DE102023103727A1 - Contact system and method for producing such a contact system - Google Patents

Abstract

The invention relates to a contact system (10) and a method for producing such a contact system (10), wherein the contact system (10) has a shield contact device (15) and an electrical cable (20) with a shield (40) with a shield braid (50), wherein the shield braid (50) has a connecting section (105), wherein the shield contact device (15) has a sleeve (110) extending along a straight line (120) and a contact element (115) arranged radially offset from the sleeve (110) with respect to the straight line (120), wherein the contact element (115) has at least one arm section (125) and a contact section (130) arranged axially offset from the arm section (125) and connected to the arm section (125), wherein the arm section (125) has at least one first contact arm (150) extending along the straight line (120), wherein the first contact arm (150) is arranged at least partially on the inside of the shielding braid (50) and the first contact arm (150) rests on the outside of the shielding braid (50) in the connecting section (105) and electrically contacts the shielding braid (50), wherein the sleeve (110) is arranged on the outside of the connecting section (105) of the shielding braid (50) and is mechanically fastened to the connecting section (105).

Description

The invention relates to a contact system according to claim 1 and a method for producing such a contact system according to claim 12.

Out of US 11,362,445 B2 A contact system for contacting a shield is known.

It is an object of the invention to provide an improved contact system and an improved method for producing such a contact system.

This object is achieved by means of a contact system according to patent claim 1 and by means of a method for producing such a contact system according to patent claim 12. Advantageous embodiments are specified in the dependent claims.

It has been recognized that an improved contact system can be provided in that the contact system has a shield contact device and an electrical cable with a shield with a shield braid. The shield braid has a connecting section. The shield contact device has a sleeve extending along a straight line and a contact element arranged radially offset from the sleeve with respect to the straight line. The contact element has at least one arm section and a contact section arranged offset from the arm section and connected to the arm section. The arm section has at least one first contact arm extending along the straight line. The first contact arm is arranged at least partially on the inside of the shield braid. The first contact arm rests on the outside of the shield braid in the connecting section and electrically contacts the shield braid. The sleeve is arranged on the outside of the connecting section of the shield braid and is mechanically attached to the connecting section.

This design has the advantage that this arrangement is particularly suitable for connecting the contact element to an aluminum shielding braid. This means that the contact system can be manufactured particularly cost-effectively.

It is particularly advantageous if the sleeve is shrunk onto the connecting section and/or onto the contact element, the sleeve nestling against the connecting section and/or the contact element on the inside, an outside of the sleeve preferably being free of a tool impression, in particular free of an impression of a crimping tool. The shrunk-on process can be carried out, for example, as part of an EMPT process, the sleeve suddenly narrowing and being shrunk within a very short time interval. The sudden narrowing causes the connecting section of the shielding braid to be suddenly pressed onto the first contact arm and the first contact arm to penetrate the aluminum oxide layer arranged on the shielding braid and electrically contact the shielding braid in the connecting section. In particular, the sleeve can also be pressed and shrunk onto the shielding braid in the connecting section.

In a further embodiment, the sleeve is crimped onto the connecting section and/or onto the contact element, with the sleeve being crimped to the connecting section and/or the contact element on the inside, with a crimping indentation being arranged on the outside of the sleeve. This design has the advantage that the cost of converting existing production lines can be kept to a minimum.

In a further embodiment, the sleeve acts from the radial outside on the connecting section and/or on the contact element with a force, whereby the sleeve is connected to the connecting section and/or the contact element and the contact element is connected to the connecting section in a force-locking manner by means of the force. This ensures a particularly good connection with a secure electrical contact.

In a further embodiment, the first contact arm penetrates the shielding braid in a first partial area of the connecting section. The first contact arm is arranged on a second partial area of the shielding braid that adjoins the first partial area, radially on the inside of the second partial area of the connecting section. The first contact arm is connected to the shielding braid in the second partial area in a force-fitting and/or material-fitting manner, in particular metallurgically, in particular cold-welded. This ensures a particularly low contact resistance between the first contact arm and the shielding braid. The first contact arm can be connected to the second partial area at the same time as the sleeve is connected to the connecting section.

In a further embodiment, the shielding braid comprises predominantly aluminum, in particular at least 80% by weight. Additionally or alternatively, the contact element can comprise predominantly aluminum, in particular at least 80% by weight. This embodiment has the advantage that aluminum is significantly more cost-effective than for example copper, which allows a particularly cost-effective contact system to be produced.

In a further embodiment, the first contact arm has a predefined structure on the first outer circumferential side, wherein the predefined structure is preferably pyramid-shaped or linear. The structure can, for example, be applied to the contact arm in a particularly simple and cost-effective manner using laser structuring. The predefined structure has the advantage that when the sleeve is formed onto the connecting section using the EMPT method and/or crimping, the aluminum oxide layer of the shielding braid is broken up particularly reliably by the predefined structure, thus ensuring particularly good electrical contact between the shielding braid and the first contact arm.

In a further embodiment, the arm section has at least one second contact arm that is offset in the circumferential direction relative to the straight line, with a first recess being arranged in the circumferential direction between the first contact arm and the second contact arm. The first partial area of the shielding braid is arranged in the first recess. This design has the advantage that the first contact arm can be inserted through the connecting section of the shielding braid from radially outside to radially inside, and the remaining shielding braid can therefore be accommodated in the first recess and the first contact arm only has to be pushed through the shielding braid laterally.

In a further embodiment, the second contact arm penetrates the shielding braid in the circumferential direction offset from the first contact arm relative to the straight line. This design has the advantage that a particularly low contact resistance between the contact section and the shielding braid can be provided by the fact that the first and second contact arms can each electrically contact the connecting section.

In a further embodiment, the contact element has a ring-shaped contact section, wherein the contact section extends in the circumferential direction around the straight line. The first contact arm is axially attached to the contact section at a fixed end. The ring-shaped design has the advantage that the contact section is particularly rigid. Furthermore, the contact section can provide an electrical contact to a shield housing on the outside.

In a further embodiment, the contact system has a shield housing, wherein the shield housing extends in the circumferential direction around the sleeve and electrically contacts the contact section.

It is particularly advantageous if the electrical cable and the shield contact device are provided to produce the contact system described above. The arm section and the shield braid are brought into contact with one another, the arm section and the shield braid being magnetically formed in the connecting section and the first contact arm and the shield braid being mechanically connected to one another in the connecting section. The magnetic forming can be carried out, for example, as part of an EMPT process.

This design has the advantage that when the sleeve is magnetically formed, the sleeve acts on the first contact arm and the shielding braid. In particular, the sleeve contracts suddenly during magnetic forming and the sudden contraction acts on the connecting section and the first contact arm. In the process, the contact arm breaks open a metal oxide layer of the shielding braid and is electrically connected, in particular cold-welded, to the metal shielding braid.

In a further embodiment, the first contact arm is inserted through the shielding braid in such a way that the first contact arm penetrates the shielding braid. After the first contact arm has been inserted, the sleeve is magnetically formed. This ensures that the contact element is held securely in the shielding braid.

In a further embodiment, the sleeve and/or the first contact arm are structured on the circumference to form a predefined structure, in particular laser-structured. The shielding braid is arranged on the predefined structure. This design has the advantage that when the sleeve is magnetically formed, the sleeve acts radially inwards on the predefined structure indirectly via the shielding braid and the predefined structure breaks through an aluminum oxide layer of the shielding braid in order to ensure a secure electrical mechanical contact with the shielding braid in a particularly easy and simple manner.

• 1 eine schematische Darstellung eines Kontaktsystems;
• 2 einen Ausschnitt des in 1 gezeigten elektrischen Kabels.
• 3 eine schematische Darstellung, des in den 1 und 2 gezeigten Kontaktsystems 10.
• 4 eine perspektivische Darstellung des in den 1 und 3 gezeigten Kontaktelements der Schirmkontakteinrichtung;
• 5 eine Seitenansicht auf die Hülse des in den 1 und 2 gezeigten Kontaktelements in demontiertem Zustand;
• 6 eine Schnittansicht entlang einer in 3 gezeigten Schnittebene A-A durch das in 1 gezeigte Kontaktsystem;
• 7 eine Schnittansicht entlang einer in 3 gezeigten Schnittebene B-B durch das in 3 gezeigte Kontaktsystem;
• 8 eine Schnittansicht entlang einer in 3 gezeigten Schnittebene C-C durch das Kontaktsystem; und
• 9 ein Ablaufdiagramm eines Verfahrens zur Herstellung des in den 1 bis 8 gezeigten Kontaktsystems.

The invention is explained in more detail below with reference to figures.

• 1 a schematic representation of a contact system;
• 2 an excerpt from 1 electrical cable shown.
• 3 a schematic representation of the 1 and 2 shown contact system 10.
• 4 a perspective view of the 1 and 3 shown contact element of the shield contact device;
• 5 a side view of the sleeve of the 1 and 2 shown contact element in disassembled state;
• 6 a sectional view along a 3 shown section plane AA through the in 1 contact system shown;
• 7 a sectional view along a 3 shown cutting plane BB through the 3 contact system shown;
• 8 a sectional view along a 3 shown section plane CC through the contact system; and
• 9 a flow chart of a process for producing the 1 to 8 shown contact system.

1 shows a schematic representation of a contact system 10.

The contact system 10 has a shield contact device 15, an electrical cable 20, a shield housing 25 and a power contact device 26.

The electrical cable 20 is designed as a coaxial cable for power transmission, in particular as a high-current cable. In particular, the electrical cable 20 is designed to transmit power in an electric vehicle between a traction battery and the engine control unit and/or the engine control unit and the drive motor and/or between a charging connection and the traction battery.

2 shows a section of the 1 electrical cable shown.

The electrical cable 20 has an electrical conductor 30, a first sheath 35, a shield 40 and at least one second sheath 45. The electrical conductor 30 serves to transmit an electrical current for transmitting electrical power. The maximum electrical current that can be transmitted with the electrical conductor 30 can be 50 A to 1000 A, in particular 1500 A to 300 A.

Furthermore, the electrical conductor 30 can be supplied with an electrical voltage of 200 V to 1000 V.

Preferably, a cross-sectional area of the electrical conductor 30 is at least 8 sqmm, preferably 16 sqmm, in particular at least 32 sqmm. The maximum cross-sectional area of the electrical conductor 30 can be 100 sqmm. The electrical conductor 30 is circumferentially sheathed by the first sheath 35. The first sheath 35 is preferably made of an electrically non-conductive material and electrically insulates the electrical conductor 30 from the shield 40.

The shield 40 is arranged on the outside around the first sheath 35. The shield 40 has a shield braid 50. The shield braid 50 has individual interwoven shield braid strands 55, 60, which are braided in a diamond shape, for example. Between the individual shield braid strands 55, 60, which are electrically conductive, the shield braid 50 has shield braid openings 65. The shield braid openings 65 can be diamond-shaped, for example, and are formed on the circumference by the shield braid strands 55, 60. The shield 40 is enclosed on the outside by the second sheath 45. The shield 40 is thus electrically insulated on the inside by the first sheath 35 and on the outside by the second sheath 45, which is also made of an electrically non-conductive material.

The electrical conductor 30 is electrically connected to the power contact device 26 (in 1 shown). The power contact device 26 is designed to transmit the above-described electrical current, which is transmittable via the electrical conductor 30, to a counter-power contact device.

3 shows a schematic representation of the 1 and 2 shown contact system 10.

The shield contact device 15 is designed to electrically connect the shield 40 with the shield braid 50 to the shield housing 25.

The electrical cable 20 has a first cable section 70, a second cable section 75, a third cable section 80 and preferably a fourth cable section 85. The first cable section 70 is connected to a cable end 90 of the electrical cable 20. In the first cable section 70, the first sheath 35, the shield 40 and the second sheath 45 are removed from the electrical conductor 30. As a result, the electrical conductor 30 can be exposed on its circumference or, in a particularly advantageous case, can be electrically connected to the power contact device 26. Example For example, the electrical conductor 30 can be welded or crimped to the power contact device 26.

On a side facing away from the cable end 90, the second cable section 75 adjoins the first cable section 70. In the second cable section 75, the electrical conductor 30 is circumferentially sheathed by the first sheath 35 and is electrically insulated from the environment. The shielding 40 and the second sheath 45 are removed from the electrical cable 20 in the second cable section 75.

On a side of the second cable section 75 facing away from the first cable section 70, the third cable section 80 adjoins the second cable section 75. In the third cable section 80, the shielding 40 is arranged circumferentially around the first sheathing 35. The second sheathing 45 is spaced away from the shielding 40.

The fourth cable section 85 is connected to a side of the third cable section 80 facing away from the second cable section 75. The fourth cable section 85 runs essentially outside the shield housing 25. In the fourth cable section 85, the shield 40 is circumferentially sheathed by the second sheath 45 and the electrical cable 20 is designed as a coaxial cable in the fourth cable section 85.

The shield braid 50 has a connecting section 105 between the sheath end 95 of the second sheath 45 arranged on a side facing the cable end 90 and a shield braid end 100 of the shield braid 50 arranged on the cable end 90. The shield contact device 15 is arranged essentially on the second cable section 75 and on the third cable section 80. The shield contact device 15 ensures an electrical connection of the shield 40 at the connecting section 105 to the shield housing 25.

The shield contact device 15 has a sleeve 110 and a contact element 115. The sleeve 110 extends along a straight line 120, which can overlap with a cable center axis of the cable 20, in particular of the electrical conductor 30. The sleeve 110 is arranged radially on the outside of the contact element 115. The sleeve 110 is shrunk onto the connecting section 105 and/or onto the contact element 115, wherein the sleeve 110 nestles against the inside of the connecting section 105 and/or the contact element 115, wherein an outer side 111 of the sleeve 110 is preferably free of a tool impression, in particular free of an impression of a crimping tool.

In an alternative training course of the 3 In the contact system 10 shown, the sleeve 110 is crimped onto the connecting section 105 and/or onto the contact element 115, with a crimp recess 112 on the outside 111 of the sleeve 110, in 3 shown in dashed lines. The crimping indentation 112 results from a crimping tool.

4 shows a perspective view of the 1 and 3 shown contact element 115 of the shield contact device 15.

The contact element 115 extends in the circumferential direction around the straight line 120. The contact element 115 has an arm section 125 and a contact section 130. The contact section 130 adjoins the arm section 125 in the axial direction with respect to the straight line 120. The contact section 130 is preferably hollow-cylindrical or disk-shaped or ring-shaped. The contact section 130 has a first contact surface 140 on a first outer circumferential side 135, which rests against the shield housing 25 in the assembled state of the contact system 10 and electrically contacts the shield housing.

The arm section 125 has an arm arrangement 145 with a plurality of contact arms 150, 155 arranged offset from one another in the circumferential direction. Each of the contact arms 150, 155 is mechanically connected to the contact section 130 at a fixed end. On an axial side facing away from the contact section 130, each of the contact arms 150, 155 has a free end 165, 170. The free ends 165, 170 can be arranged in a common plane 180 perpendicular to the straight line 120.

In the non-assembled state of the contact element 115 (as in 4 shown), the contact element 115 has a first inner diameter d1 at the contact section 130. Opposite in the axial direction relative to the straight line 120, the contact element 115 has a second inner diameter d2 at the respective free ends 165, 170. The arm section 125 preferably tapers from the contact section 130 towards the free ends 165, 170 of the arm section 125, so that the second inner diameter d2 is smaller than the first inner diameter d1. Furthermore, the second inner diameter d2 is preferably smaller than an outer diameter of the first casing 35 in the unassembled state.

The arm arrangement 145 has a plurality of contact arms 150, 155. For example, a first contact arm 150 of the arm arrangement 145 is arranged offset in the circumferential direction to a second contact arm 155 of the arm arrangement 145. In the circumferential direction A first recess 175 is preferably arranged between the first contact arm 150 and the second contact arm 155. The first recess 175 extends in the axial direction between the contact section 130 and the plane 180 in which the free ends 175, 180 of the respective contact arm 150, 155 are arranged. In the circumferential direction, the first contact arm 150 and/or the second contact arm 155 is tapered starting from the contact section 130 towards the respective free end 165, 170.

The first recess 175 is preferably designed as a through-opening in the radial direction relative to the straight line 120. It is particularly advantageous if a plurality of first recesses 175 are provided in the arm section 125, wherein the first recess 175 is arranged on both sides of the first contact arm 150 and/or the second contact arm 155. The first recess 175 has a first maximum extension 11 in the axial direction relative to the straight line 120.

For example, a second recess 185 can be arranged in the first contact arm 150 and/or the second contact arm 155. The second recess 185, like the first recess 175, is designed as a through-opening running in the radial direction in the arm section 125. Furthermore, the second recess 185 is designed, for example, in the form of an elongated hole in the first contact arm 150 and/or the second contact arm 155. For example, the second recess 185 ends at a distance from the free end 165, 170 of the respective corresponding contact arm 155, 160. The second recess 185 has a second length 12 in the axial direction, the second length 12 being shorter than the first length 11.

In the embodiment, a second recess 185 is arranged in each of the contact arms 150, 155. Of course, it is also possible for the second recess 185 to be arranged in only a part of the contact arms 150, 155. In the circumferential direction, relative to the straight line 120, the second recess 185 is arranged at a distance from the first recess 175.

On a second outer circumferential side 195, the arm section 125 has a defined structure 200, in particular in the area of the respective contact arm 150, 155. The defined structure can be created in the second outer circumferential side 195, for example, using a laser process. For example, the defined structure 200 can have linear elevations and valleys and/or pyramid-shaped elevations. The elevations are preferably sharp-edged on the second outer circumferential side 195 in order to achieve particularly good penetration into the sleeve 110 and/or the shielding braid 50. The defined structure 200 is preferably arranged only on the second outer circumferential side 195 on the contact arm 150, 155. The arrangement of the defined structure 200 on the inside of the contact element 115 is omitted in the embodiment.

5 shows a side view of the sleeve 110 of the 1 and 2 shown contact element 115 in dismantled state.

The sleeve 110 is made of a thin-walled material, in particular of a thin-walled metal, for example copper, in particular a copper alloy with a main component of copper, aluminum and/or steel. The sleeve 110 can have a wall thickness of 0.2 mm to 0.8 mm. The sleeve 110 extends along the straight line 120 and is hollow-cylindrical in the uninstalled state. The sleeve 110 has a third length 13 essentially in the axial direction with respect to the straight line 120, wherein the third length 13 preferably corresponds to the second length 12.

In the unassembled state, the sleeve 110 has a first inner circumferential side 190 which extends cylindrically around the straight line 120. The front side of the sleeve 110 is open on both sides.

Alternatively or in addition to the arrangement of the defined structure 200 on the second outer circumferential side 195 of the arm section 125, it is also possible for the defined structure 200 to be arranged on the first inner circumferential side 190 of the sleeve 110. It is of course also possible for the defined structure 200 on the sleeve 110 and/or the contact element 115 to be omitted. It is of course also possible for the defined structure to be arranged on both the sleeve 110 and the contact element 115.

6 shows a sectional view along a 3 shown section plane AA through the in 1 shown contact system 10.

The shielding braid 50 and the shielding braid strands 55, 60 rest on a third outer circumferential side of the first sheath 35. In a first partial area 210 of the shielding braid 50, each of the contact arms 155, 160 is inserted through a shielding braid opening 65 so that the contact arm 150, 155 penetrates the shielding braid 50. The shielding braid 50, in particular the shielding braid strands 55, 60, are each arranged in the first recess 175 arranged between the contact arms 150, 155. Thus, in a first partial area of the shielding braid 55 in the Connecting section 100, the contact arms 150, 155 and the shielding braid strands 50, 60 are arranged on a common circular path. With the first inner circumferential side 190, the sleeve 110 rests on the second outer circumferential side 195 of the arm section 125 and on a fourth outer circumferential side 215 of the shielding braid 50. The sleeve 110 electrically contacts both the contact element 115 and the shielding 50.

The sleeve 110, for example, is cold welded, has 4 a reduced inner diameter. By shrinking the sleeve 110, the sleeve 110 provides a pressing force F acting from radially outside to radially inside in the direction of the straight line 120, so that the sleeve 110 is crimped onto the shield 40 and the contact section 130 by shrinking. The pressing force F acting radially from outside to radially inside in the direction of the straight line 120 ensures a good frictional fit of the sleeve 110 on the shield 40 and the contact element 115 in the area of the contact section 130.

The defined structuring 200 applied to the first outer peripheral side 195 ensures a secure electrical contact and a reliable frictional connection between the sleeve 110 and the arm section 125, in particular the contact arms 150, 155. The defined structuring 200 has the particular advantage that, if the sleeve 110 and/or the contact element 115 predominantly comprise aluminum, an aluminum oxide layer of the sleeve 110 is broken open, thereby ensuring a secure electrical and mechanical contact between the arm section 125 and the sleeve 110. In particular, this is ensured by the sudden shrinking of the sleeve 110 in the first partial area 210.

7 shows a sectional view along a 3 shown cutting plane CC through the contact system 10.

Because the contact arms 150, 155 are inserted through the respective shielding braid opening 65 in the first partial area 210 of the connecting section 105, the contact arms 150, 155 rest with the second inner circumferential side 225 on the first sheath 35. On the outside, in a second partial area 220 of the connecting section 105, the shielding braid 50 of the shielding 40 nestles against the contact arms 150, 155. In this case, a wave-shaped configuration of the shielding braid 50 is formed on the circumferential side, since the shielding braid 40 engages in the first and second recesses 155, 185. On the radial outside, the sleeve 110 follows an outer contour of the shielding braid 50, so that the sleeve 110 in 7 also has a wave-shaped design on the outside.

Due to a force F with which the sleeve 110 presses onto the shielding braid 50 and the contact element 115 as well as the shielding braid 50 onto the contact arm 150, 155, the defined structuring 200 of the contact element 115 engages into the shielding braid 50 and penetrates an aluminum oxide layer of the shielding braid 50, which covers the shielding braid 50 in a thin layer. This ensures a secure electrical contact and a good frictional connection between the contact element 115, in particular the contact arms 150, 155, and the shielding braid 50.

8 shows a sectional view along a 3 shown cutting plane BB through the 3 shown contact system 10.

The 8 The cross section shown along the section plane BB is compared with the cross section shown in 6 shown sectional view is arranged offset towards the shield braid end 100. A third partial region 230 of the connecting section 105 of the shield braid 40 is arranged in the axial direction with respect to the straight line 120 between the shield braid end 100 and the first partial region 210.

The contact section 130 is arranged with the first and second contact arms 150, 155 radially on the outside of the third partial area 230 of the shielding braid 40. Each of the contact arms 150, 155 rests with a second inner circumferential side 225 on a fourth outer circumferential side 215 of the shielding braid 50. Each of the contact arms 150, 155 contacts the shielding braid 50 radially on the inside on the second inner circumferential side 225. On the second outer circumferential side 195, the defined structuring 200 engages in the first inner circumferential side 190 of the sleeve 110. The defined structuring 200 ensures reliable electrical contact and a good force-fitting and/or material-fitting connection of the sleeve 110 with low contact resistance in the third partial area 230 as well as in the first partial area 210 by breaking up the aluminum oxide layer. This prevents unwanted slipping in the axial direction with respect to the straight line 130 relative to the contact element 115.

The sleeve 110, which is shrunk onto the contact element 115 and the shielding braid 50, preferably by means of an EMPT process, has a wave-shaped design on the outside of the third partial area 230, wherein the sleeve 110 extends in the circumferential direction at least in sections into both the first recess 175 and the second recess 185 (in 7 not shown) and conforms to the second outer peripheral side 195 and forms a contour of the second outer peripheral side 195.

9 shows a flow chart of a process for producing the 1 to 8 shown contact system 10.

In a first method step 305, the electrical cable 20, the components of the shield contact device 15 and the components of the power contact device 26 are provided.

In a second method step 310, the second sheath 45, the shield 40 and the first sheath 35 are removed from the electrical conductor 30 to form the first cable section 30, so that the electrical conductor 30 is exposed on the circumference. In the second method step, the shield 40 and the second sheath 45 are also removed to form the second cable section 75. To form the third cable section 80, the second sheath 45 is removed from the shield 40, so that the shield 40 is exposed on the circumference. The fourth cable section 85 is not processed, so that in the fourth cable section 85, the shield 40 is circumferentially sheathed radially on the outside by the second sheath 45.

In a third method step 315, the cable section 130 of the contact element 115 is widened such that the free ends 165, 170 of the respective contact arm 150, 155 are pivoted radially outward. This can be done, for example, by means of a tool that is designed in the shape of a sleeve.

In a fourth method step 320 following the third method step 315, the contact element 115 is pushed along the straight line 120 over the first contact section 70 and the second contact section 75 onto the third contact section 80. When the first and second free ends 165, 170 reach approximately a central position of the connecting section 105 of the shield, the process continues with a fifth method step 325.

In the fifth method step 325, the contact section 130 is lifted in such a way that the contact arms 150, 155 pivot radially from the outside to the inside. The first free end 165, 170 is positioned at an outer radial opening of the shielding braid opening 65. Because the respective free end 165, 170 is preferably blunt, the contact arm 150, 155 is inserted through a shielding braid opening 65 in a further axial movement of the contact section 130. Furthermore, the contact arms 150, 155 are each pulled radially inward along the straight line 120 through the shielding braid 50 and pressed radially inward through the shielding 40.

If an end position of the contact element 115 relative to the connecting section 105 is reached, the free ends 165, 170 are arranged near or at the end of the third cable section 80 on the side facing the fourth cable section 85. The contact section 130 can abut one end of the shielding braid 50 on the front side.

In a sixth method step 330, which in the embodiment is carried out by way of example after the fifth method step 325, the sleeve 110 is pushed along the straight line 120 onto the contact element 115 arranged on the connecting section 105. This can be done, for example, by the sleeve 110 having a larger minimum inner diameter in the unassembled state (cf. 5 ) as a maximum outer diameter of the contact element 115. It is also possible for the sleeve 110 coming from the fourth cable section 85 to be pushed onto the third cable section 80 with the contact element mounted on the third cable section 80. The sleeve 110 is placed in such a way that the sleeve 110 only has a radial overlap with respect to the straight line 120 to the arm section 125 and a radial overlap with the contact section 130 is avoided. A radial overlap is understood to mean that when two components are projected in the radial direction into a projection plane in which the straight line 120 runs, the two components overlap in the projection plane.

In a seventh method step 335 following the sixth method step 330, the contact system 10 is placed in a connection machine. For example, a coil is arranged around the circumference of the contact system 10.

In the seventh method step 335, the connecting machine generates an electromagnetic pulse that acts on the sleeve 110. The electromagnetic pulse causes the thin-walled sleeve 110 to contract suddenly and shrink in the radial direction. The sleeve 110 acts with a shrinking force FS (see 6 and 8 ), which is directed radially inwards in the direction of the straight line 120, onto the shielding braid 40 in the second partial region 220 (cf. 7 ) and on the contact arms 150, 155 in the third sub-area 230 (cf. 8 ). The suddenly applied shrinking force FS causes a mechanical impact of the sleeve 110 in the second partial area 220 on the shielding braid 50 and in the third partial area 230 on the contact arms 150, 155. Due to the impact, the second partial area In the second partial region 220, the predefined structuring 200 covers the aluminum oxide layer of the shielding braid 50, so that direct metallic contact between the predefined structuring 200 and the shielding braid 50 below the aluminum oxide layer is ensured. Furthermore, the mechanical impact of the sleeve 110 preferably causes a metallurgical connection to form in the second partial region 220 between the contact arm 150, 155 and the shielding braid 50 and between the sleeve 110 and the contact element 115 and between the sleeve 110 and the shielding braid 50. The metallurgical connection ensures reliable electrical contact with low contact resistance between the shielding braid 50 and the contact arm 40. The metallurgical connection can be designed as a cold weld connection.

At the third partial area 230, the sleeve 110 strikes the contact arm 150, 155 on the outside due to the electromagnetic pulse. In the area of the recesses 175, 185, the sleeve 110 strikes the connecting section 105 of the shielding braid 50 at high speed. Due to the predefined structuring 200, which is advantageously also arranged on the inside of the sleeve 110, the predefined structuring 200 breaks up the oxide layer, in particular the aluminum oxide layer, on the shielding braid 50 and penetrates into the shielding braid 50. In this case, a metallic contact and a metallurgical connection, for example a cold weld, advantageously form between the sleeve 110 and the shielding braid 50 and between the sleeve 110 and the contact element 115. Likewise, the predefined structuring 200 of the contact arm 150, 155 and/or the sleeve 110 penetrates into the sleeve 110 and/or the outside of the contact arm 150, 155 at the third partial area 230 of the shielding braid 50, so that an oxide layer, in particular an aluminum oxide layer on the contact arm 150, 155 and/or on the sleeve 110, is broken up and a metallic contact, in particular a metallurgical connection, is formed between the sleeve 110 and the contact arm 150, 155. This prevents axial displacement of the sleeve 110 relative to the contact element 115. As a result, the sleeve 110 nestles against the connecting section 105 arranged radially on the inside and the contact element 115. An outer contour of the contact element 115 and/or the connecting section 105 can be seen in a shape of the outside of the sleeve.

The sleeve 110 can also be crimped by the connection machine in the seventh process step 335. In this case, the 3 shown crimp impression 112. Also, the sleeve 110 is not shrunk onto the connecting section 105 and the contact element 115, but pressed/crimped on.

Furthermore, it is possible that the above-described shrinking of the sleeve by means of the EMPT pulse is combined with the crimping of the sleeve 110 onto the connecting section 105 and the contact element 115 and is carried out simultaneously or sequentially one after the other.

In an eighth method step 340 following the seventh method step 335, the power contact device 26 is mounted on the electrical conductor 35.

In a ninth method step 345 following the eighth method step 340, the shield housing 25 is mounted on the shield contact device 15, wherein the contact element 115 with the contact section 130 electrically contacts the shield housing 25.

The manufacturing process described in the figures and the contact system 10 described in the figures have the advantage that the contact system 10 is particularly suitable for electrically contacting the braided shield 50 with predominantly aluminum (i.e. with at least 50 percent by weight) as the main component reliably with a low contact resistance, without having to use chemical processes. In particular, the contact system 10 also ensures that the braided shield 50 of the shield 40 can be electrically contacted particularly quickly and reliably and that the manufacturing process for producing the contact system 10 requires only very few steps.

List of reference symbols

10

Contact system

15

Shield contact device

20

Cable

25

Shield housing

26

Power contact device

30

electrical conductor

35

first coating

40

Shielding

45

second sheath

50

Shielding braid

55

first shield braid strand

60

second shielding braid strand

65

Shield braid opening

70

first cable section

75

further cable section

80

third cable section

85

fourth cable section

90

Cable end

95

Sheath end

100

Shield braids

105

Connecting section

110

Sleeve

115

Contact element

120

Straight

125

Arm section

130

Contact section

135

first outer peripheral side

140

first contact surface

145

Arm arrangement

150

first contact arm

155

second contact arm

160

fixed end

165

first free end

170

second free end

175

first recess

180

level

185

second recess

190

first inner circumferential side

195

second outer peripheral side

200

defined structuring

205

third outer peripheral side

210

first section

215

fourth outer circumferential side

220

second part

225

second inner circumferential side

230

third sub-area

305

first procedural step

310

second process step

315

third procedural step

320

fourth procedural step

325

fifth procedural step

330

sixth procedural step

335

seventh process step

340

eighth process step

345

ninth procedural step

d1

first inner diameter

d2

second inner diameter

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions.

Cited patent literature

• US 11362445 B2 [0002]

Claims (14)

Contact system (10), - wherein the contact system (10) has a shield contact device (15) and an electrical cable (20) with a shield (40) with a shield braid (50), - wherein the shield braid (50) has a connecting section (105), - wherein the shield contact device (15) has a sleeve (110) extending along a straight line (120) and a contact element (115) arranged radially offset from the sleeve (110) with respect to the straight line (120), - wherein the contact element (115) has at least one arm section (125) and a contact section (130) arranged axially offset from the arm section (125) and connected to the arm section (125), - wherein the arm section (125) has at least one first contact arm (150) extending along the straight line (120), - wherein the first contact arm (150) has at least is arranged in sections on the inside of the shielding braid (50) and the first contact arm (150) rests on the shielding braid (50) in the connecting section (105) and electrically contacts the shielding braid (50), - wherein the sleeve (110) is arranged on the outside of the connecting section (105) of the shielding braid (50) and is mechanically fastened to the connecting section (105). Contact system (10) according to Claim 1 , - wherein the sleeve (110) is shrunk onto the connecting portion (105) and/or onto the contact element (115), - wherein the sleeve (110) conforms on the inside to the connecting portion (105) and/or the contact element (115), - wherein an outer side (111) of the sleeve (110) is preferably free of a tool impression, in particular free of an impression of a crimping tool. Contact system (10) according to Claim 1 , - wherein the sleeve (110) is crimped onto the connecting portion (105) and/or onto the contact element (115), - wherein a crimping indentation (112) is arranged on an outer side (111) of the sleeve (110). Contact system (10) according to one of the preceding claims, - wherein the sleeve (110) acts from the radial outside on the connecting section (105) and/or on the contact element (115) with a force (F), - wherein the sleeve (110) is non-positively connected to the connecting section (105) and/or the contact element (115) by means of the force (F), and the contact element (115) is non-positively connected to the connecting section (105). Contact system (10) according to one of the preceding claims, - wherein the first contact arm (150) of the shielding braid (50) penetrates a first partial region (210) of the connecting section (105), - wherein the first contact arm (150) is arranged on a second partial region (220) of the shielding braid (50) adjoining the first partial region (210) on the radially inner side of the second partial region (220) of the connecting section (105), - wherein the first contact arm (150) in the second partial region (220) is connected to the shielding braid (50) in a force-fitting and/or material-fitting manner, in particular metallurgically, in particular cold-welded. Contact system (10) according to one of the preceding claims, - wherein the shielding braid (50) predominantly comprises aluminum, in particular at least 80 percent by weight, - and/or - wherein the contact element (115) predominantly comprises aluminum, in particular at least 80 percent by weight. Contact system (10) according to one of the preceding claims, - wherein the first contact arm (150) has a predefined structure (200) on the first circumferential side, - wherein the predefined structure (200) is preferably pyramid-shaped or linear. Contact system (10) according to one of the Claims 5 until 7 , - wherein the arm section (125) has at least one second contact arm (155) arranged offset in the circumferential direction with respect to the straight line (120), - wherein a first recess (175) is arranged in the circumferential direction between the first contact arm (150) and the second contact arm (155) of the arm section (125), - wherein the first partial region (210) of the shielding braid (50) is arranged in the first recess (175). Contact system (10) according to Claim 8 , - wherein the second contact arm (155) penetrates the shielding braid (50) in the first partial region of the shielding braid (50) in the circumferential direction relative to the straight line (120) offset from the first contact arm (150). Contact system (10) according to one of the preceding claims, - wherein the contact element (115) has an annular contact section (130), - wherein the contact section (130) extends in the circumferential direction around the straight line (120), - wherein the first contact arm (150) is axially attached to the contact section (130) at a fixed end (160). Contact system (10) according to one of the preceding claims, - comprising a shield housing (25), - wherein the shield housing (25) extends in the circumferential direction around the sleeve (110) and electrically contacts the contact section (130). Method for producing a contact system (10) according to one of the preceding claims, - wherein the electrical cable (20) and the shield contact device (15) are provided, - wherein the arm section (125) and the shield braid (50) are brought into contact with one another, - wherein the sleeve (110) is magnetically formed and the first contact arm (150) and the shield braid (50) are mechanically connected to one another in the connecting section (105). Procedure according to Claim 12 , - wherein the first contact arm (150) is inserted through the shielding braid (50) in such a way that the first contact arm (150) penetrates the shielding braid (50), - wherein after the insertion of the first contact arm (150), the sleeve (110) is magnetically deformed. Procedure according to Claim 12 or 13 , - wherein at least one circumferential side, in particular a first outer circumferential side of the first contact arm, is structured, in particular laser-structured, to form a predefined structuring (200), - wherein the shielding braid (50) is arranged on the predefined structuring (200).

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