Plug Connecting Element for a Motor Vehicle and Method for Producing a Plug Connecting Element of This Type

Abstract

A plug connecting element for a motor vehicle includes an electrical conduction element, to which at least one plug of an electronic component of the motor vehicle is able to be connected, and a casing element made of plastic, by way of which the conduction element is at least partially electrically insulated. The electrical conduction element is connected to the casing element in a fixed and non-releasable manner by primary forming of the plastic.

Claims

1-10. (canceled)

11. A plug connecting element for a motor vehicle, comprising: at least one electrical conducting element to which at least one plug of an electric component of the motor vehicle is connectable; and a casing element made of plastic, by which the conducting element is at least partially electrically insulated, wherein the electrical conducting element is connected to the casing element fixedly and non-detachably through primary forming of the plastic.

12. The plug connecting element according to claim 11, further comprising: at least one plug socket formed integrally along with the casing element, into which plug socket the plug of the electronic component of the motor vehicle is insertable and, when inserted, held detachably therein.

13. The plug connecting element according to claim 12, further comprising: at least one sealing element provided between the plug socket and the plug.

14. The plug connecting element according to claim 11, wherein the electrical conducting element has a contact region cut from the casing element.

15. The plug connecting element according to claim 11, further comprising: a connecting element fixedly held in the casing element and in contact with the electrical conducting element, via which the electrical conducting element and a ground point of the motor vehicle are brought into electrically conductive contact with one another

16. The plug connecting element according to claim 15, wherein the connecting element is cut from the casing element at least at a head bearing surface for a fastening element.

17. The plug connecting element according to claim 15, wherein the connecting element has a fastening mechanism via which the connecting element is held in the casing element in a positionally-fixed manner.

18. The plug connecting element according to claim 11, wherein the casing element has a holding region, via which the plug connecting element is held in a positionally-fixed manner at a holding element on a vehicle side which corresponds to the holding region.

19. The plug connecting element according to claim 11, wherein the casing element is configured as an injection-molded component in which the electrical conducting element is partially molded.

20. A method for producing a plug connecting element for a motor vehicle having an electrical conducting element to which at least one plug of an electric component of the motor vehicle is connectable, the method comprising: connecting a casing element to the electrical conducting element, the casing element being made of plastic so as to at least partially electrically insulate the electrical conducting element, wherein the connecting of the electrical conducting element to the casing element is carried out through primary forming of the plastic such that the electrical conducting element is connected to the casing element fixedly and non-detachably.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] FIG. 1 shows as a schematic sectional representation a plug connecting element fastened to a ground point;

[0029] FIG. 2 shows as a partially sectional representation the plug connecting element which is remote from the ground point;

[0030] FIG. 3 shows as a sectional representation a casing element, a connecting element, and an electrical conducting element of the plug connecting element;

[0031] FIG. 4 shows the plug connecting element as a schematic and perspective representation; and

[0032] FIG. 5 shows the plug connecting element in plan view.

[0033] Identical or functionally identical elements are provided with the same reference numbers in the figures.

DETAILED DESCRIPTION OF THE DRAWINGS

[0034] FIG. 1 shows as a schematic sectional representation along a sectional plane A-A (see FIG. 5) a plug connecting element 1 which is fastened to a ground point 2. In particular, the plug connecting element 1 is used in a motor vehicle 3 which is not shown in full. In this case, the ground point 2 is formed by a metal and an electrically conductive component 4 of the motor vehicle 3. In particular, the metal component 4 may be an engine, for example, an internal combustion engine, of the motor vehicle 3. At least one electronic component 5 of the motor vehicle 3 may be connectable to the plug connecting element 1, in that a plug 6 of the electronic component 5 in each case assigned to the corresponding electronic component 5 or the corresponding electronic components 5 is connected to an electrical conducting element 7 of the plug connecting element 1. The electrical conducting element 7 may be configured as an electrically conductive board and/or have multiple elongate conducting elements which are arranged separately from one another and are electrically conductive, for example metal cores, cables, wires, etc. In particular, the plug connecting element 1 may comprise more than one electrical conducting element 7.

[0035] By way of example, three electronic components 5 are shown in FIG. 1 which are each connected, or connectable, to the plug connecting element 1 via a plug 6 in each case, in order to establish an electrically conductive connection between the respective electronic component 5 and the electrical conducting element 7. It should be understood, however, that precisely one electronic component 5, two electronic components 5, or more than three electronic components 5 may be present which can in this way be brought into electrical contact with the electrical conducting element 7.

[0036] FIG. 1 furthermore shows a casing element 8 which electrically insulates the electrical conducting element 7 at least partially. Accordingly, the casing element 8 comprises an electrically insulating material, for example plastic, or is at least substantially formed therefrom. In the event that a plurality of electrical conducting elements 7 is used, the electrical conducting elements 7 in each case can be insulated from one another by means of the plastic of the casing element 8 and at least partially electrically insulated in respect of an environment of the plug connecting element 1.

[0037] So that the plug connecting element 1 is particularly reliably configured, the electrical conducting element 7 and the casing element 8 are fixedly and non-detachably connected to one another by primary forming of the plastic. For example, the electrical conducting element 7 may be immersed in the initially at least substantially liquid or paste-like plastic, so that when the plastic hardens, the casing element 8 is formed and at the same time the fixed and non-detachable connection between the electrical conducting element 7 and the casing element 8 is produced. However, it is just as conceivable for the liquid or paste-like plastic to be arranged in a mold around the electrical conducting element 7, for example. Consequently, the casing element 8 is in particular an injection-molded component in which the electrical conducting element 7 is partially embedded, for example molded. Consequently, the electrical conducting element 7 is held therein in a positionally fixed manner with respect to the casing element 8 and can only be separated therefrom as a consequence of the destruction of the casing element 8, as soon as the plastic has properly hardened.

[0038] In addition, FIG. 1 shows at least one plug socket 9, in this case three plug sockets 9. The respective plug socket 9 at least corresponds to an assigned plug 6 and/or to an assigned dummy plug (not shown), so that when the plug 6 or the dummy plug is plugged into the respective plug socket 9, a force-fitting and/or form-fitting mechanical connection is established between the respective plug socket 9 and the plug 6 assigned in each case or the dummy plug assigned in each case. For better understanding, a plug-in direction 10 is shown in FIG. 1, wherein the respective plug socket 9 and the plug 6 assigned in each case, or else the dummy plug assigned in each case, are moved towards one another, for example in that the respective plug 6 is moved in the plug-in direction 10 towards the plug socket 9 and into the plug socket. It should be understood that the dummy plug in each case is identical in design to the corresponding plug 6 in terms of its shape and dimensions. This means that the plug 6 and the corresponding dummy plug are mutually exchangeable and fit in the same way into the correspondingly assigned plug socket 9.

[0039] As the respective plug 6 is moved into the respective plug socket 9, in other words into a plug socket space 11 formed by the corresponding plug socket 9 in each case, an electrical connection is produced between the electrical conducting element 7 and the corresponding electronic component 5 connected to the respective plug 6. In order to release this connection again in a non-destructive manner, the respective plug socket 9 and the respective plug 6 must be moved away from one another, for example in that the respective plug 6 is moved out of the respective plug socket 9 contrary to the plug-in direction 10.

[0040] The plug socket 9 in each case is integrally produced along with the casing element 8 during the primary forming of the plastic of the casing element 8. This means that during the injection molding of the plastic, the casing element 8 is produced along with the plug sockets 9 in a joint working step, so that the casing element 8 and the plug socket 9 are connected to one another in a substance-bonded manner.

[0041] In order to prevent foreign bodies or liquids, in particular electrically conductive or conducting liquids, from penetrating the respective plug socket space 11, at least one sealing element 12 is provided which, when the plug 6 or the dummy plug is in the plugged-in state, is arranged between the plug and the respective plug socket 9. In particular, the sealing element 12 may be a ring-shaped, for example toroidal, seal which is arranged between an outer peripheral surface of the corresponding plug 6, or of the corresponding dummy plug, and an inner peripheral surface of the corresponding plug socket 9, as soon as the plug 6 or the dummy plug is received in the corresponding plug socket 9. In other words, it may be provided that the sealing element 12 can be inserted, for example slid, into the corresponding plug socket 9, or into the corresponding plug socket space 11, along with the plug 6 or the dummy plug. This means that the sealing element 12 can be formed on the plug, or dummy plug, side. Alternatively or additionally, a sealing element 13 may be provided on the socket side, which sealing element functions in a similar manner to the sealing element 12 on the plug side or on the dummy plug side, but unlike this is arranged in the plug socket space 11 even before the corresponding plug 6 or dummy plug is actually moved into the corresponding plug socket space 11. In order to retain the sealing elements 12, 13 at the respective plug 6/dummy plug and/or at the respective plug socket 9, the sealing elements 12, 13 may be held in grooves in each case which are formed on the plug or dummy plug side and/or on the socket side. In this way, the sealing elements 12, 13 are effectively prevented from disengaging from their desired position, particularly when the plugs 6 or dummy plugs are connected to the plug sockets 9.

[0042] By means of a fastening element 14 which is configured as a threaded screw in the present example, the plug connecting element 1 is firstly mechanically fastened or fastenable to the motor vehicle 3, in particular to the component 4 of the motor vehicle 3. The fastening element 14 is electrically conductive in the present case, in other words it comprises an electrically conductive material or is at least substantially produced therefrom. A threaded portion 16 of the fastening element 14 or of the threaded screw which is provided with an outer thread 15 engages with a hole 17, thereby producing a threaded connection which has an inner thread 18 matching the outer thread 15. On the other hand, due to a screwing-in of the fastening element 14 which—as shown in FIG. 1—extends right through the casing element 8, a contact region 19 of the electrical conducting element 7 is clamped to the component 4 of the motor vehicle 3, as a result of which an electrically conductive connection between the electrical conducting element and the ground point 2 of the motor vehicle 3 is formed. For this purpose, the contact region 19 is cut from the casing element 8, so that a direct and immediate contact between the component 4, or the ground point 2, and the electrical conducting element 7 can be produced or is produced. It should be understood that to provide a better overview in FIG. 1, the component 4 and the plug connecting element 1 are depicted spaced apart from one another. However, it can easily be seen from the function known per se of the fastening element 14 configured as a threaded screw, how a direct contact is ultimately established between the contact region 19 or the electrical conducting element 7 and the component 4 or the ground point 2.

[0043] Alternatively, the fastening element 14 may comprise a stud bolt, in particular a headless stud bolt, exhibiting the outer thread 15 and a threaded nut exhibiting the inner thread 18. The stud bolt may project forwards from the component, in particular perpendicularly, at the ground point 2. The plug connecting element 1 can then be fastened to the component 4, in that the stud bolt connected to the component 4 is passed through the plug connecting element 1 and the threaded nut is then screwed onto a free end of the threaded bolt, and subsequently screwed tightly. The stud bolt may be integrally formed with the component 4.

[0044] FIG. 2 shows a representation the plug connecting element 1 in part section, the plug connecting element being depicted spaced apart from the ground point 2 for reasons of clarity. The plug sockets 9 shown in this figure are partially depicted with auxiliary sections to provide the viewer with a glimpse into the respective plug socket space 11. It can be particularly recognized in this case that the respective plug socket spaces 11 each house coding elements 20 which correspond to matching (not shown) coding elements of the plugs 6, so that it can easily be ensured that only a predefined plug 6 can be inserted into a matching assigned plug socket 9. In other words, it is particularly easily guaranteed that a plug 6 cannot be accidently inserted into a non-assigned plug socket 9. In particular, the coding elements 20 are integrally formed along with the corresponding plug sockets 9 and, as a consequence, along with the casing element 8.

[0045] In a further auxiliary drawing section which runs along a sectional plane A-A (see FIG. 5), a connecting element 21 can be identified which is held fixedly and non-detachably in the casing element 8 or in the plastic of the casing element 8. The connecting element 21 can be produced particularly easily, in that it has a rotationally symmetrical design with respect to a longitudinal center axis 22 of the connecting element 21. The connecting element 21, which comprises an electrically conductive material or is at least substantially formed from an electrically conductive material of this kind, is in direct contact with the electrical conducting element 7, so that an electrically conductive connection prevails between the electrical conducting element 7 and the connecting element 21. If the fastening element 14 which is not shown in FIG. 2 is arranged through the connecting element 21 and, consequently, through the casing element 8 or through the plug connecting element 1 and into the hole 17 and clamped therein, for example screwed tightly therein, the electrical conducting element 7 which is in electrically conductive contact with the connecting element 21 can be brought, or is brought, into electrical contact with the ground point 2 via this connecting element and via the electrically conductive fastening element 14. To this end, a depth of the hole 17 and also a longitudinal extent of this fastening element 14 must each be selected in such a manner that the electrical conducting element 7 and/or the connecting element 21 is/are clamped between the ground point 2 or between the component 4 of the motor vehicle 3 and a head portion 23 (see FIG. 1) of the fastening element 14.

[0046] When FIG. 2 and FIG. 1 are viewed together, it can clearly be seen that the respective pins 24 of the respective plug sockets 9 are connected to the electrical conducting element 7 in an electrically conductive manner. This may mean that the electrical conductive element 7 comprises the respective pins 24. Alternatively or additionally, it may be provided that the respective pins 24 are integrally formed along with the electrical conducting element 7 and/or that the pins 24 are each connected to the electrical conducting element 7 in a substance-bonded manner.

[0047] The plug connecting element 1—as depicted in FIG. 2—has a holding region 25 via which the plug connecting element 1 or the casing element 8 can be held in a positionally fixed manner on a holding element 26 which corresponds to the holding region 25 on the vehicle side. It is provided for this purpose that the holding region 25 and the holding element 26 at least substantially correspond to one another in terms of their respective dimensions and geometries. The holding element 26 on the vehicle side, which projects beyond the component 4 or the engine of the motor vehicle 3, for example, is depicted. In particular, an inner peripheral surface 27 of the holding region 25 and an outer peripheral surface 28 of the holding element 26 may correspond to one another at least substantially in terms of their respective geometry and in terms of their respective dimensions, so that the holding element 26 can be plugged into the holding region 25 or the holding region 25 can be fitted onto the holding element 26, or vice versa. It is particularly conceivable for the inner peripheral surface 27 and the corresponding outer peripheral surface 28 each to have a cross section that differs from a circle or a circular ring, so that the plug connecting element 1 is held, or can be held, in a non-rotatable manner in relation to the component 4 as soon as the holding element 26 and the holding region 25 interact with one another. It may be provided that the holding element 26 has an excess in relation to the holding region 25 or vice versa, so that when the holding element 26 and the holding region 25 are brought together, a force-fitting or frictional connection is produced between the component 4 and the plug connecting element 1.

[0048] The connecting element 21 is described in greater detail below; in relation to this, FIG. 3 shows as a sectional representation the casing element 8, the connecting element 21, and the electrical conducting element 7 of the plug connecting element 1. As in FIG. 2, the corresponding sectional plane A-A runs along the sectional plane A-A shown in FIG. 5. It can be seen particularly clearly in FIG. 3 that the connecting element 21 abuts the electrical conducting element 7 directly and immediately, so that the connecting element 21 and the electrical conducting element 7 are in direct contact. Since, as has already been described, both the electrical conducting element 7 and the connecting element 21 are each configured in an electrically conductive manner, the connecting element 21 and the electrical conducting element 7 are in electrically conductive contact with one another.

[0049] In the present example, the connecting element 21 has a rotationally symmetrical design with respect to the longitudinal center axis 22. The connecting element 21 therefore has an annular-shaped cross section along the longitudinal center axis 22, so that an inner peripheral area 29 of the connecting element 21 represents a straight circular cylinder. In other words, the connecting element 21 follows a straight annular-shaped cylinder, at least substantially. An outer peripheral surface 30 of the connecting element 21 has a fastening mechanism 31 which is configured as a material recess in the present example which extends radially starting from the outer peripheral surface 30 in the direction of the longitudinal center axis 22. In this way, during the primary forming or injection-molding of the plastic of the casing element 8 it is ensured that the plastic penetrates the fastening mechanism 31 or the material recess and engages therein, as a result of which the connecting element 21 is held in the casing element 8, or in the plastic thereof, in a particularly reliable and positionally stable manner as soon as the plastic has hardened and, as a consequence, the casing element 8 is produced. Alternatively or in addition, it is conceivable for the fastening mechanism 31 to have a material projection which extends starting from the outer peripheral surface 30 in a direction away from the longitudinal center axis 22. An effect of this kind securing the position of the connecting element 21 in the casing element 8 is in any event guaranteed by a discontinuously or unevenly configured outer peripheral surface 30 and/or by a particularly rough outer peripheral surface 30.

[0050] The fastening mechanism configured as a material recess further provides a sealing effect, since because the plastic of the casing element 8 extends at least sectionally into the material recess, a labyrinth sealing effect is produced. In this way, moisture is prevented from creeping from outside into and along a joint between the plastic and the material of the connecting element 21 and finally making unwanted direct contact with the electrical conducting element 7.

[0051] The connecting element 21 abuts the electrical conducting element 7 via a first end face 32 directly on a bearing surface 32 of the electrical conducting element. A second end face 35 opposing or opposite the first end face 32 along the longitudinal center axis 22 and spaced apart therefrom by a longitudinal extent 34 forms a head bearing surface 36 for the fastening element 14 or for the head portion 23 thereof. For this purpose, the second end face 35 or the head bearing surface 36 is cut from the casing element 8.

[0052] In the case of a further exemplary embodiment, the connecting element 21 and the electrical conducting element 7 can be in electrically conductive or conducting contact with one another, in that a portion of the outer peripheral surface 30 running at least substantially parallel to the longitudinal center axis 22 and a portion of the electrical conducting element 7 opposite this portion are directly or immediately in contact in planar fashion. In this case, the connecting element 21 completely penetrates the plastic of the casing element 8, in other words the two end faces 32, 35 are exposed, so that the connecting element 21 is in direct contact with the component 4, in particular the holding element 26, as soon as the plug connecting element 1 is functionally connected to the component 4.

[0053] The end face 32 may have a structure that differs from a smooth or even surface and/or may be arranged obliquely with respect to the longitudinal center axis 22. If the holding element 26 has a structure corresponding to the end face 32 and/or a profile corresponding to the end face 32 in relation to the longitudinal center axis 22, a positioning aid is thereby created when the plug connecting element 1 is arranged on the component 4. This is because the structures of the end face 32 and of the holding element 26 which correspond to one another can interact in a force-fitting and/or form-fitting manner, for example mesh with one another. In addition, a securing mechanism to prevent accidental twisting of the plug connecting element 1 in relation to the component 4 is then created.

[0054] In order to create an electrically conductive connection between the respective electronic component 5 and the ground point 2 by means of the plug connecting element 1, in one step the corresponding plug 6 assigned to the electronic component 5 is plugged into the plug socket 9 assigned thereto, so that an electrically conductive connection is made between the pin 24 and the portion of the electronic component 5 being connected. Alternatively, the corresponding plug socket 9 can be fitted onto the corresponding plug 6 for this purpose. Since the pin 24 is connected to the electrical conducting element 7 in an electrically conductive manner and/or the electrical conducting element 7 comprises the pin 24, so that they are connected to one another in a substance-bonded manner, the bringing-together of the plug 6 and the corresponding plug socket 9 means that the corresponding electronic component 5 is connected to the electrical conducting element 7 in an electrically conductive manner, so that it is possible for an electric current to flow between the electrical conducting element 7 and the electronic component 5.

[0055] In a preceding or subsequent further step, the plug connecting element 1 is connected to the component 4 and, as a consequence of this, to the ground point 2, in that the plug connecting element 1 is clamped via the casing element 8 between the component 4 or the ground point 2 and the head portion 23 of the fastening element 14. Since the fastening element 14 is particularly configured as a threaded screw, it is arranged through the plug connecting element 1 or through the casing element 8 and into the hole 17 formed in the component 4, particularly screwed into the hole 17, thereby creating the threaded connection between the outer thread 15 and the inner thread 18. In this way, on the one hand the plug connecting element 1 is held particularly securely at the component 4 and, on the other hand, a particularly reliable electrically conductive connection is made between the contact region 19 which is connected to the electrical conducting element 7 in an electrically conductive manner and/or is an integral constituent of the electrical conducting element 7 and the ground point 2. Consequently, the electronic component 5 is connected to the ground point 2 via the plug 6, via the plug socket 9, via the electrical conducting element 7 and via the contact region 19.

[0056] In order to achieve a particularly reliable electrically conductive connection between the electronic component 5 and the ground point 2, it is further provided that the fastening element 14, as already described, is electrically conductive, so that between the electrical conducting element 7 and the ground point 2, or the component 4, the electrical connection is made via the head bearing surface 36 or the end face 35 and via the fastening element 14 itself, insofar as the fastening element 14 or the threaded screw is introduced or screwed into the hole 17. Accordingly, a current starting from the electronic component 5 can flow via the pin 24 and via the electrical conducting element 7 through the connecting element 21 and, further on, via the head bearing surface 36 into the fastening element 14 and finally out of the fastening element 14, in particular in the region of the inner thread 18, and into the component 4 or the engine of the motor vehicle 3.

[0057] FIG. 4 shows the plug connecting element 1 in a schematic and perspective representation, wherein it is particularly easy to identify how the second end face 35, or the head bearing surface 36, is cut from the casing element 8. Furthermore, a locking element 37 is shown which is designed to engage with a corresponding locking element socket (not shown), wherein the locking element 37 is arranged on the respective plug socket 9 and the respective locking element socket on a plug 6 not shown in FIG. 4. In this way, it is particularly easy to ensure that the plug 6 inserted in the plug socket 9 is secured to prevent unwanted movement out of the plug socket space 11.

[0058] FIG. 5 shows in plan view the plug connecting element 1, wherein the pins 24 extend perpendicularly to the drawing plane in the direction of an observer of FIG. 5. In order to configure the plug connecting element 1 in a particularly ground-efficient manner, a plurality of material recesses 39 is formed on a surface 38 of the casing element 8. Through the material recesses 39 it is furthermore made possible for the plug connecting element 1 to be produced in a particularly material-efficient manner, while the plug connecting element 1 nevertheless still satisfies predefined criteria in respect of stability, bend resistance, etc.

[0059] The invention shows overall that unlike a traditional plug connecting element the plug connecting element 1 can be used in a particularly flexible manner and is particularly reliable. Furthermore, the plug connecting element 1 is particularly easy to apply to and/or in the motor vehicle 3, since via the fastening element 14, on the one hand, the mechanical connection between the plug connecting element 1 and the component 4 and, on the other hand, the electrical connection between the electrical conducting element 7 and the ground point 2, is achieved. For this purpose, only the fastening element 14, which may be configured by way of example as the threaded screw, as a stud bolt/threaded nut combination described above, as a rivet, as an electrically conductive adhering connection, etc., can be used as designated. Furthermore, it is made possible by means of the plug connecting element 1 according to the invention for the plug 6 to be used to actively connect the corresponding electronic component 5 to the ground point 2. This is advantageous since plugs 6 can be used which are in any event included in the range of a manufacturer of the motor vehicle 3. Consequently, a number of plugs 6 with different designs can be reduced and a particularly efficient modular system can be established.

[0060] A particular advantage of the plug connecting element 1 should be regarded as being that traditional crimp connectors or cable harnesses are rendered obsolete during the manufacture, or series manufacture, of the motor vehicle 3, since a reliable ground connection between the corresponding electronic component 5 and the ground point 2 is made by inserting a corresponding plug 6 into an assigned plug socket 9 when the plug connecting element 1 is fastened to the component 4 according to the measures described herein. In this way, particular account is taken of a basic idea of an at least partially automated production of the motor vehicle 3.

LIST OF REFERENCE NUMBERS

[0061] 1 plug connecting element [0062] 2 ground point [0063] 3 motor vehicle [0064] 4 component [0065] 5 electronic component [0066] 6 plug [0067] 7 conducting element [0068] 8 casing element [0069] 9 plug socket [0070] 10 plug-in direction [0071] 11 plug socket space [0072] 12 sealing element [0073] 13 sealing element [0074] 14 fastening element [0075] 15 outer thread [0076] 16 thread portion [0077] 17 hole [0078] 18 inner thread [0079] 19 contact region [0080] 20 coding element [0081] 21 connecting element [0082] 22 longitudinal center axis [0083] 23 head portion [0084] 24 pin [0085] 25 holding region [0086] 26 holding clement [0087] 27 inner peripheral surface [0088] 28 outer peripheral surface [0089] 29 inner peripheral surface [0090] 30 outer peripheral surface [0091] 31 fastening mechanism [0092] 32 end face [0093] 33 bearing surface [0094] 34 longitudinal extent [0095] 35 end face [0096] 36 head bearing surface [0097] 37 locking element [0098] 38 surface [0099] 39 material recess