EP2266167B1 - Système de borne électrique - Google Patents

Système de borne électrique Download PDF

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Publication number
EP2266167B1
EP2266167B1 EP08789094.3A EP08789094A EP2266167B1 EP 2266167 B1 EP2266167 B1 EP 2266167B1 EP 08789094 A EP08789094 A EP 08789094A EP 2266167 B1 EP2266167 B1 EP 2266167B1
Authority
EP
European Patent Office
Prior art keywords
terminal
welding
stranded wire
cable
electrical
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
Application number
EP08789094.3A
Other languages
German (de)
English (en)
Other versions
EP2266167A1 (fr
Inventor
Thomas Pabst
Mirko Posmik
Armin Studt
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.)
Delphi International Operations Luxembourg SARL
Original Assignee
FCI Automotive Holding SAS
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 FCI Automotive Holding SAS filed Critical FCI Automotive Holding SAS
Publication of EP2266167A1 publication Critical patent/EP2266167A1/fr
Application granted granted Critical
Publication of EP2266167B1 publication Critical patent/EP2266167B1/fr
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—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
    • 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 an electrical terminal system, in particular for automotive applications, comprising an elongated terminal and a wire or cable attached thereto as well as a method for the production of such an electrical terminal system.
  • Electrical terminal systems comprising a terminal having a contacting portion for electrical connection and a mounting part for the attachment of a cable or wire are known from the art.
  • cable denotes a single conductor comprising a conducting wire or wires and an insulating sheath surrounding and insulating the wire or wires.
  • wire denotes the conductive core of the cable and may consist of one or more wire strands.
  • the terminal is commonly formed of bend and stamped metal sheet.
  • the terminal is formed integrally from a piece of metal sheet, which can be folded at one end in the form of a box to receive an end of a separate contact pin, or is shaped so that it is adapted to connect with a second terminal counterpart, and on the other end it is provided with means for connecting a cable or wire, respectively surrounded by an insulating sheath.
  • the cable or wire is mechanically and electrically connected at one end to the terminal and at the other end for example with some kind of power source or electrical device or similar.
  • the other end of the cable or wire is usually connected to airbag control means for triggering the airbag inflation.
  • a usual practice to achieve electrical connectivity between a cable and a terminal consists in fitting the terminal with end sleeves which are crimped around the wire strands of the cable.
  • gas could be entrapped inside the crimped connection and further the crimped elements may tend to "spring back", what can create fluctuations of the overall connection electrical resistance, at an eventually unacceptable level for critical applications. This can be overcome by welding or brazing the wire to the terminal instead of crimping.
  • the shape of a stranded wire termination is usually not well defined, since the individual strands spread randomly around the wire axis. For this reason, the welding of such wire strands is difficult, since when e.g. the welding electrode presses the strand bundle onto the terminal portion to be welded with, the electrical contact area is not well defined. Therefore the welding power is changing from a terminal to another for the same tuning of the welding apparatus and during a welding operation the heat generation is not evenly spread over the welding area, so that some individual strands receive more heat than others. For these reasons the welding quality may not be satisfying.
  • Such electrical terminal systems i.e. the terminal and the respective wire or cable connected therewith, are mass products so that production costs and the reliability of the manufacturing process with respect to quality and the reduction of defective products is of high importance.
  • the compacted and essentially solid portion of the stranded wire has an essentially rectangular cross section, most preferably a square cross section.
  • Compacting advantageously but not necessarily in a rectangular shape, allows well defined and constant shapes and dimensions of the stranded wire, which in turn allows stable welding characteristics. The location of the wire relative to the terminal and the welding electrode is accurate.
  • the elongated terminal is formed from a piece of metal sheet.
  • the preferred material for the terminal is copper alloy.
  • the terminal has a metal sheet frame, at the end of which the contacting portion is folded in the form of a box to receive e.g. a separate connector pin.
  • the welding portion of the elongated terminal has an essentially semi-circular cross section forming an open rounded channel for the reception of the essentially solid portion of the compacted stranded wire. Due to this half-shell shape, which is semi-circular, an easy positioning of the wire relatively/within the terminal is possible. For resistance welding it is required that the electrode, at least at the beginning of the welding process, reaches the wire without contacting the metal sheet of the terminal.
  • dimensions of half-shell shape and compacted wire are adapted so that the upper face of the compacted wire projects above upper face of the half -shell.
  • Another aspect of the invention relates to a method for the production of an electrical terminal system according to claim 4.
  • Fig. 1a shows a schematic view of a terminal 10 comprising a cable connecting end 11 having two fixing flanges 14, which are shown in their bent position after fastening on the insulating sheath of a cable (not shown).
  • the cable is first inserted between the flanges 14 which are then crimped around the outer insulating sheath of the cable.
  • Terminal 10 further comprises a welding portion 12 in the form of a rounded open channel.
  • the cross section of the channel can best be seen from figure 1b (see hatched area), which is a sectional view seen along the line A-A of figure 1a .
  • Terminal 10 is further provided with contacting portion 13 into which for example a separate connector pin may be inserted.
  • terminal 10 is made from a piece of stamped and bend metal sheet, preferably from a piece of copper alloy or the like.
  • Fig. 2a shows a cable 20 comprising a stranded wire 22 and an insulating sheath 21 formed around the stranded wire 22 to electrically insulate the same from the environment.
  • the stranded wire 22 comprises for example a number of single strands 24 (see fig. 2b ), for example between ten and twenty strands.
  • the insulating sheath 21 is removed from the end of cable 20.
  • the portion of the stranded wire 22 where the insulating sheath is removed is then compacted and welded into an essentially solid portion 23. This is preferably achieved by compacting and resistance welding of the strands.
  • Figure 2b shows a cross section of the compacted and resistance welded strands 24. As can be seen from the figure almost all the surfaces of the single strands 24 are bounded together.
  • Figure 3 shows a schematic view of an electrical terminal system 3 before welding the wire 20 on the terminal 10 according to the invention.
  • the terminal 10 is further provided with a separate contact pin 15 for inserting into e.g. a female counter part (not shown). It is of course also possible to provide the electrical terminal 10 in form of a female terminal, into which a pin of a corresponding male counterpart can be inserted.
  • the cable 20 is mounted to the terminal 10 and mechanically fastened to the same by means of the flanges 14, which are bent or crimped around the cable 20 respectively around its insulating sheath 21.
  • the cable 20 is arranged such that the compacted solid portion 23 of the stranded wire is arranged in the welding portion 12 of terminal 10.
  • Figures 4a and 4b show a sectional view of the terminal system 3 shown in figure 3 .
  • the cross section of the welding portion 12 (see hatched area) is essentially semi-circular and has the form of an open rounded pipe.
  • the solid portion 23 rests in the rounded channel of the welding portion 12. Since the solid portion 23 has preferably a square cross section a space 40, 40' remains between the inner channel wall of welding portion 12 and the two lateral side walls of portion 23.
  • the solid potion 23 is welded to the walls of the terminal 10 by means of, for example, spot resistance welding or a welding seam in order to achieve a good electrical continuity therebetween. It is also possible to use a brazing operation instead of welding.
  • Figure 2c shows the wire 23 with a wall of the welding portion 12 of the terminal after welding. Due to the pressure of electrode on the wire 23 during welding, the wire is squeezed together with the walls of the welding portion of the terminal to a more or less flat cross-sectional shape.
  • the electrode For resistance welding it is required that the electrode reaches the wire without contacting the metal sheet of the terminal.
  • the upper face of compacted wire 23 projects above the upper face of the half-shell of the welding portion wall.
  • the half-shell may have been cut sufficiently low.
  • the resulting terminal has to be rigid enough.
  • the welding portion 12 complies nevertheless with this requirement because the wire and metal sheet hold firmly together after welding.
  • the front and rearward zones of the welding portion 12 are reinforced, i.e. the walls of contacting portion 13 are e.g. higher to increase the cross section, with an as short as possible slope portion in the transition zone between the welding and the contacting portions.
  • the welding power is well defined and better spread over the welding area so that a better and manageable welding quality can be achieved.
  • the figures show the embodiments in an enlarged view.
  • the length of the terminal 10 is for example in the range of a few centimeters, for example 2 to 4 cm, and the strength of the metal sheet from which the terminal is made of is in the range of 0,1 to 0,5 mm, preferably around 0,2 mm.
  • the solid portion 23 may have a length in the order of 1 cm, for example 0,3 to 1 cm, and a thickness of maybe 0,5 mm up to 2 mm.

Landscapes

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

Claims (6)

  1. Système de borne électrique (3), comprenant :
    - au moins un câble (20) comprenant un fil torsadé (22) ;
    - au moins une borne (10) allongée pour la réception du câble, laquelle borne comporte une partie de contact (13) pour une connexion électrique et/ou mécanique et une partie de soudage (12) pour une connexion électrique entre la borne et le fil torsadé, dans lequel
    - à l'extrémité libre du câble, le fil torsadé (22) est compacté et soudé en une partie essentiellement pleine (23) ; et
    - ladite partie essentiellement pleine (23) est soudée directement à la partie de soudage (12) de la borne pour réaliser une continuité électrique entre elles,
    caractérisé en ce que la partie de soudage (12) de la borne (10) allongée a une section essentiellement semi-circulaire formant un canal ouvert arrondi pour la réception de la partie essentiellement pleine (23) du fil torsadé compacté.
  2. Système de borne électrique selon la revendication 1, dans lequel le fil torsadé (22) est compacté au moyen d'un soudage par résistance.
  3. Système de borne électrique selon l'une quelconque des revendications précédentes, dans lequel la borne (10) comprend au moins une paroi qui est renforcée dans une zone avant de la partie de soudage (12) en augmentant sa hauteur et par conséquent sa section.
  4. Procédé pour la production d'un système de borne électrique (3), particulièrement pour des systèmes d'amorçage de coussin de sécurité gonflable, comprenant les étapes suivantes :
    - de fourniture d'un câble comprenant un fil torsadé à une extrémité libre ;
    - de compactage et de soudage du fil torsadé à l'extrémité libre du câble pour former une partie essentiellement pleine (23) ;
    - de fourniture d'une borne (10) allongée pour la réception du câble comportant une partie de contact pour une connexion électrique et/ou mécanique entre la borne et le fil torsadé et une partie de soudage (12), ayant une section essentiellement semi-circulaire formant un canal ouvert arrondi, pour une connexion électrique entre la borne et le fil torsadé,
    - de montage de l'extrémité libre du câble avec la partie compactée du fil torsadé avec la borne de sorte que la partie essentiellement pleine se trouve dans la partie de soudage ; et
    - de soudage de la partie compactée du fil torsadé avec la borne pour réaliser une continuité électrique entre elles.
  5. Procédé selon la revendication 4, dans lequel le fil torsadé est compacté au moyen d'un soudage par résistance.
  6. Procédé selon la revendication 4 ou 5, dans lequel la partie pleine (23) a une section essentiellement rectangulaire, de préférence carrée.
EP08789094.3A 2008-03-11 2008-03-11 Système de borne électrique Not-in-force EP2266167B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/IB2008/002148 WO2009112881A1 (fr) 2008-03-11 2008-03-11 Système de borne électrique

Publications (2)

Publication Number Publication Date
EP2266167A1 EP2266167A1 (fr) 2010-12-29
EP2266167B1 true EP2266167B1 (fr) 2013-05-15

Family

ID=39875253

Family Applications (1)

Application Number Title Priority Date Filing Date
EP08789094.3A Not-in-force EP2266167B1 (fr) 2008-03-11 2008-03-11 Système de borne électrique

Country Status (3)

Country Link
EP (1) EP2266167B1 (fr)
CN (1) CN101999192B (fr)
WO (1) WO2009112881A1 (fr)

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102010005841B4 (de) * 2010-01-26 2011-12-08 Auto-Kabel Managementgesellschaft Mbh Kabelschuh mit schalenförmiger Ausformung und Befestigungseinrichtung
JP5903231B2 (ja) * 2011-09-12 2016-04-13 富士電線工業株式会社 電線接続構造
JP6164531B2 (ja) 2014-06-23 2017-07-19 住友電装株式会社 シールド導電路
JP6766437B2 (ja) * 2016-05-10 2020-10-14 株式会社オートネットワーク技術研究所 端子付き電線及び端子
DE102017112947A1 (de) * 2017-06-13 2018-12-13 Te Connectivity Germany Gmbh Elektrischer Hochstromverbinder sowie Verfahren zum Herstellen eines elektrischen Hochstromverbinders
US10639737B1 (en) * 2018-10-19 2020-05-05 Aptiv Technologies Limited Welding system and method
CN111725633A (zh) * 2019-03-20 2020-09-29 金笔企业股份有限公司 闭端导线连接器

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH02132785A (ja) * 1988-07-08 1990-05-22 Yazaki Corp 圧着端子の導電体結合構造およびその形成法
DE9218732U1 (de) * 1991-06-03 1995-06-29 Whitaker Corp Elektrischer Kontakt
JP4021734B2 (ja) * 2002-08-30 2007-12-12 矢崎総業株式会社 電線の超音波接合方法

Also Published As

Publication number Publication date
CN101999192A (zh) 2011-03-30
WO2009112881A1 (fr) 2009-09-17
EP2266167A1 (fr) 2010-12-29
CN101999192B (zh) 2013-04-24

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