EP2899810A1 - Cosse - Google Patents

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Publication number
EP2899810A1
EP2899810A1 EP14152535.2A EP14152535A EP2899810A1 EP 2899810 A1 EP2899810 A1 EP 2899810A1 EP 14152535 A EP14152535 A EP 14152535A EP 2899810 A1 EP2899810 A1 EP 2899810A1
Authority
EP
European Patent Office
Prior art keywords
cable
lug
connection region
connection
region
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.)
Withdrawn
Application number
EP14152535.2A
Other languages
German (de)
English (en)
Inventor
Christoph Baumgartner
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.)
Intercable GmbH
Original Assignee
Intercable GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Intercable GmbH filed Critical Intercable GmbH
Priority to EP14152535.2A priority Critical patent/EP2899810A1/fr
Publication of EP2899810A1 publication Critical patent/EP2899810A1/fr
Withdrawn legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/70—Insulation of connections
    • H01R4/72—Insulation of connections using a heat shrinking insulating sleeve
    • 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
    • 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
    • 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
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/005—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for making dustproof, splashproof, drip-proof, waterproof, or flameproof connection, coupling, or casing

Definitions

  • the invention relates to the technical field of connection technology.
  • the invention relates to a cable lug, a cable end connection between a cable lug and a cable and a method for producing a cable lug.
  • cable lugs can be used, which are electrically and mechanically connected to one end of the current-carrying cable.
  • the cable lug at the end of the cable can then be screwed or plugged together, for example, with a current-carrying element.
  • the EP 2 579 390 A1 shows a cable lug, in which the claw area with the connection point for the aluminum cable is made of aluminum and the connection area is made of copper. The transition region between copper and aluminum is sealed by an encapsulation.
  • the production of this cable lug is relatively expensive, since a plurality of parts made of different materials must be connected to each other.
  • the EP 2 141 771 A1 shows a cable lug, in which a junction is closed with an aluminum cable with cured plastic.
  • a cable lug or terminal for connection to a cable.
  • a cable lug comprises a metal strip usually made of sheet metal, which at one end (at a Terminal area) with an electrical element and at another end (at a connection area) can be connected to the cable.
  • the cable lug comprises a strip-shaped sheet metal element having a connection region for connecting the cable lug to a current-carrying element and a connection region for connecting the cable lug to the cable, wherein the connection region and the connection region are made of the same metal material (for example in one piece), and a plastic element, which surrounds the sheet-metal element in an annular manner between the connection region and the connection region and in particular secures and / or seals the connection region with respect to the connection region in a media-tight manner.
  • the plastic element can be designed to form a transition to a shrinking tube enclosing the connection region.
  • the cable lug can have a cover cap (26) for the connection area.
  • the metal components of the cable lug are in particular made in one piece and / or one-material.
  • the sheet metal element such as a stamped and bent part of a sheet, can be punched out in a simple manner.
  • a plastic element is placed, which allows a seal between a shrink tube and the sheet metal part.
  • the sheet metal element is made of copper.
  • the sheet metal element can also be nickel-plated.
  • the electrical conductor of the cable may for example comprise at least one or more aluminum strands.
  • the contact between the cable and the cable lug can be realized, for example, by means of ultrasonic welding, by pressing the electrical conductor of the cable approximately with the welding electrode against the connection region.
  • the connection region comprises a flat contact region, which is connectable to an electrical conductor of the cable, and has a rounded receiving region for receiving an end portion of the cable.
  • An insulated area of the cable can be placed in the rounded receiving area and fixed therein (for example with one or two claws).
  • a stripped end of the cable, which comes to lie in the flat contact area, and which comprises, for example, a strand bundle, can then be welded to the cable lug.
  • the connecting region has at least one or two claws which protrude from the cable lug and which can be clamped around the cable for mechanically fixing the cable to the lug.
  • the claws may for example be designed asymmetrically, so that they are deposited after bending one behind the other on the cable.
  • the claw (and optionally the rounded receiving area) has a smaller thickness than the connecting area or a front part of the connecting area.
  • the claw for example, placed around the insulation of the cable can be made of thinner material than the rest of the sheet metal element to keep the space around the cable as low as possible in order to simplify the transfer and / or to save weight. Manufacturing technology, this can be realized by reducing or compressing the starting sheet in this area.
  • connection region and at least part of the connection region run parallel and are connected to one another by means of a step with two right-angled kinks in the strip-shaped sheet metal element.
  • a front gradation to the connection area of the cable lug can be realized by means of two 90 ° kinks or bends. On the one hand, this can shorten the component length.
  • the step can serve as a stop when positioning the shrink tube, so that it does not unintentionally partially cover the connection area.
  • the double 90 ° bend can additionally serve as a sound barrier during ultrasonic welding. During the welding process by means of ultrasound sound waves in the component can not spread uncontrollably and continue to run at the other end of the component then cracking or destruction.
  • the plastic element is injected around the strip-shaped sheet metal element.
  • the strip-shaped sheet metal element which was subsequently possibly provided with a surface coating, be surrounded after punching with the plastic element.
  • the plastic element has at least one inner sealing element of a first plastic material and an outer sealing element of a second plastic material, which completely covers the inner sealing element.
  • the plastic element may also have two inner sealing elements which surround the strip-shaped sheet metal element in succession.
  • the one or more inner sealing elements can be injected in a first step around the strip-shaped sheet metal element or applied by injection molding.
  • the inner peripheral sealing elements may be made of a thermoplastic, which allows adhesion to the metal part, be prepared. Two consecutive sealing elements serve as a double barrier.
  • the plastic element has a wavy outer contour.
  • a labyrinth-shaped wave structure and optionally convex outer surfaces can be well grasped by the shrink tube and fix the shrink tube relative to the cable lug.
  • the cable lug further comprises a cap adapted to cover a contact region of the connection region to cover an electrical connection between an electrical conductor of the cable and the cable lug.
  • the cap may be provided to be placed over a welding node after welding. The cap is to prevent individual, projecting individual wires or strands of the electrical conductor of the cable protrude outward and can pierce the shrink tube.
  • the cable lug has lateral depressions and the cap has snap-action elements which are designed to latch in the lateral depressions.
  • the cap may be molded from plastic material so that the snap elements can be easily manufactured. After establishing the connection between the cable and cable lug, the cap can be placed and latched or clipped on the sheet metal element. Thereafter, the shrink tubing can be pulled over and shrunk.
  • the cable end connection may further include a cable having an electrical conductor to be used with welded to the connecting portion of the cable lug, and a shrink tube, which is shrunk onto the plastic element and the connecting portion include.
  • the shrink tubing may additionally be shrunk onto a claw region (in which the claws fix the cable lug to the cable) and an insulated portion of the cable.
  • the shrink tube covers a cap for covering a weld between the cable lug and the electrical conductor.
  • the cap protects the shrink tube from damage, for example, by strands that protrude from the weld.
  • a further aspect of the invention relates to a method for producing a cable lug, for example a cable lug, as described above and below.
  • the method comprises: producing a strip-shaped sheet metal element made of a metal material with a connection region for connecting the cable lug to a current-carrying element and a connection region for connecting the cable lug to the cable, and encapsulating the strip-shaped sheet metal element with a plastic element that surrounds the sheet metal element between the connection area and the connection area annularly encloses and separates the connection area with respect to the connection area and / or seals.
  • the strip-shaped sheet-metal element can be punched out and bent, and the preformed (and possibly coated) sheet metal part can then be extrusion-coated with the plastic element in the region between the connection region and the connection region.
  • the method further comprises: providing or finishing the surface of the strip-shaped sheet-metal element a surface coating, for example by electroplating and / or nickel plating.
  • the sheet metal element may be provided with a surface coating as a corrosion protection and / or as a primer for a welded joint.
  • the method further comprises: providing a cap for covering a weld in the joint area.
  • This cap can be clipped onto the cable lug after the aluminum cable has been welded to the cable lug, for example.
  • the method for producing the cable lug can be part of a method for producing a cable end connection, in which, for example, the cable lug is welded to an electrical conductor of the cable, the welding point is optionally covered with a cap, and then a shrinking loop is shrunk onto the plastic body and the welding point.
  • the cable end connection can be sealed with the heat-shrinkable tube which, for example, can also be connected to the plastic element with an internal adhesive and / or insulation at the cable end.
  • the Fig. 1 shows a perspective view of a cable end connection according to an embodiment of the invention.
  • the Fig. 2 shows a longitudinal section through the cable end of the Fig. 1 ,
  • the Fig. 3 shows a longitudinal section through a cable lug according to an embodiment of the invention.
  • the Fig. 4 shows a view of a cable lug in the longitudinal direction according to an embodiment of the invention.
  • Fig. 4 to 7 show perspective views of elements of a cable lug according to an embodiment of the invention and illustrate a method of manufacturing a cable lug.
  • Figs. 8A and 8B show two perspective views of a cap for a cable lug according to an embodiment of the invention
  • FIGS. 9 and 10 12 show perspective views of a cable end connection according to an embodiment of the invention and illustrate a method for producing a cable end connection.
  • the Fig. 1 and 2 show a cable end connection 10 of a cable 12 and a cable lug 14 in a three-dimensional view and in longitudinal section.
  • the cable 12 comprises an outer insulation 16 and an electrical conductor 18, which is usually composed of a plurality of strands 20. However, it is also possible that the electrical conductor only from a single strand or as Solid conductor is constructed.
  • the electrical conductor 18 and the strands 20 are approximately made of aluminum, a light metal or an aluminum alloy.
  • the cable lug 14 comprises a multi-curved strip-shaped sheet metal element 22, a plastic element 24 surrounding the sheet metal element and a cap 26.
  • the sheet member 22 is unitary and made of the same metal material, such as copper or a copper alloy.
  • the sheet metal element 22 may additionally be galvanized, for example nickel-plated.
  • the sheet metal element 22 is constructed from a first portion 28 of equal thickness and a second portion 30 of lesser thickness.
  • the first portion 28 comprises two planar portions 32, 34 which are interconnected via a right-angled step 36 (with two 90 ° angles).
  • the two regions 32, 34 are substantially parallel and are interconnected by the step 36 via two 90 ° curves.
  • the second section 30 comprises a trough-shaped receiving region 38 with a circular cross section, which merges laterally into two claws 40. Both the receiving area 38 and the claws 40 have a reduced thickness relative to the first section in order to save weight and to facilitate curling of the claws.
  • the claws 40 may be configured asymmetrically, so that they do not overlap when bent over the cable 12, but come in succession on the cable 12 to lie down.
  • the first section 28 provides with the planar region 32 a connection region 32 which, as shown here, may have a hole 42 with which the cable lug can be fastened to a current-carrying element by means of a screw or rivet.
  • the planar region 34 of the first section 28 and the second section 30 represent a connection region 44 of the cable lug 14.
  • the planar region 34 serves for electrically connecting the cable 12 and the second section 30 for mechanically connecting the cable 12.
  • the plastic element 24 encloses the cable lug 14 in the first section 28 between the connection region 32 and the contact region 34.
  • the plastic element 24 is located on the side of the contact region 34 with respect to the step 36.
  • the plastic element 24 has a wavy outer contour 46 (or labyrinth), which serves to prevent a shrink tubing slipping in the longitudinal direction.
  • the shrink tube can lay down in several circumferentially extending recesses, which fix it to the cable lug 14.
  • the plastic element 24 is made of two different materials. However, it is also possible to manufacture a corresponding plastic element from only one material.
  • Two inner sealing elements 48 surround the strip-shaped sheet metal element 22 annularly one behind the other. However, it is also possible that the cable lug is provided with only one inner sealing element. However, two inner sealing elements 48 can increase the sealing effect.
  • the inner sealing elements 48 or their plastic material is chosen such that they develop a sealing action between the connection region 32 and the connection region 44 even when the sheet metal element 22 is deformed (for example due to thermal expansion). By providing two inner ones Sealing elements 48 creates a double barrier against penetrating liquid.
  • the plastic material of the inner sealing member 48 may be a special thermoplastic such as a thermoplastic for metal insert insert molding.
  • the inner sealing elements 48 are completely covered by an outer sealing element 50 which, just like the inner sealing elements 48, touches the surface of the sheet metal element 22.
  • the outer sealing element 50 has on its outer side and the wavy outer contour 46.
  • the plastic material of the outer sealing member 50 may include a thermoplastic such as a special thermoplastic as the housing material and for enclosing the inner sealing members 48
  • the plastic element 24 has a substantially rectangular cross-section in the longitudinal direction.
  • the plastic element 24 has a rounded cross section orthogonal to the longitudinal direction. In the case shown, for example, a rectangle with rounded corners and outwardly curved sides.
  • the cap 26 which can be considered as a protective cap and / or cap 26, covers the contact region 34 of the cable lug 14, for example, to strands 20, which protrude from the cable lug 14 by a welding operation Cover and protect an overlying shrink tubing from these strands.
  • the cap 26 is formed like a blade to receive one end of the electrical conductor under it.
  • snap elements or clips 52 are mounted, which can engage in lateral recesses or recesses 54 which are provided in the contact region 34.
  • the plastic material of the cap 26 may be a thermoplastic such as PP.
  • the Fig. 5 to 8B illustrate a method of manufacturing a cable lug 14.
  • the strip-shaped sheet member 22 is made of a metal material such as a sheet (such as a copper sheet).
  • a metal material such as a sheet (such as a copper sheet).
  • the sheet metal element can be punched out of the sheet, at the same time the receiving area 38 can be pressed thinner with the claws 40.
  • Stage 36 can also be created in this step.
  • the hole 42 can be generated during punching. After that, all edges can be embossed all around. On the one hand, in order not to leave any sharp edges, which could hurt the heat shrink tube or the cable insulation, on the other hand rounded edges reduce the risk of cracking during ultrasonic welding.
  • the strip-shaped sheet metal element 22 can still be provided with a surface coating, such as a nickel layer.
  • the strip-shaped sheet metal element 22 is then encapsulated between the connection region 32 and the connection region 44 with the two annular inner sealing elements 48.
  • the strip-shaped sheet metal element 22 and the inner sealing elements 48 located thereon are encapsulated with the outer sealing element 50.
  • the cap 26 can be made separately from the sheet metal element 22 with the encapsulation 24, for example in a further injection process.
  • FIGS. 9 and 10 illustrate a method for making a cable end connection with the cable lug 14, in which the cable end connection 10 can be assembled, for example, in another factory.
  • the cable 12 is placed on the connecting portion 44 of the cable lug 14 so that the electrical conductor 18 comes to rest on the contact portion 34 and the insulation 16 in the receiving area 38.
  • the electrical conductor 18 is welded to the sheet metal element 22, for example by means of ultrasonic welding.
  • the right-angled step 36 prevents sound waves from propagating into the contact region 32.
  • the weld is covered with the cap 26.
  • the claws 40 are bent over the insulation 16 to mechanically attach the cable to the cable lug 14.
  • a shrink tube 56 is pulled over the end of the insulation 16, the claws 40, the cap 26 and the plastic element.
  • the shrink tube 56 can be pulled on the cable 12 before welding. When positioning the shrink tubing over the cable lug 14 can then serve the stage 36 as a stop for an end of the shrink tube, so that it can not be pulled over the contact area.
  • One end of the shrink tube 56 may be positioned so that its edge is located at the plastic element 24.
  • the shrink tube 56 is shrunk, for example, by heating on the cable lug 14, whereby the transition point (the weld) between the cable lug 14 and the electrical conductor 18 of the cable 12 is sealed from the environment.

Landscapes

  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
EP14152535.2A 2014-01-24 2014-01-24 Cosse Withdrawn EP2899810A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP14152535.2A EP2899810A1 (fr) 2014-01-24 2014-01-24 Cosse

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP14152535.2A EP2899810A1 (fr) 2014-01-24 2014-01-24 Cosse

Publications (1)

Publication Number Publication Date
EP2899810A1 true EP2899810A1 (fr) 2015-07-29

Family

ID=49998149

Family Applications (1)

Application Number Title Priority Date Filing Date
EP14152535.2A Withdrawn EP2899810A1 (fr) 2014-01-24 2014-01-24 Cosse

Country Status (1)

Country Link
EP (1) EP2899810A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3579344A1 (fr) * 2018-06-07 2019-12-11 Gebauer & Griller Kabelwerke Gesellschaft m.b.H. Procédé de surmoulage de cosses de câble à géométries complexes
JP7060319B2 (ja) 2016-07-08 2022-04-26 矢崎総業株式会社 端子付き電線、及び、端子付き電線の製造方法

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2002110263A (ja) * 2000-09-29 2002-04-12 Yazaki Corp 圧着端子
EP2141771A1 (fr) 2008-07-03 2010-01-06 Lisa Dräxlmaier GmbH Mise en contact de conduites en métal léger
EP2579390A1 (fr) 2011-10-05 2013-04-10 WEITKOWITZ Kabelschuhe und Werkzeuge GmbH Terminal en aluminium-cuivre et procédé de fabrication de celui-ci
EP2608318A1 (fr) * 2010-08-17 2013-06-26 Sumitomo Wiring Systems, Ltd. Accessoire de borne
WO2013124151A1 (fr) 2012-02-26 2013-08-29 Kromberg & Schubert Kg Liaison entre une première pièce métallique et une deuxième pièce métallique enrobée

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2002110263A (ja) * 2000-09-29 2002-04-12 Yazaki Corp 圧着端子
EP2141771A1 (fr) 2008-07-03 2010-01-06 Lisa Dräxlmaier GmbH Mise en contact de conduites en métal léger
EP2608318A1 (fr) * 2010-08-17 2013-06-26 Sumitomo Wiring Systems, Ltd. Accessoire de borne
EP2579390A1 (fr) 2011-10-05 2013-04-10 WEITKOWITZ Kabelschuhe und Werkzeuge GmbH Terminal en aluminium-cuivre et procédé de fabrication de celui-ci
WO2013124151A1 (fr) 2012-02-26 2013-08-29 Kromberg & Schubert Kg Liaison entre une première pièce métallique et une deuxième pièce métallique enrobée

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP7060319B2 (ja) 2016-07-08 2022-04-26 矢崎総業株式会社 端子付き電線、及び、端子付き電線の製造方法
EP3579344A1 (fr) * 2018-06-07 2019-12-11 Gebauer & Griller Kabelwerke Gesellschaft m.b.H. Procédé de surmoulage de cosses de câble à géométries complexes

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