CN105932430A - 套管、接触装置以及用于借助超声波来焊接细束状导线的方法 - Google Patents

套管、接触装置以及用于借助超声波来焊接细束状导线的方法 Download PDF

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CN105932430A
CN105932430A CN201610308833.3A CN201610308833A CN105932430A CN 105932430 A CN105932430 A CN 105932430A CN 201610308833 A CN201610308833 A CN 201610308833A CN 105932430 A CN105932430 A CN 105932430A
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M·伊斯勒
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WET Automotive Systems AG
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Abstract

本发明涉及通过用于接收束状导线的端部段的套管改进束状导线和承载件物体之间的连接的改进方案，所述端部段可与所述套管压紧并且所述套管可通过超声波焊接到承载件物体上或者通过压紧与该承载件物体连接。

Description

套管、接触装置以及用于借助超声波来焊接细束状导线的 方法
技术领域
本发明的主题涉及接触装置、套管、电装置以及运输工具，尤其如权利要求1前序部分所述。
背景技术
可以借助超声波技术将铜导线焊接在导电金属上。尤其0.5mm2以上的横截面可以有良好的拉脱值。由于焊接时的压紧，通常会出现材料弱化以及尤其使0.35mm2及更小的横截面的焊接变困难的预定断裂部位。减小的拉脱力使得此类细导线不再能使用。在焊接之前进行压实所起到的帮助作用也很小。
为了获得较大的横截面，通常应急地使用敞口的压接套管。在这里的缺点是：连接质量取决于连接片上的压接几何形状的取向，并且压接强度原则上会由于超声波能量而被弱化，因为压接侧壁仅卷起来并且在压紧时可能会重新张开。在压接部的内部可能会出现相对运动，也可能由此破坏压接。
发明内容
在此背景下，提出具有权利要求1、7、10、13和14特征的技术方案。其它有利构型可由其它权利要求和后续说明得知。
本发明尤其涉及套管4，所述套管用于接收束状导线3的端部段，以形成用于与承载件物体1焊接的触头。
在此特别希望的是，套管4至少在局部360°地围绕导线5的周边闭合。这保护接触部位的边界区域免受腐蚀。
有利的是，至少一个用于导入束状导线5的插入开口具有呈从该插入开口的外径到该插入开口的内径的、斗形地收缩的过渡区形式的导入斗，以避免出现危害导线5、6稳定性的锐棱边。
当所述导入斗避免了0.5mm以下的曲率半径时，可避免预定断裂部位。
当套管4在其两个端部上各有一个导入斗时，可使装配简化。
当套管4和导线5、6的总横截面为至少0.5mm2时，可提高抗弯强度。
当束状导线3通过本发明所述的套管4固定在包括承载件物体1和束状导线3的接触装置上，尤其是超声波焊接或者压紧在其上时(其中，优选，导线3与套管4压紧)，该接触装置特别耐腐蚀。
在一接触装置中，所述压紧并非实施到套管4的整个长度上、而是仅实施到该长度的一部分上，并且套管4在该长度的未被压紧的部分中固定在承载件物体1上，该接触装置是更稳定的。
在一接触装置中，导线3的芯体的金属材料和承载件物体1的金属材料具有0.3V以上的电化学电位差，并且套管4由电化学电位介于导线3芯体和承载件物体1的电化学电位之间的金属材料构成，其中，所述承载件物体1优选由铝材料构成，导线3的芯体优选由铜材料构成而套管4优选由黄铜材料或者CuZn材料构成，该接触装置可使得避免腐蚀问题。
符合目的的是，用于将束状电导线3、5、6与承载件物体1连接以形成如权利要求7到9中任一项所述的接触装置的方法包括以下方法步骤：
a)将束状电导线5导入到如权利要求1到6中任一项所述的套管4中，
b)将所述套管4与导线5进行第一压紧，使得电导线6固定在该套管4中，
c)将带有套管4的导线5放到承载件物体1上，
d)通过借助超声波焊接和/或通过第二压紧使包围导线5的套管4与承载件物体1连接。
当并非在整个长度上、而是仅在局部上实施所述第一压紧，并且仅在未被压紧的套管区域中建立套管4和承载件物体1之间的所述连接时，这种方法是特别有利的。
在一种方法中，套管4在未被压紧的状态下具有旋转对称的横截面并且在压紧之后仍至少区段地保持旋转对称，该方法改善所形成的套管的可焊接性。
具有这种接触装置的蓄电池可靠地受到防腐蚀保护，所述接触装置尤其具有铝材料构成的承载件物体1。
具有这种接触装置的运输工具是有利的，所述接触装置尤其是根据本发明的蓄电池的接触装置。
根据本发明的套管4的用于接触装置的、用于相应的方法的、用于蓄电池的或用于运输工具的应用可产生所提到的优点。
接触装置的用于方法的、用于蓄电池的或用于运输工具的应用同样如此。
在下文中解释本发明的细节。下面的实施方案会使本发明易于理解。但是，所述实施方案仅具有示例性特征。当然，在独立权利要求定义的发明范围内，也可去掉、改变或者补充所说明的单个或多个特征。当然，也可将不同实施方式的特征相互组合。关键是，本发明的方案基本上实现。如果应当至少部分满足某一特征，则这也包括：该特征完全或者基本上完全被满足。在此，“基本上”尤其表示实施方案可使得以可感知的程度获得所希望的成果。这尤其可表示，相应特征被满足了至少50％、90％、95％或99％。如果给出的是最小量，则当然也可以使用比该最小量多的量。如果一构件的数量以“至少一个”进行说明，那么这尤其也包括具有两个、三个或更多个构件的实施方式。针对某一物体进行的说明也可以被运用到所有其它同类物体的整体或者大部分上。如果没有其它说明，则区间均包括其边界点。“一个”在下文中指的是不定冠词，并且表示“至少一个”。
附图说明
附图示出：
图1用于压紧和焊接的套管的
a)俯视图，b)横剖图，c)纵剖图；
图2具有束状导线和根据本发明的套管的承载件物体在焊接状态下的视图；
图3具有根据图1的套管的束状导线在部分压紧状态下的
a)俯视图，b)和c)横剖图；
图4具有束状导线和根据本发明的套管的承载件物体在焊接状态下的放大纵剖图。
具体实施方式
本发明涉及一种运输工具。概念“运输工具”尤其指一种用于运输人和/或物的装置。可想到的例如是：陆上运输工具、水路运输工具、轨道运输工具和空中运输工具，尤其是飞机、船舶以及车辆运输工具，尤其是电动机动车。
本发明还涉及一种蓄电池，该蓄电池尤其用于运输工具并且优选用于电动运输工具。在此，本发明尤其可对于蓄电池的由铝材料构成的部分的接触有意义，尤其对于用于蓄电池基本单体的接触板件的接触有意义。在此，将套管套在束状导线上。然后部分压紧该套管，使得该导线和该套管相互连接。接着将带有该导线的该套管焊接在承载件物体上和/或与其压紧。
本发明的有利特性尤其是：
1.所述套管是闭合的，其中，所述套管例如可由板材弯曲而成并且设有未闭合的缝隙类接缝，但也可完全闭合(尤其焊接)，或者可由管材料完全无缝地制成；所述套管可由此不张开或很微弱地张开，特别是在压紧时不张开或很微弱地张开；
2.所述套管是旋转对称的，并且旋转对称地实施压接/压紧或者所述压接/压紧旋转对称地得到未被压紧的区域。由此保证，可将所述套管与围绕纵向轴线的取向无关地定位在承载件物体上；
3.并非在整个长度上、而是仅在局部实施所述压接/压紧。因此导线和套管的真正压紧部位在焊接过程期间保持不受损。可以例如借助超声波使未被压紧的套管区域与承载件物体形成连接；
4.至少一个用于所述导线的导入斗位于所述套管上，以不出现可能使导线弱化的锐棱边；
5.有两个导入斗位于所述套管上，从而可对所述套管进行自动化加工；
6.套管和导线的总横截面为至少0.35mm2，优选为至少0.5mm2。其原因是从技术上来说难以对0.35mm2以下的圆导线进行超声波焊接，因为机械强度(连接的稳健性)变得很小。
所述方案特别适合于焊接两个电化学电位相差很大(即大于0.3V)并因此有接触腐蚀问题倾向的金属构件。如果套管符合目的地由电化学电位介于待焊接构件的电化学电位之间的材料构成，就能以巧妙方式分开电位差。由此减小或者甚至完全抑制腐蚀倾向。
特别适合的是，铝质构件(例如接触板件)借助由黄铜或包含铜和/或锌的其他合金构成的套管来与铜缆/铜线焊接。在此特别有利的是，套管材料至少在与另一构件接触的区域中具有介于两个待接触构件的电化学电位之间的电化学电位。优选，套管材料的电化学电位对铜来说在+0.52V到+0.34V之间，对铝来说约为-1.66V。
也能符合目的的是，由“混合材料”、即具有至少两种不同组成部分的材料制作套管，所述组成部分至少在局部未相互混合。然而所述组成部分这么紧密地密封连接，使得在接触面上不会形成接触腐蚀。为此，所述套管优选两层式地实施，即由具有两个层的材料构成，所述两个层具有相互不同的特性。所述材料例如可以借助冷轧覆镀法来制造。第一层优选由软导电材料、例如铜构成。“软”在这里尤其表示比黄铜软。铜(Kupfer)不可压接在铜导线上，因为铜不能形成保持力，但是铜可以良好地与柔软的铝焊接。第二层优选由较硬的材料、例如黄铜构成。黄铜可以压接，但是无法足够好地焊接在柔软的铝上。
因此，所述套管优选至少区段地具有由黄铜构成的管形内层。所述管形内层至少区段地被由铜构成的管形外层所包围。
在图1中可以看出根据本发明的套管4、更确切地说构造为具有锥形扩宽的口部的空心柱，参看图1c)。在此，在锥形扩宽部与柱形空腔之间的过渡段中绘出的棱边可以被倒圆角，以使导线3的穿过去的芯体的负荷最小化。这也可适用于锥形扩宽部的外端部上的棱边。
在图3中可以看出，已将导线3的芯体5插入到套管4中(图3c)。在该情况下还存在旋转对称性(其中，芯体5的各个丝线不算)。随后使用已知的压接钳关于套管4的长度进行局部压紧，更确切地说在图3a)中示出的两个区域中进行局部压紧。所述两个区域在图3b)中以剖面图示出。芯体5被压缩且其在该压紧状态中用6来标记，套管4的外周在压紧区域中具有大致为正方形的形状，该形状具有倒圆角的角。也可设想其它压紧几何形状(六角形的，四次点压式的等等)。在图3a)中俯视到一个这样的角(在中间)并且在其上方看到正方形的一个棱边、在其下面看到另一个棱边。此外，所述套管在各个压紧区域的前面和后面保持旋转对称。
因此，所述套管能在任意位置中被施加到接触板件、即根据图2的承载件1上，例如通过超声波焊接或者另一压紧步骤。该取向不重要，因为主要仅套管4的未被压紧的部分用于固定和接触。附图4象征性地示出超声波焊接过的状态，其中，套管4的上侧(通过附图标记7标识，因为在这里被焊接)和承载件1的下侧由于超声波焊接而以已知的方式被改变。
所述接触板件或者说承载件1可例如是运输工具蓄电池的基本单体的由铝材料构成的接触板件，所述运输工具尤其是电动机动车。在这里，由于电化学电位差，尤其在通过铜材料电缆形成接触时会存在困难，该困难可通过适当地选择套管材料来解决。
此外，由于对套管4与承载件1进行所述连接时的位置不敏感性(旋转对称)以及由于套管4在其锥形扩宽部方面的镜像对称性(附图1c))，本发明特别适合用于自动化装配。
附图标记列表
1 作为连接配对件的承载件物体(片)
2 套管，被压紧
3 具有绝缘护套的电导线
4 套管，未被压紧
5 导线的铜芯，未被压紧
6 导线的铜芯，被压紧
7 套管，被压紧并且被超声波焊接

Claims (17)

1.用于接收束状导线(3)的端部段以形成用于与承载件物体(1)焊接的触头的套管(4)。
2.根据权利要求1所述的套管(4)，其特征在于，所述套管(4)至少在局部360°地围绕导线(5)的周边闭合。
3.根据权利要求1和2中任一项所述的套管(4)，其特征在于，至少一个用于导入束状导线(5)的插入开口具有导入斗，所述导入斗呈从该插入开口的外径到该插入开口的内径斗形地变细的过渡区的形式，以避免出现危害导线(5，6)稳定性的锐棱边。
4.根据权利要求3所述的套管(4)，其特征在于，所述导入斗避免0.5mm以下的曲率半径。
5.根据权利要求3和4中任一项所述的套管(4)，其特征在于，所述套管(4)在其两个端部上各有一个导入斗。
6.根据前述权利要求中任一项所述的套管(6)，其特征在于，套管(4)和导线(5，6)的总横截面为至少0.5mm2。
7.具有承载件物体(1)和束状导线(3)的接触装置，其特征在于，所述束状导线(3)通过如前述权利要求中任一项所述的套管(4)固定在所述接触装置上、尤其超声波焊接或者压紧在所述接触装置上，其中优选，所述导线(3)与所述套管(4)压紧。
8.根据权利要求7所述的接触装置，在所述接触装置中，压紧并非在所述套管(4)的整个长度上实施、而是仅在所述长度的一部分上实施，并且，所述套管(4)在所述长度的未被压紧的部分中固定在所述承载件物体(1)上。
9.根据权利要求7和8中任一项所述的接触装置，在所述接触装置中，所述导线(3)的芯体的金属材料和所述承载件物体(1)的金属材料具有0.3V以上的电化学电位差，并且所述套管(4)由电化学电位介于所述导线(3)的芯体和所述承载件物体(1)的电化学电位之间的金属材料构成，其中，所述承载件物体(1)优选由铝材料构成，所述导线(3)的芯体优选由铜材料构成而所述套管(4)优选由黄铜材料或者CuZn材料构成。
10.用于将束状电导线(3，5，6)与承载件物体(1)连接以形成如权利要求7到9中任一项所述的接触装置的方法，包括以下方法步骤：
a)将所述束状电导线(5)导入到如权利要求1到6中任一项所述的套管(4)中，
b)对所述套管(4)与所述导线(5)进行第一压紧，使得所述电导线(6)固定在所述套管(4)之中，
c)将带有所述套管(4)的所述导线(5)放在所述承载件物体(1)上，
d)通过借助超声波焊接和/或通过第二压紧使包围所述导线(5)的所述套管(4)与所述承载件物体(1)连接。
11.根据权利要求10所述的方法，其特征在于，并非在整个长度上、而是仅在局部上实施所述第一压紧，并且，仅在未被压紧的套管区域中建立所述套管(4)和所述承载件物体(1)之间的连接。
12.根据权利要求10和11中任一项所述的方法，在所述方法中，所述套管(4)在未被压紧的状态下具有旋转对称的横截面，并且即使在压紧之后也至少区段地保持旋转对称。
13.具有如权利要求7到9中任一项所述的接触装置的蓄电池，所述接触装置尤其具有由铝材料构成的承载件物体(1)。
14.具有如权利要求7到9中任一项所述的接触装置的运输工具，所述接触装置尤其是如权利要求13所述的蓄电池的接触装置。
15.如权利要求1到6中任一项所述的套管(4)的用于如权利要求7到9中任一项所述的接触装置的、用于如权利要求10到12中任一项所述的方法的、用于如权利要求13所述的蓄电池的、用于如权利要求14所述的运输工具的应用。
16.如权利要求7到9中任一项所述的接触装置的用于如权利要求10到12中任一项所述的方法、用于如权利要求13所述的蓄电池、用于如权利要求14所述的运输工具的应用。
17.如权利要求13所述的蓄电池的用于如权利要求14所述的运输工具的应用。
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