EP2621021A1 - Cosse destinée à relier un élément conducteur à l'aide d'un câble en aluminium - Google Patents

Cosse destinée à relier un élément conducteur à l'aide d'un câble en aluminium Download PDF

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Publication number
EP2621021A1
EP2621021A1 EP12152471.4A EP12152471A EP2621021A1 EP 2621021 A1 EP2621021 A1 EP 2621021A1 EP 12152471 A EP12152471 A EP 12152471A EP 2621021 A1 EP2621021 A1 EP 2621021A1
Authority
EP
European Patent Office
Prior art keywords
cable
aluminum
lug
sleeve
tubular
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP12152471.4A
Other languages
German (de)
English (en)
Inventor
Christoph Baumgartner
Waldemar Ziebarth
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.)
Intercable GmbH
Original Assignee
Intercable 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 Intercable GmbH filed Critical Intercable GmbH
Priority to EP12152471.4A priority Critical patent/EP2621021A1/fr
Priority to EP13152198.1A priority patent/EP2621022A1/fr
Publication of EP2621021A1 publication Critical patent/EP2621021A1/fr
Withdrawn legal-status Critical Current

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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00Individual 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
    • H01R11/11End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H01R11/12End pieces terminating in an eye, hook, or fork
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00Electrically-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
    • H01R4/02Soldered or welded connections
    • H01R4/029Welded connections
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00Electrically-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
    • H01R4/10Electrically-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
    • H01R4/18Electrically-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
    • H01R4/183Electrically-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 for cylindrical elongated bodies, e.g. cables having circular cross-section
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46Bases; Cases
    • H01R13/52Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2201/00Connectors or connections adapted for particular applications
    • H01R2201/26Connectors or connections adapted for particular applications for vehicles

Definitions

  • the invention relates to the technical field of the connection technology of electrical conductors.
  • the invention relates to a cable lug for connecting an aluminum cable to a current-carrying element, an electrical connection between an aluminum cable and a current-carrying element, a sleeve for accommodating in a lug body and a manufacturing method for a cable lug.
  • copper cables instead of copper cables, especially in the automotive sector, aluminum cables are also used, as these can have various advantages, such as a weight reduction, an alternative to copper (for example in the case of a bottleneck) or a price advantage.
  • copper conductors and aluminum cables are then used together, with the result that electrical connections between copper conductors and aluminum cables must be created.
  • cable lugs can be used for electrical connection of live copper cables with other current-carrying elements.
  • An end to one Copper cable can be pushed into a tubular opening of the cable lug and then the cable lug, for example, by pressing mechanically and electrically connected to the end of the copper cable.
  • the other end of the cable lug may have a flat contact surface with a bore for receiving a fastening bolt or a screw with which a current-carrying element can be connected.
  • the contact point with the current-carrying element should not be made of aluminum, since this material normally forms a non-conductive oxide layer, which usually has to be removed before electrical connection.
  • the transitional range of aluminum to copper may also be critical in terms of electrocorrosion and similar phenomena.
  • an aluminum cable may include one or more strands of aluminum that may be closed by an insulated layer of plastic.
  • the current-carrying element is usually made of metal, such as copper, iron or brass.
  • the current-carrying element may, for example, comprise a cable or a conductor track on a circuit board.
  • the current-carrying element can also be a battery terminal, a battery terminal, a body (as ground) or a starter terminal
  • the cable lug comprises a copper lug body having a contact end for connection to the current-carrying element and a receiving area for receiving one end of the aluminum cable.
  • the receiving area has a tubular receptacle for the (eg, uninsulated or stripped) end of the aluminum cable, which is lined with aluminum (on the inside).
  • a tubular opening made of copper is formed in the lug body in the receiving area, wherein in the tubular opening a sleeve is received, which on an outer side a Copper layer and on an inner side an aluminum layer, which are interconnected or intermetallic.
  • the sleeve provides with its inside the tubular aluminum-lined receptacle.
  • the sleeve may for example be tubular or comprise a tubular portion and / or have an outer diameter corresponding to an inner diameter of the tubular opening in the cable shoe body.
  • the lug body may be a conventional lug body in which the sleeve is inserted.
  • This can be constructed with a sleeve together with a conventional lug body in a simple manner, a cable lugs, which is adapted to connect an aluminum cable with an electrical conductor.
  • the sleeve is formed of CUPAL (copper clad aluminum).
  • CUPAL or so-called CUPAL sheet metal may be a sheet metal material which consists of a copper layer and an aluminum layer or comprises these layers. These layers are joined together by rolling and compacting in such a way that they are metallically bonded or welded together.
  • CUPAL may also be in the form of tubes which consist of an aluminum layer inside and a copper layer outside. Such pipes can be formed by extrusion. Tubular sleeves can be made, for example, from such a CUPAL tube.
  • the sleeve is cup-shaped and is designed to tightly enclose the end of the aluminum cable. seal this end against the environment.
  • CUPAL material can be used to form cups or cup-shaped sleeves. These cups can then be formed inside of aluminum and outside of copper.
  • the cup, or generally the sleeve may have a funnel-shaped lead-in area to protect individual leads from the end of the aluminum cable from kinking upon insertion of the cable into the sleeve.
  • Such cup-shaped sleeves can then be inserted into a conventional copper pipe lug.
  • the cup-shaped sleeve can completely enclose the end of an aluminum cable, which is inserted into the cable lug, and thus seal with respect to the environment, in order to avoid electrocorrosion in this way.
  • cup or the sleeve in the pipe cable lug is pre-assembled.
  • the pre-assembly can be done by pressing, snapping and / or clipping.
  • the cable lug may be formed from a lug body made of copper and a sleeve made from CUPAL received therein.
  • the cable lug is formed directly from a CUPAL tube.
  • the cable lug body is formed from a tube having on an inner side an aluminum layer and on an outer side a copper layer, which are interconnected.
  • the pipe can be a CUPAL pipe.
  • the contact end of the lug body is formed by removing the aluminum layer in an end portion of the tube and compressing the end portion.
  • the tubular receptacle is formed by an opposite end region of the tube.
  • the tubular receptacle for receiving the end of the aluminum cable can be made of CUPAL.
  • a sealing compound is received between the tubular receptacle and the contact end.
  • the sleeve may be open in the direction of the contact end of the cable shoe body and the sealant may be received between the sleeve and the contact end.
  • an open cup which is shaped, for example, like an end sleeve, or a tubular sleeve can thus also be used.
  • the cable lug can be sealed inwardly towards the contact end, for example by sealing, injecting a silicone plug, soldering and / or pressing a sealing element.
  • a seal may be advantageous, in particular, in the case of a lug body with a flat pressed-on area, because under certain circumstances moisture can penetrate into the interior of the lug body due to the flat pressed-on area.
  • the receiving area has an end area which is widened in relation to the tubular receptacle and which is designed to receive an insulated section of the aluminum cable.
  • the cable lug can be made such that it is widened in the rear area and extends over the insulation of the aluminum cable. This flared end portion may serve to seal and / or topple the end of the aluminum cable.
  • Another aspect of the invention relates to an electrical connection of an aluminum cable and a cable lug.
  • the electrical connection comprises a cable lug, as described above and below.
  • a (eg, uninsulated or stripped) end of the aluminum cable is received within the tubular receptacle and metallically connected to the aluminum lined interior of the tubular receptacle. In this way, a stable electrical connection between an aluminum cable and an electrical contact element made of copper can be created.
  • the tubular receptacle has been connected to the stripped end of the aluminum cable under pressure and / or heat.
  • a metallic connection can be effected by crimping, for example radial crimping, or welding, for example resistance welding or ultrasonic welding.
  • crimping for example radial crimping
  • welding for example resistance welding or ultrasonic welding.
  • a combination of pressure and temperature is possible, such as hot crimping.
  • the receiving region or the widened end region of the cable lug is pressed with an insulated section of the aluminum cable.
  • the protruding from the cable lugs section of the aluminum cable can be sealed from the environment.
  • This can be done, for example, by pressing the cable lug area, which protrudes beyond the insulation.
  • the compression can be done in various ways, for example as a hexagon. The pressing can be carried out twice in succession (at different places) to produce a double insulation. A radial compression is possible.
  • an additional seal such as an O-ring or a Insert silicone seal between the aluminum cable and the end of the cable lug that extends beyond the aluminum cable. The compression can be done after inserting the additional seal.
  • an end region of the cable lug and an insulation of the aluminum cable are covered and connected with a shrink tube.
  • a heat-shrinkable tube possibly with an inner adhesive between the heat-shrinkable tube and the cable lug and / or aluminum cable, for sealing and / or stabilizing.
  • transition region between aluminum cable and live elements can be completely sealed: To the aluminum cable through the compression of the insulation and / or the shrink tube and the connection area through the cup-shaped sleeve and / or the sealant.
  • Another aspect of the invention relates to a cup-shaped sleeve, in particular a cup-shaped sleeve as described, for example, already above.
  • the cup-shaped sleeve comprises a tubular wall and a bottom which closes the tubular wall in one direction.
  • An inner side of the sleeve has an aluminum layer and an outer side of the sleeve has a copper layer, which are connected to each other and in particular intermetallically.
  • Such sleeves can be produced for example by deep drawing a CUPAL sheet.
  • Another aspect of the invention relates to a use of such a cup-shaped sleeve as a receptacle for an end of an aluminum cable in a cable lug. This can be done in a cost effective and easy way together with a conventional cable lug body made of copper, a cable lug for connecting an aluminum cable to a current-carrying element are produced.
  • Another aspect of the invention relates to a manufacturing method for a cable lug.
  • the method comprises the steps of: providing a sleeve of CUPAL which has an aluminum layer on one inner side and a copper layer on an outer side; Providing a copper spade body having a contact end and a receiving portion for receiving the sleeve; Inserting the sleeve into the cable shoe body, so that in the receiving area of the cable shoe body, a receptacle for an end of an aluminum cable is formed.
  • the already described cable lug can be produced with the sleeve made of CUPAL.
  • the method comprises the steps of: providing a tube of CUPAL having an aluminum layer on an inner side and a copper layer on an outer side; Removing the aluminum layer in an end region of the tube; Compressing the end portion to form a contact end of the lug; Forming a tubular receptacle for an aluminum cable through the opposite end portion of the tube.
  • CUPAL can be used to produce a one-piece cable lug with which an electrical connection between an aluminum cable and a current-carrying element can be made.
  • Fig. 1A, 1B, 1C and 2 show a cup-shaped sleeve 10 in side view, front view, in cross-section and in two three-dimensional views.
  • the rotationally symmetrical sleeve 10 has an annular wall 12, a dome-shaped cover or bottom 14 and an outwardly flared edge 16 on.
  • the rim 16 may be angled, for example, at an angle of 45 ° to form a funnel-shaped opening.
  • the sleeve 10 is deep-drawn from a CUPAL sheet, whereby the sleeve 10 consists of an aluminum layer 18 on the inside and a copper layer 20 on the outside.
  • Fig. 3 shows a three-dimensional view of a cable shoe body 30, which has a tubular receiving portion 32 and a flat contact end 34 with a bore 36.
  • the one-piece lug body 30 is made of copper and may for example be formed from a copper tube, wherein the contact end 34 is formed by squeezing the copper tube.
  • the receiving region 32 of the lug body 30 comprises a portion 38 for receiving the sleeve 10 and an extended end portion 40 for receiving an insulated portion of a cable.
  • Fig. 4A shows a side view of elements of an electrical connection 50, which in the Fig. 5A are shown in a cross-sectional view.
  • the electrical connection comprises an aluminum cable 52 which has a section 56 insulated with a plastic jacket or insulation 54 and a stripped end 58.
  • the conductor 60 of the aluminum cable 52 may comprise a single wire of aluminum or a plurality of aluminum strands.
  • the sleeve 10 is inserted into the lug body 30.
  • the interior of the sleeve 10 then provides a tubular receptacle 64 for the aluminum cable 52 lined with aluminum 18 on the inside.
  • the cable shoe body 30 in section 38 a tubular opening 66 in the receiving area 32, which is designed to To absorb sleeve 10.
  • the inner diameter of the opening 66 or the portion 38 is just as large or only slightly larger than the outer diameter of the annular wall 12 of the sleeve 10th
  • Fig. 4B shows a side view of a preassembled electrical connection 50, which in the Fig. 5B is shown in cross-sectional view.
  • the sleeve 10 is inserted into the opening 66 of the lug body 30 until it stops and then eigeschoben the end 58 of the aluminum cable 52 into the receptacle 64.
  • the sleeve 10 can be pushed over the end 58 and then the sleeve together with the aluminum cable 52 are inserted into the receiving area 32 of the lug body 30 until it stops.
  • the conductor 60 at the end 58 of the aluminum cable 52 now contacts the aluminum layer 18 of the sleeve 10 and the receptacle 64 and the copper layer 20 on the outside of the sleeve 10 contacts the inside of the cable lug 30 and the opening 66 made of copper.
  • Figs. 6A, 6B, 6C show the electrical connection from the Fig. 4B and 5B in a side view, in plan view and in a three-dimensional view after a permanent electrical contacting of the electrical conductors 60, 18, 20, 30 has occurred.
  • the central portion 38 of the receiving portion 32 of the cable lug 62 is pressed together with the sleeve 10 by hot crimping and heated. This creates a metallic connection between the aluminum conductor 60 of the cable 52 and the aluminum layer 18 of the sleeve 10th
  • Crimping produces two recesses 80 in section 38.
  • Figs. 7A, 7B, 7C show the electrical connection 50 from the Figs. 6A, 6B and 6C in side view, in plan view and in a three-dimensional view after the receiving area 32 of the cable lug 62 and the lug body 30 has been sealed.
  • the end portion 40 of the lug body 30 is compressed so that no liquid can penetrate along the insulation 54 into the interior of the electrical connection 50.
  • the compression can take place in such a way that a polygonal depression (as here hexagon) 82 is produced in the end region 40.
  • Fig. 8 shows a further embodiment of an electrical connection 50 '.
  • the cable lug 62 'in this case comprises an alternative sleeve 10' which has only one annular wall 12 and a bevelled edge 16, but no lid or bottom.
  • the sleeve 10 ' is thus open in both directions.
  • a sealing compound 84 is used, which fills the space in the interior of the cable shoe body 30 between the sleeve 10' and the end 58 of the aluminum cable 52 and the contact end 34.
  • the cable lug 30 also has a receiving region 32 which comprises only the portion 38, that is to say has no flared end.
  • a shrink tube 86th used, which extends over an insulated portion 56 of the aluminum cable 52 and at least a portion of the receiving portion 32 of the cable shoe body 30.
  • a tube may be drawn from CUPAL material which has an aluminum layer 18 'on the inside and a copper layer 20' on the outside of that tube is machined in an end region 90 such that, on the inside, the aluminum layer 18 'is removed, for example by unscrewing it, and the end region 90 is then pressed flat to form the flat contact end of the cable lug 62'.
  • the opposite end portion 92 is machined on the outside so that the copper layer 20 'of the tube is removed, for example by turning off.
  • the end region 92 then forms the receiving region 32 of the lug 62 "which provides the tubular receptacle 64 for the aluminum cable 52.
  • the copper layer 20 'in the end region 92 is removed so that no electro-corrosion occurs between the copper layer 20' and the aluminum conductor 60 of the aluminum cable 52 can.
  • a permanent electrical connection can now be made by inserting one end 58 of the aluminum cable 52 into the receptacle 64 and, for example, metallically bonding it to the inside 18 'of the receptacle 64 by ultrasonic welding.
  • An inner seal to the contact end 34 may be made via a sealant 84 as described above.
  • a shrink tube 86 may be used as described above.

Landscapes

  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
EP12152471.4A 2012-01-25 2012-01-25 Cosse destinée à relier un élément conducteur à l'aide d'un câble en aluminium Withdrawn EP2621021A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP12152471.4A EP2621021A1 (fr) 2012-01-25 2012-01-25 Cosse destinée à relier un élément conducteur à l'aide d'un câble en aluminium
EP13152198.1A EP2621022A1 (fr) 2012-01-25 2013-01-22 Cosse destinée à relier un élément conducteur à l'aide d'un câble en aluminium

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP12152471.4A EP2621021A1 (fr) 2012-01-25 2012-01-25 Cosse destinée à relier un élément conducteur à l'aide d'un câble en aluminium

Publications (1)

Publication Number Publication Date
EP2621021A1 true EP2621021A1 (fr) 2013-07-31

Family

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Family Applications (2)

Application Number Title Priority Date Filing Date
EP12152471.4A Withdrawn EP2621021A1 (fr) 2012-01-25 2012-01-25 Cosse destinée à relier un élément conducteur à l'aide d'un câble en aluminium
EP13152198.1A Withdrawn EP2621022A1 (fr) 2012-01-25 2013-01-22 Cosse destinée à relier un élément conducteur à l'aide d'un câble en aluminium

Family Applications After (1)

Application Number Title Priority Date Filing Date
EP13152198.1A Withdrawn EP2621022A1 (fr) 2012-01-25 2013-01-22 Cosse destinée à relier un élément conducteur à l'aide d'un câble en aluminium

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2018069300A1 (fr) 2016-10-14 2018-04-19 Bremi Fahrzeug-Elektrik Gmbh + Co.Kg Procédé de fabrication d'une cosse de câble et cosse de câble pour relier électriquement un câble à un élément conducteur de courant
CN108493735A (zh) * 2018-03-28 2018-09-04 王珍珍 一种铝合金高压电缆铝铜复合接线端子制备方法
EP3379652A1 (fr) * 2017-03-24 2018-09-26 Nexans Mise en contact d'un conducteur électrique
TWI670901B (zh) * 2014-09-17 2019-09-01 馬來西亞商杰馮科技有限公司 無線積體電路測試設備中之短接點

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US9356438B2 (en) 2014-02-27 2016-05-31 Delphi Technologies, Inc. Wire cable assembly having a terminal with an encapsulated wire end
DE102014112701A1 (de) 2014-09-03 2016-03-03 Harting Electric Gmbh & Co. Kg Crimpkontakt
DE202016104959U1 (de) 2016-09-08 2016-09-28 Kromberg & Schubert Gmbh Kontaktteile für die Anbindung an Aluminiumleiter
DE102017215233A1 (de) * 2017-08-31 2019-02-28 Seg Automotive Germany Gmbh NTC-Bauteil zum Einbau in den Stromkreis einer elektrischen Baueinheit
DE102018127729A1 (de) * 2018-11-07 2020-05-07 Auto-Kabel Management Gmbh Verfahren zur Herstellung eines Anschlussteils für elektrische Anlagen, Anschlussteil sowie Verbindung eines Anschlussteils mit einem Kabel
US11491935B2 (en) * 2019-10-25 2022-11-08 Sea Clear Power Inc. Systems and methods for distribution of power in a marine vessel, ATVS, and vehicles
DE102021129706A1 (de) 2021-11-15 2023-05-17 Strunk Connect automated solutions GmbH & Co. KG Verfahren zum Verbinden einer elektrischen Leitung aus Aluminium mit einem Rohr aus Kupfer

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
TWI670901B (zh) * 2014-09-17 2019-09-01 馬來西亞商杰馮科技有限公司 無線積體電路測試設備中之短接點
WO2018069300A1 (fr) 2016-10-14 2018-04-19 Bremi Fahrzeug-Elektrik Gmbh + Co.Kg Procédé de fabrication d'une cosse de câble et cosse de câble pour relier électriquement un câble à un élément conducteur de courant
DE102016119656A1 (de) 2016-10-14 2018-05-03 Bremi Fahrzeug-Elektrik Gmbh + Co. Kg Verfahren zum Herstellen eines Kabelschuhs und Kabelschuh zum elektrischen Verbinden eines Kabels mit einem stromführenden Element
EP3379652A1 (fr) * 2017-03-24 2018-09-26 Nexans Mise en contact d'un conducteur électrique
CN108493735A (zh) * 2018-03-28 2018-09-04 王珍珍 一种铝合金高压电缆铝铜复合接线端子制备方法

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