One-piece metal blank for joining a connector to an insulated cable by crimping, pre-assembled connector sub-assembly incorporating the blank or comprising a central contact and two crimping portions of different materials and/or thicknesses, and associated methods for joining a connector to a cable

A first alternative of the application first defines a one-piece metal blank that will make it possible to produce a connector sub-assembly ready to be directly crimped to an insulated and shielded cable, prepared beforehand. A second alternative of the application first defines a pre-assembled connector sub-assembly that incorporates front and rear crimping portions with different electrical and/or mechanical characteristics, and which is ready to be directly crimped to an insulated and shielded cable, prepared beforehand. Either of the two alternatives makes it possible to minimize assembly steps and associated risks such as those due to the processes of fitting together a great many components according to the prior art.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of French Application No. 2101584 filed on Feb. 18, 2021 and French Application No. 2111228 filed on Oct. 22, 2021, the entire disclosures of which are incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to the technical field of electrical connectors.

In particular, the invention aims to improve the joining of a connector to an insulated cable, in particular a power connector to a cable of large cross section for carrying large currents. These may be power connectors that connect, for example, a vehicle's battery to the electric motor or to the power electronics.

These may be connectors carrying other types of signal, such as RF signals, or data.

Although described with reference to a favored application, namely connectors for motor vehicles, and more particularly for hybrid and electric vehicles, the invention may be implemented in any other application.

PRIOR ART

The rapid development of hybrid and electric vehicles demands reliable and easy-to-implement solutions, in particular for making connections between shielded cables and power connectors, either for equipment manufacturers or for the vehicle manufacturers themselves.

A number of connectors have thus been proposed.

Mention may be made here of the two-channel connectors sold by Tyco Electronics Connectivity under the market name “HVP-800 range”, Aptiv under the name “RCS800 range” or Rosenberger under the name “HVR200 range”.

Every time different components (contacts, shielded cables, connectors) are joined to these existing connectors, it has to be done in multiple successive and ordered steps, with a precise orientation of assembly.

The risk of forgetting a part and/or of making a mistake in the orientation or order of assembly is high and results in those connectors that have been joined to a cable poorly being discarded.

Additionally, with existing connectors, automatic joining is complex or even impossible to implement.

For example, with reference to a two-channel connector from the aforementioned HVP-800 range, joining has to be performed by successively fitting the various components (retaining part, seal, internal and external ferrules, electrical insulator, protective cage for the central contact, electromagnetic shielding ring) of the connector onto a cable, with crimping of an electrically conductive component (contact) at each step in assembly.

Consequently, there is a need to improve the joining of connectors, in particular of power connectors, to a shielded cable, in particular with a view to overcoming the aforementioned drawbacks.

The invention aims to address all or part of this need.

DISCLOSURE OF THE INVENTION

To achieve this, one object of the invention, according to one of the aspects thereof, and according to a first alternative, is a one-piece metal blank for joining a connector to a cable by crimping, comprising:a peripheral rim forming a preferably planar support which extends along a longitudinal axis;at least two aligned portions, each extending along the longitudinal axis while being separated from one another, each of the two portions being held to the support by at least one strip forming a tie, the front portion being a crimping, clip-fastening, force-fitting-by-catching or overmolding portion, designed to accommodate and to hold by crimping, clip-fastening, force-fitting by catching or overmolding, respectively, an electrical component of the connector, while the rear portion, which is preferably continuous, is a portion for crimping the cable, comprising openings for allowing crimping jaws to pass through.

According to one advantageous embodiment, the front portion is a crimping portion.

According to this embodiment, each of the two crimping portions advantageously comprises an accommodating hollow and at least one crimping wing connected to the hollow, one of the hollows being intended to accommodate the electrical component of the connector.

According to one embodiment, the one-piece blank comprises at least one bearing strip, which is connected to the support and extends inside same between the two crimping portions so as to form a bearing region for an electrical component of the connector accommodated in one of the two crimping portions.

Advantageously, the front crimping portion comprises at least one crimping wing designed to be crimped around the electrical component, preferably around an electrically insulating part housing a pre-assembled central contact.

The rear crimping portion preferably comprises at least one crimping wing designed to be crimped around the shielding braid of the insulated cable.

The rear crimping portion may comprise at least one crimping wing designed to be crimped around the outer and/or inner insulating sheath of the insulated cable or around a seal fitted around the outer sheath of the insulated cable.

Advantageously, the rear crimping portion is continuous.

Each of the two portions is preferably held to the support by at least one tie which extends along the longitudinal axis (X) and/or laterally thereto.

Another subject of the invention, according to another of its aspects, is a connector sub-assembly, comprising:an electrical component comprising a pre-assembled central contact, where applicable, housed in an electrically insulating part,a one-piece blank as described above, one of the two portions of which accommodates the electrical component.

Advantageously, the electrical component is crimped onto the one-piece blank by the front portion.

The invention also relates to a reel for automatically or semi-automatically joining a connector to a cable by crimping, comprising a plurality of sub-assemblies as above, joined together by an edge of the supports of the blanks and wound around a spool.

The invention also relates to a method for joining at least one connector to a cable, comprising the following steps:

i1/ providing a shielded and insulated cable, the one or more conductive wires and the shielding braid being exposed at one end of the cable;

ii1/ providing a sub-assembly as above, preferably using a reel described above;

iii1/ positioning the cable in the sub-assembly such that the exposed portion of the one or more conductive wires is accommodated in the rear crimping portion of the pre-assembled central contact and that the exposed portion of the shielding braid is accommodated in the crimping portion of the sub-assembly which is separated from the central contact;

iv1/ crimping, by means of a jaw-anvil crimping tool (M), inserted into the openings between the support and the one or more ties and bearing strips, of the rear crimping portion of the pre-assembled central contact onto the one or more conductive wires and, preferably simultaneously, of the crimping portion of the sub-assembly onto the shielding braid;

v1/ cutting the one or more ties, so as to obtain a unitary contact pre-assembled with the cable.

According to one advantageous variant, step i1/ preferably further comprises the provision of a seal fitted around the outer or inner sheath of the cable, step iv/ further comprising the crimping of the rear portion of the sub-assembly, preferably simultaneously with the crimping thereof onto the shielding braid, onto the seal.

Preferably, step v1/ is mechanical cutting using a blade or mechanical cutting by shearing or laser cutting.

According to the advantageous embodiment, the method comprises, after cutting step v/, the following step:

vi1/ fitting the central contact crimped around the one or more conductive wires into the electrically insulating part (3), thereby joining them together definitively.

According to another advantageous embodiment, the method comprises, after step vi1/, when the seal is fitted around the outer sheath of the cable, the following steps:

vii1/ mounting, by snap-fitting, at least one shielding envelope that surrounds both the electrically insulating part and the front portion, so as to obtain a shielded unitary contact;

viii1/ fitting at least one cable-connected unitary contact, shielded according to step vii1/, into a one-piece connector housing, preferably with the unitary contact being held by retaining clamps at the rear of the connector.

According to yet another advantageous embodiment, the method comprises, after step vi1/, when the seal is fitted around the inner sheath of the cable and preferably around the braid of the cable, the following steps:

vii′1/ mounting at least one shielding envelope that surrounds the crimped rear portion, and a shielding envelope that surrounds both the electrically insulating part and the front portion, so as to obtain a shielded unitary contact;

viii′1/ mounting two interface housing half-shells around the one or more unitary contacts shielded according to step vii″1/, preferably with the unitary contact being held by retaining clamps at the rear of the connector.

According to another advantageous embodiment, the method comprises, after step vi1/, when the seal is fitted around the inner sheath of the cable, the following steps:

vii″1/ mounting two shielding half-shells, covering the unitary contacts;

viii″1/ mounting two interface housing half-shells around the two shielding half-shells according to step vii″1/.

Another subject of the invention is a cable-connected unitary contact, where applicable shielded, obtained using the method described above.

Lastly, another subject of the invention is a connector, in particular a multichannel connector, obtained using the method described above.

Thus, the invention according to this first alternative first consists in defining a one-piece metal blank that will make it possible to produce a connector sub-assembly ready to be directly crimped to an insulated and shielded cable, prepared beforehand, which makes it possible to minimize assembly steps and associated risks such as those due to the processes of fitting together a great many components according to the prior art.

Another subject of the invention, according to a second alternative of the invention, is a pre-assembled sub-assembly, which is electrically conductive and extends along a longitudinal axis (X), to be joined by crimping to a cable comprising an electrically conductive core and at least one electrically insulating sheath, and, where applicable, a shielding braid around the core, the sub-assembly comprising a central contact and comprising at least two, electrically conductive, crimping portions, in the axial continuation of the cylindrical body, the portion of which closest to the body, called the front portion, is designed to be crimped around the core of the cable, while the portion of which furthest from the body, called the rear portion, is designed to be crimped around the insulating sheath and/or, where applicable, around the shielding braid, the front and rear crimping portions being of different constituent materials and/or thicknesses.

According to one embodiment, the front and rear crimping portions are of different constituent materials and joined by an electrically conductive or insulating joint. The nature of the materials may thus be different depending on the portion of a cable to be crimped: since the core is directly subjected to the flow of the current, in particular a power current, the front crimping portion may be made of a material with high conductivity, whereas, since the metal braid is only there for providing electromagnetic shielding, the rear crimping portion may be made of a material of lower conductivity. It is also possible to envisage an electrically insulating rear portion.

In other words, it is possible to produce a rear crimping portion of lesser thickness and/or conductivity for smaller currents and for crimping over a larger diameter, it is possible to adjust its mechanical characteristics as desired. It is therefore possible to select the materials or thicknesses according to their mechanical and electrical properties for each crimping portion independently and thereby reduce costs.

Preferably, the joint is formed by riveting, clinching, brazing, welding or bonding.

Advantageously, the rear crimping portion is continuous.

According to one advantageous embodiment, each of the two crimping portions comprises at least one accommodating hollow and at least one crimping wing connected to the hollow, the hollow of the front crimping portion being intended to accommodate the core of the cable while the hollow of the rear crimping portion is intended to accommodate the insulating sheath and/or the braid of the cable.

According to one advantageous variant, the rear crimping portion comprises at least one crimping wing designed to be crimped around the outer and/or inner insulating sheath of the insulated cable or around a seal fitted around the outer sheath of the insulated cable.

According to this variant, the rear crimping portion advantageously comprises at least one crimping wing designed to be crimped around the shielding braid of the cable.

Preferably, the pre-assembled central contact comprises an electrically insulating part in which the electrically conductive body is housed.

The invention also relates to a reel for automatically or semi-automatically joining a connector to a cable by crimping, comprising a plurality of sub-assemblies according to the second alternative of the invention as above, which are mechanically linked to one another by at least one carrier strip and wound around a spool.

Advantageously, the carrier strip is mechanically linked to or integral with the front or rear crimping portion or, where applicable, linked to the joint between the front and rear portions. Further advantageously, the carrier strip is pierced with a plurality of guide holes for guiding the carrier strip as the reel is unreeled.

The invention also relates to a method for joining at least one connector to a cable, comprising the following steps:

i2/ providing a shielded and insulated cable, the one or more conductive wires and the shielding braid being exposed at one end of the cable;

ii2/ providing a sub-assembly as above, preferably using a reel described above;

iii2/ positioning the cable in the pre-assembled sub-assembly such that the exposed portion of the one or more conductive wires is accommodated in the front crimping portion of the pre-assembled central contact and that the exposed portion of the shielding braid is accommodated in the rear crimping portion of the sub-assembly;

iv2/ crimping the front crimping portion of the pre-assembled central contact onto the one or more conductive wires and, preferably simultaneously, the rear crimping portion of the pre-assembled central contact onto the shielding braid, so as to obtain a unitary contact pre-assembled with the cable.

Advantageously, the method comprises, when step ii2/ is performed using the reel, a step iii′2/ of cutting the carrier strip, where applicable simultaneously with step iii2/ of positioning the cable,

Step iii′2/ is preferably mechanical cutting of the carrier strip using a blade or mechanical cutting by shearing or by means of laser cutting.

According to one variant, step iv2/ is carried out with at least part of the pre-assembled sub-assembly placed on a crimping support.

According to one advantageous variant, step i2/ further comprises the provision of a seal fitted around the outer or inner sheath of the cable, step iv2/ further comprising the crimping of the rear portion of the sub-assembly, preferably simultaneously with the crimping thereof onto the shielding braid, onto the seal.

Another subject of the invention is a cable-connected unitary contact, where applicable shielded, obtained using the method described above.

Thus, the invention according to the second alternative first consists in defining a pre-assembled connector sub-assembly that incorporates front and rear crimping portions with different electrical and/or mechanical characteristics, and which is ready to be directly crimped to an insulated and shielded cable, prepared beforehand, which makes it possible to minimize assembly steps and associated risks such as those due to the processes of fitting together a great many components according to the prior art.

The advantages of the invention according to both the first and the second alternatives are numerous with respect to the prior art, among which may be mentioned:the manufacture of a connector sub-assembly, preferably within a continuous reel, that is ready to be joined by crimping to a cable in a single step compatible with the use of robust crimping tools (jaws that are oversized with respect to the prior art);assembly that allows the straightforward integration of a sealing function per unitary assembly within a single-channel connector or per multichannel connector;assembly that allows the possibility of modularity in electromagnetic shielding functions at the level of a unitary contact or at the level of a multichannel connector of the contact;assembly that is easy to implement automatically.

In addition, with respect to the first alternative, the advantages of the solution according to the second alternative of the invention are the saving of space and the possibility of using less metal material when assembling in a continuous process, by implementing just a carrier strip, and by virtue of a smaller spacing between two successive pre-assembled sub-assemblies, and therefore lower cost.

The applications envisaged for the invention are numerous, among which may be mentioned the power electrical connections in hybrid or electric motor vehicles. More generally, the invention may be adapted for different applications and cable diameters (from 6 kW to around 300 kW).

Other advantages and features of the invention will become more clearly apparent from reading the detailed description of exemplary implementations of the invention, given by way of non-limiting illustration with reference to the following figures.

Throughout the present application, the terms “vertical”, “lower”, “upper”, “bottom”, “top”, “below” and “above” should be understood by way of reference with respect to a one-piece blank, a connector sub-assembly and an electrical connector according to the invention in horizontally arranged configuration.

Likewise, the terms “front” and “rear” should be understood with respect to the connecting face of an electrical connector according to the invention. Thus, the front crimping portion of a one-piece blank is that intended to be crimped at the front of a connector while the rear portion is that intended to be crimped at the rear of the connector where the shielded cable is positioned.

For the sake of clarity, one same reference numeral is used for any element that is the same in the first and second alternatives of the invention.

FIG.1shows one example of a shielded and insulated power cable, denoted overall by the reference numeral1, intended to be joined to a connector sub-assembly according to the invention.

The cable1comprises one or more electrical conductors10, of large cross section and insulated from the outside by an outer sheath11made of electrically insulating material.

The cable1also comprises a metal braid12for electromagnetic shielding surrounding the one or more conductors10and insulated therefrom by an inner sheath13made of electrically insulating material.

Where applicable, the cable1may comprise a ribbon made of metal or of a metal/plastic composite material14, the advantage of which is excellent electromagnetic coverage, typically of the order of 100%.

The various steps in the assembly of a pre-assembled connector sub-assembly according to a first alternative of the invention will now be described with reference toFIGS.2A to2F.

Step 1/: A central contact2is pre-assembled. To do this, a portion forming a petalled sleeve21, made of electrically conductive material, is fitted into and crimped to an electrically conductive cylindrical body20(FIGS.2A,2B). The crimping operation may be replaced with a snap-fitting operation. The sleeve21is extended at the rear by a crimping portion that takes the overall shape of a U comprising an accommodating hollow22and two crimping wings23that are connected to the hollow22, and are preferably symmetrical on each side of the hollow.

Step 2/: The pre-assembled central contact2is then fitted into and secured to an electrically insulating part3. More precisely, this assembly is carried out so that the cylindrical body20is completely housed and secured inside an electrically insulating cylindrical body30and the crimping portion22,23which protrudes from the rear of the insulating body30is delimited by a cylindrical bearing segment31, as described in detail hereinafter (FIGS.2C,2D).

Step 3/: A metal one-piece blank5is provided for assembly by crimping (FIG.2E). Assembly may also be performed using a force-fitting, clip-fastening or overmolding technique, as described in detail hereinafter. This metal blank is produced by means of a die-cutting technique, preferably rolled off a continuous strip.

This one-piece blank5first comprises a peripheral rim50forming an openwork support which extends along a longitudinal axis X and which, in the example illustrated, takes the overall shape of a rectangle.

Two, respectively front and rear, crimping portions51,52each extend along the longitudinal axis X while being separated from one another, and are held to the support50by at least one strip53,54forming a tie. These ties may also be located along the longitudinal axis X. In the example illustrated, two lateral ties53,54are provided which extend from either side of each of the crimping portions51,52. The function of these lateral ties53,54is to hold the crimping portions51,52once the connector sub-assembly has been produced.

The front crimping portion51comprising an accommodating hollow56and at least one crimping wing57connected to the hollow56and designed to accommodate and to be crimped around the electrically insulating part3housing the pre-assembled central contact2. In the example illustrated, two crimping wings57connected to the hollow56are provided, preferably facing one another on either side of the hollow56.

The rear crimping portion52comprising an accommodating hollow58and at least one crimping wing59connected to the hollow58and designed to be crimped around the shielding braid12of the insulated cable1. The rear crimping portion also comprises at least one crimping wing59.2designed to be crimped around a seal7. In the event that no sealing is required, the seal is not needed and the crimping wing is directly crimped around the outer sheath of the cable.

In the example illustrated, two pairs of crimping wings59.1,59.2connected to the hollow58are provided, preferably facing one another on either side of the hollow58.

Preferably, the rear crimping portion52is continuous in order to ensure the electrical ground continuity.

The one-piece blank5further comprises a bearing strip55, which is connected to the support50and extends inside same between the two crimping portions51,52so as to form a bearing region for the electrically insulating part3.

In the example illustrated, the bearing strip55is continuous from one longitudinal edge of the support50to the other. The central segment of the bearing strip55is shaped into a segment of a cylinder complementary to the bearing segment31. It may take the form of a strip where one end thereof is connected to a longitudinal edge of the support50and the free end thereof serves to support the segment31of the electrical insulator3.

The arrangement of the front and rear crimping portions51,52of the different ties53,54and of the bearing strip55relative to the preferably planar support50defines empty spaces (V) or openings between and around the crimping portions. These empty spaces (V) allow crimping jaws to pass through, specifically crimping jaws that are sized so as to be robust and therefore to crimp cables1of large cross section, in particular power cables.

Step 4/: The electrical insulator3is positioned in the front crimping portion51of the blank5(FIG.2E). More precisely, it is positioned so that the body30of the insulator3fits snugly in the crimping hollow56and the cylindrical segment31bears against the bearing strip55.

The crimping wings57are then folded around the cylindrical body30. The electrical insulator3is then crimped within the one-piece blank5, which forms a connector sub-assembly6intended to be joined by crimping to a cable1(FIG.2F).

To facilitate automation and assembly in a continuous process, it is possible to produce a continuous strip of a plurality of unitary sub-assemblies6.1to6.5which are joined together by one of the longitudinal edges of their supports50(FIG.3).

To further optimize assembly, for compactness, to facilitate storage and transport, the continuous strip may take the form of a continuous reel60wound around a spool (FIG.4). This reel60may be entirely produced in an independent assembly unit with respect to an assembly unit for joining to a cable1.

The various steps in preparing a shielded and insulated cable1according to the invention will now be described with reference toFIGS.5A to5C.

Step 1/: The outer sheath11and the inner sheath13are pre-stripped to reveal the one or more conductors10and the metal braid12, respectively, over a predetermined length (FIG.5A).

Step 2/: A seal7is fitted around the outer sheath11of the cable1(FIG.5B). According to one variant, this step 2/ may take place before step 1/ in order to avoid any potential damage to the metal braid.

Step 3/: The stripped portion of the inner sheath13of the cable1is removed (FIG.5C). The various steps in the joining of a pre-assembled connector sub-assembly6according to the first alternative to an insulated and shielded cable in order to obtain a cable-connected unitary contact9will now be described with reference toFIGS.6A to6F.

Step ii1/: A sub-assembly6cut from the reel60is provided.

Step iii1/: The cable1is positioned in the sub-assembly6such that the exposed portion10of the one or more conductive wires1is accommodated in the crimping portion22,23of the pre-assembled central contact2and that the exposed portion of the shielding braid12and the seal7are accommodated in the hollow58of the rear crimping portion52of the sub-assembly6(FIG.6A).

Step iv1/: Simultaneously, by means of a jaw-anvil crimping tool (M), inserted into the openings or empty spaces (V) between the support50and the one or more ties53,54and the one or more bearing strips55, the crimping portion22,23of the pre-assembled central contact is crimped onto the one or more conductive wires10and the rear crimping portion52of the sub-assembly is crimped onto the shielding braid12and onto the seal7(FIG.6B). Thus, the robust jaws M simultaneously fold the pair of crimping wings23around the one or more conductors10and each of the two pairs of crimping wings59.1and59.2around the metal shielding braid12and the seal7, respectively.

Step v1/: The ties53,54are cut either mechanically, using a blade, or by means of laser (FIG.6C).

Step vi1/: The central contact2crimped around the one or more conductive wires10is then fitted into the insulating part3, joining them together definitively by snap-fitting (FIG.6D).

Step vii1/: A shielding envelope8is positioned and snap-fitted around both the electrically insulating part and the crimped front portion51, so as to obtain a shielded unitary contact9(FIGS.6E and6F).

It is snap-fitted such that the rear of the shielding envelope8abuts against the front of the seal7. Lastly, the envelope8is crimped at the level of the crimping of the wings59.2and of the hollow for the seal7, thereby ensuring electrical continuity between the shielding braid of the cable, the hollow58of the support and the shielding envelope8. Effective shielding is then ensured.

The assembly of a two-channel connector100on the basis of two unitary connectors9.1,9.2obtained from step vii1/ will now be described with reference toFIGS.7A to7D.

Step viii1/: the two unitary connectors9.1,9.2are inserted into a one-piece connector housing90until their fronts come into abutment inside the housing (FIGS.7A,7B). The contacts are snap-fitted into the housing90.

Step ix1/: The forces on the cable are absorbed and the two unitary contacts9.1,9.2are protected by attaching two retaining clamps91,92at the rear of the connector housing90(FIGS.7C,7D).

The front of the two-channel connector100, as finally assembled, is shown inFIG.8. The connector100obtained therefore has individual electromagnetic shielding for each unitary contact9.1,9.2and overall fluid sealtightness at the level of the housing90.

Different variants may be envisaged for the ties53,54for the front and rear crimping portions51,52, respectively, of the one-piece blank5according to the first alternative of the invention.

It is further possible to envisage a pair of additional crimping wings59.3to be crimped to the rear of the insulator of the component.

The crimping portions51,52are raised with respect to the plane of the support frame50. This allows the cable to be inserted without the support frame50getting in the way.

Conversely, it is possible to envisage only ties53,54, preferably in pairs, for each of the portions51,52which extend transverse to the longitudinal axis X (FIG.10). These lateral ties53,54allow the crimping portions51,52to be held with better stability.

It is also possible to combine longitudinal and lateral ties53,54(FIG.11).

FIGS.12A to12Gshow the various steps in one alternative method for assembling a two-channel connector100incorporating two cable-connected unitary contacts obtained from a sub-assembly according to the first alternative of the invention.

Steps i1/ to v1/ are not described here, these being the same as those described previously with the exception that the seal7is fitted around the inner sheath13between the shielding braid and the crimping region of the central contact, a pair of crimping wings59.2then being folded beforehand around the seal7(FIGS.12A,12B). A unitary contact9′ is thus obtained. Upon completion of this step, the unitary contact9′ is not shielded.

Step vii′1/: At least one shielding envelope80that surrounds the rear portion52with the wings59.1,59.2,59.3crimped is then mounted (FIGS.12C,12D), and then a shielding envelope81that surrounds both the electrically insulating part3and the crimped front portion51is mounted (FIGS.12E,12F), so as to obtain a shielded unitary contact9.

Step viii′1/: Next, two interface housing half-shells93,94are mounted around two shielded unitary contacts9.1,9.2according to step vii′1/ (FIG.12G).

The connector100obtained according to this alternative embodiment and shown inFIG.12Htherefore has individual electromagnetic shielding for each unitary contact9.1,9.2and also individual fluid sealtightness for each unitary contact9.1,9.2. The electromagnetic shielding of this connector may be of higher performance than that obtained with unitary contacts9shown inFIG.6F.

FIG.13shows one alternative embodiment of a connector100based on unshielded unitary contacts9′1,9′2like that9′ illustrated inFIG.12B, obtained from a sub-assembly according to the first alternative of the invention.

Steps i1/ to v1/ are not described here, these being the same as those described previously with the exception that the seal7is fitted around the inner sheath13, a pair of crimping wings59.2then being folded beforehand around the seal7(FIGS.12A and12B).

Step vi″1/: The central contact crimped around the one or more conductive wires is fitted into the electrically insulating part3, joining them together definitively, and the wings59.3are crimped onto the insulator3to hold the assembly together.

Step vii″1/: Two shielding half-shells82,83are mounted which cover both the electrically insulating part3and the front crimping portion51and the crimped wings59.3,59.2and59.1(FIG.13).

Step viii″1/: Two interface housing half-shells93,94are mounted around the unshielded contacts9′1,9′2according to step vii″1/.

In this embodiment, two support half-shells95,96may be inserted, each being inserted between the two unitary contacts9′1,9′2and a shielding half-shell82,83(FIG.13) for support and to absorb the forces that may be exerted on the sub-assemblies9.

The connector100obtained according to this other alternative embodiment therefore has overall electromagnetic shielding for the two unitary contacts9′1,9′2and individual fluid sealtightness for each unitary contact9′1,9′2.

FIG.14shows one variant embodiment of a two-channel connector housing.

Protruding projections930may be incorporated inside the housing to support the front of the sub-assembly9′, typically bearing against the crimped wings57or hollow56. These positioning projections replace the support half-shells95,96.

One or more metal projections831may also be incorporated into the shieldings82and83to ensure electrical continuity with the one or more shieldings of the one or more contacts9′1,9′2.

While in the preceding figures the metal one-piece blank5according to the first alternative of the invention is produced by means of a die-cutting technique, preferably rolled off a continuous strip and then joined by crimping to the sub-assembly consisting of a central contact2pre-assembled in an electrically insulating part3, it is also possible to envisage other techniques for producing a connector sub-assembly.

For example, it is possible to envisage assembly of a metal one-piece blank5′ by clip-fastening the electrically insulating part3housing the pre-assembled central contact2into the planar support50(FIGS.15A,15B). To do this, the ties53of the front portion51are each provided at their free end with a flexible hook531which snaps into an eye32protruding from the periphery of the electrically insulating portion30.

Alternatively, it is possible to envisage assembly of a metal one-piece blank5′ by force-fitting by catching of the electrically insulating part3housing the pre-assembled central contact2into the planar support50(FIGS.16A,16B). To do this, the ties53of the front portion51are each provided at their free end with a catch532which is caught in an eye32protruding from the periphery of the electrically insulating portion30.

Alternatively, it is possible to envisage assembly of a metal one-piece blank5″′ by overmolding of the electrically insulating part3housing the pre-assembled central contact2onto the planar support50(FIGS.17A,17B). To do this, the ties53of the front portion51are each provided at their free end with an overmolding support533over which the periphery of the electrically insulating portion30is overmolded.

The various steps in the assembly of a pre-assembled connector sub-assembly according to a second alternative of the invention will now be described with reference toFIGS.18A to18F.

Step 1/: A central contact2is pre-assembled. To do this, a portion forming a petalled sleeve21, made of electrically insulating material, is fitted into and crimped to an electrically conductive cylindrical body20(FIGS.18A,18B). The crimping operation may be replaced with a snap-fitting operation.

The sleeve21is extended at the rear by a front crimping portion that takes the overall shape of a U comprising an accommodating hollow22and two crimping wings23that are connected to the hollow22, and are preferably symmetrical on each side of the hollow. These crimping wings23are intended to accommodate and to be crimped around the one or more conductors10of the cable1.

An outgrowth of material24is provided in the rear continuation of the accommodating hollow22. This outgrowth of material24forms an assembly joining portion, as described in detail hereinafter.

Step 2/: A metal crimping rear portion4is provided for assembly with the central contact sub-assembly2(FIG.18C).

This crimping portion4is produced by means of a die-cutting technique, preferably rolled off a continuous strip. Advantageously, the material and/or the thickness of this crimping rear portion4is different from that of the sleeve21.

This rear crimping portion4comprising an accommodating hollow40and at least one crimping wing41connected to the hollow40and designed to be crimped around the shielding braid12of the insulated cable1.

The rear crimping portion4also comprises at least one crimping wing42designed to be crimped around a seal7. In the event that no sealing is required, the seal is not needed and the crimping wing42is directly crimped around the outer sheath of the cable.

Preferably, the rear crimping portion4is continuous in order to ensure the electrical ground continuity.

This crimping rear portion4further comprises an outgrowth of material43provided in the front continuation of the accommodating hollow40.

Step 3/: The rear crimping portion4is positioned facing the front crimping portion22,23formed in the sleeve21(FIG.18C). More precisely, they are positioned such that the two outgrowths of material24,43are in contact with one another.

These outgrowths24,43are then welded together in order to produce the assembly.

They may also be joined using a riveting, clinching, brazing or bonding technique between the two outgrowths24,43which may be adapted depending on the technique used.

A sub-assembly2′ is thus obtained here.

Step 4/: The central contact2of the sub-assembly2′ is then fitted into and secured to an electrically insulating part3(FIG.18D). More precisely, this assembly is carried out so that the cylindrical body20is completely housed and secured inside an electrically insulating cylindrical body30and the crimping portion22,23which protrudes from the rear of the insulating body30is delimited by a cylindrical bearing segment31, as described in detail hereinafter (FIG.18E).

This step 4/ of adding an electrically insulating part is optional. It may also take place after step 1/ or step 2/.

A pre-assembled connector sub-assembly6′ is then ready.

To facilitate automation and assembly in a continuous process, it is possible to produce a continuous carrier strip44of a plurality of unitary sub-assemblies2′1to2′5or6′1to6′5which are adjacent and therefore joined together mechanically by this carrier strip44(FIGS.19,20).

The width L, which defines the spacing between two adjacent sub-assemblies6′ or2′, may be adjusted as needed. By decreasing it, the density of sub-assemblies on the reel, i.e. the number of sub-assemblies that one same reel61can hold, is increased.

Multiple positions for the carrier strip44, also called the edge strip, are possible.

For example, as shown inFIG.19, the carrier strip44may be arranged on the outside of each unitary sub-assembly6′, secured to the rear crimping portion4.

It is also possible to arrange it between the front22,23and rear crimping portions4, preferably at the level of the assembly joint between the outgrowths of material24,43(FIG.20).

It may also be secured to the front crimping portion22,23. It is also possible to secure it to an element outside of the front and rear crimping portions.

To move the carrier strip44along during assembly in a continuous process, at least one guide or driving hole45for guiding or driving this strip is provided. Preferably, there is at least one guide hole45facing each sub-assembly5. These guide holes45have multiple functions, including:allowing the strip44to be moved along with a high degree of precision;allowing, in subsequent cutting or rolling steps, the sub-assembly2′ or6′ to be positioned on the rolling or cutting tools;allowing, in an operation of assembly between two strips44, the strips to be guided and moved along and positioned;allowing the strip44to be driven and then held and positioned during a crimping operation;facilitating winding onto a reel.

As shown inFIG.21with respect to the variant in which the carrier strip44is secured to the rear crimping portion4, on the outside of the sub-assembly5, a driving hole45is pierced directly facing the hollow40.

Additional holes45may be pierced at other locations in the carrier strip44(FIG.22).

To further optimize assembly, for compactness, to facilitate storage and transport, the continuous strip may take the form of a continuous reel61wound around a spool (FIG.23). This reel61may be entirely produced in an independent assembly unit with respect to an assembly unit for joining to a cable1.

The various steps in preparing a shielded and insulated cable1according to the invention will now be described with reference toFIGS.24A to24C.

Step 1/: A seal7is fitted around the outer sheath11of the cable1(FIG.24A) to avoid any potential damage to the metal braid12, the one or more conductors10or the seal7itself.

Step 2/: The outer sheath11and the inner sheath13are pre-stripped to reveal the one or more conductors10and the metal braid12, respectively, over a predetermined length (FIG.24B). Alternatively, step 2/ may be carried out before step 1/.

Step 3/: The stripped portion of the inner sheath13of the cable1is removed (FIG.24C). The various steps in the joining of a pre-assembled sub-assembly2′ or6′ to an insulated and shielded cable in order to obtain a cable-connected unitary contact9will now be described with reference toFIGS.25A to25H.

Step ii2/: A pre-assembled sub-assembly2′ or6′ secured to the reel61by the carrier strip44is provided, which is placed on a crimping support S.

The crimping support S supports at least the hollow22and40of the front and rear crimping portions and preferably also the electrically insulating cylindrical body30(FIG.25A). This crimping support S advantageously features cylindrical portions which snugly fit the hollows22,40of the front and rear crimping portions of the pre-assembled sub-assembly2′ or5, respectively.

A mechanical cutting tool D for cutting the carrier strip44is positioned around same (FIG.25A).

Step iii2/: The cable1equipped with the seal7is positioned in the sub-assembly2′ or6′ such that the exposed portion10of the one or more conductive wires1is accommodated in the front crimping portion22,23of the pre-assembled central contact2′ or6′ and that the exposed portion of the shielding braid12and the seal7are accommodated in the hollow40of rear crimping portion4of the sub-assembly2′ or6′ (FIG.25B).

Step iii′2/: The jaws M are brought as close as possible to, preferably in contact with, the crimping wings23,41,42in order to prevent them from rotating when the carrier strip is cut. Next, the carrier strip44is cut which is done by shearing the cutting tool D downward (arrow ofFIG.25C), once the cable has been positioned.

Step iv2/: Next, by means of a jaw-anvil crimping tool (M/S), the front crimping portion22,23of the pre-assembled central contact is crimped onto the one or more conductive wires10and the rear crimping portion4of the sub-assembly is crimped onto the shielding braid12and onto the seal7(FIG.25D).

Thus, the jaws M simultaneously fold the pair of crimping wings23around the one or more conductors10and each of the two pairs of crimping wings41and42around the metal shielding braid12and the seal7, respectively. The crimping jaws M are advantageously sized so as to be robust and therefore to crimp cables1of large cross section, in particular power cables.

Once crimping has been carried out, the crimping jaws M are withdrawn and the unitary contact9′ crimped onto the cable then just has to be removed from the crimping support S (FIGS.25E,25F).

Step v2/: To finish the cable-connected unitary contact9′, the electrically insulating part3is pushed into its final position of use (FIG.25G).

Step vi2/: At least one shielding envelope8that surrounds both the electrically insulating part3and the crimped portions is mounted so as to obtain a shielded unitary contact9(FIG.25H).

On the basis of this shielded unitary contact9, it is possible to produce multichannel connectors like according to the variants described with reference toFIGS.12G and12HorFIGS.13and14.

Other variants and improvements may be made without however departing from the scope of the invention.

In the illustrated examples of the invention, the central contact2is of female type and is produced from two distinct parts20and21. It is possible to envisage producing a central contact of male type and a central contact as just one part.