EP1759439B1 - Liaison de contact electrique et procede pour realiser une telle liaison de contact - Google Patents

Liaison de contact electrique et procede pour realiser une telle liaison de contact Download PDF

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Publication number
EP1759439B1
EP1759439B1 EP05744312A EP05744312A EP1759439B1 EP 1759439 B1 EP1759439 B1 EP 1759439B1 EP 05744312 A EP05744312 A EP 05744312A EP 05744312 A EP05744312 A EP 05744312A EP 1759439 B1 EP1759439 B1 EP 1759439B1
Authority
EP
European Patent Office
Prior art keywords
conductor
contact
connection
sprayed
conductive material
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.)
Not-in-force
Application number
EP05744312A
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German (de)
English (en)
Other versions
EP1759439A1 (fr
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/fr
Application granted granted Critical
Publication of EP1759439B1 publication Critical patent/EP1759439B1/fr
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00Electrically-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
    • H01R4/58Electrically-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
    • H01R4/62Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02Contact members
    • H01R13/03Contact members characterised by the material, e.g. plating, or coating materials
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R9/00Structural 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
    • H01R9/03Connectors arranged to contact a plurality of the conductors of a multiconductor cable, e.g. tapping connections
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00Individual 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
    • H01R11/11End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H01R11/28End pieces consisting of a ferrule or sleeve
    • H01R11/281End pieces consisting of a ferrule or sleeve for connections to batteries
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00Electrically-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
    • H01R4/10Electrically-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
    • H01R4/18Electrically-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
    • H01R4/20Electrically-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
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49002Electrical device making
    • Y10T29/49117Conductor or circuit manufacturing
    • Y10T29/49174Assembling terminal to elongated conductor
    • Y10T29/49179Assembling terminal to elongated conductor by metal fusion bonding
    • YGENERAL 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
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49002Electrical device making
    • Y10T29/49117Conductor or circuit manufacturing
    • Y10T29/49204Contact or terminal manufacturing
    • Y10T29/49208Contact or terminal manufacturing by assembling plural parts
    • Y10T29/4921Contact or terminal manufacturing by assembling plural parts with bonding
    • Y10T29/49211Contact or terminal manufacturing by assembling plural parts with bonding of fused material
    • Y10T29/49213Metal

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 according to the preamble of claim 1.
  • the invention further relates to a method for forming such a contact connection according to the preamble of claim 8.
  • Such a contact connection is known from GB 755 272 A refer to.
  • an aluminum conductor is inserted with its end in an aluminum sleeve, and inserted together with this in a crimp sleeve of a contact element and connected thereto by crimping.
  • 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. Thereafter, it is provided that an electrical conductor of a soft, prone to cold flow material in its contact region at least partially by means of a spraying process 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-Harttress 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.
  • 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 cross-sectional area of contact 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 injection molding of the material is not necessarily a 100% areal connection between the soft material and the sprayed hard material is formed by increasing the contact cross-sectional area of the effective contact surface, ie the area at which an actual contact between the sprayed material and the soft material, for example, increases and amounts to 100% of the normal conductor cross-sectional area.
  • the contact resistance is kept as low as possible.
  • Under normal conductor cross-sectional area 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 chosen 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 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.
  • 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 the stripped end of a particular designed as an aluminum conductor conductor 2 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 designed in the manner of an end cap, made of a material that 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 overall has a high intrinsic 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 at most about 60 °, as in Fig. 1 is shown.
  • Fig. 2 is in particular the in Fig. 1 represented conductor 2 inserted in a trained as a battery terminal 18 terminal.
  • the terminal is a contact element for contacting the conductor 2.
  • the battery terminal 18 has two clamping halves 20A, B, between which the conductor 2 rests with the jacket 8A.
  • the two clamping halves 20A, B are braced against each other via screws not shown here, 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 formed 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 total 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.

Claims (12)

  1. Liaison de contact électrique entre une ligne électrique (2) en matériau tendre, en particulier une ligne en aluminium constituée de plusieurs brins individuels (4), et un élément de contact (18, 24),
    caractérisée en ce que la ligne (2) est enrobée, dans une zone de contact (6), au moins partiellement à l'aide d'un procédé par projection, avec un matériau électriquement conducteur plus dur par comparaison au matériau tendre de la ligne (2), de sorte qu'il se produit une liaison électrique exempte de pression entre le matériau tendre et le matériau enrobé par projection, et la mise en contact électrique vers l'élément de contact (18, 24) a lieu via le matériau enrobé par projection.
  2. Liaison de contact selon la revendication 1, dans laquelle la ligne (2) est entourée, dans la zone de contact (6), sur la totalité de sa périphérie par une enveloppe (8A) du matériau plus dur.
  3. Liaison de contact selon la revendication 2, dans laquelle l'enveloppe (8A) est en alliage Ni-Cr-Ni.
  4. Liaison de contact selon l'une des revendications précédentes, dans laquelle une liaison mécanique par compression ou par coincement est réalisée entre le matériau enrobé par projection et l'élément de contact (18).
  5. Liaison de contact selon l'une des revendications précédentes, dans laquelle la ligne (2) comporte du côté terminal une surface de section transversale de contact (10) agrandie par comparaison à la surface transversale (12) de la ligne, sur laquelle le matériau conducteur est enrobé par projection.
  6. Liaison de contact selon la revendication 5, dans laquelle la ligne (2) est biseautée du côté terminal.
  7. Liaison de contact selon l'une des revendications précédentes, dans laquelle la ligne (2) est un câble de batterie en aluminium, en particulier pour un véhicule automobile, et l'élément de contact est une borne de batterie (18).
  8. Procédé pour engendrer une liaison de contact électrique entre une ligne (2) en un matériau tendre, en particulier une ligne en aluminium, et un élément de contact (18, 24),
    caractérisé en ce que
    la ligne (2) est enrobée, dans une zone de contact (6), au moins partiellement à l'aide d'un procédé de projection en particulier thermique, avec un matériau électriquement conducteur plus dur par comparaison au matériau tendre de la ligne (2), de sorte qu'il se forme une liaison exempte de pression entre le matériau tendre et le matériau enrobé par projection, et dans lequel la mise en contact électrique vers l'élément de contact (18, 24) a lieu via le matériau enrobé par projection.
  9. Procédé selon la revendication 8, dans lequel le matériau conducteur pénètre au moins partiellement dans la ligne (2), et traverse au moins partiellement une couche d'oxyde éventuellement présente sur la surface de la ligne.
  10. Procédé selon la revendication 8 ou 9, dans lequel par projection du matériau conducteur la ligne (2) est enrobée par projection et simultanément la liaison de contact électrique est établie entre le matériau conducteur et l'élément de contact (24).
  11. Procédé selon la revendication 8 ou 9, dans lequel dans une première étape le matériau conducteur est projeté sur la zone de contact (6) de la ligne (2), et dans une seconde étape, on procède à la mise en contact avec l'élément de contact (18), en particulier par une liaison mécanique à coincement ou à compression.
  12. Procédé selon la revendication 11, dans lequel en particulier par enrobage-projection multiple de la zone de contact (6), on réalise une enveloppe (8A) avec le matériau conducteur.
EP05744312A 2004-06-25 2005-05-25 Liaison de contact electrique et procede pour realiser une telle liaison de contact Not-in-force EP1759439B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102004030784A DE102004030784A1 (de) 2004-06-25 2004-06-25 Elektrische Kontaktverbindung und Verfahren zum Ausbilden einer solchen Kontaktverbindung
PCT/EP2005/005629 WO2006000279A1 (fr) 2004-06-25 2005-05-25 Liaison de contact electrique et procede pour realiser une telle liaison de contact

Publications (2)

Publication Number Publication Date
EP1759439A1 EP1759439A1 (fr) 2007-03-07
EP1759439B1 true EP1759439B1 (fr) 2009-09-30

Family

ID=34970630

Family Applications (1)

Application Number Title Priority Date Filing Date
EP05744312A Not-in-force EP1759439B1 (fr) 2004-06-25 2005-05-25 Liaison de contact electrique et procede pour realiser une telle liaison de contact

Country Status (9)

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

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Also Published As

Publication number Publication date
CN100409489C (zh) 2008-08-06
WO2006000279A1 (fr) 2006-01-05
EP1759439A1 (fr) 2007-03-07
ATE444578T1 (de) 2009-10-15
PT1759439E (pt) 2009-11-13
US7282679B2 (en) 2007-10-16
ES2333027T3 (es) 2010-02-16
US20060201934A1 (en) 2006-09-14
DE102004030784A1 (de) 2006-01-19
CN1820393A (zh) 2006-08-16
DE502005008243D1 (de) 2009-11-12
JP2008503859A (ja) 2008-02-07

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