Prefabricated electrical cable, plug connector assembly, and method and apparatus for manufacturing an electrical cable

Abstract

A prefabricated electrical cable comprises an outer conductor shield and an insulation element. The insulation element has a first longitudinal section in which the insulation element is exposed from the outer conductor shield, and a second longitudinal section which adjoins the first longitudinal section and in which the insulation element is enclosed by the outer conductor shield. A cross-sectional area of the insulation element in the first longitudinal section is changed with respect to the cross-sectional area of the insulation element in the second longitudinal section in such a way that the first longitudinal section of the insulation element can be inserted into a first longitudinal section of an outer conductor contact element of an electrical plug connector, and the insulation element is calibrated to the outer conductor contact element.

Claims

1. A plug connector assembly (100), comprising: a prefabricated electrical cable (1); and a plug connector (15) having an outer conductor contact element (14) that defines a first plug connector portion (S.sub.1), and the plug connector (15) is connected to at least one cable end of the prefabricated electrical cable (1); and the prefabricated electrical cable (1), has an outer conductor shield (5) and an insulation element (4), and wherein the insulation element (4) has a first longitudinal portion (L.sub.1) in which the insulation element (4) is laid bare from the outer conductor shield (5), and the insulation element (4) has a second longitudinal portion (L.sub.2) which adjoins the first longitudinal portion (L.sub.1) and in which the insulation element (4) is enclosed by the outer conductor shield (5), and wherein a cross-sectional area of the insulation element (4) in the first longitudinal portion (L.sub.1) is modified so that a diameter of the cross-sectional area of the insulation element (4) in the first longitudinal portion (L.sub.1) is different from a diameter of the cross-sectional area of the insulation element (4) in the second longitudinal portion (L.sub.2); and the diameter of the cross-sectional area of the insulation element (4) in the first longitudinal portion (L.sub.1) is calibrated to the outer conductor contact element (14) so that the modified first longitudinal portion (L.sub.1) of the insulation element (4) may be inserted into the first plug connector portion (S.sub.1); and wherein the modified cross-sectional area of the insulation element (4) may be Inserted into the first plug connector portion(S) without an intervening layer of air.

2. The plug connector assembly (100) as claimed in claim 1 and wherein an external diameter of the second longitudinal portion (L.sub.2) of the Insulation element (4) differs from an internal diameter of the first plug connector portion (S.sub.1) of the outer conductor contact element (14).

3. The plug connector assembly (100) as claimed in claim 1 and wherein within the first longitudinal portion (L.sub.1) and the first plug connector portion (S.sub.1) a region between the outer conductor contact element (14) and an inner conductor (3) of the prefabricated electrical cable (1) is completely filled by the insulation element (4).

4. The plug connector assembly (100) as claimed in claim 1 and wherein the insulation element (4) defines a circumferential groove (11) in a transition between the first longitudinal portion (L.sub.1) and the second longitudinal portion (L.sub.2).

5. The plug connector assembly (100) as claimed in claim 1 and wherein the cross-sectional area of the insulation element (4) in the entire first longitudinal portion (L.sub.1) is constant, and is reduced in size in relation to the cross-sectional area of the insulation element (4) in the second longitudinal portion (L.sub.2).

6. The plug connector assembly (100) as claimed in claim 1 and wherein an external diameter of the insulation element (4) along the entire first longitudinal portion (L.sub.1) is constant and is reduced in diameter in relation to an external diameter of the insulation element (4) in the second longitudinal portion (L.sub.2).

7. The plug connector assembly (100) as claimed in claim 1 and wherein at least one recess (18), is configured on a circumference of the insulation element (4), said at least one recess (18) in the longitudinal direction extending across the entire first longitudinal portion (L.sub.1).

8. The plug connector assembly (100) as claimed in claim 1 and wherein an external diameter of the insulation element (4) in the entire first longitudinal portion (L.sub.1) is constant and is enlarged in diameter in relation to an external diameter of the insulation element (4) in the second longitudinal portion (L.sub.2).

9. The plug connector assembly (100) as claimed in claim 1 and wherein the outer conductor contact element (14) of the plug connector (15), has at least one insulating element (17) for compensation of a change in impedance between the first longitudinal portion (L.sub.1) and the second longitudinal portion (L.sub.2) and the at least one dielectric is situated in a second plug connector portion (S.sub.2) that adjoins the first plug connector portion (S.sub.1).

10. A method for fabricating an electrical cable (1) comprising the steps: providing an electrical cable (1) that has an insulation element (4) in a first longitudinal portion (L.sub.1) and in an adjoining second longitudinal portion (L.sub.2); laying bare the insulation element (4) from an outer conductor shield (5) of the electrical cable (1) in the first longitudinal portion (L.sub.1); modifying a cross-sectional area of the laid bare insulation element (4) in the first longitudinal portion (L.sub.1) so that a diameter of the modified cross-sectional area of the insulation element (4) in the first longitudinal portion (L.sub.1) is different from a diameter of the cross-sectional area of the insulation element (4) in the adjoining second longitudinal portion (L.sub.2); and providing a plug connector (15) that has an outer conductor contact element (14) that defines a first plug connector portion (S.sub.1); and calibrating the diameter of the modified cross-sectional area of the first longitudinal portion (L.sub.1) of the insulation element (4) to the outer conductor contact element (14) so that the first longitudinal portion (L.sub.1) of the insulation element (4) is insertable into the first plug connector portion (S.sub.1); and inserting the modified cross-sectional area of the first longitudinal portion (L.sub.1) of the insulation element (4) into the first plug connector portion (S.sub.1) of the outer conductor contact element (14) of the plug connector (15); and inserting a cable end of the electrical cable (1) into the outer conductor contact element (14) of the plug connector (15); and connecting the inserted electrical cable (1) to the outer conductor contact element (14); and wherein the modified cross-sectional area of the insulation element (4) may be inserted into the first plug connector portion(S)) without an intervening layer of air.

11. The method for fabricating an electrical cable (1) as claimed in claim 10, and wherein the modification of the cross-sectional area in the first longitudinal portion (L.sub.1) takes place by means of compressing the first longitudinal portion (L.sub.1).

12. The method for fabricating an electrical cable (1) as claimed in claim 10 and wherein the modification of the cross-sectional area in the first longitudinal portion (L.sub.1) takes place by means of swaging the first longitudinal portion (L.sub.1) in a forming process, preferably in a stamping or hot-stamping process.

13. The method for fabricating an electrical cable (1) as claimed in claim 10 and wherein the modification of the cross-sectional area in the first longitudinal portion (L.sub.1) of the insulation element (4) is by means of a separation tool (23) that scores the insulation element (4) in a radial direction, and whereupon the separation tool (23) while in the radial cutting position is moved axially relative to the insulation element (4), and in a direction toward the cable end, so as to peel away an insulation layer (25) from the insulation element (4).

14. The method for fabricating an electrical cable (1) as claimed in claim 13 and wherein the separation tool (23) has at least one shaped knife (24) that is adapted to the shape of the provided cross-sectional area of the first longitudinal portion (L.sub.1) and actuatable toward the insulation element (4).

15. The method for fabricating an electrical cable (1) as claimed in claim 10 and wherein the insulation material (4), at least in the first longitudinal portion (L.sub.1), is heated immediately prior to and/or during the modification of the cross-sectional area.

16. The method for fabricating an electrical cable (1) as claimed in claim 13 and wherein the separation tool (23) is heated, preferably to an operating temperature between approximately 50 C. and 250 C.

17. The method for fabricating an electrical cable (1) as claimed in claim 10 and wherein in parallel to the modification of the cross-sectional area in the first longitudinal portion (L.sub.1), a sharp-edged web (10) of a stamping installation (8) is scored into the insulation element (4) in a preferably fully circumferential groove (11) in a transition between the first longitudinal portion (L.sub.1) and the second longitudinal portion (L.sub.2).

18. The method for fabricating an electrical cable (1) as claimed in claim 10 and wherein the modification of the cross-sectional area in the first longitudinal portion (L.sub.1) takes place by means of a separation process, preferably by a laser, photon, electron or ion beam, or a water jet.

19. The method for fabricating an electrical cable (1) as claimed in claim 15 and wherein the separation tool (23) has at least two shaped knifes (24) that are adapted to the shape of the provided cross-sectional area of the first longitudinal portion (L.sub.1) of the insulation element (4) and the two shaped knives (24) are actuatable toward one another.

20. The method for fabricating an electrical cable (1) as claimed in claim 13 and wherein the separation tool (23) is heated, preferably to an operating temperature between approximately between 170 C. and 200 C.

21. An apparatus for fabrication of an electrical cable (1), comprising: a processing installation (21) for modifying a cross-sectional area of the electrical cable (1) in a first longitudinal portion (L.sub.1) of an insulation element (4) of the electrical cable (1) that has been laid bare from an outer conductor shield (5); and a joining installation (20) for inserting the electrical cable (1) into an outer conductor contact element (14) of a plug connector (15); and wherein, the processing installation (21) modifies a cross-sectional area of the insulation element (4) of the electrical cable (1) in the first longitudinal portion (L.sub.1) in such a manner that the first longitudinal portion (L.sub.1) is insertable into a first plug connector portion (S.sub.1) of the outer conductor contact element (14); and wherein the first longitudinal portion (L.sub.1) the insulation element (4) is calibrated to the outer conductor contact element (14).

Description

BRIEF DESCRIPTIONS OF THE FIGURES

(1) The present invention will be explained in more detail hereunder by means of the exemplary embodiments set forth in the schematic figures of the drawing, in which:

(2) FIG. 1A is an isometric illustration of a first embodiment of an electrical cable to be fabricated showing a first of the individual fabrication steps.

(3) FIG. 1B is an isometric illustration of a first embodiment of an electrical cable to be fabricated showing a further of the individual fabrication steps.

(4) FIG. 1C is an isometric illustration of a first embodiment of an electrical cable to be fabricated showing a further of the individual fabrication steps.

(5) FIG. 1D is an isometric illustration of a first embodiment of an electrical cable to be fabricated showing a further of the individual fabrication steps.

(6) FIG. 1E is an isometric illustration of a first embodiment of an electrical cable to be fabricated showing a further of the individual fabrication steps.

(7) FIG. 1F is an isometric illustration of a first embodiment of an electrical cable to be fabricated showing a further of the individual fabrication steps.

(8) FIG. 1G is an isometric illustration of a first embodiment of an electrical cable to be fabricated showing a further of the individual fabrication steps.

(9) FIG. 2A is a cross-sectional illustration of a first embodiment of an electrical cable to be fabricated, showing a first of the individual fabrication steps.

(10) FIG. 2B is a cross-sectional illustration of a first embodiment of an electrical cable to be fabricated, showing a further of the individual fabrication steps.

(11) FIG. 2C is a cross-sectional illustration of a first embodiment of an electrical cable to be fabricated, showing a further of the individual fabrication steps.

(12) FIG. 2D is a cross-sectional illustration of a first embodiment of an electrical cable to be fabricated, showing a further of the individual fabrication steps.

(13) FIG. 2E is a cross-sectional illustration of a first embodiment of an electrical cable to be fabricated, showing a further of the individual fabrication steps.

(14) FIG. 3A is a first isometric illustration of a second embodiment of an electrical cable to be fabricated in the individual fabrication steps.

(15) FIG. 3B is a second isometric illustration of a second embodiment of an electrical cable to be fabricated in the individual fabrication steps.

(16) FIG. 4A is a first cross-sectional illustration of a second embodiment of an electrical cable to be fabricated according to the individual fabrication steps.

(17) FIG. 4B is a second cross-sectional illustration of a second embodiment of an electrical cable to be fabricated according to the individual fabrication steps.

(18) FIG. 5A is an isometric illustration of a third embodiment of an electrical cable to be fabricated showing a first of the individual fabrication steps.

(19) FIG. 5B is an isometric illustration of a third embodiment of an electrical cable to be fabricated showing a further of the individual fabrication steps.

(20) FIG. 5C is an isometric illustration of a third embodiment of an electrical cable to be fabricated showing a further of the individual fabrication steps.

(21) FIG. 5D is an isometric illustration of a third embodiment of an electrical cable to be fabricated showing a further of the individual fabrication steps.

(22) FIG. 5E is an isometric illustration of a third embodiment of an electrical cable to be fabricated showing a further of the individual fabrication steps.

(23) FIG. 6A is a first cross-sectional illustration of a third embodiment of an electrical cable to be fabricated according to the individual fabrication steps.

(24) FIG. 6B is a second cross-sectional illustration of a third embodiment of an electrical cable to be fabricated according to the individual fabrication steps.

(25) FIG. 7A shows a lateral view of a plug connector assembly.

(26) FIG. 7B shows a cross-sectional illustration of a plug connector assembly.

(27) FIG. 8A is an isometric illustration of a fourth embodiment of an electrical cable to be fabricated, according to a first of the individual fabrication steps.

(28) FIG. 8B is an isometric illustration of a fourth embodiment of an electrical cable to be fabricated, according to a further of the individual fabrication steps.

(29) FIG. 8C is an isometric illustration of a fourth embodiment of an electrical cable to be fabricated, according to a further of the individual fabrication steps.

DETAILED WRITTEN DESCRIPTION OF THE PREFERRED EMBODIMENTS

(30) This disclosure of the invention is submitted in furtherance of the Constitutional purposes of the US Patent Laws to promote the progress of Science and the useful arts (Article 1, Section 8).

(31) An electrical cable 1, in particular a high-frequency cable, can be seen in FIG. 1A, a number of fabrication steps having already been carried out on the plug-proximal end 2 of said electrical cable 1.

(32) This electrical cable 1, which represents a high-frequency cable, preferably comprises an inner conductor 3 which is enclosed by an insulation element 4. Instead of an inner conductor 3, the electrical cable 1 can also have a pair of inner conductors for transmitting a differential signal. The two inner conductors of the inner conductor pair here are mutually spaced apart and electrically isolated from one another by the insulation element 4. Finally, the electrical cable 1 can also have a plurality of pairs of inner conductors which are in each case disposed so as to be mutually parallel or so as to cross one another, and so as to be mutually spaced apart and electrically isolated by the insulation element 4.

(33) The insulation element 4 can optionally be enclosed by an electrically isolating cable film, not illustrated in the figures. The insulation element 4, or the cable film, respectively, is finally enclosed by an outer conductor shield 5 which is typically constructed from braided individual, electrically conducting wires. Finally, the outer conductor shield 5 is enclosed by an electrically isolating cable sheath 6.

(34) As is derived from FIG. 1A the outer conductor shield 5, preferably in a first fabrication step, in the region of the plug-proximal and 2 of the electrical cable 1 is laid bare from the cable sheath 6.

(35) As is indicated in the isometric illustration in FIG. 1A and more clearly visible in the cross-sectional illustration in FIG. 2A, on the outer conductor shield 5 laid bare from the cable sheath 6 a support sleeve 7 is applied to the plug-proximal end of the high-frequency cable 1 in a further fabrication step. This support sleeve 7 is preferably fastened to the outer conductor shield 5 by means of crimping. The outer conductor shield 5 is folded back about the support sleeve 7.

(36) As a result of the outer conductor shield 5 being folded back about the support sleeve 7, a region of the insulation element 4 that is laid bare from the outer conductor shield 5 is present on the plug-proximal end 2 of the high-frequency cable 1.

(37) Up to this point in the method, the cable fabrication of an electrical cable 1 is known according to the prior art.

(38) In a further method step of the cable fabrication according to the invention and according to FIG. 1B, the cross-sectional area of the insulation element 4 in a first longitudinal portion L.sub.1 (cf. FIG. 2A) in relation to the cross-sectional area in a second longitudinal portion L.sub.2 (cf. FIG. 2A) is reduced using a suitable stamping installation 8. A cross-sectional area here is understood to be the cross-sectional area of the insulation element 4 of which the surface normal vector is oriented parallel to the longitudinal axis 9 of the electrical cable 1. Said cross-sectional area thus represents the cross-sectional area of the insulation element 4 which is oriented transversely to the longitudinal axis 9 of the high-frequency cable 1.

(39) The first longitudinal portion L.sub.1 preferably extends across the entire longitudinal extent of the electrical cable 1 in which the insulation element 4 is laid bare from the outer conductor shield 5. Consequently, the second longitudinal portion L.sub.2 of the insulation element 4 extends across the entire longitudinal extent of the electrical cable 1 in which the insulation element 4 is enclosed by the outer conductor shield 5. Thus, this is the remaining longitudinal extent of the electrical cable 1.

(40) Alternatively, the first longitudinal portion L.sub.1 having a reduced cross-sectional area of the insulation element 4 can also extend only in a sub-region of the longitudinal extent of the insulation element 4 laid bare from the outer conductor shield 5.

(41) The reduction of the cross-sectional area in the first longitudinal portion L.sub.1 of the insulation element 4 is preferably configured so as to be constant along the entire first longitudinal portion L.sub.1.

(42) In the first embodiment of a prefabricated electrical cable 1 according to the invention, the reduction of the cross-sectional area in the first longitudinal portion L.sub.1 of the insulation element 4 is implemented by swaging the external diameter of the insulation element 4.

(43) The processing installation 21 which carries out the swaging of the external diameter in the first longitudinal portion L.sub.1 of the insulation element 4 is preferably a stamping installation 8.

(44) The stamping installation 8 typically has a stamping ram 8.sub.1, which is movable radially in relation to the insulation element 4, and a stamping die 8.sub.2 which is positioned radially in relation to the insulation element 4. The stamping ram 8.sub.1 and the stamping die 8.sub.2 each have a cross-sectional profile having a semi-cylindrical recess. The diameter of the semi-cylindrical recess of the stamping ram 8.sub.1 and of the stamping die 8.sub.2 corresponds to the reduced external diameter in the first longitudinal portion L.sub.1 of the insulation element 4 that is to be achieved by the stamping process. When the stamping ram 8.sub.1 and stamping die 8.sub.2 are converged in the stamping process according to FIG. 1C, the semi-cylindrical recesses thereof form a common fully cylindrical recess in which the first longitudinal portion L.sub.1 of the insulation element 4 is axially mounted. As a result thereof, the external diameter of the first longitudinal portion L.sub.1 of the insulation element 4 is thus brought to correspond to the reduced internal diameter of the common fully cylindrical recess of the stamping ram 8.sub.1 and of the stamping die 8.sub.2.

(45) A sharp-edged web 10 which acts like a knife and in the transition between the first longitudinal portion L.sub.1 and the second longitudinal portion L.sub.2 scores a preferably fully circumferential groove 11 in the insulation element 4 (see to this end FIG. 2A, in particular) is in each case configured on the cable-proximal end of the semi-cylindrical recesses of the stamping ram 8.sub.1 and of the stamping die 8.sub.2. This preferably fully circumferential groove 11 prevents an undesired displacement of the insulation material from the first longitudinal portion L.sub.1 into the second longitudinal portion L.sub.2 during the stamping process.

(46) When diverging the stamping ram 8.sub.1 and the stamping die 8.sub.2 according to FIG. 1D, an electrical cable 1 having an insulation element 4 is created, said insulation element 4 in the first longitudinal portion L.sub.1 thereof, on the plug-proximal end 2 thereof, having a reduced external diameter in relation to the external diameter in the second longitudinal portion L.sub.2. The insulation material which by virtue of the reduced external diameter is displaced from the first longitudinal portion L.sub.1 moves axially in the direction of the plug-proximal end 2 of the electrical cable 1.

(47) In a further fabrication step according to FIG. 1E the plug-proximal end region 12 of the insulation element 4 is removed using a cutting apparatus 13. As is derived from FIG. 1F, the inner conductor 3 at the plug-proximal end of the high-frequency cable 1 is laid bare from the insulation element 4. The inner conductor 3 here is in particular also laid bare from the insulation material which has been axially displaced from the first longitudinal portion L.sub.1 by the stamping process.

(48) As an alternative to the mechanical stamping process, a hot-stamping process may also be used. In the latter, the stamping ram 8.sub.1 and the stamping die 8.sub.2 are elevated to a suitable temperature. The increased temperature of the stamping ram 8.sub.1 and of the stamping die 8.sub.2 during the stamping process leads to the insulation material melting in the adjacent, preferably sleeve-shaped, region within the first longitudinal portion L.sub.1 of the insulation element 4. The melted insolation material is suctioned off axially or radially from the first longitudinal portion L.sub.1 by way of a suitably configured suctioning apparatus.

(49) In a next fabrication step, the electrical cable prefabricated in this way, in a joining process having a joining installation 20 according to FIG. 2B, is inserted into an outer conductor contact element 14 of a plug connector 15.

(50) The assembly composed of the electrical cable 1 and the plug connector 15 is presently referred to as a plug connector assembly 100.

(51) The joining installation 20 is typically an axially positionable gripper arm which grips the electrical cable 1 on the cable sheath 6 in the second longitudinal portion L.sub.1 of the insulation element 4 and axially positions the latter. In particular, the first longitudinal portion L.sub.1 of the insulation element 4 here is positioned in a first plug connector portion S.sub.1 of the outer conductor contact element 14 of a plug connector 15 in such a manner that the first longitudinal portion L.sub.1 in the axial direction is preferably situated exactly within the first plug connector portion S.sub.1. To this end, the longitudinal extent of the first longitudinal portion L.sub.1 preferably corresponds to the longitudinal extent of the first plug connector portion S.sub.1.

(52) According to the invention, the first longitudinal portion L.sub.1 of the insulation element 4 is inserted into the first plug connector portion S.sub.1 of the outer conductor contact element 14 and is calibrated to the outer conductor contact element 14. In this way, the external diameter of the insulation element 4 in the first longitudinal portion L.sub.1 preferably corresponds to the internal diameter of the first plug connector portion S.sub.1 of the outer conductor contact element 14. The original external diameter of the insulation element 4, which is still maintained in the second longitudinal portion L.sub.2 of the insulation element 4, within the first longitudinal portion L.sub.1 is thus adapted to the internal diameter of the first plug connector portion S.sub.1 of the outer conductor contact element 14 in the fabrication method according to the invention.

(53) This adaptation of the external diameter of the insulation element 4 to the internal diameter of the outer conductor contact element 14 is also referred to as calibration. In this case, the external diameter profile of the insulation element 4 associated with the electrical cable 1 is adapted to the internal diameter profile of the outer conductor contact element 14 in the plug connector 15.

(54) For the sake of completeness, an inner conductor contact element 16 of the plug connector 15 which, preferably by means of crimping, is connected to the inner conductor 3 of the high-frequency cable is illustrated in FIG. 2B. A suitably configured insulation element 17 within the plug connector 15 for electrically isolating and spacing is inserted between the inner conductor contact element 16 and the outer conductor contact element 14.

(55) The cross-sectional profile of the substantial component parts of the first embodiment of the prefabricated electrical cable 1 according to the invention is in each case schematically illustrated, i.e. not true to scale, in the individual fabrication steps in FIGS. 2C, 2D and 2E:

(56) The cross-sectional profile of the substantial component parts of the electrical cable 1 prior to the modification of the cross-sectional area in the first longitudinal portion L.sub.1 of the insulation element 4 according to the invention is derived from FIG. 2C. The insulation element 4 across the entire longitudinal extent of the electrical cable 1 has a substantially constant external diameter D.sub.1. As is derived from FIG. 2E, this external diameter D.sub.1 of the insulation element 4 is enlarged in relation to the internal diameter D.sub.2 in the first plug connector portion S.sub.1 of the outer conductor contact element 14. It is thus not possible for the prefabricated electrical cable 1 according to FIG. 2C to be inserted into the outer conductor contact element 14 of the plug connector 15.

(57) A reduction of the cross-sectional area in the first longitudinal portion L.sub.1 of the insulation element 4 in the context of reducing the external diameter in the first longitudinal portion L.sub.1 of the insulation element 4 from the larger external diameter D.sub.1 to the smaller external diameter D.sub.2 according to FIG. 2D, makes it possible for the first longitudinal portion L.sub.1 of the insulation element 4 to be inserted in a calibrated manner into the first plug connector portion S.sub.1 of the outer conductor contact element 14, according to FIG. 2E.

(58) In a second embodiment of a prefabricated electrical cable 1 according to the invention the original external diameter of the insulation element 4 is likewise enlarged in relation to the internal diameter of the outer connector contact element 14. In this case too, it is not possible for the prefabricated electrical cable 1, in particular the first longitudinal portion L.sub.1 of the insulation element 4, to be inserted into the first plug connector portion S.sub.1 of the outer conductor contact element 14. According to the invention, the cross-sectional area of the insulation element 4 within the first longitudinal portion L.sub.1 here is likewise reduced in relation to the cross-sectional area within the second longitudinal portion L.sub.2.

(59) To this end, according to FIGS. 3A and 3B, a plurality of recesses 18 which are distributed on the circumference of the first longitudinal portion L.sub.1 and extend in the longitudinal direction are shaped in the first longitudinal portion L.sub.1 of the insulation element 4 in a stamping process. These recesses 18 are in each case preferably configured as notches, in particular as V-shaped notches according to FIG. 4A. Moreover, U-shaped notches or notches having a different cross-sectional profile can also be used. The stamping ram 8.sub.1 and the stamping die 8.sub.2 each have a semi-cylindrical recess, the diameter of the latter corresponding to the original external diameter in the first longitudinal portion L.sub.1 of the insulation element 4. For configuring the notch-shaped recesses 18, webs 19 that run in each case in the longitudinal direction are configured on the internal circumference of the semi-cylindrical recesses of the stamping ram 8.sub.1 and of the stamping die 8.sub.2. These webs 19 each have a cross-sectional profile which corresponds to the cross-sectional profile of the notch-shaped recesses 18.

(60) A sharp-edged web 10 is likewise configured in each case on the cable-proximal end of the semi-cylindrical recesses of the stamping ram 8.sub.1 and of the stamping die 8.sub.2, said web 10 in the stamping process scoring a preferably fully circumferential groove 11 in the transition between the first longitudinal portion L.sub.1 and the second longitudinal portion L.sub.2. The sharp-edged web 10 prevents a disadvantageous displacement of the insulation material from the notch-shaped recesses 18 being formed in the first longitudinal portion L.sub.1 in the direction of the second longitudinal portion L.sub.2 of the insulation element 4 during the stamping process.

(61) The insulation material which in the stamping process is displaced from the notch-shaped recesses 18 in the first longitudinal portion L.sub.1 of the insulation element 4, is displaced in the actual direction toward the plug-proximal end of the prefabricated electrical cable 1. This insulation material displaced in the axial direction, in a manner analogous to the first embodiment of a prefabricated electrical cable 1, is removed in a cutting process by means of a cutting apparatus 13 according to FIGS. 1E and 1F.

(62) In a further fabrication step, the electrical cable 1 is inserted into the plug connector 15. The notch-shaped recesses 18 in the first longitudinal portion L.sub.1 of the insulation element 4 here are compressed when being inserted into the first plug connector portion S.sub.1 of the outer conductor contact element 14, so that the original external diameter of the first longitudinal portion L.sub.1 of the insulation element 4 in the inserted state is adapted to the smaller internal diameter D.sub.2 of the outer conductor contact element 14. This reduction of the external diameter in the first longitudinal portion L.sub.1 of the insulation element 4 is caused by closing the notch-shaped recesses 18.

(63) The cross-sectional profile of the substantial component parts of the second embodiment of the prefabricated electrical cable 1 according to the invention is in each case schematically illustrated, i.e. not true to scale, in the individual fabrication steps in FIGS. 4A and 4B:

(64) A cross-sectional profile of the second embodiment of a prefabricated electrical cable 1 in which a plurality of notch-shaped recesses 18 are configured so as to be distributed on the circumference of the first longitudinal portion after the stamping process can be seen in FIG. 4A. The external diameter D.sub.1 in the first longitudinal portion L.sub.1 of the insulation element 4 after the stamping process corresponds to the external diameter D.sub.1 before the stamping process and is unmodified in relation to the external diameter in the second longitudinal portion L.sub.2 of the insulation element 4.

(65) The cross-sectional profile of the electrical cable 1 inserted into the outer conductor contact element 14 can be seen in FIG. 4B. The external diameter D.sub.1 in the first longitudinal portion L.sub.1 of the insulation element 4 corresponds to the reduced internal diameter D.sub.1 of the outer conductor contact element 14. As a result of the reduction of the external diameter in the first longitudinal portion L.sub.1 of the insulation element 4, the individual notch-shaped recesses 18 are closed. In FIG. 4B this is schematically illustrated by the dashes provided at the respective locations of the insulation element 4.

(66) In a third embodiment of a prefabricated electrical cable 1 according to the invention the external diameter of the insulation element 4 is reduced in relation to the internal diameter of the outer conductor contact element 14 in the first plug connector portion S.sub.1. In this case, it is possible for the prefabricated electrical cable 1 to be inserted into the outer conductor contact element 14 of the plug connector 15. However, a layer of air is situated between the first longitudinal portion L.sub.1 of the insulation element 4 and the first plug connector portion S.sub.1 of the outer conductor contact element 14. The radial extent of the electrical cable 4 is not adapted or calibrated, respectively, to the radial internal extent of the plug connector 15.

(67) With a view to calibrating, according to the invention the cross-sectional area of the insulation element 4 within the first longitudinal portion L.sub.1 here is enlarged in relation to the cross-sectional area within the second longitudinal portion L.sub.2.

(68) To this end, the first longitudinal portion L.sub.1 of the insulation element 4 in the prefabricated electrical cable 1 in terms of the cross-sectional area thereof is deformed in a stamping process using a stamping installation 8. The stamping installation 8 in this case, according to FIG. 5A, comprises a stamping ram 8.sub.1 and a stamping die 8.sub.2 which are in each case disposed or movable, respectively, radially in relation to the first longitudinal portion L.sub.1 of the insulation element 4, and a stamping ram 8.sub.3 which is movable axially in relation to the first longitudinal portion L.sub.1 of the insulation element 4.

(69) The radially movable stamping ram 8.sub.1 and stamping die 8.sub.2 each have a semi-cylindrical recess, said recesses being in each case disposed opposite one another and in the stamping process according to FIG. 5B forming a common fully cylindrical recess into which the first longitudinal portion L.sub.1 of the insulation element 4 is inserted. The internal diameter of the two semi-cylindrical recesses, or of the common fully cylindrical recess, respectively, is larger than the original external diameter of the first longitudinal portion L.sub.1 of the insulation element 4 before the stamping process, as can be seen in FIG. 5B. The internal diameter of the semi-cylindrical recesses of the radially movable stamping ram 8.sub.1 and of the stamping die 8.sub.2 corresponds to the external diameter of the first longitudinal portion L.sub.1 of the insulation element 4 after the stamping process according to FIGS. 5D and 5E.

(70) A sharp-edged web 10 which in the stamping process scores a preferably fully circumferential groove 11 in the transition between the first longitudinal portion L.sub.1 and the second longitudinal portion L.sub.2 is likewise in each case configured on the cable-proximal end of the semi-cylindrical recesses of the radially movable stamping ram 8.sub.1 and of the stamping die 8.sub.2. The sharp-edged web 10 prevents a disadvantageous displacement of the insulation material from the first longitudinal portion L.sub.1 in the direction of the second longitudinal portion L.sub.2 of the insulation element 4 during the stamping process.

(71) In a first step of the stamping process, the radially movable stamping ram 8.sub.1 and the stamping die 8.sub.2 are converged according to FIG. 5B and by way of the two semi-cylindrical recesses thereof form in each case a common fully cylindrical recess. The first longitudinal portion L.sub.1 of the insulation element 4 is concentrically inserted into and positioned in this fully cylindrical recess of the stamping installation 8. The concentric positioning of the first longitudinal portion L.sub.1 of the insulation element 4 within the common fully cylindrical recess of the radially movable stamping ram 8.sub.1 and of the stamping die 8.sub.2 is a substantial precondition for the concentricity between the inner conductor 3 and the completely stamped first longitudinal portion L.sub.1 of the insulation element 4.

(72) In a second step of the stamping process according to FIG. 5C, the axially movable stamping ram 8.sub.3 is pressed against the end face of the first longitudinal portion L.sub.1 of the insulation element 4. As a result of this axial compression of the insulation element 4, the first longitudinal portion L.sub.1 of the insulation element 4 is compressed, and the external diameter of the first longitudinal portion L.sub.1 is enlarged in this way. The external diameter of the first longitudinal portion L.sub.1 in the second step of the stamping process is enlarged to the size of the internal diameter of the common fully cylindrical recess of the radially movable stamping ram 8.sub.1 and of the stamping die 8.sub.2.

(73) The first longitudinal portion L.sub.1 of the insulation element 4 and the inner conductor 3 enclosed therein thus fill the entire interior of the fully cylindrical recess of the stamping installation 8, as can be seen from FIG. 5D. As can be seen in FIG. 5E, the external diameter in the first longitudinal portion L.sub.1 of the insulation element 4 at the end of the stamping process is enlarged in relation to the external diameter in the second longitudinal portion L.sub.2 of the insulation element 4. The external diameter in the first longitudinal portion L.sub.1 of the insulation element 4 at the end of the stamping process corresponds to the internal diameter in the first plug connector portion S.sub.1 of the outer conductor contact element 14.

(74) The cross-sectional profile of the substantial component parts of the third embodiment of the prefabricated electrical cable 1 according to the invention is in each case schematically illustrated, i.e. not true to scale, in the individual fabrication steps in FIGS. 6A and 6B:

(75) The cross-sectional profile of a prefabricated electrical cable 1 before the stamping process is derived from FIG. 6A. The original external diameter D.sub.1 of the first longitudinal portion L.sub.1 of the insulation element 4 corresponds to the external diameter D.sub.1 of the second longitudinal portion L.sub.2 of the insulation element 4 and is smaller than the internal diameter D.sub.2 of the first plug connector portion S.sub.1 of the outer conductor contact element 14. As a result of the stamping process according to FIG. 6B, the diameter of the first longitudinal portion L.sub.1 of the insulation element 4 is compressed from the smaller diameter D.sub.1 to the larger diameter D.sub.2, thus enabling the first longitudinal portion L.sub.1 of the insulation element 4 to be inserted in a calibrated manner into the first plug connector portion S.sub.1 of the outer conductor contact element 14.

(76) A plug connector assembly 100 is illustrated in the lateral view and in a cross-sectional illustration in FIGS. 7A and 7B:

(77) The cross-sectional illustration is situated in the second plug connector portion S.sub.2 of the plug connector 15 (cf, FIG. 2B) which preferably adjoins the first plug connector portion S.sub.1. In this second plug connector portion S.sub.2 an insulation element 4 is inserted within the outer conductor contact element 14, said insulation element 4 not fully filling the region between the outer conductor contact element 14 and the inner conductor contact element 16.

(78) To this end, the insulation element 4 across the entire extent of the second plug connector portion S.sub.2 has in each case at least one recess 22 (a total of two recesses 22 in the illustration of FIG. 7B). This at least one recess 22 is in each case designed on the sheath-proximal circumference of the insulation element 4, thus forming in each case a cavity between the outer conductor contact element 14 and the inner conductor contact element 16, said cavity being filled with air. As is known, the permittivity of air is one, while the permittivity of the dielectric material of the insulation element 4 is typically more than one. This results in an effective permittivity as a combination of the two dielectric materials in the second plug connector portion S.sub.2 that is less than the permittivity of an insulation element 4 that completely fills the intermediate space between the outer conductor contact element 14 and the inner conductor contact element 16. In this way, the longitudinal portion L.sub.4, when the insulation element 4 is designed with at least one recess 22, has a transmission characteristic which is more inductive than a fully cylindrically designed insulation element 4 that completely fills the intermediate region between the outer conductor contact element 14 and the inner conductor contact element 16. In this way, a capacitive discontinuity in the electrical cable 1 having an insulation element 4 designed in such a manner can be compensated for by virtue of an abrupt reduction of the cross-sectional area, and a signal transmission distance adapted to the impedance can be implemented across the entire longitudinal extent of the plug connector assembly 100.

(79) Finally, a further, very particularly advantageous, method for reducing the cross-sectional area in the first longitudinal portion L.sub.1 of the insulation element 4 is described by means of FIGS. 8A to 8C. FIG. 8A shows an insulation element 4 which is not yet been machined; FIG. 8B shows the machining of the insulation element 4; and FIG. 8C shows the completely machined insulation element 4.

(80) The processing installation 21 can have the separation tool 23 illustrated, the latter preferably having two shaped knives 24 that are adapted to the provided cross-sectional area of the first longitudinal portion L.sub.1. The shaped knives 24 are disposed so as to be mutually opposite and are actuatable toward one another (cf. arrows in FIG. 8A) so as to score the insulation element 4 in the radial direction down to the provided depth.

(81) A relative axial movement between the separation tool 23 and the cable 1 can subsequently be initiated, while the separation tool 23 is still situated within the insulation element 4, for example by a linear displacement of the separation tool 23, as is indicated in FIG. 8B. In this way, the excess insulation layer 25 to be removed can be peeled or scraped, respectively, from the remaining insulation element 4. The excess insulation layer 25 here can initially be pushed along in the manner of a bead in front of the shaped knives 24 until said bead reaches the end of the cable. This process can be advantageously facilitated by heating the insulation element 4, in particular when the separation tool 23, or the shaped knives 24 thereof, respectively, is/are heated. As a result thereof, the insulation layer 25 can become softer and thus easier to strip.

(82) The insulation layer 25 which is displaced by the separation tool 23, in a manner analogous to the first embodiment, can be removed by means of a cutting apparatus in a cutting process, if required.

(83) The exemplary embodiment of the invention described in FIGS. 8A to 8C can in principle be combined in an arbitrary manner with the exemplary embodiments, variants and refinements of the invention already described above. For example, in the case of a corresponding design embodiment of the blades of the shaped knives 24, it can also be provided, alternatively or additionally to removing the sleeve-shaped insulation layer 25, that a groove 11 and/or recesses 18 is/are incorporated in the insulation element 4 by the shaped knives 24.

(84) While the present invention has been completely described above by means of preferred exemplary embodiments, said invention is not limited thereto but can be modified in various ways.

Operation

(85) Having described the structure of my metallic plug connector component, and method and device for producing a metallic plug connector component, its operation is briefly described.

(86) A principal object of the present invention is a plug connector assembly (100), comprising: a prefabricated electrical cable (1); and a plug connector (15) having an outer conductor contact element (14) that defines a first plug connector portion (S.sub.1), and the plug connector (15) is connected to at least one cable end of the prefabricated electrical cable (1); and the prefabricated electrical cable (1), has an outer conductor shield (5) and an insulation element (4), and wherein the insulation element (4) has a first longitudinal portion (L.sub.1) in which the insulation element (4) is laid bare from the outer conductor shield (5), and the insulation element (4) has a second longitudinal portion (L.sub.2) which adjoins the first longitudinal portion (L.sub.1) and in which the insulation element (4) is enclosed by the outer conductor shield (5), and wherein a cross-sectional area of the insulation element (4) in the first longitudinal portion (L.sub.1) in relation to a cross-sectional area of the insulation element (4) in the second longitudinal portion (L.sub.2) is modified in such a manner that the first longitudinal portion (L.sub.1) is insertable into the first plug connector portion (S.sub.1) of the outer conductor contact element (14) of the plug connector (15), and the insulation element (4) is calibrated to the outer conductor contact element (14) in the first longitudinal portion (L.sub.1); and wherein the first longitudinal portion (L.sub.1) of the insulation element (4) is inserted into the first plug connector portion (S.sub.1).

(87) A further object of the invention is a plug connector assembly (100) and wherein an external diameter of the second longitudinal portion (L.sub.2) of the insulation element (4) differs from an internal diameter of the first plug connector portion (S.sub.1) of the outer conductor contact element (14).

(88) A further object of the invention is a plug connector assembly (100) and wherein within the first longitudinal portion (L.sub.1) and the first plug connector portion (S.sub.1) a region between the outer conductor contact element (14) and an inner conductor (3) of the prefabricated electrical cable (1) is completely filled by the insulation element (4).

(89) A further object of the invention is a plug connector assembly (100) and wherein the insulation element (4) defines a preferably fully circumferential groove (11) in a transition between the first longitudinal portion (L.sub.1) and the second longitudinal portion (L.sub.2).

(90) A further object of the invention is a plug connector assembly (100) and wherein the cross-sectional area of the insulation element (4) in the entire first longitudinal portion (L.sub.1) is constant, and is reduced in size in relation to the cross-sectional area of the insulation element (4) in the second longitudinal portion (L.sub.2).

(91) A further object of the invention is a plug connector assembly (100) and wherein an external diameter of the insulation element (4) along the entire first longitudinal portion (L.sub.1) is constant and is reduced in diameter in relation to an external diameter of the insulation element (4) in the second longitudinal portion (L.sub.2).

(92) A further object of the invention is a plug connector assembly (100) and wherein at least one recess (18), is configured on a circumference of the insulation element (4), said at least one recess (18) in the longitudinal direction extending in each case, across the entire first longitudinal portion (L.sub.1).

(93) A further object of the invention is a plug connector assembly (100) and wherein an external diameter of the insulation element (4) in the entire first longitudinal portion (L.sub.1) is constant and is enlarged in diameter in relation to an external diameter of the insulation element (4) in the second longitudinal portion (L.sub.2).

(94) A further object of the invention is a plug connector assembly (100) and further comprising a chamfer on the insulation element (4) on a plug-proximal end of the first longitudinal portion (L.sub.1).

(95) A further object of the invention is a plug connector assembly (100) and wherein the outer conductor contact element (14) of the plug connector (15), has at least one dielectric material for compensation of a change in impedance between the first longitudinal portion (L.sub.1) and the second longitudinal portion (L.sub.2) and the at least one dielectric is situated in a second plug connector portion (S.sub.2) that adjoins the first plug connector portion (S.sub.1).

(96) A further object of the invention is a method for fabricating an electrical cable (1) comprising the steps:providing an electrical cable (1) that has an insulation element (4) in a first longitudinal portion (L.sub.1); laying bare the insulation element (4) from an outer conductor shield (5) of the electrical cable (1), whereby a cross-sectional area of the insulation element (4) in the first longitudinal portion (L.sub.1) in relation to a cross-sectional area of the insulation element (4) in a second longitudinal portion (L.sub.2) that adjoins the first longitudinal portion (L.sub.1) is modified; and providing a plug connector (15) that has an outer conductor contact element (14) that defines a first plug connector portion (S.sub.1); and inserting a cable end of the electrical cable (1) into the outer conductor contact element (14) of the plug connector (15); and connecting the inserted electrical cable (1) to the outer conductor contact element (14); and wherein the cross-sectional area of the first longitudinal portion (L.sub.1) in relation to the cross-sectional area of the second longitudinal portion (L.sub.2) is modified in such a manner that the first longitudinal portion (L.sub.1) is insertable into the first plug connector portion (S.sub.1) of the outer conductor contact element (14) of the plug connector (15); and in the first longitudinal portion (L.sub.1) the insulation element (4) is calibrated to the outer conductor contact element (14).

(97) A further object of the invention is a method for fabricating an electrical cable (1) and wherein the modification of the cross-sectional area in the first longitudinal portion (L.sub.1) takes place by means of compressing the first longitudinal portion (L.sub.1).

(98) A further object of the invention is a method for fabricating an electrical cable (1) and wherein the modification of the cross-sectional area in the first longitudinal portion (L.sub.1) takes place by means of swaging the first longitudinal portion (L.sub.1) in a forming process, preferably in a stamping or hot-stamping process.

(99) A further object of the invention is a method for fabricating an electrical cable (1) and wherein the modification of the cross-sectional area in the first longitudinal portion (L.sub.1) of the insulation element (4) is by means of a separation tool (23) that scores the insulation element (4) in a radial direction, and whereupon the separation tool (23) while in the radial cutting position is moved axially relative to the insulation element (4), and in a direction toward the cable end, so as to peel away an insulation layer (25) from the insulation element (4).

(100) A further object of the invention is a method for fabricating an electrical cable (1) and wherein the separation tool (23) has at least one shaped knife (24) that is adapted to the shape of the provided cross-sectional area of the first longitudinal portion (L.sub.1) and actuatable toward the insulation element (4).

(101) A further object of the invention is a method for fabricating an electrical cable (1) and wherein the insulation material (4), at least in the first longitudinal portion (L.sub.1), is heated immediately prior to and/or during the modification of the cross-sectional area.

(102) A further object of the invention is a method for fabricating an electrical cable (1) and wherein the separation tool (23) is heated, preferably to an operating temperature between approximately 50 C. and 250 C.

(103) A further object of the invention is a method for fabricating an electrical cable (1) and wherein in parallel to the modification of the cross-sectional area in the first longitudinal portion (L.sub.1), a sharp-edged web (10) of a stamping installation (8) is scored into the insulation element (4) in a preferably fully circumferential groove (11) in a transition between the first longitudinal portion (L.sub.1) and the second longitudinal portion (L.sub.2).

(104) A further object of the invention is a method for fabricating an electrical cable (1) and wherein the modification of the cross-sectional area in the first longitudinal portion (L.sub.1) takes place by means of a separation process, preferably by a laser, photon, electron or ion beam, or a water jet.

(105) A further object of the invention is an apparatus for fabrication of an electrical cable (1), comprising a processing installation (21) for modifying a cross-sectional area of the electrical cable (1) in a first longitudinal portion (L.sub.1) of an insulation element (4) of the electrical cable (1) that has been laid bare from an outer conductor shield (5); and a joining installation (20) for inserting the electrical cable (1) into an outer conductor contact element (14) of a plug connector (15); and wherein, the processing installation (21) modifies a cross-sectional area of the insulation element (4) of the electrical cable (1) in the first longitudinal portion (L.sub.1) in such a manner that the first longitudinal portion (L.sub.1) is insertable into a first plug connector portion (S.sub.1) of the outer conductor contact element (14); and wherein the first longitudinal portion (L.sub.1) the insulation element (4) is calibrated to the outer conductor contact element (14).

(106) A still further object of the invention is a method for fabricating an electrical cable (1) as claimed in claim 15 and wherein the separation tool (23) has at least two shaped knifes (24) that are adapted to the shape of the provided cross-sectional area of the first longitudinal portion (L.sub.1) of the insulation element (4) and the two shaped knives (24) are actuatable toward one another.

(107) An even still further object of the invention is a method for fabricating an electrical cable (1) as claimed in claim 15 and wherein the separation tool (23) is heated, preferably to an operating temperature between approximately between 170 C. and 200 C.

(108) 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 Equivalents.