ASSEMBLED ELECTRICAL CABLE, METHOD FOR ASSEMBLING AN ELECTRICAL CABLE, AND ELECTRICAL PLUG CONNECTION

Abstract

The invention relates to an assembled electrical cable (1). The cable (1) has a cooling channel (2) extending along the center axis (M) of the cable (1) and at least one inner conductor (4) extending along the outer surface of the cooling channel (2). The cable (1) furthermore has a cable sheath (7) guiding the inner conductor (4) and the cooling channel (2) within itself and a contact element (9) for an electrical plug connector (10), wherein the contact element (9) is electrically and mechanically connected to at least one portion of the inner conductor (4) exposed from the cable sheath (7). According to the invention, the inner conductor (4) is integrally joined to the contact element (9) or is compacted in a planar manner in order to form the contact element (9).

Claims

1. An assembled electrical cable that defines a center axis (M), the assembled electrical cable comprising: a cooling channel that, extends along the center axis (M) of the assembled electrical cable, the cooling channel having an outer surface: at least one inner conductor, the at least one inner conductor running along the outer surface of the cooling channel; cable sheath enclosing both the at least one inner conductor and the cooling channel; a contact element that is electrically and mechanically connected to the at least one inner conductor at a portion of the at least one inner conductor that is exposed from the cable sheath; and wherein the at least one inner conductor is connected to the contact element in an integrally bonded manner, or is compacted in a plate-like manner in order to form the contact element.

2. The assembled electrical cable as claimed in claim 1, and wherein the cooling channel is coaxial with the center axis (M) of the assembled electrical cable.

3. The assembled electrical cable as claimed in claim 1, and wherein the at least one inner conductor is as a stranded wire formed from a plurality of individual wires which are distributed individually, or in groups, about the outer surface circumference of the cooling channel.

4. The assembled electrical cable as claimed in claim 3, and wherein the individual wires of the stranded wire are amalgamated at a location where the individual wires of the stranded wire are exposed from the cable sheath.

5. The assembled electrical cable as claimed in claim 1 and wherein the contact element has a surface that faces away from the cooling channel; and the at least one inner conductor is connected to the surface of the contact element that faces away from the cooling channel in an integrally bonded manner.

6. The assembled electrical cable as claimed in claim 1 and wherein the at least one inner conductor is welded to the contact element to form an integrally bonded connection.

7. The assembled electrical cable as claimed in claim 1 and wherein the at least one inner conductor is welded, preferably press-welded, resistance-welded or fusion-welded, to form the contact element.

8. The assembled electrical cable as claimed in claim 1 and further comprising: an electrical mating plug connector; and the contact element forms a connection region that defines a centering bore, for connection to a mating contact element of the electrical mating plug connector.

9. The assembled electrical cable as claimed in claim 1 and wherein a portion of the contact element bears directly against the outer surface of the cooling channel to produce a heat-conductive connection to the cooling channel.

10. The assembled electrical cable as claimed in claim 1 and further comprising: a connection element between the contact element and the cooling channel; and the connection element bears against the contact element and against the outer surface of the cooling channel to produce a heat-conductive connection between the cooling channel and the contact element.

11. The assembled electrical cable as claimed in claim 10, and wherein the connection element has a contact face on a surface facing the cooling channel, and the contact face defines, an indentation that is complimentary to the outer surface of the cooling channel or which surrounds the cooling channel about an outer circumference of the cooling channel at least along a circumferential portion.

12. The assembled electrical cable as claimed in claim 1 and further comprising: heat conducting, paste, the heat conducting paste coating at least one of the at, least one inner conductor and the contact element.

13. An electrical plug connector comprising: a housing module; and an assembled electrical cable with a center axis (M), the assembled electrical cable, having, a cooling channel extending along the center axis (M) of the assembled electrical cable, the cooling channel having an outer surface, and at least one inner conductor running along the outer surface of the cooling channel, and a cable sheath guiding the at least one inner conductor and the cooling channel within the cable sheath, and an electrical plug connector, having a contact element, and the contact element is electrically and mechanically connected to at least a portion of the at least one inner conductor at a location where the at least one inner conductor is exposed from the cable sheath, and wherein the at least one inner conductor is connected to the contact element in an integrally bonded manner, or is compacted in a plate-like manner in order to form the contact element.

14. (canceled)

15. A method for assembling an electrical cable which has a cooling channel that extends along center axis (M), of the electrical cable, the method comprising the steps: providing an electrical cable that defines the center axis (M), the electrical cable having the cooling channel and at least one inner conductor, and the cooling channel and the at least one inner conductor are circumferentially surrounded by a cable sheath; exposing at least a portion of the at least one inner conductor from the cable sheath; providing a contact element; connecting the exposed portion of the at least one inner conductor to the contact element; and wherein the connection between the exposed portion of the at least one inner conductor to the contact element is an integrally bonded connection.

16. An assembled electrical cable that defines a center axis (M), the assembled electrical cable comprising: a cooling channel that extends along the center axis of the assembled electrical cable, the cooling channel having an outer surface; at least one inner conductor that is a stranded wire formed from a plurality of individual wires which are distributed individually, or in groups, about the outer surface of the cooling channel; a cable sheath enclosing the at least one inner conductor and the cooling channel; a contact element that is electrically and mechanically connected to the at least one inner conductor at a portion of the at least one inner conductor element that is exposed from the cable sheath, and the individual wires of the stranded wire are amalgamated at a location where the individual wires of the stranded wire are exposed from the cable sheath; and wherein the at least one inner conductor is connected to the contact element in an integrally bonded manner, or is compacted in a plate-like manner in order to form the contact element.

17. The assembled electrical cable as claimed in claim 6 and wherein the at least one inner conductor is press-welded or resistance-welded to form the integrally bonded connection.

18. The assembled electrical cable as claimed in claim 9, and wherein the contact element has a contact face on a surface facing the cooling channel, and the contact face defines an indentation that is complimentary to the outer surface of the cooling channel or which surrounds the cooling channel about an outer circumference of the cooling channel at least along a circumferential portion.

19. A method for assembling an electrical cable which has a cooling channel that extends along a center axis (M), of the electrical cable, the method comprising the steps: providing an electrical cable that defines the center axis (M), the electrical cable having the cooling channel and at least one inner conductor, and the cooling channel and the at least one inner conductor are circumferentially surrounded by a cable sheath; exposing at least a portion of the at least one inner conductor from the cable sheath; and compacting the exposed portion of the at least one inner conductor in a plate-like manner to form a contact element in one part of the at least one inner conductor.

Description

[0112] The figures show schematically;

[0113] FIG. 1 an assembled electrical cable with a cooling channel, an inner conductor, a cable sheath and a contact element according to a first exemplary embodiment, in a perspective view:

[0114] FIG. 2 an assembled electrical cable with a cooling channel, an inner conductor, a cable sheath and a contact element according to a second exemplary embodiment, in a perspective view;

[0115] FIG. 3 an assembled electrical cable with a cooling channel, an inner conductor, a cable sheath and a contact element according to a third exemplary embodiment, in a perspective view;

[0116] FIG. 4 an assembled electrical cable with a cooling channel, an inner conductor, a cable sheath and a contact element according to a fourth exemplary embodiment, in a perspective view;

[0117] FIG. 5 the assembled electrical cable from FIG. 4 in a sectional view:

[0118] FIG. 6 an assembled electrical cable with a cooling channel, an inner conductor, a cable sheath and a contact element according to a fifth exemplary embodiment, in a perspective view;

[0119] FIG. 7 the assembled electrical cable from FIG. 6 in a sectional view;

[0120] FIG. 8 an electrical cable with a cooling channel according to a first embodiment in cross section,

[0121] FIG. 9 an electrical cable with a cooling channel according to a second embodiment in cross section;

[0122] FIG. 10 an electrical cable with a cooling channel according to a third embodiment in cross section,

[0123] FIG. 11 an electrical plug connector with two assembled electrical cables and a perspective exploded view;

[0124] FIG. 12 an electrical plug connection formed from an electrical plug connector and an electrical mating plug connector in a perspective view: and

[0125] FIG. 13 a method for assembling an electrical cable with exemplary method steps.

[0126] FIG. 1 shows an assembled electrical cable 1. The cable 1 has a cooling channel 2 extending along the center axis M of the cable 1. In the exemplary embodiments, the cooling channel 2 runs coaxially with the center axis M of the cable 1 and is preferably flexible, in the manner of a hose, so as not to compromise the ability of the cable 1 to bend. The cooling channel 2 is preferably formed from a non-conductive material, for example from a plastic. The cooling channel 2 can be connected to a cooling device 3 (indicated in FIG. 1 by a dashed line as a black box), for example of a vehicle. By means of the cooling channel 2, the heat introduced into the electrical cable 1 on account of a high current flow can be dissipated advantageously. For this purpose, a coolant, in particular a cooling liquid, is preferably pumped through the cooling channel 2.

[0127] The cable 1 also has at least one inner conductor 4, which runs along the outer surface of the cooling channel 2. In the exemplary embodiments according to FIGS. 1 to 7, a coaxially running inner conductor 4 is provided, which runs on the outer surface of the cooling channel 2. The inner conductor 4 is preferably formed as a stranded wire formed from a plurality of individual wires, which are distributed along the circumference of the cooling channel 2, as shown in the exemplary embodiments. The individual wires can be distributed individually or in groups along the curcumference of the cooling channel 2.

[0128] In order to guide the at least one inner conductor 4 and/or the individual wires of the at least one inner conductor 4 along the outer surface of the cooling channel 2, the cooling channel 2 can optionally be profiled on its outer circumference. The cooling, channel 2, however, can also be non-profiled, i.e. it can be smooth at its outer surface. It can also be provided that the cooling channel 2 is enveloped at least in some sections by an inner conductor guide 6, which for example is as shown in cross section in FIGS. 8 to 10. For example, grooves according to FIG. 8, rib-like extensions according to FIG. 9, or claw-like guide means according to FIG. 10 can be provided on the outer surface of the inner conductor guide 6 or of the cooling channel 2.

[0129] The cable 1 also has a cable sheath 7 guiding the inner conductor 4 and the cooling channel 2 within itself. The individual wires of the inner conductor 4 formed as a stranded wire are amalgamated in an angular segment or circle segment K at their exit point 8 from the cable sheath 7.

[0130] The assembled cable 1 also has a contact element 9 for an electrical plug connector 10 (see FIG. 11 or FIG. 12), which is connected electrically and mechanically to at least a portion of the inner conductor 4 exposed from the cable sheath 7, In the exemplary embodiment the contact element 9 is connected to an end portion of the inner conductor 4; in principle, however, it can also be provided that the contact element 9 is connected to a middle portion of the inner conductor 4, which has been exposed accordingly. The contact element 9 is preferably an elongate component with flat geometry, which extends primarily in the longitudinal direction along a longitudinal axis L.

[0131] According to a first variant of the invention it is provided that the inner conductor 4 is connected in an integrally bonded manner to the contact element 9 (see FIGS. 1 and 2, 4 to 7 and 11). The inner conductor 4 is for this purpose, as shown in the exemplary embodiments, preferably connected to a surface 11 of the contact element 9 facing away from the cooling channel 2. In this case, the inner conductor 4 is preferably welded to the contact element 9, for example press-welded, resistance-welded or fusion-welded, in order to form the integrally bonded connection.

[0132] A second variant of the invention is shown in FIG. 3, in which the inner conductor 4 is compacted in a plate-like manner in order to itself form the contact element 9. A separate contact element 9 can thus be omitted. The inner conductor 4 can preferably be welded, for example press-welded, resistance-welded or fusion-welded, in order to form the contact element 9.

[0133] The invention is described in the exemplary embodiments substantially on the basis of the first variant (integrally bonded connection between inner conductor 4 and contact element 9). Features and advantages that are mentioned in this regard, however, can also be related to the second variant of the invention, provided this is not technically impossible.

[0134] The contact element 9 has a connection region 12 for connection to a mating contact element 13 (see FIGS. 4 to 7) for an electrical mating plug connector 14 (see FIG. 12) connectable to the electrical plug connector 10. The connection region 12 in the exemplary embodiment has, a centering bore 15 for receiving or for connection to a sleeve-like or pin-like mating contact element 13. The connection region 16 is preferably arranged between the inner conductor 4 and the contact element 9 at an end of the contact element 9 opposite the connection region 12.

[0135] Since the inner conductor 4 is connected in an integrally bonded manner to the contact element 9 or itself forms the contact element 9, an orientation 0 (see FIG. 1) or a tilting of the contact element 9 in relation to its longitudinal axis L can advantageously be predefined or compensated. Furthermore, the position P (see FIG. 1) of the contact element 9 relative to the cable 1, for example the position of the front end (for example of the connection region 12) of the contact element 9, can advantageously be predefined or corrected. Lastly, an outlet angle α (see FIG. 2) between the center axis M of the cable 1 and the longitudinal axis L of the contact element 9 can also advantageously be predefined or corrected. The distance between the contact element 9 and the center axis M of the cable 1 or between the contact element 9 and the cooling channel 2 can be advantageously predefined or corrected by the flexible connection according to the invention.

[0136] In particular it can be provided that the contact element 9 in respect of its longitudinal axis. L is oriented parallel to the center axis M of the cable 1 (outlet angle α equal to zero, see for example FIG. 1) or orthogonal (outlet angle α equal to 90′; see FIG. 2) to the center axis M of the cable 1. However, in principle any outlet angle α can be provided.

[0137] It can be provided that the contact element 9 is distanced from the outer surface of the cooling channel 2, However, the contact element 9 preferably bears indirectly or directly against the outer surface of the cooling channel 2 in order to produce a heat-conductive connection to the cooling channel 2. In order to increase the contact area between the cooling channel 2 and the contact element 9 further still, it can additionally be provided that the contact element 9 has a contact face, in particular an indentation, in order to surround the outer circumference of the cooling channel 2 at least along a circumferential portion (for example partly annular) or fully (annularly).

[0138] It can also be provided that a connection element 17 rests between the contact element 9 and the cooling channel 2, as shown in FIGS. 4 to 7. The connection element 17 can preferably be formed from a plastic which is a good conductor of heat and can produce a heat-conductive connection between the cooling channel 2 and the contact element 9. In order to increase the contact area between the connection element 17 and the cooling channel 2 further still, it can be provided that the connection element 17 has a contact face, in particular an indentation, for example a trough-like or channel-like (part-annular) indentation, as shown in FIGS. 4 and 5. However, it can also be provided that the connection element 17 has a through-bore, in order to surround the cooling channel 2 fully (annularly), as shown in FIGS. 6 and 7.

[0139] In principle, the invention is suitable for use with an unshielded or with a shielded cable 1. A shielded cable 1 is shown in FIG. 4 purely by way of example, wherein the features can of course be transferred to all exemplary embodiments.

[0140] The shielded cable 1 has an outer conductor shield 18, which runs between the cable sheath 7 and the inner conductor 4 or the cooling channel 2 and which is electrically separated from the inner conductor 4 by an insulator 19. In order to connect the inner conductor 4 to the contact element 9 in an integrally bonded manner or in order to form the contact element 9 by the inner conductor 4, the inner conductor 4 can thus also be exposed from the insulator 19 and the outer conductor shield 18. In order to further improve the electromagnetic compatibility, it can be provided to connect the outer conductor shield 18 to a housing shielding (not shown) in the region of the contact element 9.

[0141] An electrical plug connector 10 according to the invention is shown in an exploded view in FIG. 11 and has two of the assembled electrical cables 1 already described. Besides the components of the electrical able 1 already described, the plug connector 10 has, inter aim, a housing module 20. The housing module 20 can have, in particular, an outer housing, for example made of a plastic. Furthermore, the plug connector 10 can have insulation shells 21, 22 for receiving the contact elements 9. In the exemplary embodiment of FIG. 11, two-part insulation shells 21, 22 are provided for receiving the contact elements 9 and consist of an upper insulation shell 21 and a lower insulation shell 22.

[0142] The electrical plug connector 10 shown by way of example in FIG. 11 has two assembled electrical cabies 1, for example for connection to a positive and a negative terminal of a vehicle battery. In principle, however; an electrical plug connector 10 within the scope of the invention can have any number of assembled electrical cables 1, for example also only one electrical cable 1 or also more than two electrical cables 1, for example three electrical cables 1, four electrical cables 1, five electrical cables 1, or six electrical cables 1.

[0143] The electrical plug connector 10 shown merely by way of example can also have anti-contact sleeves 23 for the contact elements 9 in order to prevent unintentional contact with the contact elements 9, which will be live during subsequent operation.

[0144] The electrical plug connectors 10 can also have connection couplings 24 for connection to the cooling device 3. For connection of the connection coupling 24 to the cooling channel 2, a press-fit connection formed in particular of a hose connector 25 and a crimp sleeve 26 can be provided.

[0145] The electrical plug connector 10 can also have a corresponding line seal 27, a cable holder 28 and a termination cap 29 in order to prevent an infiltration of dust and moisture into the plug connector 10 at the entry points of the cable 1 anchor in order to provide a sufficient cable retention for the cable 1.

[0146] A transport protection cap 30 can optionally be provided.

[0147] It is again noted that the shown electrical plug connector 10 is to be understood merely in an exemplary manner for use with the invention. In principle, the invention can be suitable for use with any electrical plug connector 10 (even for plug connectors with angled cable outlet), but in particular for use with an electrical plug connector 10 for high-voltage technology, preferably in the field of electromobility,

[0148] FIG. 12 shows an electrical plug connection 31 according to the invention, having an electrical plug connector 10, for example the plug connector 10 already described within the scope of FIG. 11, and a schematically indicated electrical mating plug connector 14 of an electrical device 32 in the form of a socket with two sleeve-like mating contact elements 13.

[0149] FIG. 13 shows a method according to the invention for assembling the electrical cable 1 on the basis of an exemplary process sequence. It should be mentioned in principle that the shown method sequence can also be extended by further method steps. Furthermore, method steps can be functionally subdivided further or also omitted.

[0150] In a first method step S1 it can firstly be provided that the electrical cable 1 provided in the form of a product sold by the meter is trimmed according to a predefined length.

[0151] In a following, second method step S2 it can be provided that the inner conductor 4 at at least one cable end is exposed from the cable sheath 7 and, as applicable, from the insulator 19 and the outer conductor shield 16.

[0152] In a subsequent, third method step S3 it can be provided that the inner conductor 4, in particular an inner conductor 4 formed as a stranded wire, is fanned out.

[0153] In a following, fourth method step S4 it can be provided that the previously fanned-out inner conductor 4 is bundled in the angular segment or circle segment K.

[0154] In a following, fifth method step S5 it can be provided that the fanned-out and bundled inner conductor 4 is connected in an integrally bonded manner to a separate contact element 9, in particular is welded. Alternative, it can be provided in the fifth method step S5 that the fanned-out and bundled inner conductor 4 is compacted in a plate-like manner to form a one-part contact element 9, preferably by a welding technique.

[0155] In an optional, sixth method step S6 it can be provided for example that further components of the electrical plug connector 10 are mounted on the electrical cable 1.

[0156] The method according to the invention, for example according to the described method sequence, can be carried out as a computer program product with program code means on a control device 33 of a cable assembly device.