EP1658662A1 - Electric contact crimping method and contact obtained according to said method - Google Patents

Electric contact crimping method and contact obtained according to said method

Info

Publication number
EP1658662A1
EP1658662A1 EP04720635A EP04720635A EP1658662A1 EP 1658662 A1 EP1658662 A1 EP 1658662A1 EP 04720635 A EP04720635 A EP 04720635A EP 04720635 A EP04720635 A EP 04720635A EP 1658662 A1 EP1658662 A1 EP 1658662A1
Authority
EP
European Patent Office
Prior art keywords
crimping
fins
wire
barrel
section
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.)
Granted
Application number
EP04720635A
Other languages
German (de)
French (fr)
Other versions
EP1658662B1 (en
Inventor
Thierry Courtin
El Mostafa Zindine
Flavio Fantini
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.)
Delphi International Operations Luxembourg SARL
Original Assignee
FCI SA
Framatome Connectors International SAS
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 FCI SA, Framatome Connectors International SAS filed Critical FCI SA
Publication of EP1658662A1 publication Critical patent/EP1658662A1/en
Application granted granted Critical
Publication of EP1658662B1 publication Critical patent/EP1658662B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime 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
    • H01R43/048—Crimping apparatus or processes
    • 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
    • H01R43/048—Crimping apparatus or processes
    • H01R43/0488—Crimping apparatus or processes with crimp height adjusting means
    • 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

Definitions

  • the present invention relates to a method of crimping an electrical contact and the contact obtained by this method. It is known to make electrical contact between an electrical wire, in particular multi-strand, and a metallic contact element by a crimping operation for which the fins cut out from the metallic contact element are folded around the exposed electrical wire by a crimping tool. type anvil punch. This technique is applied for contacts made from a folded cut metal blank.
  • Document US 5,561,267 relates for example to a crimp contact comprising fins of different size allowing an overlap of a crimping fin on another and a crimping process with punch-anvil adapted.
  • the crimped contacts encounter reliability problems for low current and low voltage applications and more particularly micro-breaks appear over time.
  • the present invention relates to a method of crimping an electrical contact on an electrical wire, the contact comprising a crimping section provided with a barrel for receiving the electrical wire, the barrel comprising a part intended to grip the wire by deformation, the method comprising a first crimping step at a first crimping height by folding a first surface of the crimping section onto the wire by a crimping tool comprising a punch and an anvil and a second crimping step at a second crimping height , lower than the first, of a localized region of the crimping section.
  • the first crimping step folds up a first surface of the fins at said first height on the wire and the second crimping step folds a localized area of the fins at said second height, less than the first.
  • the second crimping can be carried out on two zones separated from the fins. More particularly, the second crimping can in particular be carried out on end zones of the fins. In an alternative embodiment, the second crimping can be carried out on a central zone of the fins.
  • the first crimping step can be carried out on all of the fins so as to close the fins on the wire.
  • the second crimping step is carried out on a part of the surface of the fins having undergone the first crimping step.
  • the method may in particular be such that the crimping tool comprises a common anvil and separable punch elements.
  • the barrel can in particular be deformed during the first crimping step and keep its shape during the second crimping step.
  • the invention further relates to an electrical contact element comprising a crimping section provided with an open barrel provided with crimping fins on an electric wire, the crimping section being crimped on the wire by the method described above such that, after crimping, the crimping section comprises three successive zones of crushing of the fins on the wire, two of the three zones being of reduced thickness compared to the third zone so that the wire exerts an elastic stress on the fins at the third zone.
  • one of the three zones is of reduced thickness compared to the other two zones so that the wire exerts an elastic stress on the fins at the level of the two other zones.
  • FIG. 1 A tool crimping according to one aspect of the invention
  • Figure 2 An electrical contact element and a wire to be crimped according to the method of the invention
  • FIGS. 3a and 3b a contact crimped using the method according to the invention
  • Figure 4 A schematic sectional view of a crimping of electric wire obtained by a method according to the invention
  • FIGS. 5a and 5b two versions of the second crimping step of the method according to the invention
  • Figure 6 A schematic representation of the first crimping step of the method according to the invention.
  • the crimping is carried out on electrical contacts with open barrel.
  • Such contacts comprise a front part A, in particular for connection to a complementary contact traditionally known, and comprise, in an intermediate part, for connection by crimping, a crimping section 30 provided with an open barrel 3 provided with fins 4, 5 for crimping on a stripped part 12 of an electric wire 2, the crimping section being intended to be crimped on the wire to make an electrical contact between the wire 2 and the contact element 1.
  • the contact 1 has an end section 31 forming a force recovery zone provided with wings 10, 11 intended to close on the insulator 13 of the wire 2.
  • the front part A of the contact element may be of any type and may even possibly consist of a second connection section by crimping, for example to make a splice.
  • Such contact elements are produced by cutting and folding a metal strip of small thickness of the order of 0.2 mm to a few millimeters in thickness. Due to the need for these contacts to have good rigidity and, in the case of contacts with spring contact blades, good elasticity, the material used is very little ductile and is subject to elastic return during bending operations or forming. It has been shown that this elastic return exists at the level of the crimping fins 4, 5 and that even if the variations in dimensions are only of the order of a few microns, this elastic return can cause intermittent losses of contact between the strands.
  • the wire generally based on copper, has a low elastic return capacity and in particular less than that of alloys such as a cuproberyllium often used for the contact elements.
  • the invention tends to modify the mechanical behavior of crimping in order to use the physical phenomenon of elastic return in a favorable direction over a particular area of the contact.
  • the crimping method of a crimping section of an electrical contact element 1 on an electrical wire 2 comprises a first step of crimping the crimping section 30 on the stripped part 12 of the wire at a first height h1 by folding the fins 4, 5 onto the wire 2 by a crimping tool comprising a punch 6 and an anvil 7.
  • a crimping tool comprising a punch 6 and an anvil 7.
  • the punch 6 formed according to the 'example of three parts 6a, 6b, 6c, presses with its three parts on all of the fins 4 and 5 and the anvil presses under the barrel 3, the fins 4 and 5 being continuous fins.
  • the crimping height h1 is obtained as a function of the dimensions of the contact and of the wire by conventional crimping so that a minimum compression ratio of the order of 5% is obtained so as to close the fins on the wire.
  • This first crimping step is carried out on a major part of the surface of the fins 4, 5 see on all of these fins by the punch 6 and on a major part see all of the barrel 3 by the anvil 7.
  • the method comprises a second step or crimping operation, this operation is carried out at a second height h2, lower than the first on a localized area of the fins. This step is carried out so that a compression ratio greater than 15% and typically of the order of 25 to 30% is obtained under the crimping tool.
  • FIGS. 4 and 5b representing a first embodiment for which only the elements 6a, 6c of the punch 6 press on the ends 4a, 4c, 5a, 5c of the fins, the element 6b remaining in withdrawal and not coming into contact with the fins and, in FIG. 5a for a second embodiment for which only the punch element 6b presses on the fin parts 4b and 5b, the punch elements 6a and 6c remaining set back and not coming into contact with the fins.
  • the second crimping step is carried out on a part of the surface of the fins having undergone the first crimping step.
  • the crimped contact comprises three successive zones of crushing of the fins on the wire, two of the three zones being of reduced thickness compared to the third zone so that the wire exerts an elastic stress on the fins at the level of the third zone.
  • the crimped contact comprises three successive zones of crushing of the fins on the wire, one of the three zones being of reduced thickness compared to the other two zones so that the wire exerts a stress. elastic on the fins at the two other zones.
  • the double crimping reverses the elastic return to make it play a positive role, that is to say creating contact pressure between the barrel and the strands.
  • the strands locally swell in the area 20b between the two tools 6a and 6c performing the second step of crimping. Consequently, while for the zones of the fins under the tools 6a and 6c, the elastic return of the fins remains greater than that of the strands of the wire, in zone 20b, it is the wire which comes to deform the wing by effect of swelling. The elasticity of the fins then has in this part 20b a positive effect because it tends to compress the wire which implies a mechanical contact pressure and therefore good electrical conduction even under mechanical or thermal stresses.
  • the crimping tool shown in FIG. 1 and adapted to the method according to the invention comprises a common anvil 7 and elements 6a, 6b, 6c of separable punch.
  • Such a tool can operate on a traditional automatic press by means of a separate control of the punch elements. It is of course possible to carry out the crimping operations on two separate stations, a first station comprising a first punch performing the first crimping and a second station comprising a punch suitable for performing the second crimping on a particular area of the contact.
  • a first station comprising a first punch performing the first crimping
  • a second station comprising a punch suitable for performing the second crimping on a particular area of the contact.
  • the fact remains that the embodiment for which the punch 6 is divided into elements of movable punches which can be actuated separately makes it possible to maintain perfect alignment of the contact element with the punches and to carry out the two operations successively on the same press.
  • the advantage of the common anvil is that the barrel 3 is deformed during the first crimping step and retains its shape during the second crimping step.
  • the barrel thus retains good mechanical rigidity and good resistance to mechanical stress in the event of traction on the wire.
  • Such a method is applicable to crimp contacts with open barrel for folded cut electrical contacts but also to closed barrel contacts such as cut cut contacts rolled on the basis of a metal strip.
  • the first crimping step can be carried out by means of the single element 6b of the punch (for a final second stage result of the type shown in Figure 3a) or by using only elements 6a and 6c of this punch (for a final second stage result of the type shown in Figure 3b), this means that the elements 6a and 6c, respectively the element 6b, remains (s) during this first step in a high position without themselves coming to press force on the fins 4 and 5 of the barrel placed on the anvil.
  • the fins 4 and 5 will nevertheless undergo a more or less marked folding / crimping operation over all or a very significant part of their length beyond the sole area (s) of the fin (s) on the / Which (s) element 6b, respectively, the elements 6a / 6c of the punch have come to bear.
  • the first crimping height defines the crimping height on the central zone of the fins respectively the crimping height on the end zones of the fins.
  • the second crimping step which follows the first step is then carried out by means of elements 6a, 6c, respectively of element 6b, according to the invention, element 6b of the punch, respectively elements 6a and 6c of this punch remaining in an end position of the first stage to keep the barrel in the shape it has at the end of the first stage.
  • the first crimping step crimps at least a first zone of each fin 4 and 5 of the barrel at a first crimping height, by more or less markedly folding the fins on a surface extending beyond said at least a first zone
  • the second crimping step crimps at the second crimping height at least a second zone of each fin 4 and 5, called localized region of the crimping section, complementary (s) of said at least a first zoned.

Landscapes

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

Abstract

The invention relates to a an electric contact crimping method carried out on an electric wire, said contact comprising a crimped section provided with a barrel (3) for receiving the electric wire (2), said barrel comprising a part which is used to clasp the wire by deformation. The method comprises a first crimping stage for a localized area of the crimping section carried out at a first crimping height (hl) folding a first surface of the crimping section on the wire (2) by means of a crimping tool comprising a first stamping element (6) and an anvil (7) and a second crimping stage carried out at a second crimping height (h2) which is lower than the first. The invention also relates to a contact obtained according to said method.

Description

PROCEDE DE SERTISSAGE DE CONTACT ELECTRIQUE ET CONTACT OBTENU PAR CE PROCEDE ELECTRICAL CONTACT CRIMPING METHOD AND CONTACT OBTAINED BY THIS PROCESS
La présente invention concerne un procédé de sertissage de contact électrique et le contact obtenu par ce procédé. Il est connu de réaliser un contact électrique entre un fil électrique notamment multibrins et un élément de contact métallique par une opération de sertissage pour laquelle des ailettes découpées dans l'élément de contact métallique sont repliées autour du fil électrique dénudé par un outil de sertissage de type poinçon-enclume. Cette technique est appliquée pour des contacts réalisés à partir d'un flan métallique découpé plié. Le document US 5 561 267 concerne par exemple un contact à sertir comportant des ailettes de taille différente permettant un recouvrement d'une ailette de sertissage sur une autre et un procédé de sertissage avec poinçon- enclume adaptés. Les contacts sertis rencontrent des problèmes de fiabilité pour des applications faibles courants et faibles tensions et plus particulièrement des micro- coupures apparaissent dans le temps. Il a été mis en évidence que le sertissage pouvait perdre de son efficacité en raison d'un phénomène de retour élastique des ailettes de sertissage ce qui cause une diminution de la pression de contact entre les ailettes et les brins des fils sertis et peut conduire à des augmentations ou des instabilités de résistance de contact, voire à des pertes de contact électrique. Le document US 5 025 554 pour sa part concerne un sertissage auquel de la pâte à souder a été ajoutée afin d'améliorer la conduction électrique. Le problème d'une telle combinaison est la difficulté de localiser une petite quantité de pâte à souder dans un procédé de sertissage automatisé sur une chaîne de production de faisceaux automobiles et aux cadences associées. La présente invention vise à perfectionner les contacts électriques sertis et à remédier au problème de retour élastique afin de conserver une pression de contact importante au long de la vie du contact. Plus particulièrement, la présente invention concerne un procédé de sertissage de contact électrique sur un fil électrique, le contact comportant une section de sertissage munie d'un fût de réception du fil électrique, le fût comportant une partie destinée à enserrer le fil par déformation, le procédé comportant une première étape de sertissage à une première hauteur de sertissage en repliant une première surface de la section de sertissage sur le fil par un outil de sertissage comportant un poinçon et une enclume et une seconde étape de sertissage à une seconde hauteur de sertissage, inférieure à la première, d'une région localisée de la section de sertissage. Plus particulièrement, dans le cas où la section de sertissage comporte un fût ouvert de réception du fil électrique et des ailettes de sertissage dépassant du fût et destinées à enserrer le fil, la première étape de sertissage replie une première surface des ailettes à ladite première hauteur sur le fil et la seconde étape de sertissage replie une zone localisée des ailettes à ladite seconde hauteur, inférieure à la première. En mode de réalisation particulier, le second sertissage peut être réalisé sur deux zones disjointes des ailettes. Plus particulièrement, le second sertissage peut notamment être réalisé sur des zones extrêmes des ailettes. En mode de réalisation alternatif, le second sertissage peut être réalisé sur une zone centrale des ailettes. Avantageusement, la première étape de sertissage peut être effectuée sur la totalité des ailettes de manière à refermer les ailettes sur le fil. Selon un mode de réalisation préférentiel de l'invention, la seconde étape de sertissage est effectuée sur une partie de la surface des ailettes ayant subi la première étape de sertissage. Le procédé peut être notamment tel que l'outil de sertissage comporte une enclume commune et des éléments de poinçon dissociables. Le fût peut en particulier être déformé lors de la première étape de sertissage et conserver sa forme lors de la seconde étape de sertissage. L'invention concerne en outre un élément de contact électrique comportant une section de sertissage pourvue d'un fût ouvert muni d'ailettes de sertissage sur un fil électrique, la section de sertissage étant sertie sur le fil par le procédé décrit précédemment tel que, après sertissage, la section de sertissage comporte trois zones successives d'écrasement des ailettes sur le fil, deux des trois zones étant d'épaisseur réduite par rapport à la troisième zone de sorte que le fil exerce une contrainte élastique sur les ailettes au niveau de la troisième zone. En alternative, l'une des trois zones est d'épaisseur réduite par rapport aux deux autres zones de sorte que le fil exerce une contrainte élastique sur les ailettes au niveau des deux autres zones. D'autres avantages et caractéristiques seront mieux comprises à la lecture de la description qui va suivre d'un mode de réalisation particulier de l'invention donné à titre d'exemple non limitatif en référence aux figures qui représentent: En figure 1 : Un outil de sertissage selon un aspect de l'invention; En figure 2: Un élément de contact électrique et un fil à sertir selon le procédé de l'invention; En figures 3a et 3b: un contact serti à l'aide du procédé selon l'invention; En figure 4: Une vue schématique en coupe d'un sertissage de fil électrique obtenu par un procédé selon l'invention; En figures 5a et 5b: deux versions de la seconde étape de sertissage du procédé selon l'invention; En figure 6: Une représentation schématique de la première étape de sertissage du procédé selon l'invention. Selon l'exemple d'application représenté en figure 2 le sertissage est réalisé sur des contacts électriques à fût ouvert. De tels contacts comportent une partie avant A, notamment de raccordement à un contact complémentaire traditionnellement connue, et comportent, dans une partie intermédiaire, pour le raccordement par sertissage une section 30 de sertissage pourvue d'un fût 3 ouvert muni d'ailettes 4, 5 de sertissage sur un la partie dénudée 12 d'un fil 2 électrique, la section de sertissage étant destinée à être sertie sur le fil pour réaliser un contact électrique entre le fil 2 et l'élément de contact 1. Selon l'exemple, le contact 1 comporte une section terminale 31 formant une zone de reprise d'efforts pourvue d'ailes 10, 11 destinées à se refermer sur l'isolant 13 du fil 2. La partie avant A de l'élément de contact peut être de tout type et peut même éventuellement être constituée d'une seconde section de raccordement par sertissage pour réaliser par exemple une épissure. De tels éléments de contact sont réalisés par découpe et pliage d'une bande métallique d'épaisseur faible de l'ordre de 0,2 mm à quelques millimètres d'épaisseur. Du fait de la nécessité pour ces contacts de posséder une bonne rigidité et, dans le cas de contacts à lames de contact ressort, une bonne élasticité, le matériau employé est très peu ductile et est sujet à retour élastique lors d'opérations de pliage ou formage. Il a été montré que ce retour élastique existe au niveau des ailettes 4, 5 de sertissage et que même si les variations de dimensions ne sont que de l'ordre de quelques microns, ce retour élastique peut causer des pertes de contact intermittentes entre les brins et l'élément de contact notamment pour des applications à faibles courant et tension comme les procédures d'auto diagnostic des dispositifs embarqués sur véhicules automobiles. De plus, le fil, généralement à base de cuivre, possède une faible capacité de retour élastique et notamment inférieure à celle d'alliages tels qu'un cuprobéryllium souvent employé pour les éléments de contacts. L'invention tend à modifier le comportement mécanique du sertissage afin d'utiliser le phénomène physique du retour élastique dans un sens favorable sur une zone particulière du contact. Pour ce faire, le procédé de sertissage d'une section de sertissage d'un élément 1 de contact électrique sur un fil 2 électrique selon l'invention comporte une première étape de sertissage de la section de sertissage 30 sur la partie dénudée 12 du fil à une première hauteur h1 en repliant les ailettes 4, 5 sur le fil 2 par un outil de sertissage comportant un poinçon 6 et une enclume 7. Pour cette première étape dont le début est décrit en figure 6, le poinçon 6, constitué selon l'exemple de trois parties 6a, 6b, 6c, appuie avec ses trois parties sur la totalité des ailettes 4 et 5 et l'enclume appuie sous le fût 3, les ailettes 4 et 5 étant des ailettes continues. La hauteur de sertissage h1 est obtenue en fonction des dimensions du contact et du fil par un sertissage classique de telle sorte que l'on obtienne un taux de compression minimal de l'ordre de 5% de façon à refermer les ailettes sur le fil. Cette première étape de sertissage est effectuée sur une majeure partie de la surface des ailettes 4, 5 voir sur la totalité de ces ailettes par le poinçon 6 et sur une majeure partie voir la totalité du fût 3 par l'enclume 7. Le procédé comporte une seconde étape ou opération de sertissage, cette opération est effectuée à une seconde hauteur h2, inférieure à la première sur une zone localisée des ailettes. Cette étape est réalisée de telle sorte qu'un taux de compression supérieur à 15% et typiquement de l'ordre de 25 à 30% soit obtenu sous l'outil de sertissage. Cette seconde étape est représentée schématiquement aux figures 4 et 5b représentant un premier mode de réalisation pour lequel seuls les éléments 6a, 6c du poinçon 6 appuient sur les extrémités 4a, 4c, 5a, 5c des ailettes, l'élément 6b restant en retrait et ne venant pas en contact avec les ailettes et, à la figure 5a pour un second mode de réalisation pour lequel seul l'élément de poinçon 6b appuie sur les parties d'ailettes 4b et 5b, les éléments de poinçon 6a et 6c restant en retrait et ne venant pas en contact avec les ailettes. dans les deux modes de réalisation, la seconde étape de sertissage est effectuée sur une partie de la surface des ailettes ayant subi la première étape de sertissage. Ces deux modes de réalisation du second sertissage conduisent pour le contact à deux variantes, l'une pour laquelle les zones extrêmes longitudinales 4b, 4c, 5b, 5c des ailettes comme représenté en figure 3a sont plus écrasées, la hauteur h2 correspondant pour le contact résultant à une épaisseur e2, que la zone centrale d'épaisseur e1 résultant de la hauteur de sertissage h1 effectuée sur ces ailettes, l'autre pour laquelle le second sertissage est réalisé sur la zone centrale 4a, 5a des ailettes comme représenté en figure 3b, les épaisseurs e1 et e2 correspondant ici aussi respectivement aux hauteurs de sertissage h1 et h2. Selon l'exemple de la figure 3a, le contact serti comporte trois zones successives d'écrasement des ailettes sur le fil, deux des trois zones étant d'épaisseur réduite par rapport à la troisième zone de sorte que le fil exerce une contrainte élastique sur les ailettes au niveau de la troisième zone. Selon l'exemple de la figure 3b, le contact serti comporte trois zones successives d'écrasement des ailettes sur le fil, l'une des trois zones étant d'épaisseur réduite par rapport aux deux autres zones de sorte que le fil exerce une contrainte élastique sur les ailettes au niveau des deux autres zones. Le double sertissage inverse le retour élastique pour lui faire jouer un rôle positif c'est à dire créer une pression de contact entre le fût et les brins. Selon le procédé et, comme décrit en figure 4, en fin de la seconde opération de sertissage, pour le mode de réalisation de la figure 3a, les brins gonflent localement dans la zone 20b entre les deux outils 6a et 6c réalisant la seconde étape de sertissage. En conséquence, alors que pour les zones des ailettes sous les outils 6a et 6c, le retour élastique des ailettes reste supérieur à celui des brins du fil, dans la zone 20b, c'est le fil qui vient déformer l'aile par effet de gonflement. L'élasticité des ailettes a alors dans cette partie 20b un effet positif car elle tend à comprimer le fil ce qui implique une pression de contact mécanique et donc une bonne conduction électrique même sous des sollicitations mécaniques ou thermiques. L'outil de sertissage représenté en figure 1 et adapté au procédé selon l'invention comporte une enclume 7 commune et des éléments 6a, 6b, 6c de poinçon dissociables. Un tel outil peut fonctionner sur une presse automatique traditionnelle moyennant une commande dissociée des éléments de poinçon. Il est bien sûr possible de réaliser les opérations de sertissage sur deux postes séparés, un premier poste comportant un premier poinçon effectuant le premier sertissage et un second poste comportant un poinçon adapté à effectuer le second sertissage sur une zone particulière du contact. Il reste que le mode de réalisation pour lequel le poinçon 6 se divise en éléments de poinçons mobiles pouvant être actionnés séparément permet de conserver un parfait alignement de l'élément de contact avec les poinçons et de réaliser successivement les deux opérations sur la même presse. L'intérêt de l'enclume commune est que le fût 3 est déformé lors de la première étape de sertissage et conserve sa forme lors de la seconde étape de sertissage. Le fût garde ainsi une bonne rigidité mécanique et une bonne résistance aux contraintes mécaniques en cas de traction sur le fil. Un tel procédé est applicable aux contacts à sertir à fût ouvert pour contacts électriques découpés plies mais aussi à des contacts à fût fermés tels que contacts découpés roulés à base d'un feuillard métallique. Il est à noter que selon l'invention pour laquelle le poinçon se divise en éléments de poinçons mobiles pouvant être actionnés séparément, la première étape de sertissage peut être effectuée au moyen du seul élément 6b du poinçon (pour un résultat final de seconde étape du type montré à la figure 3a) ou au moyen des seuls éléments 6a et 6c de ce poinçon (pour un résultat final de seconde étape du type montré à la figure 3b), cela signifiant que les éléments 6a et 6c, respectivement l'élément 6b, reste(nt) lors de cette première étape dans une position haute sans venir eux-mêmes appuyer en force sur les ailettes 4 et 5 du fût placé sur l'enclume. Les ailettes 4 et 5 subiront néanmoins une opération de pliage/sertissage plus ou moins marquée sur toute ou une partie très significative de leur longueur au-delà de la/des seule(s) zone(s) d'ailette(s) sur la/lesquelle(s) l'élément 6b, respectivement, les éléments 6a/6c du poinçon sont venus s'appuyer. Dans ce cas, la première hauteur de sertissage définit la hauteur de sertissage sur la zone centrale des ailettes respectivement la hauteur de sertissage sur les zones d'extrémité des ailettes. La seconde étape de sertissage qui suit la première étape est alors effectuée au moyen des éléments 6a, 6c, respectivement de l'élément 6b, selon l'invention, l'élément 6b du poinçon, respectivement les éléments 6a et 6c de ce poinçon restant dans une position de fin de parcours de première étape pour conserver le fût dans la forme qu'il a à l'issue de la première étape. Ainsi donc, la première étape de sertissage sertit au moins une première zone de chaque ailette 4 et 5 du fût à une première hauteur de sertissage, en repliant de manière plus ou moins marquée les ailettes sur une surface s'étendant au-delà de ladite au moins une première zone, et la seconde étape de sertissage sertit à la seconde hauteur de sertissage au moins une seconde zone de chaque ailette 4 et 5, dite région localisée de la section de sertissage, complémentaire(s) de ladite au moins une première zone. The present invention relates to a method of crimping an electrical contact and the contact obtained by this method. It is known to make electrical contact between an electrical wire, in particular multi-strand, and a metallic contact element by a crimping operation for which the fins cut out from the metallic contact element are folded around the exposed electrical wire by a crimping tool. type anvil punch. This technique is applied for contacts made from a folded cut metal blank. Document US 5,561,267 relates for example to a crimp contact comprising fins of different size allowing an overlap of a crimping fin on another and a crimping process with punch-anvil adapted. The crimped contacts encounter reliability problems for low current and low voltage applications and more particularly micro-breaks appear over time. It has been shown that crimping could lose its effectiveness due to a phenomenon of elastic return of the crimping fins which causes a decrease in the contact pressure between the fins and the strands of the crimped wires and can lead to increases or instabilities in contact resistance, or even loss of electrical contact. Document US 5,025,554 for its part relates to a crimp to which solder paste has been added in order to improve the electrical conduction. The problem with such a combination is the difficulty of locating a small amount of weld in an automated crimping process on a production line for automotive harnesses and at associated rates. The present invention aims to improve the crimped electrical contacts and to remedy the problem of elastic return in order to maintain a high contact pressure throughout the life of the contact. More particularly, the present invention relates to a method of crimping an electrical contact on an electrical wire, the contact comprising a crimping section provided with a barrel for receiving the electrical wire, the barrel comprising a part intended to grip the wire by deformation, the method comprising a first crimping step at a first crimping height by folding a first surface of the crimping section onto the wire by a crimping tool comprising a punch and an anvil and a second crimping step at a second crimping height , lower than the first, of a localized region of the crimping section. More particularly, in the case where the crimping section comprises an open barrel for receiving the electric wire and crimping fins protruding from the barrel and intended to grip the wire, the first crimping step folds up a first surface of the fins at said first height on the wire and the second crimping step folds a localized area of the fins at said second height, less than the first. In a particular embodiment, the second crimping can be carried out on two zones separated from the fins. More particularly, the second crimping can in particular be carried out on end zones of the fins. In an alternative embodiment, the second crimping can be carried out on a central zone of the fins. Advantageously, the first crimping step can be carried out on all of the fins so as to close the fins on the wire. According to a preferred embodiment of the invention, the second crimping step is carried out on a part of the surface of the fins having undergone the first crimping step. The method may in particular be such that the crimping tool comprises a common anvil and separable punch elements. The barrel can in particular be deformed during the first crimping step and keep its shape during the second crimping step. The invention further relates to an electrical contact element comprising a crimping section provided with an open barrel provided with crimping fins on an electric wire, the crimping section being crimped on the wire by the method described above such that, after crimping, the crimping section comprises three successive zones of crushing of the fins on the wire, two of the three zones being of reduced thickness compared to the third zone so that the wire exerts an elastic stress on the fins at the third zone. Alternatively, one of the three zones is of reduced thickness compared to the other two zones so that the wire exerts an elastic stress on the fins at the level of the two other zones. Other advantages and characteristics will be better understood on reading the following description of a particular embodiment of the invention given by way of nonlimiting example with reference to the figures which represent: In FIG. 1: A tool crimping according to one aspect of the invention; In Figure 2: An electrical contact element and a wire to be crimped according to the method of the invention; In FIGS. 3a and 3b: a contact crimped using the method according to the invention; In Figure 4: A schematic sectional view of a crimping of electric wire obtained by a method according to the invention; In FIGS. 5a and 5b: two versions of the second crimping step of the method according to the invention; In Figure 6: A schematic representation of the first crimping step of the method according to the invention. According to the example of application shown in FIG. 2, the crimping is carried out on electrical contacts with open barrel. Such contacts comprise a front part A, in particular for connection to a complementary contact traditionally known, and comprise, in an intermediate part, for connection by crimping, a crimping section 30 provided with an open barrel 3 provided with fins 4, 5 for crimping on a stripped part 12 of an electric wire 2, the crimping section being intended to be crimped on the wire to make an electrical contact between the wire 2 and the contact element 1. According to the example, the contact 1 has an end section 31 forming a force recovery zone provided with wings 10, 11 intended to close on the insulator 13 of the wire 2. The front part A of the contact element may be of any type and may even possibly consist of a second connection section by crimping, for example to make a splice. Such contact elements are produced by cutting and folding a metal strip of small thickness of the order of 0.2 mm to a few millimeters in thickness. Due to the need for these contacts to have good rigidity and, in the case of contacts with spring contact blades, good elasticity, the material used is very little ductile and is subject to elastic return during bending operations or forming. It has been shown that this elastic return exists at the level of the crimping fins 4, 5 and that even if the variations in dimensions are only of the order of a few microns, this elastic return can cause intermittent losses of contact between the strands. and the contact element in particular for low current and voltage applications such as self-diagnostic procedures for devices on board motor vehicles. In addition, the wire, generally based on copper, has a low elastic return capacity and in particular less than that of alloys such as a cuproberyllium often used for the contact elements. The invention tends to modify the mechanical behavior of crimping in order to use the physical phenomenon of elastic return in a favorable direction over a particular area of the contact. To do this, the crimping method of a crimping section of an electrical contact element 1 on an electrical wire 2 according to the invention comprises a first step of crimping the crimping section 30 on the stripped part 12 of the wire at a first height h1 by folding the fins 4, 5 onto the wire 2 by a crimping tool comprising a punch 6 and an anvil 7. For this first step, the start of which is described in FIG. 6, the punch 6, formed according to the 'example of three parts 6a, 6b, 6c, presses with its three parts on all of the fins 4 and 5 and the anvil presses under the barrel 3, the fins 4 and 5 being continuous fins. The crimping height h1 is obtained as a function of the dimensions of the contact and of the wire by conventional crimping so that a minimum compression ratio of the order of 5% is obtained so as to close the fins on the wire. This first crimping step is carried out on a major part of the surface of the fins 4, 5 see on all of these fins by the punch 6 and on a major part see all of the barrel 3 by the anvil 7. The method comprises a second step or crimping operation, this operation is carried out at a second height h2, lower than the first on a localized area of the fins. This step is carried out so that a compression ratio greater than 15% and typically of the order of 25 to 30% is obtained under the crimping tool. This second step is shown diagrammatically in FIGS. 4 and 5b representing a first embodiment for which only the elements 6a, 6c of the punch 6 press on the ends 4a, 4c, 5a, 5c of the fins, the element 6b remaining in withdrawal and not coming into contact with the fins and, in FIG. 5a for a second embodiment for which only the punch element 6b presses on the fin parts 4b and 5b, the punch elements 6a and 6c remaining set back and not coming into contact with the fins. in the two embodiments, the second crimping step is carried out on a part of the surface of the fins having undergone the first crimping step. These two embodiments of the second crimping lead to contact with two variants, one for which the longitudinal end zones 4b, 4c, 5b, 5c of the fins as shown in FIG. 3a are more flattened, the height h2 corresponding for the contact resulting in a thickness e2, that the central zone of thickness e1 resulting from the crimping height h1 carried out on these fins, the other for which the second crimping is carried out on the central area 4a, 5a of the fins as shown in FIG. 3b , the thicknesses e1 and e2 here also corresponding respectively to the crimp heights h1 and h2. According to the example of FIG. 3a, the crimped contact comprises three successive zones of crushing of the fins on the wire, two of the three zones being of reduced thickness compared to the third zone so that the wire exerts an elastic stress on the fins at the level of the third zone. According to the example of FIG. 3b, the crimped contact comprises three successive zones of crushing of the fins on the wire, one of the three zones being of reduced thickness compared to the other two zones so that the wire exerts a stress. elastic on the fins at the two other zones. The double crimping reverses the elastic return to make it play a positive role, that is to say creating contact pressure between the barrel and the strands. According to the method and, as described in FIG. 4, at the end of the second crimping operation, for the embodiment of FIG. 3a, the strands locally swell in the area 20b between the two tools 6a and 6c performing the second step of crimping. Consequently, while for the zones of the fins under the tools 6a and 6c, the elastic return of the fins remains greater than that of the strands of the wire, in zone 20b, it is the wire which comes to deform the wing by effect of swelling. The elasticity of the fins then has in this part 20b a positive effect because it tends to compress the wire which implies a mechanical contact pressure and therefore good electrical conduction even under mechanical or thermal stresses. The crimping tool shown in FIG. 1 and adapted to the method according to the invention comprises a common anvil 7 and elements 6a, 6b, 6c of separable punch. Such a tool can operate on a traditional automatic press by means of a separate control of the punch elements. It is of course possible to carry out the crimping operations on two separate stations, a first station comprising a first punch performing the first crimping and a second station comprising a punch suitable for performing the second crimping on a particular area of the contact. The fact remains that the embodiment for which the punch 6 is divided into elements of movable punches which can be actuated separately makes it possible to maintain perfect alignment of the contact element with the punches and to carry out the two operations successively on the same press. The advantage of the common anvil is that the barrel 3 is deformed during the first crimping step and retains its shape during the second crimping step. The barrel thus retains good mechanical rigidity and good resistance to mechanical stress in the event of traction on the wire. Such a method is applicable to crimp contacts with open barrel for folded cut electrical contacts but also to closed barrel contacts such as cut cut contacts rolled on the basis of a metal strip. It should be noted that according to the invention for which the punch is divided into elements of movable punches which can be actuated separately, the first crimping step can be carried out by means of the single element 6b of the punch (for a final second stage result of the type shown in Figure 3a) or by using only elements 6a and 6c of this punch (for a final second stage result of the type shown in Figure 3b), this means that the elements 6a and 6c, respectively the element 6b, remains (s) during this first step in a high position without themselves coming to press force on the fins 4 and 5 of the barrel placed on the anvil. The fins 4 and 5 will nevertheless undergo a more or less marked folding / crimping operation over all or a very significant part of their length beyond the sole area (s) of the fin (s) on the / Which (s) element 6b, respectively, the elements 6a / 6c of the punch have come to bear. In this case, the first crimping height defines the crimping height on the central zone of the fins respectively the crimping height on the end zones of the fins. The second crimping step which follows the first step is then carried out by means of elements 6a, 6c, respectively of element 6b, according to the invention, element 6b of the punch, respectively elements 6a and 6c of this punch remaining in an end position of the first stage to keep the barrel in the shape it has at the end of the first stage. Thus, the first crimping step crimps at least a first zone of each fin 4 and 5 of the barrel at a first crimping height, by more or less markedly folding the fins on a surface extending beyond said at least a first zone, and the second crimping step crimps at the second crimping height at least a second zone of each fin 4 and 5, called localized region of the crimping section, complementary (s) of said at least a first zoned.

Claims

R E V E N D I C A T I O N SR E V E N D I C A T I O N S
1 - Procédé de sertissage de contact (1) électrique sur un fil (2) électrique, le contact comportant une section (30) de sertissage munie d'un fût (3) de réception du fil (2) électrique, le fût comportant une partie destinée à enserrer le fil par déformation, caractérisé en ce qu'il comporte une première étape de sertissage à une première hauteur de sertissage (h1) en repliant une première surface de la section de sertissage sur le fil (2) par un outil de sertissage comportant un poinçon (6) et une enclume (7) et une seconde étape de sertissage à une seconde hauteur de sertissage (h2), inférieure à la première, d'une région localisée (4a, 4b, 4c, 5a, 5b, 5c) de la section de sertissage. 2 - Procédé de sertissage de contact (1) électrique selon la revendication 1 caractérisé en ce que, la section (30) de sertissage comportant un fût (3) ouvert de réception du fil (2) électrique et des ailettes (4, 5) de sertissage dépassant du fût et destinées à enserrer le fil, la première étape de sertissage replie une première surface des ailettes (4, 5) à ladite première hauteur (h1) sur le fil (2) et la seconde étape de sertissage replie une zone localisée (4a, 4b, 4c, 5a, 5b, 5c) des ailettes à ladite seconde hauteur (h2), inférieure à la première. 3 - Procédé selon la revendication 2 caractérisé en ce que le second sertissage est réalisé sur deux zones disjointes (4b, 4c, 5b, 5c) des ailettes. 4 - Procédé selon la revendication 3 caractérisé en ce que le second sertissage est réalisé sur des zones extrêmes (4b, 4c, 5b, 5c) des ailettes. 5 - Procédé selon la revendication 2 caractérisé en ce que le second sertissage est réalisé sur une zone centrale (4a, 5a) des ailettes. 6 - Procédé selon l'une des revendications précédentes caractérisé en ce que la première étape de sertissage est effectuée sur la totalité de la surface des ailettes (4, 5). 7 - Procédé selon la revendication 6 caractérisé en ce que la seconde étape de sertissage est effectuée sur une partie (4a, 4b, 4c, 5a, 5b, 5c) de la surface des ailettes ayant subi la première étape de sertissage. 8 - Procédé selon l'une des revendications précédentes caractérisé en ce que l'outil de sertissage comporte une enclume (7) commune et des éléments1 - Method for crimping an electrical contact (1) on an electrical wire (2), the contact comprising a crimping section (30) provided with a barrel (3) for receiving the electrical wire (2), the barrel comprising a part intended to grip the wire by deformation, characterized in that it comprises a first crimping step at a first crimping height (h1) by folding a first surface of the crimping section onto the wire (2) by a tool crimping comprising a punch (6) and an anvil (7) and a second crimping step at a second crimping height (h2), lower than the first, of a localized region (4a, 4b, 4c, 5a, 5b, 5c) of the crimping section. 2 - A method of crimping an electrical contact (1) according to claim 1 characterized in that, the crimping section (30) comprising a barrel (3) open for receiving the electric wire (2) and the fins (4, 5) crimping projecting beyond the barrel and intended to grip the wire, the first crimping step folds a first surface of the fins (4, 5) at said first height (h1) on the wire (2) and the second crimping step folds an area located (4a, 4b, 4c, 5a, 5b, 5c) of the fins at said second height (h2), less than the first. 3 - Method according to claim 2 characterized in that the second crimping is carried out on two disjoint areas (4b, 4c, 5b, 5c) of the fins. 4 - Method according to claim 3 characterized in that the second crimping is carried out on end zones (4b, 4c, 5b, 5c) of the fins. 5 - Method according to claim 2 characterized in that the second crimping is carried out on a central area (4a, 5a) of the fins. 6 - Method according to one of the preceding claims characterized in that the first crimping step is carried out on the entire surface of the fins (4, 5). 7 - Method according to claim 6 characterized in that the second crimping step is carried out on a part (4a, 4b, 4c, 5a, 5b, 5c) of the surface of the fins having undergone the first crimping step. 8 - Method according to one of the preceding claims characterized in that the crimping tool comprises a common anvil (7) and elements
(6a, 6b, 6c) de poinçon dissociables. 9 - Procédé selon l'une des revendications précédentes caractérisé en ce que le fût (3) est déformé lors de la première étape de sertissage et conserve sa forme lors de la seconde étape de sertissage. 10 - Elément de contact électrique comportant une section (30) de sertissage pourvue d'un fût (3) ouvert muni d'ailettes (4, 5) de sertissage sur un fil (2) électrique, la section de sertissage étant sertie sur le fil par un procédé selon l'une des revendications 1 à 9, caractérisé en ce que, après sertissage, la section (30) de sertissage comporte trois zones successives d'écrasement des ailettes sur le fil, deux des trois zones étant d'épaisseur réduite par rapport à la troisième zone de sorte que le fil exerce une contrainte élastique sur les ailettes au niveau de ladite troisième zone. 11 - Elément de contact électrique comportant une section (30) de sertissage pourvue d'un fût (3) ouvert muni d'ailettes (4, 5) de sertissage sur un fil (2) électrique, la section de sertissage étant sertie sur le fil par un procédé selon l'une des revendications 1 à 9, caractérisé en ce que, après sertissage, la section (30) de sertissage comporte trois zones successives d'écrasement des ailettes sur le fil, l'une des trois zones étant d'épaisseur réduite par rapport aux deux autres zones de sorte que le fil exerce une contrainte élastique sur les ailettes au niveau desdites deux autres zones. (6a, 6b, 6c) of separable punch. 9 - Method according to one of the preceding claims characterized in that the barrel (3) is deformed during the first crimping step and retains its shape during the second crimping step. 10 - Electric contact element comprising a crimping section (30) provided with an open barrel (3) provided with fins (4, 5) crimping on an electric wire (2), the crimping section being crimped on the wire by a method according to one of claims 1 to 9, characterized in that, after crimping, the crimping section (30) comprises three successive zones of crushing of the fins on the wire, two of the three zones being thick reduced relative to the third zone so that the wire exerts an elastic stress on the fins at the level of said third zone. 11 - Electrical contact element comprising a crimping section (30) provided with an open barrel (3) provided with fins (4, 5) crimping on an electric wire (2), the crimping section being crimped on the wire by a method according to one of claims 1 to 9, characterized in that, after crimping, the crimping section (30) comprises three successive zones for crushing the fins on the wire, one of the three zones being d 'reduced thickness compared to the other two zones so that the wire exerts an elastic stress on the fins at said two other zones.
EP04720635.4A 2003-08-19 2004-03-15 Electric contact crimping method and contact obtained according to said method Expired - Lifetime EP1658662B1 (en)

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FR0310011A FR2859047A1 (en) 2003-08-19 2003-08-19 Improved electrical wire contact crimping method having outer shaft two stages deformed using die stamps with second crimping stage forming smaller localised gap size.
PCT/FR2004/000631 WO2005029653A1 (en) 2003-08-19 2004-03-15 Electric contact crimping method and contact obtained according to said method

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EP (1) EP1658662B1 (en)
JP (1) JP4413926B2 (en)
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BR (1) BRPI0412982A (en)
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FR3069965A1 (en) * 2017-08-01 2019-02-08 VM Industries OPTIMIZED CRIMPING OF TWO ELECTRICAL CONNECTORS

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KR101273881B1 (en) 2013-06-17
US20070054565A1 (en) 2007-03-08
WO2005029653A1 (en) 2005-03-31
CN1836354A (en) 2006-09-20
BRPI0412982A (en) 2006-10-03
CA2534403A1 (en) 2005-03-31
KR20060065696A (en) 2006-06-14
FR2859047A1 (en) 2005-02-25
JP4413926B2 (en) 2010-02-10
KR20110063582A (en) 2011-06-10
CN100452566C (en) 2009-01-14
MXPA06001829A (en) 2006-05-31
JP2007503083A (en) 2007-02-15
EP1658662B1 (en) 2016-07-27
CA2534403C (en) 2013-05-07

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