EP3113287B1 - Verfahren zur herstellung einer verbindungsanordnung - Google Patents

Verfahren zur herstellung einer verbindungsanordnung Download PDF

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Publication number
EP3113287B1
EP3113287B1 EP16173040.3A EP16173040A EP3113287B1 EP 3113287 B1 EP3113287 B1 EP 3113287B1 EP 16173040 A EP16173040 A EP 16173040A EP 3113287 B1 EP3113287 B1 EP 3113287B1
Authority
EP
European Patent Office
Prior art keywords
faces
conductor
sealing material
connection device
connection
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.)
Active
Application number
EP16173040.3A
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English (en)
French (fr)
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EP3113287A1 (de
Inventor
Alain Bednarek
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Tyco Electronics France SAS
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Tyco Electronics France SAS
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Publication of EP3113287A1 publication Critical patent/EP3113287A1/de
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Publication of EP3113287B1 publication Critical patent/EP3113287B1/de
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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
    • H01R4/10—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
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048—Crimping apparatus or processes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • 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
    • H01R43/0214—Resistance 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
    • H01R43/04—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
    • H01R43/058—Crimping mandrels

Definitions

  • the invention relates to a connection assembly comprising at least one conductor and at least one connection device which is plastically deformed about the conductor to form two faces which face each other.
  • the invention further relates to a method of manufacturing such a connection assembly and to a tool for manufacturing such a connection assembly.
  • connection assembly can, for example, comprise a conductor of a cable and a crimp terminal.
  • connection assemblies usually provide a good connection in terms of a low resistance and a good long term stability. However, for example, when it comes to small wire sizes and/or when aluminum is used, such connections can be problematic.
  • a corresponding method can include the step of materially bonding the two adjacent faces to each other.
  • a corresponding tool can comprise a bonding unit for materially bonding the two faces of the connection device to each other.
  • WO 2014/021336 A1 and US 2015/140856 A1 show crimped terminals comprising elastic sealing material.
  • WO 2013/145670 A1 discloses a crimped terminal in which solder is used for sealing.
  • EP 2650972 A1 a coating of a nobler metal is applied to an inside of a crimp terminal.
  • WO 98/35405 A1 shows the application of sealing material on a metal piece used for manufacturing crimp terminals.
  • a sealant is released upon rupture of a film.
  • the object of the invention is to provide a solution in which the application of a sealing material is improved.
  • this is achieved by the method of claim 1, said method manufacturing a connection assembly by plastically deforming a connection device about a conductor and thus moving two faces of the connection device into a position adjacent to each other, and by then materially bonding the two adjacent faces to each other, wherein sealing material for sealing the connection assembly in a finished state is applied during manufacturing, wherein sealing material is applied to a metal strip before blanks for the connection devices are being cut out or that the sealing material is applied to cut-out blanks for the connection devices before the connection devices are being deformed, wherein the sealing material is applied as a foam and wherein the sealing material is heated during the production process.
  • the conductor can be part of a cable.
  • the cable can further comprise an insulation around the conductor.
  • the conductor can be a single wire or comprise more than one wire. It can be a bundle of wires.
  • connection device When the connection device is plastically deformed about the conductor, the conductor can also be plastically deformed.
  • the conductor can also be plastically deformed.
  • a single wire or more than one wire of a cable can be squeezed and the cross section can change.
  • connection device can comprise one or more deformation sections that are adapted for being plastically deformed about the conductor.
  • a deformation section can be flap-like or wing-like or it can have one or more legs so that it can be deformed easily. Free ends of a deformation section can protrude into a volume of the conductor to achieve a high contact area and thus a good contact.
  • the faces can face in a circumferential direction of the conductor. This can give a good gripping of the conductor.
  • the faces can be parallel to an axial direction or to an extension direction of the conductor. This allows an easy manufacturing and gives a good gripping.
  • the faces can be part of a surface that continues on the outside of the connection device and/or the connection assembly.
  • the faces can be part of an outer surface or a back surface of the connection device in order to allow an easy manufacturing.
  • the faces can be located on portions that are bent inwards.
  • the conductor and the connection device can be made from a variety of different conductive materials.
  • Preferred materials are aluminum, copper, or alloys containing these materials, for example, CuSn0.15 or CuSn4.
  • high electrical conductivity materials having low mechanical properties, for example little elasticity at operation temperature or at elevated temperatures, can be used. Due to the inventive solution, the risk of a relaxation during the life time of the connection assembly, in particular if the connection assembly is subjected to higher temperatures, is reduced.
  • the connection device can have one material in a base or a support section and a coating or a layer of a different material.
  • the coating can in particular comprise tin or zinc. This can be advantageous, for example, when the connection is made by melting a layer, as tin and zinc and alloys containing these materials melt more easily than other materials.
  • faces can be materially bonded by at least partially melting and joining the faces. This can, for example, be done by melting a coating or a top layer that can, for example, contain tin or zinc and by then joining the faces. After cooling down, the faces are then joined by a material bond, in this case a material bond that can be called a solder bond, as the joining process resembles a soldering operation.
  • a flux can be added, for example as a liquid, a grease, or a meltable solid. The flux can also be present in an additional layer.
  • the faces are welded to each other.
  • it is not just a coating, if such a coating is present, but also part of a base or a support of the conductor device that melts in the area of the faces.
  • Such a welding connection can provide a more rigid and stable connection. However, usually higher temperatures are necessary for melting the base material.
  • such molten und joined faces can for example be seen by a microscopic inspection of a cut and ground cross section of the connection assembly. Due to the melting, the faces can be deformed relative to their original shape. The faces can be at least partially intermixed. Parts of one face can be located in the other face. The faces can be united to form a single molten and subsequently cooled and solidified area.
  • connection assembly In particular if the two faces are soldered to each other, this can also help to improve the resistance of the connection assembly against salt spray or other climatic phenomena.
  • the soldering seals a possible entrance channel for substances that can damage the connection assembly, for example by corrosion.
  • the energy for heating and melting can come from different sources.
  • a current can be used to generate heat and thus melt the faces. Due to the resistance in the material, the current creates heat.
  • the area in which the current flows can advantageously be limited to essentially the area of the faces.
  • the current can run from one face to the other.
  • the faces can be the section of a current path with the highest resistance so that the highest amount of heat is generated in the faces and the faces melt while other regions stay solid.
  • the resistance can for example be adjusted by the choice of materials and the cross section of the current path. For example, the resistance can be increased by making the cross section of the current path smaller at the faces.
  • the current runs along an extension direction of the conductor.
  • the extension direction of the conductor is the direction in which the conductor extends through the loop formed by the plastically deformed connection device. This extension direction is thus usually perpendicular to directions in which the faces face, that means to the normals of the faces. If a wire or a cable is used, the extension direction is the longitudinal direction of the wire or a cable. If the current runs along the extension direction of the conductor, the current also runs along the faces so that heat can be generated in the face. In order to avoid unnecessary heating of other regions which could, for example, melt or insulate the outer cable, the current can be limited to the region of the faces.
  • connection device or the conductor can be cooled while the faces or heated and molten.
  • the tool can therefore comprise a cooling unit.
  • the steps of plastically deforming the connection device about the conductor and the material bonding of the faces to each other take place at substantially the same time.
  • the material bonding can take place at the end of the plastic deformation step in which the two faces are brought into an abutting or adjacent position.
  • the forces that are used for plastically deforming can also be used to push the two faces together and thus, join them.
  • the heating of the faces might take some time, it can start before the two faces come into contact so that the faces are already molten when they start to touch each other.
  • a tool for manufacturing a connection assembly can comprise at least one conductor and at least one connection device which is plastically deformed about the conductor comprises at least one deformation unit for deforming the connection device about the conductor, wherein the deformation unit moves the two faces of the connection device into a position adjacent to each other and further, a bonding unit for materially bonding the two faces of the connection device to each other.
  • the bonding unit is adapted for materially bonding the two faces to each other while the connection device is being deformed about the conductor.
  • the deformation unit can comprise two deformation parts that are adapted for deforming the connection device about the conductor when they are being moved toward each other.
  • One of the deformation parts can be static or stationary, while the other can be movable.
  • the static part can be seen as an anvil, the other part can be seen as a punch or hammer. In an alternative, both deformation parts can be movable.
  • One of the deformation parts can be adapted for holding the conductor and/or the connection device.
  • one deformation part can comprise holding means.
  • the bonding unit can be adapted for melting the faces.
  • the bonding unit can, in particular, comprise a laser, for example, a laser diode.
  • the laser can be directed to the area of the faces for heating the faces. Depending on the intensity and duration of the laser treatment, the laser can melt only a coating or a top layer of the connection device in the area of the faces so that a soldering bond can be achieved. In an alternative, higher intensities and longer durations can lead to more profound melting of the connection device in the area of the faces so that a welding of the faces to each other can be achieved.
  • currents can be used for heating and melting the face. This can for example, be achieved by running a current through the connection device and/or the conductor.
  • the current can be induced by a magnetic field.
  • the current is applied electrically, that means by applying a voltage between two contact points on the connection device.
  • the bonding unit can comprise two electrodes that are adapted for contacting the connection device.
  • the construction can be such that the connection device connects the two electrodes when it is inserted or when it touches the two electrodes, while an insulating gap is present between the two electrodes when the connection device is not present.
  • the two electrodes can be located on one deformation part.
  • the two electrodes can be located on a deformation part with holding means so that the heating of the connection device can start before the other deformation unit starts to deform the connection device. By this, time can be saved.
  • the electrodes can be located on the deformation unit that does not have the holding means.
  • Such a design can be safer, as the heating of the connection device only takes place when the tool is in operation. An unnecessary and possible dangerous heating of the connection device during a non operation interval is thus avoided. Further, as the time interval, in which the current is applied, is defined accurately, more accurate and reliable connections can be made.
  • one electrode can be located on one deformation unit and the other electrode can be located on the other deformation unit so that a current can only flow when the two are in contact and deform the connection device and/or the conductor.
  • the two electrodes are located on one deformation part, it is advantageous if the two electrodes are arranged behind each other in an extension direction of the conductor on one deformation part.
  • the electrodes can be part of the deformation part and take an active role in the deformation itself. They can have shapes that are adapted for deforming the connection device about the conductor. As the deformation takes place around the extension direction of the conductor, the electrodes and/or the deformation parts are more stable because they do not have to be split in the center to achieve an insulation. Rather, every electrode can be integral and surround the conductor and/or the connection device at least partially.
  • the two electrodes can be adapted to be behind each other in a direction that is perpendicular to the extension direction of the conductor.
  • the current can thus flow in a direction perpendicular to the extension direction and thus through the two faces subsequently.
  • the tool can comprise a cooling unit for cooling the connection device and/or the conductor.
  • a cooling unit for cooling the connection device and/or the conductor.
  • additional bonding material can be added.
  • additional material can be added when the material bond has already been made. It can for instance be added on the outside next to the faces.
  • the additional bonding material could be added during the manufacturing just before the connection device is deformed, for example by a micro-metering device that can inject the additional material onto or into the conductor and/or into or onto the connection device.
  • additional bonding material might be already be added to the conductor during the manufacturing of the conductor.
  • the conductor could be coated or additional material could be added between strands of a multi-stranded conductor.
  • the additional bonding material can in particular be a material that melts when the faces are heated during the manufacturing. It could for example be solder or hot melt glue.
  • additional sealing material can be added.
  • additional material can be added when the material bond has already been made. It can for instance be added on the outside next to the faces.
  • the additional bonding material could be added during the manufacturing just before the connection device is deformed, for example by a micro-metering device that can inject the additional material onto or into the conductor and/or into or onto the connection device.
  • additional sealing material might be already be added to the conductor during the manufacturing of the conductor.
  • the conductor could be coated or additional material could be added between strands of a multi-stranded conductor.
  • the additional sealing material can in particular be a material that melts when the faces are heated during the manufacturing. It could for example be solder or hot melt glue. It can especially by a material that gives additional bonding and sealing performance at the same time.
  • the deformation parts can have additional gaps or recesses in the area where the two faces should touch each other so that the additional material can exit through the gap between the faces just before this gap is closed.
  • connection assembly comprises sealing material that seals the connection assembly.
  • the sealing material can, for example, fill a volume defined by the plastically deformed connection device and the conductor.
  • the sealing material can also only partially fill this volume.
  • the sealing material can, for example, define and seal an inner volume inside the connection assembly in which no sealing material is present.
  • the sealing material can comprise grease if a simple manufacturing is desired and the required sealing performance is low or medium.
  • the sealing material can comprise hot melt material.
  • This hot melt material can be heated during the manufacturing so that it can flow into small cavities. Afterwards, the hot melt material can cool down and solidify. In the solid state, a stable sealing performance can be achieved. Furthermore, the hot melt material can also act as a glue or adhesive.
  • the sealing material can comprise heat-activatable polymerizable material, for example, epoxy resin.
  • the sealing material can be applied in a liquid or viscous form so that it can flow into small cavities.
  • the sealing material can be heated to elevated temperatures in order to activate the polymerization process.
  • the viscosity can increase.
  • the sealing material can become solid.
  • the polymerization can either only be started so that a connection assembly manufactured in this way has a sealing material that is only partially polymerized.
  • the polymerization can then continue after the manufacturing process, for example, during the time in a warehouse. Of course, the polymerization can also be finished during the manufacturing process.
  • the sealing material can be applied during different production steps.
  • the sealing material can be applied during or shortly before the deformation of the connection device about the conductor. It can, for example, be injected in a liquid or viscous state.
  • hot melt material can be molten and injected in a warm or hot state.
  • Hot melt material can also be applied in a solid form that then melts during or after the deformation process.
  • the material bonding process can create heat that melts the hot melt material. If a heat-activatable, polymerizable material is used, it can be injected in a liquid or viscous state in which it is still cold. It can then be activated by the heat generated by the material bonding process or by a dedicated heating step.
  • sealing material is applied to a metal strip from which blanks for the connection devices will be cut out or from which the blanks for the connection devices are already cut out.
  • sealing material can be provided on a metal strip for producing a connection device.
  • the metal strip can still be strip-like or already comprise cut out blanks of the connection devices that are still connected to each other and form a single piece.
  • the sealing material can be provided only on parts of the metal strip. It can, for example, be located in areas that form the two ends of a barrel in the finished state.
  • the sealing material can be applied in different shapes. If the sealing material is soft, it can be applied in the form of a blob. If the sealing material is harder, it can be applied in the form of a layer to avoid localized mechanical stress when the sealing material is spread.
  • the sealing material is applied as a foam. Such a foam can be deformed more easily and with less force so that the mechanical stress during a deformation step is less severe and the risk of mechanical damage is lower. Further, a conductor can easily be inserted into the foam so that the conductor is then automatically surrounded by sealing material.
  • the foam has big cells so that it is soft and easily deformable.
  • the tool comprises a dispensing unit for dispensing sealing material into the connection assembly when the connection device is being deformed.
  • the tool can further comprise a heating device for heating and thus melting or activating the sealing material.
  • the heating device can be integral with the bonding unit.
  • the application also discloses a tool for cutting blanks for connection devices from a metal strip, wherein the tool comprises a dispensing unit for dispensing sealing material.
  • the tool can be adapted to dispense the sealing material before the blanks are being cut from the metal strip.
  • the sealing material can be dispensed in a strip-like form.
  • the tool can also be adapted to dispense the sealing material onto the cut out blanks for the connection devices. By this, the amount of sealing material that is dispensed can be lower.
  • connection assembly 1 comprises a conductor 2 (hidden in Fig. 1 ) and a connection device 3.
  • the conductor 2 is part of a cable 4 and is surrounded by the insulation 5 of the cable 4.
  • connection device 3 is in this case a terminal that can for example be used in a connector or plug in order to make contact to a counter connector or a counter plug.
  • the connection device 3 comprises a deformation section 31 in which the connection device 3 is plastically deformed about the conductor 2 to form two faces 7 which face each other.
  • the faces 7 are connected to each other by a material bond 15.
  • a material bond can for example be a solder or a weld bond. Due to the material bond 15, the connection device 3 exerts a compressive force onto the conductor 2.
  • the compressive force is longtime stable and does not decrease over time.
  • the deformation section 31 in Fig.1 is embodied as a crimp barrel 32 which has wing-like sections 33 that can be wound or wrapped about or around the conductor 2.
  • connection device 3 further comprises an insulation crimp section 8 that is adapted for being crimped onto the insulation 5 of the cable 4. It thus helps to relieve the strain applied to the cable 4. Further, grease 9 is present in order to seal the conductor 2 from the environment and to avoid oxidation of the conductor and ingress of dirt or water.
  • FIG. 2 a cross-sectional view of a step of the manufacturing method is shown.
  • a tool 10 is used for manufacturing the connection assembly 1.
  • the tool 10 comprises a first deformation part 11 and a second deformation part 12.
  • the first deformation part 11 is static and immovable, whereas the second deformation part 12 is movable.
  • the conductor 2 and the connection device 3 are placed on the first deformation part 11.
  • the first deformation part 11 can comprise holding means for holding the conductor 2 and/or the connection device 3 in its place.
  • the wing-like sections 33 or legs of the crimp barrel 32 are not yet fully wrapped around the conductor 2.
  • the second deformation part 12 is then moved along the actuation direction A towards the first deformation part 11 and onto and around the conductor 2 and the connection device 3.
  • the wing-like sections 33 of the crimp barrel 32 and thus the deformation section 31 of the connection device 3 are bent inwards towards the conductor 2 and wrapped around the conductor 2. Free ends or tips 34 of the wing-like section 33 are pressed into the conductor 2 which in this case comprises several strands of wire.
  • the tips 34 are located in a volume of the conductor 2.
  • the volume is surrounded and limited by the wing-like sections 33 of the connection device 3. By this, a large contact area can be achieved.
  • Two faces 7 of the deformation section 31 are moved into a position adjacent to each other.
  • the tool 10 comprises a bonding unit 14.
  • the bonding unit 14 can for example comprise the second deformation part 12 which could for example be heated in order to heat the connection device 3 and thus the faces 7 so that the coating on the connection device 3 melts in the area of the faces 7.
  • a material bond 15, for example in the form of a solder bond is thus achieved.
  • the bonding unit 14 could also be adapted to run a current through the conductor 2 and/or the connection device 3.
  • the current can heat and at least partially melt the faces 7.
  • the connection device 3 comprises a coating comprising for example tin or zinc, this coating can melt in the area of the faces 7 and produce a material bond 15 in the form of a soldering bond. If no such coating is present or if high currents and temperatures are used, the base material of the connection device 3 in the area of the deformation section 31, in particular in the area of the faces 7 can melt and thus lead to a welding bond as a material bond 15.
  • the faces 7 in Fig. 2 are faces of an outside or back side of the connection device 3 and the connection assembly 1. In other words, the faces 7 continue outside the area in which they touch each other to be an outside of the connection device 3. Due to this, the coating which can already be present on the outside of the connection device 3, for example for protection purposes, can also be used for making the material bond 15.
  • the faces 7 face in a circumferential direction C of the conductor 2.
  • the faces 7 are parallel to an axial direction or an extension direction E of the conductor.
  • connection device 3 that is deformed plastically during manufacturing.
  • the conductor 2 is also deformed plastically.
  • connection device 3 Due to the material bond 15, the connection device 3 surrounds the conductor 2 around 360°, which is indicated by the continuous line 16. No gap is present between the faces 7. Due to this, the connection device 3 can permanently exert high forces onto the conductor 2. It compresses the conductor 2. Thus, a good electrical contact is made between the two, the electrical contact being longtime stable. In particular, movements of the conductor 2 within the connection device 3 are minimized and cannot lead to a loosening of the connection between the two.
  • Figs. 3 , 4 and 5 an advantageous embodiment of a method of manufacturing a connection assembly 2 is depicted.
  • a current is used to establish the material bond 15.
  • the tool 10 for making the connection comprises a deformation unit 13 which comprises the first deformation part 11 and the second deformation part 12.
  • the first deformation part 11 is again static or stationary and thus could be designated as an anvil.
  • the second deformation part 12 is movable and can thus be designated as a hammer or a punch.
  • the two deformation parts 11, 12 are relatively movable to each other and are adapted to deform the connection device 3 around the conductor 2 when they are moved toward each other.
  • the second deformation part 12 is also part of a bonding unit 14 that makes the material bond 15 between the faces 7.
  • the material bond 15 is made by melting parts of the faces 7 with a current I.
  • the current I only runs through the upper side of the connection assembly 1.
  • the second deformation part 12 comprises a first electrode 121 and a second electrode 122 which are located behind each other in an extension direction E of the conductor 2 and are separated by an insulating part 123. Voltage can be applied between the first electrode 121 and the second electrode 122.
  • the current I can thus flow between the first electrode 121 and a second electrode 122 through the connection device 3 and the conductor 2.
  • the tool 10 comprises a cooling unit 17 which, in this case, comprises the first deformation part 11.
  • the voltage between the first electrode 121 and the second electrode 122 can be present at all times.
  • the conductor 2 and the connection device 3 can be held in the first deformation part 11 and the second deformation part 12 can be moved onto the conductor 2 and the connection device 3.
  • the current I flows.
  • the second deformation part 12 moves away again, the current I is automatically interrupted.
  • the flow of the current I can be controlled by an external source.
  • the second deformation part 12 can first come into contact with the conductor 2 and the connection device 3 with no voltage applied.
  • the flow of the current I can be activated and deactivated after a certain time.
  • the material bond can then cool down with no current flow while the second deformation part 12 is still in contact with the conductor 2 and the connection device 3.
  • the second deformation part 12 can be moved away so that a material bond 15 is already solid when the second deformation part 12 moves away.
  • the material bond 15 is made at substantially the same time as the plastic deformation takes place and the two faces 7 are brought into a position adjacent to each other.
  • Fig. 6 a cross-section through a connection assembly 1 according to the invention is depicted. No gap is visible between the faces 7. Rather, the material bond 15 makes a seamless connection between the two faces 7.
  • the two faces 7 are still clearly visible in a cross section of the connection assembly 1, as only coatings of the faces 7 were molten and joined.
  • the base section or support section has not been deformed substantially. If higher temperatures are used, for example by using higher intensities or longer time intervals, the base section can also be molten, at least partially.
  • the cross section of the connection assembly 1 would be slightly different.
  • the shape of the faces 7 after the manufacturing process might be different from the shape of the faces 7 before the manufacturing process. Parts of one face 7 could have flown into the other face 7.
  • the faces 7 could be united and form a single molten and solidified region.
  • the tool 10 comprises a deformation unit 13 with a first deformation part 11 at the bottom and a second deformation part 12 above the first deformation part 11.
  • the conductor 2 and the connection device 3 are again located between the first and the second deformation part 11, 12. Faces 7 are brought into contact with each other in the upper region of the connection assembly 1.
  • the tool 10 comprises a bonding unit 14.
  • the bonding unit 14 comprises a laser 140 for example a laser diode, that emits a laser beam 141 that is directed onto the area of the faces 7.
  • the laser beam 141 is at least partially absorbed by the material of the faces 7 and melts the faces 7 at least partially.
  • the laser beam 141 can then be tumed off and the material bond 15 between the two faces can then cool down so that a tight connection between the two faces is established.
  • the laser beam 141 can only melt a coating on the faces 7 so that a soldering bond between the faces 7 is made. If higher intensities and/or longer time intervals are used, the laser beam 141 can also melt a base material so that a welding connection between the faces 7 can be made.
  • Fig. 10 a third advantageous embodiment of the method of manufacturing is depicted. Again a current I is used for heating and melting. However, in this embodiment the current I flows from the second deformation part 12 to the first deformation part 11. To achieve this, a voltage can be applied between a first and a second deformation part 11, 12.
  • connection assembly 1 can be seen in detail. Due to the soldered joint the resistance of the connection assembly 1 against salt spray or other climatic phenomena is improved.
  • the soldered material bond 15 seals a possible entrance channel for substances like water, oxygen or other material that can damage the connection assembly, for example by corrosion. Further, it can be seen that the three parts of the second deformation unit 14 that have been used for deforming and for running a current I along the extension direction E have left marks on the connection device 3.
  • a cross section of a connection assembly 1 with additional bonding material 41 and/or additional sealing material 42 is depicted. This could have be added after the material bond 15 has been made. It can also be that the additional bonding and/or sealing material 41, 42 had already been present in the area of the conductor 2 before the connection device 3 was wrapped around it. It could for example have been molten during the heating of the faces 7 and then have, at least partially, exited through the still existing gap between the faces 7 before the gap was closed during the deformation step.
  • sealing material 50 for sealing the connection assembly 1 in the finished state can be added.
  • the sealing material 50 shown in Fig. 13 is applied as blobs 51 with a first blob 51 applied on a contact side and a second blob 51 applied to the cable side so that, in the closed state of the barrel 52, no water or dirt can get into the inner space defined by the then deformed barrel 52.
  • the finished connection assembly 1 is shown in Fig. 14 . It can be seen that the sealing material 50 seals the barrel 51 at the front and at the back. With the additional sealing at the materially bonded faces 7, an interiour volume defined by the barrel 52 is protected from dirt and water.
  • the sealing material 50 shown in Figures 13 and 14 could, for example, be grease in a simple case. It could also be hot melt material or a heat-activatable polymerizable material.
  • the heat generated by the material bonding of the faces 7 can be used to melt and/or activate the sealing material 50.
  • the heating/melting can make the sealing material more viscous and even liquid so that it can flow easily.
  • the heat can start a polymerization reaction which might or might not be finished during the manufacturing process.
  • Fig. 15 another advantageous development of a method is depicted.
  • the sealing material 50 is applied on a metal strip 60 from which connection devices 3 will be cut.
  • the sealing material 50 is applied as strips 55.
  • the strips are layers 56 of the sealing material 50.
  • the strips 55 are located on positions where the front and the back of the barrel will be.
  • the sealing material 50 can, for example, be applied by printing or pressing the sealing material 50 onto the metal strip 60.
  • the sealing material 50 can be solid or liquid when it is being applied.
  • Fig. 16 it is shown that the metal strip 60 is further processed and blanks 63 for the connectional devices 3 are cut out.
  • the strip-like shape of the sealing material guarantees that sealing material 50 is applied around the entire circumference of the conductor 2 so that a tight seal is guaranteed.
  • Fig. 17 a different method is shown in which the sealing material 50 is applied when the blanks 63 are already cut from the metal strip 60. This has the advantage that less sealing material 50 is wasted.
  • the sealing material 50 is applied as a foam 57 with large cells.
  • the foam could be applied in a large area so that it would cover large areas of the conductor. However, it can also be sufficient if only the areas where water or dirt can penetrate into critical areas are covered. Thus, the foam can only be applied in these areas.
  • a cable or another conductor 2 can be introduced along an insertion direction 70 into a receptacle formed by the partially deformed blank 63 for the connection device 3. Due to the soft structure of the foam 57, the conductor 2 will sink or penetrate into the foam 57 and be surrounded by the foam 57 on the sides.
  • the foam 57 will be wrapped around the conductor 2 and thus also be present above the conductor. This situation is shown in Fig. 21 .
  • the conductor 2 is surrounded entirely by the sealing material 50 which has approximately the same thickness in all areas.
  • FIGs 22 and 23 a fourth development of a method is shown.
  • the method is similar to the one depicted in Figures 18 to 20 .
  • the foam 57 is denser and has smaller cells.
  • more sealing material 50 is present which can, for example, help to make a connection to smaller conductors.

Landscapes

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

Claims (4)

  1. Verfahren zum Herstellen einer Verbindungsanordnung (1) mittels plastischem Verformen einer Verbindungsvorrichtung (3) um einen Leiter (2) herum und damit Bewegen von zwei Flächen (7) der Verbindungsvorrichtung (3) in eine aneinander angrenzende Position sowie anschließendem stoffschlüssigem Verbinden der beiden aneinander angrenzenden Flächen (7) miteinander, wobei beim Herstellen Dichtungsmaterial (50) zum Abdichten der Verbindungsanordnung (1) in einem fertigen Zustand aufgebracht wird, das Dichtungsmaterial (50) auf Zuschnitte (63) eines Metallstreifens (60) für die Verbindungsvorrichtungen (3) aufgebracht wird, bevor die Verbindungsvorrichtungen (3) vollständig verformt werden, dadurch gekennzeichnet, dass das Dichtungsmaterial (50) als ein Schaum (57) aufgebracht wird, wobei das Dichtungsmaterial (50) während des Produktionsprozesses erhitzt wird.
  2. Verfahren nach Anspruch 1, wobei weiteres Dichtungsmaterial (50) als ein Feststoff aufgebracht wird, der während des Produktionsprozesses zum Schmelzen gebracht wird.
  3. Verfahren nach einem der Ansprüche 1 bis 2, wobei weiteres Dichtungsmaterial (50) während des Produktionsprozesses wenigstens teilweise polymerisiert wird.
  4. Verfahren nach einem der Ansprüche 1 bis 3, wobei die bei dem Materialverbindungsprozess erzeugte Wärme zum Erhitzen des Dichtungsmaterials (50) genutzt wird.
EP16173040.3A 2015-06-29 2016-06-06 Verfahren zur herstellung einer verbindungsanordnung Active EP3113287B1 (de)

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Publication number Priority date Publication date Assignee Title
FR3065330B1 (fr) 2017-04-13 2019-05-03 Tyco Electronics France Sas Outil pour souder un conducteur electrique avec un dispositif de connexion
FR3086875B1 (fr) * 2018-10-05 2021-04-30 Tyco Electronics France Sas Dispositif pour souder un conducteur electrique avec un dispositif de connexion
JP2021150235A (ja) * 2020-03-23 2021-09-27 矢崎総業株式会社 端子付き電線および端子付き電線の製造方法
CN113113823B (zh) * 2021-02-24 2023-09-15 上海威克鲍尔通信科技有限公司 一种嵌入棱镜的穿线检测压接一体化装置

Citations (2)

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Publication number Priority date Publication date Assignee Title
US3410950A (en) * 1966-06-01 1968-11-12 Amp Inc Insulated moisture-proof connecting device
WO1998035405A1 (en) * 1997-02-07 1998-08-13 The Whitaker Corporation Seal for sealing an electrical conductor in an entry opening, and a method for producing a seal

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103250303B (zh) * 2010-12-08 2015-11-25 古河电气工业株式会社 压接端子、连接构造体以及它们的制造方法
KR20140134329A (ko) * 2012-03-30 2014-11-21 야자키 소교 가부시키가이샤 단자 크림핑된 와이어
JP5899593B2 (ja) * 2012-07-31 2016-04-06 矢崎総業株式会社 圧着端子付きアルミ電線

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3410950A (en) * 1966-06-01 1968-11-12 Amp Inc Insulated moisture-proof connecting device
WO1998035405A1 (en) * 1997-02-07 1998-08-13 The Whitaker Corporation Seal for sealing an electrical conductor in an entry opening, and a method for producing a seal

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