CONDUCTOR ARRANGEMENT FOR AN ELECTRICAL ENERGY AND/OR DATA TRANSMISSION CONNECTION

Abstract

A conductor arrangement for an electrical connection includes a flexible multi-core internal conductor, an electromagnetic shield surrounding the flexible multi-core internal conductor, a thermoplastic hard plastic sheath surrounding a first portion of the flexible multi-core internal conductor, and a flexible corrugated tube surrounding a second portion the flexible multi-core internal conductor. A first portion of the thermoplastic hard plastic sheath includes an elongated flattened shape. A second portion of the thermoplastic hard plastic sheath includes an essentially round shape. The second portion of the thermoplastic hard plastic sheath is adjacent the first portion of the thermoplastic hard plastic sheath.

Claims

1. A conductor assembly for an electrical connection, comprising: a flexible multi-core internal conductor, each core of the flexible multi-core internal conductor including a metal strand surrounded by a flexible insulation layer; an electromagnetic shield surrounding the flexible multi-core internal conductor; a thermoplastic hard plastic sheath surrounding a first portion of the flexible multi-core internal conductor; and a flexible corrugated tube surrounding a second portion the flexible multi-core internal conductor; wherein a first portion of the thermoplastic hard plastic sheath includes an elongated flattened shape, a second portion of the thermoplastic hard plastic sheath includes an essentially round shape, and the second portion of the thermoplastic hard plastic sheath is adjacent the first portion of the thermoplastic hard plastic sheath.

2. The conductor assembly of claim 1, further comprising: a first multi-pole plug connector connected to a first end of the flexible multi-core internal conductor; and a second multi-pole plug connector connected to a second end of the flexible multi-core internal conductor.

3. The conductor assembly of claim 1, wherein the thermoplastic hard plastic sheath includes a bending strength of more than 50 N/mm2 at an operating temperature of 25° C.

4. The conductor assembly of claim 1, wherein the flexible internal conductor includes copper or aluminum.

5. The conductor assembly of 1, wherein the flexible insulation includes PVC, PE, TEP, PTFE, silicone or silicone-coated fiberglass.

6. A method of reshaping a conductor arrangement for an electrical connection, comprising: surrounding a flexible multi-core internal conductor with an electromagnetic shield, each core of the flexible multi-core internal conductor including a metal strand surrounded by a flexible insulation layer; surrounding a first portion of the flexible multi-core internal conductor with a thermoplastic hard plastic sheath; surrounding a second portion of the flexible internal conductor with a first flexible corrugated tube; transforming a first portion of the thermoplastic hard plastic sheath into a formable state by heating the thermoplastic hard plastic sheath to a threshold temperature defined at a specific softening point before installation; deforming the first portion of the thermoplastic hard plastic sheath lengthwise and with respect to a cross-section from an essentially round shape to an elongated flattened shape during installation; cooling the first portion the thermoplastic hard plastic sheath to a lower temperature below the threshold temperature hardening the thermoplastic hard plastic sheath to retain the elongated flattened shape after installation; and maintaining a second portion of the thermoplastic hard plastic sheath in an essentially round shape, the second portion of the thermoplastic hard plastic sheath adjacent the first portion of the thermoplastic hard plastic sheath.

7. The method of claim 6, further comprising: connecting a first multi-pole plug connector to a first end of the flexible multi-core internal conductor; and connecting a multi-pole plug connector to a second end of the flexible multi-core internal conductor.

8. The method of claim 6, wherein the thermoplastic hard plastic sheath includes a bending strength of more than 50 N/mm2 at an operating temperature of 25° C.

9. The method of claim 6, wherein the flexible internal conductor includes copper or aluminum.

10. The method of claim 6, wherein the flexible insulation includes PVC, PE, TEP, PTFE, silicone or silicone-coated fiberglass.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The above-mentioned aspects of the present disclosure and the manner of obtaining them will become more apparent and the disclosure itself will be better understood by reference to the following description of the embodiments of the disclosure, taken in conjunction with the accompanying drawings, wherein:

[0015] FIG. 1 shows a first embodiment of the conductor arrangement according to the present disclosure of a single-core electrical energy transmission connection,

[0016] FIG. 2 shows a section view of the conductor arrangement of FIG. 1,

[0017] FIG. 3 shows the conductor arrangement of FIG. 1 after heating and shaping,

[0018] FIG. 4 shows a second embodiment of a conductor arrangement according to the present disclosure of a multi-core electrical data transmission connection, and

[0019] FIG. 5 shows a cross-sectional view of the conductor arrangement of FIG. 4.

[0020] Corresponding reference numerals are used to indicate corresponding parts throughout the several views.

DETAILED DESCRIPTION

[0021] The embodiments of the present disclosure described below are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present disclosure.

[0022] FIG. 1 shows a first embodiment of a conductor arrangement according to the present disclosure for the case of an electrical energy transmission connection. The conductor arrangement 10 includes a central first conductor portion 12 and outer second and third conductor portions 14, 16 adjoining the latter. As can be seen in FIG. 2, a continuous flexible internal conductor 18 extends inside the conductor portions 12, 14 and 16. The flexible internal conductor 18 is a copper strand 20 consisting of a plurality of individual bare wires. In the present case, the flexible internal conductor 18 has a single-core design and is surrounded by a flexible insulation layer 22. The flexible insulation layer 22 is made from soft PVC, PE, TEP, PTFE, silicone or silicone-coated fiberglass.

[0023] The flexible internal conductor 18 is surrounded in the region of the central first conductor portion 12 by a thermoplastic hard plastic sheath 24. The thermoplastic hard plastic sheath 24, or sheath layer, has a bending strength of more than 50 N/mm.sup.2 at an operating temperature of 25° C. It may be a hard PVC, PA6 or the like.

[0024] The flexible internal conductor 18 is furthermore surrounded in the outer second and third conductor portion 14, 16 by a flexible protective sheath 26, 28 in the form of a corrugated tube 30, 32. The flexible protective sheath 26, 28, or sheath layer, is made from soft PVC, PE, TEP, PTFE, silicone or silicone-coated fiberglass. Alternatively, a fabric hose or the like can also be provided instead of a corrugated tube 30, 32. A plurality of contacting elements 34, 36, 38, which in the present case may be high-power connectors designed as cable lugs 40, 42, 44, are fitted at the outer second and third conductor portion 14, 16. The connectors are electrically contacted with the outer second and third conductor portion 14, 16 by a respective crimped connection 46, 48.

[0025] The thermoplastic hard plastic sheath 24 provided in the region of the central first conductor portion 12 can be transformed into a formable state by heating to a threshold temperature T.sub.g provided by a specific softening point. The central first conductor portion 12 is heated selectively at a desired bending point by means of a hot-air gun or alternatively as a whole in an oven. The conductor arrangement 10 can then be brought into the desired shape by hand for the purpose of installation, for example, inside an engine compartment of a motor vehicle. After cooling, the thermoplastic hard plastic sheath 24 hardens or stiffens again such that the central first conductor portion 12 retains its shape, shown by way of example in FIG. 3.

[0026] The thermoplastic hard plastic sheath 24 here represents both an outer sleeve protecting the flexible conductor 18 and also a supporting skeleton which maintains the flexible internal conductor 18 in the shape which has been established.

[0027] The softening point of the thermoplastic hard plastic sheath 24 is, depending on the additives contained, 80 to 150° C.

[0028] FIG. 4 shows a second embodiment of a conductor arrangement according to the present disclosure for the case of an electrical data transmission connection.

[0029] The conductor arrangement 50 of the data transmission connection in FIG. 4 differs from that of the energy transmission connection of the first embodiment reproduced in FIG. 1 in that the flexible internal conductor 52 according to FIG. 5 has a multi-core structure. Each core 54 is formed by an associated copper strand 56 which in turn is surrounded by a flexible insulation layer 58. In addition, a metal braiding 60 or a metal film 62 indicated in FIG. 5 is provided for the purpose of shielding from electromagnetic interference.

[0030] The flexible internal conductor 52 extending in the central first conductor portion 12 is further designed in such a way that it can be deformed not only lengthwise but also with respect to its cross-section shown in FIG. 5. This is achieved by the individual cores 54 being bundled sufficiently loosely inside the surrounding thermoplastic hard plastic sheath 24. In this case, the central first conductor portion can, by corresponding heating and cooling, be changed from an essentially round state to a flattened one in which it can pass through a slit-like region 64 reproduced in FIG. 4 or a comparable narrow place.

[0031] Multi-pole plug connectors 66, 68 are fitted to the outer second and third conductor portions 14, 16, in accordance with the multi-core structure of the flexible internal conductor 52. The plug connectors 66, 68 are hereby electrically contacted with the outer second and third conductor portions 14, 16 via respective crimped connections 70, 72.

[0032] For the sake of completeness, it should be noted that the use of the conductor arrangement 10 or 50 is not limited to the field of vehicles. Instead, its use can also be envisaged in any other connection such as, for example, in the construction of devices or systems.

[0033] While embodiments incorporating the principles of the present disclosure have been disclosed hereinabove, the present disclosure is not limited to the disclosed embodiments. Instead, this application is intended to cover any variations, uses, or adaptations of the disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains and which fall within the limits of the appended claims.