EP2001085B1 - Method for manufacturing an electrically conducting connection - Google Patents

Method for manufacturing an electrically conducting connection Download PDF

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Publication number
EP2001085B1
EP2001085B1 EP07290704A EP07290704A EP2001085B1 EP 2001085 B1 EP2001085 B1 EP 2001085B1 EP 07290704 A EP07290704 A EP 07290704A EP 07290704 A EP07290704 A EP 07290704A EP 2001085 B1 EP2001085 B1 EP 2001085B1
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EP
European Patent Office
Prior art keywords
conductor
contact element
contact
electrical
crimping
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
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EP07290704A
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German (de)
French (fr)
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EP2001085A1 (en
Inventor
Udo Dr. Dipl.-Chem. Mayer
Thomas Noetzel
Helmut Dr. Ing. Steinberg
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Nexans SA
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Nexans SA
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Publication date
Application filed by Nexans SA filed Critical Nexans SA
Priority to EP07290704A priority Critical patent/EP2001085B1/en
Priority to AT07290704T priority patent/ATE468629T1/en
Priority to DE502007003854T priority patent/DE502007003854D1/en
Priority to ES07290704T priority patent/ES2357827T3/en
Publication of EP2001085A1 publication Critical patent/EP2001085A1/en
Application granted granted Critical
Publication of EP2001085B1 publication Critical patent/EP2001085B1/en
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Anticipated expiration legal-status Critical

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—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
    • H01R13/46—Bases; Cases
    • H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
    • H01R13/5219—Sealing means between coupling parts, e.g. interfacial seal
    • H01R13/5221—Sealing means between coupling parts, e.g. interfacial seal having cable sealing means
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • 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

Definitions

  • the invention relates to a method for producing an electrically conductive connection between an aluminum-containing electrical conductor and a contact part of an electrical or electronic device, in which a conductor is used, which consists of a plurality of stranded, aluminum-containing individual wires, of a Insulation are surrounded, with which the end of the conductor is freed from its insulation, with which at the end of the conductor an electrical contact element is fixed by crimping and with which the contact element with the Kunststofftei! is connected ( DE-OS 22 50 836 ).
  • Device in the context of the invention may be equipped with externally accessible contact parts units. But it may also be contact parts having coupling elements, such as connectors and mating connector.
  • Aluminum-containing conductors are increasingly used as a replacement for copper conductors, for example in the automotive and aircraft technology.
  • the aluminum-containing conductors used therein are either entirely aluminum or an aluminum alloy.
  • the conductors may also have a central tensile element to increase their tensile strength.
  • a significant advantage of such electrical conductors is their lower weight compared to copper.
  • the lower electrical conductivity of the aluminum compared to copper is of minor importance for most applications.
  • the problem is considered to be the fact that aluminum reacts with oxygen, which very quickly a corresponding conductor surrounding, electrically insulating oxide layer is formed. Therefore, measures have repeatedly been taken to rupture the oxide layer for an electrically conductive connection to an electrical contact element to be attached to such a conductor and to surround the conductor treated therewith with a layer of electrically highly conductive material, for example with a tin layer.
  • a corresponding method for example, from the above-mentioned DE-OS 22 50 836 from 1972, with which an aluminum conductor surrounding oxide layer is broken in a tin bath by means of ultrasound, in which simultaneously a tin layer is applied to the conductor.
  • Other methods from the last 15 years go from the writings DE 102 23 397 B4 . DE 103 46 160 B3 . DE 103 60 614 B4 . DE 10 2005 030 248 B3 . WO 2005/055371 A1 and WO 2005/091439 A1 out.
  • contact elements are attached to the ends of aluminum conductors.
  • the oxide layers surrounding the conductor by means of ultrasound or mechanically and tin or zinc layers are applied with appropriate effort, for example, from an existing in a contact element stock of these materials, which are initially still melted.
  • the invention has for its object to simplify the initially described method.
  • the contact element to be attached to the end of an aluminum-containing conductor which is dimensioned as a function of parameters of the respective conductor, only needs to be used to be crimped on a commercially available tool on the ladder freed from its insulation. Prior treatment of the conductor is not required when using this method. In particular, the measure prescribed by the experts for more than 35 years is not applied, according to which the oxide surrounding the conductor must first be broken and the conductor then or simultaneously embedded in a completely closed, covering layer of good electrically conductive material.
  • a sealing element is advantageously applied before the crimping of the contact element on the insulation of the conductor, which optionally serves as a closure of a bore in a cover of the contact points.
  • Fig. 1 is shown as a conductor 1, a so-called stranded conductor, which is surrounded by an insulation 2. The end of the conductor 1 is stripped to a length provided for contacting purposes.
  • the conductor 1 consists of a plurality of individual wires 3, which are stranded together. Each individual wire 3 has aluminum or an aluminum alloy as the electrically conductive material.
  • an existing example of copper contact element 4 is fixed by crimping. It is formed in a preferred embodiment as a socket which is plugged onto a pin as a contact part of an electrical or electronic device.
  • a contact element 4 a pin could be used, which is inserted into a then designed as a socket contact part.
  • the contact element 4 and the contact part of a device can also be electrically conductively connected to one another in other ways, for example by soldering or welding.
  • the contact element 4 is dimensioned according to parameters of the conductor 1.
  • the crimping length L of the crimping zone 5 of the contact element 4 depends on the diameter of the conductor 1 and on the number of individual wires 3 thereof. It is in a practical embodiment between 1.0 mm and 6.0 mm and in a preferred embodiment between 2.0 mm and 4.0 mm.
  • the conductor 1 has in conventional design, for example, a lying between 0.5 mm 2 and 2.5 mm 2 cross-section.
  • the contact element 4 is crimped around the conductor 1 with a commercially available crimping tool. In this case, the individual wires 3 are mechanically deformed and squeezed so that their oxide layers are broken.
  • the thereby exposed conductive material (aluminum or aluminum alloy) is brought into firm contact with the contact element 4.
  • the thus equipped with the contact element 4 conductor 1 is immediately thereafter, optionally packed together with other, treated in the same way conductors, airtight and left until further processing in this package.
  • the stocked with the contact element 4 conductor 1 can be introduced in a next step in a plastic existing housing part 6 of a connector V.
  • the housing part 6 has in its wall a bore 7, through which the conductor 1 is inserted therethrough with attached contact element 4 until it is out of Fig. 5 has reached an apparent position.
  • the bore 7 is sealed moistureproof and gas-tight after performing the conductor 1.
  • a sealing element 8 is advantageously applied to the insulation 2 of the conductor 1.
  • a sealing element 8 is for example a plug made of plastic, such as silicone, or rubber, which is pushed onto the end of the insulation 2 of the conductor 1 before the crimping of the contact element 4.
  • a plug can be stepped and equipped with sealing blades.
  • the sealing element 8 and the corresponding stopper is moved after reaching the end position of the conductor 1 in the housing part 6 on the conductor 1 and on the insulation 2 and pressed into the bore 7 until it is firmly and immovably positioned in the same, as it in Fig. 5 is drawn.
  • the hole 7 is then moisture-tight and sealed gas-tight.
  • a populated with a housing part 6 conductor 1 is optionally airtight packed with other appropriately treated conductors and left until further processing in the package.
  • a conductor 1 with housing part 6 after Fig. 5 taken out of the packaging at its mounting point is then directly electrically connected to a contact part 9 of a device 10, which in the embodiment according to Fig. 5 a to the housing part 6 complementary housing part 11 is made of plastic, in which an electrical conductor 12 in the same manner as the conductor 1 in its housing part 6 is moisture-tight and gas-tight.
  • the conductor 12 is passed through a bore 13 of the housing part 11, which is sealed by a sealing element 8 corresponding to the sealing element 14.
  • the connector V after Fig. 5 is a connector.
  • Contact element 4 and contact part 9, which is connected as a pin or socket with the conductor 12, 6 and 11 are inserted into each other during assembly of the housing parts.
  • Plug connection is basically known. she is in Fig. 5 therefore not shown in more detail.
  • the housing part 11 is pushed over the housing part 6 until it is out of Fig. 5 has reached an apparent final position. A remaining between the housing parts 6 and 1 1 narrow gap is sealed by an O-ring 15 which is arranged in a circumferential groove of the housing part 6.
  • the connector V after Fig. 5 is explained as an exemplary embodiment of a plug connection between a contact element 4 and a contact part 9. The same procedure applies even if two or more conductors 1 and 12 or their contacts are to be connected to each other.
  • the contact elements 4 of such a connector for two or more conductors are then determined within the housing part 6 expedient in their position.
  • the connector V after Fig. 5 can also be completed when the sealing elements 8 and 14 and the housing parts 6 and 11 are first pushed separately from each other on the ladder 1 and 12 respectively.
  • the connection between contact element 4 and contact part 9 is then made in any manner, as described above.
  • the housing parts 6 and 11 are pushed over each other and the sealing elements 8 and 14 are finally pressed into the holes 7 and 13.
  • This process can also be carried out in a stepped manner by first bringing the housing part 6 into position and pressing the sealing element 8 into the bore 7. Only then are the housing part 11 pushed over the housing part 6 and the sealing element 14 is pressed into the bore 13.
  • a moisture-tight and gas-tight connection between a contact element 4 and a contact part 9 of a device 10 can also be realized if the device 10 is a unit enclosed by a housing, whose contact part 9 or contact parts is accessible from the outside.
  • a sealing element is expediently attached to the end face of the housing part 6, which bears in the mounting position hermetically sealed to the housing of the unit.
  • This embodiment also applies to two or more conductors. Again, this is analogous to the previous explanations any type of connection between contact element 4 and contact part 9 possible.

Landscapes

  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)

Abstract

The method involves masking a junction point between a contact element (4) and a contact member (9) in damp-proof and gas-tight manner. A conductor (1) has a crimping length of one millimeter to six millimeters, particularly two millimeters to four millimeters. The conductor is inserted into a housing portion (6) of a connector (V) with the contact element, where the housing is made of plastic. The conductor has aluminum.

Description

Die Erfindung betrifft ein Verfahren zur Herstellung einer elektrisch leitenden Verbindung zwischen einem Aluminium enthaltenden elektrischen Leiter und einem Kontaktteil eines elektrischen bzw. elektronischen Geräts, bei welchem ein Leiter eingesetzt wird, der aus einer Vielzahl von miteinander verseilten, Aluminium enthaltenden Einzeldrähten besteht, die von einer Isolierung umgeben sind, mit welchem das Ende des Leiters von seiner Isolierung befreit wird, mit welchem am Ende des Leiters ein elektrisches Kontaktelement durch Crimpen befestigt wird und mit welchem das Kontaktelement mit dem Kontakttei! verbunden wird ( DE-OS 22 50 836 ).The invention relates to a method for producing an electrically conductive connection between an aluminum-containing electrical conductor and a contact part of an electrical or electronic device, in which a conductor is used, which consists of a plurality of stranded, aluminum-containing individual wires, of a Insulation are surrounded, with which the end of the conductor is freed from its insulation, with which at the end of the conductor an electrical contact element is fixed by crimping and with which the contact element with the Kontakttei! is connected ( DE-OS 22 50 836 ).

"Gerät" im Sinne der Erfindung können mit von außen zugänglichen Kontaktteilen ausgerüstete Einheiten sein. Es kann sich aber auch um Kontaktteile aufweisende Kupplungselemente handeln, wie Stecker und Gegenstecker."Device" in the context of the invention may be equipped with externally accessible contact parts units. But it may also be contact parts having coupling elements, such as connectors and mating connector.

Aluminium enthaltende Leiter werden als Ersatz für Kupferleiter immer öfter beispielsweise in der Automobil- und Flugzeugtechnik eingesetzt. Die darin verwendeten, Aluminium enthaltenden Leiter bestehen entweder ganz aus Aluminium oder einer Aluminiumlegierung. Die Leiter können zur Erhöhung ihrer Zugfestigkeit auch ein zentrales zugfestes Element aufweisen.Aluminum-containing conductors are increasingly used as a replacement for copper conductors, for example in the automotive and aircraft technology. The aluminum-containing conductors used therein are either entirely aluminum or an aluminum alloy. The conductors may also have a central tensile element to increase their tensile strength.

Ein wesentlicher Vorteil von derartigen elektrischen Leitern, die als Massivleiter oder als Litzenleiter mit einer größeren Anzahl von miteinander verseilten Drähten ausgeführt sein können, ist ihr gegenüber Kupfer geringeres Gewicht. Die geringere elektrische Leitfähigkeit des Aluminiums gegenüber Kupfer ist für die meisten Anwendungen hingegen von untergeordneter Bedeutung. Als problematisch wird bisher die Tatsache angesehen, daß Aluminium mit Sauerstoff reagiert, wodurch sehr schnell eine einen entsprechenden Leiter umgebende, elektrisch isolierende Oxidschicht gebildet wird. Es sind daher immer wieder Maßnahmen unternommen worden, um die Oxidschicht für eine elektrisch leitende Verbindung zu einem an einem solchen Leiter anzubringenden elektrischen Kontaktelement aufzubrechen und den dazu behandelten Leiter mit einer Schicht aus elektrisch gut leitendem Material zu umgeben, beispielsweise mit einer Zinnschicht.A significant advantage of such electrical conductors, which may be embodied as solid conductors or as stranded conductors with a larger number of wires stranded together, is their lower weight compared to copper. The lower electrical conductivity of the aluminum compared to copper, however, is of minor importance for most applications. The problem is considered to be the fact that aluminum reacts with oxygen, which very quickly a corresponding conductor surrounding, electrically insulating oxide layer is formed. Therefore, measures have repeatedly been taken to rupture the oxide layer for an electrically conductive connection to an electrical contact element to be attached to such a conductor and to surround the conductor treated therewith with a layer of electrically highly conductive material, for example with a tin layer.

Ein entsprechendes Verfahren geht beispielsweise aus der eingangs erwähnten DE-OS 22 50 836 aus dem Jahre 1972 hervor, mit welchem eine einen Aluminiumleiter umgebende Oxidschicht in einem Zinnbad mittels Ultraschalls aufgebrochen wird, in welchem gleichzeitig eine Zinnschicht auf den Leiter aufgebracht wird. Andere Verfahren aus den letzten 15 Jahren gehen beispielsweise aus den Schriften DE 102 23 397 B4 , DE 103 46 160 B3 , DE 103 60 614 B4 , DE 10 2005 030 248 B3 , WO 2005/055371 A1 und WO 2005/091439 A1 hervor. Bei diesen Verfahren werden Kontaktelemente an den Enden von Aluminiumleitern angebracht. Dabei werden mit entsprechendem Aufwand jeweils die den Leiter umgebenden Oxidschichten mittels Ultraschalls oder mechanisch aufgebrochen und Zinn- oder Zinkschichten aufgebracht, beispielsweise aus einem in einem Kontaktelement vorhandenen Vorrat dieser Materialien, die zunächst noch aufgeschmolzen werden.A corresponding method, for example, from the above-mentioned DE-OS 22 50 836 from 1972, with which an aluminum conductor surrounding oxide layer is broken in a tin bath by means of ultrasound, in which simultaneously a tin layer is applied to the conductor. Other methods from the last 15 years, for example, go from the writings DE 102 23 397 B4 . DE 103 46 160 B3 . DE 103 60 614 B4 . DE 10 2005 030 248 B3 . WO 2005/055371 A1 and WO 2005/091439 A1 out. In these methods, contact elements are attached to the ends of aluminum conductors. In each case, the oxide layers surrounding the conductor by means of ultrasound or mechanically and tin or zinc layers are applied with appropriate effort, for example, from an existing in a contact element stock of these materials, which are initially still melted.

Der Erfindung liegt die Aufgabe zugrunde, das eingangs geschilderte Verfahren zu vereinfachen.The invention has for its object to simplify the initially described method.

Diese Aufgabe wird gemäß der Erfindung dadurch gelöst,

  • daß ein Kontaktelement mit einer vom Durchmesser D und der Anzahl der Einzeldrähte des Leiters abhängigen Crimplänge eingesetzt wird, die zwischen 1,0 mm und 6,0 mm, vorzugsweise zwischen 2,0 mm und 4,0 mm, liegt, und
  • daß die Verbindungsstelle zwischen Kontaktelement und Kontaktteil feuchtigkeitsdicht und gasdicht abgedeckt wird.
This object is achieved according to the invention characterized
  • that a contact element with a diameter of the diameter D and the number of individual wires of the conductor dependent Crimplänge is used, which is between 1.0 mm and 6.0 mm, preferably between 2.0 mm and 4.0 mm, and
  • that the junction between the contact element and contact part is moisture-tight and gas-tight covered.

Dieses Verfahren ist einfach und ohne großen Aufwand durchführbar. Das am Ende eines Aluminium enthaltenden Leiters anzubringende Kontaktelement, das in Abhängigkeit von Parametern des jeweiligen Leiters bemessen ist, braucht nur mit einem handelsüblichen Werkzeug an den von seiner Isolierung befreiten Leiter angecrimpt zu werden. Eine vorherige Behandlung des Leiters ist bei Einsatz dieses Verfahrens nicht erforderlich. Es wird insbesondere die von der Fachwelt seit über 35 Jahren vorgegebene Maßnahme nicht angewendet, nach welcher die den Leiter umgebende Oxidschicht zunächst aufgebrochen und der Leiter anschließend oder gleichzeitig in eine rundum geschlossene, abdeckende Schicht aus elektrisch gut leitendem Material eingebettet werden muß. Es reicht überraschend aus, das Kontaktelement in üblicher Technik um den Leiter herumzucrimpen, wobei die Oxidschichten der Einzeldrähte so weit aufgebrochen werden, daß ein guter Kontakt zwischen dem Aluminium des Leiters und dem Kontaktelement entsteht. Diese überraschende Tatsache, daß auch ohne eine zusätzliche, elektrisch leitfähige Schicht eine auf Dauer elektrisch gut leitende Verbindung zwischen dem Leiter und dem aufgecrimpten Kontaktelement besteht, wird dadurch ergänzt, daß sowohl die Crimpverbindung zwischen Leiter und Kontaktelement als auch die Verbindungsstelle zwischen dem Kontaktelement und einem Kontaktteil eines Geräts feuchtigkeitsdicht und gasdicht abgedeckt werden. Der Leiter und die elektrischen Kontaktstellen sind dadurch gegenüber der Umgebung und insbesondere den Einflüssen der Atmosphäre abgeschottet.This method is simple and feasible without great effort. The contact element to be attached to the end of an aluminum-containing conductor, which is dimensioned as a function of parameters of the respective conductor, only needs to be used to be crimped on a commercially available tool on the ladder freed from its insulation. Prior treatment of the conductor is not required when using this method. In particular, the measure prescribed by the experts for more than 35 years is not applied, according to which the oxide surrounding the conductor must first be broken and the conductor then or simultaneously embedded in a completely closed, covering layer of good electrically conductive material. Surprisingly, it is sufficient to crimp the contact element around the conductor in the usual way, with the oxide layers of the individual wires being broken up so far that good contact is established between the aluminum of the conductor and the contact element. This surprising fact that even without an additional, electrically conductive layer on a long term electrically good conductive connection between the conductor and the crimped contact element is complemented by the fact that both the crimp connection between conductor and contact element and the junction between the contact element and a Contact part of a device moisture-proof and gas-tight. The conductor and the electrical contact points are thereby sealed off from the environment and in particular the influences of the atmosphere.

Zur Vereinfachung der feuchtigkeitsdichten und gasdichten Abdeckung der Kontaktstellen wird mit Vorteil vor dem Crimpen des Kontaktelements auf die Isolierung des Leiters ein Dichtelement aufgebracht, das in einer Abdeckung der Kontaktstellen gegebenenfalls als Verschluß einer Bohrung dient.To simplify the moisture-proof and gas-tight covering of the contact points, a sealing element is advantageously applied before the crimping of the contact element on the insulation of the conductor, which optionally serves as a closure of a bore in a cover of the contact points.

Das Verfahren nach der Erfindung wird anhand der Zeichnungen als Ausführungsbeispiel erläutert.The method according to the invention will be explained with reference to the drawings as an exemplary embodiment.

Es zeigen:

  • Fig. 1 einen isolierten Leiter, der an seinem Ende abisoliert ist.
  • Fig. 2 einen Schnitt durch Fig. 1 längs der Linie II - II in vergrößerter Darstellung.
  • Fig. 3 den Leiter nach Fig. 1 mit daran angebrachtem Kontaktelement.
  • Fig. 4 einen Schnitt durch Fig. 3 längs der Linie IV-IV in vergrößerter Darstellung.
  • Fig. 5 schematisch eine mit dem Verfahren nach der Erfindung hergestellte elektrische Verbindungsstelle.
Show it:
  • Fig. 1 an insulated conductor stripped at its end.
  • Fig. 2 a cut through Fig. 1 along the line II - II in an enlarged view.
  • Fig. 3 following the ladder Fig. 1 with attached contact element.
  • Fig. 4 a cut through Fig. 3 along the line IV-IV in an enlarged view.
  • Fig. 5 schematically an electrical connection point produced by the method according to the invention.

In Fig. 1 ist als Leiter 1 ein sogenannter Litzenleiter dargestellt, der von einer Isolierung 2 umgeben ist. Das Ende des Leiters 1 ist auf einer für Kontaktierungszwecke vorgesehenen Länge abisoliert. Der Leiter 1 besteht aus einer Vielzahl von Einzeldrähten 3, die miteinander verseilt sind. Jeder Einzeldraht 3 weist als elektrisch leitendes Material Aluminium oder einer Aluminiumlegierung auf.In Fig. 1 is shown as a conductor 1, a so-called stranded conductor, which is surrounded by an insulation 2. The end of the conductor 1 is stripped to a length provided for contacting purposes. The conductor 1 consists of a plurality of individual wires 3, which are stranded together. Each individual wire 3 has aluminum or an aluminum alloy as the electrically conductive material.

Am abisolierten Ende des Leiters 1 ist gemäß den Fig. 3 und 4 ein beispielsweise aus Kupfer bestehendes Kontaktelement 4 durch Crimpen befestigt. Es ist in bevorzugter Ausführungsform als Buchse ausgebildet, die auf einen Stift als Kontaktteil eines elektrischen bzw. elektronischen Geräts aufgesteckt wird. Als Kontaktelement 4 könnte auch ein Stift eingesetzt werden, der in ein dann als Buchse ausgeführtes Kontaktteil eingesteckt wird. Das Kontaktelement 4 und das Kontaktteil eines Geräts können auch auf andere Art und Weise elektrisch leitend miteinander verbunden werden, beispielsweise durch Löten oder Schweißen.At stripped end of the conductor 1 is according to the 3 and 4 an existing example of copper contact element 4 is fixed by crimping. It is formed in a preferred embodiment as a socket which is plugged onto a pin as a contact part of an electrical or electronic device. As a contact element 4, a pin could be used, which is inserted into a then designed as a socket contact part. The contact element 4 and the contact part of a device can also be electrically conductively connected to one another in other ways, for example by soldering or welding.

Das Kontaktelement 4 ist nach Parametern des Leiters 1 bemessen. Die Crimplänge L der Crimpzone 5 des Kontaktelements 4 hängt vom Durchmesser des Leiters 1 und von der Anzahl der Einzeldrähte 3 desselben ab. Sie liegt in praktischer Ausführung zwischen 1,0 mm und 6,0 mm und in bevorzugter Ausführungsform zwischen 2,0 mm und 4,0 mm. Der Leiter 1 hat in üblicher Ausführung beispielsweise einen zwischen 0,5 mm2 und 2,5 mm2 liegenden Querschnitt. Das Kontaktelement 4 wird mit einem handelsüblichen Crimpwerkzeug um den Leiter 1 herumgecrimpt. Dabei werden dessen Einzeldrähte 3 mechanisch so verformt und zusammengequetscht, daß ihre Oxidschichten aufgebrochen werden. Das dadurch freigelegte leitende Material (Aluminium bzw. Aluminiumlegierung) wird dabei in festen Kontakt zum Kontaktelement 4 gebracht. Der so mit dem Kontaktelement 4 bestückte Leiter 1 wird unmittelbar danach, gegebenenfalls zusammen mit anderen, in gleicher Weise behandelten Leitern, luftdicht verpackt und bis zur Weiterverarbeitung in dieser Verpackung belassen.The contact element 4 is dimensioned according to parameters of the conductor 1. The crimping length L of the crimping zone 5 of the contact element 4 depends on the diameter of the conductor 1 and on the number of individual wires 3 thereof. It is in a practical embodiment between 1.0 mm and 6.0 mm and in a preferred embodiment between 2.0 mm and 4.0 mm. The conductor 1 has in conventional design, for example, a lying between 0.5 mm 2 and 2.5 mm 2 cross-section. The contact element 4 is crimped around the conductor 1 with a commercially available crimping tool. In this case, the individual wires 3 are mechanically deformed and squeezed so that their oxide layers are broken. The thereby exposed conductive material (aluminum or aluminum alloy) is brought into firm contact with the contact element 4. The thus equipped with the contact element 4 conductor 1 is immediately thereafter, optionally packed together with other, treated in the same way conductors, airtight and left until further processing in this package.

Der mit dem Kontaktelement 4 bestückte Leiter 1 kann in einem nächsten Arbeitsschritt in ein aus Kunststoff bestehendes Gehäuseteil 6 eines Verbinders V eingebracht werden. Das Gehäuseteil 6 hat in seiner Wandung eine Bohrung 7, durch welche der Leiter 1 mit daran angebrachtem Kontaktelement 4 hindurchgesteckt wird, bis er eine aus Fig. 5 ersichtliche Position erreicht hat. Die Bohrung 7 wird nach dem Durchführen des Leiters 1 feuchtigkeitsdicht und gasdicht verschlossen.The stocked with the contact element 4 conductor 1 can be introduced in a next step in a plastic existing housing part 6 of a connector V. The housing part 6 has in its wall a bore 7, through which the conductor 1 is inserted therethrough with attached contact element 4 until it is out of Fig. 5 has reached an apparent position. The bore 7 is sealed moistureproof and gas-tight after performing the conductor 1.

Um diesen Abdichtvorgang zu erleichtern, wird auf die Isolierung 2 des Leiters 1 mit Vorteil ein Dichtelement 8 aufgebracht. Ein solches Dichtelement 8 ist beispielsweise ein Stopfen aus Kunststoff, wie Silikon, oder Gummi, der vor dem Crimpen des Kontaktelements 4 auf das Ende der Isolierung 2 des Leiters 1 aufgeschoben wird. Ein derartiger Stopfen kann abgestuft und mit Dichtlamellen ausgerüstet sein. Das Dichtelement 8 bzw. der entsprechende Stopfen wird nach Erreichen der Endposition des Leiters 1 im Gehäuseteil 6 auf dem Leiter 1 bzw. auf dessen Isolierung 2 verschoben und in die Bohrung 7 hineingedrückt, bis es fest und unverrückbar in derselben positioniert ist, so wie es in Fig. 5 eingezeichnet ist. Die Bohrung 7 ist dann feuchtigkeitsdicht und gasdicht verschlossen. Ein so mit einem Gehäuseteil 6 bestückter Leiter 1 wird gegebenenfalls mit anderen entsprechend behandelten Leitern wieder luftdicht verpackt und bis zur Weiterverarbeitung in der Verpackung belassen.To facilitate this sealing process, a sealing element 8 is advantageously applied to the insulation 2 of the conductor 1. Such a sealing element 8 is for example a plug made of plastic, such as silicone, or rubber, which is pushed onto the end of the insulation 2 of the conductor 1 before the crimping of the contact element 4. Such a plug can be stepped and equipped with sealing blades. The sealing element 8 and the corresponding stopper is moved after reaching the end position of the conductor 1 in the housing part 6 on the conductor 1 and on the insulation 2 and pressed into the bore 7 until it is firmly and immovably positioned in the same, as it in Fig. 5 is drawn. The hole 7 is then moisture-tight and sealed gas-tight. A populated with a housing part 6 conductor 1 is optionally airtight packed with other appropriately treated conductors and left until further processing in the package.

Zur Vervollständigung des Verfahrens nach der Erfindung wird beispielsweise ein Leiter 1 mit Gehäuseteil 6 nach Fig. 5 an seiner Montagestelle aus der Verpackung herausgenommen. Das Kontaktelement 4 wird dann direkt elektrisch leitend mit einem Kontaktteil 9 eines Geräts 10 verbunden, das im Ausführungsbeispiel nach Fig. 5 ein zum Gehäuseteil 6 komplementäres Gehäuseteil 11 aus Kunststoff ist, in dem ein elektrischer Leiter 12 in gleicher Weise wie der Leiter 1 in seinem Gehäuseteil 6 feuchtigkeitsdicht und gasdicht angeordnet ist. Dazu ist der Leiter 12 durch eine Bohrung 13 des Gehäuseteils 11 hindurchgeführt, die durch ein dem Dichtelement 8 entsprechendes Dichtelement 14 abgedichtet ist.To complete the method according to the invention, for example, a conductor 1 with housing part 6 after Fig. 5 taken out of the packaging at its mounting point. The contact element 4 is then directly electrically connected to a contact part 9 of a device 10, which in the embodiment according to Fig. 5 a to the housing part 6 complementary housing part 11 is made of plastic, in which an electrical conductor 12 in the same manner as the conductor 1 in its housing part 6 is moisture-tight and gas-tight. For this purpose, the conductor 12 is passed through a bore 13 of the housing part 11, which is sealed by a sealing element 8 corresponding to the sealing element 14.

Der Verbinder V nach Fig. 5 ist ein Steckverbinder. Kontaktelement 4 und Kontaktteil 9, welches als Stift oder Buchse mit dem Leiter 12 verbunden ist, werden beim Zusammenfügen der Gehäuseteile 6 und 11 ineinander gesteckt. Eine solche Steckverbindung ist grundsätzlich bekannt. Sie ist in Fig. 5 daher nicht genauer dargestellt. Zur Fertigstellung der Steckverbindung wird das Gehäuseteil 11 über das Gehäuseteil 6 geschoben, bis es die aus Fig. 5 ersichtliche Endposition erreicht hat. Ein zwischen den Gehäuseteilen 6 und 1 1 verbleibender schmaler Spalt wird durch einen O-Ring 15 abgedichtet, der in einer umlaufenden Nut des Gehäuseteils 6 angeordnet ist.The connector V after Fig. 5 is a connector. Contact element 4 and contact part 9, which is connected as a pin or socket with the conductor 12, 6 and 11 are inserted into each other during assembly of the housing parts. Such Plug connection is basically known. she is in Fig. 5 therefore not shown in more detail. To complete the connector, the housing part 11 is pushed over the housing part 6 until it is out of Fig. 5 has reached an apparent final position. A remaining between the housing parts 6 and 1 1 narrow gap is sealed by an O-ring 15 which is arranged in a circumferential groove of the housing part 6.

Der Verbinder V nach Fig. 5 ist als Ausführungsbeispiel für eine Steckverbindung zwischen einem Kontaktelements 4 und einem Kontaktteil 9 erläutert. Die gleiche Vorgehensweise gilt auch dann, wenn jeweils zwei oder mehr Leiter 1 und 12 bzw. deren Kontakte miteinander zu verbinden sind. Insbesondere die Kontaktelemente 4 eines solchen Verbinders für zwei oder mehr Leiter werden dann innerhalb des Gehäuseteils 6 zweckmäßig in ihrer Position festgelegt.The connector V after Fig. 5 is explained as an exemplary embodiment of a plug connection between a contact element 4 and a contact part 9. The same procedure applies even if two or more conductors 1 and 12 or their contacts are to be connected to each other. In particular, the contact elements 4 of such a connector for two or more conductors are then determined within the housing part 6 expedient in their position.

Der Verbinder V nach Fig. 5 kann auch dann fertiggestellt werden, wenn die Dichtelemente 8 und 14 sowie die Gehäuseteile 6 und 11 zunächst getrennt voneinander jeweils auf die Leiter 1 und 12 aufgeschoben werden. Die Verbindung zwischen Kontaktelement 4 und Kontaktteil 9 wird dann auf beliebige Art und Weise hergestellt, so wie es weiter oben geschildert ist. Anschließend werden die Gehäuseteile 6 und 11 übereinander geschoben und die Dichtelemente 8 und 14 werden abschließend in die Bohrungen 7 und 13 gedrückt. Dieser Vorgang kann auch abgestuft erfolgen, indem zunächst das Gehäuseteil 6 in Position gebracht und das Dichtelement 8 in die Bohrung 7 gedrückt wird. Erst danach werden dann das Gehäuseteil 11 über das Gehäuseteil 6 geschoben und das Dichtelement 14 in die Bohrung 13 gedrückt.The connector V after Fig. 5 can also be completed when the sealing elements 8 and 14 and the housing parts 6 and 11 are first pushed separately from each other on the ladder 1 and 12 respectively. The connection between contact element 4 and contact part 9 is then made in any manner, as described above. Subsequently, the housing parts 6 and 11 are pushed over each other and the sealing elements 8 and 14 are finally pressed into the holes 7 and 13. This process can also be carried out in a stepped manner by first bringing the housing part 6 into position and pressing the sealing element 8 into the bore 7. Only then are the housing part 11 pushed over the housing part 6 and the sealing element 14 is pressed into the bore 13.

Eine feuchtigkeitsdichte und gasdichte Verbindung zwischen einem Kontaktelement 4 und einem Kontaktteil 9 eines Geräts 10 ist auch dann realisierbar, wenn das Gerät 10 eine von einem Gehäuse umschlossene Einheit ist, deren Kontaktteil 9 bzw. Kontaktteile von außen zugänglich ist bzw. sind. Bei einer solchen Ausführungsform wird an der Stirnseite des Gehäuseteils 6 zweckmäßig ein Dichtelement angebracht, das in Montageposition hermetisch dichtend am Gehäuse der Einheit anliegt. Auch diese Ausführungsform gilt für zwei oder mehr Leiter. Auch hier ist analog zu den vorangehenden Erläuterungen eine beliebige Art der Verbindung zwischen Kontaktelement 4 und Kontaktteil 9 möglich.A moisture-tight and gas-tight connection between a contact element 4 and a contact part 9 of a device 10 can also be realized if the device 10 is a unit enclosed by a housing, whose contact part 9 or contact parts is accessible from the outside. In such an embodiment, a sealing element is expediently attached to the end face of the housing part 6, which bears in the mounting position hermetically sealed to the housing of the unit. This embodiment also applies to two or more conductors. Again, this is analogous to the previous explanations any type of connection between contact element 4 and contact part 9 possible.

Die beschriebenen Ausführungsformen der feuchtigkeitsdichten und gasdichten Abdeckung der Verbindungsstelle zwischen Kontaktelement 4 und Kontaktteil 9 sind bevorzugte Ausführungsformen. Wichtig für das Verfahren nach der Erfindung ist, daß diese Verbindungsstelle wirksam und auf Dauer feuchtigkeitsdicht und gasdicht abgeschottet ist. Das kann gegebenenfalls auch auf andere Art und Weise erreicht werden.The described embodiments of the moisture-proof and gas-tight covering of the connection point between contact element 4 and contact part 9 are preferred embodiments. Important for the method according to the invention is that this junction is effectively and permanently moisture-proof and gas-tight foreclosed. If appropriate, this can also be achieved in other ways.

Claims (3)

  1. Amethod for making an electrically connection between an aluminium containing electrical conductor (1) and a contact member (9) of an electrical or electronical device (10), where in the conductor (1) comprises a plurality of aluminium containing single wires (3) which are stranded with each other and surrounded by an insulation, by use of which the end of the conductor (1) is bared and an electrical contact element (4) is connected to the same by crimping and with which the contact element (4) is connec ted to the contact member (9), characterized in
    - that a contact element (4) is used with a crimping length which depends on the diameter and the number of single wires (3) of the conductor (1) and which lies between 1,0 mm and 6,0 mm, preferably between 2,0 mm and 4,0 mm, and
    - that the connection between contact element (4) and contact member (9) is covered in a moisture proof and gastight manner.
  2. Amethod according to claim 1, characterized in that the conductor (1) together with the crimped contact element (4) is positioned within a part of a plastic ho using (6) of a connector (V), which in mounting p o sitio n is fa ste ne d to the electrical or electronical device (10) in a moisture proof and gastight manner.
  3. A method according to claim 1 or 2, characterized in that before crimping a sealing element (8) is mounted at the end of the insulation (2) of the conductor (1) in an area in which the crimping shall be made, which afterpositioning ofthe conductor (1) within the part of the ho using (6) of the connector (V) is pressed into a bore hole (7) ofthe housing (6) through which the conductor (1) is lead through serving asa moisture proof and gastight lock of the bore hole (7).
EP07290704A 2007-06-06 2007-06-06 Method for manufacturing an electrically conducting connection Not-in-force EP2001085B1 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
EP07290704A EP2001085B1 (en) 2007-06-06 2007-06-06 Method for manufacturing an electrically conducting connection
AT07290704T ATE468629T1 (en) 2007-06-06 2007-06-06 METHOD FOR PRODUCING AN ELECTRICALLY CONDUCTIVE CONNECTION
DE502007003854T DE502007003854D1 (en) 2007-06-06 2007-06-06 Process for the preparation of an electrically conductive compound
ES07290704T ES2357827T3 (en) 2007-06-06 2007-06-06 PROCEDURE FOR THE PRODUCTION OF AN ELECTRICITY DRIVER LINK.

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP07290704A EP2001085B1 (en) 2007-06-06 2007-06-06 Method for manufacturing an electrically conducting connection

Publications (2)

Publication Number Publication Date
EP2001085A1 EP2001085A1 (en) 2008-12-10
EP2001085B1 true EP2001085B1 (en) 2010-05-19

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Application Number Title Priority Date Filing Date
EP07290704A Not-in-force EP2001085B1 (en) 2007-06-06 2007-06-06 Method for manufacturing an electrically conducting connection

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EP (1) EP2001085B1 (en)
AT (1) ATE468629T1 (en)
DE (1) DE502007003854D1 (en)
ES (1) ES2357827T3 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3270464A1 (en) 2016-07-13 2018-01-17 Nexans Method for connecting a contact element to an electrical conductor

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102011016556B4 (en) * 2011-04-08 2020-02-06 Kromberg & Schubert Kg Electrical contact device
EP2607010B1 (en) * 2011-12-23 2015-04-15 Nexans Method of welding an electrical conductor with a contact element
EP2747205B1 (en) * 2012-12-18 2021-04-14 Nexans Method for the electrically conductive connection of a stranded conductor with a contact element

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3916518A (en) * 1973-10-02 1975-11-04 Coatings Inc Method for making one-piece bimetallic connector
US5066242A (en) * 1990-10-15 1991-11-19 Molex Incorporated Environment-proof electrical connector assembly
US5749756A (en) * 1995-10-27 1998-05-12 The Whitaker Corporation Sealed corrosion-proof crimped terminal of splice

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3270464A1 (en) 2016-07-13 2018-01-17 Nexans Method for connecting a contact element to an electrical conductor

Also Published As

Publication number Publication date
EP2001085A1 (en) 2008-12-10
ES2357827T3 (en) 2011-05-03
ATE468629T1 (en) 2010-06-15
DE502007003854D1 (en) 2010-07-01

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