EP2025046A1 - Method for connecting two electrically conductive components to one another - Google Patents

Method for connecting two electrically conductive components to one another

Info

Publication number
EP2025046A1
EP2025046A1 EP07718383A EP07718383A EP2025046A1 EP 2025046 A1 EP2025046 A1 EP 2025046A1 EP 07718383 A EP07718383 A EP 07718383A EP 07718383 A EP07718383 A EP 07718383A EP 2025046 A1 EP2025046 A1 EP 2025046A1
Authority
EP
European Patent Office
Prior art keywords
electrically conductive
electrical line
sleeve
flexible
components
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP07718383A
Other languages
German (de)
French (fr)
Other versions
EP2025046B1 (en
Inventor
Karl Franz FRÖSCHL
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.)
Gebauer and Griller Kabelwerke GmbH
Original Assignee
Gebauer and Griller Kabelwerke GmbH
Gebauer and Griller
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 Gebauer and Griller Kabelwerke GmbH, Gebauer and Griller filed Critical Gebauer and Griller Kabelwerke GmbH
Priority to PL07718383T priority Critical patent/PL2025046T3/en
Publication of EP2025046A1 publication Critical patent/EP2025046A1/en
Application granted granted Critical
Publication of EP2025046B1 publication Critical patent/EP2025046B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H01R4/029—Welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—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
    • H01R4/02—Soldered or welded connections
    • H01R4/027—Soldered or welded connections comprising means for positioning or holding the parts to be soldered or welded
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/53—Means to assemble or disassemble
    • Y10T29/5313—Means to assemble electrical device
    • Y10T29/532—Conductor

Definitions

  • the subject invention relates to a method of connecting a first electrically conductive member in the form of a metallic wires having flexible electrical line to a second electrically conductive metallic component, e.g. a second electrical line or a connection element.
  • a second metallic component e.g. a one-piece metallic conductor or a connection element
  • the two electrical components are brought into contact with each other during passage of the stream under pressure.
  • the electrically conductive, metallic second component is formed by an electrical line with a band-shaped or rod-shaped or electrical conductor, which is connected to a flexible electrical line with a plurality of wires.
  • the second electrically conductive Component be formed by a connection element which is connected to a flexible electrical line with a plurality of wires.
  • the end face of the second component facing the first component can be profiled, the profiling preferably being in the form of a waffle pattern.
  • the flexible electric wire may include a plurality of aluminum wires reinforced by a wire made of a chromium-nickel alloy.
  • the two electrically conductive components may be made of aluminum, copper, brass or aluminum and a wire of a chromium-nickel alloy.
  • the sleeve can be made of sheet steel.
  • insulation in particular in the form of a shrink film, is preferably applied via the connection point.
  • FIG. 1 shows two electrical components, which by means of the invention
  • FIG. IA, IB, IC are sections according to the lines IA, IB and IC of FIG. 2, 2 A, 2B, the components used in the method according to the invention in three successive steps, each in axial
  • Cut 3A, 3B, the components of a second embodiment, in which the method according to the invention is applied; 4A, 4A the components of a third embodiment to which the method according to the invention is applied; such as
  • connection element used in the method according to the invention, in axonometric representation and in front view.
  • FIGS. L and IA to IC are a flexible electric wire 1 which has a plurality of metallic wires 11 and which is formed with an insulation 12, and an electric wire 2 with a one-piece metallic electrical conductor 21 which is also formed with an insulation 22 is shown, which two lines 1 and 2 to be connected to each other. For this purpose, these two electrical lines 1 and 2 are stripped at the ends facing each other.
  • a metallic Sleeve 3 is provided, whose clear cross section is approximately equal to the cross section of the wires 11 and the conductor 21, which are to be connected to each other.
  • the stripped free end of the flexible line 1 comprising a plurality of wires 11 is pushed into the sleeve 3 over at least two-thirds of the length of the sleeve 3, and the sleeve 3 is pushed along the wires 11 pressed. Subsequently, from the other side, the free end of the conductor 21 is pushed into the sleeve 3 so far that the end faces of the conductor 21 and the wires 11 come into contact with each other under pressure. Reference is made to the illustration of FIG. 2A. Then, electric current is passed through these two lines 1 and 2, whereby due to the transition resistance occurring thereby within the sleeve 3 so high temperatures occur that the free ends of the lines 1 and 2 are fused together.
  • the sleeve 3 In order to enable this operation, the sleeve 3 must be made of a metal whose melting point is above the melting point or melting points of the metal or metals from which the wires 11 and the conductor 21 are made.
  • the wires 11 and the conductor 21 are made of aluminum or of copper and the sleeve 3 is made of sheet steel. Insofar as the metals used are weldable together, the wires 11 and the conductor 21 may be made of different metals.
  • a flexible line Ia which has a plurality of wires I Ia and which is formed with an insulation 12a, with a connection element 5 which is provided with a cylindrical part 51 and is formed with a terminal lug 52 connected.
  • the wires I Ia of the stripped free end of the line Ia are inserted from one side into a sleeve 3a, the sleeve 3a is pressed with the wires I Ia, is from the other side of the cylindrical part 51 of the connecting element 5 in the Sleeve 3a is inserted and the end faces of these two components Ia and 5 are brought under pressure to each other for conditioning. Then electric current is passed through the line Ia and the terminal 5, whereby they are heated so much that they are fused together.
  • the flexible electric wire 1b is made up of a plurality of wires 1b sandwiched by an insulation 12b, which are made of aluminum and which includes a middle wire 13 which is substantially aluminum more tensile metal, eg from a chrome nickel alloy. Such reinforced by an additional wire 13 line Ib is used for example in elevator shafts.
  • the stripped free end of the line Ib is inserted from one side into a sleeve 3b and pressed with the sleeve 3b, the cylindrical part 51 of the connecting element 5 is inserted from the other side into the sleeve 3b and the end faces of these two Components Ib and 5 brought under pressure to each other to the plant. Then, electrical current is passed through the line Ib and the connecting element 5, whereby they are heated so strongly that they are fused together.
  • a flexible electrical lead made of aluminum the tensile strength of which is substantially increased by means of an additional wire, are connected to a connection element by means of resistance welding, which on the one hand meets the requirements the lowest possible contact resistance and on the other hand to high mechanical strength is optimally met.
  • tensile strength it is pointed out that aluminum has a tensile strength of about 80 N / mm 2 , copper has a tensile strength of about 250 N / mm 2 and chromium-nickel alloys have a tensile strength of about 2000 N / mm 2 .
  • the wires 11, IIa and IIb facing end face of the conductor 21 and the connecting element 5 is formed profiled.
  • the achieved by the welding of these two components compound is optimized in terms of a low contact resistance and on increasing the tensile strength.
  • connection element 5a with a cylindrical connection part 51a and with a connection lug 52a is shown in FIGS. 5 and 5A, wherein the connection part 51a is formed on the side facing away from the connection lug 52a with a profiling in the form of a waffle pattern 53a. Because of this profiling, a particularly effective connection of the connection element 5a with the subsequent electrical line takes place, whereby the mechanical strength of this connection is optimized and the electrical contact resistance of this connection is minimized.

Abstract

Method for connecting a first electrically conductive component in the form of a flexible electrical line (1) which has a plurality of wires (11) to a second electrically conductive metallic component, for example a second electrical line (2) or a connecting element. In this case, the free end of the flexible electrical line (1) is inserted into a sleeve (3) and is compressed with it and, furthermore, that end of the second electrically conductive component (2) which is associated with the flexible electrical line (1) is inserted into the free end of the sleeve (3) and is brought into contact with the flexible electrical line (I) and electric current is passed through these two components (1, 2) as a result of which their ends resting on one another are fused, with the sleeve (3) being produced from a metal which has a higher melting point than the metal(s) of the two components (1, 2) to be connected to one another.

Description

Verfahren zum Verbinden von zwei elektrisch leitenden Bauteilen miteinander Method for connecting two electrically conductive components together
Die gegenständliche Erfindung betrifft ein Verfahren zum Verbinden eines ersten elektrisch leitenden Bauteiles in Form einer metallische Drähte aufweisenden flexiblen elektrischen Leitung mit einem zweiten elektrisch leitenden metallischen Bauteil, z.B. einer zweiten elektrischen Leitung oder einem Anschlusselement.The subject invention relates to a method of connecting a first electrically conductive member in the form of a metallic wires having flexible electrical line to a second electrically conductive metallic component, e.g. a second electrical line or a connection element.
Es besteht das Bestreben, die in einem Kraftfahrzeug befindlichen, von der Batterie zum Starter führenden elektrischen Leitungen vorzufertigen, um hierdurch den Montageaufwand bei der Verlegung dieser Leitungen weitgehend herabzusetzen. Diese elektrischen Leitungen werden einerseits mit vorgegebenen Längen hergestellt und werden andererseits über ihren Verlauf mit Krümmungen bzw. mit Abwinkelungen ausgebildet, um hierdurch deren Verlegung maßgeblich zu vereinfachen. Um eine derartige Vorkonfektionierung durchführen zu können, müssen diese Leitungen eine entsprechende Steifigkeit aufweisen, welche dadurch erzielt wird, dass die elektrische Leitung mit einem einstückigen metallischen Band oder mit einem einstückigen Draht bzw. Stab ausgebildet ist.There is a desire to prefabricate located in a motor vehicle, leading from the battery to the starter electrical lines to thereby reduce the assembly costs when laying these lines largely. These electrical lines are made on the one hand with predetermined lengths and on the other hand formed on their course with curvatures or with bends, thereby simplifying their installation significantly. In order to be able to carry out such a pre-assembly, these lines must have a corresponding rigidity, which is achieved in that the electrical line is formed with a one-piece metallic band or with a one-piece wire or rod.
Da jedoch derartige elektrische Leitungen auch flexible Bereiche enthalten müssen bzw. da ungeachtet von deren Vorkonfektionierung die Möglichkeit bestehen muss, einen Längenausgleich vorzunehmen, besteht das Erfordernis, diese elektrischen Leitungen mit flexiblen Leitungsstücken auszubilden.However, since such electrical lines must also contain flexible areas or since regardless of their prefabrication must be able to make a length compensation, there is a need to form these electrical lines with flexible pipe sections.
Aufgrund der vergleichsweise geringen Kosten werden derartige Leitungen vorzugsweise aus Aluminium hergestellt.Due to the comparatively low cost such lines are preferably made of aluminum.
Aluminium ist aufgrund seines Preis-Leistungsverhältnisses im Vergleich zu Kupfer auch für Leitungen in außerhalb der Automobilindustrie befindlichen Anwendungsgebieten von Interesse. Eines dieser Anwendungsgebiete besteht im Bereich der Aufzugssteuertechnik. Dabei werden Flachleitungen verwendet, welche im Aufzugsschacht als Verbindung zwischen einem ortsfesten Schaltschrank und der Aufzugskabine eingesetzt werden. Bei derartigen Leitungen muss die Zugfestigkeit der Leitungen auf die Förderhöhe des Aufzugs abgestimmt werden. Ab einer bestimmten Förderhöhe müssen gebräuchliche Leitungen durch Tragelemente in Form von Tex- tilschnüren oder Stahlseilen verstärkt werden. Dies trifft insbesondere für solche Leitungen zu, welche aus Aluminium hergestellt sind, da Aluminium eine vergleichsweise geringe Zugfestigkeit aufweist. Aus diesem Grund ist es bekannt, aus Aluminium hergestellte Leitungen, welche eine Mehrzahl von Drähten aufweisen, durch einen aus einer Chrom-Nickellegierung hergestellten Draht zu verstärken. Bei flexiblen elektrischen Leitungen, welche mit einem zweiten elektrisch leitenden Bauteil, wie mit einer steifen elektrischen Leitung oder mit einem Anschlusselement, ausgebildet sind, besteht das Erfordernis, diese beiden Teile miteinander zu verbinden, wobei an der Verbindungsstelle durch diese Verbindung bedingte Übergangswiderstände weitestgehend vermieden werden müssen.Due to its price-performance ratio compared to copper, aluminum is also of interest for lines in non-automotive applications. One of these fields of application is in the area of elevator control technology. In this case, flat cables are used, which are used in the elevator shaft as a connection between a stationary control cabinet and the elevator car. In such lines, the tensile strength of the lines must be matched to the lift height of the elevator. Starting at a certain head, conventional lines must be reinforced by supporting elements in the form of textile cords or steel cables. This is particularly true for such lines, which are made of aluminum, since aluminum has a comparatively low tensile strength. For this reason, it is known to reinforce wires made of aluminum having a plurality of wires by a wire made of a chromium-nickel alloy. In flexible electrical lines, which are formed with a second electrically conductive component, such as a rigid electrical line or with a connection element, there is a need to connect these two parts together, wherein at the junction by this connection conditional contact resistance are largely avoided have to.
Es ist bekannt, steife metallische Bauteile miteinander mittels Widerstands- schweißung zu verbinden. Es ist dies deshalb möglich, da die beiden steifen metallischen Bauteile aneinander dicht zur Anlage gebracht und mittels eines durch diese hindurchgeführten elektrischen Stromes miteinander durch Schweißung verbunden werden können. Es ist jedoch bisher deshalb nicht möglich, eine mit einer Mehrzahl von metallischen Drähten ausgebildete flexible elektrische Leitung mit einem steifen metallischen Bauteil mittels Widerstandsschweißung zu verbinden, da die Drähte der flexiblen elektrischen Leitung an den steifen Bauteil nicht in der für die Wider- standsschweissung erforderlichen Weise unter Druck zur Anlage gebracht werden können.It is known to connect rigid metallic components to one another by means of resistance welding. This is possible because the two rigid metallic components can be brought into close contact with each other and can be connected to one another by welding by means of an electric current passed through them. However, it has not heretofore been possible to connect a flexible electric wire formed with a plurality of metallic wires to a rigid metallic member by resistance welding since the wires of the flexible electric wire to the rigid member are not required in the manner required for the resistance welding can be brought under pressure to the plant.
Der gegenständlichen Erfindung liegt somit die Aufgabe zugrunde, ein Verfahren zu schaffen, durch welches auch eine flexible elektrische Leitung, welche eine Mehrzahl von Drähten aufweist, mit einem zweiten metallischen Bauteil, z.B. einem einstückigen metallischen Leiter oder einem Anschlusselement, durch Widerstandsschweißung verbunden werden kann.It is therefore an object of the present invention to provide a method by which a flexible electrical conductor comprising a plurality of wires can also be connected to a second metallic component, e.g. a one-piece metallic conductor or a connection element, can be connected by resistance welding.
Dies wird erfindungsgemäß dadurch erzielt, dass das freie Ende der flexiblen elektrischen Leitung in eine Hülse eingesetzt und mit dieser verpresst wird, dass weiters in das freie Ende der Hülse das der flexiblen elektrischen Leitung zugeordnete Ende des zweiten elektrisch leitenden Bauteiles eingesetzt sowie an die flexible elektrische Leitung zur Anlage gebracht wird und dass durch diese beiden Bauteile elektrischer Strom hindurchgeleitet wird, wodurch deren aneinander liegenden Enden miteinander verschmolzen werden, wobei die Hülse aus einem solchen Metall hergestellt ist, welches gegenüber dem Metall bzw. den Metallen der beiden miteinander zu verbindenden Bauteile einen höheren Schmelzpunkt aufweist.This is inventively achieved in that the free end of the flexible electrical line is inserted into a sleeve and pressed with this, that further used in the free end of the sleeve of the flexible electrical line associated end of the second electrically conductive member and the flexible electrical Conduction is brought to the plant and that electrical current is passed through these two components, whereby their abutting ends are fused together, wherein the sleeve is made of such a metal, which compared to the metal or the metals of the two components to be joined together has higher melting point.
Vorzugsweise werden die beiden elektrischen Bauteile während des Hindurchleitens des Stromes aneinander unter Druck zur Anlage gebracht.Preferably, the two electrical components are brought into contact with each other during passage of the stream under pressure.
Vorzugsweise ist der elektrisch leitende, metallische zweite Bauteil durch eine elektrische Leitung mit einem bandförmigen oder stabförmigen bzw. drahtförmigen elektrischen Leiter gebildet, welcher mit einer flexiblen elektrischen Leitung mit einer Mehrzahl von Drähten verbunden wird. Weiters kann der zweite elektrisch leitende Bauteil durch ein Anschlusselement gebildet sein, welches mit einer flexiblen elektrischen Leitung mit einer Mehrzahl von Drähten verbunden wird. Dabei kann die dem ersten Bauteil zugewandte Stirnfläche des zweiten Bauteils profiliert ausgebildet sein, wobei vorzugsweise die Profilierung als Waffelmuster ausgebildet ist. Zudem kann die flexible elektrische Leitung eine Mehrzahl von Drähten aus Aluminium aufweisen, welche durch einen aus einer Chrom-Nickellegierung bestehenden Draht verstärkt sind. Dabei können die beiden elektrisch leitenden Bauteile aus Aluminium, aus Kupfer, aus Messing oder aus Aluminium und einem Draht aus einer Chrom-Nickellegierung hergestellt sein. Weiters kann die Hülse aus Stahlblech hergestellt sein.Preferably, the electrically conductive, metallic second component is formed by an electrical line with a band-shaped or rod-shaped or electrical conductor, which is connected to a flexible electrical line with a plurality of wires. Furthermore, the second electrically conductive Component be formed by a connection element which is connected to a flexible electrical line with a plurality of wires. In this case, the end face of the second component facing the first component can be profiled, the profiling preferably being in the form of a waffle pattern. In addition, the flexible electric wire may include a plurality of aluminum wires reinforced by a wire made of a chromium-nickel alloy. The two electrically conductive components may be made of aluminum, copper, brass or aluminum and a wire of a chromium-nickel alloy. Furthermore, the sleeve can be made of sheet steel.
Sobald die beiden elektrisch leitenden Bauteile miteinander verschweißt worden sind, wird vorzugsweise über die Verbindungsstelle eine Isolierung, insbesondere in Form einer Schrumpffolie, aufgebracht.As soon as the two electrically conductive components have been welded together, insulation, in particular in the form of a shrink film, is preferably applied via the connection point.
Das erfindungsgemäße Verfahren und eine erfindungsgemäße elektrische Leitung sind nachstehend anhand von drei in der Zeichnung dargestellten Ausführungsbeispielen näher erläutert. Es zeigen: FIG.l zwei elektrische Bauteile, welche mittels des erfindungsgemäßenThe inventive method and an electrical line according to the invention are explained below with reference to three exemplary embodiments illustrated in the drawing. FIG. 1 shows two electrical components, which by means of the invention
Verfahrens durch Widerstandsschweissung miteinander verbunden werden, in Seitenansicht;Method are joined together by resistance welding, in side view;
FIG. IA, IB, IC jeweils Schnitte nach den Linien IA, IB und IC der FIG.l; FIG.2, 2 A, 2B die beim erfindungsgemäßen Verfahren verwendeten Bauteile in drei aufeinanderfolgenden Verfahrensschritten, jeweils in axialemFIG. IA, IB, IC are sections according to the lines IA, IB and IC of FIG. 2, 2 A, 2B, the components used in the method according to the invention in three successive steps, each in axial
Schnitt; FIG.3, 3A die Bauteile eines zweiten Ausführungsbeispiels, bei welchem das erfindungsgemäße Verfahren angewendet wird; FIG.4, 4A die Bauteile eines dritten Ausführungsbeispieles, bei welchem das erfindungsgemäße Verfahren angewendet wird; sowieCut; 3A, 3B, the components of a second embodiment, in which the method according to the invention is applied; 4A, 4A the components of a third embodiment to which the method according to the invention is applied; such as
FIG.5, 5 A ein beim erfindungsgemäßen Verfahren verwendetes Anschlusselement, in axonometrischer Darstellung und in Stirnansicht.5, 5 A a connection element used in the method according to the invention, in axonometric representation and in front view.
In den FIG. l und IA bis IC sind eine flexible elektrische Leitung 1, welche eine Mehrzahl von metallischen Drähten 11 aufweist und welche mit einer Isolierung 12 ausgebildet ist, sowie eine elektrische Leitung 2 mit einem einstückigen metallischen, elektrischen Leiter 21, welcher gleichfalls mit einer Isolierung 22 ausgebildet ist, dargestellt, welche beiden Leitungen 1 und 2 miteinander verbunden werden sollen. Hierfür werden diese beiden elektrischen Leitungen 1 und 2 an den einander zugewandten Enden abisoliert. Zur Herstellung der Verbindung ist eine metallische Hülse 3 vorgesehen, deren lichter Querschnitt dem Querschnitt der Drähte 11 und des Leiters 21, welche miteinander verbunden werden sollen, angenähert gleich ist.In FIGS. L and IA to IC are a flexible electric wire 1 which has a plurality of metallic wires 11 and which is formed with an insulation 12, and an electric wire 2 with a one-piece metallic electrical conductor 21 which is also formed with an insulation 22 is shown, which two lines 1 and 2 to be connected to each other. For this purpose, these two electrical lines 1 and 2 are stripped at the ends facing each other. For the preparation of the compound is a metallic Sleeve 3 is provided, whose clear cross section is approximately equal to the cross section of the wires 11 and the conductor 21, which are to be connected to each other.
Wie dies in FIG.2 dargestellt ist, wird in einem ersten Verfahrensschritt das abisolierte freie Ende der eine Mehrzahl von Drähten 11 aufweisenden flexiblen Leitung 1 in die Hülse 3 über mindestens zwei Drittel der Länge der Hülse 3 in diese hineingeschoben und wird die Hülse 3 mit den Drähten 11 verpresst. In weiterer Folge wird von der anderen Seite her das freie Ende des Leiters 21 in die Hülse 3 so weit eingeschoben, dass die Stirnflächen des Leiters 21 und der Drähte 11 aneinander unter Druck zur Anlage kommen. Es wird hiezu auf die Darstellung der FIG.2A verwiesen. Hierauf wird durch diese beiden Leitungen 1 und 2 elektrischer Strom hindurchgeleitet, wodurch aufgrund des hierdurch auftretenden Übergangswiderstandes innerhalb der Hülse 3 so hohe Temperaturen auftreten, dass die freien Enden der Leitungen 1 und 2 miteinander verschmolzen werden.As shown in FIG. 2, in a first method step, the stripped free end of the flexible line 1 comprising a plurality of wires 11 is pushed into the sleeve 3 over at least two-thirds of the length of the sleeve 3, and the sleeve 3 is pushed along the wires 11 pressed. Subsequently, from the other side, the free end of the conductor 21 is pushed into the sleeve 3 so far that the end faces of the conductor 21 and the wires 11 come into contact with each other under pressure. Reference is made to the illustration of FIG. 2A. Then, electric current is passed through these two lines 1 and 2, whereby due to the transition resistance occurring thereby within the sleeve 3 so high temperatures occur that the free ends of the lines 1 and 2 are fused together.
Um diese Wirkungsweise zu ermöglichen, muss die Hülse 3 aus einem Metall hergestellt sein, dessen Schmelzpunkt über dem Schmelzpunkt bzw. den Schmelzpunkten des Metalles bzw. derjenigen Metalle liegt, aus welchen die Drähte 11 und der Leiter 21 hergestellt sind. Nach bevorzugten Ausführungsbeispielen sind die Drähte 11 und der Leiter 21 aus Aluminium bzw. aus Kupfer hergestellt und ist die Hülse 3 aus Stahlblech hergestellt. Insoweit als die verwendeten Metalle miteinander verschweißbar sind, können die Drähte 11 und der Leiter 21 aus unterschiedlichen Metallen hergestellt sein. Sobald die Drähte 11 und der Leiter 21 miteinander fest verbunden worden sind, wird die Verbindungsstelle mittels einer über diese aufgeschobenen Schrumpffolie 4 isoliert. Es wird hiezu auf die Darstellung der FIG.2B verwiesen.In order to enable this operation, the sleeve 3 must be made of a metal whose melting point is above the melting point or melting points of the metal or metals from which the wires 11 and the conductor 21 are made. According to preferred embodiments, the wires 11 and the conductor 21 are made of aluminum or of copper and the sleeve 3 is made of sheet steel. Insofar as the metals used are weldable together, the wires 11 and the conductor 21 may be made of different metals. Once the wires 11 and the conductor 21 have been firmly connected to each other, the joint is isolated by means of a pushed over this shrink film 4. Reference is made to the illustration of FIG. 2B.
Mit diesem Verfahren können somit entsprechend den Erfordernissen bei deren Verwendung elektrische Leitungen hergestellt werden, welche' mit steifen Bereichen und dazwischen bzw. anschließend mit flexiblen Bereichen ausgebildet sind. Durch derartige elektrische Leitungen kann somit speziellen Erfordernissen bei der Verlegung von elektrischen Leitungen in Kraftfahrzeugen entsprochen werden. Maßgeblich dabei ist es, dass mit diesem Verfahren eine flexible elektrische Leitung 1, welche eine Mehrzahl von Drähten 11 aufweist, mit einer steifen Leitung 2 mittels Verschweißung verbunden werden kann. Durch die an der Verbindungsstelle befindliche metallische Hülse 3 wird zudem die Verbindungsstelle dieser elektrischen Leitung gegenüber Beschädigungen durch Abbiegen geschützt. Durch diese Verschweißung wird die erforderliche elektrische und mechanische Verbindung der beiden Leitungen 1 und 2 miteinander erzielt. Gemäß dem in den FIG.3 und 3A dargestellten zweiten Ausführungsbeispiel wird nach diesem Verfahren eine flexible Leitung Ia, welche eine Mehrzahl von Drähten I Ia aufweist und welche mit einer Isolierung 12a ausgebildet ist, mit einem Anschlusselement 5, welches mit einem zylindrischen Teil 51 und mit einer Anschlussfahne 52 ausgebildet ist, verbunden. Auch dabei werden die Drähte I Ia des abisolierten freien Endes der Leitung Ia von einer Seite her in eine Hülse 3a eingeschoben, wird die Hülse 3a mit den Drähten I Ia verpresst, wird von der anderen Seite her der zylindrische Teil 51 des Anschlusselementes 5 in die Hülse 3a eingeschoben und werden die Stirnflächen dieser beiden Bauteile Ia und 5 unter Druck aneinander zur Anlage gebracht. Hierauf wird durch die Leitung Ia und das Anschlusselement 5 elektrischer Strom hindurchgeleitet, wodurch diese so stark erhitzt werden, dass sie miteinander verschmolzen werden.With this method, electrical lines can thus be produced according to the requirements of their use, which are formed with rigid areas and between or subsequently with flexible areas. By such electrical lines can thus be met with special requirements in the laying of electrical lines in motor vehicles. Decisive here is that with this method, a flexible electrical line 1, which has a plurality of wires 11, can be connected to a rigid conduit 2 by means of welding. By the metal sleeve 3 located at the junction also the junction of this electrical line is protected against damage by bending. By this welding, the required electrical and mechanical connection of the two lines 1 and 2 is achieved with each other. According to the second embodiment shown in FIGS. 3 and 3A, according to this method, a flexible line Ia which has a plurality of wires I Ia and which is formed with an insulation 12a, with a connection element 5 which is provided with a cylindrical part 51 and is formed with a terminal lug 52 connected. Also, the wires I Ia of the stripped free end of the line Ia are inserted from one side into a sleeve 3a, the sleeve 3a is pressed with the wires I Ia, is from the other side of the cylindrical part 51 of the connecting element 5 in the Sleeve 3a is inserted and the end faces of these two components Ia and 5 are brought under pressure to each other for conditioning. Then electric current is passed through the line Ia and the terminal 5, whereby they are heated so much that they are fused together.
Es ist dies ein weiteres Anwendungsbeispiel dafür, dass mittels einer auf eine flexible elektrische Leitung mit einer Mehrzahl von metallischen Drähten aufgebrachten Hülse diese Leitung durch Widerstandsschweißung mit einem anderen elektrisch leitenden Bauteil dauerhaft verbunden werden kann.This is another example of application in that by means of a sleeve applied to a flexible electrical line with a plurality of metallic wires, this line can be permanently connected to another electrically conductive component by resistance welding.
Gemäß dem in den FIG.4 und 4A dargestellten dritten Ausführungsbeispiel besteht die flexible elektrische Leitung Ib aus einer Mehrzahl von durch eine Isolierung 12b umhüllten Drähten I Ib, welche aus Aluminium hergestellt sind und welche einen mittleren Draht 13 enthält, welcher aus einem gegenüber Aluminium wesentlich zugfesterem Metall, z.B. aus einer Chromnickellegierung, besteht. Eine derartige durch einen zusätzlichen Draht 13 verstärkte Leitung Ib wird beispielsweise in Aufzugsschächten verwendet.According to the third embodiment shown in FIGS. 4 and 4A, the flexible electric wire 1b is made up of a plurality of wires 1b sandwiched by an insulation 12b, which are made of aluminum and which includes a middle wire 13 which is substantially aluminum more tensile metal, eg from a chrome nickel alloy. Such reinforced by an additional wire 13 line Ib is used for example in elevator shafts.
Auch dabei wird das abisolierte freie Ende der Leitung Ib von einer Seite her in eine Hülse 3b eingeschoben und mit der Hülse 3b verpresst, wird von der anderen Seite her der zylindrische Teil 51 des Anschlusselementes 5 in die Hülse 3b eingeschoben und werden die Stirnflächen dieser beiden Bauteile Ib und 5 unter Druck aneinander zur Anlage gebracht. Hierauf wird durch die Leitung Ib und das Anschlusselement 5 elektrischer Strom hindurchgeleitet, wodurch diese so stark erhitzt werden, dass sie miteinander verschmolzen werden.Also, the stripped free end of the line Ib is inserted from one side into a sleeve 3b and pressed with the sleeve 3b, the cylindrical part 51 of the connecting element 5 is inserted from the other side into the sleeve 3b and the end faces of these two Components Ib and 5 brought under pressure to each other to the plant. Then, electrical current is passed through the line Ib and the connecting element 5, whereby they are heated so strongly that they are fused together.
Somit kann mittels des erfindungsgemäßen Verfahrens auch eine aus Aluminium hergestellte flexible elektrische Leitung, deren Zugfestigkeit mittels eines zusätzlichen Drahtes wesentlich erhöht ist, mit einem Anschlusselement mittels Widerstandsschweißung verbunden werden, wodurch einerseits den Erfordernissen auf einen möglichst geringen Übergangswiderstand und andererseits auf hohe mechanische Festigkeit in optimaler Weise entsprochen ist.Thus, by means of the method according to the invention, a flexible electrical lead made of aluminum, the tensile strength of which is substantially increased by means of an additional wire, are connected to a connection element by means of resistance welding, which on the one hand meets the requirements the lowest possible contact resistance and on the other hand to high mechanical strength is optimally met.
Betreffend die Zugfestigkeit wird darauf verwiesen, dass Aluminium eine Zugfestigkeit von etwa 80 N/mm2, Kupfer eine Zugfestigkeit von etwa 250 N/mm2 und Chrom- Nickellegierungen eine Zugfestigkeit von etwa 2000 N/mm2 aufweisen.In terms of tensile strength, it is pointed out that aluminum has a tensile strength of about 80 N / mm 2 , copper has a tensile strength of about 250 N / mm 2 and chromium-nickel alloys have a tensile strength of about 2000 N / mm 2 .
Vorzugsweise ist die den Drähten 11, IIa bzw. IIb zugewandte Stirnfläche des Leiters 21 bzw. des Anschlusselementes 5 profiliert ausgebildet. Hierdurch wird die durch die Verschweißung dieser beiden Bauteile erzielte Verbindung im Hinblick auf einen geringen Übergangswiderstand und auf Vergrößerung der Zugfestigkeit optimiert.Preferably, the wires 11, IIa and IIb facing end face of the conductor 21 and the connecting element 5 is formed profiled. As a result, the achieved by the welding of these two components compound is optimized in terms of a low contact resistance and on increasing the tensile strength.
In den FIG.5 und 5A ist ein Anschlusselement 5a mit einem zylindrischen Anschlussteil 51a und mit einer Anschlussfahne 52a dargestellt, wobei der Anschlussteil 51a an der der Anschlussfahne 52a abgewandten Seite mit einer Profilierung in Form eines Waffelmusters 53a ausgebildet ist. Aufgrund dieser Profilierung erfolgt eine besonders wirkungsvolle Verbindung des Anschlusselements 5a mit der anschließenden elektrischen Leitung, wodurch die mechanische Festigkeit dieser Verbindung optimiert wird und der elektrische Übergangswiderstand dieser Verbindung minimiert wird.A connection element 5a with a cylindrical connection part 51a and with a connection lug 52a is shown in FIGS. 5 and 5A, wherein the connection part 51a is formed on the side facing away from the connection lug 52a with a profiling in the form of a waffle pattern 53a. Because of this profiling, a particularly effective connection of the connection element 5a with the subsequent electrical line takes place, whereby the mechanical strength of this connection is optimized and the electrical contact resistance of this connection is minimized.
Dies gilt auch dann, wenn die Stirnfläche des Leiters 21 mit einer derartigen Profilierung ausgebildet ist. This also applies if the end face of the conductor 21 is formed with such a profiling.

Claims

ANSPRUCHE
1. Verfahren zum Verbinden eines ersten elektrisch leitenden Bauteiles in Form einer metallische Drähte (11) aufweisenden flexiblen elektrischen Leitung (1) mit einem zweiten elektrisch leitenden, metallischen Bauteil, z.B. einer zweiten elektrischen Leitung (2) oder einem Anschlusselement (5), dadurch gekennzeichnet, dass das freie Ende der flexiblen elektrischen Leitung (1) in eine Hülse (3) eingesetzt und mit dieser verpresst wird, dass weiters in das freie Ende der Hülse (3) das der flexiblen elektrischen Leitung (1) zugeordnete Ende des zweiten elektrisch leitenden Bauteiles (2, 5) eingesetzt sowie an die flexible elektrischen Leitung (1) zur Anlage gebracht wird und dass durch diese beiden Bauteile (1; 2, 5) elektrischer Strom hindurch geleitet wird, wodurch deren aneinander liegenden Enden miteinander verschmolzen werden, wobei die Hülse (3) aus einem solchen Metall hergestellt ist, welches gegenüber dem Metall bzw. den Metallen der beiden miteinander zu verbindenden Bauteile (1; 2, 5) einen höheren Schmelzpunkt aufweist.Method for connecting a first electrically conductive component in the form of a metallic electrical wire (11) having flexible electrical line (1) with a second electrically conductive, metallic component, e.g. a second electrical line (2) or a connecting element (5), characterized in that the free end of the flexible electrical line (1) in a sleeve (3) is inserted and pressed with this, that further into the free end of the sleeve ( 3) of the flexible electrical line (1) associated end of the second electrically conductive member (2, 5) is used and brought to the flexible electrical line (1) to the plant and that by these two components (1, 2, 5) electrical Current is passed therethrough, whereby their abutting ends are fused together, wherein the sleeve (3) is made of such a metal, which compared to the metal or the metals of the two components to be interconnected (1, 2, 5) has a higher Has melting point.
2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass die beiden elektrisch leitenden Bauteile (1; 2, 5} während der Hindurchleitung des elektrischen Stroms aneinander unter Druck zur Anlage gebracht werden.2. The method according to claim 1, characterized in that the two electrically conductive components (1, 2, 5) are brought into contact with each other during the passage of the electrical current to each other under pressure.
3. Verfahren nach einem der Ansprüche 1 und 2, dadurch gekennzeichnet, dass der elektrisch leitende, metallische zweite Bauteil (2) durch eine elektrische Leitung mit einem bandförmigen oder stabförmigen bzw. drahtförmigen elektrischen Leiter (21) gebildet ist, welcher mit einer flexiblen elektrischen Leitung (1) mit einer Mehrzahl von Drähten (11) verbunden wird.3. The method according to any one of claims 1 and 2, characterized in that the electrically conductive, metallic second component (2) by an electrical line with a band-shaped or rod-shaped or wire-shaped electrical conductor (21) is formed, which with a flexible electrical Line (1) with a plurality of wires (11) is connected.
4. Verfahren nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass der zweite elektrisch leitende Bauteil durch ein Anschlusselement (5, 5a) gebildet ist, welches mit einer flexiblen elektrischen Leitung (1) mit einer Mehrzahl von Drähten (11) verbunden wird.4. The method according to any one of claims 1 to 3, characterized in that the second electrically conductive member by a connection element (5, 5a) is formed, which is connected to a flexible electrical line (1) having a plurality of wires (11) ,
5. Verfahren nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass die dem ersten Bauteil (1, Ia) zugewandte Stirnfläche des zweiten Bauteiles (2, 5, 5a) mit einer Profilierung ausgebildet ist. 5. The method according to any one of claims 1 to 4, characterized in that the said first component (1, Ia) facing end face of the second component (2, 5, 5a) is formed with a profiling.
6. Verfahren nach Anspruch 5, dadurch gekennzeichnet, dass die Profilierung als Waffelmuster (51c) ausgebildet ist.6. The method according to claim 5, characterized in that the profiling as a waffle pattern (51c) is formed.
7. Verfahren nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, dass die flexible Leitung [Ib) eine Mehrzahl von Drähten (I Ib), welche durch einen aus einer Chrom-Nickellegierung hergestellten Draht (13) verstärkt sind, aufweist.7. The method according to any one of claims 1 to 6, characterized in that the flexible line [Ib] a plurality of wires (I Ib), which are reinforced by a wire made of a chromium-nickel alloy wire (13).
8. Verfahren nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, dass die beiden elektrisch leitenden Bauteile (1, Ia, 2) aus Aluminium, aus Kupfer oder aus Messing bzw. aus Aluminium und einem Draht aus einer Chrom- Nickellegierung hergestellt sind und dass die Hülse (3, 3a) aus Stahlblech hergestellt ist.8. The method according to any one of claims 1 to 7, characterized in that the two electrically conductive components (1, Ia, 2) are made of aluminum, copper or brass or of aluminum and a wire of a chromium-nickel alloy and that the sleeve (3, 3a) is made of sheet steel.
9. Verfahren nach einem der Ansprüche 1 bis 8, dadurch gekennzeichnet, dass über die Verbindungsstelle eine Isolierung, insbesondere in Form einer Schrumpffolie (4), aufgebracht wird.9. The method according to any one of claims 1 to 8, characterized in that on the connection point insulation, in particular in the form of a shrink film (4), is applied.
10. Elektrische Leitung, insbesondere Batterieleitung für Kraftfahrzeuge, welche mit mindestens einem steifen Bereich und mit mindestens einem flexiblen Bereich ausgebildet ist, wobei die aneinanderliegenden Enden der metallischen Bauteile (1, Ia, Ib, 2, 5) unter Verwendung einer die Verbindungsstelle umgebenden metallischen Hülse (3, 3a) durch Widerstandsschweißung miteinander verbunden sind. 10. Electrical line, in particular battery line for motor vehicles, which is formed with at least one rigid region and at least one flexible region, wherein the adjacent ends of the metallic components (1, Ia, Ib, 2, 5) using a metal surrounding the joint Sleeve (3, 3a) are connected to each other by resistance welding.
EP07718383A 2006-06-02 2007-04-12 Method for connecting two electrically conductive components to one another Active EP2025046B1 (en)

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AT0009107A AT503774B1 (en) 2006-06-02 2007-01-18 METHOD FOR CONNECTING TWO ELECTRICALLY CONDUCTIVE COMPONENTS TO EACH AND ELECTRICAL CIRCUIT
PCT/AT2007/000166 WO2007140489A1 (en) 2006-06-02 2007-04-12 Method for connecting two electrically conductive components to one another

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JP2009539207A (en) 2009-11-12
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EP2025046B1 (en) 2011-10-19
AT503774A1 (en) 2007-12-15
WO2007140489A1 (en) 2007-12-13
ATE529919T1 (en) 2011-11-15
KR20090018814A (en) 2009-02-23
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MX2008015333A (en) 2009-02-16
PL2025046T3 (en) 2012-03-30

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