Prefabricated electrical cable, plug connector assembly, and method and apparatus for manufacturing an electrical cable
View Patent ↗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.
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 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 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 2 ) which adjoins the first longitudinal portion (L 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 1 ) is modified so that a diameter of the cross-sectional area of the insulation element ( 4 ) in the first longitudinal portion (L 1 ) is different from a diameter of the cross-sectional area of the insulation element ( 4 ) in the second longitudinal portion (L 2 ); and
the diameter of the cross-sectional area of the insulation element ( 4 ) in the first longitudinal portion (L 1 ) is calibrated to the outer conductor contact element ( 14 ) so that the modified first longitudinal portion (L 1 ) of the insulation element ( 4 ) may be inserted into the first plug connector portion (S 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 2 ) of the Insulation element ( 4 ) differs from an internal diameter of the first plug connector portion (S 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 1 ) and the first plug connector portion (S 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 1 ) and the second longitudinal portion (L 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 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 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 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 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 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 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 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 1 ) and the second longitudinal portion (L 2 ) and the at least one dielectric is situated in a second plug connector portion (S 2 ) that adjoins the first plug connector portion (S 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 1 ) and in an adjoining second longitudinal portion (L 2 );
laying bare the insulation element ( 4 ) from an outer conductor shield ( 5 ) of the electrical cable ( 1 ) in the first longitudinal portion (L 1 );
modifying a cross-sectional area of the laid bare insulation element ( 4 ) in the first longitudinal portion (L 1 ) so that a diameter of the modified cross-sectional area of the insulation element ( 4 ) in the first longitudinal portion (L 1 ) is different from a diameter of the cross-sectional area of the insulation element ( 4 ) in the adjoining second longitudinal portion (L 2 ); and
providing a plug connector ( 15 ) that has an outer conductor contact element ( 14 ) that defines a first plug connector portion (S 1 ); and
calibrating the diameter of the modified cross-sectional area of the first longitudinal portion (L 1 ) of the insulation element ( 4 ) to the outer conductor contact element ( 14 ) so that the first longitudinal portion (L 1 ) of the insulation element ( 4 ) is insertable into the first plug connector portion (S 1 ); and
inserting the modified cross-sectional area of the first longitudinal portion (L 1 ) of the insulation element ( 4 ) into the first plug connector portion (S 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 1 ) takes place by means of compressing the first longitudinal portion (L 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 1 ) takes place by means of swaging the first longitudinal portion (L 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 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 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 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 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 1 ) and the second longitudinal portion (L 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 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 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 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 1 ) in such a manner that the first longitudinal portion (L 1 ) is insertable into a first plug connector portion (S 1 ) of the outer conductor contact element ( 14 ); and wherein
the first longitudinal portion (L 1 ) the insulation element ( 4 ) is calibrated to the outer conductor contact element ( 14 ).