EP2747205A1 - Method for the electrically conductive connection of a stranded conductor with a contact element - Google Patents

Method for the electrically conductive connection of a stranded conductor with a contact element Download PDF

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Publication number
EP2747205A1
EP2747205A1 EP12306605.2A EP12306605A EP2747205A1 EP 2747205 A1 EP2747205 A1 EP 2747205A1 EP 12306605 A EP12306605 A EP 12306605A EP 2747205 A1 EP2747205 A1 EP 2747205A1
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EP
European Patent Office
Prior art keywords
contact element
conductor
stranded conductor
wires
electrically conductive
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
Application number
EP12306605.2A
Other languages
German (de)
French (fr)
Other versions
EP2747205B1 (en
Inventor
Helmut Dr. Steinberg
Udo Dr. Mayer
Johannes Denteler
Sunhilde Fleischer
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.)
Bayerische Motoren Werke AG
Nexans SA
Original Assignee
Bayerische Motoren Werke AG
Nexans SA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bayerische Motoren Werke AG, Nexans SA filed Critical Bayerische Motoren Werke AG
Priority to EP12306605.2A priority Critical patent/EP2747205B1/en
Priority to US14/102,863 priority patent/US20140165394A1/en
Priority to BRBR102013032275-0A priority patent/BR102013032275A2/en
Publication of EP2747205A1 publication Critical patent/EP2747205A1/en
Application granted granted Critical
Publication of EP2747205B1 publication Critical patent/EP2747205B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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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
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048—Crimping apparatus or processes
    • 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
    • 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
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49174—Assembling terminal to elongated conductor
    • Y10T29/49179—Assembling terminal to elongated conductor by metal fusion bonding
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49174—Assembling terminal to elongated conductor
    • Y10T29/49181—Assembling terminal to elongated conductor by deforming
    • Y10T29/49185—Assembling terminal to elongated conductor by deforming of terminal

Definitions

  • the invention relates to a method of electrically connecting a stranded conductor having a plurality of aluminum-containing wires, with an electrical contact element, in which a component consisting of metal is attached to the conductor by crimping ( EP 2 001 085 B1 ).
  • Aluminum-containing conductors are being used more and more often as a replacement for copper conductors, for example in automotive and aircraft technology.
  • the aluminum-containing conductors used therein are made of either aluminum or an aluminum alloy.
  • a significant advantage of such electrical conductors is compared to copper lighter weight.
  • the lower electrical conductivity of aluminum compared to copper, however, is of minor importance for most applications.
  • a disadvantage of these conductors is the fact that aluminum reacts with oxygen, forming electrically insulating oxide layers surrounding the wires of a corresponding conductor.
  • the invention has the object of developing the initially described method so that the contact point between the conductor and the contact element is effectively protected against vibrations.
  • the electrically conductive connection between the contact element and the conductor and the mechanical discharge of the contact point are separated from each other, but using a one-piece component.
  • the electrically conductive connection is made, for example by ultrasonic welding, so that optionally present oxide layers are broken, so that the electrically conductive material of the conductor is connected directly to the contact element. Oxide layers, which optionally form after completion of the contact point, remain without influence.
  • the mechanical relief of the contact point is achieved by the crimped holding part, which surrounds the conductor in the immediate vicinity of the contact point sufficiently strong, so that neither bending loads nor tensile loads and in particular coarser vibrations can not affect the contact point even in the long term. It is important that the holding part is only the mechanically stable fixing of the conductor, while the electrical connection is made directly between the conductor and the contact element.
  • Fig. 1 schematically illustrated contact element 1 consists for example of copper. But it can also consist of another good electrically conductive metal.
  • the contact element 1 is to be used for example in motor vehicles. It is connected in the case of installation with electrical contact parts, which are attached for example to a starter, an electric motor or other, electrical current leading devices. The connection can be made for example by plugging, screwing or welding.
  • the contact element 1 is according to Fig. 1 a flat component with an approximately rectangular cross-section. It can also have a different geometric shape. Integral with the contact element 1 is a suitable for a crimping holding part 2 is connected.
  • a with the contact element 1 both electrically and mechanically to be connected electrical conductor is according to Fig. 2 a stranded conductor 3 - hereinafter referred to as "conductor 3" called - which consists of a plurality of combined into a unit wires 4.
  • the wires 4 may, for example, be stranded together. They consist in the present case of aluminum or an aluminum alloy.
  • the conductor 3, which is readily bendable as a stranded conductor by the construction, is surrounded by an insulation 5, which is removed from the end of the conductor 3 for carrying out the method according to the invention.
  • an arrangement which ensures that oxide layers are broken, which surround the individual wires 4 of the conductor 3. This ensures that the electrically conductive material of the conductor 3 and the wires 4 thereof is electrically connected after completion of the process with the contact element 1.
  • Such an arrangement is in a preferred embodiment, an ultrasonic welding machine. But it could also be used, for example, an electric welding system, whose current strength is high enough to destroy the oxide layers or which is coupled with a mechanical system, through which the mentioned oxide layers are broken.
  • the conductor 3 - as described - initially without actuation of the holding part 2 are connected to the contact element 1.
  • the holding part 2 is then crimped around the conductor 3 after completion of the electrically conductive connection between the conductor 3 and the contact element 1 for mechanical relief of the contact point 6.

Abstract

The method involves electric-conductively connecting an end of a stranded conductor (3) to a rectangular contact point (6) that is formed on an electrical contact element (1) destroying oxide layers of wires (4), where the conductor contains the wires made of aluminum or aluminum alloy. Upper layers of the oxide layers surrounding the wires are destroyed by the electrical contact element. A structural component is integrally connected to the contact element and formed as a mechanical holding part (2) that is crimped around the stranded conductor at a distance from the contact point.

Description

Die Erfindung bezieht sich auf ein Verfahren zum elektrisch leitenden Verbinden eines Litzenleiters, der eine Vielzahl von Aluminium enthaltenden Drähten aufweist, mit einem elektrischen Kontaktelement, bei welchem ein aus Metall bestehendes Bauteil durch Crimpen an dem Leiter befestigt wird ( EP 2 001 085 B1 ).The invention relates to a method of electrically connecting a stranded conductor having a plurality of aluminum-containing wires, with an electrical contact element, in which a component consisting of metal is attached to the conductor by crimping ( EP 2 001 085 B1 ).

Aluminium enthaltende Leiter werden als Ersatz für Kupferleiter immer öfter eingesetzt, beispielsweise in der Automobil- und Flugzeugtechnik. Die darin verwendeten, Aluminium enthaltenden Leiter bestehen entweder aus Aluminium oder aus einer Aluminiumlegierung. Ein wesentlicher Vorteil von derartigen elektrischen Leitern ist ihr gegenüber Kupfer geringeres Gewicht. Die geringere elektrische Leitfähigkeit des Aluminiums gegenüber Kupfer ist für die meisten Anwendungen hingegen von untergeordneter Bedeutung. Ein Nachteil dieser Leiter ist die Tatsache, daß Aluminium mit Sauerstoff reagiert, wodurch elektrisch isolierende Oxidschichten gebildet werden, welche die Drähte eines entsprechenden Leiters umgeben.Aluminum-containing conductors are being used more and more often as a replacement for copper conductors, for example in automotive and aircraft technology. The aluminum-containing conductors used therein are made of either aluminum or an aluminum alloy. A significant advantage of such electrical conductors is compared to copper lighter weight. The lower electrical conductivity of aluminum compared to copper, however, is of minor importance for most applications. A disadvantage of these conductors is the fact that aluminum reacts with oxygen, forming electrically insulating oxide layers surrounding the wires of a corresponding conductor.

Aus der eingangs erwähnten EP 2 001 085 B1 ist ein Verfahren zur Herstellung einer elektrisch leitenden Verbindung zwischen einem Aluminium enthaltenden elektrischen Litzenleiter und einem Kontaktteil eines elektrischen bzw. elektronischen Geräts bekannt. An dem von seiner Isolierung befreiten Ende des Leiters wird ein Kontaktelement durch Crimpen elektrisch leitend befestigt. Das Kontaktelement wird danach mit dem Kontaktteil des Geräts verbunden. Beim Crimpen des Kontaktelements werden die Oxidschichten des Litzenleiters durchbrochen, so daß sich eine elektrisch leitende Verbindung zwischen Kontaktelement und Leiter ergibt. Diese Verbindung hat sich in der Praxis bewährt. Sie kann aber in ungünstigen Fällen bei größeren Erschütterungen beeinträchtigt werden, wie sie beispielsweise beim Betrieb eines Kraftfahrzeugs auftreten.From the above-mentioned EP 2 001 085 B1 For example, there is known a method for producing an electrically conductive connection between an aluminum-containing electrical wire conductor and a contact part of an electrical or electronic device. At the end of the conductor which has been freed from its insulation, a contact element is fixed in an electrically conductive manner by crimping. The contact element is then connected to the contact part of the device. When crimping the contact element, the oxide layers of the stranded conductor are broken, so that there is an electrically conductive connection between the contact element and conductor. This compound has proven itself in practice. But you can in unfavorable cases be affected by major shocks, such as occur during operation of a motor vehicle.

Der Erfindung liegt die Aufgabe zugrunde, das eingangs geschilderte Verfahren so weiterzubilden, daß die Kontaktstelle zwischen dem Leiter und dem Kontaktelement wirksam gegen Erschütterungen geschützt ist.The invention has the object of developing the initially described method so that the contact point between the conductor and the contact element is effectively protected against vibrations.

Diese Aufgabe wird gemäß der Erfindung dadurch gelöst,

  • daß der Litzenleiter an seinem Ende unter Zerstörung von die Drähte desselben gegebenenfalls umgebenden Oxidschichten elektrisch leitend an das Kontaktelement angeschlossen wird und
  • daß das einstückig mit dem Kontaktelement verbundene, als mechanisches Halteteil wirkende Bauteil neben der Kontaktstelle um den Litzenleiter herumgecrimpt wird.
This object is achieved according to the invention characterized
  • that the stranded conductor is electrically connected to the contact element at its end by destroying the wires of the same possibly surrounding oxide layers and
  • in that the component, which is connected in one piece with the contact element and acts as a mechanical holding part, is crimped around the stranded conductor next to the contact point.

Bei diesem Verfahren sind die elektrisch leitende Verbindung zwischen dem Kontaktelement und dem Leiter sowie die mechanische Entlastung der Kontaktstelle voneinander getrennt, allerdings unter Einsatz eines einstückigen Bauteils. Die elektrisch leitende Verbindung wird, beispielsweise durch Ultraschallschweißung, so hergestellt, daß gegebenenfalls vorhandene Oxidschichten aufgebrochen werden, so daß das elektrisch leitende Material des Leiters direkt mit dem Kontaktelement verbunden wird. Oxidschichten, die sich nach Fertigstellung der Kontaktstelle gegebenenfalls bilden, bleiben ohne Einfluß. Die mechanische Entlastung der Kontaktstelle wird durch das gecrimpte Halteteil erreicht, welches den Leiter in unmittelbarer Nähe der Kontaktstelle ausreichend fest umgibt, so daß weder Biegebelastungen noch Zugbelastungen und insbesondere auch gröbere Erschütterungen sich auch auf Dauer nicht auf die Kontaktstelle auswirken können. Dabei ist von Bedeutung, daß das Halteteil nur der mechanisch stabilen Festlegung des Leiters dient, während die elektrische Verbindung direkt zwischen dem Leiter und dem Kontaktelement hergestellt wird.In this method, the electrically conductive connection between the contact element and the conductor and the mechanical discharge of the contact point are separated from each other, but using a one-piece component. The electrically conductive connection is made, for example by ultrasonic welding, so that optionally present oxide layers are broken, so that the electrically conductive material of the conductor is connected directly to the contact element. Oxide layers, which optionally form after completion of the contact point, remain without influence. The mechanical relief of the contact point is achieved by the crimped holding part, which surrounds the conductor in the immediate vicinity of the contact point sufficiently strong, so that neither bending loads nor tensile loads and in particular coarser vibrations can not affect the contact point even in the long term. It is important that the holding part is only the mechanically stable fixing of the conductor, while the electrical connection is made directly between the conductor and the contact element.

Das Verfahren nach der Erfindung wird anhand der Zeichnungen in einem Ausführungsbeispiel erläutert.The method according to the invention will be explained with reference to the drawings in an embodiment.

Es zeigen:

  • Fig. 1 in schematischer Darstellung ein bei dem Verfahren nach der Erfindung einsetzbares Kontaktelement.
  • Fig. 2 das Ende eines elektrischen Leiters.
  • Fig. 3 und 4 zwei unterschiedliche Ansichten einer Verbindungsstelle zwischen einem Leiter und dem Kontaktelement nach Fig. 1.
Show it:
  • Fig. 1 a schematic representation of an insertable in the method according to the invention contact element.
  • Fig. 2 the end of an electrical conductor.
  • 3 and 4 two different views of a junction between a conductor and the contact element according to Fig. 1 ,

Das in Fig. 1 schematisch dargestellte Kontaktelement 1 besteht beispielsweise aus Kupfer. Es kann aber auch aus einem anderen elektrisch gut leitenden Metall bestehen. Das Kontaktelement 1 soll beispielsweise in Kraftfahrzeugen eingesetzt werden. Es wird im Montagefall mit elektrischen Kontaktteilen verbunden, die beispielsweise an einem Anlasser, einem Elektromotor oder anderen, elektrischen Strom führenden Geräten angebracht sind. Die Verbindung kann beispielsweise durch Aufstecken, Verschrauben oder Schweißen erfolgen. Das Kontaktelement 1 ist gemäß Fig. 1 ein flaches Bauteil mit einem etwa rechteckigen Querschnitt. Es kann aber auch eine andere geometrische Form haben. Einstückig mit dem Kontaktelement 1 ist ein für einen Crimpvorgang geeignetes Halteteil 2 verbunden.This in Fig. 1 schematically illustrated contact element 1 consists for example of copper. But it can also consist of another good electrically conductive metal. The contact element 1 is to be used for example in motor vehicles. It is connected in the case of installation with electrical contact parts, which are attached for example to a starter, an electric motor or other, electrical current leading devices. The connection can be made for example by plugging, screwing or welding. The contact element 1 is according to Fig. 1 a flat component with an approximately rectangular cross-section. It can also have a different geometric shape. Integral with the contact element 1 is a suitable for a crimping holding part 2 is connected.

Ein mit dem Kontaktelement 1 sowohl elektrisch als auch mechanisch zu verbindender elektrischer Leiter ist gemäß Fig. 2 ein Litzenleiter 3 - im folgenden kurz "Leiter 3" genannt -, der aus einer Vielzahl von zu einer Einheit zusammengefaßten Drähten 4 besteht. Die Drähte 4 können beispielsweise miteinander verseilt sein. Sie bestehen im vorliegenden Fall aus Aluminium oder einer Aluminiumlegierung. Der durch den Aufbau als Litzenleiter gut biegbare Leiter 3 ist von einer Isolierung 5 umgeben, die zur Durchführung des Verfahrens nach der Erfindung vom Ende des Leiters 3 entfernt ist.A with the contact element 1 both electrically and mechanically to be connected electrical conductor is according to Fig. 2 a stranded conductor 3 - hereinafter referred to as "conductor 3" called - which consists of a plurality of combined into a unit wires 4. The wires 4 may, for example, be stranded together. They consist in the present case of aluminum or an aluminum alloy. The conductor 3, which is readily bendable as a stranded conductor by the construction, is surrounded by an insulation 5, which is removed from the end of the conductor 3 for carrying out the method according to the invention.

Zum elektrisch leitenden Verbinden des Leiters 3 mit dem Kontaktelement 1 wird eine Anordnung eingesetzt, die sicherstellt, daß Oxidschichten aufgebrochen werden, welche die einzelnen Drähte 4 des Leiters 3 umgeben. Dadurch ist erreicht, daß das elektrisch leitende Material des Leiters 3 bzw. der Drähte 4 desselben nach Abschluß des Verfahrens mit dem Kontaktelement 1 elektrisch leitend verbunden ist. Eine solche Anordnung ist in bevorzugter Ausführungsform eine Ultraschallschweißanlage. Es könnte aber auch beispielsweise eine Elektro-Schweißanlage eingesetzt werden, deren Stromstärke zur Zerstörung der Oxidschichten hoch genug ist oder die mit einer mechanischen Anlage gekoppelt ist, durch welche die erwähnten Oxidschichten aufgebrochen werden.For electrically conductive connection of the conductor 3 to the contact element 1, an arrangement is used which ensures that oxide layers are broken, which surround the individual wires 4 of the conductor 3. This ensures that the electrically conductive material of the conductor 3 and the wires 4 thereof is electrically connected after completion of the process with the contact element 1. Such an arrangement is in a preferred embodiment, an ultrasonic welding machine. But it could also be used, for example, an electric welding system, whose current strength is high enough to destroy the oxide layers or which is coupled with a mechanical system, through which the mentioned oxide layers are broken.

Das Verfahren nach der Erfindung wird beispielsweise wie folgt durchgeführt:

  • Der gemäß Fig. 2 vorbereitete Leiter 3 wird mit seinem Ende auf das Kontaktelement 1 aufgelegt. Die entsprechende Position kann durch das Halteteil 2 mechanisch stabilisiert werden, welches um den Leiter 3 herumgecrimpt wird. Danach werden der Leiter 3 bzw. die Drähte 4 auf das Kontaktelement 1 aufgelegt und mittels einer Ultraschallschweißanlage elektrisch leitend mit demselben verschweißt. Es ergibt sich bei der dargestellten geometrischen Form des Kontaktelements 1 als flaches Bauteil eine etwa rechteckige, in Fig. 4 gestrichelt umrandete Kontaktstelle 6. Die dem Leiter 3 zugewandte Oberfläche der Sonotrode der Ultraschallschweißanlage wird zweckmäßig stets in ihrer geometrischen Form so angepaßt, daß sie den Leiter 3 vollständig abdeckt. Das gilt insbesondere auch dann, wenn das Kontaktelement 1 nicht als flaches Bauteil entsprechend Fig. 1 bis 3 ausgeführt ist, sondern eine andere geometrische Form hat.
The method according to the invention is carried out, for example, as follows:
  • The according to Fig. 2 Prepared conductor 3 is placed with its end on the contact element 1. The corresponding position can be mechanically stabilized by the holding part 2, which is crimped around the conductor 3. Thereafter, the conductor 3 and the wires 4 are placed on the contact element 1 and electrically welded by means of an ultrasonic welding machine with the same. It results in the illustrated geometric shape of the contact element 1 as a flat component is an approximately rectangular, in Fig. 4 dashed bordered contact point 6. The conductor 3 facing surface of the sonotrode of the ultrasonic welding system is expediently always adapted in its geometric shape so that it completely covers the conductor 3. This also applies in particular if the contact element 1 does not correspond to a flat component Fig. 1 to 3 is executed, but has a different geometric shape.

In einer anderen Ausführungsform des Verfahrens kann der Leiter 3 - so wie beschrieben - zunächst ohne Betätigung des Halteteils 2 mit dem Kontaktelement 1 verbunden werden. Das Halteteil 2 wird dann nach Fertigstellung der elektrisch leitenden Verbindung zwischen Leiter 3 und Kontaktelement 1 zur mechanischen Entlastung der Kontaktstelle 6 um den Leiter 3 herumgecrimpt.In another embodiment of the method, the conductor 3 - as described - initially without actuation of the holding part 2 are connected to the contact element 1. The holding part 2 is then crimped around the conductor 3 after completion of the electrically conductive connection between the conductor 3 and the contact element 1 for mechanical relief of the contact point 6.

Claims (4)

Verfahren zum elektrisch leitenden Verbinden eines Litzenleiters, der eine Vielzahl von Aluminium enthaltenden Drähten aufweist, mit einem elektrischen Kontaktelement, bei welchem ein aus Metall bestehendes Bauteil durch Crimpen an dem Leiter befestigt wird, dadurch gekennzeichnet, - daß der Litzenleiter (3) an seinem Ende unter Zerstörung von die Drähte (4) desselben gegebenenfalls umgebenden Oxidschichten elektrisch leitend an das Kontaktelement (1) angeschlossen wird und - daß das einstückig mit dem Kontaktelement (1) verbundene, als mechanisches Halteteil (2) wirkende Bauteil neben der Kontaktstelle (6) um den Litzenleiter (3) herumgecrimpt wird. A method of electrically connecting a stranded conductor having a plurality of aluminum-containing wires to an electrical contact element in which a metal-made component is attached to the conductor by crimping, characterized - That the stranded conductor (3) at its end under destruction of the wires (4) of the same possibly surrounding oxide layers is electrically connected to the contact element (1) and - That the integrally connected to the contact element (1), acting as a mechanical holding part (2) component next to the contact point (6) around the stranded conductor (3) is herumgecrimpt. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß zuerst der Litzenleiter (3) und das Kontaktelement (1) elektrisch leitend miteinander verbunden werden und danach das Halteteil (2) um den Litzenleiter (3) herumgecrimpt wird.A method according to claim 1, characterized in that first the stranded conductor (3) and the contact element (1) are electrically conductively connected together and then the holding part (2) is crimped around the stranded conductor (3). Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß zuerst das Halteteil (2) um den Litzenleiter (3) herumgecrimpt und der Litzenleiter (3) danach elektrisch leitend mit dem Kontaktelement (1) verbunden wird.Method according to Claim 1, characterized in that first the holding part (2) is crimped around the stranded conductor (3) and the stranded conductor (3) is then electrically conductively connected to the contact element (1). Verfahren nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, daß der Litzenleiter (3) und das Kontaktelement (1) mittels einer Ultraschallschweißanlage elektrisch leitend miteinander verbunden werden.Method according to one of claims 1 to 3, characterized in that the stranded conductor (3) and the contact element (1) by means of an ultrasonic welding system are electrically conductively connected to each other.
EP12306605.2A 2012-12-18 2012-12-18 Method for the electrically conductive connection of a stranded conductor with a contact element Active EP2747205B1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
EP12306605.2A EP2747205B1 (en) 2012-12-18 2012-12-18 Method for the electrically conductive connection of a stranded conductor with a contact element
US14/102,863 US20140165394A1 (en) 2012-12-18 2013-12-11 Method for electrically conductively connecting a stranded conductor to a contact element
BRBR102013032275-0A BR102013032275A2 (en) 2012-12-18 2013-12-16 METHOD FOR ELECTRICAL CONNECTION OF A WIRE CONDUCTOR WITH A CONTACT ELEMENT

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP12306605.2A EP2747205B1 (en) 2012-12-18 2012-12-18 Method for the electrically conductive connection of a stranded conductor with a contact element

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EP2747205A1 true EP2747205A1 (en) 2014-06-25
EP2747205B1 EP2747205B1 (en) 2021-04-14

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US20140165394A1 (en) 2014-06-19
EP2747205B1 (en) 2021-04-14
BR102013032275A2 (en) 2014-09-02

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