EP1817819B1 - Verfahren zum herstellen einer elektrischen verbindung zwischen einem aluminiumleiter und einem kontaktelement - Google Patents

Verfahren zum herstellen einer elektrischen verbindung zwischen einem aluminiumleiter und einem kontaktelement Download PDF

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Publication number
EP1817819B1
EP1817819B1 EP04819620A EP04819620A EP1817819B1 EP 1817819 B1 EP1817819 B1 EP 1817819B1 EP 04819620 A EP04819620 A EP 04819620A EP 04819620 A EP04819620 A EP 04819620A EP 1817819 B1 EP1817819 B1 EP 1817819B1
Authority
EP
European Patent Office
Prior art keywords
contact element
contact
aluminum conductor
shaping
forming
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
EP04819620A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP1817819A1 (de
Inventor
Frank Beuscher
Matthias Ebert
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 Bordnetz Systeme GmbH
Original Assignee
Leoni Bordnetz Systeme GmbH
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 Bordnetz Systeme GmbH filed Critical Leoni Bordnetz Systeme GmbH
Publication of EP1817819A1 publication Critical patent/EP1817819A1/de
Application granted granted Critical
Publication of EP1817819B1 publication Critical patent/EP1817819B1/de
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • 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
    • 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
    • H01R4/203—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 having an uneven wire-receiving surface to improve the contact

Definitions

  • the invention relates to a method for producing an electrical connection between an aluminum conductor and a contact element, in which a stripped end of the aluminum conductor is inserted into the contact element and electrically contacted with this and in which to form a mechanical strain relief of the aluminum conductor by forming the contact element in this is clamped.
  • the invention has for its object to provide an easy to manufacture and safe and long-term stable contact between an aluminum conductor and a contact element with low contact resistance.
  • a stripped end of the aluminum conductor is inserted into the contact element and contacted with this electrically.
  • a supply of a contacting agent is provided, wherein the contacting agent is heated at least to the region of its melting temperature, so that it is preferably present in molten form.
  • the contacting agent in particular tin or a tin alloy, a material connection between the aluminum conductor and the contact element is produced.
  • the aluminum conductor is immersed in particular in a recorded in the contact element melt of the contacting agent.
  • the heating of the contacting takes place here for example by irradiation of a high-frequency field, by irradiation of high-energy light (laser light) or directly by a flame or by another heating element.
  • the contact element is mechanically deformed during or after the formation of the electrical contact, so that the aluminum conductor is clamped in the contact element to form a mechanical strain relief.
  • the contact element is formed in a forming zone, which is spaced from a contacting zone in which the electrical contacting takes place.
  • This measure again serves to separate the mechanical from the electrical function.
  • this has the advantage that the formed prior to forming contact, in particular via tin or a tin alloy, is not affected by the exercise of the pressure necessary for the forming.
  • the contacting zone is not exposed to pressure, so that there is no risk of subsequent flow of the contacting agent, which could worsen the electrical contact.
  • the contact element is additionally heated in the forming zone in order to allow material-saving forming with improved flow behavior without cracking compared to cold forming.
  • the contacting agent is heated to a maximum of about 280 ° C. By this measure, damage to an insulation of the aluminum conductor is avoided.
  • the insulation can be protected by special terminals or other protective mechanisms.
  • a temperature of 280 ° smelting is assured with the use of tin or a tin alloy because the melting temperature of tin is about 232 ° C and the melting temperature of a tin alloy with 10% zinc is 198 ° C.
  • solder paste which is in molten form at 280.degree. C. can in principle also be used as the contacting agent.
  • solder paste halogen-free, non-corrosive flux to avoid subsequent corrosion of the solder joint.
  • the portion to be tinned is shock-heated for this purpose and then immersed in a tin bath.
  • the section is heated to about 400 ° C or more.
  • This rapid heating can be done inductively by irradiation of a high-frequency field or by the use of a high-energy laser light. The shock heating leads to a different elongation behavior of the aluminum and the oxide layer.
  • a protective gas atmosphere is preferably provided.
  • the tinning of the section is carried out by ultrasonic tinning in a tin bath.
  • ultrasonic tinning takes advantage of the fact that the irradiation of ultrasound in the tin bath creates small cavities, so-called cavitations, which collapse explosively. This results in locally significant pressure forces, which lead to damage and spalling of the oxide layer, so that the pure aluminum is in turn largely wetted over the entire surface of the tin.
  • the aluminum conductor is immersed in a tin bath and a part of the aluminum conductor is separated or cut in the tin bath.
  • a "fresh" separation or cutting surface is formed, which is wetted directly and without contact with atmospheric oxygen with tin. This measure ensures that the cut surface is tinned over the entire surface.
  • the separating surface corresponds to the cross-section, so that no reduction in the cross-sectional area takes place in the contacting region with regard to the electrical contact surface.
  • the forming process takes place within a very short forming time, which is in the ⁇ s range in particular in the range to about 10 microseconds.
  • the decisive advantage of such a rapid forming process is the fact that the individual stranded wires of the aluminum conductor behave less like solid stranded wires than rather like a liquid, so that the individual stranded wires are caked or melted together. This effect is similar to a projectile piercing a metal plate at high speed. In the reference system of the projectile, the metal plate does not appear as a solid. Rather, the projectile penetrates the metal plate like a liquid.
  • the inner surface of the contact element is roughened or structured.
  • the inner surface of the contact element is in this case provided, for example, with grooves or with threads which are preferably sharp-edged. When forming, therefore, these grooves or threads virtually intersect in the individual stranded wires.
  • This contacting can be done in addition to the contact via the contacting or as an independent contact. In particular, in the independent design without the use of the contacting can be realized by the sudden reshaping and the simultaneous formation of electrical and mechanical connection easily an automated process, so an automated striking the contact element on the aluminum conductor with very high clock rates.
  • the shaping takes place by magnetocompression rapid magnetic forming.
  • Magnetocompression are to be reshaped
  • Contact element generates very high magnetic fields, so that high currents are induced in the contact element, which in turn form a magnetic field, so that due to the Lorentine force the contact element is repelled and thereby reshaped.
  • the contact element is preformed for this purpose, for example, in the manner of a sleeve or slotted sleeve, in which the aluminum conductor is inserted.
  • the externally applied magnetic field in this case leads to a radially inwardly directed forming of the sleeve, so that the inserted aluminum conductor is clamped.
  • magnetocompression pressures can be achieved in the range of, for example, 2000 bar in the choice of suitable magnetic fields. Since no mechanical forming elements are necessary in this case, the contact element is not damaged despite these high pressures.
  • the abrupt reshaping takes place by means of a forming element by mechanical impact pressing.
  • Conventional hydraulic presses do not reach these speeds and are therefore not suitable for abrupt reshaping.
  • the speeds for the forming element are in this case preferably generated solely by the weight, that is, for example, formed as a mandrel or claw forming element applies in the manner of a Fallbeils on the reshaped contact element.
  • connection between the aluminum conductor and the contact element is isolated from moisture.
  • a shrink tube is mounted or the compound is coated with an insulating varnish or insulation adhesive.
  • Fig. 1 is an already finished connection between a particular existing copper and designed as a cable lug contact element and an aluminum conductor 4 is shown.
  • the contact element 2 is in this case designed in the manner of a sleeve and has a receiving space into which a stripped end piece 6 of the aluminum conductor 4 is inserted.
  • the stranded wires are tinned at least at their frontal portion.
  • a supply or reservoir of a contacting means 8 is provided between the front end of the stranded wires and the rear wall or the bottom of the contact element 2.
  • this tin or a tin alloy is provided.
  • the electrical contact between the aluminum conductor 4 and the contact element 2 takes place via the tin alloy.
  • the inner surface of the contact element 2 is preferably also pre-tinned.
  • the tin alloy is introduced into the contact element 2 and melted. Subsequently, or even before the melting of the aluminum conductor 4 is inserted with the stripped end piece 6 in the contact element 2. In particular, the front ends of the stranded wires are immersed in the molten tin alloy 8. After cooling, therefore, there is a cohesive material connection between the contact element 2 and the individual stranded wires of the aluminum conductor 4. It is in the region of the contacting means 8 and the front ends of the stranded wires a contacting zone 10 is formed.
  • a forming zone 12 Spaced apart from the contacting zone 10, a forming zone 12 is provided, within which a deformation of the contact element 2 takes place.
  • the Fig. 1 already shows the deformed state in which a reshaped portion 14 of Contact element 2 has penetrated into the stripped end piece 6.
  • the aluminum conductor 4 is clamped in the contact element 2, whereby an effective mechanical strain relief is formed.
  • the connecting region in the exemplary embodiment is still surrounded by a shrink tube 16 as insulation against moisture.
  • the contact element 2 is heated at least in the forming zone 12.
  • a heating element 18 is provided, which is constructed in two parts in the embodiment and at the same time also serves to heat the contacting agent 8 into the region of its melting temperature.
  • the heating element 18 is divided in the exemplary embodiment into two functional zones, which are designed for the different requirements, namely the heating of the supply 8 and the heating of the contact element 2.
  • only one heating element 18 may be provided for heating the contacting means 8. In this case, there is inevitably also a heating of the contact element 2.
  • an ultrasonic generator 20 is provided.
  • the Kotaktelement serves to form the electrical function by the tinning of unleaded stranded wires by means of the ultrasound irradiation when the stranded wires are immersed in the molten pool.
  • the Kotaktelement is hereby suitably mechanically fixed to an ultrasound sono-red or acoustically coupled by a transmission medium for the transmission of the required ultrasound energies.
  • the forming process can be carried out in a conventional manner by mechanical or hydraulic pressing of forming elements against the contact element 2.
  • a shaping provided by means of magnetocompression Namely, a very strong magnetic field is thereby generated by magnetic coils 22 in the immediate outer region of the contact element 2, so that currents are induced in the conductive contact element 2 and the Lorenz force is formed. This works in the direction of in the Fig. 2 Arrows shown on the contact element 2 and thereby causes the forming of the contact element 2 forth.
  • a forming element 24 is struck at very high speed against the contact element.
  • the forming element 24 is formed like a mandrel.
  • a counter element 26 is arranged, which can in particular also give shape for the forming process.
  • the high speed of the forming element 24 in the direction of in the Fig. 3 shown arrow direction is preferably achieved solely by acceleration due to gravity. Alternatively, it is possible to accelerate the forming element 24 by compressed air using a hammer blower or pyrotechnic.
  • FIGS. 2 and 3 Therefore, in addition to the mechanical connection, it is also possible to carry out electrical contacting additionally or alternatively to the electrical contacting via the contacting means 8.
  • the inner surface of the contacting element 2 is roughened or structured at least in the forming zone 12.
  • a thread 28 is cut into the sleeve-like contact element 2.
  • FIGS. 2 and 3 show the situation before the forming process. After forming, the threads of the thread 28, which are in particular sharp-edged, cut into the stranded wires and in particular penetrate the oxide layer.
  • the partial processes B, C and D are characterized by a very good tinning result, so that these partial process can be used independently of the electrical contact of the aluminum conductor 4 with the contact element 2 as an independent tinning process.
  • tinning the electrical contact takes place, as they are Fig. 1 has been described.
  • the individual stranded wires are in this case immersed in a molten reservoir of the tin or the tin alloy, so that via the tin after solidification a cohesive connection between the individual stranded wires and the contact element 2 is formed.
  • the process step III the forming, in particular according to one of the Fig. 2 or 3 described method (ii, iii).
  • the process steps II and III can also take place simultaneously, that is to say that the transformation does not necessarily have to take place after the melt has cooled down. All that matters is that the melting does not take place after the forming process.
  • Fig. 6 The procedure according to Fig. 6 Overall, it is characterized by a one-step process, in which process step I, namely the tinning of the stranded wires can be dispensed with.
  • the electrical contact (II) and the mechanical connection (III) take place within a single process step in accordance with sub-procedures ii or iii.
  • This on the basis of Fig. 6 illustrated one-step process for the production of electrical and mechanical connection is particularly suitable for high-speed automation.

Landscapes

  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Conductive Materials (AREA)
  • Coupling Device And Connection With Printed Circuit (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
EP04819620A 2003-12-04 2004-11-25 Verfahren zum herstellen einer elektrischen verbindung zwischen einem aluminiumleiter und einem kontaktelement Not-in-force EP1817819B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10357048A DE10357048A1 (de) 2003-12-04 2003-12-04 Verfahren zum Herstellen einer elektrischen Verbindung zwischen einem Aluminiumleiter und einem Kontaktelement
PCT/EP2004/013366 WO2005055371A1 (de) 2003-12-04 2004-11-25 Verfahren zum herstellen einer elektrischen verbindung zwischen einem aluminiumleiter und einem kontaktelement

Publications (2)

Publication Number Publication Date
EP1817819A1 EP1817819A1 (de) 2007-08-15
EP1817819B1 true EP1817819B1 (de) 2009-01-21

Family

ID=34638430

Family Applications (1)

Application Number Title Priority Date Filing Date
EP04819620A Not-in-force EP1817819B1 (de) 2003-12-04 2004-11-25 Verfahren zum herstellen einer elektrischen verbindung zwischen einem aluminiumleiter und einem kontaktelement

Country Status (10)

Country Link
US (1) US20060208838A1 (es)
EP (1) EP1817819B1 (es)
JP (1) JP2007513475A (es)
CN (1) CN100405663C (es)
AT (1) ATE421784T1 (es)
BR (1) BRPI0407953A (es)
DE (2) DE10357048A1 (es)
ES (1) ES2318369T3 (es)
PT (1) PT1817819E (es)
WO (1) WO2005055371A1 (es)

Cited By (6)

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Publication number Priority date Publication date Assignee Title
WO2011128225A2 (en) 2010-04-12 2011-10-20 Fci Electrical contact terminal with improved connection portion
DE202011104677U1 (de) 2011-08-22 2012-01-24 Leoni Bordnetz-Systeme Gmbh Kontaktierungsvorrichtung sowie Kontaktverbindung
DE102011119699A1 (de) 2011-11-29 2013-05-29 Leoni Bordnetz-Systeme Gmbh Kabel, insbesondere Aluminiumkabel
DE102014206283B3 (de) * 2014-04-02 2015-07-02 Leoni Bordnetz-Systeme Gmbh Elektrische Kontaktverbindung sowie Verfahren zur Herstellung einer Kontaktverbindung
DE102014108347A1 (de) 2014-06-13 2015-12-17 Leoni Bordnetz-Systeme Gmbh Elektrischer Litzenleiter sowie Verfahren zur Herstellung eines elektrischen Litzenleiters
DE102011089206B4 (de) 2011-12-20 2023-10-05 Lisa Dräxlmaier GmbH Verfahren zum Kontaktieren einer Litzenleitung mit einem Kontakt

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EP3109944B1 (de) 2015-06-23 2021-12-08 Nexans Verfahren zur herstellung einer elektrisch wirksamen kontaktstelle am ende eines elektrischen leiters
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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011128225A2 (en) 2010-04-12 2011-10-20 Fci Electrical contact terminal with improved connection portion
DE202011104677U1 (de) 2011-08-22 2012-01-24 Leoni Bordnetz-Systeme Gmbh Kontaktierungsvorrichtung sowie Kontaktverbindung
DE102011119699A1 (de) 2011-11-29 2013-05-29 Leoni Bordnetz-Systeme Gmbh Kabel, insbesondere Aluminiumkabel
DE102011089206B4 (de) 2011-12-20 2023-10-05 Lisa Dräxlmaier GmbH Verfahren zum Kontaktieren einer Litzenleitung mit einem Kontakt
DE102014206283B3 (de) * 2014-04-02 2015-07-02 Leoni Bordnetz-Systeme Gmbh Elektrische Kontaktverbindung sowie Verfahren zur Herstellung einer Kontaktverbindung
DE102014108347A1 (de) 2014-06-13 2015-12-17 Leoni Bordnetz-Systeme Gmbh Elektrischer Litzenleiter sowie Verfahren zur Herstellung eines elektrischen Litzenleiters

Also Published As

Publication number Publication date
PT1817819E (pt) 2009-03-24
US20060208838A1 (en) 2006-09-21
BRPI0407953A (pt) 2006-03-07
WO2005055371A1 (de) 2005-06-16
CN100405663C (zh) 2008-07-23
EP1817819A1 (de) 2007-08-15
ATE421784T1 (de) 2009-02-15
CN1748343A (zh) 2006-03-15
DE10357048A1 (de) 2005-07-21
DE502004008930D1 (de) 2009-03-12
JP2007513475A (ja) 2007-05-24
ES2318369T3 (es) 2009-05-01

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