DE102018100440A1 - A method of making a cold-formable crimp contact, method of making an electro-mechanical crimp connection and crimp contact - Google Patents

Abstract

crimp contact,
- With an opening (4) for insertion of a conductor end to be pressed (16),
- And with one of the opening (4) facing away from connection area (6, 14),
- Wherein the crimp contact (2, 10, 12) consists of a brass material CuZn40, wherein the brass material
- 59.5 - 61.5 wt .-% copper (Cu),
up to 0.2% by weight of iron (Fe),
up to 0.1% by weight of lead (Pb),
up to 0.05% by weight of aluminum (Al),
up to 0.3% by weight of nickel (Ni)
up to 0.2% by weight of tin (Sn),
- up to 0,2% by weight of other ingredients,
- and the remainder zinc
having.

Description

The present invention relates to a method for producing a cold-formable crimp contact, a method for producing an electromechanical crimp connection, and a crimp contact.

When selecting the material for a crimp contact resulting from the required Crimpfähigkeit and machinability opposite requirements for the material. Thus, a crimpable material is characterized by a finely distributed structure without precipitates and with a high α content in the microstructure. Such a crimpable material may be a 2-material alloy having a low tensile strength and a high elongation at break, but this material is poorly machinable. In contrast, a good machinable material has a multi-phase structure with precipitates and with a higher β-content. Such a good machinable material has a high tensile strength and a low elongation at break.

It is possible to produce crimp contacts from a CuZn35Pb2 high-brass chipping brass, which is characterized by good machinability and good cold workability. It is disadvantageous that the material contains about 2 wt .-% lead, since lead-containing alloys with a lead content of 0.3 wt .-% are considered to be reprotoxic.

Tests have shown that the lead-free brass material CnZn42, e.g. is used for producing machined clamping sleeves, is unsuitable for crimp contacts, since the required for a crimped formations, especially at low conductor cross-sections are not achieved and it can come to rupture of the crimp. This applies equally to the material CuZn21Si3P, which is used in the sanitary industry and because of its low electrical conductivity for electromechanical connections is only limited suitable. Furthermore, CuZn21Si3P is only partially cold-formed due to the silicon precipitations.

Against this background, the technical problem underlying the present invention is to specify an improved method for producing a cold-formable crimp contact, an improved method for producing an electromechanical crimp connection and an improved crimp contact. The technical problem is solved in each case by a method for producing a cold-formable crimp according to claim 1, a method for producing an electro-mechanical crimp according to claim 5 and a crimp according to claim 8. Further embodiments of the invention will become apparent from the dependent claims and the description below.

• - Bereitstellen eines metallischen Rohlings, der aus einem Messingwerkstoff CuZn40 besteht, wobei der Messingwerkstoff
  • - 59,5 - 61,5 Gew.-% Kupfer (Cu),
  • - bis zu 0,2 Gew.-% Eisen (Fe),
  • - bis zu 0,1 Gew.-% Blei (Pb),
  • - bis zu 0,05 Gew.-% Aluminium (Al),
  • - bis zu 0,3 Gew.-% Nickel (Ni)
  • - bis zu 0,2 Gew.-% Zinn (Sn),
  • - bis zu 0,2 Gew.-% sonstige Bestandteile,
  • - und als Rest Zink
  aufweist;
• - Drehbearbeitung einer Mantelfläche des Rohlings mit einem Drehwerkzeug;
• - Herstellen einer Öffnung zum Einführen eines Leiterendes.

According to a first aspect, the invention relates to a method for producing a cold-formable crimp contact, with the method steps:

• - Providing a metallic blank, which consists of a brass material CuZn40, wherein the brass material
  • - 59.5 - 61.5 wt .-% copper (Cu),
  • up to 0.2% by weight of iron (Fe),
  • up to 0.1% by weight of lead (Pb),
  • up to 0.05% by weight of aluminum (Al),
  • up to 0.3% by weight of nickel (Ni)
  • up to 0.2% by weight of tin (Sn),
  • - up to 0,2% by weight of other ingredients,
  • - and the remainder zinc
  having;
• - Turning a lateral surface of the blank with a rotary tool;
• - Making an opening for insertion of a conductor end.

In the present case, the term "other constituents" refers to unavoidable impurities and / or deliberately alloyed alloy constituents in the range of impurities.

Investigations have shown that the brass material CuZn40 is suitable for the production and intended use of a crimp contact. Thus, the material for machining the crimp contact can be machined and reliably cold-formed to form an electromechanical crimped connection without causing the crimp contact to tear circumferentially.

The metallic blank may be cut to length rod or wire material.

The opening for insertion of a conductor end can be produced by machining, in particular turning and / or drilling.

A wall section of the crimp contact which delimits the opening on the circumference can be produced as a circular-cylindrical sleeve section or in the manner of a circular pipe section.

A wall of the crimp contact may have a transverse bore for visual inspection of the crimped connection. Furthermore, the transverse bore serves as a flow opening during galvanization of the crimp contact.

According to a further embodiment of the method, shavings detached from the metallic blank are broken and / or guided by means of the turning tool during turning, wherein a rake face of the turning tool has at least one depression and / or at least one elevation for breaking and / or guiding one of the metallic blank detached Span has. Thus, the formation of winding chips during turning can be avoided.

According to a further embodiment of the method, the brass material CuZn40 less than 0.1 wt .-% lead (Pb) on. It is therefore possible to use a substantially lead-free material with less than 0.1% by weight of lead (Pb), the lead content of which is below the value considered to be harmful to health.

It can be provided that the brass material has an α-structure with β-precipitates. Thus, the α-microstructure with β-precipitates can be used to achieve a compromise between the required forming capability and the machinability of the material that is suitable for a crimp contact.

• - Bereitstellen eines Crimpkontakts, wobei der Crimpkontakt nach dem voranstehend beschriebenen, erfindungsgemäßen Verfahren hergestellt worden ist;
• - Einführen eines zu verpressenden Leiterendes in die Öffnung;
• - Verpressen des Crimpkontakts mit dem Leiterende durch Kaltumformen des Crimpkontakts mithilfe eines Crimpwerkzeugs.

According to a second aspect, the invention relates to a method for producing an electromechanical crimp connection, with the method steps:

• - Providing a crimp contact, wherein the crimp contact has been prepared by the above-described method according to the invention;
• Inserting a conductor end to be pressed into the opening;
• - Pressing the crimp contact with the conductor end by cold forming the crimp contact using a crimping tool.

Thus, a crimped connection can be reliably produced without causing the crimping contact to rupture.

According to a further embodiment of the method, it is provided that a cross-sectional area of a conductor end is reduced by the pressing by at least 10%, in particular at least 20%. Thus, a reliable electromechanical connection between the conductor end of a stranded conductor and the crimp contact can be formed.

Alternatively or additionally, it can be provided that a minimum wall thickness of the crimp contact after pressing corresponds to at least half the wall thickness before pressing. The material is therefore so ductile that even small conductor cross-sections can be pressed reliably.

Alternatively or additionally, it may be provided that pressing of the crimp contact into a square crimp takes place. Thus, a symmetrical deformation of the crimp contact and a symmetrical, multi-sided pressing of a strand package of a conductor end to be pressed can be achieved.

With the method according to the invention, according to a further embodiment, even small conductor cross sections can be reliably pressed, wherein the conductor end to be pressed has a conductor cross section in a range of 0.25 mm ² to 1 mm ² .

• - mit einer Öffnung zum Einführen eines zu verpressenden Leiterendes,
• - und mit einem der Öffnung abgewandten Anschlussbereich,
• - wobei der Crimpkontakt aus einem Messingwerkstoff CuZn40 besteht, wobei der Messingwerkstoff
  • - 59,5 - 61,5 Gew.-% Kupfer (Cu),
  • - bis zu 0,2 Gew.-% Eisen (Fe),
  • - bis zu 0,1 Gew.-% Blei (Pb),
  • - bis zu 0,05 Gew.-% Aluminium (Al),
  • - bis zu 0,3 Gew.-% Nickel (Ni)
  • - bis zu 0,2 Gew.-% Zinn (Sn),
  • - bis zu 0,2 Gew.-% sonstige Bestandteile,
  • - und als Rest Zink

aufweist.According to a third aspect, the invention relates to a crimp contact,

• with an opening for insertion of a conductor end to be pressed,
• and with a connecting region facing away from the opening,
• - The crimp contact consists of a brass material CuZn40, wherein the brass material
  • - 59.5 - 61.5 wt .-% copper (Cu),
  • up to 0.2% by weight of iron (Fe),
  • up to 0.1% by weight of lead (Pb),
  • up to 0.05% by weight of aluminum (Al),
  • up to 0.3% by weight of nickel (Ni)
  • up to 0.2% by weight of tin (Sn),
  • - up to 0,2% by weight of other ingredients,
  • - and the remainder zinc

having.

Investigations have shown that the brass material CuZn40 is suitable for the production and intended use of a crimp contact. Thus, the material for machining the crimp contact can be machined and reliably cold-formed to form an electromechanical crimped connection without causing the crimp contact to tear circumferentially.

According to a further embodiment of the crimp contact is provided that the Brass material CuZn40 less than 0.1 wt.% Lead (Pb). It is therefore possible to use a substantially lead-free material with less than 0.1% by weight of lead (Pb), the lead content of which is below the value considered to be harmful to health.

A further embodiment of the crimp contact is characterized in that the crimp contact is adapted for establishing an electromechanical connection with a conductor having a conductor cross-section in a range of 0.25 mm ² to 1 mm ² , one opening for insertion of a conductor end limiting wall is set up such that a minimum wall thickness of the wall after pressing at least half of the wall thickness before pressing corresponds and that the conductor cross-section is reduced by the pressing by at least 10%, in particular at least 20%.

According to alternative embodiments of the crimp contact it can be provided that the crimp contact for establishing an electromechanical connection is arranged with a conductor having a conductor cross section in one of the areas of 10 mm ² to 6 mm ² , 6 mm ² to 4 mm ² , 4 mm ² to 2.5 mm ² , 2.5 mm ² to 1 mm ² , 1 mm ² to 0.14 mm ² , 0.5 mm ² to 0.14 mm ² or 0.34 mm ² to 0.08 mm ² having.

A wall section of the crimp contact which delimits the opening on the circumference can be produced as a circular-cylindrical sleeve section or in the manner of a circular pipe section.

The terminal region of the crimp contact remote from the opening can be designed as a socket contact. Alternatively, the connection region of the crimp contact remote from the opening can be designed as a pin contact or a solder contact.

• 1 einen erfindungsgemäßen Crimpkontakt in einer perspektivischen Ansicht;
• 2 einen weiteren erfindungsgemäßen Crimpkontakt in einer Schnittdarstellung;
• 3 einen weiteren erfindungsgemäßen Crimpkontakt in einer perspektivischen Ansicht;
• 4 eine Crimpverbindung in einer Schnittdarstellung.

The invention will be described in detail with reference to an exemplary embodiments illustrative drawing. Each show schematically:

• 1 a crimp contact according to the invention in a perspective view;
• 2 another crimp contact according to the invention in a sectional view;
• 3 another crimp contact according to the invention in a perspective view;
• 4 a crimp connection in a sectional view.

1 shows a crimp contact 2 with an opening 4 for inserting a conductor end to be pressed and with a connecting region facing away from the opening 6 , the present as a socket contact 6 is executed.

• - 59,5 - 61,5 Gew.-% Kupfer (Cu),
• - bis zu 0,2 Gew.-% Eisen (Fe),
• - bis zu 0,1 Gew.-% Blei (Pb),
• - bis zu 0,05 Gew.-% Aluminium (Al),
• - bis zu 0,3 Gew.-% Nickel (Ni)
• - bis zu 0,2 Gew.-% Zinn (Sn),
• - bis zu 0,2 Gew.-% sonstige Bestandteile,
• - und als Rest Zink

aufweist.The crimp contact 2 consists of a brass material CuZn40, where the brass material

• - 59.5 - 61.5 wt .-% copper (Cu),
• up to 0.2% by weight of iron (Fe),
• up to 0.1% by weight of lead (Pb),
• up to 0.05% by weight of aluminum (Al),
• up to 0.3% by weight of nickel (Ni)
• up to 0.2% by weight of tin (Sn),
• - up to 0,2% by weight of other ingredients,
• - and the remainder zinc

having.

One the opening 4 peripherally delimiting wall section 8th the crimp contact is a circular cylindrical sleeve section 8th , An outer jacket surface 9 of the circular cylindrical sleeve section 8th has been made by turning. The opening has been created by drilling.

The crimp contact 2 is adapted for making an electromechanical connection with stranded conductors, which have a conductor cross section of 0.25 mm ² to 1 mm ² , wherein one of the opening 4 for introducing a conductor end limiting wall 8th is set up such that a minimum wall thickness of the wall after pressing corresponds to at least half of the wall thickness before pressing and that the conductor cross-section is reduced by the pressing by at least 20%.

2 shows another crimp contact 10 in a cross section, wherein like reference numerals are assigned to the same features in comparison to the preceding embodiment. To avoid repetition, only the differences from the embodiment described above will be discussed below.

The crimp contact 10 is configured to make an electromechanical connection with a conductor, one of which is the opening 4 for introducing a conductor end limiting wall 8th is set up such that a minimum wall thickness of the wall after pressing corresponds to at least half of the wall thickness before pressing and that the conductor cross-section is reduced by the pressing by at least 20%.

3 shows another crimp contact 12 , characterized by the embodiment of the 1 distinguishes that one of the opening 4 remote connection area as pin or solder contact 14 is executed.

4 shows a crimp in an enlarged sectional view, by pressing a crimp according to the invention 2 . 10 . 12 with a conductor end of a stranded conductor 16 has been generated. The crimp contact 1 . 10 . 12 is in the area 8th deformed into a square crimp.

A minimal wall thickness d1 the wall 8th corresponds after pressing ( 4 ) at least half the wall thickness d0 before pressing (eg 2 ). The conductor cross-section of the stranded conductor 16 has been reduced by the compression by at least 20%, in this case for example from 0.250 mm ² to 0.180 mm ² .

LIST OF REFERENCE NUMBERS

2

crimp contact

4

opening

6

Connection area / socket contact

8th

Wall / pipe section

9

lateral surface

10

crimp contact

12

crimp contact

14

Connection area / pin contact / solder contact

16

Stranded conductor / conductor end

d0

Wall thickness unpressed

d1

Wall thickness pressed

Claims (10)

Method for producing a cold-formable crimp contact, comprising the steps of: - Providing a metallic blank, which consists of a brass material CuZn40, wherein the brass material - 59.5 - 61.5 wt .-% copper (Cu), up to 0.2% by weight of iron (Fe), up to 0.1% by weight of lead (Pb), up to 0.05% by weight of aluminum (Al), up to 0.3% by weight of nickel (Ni) up to 0.2% by weight of tin (Sn), - up to 0,2% by weight of other ingredients, - and the remainder is zinc; - Turning a lateral surface (9) of the blank with a rotary tool; - Making an opening (8) for insertion of a conductor end. Method according to Claim 1 wherein a chip surface of the lathe tool has at least one recess and / or at least one projection for breaking and / or guiding a chip detached from the metallic blank, by means of the lathe tool being broken and / or guided by the lathe tool during the turning operation Has. Method according to Claim 1 or Claim 2 , characterized in that - the brass material CuZn40 less than 0.1 wt .-% lead (Pb) has. Method according to one of Claims 1 to 3 , characterized in that - the brass material has an α-structure with β-precipitates. Method for producing an electromechanical crimp connection, comprising the following steps: - providing a crimp contact (2, 10, 12), wherein the crimp contact (2, 10, 12) is produced by a method according to one of the Claims 1 to 4 has been prepared; Inserting a conductor end (16) to be pressed into the opening (4); - Pressing the crimp contact (2, 10, 12) with the conductor end by cold forming the crimp contact (2, 10, 12) by means of a crimping tool. Method according to Claim 5 - wherein the one cross-sectional area of the conductor end (16) is reduced by the pressing by at least 10%, in particular at least 20%; and / or - wherein a minimum wall thickness (d1) of the crimp contact after pressing corresponds to at least half of the wall thickness (d0) before compression; - And / or pressing the crimp contact (2, 10, 12) to a square crimp takes place. Method according to Claim 5 or Claim 6 - Wherein the conductor end to be pressed has a conductor cross section in a range of 0.25 mm ² to 1 mm ² . Crimp contact, - with an opening (4) for insertion of a conductor end to be pressed (16), - and with one of the opening (4) facing away from connection area (6, 14), - wherein the crimp contact (2, 10, 12) made of a brass material CuZn40, whereby the brass material - 59.5 - 61.5 wt .-% copper (Cu), - up to 0.2% by weight of iron (Fe), up to 0.1% by weight of lead (Pb), up to 0.05% by weight of aluminum (Al), up to 0.3 Wt .-% nickel (Ni) - up to 0.2 wt .-% tin (Sn), - up to 0.2 wt .-% of other ingredients, - and the remainder zinc. Crimp contact after Claim 8 , characterized in that - the brass material CuZn40 less than 0.1 wt .-% lead (Pb) has. Crimp contact after one of Claims 8 or 9 characterized in that - the crimp contact (2, 10, 12) is adapted for making an electromechanical connection with a conductor end (16) having a conductor cross section in a range of 0.25 mm ² to 1 mm ² , - wherein a the opening (4) for introducing a conductor end (16) limiting wall is set up such that a minimum wall thickness (d1) of the wall (8) after pressing at least half of the wall thickness (d0) before pressing corresponds and that the conductor cross section through the compression is reduced by at least 10%, in particular at least 20%.

Images