EP1730813B1 - Method for joining a connecting element to an electric conductor made of aluminium and electric conductor produced according to said method - Google Patents

Method for joining a connecting element to an electric conductor made of aluminium and electric conductor produced according to said method Download PDF

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Publication number
EP1730813B1
EP1730813B1 EP04789548A EP04789548A EP1730813B1 EP 1730813 B1 EP1730813 B1 EP 1730813B1 EP 04789548 A EP04789548 A EP 04789548A EP 04789548 A EP04789548 A EP 04789548A EP 1730813 B1 EP1730813 B1 EP 1730813B1
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EP
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Prior art keywords
conductor
aluminium
aluminum
zinc
sleeve
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EP04789548A
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German (de)
French (fr)
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EP1730813A1 (en
Inventor
Karl Franz FRÖSCHL
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Gebauer and Griller Kabelwerke GmbH
Gebauer and Griller
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Gebauer and Griller Kabelwerke GmbH
Gebauer and Griller
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    • 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
    • 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
    • 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
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • 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
    • H01R4/58—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 characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • H01R4/625—Soldered or welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • 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
    • H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2201/00—Connectors or connections adapted for particular applications
    • H01R2201/26—Connectors or connections adapted for particular applications for vehicles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/20—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve

Definitions

  • the subject invention relates to a method for connecting a copper or copper alloy connecting element for a cable, in particular a cable lug, with an electrical cable having a conductor made of aluminum.
  • the invention further relates to a manufactured according to this method, formed with a connection element electrical conductor.
  • the present invention is therefore based on the object to provide a method by which, using the above-mentioned difficulties, an existing conductor made of aluminum with a copper or a copper alloy connecting element is permanently connected.
  • This is inventively achieved in that the connection element, which is provided on its the head of aluminum facing surfaces with a coating of nickel, with the conductor made of aluminum by means of a layer of zinc is welded.
  • the zinc present between the connection element and the conductor made of aluminum is fused to the conductor made of aluminum, in particular by means of a plasma welding process.
  • the connecting element has a sleeve which is placed on the conductor made of aluminum and the zinc is applied to the inside of the sleeve located end face of the conductor made of aluminum and fused with the conductor made of aluminum and with the connecting element.
  • the sleeve and the conductor made of aluminum can also be connected to each other by mechanical deformation of the sleeve.
  • An inventive electrical conductor made of aluminum, which is formed with at least one of copper or a copper alloy connecting element is characterized in that the connecting element is formed on the head of the aluminum facing surfaces with a coating of nickel and that further between the coating made of nickel and the aluminum conductor is a layer of zinc, wherein the layer of zinc is preferably provided on the inside of the sleeve located end face of the aluminum conductor.
  • an electrical cable 1 which consists of an electrical conductor 11, which is preferably formed by a plurality of wires made of aluminum and which is enclosed by an insulation 12.
  • a connecting element 2 is applied to the electrical conductor 11, which is formed by a sleeve 21 and by a connecting lug 22.
  • the connection element 2 is provided on the surfaces facing the electrical conductor 11 with a coating 3 made of nickel.
  • a layer 4 of zinc is applied to the end face of the electrical conductor 11, which is connected to the conductor 11 by means of a plasma welding process by a reflow process.
  • the electrical connection of the connecting element 2 made of copper with the conductor 11 made of aluminum thus takes place via the coating 3 of nickel and the layer 4 of zinc.
  • the sleeve 21 may be connected to the conductor 11 by mechanical deformation of the sleeve 21.
  • Copper has a melting point of 1085 ° C
  • nickel has a melting point of 1453 ° C
  • zinc has a melting point of 419 ° C
  • aluminum has a melting point of 660 ° C.
  • connection of the connection element 2 to the cable 1 it is relevant that the existing conductor 11 of the aluminum cable 1 with the existing copper or a copper alloy connection element 2 is not directly connected, but that between these two components two layers 3 and 4, which are made of such metals, which lie in the electrochemical voltage series between aluminum and copper, whereby the risk of decomposition of the existing aluminum conductor 11 is greatly reduced.
  • connection element 2 In addition to this combination of metal, by which an electrolytic decomposition of the connection between the conductor 11 made of aluminum and the connection element 2 is largely the method for producing this compound is essential, which consists in that between the nickel existing coating 3 of the connecting element 2 and the conductor 11 made of aluminum layer 4 made of zinc, in particular by means of a plasma welding process with a large amount of energy is applied through which the zinc and the adjacent aluminum wires are melted and form an alloy together.
  • the connection element 2 provided with the coating 3 of nickel is connected in an optimum manner to the conductor 11 made of aluminum. Since the nickel coating 3 has a very high melting point compared with the layer 4 of zinc, the contact surfaces of the nickel coating 3 are not damaged or the surface quality of the nickel coating 3 on the connection element 2 is maintained.

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

Abstract

A method for joining a connecting element, which is made of copper or a copper alloy, for a cable, particularly a cable lug, to an electric cable provided with a conductor that is made of aluminium. The connecting element, which is provided with a nickel coating on the surfaces thereof facing away from the aluminium conductor, is welded to the aluminium conductor by way of zinc.

Description

Die gegenständliche Erfindung betrifft ein Verfahren zur Verbindung eines aus Kupfer oder aus einer Kupferlegierung bestehenden Anschlusselementes für ein Kabel, insbesondere eines Kabelschuhs, mit einem elektrischen Kabel, welches einen aus Aluminium bestehenden Leiter aufweist. Die Erfindung betrifft weiters einen nach diesem Verfahren hergestellten, mit einem Anschlusselement ausgebildeten elektrischen Leiter.The subject invention relates to a method for connecting a copper or copper alloy connecting element for a cable, in particular a cable lug, with an electrical cable having a conductor made of aluminum. The invention further relates to a manufactured according to this method, formed with a connection element electrical conductor.

Es ist bekannt, elektrische Leiter, insbesondere solche, welche in Kraftfahrzeugen verwendet werden, aus Aluminium herzustellen. Die Vorteile von aus Aluminium hergestellten elektrischen Leitern bestehen darin, dass Aluminium gegenüber anderen Metallen, insbesondere Kupfer, aus welchen gleichfalls elektrische Leiter hergestellt werden, wesentlich billiger ist, dass es ein geringes Gewicht aufweist, dass es leicht verarbeitbar ist und dass es sehr korrosionsbeständig ist. Der Grund dafür allerdings, dass ungeachtet seiner besonderen Vorteile Aluminium für die Herstellung von elektrischen Leitern nicht allgemein verwendet wird, liegt darin, dass es gegenüber anderen Metallen eine wesentlich geringere Festigkeit aufweist, weswegen die Anschlusselemente, insbesondere Kabelschuhe, aus anderen Metallen, insbesondere aus Kupferlegierungen, wie Messing, hergestellt werden müssen. Dabei besteht jedoch das Erfordernis, die insbesondere aus Kupferlegierungen hergestellten Anschlusselemente mit den Leitern aus Aluminium dauerhaft zu verbinden.It is known to produce electrical conductors, especially those used in motor vehicles, from aluminum. The advantages of electrical conductors made of aluminum are that aluminum is much cheaper than other metals, especially copper, from which electrical conductors are also made, that it is lightweight, that it is easily processable and that it is very resistant to corrosion , However, the reason why aluminum is not generally used for the manufacture of electrical conductors, despite its particular advantages, is that it has a much lower strength than other metals, and therefore the connecting elements, in particular cable lugs, are made of other metals, in particular copper alloys , like brass, have to be made. However, there is a need to permanently connect the connecting elements made in particular of copper alloys with the conductors made of aluminum.

Um aus Aluminium hergestellte Leiter mit Anschlusselementen, insbesondere mit Kabelschuhen, zu verbinden, ist es bekannt, diese mittels eines elektrisch leitenden Kunststoffmaterials zu verkleben, diese miteinander zu verlöten oder zu verschweißen oder diese durch Verformung bzw. Verpressung miteinander formschlüssig zu verbinden. Dabei besteht jedoch weiters das Erfordernis zu gewährleisten, dass der aus Aluminium hergestellte Leiter mit dem aus Kupfer oder einer Kupferlegierung od.dgl. bestehenden Anschlusselement nicht in direktem Kontakt steht, da andernfalls dann, soferne an dieser Verbindung eine als Elektrolyt wirkende Flüssigkeit zur Wirkung kommt, ein elektrochemischer Prozess auftritt, durch welchen der aus Aluminium bestehende Leiter zersetzt wird, wodurch die elektrische und mechanische Verbindung zerstört wird.In order to connect conductors made of aluminum with connecting elements, in particular with cable lugs, it is known to glue them by means of an electrically conductive plastic material, to solder them together or to weld or to connect them by deformation or pressing together form-fitting. However, there is still the need to ensure that the conductor made of aluminum with the copper or a copper alloy or the like. existing connection element is not in direct contact, otherwise then, as far as at this compound acting as an electrolyte liquid acts, an electrochemical process occurs by which the existing conductor of aluminum is decomposed, whereby the electrical and mechanical connection is destroyed.

Ein Verfahren bekannter Art ist in Dokument US 2002/0162683A offenbartA method of known type is disclosed in document US 2002 / 0162683A

Der gegenständlichen Erfindung liegt somit die Aufgabe zugrunde, ein Verfahren zu schaffen, durch welches unter Verwendung der vorstehend erläuterten Schwierigkeiten ein aus Aluminium bestehender Leiter mit einem aus Kupfer oder einer Kupferlegierung bestehenden Anschlusselement in dauerhafter Weise verbunden wird. Dies wird erfindungsgemäß dadurch erzielt, dass das Anschlusselement, welches an seinen dem Leiter aus Aluminium zugewandten Flächen mit einer Beschichtung aus Nickel versehen ist, mit dem Leiter aus Aluminium mittels einer Lage aus Zink verschweißt wird.The present invention is therefore based on the object to provide a method by which, using the above-mentioned difficulties, an existing conductor made of aluminum with a copper or a copper alloy connecting element is permanently connected. This is inventively achieved in that the connection element, which is provided on its the head of aluminum facing surfaces with a coating of nickel, with the conductor made of aluminum by means of a layer of zinc is welded.

Vorzugsweise wird das zwischen dem Anschlusselement und dem Leiter aus Aluminium befindliche Zink mit dem Leiter aus Aluminium, insbesondere mittels eines Plasmaschweißverfahrens, verschmolzen. Nach einer weiters bevorzugten Ausführungsform weist das Anschlusselement eine Hülse auf, welche auf den Leiter aus Aluminium aufgesetzt wird und wird das Zink auf die innerhalb der Hülse befindliche Stirnfläche des Leiters aus Aluminium aufgebracht und mit dem Leiter aus Aluminium sowie mit dem Anschlusselement verschmolzen. Weiters können die Hülse und der Leiter aus Aluminium miteinander auch durch mechanische Verformung der Hülse verbunden werden.Preferably, the zinc present between the connection element and the conductor made of aluminum is fused to the conductor made of aluminum, in particular by means of a plasma welding process. According to a further preferred embodiment, the connecting element has a sleeve which is placed on the conductor made of aluminum and the zinc is applied to the inside of the sleeve located end face of the conductor made of aluminum and fused with the conductor made of aluminum and with the connecting element. Furthermore, the sleeve and the conductor made of aluminum can also be connected to each other by mechanical deformation of the sleeve.

Ein erfindungsgemäßer elektrischer Leiter aus Aluminium, welcher mit mindestens einem aus Kupfer oder einer Kupferlegierung bestehenden Anschlusselement ausgebildet ist, ist dadurch gekennzeichnet, dass das Anschlusselement an den dem Leiter aus Aluminium zugewandten Flächen mit einer Beschichtung aus Nickel ausgebildet ist und dass sich weiters zwischen der Beschichtung aus Nickel und dem Leiter aus Aluminium eine Lage von Zink befindet, wobei die Lage aus Zink vorzugsweise auf der innerhalb der Hülse befindlichen Stirnfläche des Leiters aus Aluminium vorgesehen ist.An inventive electrical conductor made of aluminum, which is formed with at least one of copper or a copper alloy connecting element is characterized in that the connecting element is formed on the head of the aluminum facing surfaces with a coating of nickel and that further between the coating made of nickel and the aluminum conductor is a layer of zinc, wherein the layer of zinc is preferably provided on the inside of the sleeve located end face of the aluminum conductor.

Das erfindungsgemäße Verfahren ist nachstehend anhand eines in der Zeichnung dargestellten Ausführungsbeispieles näher erläutert.

Fig.1
zeigt ein mit einem Anschlusselement ausgebildetes elektrisches Kabel, in axialem Schnitt.
The inventive method is explained below with reference to an embodiment shown in the drawing.
Fig.1
shows an electrical cable formed with a connection element, in axial section.

In Fig.1 ist ein elektrisches Kabel 1 dargestellt, welches aus einem elektrischen Leiter 11 besteht, welcher vorzugsweise durch eine Vielzahl von Drähten aus Aluminium gebildet ist und welcher von einer Isolierung 12 umschlossen ist.In Fig.1 an electrical cable 1 is shown, which consists of an electrical conductor 11, which is preferably formed by a plurality of wires made of aluminum and which is enclosed by an insulation 12.

Am abisolierten Ende des Kabels 1 ist auf den elektrischen Leiter 11 ein Anschlusselement 2 aufgebracht, welches durch eine Hülse 21 und durch eine Anschlussfahne 22 gebildet ist. Das Anschlusselement 2 ist jedenfalls an den dem elektrischen Leiter 11 zugewandten Flächen mit einer aus Nickel bestehenden Beschichtung 3, versehen.At the stripped end of the cable 1, a connecting element 2 is applied to the electrical conductor 11, which is formed by a sleeve 21 and by a connecting lug 22. In any case, the connection element 2 is provided on the surfaces facing the electrical conductor 11 with a coating 3 made of nickel.

Innerhalb der Hülse 21 ist auf die Stirnfläche des elektrischen Leiters 11 eine Lage 4 aus Zink aufgebracht, welche mit dem Leiter 11 mittels eines Plasmaschweißverfahrens durch einen Aufschmelzvorgang verbunden ist. Die elektrische Verbindung des Anschlusselementes 2 aus Kupfer mit dem Leiter 11 aus Aluminium erfolgt somit über die Beschichtung 3 aus Nickel und die Lage 4 aus Zink. Zudem kann die Hülse 21 mit dem Leiter 11 durch mechanische Verformung der Hülse 21 verbunden sein.Within the sleeve 21, a layer 4 of zinc is applied to the end face of the electrical conductor 11, which is connected to the conductor 11 by means of a plasma welding process by a reflow process. The electrical connection of the connecting element 2 made of copper with the conductor 11 made of aluminum thus takes place via the coating 3 of nickel and the layer 4 of zinc. In addition, the sleeve 21 may be connected to the conductor 11 by mechanical deformation of the sleeve 21.

Kupfer weist einen Schmelzpunkt von 1.085°C auf, Nickel weist einen Schmelzpunkt von 1.453°C auf, Zink weist einen Schmelzpunkt von 419°C auf und Aluminium weist einen Schmelzpunkt von 660°C auf.Copper has a melting point of 1085 ° C, nickel has a melting point of 1453 ° C, zinc has a melting point of 419 ° C and aluminum has a melting point of 660 ° C.

Bei dieser Ausbildung der Verbindung des Anschlusselementes 2 mit dem Kabel 1 ist es maßgeblich, dass der aus Aluminium bestehende Leiter 11 des Kabels 1 mit dem aus Kupfer oder einer Kupferlegierung bestehenden Anschlusselement 2 nicht unmittelbar verbunden ist, sondern dass sich zwischen diesen beiden Bauteilen zwei Lagen 3 und 4 befinden, welche aus solchen Metallen bestehen, welche in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer liegen, wodurch die Gefahr einer Zersetzung des aus Aluminium bestehenden Leiters 11 sehr stark verringert wird.In this embodiment, the connection of the connection element 2 to the cable 1, it is relevant that the existing conductor 11 of the aluminum cable 1 with the existing copper or a copper alloy connection element 2 is not directly connected, but that between these two components two layers 3 and 4, which are made of such metals, which lie in the electrochemical voltage series between aluminum and copper, whereby the risk of decomposition of the existing aluminum conductor 11 is greatly reduced.

Maßgeblich für diesen Effekt ist es, dass Aluminium ein Normpotential von -1.676 Volt und Kupfer ein Normpotential von zumindest 0.337 Volt, jeweils gemessen gegen eine Wasserstoff-Normalelektrode, aufweisen. Die zwischen diesen beiden Metallen bestehende Potentialfrequenz verursacht bei Vorhandensein eines Elektrolyten eine Zersetzung des Aluminiums. Sofern sich jedoch zwischen diesen beiden Metallen mindestens ein solches Metall befindet, dessen Normpotential zwischen demjenigen von Aluminium und Kupfer liegt, tritt eine Verminderung der jeweils zwischen den Metallen auftretenden Potentialdifferenzen auf, wodurch die Gefahr einer elektrochemischen Zersetzung stark herabgesetzt wird.Decisive for this effect is that aluminum has a standard potential of -1.676 volts and copper a standard potential of at least 0.337 volts, each measured against a hydrogen normal electrode. The potential frequency existing between these two metals causes a decomposition of the aluminum in the presence of an electrolyte. However, if there is at least one metal between these two metals whose standard potential is between that of aluminum and copper, a reduction in the potential differences occurring between the metals occurs, which greatly reduces the risk of electrochemical decomposition.

Neben dieser Kombination von Metall, durch welche ein elektrolytisches Zersetzen der Verbindung zwischen dem Leiter 11 aus Aluminium und dem Anschlusselement 2 weitgehend vermieden wird, ist auch das Verfahren zur Herstellung dieser Verbindung wesentlich, welches darin besteht, dass die zwischen der aus Nickel bestehenden Beschichtung 3 des Anschlusselementes 2 und dem Leiter 11 aus Aluminium befindliche Lage 4 aus Zink, insbesondere mittels eines Plasmaschweißverfahrens, mit einer großen Energiemenge beaufschlagt wird, durch welche das Zink und die anliegenden Drähte aus Aluminium geschmolzen werden und miteinander eine Legierung bilden. Hierdurch wird das mit der Beschichtung 3 aus Nickel versehene Anschlusselement 2 mit dem Leiter 11 aus Aluminium in optimaler Weise verbunden. Da die Beschichtung 3 aus Nickel einen gegenüber der Lage 4 aus Zink sehr hohen Schmelzpunkt aufweist, werden die Kontaktflächen der Beschichtung 3 aus Nickel nicht geschädigt bzw. bleibt die Oberflächengüte der Beschichtung 3 aus Nickel am Anschlusselement 2 erhalten.In addition to this combination of metal, by which an electrolytic decomposition of the connection between the conductor 11 made of aluminum and the connection element 2 is largely the method for producing this compound is essential, which consists in that between the nickel existing coating 3 of the connecting element 2 and the conductor 11 made of aluminum layer 4 made of zinc, in particular by means of a plasma welding process with a large amount of energy is applied through which the zinc and the adjacent aluminum wires are melted and form an alloy together. As a result, the connection element 2 provided with the coating 3 of nickel is connected in an optimum manner to the conductor 11 made of aluminum. Since the nickel coating 3 has a very high melting point compared with the layer 4 of zinc, the contact surfaces of the nickel coating 3 are not damaged or the surface quality of the nickel coating 3 on the connection element 2 is maintained.

Durch die erläuterte Kombination aus Metallen und das erläuterte Verfahren durch Verschweißung zur Verbindung des Anschlusselementes 2 aus Kupfer bzw. aus einer Kupferlegierung mit dem Leiter 11 aus Aluminium wird eine so hohe Korrosionsbeständigkeit dieser Verbindung gewährleistet, dass auf Maßnahmen zu deren Abdichtung, z.B. durch Aufbringung von Fetten, verzichtet werden kann.By the illustrated combination of metals and the method described by welding to connect the connecting element 2 made of copper or a copper alloy with the conductor 11 made of aluminum so high corrosion resistance of this compound is ensured that measures for their sealing, e.g. by applying fats, can be dispensed with.

Claims (6)

  1. A method of connecting a terminal element (2) for a cable (1), in particular a cable lug, consisting of copper or a copper alloy, to an electrical cable (1) comprising a conductor (11) consisting of aluminium, the terminal element (2) being provided with a nickel coating (3) on its surfaces facing the aluminium conductor (11), characterised in that the terminal element (2) is welded together with the aluminium conductor (11) by means of a layer (4) of zinc.
  2. A method according to claim 1, characterised in that the zinc (4) located between the terminal element (2) and the aluminium conductor (11) is fused with the aluminium conductor (11), in particular by means of a plasma arc welding method.
  3. A method according to one of claims 1 and 2, characterised in that the terminal element (2) comprises a sleeve (21), which is positioned on the aluminium conductor (11), and in that the zinc (4) is applied to the end face of the aluminium conductor (11) located inside the sleeve (21) and is fused together with the aluminium conductor (11) and with the terminal element (2).
  4. A method according to claim 3, characterised in that the sleeve (21) and the aluminium conductor (11) may also be connected together by mechanical deformation of the sleeve (21).
  5. An electrical conductor of aluminium, which is provided with at least one terminal element (1) consisting of copper or a copper alloy and which is produced by the method according to claims 1 to 4, characterised in that the terminal element (2) is provided with a coating (3) of nickel on the surfaces facing the aluminium conductor (11) and in that in addition a layer (4) of zinc is located between the nickel coating (3) and the aluminium conductor (11).
  6. An electrical conductor according to claim 5, characterised in that the terminal element (2) is provided with a sleeve (21), which surrounds the aluminium conductor (11), characterised in that a layer (4) of zinc is located on the end face of the aluminium conductor (11) located inside the sleeve (21).
EP04789548A 2004-03-23 2004-10-21 Method for joining a connecting element to an electric conductor made of aluminium and electric conductor produced according to said method Active EP1730813B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AT5072004 2004-03-23
PCT/AT2004/000358 WO2005091439A1 (en) 2004-03-23 2004-10-21 Method for joining a connecting element to an electric conductor made of aluminium and electric conductor produced according to said method

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Also Published As

Publication number Publication date
KR20060129364A (en) 2006-12-15
JP2007531208A (en) 2007-11-01
ATE362203T1 (en) 2007-06-15
ES2282910T3 (en) 2007-10-16
US20060292922A1 (en) 2006-12-28
DE502004003811D1 (en) 2007-06-21
WO2005091439A1 (en) 2005-09-29
EP1730813A1 (en) 2006-12-13

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