EP2371036B1 - Electrical contact connection and method for producing an electrical contact connection - Google Patents

Electrical contact connection and method for producing an electrical contact connection Download PDF

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Publication number
EP2371036B1
EP2371036B1 EP09796944.8A EP09796944A EP2371036B1 EP 2371036 B1 EP2371036 B1 EP 2371036B1 EP 09796944 A EP09796944 A EP 09796944A EP 2371036 B1 EP2371036 B1 EP 2371036B1
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EP
European Patent Office
Prior art keywords
connection
contact
adapter element
electrical contact
aluminium conductor
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EP09796944.8A
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German (de)
French (fr)
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EP2371036A1 (en
Inventor
Frank Beuscher
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Leoni Bordnetz Systeme GmbH
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Leoni Bordnetz Systeme GmbH
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Publication of EP2371036A1 publication Critical patent/EP2371036A1/en
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    • 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
    • H01R35/00—Flexible or turnable line connectors, i.e. the rotation angle being limited
    • 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

Definitions

  • the invention relates to an electrical contact connection between a stripped aluminum conductor and a contact element connected thereto.
  • the invention further relates to a method for producing such a contact connection.
  • the contact element is in this case designed in particular as a so-called cable lug, for example, in the manner of a screw contact element or a plug contact element or another contact element for a mechanically reversible detachable contact connection.
  • From the DE 10 223 397 A1 is to remove a method and a connection for contacting an aluminum cable, with stripped aluminum strands are inserted into a dimensionally stable, metallic sleeve.
  • the sleeve is closed at the front by a lid-like Zinnpropfen, via the tin, a contact connection between the sleeve and the individual conductors takes place.
  • the sleeve is finally inserted into a trained in the manner of a cable terminal contact terminal and secured in this by pressing.
  • the invention has for its object to provide a safe and long-term stable contact between an aluminum conductor and a contact element.
  • the object is achieved by an electrical contact connection between a stripped aluminum conductor and a contact element connected thereto, wherein the aluminum conductor is integrally connected to an adapter element and the adapter element is mechanically connected to the contact element, so that the aluminum conductor indirectly via the adapter element with the contact element electrically is contacted.
  • the adapter element is a foil.
  • the adapter element On the one hand a secure and permanently reliable electrical contact between the adapter element and the aluminum conductor is given by the cohesive connection with the aluminum conductor.
  • the adapter element in this case consists of a material other than aluminum and is in particular made of copper or a copper alloy. Therefore, a conventional copper conductor for the formation of the contact connection with the contact element is "simulated" as it were via the adapter element. Therefore, it can be used for the contact element on conventional contact elements and cable lugs and on conventional types of attachment of the conductor in these contact elements. Due to the arrangement of the adapter element therefore a conventional mechanical contact connection to the contact element for a permanently secure electrical contact connection is sufficient.
  • the adapter element Due to the thin and thus easily deformable design of the adapter element in the manner of a film, it can be easily between the aluminum conductor and the contact element bring in so that conventional contact elements can be used. Due to the easy deformability, the adapter element is particularly suitable for use in a crimped connection.
  • the contact connection is a crimp connection and the contact element is a crimping element.
  • Crimp connections are preferably used for smaller conductor cross sections with a conductor cross-sectional area smaller than 10 mm 2 and have proven to be particularly reliable and are easy to manufacture.
  • a modified crimped connection is provided which on the one hand ensures a reliable and secure permanent contact connection and on the other hand enables the use of previous crimp contact systems.
  • this measure makes it possible to construct an aluminum electrical system with aluminum cables with small conductor cross-sections, in which case it is possible to resort to conventional technologies and contact elements, except for the use of the adapter element.
  • crimping ie during the formation of the crimped connection, so-called crimpfs of the crimping element are generally deformed mechanically, so that the conductor in the crimping element is clamped by the crimped edges.
  • crimp connection it is preferred to use standard crimping elements. These are or are in particular tinned, so that the electrical contact connection is made corrosion-resistant.
  • the film preferably has an anti-corrosion coating.
  • an anticorrosive coating electrochemically related materials are added to aluminum, e.g. Chromium, nickel and / or zinc or their alloys used
  • the cohesive connection between the aluminum conductor and the adapter element is a welded connection. It is thus made a non-detachable connection, which ensures a secure hold of the adapter element on the aluminum conductor.
  • Preferred welding methods suitable for this application are suitable, for example, ultrasonic welding, laser welding and arc welding.
  • the aluminum conductor is preferably a stranded conductor with a plurality of stranded wires.
  • the aluminum conductor is expediently flattened in the contact region.
  • the individual stranded wires are arranged adjacent to each other.
  • Preferably, only a few layers of stranded wires are arranged one above the other. In particular, only one layer is formed, so that each or almost every stranded wire rests against the adapter element and is connected thereto.
  • By flattening the stranded wires are thus arranged in the manner of a row next to each other and welded to the adapter element, so that the contact surface between the aluminum conductor and the adapter element is particularly large.
  • the stranded wires in this case form an approximately U-shaped contour, the stringing together of the stranded wires is therefore designed to be bent overall. Due to the curved configuration, therefore, the outer contour of a conventionally used conductor for a crimp connection is virtually simulated, so that the outer contour also adapts to the contour of the crimping element used by default. As a result, the largest possible contact surface is formed between the adapter element and the contact element.
  • the curved or U-shaped contour is preferably formed during the formation of the integral connection, in particular during welding of the stranded conductor to the film.
  • the paint encloses a contact zone of the contact element, in which the electrical contact takes place and in which the aluminum conductor is located with the adapter element, so that no atmospheric oxygen can reach the electrical contact points.
  • the object is further achieved according to the invention by a method for producing a contact connection between a stripped aluminum conductor and a contact element connected thereto, in which the aluminum conductor with an adapter element, in particular a copper foil, is integrally connected, and the adapter element is mechanically connected to the contact element, so that the aluminum conductor is indirectly contacted via the adapter element with the contact element electrically.
  • first of all the aluminum conductor is adhesively bonded to the copper foil, in particular welded together.
  • the aluminum conductor comprises a plurality of stranded wires, these are preferably flattened and arranged side by side on the adapter element, such that they are connected in particular in the manner of a U-shaped contour with the adapter element.
  • the U-shaped contour is preferably realized by the shape of the welding electrodes, via which therefore the stranded wire and the adapter foil are pressed into the U-shaped contour.
  • the adapter element and the aluminum conductor are clamped in the contact zone in the contact element in the subsequent second production step, in particular by crimping.
  • the position of the adapter element is - depending on the nature of the individual Crimpflanken the crimp - positioned at the bottom of the contact element or even above the head directly under the Crimpflanken.
  • a complete enclosure of the stranded wires of the conductor is provided with the adapter element for increased stability of the holding forces in the contact zone.
  • a lacquer is applied to the contact connection, if necessary, in such a way that the lacquer layer surrounds the contact connection in the contact zone.
  • the method for producing such an electrical contact connection can be used in particular for aluminum conductors with small cross-sections and allows the use of crimp contact systems in an aluminum electrical system.
  • an electrical contact connection 2 essentially comprises the stripped end of an aluminum conductor 4, an adapter element 6 and a contact element 8.
  • the aluminum conductor 4 is in this case a stranded conductor and has a plurality of stranded wires 10, which are intertwined.
  • the aluminum conductor 4 is formed as aluminum cable and further comprises outside of the contact area a (not shown) insulating jacket.
  • the adapter element 6 is a copper foil which has an anticorrosion coating of chromium, nickel and / or zinc (not shown here).
  • a contact element 8 a crimping element is provided which comprises two Crimpflanken 12.
  • the aluminum conductor 4 is joined in a materially bonded manner to the copper foil 6 by welding in a first step.
  • Suitable welding methods for this application are, for example, ultrasonic welding, laser welding or arc welding.
  • the individual stranded conductors 10 are lined up next to each other, so that preferably each of the stranded conductor 10 rests against the copper foil 6 and is welded directly to this.
  • the originally substantially circular stranded conductor 4 is therefore pressed to form the integral connection with the copper foil 6 in a flat cross-sectional geometry.
  • the individual stranded wires 10 preferably assume a contour which is adapted in particular to the curved contour of the contact element 8.
  • the flattening of the aluminum conductor 4 and its contouring in a U-shape takes place directly during the welding process.
  • the U-shaped contour is adjusted in particular by a corresponding contouring of the welding electrodes, which are pressed against the aluminum conductor 4 and the copper foil 6.
  • the copper foil 6 likewise bears only U-shaped on the individual stranded wires 10.
  • the copper foil 6 continues to surround the aluminum conductor 4 and, for example, completely or almost completely, so that the individual stranded wires are connected to the copper foil 6 on two sides, for example. If a plurality of rows-for example 2 rows / layers-are arranged one above the other on stranded wires 10, the possibility of each of the individual stranded wires 10 being welded to the copper foil 6 is increased by an enclosing arrangement of the copper foil 6.
  • the welding takes place in a first method step outside the contact element 8.
  • a conventional copper cable is virtually simulated.
  • conventional contact elements and methods for forming the contact connection can be used.
  • the formation of a crimp connection is provided.
  • the prepared with the copper foil 6 aluminum conductor 4 is stripped with his and the copper foil 6 having end inserted into the contact element 8. This condition is in Fig. 2 shown.
  • the in Fig. 3 is shown, the crimped connection 12 by means of a crimping tool, not shown, are bent inwardly towards the aluminum conductor 4, so that the copper foil 6 is clamped with the aluminum conductor 4 in the crimping element 8 and thereby a mechanical connection between the adapter element. 6 and the crimping element 8 is formed.
  • the copper foil 6 is oriented towards the rounded bottom of the crimping element 8.
  • the copper foil 6 is arranged in the region of the Crimpflanken 12 or - as already mentioned above - that the copper foil 6 is placed around the stranded wires 10 so that both the bottom and the Crimpflanken 12 of the crimping element 8 with the copper foil 6 are contacted.
  • the contact element 8 is in this case generally formed in the manner of a cable lug, in which generally at one end of a clamping attachment of the conductor takes place and the other end is designed for a screw or plug connection.
  • the other end is formed, for example, as an eyelet or fork (screw) or in the manner of a flat connector.
  • For clamping attachment of the conductor end can be provided in addition to a crimp connection and a crimp connection in which the conductor end is first inserted into a corresponding sleeve of the contact element and this sleeve is then deformed by means of a crimping pliers, so that a force and form fit formed with the stripped conductor end.
  • the contact connection described here with the particular designed as a foil adapter element 8 formed, which consists for example of copper or a copper alloy / brass.
  • a conventional copper wire is "simulated" so that conventional contact elements, in particular crimp contact elements 8, can be used.
  • the contact connection described here is used in particular in a motor vehicle electrical system, preferably for smaller conductor cross sections of up to 10 mm 2 . Thanks to this special technology, a conventional copper crimp contact system within such a vehicle electrical system can be reliably and reliably replaced by a modified aluminum conductor crimp contact system.

Description

Die Erfindung betrifft eine elektrische Kontaktverbindung zwischen einem abisolierten Aluminiumleiter und einem daran angeschlossenen Kontaktelement. Die Erfindung betrifft weiterhin ein Verfahren zur Herstellung einer solchen Kontaktverbindung.The invention relates to an electrical contact connection between a stripped aluminum conductor and a contact element connected thereto. The invention further relates to a method for producing such a contact connection.

Insbesondere im Automobilbereich werden erhebliche Anstrengungen zur Gewichtseinsparung unternommen. Ein Mittel hierzu ist die Verwendung von Aluminiumleitern anstelle der ansonsten üblicherweise vorgesehenen Kupferleiter. Soweit hier von Aluminiumleitern gesprochen wird, wird hierunter verstanden, dass die Leiter zumindest zu einem großen Teil aus Aluminium oder einer Aluminiumlegierung bestehen. Aufgrund des deutlich geringeren spezifischen Gewichts von Aluminium lässt sich eine Gewichtseinsparung erzielen.Significant weight-saving efforts are being made, especially in the automotive sector. One means of doing so is to use aluminum conductors instead of the otherwise commonly provided copper conductors. As far as aluminum conductors are concerned, it is understood here that the conductors consist at least to a large extent of aluminum or an aluminum alloy. Due to the significantly lower specific weight of aluminum, a weight saving can be achieved.

Über das Kontaktelement wird üblicherweise der mit diesem Kontaktelement vorkonfektionierte Aluminiumleiter (Aluminiumkabel) an einem elektrischen Bauteil angeschlossen. Das Kontaktelement ist hierbei insbesondere als ein so genannter Kabelschuh beispielsweise nach Art eines Schraubkontaktelements oder eines Steckkontaktelements oder eines sonstigen Kontaktelements für eine mechanisch reversibel lösbare Kontaktverbindung ausgebildet.About the contact element usually with this contact element prefabricated aluminum conductor (aluminum cable) is connected to an electrical component. The contact element is in this case designed in particular as a so-called cable lug, for example, in the manner of a screw contact element or a plug contact element or another contact element for a mechanically reversible detachable contact connection.

Da Aluminium in Verbindung mit dem Luftsauerstoff eine Oxidschicht ausbildet, die den Aluminiumleiter überzieht und die eine nur geringe Leitfähigkeit aufweist, ist die Kontaktierung eines Aluminiumleiters problematisch. Für eine zuverlässige Kontaktverbindung mit einem möglichst geringen Kontaktwiderstand ist daher im Bereich der Kontaktfläche zwischen dem Aluminiumleiter und dem Kontaktelement die Ausbildung der Oxidschicht zu vermeiden.Since aluminum in conjunction with atmospheric oxygen forms an oxide layer that covers the aluminum conductor and that has only low conductivity, the contacting of an aluminum conductor is problematic. For a reliable contact connection with the lowest possible contact resistance, the formation of the oxide layer is therefore to be avoided in the area of the contact surface between the aluminum conductor and the contact element.

Bei bisherigen Kontaktverbindungen mit Aluminiumleitern wurden daher speziell angepasste Verfahren sowie speziell ausgebildete Kontaktelemente eingesetzt.In previous contact connections with aluminum conductors, therefore, specially adapted methods and specially designed contact elements were used.

Aus der DE 10 223 397 A1 ist ein Verfahren und eine Verbindung zur Kontaktierung eines Aluminiumkabels zu entnehmen, wobei abisolierte Aluminiumlitzen in eine formstabile, metallische Hülse eingeschoben werden. Die Hülse wird stirnseitig über einen deckelartigen Zinnpropfen verschlossen, wobei über das Zinn eine Kontaktverbindung zwischen der Hülse und den Einzelleitern erfolgt. Die Hülse wird schließlich in eine nach Art eines Kabelschluss ausgebildete Kontaktklemme eingesteckt und in dieser durch Verpressen befestigt.From the DE 10 223 397 A1 is to remove a method and a connection for contacting an aluminum cable, with stripped aluminum strands are inserted into a dimensionally stable, metallic sleeve. The sleeve is closed at the front by a lid-like Zinnpropfen, via the tin, a contact connection between the sleeve and the individual conductors takes place. The sleeve is finally inserted into a trained in the manner of a cable terminal contact terminal and secured in this by pressing.

Der Erfindung liegt die Aufgabe zugrunde, eine sichere sowie langzeitbeständige Kontaktierung zwischen einem Aluminiumleiter und einem Kontaktelement zu ermöglichen.The invention has for its object to provide a safe and long-term stable contact between an aluminum conductor and a contact element.

Die Aufgabe wird erfindungsgemäß gelöst durch eine elektrische Kontaktverbindung zwischen einem abisolierten Aluminiumleiter und einem daran angeschlossenen Kontaktelement, wobei der Aluminiumleiter stoffschlüssig mit einem Adapterelement verbunden ist und das Adapterelement mit dem Kontaktelement mechanisch verbunden ist, so dass der Aluminiumleiter mittelbar über das Adapterelement mit dem Kontaktelement elektrisch kontaktiert ist. Das Adapterelement ist dabei eine Folie.The object is achieved by an electrical contact connection between a stripped aluminum conductor and a contact element connected thereto, wherein the aluminum conductor is integrally connected to an adapter element and the adapter element is mechanically connected to the contact element, so that the aluminum conductor indirectly via the adapter element with the contact element electrically is contacted. The adapter element is a foil.

Ein wesentlicher Gesichtspunkt hierbei ist in der Verwendung des Adapterelements zu sehen. Auf der einen Seite ist durch die stoffschlüssige Verbindung mit dem Aluminiumleiter eine sichere und dauerhaft zuverlässige elektrische Kontaktierung zwischen dem Adapterelement und dem Aluminiumleiter gegeben. Das Adapterelement besteht hierbei aus einem von Aluminium verschiedenen Material und ist insbesondere aus Kupfer oder einer Kupferlegierung. Über das Adapterelement wird daher quasi ein herkömmlicher Kupferleiter für die Ausbildung der Kontaktverbindung mit dem Kontaktelement "nachgebildet". Daher kann für das Kontaktelement auf herkömmliche Kontaktelemente und Kabelschuhe sowie auf herkömmliche Befestigungsarten des Leiters in diesen Kontaktelementen zurückgegriffen werden. Aufgrund der Anordnung des Adapterelements ist daher eine herkömmliche mechanische Kontaktverbindung zum Kontaktelement für eine dauerhaft sichere elektrische Kontaktverbindung ausreichend. Durch die dünne und damit leicht verformbare Ausbildung des Adapterelements nach Art einer Folie lässt es sich problemlos zwischen dem Aluminiumleiter und dem Kontaktelement einbringen, so dass herkömmliche Kontaktelemente eingesetzt werden können. Durch die leichte Verformbarkeit eignet sich das Adapterelement insbesondere für den Einsatz in einer Crimpverbindung.An essential aspect here is to be seen in the use of the adapter element. On the one hand a secure and permanently reliable electrical contact between the adapter element and the aluminum conductor is given by the cohesive connection with the aluminum conductor. The adapter element in this case consists of a material other than aluminum and is in particular made of copper or a copper alloy. Therefore, a conventional copper conductor for the formation of the contact connection with the contact element is "simulated" as it were via the adapter element. Therefore, it can be used for the contact element on conventional contact elements and cable lugs and on conventional types of attachment of the conductor in these contact elements. Due to the arrangement of the adapter element therefore a conventional mechanical contact connection to the contact element for a permanently secure electrical contact connection is sufficient. Due to the thin and thus easily deformable design of the adapter element in the manner of a film, it can be easily between the aluminum conductor and the contact element bring in so that conventional contact elements can be used. Due to the easy deformability, the adapter element is particularly suitable for use in a crimped connection.

Gemäß einer bevorzugten Ausgestaltung ist die Kontaktverbindung eine Crimpverbindung und das Kontaktelement ein Crimpelement. Crimpverbindungen wer- den bevorzugt für kleinere Leiterquerschnitte mit einer Leiterquerschnittfläche kleiner 10 mm2 eingesetzt und haben sich als besonders zuverlässig erwiesen und sind einfach zum Herstellen. Mit der neuartigen Crimpverbindung unter Verwendung des Adapterelements zur Kontaktierung des Aluminiumleiters ist daher eine modifizierte Crimpverbindung geschaffen, die auf der einen Seite eine zuverlässige und sichere dauerhafte Kontaktverbindung gewährleistet und andererseits den Einsatz von bisherigen Crimpkontaktsystemen ermöglicht. Insgesamt ist durch diese Maßnahme der Aufbau eines Aluminium-Bordnetzes mit Aluminium- kabeln mit kleinen Leiterquerschnitten möglich, wobei hierbei - bis auf die Verwendung des Adapterelements auf herkömmliche Technologien und Kontaktelemente zurückgegriffen werden kann.According to a preferred embodiment, the contact connection is a crimp connection and the contact element is a crimping element. Crimp connections are preferably used for smaller conductor cross sections with a conductor cross-sectional area smaller than 10 mm 2 and have proven to be particularly reliable and are easy to manufacture. With the novel crimp connection using the adapter element for contacting the aluminum conductor, therefore, a modified crimped connection is provided which on the one hand ensures a reliable and secure permanent contact connection and on the other hand enables the use of previous crimp contact systems. Overall, this measure makes it possible to construct an aluminum electrical system with aluminum cables with small conductor cross-sections, in which case it is possible to resort to conventional technologies and contact elements, except for the use of the adapter element.

Beim Crimpen, also bei der Ausbildung der Crimpverbindung, werden allgemein so genannte Crimpflanken des Crimpelements mechanisch verformt, so dass der Leiter im Crimpelement von den Crimpflanken geklemmt wird. Es werden für die hier beschriebene Crimpverbindung bevorzugt standardmäßig verwendete Crimpelemente eingesetzt. Diese werden bzw. sind insbesondere auch verzinnt, so dass die elektrische Kontaktverbindung korrosionsfest ausgeführt ist.When crimping, ie during the formation of the crimped connection, so-called crimpfs of the crimping element are generally deformed mechanically, so that the conductor in the crimping element is clamped by the crimped edges. For the crimp connection described here it is preferred to use standard crimping elements. These are or are in particular tinned, so that the electrical contact connection is made corrosion-resistant.

Im Hinblick auf eine Minimierung der Korrosionsrisiken weist die Folie bevorzugt eine Antikorrosionsbeschichtung auf. Insbesondere werden als Antikorrosionsbeschichtung elektrochemisch verwandte Materialien zu Aluminium wie z.B. Chrom, Nickel und/oder Zink oder deren Legierungen eingesetztWith a view to minimizing the risk of corrosion, the film preferably has an anti-corrosion coating. In particular, as an anticorrosive coating, electrochemically related materials are added to aluminum, e.g. Chromium, nickel and / or zinc or their alloys used

Vorteilhafterweise ist die stoffschlüssige Verbindung zwischen dem Aluminiumleiter und dem Adapterelement eine Schweißverbindung. Es wird somit eine unlösbare Verbindung hergestellt, die einen sicheren Halt des Adapterelements am Aluminiumleiter gewährleistet. Bevorzugte Schweißverfahren, die für diese Anwendung geeignet sind, sind z.B. Ultraschallschweißen, Laserschweißen und Elektroschweißen.Advantageously, the cohesive connection between the aluminum conductor and the adapter element is a welded connection. It is thus made a non-detachable connection, which ensures a secure hold of the adapter element on the aluminum conductor. Preferred welding methods suitable for this application are suitable, for example, ultrasonic welding, laser welding and arc welding.

Bevorzugt ist der Aluminiumleiter ein Litzenleiter mit mehreren Litzendrähten. Der Aluminiumleiter ist im Kontaktbereich zweckdienlicherweise abgeflacht ausgebildet. Hierdurch sind die einzelnen Litzendrähte nebeneinander anliegend angeordnet. Bevorzugt sind nur wenige Lagen von Litzendrähten übereinander angeordnet. Insbesondere ist nur eine Lage ausgebildet, so dass jeder oder nahezu jeder Litzendraht an dem Adapterelement anliegt und mit diesem verbunden ist. Durch das Abflachen sind die Litzendrähte also nach Art einer Reihe nebeneinander angeordnet und mit dem Adapterelement verschweißt, so dass die Kontaktfläche zwischen dem Aluminiumleiter und dem Adapterelement besonders groß ist.The aluminum conductor is preferably a stranded conductor with a plurality of stranded wires. The aluminum conductor is expediently flattened in the contact region. As a result, the individual stranded wires are arranged adjacent to each other. Preferably, only a few layers of stranded wires are arranged one above the other. In particular, only one layer is formed, so that each or almost every stranded wire rests against the adapter element and is connected thereto. By flattening the stranded wires are thus arranged in the manner of a row next to each other and welded to the adapter element, so that the contact surface between the aluminum conductor and the adapter element is particularly large.

Gemäß einer bevorzugten Ausgestaltung bilden die Litzendrähte hierbei eine in etwa U-förmige Kontur aus, die Aneinanderreihung der Litzendrähte ist daher insgesamt gebogen ausgebildet. Durch die gebogene Ausgestaltung ist daher quasi die Außenkontur eines herkömmlich verwendeten Leiters für eine Crimpverbindung simuliert, so dass sich die Außenkontur auch an die Kontur des standardmäßig verwendeten Crimpelements anpasst. Dadurch ist auch zwischen dem Adapterelement und dem Kontaktelement eine möglichst große Kontaktfläche gebildet. Bevorzugt wird hierbei die gebogene oder U-förmige Kontur beim Ausbilden der stoffschlüssigen Verbindung ausgebildet, insbesondere beim Verschweißen des Litzenleiters mit der Folie.According to a preferred embodiment, the stranded wires in this case form an approximately U-shaped contour, the stringing together of the stranded wires is therefore designed to be bent overall. Due to the curved configuration, therefore, the outer contour of a conventionally used conductor for a crimp connection is virtually simulated, so that the outer contour also adapts to the contour of the crimping element used by default. As a result, the largest possible contact surface is formed between the adapter element and the contact element. In this case, the curved or U-shaped contour is preferably formed during the formation of the integral connection, in particular during welding of the stranded conductor to the film.

Zur Verhinderung der Korrosion der elektrischen Kontaktverbindung ist vorzugsweise zur Abdichtung der Kontaktverbindung diese mit einem Lack überzogen. Der Lack umschließt dabei eine Kontaktzone des Kontaktelements, in der die elektrische Kontaktierung erfolgt und in der sich der Aluminiumleiter mit dem Adapterelement befindet, so dass kein Luftsauerstoff an die elektrischen Kontaktstellen gelangen kann.To prevent the corrosion of the electrical contact connection is preferably coated to seal the contact connection with a lacquer. The paint encloses a contact zone of the contact element, in which the electrical contact takes place and in which the aluminum conductor is located with the adapter element, so that no atmospheric oxygen can reach the electrical contact points.

Die Aufgabe wird weiterhin erfindungsgemäß gelöst durch ein Verfahren zur Herstellung einer Kontaktverbindung zwischen einem abisolierten Aluminiumleiter und einem daran angeschlossenen Kontaktelement, bei dem der Aluminiumleiter mit einem Adapterelement, insbesondere einer Kupferfolie, stoffschlüssig verbunden wird, und das Adapterelement mit dem Kontaktelement mechanisch verbunden wird, so dass der Aluminiumleiter mittelbar über das Adapterelement mit dem Kontaktelement elektrisch kontaktiert wird.The object is further achieved according to the invention by a method for producing a contact connection between a stripped aluminum conductor and a contact element connected thereto, in which the aluminum conductor with an adapter element, in particular a copper foil, is integrally connected, and the adapter element is mechanically connected to the contact element, so that the aluminum conductor is indirectly contacted via the adapter element with the contact element electrically.

Die in Bezug auf die elektrische Kontaktverbindung angeführten Vorteile und bevorzugten Ausgestaltungen sind sinngemäß auf das Verfahren zu übertragen.The advantages and preferred embodiments mentioned in relation to the electrical contact connection are to be transferred analogously to the method.

Bevorzugt wird zunächst der Aluminiumleiter mit der Kupferfolie stoffschlüssig verbunden, insbesondere zusammengeschweißt. Wenn der Aluminiumleiter mehrere Litzendrähte umfasst, werden diese bevorzugt abgeflacht und an dem Adapterelement nebeneinander angeordnet, derart, dass sie insbesondere nach Art einer U-förmigen Kontur mit dem Adapterelement verbunden werden. Die U-förmige Kontur wird bevorzugt durch die Form der Schweißelektroden realisiert, über die also der Litzendraht und die Adapterfolie in die U-förmige Kontur gepresst werden.Preferably, first of all the aluminum conductor is adhesively bonded to the copper foil, in particular welded together. If the aluminum conductor comprises a plurality of stranded wires, these are preferably flattened and arranged side by side on the adapter element, such that they are connected in particular in the manner of a U-shaped contour with the adapter element. The U-shaped contour is preferably realized by the shape of the welding electrodes, via which therefore the stranded wire and the adapter foil are pressed into the U-shaped contour.

Zum Herstellen der mechanischen Verbindung zwischen dem Adapterelement und dem Kontaktelement werden im darauf folgenden zweiten Herstellungsschritt das Adapterelement und der Aluminiumleiter im Bereich der Kontaktzone im Kontaktelement geklemmt, und zwar insbesondere durch ein Vercrimpen. Die Lage des Adapterelements ist - je nach Ausprägung der einzelnen Crimpflanken des Crimpelements - am Boden des Kontaktelements oder auch oberhalb des Leiters direkt unter den Crimpflanken positioniert. Alternativ ist eine komplette Umfassung der Litzendrähte des Leiters mit dem Adapterelement für eine erhöhte Stabilität der Haltekräfte in der Kontaktzone vorgesehen.To produce the mechanical connection between the adapter element and the contact element, the adapter element and the aluminum conductor are clamped in the contact zone in the contact element in the subsequent second production step, in particular by crimping. The position of the adapter element is - depending on the nature of the individual Crimpflanken the crimp - positioned at the bottom of the contact element or even above the head directly under the Crimpflanken. Alternatively, a complete enclosure of the stranded wires of the conductor is provided with the adapter element for increased stability of the holding forces in the contact zone.

Schließlich wird vorzugsweise bei Bedarf zur Abdichtung ein Lack auf die Kontaktverbindung aufgetragen derart, dass die Lackschicht die Kontaktverbindung in der Kontaktzone umschließt.Finally, if necessary, a lacquer is applied to the contact connection, if necessary, in such a way that the lacquer layer surrounds the contact connection in the contact zone.

Das Verfahren zum Herstellen einer solchen elektrischen Kontaktverbindung ist insbesondere für Aluminiumleiter mit kleinen Querschnitten einsetzbar und ermöglicht den Einsatz von Crimpkontaktsystemen in einem Aluminium-Bordnetz.The method for producing such an electrical contact connection can be used in particular for aluminum conductors with small cross-sections and allows the use of crimp contact systems in an aluminum electrical system.

Ein Ausführungsbeispiel der Erfindung wird anhand einer Zeichnung näher erläutert. Hierin zeigen schematisch und stark vereinfacht:

Fig. 1
die Komponenten einer elektrischen Kontaktverbindung bevor diese zusammengefügt werden,
Fig. 2
die Komponenten der elektrischen Kontaktverbindung gemäß Fig. 1 nach einem Schweißprozess, und
Fig. 3
die fertiggestellte Kontaktverbindung.
An embodiment of the invention will be explained in more detail with reference to a drawing. Herein schematically and greatly simplified show:
Fig. 1
the components of an electrical contact connection before they are joined together,
Fig. 2
the components of the electrical contact connection according to Fig. 1 after a welding process, and
Fig. 3
the finished contact connection.

In den verschiedenen Figuren haben gleiche Bezugszeichen die gleiche Bedeutung.In the various figures, like reference numerals have the same meaning.

Wie aus Fig. 1 ersichtlich, umfasst eine elektrische Kontaktverbindung 2 im Wesentlichen das abisolierte Ende eines Aluminiumleiters 4, ein Adapterelement 6 und ein Kontaktelement 8. Der Aluminiumleiter 4 ist hierbei ein Litzenleiter und weist mehrere Litzendrähte 10 auf, die miteinander verflochten sind. Der Aluminiumleiter 4 ist als Aluminiumkabel ausgebildet und umfasst weiterhin außerhalb des Kontaktbereiches einen (hier nicht dargestellten) Isoliermantel. Das Adapterelement 6 ist im gezeigten Ausführungsbeispiel eine Kupferfolie, die eine hier nicht näher gezeigte Antikorrosionsbeschichtung aus Chrom, Nickel und/oder Zink aufweist. Als Kontaktelement 8 ist ein Crimpelement vorgesehen, welches zwei Crimpflanken 12 umfasst.How out Fig. 1 can be seen, an electrical contact connection 2 essentially comprises the stripped end of an aluminum conductor 4, an adapter element 6 and a contact element 8. The aluminum conductor 4 is in this case a stranded conductor and has a plurality of stranded wires 10, which are intertwined. The aluminum conductor 4 is formed as aluminum cable and further comprises outside of the contact area a (not shown) insulating jacket. In the exemplary embodiment shown, the adapter element 6 is a copper foil which has an anticorrosion coating of chromium, nickel and / or zinc (not shown here). As a contact element 8, a crimping element is provided which comprises two Crimpflanken 12.

Zur Herstellung der elektrischen Kontaktverbindung 2 wird in einem ersten Schritt der Aluminiumleiter 4 durch Schweißen stoffschlüssig mit der Kupferfolie 6 verbunden. Geeignete Schweißverfahren für diesen Anwendungsfall sind z.B. Ultraschallschweißen, Laserschweißen oder Elektroschweißen.In order to produce the electrical contact connection 2, the aluminum conductor 4 is joined in a materially bonded manner to the copper foil 6 by welding in a first step. Suitable welding methods for this application are, for example, ultrasonic welding, laser welding or arc welding.

Wie aus der Fig. 2 zu entnehmen ist, sind die einzelnen Litzenleiter 10 nebeneinander angereiht, so dass vorzugsweise jeder der Litzenleiter 10 an der Kupferfolie 6 anliegt und unmittelbar mit dieser verschweißt ist. Der ursprünglich im Wesentlichen kreisrunde Litzenleiter 4 wird daher zur Ausbildung der stoffschlüssigen Verbindung mit der Kupferfolie 6 in eine flache Querschnittsgeometrie gepresst.Like from the Fig. 2 can be seen, the individual stranded conductors 10 are lined up next to each other, so that preferably each of the stranded conductor 10 rests against the copper foil 6 and is welded directly to this. The originally substantially circular stranded conductor 4 is therefore pressed to form the integral connection with the copper foil 6 in a flat cross-sectional geometry.

Bevorzugt nehmen die einzelnen Litzendrähte 10 hierbei eine Kontur an, die insbesondere an die gebogene Kontur des Kontaktelements 8 angepasst ist.In this case, the individual stranded wires 10 preferably assume a contour which is adapted in particular to the curved contour of the contact element 8.

Bevorzugt erfolgt das Abflachen des Aluminiumleiters 4 sowie dessen Konturierung in eine U-Form unmittelbar beim Schweißprozess. Die U-förmige Kontur wird insbesondere durch eine entsprechende Konturierung der Schweißelektroden eingestellt, die gegen den Aluminiumleiter 4 und die Kupferfolie 6 gepresst werden.Preferably, the flattening of the aluminum conductor 4 and its contouring in a U-shape takes place directly during the welding process. The U-shaped contour is adjusted in particular by a corresponding contouring of the welding electrodes, which are pressed against the aluminum conductor 4 and the copper foil 6.

Im Ausführungsbeispiel ist vorgesehen, dass die Kupferfolie 6 ebenfalls lediglich U-förmig an den einzelnen Litzendrähten 10 anliegt. Alternativ besteht auch die Möglichkeit, dass die Kupferfolie 6 den Aluminiumleiter 4 weitergehend und beispielsweise vollständig oder nahezu vollständig umschließt, so dass die einzelnen Litzendrähte beispielsweise an zwei Seiten mit der Kupferfolie 6 verbunden sind. Falls mehrere Reihen - beispielsweise 2 Reihen/Lagen - an Litzendrähten 10 übereinander angeordnet sind, ist durch eine umschließende Anordnung der Kupferfolie 6 zumindest die Wahrscheinlichkeit erhöht, dass jeder der einzelnen Litzendrähte 10 mit der Kupferfolie 6 verschweißt ist.In the exemplary embodiment, it is provided that the copper foil 6 likewise bears only U-shaped on the individual stranded wires 10. Alternatively, there is also the possibility that the copper foil 6 continues to surround the aluminum conductor 4 and, for example, completely or almost completely, so that the individual stranded wires are connected to the copper foil 6 on two sides, for example. If a plurality of rows-for example 2 rows / layers-are arranged one above the other on stranded wires 10, the possibility of each of the individual stranded wires 10 being welded to the copper foil 6 is increased by an enclosing arrangement of the copper foil 6.

Das Verschweißen erfolgt in einem ersten Verfahrensschritt außerhalb des Kontaktelements 8. Durch das Anschweißen der Kupferfolie 6 als Adapterelement wird daher quasi ein herkömmliches Kupfer-Kabel simuliert. Zur Kontaktierung mit dem Kontaktelement 8 können daher herkömmliche Kontaktelemente und Verfahren zur Ausbildung der Kontaktverbindung herangezogen werden. Im Ausführungsbeispiel ist die Ausbildung einer Crimpverbindung vorgesehen. Hierzu wird der mit der Kupferfolie 6 vorbereitete Aluminiumleiter 4 mit seinem abisolierten und die Kupferfolie 6 aufweisenden Ende in das Kontaktelement 8 eingelegt. Dieser Zustand ist in Fig. 2 dargestellt.The welding takes place in a first method step outside the contact element 8. By welding the copper foil 6 as an adapter element, therefore, a conventional copper cable is virtually simulated. For contacting with the contact element 8, therefore, conventional contact elements and methods for forming the contact connection can be used. In the embodiment, the formation of a crimp connection is provided. For this purpose, the prepared with the copper foil 6 aluminum conductor 4 is stripped with his and the copper foil 6 having end inserted into the contact element 8. This condition is in Fig. 2 shown.

Im nächsten Schritt, der in Fig. 3 dargestellt ist, wird die Crimpverbindung hergestellt, indem die Crimpflanken 12 mit Hilfe eines nicht dargestellten Crimpwerkzeuges nach innen zum Aluminiumleiter 4 hin umgebogen werden, so dass die Kupferfolie 6 mit dem Aluminiumleiter 4 im Crimpelement 8 geklemmt wird und dadurch eine mechanische Verbindung zwischen dem Adapterelement 6 und dem Crimpelement 8 entsteht.In the next step, the in Fig. 3 is shown, the crimped connection 12 by means of a crimping tool, not shown, are bent inwardly towards the aluminum conductor 4, so that the copper foil 6 is clamped with the aluminum conductor 4 in the crimping element 8 and thereby a mechanical connection between the adapter element. 6 and the crimping element 8 is formed.

Im Ausführungsbeispiel ist die Kupferfolie 6 zum gerundeten Boden des Crimpelements 8 hin orientiert. Alternativ besteht auch die Möglichkeit, dass die Kupferfolie 6 im Bereich der Crimpflanken 12 angeordnet ist oder - wie bereits oben erwähnt - dass die Kupferfolie 6 umfassend um die Litzendrähte 10 gelegt ist, so dass sowohl der Boden als auch die Crimpflanken 12 des Crimpelements 8 mit der Kupferfolie 6 kontaktiert sind.In the exemplary embodiment, the copper foil 6 is oriented towards the rounded bottom of the crimping element 8. Alternatively, there is also the possibility that the copper foil 6 is arranged in the region of the Crimpflanken 12 or - as already mentioned above - that the copper foil 6 is placed around the stranded wires 10 so that both the bottom and the Crimpflanken 12 of the crimping element 8 with the copper foil 6 are contacted.

Mit dem Anschlagen des Kontaktelements 8 an dem Aluminiumkabel ist somit ein vorkonfektioniertes Kabel gebildet. Das Kontaktelement 8 ist hierbei allgemein nach Art eines Kabelschuhs ausgebildet, bei dem allgemein an seinem einen Ende eine Klemmbefestigung des Leiters erfolgt und dessen anderes Ende für eine Schraub- oder Steckverbindung ausgebildet ist. Hierzu ist das andere Ende beispielsweise als eine Öse oder Gabel (Schraubverbindung) oder nach Art eines Flachsteckverbinders ausgebildet. Zur klemmenden Befestigung des Leiterendes kann neben einer Crimpverbindung auch eine Press- oder Quetschverbindung vorgesehen sein, bei denen das Leiterende zunächst in eine entsprechende Hülse des Kontaktelements eingelegt wird und diese Hülse dann mit Hilfe einer Presszange verformt wird, so dass sich ein Kraft- und Formschluss mit dem abisolierten Leiterende ausbildet.With the abutment of the contact element 8 on the aluminum cable thus a prefabricated cable is formed. The contact element 8 is in this case generally formed in the manner of a cable lug, in which generally at one end of a clamping attachment of the conductor takes place and the other end is designed for a screw or plug connection. For this purpose, the other end is formed, for example, as an eyelet or fork (screw) or in the manner of a flat connector. For clamping attachment of the conductor end can be provided in addition to a crimp connection and a crimp connection in which the conductor end is first inserted into a corresponding sleeve of the contact element and this sleeve is then deformed by means of a crimping pliers, so that a force and form fit formed with the stripped conductor end.

Insgesamt ist durch die hier beschriebene Kontaktverbindung mit dem insbesondere als Folie ausgebildeten Adapterelement eine zuverlässige und dauerhaft sichere Kontaktverbindung zwischen dem Aluminiumleiter 4 und dem Kontaktelement 8 ausgebildet, welches beispielsweise aus Kupfer oder einer Kupferlegierung/Messing besteht. Durch das Adapterelement 6 wird quasi ein herkömmlicher Kupferdraht "simuliert", so dass herkömmliche Kontaktelemente, insbesondere Crimpkontaktelemente 8, herangezogen werden können. Die hier beschriebene Kontaktverbindung wird insbesondere in einem Kraftfahrzeug-Bordnetz eingesetzt, vorzugsweise für kleinere Leiterquerschnitte von bis zu 10 mm2. Durch diese spezielle Technologie kann ein herkömmliches Kupfer-Crimpkontaktsystem innerhalb eines solchen Bordnetzes prozesssicher und zuverlässig durch ein modifiziertes Crimpkontaktsystem für Aluminiumleiter ersetzt werden.Overall, a reliable and permanently secure contact connection between the aluminum conductor 4 and the contact element is described by the contact connection described here with the particular designed as a foil adapter element 8 formed, which consists for example of copper or a copper alloy / brass. As a result of the adapter element 6, a conventional copper wire is "simulated" so that conventional contact elements, in particular crimp contact elements 8, can be used. The contact connection described here is used in particular in a motor vehicle electrical system, preferably for smaller conductor cross sections of up to 10 mm 2 . Thanks to this special technology, a conventional copper crimp contact system within such a vehicle electrical system can be reliably and reliably replaced by a modified aluminum conductor crimp contact system.

BezugszeichenlisteLIST OF REFERENCE NUMBERS

22
elektrische Kontaktverbindungelectrical contact connection
44
Aluminiumleiteraluminum ladder
66
Adapterelementadapter element
88th
Kontaktelementcontact element
1010
Litzendrahtlitz
1212
CrimpflankeCrimpflanke

Claims (14)

  1. Electrical contact connection (2) between a stripped aluminium conductor (4) and a contact element (8) connected thereto, wherein the aluminium conductor (4) is firmly connected to an adapter element (6) and the adapter element (6) is connected mechanically to the contact element (8), such that the aluminium conductor (4) is in electrical contact with the contact element (8) indirectly via the adapter element (6),
    characterised in that
    the adapter element (6) is a foil.
  2. Electrical contact connection (2) according to claim 1,
    wherein the contact element (8) is a crimp element.
  3. Electrical contact connection (2) according to one of the preceding claims,
    wherein the adapter element (6) is a foil, in particular made from copper.
  4. Electrical contact connection (2) according to one of the preceding claims,
    wherein the adapter element (6) has an anti-corrosion coating which contains in particular chromium, nickel and/or zinc.
  5. Electrical contact connection (2) according to one of the preceding claims,
    wherein the firm connection between the aluminium conductor (4) and the adapter element (6) is a welded connection.
  6. Electrical contact connection (2) according to one of the preceding claims,
    wherein the aluminium conductor (4) is a stranded conductor having several stranded wires (10) and the aluminium conductor (4) has a flattened cross-sectional shape which deviates from the circle shape in such a way that the individual stranded wires (10) abut onto one another adjacent to the adapter element (6).
  7. Electrical contact connection (2) according to claim 6,
    wherein the stranded wires (10) form a U-shaped contour.
  8. Electrical contact connection (2) according to one of the preceding claims,
    to which a lacquer is applied for sealing.
  9. Method for the production of an electrical contact connection (2) between a stripped aluminium conductor (4) and a contact element (8) connected thereto, in which
    the aluminium conductor (4) is firmly connected to an adapter element (6), in particular a copper foil, and
    the adapter element (6) is connected mechanically to the contact element (8), such that the aluminium conductor (4) is in electrical contact with the contact element (8) indirectly via the adapter element (6).
  10. Method according to claim 9,
    in which the aluminium conductor (4) is welded to the adapter element (6).
  11. Method according to claim 9 or 10,
    in which, for the production of the mechanical connection between the adapter element (6) and the contact element (8), in particular for the production of a crimp connection, the contact element (8) is pressed with the aluminium conductor (4) including the adapter element (6).
  12. Method according to one of claims 9 to 11,
    in which the aluminium conductor (4) comprises several stranded wires (10) and the aluminium conductor (4) is flattened such that the individual stranded wires (10) are connected to the adapter element (6) to abut on one another.
  13. Method according to claim 12,
    in which the stranded wires (10) are brought into a U-shaped contour during formation of the firm connection between the aluminium conductor (4) and the adapter element (6)
  14. Method according to one of claims 9 to 13,
    in which, for the sealing, a lacquer is applied to the contact connection (2).
EP09796944.8A 2008-12-09 2009-12-04 Electrical contact connection and method for producing an electrical contact connection Not-in-force EP2371036B1 (en)

Applications Claiming Priority (2)

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DE200810061186 DE102008061186B4 (en) 2008-12-09 2008-12-09 Electronic contact connection and method for producing an electrical contact connection
PCT/EP2009/008645 WO2010066376A1 (en) 2008-12-09 2009-12-04 Electrical contact connection and method for producing an electrical contact connection

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EP2371036A1 (en) 2011-10-05
CN102246353B (en) 2013-12-25
CN102246353A (en) 2011-11-16
RU2490763C2 (en) 2013-08-20
DE102008061186B4 (en) 2010-07-29
RU2011127992A (en) 2013-01-20
WO2010066376A1 (en) 2010-06-17

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