EP2371036B1 - Liaison de contact électrique et procédé pour réaliser une liaison de contact électrique - Google Patents

Liaison de contact électrique et procédé pour réaliser une liaison de contact électrique 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
Authority
EP
European Patent Office
Prior art keywords
connection
contact
adapter element
electrical contact
aluminium conductor
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
EP09796944.8A
Other languages
German (de)
English (en)
Other versions
EP2371036A1 (fr
Inventor
Frank Beuscher
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.)
Leoni Bordnetz Systeme GmbH
Original Assignee
Leoni Bordnetz Systeme 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 Leoni Bordnetz Systeme GmbH filed Critical Leoni Bordnetz Systeme GmbH
Publication of EP2371036A1 publication Critical patent/EP2371036A1/fr
Application granted granted Critical
Publication of EP2371036B1 publication Critical patent/EP2371036B1/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
    • H01R4/58—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.

Landscapes

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

Claims (14)

  1. Liaison de contact électrique (2) entre un conducteur en aluminium (4) dénudé et un élément de contact (8) qui y est raccordé, le conducteur en aluminium (4) étant lié par continuité de matière à un élément d'adaptation (6), et l'élément d'adaptation (6) étant lié mécaniquement à l'élément de contact (8) de sorte que le conducteur en aluminium (4) est contacté électriquement à l'élément de contact (8) indirectement par l'intermédiaire de l'élément d'adaptation (6),
    caractérisée
    en ce que l'élément d'adaptation (6) et une feuille.
  2. Liaison de contact électrique (2) selon la revendication 1,
    dans laquelle l'élément de contact (8) est un élément à sertir (crimp).
  3. Liaison de contact électrique (2) selon l'une des revendications précédentes,
    dans laquelle l'élément d'adaptation (6) est une feuille, notamment en cuivre.
  4. Liaison de contact électrique (2) selon l'une des revendications précédentes,
    dans laquelle l'élément d'adaptation (6) présente un revêtement anticorrosion, qui renferme notamment du chrome, du nickel et/ou du zinc.
  5. Liaison de contact électrique (2) selon l'une des revendications précédentes,
    dans laquelle la liaison par continuité de matière entre le conducteur en aluminium (4) et l'élément d'adaptation (6) est une liaison par soudage.
  6. Liaison de contact électrique (2) selon l'une des revendications précédentes,
    dans laquelle le conducteur en aluminium (4) est un conducteur toronné à plusieurs fils de toron (10), et le conducteur en aluminium (4) présente une forme de section transversale aplatie s'écartant d'une forme circulaire, de manière telle que les fils de toron individuels (10) s'appuient de manière mutuellement adjacente sur l'élément d'adaptation (6).
  7. Liaison de contact électrique (2) selon la revendication 6,
    dans laquelle les fils de toron (10) forment un contour en forme de U.
  8. Liaison de contact électrique (2) selon l'une des revendications précédentes,
    sur laquelle est appliqué un vernis pour l'étanchéité.
  9. Procédé pour la réalisation d'une liaison de contact électrique (2) entre un conducteur en aluminium (4) dénudé et un élément de contact (8) qui y est raccordé, procédé d'après lequel
    on relie le conducteur en aluminium (4), par continuité de matière, à un élément d'adaptation (6), notamment une feuille de cuivre, et
    on relie mécaniquement l'élément d'adaptation (6) à l'élément de contact (8), de sorte que le conducteur en aluminium (4) est contacté électriquement à l'élément de contact (8) indirectement par l'intermédiaire de l'élément d'adaptation (6).
  10. Procédé selon la revendication 9,
    d'après lequel on soude le conducteur en aluminium (4) à l'élément d'adaptation (6).
  11. Procédé selon la revendication 9 ou la revendication 10,
    d'après lequel pour réaliser la liaison mécanique entre l'élément d'adaptation (6) et l'élément de contact (8), notamment pour réaliser une liaison de sertissage, on produit une compression réciproque de l'élément de contact (8) et du conducteur en aluminium (4) avec interposition de l'élément d'adaptation (6).
  12. Procédé selon l'une des revendications 9 à 11,
    d'après lequel le conducteur en aluminium (4) comprend plusieurs fils de toron (10), et l'on aplatit le conducteur en aluminium (4) de manière à ce que les fils de toron individuels (10) soient reliés à l'élément d'adaptation (6) en s'appuyant de manière adjacente les uns contre les autres.
  13. Procédé selon la revendication 12,
    d'après lequel les fils de toron (10), lors de la réalisation de la liaison par continuité de matière entre le conducteur en aluminium (4) et l'élément d'adaptation (6), sont amenés dans une disposition à contour en forme de U.
  14. Procédé selon l'une des revendications 9 à 13,
    d'après lequel on applique un vernis sur la liaison de contact (2) pour l'étanchéité.
EP09796944.8A 2008-12-09 2009-12-04 Liaison de contact électrique et procédé pour réaliser une liaison de contact électrique Not-in-force EP2371036B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE200810061186 DE102008061186B4 (de) 2008-12-09 2008-12-09 Elektronische Kontaktverbindung und Verfahren zur Herstellung einer elektrischen Kontaktverbindung
PCT/EP2009/008645 WO2010066376A1 (fr) 2008-12-09 2009-12-04 Liaison de contact électrique et procédé pour réaliser une liaison de contact électrique

Publications (2)

Publication Number Publication Date
EP2371036A1 EP2371036A1 (fr) 2011-10-05
EP2371036B1 true EP2371036B1 (fr) 2015-10-21

Family

ID=41693149

Family Applications (1)

Application Number Title Priority Date Filing Date
EP09796944.8A Not-in-force EP2371036B1 (fr) 2008-12-09 2009-12-04 Liaison de contact électrique et procédé pour réaliser une liaison de contact électrique

Country Status (5)

Country Link
EP (1) EP2371036B1 (fr)
CN (1) CN102246353B (fr)
DE (1) DE102008061186B4 (fr)
RU (1) RU2490763C2 (fr)
WO (1) WO2010066376A1 (fr)

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DE102010053919A1 (de) 2010-12-09 2012-06-14 Bayerische Motoren Werke Aktiengesellschaft Verfahren zur Kontaktierung eines isolierten Kabels und elektrische Kontaktverbindung
DE102011119699A1 (de) 2011-11-29 2013-05-29 Leoni Bordnetz-Systeme Gmbh Kabel, insbesondere Aluminiumkabel
DE102011089206B4 (de) 2011-12-20 2023-10-05 Lisa Dräxlmaier GmbH Verfahren zum Kontaktieren einer Litzenleitung mit einem Kontakt
DE102011089207B4 (de) * 2011-12-20 2021-02-04 Lisa Dräxlmaier GmbH Verfahren zum Kontaktieren einer Litzenleitung mit einem Kontakt
DE102014206283B3 (de) * 2014-04-02 2015-07-02 Leoni Bordnetz-Systeme Gmbh Elektrische Kontaktverbindung sowie Verfahren zur Herstellung einer Kontaktverbindung
DE102014112701A1 (de) * 2014-09-03 2016-03-03 Harting Electric Gmbh & Co. Kg Crimpkontakt
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CN108418004A (zh) * 2018-04-28 2018-08-17 深圳供电局有限公司 一种板型双层压接中间连接头

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Also Published As

Publication number Publication date
CN102246353B (zh) 2013-12-25
CN102246353A (zh) 2011-11-16
RU2011127992A (ru) 2013-01-20
RU2490763C2 (ru) 2013-08-20
DE102008061186B4 (de) 2010-07-29
WO2010066376A1 (fr) 2010-06-17
DE102008061186A1 (de) 2010-06-10
EP2371036A1 (fr) 2011-10-05

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