EP2672569B1 - Procédé destiné à relier des conducteurs électriques et un faisceau conducteur - Google Patents

Procédé destiné à relier des conducteurs électriques et un faisceau conducteur 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
Authority
EP
European Patent Office
Prior art keywords
conductor
sleeve
welding
conductors
contact
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.)
Active
Application number
EP13170837.2A
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German (de)
English (en)
Other versions
EP2672569A1 (fr
Inventor
Dominik Dendorfer
Lutz Lehmann
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.)
Lisa Draexlmaier GmbH
Original Assignee
Lisa Draexlmaier 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
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Publication of EP2672569A1 publication Critical patent/EP2672569A1/fr
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Publication of EP2672569B1 publication Critical patent/EP2672569B1/fr
Active legal-status Critical Current
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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—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.

Landscapes

  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Manufacturing Of Electrical Connectors (AREA)

Claims (9)

  1. Procédé pour joindre un premier conducteur (10) à un deuxième conducteur (14), les conducteurs (10, 14) possédant respectivement plusieurs brins, comprenant les étapes suivantes :
    gainage du premier conducteur (10) avec une douille (12) métallique, un contact électriquement conducteur et d'immobilisation mécanique étant ainsi établi entre le premier conducteur (10) et la douille (12),
    mise en contact côté extérieur de la douille (12) avec le deuxième conducteur (14), de sorte que la douille est touchée par le premier conducteur du côté intérieur et par le deuxième conducteur du côté extérieur, et
    soudage du deuxième conducteur (14) avec la douille (12).
  2. Procédé selon la revendication 1, la douille (12) munie du premier conducteur (10) étant compressée.
  3. Procédé selon l'une des revendications précédentes, la douille (12) étant soudée avec le premier conducteur (10).
  4. Procédé selon l'une des revendications précédentes, la douille (12) étant façonnée en vue de la mise en contact avec le deuxième conducteur (14) de telle sorte qu'elle forme une surface de contact (18) plate et plane.
  5. Procédé selon l'une des revendications précédentes, le deuxième conducteur (10) étant soudé avec la buse (12) par soudage aux ultrasons.
  6. Assemblage de conducteurs (16) comprenant un premier conducteur (10) et un deuxième conducteur (14), les conducteurs (10, 14) possédant respectivement plusieurs brins,
    le premier conducteur (10) étant gainé par une douille (12), un contact électriquement conducteur et d'immobilisation mécanique étant ainsi établi entre la douille (12) et le premier conducteur (10),
    le deuxième conducteur (14) est soudé avec la douille (12) du côté extérieur, de sorte que la douille est touchée par le premier conducteur du côté intérieur et par le deuxième conducteur du côté extérieur.
  7. Procédé selon l'une des revendications 1 à 5 ou assemblage de conducteurs (16) selon la revendication 6, l'un des premier (10) et deuxième (14) conducteurs, de préférence le premier conducteur (10), contenant de l'aluminium et l'autre des premier (10) et deuxième (14) conducteurs, de préférence le deuxième conducteur (14), contenant du cuivre.
  8. Procédé selon l'une des revendications 1 à 5 et 7 ou assemblage de conducteurs (16) selon l'une des revendications 6 et 7, la douille (12) contenant du cuivre.
  9. Assemblage de conducteurs (16) selon l'une des revendications 6 à 8 qui est fabriqué par un procédé selon l'une des revendications 1 à 5 ou 7 à 8.
EP13170837.2A 2012-06-08 2013-06-06 Procédé destiné à relier des conducteurs électriques et un faisceau conducteur Active EP2672569B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE102012209639A DE102012209639A1 (de) 2012-06-08 2012-06-08 Verfahren zum Verbinden elektrischer Leiter und Leiterverbund

Publications (2)

Publication Number Publication Date
EP2672569A1 EP2672569A1 (fr) 2013-12-11
EP2672569B1 true EP2672569B1 (fr) 2017-07-26

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EP13170837.2A Active EP2672569B1 (fr) 2012-06-08 2013-06-06 Procédé destiné à relier des conducteurs électriques et un faisceau conducteur

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EP (1) EP2672569B1 (fr)
DE (1) DE102012209639A1 (fr)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ES2734295T3 (es) * 2016-09-01 2019-12-05 Nexans Procedimiento para la conexión conductora de electricidad de conductores eléctricos
DE102018106033B3 (de) * 2018-03-15 2019-08-08 Rosenberger Hochfrequenztechnik Gmbh & Co. Kg Kabelanordnung und Verfahren zur Herstellung einer elektrischen und mechanischen Verbindung

Family Cites Families (5)

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Publication number Priority date Publication date Assignee Title
DE19908031B4 (de) * 1999-02-24 2009-08-13 Auto-Kabel Management Gmbh Verbindung eines elektrischen Aluminiumkabels mit einem aus Kupfer oder dergleichen Metall bestehenden Anschlußteil
DE102006021422B8 (de) * 2006-05-05 2008-06-26 Schunk Ultraschalltechnik Gmbh Verfahren zur Herstellung eines Durchgangs- oder Endknotens sowie Durchgangs- oder Endknoten
JP5235369B2 (ja) 2007-09-18 2013-07-10 株式会社オートネットワーク技術研究所 ワイヤーハーネスおよびその製造方法ならびに絶縁電線の接続方法
US9255566B2 (en) 2010-02-10 2016-02-09 Vestas Wind Systems A/S Sectional blade
JP2012221831A (ja) * 2011-04-12 2012-11-12 Auto Network Gijutsu Kenkyusho:Kk ワイヤハーネス

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Publication number Publication date
EP2672569A1 (fr) 2013-12-11
DE102012209639A1 (de) 2013-12-12

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