EP0069804B1 - Method of making an electrical connection between crimping sleeve and a conductor - Google Patents

Method of making an electrical connection between crimping sleeve and a conductor Download PDF

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Publication number
EP0069804B1
EP0069804B1 EP81109357A EP81109357A EP0069804B1 EP 0069804 B1 EP0069804 B1 EP 0069804B1 EP 81109357 A EP81109357 A EP 81109357A EP 81109357 A EP81109357 A EP 81109357A EP 0069804 B1 EP0069804 B1 EP 0069804B1
Authority
EP
European Patent Office
Prior art keywords
sleeve
cable
moulded
conductor
moulded sleeve
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
Application number
EP81109357A
Other languages
German (de)
French (fr)
Other versions
EP0069804A3 (en
EP0069804A2 (en
Inventor
Dieter Sander
Norbert Büchele
Karl Kübler
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Karl Pfisterer Elektrorechnische Spezialartikel GmbH and Co KG
Original Assignee
Karl Pfisterer Elektrorechnische Spezialartikel GmbH and Co KG
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Karl Pfisterer Elektrorechnische Spezialartikel GmbH and Co KG filed Critical Karl Pfisterer Elektrorechnische Spezialartikel GmbH and Co KG
Priority to AT81109357T priority Critical patent/ATE15571T1/en
Publication of EP0069804A2 publication Critical patent/EP0069804A2/en
Publication of EP0069804A3 publication Critical patent/EP0069804A3/en
Application granted granted Critical
Publication of EP0069804B1 publication Critical patent/EP0069804B1/en
Expired legal-status Critical Current

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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
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • 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
    • H01R4/10—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping

Definitions

  • the invention relates to a method for producing an electrical connection between a compression sleeve and a conductor in the form of a rope, in which the compression sleeve by a pressing force exerted on its outer lateral surface by means of a tool in different areas of its circumference in different dimensions in the radial direction, changing its contour shape permanently deformed and the rope is compressed to varying degrees in the radial direction, changing its contour shape on its circumference.
  • the invention has for its object to provide a method for producing an electrical connection between a compression sleeve and a conductor in the form of a rope, which can be used not only for thin-walled, but also for thick-walled compression sleeves and those that do not have locally very deep deformations can be provided, but which can still achieve high contact quality and transverse conductivity and can be carried out with the simplest possible pressing tool.
  • the method according to the invention is also particularly suitable for compression sleeves made of aluminum or an aluminum alloy which are to be connected with a rope made of aluminum wires.
  • the implementation of the method is simple because the press sleeve only has to be inserted into the circular-cylindrical press channel of a press tool and then needs to be brought into the shape of the press channel by closing the press tool.
  • the angular position of the press sleeve in the press channel is irrelevant, which in many cases makes it much easier to attach and handle the press tool.
  • a compression sleeve 1 which in the exemplary embodiment forms a connector, that is to say a clamp, by means of which two mutually facing and coaxially arranged conductor ends can be connected to one another, but which, for example, can also be formed with one end on another clamp body, for example the flange of a battery clamp could, consists of a compressible material, which is an aluminum alloy in the embodiment.
  • the hardness of this aluminum alloy is significantly greater than the hardness of the aluminum from which the wires of a conductor 2 of an insulated cable 3, which is designed as a rope, are made.
  • the central, continuous longitudinal channel 4 of the compression sleeve 1 is adapted in its central section to the outside diameter of the conductor 2, while in the two end sections the inside diameter of the longitudinal channel 4 is enlarged to the outside diameter of the cable 3, so that the end of the insulation 5 of the cable 3 in the compression sleeve 1 can be inserted.
  • the compression sleeve 1 can also be used to establish a connection with a non-insulated conductor cable.
  • the cross-sectional shape of the press sleeve 1 is delimited on the outside by a polygon, in the present example a square, to which the longitudinal channel 4 is concentric.
  • this polygonal shape is to be converted into a circular shape in the area of the pressing point or locations so that, as shown in FIG.
  • the egg NEN circular cylindrical press channel 7 form on the outer surface of the press sleeve 1 jaws 6 of a press are therefore created.
  • the diameter of this press channel is equal to or slightly larger than the side length of the square forming the contour of the press sleeve 1 in the uncompressed state.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Connections By Means Of Piercing Elements, Nuts, Or Screws (AREA)
  • Multi-Conductor Connections (AREA)
  • Coupling Device And Connection With Printed Circuit (AREA)

Abstract

1. Method of producing an electrical connection between a moulded sleeve and a conductor in the form of a cable, wherein by means of pressure exerted by a tool onto its outer face and in a radial direction to a differing extent in various zones of its periphery, the moulded sleeve is lastingly deformed, undergoing a change of contour, the cable being compressed in a radial direction in varying degress and altering its contours over its periphery, characterised in that when the pressing process is applied to the moulded sleeve, the premise adopted for a sleeve cross-section is that of a polygon as the outer boundary and a circle as the inner boundary and in that the pressing process imparts to the moulded sleeve a cross-sectional form which is outwardly at least approximately defined by a circle and on the inside by a line which, like the contours of the compressed cable, has in its peripheral direction repetitive portions with a differing spacing from the centre.

Description

Die Erfindung betrifft ein Verfahren zum Herstellen einer elektrischen Verbindung zwischen einer Preßhülse und einem Leiter in Form eines Seiles, bei dem die Preßhülse durch eine mittels eines Werkzeuges auf ihre Außenmantelfläche ausgeübte Preßkraft in unterschiedlichen Bereichen ihres Umfangs in unterschiedlichem Ausmaße in radialer Richtung unter Änderung ihrer Konturform bleibend verformt und das Seil unter Änderung seiner Konturform auf seinem Umfang in unterschiedlichem Maße in radialer Richtung zusammengepreßt wird.The invention relates to a method for producing an electrical connection between a compression sleeve and a conductor in the form of a rope, in which the compression sleeve by a pressing force exerted on its outer lateral surface by means of a tool in different areas of its circumference in different dimensions in the radial direction, changing its contour shape permanently deformed and the rope is compressed to varying degrees in the radial direction, changing its contour shape on its circumference.

Es ist bekannt (US-A-2 109 837), eine vor dem Verpressen kreiszylindrische Preßhülse einseitig bleibend zu deformieren mittels einer in Hülsenlängsrichtung verlaufenden Rippe eines Preßwerkzeuges, das in die Preßhülse eine rinnenförmige, bleibende Vertiefung eindrückt und dadurch dem in der Preßhülse liegenden Leiterseil eine halbmondartige Querschnittsform gibt. Nachteilig ist hierbei in erster Linie, daß eine solche Verpressung nur bei relativ dünnwandigen Preßhülsen möglich ist, daß bei größeren Querschnitten die erreichbare Kontaktqualität und Querleitfähigkeit des Seiles ungenügend ist und daß das Verpressen ein spezielles Preßwerkzeug erfordert.It is known (US Pat. No. 2,109,837) to permanently deform a circular cylindrical press sleeve on one side before pressing by means of a rib of a press tool running in the longitudinal direction of the sleeve, which presses a channel-shaped, permanent depression into the press sleeve and thereby the conductor cable lying in the press sleeve gives a crescent-like cross-sectional shape. The main disadvantage here is that such compression is only possible with relatively thin-walled compression sleeves, that the contact quality and cross-conductivity of the rope that can be achieved is inadequate for larger cross-sections, and that the compression requires a special pressing tool.

Der Erfindung liegt die Aufgabe zugrunde, ein Verfahren zum Herstellen einer elektrischen Verbindung zwischen einer Preßhülse und einem Leiter in Form eines Seiles zu schaffen, das nicht nur für dünnwandige, sondern auch für dickwandige Preßhülsen sowie solche verwendbar ist, die nicht mit örtlich sehr tiefen Verformungen versehen werden können, das aber dennoch eine hohe Kontaktqualität und Querleitfähigkeit erreichen läßt und mit einem möglichst einfachen Preßwerkzeug durchgeführt werden kann.The invention has for its object to provide a method for producing an electrical connection between a compression sleeve and a conductor in the form of a rope, which can be used not only for thin-walled, but also for thick-walled compression sleeves and those that do not have locally very deep deformations can be provided, but which can still achieve high contact quality and transverse conductivity and can be carried out with the simplest possible pressing tool.

Diese Aufgabe löst ein Verfahren mit den Merkmalen des Anspruches 1.This object is achieved by a method having the features of claim 1.

Dadurch, daß man von einer polygonen Außenform der Preßhülse ausgeht und während des Verpressens diese Außenform in eine kreiszylindrische Form umwandelt, erfährt das in der Preßhülse liegende Seil in denjenigen Bereichen, auf die die Ecken des Polygons ausgerichtet sind, eine stärkere radiale Verpressung als in den zwischenliegenden Bereichen, was nicht nur einen sehr guten Kontakt zwischen der Preßhülse und dem Seil ergibt, sondern auch zu einer optimalen Querleitfähigkeit des Seils führt. Daher ist das erfindungsgemäße Verfahren auch besonders für Preßhülsen aus Aluminium oder einer Aluminiumlegierung geeignet, die mit einem Seil aus Aluminiumdrähten verbunden werden sollen. Die Durchführung des Verfahrens ist einfach, weil die Preßhülse nur in den kreiszylindrischen Preßkanal eines Preßwerkzeuges eingelegt und dann durch Schließen des Preßwerkzeuges in die Form des Preßkanals gebracht zu werden braucht. Die Winkellage der Preßhülse im Preßkanal spielt dabei keine Rolle, was das Ansetzen und Handhaben des Preßwerkzeuges in vielen Fällen wesentlich erleichtert.Because one assumes a polygonal outer shape of the press sleeve and converts this outer shape into a circular cylindrical shape during the pressing, the rope lying in the press sleeve is subjected to a stronger radial pressing in those areas to which the corners of the polygon are aligned than in intermediate areas, which not only results in very good contact between the compression sleeve and the rope, but also leads to optimal transverse conductivity of the rope. Therefore, the method according to the invention is also particularly suitable for compression sleeves made of aluminum or an aluminum alloy which are to be connected with a rope made of aluminum wires. The implementation of the method is simple because the press sleeve only has to be inserted into the circular-cylindrical press channel of a press tool and then needs to be brought into the shape of the press channel by closing the press tool. The angular position of the press sleeve in the press channel is irrelevant, which in many cases makes it much easier to attach and handle the press tool.

Da die erforderlichen Unterschiede der radialen Verpressung des Seiles mit zunehmender Ekkenzahl des Polygons der Preßhülse kleiner werden, wird zweckmäßigerweise von einem regelmäßigen Polygon mit maximal acht Ecken, vorzugsweise drei bis sechs Ecken, ausgegangen.Since the required differences in the radial compression of the rope become smaller as the number of corners of the polygon of the press sleeve increases, it is expedient to assume a regular polygon with a maximum of eight corners, preferably three to six corners.

Im Hinblick auf die erreichbare Kontaktqualität ist es vorteilhaft, für die Preßhülse ein Material zu wählen, das wesentlich härter ist als das Material, aus dem die Drähte des Seiles bestehen.In view of the contact quality that can be achieved, it is advantageous to choose a material for the press sleeve that is considerably harder than the material from which the wires of the rope are made.

Im folgenden ist die Erfindung anhand eines in der Zeichnung dargestellten Ausführungsbeispiels im einzelnen erläutert. Es zeigt

  • Fig. 1 einen Querschnitt durch eine Preßhülse mit eingelegtem Leiterseil vor dem Verpressen sowie eine schematisch dargestellte Ansicht der für das Verpressen vorgesehenen Backen einer Presse,
  • Fig. 2 einen Querschnitt der Hülse und des eingelegten Leiterseils nach dem Verpressen sowie eine schematisch dargestellte Ansicht der Bakken der Presse,
  • Fig. 3 einen unvollständig dargestellten Längsschnitt durch die Preßhülse und ein Kabel.
The invention is explained in detail below using an exemplary embodiment shown in the drawing. It shows
  • 1 shows a cross section through a press sleeve with an inserted conductor rope before pressing, and a schematically illustrated view of the jaws of a press intended for pressing,
  • 2 shows a cross section of the sleeve and the inserted conductor cable after the pressing and a schematically illustrated view of the jaws of the press,
  • Fig. 3 shows an incomplete longitudinal section through the compression sleeve and a cable.

Eine Preßhülse 1, die im Ausführungsbeispiel einen Verbinder bildet, also eine Klemme, mittels deren zwei gegeneinander weisende und gleichachsig angeordnete Leiterenden miteinander verbunden werden können, die aber auch beispielsweise mit ihrem einen Ende an einen anderen Klemmenkörper, beispielsweise den Flansch einer Batterieklemme, angeformt sein könnte, besteht aus einem verpreßbaren Material, bei dem es sich im Ausführungsbeispiel um eine Aluminiumlegierung handelt. Die Härte dieser Aluminiumlegierung ist wesentlich größer als die Härte des Aluminiums, aus dem die Drähte eines als Seil ausgebildeten Leiters 2 eines isolierten Kabels 3 bestehen. Der zentrale, durchgehende Längskanal 4 der Preßhülse 1 ist in seinem Mittelabschnitt an den Außendurchmesser des Leiters 2 angepaßt, während in den beiden Endabschnitten der Innendurchmesser des Längskanals 4 auf den Außendurchmesser des Kabels 3 vergrößert ist, damit das Ende der Isolation 5 des Kabels 3 in die Preßhülse 1 eingeführt werden kann. Selbstverständlich ist die Preßhülse 1 auch zur Herstellung einer Verbindung mit einem nichtisolierten Leiterseil verwendbar.A compression sleeve 1, which in the exemplary embodiment forms a connector, that is to say a clamp, by means of which two mutually facing and coaxially arranged conductor ends can be connected to one another, but which, for example, can also be formed with one end on another clamp body, for example the flange of a battery clamp could, consists of a compressible material, which is an aluminum alloy in the embodiment. The hardness of this aluminum alloy is significantly greater than the hardness of the aluminum from which the wires of a conductor 2 of an insulated cable 3, which is designed as a rope, are made. The central, continuous longitudinal channel 4 of the compression sleeve 1 is adapted in its central section to the outside diameter of the conductor 2, while in the two end sections the inside diameter of the longitudinal channel 4 is enlarged to the outside diameter of the cable 3, so that the end of the insulation 5 of the cable 3 in the compression sleeve 1 can be inserted. Of course, the compression sleeve 1 can also be used to establish a connection with a non-insulated conductor cable.

Im unverpreßten Zustand ist die Querschnittsform der Preßhülse 1 außen durch ein Polygon, im vorliegenden Beispiel ein Quadrat, begrenzt, zu dem konzentrisch der Längskanal 4 iiegt. Beim Verpressen der Preßhülse 1 soll diese Polygonform im Bereich der Preßstelle oder -stellen in eine Kreisform übergeführt werden, damit, wie Fig. 2 zeigt, der Leiter 2 in sich in Umfangsrichtung wiederholenden Abschnitten in radialer Richtung unterschiedlich stark verpreßt wird. An die Außenmantelfläche der Preßhülse 1 werden deshalb Backen 6 einer Presse angelegt, die einen kreiszylindrischen Preßkanal 7 bilden. Der Durchmesser dieses Preßkanals ist gleich oder geringfügig größer als die Seitenlänge des die Kontur der Preßhülse 1 im unverpreßten Zustand bildenden Quadrates.In the uncompressed state, the cross-sectional shape of the press sleeve 1 is delimited on the outside by a polygon, in the present example a square, to which the longitudinal channel 4 is concentric. When pressing the compression sleeve 1, this polygonal shape is to be converted into a circular shape in the area of the pressing point or locations so that, as shown in FIG. On the outer surface of the press sleeve 1 jaws 6 of a press are therefore created, the egg NEN circular cylindrical press channel 7 form. The diameter of this press channel is equal to or slightly larger than the side length of the square forming the contour of the press sleeve 1 in the uncompressed state.

Werden nun die Backen 6 gegeneinander gedrückt, dann wird das Material der Preßhülse 1 in denjenigen vier Bereichen, in denen die Längskanten der unverpreßten Preßhülse waren, weiter gegen das Zentrum des Längskanals 4 gedrückt als in den vier dazwischenliegenden Bereichen. Dies hat, wie Fig. 2 zeigt, zur Folge, daß die Innenkontur der Preßhülse 1 und die dieser entsprechende Außenkontur des Leiters 2 zwischen vier um je 90° versetzten Bereichen mit maximalem Abstand vom Zentrum vier Bereiche aufweist, in denen dieser Abstand zur Bereichsmitte hin abnimmt.If the jaws 6 are pressed against each other, the material of the press sleeve 1 is pressed further against the center of the longitudinal channel 4 in those four areas in which the longitudinal edges of the uncompressed press sleeve were located than in the four areas in between. As shown in FIG. 2, this has the consequence that the inner contour of the compression sleeve 1 and the corresponding outer contour of the conductor 2 have four areas between four areas, each offset by 90 °, with a maximum distance from the center, in which this distance from the center of the area decreases.

Da eine entsprechende Verpressung der Preßhülse auch in den Endabschnitten erfolgt, in die hinein auch die Isolation 5 ragt, wird dort ein dichter Verschluß erzielt, der es verhindert, daß äußere Störeinflüsse zu dem Kontakt zwischen de Preßhülse und dem Leiter sowie den Kontakten zwischen den einzelnen Drähten des Leiters 2 gegangen können. Der Kontakt zwischen der Preßhütse 1 und dem Leiter ist deshalb besonders hoch elektrisch belastbar und von gleichbleibender Qualität über lange Zeiträume hinweg.Since a corresponding compression of the compression sleeve also takes place in the end sections into which the insulation 5 also projects, a tight seal is achieved there, which prevents external interference from the contact between the compression sleeve and the conductor and the contacts between the individual Wires of the conductor 2 can go. The contact between the press sleeve 1 and the conductor is therefore particularly highly electrically loadable and of constant quality over long periods of time.

Claims (4)

1. Method of producing an electrical connection between a moulded sleeve and a conductor in the form of a cable, wherein by means of pressure exerted by a tool onto its outer face and in a radial direction to a differing extent In various sones of its periphery, the moulded sleeve is lastingly deformed, undergoing a change of contour, the cable being compressed in a radial direction in varyipg depress and altering its contours over its periphery, characterised in that when the pressing process is applied to the moulded sleeve, the premise adopted for a sleeve corss-section is that of a polygon as the outer boundary and a circle as the inner boundary and in that the presssing process imparts to the moulded sleeve a cross-sectional form which is outwardly at least approximately defined by a circle and on the inside by a line which, like the contours of the compressed cable, has in its peripheral direction repetitive portions with a differing spacing from the centre.
2. A method according to claim 1, characterised in that the premise adopted is that of a regular polygon with a maximum of eight corners and preferably three to six corners.
3. A method according to claim 1 or 2, characterised in that for the moulded sleeve a material is chosen which is substantially harder than the material of which the wires of the cable consist.
4. A method according to ctaim 3, characterised in that in the case of a conductor which consists of aluminium wires, the material chosen for the moulded steeve is aluminium or an aluminium alloy.
EP81109357A 1981-07-10 1981-10-30 Method of making an electrical connection between crimping sleeve and a conductor Expired EP0069804B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AT81109357T ATE15571T1 (en) 1981-07-10 1981-10-30 PROCEDURE FOR MAKING AN ELECTRICAL CONNECTION BETWEEN A FERRULE AND A CONDUCTOR.

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE3127283A DE3127283C2 (en) 1981-07-10 1981-07-10 Method for establishing an electrical connection between a compression sleeve and a conductor
DE3127283 1981-07-10

Publications (3)

Publication Number Publication Date
EP0069804A2 EP0069804A2 (en) 1983-01-19
EP0069804A3 EP0069804A3 (en) 1983-08-03
EP0069804B1 true EP0069804B1 (en) 1985-09-11

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP81109357A Expired EP0069804B1 (en) 1981-07-10 1981-10-30 Method of making an electrical connection between crimping sleeve and a conductor

Country Status (3)

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EP (1) EP0069804B1 (en)
AT (1) ATE15571T1 (en)
DE (1) DE3127283C2 (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4991289A (en) * 1989-06-23 1991-02-12 Amp Incorporated Crimping die and crimped electrical connection therefrom
DE102010032067A1 (en) 2010-07-23 2012-01-26 Daimler Ag Contact arrangement for e.g. cylindrical lithium ion cylindrical cell of high-voltage battery, has current collector pressed, crimped and blocked with pole contact of cell or electrical component by deformation of portions of collector

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2109837A (en) * 1936-01-02 1938-03-01 Grace P Davis Method of joining power transmitting cables
NL198024A (en) * 1954-07-06
BE563464A (en) * 1956-12-28
US3330903A (en) * 1965-06-18 1967-07-11 Kearney National Inc Compression connector with removable tabs for a range of conductor sizes

Also Published As

Publication number Publication date
EP0069804A3 (en) 1983-08-03
DE3127283A1 (en) 1983-01-27
DE3127283C2 (en) 1983-12-08
EP0069804A2 (en) 1983-01-19
ATE15571T1 (en) 1985-09-15

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