrane, and therefore forms a ventilating opening which likewise prevents the penetration of moisture. On account of the arrangement of the membrane 44 within the housing 20, it is protected from the outside. As an alternative, the membrane 44 can also be arranged on the inlet/outlet opening 42 on the second end region 31.

(16) FIGS. 5a-5f show the method according to the invention for producing a plug 1 for a plug-in connection on a water pump 2 in a first embodiment.

(17) In a first method step according to FIG. 5a, contact tongues 50 which establish an electric contact with the individual cores 47 of the current supply line/cable 46 of the vehicle electrics are first of all provided. Here, the number of contact tongues 50 corresponds to the number of individual wires/cores 47 of the current supply cable 46 which are to be contacted. The contact tongues 50 are produced from an electrically conductive material, and are configured as elongate contact pins with a first end region 51, a central region 52 and a second end region 53. The second end region 53 has ends 54 which are angled away by 90 degrees. The contact pins are arranged spaced apart in parallel from one another, and are connected to one another in the first end region 51 via transverse webs 55. The contact tongues/contact pins 50 are received in a stored manner on a reel, and contact tongues are separated and made available in accordance with the required number, namely four contact tongues 50 which are arranged parallel to one another in accordance with the illustration.

(18) In a second method step according to FIG. 5b, the contact tongues 50 are inserted into a mold and, in a molding method, the plug housing 34 is formed from a plastic material, is preferably cast or transfer molded from a thermosetting plastic material. Here, the mold for producing the plug housing 34 is configured in such a way that the plug housing 34 is configured substantially as a plate-shaped element with a first end region 30 and an opposite second end region 31. Between the first end region 30 and the second end region 31, the plug housing 34 has a central region 32 which comprises a window-like recess 33. The second end region 31 is configured with through bores 35 which are arranged spaced apart in parallel for receiving the individual wires 47. After the molding method, the contact tongues 50 are held in the first end region 30 such that they are overmolded in their central region 52 in such a way that the angled-away ends 54 of the second end region 53 project freely toward the outside, starting from the plate-shaped element. Starting from the first end region 30 of the plug housing 34, the first end regions of the contact tongues 51 protrude freely into the window-like recess 33.

(19) Furthermore, the plug housing 34 is configured with a ventilating duct 40 which, starting from an inlet/outlet opening 42 which is arranged in the longitudinal direction in the second end region 31, runs into an inlet/outlet opening 41 which is configured angled-away by 90 degrees in the first end region 30.

(20) After the molding of the plug housing 34, the latter is removed with embedded contact tongues 50 from the mold, and the transverse connections 55 between the contact tongues 50 are removed.

(21) In a subsequent method step 5c, the inlet/outlet opening 41 in the first end region 30 is covered by way of an ultrasonic welding method with a membrane 44, preferably a Gore-Tex membrane.

(22) FIG. 5d shows the next method step, in the case of which the individual wires 47 of the supply line 46 (in accordance with exemplary embodiment 4) are plugged by means of their stripped ends 47a through the through bores 35 in the second end region 31, and are soldered onto the exposed first end regions 51 of the contact tongues 50 in order to establish an electric contact.

(23) Afterward, a strain-resistant connection is produced between the individual wires 47 in the through bores 35 by way of the application of heat and/or pressure in said region, as a result of which melting of the encapsulation 47b of the individual wires 47 and an integrally joined connection to the plastic material of the plug housing 34 are achieved (FIG. 5e shows the plug housing from the upper side).

(24) After the production of the strain-resistant connection between the individual wires 47 and the plug housing 34 in its second end region 31, an insulation and sealing material 60, preferably a resin, is cast into the window-like recess 33 in a final method step according to FIG. 5f, and is distributed there completely. As a result, the soldered contact points between the individual wires 47 and the contact tongues 50 are overmolded and embedded completely by the material, with the result that a protection and/or a seal against environmental influences are/is achieved. In particular, said region which is overmolded with resin produces a barrier 60, with the result that, starting from the second end region 31 of the plug 1, which second end region 31 is exposed to the surroundings U in the mounted state, no environmental influences at all, such as moisture, can pass along the individual wires 47 into the plug housing 34 to the first end region 30 of the plug 1, which first end region 30 is arranged in the housing 20 of the water pump 2.

(25) FIG. 6 shows the finished plug 1 in a perspective view from below of the free angled-away ends 54 of the contact tongues 50 and of the soldered contacts which are embedded into the potting compound 60 between the contact tongues and the individual wires/cores 47 of the supply line in the central region 32 of the plug 1.

(26) The illustration of FIG. 7 shows the barrier 60 by way of the arrows P1, which barrier 60 is formed in the window-like recess 33 by way of the potting compound. Furthermore, the region which forms the strain relief means of the individual wires 47 is marked by way of the arrows P2. The right hand side of the figure shows the supply cable 46 which is formed from the individual wires 47 and which comprises an encapsulation 46a.

(27) The sectional illustration of FIG. 8 shows the course of the ventilating bore with the inlet and outlet openings.

(28) FIGS. 9a-9c show a further method according to the invention for producing a plug for a plug-in connection on a water pump in a second embodiment.

(29) In contrast to the above-described production method, in accordance with the second embodiment (shown in FIG. 9a) of a plug 1a, the contact tongues 50 are connected in a first method step via a crimp connection C on their first end region 51 to the stripped ends 47a of the individual wires 47 of the supply line 46, and are therefore contacted electrically. As has already been described above, the contact tongues 50 are produced from an electrically conductive material, and are configured as elongate contact pins with a first end region 51, a central region 52 and a second end region 53. The second end region 53 has ends 54 which are angled away by 90 degrees. The contact pins are arranged spaced apart in parallel from one another, and are connected to one another via transverse webs 55 in the first end region 51, and are configured to produce a crimp connection C. The contact tongues/contact pins 50 are received in a stored manner on a reel, and are separated and made available in accordance with the required number of contact tongues, namely four contact tongues 50 which are arranged parallel to one another in accordance with the illustration.

(30) In a second method step according to FIG. 9b, the contact tongues 50 are inserted with crimped-on individual wires 47 into a mold, and, in a molding method, the plug housing 34′ is molded from a plastic material, is preferably cast or transfer molded from a thermosetting plastic material. Here, the mold for producing the plug housing 34′ is configured in such a way that the plug housing 34′ is formed substantially as a plate-shaped element with a first end region 30 and laterally integrally formed limbs 36. The plug housing 34′ has a U-shaped recess 37 between the first end region 30 and the laterally integrally formed limbs 36. Furthermore, an elongate recess 38 and a plurality of grooves 39 which connect the elongate recess 38 and the U-shaped recess 37 are formed in the first end region 30.

(31) After the molding method, the contact tongues 50 are held in the first end region 30 such that they are overmolded in their central region 52 in such a way that the angled-away ends 54 of the second end region 53 project freely toward the outside, starting from the plate-shaped element, and lie in an elongate recess 38 of the first end region 30. The first end regions 51 of the contact tongues 50 with crimped-on individual wires 47 protrude freely into the U-shaped recess 37, starting from the first end region 30 of the plug housing 34′.

(32) Furthermore, the plug housing 34′ is configured with a ventilating duct 40 which, starting from an inlet/outlet opening 42 which is arranged in the longitudinal direction in a lateral limb 36, runs into an inlet/outlet opening 41 which is configured angled-away by 90 degrees in the first end region 30.

(33) The left hand illustration of FIG. 9b shows the plug 1′ after the above-described molding method from below. The right hand illustration shows the plug 1′ in the method step in a view from above.

(34) In a subsequent method step which is shown in FIG. 9c, the plug housing 1′, in the region of the U-shaped recess 37 with the lateral side regions 36 of the contact housing 34′ which adjoin the U-shaped recess 37, with contact tongues and a contact to the individual wires 47, and the first end region 30 of the plug housing 34′, in the region of the elongate recess 38 and the grooves 39, are overmolded with a thermoplastic material, and the second end region 31 of the plug 1′ is completely configured. Said second end region 31 is extended in the direction of the supply cable 46, starting from the U-shaped recess 37.

(35) As can be seen from the right hand depiction of FIG. 9c, the elongate recess 38 is injection molded in such a way that the angled-away ends of the contact tongues 54 remain free. By way of the overmolding of the abovementioned regions, a strain-resistant connection is achieved by way of adhesion between the individual wires 47 and the thermoplastic material 61 which is molded onto the plug housing 34′. Furthermore, the crimped-on contact points between the individual wires and the contact tongues are overmolded and embedded completely by the material 61, with the result that a protection and/or a seal against environmental influences are/is achieved. In particular, said region which is overmolded with thermoplastic material 61 produces a barrier 61 between the limbs, with the result that, starting from said overmolded second end region 31 of the plug 1′, which second end region 31 is exposed to the surroundings in the mounted state, no environmental influences at all, such as moisture, can pass along the individual wires 47 into the plug housing 34′ to the first end region 30 of the plug, which first end region 30 is arranged in the housing 20 of the water pump 2.

(36) Before the injection molding with the thermoplastic material or following it, the membrane 44 can be welded by means of ultrasonic welding onto the inlet/outlet opening 41 in the first end region 30.

(37) FIGS. 10 and 11 show a radiator fan 2′ as an electric unit with an installed plug 1′ in accordance with the second exemplary embodiment. It can be seen from the illustration of FIG. 10 that at least the first end region of the plug housing 34′ is received in the interior space of the radiator fan in a manner which is enclosed by the housing 20′. It goes without saying that the plug 1 of the first exemplary embodiment can also be plugged into the housing 20′ in order to form a plug-in connection to a corresponding plug-in contact on a printed circuit board of the electronics.