EP2887459A1 - Method for electrically connecting a conductor on the basis of aluminium with a contact member - Google Patents

Method for electrically connecting a conductor on the basis of aluminium with a contact member Download PDF

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Publication number
EP2887459A1
EP2887459A1 EP13306745.4A EP13306745A EP2887459A1 EP 2887459 A1 EP2887459 A1 EP 2887459A1 EP 13306745 A EP13306745 A EP 13306745A EP 2887459 A1 EP2887459 A1 EP 2887459A1
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EP
European Patent Office
Prior art keywords
conductor
contact part
face
stable state
sleeve
Prior art date
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Granted
Application number
EP13306745.4A
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German (de)
French (fr)
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EP2887459B1 (en
Inventor
Helmut Steinberg
Udo Mayer
Gerhard Lindner
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Nexans SA
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Nexans SA
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Publication date
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Priority to ES13306745.4T priority Critical patent/ES2657835T3/en
Priority to EP13306745.4A priority patent/EP2887459B1/en
Publication of EP2887459A1 publication Critical patent/EP2887459A1/en
Application granted granted Critical
Publication of EP2887459B1 publication Critical patent/EP2887459B1/en
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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
    • H01R4/58—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
    • 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
    • H01R4/02—Soldered or welded connections
    • H01R4/027—Soldered or welded connections comprising means for positioning or holding the parts to be soldered or welded
    • 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
    • H01R4/26—Connections in which at least one of the connecting parts has projections which bite into or engage the other connecting part in order to improve the contact
    • 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
    • H01R43/0263—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 for positioning or holding parts during soldering or welding process

Definitions

  • the invention relates to a method for electrically connecting an aluminum-based conductor with a contact part, with which a cap-like contact part, which has a bottom and a connected thereto and projecting from this cylindrical sleeve, is plugged onto the conductor, that the end face of the conductor rests on the bottom of the contact part.
  • the electrical conductors are in most cases flexible aluminum insulated stranded conductors, i. consisting of aluminum or an aluminum alloy.
  • Aluminum is increasingly being used in automobiles and aircraft for cost and weight reasons, with the lower electrical conductivity of the aluminum to copper being irrelevant for most applications.
  • the contact parts based on copper are made of copper or a copper alloy, for example brass, wherein the contact parts coated, for example, tinned, can be.
  • the contact parts can be welded, for example, with a stripped conductor end.
  • the electrical conductor and the contact element are positively and / or cohesively connected to each other.
  • the EP 1 032 077 B1 describes a method for connecting an aluminum cable, in particular a stranded conductor, with a copper-based connector.
  • a sleeve made of aluminum is applied to the stripped end of the conductor, which compresses the individual wires and approaches each other to obtain a metallic surface on the front side of the cable.
  • the front side is then butt welded to the terminal part, wherein the oxide layer is removed at the end face.
  • the invention has for its object to provide a method for electrically connecting an aluminum-based conductor with a contact part, through which an effective, at least the entire cross section of the aluminum conductor detected electrically conductive connection to the contact part can be achieved.
  • the inventive method allows a solid mechanical and electrical connection between the conductor and the contact part in simple, inexpensive work steps.
  • the voltage applied to the conductor sleeve of the contact part the projections of the sleeve are pressed into the outside of the conductor so that the outer oxide layer, which may have formed on the aluminum, is destroyed.
  • an electrical connection between the conductor and the contact part is ensured not only via the end face of the conductor but also via its side surface.
  • FIG. 1 shows the contact part 1 a first stable state in a perspective and a longitudinal sectional view.
  • the first stable state corresponds to an open state, in which the contact part 1 can be easily attached to the conductor.
  • Fig. 2 shows the contact part 1 in a second stable state in a perspective and a longitudinal sectional view.
  • the second stable state corresponds to a closed state in which the contact part 1 is fixedly connected on the conductor.
  • the cap-like contact part 1 has a bottom 2 and connected to the bottom 2 and projecting from this, cylindrical sleeve 3.
  • the cylindrical sleeve 3 consists of a plurality of individual, projecting from the bottom 2 flaps 4.
  • the flaps 4 each have at their opposite ends of the bottom on a radially inwardly facing projection 5.
  • the individual projections 5 form a closed ring, as in FIG Fig. 2 shown.
  • the contact part 1 also has a connecting element 6, by means of which the conductor connected to the contact part 1 can be electrically connected to actuators, sensors, control elements, etc.
  • the contact part 1 is advantageously made of two different materials.
  • the connecting element 6 is preferably made of copper or of a copper alloy.
  • the bottom 2 and the sleeve 3 are advantageously made of a metal with suitable for the two stable states of the contact part 1 mechanical properties, such as spring steel.
  • the aluminum-based electrical conductor may be either a stranded conductor made up of a plurality of individual wires or a solid single conductor.
  • the conductor end of any existing layers, such as any existing insulation 8, must be exempted.
  • the cap-like contact part 1 is then placed so far on the conductor 7 until the end face 9 of the conductor 7 rests against the bottom 2 of the contact part 1.
  • this is in its first stable state (s. Fig. 1 ), so that the sleeve 3 is not applied to the conductor 7.
  • the bottom 2 of the contact part is curved inwards.
  • the contact part 1 in its second stable state (s. Fig. 2 ), so that the cylindrical sleeve 3 rests under tension on the outside of the conductor.
  • the projections 5 of the sleeve 3 are pressed into the outside of the conductor 7 and the end face 9 of the conductor 7 additionally pressed firmly against the bottom of the contact part. Any existing oxide layers on the conductor 7 are by in the Broken head outside pressed projections 5 so that they do not hinder the electrically conductive connection between the conductor and contact part.
  • the bottom 2 of the contact part 1 is now arched outwards. By the projections 5, the end face 9 of the conductor 7 is held in contact with the bottom 2 of the contact part 1. Finally, the bottom 2 of the contact part 1 and the end face 9 of the conductor 7 are firmly bonded together.
  • the transition between the first and the second stable state of the contact part 1 can be effected, for example, characterized in that the flaps 4 of the sleeve 3 are compressed. This elastic deformation is reversed, for example, by pressing on the bottom 2 of the contact part 1.
  • the cohesive connection of the bottom of the contact part with the end face of the conductor can be effected by a suitable welding method, for example by friction stir welding.
  • friction stir welding the increased temperature required for welding the contact part and the conductor is generated by friction.
  • the aluminum or aluminum alloy of the conductor combines at a temperature below the melting temperature of the same temperature with the copper or copper alloy of the contact part cohesively.
  • the bottom of the contact part is not broken.
  • a tool 10 is applied to the contact part 1, which may be equipped on its end face with a pin-like projection 11.
  • the tool 10 is advantageously made of steel.
  • the tool 10 is moved in the direction of the arrow P and pressed with continued pressure against the bottom 2 of the contact part 1, so that the material thereof is heated by friction.
  • the heat is transferred from the contact part 1 to the front side of the conductor 7.
  • the material of the conductor 7 then connects cohesively with the contact part 1.
  • the protruding from the end face of the tool in the axial direction projection 11 presses the bottom 2 of the contact part 1 when it rests against the same, as it out Fig. 5 evident. This increases the contact surface between the conductor 7 and the contact part 1. Again, any existing oxide layers on the conductor 7 are broken during welding, so that they do not hinder the electrically conductive connection between the conductor 7 and contact part 1.

Abstract

Es wird ein Verfahren zum elektrischen Verbinden eines Leiters (7) auf Basis von Aluminium mit einem Kontaktteil (1), mit welchem ein kappenartiges Kontaktteil (1), das einen Boden (2) und eine mit diesem verbundene und von diesem abstehende zylindrische Hülse (3) aufweist, so auf den Leiter (7) aufgesteckt wird, daß die Stirnfläche (9) des Leiters (7) am Boden (2) des Kontaktteils (1) aufliegt, angegeben. Das Kontaktteil (1) weist einen ersten stabilen Zustand auf, in dem das Kontaktteil (1) auf den Leiter (7) aufgesteckt wird, ohne daß die Hülse (3) an dem Leiter (7) anliegt. Die zylindrische Hülse (3) weist an deren dem Boden gegenüberliegenden Ende in radialer Richtung nach innen weisende Vorsprünge (5) auf und liegt in einem zweiten stabilen Zustand unter Spannung an der Außenseite des Leiters (7) an, wobei die Vorsprünge (5) in die Außenseite des Leiters (7) gedrückt und die Stirnseite (9) des Leiters (7) zusätzlich fest an den Boden (2) des Kontaktteils (1) angedrückt werden. Der Boden (2) des Kontaktteils (1) und die Stirnfläche (9) des Leiters (7) werden anschließend stoffschlüssig miteinander verbunden.The invention relates to a method for electrically connecting an aluminum-based conductor (7) to a contact part (1), with which a cap-like contact part (1) having a base (2) and a cylindrical sleeve connected thereto and projecting therefrom (2). 3), is placed on the conductor (7), that the end face (9) of the conductor (7) rests on the bottom (2) of the contact part (1) indicated. The contact part (1) has a first stable state, in which the contact part (1) is plugged onto the conductor (7), without the sleeve (3) resting against the conductor (7). The cylindrical sleeve (3) has at its bottom opposite end in the radial direction inwardly facing projections (5) and in a second stable state under tension on the outside of the conductor (7), wherein the projections (5) in the outside of the conductor (7) is pressed and the end face (9) of the conductor (7) additionally pressed firmly against the bottom (2) of the contact part (1). The bottom (2) of the contact part (1) and the end face (9) of the conductor (7) are then connected to one another in a material-locking manner.

Description

Die Erfindung bezieht sich auf ein Verfahren zum elektrischen Verbinden eines Leiters auf Basis von Aluminium mit einem Kontaktteil, mit welchem ein kappenartiges Kontaktteil, das einen Boden und eine mit diesem verbundene und von diesem abstehende zylindrische Hülse aufweist, so auf den Leiter aufgesteckt wird, daß die Stirnfläche des Leiters am Boden des Kontaktteils aufliegt.The invention relates to a method for electrically connecting an aluminum-based conductor with a contact part, with which a cap-like contact part, which has a bottom and a connected thereto and projecting from this cylindrical sleeve, is plugged onto the conductor, that the end face of the conductor rests on the bottom of the contact part.

In der Elektrotechnik und insbesondere in der Automobilelektronik kommen eine Vielzahl von elektrischen Einzelleitern und mit diesen verbundenen Kontaktelementen auf Kupferbasis zum Einsatz, um elektrische Verbindungen zu Aktuatoren, Sensoren, Steuerelementen, Batterien usw. herzustellen.In electrical engineering, and in particular in automotive electronics, a large number of individual electrical conductors and copper-based contactors connected thereto are used to make electrical connections to actuators, sensors, control elements, batteries, etc.

Bei den elektrischen Leitern handelt es sich in den meisten Fällen um flexible isolierte Litzenleiter auf Basis von Aluminium, d.h. bestehend aus Aluminium oder einer Aluminiumlegierung. Aluminium wird insbesondere in Kraftfahrzeugen und Flugzeugen aus Kosten- und Gewichtsgründen vermehrt verwendet, wobei die geringere elektrische Leitfähigkeit des Aluminiums gegenüber Kupfer für die meisten Anwendungen keine Rolle spielt.The electrical conductors are in most cases flexible aluminum insulated stranded conductors, i. consisting of aluminum or an aluminum alloy. Aluminum is increasingly being used in automobiles and aircraft for cost and weight reasons, with the lower electrical conductivity of the aluminum to copper being irrelevant for most applications.

Die Kontaktteile auf Kupferbasis bestehen aus Kupfer oder aus einer Kupferlegierung, beispielsweise Messing, wobei die Kontaktteile beschichtet, beispielsweise verzinnt, sein können. Die Kontaktteile können beispielsweise mit einem abisolierten Leiterende verschweißt werden. Der elektrische Leiter und das Kontaktelement werden dabei kraft- und/oder stoffschlüssig miteinander verbunden.The contact parts based on copper are made of copper or a copper alloy, for example brass, wherein the contact parts coated, for example, tinned, can be. The contact parts can be welded, for example, with a stripped conductor end. The electrical conductor and the contact element are positively and / or cohesively connected to each other.

An der Oberfläche von Aluminium entsteht unter Sauerstoffeinfluß eine elektrisch nicht gut leitende Oxidschicht, deren Dicke mit der Zeit zunimmt. Dieser Mangel macht sich insbesondere bei aus einer Vielzahl von Einzeldrähten bestehenden Litzenleitern bemerkbar, da jeder Einzeldraht, sofern er nicht einer Sonderbehandlung unterlegen ist, von einer solchen Oxidschicht umgeben ist. Um einen einwandfreien elektrischen Kontakt zu gewährleisten, muß die Oxidschicht entweder vor dem Verbinden des Leiters mit dem Kontaktteil entfernt oder während des Verbindens durchdrungen werden. Diese Problematik ist in zahlreichen Druckschriften beschrieben, von denen im Folgenden eine beispielhaft erwähnt wird.Under the influence of oxygen, an oxide layer which does not conduct electricity well, the thickness of which increases over time, forms on the surface of aluminum. This deficiency is particularly noticeable in existing from a plurality of individual wires stranded conductors noticeable, since each individual wire, if he is not inferior to a special treatment, of such Oxide layer is surrounded. To ensure proper electrical contact, the oxide layer must either be removed before connecting the conductor to the contact portion or penetrated during bonding. This problem is described in numerous publications, of which an example is mentioned below.

Die EP 1 032 077 B1 beschreibt ein Verfahren zum Verbinden eines Aluminiumkabels, insbesondere eines Litzenleiters, mit einem Anschlußteil auf Kupferbasis. Dazu wird auf das abisolierte Ende des Leiters eine Hülse aus Aluminium aufgebracht, welche die einzelnen Drähte zusammendrückt und einander annähert, um eine metallische Fläche an der Stirnseite des Kabels zu erhalten. Die Stirnseite wird dann mit dem Anschlußteil stumpf verschweißt, wobei die Oxidschicht an der Stirnseite beseitigt wird.The EP 1 032 077 B1 describes a method for connecting an aluminum cable, in particular a stranded conductor, with a copper-based connector. For this purpose, a sleeve made of aluminum is applied to the stripped end of the conductor, which compresses the individual wires and approaches each other to obtain a metallic surface on the front side of the cable. The front side is then butt welded to the terminal part, wherein the oxide layer is removed at the end face.

Der Erfindung liegt die Aufgabe zugrunde, ein Verfahren zum elektrischen Verbinden eines Leiters auf Aluminiumbasis mit einem Kontaktteil bereitzustellen, durch welches eine wirksame, mindestens den gesamten Querschnitt des Aluminiumleiters erfassende elektrisch leitende Verbindung zu dem Kontaktteil erreicht werden kann.The invention has for its object to provide a method for electrically connecting an aluminum-based conductor with a contact part, through which an effective, at least the entire cross section of the aluminum conductor detected electrically conductive connection to the contact part can be achieved.

Diese Aufgabe wird gemäß der Erfindung dadurch gelöst,

  • daß das Kontaktteil einen ersten stabilen Zustand aufweist, in dem das Kontaktteil auf den Leiter aufgesteckt wird, ohne daß die Hülse an dem Leiter anliegt,
  • daß die zylindrische Hülse an deren dem Boden gegenüberliegenden Ende in radialer Richtung nach innen weisende Vorsprünge aufweist und in einem zweiten stabilen Zustand unter Spannung an der Außenseite des Leiters anliegt, wobei die Vorsprünge in die Außenseite des Leiters gedrückt und die Stirnseite des Leiters zusätzlich fest an den Boden des Kontaktteils angedrückt werden, und
  • daß der Boden des Kontaktteils und die Stirnfläche des Leiters anschließend stoffschlüssig miteinander verbunden werden.
This object is achieved according to the invention characterized
  • that the contact part has a first stable state, in which the contact part is plugged onto the conductor, without the sleeve being in contact with the conductor,
  • in that the cylindrical sleeve has radially inwardly directed projections at its end opposite the bottom and bears against the outside of the conductor under tension in a second stable state, wherein the projections are pressed into the outside of the conductor and the front side of the conductor is additionally firmly fixed the bottom of the contact part are pressed, and
  • that the bottom of the contact part and the end face of the conductor are then materially connected to one another.

Das erfindungsgemäße Verfahren erlaubt eine solide mechanische und elektrische Verbindung zwischen dem Leiter und dem Kontaktteil in einfachen, kostengünstigen Arbeitsschritten. Durch die unter Spannung an dem Leiter anliegende Hülse des Kontaktteils werden die Vorsprünge der Hülse so in die Außenseite des Leiters gedrückt, daß die äußere Oxidschicht, welche sich auf dem Aluminium gebildet haben kann, zerstört wird. Dadurch ist eine elektrische Verbindung zwischen Leiter und Kontaktteil nicht nur über die Stirnseite des Leiters, sondern auch über dessen Seitenfläche gewährleistet.The inventive method allows a solid mechanical and electrical connection between the conductor and the contact part in simple, inexpensive work steps. By the voltage applied to the conductor sleeve of the contact part, the projections of the sleeve are pressed into the outside of the conductor so that the outer oxide layer, which may have formed on the aluminum, is destroyed. As a result, an electrical connection between the conductor and the contact part is ensured not only via the end face of the conductor but also via its side surface.

Ein Ausführungsbeispiel des Erfindungsgegenstandes ist in den Zeichnungen dargestellt. Es zeigen:

  • Fig. 1 eine perspektivische und eine Längsschnittansicht eines Kontaktteils in einem ersten stabilen Zustand,
  • Fig. 2 eine perspektivische und eine Längsschnittansicht des Kontaktteils in einem zweiten stabilen Zustand,
  • Fig. 3 einen Leiter und das mit dem Leiter verbundene Kontaktteil im Längsschnitt und in Draufsicht,
  • Fig. 4, in schematischer Ansicht, das vom Kontaktteil umschlossene Ende des Leiters zusammen mit einem angedeuteten Werkzeug, und
  • Fig. 5 das Leiterende mit in das Kontaktteil eingedrungenem Werkzeug.
An embodiment of the subject invention is shown in the drawings. Show it:
  • Fig. 1 a perspective and a longitudinal sectional view of a contact part in a first stable state,
  • Fig. 2 a perspective and a longitudinal sectional view of the contact part in a second stable state,
  • Fig. 3 a conductor and the contact part connected to the conductor in longitudinal section and in plan view,
  • Fig. 4 in a schematic view, the enclosed by the contact part end of the conductor together with an indicated tool, and
  • Fig. 5 the conductor end with penetrated into the contact part tool.

In den Fig. 1 und 2 ist ein Ausführungsbeispiel eines Kontaktteils schematisch dargestellt, welches mit dem erfindungsgemäßen Verfahren elektrisch mit einem Leiter auf Basis von Aluminium verbunden werden soll. Fig. 1 zeigt das Kontaktteil 1 ein einem ersten stabilen Zustand in einer perspektivischen und einer Längsschnittansicht. Der erste stabile Zustand entspricht einem offenen Zustand, in welchem das Kontaktteil 1 locker auf den Leiter aufgesteckt werden kann. Fig. 2 zeigt das Kontaktteil 1 in einem zweiten stabilen Zustand in einer perspektivischen und einer Längsschnittansicht. Der zweite stabile Zustand entspricht einem geschlossenen Zustand, in welchem das Kontaktteil 1 fest auf dem Leiter verbunden ist.In the Fig. 1 and 2 an embodiment of a contact part is shown schematically, which is to be electrically connected to the inventive method with a conductor based on aluminum. Fig. 1 shows the contact part 1 a first stable state in a perspective and a longitudinal sectional view. The first stable state corresponds to an open state, in which the contact part 1 can be easily attached to the conductor. Fig. 2 shows the contact part 1 in a second stable state in a perspective and a longitudinal sectional view. The second stable state corresponds to a closed state in which the contact part 1 is fixedly connected on the conductor.

Das kappenartige Kontaktteil 1 weist einen Boden 2 und eine mit dem Boden 2 verbundene und von diesem abstehende, zylindrische Hülse 3 auf. Im gezeigten Beispiel besteht die zylindrische Hülse 3 aus mehreren einzelnen, vom Boden 2 abstehenden Klappen 4. Die Klappen 4 weisen jeweils an deren dem Boden gegenüberliegenden Enden einen in radialer Richtung nach innen zeigenden Vorsprung 5 auf. I m geschlossen Zustand des Kontaktteils 1 bilden die einzelnen Vorsprünge 5 einen geschlossenen Ring, wie in Fig. 2 gezeigt. Das Kontaktteil 1 hat außerdem ein Verbindungselement 6, mittels welchem der mit dem Kontaktteil 1 verbundene Leiter elektrisch mit Aktuatoren, Sensoren, Steuerelementen usw. verbunden werden kann. Das Kontaktteil 1 besteht mit Vorteil aus zwei verschiedenen Materialien. Das Verbindungselement 6 besteht vorzugsweise aus Kupfer oder aus einer Kupferlegierung. Der Boden 2 sowie die Hülse 3 bestehen mit Vorteil aus einem Metall mit für die zwei stabilen Zustände des Kontaktteils 1 geeigneten mechanischen Eigenschaften, beispielsweise aus Federstahl.The cap-like contact part 1 has a bottom 2 and connected to the bottom 2 and projecting from this, cylindrical sleeve 3. In the example shown, the cylindrical sleeve 3 consists of a plurality of individual, projecting from the bottom 2 flaps 4. The flaps 4 each have at their opposite ends of the bottom on a radially inwardly facing projection 5. In the closed state of the contact part 1, the individual projections 5 form a closed ring, as in FIG Fig. 2 shown. The contact part 1 also has a connecting element 6, by means of which the conductor connected to the contact part 1 can be electrically connected to actuators, sensors, control elements, etc. The contact part 1 is advantageously made of two different materials. The connecting element 6 is preferably made of copper or of a copper alloy. The bottom 2 and the sleeve 3 are advantageously made of a metal with suitable for the two stable states of the contact part 1 mechanical properties, such as spring steel.

Der elektrische Leiter auf Aluminiumbasis kann entweder ein aus einer Vielzahl von Einzeldrähten bestehender Litzenleiter oder ein massiver Einzelleiter sein.The aluminum-based electrical conductor may be either a stranded conductor made up of a plurality of individual wires or a solid single conductor.

Die Durchführung des erfindungsgemäßen Verfahrens wird mit Bezugnahme auf Fig. 3 beschrieben. Zunächst muß das Leiterende von gegebenenfalls vorhandenen Schichten, z.B. von einer eventuell vorhandenen Isolierung 8, befreit werden. Das kappenartige Kontaktteil 1 wird anschließend so weit auf den Leiter 7 aufgesteckt, bis die Stirnfläche 9 des Leiters 7 am Boden 2 des Kontaktteils 1 anliegt. Während des Aufsteckens des Kontaktteils 1 befindet sich dieses in seinem ersten stabilen Zustand (s. Fig. 1), so daß die Hülse 3 nicht an dem Leiter 7 anliegt. Der Boden 2 des Kontaktteils ist dabei nach innen gewölbt. Anschließend wird das Kontaktteil 1 in seinen zweiten stabilen Zustand (s. Fig. 2) gebracht, so daß die zylindrische Hülse 3 unter Spannung an der Außenseite des Leiters anliegt. Dabei werden die Vorsprünge 5 der Hülse 3 in die Außenseite des Leiters 7 gedrückt und die Stirnseite 9 des Leiters 7 zusätzlich fest an den Boden des Kontaktteils angedrückt. Eventuell vorhandene Oxidschichten auf dem Leiter 7 werden durch die in die Leiteraußenseite eingedrückten Vorsprünge 5 aufgebrochen, so daß sie die elektrisch leitende Verbindung zwischen Leiter und Kontaktteil nicht behindern. Der Boden 2 des Kontaktteils 1 ist nun nach außen gewölbt. Durch die Vorsprünge 5 wird die Stirnfläche 9 des Leiters 7 in Kontakt mit dem Boden 2 des Kontaktteils 1 gehalten. Abschließend werden der Boden 2 des Kontaktteils 1 und die Stirnfläche 9 des Leiters 7 stoffschlüssig miteinander verbunden.The implementation of the method according to the invention is described with reference to Fig. 3 described. First, the conductor end of any existing layers, such as any existing insulation 8, must be exempted. The cap-like contact part 1 is then placed so far on the conductor 7 until the end face 9 of the conductor 7 rests against the bottom 2 of the contact part 1. During the attachment of the contact part 1, this is in its first stable state (s. Fig. 1 ), so that the sleeve 3 is not applied to the conductor 7. The bottom 2 of the contact part is curved inwards. Subsequently, the contact part 1 in its second stable state (s. Fig. 2 ), so that the cylindrical sleeve 3 rests under tension on the outside of the conductor. The projections 5 of the sleeve 3 are pressed into the outside of the conductor 7 and the end face 9 of the conductor 7 additionally pressed firmly against the bottom of the contact part. Any existing oxide layers on the conductor 7 are by in the Broken head outside pressed projections 5 so that they do not hinder the electrically conductive connection between the conductor and contact part. The bottom 2 of the contact part 1 is now arched outwards. By the projections 5, the end face 9 of the conductor 7 is held in contact with the bottom 2 of the contact part 1. Finally, the bottom 2 of the contact part 1 and the end face 9 of the conductor 7 are firmly bonded together.

Der Übergang zwischen dem ersten und dem zweiten stabilen Zustand des Kontaktteils 1 kann beispielsweise dadurch erfolgen, daß die Klappen 4 der Hülse 3 zusammengedrückt werden. Diese elastische Verformung ist rückgängig zu machen, indem beispielsweise auf den Boden 2 des Kontaktteils 1 gedrückt wird.The transition between the first and the second stable state of the contact part 1 can be effected, for example, characterized in that the flaps 4 of the sleeve 3 are compressed. This elastic deformation is reversed, for example, by pressing on the bottom 2 of the contact part 1.

Das stoffschlüssige Verbinden des Bodens des Kontaktteils mit der Stirnfläche des Leiters kann durch ein geeignetes Schweißverfahren erfolgen, beispielsweise durch Rührreibschweißen. Beim Rührreibschweißen wird die für eine Verschweißung von Kontaktteil und Leiter benötigte erhöhte Temperatur durch Reibung erzeugt. Dabei verbindet sich das Aluminium oder die Aluminiumlegierung des Leiters bei einer unterhalb der Schmelztemperatur derselben liegenden Temperatur sich mit dem Kupfer oder Kupferlegierung des Kontaktteils stoffschlüssig. Bei diesem Verfahrensschritt wird der Boden des Kontaktteils nicht durchbrochen. Wie in Fig. 4 schematisch angedeutet, wird an das Kontaktteil 1 ein Werkzeug 10 angelegt, welches an seiner Stirnfläche mit einem stiftartigen Vorsprung 11 ausgerüstet sein kann. Das Werkzeug 10 besteht mit Vorteil aus Stahl. Durch die Drehung des Werkzeugs 10 um seine Achse A wird der Boden 2 des Kontaktteils 1 durch Reibung erwärmt. Das Werkzeug 10 wird in Richtung des Pfeiles P bewegt und mit anhaltendem Druck gegen den Boden 2 des Kontaktteils 1 gedrückt, so daß das Material desselben durch Reibung erwärmt wird. Die Wärme wird vom Kontaktteil 1 auf die Stirnseite des Leiters 7 übertragen. Das Material des Leiters 7 verbindet sich daraufhin stoffschlüssig mit dem Kontaktteil 1. Der von der Stirnseite des Werkzeugs in axialer Richtung abstehende Vorsprung 11 drückt den Boden 2 des Kontaktteils 1 bei Anlage an demselben ein, wie es aus Fig. 5 hervorgeht. Dadurch erhöht sich die Kontaktoberfläche zwischen dem Leiter 7 und dem Kontaktteil 1. Auch hier werden eventuell vorhandene Oxidschichten am Leiter 7 beim Verschweißen aufgebrochen, so daß sie die elektrisch leitende Verbindung zwischen Leiter 7 und Kontaktteil 1 nicht behindern.The cohesive connection of the bottom of the contact part with the end face of the conductor can be effected by a suitable welding method, for example by friction stir welding. In friction stir welding, the increased temperature required for welding the contact part and the conductor is generated by friction. In this case, the aluminum or aluminum alloy of the conductor combines at a temperature below the melting temperature of the same temperature with the copper or copper alloy of the contact part cohesively. In this process step, the bottom of the contact part is not broken. As in Fig. 4 indicated schematically, a tool 10 is applied to the contact part 1, which may be equipped on its end face with a pin-like projection 11. The tool 10 is advantageously made of steel. By the rotation of the tool 10 about its axis A, the bottom 2 of the contact part 1 is heated by friction. The tool 10 is moved in the direction of the arrow P and pressed with continued pressure against the bottom 2 of the contact part 1, so that the material thereof is heated by friction. The heat is transferred from the contact part 1 to the front side of the conductor 7. The material of the conductor 7 then connects cohesively with the contact part 1. The protruding from the end face of the tool in the axial direction projection 11 presses the bottom 2 of the contact part 1 when it rests against the same, as it out Fig. 5 evident. This increases the contact surface between the conductor 7 and the contact part 1. Again, any existing oxide layers on the conductor 7 are broken during welding, so that they do not hinder the electrically conductive connection between the conductor 7 and contact part 1.

Claims (5)

Verfahren zum elektrischen Verbinden eines Leiters (7) auf Basis von Aluminium mit einem Kontaktteil (1), mit welchem ein kappenartiges Kontaktteil (1), das einen Boden (2) und eine mit diesem verbundene und von diesem abstehende zylindrische Hülse (3) aufweist, so auf den Leiter (7) aufgesteckt wird, daß die Stirnfläche (9) des Leiters (7) am Boden (2) des Kontaktteils (1) aufliegt, dadurch gekennzeichnet, - daß das Kontaktteil (1) einen ersten stabilen Zustand aufweist, in dem das Kontaktteil (1) auf den Leiter (7) aufgesteckt wird, ohne daß die Hülse (3) an dem Leiter (7) anliegt, - daß die zylindrische Hülse (3) an deren dem Boden gegenüberliegenden Ende in radialer Richtung nach innen weisende Vorsprünge (5) aufweist und in einem zweiten stabilen Zustand unter Spannung an der Außenseite des Leiters (7) anliegt, wobei die Vorsprünge (5) in die Außenseite des Leiters (7) gedrückt und die Stirnseite (9) des Leiters (7) zusätzlich fest an den Boden (2) des Kontaktteils (1) angedrückt werden, und - daß der Boden (2) des Kontaktteils (1) und die Stirnfläche (9) des Leiters (7) anschließend stoffschlüssig miteinander verbunden werden. Method for electrically connecting an aluminum-based conductor (7) to a contact part (1) to which a cap-like contact part (1) has a base (2) and a cylindrical sleeve (3) connected thereto and protruding therefrom , is placed on the conductor (7), that the end face (9) of the conductor (7) on the bottom (2) of the contact part (1) rests, characterized - That the contact part (1) has a first stable state in which the contact part (1) on the conductor (7) is fitted without the sleeve (3) on the conductor (7) is present, - That the cylindrical sleeve (3) at its bottom opposite end in the radial direction inwardly facing projections (5) and in a second stable state under tension on the outside of the conductor (7) is applied, wherein the projections (5) in pressed the outside of the conductor (7) and the end face (9) of the conductor (7) additionally pressed firmly against the bottom (2) of the contact part (1), and - That the bottom (2) of the contact part (1) and the end face (9) of the conductor (7) are then materially connected to each other. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß die Stirnfläche (9) des Leiters (7) und der Boden (2) des Kontaktteils (1) mittels Rührreibschweißen miteinander verschweißt werden, wobei der Boden (2) des Kontaktteils (1) nicht durchbrochen wird.A method according to claim 1, characterized in that the end face (9) of the conductor (7) and the bottom (2) of the contact part (1) are welded together by friction stir welding, wherein the bottom (2) of the contact part (1) is not broken , Verfahren nach Anspruch 2, dadurch gekennzeichnet, daß ein sich drehendes Werkzeug an den Boden (2) des Kontaktteils (1) mit anhaltendem Druck angelegt wird, bis infolge von dabei durch Reibung erzeugter höherer Temperatur das Material des Leiters (7) so erweicht wird, daß es sich stoffschlüssig mit dem Kontaktteil (1) verbindet.Method according to Claim 2, characterized in that a rotating tool is applied to the bottom (2) of the contact part (1) with sustained pressure until the material of the conductor (7) is softened as a result of the higher temperature generated by friction. that it connects cohesively to the contact part (1). Verfahren nach Anspruch 3, dadurch gekennzeichnet, daß das Werkzeug an seiner zur Anlage am Kontaktteil (1) bestimmten Stirnfläche einen von derselben in axialer Richtung abstehenden Vorsprung aufweist, welcher den Boden (2) des Kontaktteils (1) bei Anlage an demselben eindrückt.A method according to claim 3, characterized in that the tool has on its end face for abutment against the contact part (1) has a protruding from the same in the axial direction projection, which presses the bottom (2) of the contact part (1) when it rests against the same. Verfahren nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, daß der Leiter (7) ein aus einer Vielzahl von Einzeldrähten bestehender Litzenleiter ist.Method according to one of the preceding claims, characterized in that the conductor (7) is one of a plurality of individual wires existing stranded conductor.
EP13306745.4A 2013-12-17 2013-12-17 Method for electrically connecting a conductor on the basis of aluminium with a contact member Active EP2887459B1 (en)

Priority Applications (2)

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ES13306745.4T ES2657835T3 (en) 2013-12-17 2013-12-17 Procedure for the electrical connection of an aluminum-based conductor with a contact piece
EP13306745.4A EP2887459B1 (en) 2013-12-17 2013-12-17 Method for electrically connecting a conductor on the basis of aluminium with a contact member

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Cited By (2)

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Publication number Priority date Publication date Assignee Title
EP3291375A1 (en) * 2016-09-01 2018-03-07 Nexans Method for electrically conductive connection of electrical conductors
CN109841968A (en) * 2017-11-24 2019-06-04 矢崎总业株式会社 Terminal connection method

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US3831132A (en) * 1971-04-29 1974-08-20 Molex Inc Crimp terminal for aluminum wire
US3955044A (en) * 1970-12-03 1976-05-04 Amp Incorporated Corrosion proof terminal for aluminum wire
US4229063A (en) * 1975-06-24 1980-10-21 Yazaki Corporation Pressure terminal for use with aluminum wire
EP1032077B1 (en) 1999-02-24 2010-01-06 Auto Kabel Managementgesellschaft mbH Connection of an electrical aluminium cable with terminal made of copper or like metal
WO2010094005A1 (en) * 2009-02-16 2010-08-19 Tensolite Company Terminal having integral oxide breaker
DE102011017070A1 (en) * 2011-04-14 2012-10-18 Auto-Kabel Managementgesellschaft Mbh Production of an electric cable and method for producing a connection

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AT512881B1 (en) * 2012-05-11 2014-03-15 Gebauer & Griller Connection of an electrical cable to a contact part and method of making this connection

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US3955044A (en) * 1970-12-03 1976-05-04 Amp Incorporated Corrosion proof terminal for aluminum wire
US3831132A (en) * 1971-04-29 1974-08-20 Molex Inc Crimp terminal for aluminum wire
US4229063A (en) * 1975-06-24 1980-10-21 Yazaki Corporation Pressure terminal for use with aluminum wire
EP1032077B1 (en) 1999-02-24 2010-01-06 Auto Kabel Managementgesellschaft mbH Connection of an electrical aluminium cable with terminal made of copper or like metal
WO2010094005A1 (en) * 2009-02-16 2010-08-19 Tensolite Company Terminal having integral oxide breaker
DE102011017070A1 (en) * 2011-04-14 2012-10-18 Auto-Kabel Managementgesellschaft Mbh Production of an electric cable and method for producing a connection

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3291375A1 (en) * 2016-09-01 2018-03-07 Nexans Method for electrically conductive connection of electrical conductors
CN109841968A (en) * 2017-11-24 2019-06-04 矢崎总业株式会社 Terminal connection method

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EP2887459B1 (en) 2017-11-15

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