EP2131448A1 - Method for connecting an electrically conductive component with a flexible conductive component - Google Patents

Method for connecting an electrically conductive component with a flexible conductive component Download PDF

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Publication number
EP2131448A1
EP2131448A1 EP09162033A EP09162033A EP2131448A1 EP 2131448 A1 EP2131448 A1 EP 2131448A1 EP 09162033 A EP09162033 A EP 09162033A EP 09162033 A EP09162033 A EP 09162033A EP 2131448 A1 EP2131448 A1 EP 2131448A1
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EP
European Patent Office
Prior art keywords
electrically conductive
connection
contact element
conductor end
conductive component
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
EP09162033A
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German (de)
French (fr)
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EP2131448B1 (en
Inventor
Waldemar Ziebarth
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Schulte & Co GmbH
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Schulte & Co GmbH
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Publication of EP2131448A1 publication Critical patent/EP2131448A1/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
    • H01R4/625—Soldered or welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/187—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping combined with soldering or welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • 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
    • H01R4/023—Soldered or welded connections between cables or wires and terminals
    • 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
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/20—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0214—Resistance welding

Definitions

  • the invention relates to a method for connecting an electrically conductive component, on which a tubular connecting element is provided, with a flexible electrical conductor, consisting of wires or strands of an aluminum alloy, wherein a stripped conductor end is bordered with a metallic support sleeve.
  • Electrically conductive components such as cable lugs, battery terminals, busbars or line connectors are often already fabrikatorisch connected to an electrical connection line, especially in the automotive industry, while the compact components usually consist of a copper alloy or brass, are cost reasons flexible electrical wires or strands of aluminum alloy.
  • the attachment end of the flexible electrical conductor is stripped and usually provided in this area with an outer support sleeve made of aluminum, which is pressed with the wires.
  • the electrically conductive component such as a cable lug or a battery terminal having a correspondingly shaped portion which is inserted into the support sleeve inserted.
  • corresponding electrical components such as cable lugs, battery terminals or line connectors are used in practice, which are formed from pipe sections.
  • the components usually produced by deformation or compression have a pipe section for connection to a flexible electrical conductor. In this pipe section, the stripped end of the conductor is inserted with the support sleeve and fixed by pressing in the radial direction (crimping).
  • the object of the invention is to propose a method of this type, with which the contact of the wires of the flexible electrical conductor is improved to the connection element of a corresponding electrical component.
  • the object of the invention is achieved by the fact that a contact element made of a corrosion-resistant metal alloy is applied to the front side of the stripped conductor end in an intermetallic manner, which is brought into a tensile and electrically conductive connection with the tubular connection element of the component.
  • Another method according to claim 4 for the solution of the invention task is to insert the stripped conductor end with its frontally connected contact element in the tubular connection element and set by an externally through the tubular connection element, such as a bore, introduced solder joint.
  • the stripped conductor element is welded with its frontally connected contact element frontally on the tubular connection element of the electrically conductive component, preferably by resistance welding in the manner of butt welding or friction welding.
  • FIG. 1 is designated by the numeral 1 battery terminal, which is an electrically conductive component, manufactured in a pressing process, wherein the connection to a battery, the terminal lug 14 is used, on which a tubular connecting element 11 is formed.
  • a flexible electrical conductor 2 which consists of wires or strands 21 made of an aluminum alloy, is surrounded by a jacket 22.
  • the stripped end 23 of this conductor is surrounded by a support sleeve 4, preferably also made of an aluminum alloy.
  • a cylindrical contact element 5 is applied with a resistance welding.
  • This prepared conductor end 23 with the intermetallically connected contact element 5 is inserted into the tubular connection element 11 and fastened in the region of the correspondingly formed with an outer groove contact element 5 with a crimp 12. Due to the design of the battery terminal 1, a cavity 13 remains in front of the contact element 5. In this connection, the electrical contact essentially takes place in the region of the crimping of the contact element 5. By this type of fastening, the conductor 2 is secured with a secure electrical contact in the housing tubular connecting element 11.
  • FIG. 2 is the end face on the stripped conductor end 23, which is also enclosed with a support sleeve 11, a disc-like contact element 105 with an intermetallic compound, such as a resistance welding, applied.
  • This conductor end 23 with the support sleeve 4 and the contact element 105 is only partially inserted into the tubular connection element 11 of the battery terminal 1.
  • Solder material 6 is introduced into the chamber 3 provided for this purpose via a bore 15 in the tubular connection element 11, so that in this case the fixing and the electrical contacting of the stripped conductor end 23 via the intermetallically bonded plate 105 and the soldering material 6 with the corresponding contact surfaces of the Battery terminal 1 is done.
  • FIG. 3 there is also the possibility of the stripped conductor end 23, which is enclosed with a support sleeve 4, in turn, the contact element 105 to attach intermetallically connected end.
  • the end-side end of the tubular connection element 11 of the electrically conductive component for example a battery terminal, which is designated by the numeral 101, is fastened to this contact element 5 with resistance welding.
  • each contact elements are placed intermetallically connected to the end faces of a stripped conductor end. With these contact elements, a secure electrical contact can be made to the adjacent electrically conductive component.

Landscapes

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

Abstract

The method involves enclosing a dismantled conductor end (23) with a metallic protective casing, and applying a contact element (5) on the conductor end, where the contact element is made of non-corrosive metal alloy. The contact element is brought into tight- and electrically conductive connection with a tubular connection element (11) of an electrically conductive component (1). The contact element is inserted into the connection element, and fixed by soldering connection, which is externally placed through the connection element.

Description

Die Erfindung betrifft ein Verfahren zum Verbinden eines elektrisch leitenden Bauteils, an dem ein rohrförmiges Anschlusselement vorgesehen ist, mit einem flexiblen elektrischen Leiter, bestehend aus Drähten oder Litzen aus einer Aluminiumlegierung, wobei ein abgemanteltes Leiterende mit einer metallischen Stützhülse eingefasst ist. Elektrisch leitende Bauteile, wie Kabelschuhe, Batterieklemmen, Stromschienen oder Leitungsverbinder werden häufig, insbesondere in der Automobilindustrie, bereits fabrikatorisch mit einer elektrischen Anschlussleitung verbunden, während die kompakten Bauteile in der Regel aus einer Kupferlegierung oder Messing bestehen, werden aus Kostengründen flexible elektrische Leitungen aus Drähten oder Litzen aus einer Aluminiumlegierung vorgesehen. Zur Befestigung am kompakten elektrisch leitenden Bauteil wird das Befestigungsende des flexiblen elektrischen Leiters abgemantelt und üblicherweise in diesem Bereich mit einer äußeren Stützhülse aus Aluminium versehen, welche mit den Drähten verpresst ist.The invention relates to a method for connecting an electrically conductive component, on which a tubular connecting element is provided, with a flexible electrical conductor, consisting of wires or strands of an aluminum alloy, wherein a stripped conductor end is bordered with a metallic support sleeve. Electrically conductive components, such as cable lugs, battery terminals, busbars or line connectors are often already fabrikatorisch connected to an electrical connection line, especially in the automotive industry, while the compact components usually consist of a copper alloy or brass, are cost reasons flexible electrical wires or strands of aluminum alloy. For attachment to the compact electrically conductive component, the attachment end of the flexible electrical conductor is stripped and usually provided in this area with an outer support sleeve made of aluminum, which is pressed with the wires.

Bekannt ist aus der WO2007/140489 ein entsprechendes Verbindungsverfahren. Dabei wird die metallisch leitende Stützhülse aus einem Material mit einem Schmelzpunkt oberhalb des Schmelzpunktes der Drähte aus Aluminium nur teilweise auf das abgemantelte Leiterende aufgeschoben. In das hohle Ende dieser Stützhülse wird das zu verbindende elektrisch leitende Bauteil mit einem entsprechend angeformten zylindrischen Abschnitt eingeschoben, so dass die Stirnseite dieses zylindrischen Abschnittes an der Stirnseite des abgemantelten Leiterendes anliegt. Durch entsprechenden Stromfluss erfolgt die intermetallische Verbindung in der Art einer Widerstandsschweißung. Üblicherweise wird über die Verbindungsstelle von elektrischem Leiter mit Stützhülse und dem verbundenen elektrisch leitenden Bauteil ein Schrumpfschlauch aufgebracht, der einen gewissen Korrosionsschutz bildet.Is known from the WO2007 / 140489 a corresponding connection method. The metallically conductive support sleeve made of a material having a melting point above the melting point of the aluminum wires is only partially pushed onto the stripped conductor end. In the hollow end of this support sleeve to be connected electrically conductive member is inserted with a correspondingly shaped cylindrical portion, so that the end face of this cylindrical portion rests against the end face of the stripped conductor end. By appropriate current flow, the intermetallic compound in the manner of a resistance welding takes place. Usually, a shrink tube is applied over the junction of electrical conductor with support sleeve and the connected electrically conductive component, which forms a certain corrosion protection.

Ein solches bekanntes Verfahren lässt sich jedoch nur dann einsetzen, wenn das elektrisch leitende Bauteil, beispielsweise ein Kabelschuh oder eine Batterieklemme einen entsprechend angeformten Abschnitt aufweist, der in die Stützhülse angepasst einschiebbar ist. Aus Kostengründen werden in der Praxis auch entsprechende elektrische Bauteile, wie Kabelschuhe, Batterieklemmen oder Leitungsverbinder eingesetzt, die aus Rohrabschnitten gebildet sind. Die in der Regel durch Verformung bzw. Verpressung hergestellten Bauteile weisen zur Verbindung mit einem flexiblen elektrischen Leiter einen Rohrabschnitt auf. In diesen Rohrabschnitt wird das abgemantelte Ende des Leiters mit der Stützhülse eingeschoben und durch Verpressung in Radialrichtung (Crimpen) festgesetzt. Nachteil einer solchen Herstellungsart ist die Tatsache, dass die Aluminiumdrähte auch innerhalb der Verbindung oxidieren und damit der Übergangswiderstand von den Aluminiumdrähten auf die Stützhülse bzw. den Rohrabschnitt des elektrischen Bauteils sich in ungünstiger Weise erhöht, da im Verpressungsbereich der elektrische Kontakt sich verschlechtert.However, such a known method can only be used if the electrically conductive component, such as a cable lug or a battery terminal having a correspondingly shaped portion which is inserted into the support sleeve inserted. For cost reasons, corresponding electrical components, such as cable lugs, battery terminals or line connectors are used in practice, which are formed from pipe sections. The components usually produced by deformation or compression have a pipe section for connection to a flexible electrical conductor. In this pipe section, the stripped end of the conductor is inserted with the support sleeve and fixed by pressing in the radial direction (crimping). Disadvantage of such a production is the fact that the aluminum wires also oxidize within the compound and thus the contact resistance of the aluminum wires on the support sleeve or the pipe section of the electrical component increases unfavorably, since in the compression region of the electrical contact deteriorates.

Die Aufgabe der Erfindung besteht darin, ein Verfahren dieser Art vorzuschlagen, mit dem der Kontakt von den Drähten des flexiblen elektrischen Leiters an das Anschlusselement eines entsprechenden elektrischen Bauteiles verbessert wird.The object of the invention is to propose a method of this type, with which the contact of the wires of the flexible electrical conductor is improved to the connection element of a corresponding electrical component.

Gelöst wird die Erfindungsaufgabe dadurch, dass stirnseitig auf das abgemantelte Leiterende intermetallisch verbunden ein Kontaktelement aus einer korrosionsfesten Metalllegierung aufgebracht wird, welches mit dem rohrförmigen Anschlusselement des Bauteils in eine zugfeste und elektrisch leitende Verbindung gebracht wird.The object of the invention is achieved by the fact that a contact element made of a corrosion-resistant metal alloy is applied to the front side of the stripped conductor end in an intermetallic manner, which is brought into a tensile and electrically conductive connection with the tubular connection element of the component.

Mit einem solchen intermetallisch angebundenen, vorzugsweise plattenartigen Kontaktelement, vorzugsweise aus einer Kupferlegierung, ist es möglich, am rohrförmigen Anschlusselement des elektrisch leitenden Bauteils eine dauerhafte elektrische Kontaktierung zu erreichen, da bei diesem Verfahren der Stromschluss zum elektrisch leitenden Bauteil nicht direkt über die Aluminiumdrähte sondern jeweils über das intermetallisch angebundene Kontaktelement befindet.With such an intermetallically connected, preferably plate-like contact element, preferably made of a copper alloy, it is possible to achieve a permanent electrical contact on the tubular connection element of the electrically conductive component, since in this method the current connection to the electrically conductive component not directly over the aluminum wires but each located over the intermetallic tethered contact element.

Gemäß Anspruch 3 wird vorgeschlagen, das abgemantelte Leiterende mit seinem stirnseitig angebundenen Kontaktelement in das rohrförmige Anschlusselement einzuschieben und durch radiale Verpressung des Anschlusselementes elektrisch leitend festzusetzen, so dass das Kontaktelement mit der Innenwandung des rohrförmigen Anschlusselementes in elektrisch leitender Verbindung steht.According to claim 3, it is proposed to insert the stripped conductor end with its frontally connected contact element in the tubular connection element and by radial compression of the connection element set electrically conductive, so that the contact element with the inner wall of the tubular connection element is in electrically conductive connection.

Ein weiteres Verfahren gemäß Anspruch 4 zur Lösung der Erfindungsaufgabe besteht darin, das abgemantelte Leiterende mit seinem stirnseitig angebundenen Kontaktelement in das rohrförmige Anschlusselement einzuschieben und durch eine von außen durch das rohrförmige Anschlusselement, beispielsweise einer Bohrung, eingebrachte Lötverbindung festzusetzen.Another method according to claim 4 for the solution of the invention task is to insert the stripped conductor end with its frontally connected contact element in the tubular connection element and set by an externally through the tubular connection element, such as a bore, introduced solder joint.

Gemäß Anspruch 5 wird ein weiteres Verfahren vorgeschlagen, bei dem das abgemantelte Leiterelement mit seinem stirnseitig angebundenen Kontaktelement stirnseitig am rohrförmigen Anschlusselement des elektrisch leitenden Bauteiles angeschweißt wird, vorzugsweise durch Widerstandsschweißung in der Art einer Stumpfschweißung oder einer Reibschweißung.According to claim 5, a further method is proposed in which the stripped conductor element is welded with its frontally connected contact element frontally on the tubular connection element of the electrically conductive component, preferably by resistance welding in the manner of butt welding or friction welding.

Anhand prinzipiell abgebildeter Ausführungsbeispiele wird die Erfindung im folgenden näher erläutert. Es zeigen:

Fig. 1
einen Längsschnitt durch die Verbindung einer Batterieklemme mit einem flexiblen elektrischen Leiter, bei der das abgemantelte Leiterende in ein rohrförmiges Anschlusselement der Batterieklemme eingeschoben und dort entsprechend eingecrimpt ist,
Fig. 2
ebenfalls einen Längsschnitt durch die Verbindung einer Batterieklemme mit einem flexiblen elektrischen Leiter, bei dem das eingeschobene abgemantelte Leiterende mit einer Lötverbindung festgesetzt ist
und
Fig. 3
ebenfalls einen Längsschnitt durch die Verbindung einer anderen kleineren Batterieklemme, die mit einem endseitigen rohrförmigen Anschlusselement stirnseitig auf ein Kontaktelement am Stirnende des Leiterendes aufgeschweißt ist.
With reference to exemplary embodiments, the invention will be explained in more detail below. Show it:
Fig. 1
a longitudinal section through the connection of a battery terminal with a flexible electrical conductor, in which the stripped conductor end is inserted into a tubular connection element of the battery terminal and crimped there accordingly,
Fig. 2
also a longitudinal section through the connection of a battery terminal with a flexible electrical conductor, in which the inserted stripped conductor end is fixed with a solder joint
and
Fig. 3
also a longitudinal section through the connection of another smaller battery terminal, the end face with a tubular connecting element on a contact element welded on the front end of the conductor end.

In Figur 1 ist die mit der Ziffer 1 bezeichnete Batterieklemme, die ein elektrisch leitendes Bauteil ist, in einem Pressverfahren hergestellt, wobei dem Anschluss an einer Batterie die Anschlusslasche 14 dient, an der ein rohrförmiges Anschlusselement 11 angeformt ist. Ein flexibler elektrischer Leiter 2, der aus Drähten oder Litzen 21 aus einer Aluminiumlegierung besteht, ist mit einem Mantel 22 umgeben. Das abgemantelte Ende 23 dieses Leiters ist von einer Stützhülse 4, vorzugsweise ebenfalls aus einer Aluminiumlegierung, eingefasst. Auf die Stirnseite dieses abgemantelten Leiterendes 23 ist ein zylindrisches Kontaktelement 5 mit einer Widerstandsschweißung aufgebracht. Dieses vorbereitete Leiterende 23 mit dem intermetallisch verbundenen Kontaktelement 5 ist in das rohrförmige Anschlusselement 11 eingeschoben und im Bereich des entsprechend mit einer äußeren Nut ausgebildeten Kontaktelementes 5 mit einer Crimpverbindung 12 befestigt. Vor dem Kontaktelement 5 verbleibt dabei aufgrund der Ausbildung der Batterieklemme 1 ein Hohlraum 13. Bei dieser Verbindung erfolgt der elektrische Kontakt im wesentlichen im Bereich der Eincrimpung des Kontaktelementes 5. Durch diese Befestigungsart erfolgt eine zugfeste Festsetzung des Leiters 2 mit einer sicheren elektrischen Kontaktierung in dem rohrförmigen Anschlusselement 11.In FIG. 1 is designated by the numeral 1 battery terminal, which is an electrically conductive component, manufactured in a pressing process, wherein the connection to a battery, the terminal lug 14 is used, on which a tubular connecting element 11 is formed. A flexible electrical conductor 2, which consists of wires or strands 21 made of an aluminum alloy, is surrounded by a jacket 22. The stripped end 23 of this conductor is surrounded by a support sleeve 4, preferably also made of an aluminum alloy. On the front side of this stripped conductor end 23, a cylindrical contact element 5 is applied with a resistance welding. This prepared conductor end 23 with the intermetallically connected contact element 5 is inserted into the tubular connection element 11 and fastened in the region of the correspondingly formed with an outer groove contact element 5 with a crimp 12. Due to the design of the battery terminal 1, a cavity 13 remains in front of the contact element 5. In this connection, the electrical contact essentially takes place in the region of the crimping of the contact element 5. By this type of fastening, the conductor 2 is secured with a secure electrical contact in the housing tubular connecting element 11.

Beim Ausführungsbeispiel gemäß Figur 2 ist stirnseitig auf das abgemantelte Leiterende 23, welches ebenfalls mit einer Stützhülse 11 eingefasst ist, ein scheibenartiges Kontaktelement 105 mit einer intermetallischen Verbindung, beispielsweise eine Widerstandsschweißung, aufgebracht. Dieses Leiterende 23 mit der Stützhülse 4 und dem Kontaktelement 105 ist dabei nur teilweise in das rohrförmige Anschlusselement 11 der Batterieklemme 1 eingeschoben. Über eine Bohrung 15 in dem rohrförmigen Anschlusselement 11 ist Lötmaterial 6 in die dafür vorgesehene Kammer 3 eingebracht, so dass in diesem Falle die Festsetzung und die elektrische Kontaktierung des abgemantelten Leiterendes 23 über die intermetallisch angebundene Platte 105 und das Lötmaterial 6 mit den entsprechenden Anlageflächen der Batterieklemme 1 erfolgt.According to the embodiment FIG. 2 is the end face on the stripped conductor end 23, which is also enclosed with a support sleeve 11, a disc-like contact element 105 with an intermetallic compound, such as a resistance welding, applied. This conductor end 23 with the support sleeve 4 and the contact element 105 is only partially inserted into the tubular connection element 11 of the battery terminal 1. Solder material 6 is introduced into the chamber 3 provided for this purpose via a bore 15 in the tubular connection element 11, so that in this case the fixing and the electrical contacting of the stripped conductor end 23 via the intermetallically bonded plate 105 and the soldering material 6 with the corresponding contact surfaces of the Battery terminal 1 is done.

Gemäß Figur 3 besteht auch die Möglichkeit, auf das abgemantelte Leiterende 23, welches mit einer Stützhülse 4 eingefasst ist, wiederum endseitig das Kontaktelement 105 intermetallisch verbunden zu befestigen. Stirnseitig wird auf dieses Kontaktelement 5 mit einer Widerstandsschweißung das stirnseitige Ende des rohrförmigen Anschlusselementes 11 des mit der Ziffer 101 bezeichneten elektrisch leitenden Bauteils, beispielsweise eine Batterieklemme, befestigt.According to FIG. 3 there is also the possibility of the stripped conductor end 23, which is enclosed with a support sleeve 4, in turn, the contact element 105 to attach intermetallically connected end. On the front side, the end-side end of the tubular connection element 11 of the electrically conductive component, for example a battery terminal, which is designated by the numeral 101, is fastened to this contact element 5 with resistance welding.

Gemäß den geschilderten Verfahren können auch Stromschienen oder Leitungsverbindungen hergestellt werden, wobei jeweils Kontaktelemente an den Stirnseiten eines abgemantelten Leiterendes intermetallisch verbunden aufgesetzt sind. Mit diesen Kontaktelementen lässt sich ein sicherer elektrischer Kontakt zum benachbarten elektrisch leitenden Bauteil herstellen.According to the described method also busbars or line connections can be made, each contact elements are placed intermetallically connected to the end faces of a stripped conductor end. With these contact elements, a secure electrical contact can be made to the adjacent electrically conductive component.

BezugszeichenlisteLIST OF REFERENCE NUMBERS

11
elektrisch leitendes Bauteil, Batterieklemmeelectrically conductive component, battery terminal
1111
rohrförmiges Anschlusselementtubular connection element
1212
EincrimpungEincrimpung
1313
Hohlraumcavity
1414
Anschlusslascheconnection tab
1515
radiale Bohrungradial bore
22
flexibler elektrischer Leiterflexible electrical conductor
2121
Aluminiumdrähtealuminum wires
2222
Leitermantelconductor shell
2323
abgemanteltes Leiterendestripped ladder end
33
Kammerchamber
44
Stützhülsesupport sleeve
55
Kontaktelementcontact element
66
LötmaterialSolders
101101
Batterieklemmebattery terminal
105105
Kontaktelementcontact element

Claims (6)

Verfahren zum Verbinden eines elektrisch leitenden Bauteils, an dem ein rohrförmiges Anschlusselement vorgesehen ist, mit einem flexiblen elektrischen Leiter, bestehend aus Drähten oder Litzen aus einer Aluminiumlegierung, wobei ein abgemanteltes Leiterende mit einer metallischen Stützhülse eingefasst ist, dadurch gekennzeichnet, dass stirnseitig auf das abgemantelte Leiterende (23) intermetallisch verbunden ein Kontaktelement (5, 105) aus einer korrosionsfesten Metalllegierung aufgebracht wird, welches mit dem rohrförmigen Anschlusselement (11, 111) des Bauteils (1, 101) in eine zugfeste und elektrisch leitende Verbindung gebracht wird.Method for connecting an electrically conductive component, on which a tubular connecting element is provided, with a flexible electrical conductor, consisting of wires or strands of an aluminum alloy, wherein a stripped conductor end is bordered with a metallic support sleeve, characterized in that frontally on the stripped Conductor end (23) intermetallically connected to a contact element (5, 105) made of a corrosion-resistant metal alloy is applied, which is brought into a tensile and electrically conductive connection with the tubular connection element (11, 111) of the component (1, 101). Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass das zylindrische Kontaktelement (5, 105) aus einer Kupferlegierung besteht und mit einer Schweißverbindung stirnseitig am abgemantelten Leiterende (23) befestigt ist.A method according to claim 1, characterized in that the cylindrical contact element (5, 105) consists of a copper alloy and is fastened with a welded connection on the front side of the stripped conductor end (23). Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass das ab das abgemantelte Leiterende (23) mit seinem stirnseitig angebundenen Kontaktelement (5) in das rohrfömige Anschlusselement (11) eingeschoben und durch radiale Verpressung (12) des Anschlusselementes (11) elektrisch leitend festgesetzt wird.A method according to claim 1 or 2, characterized in that from the stripped conductor end (23) with its frontally connected contact element (5) inserted into the rohrfömige connection element (11) and fixed by radial compression (12) of the connection element (11) electrically conductive becomes. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass das abgemantelte Leiterende (23) mit seinem stirnseitig angebundenen Kontaktelement (105) in das rohrförmige Anschluss-element (11) eingeschoben und durch eine von außen durch das rohrförmige Anschlusselement (11, 15)eingebrachte Lötverbindung (6) festgesetzt wird.A method according to claim 1 or 2, characterized in that the stripped conductor end (23) with its frontally connected contact element (105) inserted into the tubular connection element (11) and introduced by an externally through the tubular connection element (11, 15) Solder connection (6) is fixed. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass das abgemantelte Leiterende (23) mit seinem stirnseitig angebundenen Kontaktelement (105) stirnseitig am rohrförmigen Anschlusselement (111) des elektrisch leitenden Bauteils (101) angeschweißt wird.A method according to claim 1 or 2, characterized in that the stripped conductor end (23) with its frontally connected contact element (105) is welded end face on the tubular connection element (111) of the electrically conductive member (101). Verfahren nach Anspruch 5, dadurch gekennzeichnet, dass die Schweißverbindung durch eine Widerstandsschweißung erfolgt.A method according to claim 5, characterized in that the welded connection is effected by a resistance welding.
EP09162033A 2008-06-06 2009-06-05 Method for connecting an electrically conductive component with a flexible conductive component Active EP2131448B1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE102008027195 2008-06-06

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EP2131448B1 EP2131448B1 (en) 2012-01-18

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ID=40834474

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EP (1) EP2131448B1 (en)
AT (1) ATE542265T1 (en)

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CN105490125A (en) * 2015-12-22 2016-04-13 安徽皖新电机有限公司 Wire connection method and special connection terminal
EP3435483A1 (en) * 2017-07-26 2019-01-30 Nordex Energy GmbH Connector for a high current cable and method for producing such a connector
EP3916920A1 (en) * 2020-05-27 2021-12-01 Yazaki Corporation Terminal connecting structure

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DE102021006221A1 (en) * 2021-01-21 2022-07-21 Sew-Eurodrive Gmbh & Co Kg Process for the production of a contacting unit, contacting unit and system for non-contact energy transmission

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EP2410612A1 (en) * 2010-07-22 2012-01-25 Nexans Method for producing cables with aluminium wires
CN103201909B (en) * 2010-10-13 2016-10-12 格鲍尔格里勒电缆有限公司 Connection member for electric conductor
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AT512881B1 (en) * 2012-05-11 2014-03-15 Gebauer & Griller Connection of an electrical cable to a contact part and method of making this connection
AT512881A1 (en) * 2012-05-11 2013-11-15 Gebauer & Griller Connection of an electrical cable to a contact part and method of making this connection
DE102014216833A1 (en) * 2014-08-25 2016-02-25 Kuka Systems Gmbh Cable connection for connecting an electric cable
CN105490125A (en) * 2015-12-22 2016-04-13 安徽皖新电机有限公司 Wire connection method and special connection terminal
EP3435483A1 (en) * 2017-07-26 2019-01-30 Nordex Energy GmbH Connector for a high current cable and method for producing such a connector
EP3916920A1 (en) * 2020-05-27 2021-12-01 Yazaki Corporation Terminal connecting structure
JP2021190209A (en) * 2020-05-27 2021-12-13 矢崎総業株式会社 Terminal connection structure
JP7140797B2 (en) 2020-05-27 2022-09-21 矢崎総業株式会社 Terminal connection structure

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