DE102015120002B4 - Connecting device and connection method - Google Patents

Abstract

The present invention discloses a connection device (1, 49) for connecting a plurality of conductors (2), with a busbar (3, 50) which is designed to electrically couple the conductors (2) to one another (8, 51) which is adapted to receive the bus bar (3, 50) and which has a coupling device (17-23, 24-30) for each of the conductors (2), and a retaining spring (31) for each of the conductors (31; 2), which has a coupling element (33, 34) which can be coupled to one of the coupling devices, wherein the retaining spring (31) is tensioned in the installed state and is formed, one end (38) of the respective conductor (2) with a predetermined contact pressure (39) to press the busbar (3, 50). Furthermore, the present invention discloses a corresponding method.

Description

Technical area

The present invention relates to a connection device for connecting a plurality of electrical conductors or lines. Furthermore, the present invention relates to a corresponding method for connecting a plurality of electrical conductors or lines.

Technical background

In modern electronic systems, such as e.g. in onboard electrical networks, it is regularly necessary to electrically connect a plurality of conductors of equal potential. Such connections not only require the electrical connection to be made. Rather, a mechanically stable connection must be made in order to prevent tearing of individual conductors.

In particular, in the electrical mass of such a vehicle electrical system, up to 20 conductors or more, e.g. also with different cross-sections, in a connector.

Usually the conductors are e.g. provided with so-called. Crimp sleeves, in which on the end of the conductor, a corresponding sleeve is pressed or soldered. Furthermore, the conductors may be e.g. be connected by ultrasonic welding. Particularly with a high number of conductors and different cross sections of the conductors, an electrically and mechanically stable connection with the said methods can only be ensured with great effort.

A connecting device according to the preamble of claim 1 is known from DE 10 2004 030 085 B4 or the DE 20 2013 100 635 U1 known. In addition, from the DE 196 54 523 C2 a similar connection device known in which a number of retaining springs are integrally formed with a carrier. Furthermore, from the DE 10 2007 017 593 A1 a connecting device with a V-shaped busbar known. Finally, out of the US 4 572 603 A an electrical connector for narrow gauge magnet wires, in which a clampable and coupleable contact member penetrates insulation of the wires to make electrical contact.

Description of the invention

The object of the present invention is therefore to provide a simple way of connecting a plurality of conductors.

The object is solved by the subject matters of the independent claims.

Accordingly, an electrical connection device is provided for connecting a plurality of electrical conductors, with a bus bar, e.g. of an electrically conductive material, such as copper or aluminum, which is designed to electrically couple the conductors to each other, to a carrier which is designed to receive the busbar and which has a coupling device for each of the conductors. The carrier may e.g. be made of plastic, glass fiber reinforced plastic, metal or the like. Furthermore, the connecting device has a holding spring for each of the conductors, which has at least one coupling element, which can be coupled to one of the coupling devices of the carrier, wherein the retaining spring is clamped in the coupled installation state and is designed, one end of the respective conductor with a predetermined contact pressure, also called normal force to press on the busbar.

The retaining springs each have at one end a clamping element for clamping the respective retaining spring and at the other end a locking element for locking the respective retaining spring. The retaining spring can therefore be clamped at one end by means of the clamping element. If the retaining spring then cocked, the locking element can be locked in the tensioned state and the retaining spring is held in the tensioned state. Consequently, the contact pressure on the conductor is permanently exerted.

In addition, the retaining springs between the clamping element and the latching element each have a connecting portion, in particular a flat connecting portion, which is coupled to the end of the respective conductor and is coupled via spring arms with the clamping element and the latching element, wherein the spring arms, the clamping element and the latching element to bias one another. The connecting portion may be e.g. correspond approximately to the length of the support surface outer contour. It is therefore pressed over the entire length of the flat side, the end of the conductor to the busbar when the retaining spring is inserted into the carrier. When inserted into the carrier, the spring arms are pressed against their biasing force and thus exert a force on the connecting portion, which transmits as a contact force on the conductor or the busbar.

The connection method for connecting a plurality of conductors comprises the following steps: arranging a busbar, which electrically couples the conductors to one another, in a carrier which receives the busbar and which has a coupling device for each of the conductors, Connecting ends of the conductors, each having a retaining spring, which has at least one coupling element, and coupling the one or more coupling elements of the retaining springs, each with one of the coupling means of the carrier, so that the end of the respective conductor is pressed with a predetermined contact force on the busbar ,

The present invention is based on the finding that it is difficult to permanently connect electrical conductors, in particular of different diameters, when the connecting element has to ensure both the mechanical and the electrical stability of the connection.

In the present invention, therefore, each conductor is pressed individually by a discrete retaining spring on the common, preferably single busbar. The retaining springs have only a mechanical function. The electrical connection between the busbar and conductor is thus generated according to the invention by the contact pressure, which presses the conductor onto the busbar.

The retaining spring itself has, unlike conventional connection options, no electrical, but only a purely mechanical function. The electrical properties of the retaining spring are therefore not relevant to the electrical connection of the conductors.

This makes it possible to optimize the retaining spring with respect to material selection and dimensioning from a purely mechanical point of view. For example, the material, the thickness and the geometry of the retaining springs can be selected according to the desired contact forces. Since the electrical connection is only between the conductor and busbar, the retaining spring can not affect this or only by the resulting contact force.

Consequently, it is possible, e.g. To provide retaining springs that generate high contact forces and thus allow a good electrical connection of the respective conductor to the busbar with low electrical resistance and thus low self-heating. Thereby, e.g. also electrically poorly conductive materials are used as the material of the spring.

Further, particularly advantageous embodiments and modifications of the invention will become apparent from the dependent claims and the following description, wherein the features of various embodiments may be combined to form new embodiments. In particular, the independent claims of a claim category can also be developed analogously to the dependent claims of another claim category.

In one embodiment, the busbar in cross-section perpendicular to its longitudinal axis an outer contour having a support surface for the ends of the conductors, in particular at the position of the contact pressure generated by the retaining spring in the installed state. The end of the conductor is thus in the installed state on the support surface and is pressed by the contact pressure on the support surface. As a result, the force with which a respective conductor rests on the busbar is maximized and the electrical resistance of the connection is minimized.

In one embodiment, the bus bar may be an approximately polygonal, e.g. triangular outer contour or an outer contour with more corners, or e.g. have a U-shaped curved, or circular or semicircular outer contour, wherein circular also includes oval. The sheet thus forms e.g. a pipe or a U-shaped structure or the like with a cavity in its inner and the corresponding outer contour. By using a sheet, which is brought into the appropriate shape, compared to a solid body, the use of material in the production of the busbar and the weight of the busbar can be reduced.

In one embodiment, the carrier may have in cross-section perpendicular to its longitudinal axis a receiving space corresponding to the outer contour of the bus bar, which is open to the ends of the ladder in the installed state. If the busbar is inserted into the receiving space, that is, in the case of a triangular outer contour of the busbar, one of the pointed ends of the approximately triangular outer contour points into the receiving space. Since the inner contour of the receiving space corresponds to the outer contour, the busbar in the receiving space can not rotate. It is thus ensured that always shows a flat side of the outer contour to the ends of the ladder and thus provides the largest possible contact surface.

In one embodiment, the busbar in cross-section perpendicular to its longitudinal axis have a planar contour, in the middle of which a survey rises in the direction of the ends of the ladder in the installed state. Further, the carrier may have in cross-section perpendicular to its longitudinal axis a receiving space for one side of the busbar, which is orthogonal to the contact pressure. The end of the conductor is thus in the installed state on the survey, which thus serves as an abutment for the retaining spring. The contact force is therefore perpendicular to the plane in which lies the flat contour. The contact force between the retaining spring and the survey can be maximized. The Busbar can be inserted with one side over its entire length in the receiving space.

In one embodiment, the projections for engaging the locking elements in the busbar may be formed on that side of the busbar, which is opposite to the receiving space. In this variant, the busbar forms part of the supporting structure and is also electrically coupled to the conductor via the retaining spring.

In one embodiment, the coupling devices can have an extension with an abutment for the corresponding clamping element and on the other side of the busbar with an inserted busbar on one side of the busbar a projection for engaging the corresponding latching element. For insertion of a retaining spring in the carrier consequently only the clamping element must be inserted into the anvil and pressed the locking element on the extension and thus locked with this. The carrier forms as for the retaining spring a receptacle in which the retaining spring can be used very easily.

In one embodiment, the retaining springs may be coupled to the respective conductor such that the connection between the respective retaining spring and the corresponding conductor withstands a predetermined pull-out force, which is substantially perpendicular to the contact force. The connection of the conductors to the respective retaining spring can e.g. by welding, soldering, gluing, clamping, crimping, clinching or the like. Furthermore, the material or the dimensioning of the retaining springs can be selected according to the desired pull-out forces.

Short description of the figures

The principle of the invention will be explained in more detail below with reference to the accompanying figures by way of example. The same components are provided with identical reference numerals in the various figures. Show it:

1 a perspective view of an embodiment of a carrier according to the invention;

2 a perspective view of the carrier of 1 with an embodiment of a bus bar according to the invention;

3 a side view of an embodiment of a retaining spring according to the invention;

4 a perspective view of an embodiment of a connecting device according to the invention;

5 a side view of the connecting device of 4 ;

6 a side view of another embodiment of a connecting device according to the invention; and

7 a flow diagram of an embodiment of a method according to the invention.

Detailed description

The carrier 8th of the 1 is shown in perspective and has along its longitudinal axis 60 a plurality of coupling devices. Each of the coupling devices consists of a recess 17 to 23 and an extension 24 to 30 ,

The recesses 17 to 23 The coupling devices are in a rear section 61 of the carrier 8th arranged. Under the back is to understand that the ladder 2 or the ends 38 the leader 2 opposite the longitudinal axis 60 of the carrier 8th on the opposite side of the carrier 8th , so the output section 62 , led out of this or be led into this.

Each of the recesses 17 to 23 is executed approximately square and has at its upper end a flat edge, which serves as a support or counter bearing for the retaining springs 31 the single conductor is used (see 4 ).

The extensions 24 to 30 are in the exit section 62 formed, which is orthogonal to the rear portion 61 stands. The extensions 24 to 30 are therefore also orthogonal to the recesses 17 to 23 and have in a radial cross section to the longitudinal axis 60 a rectangular contour.

The rear section 61 and the exit section 62 of the carrier 8th be through a section of the carrier 8th connected, which has a roughly triangular contour and is open at the top. The section is thus in cross section through the longitudinal axis 60 funnel-shaped and forms a receiving space 9 out, in which the busbar 3 can be used (see 2 ).

In 1 are each seven recesses 17 to 23 and seven corresponding extensions 24 to 30 shown. The carrier 8th can therefore up to seven conductors 2 electrically connect and fix mechanically. This is where every leader becomes 2 individually with the carrier 8th connected (see 4 ).

It is understood that the number of recesses 17 to 23 and extensions 24 to 30 depending on Application can be varied. For example, it can also be provided that the carrier 8th eg as an injection molded part with a very high number of recesses 17 to 23 and extensions 24 to 30 will be produced. Depending on the application, it can then be shortened to the required length.

In particular, for example, a carrier 8th with recesses 17 to 23 and extensions 24 to 30 different size or width are provided. This allows ladder 2 very easy to couple with different dimensions.

2 shows the wearer 8th of the 1 with one in the recording room 9 inserted busbar 3 , The length of the busbar 3 is the length of the carrier 8th customized.

The busbar 3 has an outer contour 5 on, the inner contour of the recording room 9 equivalent. So it is in an axial cross section through the longitudinal axis 60 formed in approximately triangular. A page 7 the triangular outer contour 5 forms a continuous contact surface of the busbar 3 , The page 7 points up, ie from the recording room 9 out.

The busbar 3 is formed from a sheet, eg a copper sheet, which has been folded or bent into the triangular shape. The coupling point 63 , on which the two outer edges of the sheet meet, pointing down, ie in the hopper of the receiving space 9 into it.

In 3 is a retaining spring 31 shown in a side view, with a ladder 2 on the carrier 8th . 51 can be fixed (see 4 ).

In the middle of the retaining spring 31 a flat connecting portion extends 35 over which the retaining spring 31 with one end 38 of the leader 2 is coupled. For example, the end 38 of the leader 2 with the connecting section 35 welded, soldered, glued, clinched or pressed.

At the ends of the connection section 35 extend approximately at a 45 ° angle two spring arms 36 . 37 of this.

At the first spring arm 36 closes orthogonally to the spring arm 36 a locking element 34 at whose end 64 bent in approximately U-shape, with a corresponding extension 24 to 30 to be able to lock. The locking element 34 extends from the spring arm 36 out down, so on the side on which the line 2 is appropriate.

On the second spring arm 37 closes a clamping element 33 at, which from a 90 ° angle upwards, ie on the side on which the line 2 not appropriate, pointing section exists.

The difference between the clamping element 33 and the locking element 34 is that the clamping element 33 is only passive jammed, so not active on the carrier 8th . 51 holds. The locking element 34 on the other hand, it actively locks on a corresponding extension 24 to 30 and sticks to this.

4 shows the retaining spring 31 of the 3 with the conductor 2 after this in the carrier 8th with the busbar 3 of the 2 was inserted and locked.

The clamping element 33 the retaining spring 31 was just exemplary in the recess 22 of the carrier 8th introduced. Alternatively, the clamping element 33 into every other recess 17 to 23 be introduced.

The locking element 34 the retaining spring 31 is with the extension 29 locked. The curved section is at the end 64 of the locking element 34 under the extension 29 and relies on this. A direct lifting of the locking element 34 or a removal of the retaining spring 31 is without destroying the locking element 34 therefore not possible. To remove the retaining spring 31 must be the locking element 34 or its end 64 from the extension 29 be pushed sideways away so that the curved end 64 of the locking element 34 can move up past this.

The spring arms 36 . 37 be when locking the locking element 34 from her in 3 bent rest position out and thus biased. By this bias is on the connection section 35 exerted a force that this as a contact pressure 39 on the ladder 2 or the busbar 3 transfers.

In the presentation of the 4 becomes the separation between mechanical attachment and electrical connection of different conductors 2 obviously. While the retaining spring 31 only the necessary contact pressure 39 provides connect the busbar 3 all in the carrier 8th attached ladder 2 electrically with each other.

In 5 is the connection device 1 in cross-section through the longitudinal axis 60 shown. In particular, it can be clearly seen how the clamping element 33 through the recess 22 passes through and adhere to the wearer 8th supported.

By the contact pressure 39 which the tensioned retaining spring 31 on the ladder 2 not only becomes the leader 2 on the power rail 3 pressed. Rather, the busbar is also 3 in the recording room 9 pressed and thereby kept in position and secured against slipping. It is understood that further fastening or securing measures can be provided to the busbar 3 in the recording room 9 to secure.

In the connection device shown in a sectional view 49 of the 6 serves the busbar 50 not just the electrical connection of the individual conductors 2 , Rather, the busbar serves 50 also the mechanical connection, since the extensions in the busbar 50 are formed.

The busbar 50 has a roughly flat contour 52 in the middle of which is a survey 53 located. The top of the survey 53 forms the contact point between conductors 2 and power rail 50 , To perform the mechanical function, sits the busbar 50 in a recording room 54 of the carrier 51 , which is orthogonal to the contact pressure 39 in the locked state of the retaining spring 31 lies.

The section of the carrier 51 in which the clamping element 33 is supported, can be identical to that of the wearer 8th of the 1 to 5 be educated.

The flowchart of 7 shows a connection method for connecting a plurality of conductors 2 ,

To make an electrical connection between the conductors 2 to be able to produce, in a first step S1, a busbar 3 . 50 in a carrier 8th . 51 arranged, which the busbar 3 . 50 and which one for each of the leaders 2 having a coupling device. Further, the ends become 38 the single conductor 2 each with a retaining spring 31 connected, which is a coupling element (see elements 33 and 34 in 5 ), which will be described in more detail below. Finally, the coupling elements of the retaining springs 31 each coupled to one of the coupling devices, so that the end 38 of the respective leader 2 with a given contact pressure 39 on the power rail 3 . 50 is pressed.

For a secure hold of the busbar 3 . 50 in the carrier 8th . 51 and good electrical conductivity between the conductors 2 to ensure that it can be designed such that it is in cross-section perpendicular to its longitudinal axis 60 an outer contour 5 with a support surface 7 for the ends 38 the leader 2 having. In the installed state, for example, a page 7 a triangular outer contour 5 parallel to the ends 38 the leader 2 lie. Further, in the carrier 8th . 51 in cross-section perpendicular to its longitudinal axis 60 one of the outer contour 5 the busbar 3 . 50 corresponding recording room 9 . 54 to be trained, to the ends 38 the leader 2 is open in the installed state.

A particularly high contact pressure can be provided when the retaining springs 31 when coupling each at one end with a clamping element 33 as a coupling element in a recess 17 - 23 of the carrier 8th . 51 be used with an abutment and at the other end with a locking element 34 as another coupling element on an extension 24 - 30 of the carrier 8th . 51 be locked.

Furthermore, to the retaining springs 31 via one between the clamping element 33 and the locking element 34 located connection section 35 with the end 38 of the respective leader 2 be coupled. The connecting section 35 can thereby via spring arms 36 . 37 with the clamping element 33 and the locking element 34 be coupled, which is the clamping element 33 and the locking element 34 to bias one another.

When connecting S2 also the retaining springs 31 with the respective leader 2 connected such that the connection between the respective retaining spring 31 and the corresponding leader 2 a predetermined pull-out force withstands, which is substantially perpendicular to the contact pressure 39 stands.

Since the connecting devices described in detail above and the connecting method are exemplary embodiments, they can be modified in a customary manner by a person skilled in the art to a large extent, without departing from the scope of the invention. In particular, the mechanical arrangements and the size ratios of the individual elements to each other are merely exemplary.

LIST OF REFERENCE NUMBERS

1, 49

connecting device

2

ladder

3, 50

conductor rail

5

outer contour

6

sheet

7

bearing surface

8, 51

carrier

9, 54

accommodation space

17-23

 Parts of a coupling device (for example recesses)

24-30

 Parts of a coupling device (e.g.

31

retaining spring

33

Coupling element (e.g., clamping element)

34

Coupling element (for example latching element)

35

connecting portion

36, 37

spring arms

38

The End

39

contact force

52

flat contour

53

survey

60

longitudinal axis

61

rear section

62

output section

63

coupling point

64

curved end

65

section

Claims (12)

Connecting device ( 1 . 49 ) for connecting a plurality of electrical conductors ( 2 ), with a busbar ( 3 . 50 ), which is formed, the ladder ( 2 ) electrically coupled to each other with a carrier ( 8th . 51 ), which is formed, the busbar ( 3 . 50 ) and for each of the leaders ( 2 ) a coupling device ( 17 - 23 . 24 - 30 ), and with a retaining spring ( 31 ) for each of the leaders ( 2 ), which at least one coupling element ( 33 . 34 ), which with one of the coupling devices ( 17 - 23 . 24 - 30 ), whereby the retaining spring ( 31 ) is tensioned in the installed state and the retaining spring ( 31 ) is designed in such a way, one end ( 38 ) of the respective leader ( 2 ) with a predetermined contact force ( 39 ) on the busbar ( 3 . 50 ), characterized in that the retaining springs ( 31 ) each at one end a clamping element ( 33 ) and at the other end a locking element ( 34 ), the retaining springs ( 31 ) between the clamping element ( 33 ) and the locking element ( 34 ) each have a connecting section ( 35 ), which is connected to the end ( 38 ) of the respective leader ( 2 ) is coupled and via spring arms ( 36 . 37 ) with the clamping element ( 33 ) and the locking element ( 34 ), and the spring arms ( 36 . 37 ) the clamping element ( 33 ) and the locking element ( 34 ) bias each other. Connecting device ( 1 ) according to claim 1, wherein the busbar ( 350 ) in cross-section perpendicular to its longitudinal axis ( 60 ) a curved outer contour ( 5 ) with a bearing surface ( 7 ) for the ends ( 38 ) the ladder ( 2 ) having. Connecting device ( 1 ) according to claim 2, wherein the busbar ( 3 ) an approximately polygonal or circular or semicircular outer contour ( 5 ) having. Connecting device ( 1 ) according to one of claims 2 or 3, wherein the carrier ( 8th ) in cross-section perpendicular to its longitudinal axis ( 60 ) one of the outer contour ( 5 ) of the busbar ( 3 ) corresponding receiving space ( 9 ) leading to the ends ( 38 ) the ladder ( 2 ) is open in the installed state. Connecting device ( 49 ) according to claim 1, wherein the busbar ( 50 ) in cross-section perpendicular to its longitudinal axis ( 60 ) a flat contour ( 52 ), in the middle of which a survey ( 53 ) towards the ends ( 38 ) the ladder ( 2 ) in the installed state, and wherein the carrier ( 51 ) in cross-section perpendicular to its longitudinal axis ( 60 ) a recording room ( 54 ) for one side of the busbar ( 50 ) which is orthogonal to the contact force ( 39 ) lies. Connecting device ( 1 ) according to one of claims 1 to 4, wherein the coupling devices ( 17 to 23 . 24 to 30 ) with inserted busbar ( 3 ) on one side of the busbar ( 3 ) each have a recess ( 17 - 23 ) with an abutment for the corresponding clamping element ( 33 ) and on the other side of the busbar ( 3 ) an extension ( 24 - 30 ) for locking the corresponding latching element ( 34 ) exhibit. Connecting device ( 49 ) according to claim 5, wherein the extensions for latching the latching elements ( 34 ) on the side of the busbar ( 50 ) are formed, which the receiving space ( 54 ) is opposite. Connecting device ( 1 . 49 ) according to one of the preceding claims, wherein the connecting section ( 35 ) is just. Connection method for connecting a plurality of conductors ( 2 ), comprising the steps: arranging (S1) a busbar ( 3 . 50 ), which the ladder ( 2 ) electrically coupled, in a carrier ( 8th . 51 ), which the busbar ( 3 . 50 ) and which one for each of the leaders ( 2 ) a coupling device ( 17 - 23 . 24 - 30 ), coupling (S2) ends ( 38 ) the ladder ( 2 ) each having a connecting section ( 35 ) a retaining spring ( 31 ), which at least one coupling element ( 33 . 34 ), wherein the connecting portion ( 35 ) via spring arms ( 36 . 37 ) with the clamping element ( 33 ) and the locking element ( 34 ) and coupling (S3) of the at least one coupling element ( 33 . 34 ) of the retaining springs ( 31 ) each having one of the coupling devices ( 17 - 23 . 24 - 30 ) of the carrier ( 8th . 51 ) and latching of the locking element ( 34 ) with the carrier ( 8th ) or the busbar ( 50 ), so that by the respective retaining spring ( 31 ) the end ( 38 ) of the respective leader ( 2 ) with a predetermined contact force ( 39 ) on the busbar ( 3 . 50 ) is pressed. The connection method according to claim 9, wherein the busbar ( 3 ) is shaped in such a way that in cross-section perpendicular to its longitudinal axis ( 60 ) an outer contour ( 5 ) with a bearing surface ( 7 ) For the ends ( 38 ) the ladder ( 2 ), and wherein in the carrier ( 8th ) in cross-section perpendicular to its longitudinal axis ( 60 ) one of the outer contour ( 5 ) of the busbar ( 3 ) corresponding receiving space ( 9 ) formed to the ends ( 38 ) the ladder ( 2 ) is open in the installed state. The connection method according to claim 9, wherein the busbar ( 3 . 50 ) is shaped in such a way that in cross-section perpendicular to its longitudinal axis ( 60 ) a flat contour ( 52 ), in the middle of which, in the installed state, a survey ( 53 ) towards the ends ( 38 ) the ladder ( 2 ), and wherein the carrier ( 51 ) is shaped such that it is in cross-section perpendicular to its longitudinal axis ( 60 ) a recording room ( 54 ) for one side of the busbar ( 3 . 50 ), which is perpendicular to the contact force ( 39 ) lies. Connection method according to one of the preceding claims 9 or 10, wherein the retaining springs ( 31 ) in each case at one end with a clamping element ( 33 ) in a recess ( 17 - 23 ) of the carrier ( 8th ) are used with an abutment and at the other end with a locking element ( 34 ) on an extension ( 24 - 30 ) of the carrier ( 8th ) are locked.

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