EP2621022A1 - 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

Info

Publication number
EP2621022A1
EP2621022A1 EP13152198.1A EP13152198A EP2621022A1 EP 2621022 A1 EP2621022 A1 EP 2621022A1 EP 13152198 A EP13152198 A EP 13152198A EP 2621022 A1 EP2621022 A1 EP 2621022A1
Authority
EP
European Patent Office
Prior art keywords
cable
aluminum
lug
receptacle
layer
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Withdrawn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
EP13152198.1A
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 EP13152198.1A priority Critical patent/EP2621022A1/fr
Publication of EP2621022A1 publication Critical patent/EP2621022A1/fr
Withdrawn legal-status Critical Current

Links

Images

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
    • 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
    • H01R11/12—End pieces terminating in an eye, hook, or fork
    • 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
    • H01R4/02—Soldered or welded connections
    • H01R4/029—Welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2201/00—Connectors or connections adapted for particular applications
    • H01R2201/26—Connectors 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 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.
  • One end of a copper cable can in a tubular opening or recording of the Lug are pushed 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 point of contact with the current-carrying element should not be aluminum, since this material normally forms a non-conductive oxide layer, which usually needs to be removed prior to electrical connection.
  • the transitional range of aluminum to copper may also be critical in terms of electrocorrosion and similar phenomena.
  • One aspect of the invention relates to a manufacturing method for a cable lug for connecting an aluminum cable to a live element.
  • an aluminum cable may comprise one or more strands of aluminum that may be enclosed 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 manufacturing method comprises the steps of: providing a tube having in a first portion (or an end portion of the tube) on an inner side an aluminum layer and on an outer side a copper layer connected to each other; a second portion (or a second end portion of the tube) having only the copper layer; Compressing the second portion to form a contact end of the lug, wherein a tubular receptacle for an aluminum cable is formed by the first portion of the tube which is at least partially lined with the aluminum layer.
  • a CUPAL tube may be used, which is at least partially coated on the inside with aluminum to produce a one-piece cable lug.
  • the contact end may be a flat portion at one end of the cable lug, which may for example be provided with a hole through which a screw of the current-carrying element may be inserted.
  • the tube is provided by the fact that in a tube made of CUPAL, which on an inner side of an aluminum layer and on an outer side has a copper layer, an aluminum layer is removed in the second section.
  • a (long) pipe made of CUPAL can be cut into shorter pipe sections, in which the aluminum layer in one end region (or the second section) of the pipe is removed at one end, for example, by drilling or milling.
  • the manufacturing method further comprises the step of: removing the aluminum layer in a front region of the tubular receptacle. Before or after the removal of the aluminum layer at the end region which becomes the contact end, part of the aluminum layer can also be removed at the other end region.
  • the tubular receiving receives a front portion, on the one hand has no aluminum, which may for example reduce corrosion, and on the other hand has a larger inner diameter than the rest of the tubular receptacle, so that the front portion as a receptacle for a portion of the aluminum cable can serve, which was not stripped.
  • the aluminum layer can be removed around the entire circumference of the tubular receptacle.
  • the manufacturing method further comprises the step of: removing a portion of the copper layer inside the front portion of the tubular receptacle. It is also possible that a portion of the copper layer is removed in the front region in order to further increase the inner diameter and / or to provide the front region with a thinner wall, so that this region is better deformed (like something crimped or widened) can.
  • the receiving area has an opposite end of the tubular receptacle, front portion or wide portion, which is adapted to receive an insulated portion of the aluminum cable.
  • the cable lug can be made such that it 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.
  • the manufacturing method further comprises the step of: machining a front portion of the tubular receptacle so that an inner diameter of the tube is greater in the front portion of the tubular receptacle than in a rear portion of the tubular receptacle.
  • the front area can be drilled out or milled out. It will be understood that the front portion of the receptacle may be the area located at the outer end of the receptacle which first comes in contact with an inserted cable.
  • the manufacturing method further comprises the step of: welding the contact end such that the contact end is sealed in the direction of the receptacle. This can for example be done with a weld which extends transversely to the direction of extension of the tubular receptacle over the contact end. In this way, the tubular receptacle can be sealed to the rear.
  • the receptacle can also be sealed differently.
  • a sealing compound is received between the tubular receptacle and the contact end.
  • the cable lug can be sealed inside toward the contact end, for example by sealing and / or by injecting a silicone plug, soldering and / or pressing a sealing element.
  • a seal may be advantageous, in particular, in the case of a cable shoe body with a flat pressed contact end or screw-on area, since under certain circumstances moisture can penetrate into the interior of the cable shoe body due to the flattened screw-on area.
  • the manufacturing method further comprises the step of: closing the tubular receptacle with a (removable) plastic plug, so that the interior of the tubular receptacle is protected from external influences.
  • the receptacle can be closed with a plastic plug, which has a handle end, with which it can be pulled out of the receptacle again, so that moisture can not penetrate into the receptacle during transport and / or during storage of the cable lug and / or in particular the aluminum layer is not exposed to corrosion.
  • the manufacturing method further comprises the step of: coating the lug after closing the receptacle with the plastic plug with a metal layer such that an interior of the tubular receptacle is not covered with the metal layer.
  • the cable lug can be covered with the metal layer except on a surface protected by the plastic plug.
  • the metal layer can be produced by electroplating, tinning, nickel plating, chrome plating and / or similar conventional surface coatings on contact elements.
  • the method comprises the step of: removing the plug (briefly) before the further processing of the cable lug. In this way, the sensitive aluminum layer inside the cable lug remains protected as long as possible.
  • the manufacturing method further comprises the steps of: inserting an aluminum cable into the cable lug; Welding (eg ultrasonic welding) of the cable lug in the region of the tubular receptacle, so that the aluminum cable is connected to the aluminum layer in the rohrformigen receptacle.
  • Welding eg ultrasonic welding
  • the aluminum cable is connected to the aluminum layer in the rohrformigen receptacle.
  • a permanent electrical connection between the aluminum cable and the cable lug can be produced in this way.
  • the tubular receptacle can be connected to the stripped end of the aluminum cable under pressure and / or heat.
  • a metallic connection can take place 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 manufacturing method can therefore also be suitable for producing an electrical connection from an aluminum cable and a cable lug.
  • the manufacturing method further comprises the steps of: inserting an aluminum cable into the lug so that a stripped end of the aluminum cable is placed in a rear portion of the tubular receptacle and an insulated portion of the cable is placed in the front portion; and pressing the front portion so that the aluminum cable is held in the cable lug.
  • the front portion where, for example, the aluminum layer has been removed and / or expanded, may be mechanically connected to the aluminum cable by crimping.
  • a receiving area, a flared end portion or a front portion of the tubular receptacle of the cable lug with an insulated portion of the aluminum cable is pressed.
  • the weld or the sensitive transition region between the different metal regions can be sealed from the environment, for example to avoid electrical corrosion.
  • This can be done, for example, by pressing the cable lug area, which projects beyond the insulation.
  • the compression can be done in various ways, for example as a hexagon.
  • the compression can be performed twice in succession (at different locations) to create a double seal. A radial compression is possible.
  • an additional seal such as an O-ring or a silicone seal, may be interposed between the aluminum cable and the flared end portion of the cable lug over the aluminum cable. The compression can be done after inserting the additional seal.
  • an end region or a part of the tubular receptacle 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.
  • the transition region between the aluminum cable and the current-carrying element, which is formed by the cable lug, can be completely sealed, towards the aluminum cable by the compression of the insulation and / or the shrink tube and the connection area through a weld at the contact end and / or a sealant.
  • Another aspect of the invention relates to a cable lug for connecting a Aluminum cable with a live element.
  • the cable lug has been produced by the manufacturing method as described above and below.
  • 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 may include a tubular receptacle for the end of the aluminum cable (eg, uninsulated or stripped) that is lined with aluminum (on the inside).
  • the cable lug comprises a flat contact end of copper for connection to the current-carrying element and a tubular receptacle for receiving one end of the aluminum cable, wherein the rohrformige receptacle is at least partially lined with aluminum.
  • the cable lug is formed from a tube which, in a first section, has an aluminum layer on one inner side and a copper layer on an outer side, which are connected to one another and which only has the copper layer in a second section.
  • the cable shoe body or the cable lug is formed from a tube which has an aluminum layer on one inner side and a copper layer on an outer side which are connected to one another.
  • 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 in a front region has a larger inner diameter than in a rear region, which is lined with aluminum.
  • the front area (which may also be lined with aluminum or where the aluminum layer has been removed) may serve as a receptacle for an insulated part of an aluminum cable.
  • Another aspect of the invention relates to an electrical connection of an aluminum cable and a cable lug, wherein one end of the aluminum cable is received in the tubular receptacle and is metallically connected to the aluminum lined inside of the tubular receptacle.
  • 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.
  • a further aspect of the invention relates to a plastic plug, for example a silicone plug, for closing the receptacle of a cable lug, as well as it is described above and below.
  • a plastic plug for example a silicone plug
  • the aluminum layer can be protected inside the recording from external influences.
  • the plastic plug may be a tubular body terminated at one end.
  • the plastic plug comprises a (for example tubular) head portion with a closed end adapted to be inserted into the receptacle.
  • the head region may have the same diameter as an inner diameter of the cable lug in the tubular receptacle in which the aluminum layer is present.
  • the plastic plug comprises a grip region adjoining the head region (for example tubular), which protrudes from the tubular receptacle when the head region is pushed completely into the receptacle.
  • the grip portion may have a smaller wall thickness than the head portion.
  • the head portion and the grip portion may have the same outer diameter (but different inner diameter).
  • the plastic plug or the head region has at least one peripheral projection or a circumferential rib for sealing the receptacle. It is also possible that the plastic plug or the head region has a plurality of circumferential projections or ribs. The maximum diameter of the projection or the rib may correspond to the inner diameter of a front region of the tubular receptacle.
  • a cable lug with a cup made of CUPAL can be formed.
  • such a cable lug comprises a copper lug body having a contact end for connection to the current-carrying element and a receiving region for receiving one end of the aluminum cable.
  • a tubular opening made of copper is formed in the receiving area, wherein in the tubular opening a sleeve is accommodated which has on one 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 lug, which is adapted to connect an aluminum cable with an electrical conductor.
  • the cable lug can be sealed in the direction of the contact end.
  • the sleeve may be open in the direction of the contact end of the cable shoe body and / or a sealing compound may be accommodated between the sleeve and the contact end.
  • a closed cup an open cup, which is shaped, for example, like an end sleeve, or a tubular sleeve can thus also be used.
  • the sleeve may be 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 can also work in in the form of tubes which consist of an aluminum layer inside and outside of a copper layer or comprise these layers. Such pipes can be formed by extrusion.
  • Tubular sleeves can be made, for example, from such a CUPAL tube.
  • the sleeve may be cup-shaped and may be designed to tightly enclose the end of the aluminum cable or to seal that end from 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. For example, it is possible to produce a cup-shaped sleeve by deep-drawing a CUPAL sheet.
  • the cup may have a funnel-shaped lead-in area to protect single leads from the end of the aluminum cable from kinking upon insertion of the cable into the sleeve.
  • a cup-shaped sleeve 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 molded directly from a CUPAL tube.
  • the tubular receptacle for receiving the end of the aluminum cable can be made of CUPAL.
  • a cup-shaped sleeve for a cable lug may comprise a rohrformige wall and a lid or bottom, which closes the tubular wall in one direction.
  • An inner side of the sleeve may have an aluminum layer and an outer side of the sleeve may have a copper layer, which are connected to one another and in particular intermetallically.
  • Such sleeves can be made for example by deep drawing a CUPAL sheet.
  • Such a cup-shaped sleeve can be used as a receptacle for an end of an aluminum cable in a cable lug. This can be produced in a cost effective and simple manner together with a conventional copper lug body of a cable lug for connecting an aluminum cable to a current-carrying element.
  • a lug with a sleeve can be made by a method comprising the steps of: providing a sleeve of CUPAL having an aluminum layer on one side and a copper layer on an outside; 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.
  • Fig. 1A and 1B show a cable lug 10 from different directions, which is formed from a CUPAL tube, which provided in a first portion 12 a tubular receptacle 14 and was compressed in a second portion 16 to a contact end 18.
  • the contact end 18 has at the outer end of the cable lug 10 on a rounded edge 20 and in the middle of a bore 22 and a hole 22 through which, for example, a screw for fixing the cable lug 10 can be inserted.
  • FIG. 2A is a cross section through the cable lug 10 is shown.
  • the tubular receptacle 14 has a cylindrical outer surface 24 and can be divided into a front portion 26 and a rear portion 28 having different inner diameters. Only in the rear region 28, the cable lug 10 on its inner side an aluminum layer 30 which is surrounded by a copper layer 32, from which also the contact end 18 and the front region 26 are formed. In the rear region 28 of the cable lug 10 is still formed as the CUPAL tube from which it was formed. At the contact end 18 and in the front region 26, the aluminum layer 30 was removed.
  • the rohrformige receptacle 14 may be bevelled on the inside. Also, the transition region between the rear portion 28 and the front portion 26 may be chamfered.
  • Fig. 2B 11 shows a plan view of the cable lug 10, in which it is indicated by hatching, that the contact end 18 has been welded between the hole 22 and the tubular receptacle 14 in order to prevent ingress of liquid from the contact end 18 into the receptacle 14.
  • the contact end 18 has a weld 34 (such as a weld), which may extend substantially orthogonal to the receptacle 14.
  • the Fig. 3A shows a cross section through an assembly of the cable lug 10 and a Kunststoffpfropfen 36 which has been inserted into the receptacle 14.
  • the Fig. 3A shows this arrangement from above.
  • the plastic plug 36 which is molded of silicone, for example, is a substantially tubular body having a head portion 38 and a handle portion 40.
  • the head portion 38 is rounded and closed at its front end and has an outer diameter corresponding to the inner diameter of the rear portion 28.
  • the grip area 40 has a smaller wall thickness than the head area 38 and protrudes from the receptacle 14 out, so that the plastic plug 36 can be pulled out of the cable lug 10 again.
  • the plastic plug 36 On its outer circumference, the plastic plug 36 has projections 42 or ribs 42, which contact the inner wall of the front region 26 when the plastic plug 36 is inserted into the receptacle 14.
  • the ribs 42 surround the head portion 38 annularly and are designed to protect the rear portion 28 of the receptacle 14 from ingress of liquid.
  • the plug may be used to protect the aluminum layer 30 from outside influences, such as when the cable shoe 10 is further processed or when stored or transported.
  • the Fig. 4A shows a cross section through an electrical connection 50, which in the Fig. 4B is shown in plan view.
  • an aluminum cable 52 was inserted, so that a stripped part 54 in the rear region 28 and an insulated part 56 of the cable 52 in the front region 26 is arranged.
  • the stripped part 54 can be connected in the rear region 28 with the aluminum layer 32 by ultrasonic welding 58 in the rear region 54. This can be done exactly as it is in the Figs. 12A to 12C shown below.
  • the insulated part 56 of the cable 52 can be pressed into a hexagon in order to seal the electrical connection 50 also in this area, as is the case for example in FIGS Figs. 13A to 13C shown below.
  • an additional internal seal to the contact end 18 can be made via a sealing compound 184, as described below, for example.
  • a shrink tube 186 may be used for insulating the aluminum cable 52, as described below.
  • the Fig. 5 shows a cross section of another embodiment of a cable lug 10 ', which has been made in one piece from a CUPAL tube.
  • This tube is processed in an end region 16 (or a second section 16) such that on the inside the aluminum layer 30 is removed, for example by boring, milling or drilling.
  • the end portion 16 is then flattened to form the flat contact end 18 of the lug 10 '.
  • the opposite end portion 12 (or the first portion 12) is machined on the outside so that the copper layer 32 of the tube is removed, for example by twisting.
  • the end region 12 then forms a receiving region of the cable lug 10 ', which provides the tubular receptacle 14 for the aluminum cable 52.
  • the copper layer 32 in the end region 12 is removed so that no electro-corrosion between the copper layer 32 and the aluminum conductor or the stripped part 54 of the aluminum cable 52 may occur.
  • a permanent electrical connection can now be made by plugging one end of the aluminum cable 52 into the receptacle 14 and, for example, metallically bonding it to the inside of the receptacle 14 by ultrasonic welding.
  • An inner seal to the contact end 18 can, as described for example below, take place via a sealing compound 184.
  • a shrink tube 86 may be used to isolate the aluminum cable 52.
  • the Fig. 6 shows a flowchart for a method for producing a Cable lug 10, 10 'and an electrical connection 52nd
  • a CUPAL tube which has an aluminum layer 30 on an inner side and a copper layer 32 on an outer side.
  • a pipe can be drawn from CUPAL material, which is then cut into corresponding pipe sections.
  • the CUPAL tube is then machined so that in a first section 12 the aluminum layer 30 is maintained and in a second section 16 the CUPAL tube only has the copper layer 32.
  • the CUPAL tube in the second section 16 can be turned out.
  • step 72 the second portion 16 for forming the contact end 16 is compressed. Further, in this step, the hole 22 drilled and the weld 34 are generated.
  • step 74 the lug is milled out in the front region 26, so that the aluminum layer 30 and optionally a part of the copper layer 32 are removed. Alternatively or additionally, it is possible that, for example, as in the Fig. 5 shown, the copper layer 32 is removed in the front area.
  • step 76 the plastic plug 36 is inserted into the receptacle and the cable lug 10 can be galvanized. Also for transport or storage of plastic plug 36 may remain in the receptacle 14.
  • step 78 the plastic plug 36 is removed again, the aluminum cable 52 is inserted into the cable lug 10, 10 'and then the resulting electrical connection 50 is welded and crimped, as has already been described above, or as for example in the Figs. 12A to 12C and 13A to 13C is shown.
  • the Figs. 7A, 7B, 7C and 8th show a cup-shaped sleeve 110 in side view, front view, in cross-section and in two three-dimensional views.
  • the rotationally symmetrical sleeve 110 has an annular wall 112, a dome-shaped cover or bottom 114 and an outwardly flared edge 116.
  • the rim 116 may be angled at an angle of 45 °, for example, to form a funnel-shaped opening.
  • the sleeve 110 is deep-drawn from a CUPAL sheet, whereby the sleeve 110 consists of an aluminum layer 118 on the inside and a copper layer 120 on the outside.
  • the Fig. 9 shows a three-dimensional view of a cable shoe body 130, which has a tubular receiving portion 132 and a flat contact end 134 with a bore 136.
  • the one-piece lug body 130 is made of copper and may for example be formed from a copper tube, wherein the contact end 134 is formed by compression of the copper tube.
  • the receiving portion 132 of the lug body 130 includes a portion 138 for receiving the sleeve 110 and a flared end portion 140 for receiving an insulated portion of a cable. Also, the cable lug 10 from the Fig. 1A to 6 can be provided with such a widened end region.
  • the Fig. 10A shows a side view of elements of an electrical connection 150, which in the Fig. 11A are shown in a cross-sectional view.
  • the electrical connection comprises an aluminum cable 152 having a portion 156 insulated with a plastic jacket 154 and a stripped end 158.
  • the conductor 160 of the aluminum cable 152 (as well as the cable 52) may comprise a single wire of aluminum or a plurality of aluminum strands.
  • the sleeve 110 is inserted into the lug body 130.
  • the interior of the sleeve 110 then provides a tubular receptacle 164 for the aluminum cable 152 lined with aluminum 118 on the inside.
  • the cable shoe body 130 in section 138 has a tubular opening 166 in the receiving region 132, which is designed to receive the sleeve 110.
  • the inner diameter of the opening 166 or the portion 138 is just as large or only slightly larger than the outer diameter of the annular wall 112 of the sleeve 110th
  • the receiving portion 132 of the lug body has a stop edge 168 on which the edge 116 of the sleeve 110 is crashed.
  • the Fig. 10B shows a side view of a pre-assembled electrical connection 150, which in the Fig. 11B is shown in a cross-sectional view.
  • the sleeve 110 is inserted into the opening 166 of the lug body 130 as far as the stop and then the end 158 of the aluminum cable 152 is inserted into the receptacle 164.
  • the sleeve 110 can be pushed over the end 158 and then the sleeve can be inserted together with the aluminum cable 152 in the receiving portion 132 of the lug body 130 until it stops.
  • the conductor 160 at the end 158 of the aluminum cable 152 now contacts the aluminum layer 118 of the sleeve 110 or the receptacle 164 and the copper layer 120 on the outside of the sleeve 110 contacts the inside of the cable lug 130 or the opening 166 made of copper.
  • the Figs. 12A, 12B, 12C show an electrical connection from the Fig. 10B and 11B in side view, in plan view and in a three-dimensional view, after a permanent electrical contacting of the electrical conductors 160, 118, 120, 130th is done.
  • the middle section 138 of the receiving region 132 of the cable lug 162 is pressed together with the sleeve 110 by hot crimping and heated. This results in a metallic connection between the aluminum conductor 160 of the cable 152 and the aluminum layer 118 of the sleeve 110.
  • the crimping results in the section 138 two recesses 180th
  • the Figs. 13A, 13B, 13C show the electrical connection 150 from the Figs. 12A, 12B and 12C in side view, in plan view and in a three-dimensional view, after the receiving area 132 of the cable lug 162 and the lug body 130 has been sealed.
  • the end portion 140 of the lug body 130 is compressed so that no liquid can penetrate along the insulation 154 into the interior of the electrical connection 150.
  • the compression can take place in such a way that a polygonal depression (as here hexagonal) 182 is formed in the end region 140.
  • the Fig. 14 shows a further embodiment of an electrical connection 150 '.
  • the cable lug 162 'in this case comprises an alternative sleeve 110', which has only an annular wall 112 and a bevelled edge 116, but no lid or bottom.
  • the sleeve 110 ' is thus open in both directions.
  • a sealing compound 184 is used, which fills the space inside the cable shoe body 130 between the sleeve 110' and the end 158 of the aluminum cable 152 and the contact end 134.
  • the cable lug 130 also has a receiving region 132, which comprises only the portion 138, that is, has no flared end.
  • a shrink tube 186 is used which extends over an insulated section 56 of the aluminum cable 152 and at least part of the receiving region 132 of the cable lug body 130.
  • the electrical connections 52 and 152 can be sealed and stabilized with a shrink tube 186.

Landscapes

  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
EP13152198.1A 2012-01-25 2013-01-22 Cosse destinée à relier un élément conducteur à l'aide d'un câble en aluminium Withdrawn EP2621022A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
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 (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

Publications (1)

Publication Number Publication Date
EP2621022A1 true EP2621022A1 (fr) 2013-07-31

Family

ID=47552924

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 Before (1)

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

Country Status (1)

Country Link
EP (2) EP2621021A1 (fr)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102014112701A1 (de) 2014-09-03 2016-03-03 Harting Electric Gmbh & Co. Kg Crimpkontakt
US9356438B2 (en) 2014-02-27 2016-05-31 Delphi Technologies, Inc. Wire cable assembly having a terminal with an encapsulated wire end
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
US20210122313A1 (en) * 2019-10-25 2021-04-29 Nathan MARTIN Systems and methods for distribution of power in a marine vessel, atvs, and vehicles
US20210408701A1 (en) * 2018-11-07 2021-12-30 Auto-Kabel Management Gmbh Method for Producing a Connector Part for Electrical Installations, Connector Part, and Connection of a Connector Part to a Cable
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

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
MY175337A (en) * 2014-09-17 2020-06-19 Jf Microtechnology Sdn Bhd Short contact in a testing apparatus for wireless integrated circuits
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
EP3379652B1 (fr) * 2017-03-24 2021-04-28 Nexans Dispositif pour contacter un conducteur électrique et procédé à cet effet
CN108493735B (zh) * 2018-03-28 2019-08-27 江西杰洋科技有限公司 一种铝合金高压电缆铝铜复合接线端子制备方法

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2623725A1 (de) * 1976-05-26 1977-12-08 Metalloxyd Gmbh Elektrisch leitende verbindung sowie verfahren zu ihrer herstellung
DE19843886A1 (de) * 1998-09-24 2000-03-30 Grote & Hartmann Kabelschuh
DE10223397A1 (de) * 2003-10-04 2003-12-24 Edelhoff Adolf Feindrahtwerk Verfahren und Verbindung zur Kontaktierung eines Aluminiumkabels
DE102009054831A1 (de) * 2009-12-17 2011-06-22 Robert Bosch GmbH, 70469 Kontaktgehäuseanordnung mit Blindstopfen

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10236104A1 (de) * 2002-08-07 2004-02-19 Volkswagen Ag Verbindungsanordnung für eine elektrische Leiterverbindung mit einem Kabelschuh
DE102004034038A1 (de) * 2004-07-13 2006-02-09 Yazaki Europe Ltd., Hemel Hempstead Verbindung zwischen einem Kabelendstück und einem Kabelende
DE102007005810A1 (de) * 2007-01-17 2008-07-24 Gustav Klauke Gmbh Verfahren zur Herstellung eines Kabelschuhs und Kabelschuh

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2623725A1 (de) * 1976-05-26 1977-12-08 Metalloxyd Gmbh Elektrisch leitende verbindung sowie verfahren zu ihrer herstellung
DE19843886A1 (de) * 1998-09-24 2000-03-30 Grote & Hartmann Kabelschuh
DE10223397A1 (de) * 2003-10-04 2003-12-24 Edelhoff Adolf Feindrahtwerk Verfahren und Verbindung zur Kontaktierung eines Aluminiumkabels
DE102009054831A1 (de) * 2009-12-17 2011-06-22 Robert Bosch GmbH, 70469 Kontaktgehäuseanordnung mit Blindstopfen

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
"Cupal", 28 September 2011 (2011-09-28), XP055023898, Retrieved from the Internet <URL:http://de.wikipedia.org/wiki/Cupal> [retrieved on 20120404] *

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
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
WO2016034166A2 (fr) 2014-09-03 2016-03-10 Harting Electric Gmbh & Co. Kg Contact à sertir
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
US20210408701A1 (en) * 2018-11-07 2021-12-30 Auto-Kabel Management Gmbh Method for Producing a Connector Part for Electrical Installations, Connector Part, and Connection of a Connector Part to a Cable
US11916321B2 (en) * 2018-11-07 2024-02-27 Auto-Kabel Management Gmbh Method for producing a connector part for electrical installations, connector part, and connection of a connector part to a cable
US20210122313A1 (en) * 2019-10-25 2021-04-29 Nathan MARTIN Systems and methods for distribution of power in a marine vessel, atvs, and vehicles
US20220266782A1 (en) * 2019-10-25 2022-08-25 Sea Clear Power Inc. Systems and methods for distribution of power in a marine vessel, atvs, and vehicles
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
US11577675B2 (en) 2019-10-25 2023-02-14 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
WO2023083838A1 (fr) 2021-11-15 2023-05-19 Strunk Connect automated solutions GmbH & Co. KG Procédé de connexion d'une ligne électrique en aluminium à un tuyau en cuivre

Also Published As

Publication number Publication date
EP2621021A1 (fr) 2013-07-31

Similar Documents

Publication Publication Date Title
EP2621022A1 (fr) Cosse destinée à relier un élément conducteur à l&#39;aide d&#39;un câble en aluminium
EP3061153B1 (fr) Console de connexion électrique et son utilisation
EP2697866B1 (fr) Fabrication d&#39;un cable electrique et procede de connexion
DE112011104358B4 (de) Elektrodraht-Verbindungsaufbau für einen Steckeranschluss und Verfahren zum Herstellen desselben
EP3189561B1 (fr) Contact a sertir
DE102012100142B4 (de) Verfahren zur Herstellung eines Kabelstrangs
DE102018005264B4 (de) Draht mit Anschluss, Verbindervorrichtung und Herstellungsverfahren
DE102013201125B4 (de) Steckverbinder, Verwendung eines solchen Steckverbinders sowie Verfahren zur Herstellung einer elektrischen Verbindung in einem solchen Steckverbinder
EP3361573B1 (fr) Procédé de raccordement d&#39;un dispositif électrique à un câble de raccordement et dispositif électrique pourvue d&#39;un câble de raccordement
DE102010009284B4 (de) Leitungseinheit mit Dichtfunktion
EP2579390A1 (fr) Terminal en aluminium-cuivre et procédé de fabrication de celui-ci
EP2496874B1 (fr) Système de raccordement de conduites flexibles
DE102016102948A1 (de) Verfahren und Vorrichtung zur Abdichtung von Kontaktstellen an elektrischen Leitungsverbindungen
DE102010044241A1 (de) Verbindung und Verfahren zum Verbinden eines Aluminiumkabels mit Anschlussteilen
DE102011011409B4 (de) Anschlussteil und Verbindung für elektrische Anlagen
EP2950399B1 (fr) Etanchéification de l&#39;emplacement de liaison entre deux conducteurs
DE102012214158A1 (de) Kontaktelemente zur Kontaktierung von Flachleitern
WO2016096109A1 (fr) Contact à sertir et système de liaison muni d&#39;un contact à sertir
WO2011020549A1 (fr) Élément de contact
DE102018111853A1 (de) Verfahren zur Herstellung einer Verbindung zwischen einem elektrischen Anschlusselement für ein Kraftfahrzeugbordnetz und einem Kabel des Kraftfahrzeugbordnetzes
DE102012208207B4 (de) Masseleiter-Verbindungssystem
DE102011077886B4 (de) Verfahren zur Leitungskonfektionierung
DE102011017071A1 (de) Anschlussteil für elektrische Anlagen
EP2874234B1 (fr) Procédé d&#39;isolation étanche d&#39;un point de connexion entre un conducteur et un élément de contact
EP3379652B1 (fr) Dispositif pour contacter un conducteur électrique et procédé à cet effet

Legal Events

Date Code Title Description
PUAI Public reference made under article 153(3) epc to a published international application that has entered the european phase

Free format text: ORIGINAL CODE: 0009012

AK Designated contracting states

Kind code of ref document: A1

Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

AX Request for extension of the european patent

Extension state: BA ME

17P Request for examination filed

Effective date: 20140116

RBV Designated contracting states (corrected)

Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: THE APPLICATION IS DEEMED TO BE WITHDRAWN

18D Application deemed to be withdrawn

Effective date: 20160802