EP2025046B1 - Method for connecting two electrically conductive components to one another - Google Patents

Method for connecting two electrically conductive components to one another Download PDF

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Publication number
EP2025046B1
EP2025046B1 EP07718383A EP07718383A EP2025046B1 EP 2025046 B1 EP2025046 B1 EP 2025046B1 EP 07718383 A EP07718383 A EP 07718383A EP 07718383 A EP07718383 A EP 07718383A EP 2025046 B1 EP2025046 B1 EP 2025046B1
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EP
European Patent Office
Prior art keywords
sleeve
electrical line
electrically conductive
component
metal
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.)
Active
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EP07718383A
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German (de)
French (fr)
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EP2025046A1 (en
Inventor
Karl Franz FRÖSCHL
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Gebauer and Griller Kabelwerke GmbH
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Gebauer and Griller Kabelwerke GmbH
Gebauer and Griller
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Priority to PL07718383T priority Critical patent/PL2025046T3/en
Publication of EP2025046A1 publication Critical patent/EP2025046A1/en
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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • 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 first flexible electrical wire having metallic wires to a second electrically conductive metallic member, e.g. a second electrical line or a connecting element, in which the free end of the first flexible electrical line and the first flexible electrical line associated end of the second electrically conductive member is inserted into a sleeve and the ends are brought into contact with each other, through these two components electrical Current is passed through, whereby their abutting ends are fused together.
  • a second electrically conductive metallic member e.g. a second electrical line or a connecting element
  • the invention further relates to an electrical line, in particular battery line for motor vehicles, which is formed with at least one first flexible component forming a first component and at least one rigid portion forming a second component, wherein the adjacent ends of the metallic components in a surrounding the joint metallic Sleeve are joined together by resistance welding.
  • an electrical line in particular battery line for motor vehicles, which is formed with at least one first flexible component forming a first component and at least one rigid portion forming a second component, wherein the adjacent ends of the metallic components in a surrounding the joint metallic Sleeve are joined together by resistance welding.
  • the present invention is therefore based on the object to provide a method and an electrical line, by which also a flexible electrical line, which has a plurality of wires, with a second metallic component, e.g. a one-piece metallic conductor or a connection element, can be connected by resistance welding.
  • a second metallic component e.g. a one-piece metallic conductor or a connection element
  • this is achieved in that the free end of the first flexible electrical line is inserted into the sleeve and pressed with this and then inserted into the free end of the sleeve of the flexible electrical line associated end of the second electrically conductive member and their adjacent ends are fused together, wherein the sleeve is made of such a metal, which has a higher melting point compared to the metal or the metals of the two components to be joined together.
  • the electrical line is inventively characterized in that the free end the flexible electrical lead in the sleeve is pressed with this, that the adjacent ends of the metallic components are joined together by resistance welding and that the sleeve is made of such a metal, which compared to the metal or the metals of the two interconnected components a higher Has melting point.
  • 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.
  • FIGS. 1 and 1A to 1C are a flexible electrical line 1, which has a plurality of metallic wires 11 and which is formed with an insulation 12, and an electrical line 2 with a one-piece metallic electrical conductor 21, which is also formed with an insulation 22, shown, which two lines 1 and 2 to be connected to each other.
  • these two electrical lines 1 and 2 are stripped at the ends facing each other.
  • a metallic Sleeve 3 is provided, the light cross section of the cross section of the wires 11 and the conductor 21, which are to be connected together, is approximately equal.
  • the stripped free end of the plurality of wires 11 having flexible conduit 1 is pushed into the sleeve 3 over at least two thirds of the length of the sleeve 3 in this and the sleeve 3 is pressed with the wires 11.
  • 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. It is on the representation of the 2A directed.
  • 1 and 2 electrical current is passed through these two lines, whereby due to the thereby occurring contact resistance 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 1a having a plurality of wires 11a and formed with insulation 12a is connected to a terminal 5 formed with a cylindrical portion 51 and a terminal lug 52.
  • the wires 11 a of the stripped free end of the line 1a are inserted from one side into a sleeve 3a, the sleeve 3a is pressed with the wires 11 a, 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 1a and 5 are brought under pressure to each other for conditioning. Then, electric current is passed through the lead 1a and the terminal 5, whereby they are heated so much that they are fused together.
  • the flexible electrical line 1b consists of a plurality of wires 12b covered by an insulation 12b, which are made of aluminum and which contains a central wire 13 which consists of a metal which is substantially more resistant to aluminum, for example a chromium nickel alloy. Such reinforced by an additional wire 13 line 1b is used for example in elevator shafts.
  • the stripped free end of the line 1b is inserted from one side into a sleeve 3b and pressed with the sleeve 3b, is inserted from the other side of the cylindrical part 51 of the connecting element 5 in the sleeve 3b and the end faces of these two Components 1b and 5 brought under pressure to each other to the plant. Then, electric current is passed through the line 1b and the terminal 5, whereby they are heated so much 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 noted 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, 11a and 11b 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 is shown with a cylindrical connection part 51a and with a connection lug 52a, 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. This also applies if the end face of the conductor 21 is formed with such a profiling.

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  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Insulated Conductors (AREA)

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

Die gegenständliche Erfindung betrifft ein Verfahren zum Verbinden eines ersten elektrisch leitenden Bauteiles in Form einer metallische Drähte aufweisenden ersten flexiblen elektrischen Leitung mit einem zweiten elektrisch leitenden, metallischen Bauteil, z.B. einer zweiten elektrischen Leitung oder einem Anschlusselement, bei dem das freie Ende der ersten flexiblen elektrischen Leitung und das der ersten flexiblen elektrischen Leitung zugeordnete Ende des zweiten elektrisch leitenden Bauteiles in eine Hülse eingesetzt und die Enden aneinander zur Anlage gebracht werden, wobei durch diese beiden Bauteileelektrischer Strom hindurch geleitet wird, wodurch deren aneinander liegenden Enden miteinander verschmolzen werden.The subject invention relates to a method of connecting a first electrically conductive member in the form of a first flexible electrical wire having metallic wires to a second electrically conductive metallic member, e.g. a second electrical line or a connecting element, in which the free end of the first flexible electrical line and the first flexible electrical line associated end of the second electrically conductive member is inserted into a sleeve and the ends are brought into contact with each other, through these two components electrical Current is passed through, whereby their abutting ends are fused together.

Ein derartiges Verfahren ist aus der US-A-1745180 bekannt.Such a method is known from US-A-1745180 known.

Die Erfindung betrifft des weiteren eine elektrische Leitung, insbesondere Batterieleitung für Kraftfahrzeuge, welche mit mindestens einem einen flexiblen Bereich bildenden ersten Bauteil und mit mindestens einem einen steifen Bereich bildenden zweiten Bauteil ausgebildet ist, wobei die aneinanderliegenden Enden der metallischen Bauteile in einer die Verbindungsstelle umgebenden metallischen Hülse durch Widerstandsschweißung miteinander verbunden sind.The invention further relates to an electrical line, in particular battery line for motor vehicles, which is formed with at least one first flexible component forming a first component and at least one rigid portion forming a second component, wherein the adjacent ends of the metallic components in a surrounding the joint metallic Sleeve are joined together by resistance welding.

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, thereby greatly reduce the assembly effort in the installation of these lines. 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 prefabrication, 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. Aufgrund der vergleichsweise geringen Kosten werden derartige Leitungen vorzugsweise aus Aluminium hergestellt.However, since such electrical lines must also contain flexible areas or because 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. 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 Textilschnüren oder Stahlseilen verstärkt werden. Dies trifft insbesondere für solche Leitungen zu, welche aus Aluminium hergesteilt 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 hergesteilten Draht zu verstärken.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. This flat cables are used, which in the elevator shaft as a connection between a stationary control cabinet and the elevator car are used. In such lines, the tensile strength of the lines must be matched to the lift height of the elevator. From a certain head, conventional lines must be reinforced by support 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.

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.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 Widerstandsschweißung 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 Widerstandsschweißung erforderlichen Weise unter Druck zur Anlage gebracht werden können.It is known to connect rigid metallic components to each other 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 electrical current passed through them. However, it has not heretofore been possible to join a flexible electric wire formed with a plurality of metallic wires to a rigid metallic member by resistance welding because the wires of the flexible electric wire to the rigid member are not under pressure in the manner required for the resistance welding can be brought to the plant.

Der gegenständlichen Erfindung liegt somit die Aufgabe zugrunde, ein Verfahren und eine elektrische Leitung zu schaffen, durch welche 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.The present invention is therefore based on the object to provide a method and an electrical line, by which also a flexible electrical line, which has a plurality of wires, with a second metallic component, e.g. a one-piece metallic conductor or a connection element, can be connected by resistance welding.

Beim Verfahren wird dies erfindungsgemäß dadurch erzielt, dass das freie Ende der ersten flexiblen elektrischen Leitung in die Hülse eingesetzt und mit dieser verpresst wird und dass anschließend in das freie Ende der Hülse das der flexiblen elektrischen Leitung zugeordnete Ende des zweiten elektrisch leitenden Bauteiles eingesetzt und deren aneinander liegende 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.In the method according to the invention this is achieved in that the free end of the first flexible electrical line is inserted into the sleeve and pressed with this and then inserted into the free end of the sleeve of the flexible electrical line associated end of the second electrically conductive member and their adjacent ends are fused together, wherein the sleeve is made of such a metal, which has a higher melting point compared to the metal or the metals of the two components to be joined together.

Die elektrische Leitung ist erfindungsgemäß dadurch gekennzeichnet, dass das freie Ende der flexiblen elektrischen Leitung in der Hülse mit dieser verpresst ist, dass die aneinanderliegenden Enden der metallischen Bauteile durch Widerstandsschweißung miteinander verbunden sind und dass die Hülse aus einem solchen Metall hergestellt ist, welches gegenüber dem Metall bzw. den Metallen der beiden miteinander verbundenden Bauteile einen höheren Schmelzpunkt aufweist.The electrical line is inventively characterized in that the free end the flexible electrical lead in the sleeve is pressed with this, that the adjacent ends of the metallic components are joined together by resistance welding and that the sleeve is made of such a metal, which compared to the metal or the metals of the two interconnected components a higher Has 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.1
zwei elektrische Bauteile, welche mittels des erfindungsgemäßen Verfahrens durch Widerstandsschweissung miteinander verbunden werden, in Seitenansicht;
FIG.1A, 1B, 1C
jeweils Schnitte nach den Linien IA, IB und IC der FIG.1;
FIG.2, 2A, 2B
die beim erfindungsgemäßen Verfahren verwendeten Bauteile in drei aufeinanderfolgenden Verfahrensschritten, jeweils in axialem 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; sowie
FIG. 5, 5A
ein beim erfindungsgemäßen Verfahren verwendetes Anschlussele- ment, in axonometrischer Darstellung und in Stirnansicht.
The inventive method and an electrical line according to the invention are explained below with reference to three exemplary embodiments illustrated in the drawing. Show it:
FIG.1
two electrical components, which are connected to each other by means of the method according to the invention by resistance welding, in side view;
FIGS. 1A, 1B, 1C
each sections according to the lines IA, IB and IC of FIG.1 ;
2, 2A, 2B
the components used in the method according to the invention in three successive steps, each in axial section;
3, 3A
the components of a second embodiment, in which the method according to the invention is applied;
4, 4A
the components of a third embodiment, in which the method according to the invention is applied; such as
FIG. 5, 5A
a connection element used in the method according to the invention, in axonometric representation and in end view.

In den FIG.1 und 1A bis 1C 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 the FIGS. 1 and 1A to 1C are a flexible electrical line 1, which has a plurality of metallic wires 11 and which is formed with an insulation 12, and an electrical line 2 with a one-piece metallic electrical conductor 21, which is also formed with an insulation 22, 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, the light cross section of the cross section of the wires 11 and the conductor 21, which are to be connected together, is approximately equal.

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 inner-halb der Hülse 3 so hohe Temperaturen auftreten, dass die freien Enden der Leitungen 1 und 2 miteinander verschmolzen werden.Like this in FIG.2 is shown, in a first method step, the stripped free end of the plurality of wires 11 having flexible conduit 1 is pushed into the sleeve 3 over at least two thirds of the length of the sleeve 3 in this and the sleeve 3 is pressed with the wires 11. 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. It is on the representation of the 2A directed. Then 1 and 2 electrical current is passed through these two lines, whereby due to the thereby occurring contact resistance 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. It is on the representation of the 2B directed.

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.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.

Gemäß dem in den FIG.3 und 3A dargestellten zweiten Ausführungsbeispiel wird nach diesem Verfahren eine flexible Leitung 1a, welche eine Mehrzahl von Drähten 11a 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 11 a des abisolierten freien Endes der Leitung 1a von einer Seite her in eine Hülse 3a eingeschoben, wird die Hülse 3a mit den Drähten 11 a 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 1a und 5 unter Druck aneinander zur Anlage gebracht. Hierauf wird durch die Leitung 1a und das Anschlusselement 5 elektrischer Strom hindurchgeleitet, wodurch diese so stark erhitzt werden, dass sie miteinander verschmolzen werden.According to the in the FIGS. 3 and 3A According to the second embodiment, according to this method, a flexible line 1a having a plurality of wires 11a and formed with insulation 12a is connected to a terminal 5 formed with a cylindrical portion 51 and a terminal lug 52. Also, the wires 11 a of the stripped free end of the line 1a are inserted from one side into a sleeve 3a, the sleeve 3a is pressed with the wires 11 a, 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 1a and 5 are brought under pressure to each other for conditioning. Then, electric current is passed through the lead 1a 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 an 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 1b aus einer Mehrzahl von durch eine Isolierung 12b umhüllten Drähten 11b, 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 1b wird beispielsweise in Aufzugsschächten verwendet.According to the in the FIGS. 4 and 4A In the third embodiment shown, the flexible electrical line 1b consists of a plurality of wires 12b covered by an insulation 12b, which are made of aluminum and which contains a central wire 13 which consists of a metal which is substantially more resistant to aluminum, for example a chromium nickel alloy. Such reinforced by an additional wire 13 line 1b is used for example in elevator shafts.

Auch dabei wird das abisolierte freie Ende der Leitung 1b 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 1b und 5 unter Druck aneinander zur Anlage gebracht. Hierauf wird durch die Leitung 1b 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 1b is inserted from one side into a sleeve 3b and pressed with the sleeve 3b, is inserted from the other side of the cylindrical part 51 of the connecting element 5 in the sleeve 3b and the end faces of these two Components 1b and 5 brought under pressure to each other to the plant. Then, electric current is passed through the line 1b and the terminal 5, whereby they are heated so much 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 noted 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, 11a bzw. 11b 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, 11a and 11b 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 51 a 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.
Dies gilt auch dann, wenn die Stirnfläche des Leiters 21 mit einer derartigen Profilierung ausgebildet ist.In the FIGS.5 and 5A a connection element 5a is shown with a cylindrical connection part 51a and with a connection lug 52a, 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.
This also applies if the end face of the conductor 21 is formed with such a profiling.

Claims (10)

  1. Process for connecting a first electrically conductive component in the form of a flexible electrical line (1) having metal wires (11) to a second electrically conductive metal component, e.g., a second electrical line (2) or a connecting element (5), whereby the free end of the flexible electrical line (1) is inserted into a sleeve (3) and is pressed with said sleeve (3), in that in addition, the end of the second electrically conductive component (2, 5) that is assigned to the flexible electrical line (1) is inserted into the free end of the sleeve (3) and is brought into contact on the flexible electrical line (1), and in that electrical current is run through these two components (1; 2, 5), by which their ends that lie on one another are melted together, whereby the sleeve (3) is made from such a metal, which has a higher melting point compared to the metal or the metals of the two components (1; 2, 5) that are to be connected to one another.
  2. Process according to claim 1, wherein the two electrically conductive components (1; 2, 5) are brought into contact under pressure while the electrical current is being run through.
  3. Process according to one of claims 1 and 2, characterized in that the electrically conductive, metal second component (2) is formed by an electrical line with an electrical conductor (21) that is shaped in the form of a strip, rod or wire which is connected to a flexible electrical line (1) with a large number of wires (11).
  4. Process according to one of claims 1 to 3, characterized in that the second electrically conductive component is formed by a connecting element (5, 5a), which is connected with a flexible electrical line (1) with a large number of wires (11).
  5. Process according to one of claims 1 to 4, characterized in that the face of the second component (2, 5, 5a) that faces the first component (1, 1a, 1b) is designed with a profiling.
  6. Process according to claim 5, characterized in that the profiling is designed in a waffle pattern (51c).
  7. Process according to one of claims 1 to 6, wherein the flexible line (1b) has a large number of wires (11b), which are reinforced by a wire (13) that is made from a chromium-nickel alloy.
  8. Process according to one of claims 1 to 7, characterized in that the two electrically conductive components (1, 1a, 1b; 2, 5) are made from aluminum, from copper or from brass, from aluminum, respectively, and from a wire which is made from a chromium-nickel alloy, and wherein the sleeve (3, 3a) is made from a steel sheet.
  9. Process according to one of claims 1 to 8, characterized in that insulation, in particular in the form of a shrink film (4), is applied over the connecting point.
  10. Electrical line, in particular a battery cable for motor vehicles, which is designed with at least one component having a rigid area and with at least one component having a flexible area, whereby the ends of the metal components (1, 1a, 1b; 2, 5) that lie on one another are connected to one another by resistance welding with use of a metal sleeve (3, 3a) that surrounds the connecting point, characterized in that the end of the first component (1, 1a, 1b) is pressed with the sleeve (3, 3a) inside said sleeve (3, 3a), and in that the sleeve (3, 3a) is made from such a metal, which has a higher melting point compared to the metal or metals of the two components (1; 2, 5) that are to be connected to one another.
EP07718383A 2006-06-02 2007-04-12 Method for connecting two electrically conductive components to one another Active EP2025046B1 (en)

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PL07718383T PL2025046T3 (en) 2006-06-02 2007-04-12 Method for connecting two electrically conductive components to one another

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AT9592006 2006-06-02
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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EP (1) EP2025046B1 (en)
JP (1) JP5055361B2 (en)
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TNSN08486A1 (en) 2010-04-14
AT503774A1 (en) 2007-12-15
WO2007140489A1 (en) 2007-12-13
PL2025046T3 (en) 2012-03-30
ATE529919T1 (en) 2011-11-15
US20090249616A1 (en) 2009-10-08
EP2025046A1 (en) 2009-02-18
JP5055361B2 (en) 2012-10-24
KR20090018814A (en) 2009-02-23
JP2009539207A (en) 2009-11-12
MX2008015333A (en) 2009-02-16
AT503774B1 (en) 2008-03-15

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