WIRING HARNESS PLUG CONNECTOR

Abstract

A wiring harness plug connector. The wiring harness plug connector encompasses a contact carrier and at least one electrical lead. The contact carrier has at least one passthrough conduit for the at least one electrical lead. The at least one electrical lead is passed through the passthrough conduit in an insertion direction. The contact carrier has, in front of the at least one passthrough conduit when viewed in the insertion direction, a partition that surrounds a sealing space. Provision is made that the sealing space is filled with a sealant in such a way, and that the sealant at least locally fills up the at least one passthrough conduit in such a way, that the at least one electrical lead is surrounded in fluid-tight fashion.

Claims

1. A wiring harness plug connector, comprising: a contact carrier; at least one electrical lead, the contact carrier having at least one passthrough conduit for the at least one electrical lead, the at least one electrical lead being passed through the passthrough conduit in an insertion direction, the contact carrier having, in front of the at least one passthrough conduit when viewed in the insertion direction, a partition that surrounds a sealing space, wherein the sealing space is filled with a sealant in such a way, and the sealant at least locally fills up the at least one passthrough conduit in such a way, that the at least one electrical lead is surrounded in fluid-tight fashion.

2. The wiring harness plug connector as recited in claim 1, wherein the sealing space is contiguous with an external environment of the wiring harness plug connector.

3. The wiring harness plug connector as recited in claim 1, wherein the sealant is constituted from a material that is liquid in a first state and can be converted permanently into a second, non-fluid state in such a way that in the second state it can no longer flow into the at least one passthrough conduit.

4. The wiring harness plug connector as recited in claim 1, wherein the sealant is constituted from an elastomer, the sealant encompassing silicone.

5. The wiring harness plug connector as recited in claim 1, further comprising: a locking element that is slidable into the wiring harness plug connector transversely to the insertion direction, the locking element being embodied in such a way that in the slid-in state it prevents a contact element, connected to the at least one electrical lead, from being removed from the contact carrier oppositely to the insertion direction, the locking element having a base element and at least two self-supporting arms spaced apart from one another and protruding transversely from the base element, the at least two arms each having at least one sealing lip, the sealing lips of adjacent arms facing toward one another and being configured in such a way that an interstice between the adjacent arms is at least 80% closed.

6. The wiring harness plug connected as recited in claim 5, wherein the interstice is at least 90% closed.

7. The wiring harness plug connector as recited in claim 5, wherein the at least one sealing lip has a profile along its self-supporting end that faces away from the arm, the profile being embodied complementarily to an outer contour of the at least one electrical lead that is surrounded by the sealing lip when the locking element is in an inserted state.

8. The wiring harness plug connector as recited in claim 5, wherein the at least one sealing lip is fastened on the arm displaceably, transversely to the extension direction of the arm, with respect to the associated arm.

9. A method for manufacturing a fluid-tight wiring harness plug connector, the wiring harness plug connector having a contact carrier, the contact carrier having at least one passthrough conduit for passage of at least one electrical lead, the contact carrier having, in front of the at least one passthrough conduit when viewed in an insertion direction, a partition that surrounds a sealing space, the method comprising: furnishing the contact carrier; introducing at least one electrical lead, in the insertion direction, through the sealing space and through the at least passthrough conduit; introducing an auxiliary element into the wiring harness plug connector, the auxiliary element sealing the at least one passthrough conduit at least locally in such a way that penetration of a liquid sealant from the passthrough conduit into portions downstream from the auxiliary element is prevented; introducing a liquid sealant into the sealing space; and curing the sealant.

10. The method as recited in claim 9, wherein the auxiliary element has a base element and at least two self-supporting arms spaced apart from one another and protruding transversely from the base element, the at least two arms each having at least one sealing lip, the sealing lips of adjacent arms facing toward one another and being configured in such a way that an interstice between the adjacent arms is at least 80% closed.

11. The method as recited in claim 10, wherein the interstice is at least 90% closed.

12. The method as recited in claim 9, wherein the auxiliary element is removed from the wiring harness plug connector after the step of curing the sealant, a locking element then being inserted into the wiring harness plug connector, the locking element being embodied in such a way that in the slid-in state it prevents the removal, oppositely to the insertion direction, of a contact element connected to the at least one electrical lead.

13. The method as recited in claim 9, wherein the auxiliary element acts as a locking element and is embodied in such a way that in the slid-in state it prevents the removal, oppositely to the insertion direction, of a contact element connected to the at least one electrical lead.

14. An auxiliary element for insertion into a wiring harness plug connector and suitable for preventing the removal of a contact element that is connected to an electrical lead and is slid into the wiring harness plug connector, the auxiliary element having a base element and at least two self-supporting arms spaced apart from one another and protruding transversely from the base element, the at least two arms each having at least one sealing lip, the sealing lips of adjacent arms facing toward one another and being configured in such a way that an interstice between adjacent arms is at least 80% closed.

15. The auxiliary element as recited in claim 14, wherein the interstice is at least 90% closed.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0051] Further features and advantages of the present invention are described below with reference to exemplifying embodiments and the figures, and that are nevertheless not to be construed as limiting the present invention.

[0052] FIG. 1a is a perspective view of a wiring harness plug connector.

[0053] FIG. 1b is a perspective view of a contact carrier of a wiring harness plug connector.

[0054] FIG. 2 is a cross section through a wiring harness plug connector.

[0055] FIG. 3a is a plan view, from an insertion direction, of an auxiliary element or locking element, according to an embodiment.

[0056] FIG. 3b is a cross section through a passthrough conduit and an auxiliary element or locking element according to FIG. 3a.

[0057] FIG. 4a is a plan view, from an insertion direction, of an auxiliary element or locking element, according to a further embodiment.

[0058] FIG. 4b is a cross section through a passthrough conduit and an auxiliary element or locking element according to FIG. 4a.

[0059] FIG. 5a is a plan view, from an insertion direction, of an auxiliary element or locking element, according to a further embodiment.

[0060] FIG. 5b is a cross section through a passthrough conduit and an auxiliary element or locking element according to FIG. 5a.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

[0061] FIG. 1a shows a plug connector system 9 that encompasses two wiring harness plug connectors 1 and a multipoint connector 90. The two wiring harness plug connectors 1 can be embodied physically identically as depicted in the exemplifying embodiment. In the assembled system they are placed onto multipoint connector 90 and locked to the multipoint connector. Wiring harness plug connectors 1 depicted by way of example each have a contact carrier 2 in whose wall is embodied an opening 8 for introducing or sliding in a locking element 30 or auxiliary element 10 transversely to an insertion direction E for electrical leads 4 (FIGS. 2 to 5). Wiring harness plug connectors 1 can each have a lever element 80 with which insertion of wiring harness plug connectors 1 onto multipoint connector 90 can be carried out with less energy expenditure.

[0062] FIG. 1b shows a contact carrier 2 of wiring harness plug connector 1. In the exemplifying embodiment depicted, contact carrier 2 is embodied in two parts and encompasses an upper contact carrier part 2a as well as a lower contact carrier part 2b connectable to upper contact carrier part 2a. In alternative embodiments, contact carrier 2 can also be embodied as a single part. In the exemplifying embodiment depicted, upper contact carrier part 2a has a plurality of passthrough conduits 4 through which electrical leads 4 (FIG. 2) can be passed through in insertion direction E. Typically, at least one electrical lead 4 can be passed through into each passthrough conduit. In the exemplifying embodiment depicted, lower contact carrier part 2b has an associated receiving chamber (no reference character) for each passthrough conduit 3. A respective contact element 40 can be received in each of these receiving chambers and latched therein. Typically, each contact element 40 is mechanically and electrically connected to one electrical lead 4.

[0063] In order to prevent withdrawal of contact elements 40 from the receiving chambers of lower contact carrier part 2b in addition to the latching effect, a locking element 30 can, for example, be slid transversely to insertion direction E into opening 8 of upper contact carrier part 2a. The latching or primary latching of the at least one contact element 40 can be brought about, for example, by way of at least one latching tip 41 on contact element 40, and an undercut on lower contact carrier part 2b.

[0064] In order to achieve locking between the receiving chamber and passthrough conduit 4 of contact carrier 2, viewed in the insertion direction, locking element 30 can be slid in or introduced or inserted in such a way that contact element 40 is positively prevented from moving out of contact carrier 2 oppositely from insertion direction E. Parts of the locking element can project at least partly into passthrough conduits 4, viewed transversely to insertion direction E, and thereby prevent contact elements 40 from moving out.

[0065] Contact carrier 2 (upper contact carrier part 2a in the exemplifying embodiment depicted) has on its frontmost portion in terms of insertion direction E (at the top in the Figure) a partition 6 that completely surrounds passthrough conduits 4. The partition is closed in fluid-tight fashion. The partition thus surrounds a sealing space 7. Sealing space 7 has a floor that is perforated by passthrough conduits 4. Without the openings of passthrough conduits 4, sealing space 7 along with partition would be closed off in cup-shaped fashion.

[0066] FIG. 2 is a cross section through contact carrier 2 of FIG. 1b, populated with electrical leads 4 and electrical contacts 40 or contact elements 40 fastened thereto. A sealant 5, for example an elastomer, e.g. silicone, is fed into sealing space 7. Sealant 5 extends out of sealing space 7, downward as viewed in FIG. 2, into passthrough conduits 3. Sealing agent 5 thus substantially completely surrounds electrical leads 4, and thus seals electrical leads 4 and contact elements 40 with respect to penetration of fluid media from external environment 50 of plug connector 1, not only in sealing space 7. It instead also surrounds electrical leads 4 in a fluid-tight manner, at least locally in passthrough conduits 3. The corresponding portion in passthrough conduits 3, in which sealant 5 extends, extends in insertion direction E, viewed from the floor of sealing space 7, as far as the plane in which opening 8, for introducing auxiliary element 10 or locking element 30, is disposed. As illustrated in FIG. 2, the sealant thus extends from auxiliary element 10 or locking element 30 into passthrough conduits 3, upward to the floor of sealing space 7. A very advantageous sealing effect is thereby produced by sealant 5; specifically, the positive properties of a sealing mat and of a single-wire seal are combined. The properties of a sealing mat are achieved by way of sealant 5 in sealing space 7. The properties of a single-wire seal are achieved by way of sealant 5 extending into passthrough conduits 3. It is understood that in the embodiment presented, passthrough conduits 3 in which an electrical lead 4 is not present can also be filled with sealant 5.

[0067] This highly efficient fluid-tight sealing of wiring harness plug connector 1 can be brought about as follows: [0068] firstly, in a first step, contact carrier 2 (here encompassing upper contact carrier part 2a and lower contact carrier part 2b) is furnished; [0069] in a further step, contact elements 40 and electrical leads 4 fastened thereonto are introduced into the receiving chambers through passthrough openings 3 of contact carrier 2 (in this case, through upper contact carrier part 2a and lower contact carrier part 2b). Contact elements 40 then latch into receiving chambers of contact carrier 2, for example by way of latching tips 41 fastened on contact elements 40; [0070] in a further step, either auxiliary element 10 or in fact locking element 30 is inserted into contact carrier 2, transversely to insertion direction E, through opening 8 of contact carrier 2. Auxiliary element 10 or locking element 30 is embodied in such a way that it seals off the upper (in the Figure) portions of passthrough conduits 3 (i.e. the portions located upstream) in fluid-tight fashion with respect to the receiving chambers or with respect to those portions of passthrough conduits 4 [sic; 3] which are located downstream from auxiliary element 10 or locking element 30; [0071] in a further step, a liquid sealant 5 (first state of the sealant), which e.g. contains an elastomer or can encompass silicone, is then fed into sealing space 7; the liquid sealant 5 is also distributed into those portions of passthrough conduits 3 which are located above auxiliary element 10 or locking element 30; [0072] in a further step, sealant 5 is cured (conversion into the second state of sealant 5) so that it can no longer flow. Curing can be brought about, for example, by a temporary temperature elevation or, for example, by contact with air or oxygen.

[0073] After this last step the seal has been produced. The seal is particularly effective if sealant 5 enters into in an intermaterial join with partition 6 and/or with electrical leads 4 and/or with the walls of passthrough conduits 3. Fluid media (gases or liquids) from external environment 50 of wiring harness plug connector 1 thus can no longer penetrate into the interior of wiring harness plug connector 1 (at the bottom in the illustration).

[0074] When an auxiliary element 10 is used, that auxiliary element 10 is removed from opening 8 after curing. A locking element 30 can then be used, instead of auxiliary element 10, in order to prevent contact elements 40 from moving out of the receiving chambers oppositely to insertion direction E. Alternatively, auxiliary element 10 can already be embodied as locking element 30 and can prevent contact elements 40 from moving out of contact carrier 2 oppositely to insertion direction E, for example by positive engagement with contact elements 40.

[0075] FIG. 2 furthermore depicts a radial seal 20, on the outer periphery of upper contact carrier part 2a, that can interact with a housing of multipoint connector 90 in such a way that fluid media also cannot penetrate from external environment 50 of wiring harness plug connector 1 laterally through plug connector system 9 into the interior of wiring harness plug connector 1.

[0076] Sealing space 7 is contiguous with an external environment of wiring harness plug connector 1.

[0077] It is to be understood that wiring harness plug connector 1 can also have, for example, only a single passthrough opening 3 for introduction of a single electrical lead 4 having a single contact element 40 mounted thereon.

[0078] FIG. 3a is a plan view, looking in insertion direction E, of an auxiliary element 10 or a locking element 30 in accordance with an embodiment of the invention. Insertion direction E is directed into the plane of the drawing. Auxiliary element 10 or locking element 30 encompasses a base element 11 and at least two self-supporting arms 12 spaced apart from one another and protruding transversely from the base element 11. In this exemplifying embodiment arms 12 protrude from base element 11 substantially vertically in an extension direction A. When locking element 30 is in the inserted state, extension direction A of arms 12 extends substantially perpendicularly to insertion direction E of contact elements 40 or of electrical leads 4. In the exemplifying embodiment depicted, a plurality of four arms 12 are disposed, by way of example, on base element 11. Auxiliary element 10 or locking element 30 thus has a comb-like structure, base element 11 representing the shaft of the comb and arms 12 the teeth of the comb. Arms 12 each have at least one sealing lip 16. Sealing lips 16 are disposed on arms 12 in such a way that sealing lips 16 of respectively adjacent arms 12 face toward one another and are configured in such a way that an interstice 14 between adjacent arms 12 is at least 80%, particularly preferably at least 90%, closed off. In the exemplifying embodiment depicted, sealing lips 16 of adjacent arms overlap in such a way that interstice 14 is completely closed off.

[0079] Base element 11 and arms 12 can be constituted, for example, from a first material that is relatively stiff or solid and cannot easily be deformed. For example, the first material can encompass polyamide (PA); it can also be glass fiber-reinforced (GFR), e.g. PA66 GF35. In contrast thereto, sealing lips 16 can be constituted from a soft, elastic second material that particularly effectively envelops or elastically surrounds electrical leads 4 passing through between sealing lips 16 and nevertheless produces a seal with respect to the liquid sealant 5. The second material can encompass, for example, rubber, silicone, silicone rubber, or other elastomers. The second material can encompass, for example, a two-component silicone. Sealing lips 16 can be injection-molded onto arms 12 or can be fastened onto arms by way of an adhesive join or welded join.

[0080] Electrical leads 4 can pass through into interstices 14. In other words, when auxiliary element 10 or locking element 30 is in the inserted state, the passthrough conduits can arrive at interstices 14 when viewed along the insertion direction.

[0081] FIG. 3b is a cross section through contact carrier 2, depicting an electrical lead 4 having a contact element 40 disposed thereon. Contact element 40 encompasses two latching tips 41 with which contact element 40 can latch into undercuts of contact carrier 2. Depicted farther up in the illustration (i.e. upstream from latching tips 41 viewed in insertion direction E) are two arms 12 of locking element 30 or of auxiliary element 10, and sealing lips 16 disposed thereon. Extension direction A now points into the plane of the drawing. Sealing lips 16 extend from arms 12, respectively inward toward electrical lead 4. Sealing lips 16 abut tightly against electrical lead 4; surround it, for example, elastically like a collar; and thus seal off the portion above sealing lips 16 in the illustration (upstream from sealing lips 16) with respect to a portion below sealing lips 16 in the illustration (downstream from sealing lips 16). The liquid sealant 5, for example, can thus be fed into the portion above sealing lips 16. Sealant 5 then cannot penetrate into the portion below sealing lips 16. Sealant 5 can thus be cured without penetrating into the portion disposed downstream from sealing lips 16 (toward the bottom in the Figure). Upon introduction of the liquid sealant 5, contact carrier 2 is preferably aligned as depicted in FIGS. 2 and 3a, i.e. gravity is acting downward in the Figures in insertion direction E.

[0082] FIG. 4a shows a further embodiment of auxiliary element 10 or of locking element 30 in the same view as FIG. 3a; insertion direction E is thus directed into the plane of the drawing. In this exemplifying embodiment sealing lips 16 are embodied in such a way that their free ends 18 that project into interstice 14 do not overlap but instead abut against one another or at least approximately touch one another. In another embodiment, however, free ends 18 of sealing lips 16 can also overlap. Sealing lips 16 also have in particular on their free ends 18, however, a profiling 19 or profile such that a cutout 19 is provided for each passthrough conduit 3 or for each electrical lead 4. In other words, instead of a, for example, linear or straight conformation of free end 18 of the respective sealing lips 16, sealing lip 16 is recessed toward the relevant arm 12 at those points at which sealing lip 16 surrounds an electrical lead 4. Sealing lip 16 coming from the respective other side likewise exhibits a cutout or profile 19 of this kind. The result is that a particularly advantageous sealing effect can result when auxiliary element 10 or locking element 30 is slid into opening 8 of contact carrier 2. The reason is that at those points at which an electrical lead 4 is disposed, the respective mutually facing sealing lips 16 can now tightly surround electrical lead 4 without being offset in insertion direction E or oppositely to insertion direction E.

[0083] FIG. 4b is a view like FIG. 3b, i.e. extension direction A of arms 12 is directed into the plane of the drawing. It is evident that sealing lips 16 surround the respective electrical lead 4 like a tight-fitting, for example elastic, collar. The sealing effect can thereby advantageously be improved.

[0084] FIG. 5a depicts a further embodiment of locking element 30 or of auxiliary element 10. The perspective of FIG. 5a is, as in FIG. 3a and FIG. 4a, a plan view in extension direction E. Auxiliary element 10 or locking element 30 of FIG. 5a has, in addition to base element 11 and arms 12 extending in extension direction A, sealing lips 16 displaceable relative to arms 12. The relative displacement of sealing lips 16 occurs, for example, in a direction that is perpendicular to insertion direction E and perpendicular to extension direction A. Sealing lips 16 can have at their free end 18 a profile as in the exemplifying embodiments of FIGS. 4a and 4b. A linear or straight profile can also be provided, however, as in the embodiment according to FIGS. 3a and 3b. Sealing lips 16 are displaceable relative to the arms, and in a first position can thereby, for example, leave interstice 14 almost completely open. In this first position, auxiliary element 10 or locking element 30 can be slid particularly easily into opening 8 of contact carrier 2. Once auxiliary element 10 or locking element 30 has been completely slid in, sealing lips 16 can then be caused to be displaced toward the respectively associated interstice 14 (i.e., respectively from left to right and from right to left in the Figure), for example by a movement of a slider 15a, 15b disposed on base element 11. They can thereby close off interstice 14, or interstice 14 is thereby closed off and sealed with respect to the passage of fluid media, for example sealant 5. Sealing lips 16 are thus displaceable from a first position in which interstice 14 is relatively wide (e.g. more than 40% open) into a second position. In the second position, interstice 14 between adjacent arms is relatively completely closed, for example involving more than 80% or even more than 90% of the interstice area.

[0085] FIG. 5b depicts a cross section in insertion direction E, analogously to FIGS. 3b and 4b. Extension direction A is directed into the plane of the drawing. Locking element 30 or auxiliary element 10 is, for example, completely slid in. Sealing lips 16 are displaced from the first position into the second position (i.e. into interstices 14), and in that second position almost completely close off interstices 14 between adjacent arms 12. Sealing lips 16 surround electrical leads 4, for example, elastically, in collar fashion, and tightly. The electrical leads are thereby sealed.

[0086] The proposed wiring harness plug connector can be utilized, for example, in the automotive sector for multiple-pole wiring harness plug connectors or plug connectors. Utilization in a single-pole plug connector system is also possible, however.