EP2697866A1 - Production of an electrical cable and method for producing a connection - Google Patents
Production of an electrical cable and method for producing a connectionInfo
- Publication number
- EP2697866A1 EP2697866A1 EP12705269.4A EP12705269A EP2697866A1 EP 2697866 A1 EP2697866 A1 EP 2697866A1 EP 12705269 A EP12705269 A EP 12705269A EP 2697866 A1 EP2697866 A1 EP 2697866A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- cable
- connection
- weld
- connecting part
- compound according
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000004519 manufacturing process Methods 0.000 title description 5
- 150000001875 compounds Chemical class 0.000 claims description 13
- 229910052782 aluminium Inorganic materials 0.000 claims description 11
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 11
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 8
- 229910052802 copper Inorganic materials 0.000 claims description 8
- 239000010949 copper Substances 0.000 claims description 8
- 229910000881 Cu alloy Inorganic materials 0.000 claims description 4
- 229910052751 metal Inorganic materials 0.000 claims description 4
- 239000002184 metal Substances 0.000 claims description 4
- 229910000838 Al alloy Inorganic materials 0.000 claims description 3
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 claims description 2
- 239000004020 conductor Substances 0.000 claims 1
- 238000000034 method Methods 0.000 description 14
- 238000003466 welding Methods 0.000 description 9
- 239000000463 material Substances 0.000 description 7
- 229910001369 Brass Inorganic materials 0.000 description 3
- 239000010951 brass Substances 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 238000009413 insulation Methods 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 239000011343 solid material Substances 0.000 description 2
- 229910000906 Bronze Inorganic materials 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 239000010974 bronze Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- KUNSUQLRTQLHQQ-UHFFFAOYSA-N copper tin Chemical compound [Cu].[Sn] KUNSUQLRTQLHQQ-UHFFFAOYSA-N 0.000 description 1
- 238000002788 crimping Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- -1 ferrous metals Chemical class 0.000 description 1
- 238000005242 forging Methods 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 239000002689 soil Substances 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
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
- 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
- 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
- H01R11/28—End pieces consisting of a ferrule or sleeve
- H01R11/281—End pieces consisting of a ferrule or sleeve for connections to batteries
-
- 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
-
- 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
Definitions
- the subject matter relates to the connection of an electrical cable formed from a plurality of wires or strands with a connection part, in particular for the electrical system of a motor vehicle, with a support sleeve.
- the support sleeve for receiving an end portion of the cable is formed and surrounds it.
- Support sleeve held wherein the front side of the cable formed from the individual wires or strands is welded to the connecting part by means of an at least frontal weld.
- connection of electrical cables with connection parts is commonplace in the automotive industry in particular.
- the cost pressure is enormous, so that the supplier industry is always looking for process-reliable, durable, but cost-effective connection technologies.
- European Patent EP 1 032 077 B1 discloses a connection of an aluminum cable to a connection part, which may be formed from copper. Here it is described that the end of the connection part
- Aluminum cable is pressed by means of a sleeve, so that the strands of the cable are pressed together.
- the thus-pressed end of the cable is connected to a connection part by a friction welding process.
- the sleeve ensures that the strands of the
- Connecting part also costly to produce, since it must be made available as a rule forging available, which is expensive to manufacture. For this reason, the object was the object to provide a connection of a cable with a connector available, which is on the one hand process reliable, on the other hand, however, material and weight savings.
- This object is achieved by a compound according to claim 1.
- the Connecting part on the opposite side of the weld is hollow.
- connection part is preferably formed from a sheet metal or strip, which has a bearing surface / connection surface facing the support sleeve and the end region of the cable.
- connection part is hollow on the side opposite the weld results in weight and material savings.
- the connector may have at one end a crimping shoe, a bore, a bolt, a
- connection surface Connecting part on a preferably circular pad, which is preferably flat.
- the cable together with the support sleeve can be attached to this connection surface and welded to it.
- Both pad and cable preferably have circular cross-sections, others
- Hollow in the sense of the article is to be understood in that on the opposite side of the weld, a space defined by walls of the connection part is formed. This room can be open on one side, but also completely closed.
- hollow means that an at least partially circumferential wall is provided along the circumference of the weld.
- An end region of the cable is in particular the region of the cable which is stripped.
- the end face of the cable is preferably formed by the ends of the wires or strands.
- the cable has been cut or cut so that a flat as possible end side of the cable is formed.
- the strands thus end preferably in a plane, in which case a tolerance range of +/- 1 to 2 mm is possible.
- connection part is tubular.
- the connecting part has a bottom, which forms the connection surface for the weld.
- the floor is welded to the cable along the weld. It is also possible that the weld extends beyond the cable to the support sleeve.
- the bottom is integrally formed from the walls of the connection part.
- a tubular connecting part is formed.
- the ends of the tube are bent toward the center of the tubular connection part so that the bottom forms.
- the bottom is formed from a lid arranged at the end of the tube of the connecting part.
- the lid is preferably inserted in the tube or placed on the tube.
- the lid is crimped in the tube.
- the lid has a step-shaped cross section, such that a first Diameter corresponds to the inner diameter of the connecting part and a second diameter at least equal to the outer diameter of the connecting part, but at least greater than the inner diameter. Then, the first diameter of the lid can be inserted into the tube of the connecting part, wherein the second diameter rests against the end face of the tube. Subsequently, the lid can be pressed in the tube. It is also possible that the lid is welded to the tube. Finally, it is possible that the lid is soldered or glued to the pipe. Other connection technologies are also possible, as long as an electrical connection between the lid and
- connection part is given.
- the pipe surface facing away from the lid then forms the connection surface.
- the wall of the connecting part is deformed at its end forming the bottom.
- the wall of the connection part can be bent inwards
- the wall is preferably bent to the center of the rohrformigen connection part.
- connection part in the region of the bottom is a drawn, in particular deep-drawn, cup.
- the connection part may for example be a flat part, which is formed in a drawing process so that it forms at least one end ⁇ a tubular, U-shaped, unilaterally open connection part.
- Napfes serves as a connection surface for the weld.
- the flat part has settled. Subsequently, the flat part can be deformed, in particular bent at the ends tubular, in which case the soil can be formed. Finally, the objective connection part is then formed from the flat part.
- a region of the flat part may, for example, be rectangular.
- the respectively opposite end faces of the flat part can correspond to each other projections and recesses,
- End surfaces engage behind each other and preferably
- the flat part may be rectangular in a development in a first region.
- This area can be deformed tubular.
- In order to form the bottom, can at the rectangle, on a long front side, a
- the flat part can be formed, for example by stamping so that both the rectangle, and the extension is punched directly from a sheet.
- the extension can, after the tube has been formed, be bent over, so that it on the
- connection part can be formed particularly cost-effectively if it is a tubular cable lug.
- a tubular cable lug is available as a mass-produced particularly favorable.
- connection between the support sleeve, the cable and the connection part is advantageously realized via the weld. This is an advantageous way
- Friction weld a rotary friction weld, a
- connection part a connection part formed from aluminum or an aluminum alloy with a connecting part formed from a non-ferrous metal, in particular copper, in particular a copper alloy.
- the connecting part is also made of aluminum.
- the connecting part is advantageously made of a
- End sides of the wires or strands are connected to the connecting part, but at the same time the end face of the support sleeve.
- the cable can be made of aluminum or an aluminum alloy.
- connection part of a conductive preferably
- non-ferrous metals such as copper or copper alloys such as brass or bronze are suitable here.
- Support sleeve is stripped.
- the stripped portion of the cable or the stripped end of the cable can be inserted into the support sleeve and can then be pressed with the support sleeve.
- the Slotted support sleeve so when pressing the
- Fig. 1 is a sectional view of a cable with a
- Fig. 2 is a further sectional view of a cable with a
- 3a is a sectional view of a connector according to
- 3b shows a sectional view of a connection part connected to a cable
- 3c shows a further sectional view of a connection part connected to a cable
- Fig. 4a is a sectional view of another
- connection part Embodiment of a connection part
- connection part 4b shows a side view of a connection part according to a
- FIG. 4c is a sectional view of a connector connected to a cable
- connection part 4d shows a further sectional view of a connection part connected to a cable
- connection part 5 shows a development of a connection part
- Fig. 6 is another view of an embodiment of a connection part.
- FIG. 1 shows a support sleeve 2 in a sectional view.
- the support sleeve 2 is preferably round and made of aluminum, copper or alloys thereof.
- FIG. 1 shows an electrical cable 4, in particular a battery cable of a motor vehicle, in particular for connecting a battery to a starter or a generator, as well as another electrical line of a motor vehicle.
- the cable 4 is covered with an insulation 4a.
- the cable 4 is freed from the insulation 4a in an end region 4c, so that the strands 4b of the cable 4 are exposed.
- the exposed strands 4b of the cable 4 are in the
- Front side 2a of the support sleeve 2 is flush with the front end 4d of the cable 4.
- the support sleeve 2 is preferably pressed, so that the strands 4b within the support sleeve 2 are close together.
- Figure 2 shows another embodiment of a
- FIG. 3a shows a connection part 6.
- the connection part shown in FIG. 3a is a tubular cable lug which is open at one end 6a and is pressed at the other end 6b, for example. At the end 6b, for example, a bore is provided for connecting a cable.
- the connecting part 6 is
- Connecting part 6 has a cavity 8.
- the cavity 8 is formed through the tubular end of the fitting 6 and closed by a lid 10.
- the lid 10 has two diameters. A first smaller one
- Diameter is inserted into the cavity 8 and a second diameter, which is greater than the first diameter, abuts against the end 6 a of the connecting part 6.
- the lid 10 is inserted into the cavity 8 of the connecting part 6 and at the front end 6a with the connecting part. 6
- the lid 10 is a preferably flat
- FIG. 3b shows a connection between a connection part 6 and a cable 4.
- a weld seam 16 connects the connection surface 12 with the end face 2a of the support sleeve 2 as well as the end faces 4d of the strands 4b.
- the weld 16 has been made by a friction welding process. However, it is also possible for the weld 16 to be produced by means of a laser welding method, an ultrasonic method, a resistance welding method or another welding method.
- connection part 6 does not have to be formed from a solid material. As the material usage is lower, lower material costs are also incurred.
- FIG. 3 c shows a further exemplary embodiment, in which the cable 4 and the support sleeve 2, as shown in FIG. 2, are connected to one another.
- the cover 10 together with the end portion of the
- Weld 16 is formed at least between the pad 12 and the end faces 4d of the strands 4b. At a Resistance welding would also produce the weld 16 along the outer surface of the
- connection surface 12 is formed from the walls of the connecting part 6.
- the walls of the connecting part 6 are bent inwardly in their end region in such a way that they point in the direction of the central axis 14.
- the ends 6a are preferably facing each other and optionally welded together.
- the curved walls of the connection part 6 form a bottom 13 with the connection surface 12.
- FIG. 4b A side view is shown in FIG. 4b.
- the pad 12 with a circular cross-section.
- Other cross sections are also possible.
- the central axis 14 can be seen, to which the ends 6a of
- Figure 4d shows another embodiment in which the connecting part 6 with its end in the support sleeve 2a
- connection part 6 can be formed from a sheet or strip. Preferably, the sheet thickness is between 1 and 10 mm. From a sheet, the connection part 6, as in FIG. 5
- connection tabs are punched. It can be seen that a first connection tab is provided in the region of the end 6b. At this Anschl tab is followed by a substantially rectangular area. The side facing away from the connection tab forms the end 6a of the connection part 6 in the finished state. The ends 6c along the short edges have dovetail-shaped recesses or protrusions 18a, 18b. The rectangular portion is followed by a substantially circular extension, which forms the bottom 13 in the installed state. The extension is connected via a web 20 with the rectangular part. In order to produce a connection part 6, the rectangular part becomes essentially in a first processing step
- FIG. 6 shows a further embodiment in which a flat part is bent such that a cup is formed, which has a cavity 8 with a bottom 13, as shown. Also, such a shape is advantageous because it is easy to produce.
Landscapes
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE201110017070 DE102011017070B4 (en) | 2011-04-14 | 2011-04-14 | Production of an electric cable and method for producing a connection |
PCT/EP2012/052578 WO2012139793A1 (en) | 2011-04-14 | 2012-02-15 | Production of an electrical cable and method for producing a connection |
Publications (2)
Publication Number | Publication Date |
---|---|
EP2697866A1 true EP2697866A1 (en) | 2014-02-19 |
EP2697866B1 EP2697866B1 (en) | 2015-09-30 |
Family
ID=45755329
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP12705269.4A Active EP2697866B1 (en) | 2011-04-14 | 2012-02-15 | Manufacture of an electric cable and connection method |
Country Status (6)
Country | Link |
---|---|
US (1) | US8840437B2 (en) |
EP (1) | EP2697866B1 (en) |
CN (1) | CN102986088B (en) |
DE (1) | DE102011017070B4 (en) |
ES (1) | ES2554551T3 (en) |
WO (1) | WO2012139793A1 (en) |
Families Citing this family (20)
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AT510475B1 (en) * | 2010-10-13 | 2013-02-15 | Gebauer & Griller | CONNECTING PART FOR AN ELECTRIC LADDER |
DE102013101727A1 (en) * | 2013-02-21 | 2014-09-04 | R.Stahl Schaltgeräte GmbH | Housing with a rotary friction weld |
CN104051870A (en) * | 2013-03-14 | 2014-09-17 | 美铝公司 | Durable copper to aluminum welded connection |
EP2887459B1 (en) * | 2013-12-17 | 2017-11-15 | Nexans | Method for electrically connecting a conductor on the basis of aluminium with a contact member |
DE102014105817A1 (en) * | 2014-04-24 | 2015-10-29 | Strescon Gmbh | Kabelendgarnitur |
CN104624869A (en) * | 2015-01-14 | 2015-05-20 | 泰州市艾克森电热仪表设备有限公司 | Welding technology for resistance wire and high-temperature wire in an L shape |
JP6409672B2 (en) * | 2015-05-14 | 2018-10-24 | 株式会社オートネットワーク技術研究所 | Electric wire module |
DE102015210458A1 (en) * | 2015-06-08 | 2016-12-08 | Te Connectivity Germany Gmbh | Method for connecting a conductor having a base metal with a copper-containing terminal element by means of welding and a connection arrangement produced thereby |
DE102016124583B3 (en) * | 2016-12-16 | 2018-02-15 | Auto-Kabel Management Gmbh | Joining a connection element with a stranded conductor |
EP3379652B1 (en) * | 2017-03-24 | 2021-04-28 | Nexans | Arrangement for contacting an electrical conductor and method therefor |
CN206893815U (en) | 2017-06-05 | 2018-01-16 | 吉林省中赢高科技有限公司 | A kind of copper aluminium connector |
DE102017113837B3 (en) * | 2017-06-22 | 2018-03-29 | Lisa Dräxlmaier GmbH | METHOD FOR SEALING A JOINT AREA OF AN ELECTRICAL CONNECTION ASSEMBLY AND ELECTRICAL CONNECTION ASSEMBLY |
EP3435483B1 (en) | 2017-07-26 | 2021-04-28 | Nordex Energy SE & Co. KG | Connector for a high current cable and method for producing such a connector |
EP3451455B1 (en) * | 2017-09-01 | 2019-11-06 | Nexans | Method for making an electrical connection and an electrical line |
DE102017123864B3 (en) | 2017-10-13 | 2019-04-04 | Lisa Dräxlmaier GmbH | Electric line arrangement with direct contacting and method for its production |
DE102017124693B3 (en) * | 2017-10-23 | 2018-11-29 | Lisa Dräxlmaier GmbH | Method for integrally joining an electrical line to an electrical contact part |
DE102017131371A1 (en) * | 2017-12-28 | 2019-07-04 | Te Connectivity Germany Gmbh | Mechanical connection element, electrical contact device and electrical connector |
CN109066123B (en) * | 2018-07-18 | 2024-03-26 | 深圳巴斯巴科技发展有限公司 | Cable end connection structure and manufacturing process thereof |
DE102018127729A1 (en) * | 2018-11-07 | 2020-05-07 | Auto-Kabel Management Gmbh | Process for producing a connector for electrical systems, connector and connection of a connector with a cable |
DE102020106415B4 (en) * | 2020-03-10 | 2021-09-30 | Lisa Dräxlmaier GmbH | FRICTION WELDING CONNECTOR AND METHOD FOR MANUFACTURING THEREOF |
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IL31854A (en) | 1968-04-12 | 1972-07-26 | Amp Inc | Terminals for weld connection to electrical conductor wires |
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SE357107B (en) * | 1971-10-13 | 1973-06-12 | Winemar Ab Curt | |
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US4317277A (en) * | 1978-09-15 | 1982-03-02 | General Electric Company | Low resistance electric joint between conductive members, at least one member having an insulation coating thereon, and the method of making such joint |
DE2938133A1 (en) * | 1979-09-20 | 1981-04-09 | Siemens AG, 1000 Berlin und 8000 München | Plug connector for medium and high voltage cables - has plug at end of crimp-fit sleeve having inner copper layer and outer steel layer |
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CN201699163U (en) * | 2010-06-25 | 2011-01-05 | 徐开文 | Compression joint terminal |
-
2011
- 2011-04-14 DE DE201110017070 patent/DE102011017070B4/en active Active
-
2012
- 2012-02-15 US US13/698,071 patent/US8840437B2/en active Active
- 2012-02-15 CN CN201280000752.7A patent/CN102986088B/en active Active
- 2012-02-15 WO PCT/EP2012/052578 patent/WO2012139793A1/en active Application Filing
- 2012-02-15 ES ES12705269.4T patent/ES2554551T3/en active Active
- 2012-02-15 EP EP12705269.4A patent/EP2697866B1/en active Active
Non-Patent Citations (1)
Title |
---|
See references of WO2012139793A1 * |
Also Published As
Publication number | Publication date |
---|---|
DE102011017070A1 (en) | 2012-10-18 |
DE102011017070B4 (en) | 2013-10-31 |
CN102986088A (en) | 2013-03-20 |
ES2554551T3 (en) | 2015-12-21 |
US8840437B2 (en) | 2014-09-23 |
WO2012139793A1 (en) | 2012-10-18 |
EP2697866B1 (en) | 2015-09-30 |
DE102011017070A8 (en) | 2012-12-27 |
US20130059473A1 (en) | 2013-03-07 |
CN102986088B (en) | 2016-01-13 |
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