Cable Assembly and Method for Producing an Electric and Mechanical Connection

Abstract

The invention relates to a cable assembly comprising at least three electric cables which have electric conductors that are electrically and mechanically connected together. Each of the electric conductors is free of an insulation material and is plate-shaped in a contact point. One of the cables is designed as a support cable, and the electric conductor of the support cable is formed as a support plate at the contact point in order to attach the contact points of the other electric conductors. Multiple contact points of the other electric conductors are secured to a surface of the support plate next to one another.

Claims

1. A cable arrangement for producing an electric and mechanical connection comprising: at least three electrical cables each of which have an electrical conductor and, wherein the electrical conductor of each of the at least three electrical cables is freed of insulation material and shaped in the form of a plate at a contact point; one of the at least three electrical cables is a carrier cable and the electrical conductor of the carrier cable is formed as a carrier plate at the contact point; and the contact points of the further electrical conductors are fastened next to one another on a surface of the carrier plate.

2. The cable arrangement as claimed in claim 1, and wherein the contact points of the further electrical conductors are fastened directly on the surface of the carrier plate.

3. The cable arrangement as claimed in claim 1 and wherein the contact surfaces of the electrical conductors are connected to the carrier plate, with material fit and/or with force fit.

4. The cable arrangement as claimed in claim 1 and wherein the contact surfaces of the electrical conductors are non-releasably connected to the carrier plate.

5. The cable arrangement as claimed in claim 1 and wherein the electrical conductors are litz wires, each with a plurality of individual strands.

6. The cable arrangement as claimed in claim 5, and wherein the litz wires are compacted in the form of a plate at the respective contact point.

7. The cable arrangement as claimed in claim 5 and wherein the litz wire of the carrier cable is welded, to form the carrier plate.

8. The cable arrangement as claimed in claim 1 and wherein the carrier plate of the carrier cable electrically communicates with and extends outwardly relative to a longitudinal axis of the carrier-cable.

9. The cable arrangement as claimed in claim 1 and further comprising: a housing, and the carrier plate is at least partially received within the housing.

10. The cable arrangement as claimed in claim 1 and wherein the at least three electrical cables are for use with high-voltage.

11. A method for producing an electrical and mechanical connection between at least three electrical cables, the method comprising the steps: providing at least three electrical cable, each of the at least three electrical cables formed by a litz wire; providing an electrical conductor on each of the at least three electrical cables by firstly freeing of insulation material a predetermined portion of each of the at least three electrical cables and compacting the insulation material freed predetermined portion of each of the least three electrical cables into a plate at a contact point; providing a carrier cable from one of the at least three electrical cables and, the litz wire of the carrier cable is compacted in the form of a plate in such a way that the compacted plate of the carrier cable can be used as a carrier plate; and connecting the litz wires of the further cables of the at least three electrical cables next to one another on a surface of the carrier cable carrier plate.

12. The method as claimed in claim 11, and wherein the carrier plate of the carrier cable is formed by welding.

13. The method as claimed in claim 11 and wherein the further electrical cables are electrically and mechanically connected to the carrier plate.

14. The method as claimed in claim 11 and wherein all litz wires to be connected are electrically and mechanically connected in a common process.

15. The cable arrangement as claimed in claim 1, and wherein two or more contact points of the further electrical conductors are connected to one another and fastened together on the surface of the carrier plate.

16. The cable arrangement as claimed in claim 1 and wherein the contact surfaces of the electrical conductors are connected to one another with material fit and/or with force fit.

17. The cable arrangement as claimed in claim 1 and wherein the contact surfaces of the electrical conductors are non-releasably connected to one another.

18. The cable arrangement as claimed in claim 1 and the carrier plate of the carrier cable electrically communicates with and extends outwardly linearly relative to a longitudinal axis of the carrier-cable.

19. The cable arrangement as claimed in claim 1 and the carrier plate of the carrier cable electrically communicates with and extends outwardly angularly relative to a longitudinal axis of the carrier-cable.

20. The cable arrangement as claimed in claim 1 and the carrier plate of the carrier cable electrically communicates with and extends outwardly in a U shape relative to a longitudinal axis of the carrier-cable.

21. The cable arrangement as claimed in claim 1 and the carrier plate of the carrier cable electrically communicates with and extends outwardly in a T shape, in a plan view, relative to a longitudinal axis of the carrier-cable.

22. The cable arrangement as claimed in claim 9 and wherein the housing is formed of an insulating material.

Description

BRIEF DESCRIPTIONS OF THE DRAWINGS

[0071] Exemplary embodiments of the invention are described in more detail below with reference to the drawings.

[0072] The figures each show preferred exemplary embodiments in which individual features of the present invention are illustrated in combination with one another. Features of an exemplary embodiment can also be implemented in isolation from the other features of the same exemplary embodiment and can thus be readily linked to features of other exemplary embodiments by the person skilled in the art to give further useful combinations and sub-combinations.

[0073] Functionally similar elements are denoted by the same reference signs in the figures, which show, in schematic form:

[0074] FIG. 1 is a top, side and end perspective view of a cable arrangement with a separate carrier plate according to the prior art.

[0075] FIG. 2 is a top, side and end perspective view of the inventive cable arrangement according to a first embodiment with a carrier cable and three further cables, wherein two of the cables are arranged stacked.

[0076] FIG. 3 is a top, side and end perspective view of the inventive cable arrangement of FIG. 2 in an exploded illustration or in a dismantled state.

[0077] FIG. 4 is a top, side and end perspective view of the inventive cable arrangement according to a second embodiment within a housing, wherein all cables are fastened directly to the carrier plate.

[0078] FIG. 5 is a top, side and end perspective view of the inventive cable arrangement according to a third embodiment with a tight packing density, wherein one of the cables is fastened to the carrier plate by a central region.

[0079] FIG. 6 is a top, side and end perspective view of the inventive cable arrangement according to a fourth embodiment with a linear carrier plate and different outgoing directions of the cable.

[0080] FIG. 7 is a top, side and end perspective view of a carrier cable with an L-shaped carrier plate.

[0081] FIG. 8 is a top, side and end perspective view of a carrier cable with a U-shaped carrier plate.

[0082] FIG. 9 is a top, side and end perspective view of a carrier cable with a T-shaped carrier plate.

DETAILED WRITTEN DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0083] This disclosure of the invention is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws to promote the progress of science and useful arts (Article 1, Section 8).

[0084] For better understanding of the invention, FIG. 1 shows a cable connection or a power distribution node 1 of a cable arrangement 2 according to the prior art. The cable arrangement 2 comprises four electrical cables 3, which are electrically and mechanically connected by means of a separate carrier plate 4. For the connection, the electrical conductor 5 of the respective cable 3 is freed of insulation material 6 in the region of the carrier plate 4 and is directly accessible for the connection.

[0085] In contrast to the prior art, the inventive cable arrangement 2 according to FIGS. 2 to 6 does not have a separate carrier plate 4.

[0086] FIGS. 2 and 3 show a first embodiment of the invention. In this case, FIG. 2 shows an assembled state of the cable arrangement 2, wherein the electrical and mechanical connection of the cable 3 has already been undertaken or the power distribution node 1 has already been formed, whereas FIG. 3 shows an exploded illustration or a dismantled state.

[0087] According to the invention, it is provided that one of the cables is configured as a carrier cable 7, wherein the electrical conductor 5 of the carrier cable 7 forms the carrier plate 4.

[0088] Apart from the carrier plate 4, the carrier cable 7 can be formed identically to the cables 3.

[0089] In the exemplary embodiments, the electrical cables 3 or the carrier cable 7 are formed as single-core cables 3, 7 for simplification. However, this is not to be understood as restrictive. Essentially, one, several or all of the electrical cables 3, 7 can also be formed as a multi-core cable 3, 7, for example they can have two, three, four, five, six or more cores or electrical conductors 5. However, single-core cables 3, 7 can be particularly suitable for use in high-voltage technology, in particular when they have a correspondingly large cross-section.

[0090] In the exemplary embodiments, the electrical conductors of the electrical cables 3, 7 are formed continuously as litz wires 5 with a plurality of individual strands. However, it can essentially also be provided that an electrical conductor 5 consists of an individual strand or one or more other conductive materials. However, the use of a litz wire 5 with a plurality of individual strands has proven particularly suitable for enabling the mechanical connection (described in more detail below) of the cables 3, 7 to one another.

[0091] In the exemplary embodiment of FIGS. 2 and 3, the litz wires 5 of two cables 3 are fastened directly on a surface 8 of the carrier plate 4. A further litz wire 5 of the remaining fourth electrical cable 3 is, on the other hand, connected to the litz wire 5 of one of the other cables 3. The two cables 3 form a stack. It can therefore also be provided that the cables 3 are electrically and mechanically connected by means of the carrier plate 4, wherein not all litz wires 5 of the electrical cables 3 are connected directly to the carrier plate 4. The litz wires 5 of the electrical cables 3 can also be connected to one another. Within the scope of the invention, it is provided that a plurality of litz wires 5, preferably at least two litz wires 5, are fastened next to one another on the surface 8 of the carrier plate 4. The litz wires arranged next to one another on a surface 8 of the carrier plate which is formed as an upper side are arranged next to one another in a plane, possibly at a spacing from one another. It is essentially possible that, as illustrated in FIG. 4, all litz wires 5 are arranged next to one another in a plane. However, it is also possible to stack some of the litz wires on top of one another, as illustrated with the aid of two litz wires 5 in FIGS. 2 and 3. The decision as to how the power distribution node 1 is to be configured can be made by the person skilled in the art depending on the geometric requirements.

[0092] The mechanical connection of the litz wires 5 to one another and/or the litz wires 5 to the carrier plate 4 can essentially be formed with material fit and/or with force fit.

[0093] The mechanical connection of the litz wires 5 to one another and/or the litz wires 5 to the carrier plate 4 is preferably configured to be non-releasable.

[0094] The mechanical connection can be configured, for example, as a crimped connection, soldered connection and/or welded connection. In this case, the litz wires 5 can be electrically and mechanically connected by means of the carrier plate 4 by fusion welding and/or pressure welding, preferably resistance welding. In this case, all litz wires 5 to be connected are particularly preferably electrically and mechanically connected in a common process.

[0095] In the exemplary embodiments, it is provided that the litz wires 5 for the mechanical connection are pre-shaped and/or compacted in order to form a planar contact point 9 (c.f. in particular FIG. 3). This can take place, for example, by pressure welding, friction welding and/or ultrasound compaction. So-called compacting or packing can be undertaken particularly advantageously if the electrical conductors 5 are formed as litz wires with a plurality of individual strands. The individual strands can then be shaped and/or pressed together with material fit and/or with force fit to form the planar contact point 9 by means of a corresponding welding technique or in some other manner.

[0096] The carrier plate 4 of the carrier cable 7 can essentially have any geometry. In the exemplary embodiments of FIGS. 2 and 3, the carrier plate 4 of the carrier cable 7 extends at a right angle corresponding to the angle =90 (c.f. FIG. 3) in a plan view with respect to the carrier cable longitudinal axis A. However, the angle can essentially be any angle. Further, more complex geometrical forms are also possible, of which a few more will be specified by way of example below.

[0097] An inventive method for producing an electrical and mechanical connection of the cable arrangement 2 can be provided in that the litz wires 5 of the cables 3, 7 are firstly stripped of insulation or freed of the insulation material 6, e.g. a cable sheath, and are made directly accessible for the connection, according to which the litz wires 5 are pre-shaped and/or compacted to form a planar contact point 9. In this case, the litz wires 5 of the carrier cable 7 can be processed in such a way that they form a carrier plate 4, wherein the litz wires 5 of the further cables 3 are then connected to one another by means of the carrier plate 4.

[0098] FIG. 4 shows a further embodiment, which essentially resembles the embodiment of FIGS. 2 and 3, wherein all litz wires 5 of the further cables 3 are now connected directly to the carrier plate 4. FIG. 4 furthermore indicates a housing 10, in which or on which the carrier plate 4 of the cable connection or the power distribution node 1 is received. The housing 10 has fastening means 11 for fastening a surrounding structure, in the present case comprising two webs with respective bores for receiving a screw, for example. The power distribution node 1 can be fastened to a body part 12 of a vehicle, for example, by means of the housing 10.

[0099] The housing 10 can be any housing 10, for example an insulating housing or an electrically conductive housing for electromagnetic shielding of the power distribution node 1.

[0100] An embodiment similar to the embodiment of FIG. 4 is shown in FIG. 5. In this case the packing density of the cable connection on the carrier plate 4 is increased in that the litz wires 5 of the cables 3 are fastened adjacent to one another on the carrier plate 4. The exemplary embodiment of FIG. 5 furthermore demonstrates that the litz wires 5 do not necessarily have to be accessible for the connection at a cable end. For example, the litz wire 5 in the cable 3 which is spaced furthest away from the carrier cable 7 in FIG. 5 is stripped of insulation in a central region 13 of the cable 3 in the manner of a window in order to make the litz wire 5 accessible for the connection. However, the electrical cables 3 are preferably connected to one another in the region of their cable ends, as illustrated in the other exemplary embodiments.

[0101] A carrier plate which deviates from the previous geometry of the carrier plate 4 is illustrated by way of example in FIG. 6. In the exemplary embodiment of FIG. 6, the carrier plate 4 extends linearly with respect to the carrier cable longitudinal axis A. The electrical cables 3 to be connected by means of the carrier plate 4 furthermore extend in different outgoing directions.

[0102] As already mentioned, the geometry of the carrier plate 4 can be essentially any geometry depending on the requirements of the cable arrangement 2. In particular, form-fitting fixing of the carrier cable 4 in a surrounding housing 10 can be realized in a simple manner in the case of an angled carrier plate 4. FIGS. 7 to 9 serve to illustrate furtherpurely exemplarygeometries of the carrier plate 4. FIG. 7 shows an L-shaped carrier plate 4, FIG. 8 a U-shaped carrier plate 4 and FIG. 9 a T-shaped carrier plate 4. It can essentially also be provided that the carrier plate 4 is angled upwards or downwards with respect to the carrier cable longitudinal axis A and the views shown in the figures, preferably orthogonally to the carrier cable longitudinal axis A.

[0103] The cable arrangement 2 according to the invention can be advantageously arranged in a vehicle, in particular in an electric vehicle, and connected in particular to a body part 12 of the vehicle.

[0104] A cable arrangement (2) for producing an electric and mechanical connection comprising at least three electrical cables (3, 7) each of which have an electrical conductor (5), and which are electrically and mechanically connected to one another, wherein the electrical conductor of each of the at least three electrical cables is freed of insulation material (6) and shaped in the form of a plate at a contact point; (9), characterized in that one of the at least three electrical cables (3, 7) is configured as a carrier cable (7) and the electrical conductor (5) of the carrier cable (7) is formed as a carrier plate (4) at the contact point (9) for connecting the contact points (9) of the further electrical conductors (5), wherein a plurality of contact points (9) of the further electrical conductors (5) are fastened next to one another on a surface (8) of the carrier plate (4).

[0105] A cable arrangement (2) wherein the contact points (9) of the further electrical conductors (5) are fastened directly on the surface (8) of the carrier plate (4) and/or in that two or more contact points (9) of the further electrical conductors (5) are connected to one another and fastened together on the surface (8) of the carrier plate (4).

[0106] A cable arrangement (2) wherein the contact surfaces (9) of the electrical conductors (5) are connected to one another, and/or the contact surfaces (9) of the electrical conductors (5) are connected to the carrier plate 444, with material fit and/or with force fit.

[0107] A cable arrangement (2) wherein the contact surfaces (9) of the electrical conductors (5) are non-releasable connected to one another, and/or the contact surfaces (9) of the electrical conductors (5) are non-releasable connected to the carrier plate (4), preferably via a crimped connection, a soldered connection and/or a welded connection.

[0108] A cable arrangement (2) wherein the electrical conductors are formed as litz wires (5), each with a plurality of individual strands.

[0109] A cable arrangement (2) wherein the litz wires (5) are compacted in the form of a plate at the respective contact point. [0110] A cable arrangement (2) wherein the litz wire (5) of the carrier cable (7) is welded, preferably pressure welded, resistance welded or fusion welded, in order to form the carrier plate (4).

[0111] A cable arrangement (2) and wherein the carrier plate (4) of the carrier cable (7) electrically communicates with and extends linearly, at a right angle, in a U shape and/or in a T-shape in a plan view with respect to the carrier-cable longitudinal axis (A).

[0112] A cable arrangement (2) further comprising a housing, and the carrier plate (4) is at least partially received within the housing, and the housing may be formed of an insulating material.

[0113] A cable arrangement (2) wherein the at least three electrical cables (3, 7) are designed for use with high-voltage technology.

[0114] A method for producing an electrical and mechanical connection between at least three electrical cables, the method comprising the steps: (3, 7) providing at least three electrical cables, each of the at least three electrical cables formed by a litz wire; providing an electrical conductor on each of the at least three electrical cables by firstly freeing of insulation material a predetermined portion of each of the at least three electrical cables (5), and compacting the predetermined portion of each of the least three electrical cables that is freed of insulation material (6) into the form of a plate at a contact point (9) provided for the connection; providing a carrier cable from one of the at least three electrical cables and, the litz wire (5) of the carrier cable (7) is compacted in the form of a plate in such a way that the compacted plate of the carrier cable can be used as a carrier plate (4); and connecting the litz wires (5) of the further cables of the at least three electrical cables (3 next to one another on a surface (8) of the carrier cable carrier plate (4).

[0115] A method wherein the carrier plate (4) of the carrier cable is formed/reshaped by a welding process, such as, but not limited to pressure welding, friction welding and/or ultrasound compaction.

[0116] A method wherein the litz wires (5) of the further electrical cables (3) are electrically and mechanically connected to the carrier plate (4) by a method such as, but not limited to, fusion welding and/or pressure welding, preferably resistance welding.

[0117] A method wherein all litz wires (5) to be connected are electrically and mechanically connected in a common process, which may be, but is not limited to resistance welding.

[0118] A cable arrangement (2) and wherein two or more contact points of the further electrical conductors are connected to one another and fastened together on the surface of the carrier plate (4).

[0119] A cable arrangement (2) and wherein the contact surfaces of the electrical conductors (3) are connected to one another with material fit and/or with force fit.

[0120] A cable arrangement (2) and wherein the contact surfaces of the electrical conductors are non-releasably connected to one another.

[0121] In compliance with the statute, the present invention has been described in language more or less specific, as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and described since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the Doctrine of Equivalence.