EP2349632A1 - Liaison de lignes électriques par soudage par ultrasons - Google Patents

Liaison de lignes électriques par soudage par ultrasons

Info

Publication number
EP2349632A1
EP2349632A1 EP09745027A EP09745027A EP2349632A1 EP 2349632 A1 EP2349632 A1 EP 2349632A1 EP 09745027 A EP09745027 A EP 09745027A EP 09745027 A EP09745027 A EP 09745027A EP 2349632 A1 EP2349632 A1 EP 2349632A1
Authority
EP
European Patent Office
Prior art keywords
connection
ultrasonic welding
aluminum strands
sealing means
cable
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.)
Withdrawn
Application number
EP09745027A
Other languages
German (de)
English (en)
Inventor
Franz-Josef Lietz
Sebastian Martens
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.)
Auto Kabel Management GmbH
Original Assignee
Auto Kabel Management GmbH
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 Auto Kabel Management GmbH filed Critical Auto Kabel Management GmbH
Publication of EP2349632A1 publication Critical patent/EP2349632A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic 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
    • 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
    • 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
    • H01R43/0207—Ultrasonic-, H.F.-, cold- or impact welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/006—Vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/36—Electric or electronic devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/18—Dissimilar materials
    • B23K2103/20—Ferrous alloys and aluminium or alloys thereof
    • 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
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49204—Contact or terminal manufacturing
    • Y10T29/49208—Contact or terminal manufacturing by assembling plural parts
    • Y10T29/4921—Contact or terminal manufacturing by assembling plural parts with bonding
    • Y10T29/49211—Contact or terminal manufacturing by assembling plural parts with bonding of fused material
    • Y10T29/49213—Metal

Definitions

  • the subject matter relates to the connection of electrical lines, in particular motor vehicle power lines, with a connection cable formed from aluminum and a metallic connection part.
  • a sealant for example a protective lacquer, a plastic or another hydrophobic material, is conventionally applied around the weld seam.
  • the sealant flows around the welding knot and thus prevents the ingress of moisture into the suture node.
  • the problem here is that sealant only later on the
  • Welding knots are applied. Already existing moisture can lead to contact corrosion. In addition, moisture can pass through the stranded rope itself along the forming between the strands cavities, past the seal, to the welding node. Also, an uneven application of the protective layer or mechanical stress can cause the corrosion protection is leaking and individual cavities are no longer sealed. This causes moisture to penetrate the weld nodes and cause contact corrosion on the strands.
  • the object was the object of providing a protected against contact corrosion connection between aluminum strands and a connection part, for example, non-ferrous metal in the use of ultrasonic welding available.
  • connection cable with the connector by means of
  • Ultrasonic welding is materially connected, such that a during the ultrasonic welding between the Connection cable and the connector displaced sealant between the aluminum strands is located.
  • Corrosion protection layer is possible through.
  • the sealing means displaced during welding moves between the strands and thus seals each individual strands against environmental influences.
  • the sealant is displaced so that it either melts or burns. Parts of the sealant pass from the weld into the cavities between the strands and thus seal them against environmental influences.
  • the resulting connection of the electrical leads is thus a good one
  • Corrosion protection equipped since essentially every single weld between a strand and the connector part is protected by the sealant, in contrast to conventional protection methods, in which only the outer edge of the weld is protected.
  • the sealant in the form of a surface coating of a connection part or the connecting cable may already be set or even wet.
  • the connecting cable is pressed against the connecting part and connected by means of ultrasonic welding cohesively with this.
  • the connection cable penetrates the sealant and there is an intermetallic contact between connection cable and connection part. Between the transitions, the sealant spreads.
  • the sealing means is arranged on the connection part before the ultrasonic welding.
  • the sealant may be sprayed or painted. It is also possible that the sealing means is extruded onto the connecting part.
  • the sealing means is arranged before the ultrasonic welding on and between the individual aluminum strands of the connecting cable.
  • the connection cable is immersed in a still liquid sealant and thus pulls the sealant due to the capillary action between the strands.
  • Each individual strand is then surrounded with sealant and the cavities are already filled with sealant.
  • the sealant is displaced on the sides of the aluminum strands facing the connection part.
  • the aluminum strands are welded to the end face with the connecting part. It is also possible that the aluminum strands are welded along their propagation direction with the connecting part.
  • an emerging combustion product is electrically conductive. In this case also lead the
  • sealant is an adhesive.
  • An adhesive can be optimally adjusted in terms of airtightness and moisture-proof properties.
  • connection part is formed from a non-ferrous metal.
  • a non-ferrous metal for example, the use of copper or brass is possible.
  • a non-ferrous metal for the connection part and a connecting cable made of aluminum strands results in the presence of moisture at the junction of a contact corrosion. This is prevented by the use of the sealant.
  • connection part is according to an advantageous embodiment, a flat part.
  • a flat part may for example be a cable lug or a flat conductor.
  • the sealing means according to an advantageous embodiment serves as corrosion protection.
  • Another aspect is a method for producing an electrical connection between a connection cable formed from aluminum strands and a connection part with application of a sealant to the aluminum strands and / or the connection part, followed by ultrasound welding of the aluminum strands with the
  • a sealing agent is applied to either the aluminum strands or the connecting part.
  • Aluminum strands can be immersed, for example, in a still liquid sealant. It is also possible for the sealing element to be applied to the connecting part by means of extruding, painting, dipping, powder coating or other suitable coating method.
  • the connector can be welded to the connector cable by ultrasonic welding.
  • a cohesive connection between the connection part and the aluminum strands is produced by the sealing means. This is done by the energy input during ultrasonic welding, which first melts or burns the sealant and then enter the metallic joining partner an intermetallic, cohesive connection.
  • the sealant is displaced during ultrasonic welding. Surprisingly, the sealant is not merely displaced to the outer edges of the weld, but spreads partly in the cavities between the aluminum strands of the connection cable. This ensures that each individual strand of aluminum is protected by the sealant from contact corrosion. It is proposed that the sealant is applied by dipping on the aluminum strands. In this case, it is possible, for example, for the sealing agent to be present in liquid form in a dipping bath. The front ends of the connection cable can be inserted into the
  • the sealing means fill cavities between the aluminum strands with one another and / or the connecting part after ultrasonic welding.
  • each individual intermetallic connection between the strands and the connection part is sealed in a moisture-tight and / or airtight manner by means of the sealing means according to an advantageous exemplary embodiment.
  • Another aspect is the use of such a connection for a motor vehicle power cable, in particular for a battery cable, a starter / generator cable or as part of the electrical system. Subsequently, the object is determined by a
  • Fig. 1 a front end of an aluminum stranded cable with a coated connector part
  • Fig. 2 shows an intermetallic compound by means of
  • Fig. 3 is a coated aluminum stranded conductor
  • Fig. 4 shows an intermetallic compound between
  • Fig. 5 shows a method for producing such a compound
  • FIG. 1 shows a connecting cable 2 comprising a multiplicity of aluminum strands 4.
  • the shown end-side end of the connecting cable 2 is stripped in the region of the aluminum strands 4, but can be insulated in the further course.
  • FIG. 1 shows a connection part 6 with a corrosion protection layer 8 applied to a flat surface of the connection part 6, which is a sealing means. It can be seen that the corrosion protection layer 8 has been applied to a flat surface of the connection part 6, which may be a flat part. This can be done by means of painting, dip coating, extruding, powder coating or similar methods.
  • Corrosion protection layer 8 may be, for example, an adhesive that is moisture-proof and / or airtight.
  • connection cable 2 to the connection part 6 is by means of a non-illustrated
  • Ultrasonic welding tool the connecting cable 2 in the area of aluminum strands 4 pressed against the corrosion layer 8. Subsequently, by means of ultrasonic welding, an energy is introduced into the contact point between aluminum strands and corrosion protection layer 8 such that the corrosion protection layer 8 melts, burns or displaces. The displaced corrosion protection layer penetrates into the cavities between the aluminum strands 4, as shown in FIG. In the region of essentially every contact point between an aluminum strand 4 and the contact part 6, there is material of the corrosion layer 8, such that the corrosion protection layer 8 substantially seals each individual contact point between connection part 6 and aluminum strands 4 in an air-tight and / or moisture-proof manner.
  • the aluminum strands 4 are located at the contact points on the material of the connecting part 6, which may be formed of copper.
  • the intermetallic compound is susceptible to contact corrosion due to the different potential of the connection partners. Due to the fact that the corrosion protection layer 8 in the region of the connection seals it in an air-tight and / or moisture-proof manner, contact corrosion can be avoided. Because of that Corrosion protection layer 8 passes during melting in the cavities between the individual strands, is substantially the entire weld, not only the outer region, protected from contact corrosion.
  • FIG. 3 shows an exemplary embodiment in which the connection part 6 is not surface-coated, but the corrosion-protection layer 8 lies around each individual aluminum strand 4 of the connection cable 2.
  • the corrosion protection layer 8 encloses substantially all aluminum strands 4.
  • the cavities between the aluminum strands 4 are essentially filled by the corrosion protection layer 8.
  • the front ends are, unlike shown, also coated with the anti-corrosion layer 8.
  • the corrosion protection layer 8 melts, burns or displaces.
  • the combustion product of the anticorrosion layer 8 may be such that it is electrically conductive.
  • the corrosion protection agent may be formed so that it is liquid or pasty before welding and cured by the temperatures occurring during welding.
  • the corrosion protection layer 8 flows around the aluminum strands 4 such that the cavities between them are substantially coated with corrosion protection layer 8, and in particular the contact points between the connection part 6 and the aluminum strands 4 of FIG Corrosion protection layer 8 is surrounded, whereby a contact corrosion can be reliably prevented.
  • FIG. 5 schematically shows the sequence of an exemplary method.
  • a stripped end of the connection cable 2 with the aluminum strands 4 is immersed in a liquid sealant.
  • the aluminum strands are not immersed in the sealant, but a surface of the connection part is coated with a sealant, for example the corrosion protection layer 8.
  • connection cable is pressed against the connection part 6 in the region of the aluminum strands 4 provided with corrosion protection layer 8 by means of an ultrasonic welding tool.
  • corrosion protection layer 8 is melted, burned or displaced in the region of the contact point, so that it flows into the cavities between the aluminum strands 4.
  • the aluminum strands 4 are in this step directly to the connection part 6 and by the registered energy of the ultrasonic welding tool, the aluminum strands 4 are materially intermetallically connected to the connection part 6.
  • the anti-corrosion layer 8 flows around the contact points between the
  • Aluminum strands 4 and the connection part 6 also in the region of the cavities between the aluminum strands 4th
  • the aluminum strands 4 are in the region of the contact point with the connection part 6
  • Aluminum stranded cable with connecting parts for example made of copper, without the problem of contact corrosion to connect. As a result, a permanent and secure electrical connection between aluminum strands and connector is made.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)
  • Insulated Conductors (AREA)

Abstract

L'invention concerne la liaison de lignes électriques à un câble de raccordement 2 formé de fils toronnés d'aluminium 4 et à une partie de raccordement métallique 6. Une corrosion de contact lors du soudage est évitée grâce au fait que le câble de raccordement 2 est connecté par liaison de matière à la partie de raccordement 6 au moyen d'un soudage par ultrasons, de telle sorte qu'un moyen d'étanchéité 8 refoulé entre le câble de raccordement 2 et la partie de raccordement 6 soit situé entre les fils toronnés d'aluminium 4.
EP09745027A 2008-11-18 2009-10-29 Liaison de lignes électriques par soudage par ultrasons Withdrawn EP2349632A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102008058047A DE102008058047B4 (de) 2008-11-18 2008-11-18 Verbindung von elektrischen Leitungen mittels Ultraschallschweißen
PCT/EP2009/064252 WO2010057753A1 (fr) 2008-11-18 2009-10-29 Liaison de lignes électriques par soudage par ultrasons

Publications (1)

Publication Number Publication Date
EP2349632A1 true EP2349632A1 (fr) 2011-08-03

Family

ID=41572315

Family Applications (1)

Application Number Title Priority Date Filing Date
EP09745027A Withdrawn EP2349632A1 (fr) 2008-11-18 2009-10-29 Liaison de lignes électriques par soudage par ultrasons

Country Status (5)

Country Link
US (1) US20110220385A1 (fr)
EP (1) EP2349632A1 (fr)
CN (1) CN102216021B (fr)
DE (1) DE102008058047B4 (fr)
WO (1) WO2010057753A1 (fr)

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Also Published As

Publication number Publication date
CN102216021A (zh) 2011-10-12
CN102216021B (zh) 2015-10-07
WO2010057753A1 (fr) 2010-05-27
DE102008058047B4 (de) 2013-11-07
DE102008058047A1 (de) 2010-05-20
US20110220385A1 (en) 2011-09-15

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