CN101999192B - Electrical terminal system - Google Patents
Electrical terminal system Download PDFInfo
- Publication number
- CN101999192B CN101999192B CN200880128570.1A CN200880128570A CN101999192B CN 101999192 B CN101999192 B CN 101999192B CN 200880128570 A CN200880128570 A CN 200880128570A CN 101999192 B CN101999192 B CN 101999192B
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- CN
- China
- Prior art keywords
- terminal
- electric wire
- cable
- bunchy
- electrical
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
- 239000007787 solid Substances 0.000 claims abstract description 24
- 238000000034 method Methods 0.000 claims description 9
- 238000004519 manufacturing process Methods 0.000 claims description 6
- 238000005476 soldering Methods 0.000 claims description 2
- 238000003466 welding Methods 0.000 abstract description 21
- 238000010586 diagram Methods 0.000 description 5
- 229910000881 Cu alloy Inorganic materials 0.000 description 3
- 238000009434 installation Methods 0.000 description 3
- 230000013011 mating Effects 0.000 description 3
- 238000005452 bending Methods 0.000 description 2
- 238000005056 compaction Methods 0.000 description 2
- 239000004020 conductor Substances 0.000 description 2
- 238000002788 crimping Methods 0.000 description 2
- 230000002349 favourable effect Effects 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 210000002421 cell wall Anatomy 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000009422 external insulation Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/02—Soldered or welded connections
- H01R4/023—Soldered or welded connections between cables or wires and terminals
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
- H01R43/0214—Resistance welding
Landscapes
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
- Manufacturing Of Electrical Connectors (AREA)
Abstract
The invention relates to an electrical terminal system (3), comprising at least one cable (20) comprising a stranded wire; at least one elongated terminal (10) for reception of the cable, which terminal has a contacting portion for electrical and/or mechanical connection and a welding portion (12) for electrical connection between the terminal and the stranded wire. At the free end of the cable the stranded wire is compacted and welded into an essentially solid portion (23); and said essentially solid portion (23) is welded directly to the welding portion (12) of the terminal to achieve electrical continuity therebetween.
Description
Technical field
The present invention relates to electrical terminal system, the electrical terminal system of using especially for automobile, and for the production of the method for this electrical terminal system, this electrical terminal system comprises elongate terminal and is attached to electric wire or the cable of this elongate terminal.
Background technology
From prior art known electric terminal system, this electrical terminal system comprises terminal, and this terminal has for the contact site that is electrically connected and is used for the installation portion of attached cables or electric wire.When this paper used, the term cable represented single conductor, and this conductor comprises single or multiple wires and around described wire and make the insulating case of described wire insulation.The term electric wire represents the conductive cores of cable, and can be comprised of one or more wiring harness.Terminal is formed by the metallic plate of bending and mold pressing usually.Usually, terminal integrally is made of a metallic plate, this metallic plate can at one end be folded into the form of box to receive the end of independent contact pilotage, be shaped so that perhaps it is suitable for being connected with the second terminal mating portion, and this metallic plate the other end be provided with for connect be insulated respectively cover around cable or the device of electric wire.Cable or electric wire be at one end with the terminal mechanical connection and be electrically connected, and for example be connected with certain power supply or electric device or similar device at the other end.In the situation of for example airbag ignition system, the other end of cable or electric wire is connected with the airbag control device that is used for the triggering airbag inflated usually.
The common way that realizes the electrical connection between cable and the terminal is that this end sleeve pipe is crimped around the wiring harness of cable with terminal and the assembling of end sleeve pipe.Yet gas may be captured within crimping connects and further, press-fit component may be tending towards " rebounding ", and this can cause the connection all-in resistance to fluctuate with last unacceptable degree for key is used.
This can be by with wire welding or be brazed to terminal rather than be crimped to terminal and overcome.
Because single strand wire is launched randomly around the electric wire axle, so the shape of bunchy electric wire terminal is not limited usually well.For this reason, the welding of this wiring harness is difficult, because when for example welding electrode is pressed in wire harness on the terminal part for the treatment of to weld with it, electrically contacts the district and do not limited well.Therefore identical tuning for welder, bonding power is different between terminal, and during welding operation, heating does not spread over welding region equably, so that some single strand wire receive is more hotter than other single strand wire.Owing to these reasons, welding quality may be unsatisfactory.
Further, this electrical terminal system, that is, terminal and connected corresponding electric wire or cable are mass product, so that the reliability about quality and reduce injection defect product is very important in production cost and the production process.
Therefore the object of the present invention is to provide a kind of low especially electrical terminal system of the problems referred to above and shortcoming and production cost that reduces.
Another object of the present invention is the welding that obtains the more stable and better quality of single or multiple electric wires and terminal.
Summary of the invention
According to the present invention, a kind of electrical terminal system is provided, this electrical terminal system comprises at least one cable with bunchy electric wire and is used for receiving at least one elongate terminal of at least a portion of the wiring harness of this cable.This terminal have for another electronic installation mechanical connection and/or the contact site that is electrically connected and maintenance or welding region, with the electrical connection between the part of described bunchy electric wire that described terminal and described cable are provided.Described cable preferably has the insulated cable of the bunchy electric wire that copper alloy for example makes.At the free end of described cable, that is, with the end that described terminal is connected, described bunchy electric wire is compacted and is welded into basic solid part.Described bunchy electric wire for example is compacted in suitable extruding, then carries out resistance welded by electric charge or voltage are applied on the wiring harness that is compacted simultaneously.This basically solid compaction part of the described bunchy electric wire of described cable directly is welded on the described weld part of described terminal, to realize the electrical connection between the two.
Preferably, the cross section that the described basically solid compaction part of described bunchy electric wire has substantial rectangular most preferably has square cross section.Advantageously but not necessarily be compacted into rectangle and allow that the shape and size of described bunchy electric wire are good to be limited and constant, this so that allow stable welding characteristic.Described electric wire is accurate with respect to the position of described terminal and described welding electrode.
In one aspect of the invention, described elongate terminal is made of a metallic plate.The preferred material that is used for described terminal is copper alloy.In most preferred embodiments, described terminal has the metallic plate framework, in the end of this metallic plate framework, the form that described contact site is folded into box to be receiving for example independent pin, and forms unlimited circular groove form at the receiving terminal that is used for described cable.In favourable execution mode, the described weld part of described elongate terminal has basically semi-circular cross-section, and this semi-circular cross-section is formed for receiving the circular groove of opening wide of described basic solid part of the bunchy electric wire of described compacting.Because this half hull shape shape, this half hull shape shape advantageously but need not be semicircle, described electric wire can relatively described terminal/location easily in described terminal.
For resistance welded, require described electrode at least in the beginning of welding procedure, arrive described electric wire and do not contact the described metallic plate of described terminal.As favourable solution for this purpose, revise the size of half hull shape shape and compacting electric wire, so that the end face of described compacting electric wire protrudes in the top face of described half shell.
Another aspect of the present invention relates to for the production of electrical terminal system, the method for the electrical terminal system of using especially for automobile.The method may further comprise the steps: provide the cable that comprises the bunchy electric wire, compacting and weld this bunchy electric wire to form basic solid part on the free end of this cable.In addition, elongate terminal is provided, for example be used for receiving the aforesaid terminal of described cable, this terminal have for for example electronic installation mechanical connection and the contact site that is electrically connected, and be used between described terminal and described bunchy electric wire, forming the weld part that is electrically connected.After compacting and the described bunchy electric wire of welding, described bunchy electric wire and described terminal are installed, so that described basic solid part is arranged in the described weld part.In next step, the described substantially solid compacting section of described bunchy electric wire and described terminal soldering are to realize the electrical connection between the two.Preferably, described bunchy electric wire and described terminal weld by resistance welded.In a preferred embodiment, the described bunchy electric wire of described cable also is compacted by resistance welded.
Description of drawings
Hereinafter, with reference to accompanying drawing the present invention is described exemplarily, wherein:
Fig. 1 a is the schematic diagram of terminal;
Fig. 1 b is from the being seen cutaway view of line A-A;
Fig. 2 a is the schematic diagram that comprises the cable of bunchy electric wire;
Fig. 2 b is the compacting section of bunchy electric wire and the cutaway view of weld part;
Fig. 2 c is after electric wire and terminal wall have been welded together, the schematic cross sectional views of this electric wire and terminal wall;
Fig. 3 is the schematic diagram according to electrical terminal system of the present invention;
Fig. 4 a is the schematic cross sectional views of electrical terminal system shown in Figure 3;
Fig. 4 b is the schematic elevational view of the terminal system of Fig. 4 a.
Embodiment
Fig. 1 a shows the schematic diagram of terminal 10, and this terminal 10 comprises the cable link 11 with two holding flanges 14, and these two holding flanges 14 are shown and are in its bending position after on being fastened on the insulating case (not shown) of cable.For installing cables and terminal 10, at first cable is inserted between the flange 14, then this flange 14 is crimped around the external insulation sleeve of cable.Terminal 10 also comprises the weld part 12 of rounded open trough form.The cross section of this groove is seen the best (seeing the shadow region) from Fig. 1 b, and this Fig. 1 b is the cutaway view that the line A-A along Fig. 1 a sees.Terminal 10 also has contact site 13, and for example independent pin can insert in this contact site 13.Those skilled in the art can recognize from Fig. 1 a, and terminal 10 is made by a mold pressing and crooked metallic plate, are preferably made by a copper alloy etc.
Fig. 2 a shows and comprises bunchy electric wire 22 and form so that the cable 20 of the insulating case 21 of itself and environment electric insulation around this bunchy electric wire 22.Bunchy electric wire 22 comprises for example many single strand wire 24 (seeing Fig. 2 b), for example between 10 to 20 strands.As visible from Fig. 2 a the best, insulating case 21 is removed from the end of cable 20.Then the part that the insulating case of bunchy electric wire 22 is removed is compacted and is welded into basic solid part 23.This is preferably by with the strand wire compacting and carry out resistance welded and realize.Fig. 2 b shows compacting and carries out the cutaway view of the single strand wire 24 of resistance welded.As seen from the figure, the surface of nearly all single strand wire 24 is all combined together.
Fig. 3 shows the schematic diagram of the electrical terminal system 3 before being welded on electric wire 20 on the terminal 10 according to the present invention.Terminal 10 also has for inserting for example independent pin 15 of cloudy mating portion (not shown).The electric terminal 10 that is cloudy form of terminal can certainly be provided, and the pin of corresponding positive mating portion can insert in this electric terminal 10.Cable 20 is mounted to terminal 10 and mechanically is fastened on this terminal 10 by flange 14, and this flange 14 is bent or crimping around cable 20 around the insulating case 21 of cable 20 respectively.Cable 20 is arranged so that the compacting solid part 23 of bunchy electric wire is arranged in the weld part 12 of terminal 10.
Fig. 4 a and 4b show the cutaway view of terminal system shown in Figure 33.As from scheming as seen, the cross section of weld part 12 (seeing the shadow region) is semicircle basically, and has the form of unlimited round tube.Solid part 23 places the circular groove of weld part 12.Because solid part 23 preferably has square cross section, so leaving space 40,40 ' between two lateral sidewalls of the septal fossula cell wall of weld part 12 and section 23.
For resistance welded, require electrode to arrive electric wire and the metallic plate of contact terminal not.For this reason, such as Fig. 4 b as seen, the end face of compacting electric wire 23 protrudes in the top face of half shell of weld part wall.Be this purpose, half shell can fully be cut low.Under any circumstance, after welding, the terminal that obtains must have enough rigidity.Because electric wire and metallic plate combine after welding securely, so weld part 12 still meets this requirement.Such as Fig. 1 a finding, proparea and the back zone of weld part 12 are reinforced, that is, the wall of contact site 13 is for example higher to increase cross section, and the rake in the transition region between weld part and contact site is short as far as possible.
Owing to used the compacting electric wire section of the shape with good restriction, so bonding power is limited and spread over preferably welding region well, so that can obtain preferably and manageable welding quality.
Should be noted that accompanying drawing shows execution mode with enlarged drawing.In fact, for example in several cm range, for example 2 to 4cm for the length of terminal 10, and the intensity of metallic plate of making terminal is in 0.1 to 0.5mm scope, preferably about 0.2mm.Solid part 23 can have about 1cm, and for example 0.3 to 1cm length, and its thickness may be 0.5mm to 2mm.
Claims (7)
1. an electrical terminal system (3), this electrical terminal system comprises:
At least one cable (20), this at least one cable (20) comprises bunchy electric wire (22);
Be used for receiving at least one elongated terminal (10) of described cable, the weld part (12) that this terminal has for the contact site (13) of electrical connection and/or mechanical connection and is used for being electrically connected between described terminal and described bunchy electric wire, wherein
At the free end of described cable, described bunchy electric wire (22) is compacted and is welded into solid part (23); And
Described solid part (23) directly is soldered to the described weld part (12) of described terminal, realizing the electrical connection between the two,
Described electrical terminal system is characterised in that, the described weld part (12) of described elongated terminal (10) has basically semicircular cross section, and this cross section is formed for receiving the circular open trough of described solid part (23) of the bunchy electric wire of described compacting.
2. electrical terminal system according to claim 1, wherein, described bunchy electric wire (22) is compacted by resistance welded.
3. according to each the described electrical terminal system in the aforementioned claim, wherein, described terminal (10) comprises following wall at least, thereby this wall increases its cross-sectional area and is reinforced in the proparea of described weld part (12) by increasing its height.
4. for the production of the method for electrical terminal system (3), the method may further comprise the steps:
Provide and comprise the cable that is positioned at free-ended bunchy electric wire;
In the described free end compacting of described cable and weld described bunchy electric wire, to form solid part (23);
Be provided for receiving the elongated terminal (10) of described cable, this terminal has at the weld part (12) that is electrically connected between described terminal and the described bunchy electric wire and/or the contact site of mechanical connection and being used for is electrically connected between this terminal and this bunchy electric wire, and this weld part (12) has the basically semicircular cross section that forms circular open trough;
Described free end and the described terminal of the described solid part (23) of the described bunchy electric wire of having of described cable are installed, so that described solid part (23) is arranged in described weld part; And
With described solid part (23) and the described terminal soldering of described bunchy electric wire, to realize the electrical connection between the two.
5. method according to claim 4, wherein, described bunchy electric wire is compacted by resistance welded.
6. according to claim 4 or 5 described methods, wherein, the cross section that described solid part (23) has substantial rectangular.
7. method according to claim 6, wherein, described solid part (23) has square cross section.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/IB2008/002148 WO2009112881A1 (en) | 2008-03-11 | 2008-03-11 | Electrical terminal system |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN101999192A CN101999192A (en) | 2011-03-30 |
| CN101999192B true CN101999192B (en) | 2013-04-24 |
Family
ID=39875253
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN200880128570.1A Expired - Fee Related CN101999192B (en) | 2008-03-11 | 2008-03-11 | Electrical terminal system |
Country Status (3)
| Country | Link |
|---|---|
| EP (1) | EP2266167B1 (en) |
| CN (1) | CN101999192B (en) |
| WO (1) | WO2009112881A1 (en) |
Families Citing this family (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102010005841B4 (en) * | 2010-01-26 | 2011-12-08 | Auto-Kabel Managementgesellschaft Mbh | Cable lug with cup-shaped formation and fastening device |
| JP5903231B2 (en) * | 2011-09-12 | 2016-04-13 | 富士電線工業株式会社 | Wire connection structure |
| DE102011089207C5 (en) | 2011-12-20 | 2024-09-05 | Lisa Dräxlmaier GmbH | Method for contacting a stranded wire with a contact |
| JP6164531B2 (en) | 2014-06-23 | 2017-07-19 | 住友電装株式会社 | Shield conductive path |
| JP6766437B2 (en) * | 2016-05-10 | 2020-10-14 | 株式会社オートネットワーク技術研究所 | Wires with terminals and terminals |
| DE102017112947A1 (en) * | 2017-06-13 | 2018-12-13 | Te Connectivity Germany Gmbh | High current electrical connector and method of making a high current electrical connector |
| US10639737B1 (en) * | 2018-10-19 | 2020-05-05 | Aptiv Technologies Limited | Welding system and method |
| CN111725633A (en) * | 2019-03-20 | 2020-09-29 | 金笔企业股份有限公司 | Closed end conductor connector |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH02132785A (en) * | 1988-07-08 | 1990-05-22 | Yazaki Corp | Connection structure of crimp-style terminal to electric conductor and formation of the terminal |
| DE9218732U1 (en) * | 1991-06-03 | 1995-06-29 | Whitaker Corp | Electric contact |
| JP4021734B2 (en) * | 2002-08-30 | 2007-12-12 | 矢崎総業株式会社 | Wire ultrasonic bonding method |
-
2008
- 2008-03-11 WO PCT/IB2008/002148 patent/WO2009112881A1/en active Application Filing
- 2008-03-11 EP EP08789094.3A patent/EP2266167B1/en not_active Not-in-force
- 2008-03-11 CN CN200880128570.1A patent/CN101999192B/en not_active Expired - Fee Related
Non-Patent Citations (1)
| Title |
|---|
| JP平2-132785A 1990.05.22 |
Also Published As
| Publication number | Publication date |
|---|---|
| CN101999192A (en) | 2011-03-30 |
| EP2266167A1 (en) | 2010-12-29 |
| WO2009112881A1 (en) | 2009-09-17 |
| EP2266167B1 (en) | 2013-05-15 |
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Effective date of registration: 20180105 Address after: Luxemburg salad day Patentee after: DELPHI INTERNATIONAL OPERATIONS LUXEMBOURG S.A.R.L. Address before: French guyancourt Patentee before: Fci Automotive Holding |
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Effective date of registration: 20190117 Address after: Babado J San Michaele Patentee after: Delphi Technologies, Inc. Address before: Luxemburg salad day Patentee before: DELPHI INTERNATIONAL OPERATIONS LUXEMBOURG S.A.R.L. |
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