A generic connecting arrangement is known from DE 697 12 414 T2. A first cable is in- serted into a housing bottom part. An end piece of a second cable is inserted into a housing upper part and locked by a screw-terminal. The insulated conductors of the second cable are isolated and inserted in mouldings of the housing upper part. A printed circuit board provided with piercing elements is then arranged on the housing upper part such that the piercing elements are each inserted into the isolated conductors of the second cable. By shutting the housing parts the piercing elements are also inserted into the first cable.

Assembly of the device is very complex and there is a certain susceptibility to failure in practice.

The object of the invention is to improve a connecting arrangement of the type men- tioned at the outset such that the connecting arrangement is, in an optimally simple manner, less susceptible to failure, easier to handle and assemble.

To acheive the forgoing and other objectives, the invention provides a connecting ar- rangement comprising at least first and second housings, in which at least one conduc- tor of a first cable can be electrically connected to at least one conductor of a second cable fed via a cable receiver. At least one piercing element is electrically connected to the second cable and configured to be inserted transversely into the conductor of the first cable. To improve the connecting arrangement to the extent that, in an optimally simple manner, it is less susceptible to failure, is easier to handle, and is easier to as- semble, the cable receiver is constructed as an integral unit with the second housing and the piercing element. The invention also relates to a method with which a connect- ing arrangement can be produced.

An embodiment of the invention is shown in the drawings and will be described hereinaf- ter. In the drawings: Fig. 1 shows a perspective view of the connecting arrangement according to the inven- tion with incorporated first and second cables, Fig. 2 shows a sectional view of the connecting arrangement of Fig. 1, Fig. 3 shows an enlarged view of a detail from Fig. 2, Fig. 4 shows a perspective view of an integral unit of the connecting arrangement with incorporated second cable, Fig. 5 shows a perspective view of a cable receiver, and Fig. 6 shows an exploded view of the connecting arrangement of Fig. 1.

Fig. 1 shows a connecting arrangement 1 according to the invention with a first housing 2, a second housing 3 and a cable receiver 4. A first cable 5 is received longitudinally in the first housing 2, between the first and second housings 2,3. The first cable 5 com- prises conductors 6, 7,8. The cable receiver 4 receives a second cable 9 with conduc- tors 10, 11,12.

Fig. 2 shows a section through the connecting arrangement 1 shown in Fig. 1. The cable receiver 4, piercing elements 13,14, 15 and the second housing 3 are constructed as an integral unit 16. The piercing elements 13,14, 15 are each electrically connected to a conductor 10,11, 12 of the second cable 9 by crimping. The conductor 12 and the pierc- ing element 14 are shown by way of example in Fig. 2. The piercing elements 13,14, 15 and the second cable 9 are partially embedded in the integral unit 16. The integral unit 16 of second housing 3 and cable receiver 4 is formed on the second cable 9 and the piercing elements 13,14, 15 in an interlocking and sealing manner by moulding.

A sealing element 17, with which the piercing points of the piercing elements 13,14, 15 can be sealed, is arranged on the inner side 28 (shown in Fig. 4) of the second housing 3 of the integral unit 16. The sealing element 17 is constructed in one piece with the ca- ble receiver 4 and is therefore a component of the integral unit 16. The sealing element 17 comprises connecting portions 18,19 extending through connecting cavities 46,47 of the second housing 3, and integrally connecting the sealing element 17 on the inner side 28 of the housing and the cable receiver 4 on the outer side 36 of the housing. The seal- ing element 17 is designed to be undercut with respect to the cable receiver 4 and is partially arranged in a sealing recess 48 of the second housing 3.

In another embodiment of the invention the sealing element can be arranged separately from the cable receiver 4 on the second housing 3 or can be formed thereon. The seal- ing element 17 can be a component of the integral unit 16 in this case.

The sealing element 17 comprises a sealing lip 37 oriented toward an inner side 28 of the housing of the integral unit 16. The sealing lip 37 is designed in one piece with the sealing element 17.

The cable receiver 4 is formed on the second housing 3 with an interlocking fit. The ca- ble receiver 4 is constructed so as to correspond to a toothed profile portion 20 of the second housing 3. This can be seen particularly clearly in the enlarged detail 21 of Fig. 2 shown in Fig. 3. Relatively large forces can be transmitted between the cable receiver 4 and the second housing 3, in particular in the longitudinal direction of the second cable 9, as a result of the interlocking tooth configuration between the second housing 3 and the cable receiver 4.

The piercing element 14 is also shown enlarged in the detail 21 shown in Fig. 3. This has a fastening portion 22 with which it is attached to the conductor 11 by crimping. To- ward the inner side 28 of the second housing 3 of the integral unit 16 the piercing ele- ment 14 has a piercing point 24 tapering in the direction of the inner side 28. The pierc- ing point 24 of the piercing element 14 is inserted into the conductor 7 of the first cable 5 by application of force.

The piercing element 14 comprises support shoulders 26 in the region of the piercing point 24. The support shoulders 26 are designed substantially transversely to the longi- tudinal direction of the piercing element 14 and each have a bearing face 50. The pierc- ing element 14 is connected to an abutment portion 27 of the sealing element 17 by the bearing faces 50. In the illustrated assembled state of the connecting arrangement 1 the sealing element 17 is pressed against the surface of the first cable 5 by the support shoulders 26 in the region of the abutment portion 27. The sealing element 17 is there- fore pressed against the first cable 5, particularly in the region of the piercing point 24.

The support shoulders can optionally be designed as continuous disc-shaped support collars transverse to the longitudinal direction of the piercing element 14.

The piercing element 14 is inserted transversely into the conductor 7 of the first cable 5 and is consequently electrically connected thereto.

Similarly, the piercing elements 13 and 15 may also be inserted into corresponding con- ductors 6,8 of the first cable 5.

The first and second housings 2,3 are produced from thermoplastic polymer. This pro- vides the housings 2,3 with a rigidity sufficient for secure retention of the first cable 5, for reliable connection of the housings 2,3 to one another and for reliable transmission of forces between the cable receiver 4 and the second housing 3.

The sealing element 17 and the cable receiver 4 consist of a thermoplastic elastomer.

This gives both components sufficient flexibility. The cable receiver 4 can therefore be easily reshaped within a certain range in order to be able to compensate for changes in the relative position of second housing 3 and second cable 9. The sealing element 17 has sufficient flexibility to adapt well to the bearing faces 50.

Fig. 4 shows the integral unit 16 with partially embedded piercing elements 13,14, 15 and partially embedded second cable 9 in a perspective view. The inner side 28 of the housing of the integral unit 16 in particular is shown in more detail.

The second housing 3 has a large number of ribbings 29 adapted to the outer contour of the first cable 15. The second housing 3 is reinforced by the ribbings 29. A plurality of guide holes 30 and screw recesses 31 as well as tab grooves 32 are also provided.

The piercing points 23,24, 25 of the piercing elements 13,14, 15 project beyond the inner side 28 of the second housing 3. The piercing points 23,24, 25 are each substan- tially annularly surrounded by the sealing element 17.

In another embodiment of the invention the piercing points 23,24, 25 can also be pe- ripherally surrounded in a different manner, for example angularly, elliptically or irregu- larly.

Fig. 5 shows a detail perspective view of the cable receiver 4 together with its sealing element 17. On its outer surface the cable receiver 4 comprises, on either side, a grip- ping profile 33 and stress-reducing mouldings 34. The gripping profile 33 facilitates grip- ping and handling of the cable receiver 4 and therefore of the integral unit 16 by a user, particularly with regard to the application of forces in the longitudinal direction of the second cable 9. The stress-reducing mouldings 34 are used to reduce and compensate tensile and compressive stresses resulting during bending stress of the cable receiver 4.

A terminal bead 35 is disposed at an end 51 of the cable receiver 4, remote from the second housing 3. The terminal bead 35 is substantially annular in shape and is used to reinforce the cable receiver 4, in particular with respect to forces introduced into the ca- ble receiver 4 by the second cable 9, and vice-versa.

The sealing element 17 comprises a sealing lip 37. The sealing lip is oriented toward the inner side 28 of the housing of the integrated unit 16. It surrounds respective, substan- tially annular openings 38,39, 40 of the sealing element 17 resulting from the forming of the cable receiver 4 (and therefore of the sealing element 17) to the piercing elements 13,14, 15. The sealing lip 37 is also provided all the way around and conforming to the outer contour of the bearing portion 27.

In another embodiment of the invention the sealing lip 37 can also be constructed so as to be peripheral only corresponding to the outer contour of the bearing portion 27. In this case, the sealing lip jointly seals piercing points produced by the piercing elements 13, 14,15.

Fig. 6 shows the connecting arrangement in an exploded view. According to its ar- rangement in the integral unit 16, the conductors 10,11, 12 of the second cable 9 are shown isolated and spread apart.

The first housing 2, like the second housing 3, also has a large number of ribbings 41 which are designed to conform to the outer contour of the first cable 5 and are used to stabilise the first housing 2. In addition, the first housing 2 comprises tabs 42 designed to correspond with the tab grooves 32, guide pins 43 designed to correspond to the guide holes 30, and screw holes 44 corresponding to the screw recesses 31. Screws 45 can be introduced through the screw holes 44 and can be screwed into the screw re- cesses 31.

The piercing elements 13,14, 15 are arranged diagonally, and substantially in series, with respect to a direction perpendicular to the conductors 6,7, 8 of the first cable 5..

In a modified embodiment of the invention the piercing elements 13,14, 15 can be ar- ranged substantially transversely also in a row, with respect to the conductors 6, 7,8 of the first cable 5.

The production method according to the invention of the connecting arrangement will be described hereinafter.

The conductors 10,11, 12 of the second cable 9 are isolated and bared. The piercing elements 13,14, 15 are then arranged in electrical connection on the conductors 10,11, 12. This can be done, for example, by crimping or soldering. The second housing 3 is formed on the second cable 9, connected to the piercing elements 13,14, 15 to corre- spond to the shape of the second cable and/or the piercing elements 13, 14, 15. The cable receiver 4 is formed onto the second housing 3. The cable receiver 4 is con- structed to correspond to the shapes of the second housing 3 and of the second cable 9 and optionally of the piercing elements 13,14, 15. The cable receiver 4 is preferably formed onto the second cable 9 and piercing elements 13,14, 15 by moulding. How- ever, other methods are also possible, for example sintering. The second housing 3 and the cable receiver 4 are formed into the integral unit 16 by being formed on one another.

During construction of the second housing 3 the connecting cavities 46,47 and the seal- ing recess 48 are also formed.

The toothed profile portion 20 of the second housing 3 is moulded during forming of the cable receiver 4 and the sealing element 17. The connecting cavities 46,47 of the sec- ond housing 3 and the sealing recess 48 are also filled, whereby the connecting portions 18,19 and some of the bearing portion 27 of the sealing element 17 are formed. The contour of the sealing element 17 at housing inner side 28 is determined by a mould, whereby the sealing lip 37 is also provided. The contour of the sealing element 17 annu- larly surrounding the piercing points 23, 24, 25 is also produced.

In another embodiment of the invention the sealing element 17 can also be constructed separately to and/or from the cable receiver 4 on the second housing 3. The sealing element can also be produced as part of the integral unit 16.

Thermoplastic polymer is preferably used to produce the second housing 3 and thermo- plastic elastomer to produce the cable receiver 4 and the sealing element 17.

The first housing 2 is produced independently of the construction of the integral unit 16, preferably from thermoplastic polymer.

The first cable 5 is positioned in the first housing 2 to produce an electrical connection between the piercing elements 13,14, 15 and the conductors 6,7, 8 of the first cable 5.

The integral unit 16 is then assembled on the first housing 2. During joining the piercing points 23,24, 25 of the piercing elements 13,14, 15 protruding from the second housing 3 penetrate transversely into a respective conductor 6,7, 8 of the first cable 5, an insula- tion 49 of the first cable being pierced, (as shown in Fig. 2). Electrical contact is thus produced in each case between the conductors 10,11, 12 of the second cable 9 and the conductors 6,7, 8 of the first cable 5.

During joining the sealing element 17 is also pressed against the first cable 5 by the second housing 3 and, in particular, by the support shoulders 26 of the piercing ele- ments 13,14, 15. The piercing points are thereby sealed against environmental influ- ences resulting from insertion of the piercing elements 13,14, 15 in the first cable 5.

During assembly of integral unit 16 and first housing 2, the guide pins 43 are introduced into the guide holes 30. The integral unit 16 and the first housing 2 are thereby precisely positioned with respect to one another. Consequently, the piercing elements 13,14, 15 are inserted into the first cable 5 in predetermined positions. The tabs 42 also slide into the corresponding tab grooves 32 and latch in an end position. The screws 45 are intro- duced through the screw holes 44 into the screw recesses 31 and are tightened.