EP3138160B1 - Crimp-schweissverbindung - Google Patents

Crimp-schweissverbindung Download PDF

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Publication number
EP3138160B1
EP3138160B1 EP15718771.7A EP15718771A EP3138160B1 EP 3138160 B1 EP3138160 B1 EP 3138160B1 EP 15718771 A EP15718771 A EP 15718771A EP 3138160 B1 EP3138160 B1 EP 3138160B1
Authority
EP
European Patent Office
Prior art keywords
stranded wire
connection
crimp
crimping
stranded
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
EP15718771.7A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP3138160A1 (de
Inventor
Walter Baldauf
Martin Hundseder
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.)
Rosenberger Hochfrequenztechnik GmbH and Co KG
Original Assignee
Rosenberger Hochfrequenztechnik GmbH and Co KG
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 Rosenberger Hochfrequenztechnik GmbH and Co KG filed Critical Rosenberger Hochfrequenztechnik GmbH and Co KG
Publication of EP3138160A1 publication Critical patent/EP3138160A1/de
Application granted granted Critical
Publication of EP3138160B1 publication Critical patent/EP3138160B1/de
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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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
    • 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
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0207—Ultrasonic-, H.F.-, cold- or impact welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—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
    • H01R4/20—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 using a crimping sleeve

Definitions

  • the invention relates to a method for producing a permanent mechanical and electrical connection between a stranded wire and a connection element. One end of the stranded cable is welded to the connection element. Furthermore, the invention relates to a connection produced according to the method according to the invention between a connection element and a stranded wire.
  • a stranded wire or litz wire is a conductor consisting of a number of thin individual wires.
  • the individual wires can be encircled coaxially by a common insulating sleeve and, if necessary, additionally by a common outer conductor. Several such stranded wires can run next to each other in a cable.
  • Stranded lines generally have the advantage of particularly high flexibility and only a low susceptibility to conductor breakage, even under mechanical loads such as vibrations or shearing and bending forces acting on the stranded line.
  • connection element such as a connector or a terminal
  • a connection element such as a connector or a terminal
  • ferrule that holds the individual wires of the stranded wire together and prevents damage to the individual wires by a clamping screw or the like. prevented.
  • the ferrule can, for example, be crimped to the end of the stranded wire.
  • solder the stranded wire to a connection element it is known to solder the stranded wire to a connection element.
  • connection points are regularly exposed to high forces such as vibrations, so that a particularly stable and durable attachment of the stranded wire to the connecting element is required.
  • connection element At present, stranded cables with a large cross section or with a large number of individual wires are regularly welded to the connection element. This is because a permanent material-to-material connection can be produced quickly and comparatively inexpensively by welding.
  • the stranded wire is placed on a flat contact surface of the connection element, pressed flat in such a way that as many individual wires of the stranded wire as possible are in direct contact with the contact surface, and then the individual wires are welded to the contact surface.
  • welded connections cannot be produced with the same resistance and durability due to the individual wires, which are sometimes randomly aligned during welding, so that welded connections do not always permanently withstand the vibrations to which the connection point can be exposed.
  • the connecting element is both crimped to the stranded wire and additionally welded to the stranded wire.
  • the connection element has a crimping depression in the form of a substantially cylindrical blind hole, into which one end of the stranded wire is inserted before crimping or before welding.
  • the stranded wire is not welded to a flat contact surface, but rather it is attached to a side wall of the crimping depression that runs around it in the circumferential direction.
  • the invention is based on the finding that if the stranded wire is only in contact with a contact surface of the connection element on one side, numerous individual wires are not directly connected to the connection element during welding, which impairs the fastening strength.
  • the attachment strength can be improved by the side wall of the crimping recess surrounding the stranded wire according to the invention.
  • the contact resistance can be reduced by the comparatively large-area system.
  • the stranded wire is received in a crimping recess during welding, an undesired flow of line material onto the contact surface is prevented before the individual wires of the stranded line sufficiently adhere to the contact surface.
  • the invention is also based on the finding that for a purely non-positive connection such as a crimp connection with a large number of individual wires of the stranded cable to be crimped, considerable pressing forces must be applied in order to achieve a desired plastic deformation of the individual wires over the entire cable diameter. For this reason, pure crimp connections for stranded cables with a large cross section are complex to produce and not sufficiently reliable.
  • the force-locking crimp connection and the material-locking welded connection complement each other in an optimal way according to the invention, since the individual wires already pressed against one another after the crimping process can be welded without significant welding effort and with only a short welding time Provide a material-to-material connection without the cable material escaping from the crimping recess during welding.
  • the stranded cable preferably has a diameter of more than 0.5 cm, in particular 1 cm or more and/or a stranded cross-sectional area of more than 20 mm 2 , preferably more than 40 mm 2 , in particular 50 mm 2 or more.
  • the stranded wire is not necessarily round and can also be in the form of an oval or flat stranded wire.
  • the stranded line can have more than 100, preferably more than 200, in particular 250 or more individual wires running alongside one another.
  • Such a stranded wire can be designed for currents of more than 50 A, in particular 100 A or more, as occur when used in the automotive sector.
  • the crimping depression is essentially circular-cylindrical and adapted to the diameter of the stranded wire. It is surrounded by a thin side wall, preferably essentially in the shape of a circular cylinder, so that a pressing force from the outside allows the side wall to be molded onto the individual wires of the stranded cable arranged in the recess.
  • connection element is first crimped to the stranded wire to provide a crimp connection and then the finished crimp connection is welded to provide a crimp-welded connection.
  • the crimping process in which the end of the stranded wire received in the crimping recess is pressed by the action of a predetermined radial pressing force and the individual wires are thereby plastically deformed, can namely provide a predetermined starting position for the subsequent welding process depending on the pressing force acting.
  • the individual wires of the stranded wire are no longer arranged randomly and comparatively disorderly in the crimping recess after crimping, but with a defined and predetermined crimping height. This leads to a reproducible strength of crimp-weld connections according to the invention.
  • the crimped connection is preferably welded using ultrasound.
  • the energy required for welding is generated by a high-frequency mechanical vibration, which is generated by friction between the components to be welded. At the same time, this friction breaks up an oxide layer on the surfaces of the components to be connected.
  • Ultrasonic welding is characterized by a comparatively shorter welding time. Furthermore, the ultrasonic waves can be applied to the connection element from the outside in a simple manner and thus introduced into the crimping recess.
  • connection element is crimped gas-tight with the stranded cable.
  • the stranded wire is crimped so tightly with the connection element that neither a liquid nor a gaseous medium can penetrate the crimp from the outside, so that oxidation between the pressed individual wires and an associated increase in the contact resistance can be ruled out.
  • the cavities still present between the crimped individual wires are therefore not in fluid connection with the environment.
  • a gas-tight crimp is ensured by a sufficiently high pressing force acting from several sides from the outside on the cylindrical side wall of the crimping recess. As a result, the individual wires are evenly pressed against each other and compressed.
  • the end of the stranded wire is preferably stripped and then inserted into the essentially cylindrical blind hole of the connection element.
  • the stranded wire is inserted so far into the blind hole that the front ends of the individual wires hit the bottom of the blind hole.
  • connection point can also be sealed off from environmental influences by the blind hole.
  • the invention relates to a crimp welded connection produced according to the method according to the invention.
  • a crimp-welded connection is characterized by an end of a stranded wire engaging in a crimping recess of a connecting element such as a plug connector, the stranded wire and the connecting element being crimped and welded to one another.
  • the crimp-welded connection according to the invention is first crimped and then welded.
  • Such a crimp-weld connection is characterized by practically no cavities between the individual wires and particularly uniform compression.
  • the stranded wire is designed to transmit high currents and can have a cross-sectional area of more than 20 mm 2 , preferably more than 40 mm 2 , in particular 50 mm 2 or more and/or more than 100, in particular 200 or more individual wires .
  • the individual wires of the stranded cable are made of aluminum.
  • the side wall of the crimping recess, against which the stranded wire rests, is formed at least partially from copper.
  • the force-locking as well as material-locking crimp-weld connection is particularly advantageous for increasing the fastening strength.
  • connection is sealed (liquid-tight and/or gas-tight) by means of a (possibly additional) insulation crimp in the entry area of the crimping recess.
  • a (possibly additional) insulation crimp in the entry area of the crimping recess.
  • at least a part of a jacket of the stranded wire and/or another sealing element attached to the stranded wire is inserted in sections into the crimping depression and crimped in as well.
  • connection element can be formed as a connector for electrically connecting the stranded wire with a mating connector, the connector has the crimping depression on one side and/or a preferably socket-shaped plug-in geometry on the opposite side.
  • the crimp-welded connection according to the invention is characterized in particular by the following properties: uniform strand compaction, gas-tight connection preferably without cavities in the crimp, improved contact resistance and/or improved surface structure of the contact.
  • connection element 100 in the form of a plug connector, the connection element 100 having a crimping depression 22 into which one end 12 of a stranded wire 10 engages.
  • the crimping recess 22 is formed in the connection element 100 on a side facing the stranded wire 10 in the form of a substantially cylindrical blind hole 24 .
  • the connection element 100 On the side facing away from the blind hole 24, the connection element 100 has a socket-shaped plug-in geometry 28 for connecting the connection element 100 to a mating connector (not shown).
  • the blind hole 24 is surrounded by a relatively thin side wall 26 onto which compressive forces F acting radially inwards can be applied during crimping.
  • a thin side wall offers the further advantage that better introduction of vibrations into the blind hole 24 is possible during welding.
  • a round cross-sectional geometry of the blind hole facilitates the crimping process and leads to a particularly even compression of the stranded wire. Unlike a through hole, a blind hole prevents leakage of molten wire during welding.
  • connection element 100 An outer boundary surface of the connection element 100 is formed in a crimp-optimized manner.
  • the outer boundary surface has an intermediate section which adjoins the side wall 26 of the blind hole 24 and widens conically and which merges into a transition area 29 with an enlarged diameter (see FIG 1 ).
  • the transition area 29 provides sufficient material volume to allow a radial inward deformation of the side wall 26 during crimping.
  • the tapered intermediate section minimizes cracking and other material damage during crimping and/or welding.
  • the plug-in geometry 28 is only shown as an example as a socket.
  • the plug-in geometry can also be in the form of a plug.
  • the connection element may not be formed as a plug connector, but instead represent part of a housing or another contact element.
  • the stranded wire 10 shown has a large number of conductive individual wires 14 which are surrounded by a common sheath.
  • the jacket is stripped so that the individual wires rest against the inner surface of the side wall 26 of the blind hole 24.
  • a part of the jacket and/or another sealing element is introduced at least in sections into the blind hole and is crimped in, so that an insulation crimp is produced.
  • the insulation crimp can also be created in an additional crimping process as a further crimp connection on the cable side become. As a result, the connection is sealed on the cable side by the crimp and on the front end by the blind hole.
  • the stranded line 10 has about 250 individual wires.
  • the cross-sectional area formed jointly by the individual wires (here referred to as the cross-section of the stranded wire) is approximately 50 mm 2 .
  • the stranded line can be surrounded by a common shield and/or an outer sheath.
  • the individual wires can each have an insulating coating.
  • the individual wires 14 of the stranded line are essentially made of aluminum and the connecting element 20 is essentially made of copper.
  • a pressing force F is applied radially from the outside to the side wall 26 of the blind hole.
  • the pressing force F acts circumferentially on the side wall 26 in order to achieve the most uniform possible pressing of the individual wires 14 and pressing against the side wall 26 .
  • the individual wires 14 are deformed in such a way that there are only a few cavities between the individual wires within the blind hole 24 .
  • the pressing force F is dimensioned in such a way that a gas-tight crimp is created.
  • Figures 2a and 2b the resulting crimp connection is shown in a perspective view and in a sectional view.
  • Figure 2b shows particularly clearly the individual wires 14 of the stranded cable 10 that are pressed tightly together.
  • connection can easily absorb tensile forces of 3 kN on the stranded cable, while conventional welded connections are regularly designed for a maximum tensile force of around 1.8 kN.
  • the crimp-weld connection almost achieves the tensile strength of the rest of the stranded wire or cable. With a purely welded connection, the pull-out force is significantly lower.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
EP15718771.7A 2014-04-28 2015-04-16 Crimp-schweissverbindung Active EP3138160B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102014006244.9A DE102014006244A1 (de) 2014-04-28 2014-04-28 Crimp-Schweißverbindung
PCT/EP2015/000800 WO2015165572A1 (de) 2014-04-28 2015-04-16 Crimp-schweissverbindung

Publications (2)

Publication Number Publication Date
EP3138160A1 EP3138160A1 (de) 2017-03-08
EP3138160B1 true EP3138160B1 (de) 2023-07-12

Family

ID=53008434

Family Applications (1)

Application Number Title Priority Date Filing Date
EP15718771.7A Active EP3138160B1 (de) 2014-04-28 2015-04-16 Crimp-schweissverbindung

Country Status (9)

Country Link
US (1) US10396472B2 (ja)
EP (1) EP3138160B1 (ja)
JP (1) JP2017514286A (ja)
KR (1) KR102189414B1 (ja)
CN (1) CN106463846B (ja)
CA (1) CA2944234C (ja)
DE (1) DE102014006244A1 (ja)
TW (1) TWI676326B (ja)
WO (1) WO2015165572A1 (ja)

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EP3138160A1 (de) 2017-03-08
KR20160147754A (ko) 2016-12-23
DE102014006244A1 (de) 2015-10-29
JP2017514286A (ja) 2017-06-01
TWI676326B (zh) 2019-11-01
WO2015165572A1 (de) 2015-11-05
CN106463846A (zh) 2017-02-22
KR102189414B1 (ko) 2020-12-14
CA2944234C (en) 2020-06-23
CA2944234A1 (en) 2020-03-17
US10396472B2 (en) 2019-08-27
TW201541766A (zh) 2015-11-01
CN106463846B (zh) 2020-07-07
US20170069975A1 (en) 2017-03-09

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