EP2378611A1 - Method for producing cables with aluminium wires - Google Patents

Method for producing cables with aluminium wires Download PDF

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Publication number
EP2378611A1
EP2378611A1 EP10305380A EP10305380A EP2378611A1 EP 2378611 A1 EP2378611 A1 EP 2378611A1 EP 10305380 A EP10305380 A EP 10305380A EP 10305380 A EP10305380 A EP 10305380A EP 2378611 A1 EP2378611 A1 EP 2378611A1
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EP
European Patent Office
Prior art keywords
conductor
tool
connecting part
aluminum
connecting portion
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP10305380A
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German (de)
French (fr)
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EP2378611B1 (en
Inventor
Thomas Noetzel
Udo Dr. Mayer
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.)
Nexans SA
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Nexans SA
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Publication date
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Priority to EP10305380.7A priority Critical patent/EP2378611B1/en
Publication of EP2378611A1 publication Critical patent/EP2378611A1/en
Application granted granted Critical
Publication of EP2378611B1 publication Critical patent/EP2378611B1/en
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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member

Definitions

  • the present invention relates to a method for producing an electrical cable with a conductor made of copper or aluminum, which preferably comprises or consists of a plurality of strands of copper or aluminum, particularly preferably within an insulation comprising the conductors or the strands, and a material fit having the conductor made of copper or aluminum connecting part which consists of a copper material, for example of copper or an alloy, eg Brass.
  • the invention relates to the electrical cable produced by the method according to the invention, which has one or more conductors made of aluminum or copper and a cohesively connected conductor, in particular a connecting part of a copper material.
  • the DE 19908031 B4 describes the joining of a cable, the aluminum strands are bordered with a support sleeve by welding with a copper connector by friction welding. By pressing the support sleeve, which are arranged around the aluminum strands, before or during the friction welding, a solid cylinder of aluminum is to be produced, whose end face is welded to the copper material.
  • the US 2,806,215 shows a connecting piece of copper material, which is connected by a cable with aluminum strands, that the aluminum strands are first bordered with an aluminum sleeve over which in turn slid and pressed an aluminum sleeve, which has a welded copper connector.
  • the invention has as its object to provide an alternative method for contacting conductors with a connector made of a copper material, as well as with a the method obtains alternative cable with conductors that are connected to a connector of copper material.
  • the invention solves the above object with the features of the claims and in particular by a method for producing a cohesive connection, or by a method for producing an electrical cable, in which one or more conductors, which are made of copper or preferably of aluminum, characterized with a connection part of a copper material, in particular a solid or of strands in a sleeve existing portion of a connection part, are materially connected, that the connection part is pressed in the axial direction against the or the aluminum conductor substantially.
  • the conductor or conductors are enclosed in a first tool whose inner first cross section is smaller than or equal to the cross section of the sum of the conductors of the cable and the first tool receives the conductor or conductors directly in an adjacent to its cross-sectional opening portion, in particular without a or the conductor surrounding sleeve.
  • the first tool subsequent to its first section, which directly adjoins its cross-sectional opening and receives the conductors, has a second section, the cross-section of which is sufficient to hold the insulation surrounding the conductors, and preferably has in the second Section a cross section less than or equal to the total cross-section of conductor and a comprehensive insulation to enclose the insulation form-fitting.
  • the reference to a conductor comprises copper conductors and in particular aluminum conductors, also a plurality of conductors which are copper strands and in particular aluminum strands, since the invention equally for producing the integral connection of the connection part, in particular in the section adjacent to the conductor is solid or has in a sleeve pressed-in strands, with a solid conductor and with a variety of strands, in particular of aluminum, is suitable.
  • Aluminum conductors may consist essentially of aluminum or of an aluminum alloy, for example aluminum mixed with iron and / or magnesium.
  • the term of the connection part refers in particular to the section of the connection part adjoining the conductor.
  • the first inner cross section of the first tool has, in the first section, in which the conductors are positively and / or non-positively engaged, preferably a larger cross-sectional area than the connecting part.
  • the conductor, or a plurality of stranded conductors which are taken in accordance with the preferred embodiment representative of copper strands as aluminum conductors or aluminum strands, positively and / or non-positively held in a first tool, preferably the conductors directly to the inner Surface of the first tool abut, or are not surrounded by a sleeve.
  • the conductors can be arranged in the open state of the first tool between the mold halves. In the closed state of the first tool, the conductors are held by the first tool against the axial force acting on the aluminum conductors, which is exerted by the connector on the aluminum conductors, while the connector is moved axially against the aluminum conductors.
  • the first tool substantially surrounds the aluminum conductor (s) in a positive and / or non-positive manner, the movement of the connecting part against the aluminum conductors results in a displacement of a part of the material of the aluminum conductors, because the clear cross-sectional area of the first tool is slightly larger than the cross-sectional area of the connecting part is pressed from the portion of the opening of the first tool, which is not filled by the connecting part.
  • the pressing is carried out according to the invention preferably by a substantially, preferably exclusively, linear movement of the conductor and connecting part against each other, or of the first and second tool against each other on a common axis, which is arranged in particular the longitudinal axis of the conductor and on the at least the portion of the connecting part being pressed against the ladder.
  • For guiding and pressing of the connecting part of this is positively and / or non-positively held in a second tool which surrounds the connection part at least partially directly non-positively and / or positively, or surrounds its peripheral insulation.
  • the pressing of the connecting part in a conductor of strands is preferably carried out by pressing the connecting part over a length of up to 20mm, in particular for up to 12mm or 10mm in the strands, especially aluminum strands, measured before pressing, wherein the material of the strands over this length is displaced from the connector.
  • connection part is arranged on the same axis as the entirety of the conductors, and accordingly preferably the receiving recesses of the first tool and of the second tool are arranged on a common axis.
  • the adjacent to the aluminum conductor portion or portion of the connecting part is preferably made of copper material, in particular copper, a copper alloy, for example brass, and is particularly preferably at least in the section rod-shaped and solid, in which he contacts the aluminum conductor, more preferably at least partially in the region with which it is introduced into the first tool and pressed against the aluminum conductors, optionally additionally in the area in which it is held in the second tool.
  • the connecting part may have a self-contained end face, with which it is pressed against the aluminum conductors, and may optionally be hollow at least in sections thereafter.
  • the connecting part preferably has a rod-shaped portion which is introduced into the first tool during pressing against the aluminum conductors.
  • the connecting part can, in particular in the rod-shaped portion which adjoins the aluminum conductors during the method and in the manufactured cable, have a round or angular cross-section, and / or have on its outer side axial and / or radial grooves.
  • the connecting part, or the portion of the connecting part, which is connected to the conductor preferably has a solid end face and is preferably made of solid copper material.
  • this section of the connecting part consist of strands of copper or copper material, which are covered by a sleeve made of copper or copper material, in particular by a pressed-on sleeve, wherein particularly preferably the end face is a perpendicular to the longitudinal axis arranged cut surface of the strands, the flush of the sleeve is bordered.
  • the portion of the connecting part as a stranded copper strands comprising a conductor made of aluminum or aluminum strands
  • connection part is at least in a section adjacent to the aluminum conductor substantially cylindrical and may be part of a connection part of the cable, for example, at the end facing the aluminum conductor, a cable lug, a ring or an eyelet and thus form a piece or be connected by clamping, crimping or welding.
  • the aluminum conductors are arranged in the first tool and protrude maximally to its axial opening to protrude portions of the aluminum conductors on the in the first tool during the pressing of the connecting part of copper material, which is held by the second tool Opening of the first tool to avoid.
  • the aluminum conductors could interfere with the press-fitting of the connection part in the first tool.
  • the inventive method is advantageous because a cohesive connection between the aluminum conductor and connector can be made in a single operation and has shown that by pressing the connector of copper material in the first tool in the form-fitting and / or non-positively held aluminum conductor contacting in Essentially all aluminum conductor takes place, even if this example Strands are.
  • the aluminum conductor (s) and / or the connecting piece of copper material are heated before or during the pressing of the connecting part into the aluminum conductors, preferably to a temperature below the melting temperature of the aluminum.
  • the portions of the aluminum conductors and / or the connection part held in a tool and / or the first and / or the second tool can be contacted by respective opposite poles of a current source so that they are in contact with the conductor of Electricity flowing through.
  • the conductor is heated to a temperature in the range of its softening temperature, for example in the case of aluminum conductors to 580 to 650 ° C.
  • the first and second tools are opened, preferably by radial movement of mold halves.
  • a by pressing out of conductor material, e.g. aluminum, from the first tool around the connection part resulting burr or slug can be removed.
  • the cables produced by the method according to the invention are characterized in that the connection between conductors made of copper, preferably of aluminum, and connecting part is formed directly in a boundary layer, in which the conductors meet the connecting part.
  • Electrical cables according to the invention therefore comprise a conductor made of copper, preferably of aluminum or an aluminum alloy, which preferably consists of a multiplicity of strands, and a copper-made connection piece bonded axially to the conductor, wherein the conductor adjacent to the connection member preferably without a comprehensive sleeve cohesively connected to the connection part.
  • a cable produced by the method according to the invention is therefore characterized in that the connection part and the conductors in a boundary layer are joined directly to one another.
  • the connecting part can have a completely or sectionally flat end face which is inclined at an angle of e.g. 10 ° to 90 ° to the longitudinal axis of the section pressed against the conductor portion of the connecting part is inclined to form a larger interface between the connecting part and conductors.
  • the cable according to the invention at the end, on which the connecting part is arranged consists of a stranded conductor, which is at a distance from the connection part of an insulation, and the materially connected to the front end connecting part, wherein the stranded conductor of copper strands, preferably of aluminum strands consists.
  • the attachment may optionally be located in a portion of conductor material adjacent to the conductors, e.g. aluminum, e.g. was displaced from the conductor during pressing by the connection part.
  • Connection part need not have a special shape and, for. do not have to be rotationally symmetric about the longitudinal axis of the conductor or connecting part, since the pressing takes place solely by moving the connecting part and the conductor against each other to produce the cohesive connection in a boundary layer.
  • an electrical cable can be produced, which has one or more conductors, in particular made of copper or aluminum, which are terminally materially connected to the connection part, wherein more preferably no sleeve is arranged around the conductors, since the conductors during pressing for the production of the connection between conductors and connecting part of the first tool positively and / or non-positively includes. Therefore, the method allows easier connection between lead and lead conductors than those methods which require the stranded conductors to be encased with a sleeve that becomes part of the cable.
  • a cable according to the invention can have a terminal connection, for example made of copper material, connected in a materially connected manner , which is partially surrounded by conductor material, such as aluminum.
  • the cross-sectional area of the portion of the connecting part adjoining the conductors is only slightly smaller than the cross-sectional area of the first tool in the region between the axial cross-sectional opening of the tool and the region in which the conductors are held, and / or in the region, in which the conductors are held, so that the cohesive connection is present or generated substantially along the end face of the connecting part.
  • the end face of the connecting part may be flat or curved, preferably convex, and may optionally be rotationally symmetrical to the longitudinal axis of the connecting part.
  • a flat end surface of the connecting part is preferably arranged perpendicular to the longitudinal axis or may be a surface which is inclined at an angle of less than 90 ° to the longitudinal axis of the portion of the connecting part, for example at an angle of 20 ° - 80 °, preferably 30 ° -60 °.
  • a convex end face may be conical or frusto-conical in shape, have an elliptical cross-section along the longitudinal axis or consist of converging flat surfaces, eg 3 to 8 faces.
  • FIG. 1 shows a first tool 1 and a second tool 2 in each closed state, the receiving recesses are arranged on a common axis.
  • the first tool 1 may consist of a first mold half 1a and a second mold half 1b, which are movable radially to the longitudinal axis of the receiving recess to open the first tool 1.
  • the second tool 2 can also consist of two tool halves 2a, 2b, which can be moved radially relative to one another.
  • aluminum conductors 10 are positively enclosed, wherein the first tool 1 in a first section 3, the conductor 10 directly summarizes.
  • the first section 3 of the first tool 1 extends to the cross-sectional opening 4 or to a distance from the cross-sectional opening 4 of the first tool 1, which spans this in the closed state.
  • the first tool 1 has a second section 5, in which the first tool 1 comprises the conductor 10 surrounded by a peripheral insulation 11 in a positive and / or non-positive manner.
  • the connecting part 20 is at least partially positively and / or non-positively comprises by a second tool 2 and protrudes from the second tool 2.
  • connection part 20 is generally preferably symmetrical in the section in which it projects beyond the second tool 2 in the direction of the first tool 1, for example with a square cross section or with a round cross section.
  • the connecting part 20 preferably has a planar face on, or as in FIG. 1 is shown, a convex or provided with a circumferential chamfer face.
  • the first and the second tool 1,2 are moved against each other while they hold conductor 10 or connector 20, preferably conductor 10 and connector 20 are heated.
  • conductors 10 or connection part 20 e.g. The conductor 10 and the first tool 1 or the connecting part 20 and the second tool 2 each flowed through by current.
  • connection part 20 is guided through the cross-sectional opening 4 of the first tool 1 and pressed in the axial direction against the conductor 10.
  • FIG. 2 shows the state of the along the common axis of the receiving recesses against each other moved first and second tools 1, 2, in which the connecting part 20 is partially pressed within the first tool 1 against the conductor 10.
  • a cohesive connection between the conductors 10 and the connecting part 20 is produced, in particular in the region of the end face of the connecting part 20, while displaced from the first tool 1 conductor material, such as aluminum, a ridge or slug 12 between the first and second tool 1,2 can form.
  • both tools 1, 2 can be opened and the cable, the conductor 10 of which is connected in a materially bonded manner to a connection part 20, can be removed.
  • a ridge 12 is preferably removed before or after opening the first and / or second tool 1,2.
  • the cross-sectional area of the portion of the connecting part 20 which is guided into the receiving recess of the first tool 1 is preferably slightly smaller than the clear cross-sectional area of the receiving opening of the first tool 1, in particular as the cross-sectional area of the first portion 3 of the first tool 1.
  • the radial distance between the connection part 20 and the receiving recess of the first tool 1 then forms the gap, can escape from the end face of the connecting part 20 through the material of the conductor 10, which is displaced against the conductor 10 during the pressing of the connecting part 20.
  • such a durable cohesive connection between a solid aluminum conductor or a stranded conductor, preferably made of aluminum, and a closed end connection piece is produced from a copper material which achieves the tensile strength of the conductor, e.g. in aluminum ladders.
  • the cables were produced by the method according to the invention by pressing the connecting part into the aluminum strands.
  • the cut was made with a water-cooled diamond cutting disc parallel to the longitudinal axis of the conductor.
  • the sections were optionally etched in 3% NaOH, 60 ° C (for aluminum) or 10% Al sulfate (for copper) for microscopic photographs.
  • FIG. 3 shows a micrograph of the connecting portion of the existing of aluminum strands (A199.7) conductor (in the lower part of the picture) and of the solid copper material E-Cu57 F30 existing portion of the connecting part (upper image portion). It is clear that the connection part is connected in an interface cohesively with the aluminum strands, wherein the interface is determined by the roughness or surface geometry of the connection part of the copper material.
  • the aluminum strands are pressed outward in the edge region, which is currently attributed to the pressing out of the aluminum from the tool by means of the connecting part.
  • the aluminum strands are arranged parallel to each other and protrude substantially to the interface.
  • FIG. 4 shows the connecting portion of the portion of a connecting part, which consists of copper strands (E-Cu58) with a circumferentially pressed sleeve, with a solid aluminum conductor (A199.7).
  • the aluminum conductor shown in the upper half of the picture is bordered in an interface with the copper strands of the connecting part, which are shown in the lower half of the picture, the interface being determined by the copper strands.
  • the copper strands are folded over adjacent to their common face and show between the copper strands penetrated aluminum.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Processing Of Terminals (AREA)

Abstract

The method for producing an electrical cable having a conductor (10) and a connecting portion (20) of copper metal axially fixed on the conductor, comprises pressing the connecting portion against the conductor. The conductor consists of strands and positive-fitting and/or force-fitting into a receiving recess in a first portion of a first tool (1), or distance of an opening cross-section of the first tool. The connecting portion is moved along the axis of the conductor against a wire. The method for producing an electrical cable having a conductor (10) and a connecting portion (20) of copper metal axially fixed on the conductor comprises pressing the connecting portion against the conductor. The conductor consists of strands and positive-fitting and/or force-fitting into a receiving recess in a first portion of a first tool (1), or distance of an opening cross-section of the first tool. The connecting portion is moved along the axis of the conductor against a wire. The conductor and the connecting portion during the pressing in contact to the wire with the connecting portion flow through electricity. The conductor is heated to a maximum of a softening temperature. The connecting portion in the receiving recess of the first tool is pressed out against the conductor. The connecting portion has a smaller cross sectional area than the inside cross sectional area of the receiving recess of the first tool. The connecting portion is held into a second tool (2) of positive-fitting and/or force-fitting, and a section (5) protrudes over the second tool, which is partially moved in the receiving recess of the first tool, where a front surface of the connecting portion is pressed into the first section of the first tool, in which the conductor is held. The front surface of the connecting portion is moved against the axial extension (10-90%) of the first section of the conductor. The connecting portion has a flat or convex face that is disposed at an angle of 10-90o? against the longitudinal axis of the conductor pressed portion of the connecting part. An independent claim is included for an electrical cable.

Description

Die vorliegende Erfindung betrifft ein Verfahren zur Herstellung eines elektrischen Kabels mit einem Leiter aus Kupfer oder Aluminium, der vorzugsweise eine Vielzahl von Litzen aus Kupfer oder Aluminium aufweist oder daraus besteht, insbesondere bevorzugt innerhalb einer die Leiter bzw. die Litzen umfassenden Isolierung, und ein stoffschlüssig mit dem Leiter aus Kupfer oder Aluminium verbundenes Anschlussteil aufweist, das aus einem Kupferwerkstoff besteht, beispielsweise aus Kupfer oder einer Legierung, z.B. Messing.The present invention relates to a method for producing an electrical cable with a conductor made of copper or aluminum, which preferably comprises or consists of a plurality of strands of copper or aluminum, particularly preferably within an insulation comprising the conductors or the strands, and a material fit having the conductor made of copper or aluminum connecting part which consists of a copper material, for example of copper or an alloy, eg Brass.

Weiterhin betrifft die Erfindung das mit dem erfindungsgemäßen Verfahren hergestellte elektrische Kabel, das einen oder mehrere Leiter aus Aluminium oder Kupfer aufweist und einen damit stoffschlüssig verbundenen Leiter, insbesondere ein Anschlussteil aus einem Kupferwerkstoff.Furthermore, the invention relates to the electrical cable produced by the method according to the invention, which has one or more conductors made of aluminum or copper and a cohesively connected conductor, in particular a connecting part of a copper material.

Stand der TechnikState of the art

Die DE 19908031 B4 beschreibt das Verbinden eines Kabels, dessen Aluminiumlitzen mit einer Stützhülse eingefasst sind, durch Verschweißung mit einem Anschlussteil aus Kupfer mittels Reibschweißung. Durch Verpressen der Stützhülse, die um die Aluminiumlitzen angeordnet sind, vor oder während des Reibschweißens soll ein Vollzylinder aus Aluminium erzeugt werden, dessen Stirnseite mit dem Kupferwerkstoff verschweißt wird.The DE 19908031 B4 describes the joining of a cable, the aluminum strands are bordered with a support sleeve by welding with a copper connector by friction welding. By pressing the support sleeve, which are arranged around the aluminum strands, before or during the friction welding, a solid cylinder of aluminum is to be produced, whose end face is welded to the copper material.

Die US 2,806,215 zeigt ein Anschlussteil aus Kupferwerkstoff, dass dadurch mit einem Kabel mit Aluminiumlitzen verbunden wird, dass die Aluminiumlitzen zunächst mit einer Aluminiumhülse eingefasst werden, über die wiederum eine Aluminiumhülse aufgeschoben und verpresst wird, welche ein angeschweißtes kupfernes Anschlussstück aufweist.The US 2,806,215 shows a connecting piece of copper material, which is connected by a cable with aluminum strands, that the aluminum strands are first bordered with an aluminum sleeve over which in turn slid and pressed an aluminum sleeve, which has a welded copper connector.

Aufgabe der ErfindungObject of the invention

Der Erfindung stellt sich die Aufgabe, ein alternatives Verfahren zur Kontaktierung von Leitern mit einem Anschlussteil aus einem Kupferwerkstoff bereitzustellen, sowie ein mit dem Verfahren erhältliches alternatives Kabel mit Leitern, die mit einem Anschlussteil aus Kupferwerkstoff verbunden sind.The invention has as its object to provide an alternative method for contacting conductors with a connector made of a copper material, as well as with a the method obtains alternative cable with conductors that are connected to a connector of copper material.

Allgemeine Beschreibung der ErfindungGeneral description of the invention

Die Erfindung löst die voranstehende Aufgabe mit den Merkmalen der Ansprüche und insbesondere durch ein Verfahren zur Herstellung einer stoffschlüssigen Verbindung, bzw. durch ein Verfahren zur Herstellung eines elektrischen Kabels, bei dem ein oder mehrere Leiter, die aus Kupfer oder vorzugsweise aus Aluminium sind, dadurch mit einem Anschlussteil aus einem Kupferwerkstoff, insbesondere einem massiven oder aus Litzen in einer Hülse bestehenden Abschnitt eines Anschlussteils, stoffschlüssig verbunden werden, dass das Anschlussteil im Wesentlichen in axialer Richtung gegen den oder die Aluminiumleiter gepresst wird. Dabei sind der oder die Leiter in einem ersten Werkzeug eingefasst, dessen innerer erster Querschnitt kleiner oder gleich dem Querschnitt der Summe der Leiter des Kabels ist und das erste Werkzeug den oder die Leiter unmittelbar in einem an seine Querschnittsöffnung angrenzenden Abschnitt aufnimmt, insbesondere ohne eine den oder die Leiter umgebende Hülse. Besonders bevorzugt weist das erste Werkzeug im Anschluss an seinen ersten Abschnitt, der unmittelbar an seine Querschnittsöffnung angrenzt und die Leiter aufnimmt, einen zweiten Abschnitt auf, dessen Querschnitt ausreicht, um die die Leiter umgebende Isolierung aufzunehmen bzw. zu halten, und weist vorzugsweise im zweiten Abschnitt einen Querschnitt kleiner oder gleich dem Gesamtquerschnitt aus Leiter und einer diese umfassenden Isolierung auf, um die Isolierung formschlüssig zu umfassen.The invention solves the above object with the features of the claims and in particular by a method for producing a cohesive connection, or by a method for producing an electrical cable, in which one or more conductors, which are made of copper or preferably of aluminum, characterized with a connection part of a copper material, in particular a solid or of strands in a sleeve existing portion of a connection part, are materially connected, that the connection part is pressed in the axial direction against the or the aluminum conductor substantially. In this case, the conductor or conductors are enclosed in a first tool whose inner first cross section is smaller than or equal to the cross section of the sum of the conductors of the cable and the first tool receives the conductor or conductors directly in an adjacent to its cross-sectional opening portion, in particular without a or the conductor surrounding sleeve. Particularly preferably, the first tool, subsequent to its first section, which directly adjoins its cross-sectional opening and receives the conductors, has a second section, the cross-section of which is sufficient to hold the insulation surrounding the conductors, and preferably has in the second Section a cross section less than or equal to the total cross-section of conductor and a comprehensive insulation to enclose the insulation form-fitting.

Für die Zwecke der Erfindung umfasst die Bezugnahme auf einen Leiter Kupferleiter und insbesondere Aluminiumleiter, auch eine Vielzahl von Leitern, die Kupferlitzen und insbesondere Aluminiumlitzen sind, da die Erfindung gleichermaßen zur Herstellung der stoffschlüssigen Verbindung des Anschlussteils, das insbesondere in dem an den Leiter angrenzenden Abschnitt massiv ist oder in eine Hülse eingepresste Litzen aufweist, mit einem massiven Leiter als auch mit einer Vielzahl von Litzen, insbesondere aus Aluminium, geeignet ist. Aluminiumleiter können im Wesentlichen aus Aluminium bestehen oder aus einer Aluminiumlegierung, z.B. Aluminium in Mischung mit Eisen und/oder Magnesium. Für die Zwecke der Erfindung bezieht sich der Begriff des Anschlussteils insbesondere auf den an den Leiter angrenzenden Abschnitt des Anschlussteils.For the purposes of the invention, the reference to a conductor comprises copper conductors and in particular aluminum conductors, also a plurality of conductors which are copper strands and in particular aluminum strands, since the invention equally for producing the integral connection of the connection part, in particular in the section adjacent to the conductor is solid or has in a sleeve pressed-in strands, with a solid conductor and with a variety of strands, in particular of aluminum, is suitable. Aluminum conductors may consist essentially of aluminum or of an aluminum alloy, for example aluminum mixed with iron and / or magnesium. For the purposes of the invention, the term of the connection part refers in particular to the section of the connection part adjoining the conductor.

Der erste innere Querschnitt des ersten Werkzeugs weist in den ersten Abschnitt, in dem die Leiter form- und/oder kraftschlüssig gefasst sind, vorzugsweise eine größere Querschnittsfläche als das Anschlussteil auf.The first inner cross section of the first tool has, in the first section, in which the conductors are positively and / or non-positively engaged, preferably a larger cross-sectional area than the connecting part.

Erfindungsgemäß wird der Leiter, bzw. eine Vielzahl von Litzenleitern, die entsprechend der bevorzugten Ausführungsform stellvertretend für Kupferlitzen auch als Aluminiumleiter oder Aluminiumlitzen in Bezug genommen werden, form- und/oder kraftschlüssig in einem ersten Werkzeug gehalten, wobei vorzugsweise die Leiter unmittelbar an der inneren Oberfläche des ersten Werkzeugs anliegen, bzw. nicht von einer Hülse umgeben sind. Die Leiter können im geöffneten Zustand des ersten Werkzeugs zwischen dessen Formhälften angeordnet werden. Im geschlossenem Zustand des ersten Werkzeugs werden die Leiter von dem ersten Werkzeug gegen die axial auf die Aluminiumleiter wirkende Kraft gehalten, die von dem Anschlussteil auf die Aluminiumleiter ausgeübt wird, während das Anschlussteil axial gegen die Aluminiumleiter bewegt wird. Da das erste Werkzeug den bzw. die Aluminiumleiter im Wesentlichen form- und/oder kraftschlüssig umgibt, führt die Bewegung des Anschlussteils gegen die Aluminiumleiter zu einer Verdrängung eines Teils des Materials der Aluminiumleiter, das deshalb, weil die lichte Querschnittsfläche des ersten Werkzeugs etwas größer als die Querschnittsfläche des Anschlussteils ist, aus dem Anteil der Öffnung des ersten Werkzeugs gepresst wird, die nicht vom Anschlussteil ausgefüllt ist. Das Pressen erfolgt erfindungsgemäß vorzugsweise durch eine im Wesentlichen, vorzugsweise ausschließlich, lineare Bewegung von Leiter und Anschlussteil gegeneinander, bzw. von erstem und zweitem Werkzeug gegeneinander auf einer gemeinsamen Achse, die insbesondere die Längsachse des Leiters und auf der zumindest der Abschnitt des Anschlussteils angeordnet ist, der gegen die Leiter gepresst wird. Für das Führen und Pressen des Anschlussteils ist dieses form- und/oder kraftschlüssig in einem zweiten Werkzeug gehalten, das das Anschlussteil zumindest abschnittsweise unmittelbar kraft- und/oder formschlüssig umgibt, oder dessen umfängliche Isolierung umgibt.According to the invention, the conductor, or a plurality of stranded conductors, which are taken in accordance with the preferred embodiment representative of copper strands as aluminum conductors or aluminum strands, positively and / or non-positively held in a first tool, preferably the conductors directly to the inner Surface of the first tool abut, or are not surrounded by a sleeve. The conductors can be arranged in the open state of the first tool between the mold halves. In the closed state of the first tool, the conductors are held by the first tool against the axial force acting on the aluminum conductors, which is exerted by the connector on the aluminum conductors, while the connector is moved axially against the aluminum conductors. Since the first tool substantially surrounds the aluminum conductor (s) in a positive and / or non-positive manner, the movement of the connecting part against the aluminum conductors results in a displacement of a part of the material of the aluminum conductors, because the clear cross-sectional area of the first tool is slightly larger than the cross-sectional area of the connecting part is pressed from the portion of the opening of the first tool, which is not filled by the connecting part. The pressing is carried out according to the invention preferably by a substantially, preferably exclusively, linear movement of the conductor and connecting part against each other, or of the first and second tool against each other on a common axis, which is arranged in particular the longitudinal axis of the conductor and on the at least the portion of the connecting part being pressed against the ladder. For guiding and pressing of the connecting part of this is positively and / or non-positively held in a second tool which surrounds the connection part at least partially directly non-positively and / or positively, or surrounds its peripheral insulation.

Das Pressen des Anschlussteils in einen Leiter aus Litzen erfolgt vorzugsweise durch Pressen des Anschlussteils über eine Länge von bis zu 20mm, insbesondere für bis 12mm oder bis 10mm in die Litzen, insbesondere Aluminiumlitzen, gemessen vor dem Einpressen, wobei das Material der Litzen über diese Länge vom Anschlussteil verdrängt wird.The pressing of the connecting part in a conductor of strands is preferably carried out by pressing the connecting part over a length of up to 20mm, in particular for up to 12mm or 10mm in the strands, especially aluminum strands, measured before pressing, wherein the material of the strands over this length is displaced from the connector.

Vorzugsweise ist das Anschlussteil auf derselben Achse angeordnet wie die Gesamtheit der Leiter, und entsprechend sind vorzugsweise die Aufnahmeausnehmungen des ersten Werkzeugs und des zweiten Werkzeugs auf einer gemeinsamen Achse angeordnet.Preferably, the connection part is arranged on the same axis as the entirety of the conductors, and accordingly preferably the receiving recesses of the first tool and of the second tool are arranged on a common axis.

Der an die Aluminiumleiter angrenzende Abschnitt bzw. Bereich des Anschlussteils ist vorzugsweise aus Kupferwerkstoff, insbesondere aus Kupfer, einer Kupferlegierung, beispielsweise Messing, und ist besonders bevorzugt zumindest in dem Abschnitt stabförmig und massiv, in dem er den Aluminiumleiter kontaktiert, besonders bevorzugt zumindest abschnittsweise in dem Bereich, mit dem er in das erste Werkzeug eingeführt und gegen die Aluminiumleiter gepresst wird, optional zusätzlich in dem Bereich, in dem er in dem zweiten Werkzeug gehalten wird. In einer alternativen Ausführung kann das Anschlussteil eine in sich geschlossene Stirnfläche aufweisen, mit der es gegen die Aluminiumleiter gepresst wird, und kann optional im Anschluss daran zumindest abschnittsweise hohl sein. Das Anschlussteil weist vorzugsweise einen stabförmigen Abschnitt auf, der beim Pressen gegen die Aluminiumleiter in das erste Werkzeug eingeführt wird. Das Anschlussteil kann, insbesondere in dem stabförmigen Abschnitt, der während des Verfahrens und im hergestellten Kabel an die Aluminiumleiter angrenzt, einen runden oder eckigen Querschnitt aufweisen, und/oder auf seiner Außenseite axiale und/oder radiale Nuten aufweisen. Das Anschlussteil, bzw. der Abschnitt des Anschlussteils, der mit dem Leiter verbunden wird, weist vorzugsweise eine massive Stirnfläche auf und besteht vorzugsweise aus massivem Kupferwerkstoff. Alternativ kann dieser Abschnitt des Anschlussteils aus Litzen aus Kupfer oder Kupferwerkstoff bestehen, die von einer Hülse aus Kupfer oder Kupferwerkstoff umfasst sind, insbesondere von einer aufgepressten Hülse umfasst, wobei besonders bevorzugt die Stirnfläche eine senkrecht zur Längsachse angeordnete Schnittfläche der Litzen ist, die bündig von der Hülse eingefasst ist. In der Ausführungsform des Abschnitts des Anschlussteils als von einer Hülse umfasste Litzen aus Kupfer mit einem Leiter aus Aluminium oder Aluminiumlitzen ergibt sich der Vorteil, dass das Verfahren zum Eindringen des Aluminiumwerkstoffs des Leiters zwischen die Kupferlitzen des Anschlussteils führt, so dass zusätzlich zur stoffschlüssigen Verbindung entlang der Stirnfläche von Anschlussteil und Aluminiumleiter eine mechanische Verklammerung erzeugt wird. Es hat sich gezeigt, dass das Aluminium zu 5-10mm, insbesondere zu 6mm zwischen die Litzen des Anschlussteils dringt.The adjacent to the aluminum conductor portion or portion of the connecting part is preferably made of copper material, in particular copper, a copper alloy, for example brass, and is particularly preferably at least in the section rod-shaped and solid, in which he contacts the aluminum conductor, more preferably at least partially in the region with which it is introduced into the first tool and pressed against the aluminum conductors, optionally additionally in the area in which it is held in the second tool. In an alternative embodiment, the connecting part may have a self-contained end face, with which it is pressed against the aluminum conductors, and may optionally be hollow at least in sections thereafter. The connecting part preferably has a rod-shaped portion which is introduced into the first tool during pressing against the aluminum conductors. The connecting part can, in particular in the rod-shaped portion which adjoins the aluminum conductors during the method and in the manufactured cable, have a round or angular cross-section, and / or have on its outer side axial and / or radial grooves. The connecting part, or the portion of the connecting part, which is connected to the conductor, preferably has a solid end face and is preferably made of solid copper material. Alternatively, this section of the connecting part consist of strands of copper or copper material, which are covered by a sleeve made of copper or copper material, in particular by a pressed-on sleeve, wherein particularly preferably the end face is a perpendicular to the longitudinal axis arranged cut surface of the strands, the flush of the sleeve is bordered. In the embodiment of the portion of the connecting part as a stranded copper strands comprising a conductor made of aluminum or aluminum strands, there is the advantage that the process of penetrating the aluminum material of the conductor between the copper strands of the connecting part, so that in addition to the material connection along the end face of the connection part and aluminum conductor, a mechanical clamping is generated. It has been shown that the aluminum penetrates to 5-10mm, in particular to 6mm between the strands of the connection part.

Besonders bevorzugt ist das Anschlussteil zumindest in einem an die Aluminiumleiter angrenzenden Abschnitt im Wesentlichen zylindrisch und kann Teil eines Anschlussteils des Kabels sein, beispielsweise an dem Ende, das dem Aluminiumleiter gegenüber liegt, einen Kabelschuh, einen Ring oder eine Öse aufweisen und damit ein Stück bilden oder damit durch Klemmen, Crimpen oder Verschweißen verbunden sein.Particularly preferably, the connection part is at least in a section adjacent to the aluminum conductor substantially cylindrical and may be part of a connection part of the cable, for example, at the end facing the aluminum conductor, a cable lug, a ring or an eyelet and thus form a piece or be connected by clamping, crimping or welding.

Beim erfindungsgemäßen Verfahren ist bevorzugt, dass die Aluminiumleiter im ersten Werkzeug angeordnet sind und maximal bis an dessen axiale Öffnung ragen, um beim Einpressen des Anschlussteils aus Kupferwerkstoff, das vom zweiten Werkzeug gehalten wird, in das erste Werkzeug das Hervorstehen von Abschnitten der Aluminiumleiter über die Öffnung des ersten Werkzeugs zu vermeiden. Denn solche über das erste Werkzeug vorstehenden Aluminiumleiter könnten das Einpressen des Anschlussteils in das erste Werkzeug stören.In the method according to the invention it is preferred that the aluminum conductors are arranged in the first tool and protrude maximally to its axial opening to protrude portions of the aluminum conductors on the in the first tool during the pressing of the connecting part of copper material, which is held by the second tool Opening of the first tool to avoid. For such over the first tool projecting aluminum conductors could interfere with the press-fitting of the connection part in the first tool.

Das erfindungsgemäße Verfahren ist vorteilhaft, weil eine stoffschlüssige Verbindung zwischen Aluminiumleiter und Anschlussteil in einem einzigen Arbeitsgang hergestellt werden kann und sich gezeigt hat, dass durch das Einpressen des Anschlussteils aus Kupferwerkstoff in die im ersten Werkzeug form- und/oder kraftschlüssig gehaltenen Aluminiumleiter eine Kontaktierung im Wesentlichen sämtlicher Aluminiumleiter erfolgt, auch wenn diese z.B. Litzen sind. Denn beim Einpressen des Anschlussteils senkrecht zum Querschnitt der Aufnahme des ersten Werkzeugs in die Aluminiumleiter, d.h. koaxial zu dem oder den Aluminiumleitern, erfolgt eine stoffschlüssige Kontaktierung im Wesentlichen sämtlicher Aluminiumleiter durch das Anschlussteil. Dies wird gegenwärtig darauf zurückgeführt, dass während des Einpressens eine etwaige Oxidschicht auf den Aluminiumleitern vom Anschlussteil verdrängt wird.The inventive method is advantageous because a cohesive connection between the aluminum conductor and connector can be made in a single operation and has shown that by pressing the connector of copper material in the first tool in the form-fitting and / or non-positively held aluminum conductor contacting in Essentially all aluminum conductor takes place, even if this example Strands are. For when pressing the connecting part perpendicular to the cross section of the recording of the first tool in the aluminum conductor, i. coaxial with the aluminum conductors or, there is a cohesive contacting substantially all aluminum conductors through the connection part. This is currently attributed to the fact that during the pressing a possible oxide layer on the aluminum conductors is displaced from the connecting part.

In bevorzugter Ausführungsform werden der oder die Aluminiumleiter und/oder das Anschlussteil aus Kupferwerkstoff vor oder während des Pressens des Anschlussteils in die Aluminiumleiter erwärmt, vorzugsweise auf eine Temperatur unterhalb der Schmelztemperatur des Aluminiums. Für die Erwärmung können beispielsweise die in einem Werkzeug gehaltenen Abschnitte der Aluminiumleiter und/oder des Anschlussteils und/oder das erste und/oder das zweite Werkzeug von jeweils entgegengesetzten Polen einer Stromquelle kontaktiert sein, so dass sie bei Kontakt des Anschlussteils mit dem Leiter von Strom durchflossen werden. Bevorzugt wird der Leiter auf eine Temperatur im Bereich seiner Erweichungstemperatur erwärmt, z.B. im Falle von Aluminiumleitern auf 580 bis 650 °C.In a preferred embodiment, the aluminum conductor (s) and / or the connecting piece of copper material are heated before or during the pressing of the connecting part into the aluminum conductors, preferably to a temperature below the melting temperature of the aluminum. For heating, for example, the portions of the aluminum conductors and / or the connection part held in a tool and / or the first and / or the second tool can be contacted by respective opposite poles of a current source so that they are in contact with the conductor of Electricity flowing through. Preferably, the conductor is heated to a temperature in the range of its softening temperature, for example in the case of aluminum conductors to 580 to 650 ° C.

Nach dem Einpressen des Anschlussteils in die im ersten Werkzeug gehaltenen Leiter werden das erste und zweite Werkzeug geöffnet, vorzugsweise durch radiales Verfahren von Werkzeughälften. Ein durch das Herauspressen von Leitermaterial, z.B. von Aluminium, aus dem ersten Werkzeug um das Anschlussteil entstandener Grat oder Butzen kann entfernt werden.After pressing the connection part into the conductor held in the first tool, the first and second tools are opened, preferably by radial movement of mold halves. A by pressing out of conductor material, e.g. aluminum, from the first tool around the connection part resulting burr or slug can be removed.

Die mit dem erfindungsgemäßen Verfahren hergestellten Kabel zeichnen sich dadurch aus, dass die Verbindung zwischen Leitern aus Kupfer, bevorzugt aus Aluminium, und Anschlussteil unmittelbar in einer Grenzschicht ausgebildet ist, in der die Leiter auf das Anschlussteil treffen. Erfindungsgemäße elektrische Kabel weisen daher einen Leiter aus Kupfer, vorzugsweise aus Aluminium oder einer Aluminiumlegierung, der vorzugsweise aus einer Vielzahl von Litzen besteht, und ein axial an den Leiter gebundenes Anschlussteil aus Kupferwerkstoff auf, wobei der Leiter angrenzend an das Anschlussteil vorzugsweise ohne eine umfassende Hülse stoffschlüssig mit dem Anschlussteil verbunden ist. Ein mit dem erfindungsgemäßen Verfahren hergestelltes Kabel zeichnet sich daher dadurch aus, dass das Anschlussteil und die Leiter in einer Grenzschicht unmittelbar aneinander gefügt sind. Das Anschlussteil kann eine vollständig oder abschnittsweise ebene Stirnfläche aufweisen, die in einem Winkel von z.B. 10° bis 90° gegen die Längsachse des gegen die Leiter gepressten Abschnitts des Anschlussteils geneigt ist, um eine größere Grenzfläche zwischen Anschlussteil und Leitern zu bilden. Bevorzugt besteht das erfindungsgemäße Kabel an dem Ende, an dem das Anschlussteil angeordnet ist, aus einem Litzenleiter, der in einem Abstand vom Anschlussteil von einer Isolierung umfasst ist, und dem stoffschlüssig mit der Stirnseite verbundenen Anschlussteil, wobei der Litzenleiter aus Kupferlitzen, bevorzugt aus Aluminiumlitzen besteht.The cables produced by the method according to the invention are characterized in that the connection between conductors made of copper, preferably of aluminum, and connecting part is formed directly in a boundary layer, in which the conductors meet the connecting part. Electrical cables according to the invention therefore comprise a conductor made of copper, preferably of aluminum or an aluminum alloy, which preferably consists of a multiplicity of strands, and a copper-made connection piece bonded axially to the conductor, wherein the conductor adjacent to the connection member preferably without a comprehensive sleeve cohesively connected to the connection part. A cable produced by the method according to the invention is therefore characterized in that the connection part and the conductors in a boundary layer are joined directly to one another. The connecting part can have a completely or sectionally flat end face which is inclined at an angle of e.g. 10 ° to 90 ° to the longitudinal axis of the section pressed against the conductor portion of the connecting part is inclined to form a larger interface between the connecting part and conductors. Preferably, the cable according to the invention at the end, on which the connecting part is arranged, consists of a stranded conductor, which is at a distance from the connection part of an insulation, and the materially connected to the front end connecting part, wherein the stranded conductor of copper strands, preferably of aluminum strands consists.

Das Anschlussteil kann optional in einem an die Leiter angrenzenden Abschnitt von Leitermaterial, z.B. aus Aluminium umfasst sein, das z.B. beim Pressen durch das Anschlussteil vom Leiter verdrängt wurde.The attachment may optionally be located in a portion of conductor material adjacent to the conductors, e.g. aluminum, e.g. was displaced from the conductor during pressing by the connection part.

Das Verfahren ist auch deshalb vorteilhaft, weil die gegeneinander zu pressenden Stirnflächen des Leiter oder die gemeinsame Stirnfläche eines Litzenleiters sowie die Stirnfläche desThe method is also advantageous because the mutually to be pressed end faces of the conductor or the common end face of a stranded conductor and the end face of the

Anschlussteils keine besondere Form aufweisen müssen und z.B. nicht um die Längsachse von Leiter oder Anschlussteil rotationssymmetrisch sein müssen, da das Pressen allein durch Bewegen von Anschlussteil und Leiter gegeneinander erfolgt, um die stoffschlüssige Verbindung in einer Grenzschicht zu erzeugen.Connection part need not have a special shape and, for. do not have to be rotationally symmetric about the longitudinal axis of the conductor or connecting part, since the pressing takes place solely by moving the connecting part and the conductor against each other to produce the cohesive connection in a boundary layer.

Mit dem erfindungsgemäßen Verfahren ist ein elektrisches Kabel herstellbar, das einen oder mehrere Leiter, insbesondere aus Kupfer oder Aluminium aufweist, die endständig stoffschlüssig mit dem Anschlussteil verbunden sind, bei dem besonders bevorzugt keine Hülse um die Leiter angeordnet ist, da die Leiter während des Pressens zur Herstellung der Verbindung zwischen Leitern und Anschlussteil von dem ersten Werkzeug form- und/oder kraftschlüssig umfasst sind. Daher erlaubt das Verfahren eine einfachere Herstellung der Verbindung zwischen Anschlussteil und Litzenleiter als solche Verfahren, die die Einfassung der Litzenleiter mit einer Hülse erfordern, die Bestandteil des Kabels wird.With the method according to the invention, an electrical cable can be produced, which has one or more conductors, in particular made of copper or aluminum, which are terminally materially connected to the connection part, wherein more preferably no sleeve is arranged around the conductors, since the conductors during pressing for the production of the connection between conductors and connecting part of the first tool positively and / or non-positively includes. Therefore, the method allows easier connection between lead and lead conductors than those methods which require the stranded conductors to be encased with a sleeve that becomes part of the cable.

Abhängig von der Querschnittsfläche des Anschlussteils im Verhältnis zu der Querschnittsfläche des ersten Werkzeugs und der Masse des Leitermaterials, insbesondere des Aluminiums, das beim axialen Einpressen des Anschlussteils gegen die Leiter verdrängt wird, kann ein erfindungsgemäßes Kabel endständig ein stoffschlüssig verbundenes Anschlussteil, z.B. aus Kupferwerkstoff aufweisen, das abschnittsweise von Leitermaterial, z.B. von Aluminium umgeben ist. In alternativer Ausführungsform ist die Querschnittsfläche des an die Leiter angrenzenden Abschnitts des Anschlussteils nur geringfügig kleiner als die Querschnittsfläche des ersten Werkzeugs im Bereich zwischen der axialen Querschnittsöffnung des Werkzeugs und dem Bereich, in dem die Leiter gehalten sind, und/oder als in dem Bereich, in dem die Leiter gehalten sind, sodass die stoffschlüssige Verbindung im Wesentlichen entlang der Stirnfläche des Anschlussteils vorliegt bzw. erzeugt ist. Die Stirnfläche des Anschlussteils kann eben oder gewölbt sein, vorzugsweise konvex, und kann wahlweise zur Längsachse des Anschlussteils rotationssymmetrisch sein. Eine ebene Stirnfläche des Anschlussteils ist vorzugsweise senkrecht zur Längsachse angeordnet oder kann eine Fläche sein, die in einem Winkel von kleiner 90° zur Längsachse des Abschnitts des Anschlussteils geneigt ist, beispielsweise in einem Winkel von 20°- 80°, vorzugsweise 30°-60°. Eine konvexe Stirnfläche kann kegelförmig oder kegelstumpfförmig sein, einen elliptischen Querschnitt längs der Längsachse haben oder aus aufeinander zulaufenden ebenen Flächen, z.B. 3 bis 8 Flächen bestehen.Depending on the cross-sectional area of the connecting part in relation to the cross-sectional area of the first tool and the mass of the conductor material, in particular of the aluminum, which is displaced against the conductors during axial pressing in of the connecting part, a cable according to the invention can have a terminal connection, for example made of copper material, connected in a materially connected manner , which is partially surrounded by conductor material, such as aluminum. In an alternative embodiment, the cross-sectional area of the portion of the connecting part adjoining the conductors is only slightly smaller than the cross-sectional area of the first tool in the region between the axial cross-sectional opening of the tool and the region in which the conductors are held, and / or in the region, in which the conductors are held, so that the cohesive connection is present or generated substantially along the end face of the connecting part. The end face of the connecting part may be flat or curved, preferably convex, and may optionally be rotationally symmetrical to the longitudinal axis of the connecting part. A flat end surface of the connecting part is preferably arranged perpendicular to the longitudinal axis or may be a surface which is inclined at an angle of less than 90 ° to the longitudinal axis of the portion of the connecting part, for example at an angle of 20 ° - 80 °, preferably 30 ° -60 °. A convex end face may be conical or frusto-conical in shape, have an elliptical cross-section along the longitudinal axis or consist of converging flat surfaces, eg 3 to 8 faces.

Genaue Beschreibung der ErfindungDetailed description of the invention

Die Erfindung wird nun anhand der Figuren genauer beschrieben, die stellvertretend für Leiter aus Kupfer oder Aluminium schematisch

  • in Figur 1 ein Anschlussteil und Leiter vor dem Verbinden,
  • in Figur 2 ein mit Leitern verbundenes Anschlussteil,
  • in Figur 3 ein ausschnittsweises lichtmikroskopisches Schliffbild eines erfindungsgemäßen Kabels mit einem Leiter aus Aluminiumlitzen und massivem Anschlussteil aus Kupfer und
  • in Figur 4 ein ausschnittsweises lichtmikroskopisches Schliffbild eines erfindungsgemäßen Kabels mit einem massiven Leiter aus Aluminium und einem Anschlussteil aus Kupferlitzen in einer Hülse zeigen.
The invention will now be described in more detail with reference to the figures, which represent schematically copper or aluminum ladder
  • in FIG. 1 a connector and conductor before connecting,
  • in FIG. 2 a connector connected to conductors,
  • in FIG. 3 a partial optical microscopic micrograph of a cable according to the invention with a conductor of aluminum strands and solid copper connector and
  • in FIG. 4 a section-wise light microscopic micrograph of a cable according to the invention with a solid conductor of aluminum and a connecting part of copper strands in a sleeve show.

Figur 1 zeigt ein erstes Werkzeug 1 und ein zweites Werkzeug 2 im jeweils geschlossenen Zustand, deren Aufnahmeausnehmungen auf einer gemeinsamen Achse angeordnet sind. Das erste Werkzeug 1 kann aus einer ersten Formhälfte 1a und einer zweiten Formhälfte 1b bestehen, die radial zur Längsachse der Aufnahmeausnehmung verfahrbar sind, um das erste Werkzeug 1 zu öffnen. Entsprechend kann auch das zweite Werkzeug 2 aus zwei radial gegeneinander verfahrbaren Werkzeughälften 2a, 2b bestehen. Im ersten Werkzeug 1 sind Aluminiumleiter 10 formschlüssig umfasst, wobei das erste Werkzeug 1 in einem ersten Abschnitt 3 die Leiter 10 unmittelbar fasst. Der erste Abschnitt 3 des ersten Werkzeugs 1 erstreckt sich bis an die Querschnittsöffnung 4 oder bis in einen Abstand von der Querschnittsöffnung 4 des ersten Werkzeugs 1, die dieses im geschlossenen Zustand aufspannt. Entsprechend einer möglichen Ausführungsform weist das erste Werkzeug 1 einen zweiten Abschnitt 5 auf, in dem das erste Werkzeug 1 die von einer umfänglichen Isolierung 11 umgebenen Leiter 10 form- und/oder kraftschlüssig umfasst. Das Anschlussteil 20 wird zumindest abschnittsweise von einem zweiten Werkzeug 2 form- und/oder kraftschlüssig umfasst und ragt aus dem zweiten Werkzeug 2 hervor. FIG. 1 shows a first tool 1 and a second tool 2 in each closed state, the receiving recesses are arranged on a common axis. The first tool 1 may consist of a first mold half 1a and a second mold half 1b, which are movable radially to the longitudinal axis of the receiving recess to open the first tool 1. Correspondingly, the second tool 2 can also consist of two tool halves 2a, 2b, which can be moved radially relative to one another. In the first tool 1 aluminum conductors 10 are positively enclosed, wherein the first tool 1 in a first section 3, the conductor 10 directly summarizes. The first section 3 of the first tool 1 extends to the cross-sectional opening 4 or to a distance from the cross-sectional opening 4 of the first tool 1, which spans this in the closed state. According to one possible embodiment, the first tool 1 has a second section 5, in which the first tool 1 comprises the conductor 10 surrounded by a peripheral insulation 11 in a positive and / or non-positive manner. The connecting part 20 is at least partially positively and / or non-positively comprises by a second tool 2 and protrudes from the second tool 2.

Das Anschlussteil 20 ist in dem Abschnitt, in dem es über das zweite Werkzeug 2 in Richtung auf das erste Werkzeug 1 ragt, generell vorzugsweise symmetrisch, z.B. mit quadratischem Querschnitt oder mit rundem Querschnitt. Das Anschlussteil 20 weist vorzugsweise eine planare Stirnfläche auf, oder wie in Figur 1 gezeigt ist, eine konvexe oder mit einer umfänglichen Fase versehene Stirnfläche auf.The connection part 20 is generally preferably symmetrical in the section in which it projects beyond the second tool 2 in the direction of the first tool 1, for example with a square cross section or with a round cross section. The connecting part 20 preferably has a planar face on, or as in FIG. 1 is shown, a convex or provided with a circumferential chamfer face.

Beim erfindungsgemäßen Herstellungsverfahren werden das erste und das zweite Werkzeug 1,2 gegeneinander verfahren, während sie Leiter 10 bzw. Anschlussteil 20 halten, wobei bevorzugt Leiter 10 und Anschlussteil 20 erwärmt sind. Für die Erwärmung von Leitern 10 bzw. Anschlussteil 20 werden z.B. die Leiter 10 und das erste Werkzeug 1 bzw. das Anschlussteil 20 und das zweite Werkzeug 2 jeweils von Strom durchflossen.In the manufacturing method according to the invention, the first and the second tool 1,2 are moved against each other while they hold conductor 10 or connector 20, preferably conductor 10 and connector 20 are heated. For the heating of conductors 10 or connection part 20, e.g. The conductor 10 and the first tool 1 or the connecting part 20 and the second tool 2 each flowed through by current.

Durch das Verfahren von erstem und zweitem Werkzeug 1, 2 gegeneinander wird das Anschlussteil 20 durch die Querschnittsöffnung 4 des ersten Werkzeugs 1 geführt und in axialer Richtung gegen die Leiter 10 gepresst.By the method of the first and second tool 1, 2 against each other, the connection part 20 is guided through the cross-sectional opening 4 of the first tool 1 and pressed in the axial direction against the conductor 10.

Figur 2 zeigt den Zustand der entlang der gemeinsamen Achse der Aufnahmeausnehmungen gegeneinander verfahrenen ersten und zweiten Werkzeuge 1, 2, in dem das Anschlussteil 20 abschnittsweise innerhalb des ersten Werkzeugs 1 gegen die Leiter 10 gepresst ist. Wie schematisch gezeigt ist, wird eine stoffschlüssige Verbindung zwischen den Leitern 10 und dem Anschlussteil 20 hergestellt, insbesondere im Bereich der Stirnfläche des Anschlussteils 20, während aus dem ersten Werkzeug 1 verdrängtes Leitermaterial, z.B. Aluminium, einen Grat oder Butzen 12 zwischen erstem und zweitem Werkzeug 1,2 bilden kann. Nach dem Einpressen des Anschlussteils 20 gegen die in dem ersten Werkzeug 1 gehaltenen Leiter 10 können beide Werkzeuge 1,2 geöffnet werden und das Kabel, dessen Leiter 10 endständig stoffschlüssig mit einem Anschlussteil 20 verbunden sind, können entnommen werden. Ein Grat 12 wird vorzugsweise vor oder nach Öffnen des ersten und/oder zweiten Werkzeugs 1,2 entfernt. FIG. 2 shows the state of the along the common axis of the receiving recesses against each other moved first and second tools 1, 2, in which the connecting part 20 is partially pressed within the first tool 1 against the conductor 10. As shown schematically, a cohesive connection between the conductors 10 and the connecting part 20 is produced, in particular in the region of the end face of the connecting part 20, while displaced from the first tool 1 conductor material, such as aluminum, a ridge or slug 12 between the first and second tool 1,2 can form. After pressing in the connection part 20 against the conductor 10 held in the first tool 1, both tools 1, 2 can be opened and the cable, the conductor 10 of which is connected in a materially bonded manner to a connection part 20, can be removed. A ridge 12 is preferably removed before or after opening the first and / or second tool 1,2.

Die Querschnittsfläche des Abschnitts des Anschlussteils 20, der in die Aufnahmeausnehmung des ersten Werkzeugs 1 geführt wird, ist vorzugsweise geringfügig kleiner als die lichte Querschnittsfläche der Aufnahmeöffnung des ersten Werkzeugs 1, insbesondere als die Querschnittsfläche des ersten Abschnitts 3 des ersten Werkzeugs 1. Der radiale Abstand zwischen dem Anschlussteil 20 und der Aufnahmeausnehmung des ersten Werkzeugs 1 bildet dann den Spalt, durch den Material der Leiter 10, das beim Einpressen des Anschlussteils 20 gegen die Leiter 10 verdrängt wird, von der Stirnfläche des Anschlussteils 20 entweichen kann.The cross-sectional area of the portion of the connecting part 20 which is guided into the receiving recess of the first tool 1 is preferably slightly smaller than the clear cross-sectional area of the receiving opening of the first tool 1, in particular as the cross-sectional area of the first portion 3 of the first tool 1. The radial distance between the connection part 20 and the receiving recess of the first tool 1 then forms the gap, can escape from the end face of the connecting part 20 through the material of the conductor 10, which is displaced against the conductor 10 during the pressing of the connecting part 20.

Es hat sich gezeigt, dass mit dem erfindungsgemäßen Verfahren eine derart beständige stoffschlüssige Verbindung zwischen einem massiven Aluminiumleiter oder einem Litzenleiter, vorzugsweise aus Aluminium, und einem Anschlussteil mit geschlossener Stirnfläche aus einem Kupferwerkstoff erzeugt wird, die die Zugfestigkeit des Leiters erreicht, z.B. bei Aluminiumleitern.It has been found that with the method according to the invention, such a durable cohesive connection between a solid aluminum conductor or a stranded conductor, preferably made of aluminum, and a closed end connection piece is produced from a copper material which achieves the tensile strength of the conductor, e.g. in aluminum ladders.

Für die in den Figuren 3 und 4 gezeigten Schliffe wurden die Kabel mit dem erfindungsgemäßen Verfahren durch Pressen des Anschlussteils in die Aluminiumlitzen hergestellt. Der Schliff wurde mit einer wassergekühlten Diamanttrennscheibe parallel zur Längsachse des Leiters angefertigt. Die Schliffe wurden für die mikroskopischen Aufnahmen wahlweise in 3% NaOH, 60°C (für Aluminium) oder 10% Al-sulfat (für Kupfer) geätzt.For those in the FIGS. 3 and 4 The cables were produced by the method according to the invention by pressing the connecting part into the aluminum strands. The cut was made with a water-cooled diamond cutting disc parallel to the longitudinal axis of the conductor. The sections were optionally etched in 3% NaOH, 60 ° C (for aluminum) or 10% Al sulfate (for copper) for microscopic photographs.

Figur 3 zeigt ein Schliffbild des Verbindungsbereichs des aus Aluminiumlitzen (A199,7) bestehenden Leiters (im unteren Bildabschnitt) und des aus massivem Kupferwerkstoff E-Cu57 F30 bestehenden Abschnitts des Anschlussteils (oberer Bildabschnitt). Es wird deutlich, dass das Anschlussteil in einer Grenzfläche stoffschlüssig mit den Aluminiumlitzen verbunden ist, wobei die Grenzfläche durch die Rauheit bzw. Oberflächengeometrie des Anschlussteils aus dem Kupferwerkstoff bestimmt wird. Die Aluminiumlitzen sind im Randbereich nach außen gedrückt, was derzeit auf das Herauspressen des Aluminiums aus dem Werkzeug mittels des Anschlussteils zurückgeführt wird. Die Aluminiumlitzen sind parallel zueinander angeordnet und ragen im Wesentlichen bis an die Grenzfläche. FIG. 3 shows a micrograph of the connecting portion of the existing of aluminum strands (A199.7) conductor (in the lower part of the picture) and of the solid copper material E-Cu57 F30 existing portion of the connecting part (upper image portion). It is clear that the connection part is connected in an interface cohesively with the aluminum strands, wherein the interface is determined by the roughness or surface geometry of the connection part of the copper material. The aluminum strands are pressed outward in the edge region, which is currently attributed to the pressing out of the aluminum from the tool by means of the connecting part. The aluminum strands are arranged parallel to each other and protrude substantially to the interface.

Figur 4 zeigt den Verbindungsbereich des Abschnitts eines Anschlussteils, der aus Kupferlitzen (E-Cu58) mit einer umfänglich aufgepressten Hülse besteht, mit einem Leiter aus massivem Aluminium (A199,7). Der in der oberen Bildhälfte gezeigte Aluminiumleiter grenzt in einer Grenzfläche an die Kupferlitzen des Anschlussteils, die in der unteren Bildhälfte gezeigt sind, wobei die Grenzfläche von den Kupferlitzen bestimmt wird. Die Kupferlitzen sind angrenzend an ihre gemeinsame Stirnfläche umgeknickt und zeigen zwischen die Kupferlitzen eingedrungenes Aluminium. FIG. 4 shows the connecting portion of the portion of a connecting part, which consists of copper strands (E-Cu58) with a circumferentially pressed sleeve, with a solid aluminum conductor (A199.7). The aluminum conductor shown in the upper half of the picture is bordered in an interface with the copper strands of the connecting part, which are shown in the lower half of the picture, the interface being determined by the copper strands. The copper strands are folded over adjacent to their common face and show between the copper strands penetrated aluminum.

Claims (15)

Verfahren zur Herstellung eines elektrischen Kabels, das zumindest einen Leiter (10) und ein axial am Leiter (10) fixiertes Anschlussteil (20) aus Kupferwerkstoff aufweist, mit dem Schritt des Pressens des Anschlussteils (20) gegen den Leiter (10), dadurch gekennzeichnet, dass der Leiter (10) formschlüssig und/oder kraftschlüssig in einer Aufnahmeausnehmung eines ersten Werkzeugs (1) gehalten wird und das Anschlussteil (20) im Wesentlichen ausschließlich entlang der Achse des Leiters (10) gegen den Leiter (10) bewegt wird.A process for producing an electric cable having at least one conductor (10) and an axially on the conductor fixed (10) connecting part (20) made of copper material, comprising the step of pressing the terminal portion (20) against the head (10), characterized in that the conductor (10) is held positively and / or non-positively in a receiving recess of a first tool (1) and the connecting part (20) is moved against the conductor (10) substantially exclusively along the axis of the conductor (10). Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass das Anschlussteil (20) in die Aufnahmeausnehmung des ersten Werkzeugs (1) geführt und gegen den Leiter (10) gepresst wird, wobei das Anschlussteil (20) eine geringere Querschnittsfläche aufweist als die lichte Querschnittsfläche der Aufnahmeausnehmung des ersten Werkzeugs (1).A method according to claim 1, characterized in that the connecting part (20) is guided in the receiving recess of the first tool (1) and pressed against the conductor (10), wherein the connecting part (20) has a smaller cross-sectional area than the clear cross-sectional area of the receiving recess of the first tool (1). Verfahren nach einem der voranstehenden Ansprüche, dadurch gekennzeichnet, dass der Leiter (10) massiv ist und aus Aluminium oder einer Aluminiumlegierung besteht oder aus Litzen aus Aluminium, einer Aluminiumlegierung und/oder aus Kupferwerkstoff besteht.Method according to one of the preceding claims, characterized in that the conductor (10) is solid and consists of aluminum or an aluminum alloy or consists of strands of aluminum, an aluminum alloy and / or copper material. Verfahren nach einem der voranstehenden Ansprüche, dadurch gekennzeichnet, dass das Anschlussteil (20) abschnittsweise in einem zweiten Werkzeug (2) kraftschlüssig und/oder formschlüssig gehalten wird und mit einem Abschnitt über das zweite Werkzeug (2) hervorsteht, der zumindest anteilig in die Aufnahmeausnehmung eines ersten Werkzeugs (1) bewegt wird, bis die Stirnfläche des Anschlussteils (10) bis in den ersten Abschnitt (3) des ersten Werkzeugs (1) gepresst wird, in welchem der Leiter (10) gehalten ist.Method according to one of the preceding claims, characterized in that the connecting part (20) is partially held in a second tool (2) non-positively and / or positively and protrudes with a portion on the second tool (2), at least partially in the receiving recess a first tool (1) is moved until the end face of the connecting part (10) is pressed into the first portion (3) of the first tool (1), in which the conductor (10) is held. Verfahren nach Anspruch 4, dadurch gekennzeichnet, dass die Stirnfläche des Anschlussteils (20) zu 10% bis 90% der axialen Erstreckung des ersten Abschnitts (3) gegen den Leiter (10) bewegt wird.A method according to claim 4, characterized in that the end face of the connecting part (20) is moved to 10% to 90% of the axial extent of the first portion (3) against the conductor (10). Verfahren nach einem der voranstehenden Ansprüche, dadurch gekennzeichnet, dass der Leiter (10) und/oder das Anschlussteil (20) während des Pressens des Anschlussteils (20) gegen den Leiter (10) bei Kontakt des Leiters (10) mit dem Anschlussteil (20) von Strom durchflossen werden und bis auf maximal die Erweichungstemperatur des Leiters (10) erwärmt wird.Method according to one of the preceding claims, characterized in that the conductor (10) and / or the connecting part (20) during pressing of the connecting part (20) against the conductor (10) upon contact of the conductor (10) with the connecting part (20 ) are flowed through by current and is heated to a maximum of the softening temperature of the conductor (10). Verfahren nach einem der voranstehenden Ansprüche, dadurch gekennzeichnet, dass der Leiter (10) aus einer Vielzahl von Litzen besteht und in einem ersten Abschnitt (3) des ersten Werkzeugs (1) unmittelbar vom ersten Werkzeug (1) umfasst wird, der unmittelbar oder mit einem Abstand an die Querschnittsöffnung (4) des ersten Werkzeugs (1) angrenzt.Method according to one of the preceding claims, characterized in that the conductor (10) consists of a plurality of strands and in a first portion (3) of the first tool (1) directly from the first tool (1) is included, directly or with a distance adjacent to the cross-sectional opening (4) of the first tool (1). Verfahren nach einem der voranstehenden Ansprüche, dadurch gekennzeichnet, dass das Anschlussteil (20) eine ebene oder konvexe Stirnfläche aufweist, die in einem Winkel von 10° bis 90° gegen die Längsachse des gegen die Leiter (10) gepressten Abschnitts des Anschlussteils (20) geneigt ist.Method according to one of the preceding claims, characterized in that the connecting part (20) has a flat or convex end face, which at an angle of 10 ° to 90 ° against the longitudinal axis of the against the conductor (10) pressed portion of the connecting part (20). is inclined. Elektrisches Kabel mit einem Leiter (10) und einem axial an den Leiter (10) gebundenen Anschlussteil (20) aus Kupferwerkstoff, dadurch gekennzeichnet, dass der Leiter (10) in seinem an das Anschlussteil (20) angrenzenden Abschnitt aus einer Vielzahl von Litzen besteht und das Anschlussteil (20) und die Leiter (10) in einer Grenzschicht stoffschlüssig aneinander gefügt sind.Electrical cable comprising a conductor (10) and a copper-material connection part (20) bonded axially to the conductor (10), characterized in that the conductor (10) consists of a multiplicity of strands in its section adjoining the connection part (20) and the connecting part (20) and the conductors (10) are joined together in a boundary layer by a material fit. Elektrisches Kabel nach Anspruch 9, dadurch gekennzeichnet, dass der Leiter (10) in seinem an das Anschlussteil (20) angrenzenden Abschnitt keine die Litzen des Leiters (10) umfassende Hülse aufweist.Electrical cable according to claim 9, characterized in that the conductor (10) in its adjacent to the connecting part (20) portion does not comprise the strands of the conductor (10) comprising sleeve. Elektrisches Kabel nach einem der Ansprüche 9 oder 10, dadurch gekennzeichnet, dass der Leiter (10) aus Kupfer, einer Kupferlegierung und/oder Aluminium oder einer Aluminiumlegierung besteht.Electrical cable according to one of claims 9 or 10, characterized in that the conductor (10) consists of copper, a copper alloy and / or aluminum or an aluminum alloy. Elektrisches Kabel nach einem der Ansprüche 9 bis 11, dadurch gekennzeichnet, dass das Anschlussteil (20) eine ebene Stirnfläche aufweist, die in einem Winkel von 10° bis 90° gegen die Längsachse des gegen die Leiter (10) gepressten Abschnitts des Anschlussteils (20) geneigt ist.Electrical cable according to one of claims 9 to 11, characterized in that the connecting part (20) has a flat end face which is at an angle of 10 ° is inclined at 90 ° to the longitudinal axis of the against the conductor (10) pressed portion of the connecting part (20). Elektrisches Kabel nach einem der Ansprüche 9 bis 11, dadurch gekennzeichnet, dass das Anschlussteil (20) eine konvexe Stirnfläche aufweist, die rotationssymmetrisch zur Längsachse des gegen die Leiter (10) gepressten Abschnitts des Anschlussteils (20) angeordnet ist.Electrical cable according to one of claims 9 to 11, characterized in that the connecting part (20) has a convex end face, which is rotationally symmetrical to the longitudinal axis of the pressed against the conductor (10) portion of the connecting part (20). Elektrisches Kabel nach einem der Ansprüche 9 bis 13, dadurch gekennzeichnet, dass das Anschlussteil (20) in einem an die Leiter (10) angrenzenden Abschnitt von Aluminium umfasst ist.Electrical cable according to one of Claims 9 to 13, characterized in that the connection part (20) is comprised in a section of aluminum adjoining the conductors (10). Elektrisches Kabel nach einem der Ansprüche 9 bis 14, dadurch gekennzeichnet, dass das Anschlussteil (20) in seinem mit dem Leiter (10) verbundenen Abschnitt aus von einer Hülse umfassten Litzen aus Kupfer oder Kupferwerkstoff besteht.Electrical cable according to one of Claims 9 to 14, characterized in that the connection part (20) in its section connected to the conductor (10) consists of strands of copper or copper material enclosed by a sleeve.
EP10305380.7A 2010-04-13 2010-04-13 Method for producing cables with aluminium wires Active EP2378611B1 (en)

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