EP1518303B1 - Method for joining lacquered wires in an electrically conducting manner - Google Patents

Method for joining lacquered wires in an electrically conducting manner Download PDF

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Publication number
EP1518303B1
EP1518303B1 EP03761558A EP03761558A EP1518303B1 EP 1518303 B1 EP1518303 B1 EP 1518303B1 EP 03761558 A EP03761558 A EP 03761558A EP 03761558 A EP03761558 A EP 03761558A EP 1518303 B1 EP1518303 B1 EP 1518303B1
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EP
European Patent Office
Prior art keywords
wires
electrically conductive
conductive material
lacquered
ultrasound
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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.)
Revoked
Application number
EP03761558A
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German (de)
French (fr)
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EP1518303A1 (en
Inventor
Anton Stapel
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Stapla Ultraschalltechnik GmbH
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Stapla Ultraschalltechnik GmbH
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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
    • H01R43/02—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
    • 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
    • H01R43/0228—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 without preliminary removing of insulation before soldering or welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • 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
    • H01R43/0207—Ultrasonic-, H.F.-, cold- or impact welding
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing

Definitions

  • the invention relates to a method for electrically conductive bonding of at least two wires provided with an insulating varnish (painted wires).
  • connection types are z. B. of electric motors.
  • an insulated armature winding is welded to a copper plate, from which in turn emanates an insulated wire.
  • the present invention is based on the problem, a method of the type mentioned in such a way that several painted wires can be interconnected without between them an electrically conductive connection part and without the paint must be removed beforehand.
  • the painted wires in the area where they are connected are at least partially enclosed by an electrically conductive uninsulated material and that are then connected non-positively by ultrasonic action of the wires with the material with simultaneous breaking of the insulating , It is not absolutely necessary that the painted wires themselves come into direct contact with the electrically conductive material.
  • ultrasound is applied to the material forming an envelope surrounding the painted wires, whereby the material is shaped such that it applies to the exterior painted wires with simultaneous frictional confinement of all painted wires.
  • a relative movement between the enamel wires and the envelope is caused by the action of ultrasound, with the result that the lacquer layer breaks up to the extent that the lacquer layer is removed between contacting lacquered wires and thus the desired electrically conductive connection takes place.
  • the removed insulating varnish itself migrates into the space between the wires, so that in this way the desired electrical contact is not adversely affected.
  • a copper braid surrounding the painted wires are used as the material -, it is preferably provided that as an electrically conductive material such is used in a sleeve or cup shape.
  • a related solution may, for. B. be used for a connection between an armature winding wire and a connecting wire.
  • the electrically conductive material may be a sheet metal strip formed as a crimp. Also, a sheet or strip can be wound in one or more layers around the wires to be connected.
  • a preformed sheet metal which may have a U-shape, circular section or open trapezoidal in section
  • the enameled wires and optionally further conductors to be connected with these are introduced, then by means of sonotrode or anvil to be inserted into the preformed sheet metal to close the enameled wires and the optionally present conductor and then produce a compound according to the teaching of the invention.
  • the enameled wire can be used one which consists of aluminum and / or copper.
  • the material surrounding the enamel wires forming the envelope itself should also or preferably be made of or include copper.
  • a painted wire 10 which consists of a core 12 consisting of electrically conductive material, such as copper or aluminum, and outer coating layer 14 to an electrically conductive carrier 16.
  • This is done by ultrasonic welding.
  • the wire 10 is deformed, wherein in the contact area between the carrier 16 and the coated wire 10 due to the relative movement to each other, the resist layer 14 is removed and thus the desired intimate contact 14 is achieved as the welding.
  • Removed varnish material builds up between the in Fig. 2 with the reference numerals 18 and 20 provided contact or welds.
  • a related type of connection is not possible, however, if several painted wires (enameled wires) like their ends or several painted wires are to be connected to a carrier. In this case, it is either necessary to remove the insulating sleeve or to use a connecting beam by first connecting one end of a painted wire to the carrier and then connecting it to the end of another painted wire or tools (sonotrode, anvil). an ultrasound welding device geometrically in such a way that the enamel wires are fixed accurately.
  • the ends 22, 24, 26 - are introduced into a cup-shaped sleeve 28 made of electrically conductive material such as copper material.
  • the wire ends 22, 24, 26 are more or less densely packed.
  • an electrically conductive connection is due to the lacquer layer neither with each other nor to the sleeve 28.
  • the sleeve 28 is introduced with the wire ends 22, 24 between the tools, so the sonotrode and the counter electrode or: the anvil of an ultrasonic welding device and then applied ultrasound , This results in a deformation of the sleeve 28 such that it surrounds the wire ends 22, 24, 26 frictionally.
  • the broken lacquer migrates into the spaces between the wire ends 22, 24, 26 and is in the Fig. 5 indicated by dots 30.
  • a plurality of painted wire ends 32, 34, 36 can be connected to each other and at the same time with a carrier 38, as is apparent from the 6 and 7 results.
  • the wire ends 32, 34, 36 are inserted into a sleeve 40, which is then placed on the support 38, which in turn is placed on a counter electrode of an ultrasonic welding device.
  • a sonotrode then acts on the sleeve 40 with the result that the sleeve is deformed and the wire ends 32, 34, 36 are enclosed in a form-fitting manner, at the same time welding to the carrier 38.
  • Fig. 8a to 8e are further highlighted embodiments of molded electrically conductive material to refer to the painted wires and any other existing electrical conductors are positively connected. So is in Fig. 8a a formed as a crimp 44 formed sheet surrounding the conductor 46 to be welded. In the embodiment of Fig. 8b Enamel wires 48 are one or more layers surrounded by a sheet material 50 and then connected according to the teaching of the invention.
  • the enameled wires 52, 54, 56 in one-sided open preformed receptacles 58, 60, 62 introduce, which has a trapezoidal shape ( Fig. 8c ), a circular section shape ( Fig. 8d ) or a U-shape ( Fig. 8e ) in section.
  • the enameled wires 52, 54, 56 and optionally further conductor 64 to be welded are introduced and then closed during the ultrasonic welding process.
  • the corresponding tool of the ultrasonic welding device can have a geometry enabling the closing or folding of the receptacles 58, 60, 62.
  • the wires 52, 54, 56 are surrounded and frictionally surrounded by the receptacles 68, 62, whereby at the same time the insulating varnish of the wires 52, 54, 56 flakes off and then the stripped wires 52, 54, 56 are welded together.
  • Typical dimensions of painted wires which are electrically conductively connected by the method according to the invention, are those with inner diameters between 0.2 mm and 4 mm at a paint layer thickness between 0.1 mm and 0.2 mm, without thereby restricting the teaching of the invention should be done.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Processing Of Terminals (AREA)

Abstract

A method for joining in an electrically conducting manner at least two wires that are provided with an insulating lacquer. In order to be able to interconnect several lacquered wires without using an electrically conducting joining piece therebetween and without having to remove the lacquer first, at least some of the areas of the lacquered wires which are to be joined, are enveloped by an electrically conducting material, and the wires are connected in a positive manner to the material by applying ultrasound while breaking up the insulating lacquer.

Description

Die Erfindung bezieht sich auf ein Verfahren zum elektrisch leitenden Verbinden von zumindest zwei mit einem Isolierlack versehenen Drähten (lackierte Drähte).The invention relates to a method for electrically conductive bonding of at least two wires provided with an insulating varnish (painted wires).

Um einen lackierten Draht mit einem Leiter zu verbinden, ist es bekannt, diese mittels Ultraschall zu verschweißen. Hierbei erfolgt unmittelbar eine innige Verbindung zwischen dem Draht und dem Leiter. Ferner ist es bekannt, ein Ende eines lackierten Drahtes mit einer Litze zu verbinden.In order to connect a painted wire with a conductor, it is known to weld them by means of ultrasound. Here, an intimate connection between the wire and the conductor takes place immediately. Furthermore, it is known to connect one end of a painted wire with a stranded wire.

Um zwei lackierte Drähte miteinander zu verbinden, ohne dass die Lackschicht vorher entfernt werden muss, ist es bekannt, zunächst ein Ende des Lackdrahtes mit einem Leiter zu verbinden, um sodann den Leiter wiederum mit dem anderen Ende mittels Ultraschallschweißens zu verbinden. Diesbezügliche Verbindungsarten sind z. B. von Elektromotoren bekannt. So wird eine isolierte Ankerwicklung mit einem Kupferplättchen verschweißt, von dem wiederum ein isolierter Draht ausgeht.In order to connect two painted wires together, without having to remove the lacquer layer beforehand, it is known to first connect one end of the enameled wire to a conductor and then to connect the conductor again to the other end by means of ultrasonic welding. Such connection types are z. B. of electric motors. Thus, an insulated armature winding is welded to a copper plate, from which in turn emanates an insulated wire.

Um mehrere Enden von lackierten Drähten elektrisch leitend zu verbinden, ist es auch bekannt, diese in eine Hülse einzubringen, die von einer Fläche ausgehende Grate aufweist, die sich beim Zusammendrücken der Hülse in die Lackierung einkerben, die ihrerseits aufplatzt. Allerdings ist durch diese Maßnahme nicht gewährleistet, dass Drähte, die nicht unmittelbar mit der Hülse Kontakt haben, auf diesem Wege freigelegt werden, um die gewünschte elektrisch leitende Verbindung mit weiteren Drähten zu erzielen.In order to electrically connect a plurality of ends of painted wires, it is also known to incorporate them into a sleeve which has ridges emanating from a surface which are indented when the sleeve is compressed into the paint, which in turn bursts. However, this measure does not guarantee that wires, not directly in contact with the sleeve are exposed in this way to achieve the desired electrically conductive connection with other wires.

Aus der DE 196 36 217 A1 sind ein Verfahren und eine Vorrichtung zum Verschweißen von Lackdrähten bekannt. Die Lackdrähte werden in eine Sonotrode bzw. einen Amboss einer Ultraschallschweißvorricbtung gelegt, um sodann verschweißt zu werden.From the DE 196 36 217 A1 For example, a method and an apparatus for welding enameled wires are known. The enameled wires are placed in a sonotrode or anvil of a Ultraschallschweißvorricbtung, to then be welded.

Der vorliegenden Erfindung liegt das Problem zu Grunde, ein Verfahren der eingangs genannten Art so weiterzubilden, dass mehrere lackierte Drähte untereinander verbunden werden können, ohne dass zwischen diesen ein elektrisch leitendes Verbindungsteil verlaufen und ohne dass zuvor der Lack entfernt werden muss.The present invention is based on the problem, a method of the type mentioned in such a way that several painted wires can be interconnected without between them an electrically conductive connection part and without the paint must be removed beforehand.

Zur Lösung des Problems wird im Wesentlichen vorgeschlagen, dass die lackierten Drähte im Bereich, in dem diese verbunden werden, von einem elektrisch leitenden unisolierten Material zumindest bereichsweise umschlossen werden und dass anschließend durch Ultraschalleinwirkung der Drähte mit dem Material bei gleichzeitigem Aufbrechen des Isolierlacks kraftschlüssig verbunden werden. Dabei ist es nicht zwingend erforderlich, dass die lackierten Drähte selbst unmittelbar mit dem elektrisch leitenden Material in Berührung gelangen.To solve the problem is essentially proposed that the painted wires in the area where they are connected, are at least partially enclosed by an electrically conductive uninsulated material and that are then connected non-positively by ultrasonic action of the wires with the material with simultaneous breaking of the insulating , It is not absolutely necessary that the painted wires themselves come into direct contact with the electrically conductive material.

Erfindungsgemäß wird insbesondere mittels Werkzeuge einer Ultraschallschweißvorrichtung Ultraschall auf das die lackierten Drähte umgebende eine Umhüllende bildende Material appliziert, wodurch eine Formgebung des Materials derart erfolgt, dass sich dieses an die außen liegenden lackierten Drähte bei gleichzeitigem kraftschlüssigen Umschließen gegebenenfalls sämtlicher lackierter Drähte anlegt. Gleichzeitig wird durch die Ultraschalleinwirkung eine Relativbewegung zwischen den Lackdrähten und der Umhüllenden mit der Folge hervorgerufen, dass die Lackschicht in einem Umfang aufbricht, dass zwischen sich berührenden lackierten Drähten die Lackschicht entfernt wird und somit die gewünschte elektrisch leitende Verbindung erfolgt. Gleiches gilt im Berührungsbereich mit der Umhüllenden. Der entfernte Isolierlack selbst wandert dabei in den Zwischenraum zwischen den Drähten, so dass hierdurch der gewünschte elektrische Kontakt nicht negativ beeinflusst wird.According to the invention, in particular by means of tools of an ultrasonic welding device, ultrasound is applied to the material forming an envelope surrounding the painted wires, whereby the material is shaped such that it applies to the exterior painted wires with simultaneous frictional confinement of all painted wires. At the same time, a relative movement between the enamel wires and the envelope is caused by the action of ultrasound, with the result that the lacquer layer breaks up to the extent that the lacquer layer is removed between contacting lacquered wires and thus the desired electrically conductive connection takes place. The same applies in the area of contact with the envelope. The removed insulating varnish itself migrates into the space between the wires, so that in this way the desired electrical contact is not adversely affected.

Insbesondere ist vorgesehen, dass mehrere lackierte Drähte zusammen mit Litzen von dem Material bereichsweise umschlossen werden, um sodann die kraftschlüssige und leitende Verbindung durch Ultraschalleinwirkung zu erzielen.In particular, it is envisaged that several coated wires are partially enclosed together with strands of the material in order then to achieve the non-positive and conductive connection by ultrasonic action.

Auch besteht die Möglichkeit, in einem Arbeitsgang einerseits lackierte Drähte und/oder Litzen mit dem diese zumindest bereichsweise umgebenden Material zu verbinden und gleichzeitig das Material selbst mittels Ultraschall mit einem Träger wie z. B. Kupferplatte mittels Ultraschallschweißens zu verbinden.It is also possible to connect in one step, on the one hand painted wires and / or strands with this at least partially surrounding material and at the same time the material itself by means of ultrasound with a support such. B. copper plate to connect by means of ultrasonic welding.

Auch wenn das die lackierten Drähte umgebende Material nicht zwingend eigensteif sein muss - so kann z. B. ein die lackierten Drähte umgebendes Kupfergeflecht als das Material verwendet werden -, so ist bevorzugterweise vorgesehen, dass als elektrisch leitendes Material ein solches in Hülsen- oder Topfform verwendet wird. Eine diesbezügliche Lösung kann z. B. für eine Verbindung zwischen einem Ankerwicklungsdraht und einem Anschlussdraht benutzt werden.Even if the material surrounding the painted wires does not necessarily have to be inherently rigid, it is possible, for example. B. a copper braid surrounding the painted wires are used as the material -, it is preferably provided that as an electrically conductive material such is used in a sleeve or cup shape. A related solution may, for. B. be used for a connection between an armature winding wire and a connecting wire.

Als das elektrisch leitende Material kann ein als Crimp geformter Blechstreifen sein. Auch kann ein Blech bzw. -streifen ein- oder mehrlagig um die zu verbindenden Drähte gewickelt werden.As the electrically conductive material may be a sheet metal strip formed as a crimp. Also, a sheet or strip can be wound in one or more layers around the wires to be connected.

Nach einem weiteren Vorschlag können in ein vorgeformtes Blech, das im Schnitt eine U-Form, Kreisabschnitt oder offene Trapezform aufweisen kann, die Lackdrähte und gegebenenfalls weitere mit diesen zu verbindende Leiter eingebracht werden, um sodann mittels einzulegender Sonotrode bzw. Amboss das vorgeformte Blech um die Lackdrähte und die gegebenenfalls vorliegenden Leiter zu schließen und sodann nach der erfindungsgemäßen Lehre eine Verbindung herzustellen.According to a further proposal, in a preformed sheet metal, which may have a U-shape, circular section or open trapezoidal in section, the enameled wires and optionally further conductors to be connected with these are introduced, then by means of sonotrode or anvil to be inserted into the preformed sheet metal to close the enameled wires and the optionally present conductor and then produce a compound according to the teaching of the invention.

Als Lackdraht kann ein solcher verwendet werden, der aus Aluminium und/oder Kupfer besteht. Das die Lackdrähte umgebende Material, das die Umhüllende bildet, selbst sollte ebenfalls oder vorzugsweise aus Kupfer bestehen oder dieses enthalten.As the enameled wire can be used one which consists of aluminum and / or copper. The material surrounding the enamel wires forming the envelope itself should also or preferably be made of or include copper.

Weitere Einzelheiten, Vorteile und Merkmale der Erfindung ergeben sich nicht nur aus den Ansprüchen, den diesen zu entnehmenden Merkmalen -für sich und/oder in Kombination-, sondern auch aus der nachfolgenden Beschreibung von der Zeichnung zu entnehmenden bevorzugten Ausführungsbeispielen.Further details, advantages and features of the invention will become apparent not only from the claims, the features to be taken from them-alone and / or in combination-but also from the following description of preferred embodiments to be taken from the drawings.

Es zeigen:

Fig. 1
einen mit einem Träger zu verbindenden lackierten Draht,
Fig. 2
der mit dem Träger verbundene lackierte Draht nach dem Stand der Technik,
Fig. 3
eine lackierte Drähte aufnehmende Hülse in Längsschnitt,
Fig. 4
einen Schnitt entlang der Linie IV - IV in Fig. 3,
Fig. 5
die in der Hülse nach den Fig. 3 und 4 untereinander und mit dieser verbundenen lackierten Drähte,
Fig. 6
mehrere mit einem Träger zu verbindende lackierte Drähte,
Fig. 7
die mit dem Träger verbundenen lackierten Drähte gemäß Fig. 6 und
Fig. 8a - 8e
Prinzipdarstellungen von zu verschweißenden lackierten Drähten zumindest teilweise umgebenden Umhüllenden.
Show it:
Fig. 1
a painted wire to be connected to a support,
Fig. 2
the lacquered wire associated with the carrier according to the prior art,
Fig. 3
a painted wire receiving sleeve in longitudinal section,
Fig. 4
a section along the line IV - IV in Fig. 3 .
Fig. 5
in the sleeve after the Fig. 3 and 4 with each other and with these connected painted wires,
Fig. 6
a plurality of painted wires to be connected to a carrier,
Fig. 7
the coated wires connected to the carrier according to Fig. 6 and
Fig. 8a - 8e
Schematic diagrams of coated wires to be welded at least partially surrounding sheaths.

Nach dem Stand der Technik besteht die Möglichkeit, einen lackierten Draht 10, der aus einem aus elektrisch leitendem Material wie Kupfer oder Aluminium bestehenden Kern 12 und äußerer Lackierschicht 14 besteht, mit einem elektrisch leitenden Träger 16 zu verbinden. Dies erfolgt mittels Ultraschallschweißens. Entsprechend der Formgebung der Sonotrode und erfolgender Ultraschallapplizierung und Druckeinwirkung wird der Draht 10 verformt, wobei im Kontaktbereich zwischen dem Träger 16 und dem lackierten Draht 10 aufgrund der Relativbewegung zueinander die Lackschicht 14 entfernt wird und somit der gewünschte innige Kontakt 14 als das Verschweißen erzielbar ist. Entferntes Lackmaterial lagert sich dabei zwischen den in Fig. 2 mit den Bezugszeichen 18 und 20 versehenen Kontakt bzw. Schweißstellen ab.According to the prior art, it is possible to connect a painted wire 10, which consists of a core 12 consisting of electrically conductive material, such as copper or aluminum, and outer coating layer 14 to an electrically conductive carrier 16. This is done by ultrasonic welding. According to the shape of the sonotrode and successful Ultraschallplplizierung and pressure, the wire 10 is deformed, wherein in the contact area between the carrier 16 and the coated wire 10 due to the relative movement to each other, the resist layer 14 is removed and thus the desired intimate contact 14 is achieved as the welding. Removed varnish material builds up between the in Fig. 2 with the reference numerals 18 and 20 provided contact or welds.

Eine diesbezügliche Verbindungsart ist jedoch nicht möglich, wenn mehrere lackierte Drähte (Lackdrähte) wie deren Enden oder mehrere lackierte Drähte mit einem Träger verbunden werden sollen. In diesem Fall ist es entweder erforderlich, die Isolierhülle zu entfernen oder einen Verbindungsträger zu verwenden, indem zunächst das eine Ende eines lackierten Drahtes mit dem Träger verbunden wird und sodann dieser mit dem Ende eines anderen lackierten Drahtes, oder aber Werkzeuge (Sonotrode, Amboss) einer Ultraschallschweißvorrichtung geometrisch so auszubilden, dass die Lackdrähte positionsgenau fixiert werden.A related type of connection is not possible, however, if several painted wires (enameled wires) like their ends or several painted wires are to be connected to a carrier. In this case, it is either necessary to remove the insulating sleeve or to use a connecting beam by first connecting one end of a painted wire to the carrier and then connecting it to the end of another painted wire or tools (sonotrode, anvil). an ultrasound welding device geometrically in such a way that the enamel wires are fixed accurately.

Erfindungsgemäß besteht nun die Möglichkeit, mittels einer Ultraschallschweißvorrichtung mehrere lackierte Drähte elektrisch leitend untereinander zu verbinden. Hierzu ist entsprechend der Fig. 3 bis 8 vorgesehen, dass entsprechende lackierte Drähte - im Ausführungsbeispiel deren Enden 22, 24, 26 - in eine topfförmige Hülse 28 aus elektrisch leitenden Material wie aus Kupfermaterial eingebracht werden. In der Hülse 28 sind die Drahtenden 22, 24, 26 mehr oder weniger dicht gepackt. Eine elektrisch leitende Verbindung besteht jedoch aufgrund der Lackschicht weder untereinander noch zu der Hülse 28. Erfindungsgemäß wird sodann die Hülse 28 mit den Drahtenden 22, 24 zwischen den Werkzeugen, also der Sonotrode und der Gegenelektrode bzw: dem Amboß einer Ultraschallschweißvorrichtung eingebracht und sodann Ultraschall appliziert. Hierdurch erfolgt eine Verformung der Hülse 28 derart, dass diese die Drahtenden 22, 24, 26 kraftschlüssig umschließt. Gleichzeitig erfolgt aufgrund der applizierten Ultraschallenergie eine Relativbewegung sowohl der Hülse 28 zu den Drahtenden 22, 24 als zwischen diesen selbst, so dass in deren Berührungspunkten die Lackierung wegbricht mit der Folge, dass die gewünschte elektrisch leitende Verbindung gegeben ist. Durch den Kraftschluss ist gleichzeitig der innige Kontakt gewährleistet, wobei zusätzlich bereichsweise ein Verschweißen der Drahtenden 22, 24 untereinander bzw. zu der Hülse 28 erfolgen kann. Der weggebrochene Lack wandert in die Zwischenräume zwischen den Drahtenden 22, 24, 26 und ist in der Fig. 5 durch Punkte 30 angedeutet.According to the invention, it is now possible, by means of an ultrasonic welding device, to connect a plurality of painted wires to one another in an electrically conductive manner. This is in accordance with the Fig. 3 to 8 provided that corresponding painted wires - in the embodiment, the ends 22, 24, 26 - are introduced into a cup-shaped sleeve 28 made of electrically conductive material such as copper material. In the sleeve 28, the wire ends 22, 24, 26 are more or less densely packed. However, an electrically conductive connection is due to the lacquer layer neither with each other nor to the sleeve 28. According to the invention then the sleeve 28 is introduced with the wire ends 22, 24 between the tools, so the sonotrode and the counter electrode or: the anvil of an ultrasonic welding device and then applied ultrasound , This results in a deformation of the sleeve 28 such that it surrounds the wire ends 22, 24, 26 frictionally. At the same time due to the applied ultrasonic energy, a relative movement of both the sleeve 28 to the wire ends 22, 24 as between themselves, so that in their points of contact the paint breaks away with the result that the desired electrically conductive connection is given. Due to the traction at the same time the intimate contact is ensured, in addition, in some areas a welding of the wire ends 22, 24 with each other or to the sleeve 28 can take place. The broken lacquer migrates into the spaces between the wire ends 22, 24, 26 and is in the Fig. 5 indicated by dots 30.

Entsprechend können auch mehrere lackierte Drahtenden 32, 34, 36 untereinander und gleichzeitig mit einem Träger 38 verbunden werden, wie sich aus den Fig. 6 und 7 ergibt. So werden die Drahtenden 32, 34, 36 in eine Hülse 40 eingebracht, die sodann auf dem Träger 38 angeordnet wird, der seinerseits auf eine Gegenelektrode einer Ultraschallschweißvorrichtung angeordnet wird. Auf die Hülse 40 wirkt sodann eine Sonotrode mit der Folge ein, dass die Hülse verformt und die Drahtenden 32, 34, 36 formschlüssig umschlossen werden, wobei gleichzeitig ein Verschweißen mit dem Träger 38 erfolgt. Bei diesem Prozess wird ebenfalls im Berührungsbereich zwischen den Drahtenden 32, 34, 36 bzw. zu der Innenwandung der Hülse 40 vorhandener Isolierlack entfernt, der sich im fertigen Produkt in dem Zwischenraum zwischen den Enden 32, 34, 36 bzw. der Innenwandung der Hülse 40 ansammelt (siehe Punkte 42).Accordingly, a plurality of painted wire ends 32, 34, 36 can be connected to each other and at the same time with a carrier 38, as is apparent from the 6 and 7 results. Thus, the wire ends 32, 34, 36 are inserted into a sleeve 40, which is then placed on the support 38, which in turn is placed on a counter electrode of an ultrasonic welding device. A sonotrode then acts on the sleeve 40 with the result that the sleeve is deformed and the wire ends 32, 34, 36 are enclosed in a form-fitting manner, at the same time welding to the carrier 38. In this process, also existing in the contact region between the wire ends 32, 34, 36 and to the inner wall of the sleeve 40 existing insulating, which is in the finished product in the space between the ends 32, 34, 36 and the inner wall of the sleeve 40th accumulates (see points 42).

Ist den Ausführungsbeispielen jeweils ein eigensteifes Element beschrieben worden, das Drahtenden in den Bereichen von lackierten Drähten aufnimmt, die untereinander elektrisch leitend verbunden werden sollen, so besteht ohne Weiteres auch die Möglichkeit, als umhüllendes Material ein flexibles zu verwenden. So kann z. B. ein Kupfergeflecht benutzt werden, das die zu verbindenden lackierten Drähte im erforderlichen Umfang umschließt, um sodann mittels Ultraschall verfestigt zu werden, wobei gleichzeitig eine kraftschlüssige Verbindung mit den lackierten Drähten in zuvor beschriebener Weise und ein Abisolieren dieser erfolgt. Auch ist erkennbar, dass das die elektrisch leitende Verbindung ermöglichende Material die lackierten Drähte nicht nur kraftschlüssig, sondern auch zumindest bereichsweise formschlüssig umgeben kann.If an intrinsically rigid element has been described in each case, which receives wire ends in the areas of painted wires which are to be electrically conductively connected to one another, then it is also readily possible to use a flexible material as the enveloping material. So z. Example, a copper braid are used, which surrounds the painted wires to be joined to the extent required, to be then solidified by means of ultrasound, at the same time a frictional connection with the painted wires in the manner described above and a stripping of this takes place. It can also be seen that the material permitting the electrically conductive connection can not only frictionally surround the painted wires, but also at least partially in a form-fitting manner.

Ferner besteht die Möglichkeit, nicht nur lackierte Drähte untereinander, sondern auch solche z. B. mit Litzen elektrisch leitend zu verbinden.It is also possible, not only painted wires with each other, but also such. B. electrically connected to strands.

Den Fig. 8a bis 8e sind weitere hervorzuhebende Ausgestaltungen von geformtem elektrisch leitendem Material zu entnehmen, mit dem lackierte Drähte und gegebenenfalls vorhandene weitere elektrische Leiter kraftschlüssig verbunden werden. So ist in Fig. 8a ein als Crimp 44 geformtes Blech dargestellt, das die zu verschweißenden Leiter 46 umgibt. Im Ausführungsbeispiel der Fig. 8b werden Lackdrähte 48 ein- oder mehrlagig von einem Blechmaterial 50 umgeben und sodann entsprechend der erfindungsgemäßen Lehre verbunden.The Fig. 8a to 8e are further highlighted embodiments of molded electrically conductive material to refer to the painted wires and any other existing electrical conductors are positively connected. So is in Fig. 8a a formed as a crimp 44 formed sheet surrounding the conductor 46 to be welded. In the embodiment of Fig. 8b Enamel wires 48 are one or more layers surrounded by a sheet material 50 and then connected according to the teaching of the invention.

Es besteht jedoch auch die Möglichkeit, zu verschweißende Lackdrähte 52, 54, 56 in einseitig geöffnete vorgeformte Aufnahmen 58, 60, 62 einzubringen, die eine Trapezform (Fig. 8c), eine Kreisabschnittsform (Fig. 8d) oder eine U-Form (Fig. 8e) im Schnitt aufweisen. In die entsprechenden Formen 58, 60, 62 werden dann die Lackdrähte 52, 54, 56 und gegebenenfalls weitere zu verschweißende Leiter 64 eingebracht und sodann beim Ultraschallschweißvorgang geschlossen. Hierzu kann das entsprechende Werkzeug der UltraschallschweiBvorrichtung eine das Schließen bzw. Falten der Aufnahmen 58, 60, 62 ermöglichende Geometrie aufweisen. Durch Ultraschalleinwirkung werden sodann die Drähte 52, 54, 56 von den Aufnahmen 68, 62 umschlossen und kraftschlüssig umgeben, wobei gleichzeitig der Isolierlack der Drähte 52, 54, 56 abplatzt und sodann die abisolierten Drähte 52, 54, 56 untereinander verschweißt werden.However, it is also possible, to be welded enamel wires 52, 54, 56 in one-sided open preformed receptacles 58, 60, 62 introduce, which has a trapezoidal shape ( Fig. 8c ), a circular section shape ( Fig. 8d ) or a U-shape ( Fig. 8e ) in section. In the corresponding molds 58, 60, 62 then the enameled wires 52, 54, 56 and optionally further conductor 64 to be welded are introduced and then closed during the ultrasonic welding process. For this purpose, the corresponding tool of the ultrasonic welding device can have a geometry enabling the closing or folding of the receptacles 58, 60, 62. As a result of the action of ultrasound, the wires 52, 54, 56 are surrounded and frictionally surrounded by the receptacles 68, 62, whereby at the same time the insulating varnish of the wires 52, 54, 56 flakes off and then the stripped wires 52, 54, 56 are welded together.

Typische Abmessungen von lackierten Drähten, die nach dem erfindungsgemäßen Verfahren elektrisch leitend verbunden werden, sind solche mit Innendurchmessern zwischen 0,2 mm und 4 mm bei einer Lackschichtdicke zwischen 0,1 mm und 0,2 mm, ohne dass hierdurch eine Einschränkung der erfindungsgemäßen Lehre erfolgen soll.Typical dimensions of painted wires, which are electrically conductively connected by the method according to the invention, are those with inner diameters between 0.2 mm and 4 mm at a paint layer thickness between 0.1 mm and 0.2 mm, without thereby restricting the teaching of the invention should be done.

Claims (14)

  1. A method for the electrically conductive connection of at least two wires provided with an insulating lacquer (lacquered wires) by effect of ultrasound,
    characterized in
    that the lacquered wires (46, 48, 52, 54, 56) are at least partially enclosed, at their regions (22, 24, 26, 32, 34, 36) which are to be connected, by an electrically conductive material, that by the ultrasound effect, on one hand, the insulating lacquer of the wires is broken away and, on the other hand, a force-fitting connection between the electrically conductive material and the wires, with simultaneous electrically conductive connection between them, is achieved.
  2. Method according to claim 1,
    characterized in
    that a plurality of lacquered wires (46, 48, 52, 54, 56) and at least one uninsulated conductor (64), such as a stranded wire, are partially enclosed by the material.
  3. Method according to claim 1 or 2,
    characterized in
    that as the electrically conductive material, one in the form of a sleeve or a cup is used.
  4. Method according to at least one of the preceding claims,
    characterized in
    that an inherently rigid material is employed as the electrically conductive material.
  5. Method according to at least one of the preceding claims,
    characterized in
    that a flexible material, such as a mesh, is employed as the electrically conductive material.
  6. Method according to at least one of the preceding claims,
    characterized in
    that the material is connected, at least peripherally and at least in sections form-fittingly, with the at least two, preferably plurality of lacquered wires.
  7. Method according to at least one of the preceding claims,
    characterized in
    that the wires connected at least force-fittingly to the material and to one another are connected as a unit to an electrical conductor, such as a carrier (38), by means of ultrasound welding.
  8. Method according to at least one of the preceding claims,
    characterized in
    that as the lacquered wire one comprising a conductor of aluminium and/or copper is used.
  9. Method according to at least one of the preceding claims,
    characterized in
    that as the electrically conductive material, one of or containing copper is used.
  10. Method according to at least one of the preceding claims,
    characterized in
    that for applying the ultrasound, one or more work tools of an ultrasound welding device are used.
  11. Method according to at least one of the preceding claims,
    characterized in
    that a sheet metal strip is used as the electrically conductive material at least partially surrounding the lacquered wires (46, 48, 52, 54, 56) and any other conductor present.
  12. Method according to at least one of the preceding claims,
    characterized in
    that a sheet metal strip formed as a crimp (44) is employed.
  13. Method according to at least one of the preceding claims,
    characterized in
    that the lacquered wires are wrapped by a single-layered or multi-layered strip material as the electrically conductive material.
  14. Method according to at least one of the preceding claims,
    characterized in
    that as the electrically conductive material surrounding the lacquered wires and any further electrical conductor present, a preformed open receptacle (58, 60, 62), in particular with a U-, circularly or trapezoidally-shaped cross section, is used.
EP03761558A 2002-07-01 2003-06-30 Method for joining lacquered wires in an electrically conducting manner Revoked EP1518303B1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE10229565 2002-07-01
DE10229565A DE10229565B4 (en) 2002-07-01 2002-07-01 Process for the electrically conductive connection of lacquered wires
PCT/EP2003/006915 WO2004004079A1 (en) 2002-07-01 2003-06-30 Method for joining lacquered wires in an electrically conducting manner

Publications (2)

Publication Number Publication Date
EP1518303A1 EP1518303A1 (en) 2005-03-30
EP1518303B1 true EP1518303B1 (en) 2008-03-19

Family

ID=29796075

Family Applications (1)

Application Number Title Priority Date Filing Date
EP03761558A Revoked EP1518303B1 (en) 2002-07-01 2003-06-30 Method for joining lacquered wires in an electrically conducting manner

Country Status (14)

Country Link
US (1) US20050266156A1 (en)
EP (1) EP1518303B1 (en)
JP (1) JP2006513680A (en)
KR (1) KR20050044870A (en)
CN (1) CN100468887C (en)
AT (1) ATE389962T1 (en)
AU (1) AU2003246641A1 (en)
BR (1) BR0312360A (en)
CA (1) CA2491856A1 (en)
DE (2) DE10229565B4 (en)
ES (1) ES2303600T3 (en)
MX (1) MXPA05000158A (en)
PT (1) PT1518303E (en)
WO (1) WO2004004079A1 (en)

Families Citing this family (6)

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Publication number Priority date Publication date Assignee Title
DE102006021422B8 (en) * 2006-05-05 2008-06-26 Schunk Ultraschalltechnik Gmbh Method of making a passage or end node, and passage or end nodes
DE102009059307A1 (en) 2009-12-23 2011-06-30 Schunk Sonosystems GmbH, 35435 Method for the electrically conductive connection of wires
WO2013183160A1 (en) * 2012-06-08 2013-12-12 株式会社オートネットワーク技術研究所 Power line with terminal metal fitting and method for fabrication of power line with terminal metal fitting
DE102013107637A1 (en) 2013-07-18 2015-01-22 Schunk Sonosystems Gmbh Method for producing a knot by welding
CN105324889B (en) * 2013-07-29 2018-06-26 西门子公司 Crimping connection
JP2017094368A (en) * 2015-11-26 2017-06-01 株式会社リソー技研 Solder for enamel-coated electric cable, and soldering method for enamel-coated electric cable

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Also Published As

Publication number Publication date
CN100468887C (en) 2009-03-11
DE10229565A1 (en) 2004-01-29
CA2491856A1 (en) 2004-01-08
DE50309419D1 (en) 2008-04-30
US20050266156A1 (en) 2005-12-01
MXPA05000158A (en) 2005-09-30
PT1518303E (en) 2008-06-30
ES2303600T3 (en) 2008-08-16
DE10229565B4 (en) 2004-07-08
ATE389962T1 (en) 2008-04-15
JP2006513680A (en) 2006-04-20
EP1518303A1 (en) 2005-03-30
CN1701474A (en) 2005-11-23
BR0312360A (en) 2005-04-05
WO2004004079B1 (en) 2004-12-16
AU2003246641A1 (en) 2004-01-19
KR20050044870A (en) 2005-05-13
WO2004004079A1 (en) 2004-01-08

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