EP1658662B1 - Krimpverfahren eines elektrischen kontakts und durch dieses verfahren hergestellten kontakt - Google Patents

Krimpverfahren eines elektrischen kontakts und durch dieses verfahren hergestellten kontakt Download PDF

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Publication number
EP1658662B1
EP1658662B1 EP04720635.4A EP04720635A EP1658662B1 EP 1658662 B1 EP1658662 B1 EP 1658662B1 EP 04720635 A EP04720635 A EP 04720635A EP 1658662 B1 EP1658662 B1 EP 1658662B1
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EP
European Patent Office
Prior art keywords
crimping
wire
wings
zones
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.)
Expired - Lifetime
Application number
EP04720635.4A
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English (en)
French (fr)
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EP1658662A1 (de
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
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Delphi International Operations Luxembourg SARL
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Publication date
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Publication of EP1658662A1 publication Critical patent/EP1658662A1/de
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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 electrical contact and the contact obtained by this method.
  • the crimped contacts have reliability problems for low current and low voltage applications and more particularly micro-cuts appear over time. It has been demonstrated that the 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 of contact resistance or even loss of electrical contact.
  • FR 242 7 702 discloses a method according to the preamble of claim 1.
  • the present invention aims to improve the crimped electrical contacts and remedy the problem of elastic return to maintain a significant contact pressure throughout the life of the contact.
  • the present invention relates to a process according to claim 1.
  • the first crimping step folds a first surface of the fins to 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 performed on two disjoint areas of the fins. More particularly, the second crimping can in particular be performed on the end zones of the fins.
  • the second crimping can be performed on a central area of the fins.
  • the first crimping step can be performed on all the fins so as to close the fins on the wire.
  • the second crimping step is performed on a portion of the surface of the fins having undergone the first crimping step.
  • the method can be such that the crimping tool comprises a common anvil and separable punch elements.
  • the drum can in particular be deformed during the first crimping step and retain its shape during the second crimping step.
  • the invention further relates to an electrical contact element having a crimping section provided with an open barrel provided with crimping fins on an electric wire, the crimping section being crimped onto the wire by the method described above such that, after crimping, the crimping section comprises three successive zones of crimping of the fins on the wire, two of the three zones being of reduced thickness relative to the third zone so that the wire exerts an elastic stress on the fins at the level of 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 in the other two zones.
  • crimping is performed on electrical contacts open drum.
  • Such contacts comprise a front part A, in particular of connection to a conventionally known complementary contact, and comprise, in an intermediate part, for the crimping connection a crimping section provided with an open shaft 3 provided with fins 4,
  • the crimping section is intended to be crimped onto the wire to make an electrical contact between the wire 2 and the contact element 1.
  • the contact 1 comprises 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 be constituted by a second crimping connection section for producing for example a splice.
  • Such contact elements are made by cutting and folding a metal strip of small thickness of the order of 0.2 mm to a few millimeters thick.
  • the wire generally copper-based, has a low elastic return capability and in particular lower than that of alloys such as cuproberyllium often used for contact elements.
  • the invention tends to modify the mechanical behavior of crimping in order to use the physical phenomenon of springback in a favorable direction on a particular zone of the contact.
  • the method of crimping a crimping section of an element 1 of electrical contact on an electrical wire 2 comprises a first crimping step of the crimping section 30 on the stripped portion 12 of the wire at a first height h1 by folding the fins 4, 5 on 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, bears with its three parts on all of the fins 4 and 5 and the anvil presses under the shaft 3, the fins 4 and 5 being fins continuous.
  • the crimping height h1 is obtained as a function of the dimensions of the contact and 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 step of crimping is performed on a major part of the surface of the fins 4, 5 see all of these fins by the punch 6 and on a major part see the entire barrel 3 by the anvil 7.
  • the method comprises a second step or crimping operation, this operation is performed at a second height h2, less 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 schematically represented in figures 4 and 5b representing a first embodiment for which only the elements 6a, 6c of the punch 6 rest on the ends 4a, 4c, 5a, 5c of the fins, the element 6b remaining in recess and not coming into contact with the fins and, the figure 5a for a second embodiment for which only the punch element 6b presses on the fin parts 4b and 5b, the punching elements 6a and 6c remaining recessed and not coming into contact with the fins.
  • the second crimping step is performed on a portion 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 relative 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 relative to the other two zones so that the wire exerts an elastic stress on the fins at the two other areas.
  • the double crimping reverses the springback to make it play a positive role that is to say create a contact pressure between the barrel and the strands.
  • the strands swell locally in the zone 20b between the two tools 6a and 6c performing the second crimping step. Consequently, whereas 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 the zone 20b, it is the wire which deforms the wing by the 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 represented in figure 1 and adapted to the method according to the invention comprises an anvil 7 and common elements 6a, 6b, 6c dissociable punch. Such a tool can operate on a traditional automatic press with a separate command of the punch elements.
  • the interest 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 stresses in case traction on the wire.
  • Such a method is applicable to crimp contacts with open barrel for bent cut electrical contacts but also to contacts with closed barrels such as rolled cut contacts based on a metal strip.
  • the first crimping step can be performed 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 means of the 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, remain (s) during this first step in a high position without themselves come 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 bending / crimping operation over all or a very significant part of their length beyond the sole area (s) of fin (s) on the where (s) the 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 area 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 the elements 6a, 6c, respectively of the element 6b, according to the invention, the element 6b of the punch, respectively the elements 6a and 6c of this punch remaining in a first-stage end-of-course position to keep the keg in the shape that it has at the end of the first stage.
  • the first crimping step crimped at least a first zone of each fin 4 and 5 of the barrel to a first crimping height, by more or less sharply 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, said 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)

Claims (18)

  1. Verfahren zum Crimpen eines elektrischen Kontakts (1) an ein Stromkabel (2), wobei der Kontakt einen Crimpabschnitt (30) mit einer Aufnahmebuchse (3) zum Aufnehmen des Stromkabels (2) enthält, wobei die Buchse einen Teilbereich aufweist, der dazu bestimmt ist, das Kabel durch Verformung einzuklemmen, dadurch gekennzeichnet, dass es einen ersten Crimpschritt in einer ersten Crimphöhe (h1) umfasst, indem eine erste Fläche des Crimpabschnitts an das Kabel (2) mit einem Crimpwerkzeug gecrimpt wird, das einen Stempel (6) und einen Amboss (7) aufweist, sowie einen zweiten Crimpschritt zum Crimpen eines begrenzten Bereichs (4a, 4b, 4c, 5a, 5b, 5c) des Crimpabschnitts in einer zweiten Crimphöhe (h2), die geringer als die erste ist, wobei mit einem der Crimpschritte durch Blähwirkung des Kabels ein Teil des bereits gecrimpten Crimpabschnitts verformt wird.
  2. Verfahren zum Crimpen eines elektrischen Kontakts (1) nach Anspruch 1, dadurch gekennzeichnet, dass bei einem Crimpabschnitt (30) mit offener Buchse (3) zum Aufnehmen des Stromkabels (2) und mit Crimpflügeln (4, 5), die von der Buchse abstehen und zum Einklemmen des Kabels bestimmt sind, mit dem ersten Crimpschritt eine erste Fläche der Flügel (4, 5) in der ersten Höhe (h1) auf das Kabel (2) umgelegt wird und mit dem zweiten Crimpschritt ein begrenzter Bereich (4a, 4b, 4c, 5a, 5b, 5c) der Flügel in der zweiten Höhe (h2) umgelegt wird, die geringer als die erste ist.
  3. Verfahren nach Anspruch 2, dadurch gekennzeichnet, dass der zweite Crimpschritt an zwei getrennten Bereichen (4a, 4c, 5a, 5c) der Flügel erfolgt.
  4. Verfahren nach Anspruch 3, dadurch gekennzeichnet, dass der zweite Crimpschritt an Endbereichen (4a, 4c, 5a, 5c) der Flügel erfolgt.
  5. Verfahren nach Anspruch 2, dadurch gekennzeichnet, dass der zweite Crimpschritt an einem Mittelbereich (4b, 5b) der Flügel erfolgt.
  6. Verfahren nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass der erste Crimpschritt über die gesamte Fläche der Flügel (4, 5) erfolgt.
  7. Verfahren nach Anspruch 6, dadurch gekennzeichnet, dass der zweite Crimpschritt über einen Teil (4a, 4b, 4c, 5a, 5b, 5c) der Fläche der Flügel erfolgt, an welchem der erste Crimpschritt bereits erfolgt ist.
  8. Verfahren nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass das Crimpwerkzeug einen gemeinsamen Amboss (7) und lösbare Stempelelemente (6a, 6b, 6c) aufweist.
  9. Verfahren nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass die Buchse (3) beim ersten Crimpschritt verformt wird und beim zweiten Crimpschritt ihre Form beibehält.
  10. Verfahren nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass der Crimpschritt in einer zweiten Höhe (h2) nach dem Crimpschritt in einer ersten Höhe (h1) erfolgt.
  11. Verfahren nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass der Crimpabschnitt einen ersten Teil (4b, 5b; 4a, 4c, 5a, 5c) und einen zweiten Teil (4a, 4c, 5a, 5c; 4b, 5b) aufweist, wobei der erste Crimpschritt zumindest an dem ersten Teil (4b, 5b; 4a, 4c, 5a, 5c) des Crimpabschnitts erfolgt,
    wobei der zweite Crimpschritt an dem zweiten Teil (4a, 4c, 5a, 5c; 4b, 5b) des Crimpabschnitts erfolgt, wodurch der erste Teil (4b, 5b; 4a, 4c, 5a, 5c) des Crimpabschnitts durch Blähwirkung des Kabels verformt wird.
  12. Elektrisches Kontaktelement, enthaltend einen Crimpabschnitt (30), der mit einer offenen Buchse (3) versehen ist, die Crimpflügel (4, 5) zum Crimpen an ein Stromkabel (2) enthält, wobei der Crimpabschnitt durch ein Crimpverfahren nach einem der Ansprüche 1 bis 11 an das Kabel gecrimpt wird, dadurch gekennzeichnet, dass nach dem Crimpen der Crimpabschnitt (30) drei aufeinanderfolgende Quetschbereiche zum Quetschen der Flügel an das Kabel aufweist, wobei zumindest einer der drei Bereiche eine verminderte Dicke gegenüber zumindest eines weiteren Bereichs aufweist, so dass das Kabel bei zumindest einem der Bereiche eine elastische Vorspannung auf die Flügel ausübt.
  13. Elektrisches Kontaktelement nach Anspruch 12, wobei zwei der drei Bereiche (4a, 4c, 5a, 5c) eine verminderte Dicke gegenüber des dritten Bereichs (4a, 5a) aufweist, so dass das Kabel bei dem dritten Bereich (4b, 5b) eine elastische Vorspannung auf die Flügel ausübt.
  14. Elektrisches Kontaktelement nach Anspruch 12, wobei einer der drei Bereiche (4b, 5b) eine verminderte Dicke gegenüber den beiden weiteren Bereichen (4a, 4c, 5a, 5c) aufweist, so dass das Kabel bei den beiden weiteren Bereichen eine elastische Vorspannung auf die Flügel ausübt.
  15. Kombination eines Stromkabels mit einem blanken Teil (12) und eines elektrischen Kontaktelements nach Anspruch 13, wobei die drei aufeinanderfolgenden Quetschbereiche an dem blanken Teil des Kabels liegen, so dass der blanke Kabelteil bei dem dritten Bereich eine elastische Vorspannung auf die Flügel ausübt.
  16. Kombination eines Stromkabels mit einem blanken Teil (12) und eines elektrischen Kontaktelements nach Anspruch 14, wobei die drei aufeinanderfolgenden Quetschbereiche an dem blanken Teil des Kabels liegen, so dass der blanke Kabelteil bei den beiden weiteren Bereichen eine elastische Vorspannung auf die Flügel ausübt.
  17. Crimpwerkzeug zum Crimpen eines elektrischen Kontakts (1) an ein Stromkabel (2), wobei der Kontakt einen Crimpabschnitt (30) mit einer Aufnahmebuchse (3) zum Aufnehmen des Stromkabels (2) enthält, wobei die Buchse einen Teilbereich aufweist, der dazu bestimmt ist, das Kabel durch Verformung einzuklemmen, dadurch gekennzeichnet, dass es einen gemeinsamen Amboss (7) zum Aufnahmen der Buchse, lösbare Stempelelemente (6a, 6b, 6c) und eine Steuerung aufweist, die dazu ausgelegt ist, die Stempelelemente separat zu steuern, um einen ersten Crimpschritt in einer ersten Crimphöhe (h1) durchzuführen, indem eine erste Fläche des Crimpabschnitts an dem Kabel (2) umgelegt wird, sowie einen zweiten Crimpschritt zum Crimpen eines begrenzten Bereichs (4a, 4b, 4c, 5a, 5b, 5c) des Crimpabschnitts in einer zweiten Crimphöhe (h2), die geringer als die erste ist, in geeigneter Art und Weise, um durch Blähwirkung des Kabels einen Teil des bereits gecrimpten Crimpabschnitts zu verformen.
  18. Crimpwerkzeug nach Anspruch 17, wobei der Crimpabschnitt einen ersten Teil (4b, 5b; 4a, 4c, 5a, 5c) und einen zweiten Teil (4a, 4c, 5a, 5c; 4b, 5b) aufweist, wobei die Steuerung dazu ausgelegt ist, den ersten Crimpschritt zumindest an dem ersten Teil (4b, 5b; 4a, 4c, 5a, 5c) des Crimpabschnitts durchzuführen und der zweite Crimpschritt an dem zweiten Teil (4a, 4c, 5a, 5c; 4b, 5b) des Crimpabschnitts erfolgt, wodurch durch Blähwirkung des Kabels der erste Teil (4b, 5b; 4a, 4c, 5a, 5c) des Crimpabschnitts verformt wird.
EP04720635.4A 2003-08-19 2004-03-15 Krimpverfahren eines elektrischen kontakts und durch dieses verfahren hergestellten kontakt Expired - Lifetime EP1658662B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR0310011A FR2859047A1 (fr) 2003-08-19 2003-08-19 Procede de sertissage de contact electrique et contact obtenu par ce procede
PCT/FR2004/000631 WO2005029653A1 (fr) 2003-08-19 2004-03-15 Procede de sertissage de contact electrique et contact obtenu par ce procede

Publications (2)

Publication Number Publication Date
EP1658662A1 EP1658662A1 (de) 2006-05-24
EP1658662B1 true EP1658662B1 (de) 2016-07-27

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EP04720635.4A Expired - Lifetime EP1658662B1 (de) 2003-08-19 2004-03-15 Krimpverfahren eines elektrischen kontakts und durch dieses verfahren hergestellten kontakt

Country Status (10)

Country Link
US (1) US20070054565A1 (de)
EP (1) EP1658662B1 (de)
JP (1) JP4413926B2 (de)
KR (2) KR20060065696A (de)
CN (1) CN100452566C (de)
BR (1) BRPI0412982A (de)
CA (1) CA2534403C (de)
FR (1) FR2859047A1 (de)
MX (1) MXPA06001829A (de)
WO (1) WO2005029653A1 (de)

Cited By (2)

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Publication number Priority date Publication date Assignee Title
DE102020105135A1 (de) 2020-02-27 2021-09-02 Komax SLE GmbH & Co. KG Vorrichtung zum Crimpen von Kabeln
EP3439111B1 (de) * 2017-08-01 2021-12-22 VM Industries Optimiertes crimpen von zwei elektrischen anschlüssen

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DE102008044064B4 (de) 2008-11-25 2016-03-24 Volkswagen Ag Crimpvorrichtung sowie ein Verfahren zur Herstellung einer Crimpverbindung
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JP5953590B2 (ja) * 2012-03-21 2016-07-20 矢崎総業株式会社 圧着端子付き電線、および圧着端子を電線に圧着する方法
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JP2015076238A (ja) * 2013-10-08 2015-04-20 矢崎総業株式会社 圧着端子及び圧着端子の加締治具
JP5714749B2 (ja) * 2014-05-15 2015-05-07 矢崎総業株式会社 端子圧着方法及び端子圧着装置
FR3033450B1 (fr) * 2015-03-06 2017-02-17 Delphi Int Operations Luxembourg Sarl Procede de sertissage d'un contact electrique sur un cable et outil pour la mise en oeuvre de ce procede
US9634419B2 (en) * 2015-05-17 2017-04-25 Manzhi Zhou Cold forming method for forming power pins and power pin formed thereof
FR3054379B1 (fr) * 2016-07-19 2020-11-20 Delphi Int Operations Luxembourg Sarl Outil de sertissage et contact obtenu avec l'outil
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JP6720929B2 (ja) * 2017-06-29 2020-07-08 住友電装株式会社 導電路及びワイヤハーネス

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Cited By (2)

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Publication number Priority date Publication date Assignee Title
EP3439111B1 (de) * 2017-08-01 2021-12-22 VM Industries Optimiertes crimpen von zwei elektrischen anschlüssen
DE102020105135A1 (de) 2020-02-27 2021-09-02 Komax SLE GmbH & Co. KG Vorrichtung zum Crimpen von Kabeln

Also Published As

Publication number Publication date
KR101273881B1 (ko) 2013-06-17
BRPI0412982A (pt) 2006-10-03
EP1658662A1 (de) 2006-05-24
US20070054565A1 (en) 2007-03-08
JP2007503083A (ja) 2007-02-15
CA2534403A1 (en) 2005-03-31
CA2534403C (en) 2013-05-07
KR20110063582A (ko) 2011-06-10
KR20060065696A (ko) 2006-06-14
CN100452566C (zh) 2009-01-14
JP4413926B2 (ja) 2010-02-10
FR2859047A1 (fr) 2005-02-25
WO2005029653A1 (fr) 2005-03-31
MXPA06001829A (es) 2006-05-31
CN1836354A (zh) 2006-09-20

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