CN105261911B - Method for connecting twisted wire - Google Patents

Method for connecting twisted wire Download PDF

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Publication number
CN105261911B
CN105261911B CN201510400814.9A CN201510400814A CN105261911B CN 105261911 B CN105261911 B CN 105261911B CN 201510400814 A CN201510400814 A CN 201510400814A CN 105261911 B CN105261911 B CN 105261911B
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China
Prior art keywords
sleeve
connecting element
welding
wire
face
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CN201510400814.9A
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Chinese (zh)
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CN105261911A (en
Inventor
托马斯·荷晶
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Lisa Draexlmaier GmbH
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Lisa Draexlmaier GmbH
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02Apparatus 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
    • H01R43/0221Laser welding
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00Electrically-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
    • H01R4/10Electrically-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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18Electrically-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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/187Electrically-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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping combined with soldering or welding
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00Electrically-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
    • H01R4/10Electrically-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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18Electrically-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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/20Electrically-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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve

Abstract

The invention relates to a method for connecting a strand (2) to a connecting element (4) by means of a sleeve (1), comprising the following steps: -attaching the connecting element (4) to a first end face of the sleeve (1); inserting the free end of the litz wire (2) into a second open end face of the sleeve (1), wherein the metal wire of the litz wire (2) and the sleeve (1) are made of the same metal; crimping the sleeve (1) with the litz wire; and welding the sleeve (1) with the metal wires of the litz wire (2) by means of laser beam welding or electron beam welding; and a corresponding contact system for connecting a strand (2) to a connecting element (4) by means of a sleeve (1).

Description

Method for connecting twisted wire
Technical Field
The invention relates to a method for connecting a strand to a connecting element by means of a sleeve. The invention further relates to a corresponding contact system or a bundled cable having litz wires and a connecting element connected thereto by means of a sleeve.
Aluminum is very important for stranded wires in the automotive industry due to its cost performance compared to copper. However, because aluminum has a relatively low tensile strength, wire harnesses made of aluminum having a plurality of wires are generally reinforced by a chrome-nickel alloy wire. In the case of a flexible wire formed with a connecting element, it is also necessary to connect the two parts together, wherein contact resistance caused by the connection is avoided at the junction point.
It is known to connect metal parts to each other by means of resistance welding. While the metal parts are assembled against each other and connected by welding with the current flowing through. However, it has not been possible to connect a stranded wire formed from a plurality of aluminum wires with a connecting element by resistance welding until now, because the wires of the flexible electric wire have a poor oxide layer at the connecting element.
Prior Art
For example, a method for connecting an electric wire with an electronic component in WO2007/140489 is known in the art, in which a free end of a flexible electric wire is inserted into a sleeve and crimped with the sleeve, after which an end portion of a conductive member corresponding to the flexible electric wire is inserted into the sleeve free end, and the end portion of the conductive member is assembled on the flexible electric wire. An electric current flows through the two wires, so that, on the basis of the resulting contact resistance, a temperature is generated inside the sleeve which is so high that the free ends of the wires melt together.
To be able to realize this principle of action, the sleeve must be made of a metal having a higher melting point than the metal or metals of which the wire is made. According to a preferred embodiment, the ends of the wires and the electronic components which are inserted into the sleeve are made of aluminum or copper, and the sleeve is made of steel plate. The regions to which the material is bonded therefore disadvantageously have only a small spatial extent and different gold phases which, because of their brittleness, meet only to a limited extent the requirements with regard to stable contact resistance over time, good corrosion resistance and strength.
Disclosure of Invention
The invention is therefore based on the following object: a method is provided by which a strand is adhesively, reliably and permanently connected to at least part of the material of a metal component, such as a single-layer metal conductor or a connecting element. Furthermore, the object is to provide a corresponding contact system or a bundled cable having a litz wire and a connecting element which is connected at least partially adhesively.
The above object is achieved according to the invention by the subject matter of the independent claims. Embodiments of the invention emerge from the dependent claims, the description below and the figures. Accordingly, the present invention includes a method having the steps of:
a) attaching a connecting element to a first end face of the sleeve;
b) inserting the free end of the strand into the second open end face of the sleeve, wherein the metal wire of the strand and the sleeve are made of the same metal;
c) pressing the stranded wire and the sleeve; and
d) the sleeve is at least partially welded to the metal wires of the litz wire by means of laser beam welding or electron beam welding.
The method of using the same metal for the metal wire of the litz wire and for the sleeve advantageously results in a single metallurgical phase during laser beam welding or electron beam welding, which phase does not have the risk of brittleness and corrosion, for example of a copper/aluminum alloy phase. The use of a sleeve furthermore ensures a defined geometry, so that a seal such as a heat shrink tube can be easily applied afterwards, and so that a penetrating laser beam or electron beam can enter a single strand of the litz wire, and in this way an excellent connection of the cable with the sleeve and the connecting element is achieved. The thinning or damage of the single wire observed at the time of resistance welding or crimping no longer occurs.
In this case, the metal wire and the sleeve of the litz wire are preferably made of aluminum or an aluminum alloy. Through the material-bonded connection of the aluminum parts, a permanent, electrically and mechanically stable contact is produced between the strand and the connecting element.
According to one embodiment, the attachment of the connecting element to the first end face of the sleeve is carried out by welding, in particular electromagnetic pulse welding (EMPT), friction welding, cold pressure welding or diffusion welding, wherein the first end face of the sleeve can be closed.
The connecting element can be formed as a screw or plug connector, so that it can be easily screwed into or inserted into the sleeve. In some embodiments, the connecting element comprises a different metal, in particular copper, than the metal wires of the sleeve and the litz wire.
The connecting element can also be attached to the first end face of the sleeve in the following method steps: after the free ends of the strands are inserted into the second open end face of the sleeve, either before or after crimping the strands to the sleeve.
The connecting element may have a surface finish, for example a silver or tin coating.
The crimping of the sleeve to the metal wire of the litz wire, which is carried out before the laser beam welding or electron beam welding, is preferably carried out radially uniformly by means of pressure forming, swaging or electromagnetic pulse welding (EMPT). In this case, a round, oval or rectangular cross-sectional shape is preferably produced, in which the individual wires are uniformly compacted, so that voids are avoided or minimized.
In the following step of laser beam welding or electron beam welding of the metal wires of the sleeve and the litz wire, the laser beam or electron beam is preferably moved linearly upwards of the sleeve, for example with a deflection system, in order to enlarge the melting zone. In this case, the single wire and the sleeve are welded to one another within a selectable volume range. In the case of circular, elliptical or rectangular crimping, the laser beam or electron beam can be moved linearly, in particular helically, over the sleeve by rotating the weld seam portion and the melting region is lengthened in the axial direction of the wire or sleeve. In crimping with a rectangular cross section, the laser beam or electron beam can be moved linearly, in particular S-shaped, over the sleeve by beam deflection with a deflection system such as a mirror or a probe, and the melting region is lengthened in the axial direction of the wire or sleeve.
In addition, in laser beam welding or electron beam welding, the metal wire of the litz wire is preferably supplied with additional aluminum or aluminum alloy for enlarging and/or compacting the melting region. Thus, the formation of voids or air holes in the twisted connection, particularly during the melting process, is prevented. The aluminum can be supplied, for example, by an aluminum wire which, on each incidence of the laser beam or electron beam, bears against the metal wire of the sleeve or strand and melts there with it. In this case, the aluminum wire can move together with the laser beam or the electron beam.
Furthermore, in laser beam welding or electron beam welding, the strands and/or the sleeve are arranged to be able to steer the laser beam or the electron beam around their axis of rotation, preferably also to be able to slide along the axis of rotation. Thus, in particular in the case of circular or elliptical crimping, a laser beam or electron beam can be driven annularly and/or helically upwards of the sleeve by rotation of the weld seam.
The laser beam welding or the electron beam welding is preferably performed in a room in an inert gas or vacuum state. The chamber may have an entrance port for a laser beam or electron beam and suitable processing optics using deflection mirrors, light conductors and positioning means.
In terms of the device, the object is achieved by a contact system for connecting a strand with a connecting element by means of a sleeve, wherein a free end of the strand is inserted into a second open end face of the sleeve and is crimped with the sleeve. The metal wires and the sleeve of the litz wire are made of the same metal and are at least partially connected to one another by adhesive bonding by means of laser beam welding or electron beam welding. Whereby the connecting element is attached to the first end surface of the sleeve.
Preferably, the metal wire and the sleeve of the litz wire are made of aluminum or an aluminum alloy.
Preferably, the first end face of the sleeve is adhesively bonded to the connecting element, wherein the sleeve and the connecting element are made in particular of different metals.
The connecting element can be formed as a screw or plug connector and in particular comprises copper.
Drawings
Next, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
FIG. 1 is a section of a compressed aluminum sleeve having (a) a rectangular and (b) a circular cross-section;
FIG. 2 is a cross-section of a compressed aluminum sleeve having a funnel-shaped melt area when laser welded;
FIG. 3 is a cross-sectional view of the free ends of the aluminum strands in the second open end face of the aluminum sleeve with the connecting element;
fig. 4 is an oblique view of the free ends of the strands in the second open end face of the aluminum sleeve with the connecting element;
FIG. 5 is a cross-sectional view of an aluminum sleeve with welded connection elements;
FIG. 6 is a side view of an aluminum sleeve with welded connection elements;
FIG. 7 is a side view of a laser chamber utilizing a sleeve to connect a strand to a connecting element; and
fig. 8 is a side view showing the free ends of the aluminum strands of the laser beam guide in the second open end face of the aluminum sleeve, with (a) no attached connecting elements and (b) attached connecting elements.
Detailed Description
Fig. 1 shows a section of a compressed aluminum sleeve 1 with a (a) rectangular and (b) circular cross section, wherein a plurality of aluminum wires 2, for example with aluminum sleeve 1, are uniformly compacted by pressure forming, swaging or electromagnetic pulse welding (EMPT) to avoid cavities. Preferably, a circular, elliptical or rectangular cross-sectional shape is produced depending on the application.
Fig. 2 shows a section of the aluminum sleeve 1 compressed during laser welding. Preferably, the incoming laser beam LS or electron beam is directed towards the aluminum sleeve 1 non-parallel to the length direction of the aluminum sleeve 1 and such that first the aluminum sleeve 1 and then the aluminum wire 2 are locally melted. According to this method, at the beginning of the laser welding, a funnel-shaped melting zone is formed, which gradually brings about a material-bonded connection between the aluminum sleeve 1 and the aluminum conductor 2. By means of a predeterminable displacement of the laser beam relative to the aluminum sleeve 1 and the aluminum conductor 2, the melting zone is pushed linearly to the periphery and thus contacts and melts all the individual conductors 2, as shown in fig. 8.
Fig. 3 shows a section of the free ends of the aluminum strands 2 in a side view in the second open end face of the aluminum sleeve 1 with the connecting element 4. The connection element 4 is a metal component, such as a one-piece metal conductor that is a screw or plug connector. The aluminum conductor 2 is at least partially bonded to the aluminum sleeve 1 by means of the method according to the invention in a positively permanent manner. The connection of the end face of the aluminum sleeve 1 to the connecting element 4 is effected by welding, in particular electromagnetic pulse welding (EMPT), friction welding, cold pressure welding, diffusion welding or by an extrusion process, wherein the first end face of the aluminum sleeve 1 is closed. The material-bonded area of the shaped wire thus contains a pure aluminum phase, without the disadvantageous copper-aluminum phase having a high brittleness.
Fig. 4 shows an oblique view of the free ends of the aluminum strands 2 in the second open end face of the aluminum sleeve 1 with the connecting element 4.
Fig. 5 and 6 show a longitudinal section and a side view of an aluminum sleeve 1 with welded connecting elements 4. On the one hand, the longitudinal section of fig. 5 illustrates the position of the attached connecting element 4 in the first end face of the aluminum sleeve 1. On the other hand, the position and the approximate extent of the melting region of the aluminum wire 2 and the aluminum sleeve 1 during the laser welding can be seen from this figure.
Fig. 7 shows a chamber 5 for carrying out the method for connecting an aluminum strand 2 to a connecting element 4 using an aluminum sleeve 1. Laser beam welding is performed in the chamber 5 under inert gas or vacuum. The chamber 5 has an irradiation aperture for the laser beam and appropriately machined optics with deflection mirrors, light conductors and positioning means. This enables the laser beam to move predetermined with respect to the aluminum sleeve 1 and the aluminum wire 2. Furthermore, the aluminum strand 2, the aluminum sleeve 1 and the connecting element 4 are arranged in a rotatable and/or pivotable manner in the chamber 5 in order to be able to manipulate the laser beams on different conductor areas in a predeterminable manner.
Fig. 8 shows an exemplary suitable laser beam guide on an aluminum sleeve 1 with aluminum strands 2 (a) without attached connecting elements and (b) with attached connecting elements.
The description of the embodiments is intended to be illustrative and not restrictive.

Claims (15)

1. A method for connecting a stranded wire (2) with a connecting element (4) by means of a sleeve (1), wherein the stranded wire (2) comprises a metal wire made of the same metal as the sleeve (1),
it is characterized in that the preparation method is characterized in that,
-attaching the connecting element (4) to a first end face of the sleeve (1);
inserting the free end of the litz wire (2) into a second open end face of the sleeve (1);
crimping the sleeve (1) with the litz wire; and
welding the sleeve (1) at least partially with the metal wires of the litz wires (2) by means of laser beam welding or electron beam welding,
wherein the connecting element (4) is formed as a screw or plug connection and the attachment of the connecting element (4) to the first end face of the sleeve (1) is effected by screwing or inserting, and
the first end face of the sleeve (1) is closed by the connecting element (4).
2. The method of claim 1, wherein the first and second light sources are selected from the group consisting of,
it is characterized in that
The metal wire of the litz wire (2) and the sleeve (1) are made of aluminum or an aluminum alloy.
3. The method according to claim 1 or 2,
it is characterized in that
The radially uniform crimping of the sleeve (1) to the metal wire of the litz wire (2) is achieved by means of pressure forming, swaging or electromagnetic pulse welding (EMPT).
4. The method of claim 1, wherein the first and second light sources are selected from the group consisting of,
it is characterized in that
In the laser beam welding or electron beam welding of the sleeve (1) to the metal wires of the litz wire (2), the laser beam or the electron beam is moved through the sleeve (1), in particular by means of a deflection mirror, in order to linearly enlarge the melting zone.
5. The method of claim 1, wherein the first and second light sources are selected from the group consisting of,
it is characterized in that
In laser beam welding or electron beam welding, the metal wires of the strands (2) are supplied with additional aluminum or aluminum alloy for enlarging and/or compacting the melting zone.
6. The method of claim 1, wherein the first and second light sources are selected from the group consisting of,
it is characterized in that
In laser beam welding or electron beam welding, the strands (2) and/or the sleeve (1) are arranged to be able to steer a laser beam or an electron beam around their axis of rotation.
7. The method of claim 1, wherein the first and second light sources are selected from the group consisting of,
it is characterized in that
In the chamber (5), the laser beam welding or the electron beam welding is carried out under inert gas or vacuum.
8. The method of claim 1, wherein the first and second light sources are selected from the group consisting of,
it is characterized in that
The attachment of the connecting element (4) to the first end face of the sleeve (1) is effected by welding.
9. The method of claim 8, wherein the first and second light sources are selected from the group consisting of,
it is characterized in that
The welding is electromagnetic pulse welding (EMPT), friction welding, cold pressure welding or diffusion welding.
10. The method of claim 1, wherein the first and second light sources are selected from the group consisting of,
it is characterized in that
The connecting element (4) comprises a metal different from the metal wires of the sleeve (1) and the litz wire (2).
11. The method of claim 10, wherein the first and second light sources are selected from the group consisting of,
it is characterized in that
The metal comprises copper.
12. A contact system for connecting a litz wire (2) to a connecting element (4) by means of a sleeve (1), wherein the litz wire (2) comprises a metal wire made of the same metal as the sleeve (1),
it is characterized in that
The connecting element (4) is attached to a first end face of the sleeve (1) and the free ends of the litz wires (2) are inserted into a second open end face of the sleeve (1) and crimped with the sleeve (1), wherein the metal wires of the litz wires (2) and the sleeve (1) are at least partially adhesively bonded to one another by means of laser beam welding or electron beam welding,
wherein the connecting element (4) is formed as a screw or plug connection and the attachment of the connecting element (4) to the first end face of the sleeve (1) is effected by screwing or inserting, and
the first end face of the sleeve (1) is closed by the connecting element (4).
13. The contact system according to claim 12, wherein,
it is characterized in that
The metal wire of the litz wire (2) and the sleeve (1) are made of aluminum or an aluminum alloy.
14. Contact system according to claim 12 or 13,
it is characterized in that
The first end face of the sleeve (1) is connected to the connecting element (4) by adhesive bonding, wherein the sleeve (1) and the connecting element (4) are made of metals that are different from each other.
15. The contact system as set forth in claim 12,
it is characterized in that
The connecting element (4) comprises copper.
CN201510400814.9A 2014-07-09 2015-07-09 Method for connecting twisted wire Active CN105261911B (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102014109604.5A DE102014109604B4 (en) 2014-07-09 2014-07-09 Contacting a stranded conductor
DE102014109604.5 2014-07-09

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CN105261911A CN105261911A (en) 2016-01-20
CN105261911B true CN105261911B (en) 2020-09-11

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CN107123867B (en) 2017-06-05 2019-05-10 吉林省中赢高科技有限公司 A kind of connector and its magnetic induction welding method of copper tip and aluminum conductor
DE102017114994B3 (en) * 2017-07-05 2018-05-09 Lisa Dräxlmaier GmbH METHOD FOR MANUFACTURING AN ELECTRICAL LINE ASSEMBLY
DE102017121924B3 (en) 2017-09-21 2019-02-21 Tdk Electronics Ag Electrical component with connection area and method for producing a connection area
DE102017121908B4 (en) 2017-09-21 2023-12-07 Tdk Electronics Ag Electrical component with stranded contact and method for producing a stranded contact
DE102019119468A1 (en) * 2019-04-24 2020-10-29 Metzner Maschinenbau Gmbh Method, device and system for assembling an electrical cable

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DE102009056799A1 (en) 2009-12-03 2011-06-09 Kromberg & Schubert Gmbh & Co. Kg Thin electrical conductor i.e. aluminum cable, for motor vehicle, has three crimp connections enclosing conductor partial areas, where conductor and contact part are connected with each other by weld joint in areas by areas
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DE102014109604B4 (en) 2023-12-07
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