CABLE AND METHOD FOR PRODUCING A CABLE

Abstract

The invention relates to a cable (1) comprising at least one strand (2) having twisted litz wires (3) for conducting electrical current and an insulation sheath (4) surround inn the at least one strand (2) for electrically insulating the at least one strand (2). The cable (1) has an interruption section (5) without an insulation sheath (4) between two cable sections (6, 6) with an insulation sheath (4). According to the invention, the twisted weave of the at least one strand (2) is loosened in the interruption section (5), in order to interrupt the transport of moisture through the cable (1), in particular through the at least one strand (2), that results from capillary pressure and/or temperature-related pressure differences along the cable (1), such that the pressure in the interruption section (5) can equalize with that of the exterior.

Claims

1. A cable comprising: at least one litz wire having twisted litz wire strands for conducting electrical current and an insulation sheath surrounding the at least one litz wire for electrical insulation of the at least one litz wire, where the cable has an interruption segment without insulation sheath disposed between two cable segments with insulation sheath, characterized in that the at least one litz wire is birdcaged in the interruption segment in order to interrupt the transport of moisture through the cable, in particular through the at least one litz wire due to capillary pressure and/or temperature-related pressure differences along the cable, so that in the interruption segment a pressure equalization to the external environment can take place.

2. The cable as in claim 1, characterized in that the at least one litz wire a bunched litz wire.

3. The cable as in claim 1, characterized in that a protective housing is provided, which is disposed around the entire interruption segment in order to electrically insulate the at least one litz wire in the interruption segment.

4. The cable as in claim 3, characterized in that the protective housing has transverse ribs, which run transverse to the run of the cable in the region of the interruption segment, where in directions looking away from the interruption segment and looking along the run of the cable the insulation sheath of the relevant cable segment with insulation sheath is disposed in each case after one of the transverse ribs.

5. The cable as in claim 4, characterized in that the transverse ribs at least segmentwise contact the at least one litz wire in the interruption segment.

6. The cable as in claim 4, characterized in that the transverse ribs respectively have at least one recess.

7. The cable as in claim 3, characterized in that the protective housing has at least one lengthwise rib, which runs essentially parallel to the run of the cable in the region of the interruption segment and is connected by force fit with at least one of the cable segments with insulation sheath, preferably with both cable segments with insulation sheath.

8. The cable as in claim 3, characterized in that the protective housing comprises an upper part and a lower part, which can be converted from an open state to a closed state and back, where in the open state the interruption segment can be taken out of the protective housing and where in the closed state a position of the interruption segment is limited to at least one position within the protective housing.

9. The cable as in claim 8, characterized in that the upper part and the lower part in the closed state are detachably connected to each other by means of a lock.

10. The cable as in claim 9, characterized in that the lock can be actuated by elastic deformation of at least one segment of the upper part and/or the lower part.

11. The cable as in claim 3, characterized in that the protective housing is made of plastic.

12. A method for producing a cable comprising: where a cable that comprises at least one litz wire having twisted litz wire strands for conducting electrical current and an insulation sheath surrounding the at least one litz wire for electrical insulation of the at least one litz wire, where an interruption segment is made by stripping the insulation sheath between two cable segments with insulation sheath, wherein the interruption segment the at least one litz wire is birdcaged by a countertwisting of the at least one litz wire against a direction of rotation of the twist, in order to interrupt the transport of moisture through the cable, in particular thorough the at least one litz wire, because of capillary pressure and/or temperature-related pressure differences along the cable, so that a pressure equalization to the external environment can take place in the interruption segment.

13. The method as in claim 12, characterized in that for electrical insulation of the at least one litz wire in the interruption segment a protective housing is disposed around the entire interruption segment.

14. The method as in claim 13, characterized in that the protective housing connected by force fit with at least one of the two cable segments with insulation sheath, preferably with both cable segments with insulation sheath.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0025] The invention will now be explained in more detail by means of an embodiment example.

[0026] The drawings are exemplary and are intended to represent the ideas of the invention, but not to limit them in any way or even to conclusively reflect them.

[0027] Here:

[0028] FIG. 1a shows an axonometric view of a cable according to the prior art

[0029] FIG. 1b shows a section view of FIG. 1a, where a lengthwise axis of the cable runs in the cutting plane

[0030] FIG. 1c shows another section view of FIG. 1a, where the lengthwise axis of the cable is perpendicular to the cutting plane

[0031] FIG. 2a shows an axonometric view of a cable according to the invention with an interruption segment

[0032] FIG. 2b shows a section view of FIG. 2a, where the lengthwise axis of the cable runs in the cutting plane

[0033] FIG. 2c shows a section view along cutting line A-A in FIG. 2b, where the arrows indicate the direction of viewing

[0034] FIG. 3a shows an axonometric view as in FIG. 2a, where a protective housing with an upper part and a lower part in an open state is additionally shown

[0035] FIG. 3b shows a section view of FIG. 3a, where the lengthwise axis of the cable runs in the cutting plane

[0036] FIG. 3c shows a section view along cutting line B-B in FIG. 3b, where the arrows indicate the direction of viewing

[0037] FIG. 3d shows a section view along cutting line C-C in FIG. 3b, where the arrows indicate the direction of viewing

[0038] FIG. 4a shows an axonometric view as in FIG. 3a, where the upper part and the lower part of the protective housing are shown in a closed state

[0039] FIG. 4b shows a section view of FIG. 4a, where the lengthwise axis of the cable runs in the cutting plane

[0040] FIG. 4c shows a section view along cutting line D-D in FIG. 4b, where the arrows indicate the direction of viewing

[0041] FIG. 4d shows a section view along cutting line E-E in FIG. 4b, where the arrows indicate the direction of viewing

[0042] FIG. 4e shows a section view along cutting line F-F in FIG. 4b, where the arrows indicate the direction of viewing

WAYS OF IMPLEMENTING THE INVENTION

[0043] FIG. 1a shows an axonometric view of a cable 1, as is known from the prior art and in particular is used in vehicles. The cable 1 comprises a litz wire 1, which has twisted litz wire strands 3, through which high flexibility and bendability of the cable 1 is ensured.

[0044] In FIG. 1b, which shows a section through the cable 1, where a lengthwise axis 14 of the cable 1 runs in the cutting plane, one can easily see that the litz wire strands 3 are twisted, where a direction of rotation of the twisting around the lengthwise axis 14 can be recognized as the twist axis. Additionally, in FIG. 1b one can easily see the insulation sheath 4 surrounding the litz wire 2, which electrically insulates the litz wire 2 or the litz wire strands 3 from the external environment. The insulation sheath 4 is usually made of plastic and is extruded onto the litz wire 2.

[0045] The dense arrangement of the twisted litz wire strands 3 emerges from FIG. 1c, which shows a section through the cable 1 perpendicular to the lengthwise axis 14. Correspondingly, voids in the form of thin channels form between the closely spaced litz wire strands 3. If moisture or liquid, in particular water, penetrates into the cable 1, these channels produce a capillary pressure, which transports the moisture or liquid further. Likewise, if there are temperature variations between the ends of the cable 1 or along the cable 1, correspondingly varying pressure differences arise in cable 1 or in the channels, which likewise cause a further transport of the moisture or liquid. The liquid can in this way migrate in the channels through the entire cable 1, which in turn can lead to corrosion of contact points (not shown).

[0046] To prevent this and to interrupt the transport of the moisture or liquid in cable 1, according to the invention an interruption segment 5 is provided in channel 1, which can be seen in the axonometric view in FIG. 2a. In interruption segment 5 the insulation sheath 4 is removed or stripped, and the interruption segment 5 is disposed between two cable segments 6, 6, in which the insulation sheath 4 is present. This means that in producing the interruption segment 5 an intermediate removal of the sheath of the litz wire 2 takes place. Further, the litz wire 2 is made into a birdcage form in the interruption segment 5, i.e., the litz wire 2 has a birdcaged segment 15 in interruption segment 5, which is preferably achieved in a simple way by a countertwisting of the litz wire 2 against the direction of rotation of the twisting. The segment 15, which has been birdcaged in this way, is particularly clearly recognizable in the section view of FIG. 2b.

[0047] The birdcaging is implemented such that the litz wire 2 is opened up wide, i.e., so that the litz wire strands 3 of the birdcaged litz wire 2 have a spacing from each other that is large enough that the capillary action or the capillary pressure is reduced or is essentially eliminated, so that the liquid or moisture, which has penetrated, for example, into the cable 1 at a contact point, can no longer be transported further. This large distance between the wire strands 3 in the birdcaged segment 15 of the litz wire 2 can readily be seen in FIG. 2c, which shows a section through cutting line A-A in FIG. 2b, where the arrows indicate the direction of viewing. Typically, adjacent litz wire strands 3 no longer contact each other in the birdcaged segment 15. A channel produced by adjacent litz wire strands 3 in this region preferably has an equivalent diameter that is larger than a diameter of the litz wire strands 3.

[0048] In addition, a reduced pressure arising in cable 1 because of temperature variations along the run of the cable or at the contact points becomes neutralized or equalized by the intermediate removal of the sheath in interruption segment 5. This means than an excess pressure can escape in interruption segment 5 or, if there is a reduced pressure, air can be drawn into the channels or voids in interruption segment 5.

[0049] For electrical insulation of the litz wire 2 in interruption segment 5 in the indicated embodiment example, a protective housing 7 of plastic is provided, which is arranged to surround the entire interruption segment 5. In this embodiment example the protective housing 7 comprises an upper part 11 and a lower part 12, which are shown in an open state in FIG. 3a. This enables simple assembly of the protective housing 7, since in the open state the interruption segment 5 can easily be guided into the protective housing 7 and optionally also backed out of the protective housing 7, or the protective housing 7 can be precisely positioned over the interruption segment 5.

[0050] The upper part 11 and lower part 12 can be converted to a closed state, which is shown, for example, in FIG. 4a. Basically, in closed state a position of the interruption segment 5 is limited to at least one position within the protective housing 7. This means that the position of protective housing 7 and interruption segment 5 with respect to each other in the closed state is already fixed at least up to a certain degree. Here it is sometimes possible that a certain minimal movement of the interruption segment 5 within the protective housing 7 can take place or that such a minimal movement cannot be excluded.

[0051] In order to be able to hold upper part 11 and lower part 12 securely in the closed state on the one hand and to be able to possibly convert them to the open state again on the other hand, a lock 13 is provided. The lock 13 in this embodiment example comprises lock hooks 16 disposed on the upper part 11 and lock eyelets 17 disposed on the lower part 12. Through elastic deformation of upper part 11 and lower part 12, in particular by a pressing together of the upper part 11 parallel to a direction transverse to the lengthwise axis 14, upper part 11 and lower part 12 can be positioned with respect to each other so that the lock hooks 16 are brought into congruence with the lock eyelets 17. Then a release of the pressure on the upper part 11 causes a latching of the lock hooks 16 in the lock eyelets 17. To switch back to the open state one analogously follows the reverse sequence of operations.

[0052] Besides the function of electrical insulation, the protective housing 7 in this embodiment example also serves to keep the insulation sheath 4 from being able to be shifted from the two cable segments 6, 6 into the interruption segment. For this, the protective housing 7 has two transverse ribs 8, 8, which respectively run transverse to the run of the cable 1 in the region of the interruption segment 5. Parts of each transverse rib 8, 8 are made both in the upper part 11 and in lower part 12. The arrangement of the transverse ribs 8 in protective housing 7 and the positioning of the protective housing 7 are chosen so that in a direction pointing away from interruption segment 5 and looking along the run of the cable 1 the insulation sheath 4 of the cable segment 6 is disposed immediately after the transverse rib 8. The arrangement of the transverse rib 8 in protective housing 7 and the positioning of the protective housing 7 are chosen so that looking in the opposite direction the insulation sheath 4 of the cable segment 6 is disposed immediately after the transverse rib 8. This means that the transverse ribs 8, 8 are still arranged in the region of the interruption segment 5, over the litz wire 2.

[0053] This arrangement follows very clearly from the section view in FIG. 3b. The section view in FIG. 3d further illustrates that the transverse ribs 8, 8 are disposed at the edge of the interruption segment 5, where the litz wire 2 is not yet birdcaged or at least by comparison with the region in the center of the interruption segment 5 that is shown in FIG. 3c is birdcaged only a very little. Because of this arrangement of the transverse ribs 8, 8, the transverse ribs 8, 8 in the closed state prevent a shifting of the insulation sheath 4 of the cable segments 6, 6 into the interruption segment 5 due to a form fit with the insulation sheath 4.

[0054] FIG. 4b, FIG. 4c, and FIG. 4d show section views corresponding to FIG. 3b, FIG. 3c, and FIG. 3d in the closed state. In particular in FIG. 4d one can see that the transverse ribs 8 contact the litz wire 2. In general, the possible form fit between the transverse ribs 8, 8 and the insulation sheath 4 of the cable segments 6, 6 is ensured by the at least sectionwise contact between the transverse ribs 8, 8 and the litz wire 2. More specifically, this keeps the insulation sheath 4 of the cable segments 6, 6 from being able to be shifted between the litz wire 2 and the transverse ribs 8, 8.

[0055] To ensure that a pressure equalization from the interruption segment 5 to the external environment can nevertheless take place even if the transverse ribs 8, 8 lie completely against the litz wire 2, each of the transverse ribs 8, 8 has four recesses 9. This means that the recesses 9 ensure that the protective housing 7 does not hermetically seal off the interruption segment 5.

[0056] The transverse ribs 8, 8 are made flattened out in the direction of the middle of the protective housing 7, in order to offer the birdcaged litz wire 15 space. Further, a free space 18 is provided along the lengthwise axis 14 between the transverse ribs 8, 8, in order to increase further the space for the birdcaged litz wire 15. This can easily be seen in the section views of FIG. 3b and FIG. 4b.

[0057] Further, the protective housing 7 in this embodiment has lengthwise ribs 10, 10, which respectively run essentially parallel to the run of the cable 1 in the region of the interruption segment 5. The lengthwise rib 10 is made in the upper part 11 and the lengthwise rib 10 is made in the lower part 12.

[0058] In the closed state the two lengthwise ribs 10, 10 are connected to the insulation sheath 4 of the cable segments 6, 6 in a force fit, as can be seen in particular in FIG. 4e. Through this a securing of position of the protective housing 7 to the cable segments 6, 6 and to interruption segment 5 is achieved on the one hand, while on the other hand a securing of position of the two cable segments 6, 6 and the interruption segment 5 mutually with respect to each other is also ensured via the protective housing 7. Correspondingly, the cable segments 6, 6 cannot be rotated with respect to one another and interruption segment 5, in particular cannot be rotated in the direction of rotation of the twist. The latter would have a back twisting of the birdcaged litz wire 2 in interruption segment 5 as a consequence, due to which the wire strands 3 there would move again closer to each other and the capillary effect would be produced or increased again.

REFERENCE NUMBER LIST

[0059] 1 Cable [0060] 2 Litz wire [0061] 3 Litz wire strand [0062] 4 Insulation sheath [0063] 5 Interruption segment of cable [0064] 6, 6 Cable segment with insulation sheath [0065] 7 Protective housing [0066] 8, 8 Transverse rib of protective housing [0067] 9 Recess of transverse rib [0068] 10, 10 Lengthwise rib [0069] 11 Upper part of protective housing [0070] 12 Lower part of protective housing [0071] 13 Lock of upper part and lower part [0072] 14 Lengthwise axis of cable [0073] 15 Birdcaged segment of litz wire [0074] 16 Lock hooks [0075] 17 Lock eyelets [0076] 18 Free space between transverse ribs