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
  • H01R4/10—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
  • H01R4/183—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 for cylindrical elongated bodies, e.g. cables having circular cross-section
  • H01R4/184—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 for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
  • H01R4/185—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 for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion combined with a U-shaped insulation-receiving portion
• • 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

Definitions

• the invention relates to a crimp connection according to patent claim 1, a crimping element according to claim 9 and claim 10 and a method and a crimping device for producing a crimp connection.
• electrical conductor which is constructed from a single wire or a plurality of line wires (strands) .
• a significant function of the crimp connection is to produce between the crimping element and the electrical conductor a good
• an object of the invention is to provide a simple connection method for aluminium-containing or aluminium- alloy-containing electrical conductors. This object is achieved by a crimp connection according to claim 1, a crimping element according to claim 9 and according to claim 10. The object is further achieved by a method according to claim 12 and a crimping device according to claim 15.
• a crimp connection comprising a crimping element which is crimped in a crimping operation onto an electrical conductor of
• the crimping element electrically contacting the electrical conductor in a conductor crimp portion.
• the conductor crimp portion is sealed by means of a flowable sealing means which is applied to the electrical conductor and/or the crimping element before the crimping operation, during the crimping operation and/or after the crimping operation.
• the technical function of the sealing means is not absolutely a hermetic sealing action but instead the prevention of an electrochemical corrosion between aluminium and copper.
• the crimping element further forms, in at least one transition portion adjoining the conductor crimp portion, a storage space for the sealing means.
• the electrical conductor are protected against the introduction of foreign bodies, such as, for example, electrolyte, by the sealing means.
• electrochemical corrosion of the aluminium conductor is effectively prevented in the contact region with the crimping element which is preferably constructed from copper.
• the storage space ensures that the at least initially flowable sealing means cannot flow out of the conductor crimp portion during the crimping operation and optionally during subsequent use. Consequently, the sealing function also remains ensured after the crimping operation.
• the collection space is formed by axial extension structures which are arranged on the crimp wings.
• the crimping element is crimped on the electrical conductor in the conductor crimp portion by means of two crimp wings.
• the sealing means is arranged in a
• the sealing means is
• Another embodiment makes provision for the crimping element further to be crimped by means of two stress relieving tabs onto an insulating covering which surrounds the electrical conductor, and for the axial extension structures to extend from the conductor-side edge regions of the crimp wings in the direction of the stress relieving tabs.
• the transition portion arranged between the conductor crimp portion and the insulation crimp portion is used as a collection space for the sealing means.
• Another embodiment makes provision for the axial extension structures to form a bell-like outlet which extends at least as far as the edge of the insulating covering.
• a belllike outlet allows a soft transition between the clamped portion and the exposed portions of the electrical conductor.
• the storage space is formed at least partially by two wing structures which rise from a contact vessel in a transition portion and which at least partially surround the electrical conductor.
• An additional protection for the sealing means is achieved by means of such wing structures.
• a control window to be provided for optically controlling the crimping result between at least one axial extension structure and a contact vessel which is arranged in a transition portion between the conductor crimp portion and the insulation crimp portion.
• Another embodiment makes provision for a permanently viscous material or a material which is viscous or highly viscous during application and which has hardened in the completed state of the crimp connection to be used as a sealing means.
• a viscous material allows flow of the sealing means during the crimping operation and therefore optimum distribution of the sealing means between the conductor and the crimp sleeve in the completed state of the crimp
• connection The use of a material which is, for example, hardenable over time or by means of UV light, as the sealing means further prevents the sealing means from flowing out or being flushed out of the crimp connection.
• the flowable sealing means is arranged in the conductor crimp portion, a first transition portion arranged between the conductor crimp portion and in an insulation crimp portion and/or in a second transition portion arranged between the conductor crimp portion and a contact portion.
• a control window for optically controlling the crimping result to be provided between the axial extension structure and a contact vessel, which is arranged in a transition portion between the conductor crimp portion and the insulation crimp portion.
• a crimping element is provided to produce a crimp connection which comprises a conductor crimp portion having two crimp wings for crimping on an electrical conductor and an insulation crimp portion having two stress relieving tabs for crimping on an insulating covering which surrounds the electrical conductor.
• An axial extension structure which extends in the direction of the stress relieving tabs is provided at the conductor-side edge regions of the crimp wings.
• Such axial extension structures can produce an increased collection space which stores a sealing means located between the electrical conductor and the crimping element and which protects the sealing produced by means of the sealing means from external influences.
• a flowable sealing material is applied to the electrical conductor and/or the crimping element before the crimping operation, during the crimping operation and/or after the crimping operation and seals the contact region in the completed state of the crimp connection. Furthermore, at least one storage space for the sealing means is formed between the crimping element and the electrical conductor when the crimping element is crimped on the electrical conductor.
• the sealing means even before the actual crimping operation allows optimum distribution of the sealing means because the sealing means is urged by the pressure produced on the crimp wings during the crimping out of the contact zone between the crimping element and the electrical conductor and accumulates at the edge regions of that contact zone in a relatively large quantity.
• the crimp connection produced in this manner can be protected against corrosion damage
• the storage space ensures that the sealing means which is flowable at least at the beginning cannot flow out of the conductor crimp portion during the crimping operation and optionally during subsequent use. Consequently, the sealing function also remains ensured after the crimping operation.
• One embodiment makes provision for a crimping element to be used which has two crimp wings each having an axial extension structure.
• the axial extension structures are bent onto the electrical conductor when the crimp wings are crimped in such a manner that a collection space for the sealing means is produced in the form of a bell-like outlet which extends at least as far as the edge of the insulating covering.
• the production of the collection space prevents a sealing means which is applied before, during or after the crimping operation from being able to flow out of the crimp connection in such a manner that the corrosion protection formed by the sealing means is impaired.
• This relatively large storage space further allows a particularly large amount of the sealing means to be received so that the sealing function of the remaining sealing means can be ensured even after a portion of the sealing means has flowed out.
• a crimping device for producing a crimp connection which comprises a first stamp for crimping stress relieving tabs in an insulation crimp portion of a crimping element, a second stamp for crimping crimp wings in a conductor crimp portion of the crimping element, a first additional stamp which is arranged between the first and the second stamp for sealing a first transition portion which is arranged between the insulation crimp portion and the conductor crimp portion during a crimping operation and a second additional stamp which is arranged at a side of the second stamp opposite the first additional stamp for sealing a second transition portion which is arranged between the conductor crimp portion and a contact portion of the crimping element during the crimping operation.
• Figure 1 is an exemplary side view of a crimp connection
• Figure 2 is a cross-section of the crimp connection from Figure 1 in order to explain the sealing function by the sealing means;
• Figure 3 shows by way of example three crimping elements each having different application types for the sealing means;
• Figure 4 is a side view of a crimp connection having axial extension structures;
• Figure 5 is a cross-section of the crimp connection from Figure 4.
• Figure 6 is a side view of a crimping element having axial extension structures
• Figure 7 is a top view of the crimping element from Figure 6;
• Figure 8 is a punched pre-product for producing the crimping element from Figures 6 and 7;
• Figure 9 shows a crimping element having axial extension structures before the crimping operation having an electrical line ;
• Figure 10 is a cross-section through a first transition portion of the crimping element from Figure 9, which
• Figure 11 is a cross-section through a conductor crimp portion of the crimping element from Figure 9 during the crimping operation;
• Figure 12 is a cross-section through a second transition portion of the crimping element from Figure 9, which
• transition portion is sealed by means of a second additional stamp
• Figure 13 shows a crimping element having additional axial extension structures before the crimping with an electrical line
• Figure 14 shows a crimping element having additional wing structures before the crimping operation with an electrical line .
• Figure 1 shows a crimp connection 400 comprising a crimping element 100 which is crimped on an electrical line 200.
• the electrical line comprises an electrical conductor 210 which is covered with an insulating material 220 and which comprises a plurality of conductor strands 211 in the present embodiment.
• the insulating covering 220 has been removed in an end portion of the electrical line 200 so that the electrical conductor 210 is exposed in this end portion.
• the crimping element 100 surrounds the exposed electrical conductor 210 in a conductor crimp portion 130 by means of two crimp wings 131, 132 which are bent round the electrical conductor.
• the crimping element 100 has two stress relieving tabs 111, 112 which are crimped round the covering 220 of the electrical line 200 for the purpose of relieving the stress of the conductor crimp portion 130.
• the crimping element 100 has a contact portion 150 which is separated from the conductor crimp portion 130 by a second transition portion 140.
• the crimping element 100 forms a typical contact 151, such as, for example, a plug type contact, in the contact portion 150.
• the crimp wings 131, 132 each form in the edge regions 133, 134 of the conductor crimp portion 130 a bell-like outlet structure 137, 138, respectively.
• Such bell-like outlet structures can be produced by using a special crimping stamp which only acts on the central portion of the crimp wings 131, 132 with pressure.
• the bell-like outlet 137 which is formed in the insulation-side edge region 133 of the conductor crimp portion 130 is
• the conductor crimp portion 130 or at least one contact region arranged in the conductor crimp portion 130 is sealed by using a sealing means 300.
• a flowable viscous or paste-like material is preferably used as the sealing means 300.
• the sealing means can be applied both before the crimping operation and during the crimping operation or after the crimping operation in accordance with the use.
• both the inner side of the crimping element 100 and the outer side of the electrical conductor 210 can be wetted with the flowable sealing means in a specific region or in different regions.
• Figure 2 is a cross-section through the crimp connection from Figure 1. This illustration shows that the sealing means accumulates in the edge regions 133, 134 of the conductor crimp portion 130 along the contact line between the
• the sealing means 300 is also arranged so as to be distributed accordingly between the individual strands 211.
• the bell-like outlets 137, 138 which are formed on the crimp wings 131, 132 in the edge regions 133, 134 of the conductor crimp portion 130 and the correspondingly bell-like contact vessel 139 of the conductor crimp portion 130 form two storage spaces 310, 320 which extend over the periphery of the electrical conductor 210 for the sealing means 300.
• the sealing means 300 which is
• the sealing means 300 can be applied both before the crimping operation or during the crimping operation to the inner side of the crimping element 100 or to the outer side of the exposed electrical conductor 210, and after the crimping operation to the locations which are correspondingly intended to be sealed.
• a preferably paste-like or gel-like sealing means can be applied to the inner side of the crimp wings even before the insertion of the electrical conductor for crimping with the crimping element.
• Figure 3 shows a stamped strip 102 having three crimping elements 100 which are produced by stamping and bending and in which a preferably paste-like, gel-like or similarly flowable sealing means 300 has already been applied at the inner side provided for receiving a conductor structure.
• the sealing means 300 is preferably applied in the conductor crimp portion 130 at the inner side of the crimp wings 131, 132 and the contact vessel 139. This can be carried out extensively (right-hand crimping element) or simply in a limited manner at the edge regions 133, 134 of the conductor crimp portion 130 (left-hand crimping element). Alternatively or additionally, the sealing means 300 can also be applied to the inner side of the contact vessels 121, 141 of the
• transition portions 120, 140 directly adjoining the conductor crimp portion 130.
• a correspondingly formed crimping element 100 is shown in the central portion of Figure 3.
• the insulation-side storage space which receives the sealing means 300 can be increased by constructive measures of the crimping element 100.
• the bell-like outlet 137 arranged at the insulation side can be extended by means of axial extension structures 135, 136 of the crimp wings 131, 132.
• Figure 4 shows a crimp connection 400 which is arranged in a crimping device 500 and which has a correspondingly formed crimping element 100.
• the crimping element 100 has at the insulation side an axially extended bell-like outlet 137 which is formed by axial extension structures 135, 136 at the crimp wings 131, 132.
• the axial extension structures extend preferably at least as far as the edge of the insulation coating 220 so that the extended bell ⁇ like outlet 137 encloses a practically closed storage space 310 for the sealing means 300.
• the closed storage space 310 preferably has at least one control window which allows optical control of the crimping result.
• a control window 126 is formed by a gap which extends in an axial direction between the axial extension structure 135 and a side wall 122 of the first transition portion 120.
• control windows can be formed in any suitable manner.
• the crimp connection 400 is produced by crimping a crimping element 100 on an electrical line 200 by means of a specially formed crimping device 500.
• a crimping device 500 comprises a support formed from one or more anvil structures 550, 560 for the crimping element 100 and a stamp arrangement which in the present case comprises two individual stamps 510, 530. By the stamps 510, 530 being displaced against the associated anvil structure 550, 560, the portion of the crimping element located
• the crimp wings 131, 132 in the conductor crimp portion 130 can be crimped on the exposed electrical conductor 210 by the second crimping stamp 530 being displaced against the second anvil structure 560.
• the central region of the crimp wings 131, 132 is conventionally, that is to say, substantially parallel with the conductor axis, crimped on the electrical conductor 210 with a first forming region 531 of the second crimping stamp 530.
• the contact-side bell-like outlet 138 is also
• the conductor-side extended bell-like outlet 137 is produced by means of a specially formed third forming region 533 of the second crimping stamp 530, which bends both the conductor-side edge region of the crimp wings 131, 132 and the two axial extension structures 135, 136 into the desired shape.
• Figure 5 is a cross-section along the longitudinal axis of the crimp connection 400 from Figure 4.
• the central portion of the electrical conductor 210 which portion is squeezed by the crimp wings 131, 132 in the conductor crimp portion 130, is sealed by means of a sealing means 300 which is located in the first and second storage space 310, 320.
• FIG. 6 is a side view of such a crimping element 100 whose crimp wings 131, 132 are provided with axial extension structures 135, 136.
• the upper edge of the axial extension structure 135 is in the form of a wedge which tapers upwards.
• Figure 7 is a top view of the crimping element from Figure 6.
• the outer edge of the axial extension structures 135, 136 which are arranged at the insulation side can, as shown in Figure 7, already have slight curvature inwards (relative to the plane of symmetry of the crimping element 100) .
• Figure 8 shows the crimping element 100 in the form of a pre- product which has been produced by being stamped out of a metal sheet.
• the axial extension structures 135, 136 can be produced by a relatively simple modification of the stamping process.
• Figure 9 shows an arrangement for producing a crimp
• the arrangement comprises a crimping device 500, a crimping element 100 which is positioned inside the crimping device 500 and an
• the crimping device 500 comprises two anvil structures 550, 560 which act as a support for the crimping element 100.
• the crimping device 500 shown here also has, in addition to the insulation crimping stamp 510 already described in connection with Figure 4 and the conductor crimping stamp 530, two additional stamps 520, 540.
• the additional stamps 520, 540 arranged at both sides of the conductor crimping stamp 530 may preferably be lowered separately from the insulation crimping stamp 510 and the conductor crimping stamp 530.
• the lowering action of one or both of the additional stamps 520, 540 can be carried out together with one or both of the main stamps 510, 530.
• the first additional stamp 520 engages in the transition portion 120 of the crimping element 100 and as a result seals it during the crimping operation so as to prevent the sealing means from flowing out.
• the crimping element 100 has axial extension structures 135, 136 which extend into the first transition portion 120
• the first additional stamp 520 can be used to bring those axial extension structures 135, 136 into the desired shape when the crimp wings 131 are crimped.
• the first additional stamp 520 is formed in a concave manner in the relevant region in accordance with the bell ⁇ like outlet structure 137 to be formed (not shown here) .
• the second additional stamp 540 is also used for sealing the crimping element during the crimping operation. To this end, the second additional stamp 540 is lowered in the second transition portion 140 onto the crimping element 100 and thus seals the enclosed storage space 310 (not shown here) so as to prevent the sealing means 300 from flowing out.
• Figure 10 is a cross-section through the second transition portion 140 of the crimping element 100 from Figure 9 during the crimping operation.
• the first additional stamp 520 is illustrated in the lowered position.
• the additional stamp 520 has a sealing element 523 which engages in this position of the additional stamp 520 in the contact vessel 141 which is formed by the base region 146 and the two side walls 142, 143.
• the shape of the sealing element 523 is preferably adapted to the profile of the contact vessel 141 in such a manner that a gap which is as small as possible is produced between the sealing element 523 and the contact vessel 141.
• the additional stamp 520 also has two extension arms 521, 522 which comprise the crimping element 100 in the second transition portion 140.
• a better sealing action of the crimping element 100 can be achieved by means of those extension arms 521, 522.
• the two extension arms 521, 522 can also be used to form the side walls 142, 143 of the contact vessel 141 in the second transition portion 140.
• the second additional stamp 520 may, as shown, for example, in the longitudinal section of Figure 11, have a chamfered profile. Additional space for the sealing means is provided by means of such a profile. Furthermore, pressure can be applied to a sealing means 300 which is located in the second transition portion of the crimping element 100 by means of the chamfered profile when the second additional stamp 540 is lowered, and the sealing means 300 can consequently be urged into the intermediate space between the electrical conductor 210 and the crimp wings 131, 132 or between individual strands 211 of the electrical conductor. Unlike the second transition portion 140 of the crimping element, the first transition portion 120 of the crimping element contains the exposed electrical conductor 210.
• the first additional stamp 520 lowered onto the crimping element in the first transition portion 120 does not have any sealing structure engaging in the contact vessel 121 in this region. Instead, the sealing action is brought about by positioning the two extension arms 541, 542 of the second additional stamp 540 on the side walls 122, 123 of the contact vessel 121.
• a sealing structure which is reduced accordingly in terms of height can be used in this instance under some circumstances.
• Figure 12 is a cross-section through the conductor crimp portion 130 of the crimping element 100 which is crimped on the conductor 210.
• the two crimp wings 131, 132 are bent round the electrical conductor 210 by the conductor crimping stamp 530 being lowered.
• a flowable sealing means 300 which is applied beforehand to the inner side of the crimp wings 131, 132 or to the outer side of the electrical conductor 210 is urged between the individual strands 211 of the electrical conductor 210 by the crimping element 100 being compressed.
• Figure 13 shows a situation similar to Figure 9, with a crimping element 100 being provided in this instance with additional axial extension structures 135, 136.
• the first additional stamp 520 is accordingly constructed so that the axial extension structures 135, 136 are brought into the desired bell-like shape when the first additional stamp 520 is lowered.
• Figure 14 shows a situation similar to Figures 9 and 13, in which a crimping element 100 is crimped on an
• the transition portions 120, 140 of the crimping element 100 shown in this instance have additional wing structures 124, 125, 144, 145, only the two front wing structures 124, 144 being visible in this side view.
• the wing structures 124, 125, 144, 145 are bent by means of the two additional stamps 520, 540 when the crimping element 100 is crimped in such a manner that a substantially shielded or sealed space is produced underneath for the sealing means 300.
• extension structures or additional wing structures By using extension structures or additional wing structures, such closed volumes which act as storage space for the
• sealing means 300 can be formed in a relatively simple manner.
• the structural measures can be freely combined with each other in accordance with the application and requirements.
• the sealing means may be in the form of a permanently soft material such as, for example, grease or gel, or in the form of a mass which hardens, for example, over time or under UV light.
• the sealing means used should be substantially
• Temperature stability of the sealing means up to approximately 120°C (preferably up to 150°C) is also necessary in the case of corresponding use in a hot environment .
• the sealing means may be present both a long time before the crimping operation as a store in the crimp sleeve or be applied shortly before the crimping operation in the crimp sleeve or to the insulated line.
• the sealing means can also be introduced after the crimping operation, for example, by being pressed into the completed crimp
• the sealing means If the sealing means has been applied before the crimping operation in the conductor crimp portion, it is urged out of the actual crimp region which is used for the electrical contacting of the crimping element and the electrical
• the urged sealing means is stored in an
• Another accumulation of the sealing means in those regions is made possible inter alia by using the additional stamps, which delimit a space between the contact vessels and the additional stamp, respectively, during the crimping operation, in which space the urged sealing means accumulates.
• the accumulation of the sealing means in the transition portions of the crimping element can then be protected by means of axially extended crimp wings or by means of special wing structures in the transition portions, which are

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• Engineering & Computer Science (AREA)
• Manufacturing & Machinery (AREA)
• Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)

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• 2013
  • 2013-03-25 DE DE102013205235.9A patent/DE102013205235A1/de active Pending
• 2014
  • 2014-03-25 EP EP14712012.5A patent/EP2979324A1/de not_active Withdrawn
  • 2014-03-25 WO PCT/EP2014/055985 patent/WO2014154706A1/en active Application Filing

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