EP2672569B1 - Method for connecting electrical conductors and composite conductor - Google Patents

Method for connecting electrical conductors and composite conductor Download PDF

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Publication number
EP2672569B1
EP2672569B1 EP13170837.2A EP13170837A EP2672569B1 EP 2672569 B1 EP2672569 B1 EP 2672569B1 EP 13170837 A EP13170837 A EP 13170837A EP 2672569 B1 EP2672569 B1 EP 2672569B1
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EP
European Patent Office
Prior art keywords
conductor
sleeve
welding
conductors
contact
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EP13170837.2A
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German (de)
French (fr)
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EP2672569A1 (en
Inventor
Dominik Dendorfer
Lutz Lehmann
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Lisa Draexlmaier GmbH
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Lisa Draexlmaier GmbH
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Publication of EP2672569A1 publication Critical patent/EP2672569A1/en
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—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
    • H01R4/187—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping combined with soldering or welding
    • 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
    • H01R4/625—Soldered or 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
    • 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
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0207—Ultrasonic-, H.F.-, cold- or impact welding

Definitions

  • the present invention relates to a method for connecting a first conductor to a second conductor, wherein these conductors are designed as stranded conductors and each having a plurality of individual wires. Furthermore, the invention relates to a conductor composite having a first and a second conductor, each having a plurality of individual wires.
  • a process-reliable and reproducible connection of electrical conductors of different materials can be achieved in the prior art only in exceptional cases and with concessions either to the quality of process reliability and reproducibility or the production cost.
  • connection of copper conductors with aluminum conductors Due to different material properties of the two conductor materials, these are very difficult to weld together. For example, in the ultrasonic welding of aluminum and copper, which is commonly used for the connection of multiple copper conductors, problems arise. Different hardnesses, expansion coefficients and thermal conductivities of the two materials make welding by means of ultrasonic welding more difficult.
  • the object of the invention is to provide a method for connecting two conductors of a plurality of strands, which is also suitable for the connection of conductors of different materials. Furthermore, it is an object of the present invention to provide a conductor assembly, which enables a secure, that is electrically and mechanically reliable, connection between conductors of different materials.
  • the inventive method of the above technical field comprises a sheath of the first conductor with a metallic sleeve, whereby an electrically conductive and mechanically fixed contact between the first conductor and the sleeve is produced.
  • a metallic sleeve with a plurality of stranded wires of the first conductor brought into contact by the sleeve, for example, circumferentially surrounds one end of the first conductor and thereby contacted so that a firm connection between the first conductor and the sleeve can be produced.
  • the sleeve is contacted with the second conductor on the outside.
  • the second conductor is deliberately not brought into the interior of the sleeve, but contacted only the outside, in particular a peripheral side of the sleeve.
  • the sleeve covering the first conductor protects and supports the first conductor in this area.
  • this sleeve need not be closed, but may for example also be formed by a stamped sheet metal or a similar element which at least partially surrounds the first conductor.
  • the sheathing of the first conductor therefore does not necessarily mean a complete sheathing. Also, a partial sheathing of the first conductor, for example over part of its peripheral surface, is sufficient to achieve the advantages of the invention.
  • the sleeve of the first conductor is protected from it, for example, due to a particularly high temperature during welding of the second conductor to the sleeve, damaged by the welding of the second conductor, for example, to be deformed uncontrollably.
  • the sleeve offers so far a support for the first conductor and ensures that this does not deform during the welding of the second conductor.
  • the process is carried out in the order presented above. That is, first the first conductor is sheathed with the sleeve, then the outside of the sleeve is contacted, and then the second conductor is welded to the sleeve. In principle, it is also possible that this order is changed. However, the preferred order makes it easier and more efficient to connect the two conductors together.
  • the sleeve is crimped with the first conductor.
  • the sheathing of the first conductor for producing an electrically conductive and mechanically fixed contact is realized in this preferred embodiment by compressing or flanging the sleeve around the first conductor.
  • compacting of the stranded wires of the first conductor is made possible, which can positively influence the line properties at the connection point between the two conductors.
  • a shape optimized for external contact and welding of the sleeve to the second conductor is preferably produced.
  • the sleeve is welded to the first conductor.
  • care must be taken that the energy input for the welded connection between the first conductor and the sleeve is matched to the materials involved.
  • ultrasonic welding is provided as the welding method. This allows a cohesive connection between the sleeve and the first conductor and a compression of the sleeve realize in approximately one step.
  • an aid in particular a welding aid, is introduced into the sleeve.
  • a tool can, for example, an additive for melting the stranded wires, a sealant such.
  • a sealant such as an adhesive, a protective gas and / or a means for easier breaking up of the oxide layer of, for example, aluminum wires.
  • Such an oxide layer breaking means could include abrasive particles in a nanostructure.
  • the aid could be supplied together with the first conductor or separately.
  • the sleeve could also be provided with a coating.
  • the sleeve for contacting with the second conductor is formed so as to form a flat, planar contact surface.
  • the sleeve may preferably be formed accordingly during the sheathing of the first conductor or thereafter to facilitate the contacting of the sleeve from the outside through the second conductor.
  • a flat and level contact surface in this Meaning may only have a very weak, ideally no curvature.
  • a minimum radius of curvature can be chosen as the limit value for considering a contact surface as flat, in particular a radius which is at least ten times the radius of the first conductor in its uncompressed, substantially circular cylindrical state.
  • Such a shaped contact surface offers the advantage of facilitating external contacting and welding of the second conductor to the sleeve, in particular using conventional welding equipment.
  • a flat contact surface facilitates the design of the sleeve with respect to the conductors to be connected, because in this way an easily identifiable and realizable number of individual stranded wires comes into contact with the sleeve.
  • a specially shaped pressing tool may be provided.
  • one or more predetermined bending points can be provided on the sleeve. These can be produced by partial stiffening, compression and / or material weakening and coatings.
  • the second conductor is welded by ultrasonic welding to the sleeve.
  • the ultrasonic welding process has proved to be efficient and versatile, especially in connection with the welding of copper conductors.
  • the method can basically also be used for welding the first conductor to the sleeve, but in particular for welding the second conductor to the sleeve.
  • the method is used to connect a first conductor with multiple aluminum stranded wires and a second conductor with multiple copper stranded wires.
  • a sleeve made of copper used is particularly preferred here.
  • an aluminum strand, a copper strand or a copper sleeve should be understood to mean an element that consists predominantly of the respective material. It is also intended to encompass alloys which preferably contain a majority of the corresponding materials, but which also contain further alloying elements or impurities which can not be avoided.
  • the method according to the invention can also be applied to the joining of conductors of other materials, wherein it demonstrates its particular advantageous effects when joining materials which otherwise can only be connected to one another in a materially bonded manner, in particular by welding, with great effort.
  • the sleeve can already be provided with a surface treatment.
  • This surface treatment can be provided, for example, with grooves.
  • a coating could be at least partially applied to the sleeve, for example to allow easier contacting of the second line.
  • a conductor assembly according to the invention of the above technical field comprises a first and a second conductor, each having a plurality of stranded wires, wherein the first conductor is encased by a sleeve, whereby an electrically conductive and mechanically fixed contact between the sleeve and the conductor is made.
  • the second conductor is welded to the outside of the sleeve.
  • the conductor composite can be designed as a passage connector.
  • the ladder assembly according to the invention forms an end connector such that the first and second wires terminate in the sleeve but extend in substantially the same direction.
  • a first conductor 10 and a sleeve 12 can be seen.
  • the first conductor 10 is an aluminum conductor with a plurality of individual wires, which has already been freed of its insulation in the region of the desired connection to a second conductor.
  • the sleeve 12 is a thin copper sleeve whose diameter is dimensioned so that it can be easily pushed over the first conductor 10.
  • Fig. 1b shows the sleeve 12 pressed as a casing with the first conductor 10, wherein in the illustrated embodiment both a pure pressing of the sleeve 12 with the first conductor 10 and a pressing in conjunction with additional steps, for example a welding of the first conductor 10 with the sleeve 12, is possible.
  • the sleeve 12 around the first conductor 10 is a protection for the first conductor 10, which supports the material of the first conductor 10 and protects against a connected to another welding step liquefying or even leakage from the sleeve 12.
  • Fig. 1b also shows a second conductor 14, which consists of four strands of wire, each with a plurality of stranded wires.
  • the second conductor 14 is the totality of four copper cables with several, in this application also referred to as stranded wires individual wires.
  • This second conductor 14 is now connected to the first conductor 10 process reliable and reproducible. This means that a reproducible on an industrial level connection between the two conductors is to be produced, which is both mechanically strong and good electrical conductivity.
  • Fig. 1c shows the product of the preferred method according to the present invention, after the sleeve 12 has been externally contacted with the second conductor 14 and the second conductor 14 has subsequently been welded to the sleeve 12.
  • the second conductor contacts the sleeve 12 peripherally and is welded thereto.
  • a direct, direct contact between the first conductor 10 and the second conductor 14 does not exist, but the conductors 10, 14 are indirectly through the sleeve 12 interconnected electrically conductive and mechanically fixed.
  • Fig. 2 shows a cross section of a ladder composite 16, as in Fig. 1c also shown from the outside. It can be clearly seen that the first aluminum conductor 10 is encased by the sleeve 12 and an electrically conductive and mechanically fixed contact between these two elements is made.
  • the existing copper sleeve 12 has been pressed into an anvil shape, in which a flat, planar contact surface 18 for contacting the outside of the sleeve 12 is formed by the second, made of copper conductor 14.
  • the stranded wires of the first conductor 10 were deformed, for example, in connection with the sheathing and contacting the aluminum conductor 10 through the copper sleeve 12 or during the welding of the copper sleeve 12 with the copper conductor 14, for example, melted or pressurized, so that the individual strand cross sections no longer , as originally, circular, but, for example, hexagonal shaped.
  • On the contact surface 18 is located on the outside of the copper sleeve 12 of the copper conductor 14 and is welded to the copper sleeve 12 to form an electrically conductive and mechanically strong contact between the sleeve 12 and the second conductor 14.
  • the first conductor 10 is an aluminum conductor of 27 mm 2 in cross-section.
  • the second conductor consists of four individual copper conductors of a cross section of 6 mm 2 , a total of 24 mm 2 , so that overall a broad agreement of the cable cross-sections between the first conductor 10 and the second conductor 14 is realized.
  • a sleeve ensures that the first conductor, despite deviating from the second conductor material properties can remain in a position defined by the sleeve, while the second conductor 14 is welded to the sleeve 12.
  • a larger process window is generally made possible, that is, a higher tolerance for deviating manufacturing parameters while ensuring the quality of the manufactured product.
  • conventional ultrasonic welding techniques can be used stably and reliably, whereby standardized tool profiles can be used, for example, to effectively weld together conductors of aluminum and copper.
  • the method according to the invention also makes it possible to automate the connection of two conductors without having to make concessions with regard to the quality of the connection thus created.
  • connection of the conductor could also be more complicated because of complicated holding devices for the first conductor and the sleeve or the flanging, as in the use of a cylinder jacket-shaped sleeve.

Description

TECHNISCHES GEBIETTECHNICAL AREA

Die vorliegende Erfindung betrifft ein Verfahren zum Verbinden eines ersten Leiters mit einem zweiten Leiter, wobei diese Leiter als Litzenleiter ausgeführt sind und jeweils mehrere Einzeldrähte aufweisen. Ferner betrifft die Erfindung einen Leiterverbund mit einem ersten und einem zweiten Leiter, die jeweils mehrere Einzeldrähte aufweisen.The present invention relates to a method for connecting a first conductor to a second conductor, wherein these conductors are designed as stranded conductors and each having a plurality of individual wires. Furthermore, the invention relates to a conductor composite having a first and a second conductor, each having a plurality of individual wires.

STAND DER TECHNIKSTATE OF THE ART

Eine prozesssichere und reproduzierbare Verbindung von elektrischen Leitern verschiedener Materialien ist im Stand der Technik nur in Ausnahmefällen und mit Zugeständnissen entweder an die Qualität der Prozesssicherheit und Reproduzierbarkeit oder den Herstellungsaufwand zu erreichen.A process-reliable and reproducible connection of electrical conductors of different materials can be achieved in the prior art only in exceptional cases and with concessions either to the quality of process reliability and reproducibility or the production cost.

Ein wichtiges Beispiel ist die Verbindung von Kupferleitern mit Aluminiumleitern. Aufgrund unterschiedlicher Materialeigenschaften der beiden Leitermaterialien können diese nur sehr schwer miteinander verschweißt werden. Beispielsweise beim Ultraschallschweißen von Aluminium und Kupfer, das für die Verbindung mehrerer Kupferleiter üblicherweise eingesetzt wird, entstehen Probleme. Unterschiedliche Härten, Dehnungskoeffizienten und Wärmeleitfähigkeiten der beiden Materialien erschweren das Verschweißen mittels Ultraschallschweißen.An important example is the connection of copper conductors with aluminum conductors. Due to different material properties of the two conductor materials, these are very difficult to weld together. For example, in the ultrasonic welding of aluminum and copper, which is commonly used for the connection of multiple copper conductors, problems arise. Different hardnesses, expansion coefficients and thermal conductivities of the two materials make welding by means of ultrasonic welding more difficult.

Ein Beispiel der erfahrenen Probleme beim Verbinden von Kupfer und Aluminium ist, dass für das Schweißen eines Kupferleiters eines bestimmten Querschnitts deutlich mehr Energie in den Leiter eingebracht werden muss, als für das Schweißen eines vergleichbar großen Aluminiumleiters. Dies führt beim Wunsch, diese unterschiedlichen Leiter miteinander zu verschweißen, dazu, dass entweder der Kupferleiter nicht ausreichend aufgeweicht oder der Aluminiumleiter viel zu stark verflüssigt wird. So ist es praktisch unmöglich, eine effiziente und gleichzeitig prozesssichere Verschweißung von Leitern aus unterschiedlichen Materialien, wie beispielsweise Kupfer und Aluminium, durchzuführen.An example of the experienced problems in joining copper and aluminum is that significantly more energy must be introduced into the conductor for welding a copper conductor of a particular cross section than for welding a comparably sized aluminum conductor. This leads to the desire, these different leaders together to weld, either that the copper conductor is insufficient softened or the aluminum conductor is too much liquefied. Thus, it is virtually impossible to perform an efficient and process-reliable welding of conductors made of different materials, such as copper and aluminum.

Aus dem Dokument WO 2011/198 506 A2 geht grundsätzlich das Ultraschallschweißen und sein Einsatz zur Verbindung mehrerer Litzenleiter hervor. Die EP 2 192 601 A1 offenbart grundsätzlich die Verwendung einer Hülse bei der Bündelung und dem Verschweißen mehrerer Litzenleiter miteinander. US-6 6 538 203 B1 wird als nächstliegender Stand der Technik angesehen und offenbart auch eine Vorrichtung zum Verbinden von Aluminiumkabeln, die aus mehreren Einzeldrähten bestehen. Es werden in diesen Dokumenten jedoch immer nur Litzen gleicher Materialien miteinander verschweißt.From the document WO 2011/198 506 A2 In principle, ultrasonic welding and its use for connecting several stranded conductors is apparent. The EP 2 192 601 A1 basically discloses the use of a sleeve in bundling and welding multiple stranded conductors together. US 6 6 538 203 B1 is considered to be the closest prior art and also discloses a device for connecting aluminum cables consisting of a plurality of individual wires. However, in these documents, only strands of the same materials are always welded together.

DARSTELLUNG DER ERFINDUNGPRESENTATION OF THE INVENTION

Vor dem Hintergrund der Problem des Stands des Technik liegt die Aufgabe der Erfindung darin, ein Verfahren zum Verbinden zweier Leiter aus mehreren Litzen bereitzustellen, das auch für die Verbindung von Leitern unterschiedlicher Materialien geeignet ist. Des Weiteren ist es Aufgabe der vorliegenden Erfindung, einen Leiterverbund bereitzustellen, der eine sichere, das heißt elektrisch und mechanisch zuverlässige, Verbindung zwischen Leitern verschiedener Materialien ermöglicht.Against the background of the problem of the prior art, the object of the invention is to provide a method for connecting two conductors of a plurality of strands, which is also suitable for the connection of conductors of different materials. Furthermore, it is an object of the present invention to provide a conductor assembly, which enables a secure, that is electrically and mechanically reliable, connection between conductors of different materials.

Diese Aufgabe wird durch das Verfahren gemäß Anspruch 1 und den Leiterverbund gemäß Anspruch 6 gelöst. Vorteilhafte Ausführungsformen der Erfindung ergeben sich aus den jeweiligen Unteransprüchen.This object is achieved by the method according to claim 1 and the ladder assembly according to claim 6. Advantageous embodiments of the invention will become apparent from the respective dependent claims.

Das erfindungsgemäße Verfahren des obigen technischen Gebiets umfasst ein Ummanteln des ersten Leiters mit einer metallischen Hülse, wodurch ein elektrisch leitender und mechanisch fixierter Kontakt zwischen dem ersten Leiter und der Hülse hergestellt wird. Mit anderen Worten wird eine metallische Hülse mit einer Vielzahl von Litzendrähten des ersten Leiters in Kontakt gebracht, indem die Hülse beispielsweise ein Ende des ersten Leiters umfangseitig umgibt und diesen dabei so kontaktiert, dass eine feste Verbindung zwischen dem ersten Leiter und der Hülse erzeugt werden kann.The inventive method of the above technical field comprises a sheath of the first conductor with a metallic sleeve, whereby an electrically conductive and mechanically fixed contact between the first conductor and the sleeve is produced. In other words, one becomes metallic sleeve with a plurality of stranded wires of the first conductor brought into contact by the sleeve, for example, circumferentially surrounds one end of the first conductor and thereby contacted so that a firm connection between the first conductor and the sleeve can be produced.

Ferner wird die Hülse mit dem zweiten Leiter außenseitig kontaktiert. Dies bedeutet, dass die Hülse innenseitig von dem ersten Leiter und außenseitig von dem zweiten Leiter berührt wird und somit elektrischen Strom zwischen dem ersten und zweiten Leiter leiten kann. Der zweite Leiter wird dabei bewusst nicht ebenfalls in das Innere der Hülse hineingebracht, sondern kontaktiert nur die Außenseite, insbesondere eine Umfangseite der Hülse. Durch ein Verschweißen des zweiten Leiters mit der Hülse wird eine mechanisch und elektrisch zuverlässige Verbindung zwischen der Hülse und dem zweiten Leiter und damit indirekt zwischen dem ersten Leiter und dem zweiten Leiter hergestellt.Furthermore, the sleeve is contacted with the second conductor on the outside. This means that the sleeve is touched on the inside of the first conductor and on the outside of the second conductor and thus can conduct electrical current between the first and second conductors. The second conductor is deliberately not brought into the interior of the sleeve, but contacted only the outside, in particular a peripheral side of the sleeve. By welding the second conductor to the sleeve, a mechanically and electrically reliable connection between the sleeve and the second conductor and thus indirectly between the first conductor and the second conductor is produced.

Durch die den ersten Leiter ummantelnde Hülse wird der erste Leiter in diesem Bereich geschützt und gestützt. Grundsätzlich muss diese Hülse jedoch nicht geschlossen sein, sondern kann beispielsweise auch durch ein Stanzblech oder ein ähnliches Element gebildet sein, das den ersten Leiter zumindest teilweise umgibt. Das Ummanteln des ersten Leiters bedeutet deshalb nicht notwendigerweise ein vollständiges Ummanteln. Auch ein teilweises Ummanteln des ersten Leiters, beispielsweise über einen Teil seiner Umfangsfläche, genügt zur Erzielung der erfindungsgemäßen Vorteile.The sleeve covering the first conductor protects and supports the first conductor in this area. In principle, however, this sleeve need not be closed, but may for example also be formed by a stamped sheet metal or a similar element which at least partially surrounds the first conductor. The sheathing of the first conductor therefore does not necessarily mean a complete sheathing. Also, a partial sheathing of the first conductor, for example over part of its peripheral surface, is sufficient to achieve the advantages of the invention.

Durch die Hülse wird der erste Leiter davor geschützt, beispielsweise aufgrund einer besonders hohen Temperatur beim Schweißen des zweiten Leiters an die Hülse, durch das Anschweißen des zweiten Leiters geschädigt, beispielsweise unkontrolliert verformt zu werden. Die Hülse bietet insofern eine Stütze für den ersten Leiter und stellt sicher, dass sich dieser während des Anschweißens des zweiten Leiters nicht verformt. Dadurch sind unterschiedliche Materialeigenschaften, die insbesondere beim direkten Verschweißen eines Aluminiumleiters mit einem Kupferleiter bisher Probleme bereitet haben, beispielsweise unterschiedliche Schmelzpunkte oder Festigkeiten der Materialien bei einer gemeinsamen Temperatur, durch das Ummanteln des ersten Leiters und das außenseitige Kontaktieren und Verschweißen der Hülse mit dem zweiten Leiter weitgehend unproblematisch, ohne das Schweißverfahren an sich, beispielsweise Ultraschallschweißen, verändern oder aufgeben zu müssen.By the sleeve of the first conductor is protected from it, for example, due to a particularly high temperature during welding of the second conductor to the sleeve, damaged by the welding of the second conductor, for example, to be deformed uncontrollably. The sleeve offers so far a support for the first conductor and ensures that this does not deform during the welding of the second conductor. As a result, different material properties, which have so far caused problems especially in the direct welding of an aluminum conductor with a copper conductor, for example, different melting points or strengths of the materials at a common temperature, by the sheathing of the first conductor and the outside contacting and welding the sleeve to the second conductor largely unproblematic, without the welding process itself, for example, ultrasonic welding, change or give up.

Bevorzugt wird das Verfahren in der oben dargestellten Reihenfolge ausgeführt. Das heißt, zuerst wird der erste Leiter mit der Hülse ummantelt, dann die Hülse außenseitig kontaktiert und dann der zweite Leiter mit der Hülse verschweißt. Grundsätzlich ist es auch möglich, dass diese Reihenfolge geändert wird. Die bevorzugte Reihenfolge ermöglicht jedoch ein leichteres und effizienteres Verbinden der beiden Leiter miteinander.Preferably, the process is carried out in the order presented above. That is, first the first conductor is sheathed with the sleeve, then the outside of the sleeve is contacted, and then the second conductor is welded to the sleeve. In principle, it is also possible that this order is changed. However, the preferred order makes it easier and more efficient to connect the two conductors together.

In einer bevorzugten Ausführungsform wird die Hülse mit dem ersten Leiter verpresst. Das Ummanteln des ersten Leiters zur Herstellung eines elektrisch leitenden und mechanisch fixierten Kontakts wird in dieser bevorzugten Ausführungsform durch ein Zusammenpressen oder Bördeln der Hülse um den ersten Leiter realisiert. Dabei wird gleichzeitig eine Kompaktierung der Litzendrähte des ersten Leiters ermöglicht, was die Leitungseigenschaften an der Verbindungsstelle zwischen den beiden Leitern positiv beeinflussen kann. Durch das Verpressen ist es außerdem besonders leicht möglich, die Hülse und damit auch den entsprechenden Teil des ersten Leiters, in eine gewünschte Form zu bringen. Bevorzugt wird also durch das Verpressen der Hülse mit dem ersten Leiter auch eine für das außenseitige Kontaktieren und Verschweißen der Hülse mit dem zweiten Leiter optimierte Form erzeugt.In a preferred embodiment, the sleeve is crimped with the first conductor. The sheathing of the first conductor for producing an electrically conductive and mechanically fixed contact is realized in this preferred embodiment by compressing or flanging the sleeve around the first conductor. At the same time, compacting of the stranded wires of the first conductor is made possible, which can positively influence the line properties at the connection point between the two conductors. By pressing it is also particularly easy to bring the sleeve and thus the corresponding part of the first conductor in a desired shape. Thus, by compressing the sleeve with the first conductor, a shape optimized for external contact and welding of the sleeve to the second conductor is preferably produced.

In einer weiteren bevorzugten Ausführungsform wird die Hülse mit dem ersten Leiter verschweißt. Je nach Material des ersten Leiters muss dabei darauf geachtet werden, dass der Energieeintrag für die Schweißverbindung zwischen dem ersten Leiter und der Hülse auf die hierbei beteiligten Materialien abgestimmt ist. Es ist auch möglich, die Hülse mit dem ersten Leiter zu verpressen und zusätzlich, insbesondere anschließend, zu verschweißen. Das Verschweißen kann beispielsweise aufgrund weiter verbesserter Leitungseigenschaften zwischen dem ersten Leiter und der Hülse in Betracht gezogen werden. Vorzugsweise ist als Schweißverfahren Ultraschallschweißen vorgesehen. Hiermit lässt sich eine Stoffschlüssige Verbindung zwischen der Hülse und dem ersten Leiter sowie eine Verpressung der Hülse in annähernd einem Arbeitsschritt realisieren.In a further preferred embodiment, the sleeve is welded to the first conductor. Depending on the material of the first conductor, care must be taken that the energy input for the welded connection between the first conductor and the sleeve is matched to the materials involved. It is also possible to press the sleeve with the first conductor and additionally, in particular subsequently, to be welded. Welding may be considered, for example, due to further improved conduction properties between the first conductor and the sleeve. Preferably, ultrasonic welding is provided as the welding method. This allows a cohesive connection between the sleeve and the first conductor and a compression of the sleeve realize in approximately one step.

Erfindungsgemäß kann vorgesehen sein, dass in die Hülse ein Hilfsmittel, insbesondere ein Schweißhilfsmittel, eingebracht wird. Ein derartiges Hilfsmittel kann beispielsweise einen Zusatzstoff zum Aufschmelzen der Litzendrähte, ein Dichtmittel, wie z. B. ein Klebstoff, ein Schutzgas und/oder ein Mittel zum leichteren Aufbrechen der Oxidschicht von bspw. Aluminiumdrähten umfassen. Ein solches Mittel zum Aufbrechen der Oxidschicht könnte Schleißpartikel in einer Nanostruktur umfassen. Das Hilfsmittel könnte zusammen mit dem ersten Leiter oder separat zugeführt werden. Alternativ oder zusätzlich könnte die Hülse auch mit einer Beschichtung versehen sein.According to the invention it can be provided that an aid, in particular a welding aid, is introduced into the sleeve. Such a tool can, for example, an additive for melting the stranded wires, a sealant such. Example, an adhesive, a protective gas and / or a means for easier breaking up of the oxide layer of, for example, aluminum wires. Such an oxide layer breaking means could include abrasive particles in a nanostructure. The aid could be supplied together with the first conductor or separately. Alternatively or additionally, the sleeve could also be provided with a coating.

In einer bevorzugten Ausführungsform wird die Hülse für das Kontaktieren mit dem zweiten Leiter derart geformt, dass sie eine flache, ebene Kontaktfläche ausbildet. Die Hülse kann dabei bevorzugt während des Ummantelns des ersten Leiters oder danach entsprechend ausgeformt werden, um das Kontaktieren der Hülse von außen durch den zweiten Leiter zu erleichtern. Eine flache und ebene Kontaktfläche in diesem Sinn darf nur eine sehr schwach ausgebildete, idealerweise gar keine Krümmung aufweisen. Als Grenzwert für die Betrachtung einer Kontaktfläche als eben kann ein minimaler Krümmungsradius gewählt werden, insbesondere ein Radius, der zumindest das Zehnfache eines Radius des ersten Leiters in dessen unkomprimiertem, im Wesentlichen kreiszylindrischem Zustand ist. Eine derart geformte Kontaktfläche bietet den Vorteil einer erleichterten außenseitigen Kontaktierung und Verschweißung des zweiten Leiters mit der Hülse, insbesondere unter Verwendung herkömmlicher Schweißgeräte. Außerdem erleichtert eine ebene Kontaktfläche die Auslegung der Hülse in Bezug auf die zu verbindenden Leiter, weil auf diese Weise eine leicht zu bestimmende und zu realisierende Anzahl an einzelnen Litzendrähten in Kontakt mit der Hülse gelangt.In a preferred embodiment, the sleeve for contacting with the second conductor is formed so as to form a flat, planar contact surface. The sleeve may preferably be formed accordingly during the sheathing of the first conductor or thereafter to facilitate the contacting of the sleeve from the outside through the second conductor. A flat and level contact surface in this Meaning may only have a very weak, ideally no curvature. A minimum radius of curvature can be chosen as the limit value for considering a contact surface as flat, in particular a radius which is at least ten times the radius of the first conductor in its uncompressed, substantially circular cylindrical state. Such a shaped contact surface offers the advantage of facilitating external contacting and welding of the second conductor to the sleeve, in particular using conventional welding equipment. In addition, a flat contact surface facilitates the design of the sleeve with respect to the conductors to be connected, because in this way an easily identifiable and realizable number of individual stranded wires comes into contact with the sleeve.

Um die Hülse in eine flache Form zu formen, kann ein besonders geformtes Presswerkzeug vorgesehen sein. Alternativ oder zusätzlich kann an der Hülse eine oder können mehrere Sollknickstellen vorgesehen sein. Diese können durch partielle Versteifungen, Verpressungen und/oder Materialschwächungen sowie Beschichtungen hergestellt werden.To form the sleeve in a flat shape, a specially shaped pressing tool may be provided. Alternatively or additionally, one or more predetermined bending points can be provided on the sleeve. These can be produced by partial stiffening, compression and / or material weakening and coatings.

Mit Vorteil wird der zweite Leiter durch Ultraschallschweißen mit der Hülse verschweißt. Das Ultraschallschweißverfahren hat sich insbesondere im Zusammenhang mit dem Verschweißen von Kupferleitern als effizient und vielseitig bewährt. Das Verfahren lässt sich grundsätzlich auch für das Verschweißen des ersten Leiters mit der Hülse einsetzen, insbesondere jedoch für das Verschweißen des zweiten Leiters mit der Hülse.Advantageously, the second conductor is welded by ultrasonic welding to the sleeve. The ultrasonic welding process has proved to be efficient and versatile, especially in connection with the welding of copper conductors. The method can basically also be used for welding the first conductor to the sleeve, but in particular for welding the second conductor to the sleeve.

In einer bevorzugten Ausführungsform wird das Verfahren für die Verbindung eines ersten Leiters mit mehreren Aluminiumlitzendrähten und eines zweiten Leiters mit mehreren Kupferlitzendrähten verwendet. Besonders bevorzugt kommt hierbei eine Hülse aus Kupfer zum Einsatz.In a preferred embodiment, the method is used to connect a first conductor with multiple aluminum stranded wires and a second conductor with multiple copper stranded wires. Particularly preferred here is a sleeve made of copper used.

In diesem Zusammenhang soll unter einer Aluminiumlitze, einer Kupferlitze oder einer Kupferhülse ein Element verstanden werden, dass mehrheitlich aus dem jeweiligen Material besteht. Es sollen hiervon auch Legierungen umfasst sein, die die entsprechenden Materialien vorzugsweise mehrheitlich beinhalten, jedoch auch noch weitere Legierungselemente oder nicht zu vermeidende Verunreinigungen aufweisen. Grundsätzlich lässt sich das erfindungsgemäße Verfahren auch auf das Verbinden von Leitern anderer Materialien anwenden, wobei es seine besonderen vorteilhaften Effekte beim Verbinden von Materialien demonstriert, die ansonsten nur mit großem Aufwand direkt miteinander stoffschlüssig verbunden, insbesondere verschweißt, werden können.In this context, an aluminum strand, a copper strand or a copper sleeve should be understood to mean an element that consists predominantly of the respective material. It is also intended to encompass alloys which preferably contain a majority of the corresponding materials, but which also contain further alloying elements or impurities which can not be avoided. In principle, the method according to the invention can also be applied to the joining of conductors of other materials, wherein it demonstrates its particular advantageous effects when joining materials which otherwise can only be connected to one another in a materially bonded manner, in particular by welding, with great effort.

Wie oben bereits angedeutet, kann die Hülse bereits mit einer Oberflächenbehandlung versehen sein. Diese Oberflächenbehandlung kann beispielsweise mit Riefen bereitgestellt werden. Darüber hinaus könnte, wie bereits angedeutet, eine Beschichtung zumindest partiell auf die Hülse aufgebracht werden, um bspw. eine leichtere Kontaktierung der zweiten Leitung zu ermöglichen.As already indicated above, the sleeve can already be provided with a surface treatment. This surface treatment can be provided, for example, with grooves. In addition, as already indicated, a coating could be at least partially applied to the sleeve, for example to allow easier contacting of the second line.

Ein erfindungsgemäßer Leiterverbund des obigen technischen Gebiets umfasst einen ersten und einen zweiten Leiter, die jeweils mehrere Litzendrähte aufweisen, wobei der erste Leiter von einer Hülse ummantelt ist, wodurch ein elektrisch leitender und mechanisch fixierter Kontakt zwischen der Hülse und dem Leiter hergestellt ist. Der zweite Leiter ist dabei außenseitig mit der Hülse verschweißt.A conductor assembly according to the invention of the above technical field comprises a first and a second conductor, each having a plurality of stranded wires, wherein the first conductor is encased by a sleeve, whereby an electrically conductive and mechanically fixed contact between the sleeve and the conductor is made. The second conductor is welded to the outside of the sleeve.

Der Leiterverbund kann als Durchgangsverbinder ausgeführt sein. Es ist jedoch auch möglich, dass der Leiterverbund gemäß der Erfindung einen Endverbinder bildet, so dass die erste und zweite Leitung in bzw. an der Hülse endet, sich jedoch im Wesentlichen in gleicher Richtung weg erstrecken. Die oben im Zusammenhang mit dem erfindungsgemäßen Verfahren beschriebenen Vorteile ergeben sich auch für den erfindungsgemäßen Leiterverbund. Insbesondere stellt der erfindungsgemäße Leiterverbund erstmals eine elektrisch und mechanisch zuverlässige Verbindung zweier Leiter aus mehreren Litzendrähten und verschiedenen Materialien, insbesondere Aluminium und Kupfer, zur Verfügung.The conductor composite can be designed as a passage connector. However, it is also possible that the ladder assembly according to the invention forms an end connector such that the first and second wires terminate in the sleeve but extend in substantially the same direction. The advantages described above in connection with the method according to the invention also result for the conductor assembly according to the invention. In particular, the conductor assembly according to the invention provides for the first time an electrically and mechanically reliable connection of two conductors made of a plurality of stranded wires and various materials, in particular aluminum and copper.

Weitere Merkmale und vorteilhafte Ausführungen der Erfindung ergeben sich aus der nachfolgenden Figurenbeschreibung und der Gesamtheit der Patentansprüche.Further features and advantageous embodiments of the invention will become apparent from the following description of the figures and the totality of the claims.

KURZE FIGURENBESCHREIBUNGBRIEF FIGURE DESCRIPTION

  • Fig. 1a-c zeigt eine schematische Seitenansicht eines bevorzugten Leiterverbunds in verschiedenen Verbindungsstadien. Fig. 1a-c shows a schematic side view of a preferred ladder composite in different connecting stages.
  • Fig. 2 zeigt eine Schnittansicht eines bevorzugten Leiterverbunds im fertiggestellten Zustand. Fig. 2 shows a sectional view of a preferred ladder composite in the finished state.
WEGE ZUR AUSFÜHRUNG DER ERFINDUNGWAYS FOR CARRYING OUT THE INVENTION

In Fig. 1a sind ein erster Leiter 10 und eine Hülse 12 zu erkennen. Bei dem ersten Leiter 10 handelt es sich um einen Aluminiumleiter mit einer Vielzahl von Einzeldrähten, der im Bereich der gewünschten Verbindung mit einem zweiten Leiter bereits von seiner Isolierung befreit wurde. Die Hülse 12 ist dabei eine dünne Kupferhülse, deren Durchmesser so bemessen ist, dass sie leicht über den ersten Leiter 10 geschoben werden kann.In Fig. 1a a first conductor 10 and a sleeve 12 can be seen. The first conductor 10 is an aluminum conductor with a plurality of individual wires, which has already been freed of its insulation in the region of the desired connection to a second conductor. The sleeve 12 is a thin copper sleeve whose diameter is dimensioned so that it can be easily pushed over the first conductor 10.

Nachdem die Hülse 12 über den ersten Leitern 10 geschoben wurde, wird diese derart verpresst, dass sie den ersten Leiter 10 so ummantelt, dass ein elektrisch leitender und mechanisch fixierter Kontakt zwischen dem ersten Leiter 10 und der Hülse 12 hergestellt ist.After the sleeve 12 has been pushed over the first conductors 10, this is pressed so that it surrounds the first conductor 10 so that an electrically conductive and mechanically fixed contact between the first conductor 10 and the sleeve 12 is made.

Fig. 1b zeigt die als Ummantelung mit dem ersten Leiter 10 verpresste Hülse 12, wobei in der dargestellten Ausführungsform sowohl ein reines Verpressen der Hülse 12 mit dem ersten Leiter 10 als auch ein Verpressen in Verbindung mit zusätzlichen Schritten, beispielsweise einem Verschweißen des ersten Leiters 10 mit der Hülse 12, möglich ist. In jedem Fall stellt die Hülse 12 um den ersten Leiter 10 einen Schutz für den ersten Leiter 10 dar, der das Material des ersten Leiters 10 stützt und gegenüber einem mit einem weiteren Schweißschritt verbundenen Verflüssigen oder gar Auslaufen aus der Hülse 12 schützt. Fig. 1b shows the sleeve 12 pressed as a casing with the first conductor 10, wherein in the illustrated embodiment both a pure pressing of the sleeve 12 with the first conductor 10 and a pressing in conjunction with additional steps, for example a welding of the first conductor 10 with the sleeve 12, is possible. In any case, the sleeve 12 around the first conductor 10 is a protection for the first conductor 10, which supports the material of the first conductor 10 and protects against a connected to another welding step liquefying or even leakage from the sleeve 12.

Fig. 1b zeigt darüber hinaus auch einen zweiten Leiter 14, der aus vier Leitungssträngen mit jeweils mehreren Litzendrähten besteht. Bei dem zweiten Leiter 14 gemäß Fig. 1b handelt es sich um die Gesamtheit von vier Kupferkabeln mit mehreren, in dieser Anmeldung auch als Litzendrähte bezeichneten Einzeldrähten. Fig. 1b also shows a second conductor 14, which consists of four strands of wire, each with a plurality of stranded wires. In the second conductor 14 according to Fig. 1b it is the totality of four copper cables with several, in this application also referred to as stranded wires individual wires.

Dieser zweite Leiter 14 wird nun mit dem ersten Leiter 10 prozesssicher und reproduzierbar verbunden. Dies bedeutet, dass eine auf industriellem Niveau reproduzierbare Verbindung zwischen den beiden Leitern hergestellt werden soll, die sowohl mechanisch fest als auch elektrisch gut leitend ist.This second conductor 14 is now connected to the first conductor 10 process reliable and reproducible. This means that a reproducible on an industrial level connection between the two conductors is to be produced, which is both mechanically strong and good electrical conductivity.

Fig. 1c zeigt das Produkt des bevorzugten Verfahrens gemäß der vorliegenden Erfindung, nachdem die Hülse 12 außenseitig mit dem zweiten Leiter 14 kontaktiert und der zweite Leiter 14 anschließend mit der Hülse 12 verschweißt wurde. In der Fig. 1c ist gut zu erkennen, dass der zweite Leiter die Hülse 12 umfangseitig kontaktiert und mit dieser verschweißt ist. Fig. 1c shows the product of the preferred method according to the present invention, after the sleeve 12 has been externally contacted with the second conductor 14 and the second conductor 14 has subsequently been welded to the sleeve 12. In the Fig. 1c It can be clearly seen that the second conductor contacts the sleeve 12 peripherally and is welded thereto.

Ein direkter, unmittelbarer Kontakt zwischen dem ersten Leiter 10 und dem zweiten Leiter 14 besteht nicht, sondern die Leiter 10, 14 sind durch die Hülse 12 indirekt miteinander elektrisch leitend und mechanisch fixiert verbunden.A direct, direct contact between the first conductor 10 and the second conductor 14 does not exist, but the conductors 10, 14 are indirectly through the sleeve 12 interconnected electrically conductive and mechanically fixed.

Fig. 2 zeigt einen Querschnitt eines Leiterverbunds 16, wie er in Fig. 1c auch von außen gezeigt ist. Deutlich zu erkennen ist, dass der erste aus Aluminium bestehende Leiter 10 von der Hülse 12 ummantelt und ein elektrisch leitender und mechanisch fixierter Kontakt zwischen diesen beiden Elementen hergestellt ist. Die aus Kupfer bestehende Hülse 12 ist dabei zu einer Ambossform gepresst worden, in der eine flache, ebene Kontaktfläche 18 zum Kontaktieren der Außenseite der Hülse 12 durch den zweiten, aus Kupfer bestehenden Leiter 14 ausgebildet ist. Fig. 2 shows a cross section of a ladder composite 16, as in Fig. 1c also shown from the outside. It can be clearly seen that the first aluminum conductor 10 is encased by the sleeve 12 and an electrically conductive and mechanically fixed contact between these two elements is made. The existing copper sleeve 12 has been pressed into an anvil shape, in which a flat, planar contact surface 18 for contacting the outside of the sleeve 12 is formed by the second, made of copper conductor 14.

Wie sich der Fig. 2 entnehmen lässt, wurden die Litzendrähte des ersten Leiters 10 beispielsweise im Zusammenhang mit der Ummantelung und Kontaktierung des Aluminiumleiters 10 durch die Kupferhülse 12 oder während des Verschweißens der Kupferhülse 12 mit dem Kupferleiter 14 verformt, beispielsweise aufgeschmolzen oder druckbeaufschlagt, so dass die einzelnen Litzenquerschnitte nicht mehr, wie ursprünglich, kreisförmig, sondern beispielsweise sechseckig geformt sind.How is the Fig. 2 can be seen, the stranded wires of the first conductor 10 were deformed, for example, in connection with the sheathing and contacting the aluminum conductor 10 through the copper sleeve 12 or during the welding of the copper sleeve 12 with the copper conductor 14, for example, melted or pressurized, so that the individual strand cross sections no longer , as originally, circular, but, for example, hexagonal shaped.

An der Kontaktfläche 18 liegt außenseitig an die Kupferhülse 12 der Kupferleiter 14 an und ist mit der Kupferhülse 12 verschweißt, um einen elektrisch leitenden und mechanisch festen Kontakt zwischen der Hülse 12 und dem zweiten Leiter 14 zu bilden.On the contact surface 18 is located on the outside of the copper sleeve 12 of the copper conductor 14 and is welded to the copper sleeve 12 to form an electrically conductive and mechanically strong contact between the sleeve 12 and the second conductor 14.

In der dargestellten Ausführungsform handelt es sich bei dem ersten Leiter 10 um einen Aluminiumleiter eines Querschnitts von 27 mm2. Der zweite Leiter besteht aus vier einzelnen Kupferleitungen eines Querschnitts von jeweils 6 mm2, insgesamt also 24 mm2, sodass insgesamt eine weitgehende Übereinstimmung der Leitungsquerschnitte zwischen dem ersten Leiter 10 und dem zweiten Leiter 14 realisiert wird.In the illustrated embodiment, the first conductor 10 is an aluminum conductor of 27 mm 2 in cross-section. The second conductor consists of four individual copper conductors of a cross section of 6 mm 2 , a total of 24 mm 2 , so that overall a broad agreement of the cable cross-sections between the first conductor 10 and the second conductor 14 is realized.

Durch die erfindungsgemäße Verwendung einer Hülse wird sichergestellt, dass der erste Leiter trotz von dem zweiten Leiter abweichender Werkstoffeigenschaften in einer durch die Hülse definierten Position verbleiben kann, während der zweite Leiter 14 mit der Hülse 12 verschweißt wird. Auf diese Weise wird im Allgemeinen ein größeres Prozessfenster ermöglicht, das heißt eine höhere Toleranz gegenüber abweichenden Fertigungsparametern unter gleichzeitiger Sicherstellung der Qualität des hergestellten Produkts. Es können nun stabil und prozesssicher herkömmliche Ultraschallschweißtechniken verwendet werden, wobei auch standardisierte Werkzeugprofile eingesetzt werden können, um beispielsweise Leiter aus Aluminium und Kupfer miteinander effektiv zu verschweißen.The inventive use of a sleeve ensures that the first conductor, despite deviating from the second conductor material properties can remain in a position defined by the sleeve, while the second conductor 14 is welded to the sleeve 12. In this way, a larger process window is generally made possible, that is, a higher tolerance for deviating manufacturing parameters while ensuring the quality of the manufactured product. Now, conventional ultrasonic welding techniques can be used stably and reliably, whereby standardized tool profiles can be used, for example, to effectively weld together conductors of aluminum and copper.

Es ist also insbesondere nicht nötig, ein aufwendiges neues Schweißverfahren zu entwickeln, um verschiedene Materialien, wie beispielsweise Kupfer und Aluminium, in industriellem Maßstab miteinander zu verbinden. Hierdurch ermöglicht das erfindungsgemäße Verfahren auch eine Automatisierung des Verbindens zweier Leiter, ohne dabei Zugeständnisse im Hinblick auf die Qualität der hierdurch erzeugten Verbindung machen zu müssen.In particular, it is therefore not necessary to develop a complex new welding process in order to connect different materials, such as copper and aluminum, on an industrial scale. As a result, the method according to the invention also makes it possible to automate the connection of two conductors without having to make concessions with regard to the quality of the connection thus created.

Abweichend von den hierin beschriebenen Materialien können sowohl für die Leiter als auch für die Hülse weitere Materialien eingesetzt werden. Um elektrisch zu leiten und verschweißbar zu sein, sollten diese Materialien jedoch zumindest teilweise metallisch sein.Unlike the materials described herein, other materials can be used for both the conductors and the sleeve. However, to be electrically conductive and weldable, these materials should be at least partially metallic.

Statt einer den ersten Leiter vollständig umgebenden Hülse ist es in einem nicht zur der Erfindung gehörend Beispiel auch möglich, den ersten Leiter beispielsweise in Form einer Bördelung (Crimp) nur teilweise zu umgeben, wobei eine Kontaktierung der Bördelung durch den zweiten Leiter vorgesehen ist, dieser also nicht unmittelbar an den ersten Leiter angeschweißt werden soll. Hierdurch kann unterInstead of a sleeve completely surrounding the first conductor, it is also possible, in an example not belonging to the invention, to partially surround the first conductor, for example in the form of a crimp, a contacting of the crimp being provided by the second conductor So not to be welded directly to the first conductor. This can under

Umständen Material eingespart werden. Andererseits könnte das Verbinden der Leiter wegen komplizierter Haltevorrichtungen für den ersten Leiter und die Hülse bzw. die Bördelung aber auch aufwendiger sein, als bei der Verwendung einer zylindermantelförmigen Hülse.Material can be saved. On the other hand, the connection of the conductor could also be more complicated because of complicated holding devices for the first conductor and the sleeve or the flanging, as in the use of a cylinder jacket-shaped sleeve.

Claims (9)

  1. Method for connecting a first conductor (10) to a second conductor (14), wherein the conductors (10, 14) each have a plurality of litz wires, comprising the following steps:
    sheathing the first conductor (10) with a metal sleeve (12), as a result of which electrically conductive and mechanically fixed contact is established between the first conductor (10) and the sleeve (12),
    the second conductor (14) making contact with the outside of the sleeve (12), so that the first conductor is in contact with the inside of the sleeve and the second conductor is in contact with the outside of the sleeve, and
    welding the second conductor (14) to the sleeve (12).
  2. Method according to Claim 1, wherein the sleeve (12) is pressed together with the first conductor (10).
  3. Method according to either of the preceding claims, wherein the sleeve (12) is welded to the first conductor (10).
  4. Method according to one of the preceding claims, wherein the sleeve (12), for the purpose of contact to be made by the second conductor (14), is shaped in such a way that it forms a flat, planar contact area (18).
  5. Method according to one of the preceding claims, wherein the second conductor (10) is welded to the sleeve (12) by ultrasonic welding.
  6. Composite conductor (16) comprising a first conductor (10) and a second conductor (14), wherein the conductors (10, 14) each have a plurality of litz wires,
    wherein the first conductor (10) is sheathed by a sleeve (12), as a result of which electrically conductive and mechanically fixed contact is established between the sleeve (12) and the conductor (10), and
    the second conductor (14) is welded to the outside of the sleeve (12), so that the first conductor is in contact with the inside of the sleeve and the second conductor is in contact with the outside of the sleeve.
  7. Method according to one of Claims 1 to 5 or composite conductor (16) according to Claim 6, wherein one of the first conductor (10) and second conductor (14), preferably the first conductor (10), comprises aluminium and the other of the first conductor (10) and second conductor (14), preferably the second conductor (14), comprises copper.
  8. Method according to one of Claims 1 to 5 and 7 or composite conductor (16) according to one of Claims 6 and 7, wherein the sleeve (12) comprises copper.
  9. Composite conductor (16) according to one of Claims 6 to 8 which is produced by a method according to one of Claims 1 to 5 or 7 to 8.
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EP2672569A1 (en) 2013-12-11

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