EP1759439A1 - Electrical contact connection and method for creating one such contact connection - Google Patents

Electrical contact connection and method for creating one such contact connection

Info

Publication number
EP1759439A1
EP1759439A1 EP05744312A EP05744312A EP1759439A1 EP 1759439 A1 EP1759439 A1 EP 1759439A1 EP 05744312 A EP05744312 A EP 05744312A EP 05744312 A EP05744312 A EP 05744312A EP 1759439 A1 EP1759439 A1 EP 1759439A1
Authority
EP
European Patent Office
Prior art keywords
conductor
contact
connection
sprayed
electrical
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
EP05744312A
Other languages
German (de)
French (fr)
Other versions
EP1759439B1 (en
Inventor
Gerhard Reichinger
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.)
Leoni AG
Original Assignee
Leoni AG
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 Leoni AG filed Critical Leoni AG
Publication of EP1759439A1 publication Critical patent/EP1759439A1/en
Application granted granted Critical
Publication of EP1759439B1 publication Critical patent/EP1759439B1/en
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—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
    • 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
    • H01R9/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, e.g. terminal strips or terminal blocks; Terminals or binding posts mounted upon a base or in a case; Bases therefor
    • H01R9/03—Connectors arranged to contact a plurality of the conductors of a multiconductor cable, e.g. tapping 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
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H01R11/28—End pieces consisting of a ferrule or sleeve
    • H01R11/281—End pieces consisting of a ferrule or sleeve for connections to batteries
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49174—Assembling terminal to elongated conductor
    • Y10T29/49179—Assembling terminal to elongated conductor by metal fusion bonding
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49204—Contact or terminal manufacturing
    • Y10T29/49208—Contact or terminal manufacturing by assembling plural parts
    • Y10T29/4921—Contact or terminal manufacturing by assembling plural parts with bonding
    • Y10T29/49211—Contact or terminal manufacturing by assembling plural parts with bonding of fused material
    • Y10T29/49213—Metal

Definitions

  • the invention relates to an electrical contact connection between an electrical conductor made of a soft material, in particular an aluminum conductor, and a contact element.
  • the invention further relates to a method for forming such a contact connection.
  • the present invention has for its object to provide a secure electrical contact connection between a soft, prone to cold flow material and another contact element.
  • an electrical contact connection with the features of claim 1.
  • an electrical conductor made of a soft, prone to cold flow material in its contact region at least partially by means of a spraying method with a compared to the soft material of the conductor harder, electrically conductive material is encapsulated.
  • the spraying of a harder material onto the electrical conductor has the decisive advantage that an intimate and pressure-free connection between the soft material of the conductor and the harder sprayed-on material is formed by the injection method.
  • a thermal spraying process such as hot gas spraying or, preferably, flame spraying
  • the material may also be conveyed via a cold process, e.g. be applied with the so-called cold gas spraying.
  • the particles to be scrubbed are not melted or fused.
  • the electrical conductor used is preferably an aluminum conductor, in particular consisting of a plurality of individual conductors or strands.
  • Soft material is to be understood here in particular as conducting materials from the elements of the third row of the Periodic Table, in particular aluminum, aluminum alloys or magnesium alloys.
  • Hard material is understood to mean, in particular, conductive materials of elements of the fourth row of the periodic table, for example copper, nickel, iron, chromium and alloys for this purpose, in particular chromium-nickel alloys.
  • the conductor in the contact region is completely surrounded by a jacket of the type of a tube made of the harder material.
  • the tube is in this case designed in particular as a hard metal tube and has a high inherent rigidity and dimensional stability, so that it has a high mechanical resistance.
  • the tube is formed of a nickel-chromium-nickel alloy, which has particularly good electrical and mechanical properties.
  • the contact connection between the sprayed material and the contact element via a mechanical pressure or clamping connection.
  • the contact connection is formed in particular via a clamping or crimp contact. Since there is the connection between two hard materials, there is little or no risk of cold flow, so that even with a pressure-sensitive mechanical connection a permanently secure electrical contact is ensured. In particular, in connection with the dimensionally stable and intrinsically stiff designed in the manner of a tube jacket secure contact is guaranteed.
  • the conductor has, at its end, an enlarged contact cross-sectional area, compared to the conductor cross-sectional area, onto which the conductive material is sprayed.
  • the conductor is preferably bevelled end side.
  • the front end of the conductor is therefore encapsulated with the conductive material, which preferably forms a kind of end cap.
  • the contact cross-sectional area increases the effective contact area, that is, the area where actual contact between the sprayed material and the soft material is present, for example, 100% of the normal conductor cross-sectional area -Querterrorisms Construction is understood here as the cross-sectional area, which is formed by a vertical section to the conductor longitudinal propagation.
  • the enlargement of the contact cross-sectional area by the chamfer is particularly advantageous in the case of a conductor with a large cross-sectional area and / or a conductor consisting of several stranded wires.
  • the increase in the contact cross-sectional area is in principle also advantageous for other types of contacting, for example when contacting with a conductive adhesive, when contacting with an elastic, conductive material which is pressed against the conductor or in the case of soldered connections.
  • the conductor is an aluminum battery cable, especially for a motor vehicle, and the contact element is a battery terminal.
  • ladders made of aluminum are increasingly used for the purpose of saving weight.
  • the battery cable which has a very large cross section due to the high currents and therefore has a very high weight when using, for example, copper, a relatively high weight saving is made possible by the use of an aluminum cable.
  • the electrical contact connection described here between such an aluminum battery cable and the battery terminal ensures a secure and permanent connection of the aluminum cable to the battery.
  • the particular thermal spraying method is expediently selected in this case and the spraying parameters are adjusted such that the conductive material at least partially penetrates into the conductor and at least partially penetrates an oxide layer possibly present on the conductor surface.
  • the spraying parameters are adjusted such that the conductive material at least partially penetrates into the conductor and at least partially penetrates an oxide layer possibly present on the conductor surface.
  • the conductive material at least partially penetrates into the conductor and at least partially penetrates an oxide layer possibly present on the conductor surface.
  • the spraying parameters are adjusted such that the conductive material at least partially penetrates into the conductor and at least partially penetrates an oxide layer possibly present on the conductor surface.
  • the spraying parameters are adjusted such that the conductive material at least partially penetrates into the conductor and at least partially penetrates an oxide layer possibly present on the conductor surface.
  • the conductor is overmolded with the conductive material and at the same time the electrical contact connection between the conductive material and the contact element is formed.
  • the formation of the electrical contact connection is therefore in a one-step process only by the spraying of the conductive material, which at least partially covers the conductor and the contact element at the same time.
  • a two-stage procedure wherein in a first step, the conductive material is sprayed onto the contact region of the conductor and in a second step, the contact with the contact element is made in particular by a mechanical clamping or pressure connection.
  • the contact region of the formed in particular as a hard metal tube sheath of the conductive material.
  • Fig. 1 is an end-chamfered conductor made of soft material with a sprayed-on end cap in a perspective side view
  • Fig. 2 is a sectional view through a trained as a battery terminal s .
  • Contact terminal with an incoming conductor and Fig. 3 is formed in a one-step injection molding contact connection between a contact element and a conductor.
  • FIG. 1 the stripped end of a conductor 2 designed in particular as an aluminum conductor is shown.
  • the conductor 2 has a plurality of individual conductors 4 designed in particular as stranded wires.
  • the conductor 2 is for example a battery cable, which is intended for use in a motor vehicle.
  • the conductor 2 is surrounded in a contact region 6 by a jacket 8A fashioned in the manner of an end cap, from a material which is harder than aluminum.
  • the jacket 8A is applied by means of a thermal spraying method, for example hot gas spraying or so-called flame spraying.
  • a thermal spraying method for example hot gas spraying or so-called flame spraying.
  • the material for the jacket 8A in particular, a nickel-chromium-nickel alloy is selected.
  • the jacket 8A is formed by multiple over-molding with a sufficiently high wall thickness such that the jacket 8A has a high overall rigidity and thus dimensional stability.
  • the jacket 8A is therefore formed in the manner of a stiff tube.
  • the conductor 2 is obliquely cut at the end, so that in the frontal region a flat, approximately elliptical contact cross-sectional area 10 is formed. This has in comparison to the normal, in the case of a circular conductor circular conductor cross-sectional area 12 an enlarged area.
  • the angle a between a conductor longitudinal axis 14 and the slope 16 is a maximum of about 60 °, as shown in Fig. 1.
  • the conductor 2 shown in FIG. 1 is inserted in a terminal formed as a battery terminal 18.
  • the terminal is a contact element for contacting the conductor 2.
  • the battery terminal 18 has two clamping halves 20A 1 B, between which the conductor 2 with the jacket 8A rests. To form the contact connection, the two clamping halves 20A 1 B are braced against each other here by screws, not shown in detail, which engage in screw receptacles 22, so that the conductor 2 is mechanically clamped in the battery terminal 18.
  • the electrical contact connection is in this case indirectly via the jacket 8A, which surrounds the individual individual conductors 4 full circumference.
  • this is preferably designed such that even with a terminal in the battery terminal 18, the contacted via the jacket 8A individual conductors 4 are substantially free of pressure.
  • the electrical contact connection is designed such that the individual conductors 4 are first placed on a contact element 24 designed in the manner of a shell and that they are then over-molded with the harder material.
  • a single conductor 4 partially enclosing jacket 8B is formed, which with its flanks 26 at the same time with the surface of the contact element 24 in particular cohesive Connection is received. The individual conductors 4 are therefore enclosed between the contact element 24 and the jacket 8B.
  • the contact element 24 is formed here, for example, in the manner of a crimp sleeve, which is additionally, ie subsequently after the spraying of the jacket 8B, still deformed in order to achieve a mechanical attachment of the jacket 8B.
  • a mechanical fastening element is provided for additional mechanical fastening, which braces the jacket 8B against the contact element 24.
  • This fastener is for example a screw which is screwed into an associated, threaded screw hole in the bottom of the contact element 24.
  • the individual conductors 4 in this case would run around the centrally arranged screw.
  • the contact elements 24 are formed such that they can be arranged one above the other and stacked, so that there are several connection levels.
  • a first contact element 24 is plugged or screwed with a bottom-side opening on the mentioned sleeve of another contact element.
  • the total height of the contact element 24 with the individual conductors 4 and the jacket 8B does not exceed a predefined maximum overall height in order to be able to insert the contact element with the contacted individual conductors into a predefined flat sleeve, for example.
  • the maximum total height is determined, for example, by the height of the trough-like contact element 24 seen in cross-section.

Landscapes

  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Coupling Device And Connection With Printed Circuit (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Connection Of Batteries Or Terminals (AREA)
  • Multi-Conductor Connections (AREA)

Abstract

In order to make it possible to produce a secure and permanent contact connection between an electrical conductor made from a soft material, in particular an aluminum conductor, and a contact element made from a harder material, the conductor is encapsulated at least partially in a contact region by an electrically conductive material. The electrically conductive material is harder than the soft material of the conductor. The electrically conductive material is applied with the aid of a thermal spraying process, with the result that there is a pressure-free electrical connection between the soft material and the sprayed-on material. Electrical contact is made with the contact element indirectly via the sprayed-on material. The thermal encapsulation by the spraying in the contact region makes it possible for a reliable electrical contact to be made even in the case of soft materials having a tendency towards cold flow.

Description

Beschreibung description
Elektrische Kontaktverbindung und Verfahren zum Ausbilden einer solchen KontaktverbindungElectrical contact connection and method for forming such a contact connection
Die Erfindung betrifft eine elektrische Kontaktverbindung zwischen einem elektrischen Leiter aus einem weichen Material, insbesondere ein Aluminiumleiter, und einem Kontaktelement. Die Erfindung betrifft weiterhin ein Verfahren zum Ausbilden einer solchen Kontaktverbindung.The invention relates to an electrical contact connection between an electrical conductor made of a soft material, in particular an aluminum conductor, and a contact element. The invention further relates to a method for forming such a contact connection.
Bei einer elektrischen Kontaktverbindung zwischen einem weichen Material, wie beispielsweise Aluminium, Magnesium oder Legierungen hiervon, mit einem härteren Material besteht das Problem, dass das weiche Material bei einer Druckbeanspruchung im Laufe der Zeit dem Druck ausweicht, so dass die elektrische Kontaktverbindung geschwächt wird und es zu Kontaktproblemen kommen kann. Diese Eigenschaft der weichen Materialien, bei einer Druckeinwirkung nachzugeben, wird allgemein als Materialfließen oder Kaltfließen bezeichnet.In an electrical contact connection between a soft material, such as aluminum, magnesium or alloys thereof, with a harder material, the problem is that the soft material evades the pressure under pressure over time, so that the electrical contact connection is weakened and it can come to contact problems. This property of soft materials to yield under pressure is commonly referred to as material flow or cold flow.
Aufgrund dieses Kaltfließens bestehen erhebliche Probleme, langzeitstabile, sichere Kontaktverbindungen zwischen einem weichen und einem harten Material zu gewährleisten.Due to this cold flow, there are considerable problems to ensure long-term stable, secure contact connections between a soft and a hard material.
Der vorliegenden Erfindung liegt die Aufgabe zugrunde, eine sichere elektrische Kontaktverbindung zwischen einem weichen, zum Kaltfluss neigenden Material und einem weiteren Kontaktelement zu ermöglichen.The present invention has for its object to provide a secure electrical contact connection between a soft, prone to cold flow material and another contact element.
Die Aufgabe wird erfindungsgemäß gelöst durch eine elektrische Kontaktverbindung mit den Merkmalen des Patentanspruchs 1. Danach ist vorgesehen, dass ein elektrischer Leiter aus einem weichen, zum Kaltfluss neigenden Material in seinem Kontaktbereich zumindest teilweise mit Hilfe eines Spritzverfahrens mit einem im Vergleich zum weichen Material des Leiters härteren, elektrisch leitfähigen Materials umspritzt ist. Die elektrische Kontaktierung zu einem Kontaktelement erfolgt über das aufgespritzte Material. Das Aufspritzen eines härteren Materials auf den elektrischen Leiter hat den entscheidenden Vorteil, dass durch das Spritzverfahren eine innige und druckfreie Verbindung zwischen dem weichen Material des Leiters und dem härteren aufgespritzten Material ausgebildet wird. Durch das Spritzverfahren lagern sich zumindest einige der aufgespritzten harten Partikel im oberflächennahen Bereich im oder auf dem weichen Material ab, so dass eine stoffschlüssige und damit dauerhafte Verbindung zwischen dem weichen und dem harten Material ausgebildet ist. Die elektrische Verbindung zum Kontaktelement erfolgt über das aufgespritzte harte Material, so dass hier eine Hart-Hartverbindung zwischen zwei nicht oder nur wenig zum Kaltfluss neigenden Materialien vorliegt. Die elektrische Kontaktierung des Leiters mit dem Kontaktelement erfolgt daher lediglich mittelbar über das aufgespritzte Material.The object is achieved by an electrical contact connection with the features of claim 1. Thereafter, it is provided that an electrical conductor made of a soft, prone to cold flow material in its contact region at least partially by means of a spraying method with a compared to the soft material of the conductor harder, electrically conductive material is encapsulated. The electrical contact with a contact element via the sprayed material. The spraying of a harder material onto the electrical conductor has the decisive advantage that an intimate and pressure-free connection between the soft material of the conductor and the harder sprayed-on material is formed by the injection method. By spraying, at least some of the sprayed hard particles deposited in the near-surface region in or on the soft material, so that a cohesive and thus permanent connection between the soft and the hard material is formed. The electrical connection to the contact element via the sprayed hard material, so that there is a Hart-Hartverbindung between two not or only slightly prone to cold flow materials. The electrical contacting of the conductor with the contact element therefore takes place only indirectly via the sprayed-on material.
Als Spritzverfahren bietet sich insbesondere ein thermisches Spritzverfahren, wie das Heißgasspritzen oder vorzugsweise das Flammspritzen an. Alternativ hierzu kann das Material auch über ein kaltes Verfahren, z.B. mit dem sogenannten Kaltgasspritzen, aufgebracht werden. Bei diesem werden im Unterschied zu den thermischen Spritzverfahren die aufzupritzenden Partikel nicht auf- oder angeschmolzen. Für die angestrebte innige Verbindung und gute Haftung zwischen dem weichen Material und dem aufgespritzten Material ist entscheidend, dass durch thermische und/oder kinetische Energie der aufgespritzten Partikel diese im Weichmaterial dauerhaft verankert werden.In particular, a thermal spraying process, such as hot gas spraying or, preferably, flame spraying, is suitable as the spraying process. Alternatively, the material may also be conveyed via a cold process, e.g. be applied with the so-called cold gas spraying. In contrast to the thermal spraying process, the particles to be scrubbed are not melted or fused. For the desired intimate connection and good adhesion between the soft material and the sprayed-on material, it is crucial that thermal and / or kinetic energy of the sprayed-on particles permanently anchor them in the soft material.
Als elektrischer Leiter wird vorzugsweise ein Aluminiumleiter, insbesondere bestehend aus mehreren Einzelleitern oder Litzen, verwendet. Unter weichem Material werden hierbei insbesondere leitende Materialien aus den Elementen der dritten Reihe des Periodensystems verstanden, insbesondere Aluminium, Aluminiumlegierungen oder Magnesiumlegierungen. Unter hartem Material werden insbesondere leitende Materialien aus Elementen der vierten Reihe des Periodensystems verstanden, beispielsweise Kupfer, Nickel, Eisen, Chrom und Legierungen hierzu, insbesondere Chrom-Nickel-Legierungen. Gemäß einer zweckdienlichen Ausgestaltung ist der Leiter im Kontaktbereich voll umfänglich von einem nach Art einer Röhre ausgebildeten Mantel aus dem härteren Material umgeben. Die Röhre ist hierbei insbesondere als Hartmetallröhre ausgebildet und weist eine hohe Eigensteifigkeit und Formstabilität auf, so dass sie eine hohe mechanische Widerstandskraft hat. Zweckdienlicherweise ist hierbei die Röhre aus einer Nickel-Chrom-Nickel-Legierung gebildet, welche besonders gute elektrische und mechanische Eigenschaften aufweist.The electrical conductor used is preferably an aluminum conductor, in particular consisting of a plurality of individual conductors or strands. Soft material is to be understood here in particular as conducting materials from the elements of the third row of the Periodic Table, in particular aluminum, aluminum alloys or magnesium alloys. Hard material is understood to mean, in particular, conductive materials of elements of the fourth row of the periodic table, for example copper, nickel, iron, chromium and alloys for this purpose, in particular chromium-nickel alloys. According to an expedient embodiment, the conductor in the contact region is completely surrounded by a jacket of the type of a tube made of the harder material. The tube is in this case designed in particular as a hard metal tube and has a high inherent rigidity and dimensional stability, so that it has a high mechanical resistance. Conveniently, in this case, the tube is formed of a nickel-chromium-nickel alloy, which has particularly good electrical and mechanical properties.
Zweckdienlicherweise erfolgt die Kontaktverbindung zwischen dem aufgespritzten Material und dem Kontaktelement über eine mechanische Druck- oder Klemmverbindung. Die Kontaktverbindung wird dabei insbesondere über einen Klemm¬ oder Crimpkontakt ausgebildet. Da hier die Verbindung zwischen zwei harten Materialien erfolgt, besteht keine oder nur eine geringe Gefahr des Kaltfließens, so dass selbst bei einer druckbehafteten mechanischen Verbindung eine dauerhaft sichere elektrische Kontaktierung gewährleistet ist. Insbesondere in Verbindung mit dem formstabilen und eigensteifen nach Art einer Röhre ausgebildeten Mantel ist eine sichere Kontaktierung gewährleistet.Conveniently, the contact connection between the sprayed material and the contact element via a mechanical pressure or clamping connection. The contact connection is formed in particular via a clamping or crimp contact. Since there is the connection between two hard materials, there is little or no risk of cold flow, so that even with a pressure-sensitive mechanical connection a permanently secure electrical contact is ensured. In particular, in connection with the dimensionally stable and intrinsically stiff designed in the manner of a tube jacket secure contact is guaranteed.
Zweckdienlicherweise weist der Leiter endseitig eine im Vergleich zur Leiter- Querschnittsfläche vergrößerte Kontakt-Querschnittsfläche auf, auf die das leitfähige Material aufgespritzt ist. Der Leiter ist hierzu endseitig bevorzugt abgeschrägt. Die Stirnendseite des Leiters wird daher mit dem leitfähigen Material umspritzt, welches vorzugsweise eine Art Stirnkappe ausbildet. Durch die Vergrößerung der Kontakt- Querschnittsfläche im Vergleich zu der normalen Querschnittsfläche wird eine möglichst große effektive Kontaktfläche für den Stromtransport erzielt.Conveniently, the conductor has, at its end, an enlarged contact cross-sectional area, compared to the conductor cross-sectional area, onto which the conductive material is sprayed. The conductor is preferably bevelled end side. The front end of the conductor is therefore encapsulated with the conductive material, which preferably forms a kind of end cap. By increasing the contact cross-sectional area compared to the normal cross-sectional area, the largest possible effective contact area for the current transport is achieved.
Dies ist insbesondere in Gleichstrom-Anwendungen oder in Anwendungen mit Wechselstrom mit niedriger Frequenz von besonderem Vorteil, da in diesen Fällen der so genannte Skin-Effekt nicht oder nur kaum auftritt und ein Stromtransport über die gesamte Leiter-Querschnittsfläche erfolgt. Eine Kontaktverbindung, die nicht die gesamte Querschnittsfläche des Leiters mit einbezieht würde zu einem sehr hohen Kontaktwiderstand führen. Im Unterschied hierzu erfolgt der Stromtransport insbesondere bei hochfrequenten Wechselströmen nur im oberflächennahen Außenbereich, der „Außenhaut" (Skin) des Leiters, so dass der Leiterkern zum Stromtransport nicht beiträgt. Da beim Aufspritzen des Materials nicht zwangsläufig eine 100%ige flächige Verbindung zwischen dem weichen Material und dem aufgespritzten harten Material ausgebildet wird, wird durch die Vergrößerung der Kontakt-Querschnittsfläche die effektive Kontaktfläche, also die Fläche, bei der ein tatsächlicher Kontakt zwischen dem aufgespritzten Material und dem weichen Material vorliegt, erhöht und beträgt beispielsweise 100% der normalen Leiter- Querschnittsfläche. Damit ist der Kontaktwiderstand möglichst gering gehalten. Unter normaler Leiter-Querschnittsfläche wird hierbei die Querschnittsfläche verstanden, die gebildet ist durch einen senkrechten Schnitt zur Leiter-Längsausbreitung.This is particularly advantageous in DC applications or in applications with alternating current at low frequency, since in these cases the so-called skin effect does not occur or hardly occurs and a current is transported over the entire conductor cross-sectional area. A contact connection that does not involve the entire cross-sectional area of the conductor would result in a very high contact resistance. In contrast to this, current transport takes place only near the surface, especially in the case of high-frequency alternating currents Outside, the "skin" of the ladder, so that the ladder core does not contribute to the flow of electricity.As the spraying of the material does not necessarily form a 100% areal connection between the soft material and the sprayed hard material, the enlargement The contact cross-sectional area increases the effective contact area, that is, the area where actual contact between the sprayed material and the soft material is present, for example, 100% of the normal conductor cross-sectional area -Querschnittsfläche is understood here as the cross-sectional area, which is formed by a vertical section to the conductor longitudinal propagation.
Die Vergrößerung der Kontakt-Querschnittsfläche durch die Anschrägung ist insbesondere bei einem Leiter mit einer großen Querschnittsfläche und/oder einem aus mehreren Litzendrähten bestehenden Leiter von besonderem Vorteil.The enlargement of the contact cross-sectional area by the chamfer is particularly advantageous in the case of a conductor with a large cross-sectional area and / or a conductor consisting of several stranded wires.
Die Erhöhung der Kontakt-Querschnittsfläche ist prinzipiell auch bei anderen Kontaktierungsarten von Vorteil, beispielsweise bei einer Kontaktierung mit einem Leitkleber, bei einer Kontaktierung mit einem elastischen, leitfähigen Material, das gegen den Leiter gepresst wird oder bei Lötverbindungen.The increase in the contact cross-sectional area is in principle also advantageous for other types of contacting, for example when contacting with a conductive adhesive, when contacting with an elastic, conductive material which is pressed against the conductor or in the case of soldered connections.
Zweckdienlicherweise ist der Leiter ein Aluminium-Batteriekabel, insbesondere für ein Kraftfahrzeug, und das Kontaktelement ist eine Batterieklemme. Im Kraftfahrzeugbereich werden nämlich zum Zwecke der Gewichtseinsparung zunehmend Leiter aus Aluminium eingesetzt. Insbesondere beim Batteriekabel, welches aufgrund der hohen Ströme einen sehr großen Querschnitt aufweist und daher bei der Verwendung beispielsweise von Kupfer ein sehr hohes Gewicht hat, ist durch die Verwendung eines Aluminiumkabels eine relativ hohe Gewichtseinsparung ermöglicht. Durch die hier beschriebene elektrische Kontaktverbindung zwischen einem solchen Aluminium-Batteriekabel und der Batterieklemme ist ein sicherer und dauerhafter Anschluss des Aluminiumkabels an die Batterie gewährleistet.Conveniently, the conductor is an aluminum battery cable, especially for a motor vehicle, and the contact element is a battery terminal. In the field of motor vehicles, ladders made of aluminum are increasingly used for the purpose of saving weight. In particular, the battery cable, which has a very large cross section due to the high currents and therefore has a very high weight when using, for example, copper, a relatively high weight saving is made possible by the use of an aluminum cable. The electrical contact connection described here between such an aluminum battery cable and the battery terminal ensures a secure and permanent connection of the aluminum cable to the battery.
Die Aufgabe wird gemäß der Erfindung weiterhin gelöst durch ein Verfahren mit den Merkmalen des Patentanspruchs 8. Die im Hinblick auf die elektrische Kontaktverbindung angeführten bevorzugten Weiterbildungen sowie Vorteile sind sinngemäß auch auf das Verfahren zu übertragen.The object is further achieved according to the invention by a method having the features of claim 8. The in terms of electrical Contact compound cited preferred developments and advantages are to be transferred analogously to the process.
Zweckdienlicherweise ist das insbesondere thermische Spritzverfahren hierbei derart „ gewählt und sind die Spritzparameter derart eingestellt, dass das leitfähige Material in den Leiter zumindest teilweise eindringt und eine eventuell auf der Leiteroberfläche vorhandene Oxidschicht zumindest teilweise durchdringt. Insbesondere bei der Kontaktierung eines Aluminiumleiters besteht nämlich generell das Problem, dass dieser eine isolierende Oxidhaut aufweist, die bei einer normalen Klemmverbindung zu einem sehr hohen Kontaktwiderstand führen würde. Durch das Eindringen in den Leiter und der damit verbundenen stofflichen Verbindung zwischen dem weichen und dem harten Material beeinflusst die Aluminium-Oxidschicht den Kontaktwiderstand nicht oder nur kaum. Unter stofflicher Verbindung wird hierbei die Einlagerung von hartem Material in das weiche Material des Leiters verstanden, so dass die harten Partikel vom weichen Material teilweise umschlossen sind.The particular thermal spraying method is expediently selected in this case and the spraying parameters are adjusted such that the conductive material at least partially penetrates into the conductor and at least partially penetrates an oxide layer possibly present on the conductor surface. In particular, when contacting an aluminum conductor, there is generally the problem that it has an insulating oxide skin, which would lead to a very high contact resistance in a normal clamping connection. Due to the penetration into the conductor and the associated material connection between the soft and the hard material, the aluminum oxide layer does not or hardly influences the contact resistance. Under material connection in this case the incorporation of hard material in the soft material of the conductor is understood, so that the hard particles are partially enclosed by the soft material.
Zweckdienlicherweise wird zur Ausbildung der elektrischen Kontaktverbindung der Leiter mit dem leitfähigen Material umspritzt und zugleich wird die elektrische Kontaktverbindung zwischen dem leitfähigen Material und dem Kontaktelement ausgebildet. Die Ausbildung der elektrischen Kontaktverbindung erfolgt daher in einem einstufigen Vorgang lediglich durch das Aufspritzen des leitfähigen Materials, welches zugleich den Leiter als auch das Kontaktelement zumindest teilweise überdeckt.Conveniently, to form the electrical contact connection, the conductor is overmolded with the conductive material and at the same time the electrical contact connection between the conductive material and the contact element is formed. The formation of the electrical contact connection is therefore in a one-step process only by the spraying of the conductive material, which at least partially covers the conductor and the contact element at the same time.
Alternativ hierzu ist gemäß einer bevorzugten Ausgestaltung ein zweistufiges Vorgehen vorgesehen, wobei in einem ersten Schritt das leitfähige Material auf den Kontaktbereich des Leiters aufgespritzt und in einem zweiten Schritt die Kontaktierung mit dem Kontaktelement insbesondere durch eine mechanische Klemm- oder Druckverbindung vorgenommen wird. Zweckdienlicherweise wird hierbei durch mehrfaches Umspritzen des Kontaktbereiches der insbesondere als Hartmetallröhre ausgebildete Mantel aus dem leitfähigen Material aufgebaut.Alternatively, according to a preferred embodiment, a two-stage procedure is provided, wherein in a first step, the conductive material is sprayed onto the contact region of the conductor and in a second step, the contact with the contact element is made in particular by a mechanical clamping or pressure connection. Conveniently, in this case is formed by multiple overmolding of the contact region of the formed in particular as a hard metal tube sheath of the conductive material.
Ausführungsbeispiele der Erfindung werden im Folgenden anhand der Figuren näher erläutert. Es zeigen jeweils in schematischen, stark vereinfachten Darstellungen: Fig. 1 einen endseitig abgeschrägten Leiter aus weichem Material mit einer aufgespritzten Stimkappe in einer perspektivischen Seitendarstellung, Fig. 2 eine Schnittansicht durch eine als Batterieklemme ausgebildete s . Kontaktklemme mit einliegendem Leiter und Fig. 3 eine in einem einstufigen Spritzvorgang ausgebildete Kontaktverbindung zwischen einem Kontaktelement und einem Leiter.Embodiments of the invention will be explained in more detail below with reference to FIGS. In each case, in schematic, highly simplified representations: Fig. 1 is an end-chamfered conductor made of soft material with a sprayed-on end cap in a perspective side view, Fig. 2 is a sectional view through a trained as a battery terminal s . Contact terminal with an incoming conductor and Fig. 3 is formed in a one-step injection molding contact connection between a contact element and a conductor.
In den Figuren sind gleich wirkende Teile jeweils mit gleichen Bezugszeichen versehen. 0 In Fig. 1 ist das abisolierte Ende eines insbesondere als Aluminiumleiter ausgebildeten Leiters 2 dargestellt. Der Leiter 2 weist eine Vielzahl von insbesondere als Litzendrähte ausgebildete Einzelleiter 4 auf. Der Leiter 2 ist beispielsweise ein Batteriekabel, welches für den Einsatz in einem Kraftfahrzeug vorgesehen ist. 5 Endseitig ist der Leiter 2 in einem Kontaktbereich 6 von einem nach Art einer Stirnkappe ausgebildeten Mantel 8A aus einem im Vergleich zum Aluminium härteren Material umgeben.In the figures, like-acting parts are each provided with the same reference numerals. In FIG. 1, the stripped end of a conductor 2 designed in particular as an aluminum conductor is shown. The conductor 2 has a plurality of individual conductors 4 designed in particular as stranded wires. The conductor 2 is for example a battery cable, which is intended for use in a motor vehicle. At the end, the conductor 2 is surrounded in a contact region 6 by a jacket 8A fashioned in the manner of an end cap, from a material which is harder than aluminum.
0 Der Mantel 8A ist mit Hilfe eines thermischen Spritzverfahrens, beispielsweise dem Heißgasspritzen oder dem so genannten Flammspritzen, aufgebracht. Durch das Aufspritzen des härteren Materials auf das weiche Material des Leiters 2 wird zwischen diesen beiden Materialien eine sichere, dauerhafte und insbesondere druckfreie Verbindung hergestellt, so dass keine Gefahr besteht, dass die Verbindung durch ein 5 Kaltfließen des Materials des Leiters 2 beeinträchtigt wird.The jacket 8A is applied by means of a thermal spraying method, for example hot gas spraying or so-called flame spraying. By spraying the harder material onto the soft material of the conductor 2, a secure, durable and, in particular, pressure-free connection is produced between these two materials, so that there is no risk that the connection will be impaired by cold flow of the material of the conductor 2.
Als Material für den Mantel 8A wird insbesondere eine Nickel-Chrom-Nickel-Legierung gewählt. Der Mantel 8A ist dabei durch mehrfaches Überspritzen mit einer ausreichend hohen Wandstärke ausgebildet derart, dass der Mantel 8A insgesamt eine hohe o Eigensteifigkeit und damit Formstabilität aufweist. Der Mantel 8A ist daher nach Art einer steifen Röhre ausgebildet. Der Leiter 2 ist endseitig schräg angeschnitten, so dass im stirnseitigen Bereich eine ebene, in etwa ellipsenförmige Kontakt-Querschnittsfläche 10 ausgebildet ist. Diese weist im Vergleich zu der normalen, im Falle eines kreisrunden Leiters kreisrunden Leiter-Querschnittsfläche 12 eine vergrößerte Fläche auf. Durch die Vergrößerung der Kontakt-Querschnittsfläche 10 wird insbesondere bei Anwendungen, bei denen kein Skin-Effekt auftritt, beispielsweise bei Gleichstromanwendungen, ein nur geringer Kontaktwiderstand erreicht.As the material for the jacket 8A, in particular, a nickel-chromium-nickel alloy is selected. The jacket 8A is formed by multiple over-molding with a sufficiently high wall thickness such that the jacket 8A has a high overall rigidity and thus dimensional stability. The jacket 8A is therefore formed in the manner of a stiff tube. The conductor 2 is obliquely cut at the end, so that in the frontal region a flat, approximately elliptical contact cross-sectional area 10 is formed. This has in comparison to the normal, in the case of a circular conductor circular conductor cross-sectional area 12 an enlarged area. By increasing the contact cross-sectional area 10, in particular in applications in which no skin effect occurs, for example in DC applications, only a small contact resistance is achieved.
Vorzugsweise beträgt hierbei der Winkel a zwischen einer Leiterlängsachse 14 und der Schräge 16 maximal etwa 60°, wie dies in Fig. 1 dargestellt ist. Je kleiner der Winkel hierbei gewählt wird, desto größer wird die Kontakt-Querschnittsfläche 10.Preferably, in this case, the angle a between a conductor longitudinal axis 14 and the slope 16 is a maximum of about 60 °, as shown in Fig. 1. The smaller the angle chosen here, the larger the contact cross-sectional area 10.
Im Ausfϋhrungsbeispiel der Fig. 2 ist insbesondere der in Fig. 1 dargestellte Leiter 2 in einer als Batterieklemme 18 ausgebildeten Klemme eingelegt. Die Klemme ist ein Kontaktelement zur Kontaktierung des Leiters 2. Die Batterieklemme 18weist zwei Klemmhälften 20A1B auf, zwischen denen der Leiter 2 mit dem Mantel 8A einliegt. Zur Ausbildung der Kontaktverbindung werden die beiden Klemmhälften 20A1B über hier nicht näher dargestellte Schrauben, die in Schraubaufnahmen 22 eingreifen, gegeneinander verspannt, so dass der Leiter 2 in der Batterieklemme 18 mechanisch geklemmt wird. Die elektrische Kontaktverbindung erfolgt hierbei mittelbar über den Mantel 8A, welcher die einzelnen Einzelleiter 4 voll umfänglich umschließt. Durch entsprechende Materialwahl und Wahl der Wandstärke des Mantels 8 ist dieser vorzugsweise derart ausgebildet, dass selbst bei einem Klemmen in der Batterieklemme 18 die über den Mantel 8A kontaktierten Einzelleiter 4 im Wesentlichen druckfrei sind.In the exemplary embodiment of FIG. 2, in particular the conductor 2 shown in FIG. 1 is inserted in a terminal formed as a battery terminal 18. The terminal is a contact element for contacting the conductor 2. The battery terminal 18 has two clamping halves 20A 1 B, between which the conductor 2 with the jacket 8A rests. To form the contact connection, the two clamping halves 20A 1 B are braced against each other here by screws, not shown in detail, which engage in screw receptacles 22, so that the conductor 2 is mechanically clamped in the battery terminal 18. The electrical contact connection is in this case indirectly via the jacket 8A, which surrounds the individual individual conductors 4 full circumference. By appropriate choice of material and choice of the wall thickness of the jacket 8, this is preferably designed such that even with a terminal in the battery terminal 18, the contacted via the jacket 8A individual conductors 4 are substantially free of pressure.
Im Unterschied hierzu ist im Ausführungsbeispiel nach der Fig. 3 die elektrische Kontaktverbindung derart ausgebildet, dass die Einzelleiter 4 zunächst auf ein nach Art einer Schale ausgebildetes Kontaktelement 24 aufgelegt werden und dass sie anschließend mit dem härteren Material überspritzt werden. Dabei bildet sich ein die Einzelleiter 4 teilweise umschließender Mantel 8B aus, welcher mit seinen Flanken 26 zugleich mit der Oberfläche des Kontaktelements 24 eine insbesondere stoffschlüssige Verbindung eingeht. Die Einzelleiter 4 sind daher zwischen dem Kontaktelement 24 und dem Mantel 8B eingeschlossen.In contrast thereto, in the exemplary embodiment according to FIG. 3, the electrical contact connection is designed such that the individual conductors 4 are first placed on a contact element 24 designed in the manner of a shell and that they are then over-molded with the harder material. Here, a single conductor 4 partially enclosing jacket 8B is formed, which with its flanks 26 at the same time with the surface of the contact element 24 in particular cohesive Connection is received. The individual conductors 4 are therefore enclosed between the contact element 24 and the jacket 8B.
Das Kontaktelement 24 ist hier beispielsweise nach Art einer Crimphülse ausgebildet, die zusätzlich, also anschließend nach dem Aufspritzen des Mantels 8B, noch umgeformt wird, um auch eine mechanische Befestigung des Mantels 8B zu erreichen.The contact element 24 is formed here, for example, in the manner of a crimp sleeve, which is additionally, ie subsequently after the spraying of the jacket 8B, still deformed in order to achieve a mechanical attachment of the jacket 8B.
Gemäß einer bevorzugten alternativen Ausgestaltung ist zur zusätzlichen mechanischen Befestigung ein mechanisches Befestigungselement vorgesehen, welches den Mantel 8B gegen das Kontaktelement 24 verspannt. Dieses Befestigungselement ist beispielsweise eine Schraube, die in ein zugeordnetes, mit einem Gewinde versehenen Schraubenloch im Boden des Kontaktelements 24 eingeschraubt wird. Die Einzelleiter 4 würden in diesem Fall um die zentral angeordnete Schraube herum verlaufen. Alternativ hierzu besteht die Möglichkeit, eine zentrale Hülse vorzusehen, die mit dem Boden des Kontaktelements 24 verbunden ist und die beispielsweise eineAußengewinde aufweist, auf das eine Mutter zur klemmenden Befestigung aufgeschraubt wird. Zweckdienlicherweise sind hierbei die Kontaktelemente 24 derart ausgebildet, dass sie übereinander angeordnet und gestapelt werden können, so dass sich mehrere Anschlussebenen ergeben. Hierzu wird beispielsweise ein erstes Kontaktelement 24 mit einer bodenseitigen Öffnung auf die erwähnte Hülse eines weiteren Kontaktelements aufgesteckt oder aufgeschraubt.According to a preferred alternative embodiment, a mechanical fastening element is provided for additional mechanical fastening, which braces the jacket 8B against the contact element 24. This fastener is for example a screw which is screwed into an associated, threaded screw hole in the bottom of the contact element 24. The individual conductors 4 in this case would run around the centrally arranged screw. Alternatively, it is possible to provide a central sleeve which is connected to the bottom of the contact element 24 and which has, for example, an external thread on which a nut is screwed on for clamping attachment. Conveniently, in this case, the contact elements 24 are formed such that they can be arranged one above the other and stacked, so that there are several connection levels. For this purpose, for example, a first contact element 24 is plugged or screwed with a bottom-side opening on the mentioned sleeve of another contact element.
Weiterhin ist zweckdienlicherweise vorgesehen, dass die Gesamthöhe des Kontaktelements 24 mit den Einzelleitern 4 und dem Mantel 8B eine vordefinierte maximale Gesamthöhe nicht überschreiten, um das Kontaktelement mit den kontaktierten Einzelleitern beispielsweise in eine vordefinierte Flachhülse einstecken zu können. Die maximale Gesamthöhe wird beispielsweise durch die Höhe des im Querschnitt gesehen wannenartigen Kontaktelements 24 bestimmt. BezugszeichenlisteFurthermore, it is expediently provided that the total height of the contact element 24 with the individual conductors 4 and the jacket 8B does not exceed a predefined maximum overall height in order to be able to insert the contact element with the contacted individual conductors into a predefined flat sleeve, for example. The maximum total height is determined, for example, by the height of the trough-like contact element 24 seen in cross-section. LIST OF REFERENCE NUMBERS
Leiter Einzelleiter Kontaktbereich A,B Mantel 0 Kontakt-Querschnittsfläche 2 Leiter-Querschnittsfläche 4 Längsachse 6 Schräge 8 Batterieklemme 0A.B Klemmhälfte 2 Schraubaufnahme 4 Kontaktelement 6 FlankeConductor Single conductor Contact area A, B Sheath 0 Contact cross-section area 2 Conductor cross-sectional area 4 Longitudinal axis 6 Slant 8 Battery terminal 0A.B Clamp half 2 Screw receptacle 4 Contact element 6 Flank
Winkel angle

Claims

Ansprüche claims
1. Elektrische Kontaktverbindung zwischen einem elektrischen Leiter (2) aus einem weichen Material, insbesondere einem Aluminiumleiter aus mehreren „ Einzelleitern (4), und einem Kontaktelement (18,24), wobei der Leiter (2) in einem Kontaktbereich (6) zumindest teilweise mit Hilfe eines Spritzverfahrens mit einem im Vergleich zum weichen Material des Leiters (2) härteren, elektrisch leitfähigen Material umspritzt ist, so dass eine druckfreie elektrische Verbindung zwischen dem weichen Material und dem aufgespritzten Material vorliegt und wobei die elektrische Kontaktierung zum Kontaktelement (18,24) über das aufgespritzte Material erfolgt.1. Electrical contact connection between an electrical conductor (2) made of a soft material, in particular an aluminum conductor of a plurality of "individual conductors (4), and a contact element (18,24), wherein the conductor (2) in a contact region (6) at least partially is injection-molded with an electrically conductive material which is harder than the soft material of the conductor (2), so that there is a pressure-free electrical connection between the soft material and the sprayed-on material, and wherein the electrical contact with the contact element (18, 24 ) over the sprayed material.
2. Kontaktverbindung nach Anspruch 1 , bei dem der Leiter (2) im Kontaktbereich (6) voll umfänglich von einem Mantel (8A) aus dem härteren Material umgeben ist.2. Contact connection according to claim 1, wherein the conductor (2) in the contact region (6) is fully surrounded by a shell (8A) of the harder material.
3. Kontaktverbindung nach Anspruch 2, bei der der Mantel (8A) aus einer Ni-Cr-Ni- Legierung besteht.3. Contact connection according to claim 2, wherein the sheath (8A) consists of a Ni-Cr-Ni alloy.
4. Kontaktverbindung nach einem der vorhergehenden Ansprüche, bei der zwischen dem aufgespritzten Material und dem Kontaktelement (18) eine mechanische Druck- oder Klemmverbindung ausgebildet ist.4. Contact connection according to one of the preceding claims, wherein between the sprayed material and the contact element (18) is formed a mechanical pressure or clamping connection.
5. Kontaktverbindung nach einem der vorhergehenden Ansprüche, bei der der Leiter (2) endseitig eine im Vergleich zur Leiter-Querschnittsfläche (12) vergrößerte Kontakt-Querschnittsfläche (10) aufweist, auf die das leitfähige Material aufgespritzt ist.5. Contact connection according to one of the preceding claims, wherein the conductor (2) has an end compared to the conductor cross-sectional area (12) enlarged contact cross-sectional area (10) on which the conductive material is sprayed.
6. Kontaktverbindung nach Anspruch 5, bei der der Leiter (2) endseitig abgeschrägt ist. 6. Contact connection according to claim 5, wherein the conductor (2) is beveled end.
7. Kontaktverbindung nach einem der vorhergehenden Ansprüche, bei der der Leiter (2) ein Aluminium-Batteriekabel, insbesondere für ein Kraftfahrzeug, und das Kontaktelement eine Batterieklemme (18) ist.7. Contact connection according to one of the preceding claims, wherein the conductor (2) is an aluminum battery cable, in particular for a motor vehicle, and the contact element is a battery terminal (18).
s _. s _.
8. Verfahren zum Erzeugen einer elektrischen Kontaktverbindung zwischen einem Leiter (2) aus einem weichen Material, insbesondere einem Aluminiumleiter, und einem Kontaktelement (18,24), wobei der Leiter (2) in einem Kontaktbereich (6) zumindest teilweise mit Hilfe eines insbesondere thermischen Spritzverfahrens mit einem im Vergleich zum weichen Material des Leiters (2) härteren, elektrisch o leitfähigen Material umspritzt wird, so dass sich eine druckfreie Verbindung zwischen dem weichen Material und dem aufgespritzten Material ausbildet und wobei die elektrische Kontaktierung zum Kontaktelement (18,24) über das aufgespritzte Material erfolgt.8. A method for producing an electrical contact connection between a conductor (2) made of a soft material, in particular an aluminum conductor, and a contact element (18,24), wherein the conductor (2) in a contact region (6) at least partially by means of a particular thermal spray process with a compared to the soft material of the conductor (2) harder, electrically o conductive material is injected so that forms a pressure-free connection between the soft material and the sprayed material and wherein the electrical contact with the contact element (18,24) over the sprayed material.
5 9. Verfahren nach Anspruch 8, bei dem das leitfähige Material in den Leiter (2) zumindest teilweise eindringt und eine eventuell auf der Leiteroberfläche vorhandene Oxidschicht zumindest teilweise durchdringt.9. The method of claim 8, wherein the conductive material in the conductor (2) at least partially penetrates and at least partially penetrates an existing on the conductor surface oxide layer.
10. Verfahren nach Anspruch 8 oder 9, bei dem durch Aufspritzen des leitfähigen 0 Materials der Leiter (2) umspritzt und zugleich die elektrische Kontaktverbindung zwischen dem leitfähigen Material und dem Kontaktelement (24) ausgebildet wird.10. The method of claim 8 or 9, wherein by spraying the conductive material of the conductor (2) overmolded and at the same time the electrical contact connection between the conductive material and the contact element (24) is formed.
11. Verfahren nach Anspruch 8 oder 9, bei dem in einem ersten Schritt das leitfähige 5 Material auf den Kontaktbereich (6) des Leiters (2) aufgespritzt und in einem zweiten Schritt die Kontaktierung mit dem Kontaktelement (18) insbesondere durch eine mechanische Klemm- oder Druckverbindung vorgenommen wird.11. The method of claim 8 or 9, wherein in a first step, the conductive 5 material sprayed onto the contact region (6) of the conductor (2) and in a second step the contacting with the contact element (18) in particular by a mechanical clamping or pressure connection is made.
12. Verfahren nach Anspruch 11 , bei dem insbesondere durch mehrfaches o Umspritzen des Kontaktbereichs (6) ein Mantel (8A) aus dem leitfähigen Material ausgebildet wird. 12. The method according to claim 11, wherein in particular by multiple o encapsulation of the contact region (6), a jacket (8A) is formed from the conductive material.
EP05744312A 2004-06-25 2005-05-25 Electrical contact connection and method for creating one such contact connection Not-in-force EP1759439B1 (en)

Applications Claiming Priority (2)

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DE102004030784A DE102004030784A1 (en) 2004-06-25 2004-06-25 Electrical contact connection and method for forming such a contact connection
PCT/EP2005/005629 WO2006000279A1 (en) 2004-06-25 2005-05-25 Electrical contact connection and method for creating one such contact connection

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EP1759439A1 true EP1759439A1 (en) 2007-03-07
EP1759439B1 EP1759439B1 (en) 2009-09-30

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EP05744312A Not-in-force EP1759439B1 (en) 2004-06-25 2005-05-25 Electrical contact connection and method for creating one such contact connection

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US (1) US7282679B2 (en)
EP (1) EP1759439B1 (en)
JP (1) JP2008503859A (en)
CN (1) CN100409489C (en)
AT (1) ATE444578T1 (en)
DE (2) DE102004030784A1 (en)
ES (1) ES2333027T3 (en)
PT (1) PT1759439E (en)
WO (1) WO2006000279A1 (en)

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Also Published As

Publication number Publication date
CN1820393A (en) 2006-08-16
EP1759439B1 (en) 2009-09-30
DE502005008243D1 (en) 2009-11-12
CN100409489C (en) 2008-08-06
US20060201934A1 (en) 2006-09-14
JP2008503859A (en) 2008-02-07
ES2333027T3 (en) 2010-02-16
PT1759439E (en) 2009-11-13
WO2006000279A1 (en) 2006-01-05
US7282679B2 (en) 2007-10-16
DE102004030784A1 (en) 2006-01-19
ATE444578T1 (en) 2009-10-15

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