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
  • 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
  • H01R4/02—Soldered or welded connections
  • H01R4/029—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
  • 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
  • H01R4/02—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
  • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
  • H01R12/50—Fixed connections
  • H01R12/59—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures
• • 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
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
  • H01R13/02—Contact members
  • H01R13/10—Sockets for co-operation with pins or blades
  • H01R13/11—Resilient sockets
• • 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
  • H01R4/02—Soldered or welded connections
  • H01R4/023—Soldered or welded connections between cables or wires and terminals
• • 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
  • H01R43/0214—Resistance welding

Definitions

• the present invention relates to a method for the electrical connection of an electrical conductor with a contact element and a plug connector with a conductor and a contact element, the connection between the conductor and the contact element being produced by the method.
• the present invention relates in particular to a method for connecting a ribbon conductor to a contact element by resistance welding.
• the invention is used, for example, in the automotive industry, where the installation of additional electrical components means that ribbon conductors are increasingly used in order to better conduct the increasing current flows over a larger conductor cross section
• the invention can be used with all types of conductors, in particular ribbon conductors, which have been manufactured, for example, by laminating, printing, etching or extrusion.
• Various contacting techniques such as crimp contacting, cohesive contacting or terminal contacting, are known for connecting a plug connector or contact element to a conductor.
• cohesive contacts the connection can be established, for example, by soldering, gluing or welding, welding processes providing better mechanical and electrical properties for the contact point than soldering or gluing.
• the welding can be carried out by resistance welding, laser welding or ultrasonic welding. Resistance welding is widely used in the field of plug contacts, since this can be carried out easily, quickly and inexpensively.
• the object of the present invention is therefore to provide an easy to carry out, inexpensive and fast mechanically and electrically durable connection. This object is achieved by a method according to claim 1.
• the electrical conductor sheathed with insulation is inserted between two legs of the contact element.
• the welding device is then placed on the two legs and the welding process is carried out, the welding current being switched on.
• the insulation of the electrical conductor is destroyed during the welding process by the welding current and the heat supplied thereby, which leads to a firm mechanical and electrical connection of the conductor to the contact element.
• the method according to the invention means that it is no longer necessary to strip the electrical conductor before the welding process.
• the electrical conductor can simply be inserted between the legs of the contact element in the non-stripped state.
• the welding process can be shortened considerably, which considerably reduces the cost of producing connector components.
• the welding process is carried out by resistance welding, where the heat supplied is generated by the current flowing during the welding process and the ohmic resistance of the conductor.
• the method according to the invention is not limited to resistance welding; other fusion welding methods such as electric arc welding are also welding or gas welding or other pressure welding processes can be used.
• the current flows over the two legs of the contact element, i.e. from the anode via one leg, then to the other leg via the cathode.
• the current does not yet flow through the insulated conductor to the cathode. Since the heat supplied is very high, and the current seeks the shortest path, the insulation between the current legs of the contact element begins to melt, so that the current then directly from the anode, the first leg, to the electrical conductor the second leg flows to the cathode.
• this must first flow in a "detour" via the two legs and the connection point between the two legs.
• the welding device is preferably attached to the outer sides of the two legs opposite the conductor.
• a welding stamp of the welding device is preferably attached to an outside of the contact element, so that the two welding stamps sandwich the two legs of the contact element and the electrical conductor inserted therein.
• the contact element is also connected to a plug connector, which can be connected to a complementary plug connector in order to continue the current path of the electrical conductor.
• the electrical conductor is preferably a ribbon conductor which is produced, for example, by lamination, printing, etching or extrusion.
• the method according to the invention is not limited to the connection of ribbon conductors to contact elements.
• the electrical conductor can have any shape.
• the contact element is preferably bent in an S shape, the conductor being inserted into one of the two openings of the S shape.
• the contact element can also be C-shaped, the conductor then being inserted into the C-shaped opening.
• the contact element can also be clipped onto the side of the conductor. It is only advantageous for the embodiment of the invention that the electrical conductor is enclosed on two interconnected sides by the contact element. A U-shaped design of the contact element is also possible.
• the invention also relates to a plug connector which has a contact element and an electrical conductor connected to the contact element, the connection between the contact element and the electrical conductor being produced by the method described above.
• FIG. 3 shows an example of a flat conductor strip for connection to a plurality of contact elements
• FIG. 6 shows a connector in which the conductor-contact element is connected according to the method according to the invention.
• Fig. 7 the contact element shown in Fig. 5 with a housing.
• FIG. 1 shows a schematic structure for carrying out the method according to the invention.
• An electrical contact element 1 is shown with two legs 2 and 3, which receive an electrical conductor 4 between their legs.
• the electrical conductor 4 is in the slot between the two legs 2 and 3 with the conductive core 5, for example Copper and insulation 6 introduced.
• welding punches 7, 8 in the form of an anode and cathode of a welding device, not shown, are placed on the outer sides of the two legs 2, 3. At the beginning, the welding current cannot flow from the welding stamp 7 via leg 2 and the conductor 5 to the welding stamp 8, since there is an open circuit.
• the current flows during the welding process from the welding stamp 7 over the leg 2 to the connection point 9 of the two legs and over the other leg 3 to the welding stamp 8, as shown by arrow A.
• the currents flowing during the welding process heat the contact element selectively to such an extent that the insulation provided between the legs is destroyed, so that the legs now directly touch the conductor 5, so that a current flow directly from the welding stamp 7 via the conductor 5 to the welding step 8 without the detour via connection point 9 is possible (arrow B).
• the mechanical strength of the welded connection is plotted over the conductor cross section.
• the force required to loosen the welded connection increases proportionally with the wire diameter.
• the tensile strength in resistance welding is slightly better than, for example, in laser welding, so that in summary it can be concluded that resistance Stand welding a stronger mechanical connection can be achieved than with laser welding.
• a circuit board 10 is shown in detail with its conductor tracks 22, which are provided with insulation 6. Furthermore, several contact elements 1 are arranged, for example, to connect the conductor tracks with plug connectors (not shown).
• the contact element 1 is equipped at its end receiving the electrical conductor with three legs, the upper leg 2 and two lower legs 3.
• the printed circuit board 10 can, for example, be fed to the visual white device, so that the welding process according to the invention is performed executes on each contact element 1.
• 4 a shows a plurality of plug connectors 11 which have been plugged onto the contact element 1 after the welding process has taken place, the contact element 1, as shown in FIG. 3, being C-shaped.
• 4b shows how the electrical conductor 4 is inserted between the two legs 2, 3 of the contact element 1.
• the contact element is bent in a C-shape.
• the depression 12 can be seen in the form of a welding bead on which the welding process according to the invention was carried out.
• 4c the contact element is bent in an S-shape, the electrical conductor 4 being inserted into the upper opening of the S-shape and then welded.
• the contact element 1 soldered to the conductor track at one end is provided at its other end with the plug connector 11, which in the embodiment shown is designed as a socket.
• the connector 11 has at its rear end inwardly bent tabs 25 on which u. a. Conductor elements of a mating connector can be attached.
• the connector has an insulating housing 26, which has a raised side wall 27 for coding and a locking leg 28 which extends resiliently upwards from a bridge 29 against the direction of insertion, with which the connector 11 is fastened in a receptacle (not shown) can.
• FIG 4d shows a further embodiment according to the invention, the contact element 1 consisting of two plates 14, 15 connected via webs 13, which were folded laterally over the electrical conductor 4.
• FIG. 5 shows a further embodiment of the contact element 1, the two legs being molded onto the top or bottom of a housing 30.
• the two legs 2, 3 and the front section of the housing 30 ensure the U-shaped configuration of the contact element 1.
• the housing 30 is closed on all four sides.
• the sides 31 and 32 of the housing 30 can also extend further in the direction of the legs 2 and 3, so that the legs 2, 3 would be enclosed on four sides at their end facing the housing 30, which would increase the rigidity of the legs 2, 3 ,
• the contact element shown in FIG. 5 is also surrounded by the housing 26 shown in FIGS. 4a and 4b.
• FIG. 6 shows a plug connector 16 which has the contact element 1 shown in FIG. 4c.
• the connector 16 has a housing 17 made of insulating material, which has a latching element 18 at the front end.
• the individual conductor tracks 22 are inserted into the connector from behind, a slide strain relief 19 being provided for the broadband conductor.
• the conductor tracks end in the here S-shaped opening between the two legs 2 and 3 of the contact element 1, which has a conventional contact socket at its front end for receiving a contact pin (not shown).
• FIG. 7 shows the U-shaped contact element shown in FIG. 5, the end opposite the legs 2, 3 being provided with the housing 26.
• the housing has a web 33 behind the locking leg 28. Behind this web are the inwardly bent tabs 25, which are bent around the forwardly extended side walls 31, 32 of the housing 30 in order to fix the housing 26 to the contact element.
• inventive method can be used to achieve a good electrical connection between an electrical conductor and a contact element in a simple and quick manner with a welding method.

Landscapes

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

Applications Claiming Priority (3)

Publications (1)

Family

ID=32185297

Family Applications (1)

Country Status (8)

Cited By (1)

Families Citing this family (11)

Family Cites Families (20)

• 2002
  • 2002-10-31 DE DE10250930A patent/DE10250930B3/de not_active Expired - Fee Related
• 2003
  • 2003-10-23 CN CNA2003801021664A patent/CN1708878A/zh active Pending
  • 2003-10-23 US US10/531,955 patent/US7084346B2/en not_active Expired - Fee Related
  • 2003-10-23 WO PCT/EP2003/011739 patent/WO2004040702A1/de active Application Filing
  • 2003-10-23 EP EP03758046A patent/EP1559172A1/de not_active Withdrawn
  • 2003-10-23 JP JP2004547550A patent/JP2006505103A/ja active Pending
  • 2003-10-23 KR KR1020057007522A patent/KR20050074513A/ko not_active Application Discontinuation
  • 2003-10-23 AU AU2003274064A patent/AU2003274064A1/en not_active Abandoned

Non-Patent Citations (1)

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