EP3189561B1 - Crimp contact - Google Patents
Crimp contact Download PDFInfo
- Publication number
- EP3189561B1 EP3189561B1 EP15766384.0A EP15766384A EP3189561B1 EP 3189561 B1 EP3189561 B1 EP 3189561B1 EP 15766384 A EP15766384 A EP 15766384A EP 3189561 B1 EP3189561 B1 EP 3189561B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- contact
- crimp
- hollow chamber
- region
- aluminum
- 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
Links
- 229910052782 aluminium Inorganic materials 0.000 claims description 46
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 46
- 239000004020 conductor Substances 0.000 claims description 39
- 238000003466 welding Methods 0.000 claims description 30
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 28
- 229910052802 copper Inorganic materials 0.000 claims description 26
- 239000010949 copper Substances 0.000 claims description 26
- 238000002788 crimping Methods 0.000 claims description 24
- 238000000034 method Methods 0.000 claims description 19
- 238000003780 insertion Methods 0.000 claims description 14
- 230000037431 insertion Effects 0.000 claims description 14
- 238000004519 manufacturing process Methods 0.000 claims description 9
- 238000005553 drilling Methods 0.000 claims description 7
- 229910000881 Cu alloy Inorganic materials 0.000 claims description 4
- 229910000838 Al alloy Inorganic materials 0.000 claims description 3
- 229910052709 silver Inorganic materials 0.000 claims description 3
- 239000004332 silver Substances 0.000 claims description 3
- 239000011248 coating agent Substances 0.000 claims description 2
- 238000000576 coating method Methods 0.000 claims description 2
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical group [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 claims 2
- 230000007704 transition Effects 0.000 description 10
- 230000007797 corrosion Effects 0.000 description 7
- 238000005260 corrosion Methods 0.000 description 7
- 239000000463 material Substances 0.000 description 5
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 3
- 230000005540 biological transmission Effects 0.000 description 3
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 229910052760 oxygen Inorganic materials 0.000 description 3
- 239000001301 oxygen Substances 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 230000007774 longterm Effects 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 229920001169 thermoplastic Polymers 0.000 description 2
- 239000004416 thermosoftening plastic Substances 0.000 description 2
- 229910001369 Brass Inorganic materials 0.000 description 1
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- WPPDFTBPZNZZRP-UHFFFAOYSA-N aluminum copper Chemical compound [Al].[Cu] WPPDFTBPZNZZRP-UHFFFAOYSA-N 0.000 description 1
- 239000010951 brass Substances 0.000 description 1
- 230000000295 complement effect Effects 0.000 description 1
- 239000003989 dielectric material Substances 0.000 description 1
- 238000009429 electrical wiring Methods 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 230000002459 sustained effect Effects 0.000 description 1
Images
Classifications
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- 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
- H01R4/203—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 having an uneven wire-receiving surface to improve the contact
- H01R4/206—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 having an uneven wire-receiving surface to improve the contact with transversal grooves or threads
-
- 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
-
- 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
- H01R4/28—Clamped connections, spring connections
- H01R4/50—Clamped connections, spring connections utilising a cam, wedge, cone or ball also combined with a screw
- H01R4/5033—Clamped connections, spring connections utilising a cam, wedge, cone or ball also combined with a screw using wedge or pin penetrating into the end of a wire in axial direction of the wire
-
- 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
- H01R43/04—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
- H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
Definitions
- the invention relates to a crimp contact according to the preamble of independent main claim 1.
- the invention also relates to a heavy-duty connector with the crimp contact.
- the invention also relates to a method for using the crimp contact
- the invention relates to a method for producing the crimp contact, with an additional silver coating.
- Such connectors and contacts are used to transmit an electrical current with currents of 500 to 650 A, for example, between electrical conductors.
- connection between the aluminum cable and the connector can take place by friction welding, rotational friction welding, ultrasonic welding or resistance welding.
- the connector can be formed from copper.
- the connecting piece is also formed from aluminum in order to avoid contact resistance or contact corrosion at the junctions between the aluminum cable and the Avoid contact piece. Furthermore, tinning or tinning and nickel plating of the surface of the connecting pieces is proposed.
- the pamphlet EP 1 032 077 A2 suggests in this context connecting a stranded conductor made of aluminum to a contact part made of copper by friction welding.
- the pamphlet EP 2 621 022 A1 describes a cable lug for connecting a current-carrying element to an aluminum cable, a first section of an associated pipe having an aluminum layer on an inside and a copper layer on an outside.
- EP 2 662 934 A2 suggests the use of a connection cap made of aluminum or an aluminum alloy. This connection cap is pressed with the aluminum conductor and welded to the contact part made of copper or a copper alloy.
- the DE 11 2011 103 392 T5 discloses a crimp termination made from two different metal materials, such as copper and aluminum. The connection area between these two materials is covered with a plastic molded part to prevent corrosion.
- the pamphlet EP 2 579 390 A1 also describes an aluminum-copper terminal that has a contact part made of aluminum and a connection part made of copper, which are welded to one another, the connection area being protected against electrical corrosion by attaching a primary seal, for example by overmoulding with a special thermoplastic Strand is welded to the contact part.
- the aforementioned documents also relate to connectors with which a supply cable is permanently connected to a power rail or to another cable for permanent installation. This installation is installed once and is basically not intended to be changed frequently.
- the pamphlet DE 2 601 952 A1 refers to a connector made of aluminum and an opening or hole having.
- the connector is intended to be clamped to one or more electrical lines, which are also made of aluminum, when these are inserted into the opening.
- the clamping should preferably be done with the help of a mold.
- the pamphlet GB 982 667 A discloses a method for improving electrical connections and thereby discloses a clamping sleeve with an internal thread and a screw mandrel.
- the pamphlet U.S. 3,350,500 A discloses a method for butt splicing coaxial cables having a core and barrel conductors separated by dielectric material. It is disclosed here that the sleeve conductors are expanded outward at the cable ends and the core conductors are connected by connecting plugs which penetrate the cable ends essentially axially and connect the sleeve conductors by a conductive sleeve.
- the pamphlet EP 1 094 557 A2 relates to a high-current circuit board connector for vibration-free contacting of circuit board connection contacts and main contacts to be plugged over, whereby the socket part of the high-current circuit board connector can be mechanically fitted to circuit boards with alignment in board bores.
- the main contacts are made of copper and silver-plated on the outside.
- the pamphlet U.S. 3,916,518 A discloses a method of making a one-piece bimetallic connector.
- the pamphlet EP 0 023 880 A1 discloses a plug element which consists of a plug part and a compression sleeve. So that the outer diameter of the compression sleeve is always smaller than the associated wire diameter, the compression sleeve is designed with at least two layers forms. An inner layer made of copper or aluminum takes on the function of conducting electricity, while an outer layer made of steel ensures the contact pressure after the pressing process.
- the object of the invention is thus to provide an electrical connector which, on the one hand, allows a comparatively uncomplicated connection of an aluminum stranded conductor, and on the other hand also enables the most flexible maneuvering possible and which continues to have a sustained good electrical conductivity even with high currents acting over a long period of time.
- the invention is a crimp contact; wherein the crimp contact has a crimp area formed from aluminum or an aluminum alloy and an adjacent contact area formed from copper or a copper alloy, wherein the contact area can be designed in the shape of a pin or socket.
- the contact area can be designed in the shape of a pin or socket.
- the transition from the copper to the aluminum material is moved into the crimp contact. This is made possible by the crimping area being welded to the contact area. In particular this connection is made during the production of the crimp contact by a friction welding process.
- the crimp contact can therefore be a high-current capable contact pin or a high-current capable contact socket. At least one such contact pin and / or such a contact socket are inserted into an insulating body and, together with this, form a component of the heavy-duty connector.
- the crimp contact is at least partially rotationally symmetrical or has at least one or more regions with a cylindrical or at least rotationally symmetrical outer contour, because it can thereby be arranged in a form-fitting manner in through bores or corresponding, likewise rotationally symmetrical through openings of the insulating body.
- aluminum is used as the material for the crimp area of the crimp contact due to its easy deformability.
- This is particularly advantageous for crimping an aluminum conductor, in particular an aluminum stranded conductor, because there is no electrical corrosion and in particular no intermetallic phase in the relevant area despite the inevitable contact with oxygen.
- the crimping area has a cavity with a cable entry opening to accommodate the aluminum stranded conductor.
- an additional through hole is then drilled in the cavity and an internal thread is cut into this through opening.
- such a mandrel which has a matching external thread and a point adjoining it, can be screwed with its point first into the cavity, preferably in the direction of the cable insertion opening, i.e. against the insertion direction of the stranded conductor.
- the crimp contact has an additional internal thread within its crimp area.
- the stranded conductor is then pressed from the inside against this additional internal thread, the additional internal thread holding the stranded wires due to the increased frictional force.
- the oxide layer of the aluminum strands is broken up. Because of this and the pressure against each other, the transverse conductivity of the stranded conductor increases. This reduces the contact resistance between the stranded conductor and the crimp contact.
- the use of the mandrel improves the conductivity over the long term, especially if the mandrel is preferably made of aluminum or some other electrically conductive material, for example a copper alloy, thereby increasing the contact area of the crimp contact with respect to the stranded conductor.
- the contact area is additionally at least partially coated, for example silver-plated or gold-plated, and thus permanently protected against corrosion. Furthermore, a permanently low-resistance plug connection with other copper contacts and above with corresponding copper lines is thereby advantageously also possible, since the problematic transition between copper and aluminum is laid according to the invention in the interior of the crimp contact.
- the crimping area which is made of aluminum
- the contact area which is made of copper
- the contact surface is located inside the contact and does not come into contact with oxygen in this way.
- the welding in particular the friction welding, ensures a particularly stable connection, so that the crimp contact is also mechanically stable.
- the use of cylindrical copper and aluminum blanks, which are attached to one another in the axial direction, according to the invention by friction welding be welded.
- rotation welding appears to be sensible at first.
- the crimping area can advantageously also be connected to the contact area by vibration welding.
- a combination of rotation welding and vibration welding has proven to be particularly advantageous, since pure rotation welding has the disadvantage that the inner areas of the contact surface experience less friction than the outer areas, so that the elements at least in the contact area have a central so-called " Blind hole "would have to have.
- With somewhat more complex vibration welding however, all areas experience the same frictional energy, so that the inner areas of the contact surface can also be welded.
- the contact area can be made into a pin or socket contact by turning and drilling, and the cavity with the cable insertion opening can be drilled into the crimping area.
- the additional internal thread which serves to increase the frictional force acting on the stranded conductor, is cut into the cavity.
- the Fig. 1a shows a cross section and the Figure 1b shows a perspective view of a first crimp contact designed as a pin contact 1.
- the pin contact 1 has a first crimping area 11 and a first contact area 12, which are in contact with one another at a first transition area 10, for example by being welded to one another, in particular by a friction welding process.
- a friction welding process for example, two cylindrical blanks, one of which is made of copper and the other of aluminum, are joined to one another in the axial direction and, for example, are welded to one another by rotation welding and / or vibration welding.
- the first contact area 12 made of copper can be given a contact pin 121 in subsequent work steps, so that this crimp contact is a pin contact 1.
- a first cavity 111 can be drilled into the first crimping area 11 made of aluminum.
- the first crimping area 11 thus has a first cable insertion opening 110 at its free-standing end adjacent to the cavity.
- the Fig.2a shows a cross section and the Figure 2b shows a perspective view of a second crimp contact designed as a socket contact 2.
- the socket contact 2 has a second crimping area 21 and a second contact area 22, which are in contact with one another at a second transition area 20, for example by being welded to one another, in particular by a friction welding process.
- two cylindrical blanks one of which is made of copper and the other of aluminum, can be joined to one another in the axial direction and welded to one another, for example by rotation welding and / or vibration welding.
- the second contact area 22, which is made of copper can be given a contact socket 221 in subsequent work steps, so that this crimp contact is a socket contact 2.
- the bushing 221 has a bushing cavity 2211, which is also preferably created by drilling.
- a cavity 211 can also be drilled into the second crimping area 21 made of aluminum.
- the second crimping area 21 as a result, has a second cable insertion opening 210 at its free-standing end adjacent to the second cavity 211.
- the Figures 3a and 3b represent in a comparable manner the pin contact 1 in a modified version, in which the pin contact 1 additionally has a first through-opening 101, which has a cylindrical shape to contain a mandrel 113 (not shown here) (shown in FIG Figure 6a ) to be able to record. Furthermore, the modified pin contact 1 has a pin cavity 1211 which is connected to the first cavity 111 via the first cylindrical through-opening 101.
- the first through opening 101 is preferably produced by drilling, so that the first through opening 101 is a through hole.
- an internal thread 103 can be cut into the first through opening 101 so that the mandrel 113, which has a matching external thread 2132, can be screwed into the first through opening 101 and above it into the first cavity 111.
- the first crimping area 11 has a first additional internal thread 112 in its first cavity 111, which is cut into the first crimping area 11 from the inside when the pin contact 1 is produced.
- This first additional internal thread 112 is used to hold a stranded conductor inserted into the first cavity 111 in it by means of an increased frictional force, even if the mandrel 113 is screwed into the first cavity 111 in the direction of the first cable insertion opening 110, i.e. against the direction of insertion of the stranded conductor becomes.
- FIG Figure 3c An advantageous embodiment of the first additional internal thread 112 is shown in FIG Figure 3c shown enlarged. It is obvious that the theoretical inside diameter D T of the first additional internal thread 112 is smaller than the real inside diameter D R of the first cavity 111. The real course of this internal thread 112 is shown by the hatched area. On the other hand, the non-hatched area indicates the theoretical course that a theoretical internal thread with the theoretical thread depth T T and the theoretical thread internal diameter D T would have. The real cavity inside diameter D R , however, is greater than the theoretical thread inside diameter D T , which is used as a measure for the internal thread to be cut into it. As a result, this internal thread 112 has a real thread depth T R which is smaller than the theoretical thread depth T T and the real course of the thread 112 is flattened more than usual.
- the Figures 4a and 4b represent the socket contact 2 in a comparable manner, which has been modified to include a mandrel 213 (shown in FIG Figure 6b ) to be able to record.
- the socket cavity 2211 is connected to the second cavity 211 via a second cylindrical through opening 201.
- this second through opening 201 is preferably produced by drilling, so that the second through opening 201 is a through hole.
- a second additional internal thread 203 can also be cut into the second through opening 201 so that the mandrel 213, which has a matching external thread 2132, can be screwed into the second through opening 201 and above it into the second cavity 211.
- the second crimping area 21 in the second cavity 211 has a second additional internal thread 212 which is cut into the crimping area 21 of the socket contact 2 from the inside during manufacture.
- This second additional internal thread 212 serves to hold a stranded conductor inserted into the second cavity 211 in it by means of an increased frictional force, even if the mandrel 213 is screwed into the second cavity 211 in the direction of the second cable insertion opening 210, i.e. against the direction of insertion of the stranded conductor becomes.
- FIG Figure 4c An advantageous embodiment of the second additional internal thread 212 is shown in FIG Figure 4c shown enlarged.
- the real course of this internal thread 212 is shown by the hatched area.
- the non-hatched area indicates the further theoretical course that a theoretical internal thread with the theoretical thread depth T T and the theoretical thread internal diameter D T would have.
- the inside diameter of the cavity D R is accordingly greater than the theoretical inside thread diameter D T , which, however, is used as a measure for the inside thread to be cut.
- this internal thread 212 has a real thread depth T R which is smaller than the theoretical thread depth T T and the real course of the thread 212 is flattened more than usual.
- the Figures 6a and 6b show the pin contact 1 and the socket contact 2 with the respective through-opening 101, 201 and an associated first and second mandrel 113, 213.
- Each of the through-openings 101, 201 has an associated internal thread 103, 203
- the mandrel 113, 213 each has a matching external thread 1132, 2132 with which it is screwed into the respective through opening 101, 201.
- the mandrel 113, 213 can have a screw head 1131, 2131 which enables it to be screwed in from the pin or socket cavity 1211, 2211.
- the Fig. 7 shows a complete heavy-duty connector in an exploded view.
- a pin contact 1 is shown as an example. But it could just as well be a socket contact 2.
- an insulating body 3 is shown, which is provided to accommodate the pin contact 1. This insulating body 3 can in turn be fastened in the connector housing 4 via fastening elements 31.
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
Description
Die Erfindung betrifft in einem ersten Aspekt einen Crimpkontakt nach dem Oberbegriff des unabhängigen Hauptanspruchs 1.In a first aspect, the invention relates to a crimp contact according to the preamble of independent main claim 1.
Desweiteren betrifft die Erfindung einen Schwerlaststeckverbinder mit dem Crimpkontakt.The invention also relates to a heavy-duty connector with the crimp contact.
Außerdem betrifft die Erfindung ein Verfahren zur Verwendung des Crimpkontakts
In einem weiteren Aspekt betrifft die Erfindung ein Verfahren zur Herstellung des Crimpkontakts, mit einer zusätzlichen Silberbeschichtung.The invention also relates to a method for using the crimp contact
In a further aspect, the invention relates to a method for producing the crimp contact, with an additional silver coating.
Derartige Steckverbinder und Kontakte werden eingesetzt, um zwischen elektrischen Leitern einen elektrischen Strom mit Stromstärken von beispielsweise 500 bis 650 A zu übertragen.Such connectors and contacts are used to transmit an electrical current with currents of 500 to 650 A, for example, between electrical conductors.
Im Stand der Technik ist es bekannt, sowohl Kupferleitungen als auch Aluminiumleitungen zur elektrischen Energieübertragung insbesondere im Hochstrombereich zu verwenden. Beispielsweise wurde seinerzeit in der DDR zu diesem Zweck vorwiegend Aluminium als verfügbarer Rohstoff eingesetzt. Meist geschah dies in Form relativ starrer Einzelleiter, so dass auch heutzutage in den neuen Bundesländern derartige Energieversorgungsleitungen anzutreffen sind. Dagegen wurden im den alten Bundesländern in der Vergangenheit vorwiegend Litzenleiter aus Kupfer verwendet.In the prior art, it is known to use both copper lines and aluminum lines for electrical energy transmission, particularly in the high-current range. For example, at the time in the GDR, aluminum was primarily used as an available raw material for this purpose. Usually this was done in the form of relatively rigid individual conductors, so that such power supply lines can also be found today in the new federal states. In contrast, stranded conductors made of copper were predominantly used in the old federal states in the past.
Aufgrund der aktuellen Preise und der nur in begrenztem Maße zur Verfügung stehenden Kupferressourcen und weiterhin auch aufgrund des deutlich geringeren spezifischen Gewichtes (AL: 2,73 Kg/dm3; CU: 8,9 Kg/dm3) wird heutzutage in vielen Bereichen zunehmend Aluminium als Material für elektrische Hochstromübertragungsleitungen verwendet. Dabei werden bevorzugt die flexibleren, d.h. weniger starren, Litzenleiter eingesetzt. Die Stromübertragung kann dabei sowohl im überirdischen Bereich, z.B. in Windkraftanlagen sowie im Bereich der Eisenbahn, aber auch bei der unterirdischen Energieverteilung, z.B. in Form von Erdleitungen als Bestandteil eines größeren Stromverteilungsnetzes, stattfinden. Der etwas geringere spezifische Leitwert von Aluminium und die daraus resultierenden entsprechend größeren notwendigen Kabelquerschnitte werden zugunsten der vorgenannten Vorteile in Kauf genommen.Due to the current prices and the limited availability of copper resources and also due to the significantly lower specific weight (AL: 2.73 kg / dm 3 ; CU: 8.9 kg / dm 3 ), it is increasing in many areas today Aluminum used as a material for high-current electric transmission lines. The more flexible, ie less rigid, stranded conductors are preferably used. The power transmission can take place both above ground, for example in wind turbines and in the railway sector, but also in the case of underground power distribution, for example in the form of underground lines as part of a larger power distribution network. The somewhat lower specific conductance of aluminum and the resulting correspondingly larger cable cross-sections are accepted in favor of the aforementioned advantages.
Der zunehmende Einsatz von Aluminiumkabeln in Windkraftanlagen ist in der Druckschrift
Weiterhin wird erwähnt, dass die Verbindung zwischen dem Aluminiumkabel und dem Verbindungsstück durch Reibschweißen, Rotationsreibschweißen, Ultraschallschweißen oder Widerstandsschweißen stattfinden kann. Das Verbindungsstück kann aus Kupfer gebildet sein. Alternativ dazu wird offenbart, dass das Verbindungsstück ebenfalls aus Aluminium gebildet ist, um Übergangswiderstände oder Kontaktkorrosionen an den Übergängen zwischen dem Aluminiumkabel und dem Kontaktstück zu vermeiden. Ferner wird ein Verzinnen oder ein Verzinnen und Vernickeln der Oberfläche der Verbindungsstücke vorgeschlagen.It is also mentioned that the connection between the aluminum cable and the connector can take place by friction welding, rotational friction welding, ultrasonic welding or resistance welding. The connector can be formed from copper. Alternatively, it is disclosed that the connecting piece is also formed from aluminum in order to avoid contact resistance or contact corrosion at the junctions between the aluminum cable and the Avoid contact piece. Furthermore, tinning or tinning and nickel plating of the surface of the connecting pieces is proposed.
Aus der Druckschrift
Die Druckschrift
Die Druckschrift
Grundsätzlich ist die Konfektionierung bei diesen Bauformen, bei denen also der Litzenleiter an den Kontakt direkt oder indirekt angeschweißt wird, leider sehr aufwändig und kann nicht ohne entsprechende Geräte vor Ort vorgenommen werden, so dass bei diesem Bauformen keine Feldkonfektionierbarkeit gegeben ist.In principle, the assembly of these types of construction, in which the stranded conductor is welded directly or indirectly to the contact, is unfortunately very complex and cannot be carried out on site without appropriate devices, so that this type of construction cannot be assembled in the field.
Die
Die Druckschrift
Somit wird in diesen beiden letztgenannten beiden Druckschriften vorgeschlagen, den betreffenden Übergangsbereich mit einer Dichtung, beispielsweise durch ein Umspritzen mit einem speziellen Thermoplast, abzudichten. Doch zum einen ist dieser Vorgang aufwändig, und zum anderen besitzt eine solche Dichtung üblicherweise eine nur begrenzte Lebensdauer. Ein so gebildeter Verbinder ist nicht als Kontaktelement für einen Steckverbinder geeignet.It is therefore proposed in these two last-mentioned two publications to seal the relevant transition area with a seal, for example by overmolding with a special thermoplastic. On the one hand, this process is complex and, on the other hand, such a seal usually only has a limited service life. A connector formed in this way is not suitable as a contact element for a connector.
Die vorgenannten Druckschriften beziehen sich weiterhin auf Verbinder, mit denen ein Versorgungskabel an eine Stromschiene oder an ein anderes Kabel dauerhaft zur Festinstallation angeschlossen wird. Diese Installation wird also einmal montiert und ist grundsätzlich nicht dafür vorgesehen, des Öfteren geändert zu werden.The aforementioned documents also relate to connectors with which a supply cable is permanently connected to a power rail or to another cable for permanent installation. This installation is installed once and is basically not intended to be changed frequently.
Im Gegensatz dazu sind im Stand der Technik, beispielsweise aus der Druckschrift
Die Druckschrift
Die Druckschrift
Die Druckschrift
Die Druckschrift
Die Druckschrift
Die Druckschrift
Auch dabei bleibt jedoch das Problem bestehen, dass die Litzen des Aluminiumleiters untereinander aufgrund ihrer Oxydierung eine schlechte sogenannte "Querleitfähigkeit" (d.h. die Leitfähigkeit zwischen den einzelnen Litzen senkrecht zum Verlauf des Kabels) aufweisen, was ebenfalls bei sämtlichen beschriebenen Anordnungen den Übergangswiderstand zum Anschlusskontakt vergrößert.Even in this case, however, the problem remains that the strands of the aluminum conductor have a poor relationship with one another due to their oxidation have so-called "transverse conductivity" (ie the conductivity between the individual strands perpendicular to the course of the cable), which also increases the transition resistance to the connection contact in all the arrangements described.
Weiterhin besteht weiterhin das Problem, dass Aluminium leicht oxydiert und sich weiterhin mit anderen Metallen wie z.B. Kupfer oder Messing schlecht verbindet. Insbesondere gilt dies aufgrund ihrer großen Oberfläche für Aluminium-Litzenleiter. Im Übergangsbereich zwischen Aluminium und beispielsweise Kupfer entsteht insbesondere unter einer langfristigen Bestromung mit hohen Stromstärken und unter gleichzeitigem Sauerstoffeinfluss eine sogenannte "Elektrokorrosion", und damit eine Schicht, die einen wesentlich höheren spezifischen Widerstand besitzt als jedes der beteiligten Metalle. Durch diesen hohen Widerstand kann im Betrieb aufgrund der hohen Stromstärken eine starke Erwärmung stattfinden, durch die sich dieser Übergangswiderstand in Form einer Wechselwirkung zusätzlich erhöht. Diese Wärmeentwicklung kann außerdem weitere Folgeschäden, beispielsweise an einer Kunststoffisolierung, nach sich ziehen.Furthermore, there is still the problem that aluminum easily oxidizes and continues to combine with other metals such as e.g. Copper or brass badly connects. This applies in particular to stranded aluminum conductors due to their large surface area. In the transition area between aluminum and copper, for example, so-called "electrocorrosion" occurs, especially when long-term current is applied with high currents and under the simultaneous influence of oxygen, and thus a layer that has a significantly higher specific resistance than any of the metals involved. Due to this high resistance, strong heating can take place during operation due to the high current strengths, through which this contact resistance is additionally increased in the form of an interaction. This heat development can also result in further consequential damage, for example to plastic insulation.
Beispielsweise im Bereich der Eisenbahn, aber auch in vielen anderen Bereichen, gibt es Anwendungen, die eine häufige Änderung der elektrischen Hochstromverkabelung erfordern. Somit existiert im Stand der Technik ein Bedarf an flexibel rangierbaren Hochstromverbindern, die bevorzugt feldkonfektionierbar oder zumindest mit möglichst geringem Aufwand konfektionierbar sind.For example, in the railway sector, but also in many other areas, there are applications that require frequent changes to the high-current electrical wiring. Thus, in the prior art, there is a need for high-current connectors that can be flexibly maneuvered, which can preferably be assembled in the field or at least can be assembled with as little effort as possible.
Die Aufgabe der Erfindung besteht somit darin, einen elektrischen Verbinder anzugeben, der einerseits ein vergleichsweise unaufwändiges Anschließen eines Aluminium-Litzenleiters gestattet, der andererseits auch ein möglichst flexibles Rangieren ermöglicht und der weiterhin auch bei über einen langen Zeitraum wirkenden hohen Stromstärken eine nachhaltig gute elektrische Leitfähigkeit aufweist.The object of the invention is thus to provide an electrical connector which, on the one hand, allows a comparatively uncomplicated connection of an aluminum stranded conductor, and on the other hand also enables the most flexible maneuvering possible and which continues to have a sustained good electrical conductivity even with high currents acting over a long period of time.
Die Aufgabe wird durch die Merkmale der unabhängigen Hauptansprüche gelöst.The object is achieved by the features of the independent main claims.
Vorteilhafte Ausgestaltungen der Erfindung sind in den Unteransprüchen angegeben.Advantageous embodiments of the invention are specified in the subclaims.
Bei der Erfindung handelt es sich gemäß dem ersten Aspekt um einen Crimpkontakt; wobei der Crimpkontakt einen aus Aluminium oder einer Aluminiumlegierung gebildeten Crimpbereich und einen dran angrenzenden, aus Kupfer oder aus einer Kupferlegierung gebildeten Kontaktbereich aufweist, wobei der Kontaktbereich Stift- oder Buchsenförmig ausgeführt sein kann. Somit kann ein Aluminium-Litzenleiter mit dem Crimpbereich vercrimpt werden, ohne dass dadurch eine sogenannte "Elektrokorrosion" entsteht.According to the first aspect, the invention is a crimp contact; wherein the crimp contact has a crimp area formed from aluminum or an aluminum alloy and an adjacent contact area formed from copper or a copper alloy, wherein the contact area can be designed in the shape of a pin or socket. In this way, an aluminum stranded conductor can be crimped with the crimping area without causing so-called "electrical corrosion".
Der Übergang vom Kupfer- zum Aluminiummaterial ist dazu erfindungsgemäß in den Crimpkontakt hinein verlegt. Dies wird ermöglicht, indem der Crimpbereich mit dem Kontaktbereich verschweißt ist. Insbesondere wird diese Verbindung bei der Herstellung des Crimpkontaktes durch einen Reibschweißvorgang hergestellt.According to the invention, the transition from the copper to the aluminum material is moved into the crimp contact. This is made possible by the crimping area being welded to the contact area. In particular this connection is made during the production of the crimp contact by a friction welding process.
Bei dem Crimpkontakt kann es sich also um einen hochstromfähigen Kontaktstift oder eine hochstromfähige Kontaktbuchse handeln. Mindestens ein solcher Kontaktstift und/oder eine solche Kontaktbuchse sind in einen Isolierkörper eingeführt und bilden mit diesem zusammen einen Bestandteil des Schwerlaststeckverbinders.The crimp contact can therefore be a high-current capable contact pin or a high-current capable contact socket. At least one such contact pin and / or such a contact socket are inserted into an insulating body and, together with this, form a component of the heavy-duty connector.
Erfindungsgemäß ist der Crimpkontakt zumindest bereichsweise rotationssymmetrisch ausgebildet ist oder zumindest einen oder mehrere Bereiche mit einer zylinderförmigen oder zumindest rotationssymmetrischen Außenkontur besitzt, weil er dadurch formschlüssig in Durchgangsbohrungen oder entsprechenden ebenfalls rotationssymmetrischen Durchgangsöffnungen des Isolierkörpers angeordnet sein kann.According to the invention, the crimp contact is at least partially rotationally symmetrical or has at least one or more regions with a cylindrical or at least rotationally symmetrical outer contour, because it can thereby be arranged in a form-fitting manner in through bores or corresponding, likewise rotationally symmetrical through openings of the insulating body.
Erfindungsgemäß wird Aluminium aufgrund seiner leichten Verformbarkeit als Material für den Crimpbereich des Crimpkontaktes verwendet. Dies ist zur Vercrimpung eines Aluminiumleiters, insbesondere eines Aluminium-Litzenleiters, besonders vorteilhaft, weil dabei an dem betreffenden Bereich trotz dem unvermeidlichen Kontakt mit Sauerstoff keine Elektrokorrosion und insbesondere auch keine intermetallische Phase entsteht.According to the invention, aluminum is used as the material for the crimp area of the crimp contact due to its easy deformability. This is particularly advantageous for crimping an aluminum conductor, in particular an aluminum stranded conductor, because there is no electrical corrosion and in particular no intermetallic phase in the relevant area despite the inevitable contact with oxygen.
Zur Aufnahme des Aluminium-Litzenleiters besitzt der Crimpbereich einen Hohlraum mit einer Kabeleinführöffnung.The crimping area has a cavity with a cable entry opening to accommodate the aluminum stranded conductor.
Erfindungsgemäß wird anschließend an den Hohlraum eine zusätzliche Durchgangsbohrung gebohrt und in diese Durchgangsöffnung wird ein Innengewinde geschnitten werden.According to the invention, an additional through hole is then drilled in the cavity and an internal thread is cut into this through opening.
Erfindungsgemäß kann so ein Dorn, welcher ein dazu passendes Außengewinde sowie daran anschließend eine Spitze aufweist, mit seiner Spitze voran in den Hohlraum, bevorzugt in Richtung der Kabeleinführöffnung, also entgegen der Einführrichtung des Litzenleiters, eingeschraubt werden.According to the invention, such a mandrel, which has a matching external thread and a point adjoining it, can be screwed with its point first into the cavity, preferably in the direction of the cable insertion opening, i.e. against the insertion direction of the stranded conductor.
Dadurch werden die Litzen des zuvor eingeführten Aluminium-Litzenleiters von Innen gegen den Crimpbereich gepresst. Erfindungsgemäß besitzt der Crimpkontakt innerhalb seines Crimpbereichs ein zusätzliches Innengewinde. Dann wird der Litzenleiter von innen gegen dieses zusätzliche Innengewinde gepresst, wobei das zusätzliche Innengewinde durch die erhöhte Reibkraft die Litzen hält. Weiterhin wird die Oxydschicht der Aluminiumlitzen aufgebrochen. Dadurch und durch den Druck gegeneinander nimmt die Querleitfähigkeit des Litzenleiters zu. Somit verringert sich der Übergangswiderstand zwischen dem Litzenleiter und dem Crimpkontakt. Auch nach dem Vercrimpen ist durch den Einsatz des Dorns die Leitfähigkeit nachhaltig verbessert, insbesondere, wenn der Dorn bevorzugt aus Aluminium oder auch einem anderen elektrisch leitfähigen Material, beispielsweise einer Kupferlegierung besteht und sich dadurch die Kontaktfläche des Crimpkontakts gegenüber dem Litzenleiter erhöht.As a result, the strands of the previously inserted aluminum stranded conductor are pressed from the inside against the crimping area. According to the invention, the crimp contact has an additional internal thread within its crimp area. The stranded conductor is then pressed from the inside against this additional internal thread, the additional internal thread holding the stranded wires due to the increased frictional force. Furthermore, the oxide layer of the aluminum strands is broken up. Because of this and the pressure against each other, the transverse conductivity of the stranded conductor increases. This reduces the contact resistance between the stranded conductor and the crimp contact. Even after crimping, the use of the mandrel improves the conductivity over the long term, especially if the mandrel is preferably made of aluminum or some other electrically conductive material, for example a copper alloy, thereby increasing the contact area of the crimp contact with respect to the stranded conductor.
Erfindungsgemäß ist der Innenradius des zylindrischen Hohlraums größer als der theoretische Innenradius des hineingeschnittenen zusätzlichen Innengewindes, so dass das in den Hohlraum hineinragende zusätzliche Innengewinde abgeflacht ist. Dies ist besonders vorteilhaft, weil dadurch einerseits zwei gewünschte Effekte des zusätziichen Innengewindes erhalten bleiben, nämlich
- 1.) dass die Oxydschicht der Aluminiumlitzen aufgebrochen wird, und
- 2.) dass der Litzenleiter entgegen seiner Einführrichtung mit besonders guter Reibwirkung im Hohlraum gehalten ist, aber dass andererseits
- 3.) die Litzen nicht beschädigt werden. Zum dritten Punkt ist es weiterhin besonders vorteilhaft, wenn die reale Tiefe des abgeflachten Gewindes kleiner ist als der Durchmesser der Litzen, so dass das Gewinde die Litzen nicht durchtrennen kann.
- 1.) that the oxide layer of the aluminum strands is broken, and
- 2.) that the stranded conductor is held in the cavity against its insertion direction with a particularly good friction effect, but that on the other hand
- 3.) the strands are not damaged. With regard to the third point, it is also particularly advantageous if the real depth of the flattened thread is smaller than the diameter of the strands, so that the thread cannot cut through the strands.
Aufgrund seiner Stabilität und seiner guten elektrischen Leitfähigkeit wird erfindungsgemäß Kupfer als Material für den Kontaktbereich eingesetzt. In einer vorteilhaften Ausgestaltung ist der Kontaktbereich zusätzlich zumindest teilweise beschichtet, beispielsweise versilbert oder vergoldet, und so dauerhaft gegen Korrosion geschützt. Weiterhin ist dadurch vorteilhafterweise auch eine dauerhaft niederohmige Steckverbindung mit anderen Kupferkontakten und darüber mit entsprechenden Kupferleitungen möglich, da der problematische Übergang zwischen Kupfer und Aluminium erfindungsgemäß in das Innere des Crimpkontaktes verlegt wird.Because of its stability and its good electrical conductivity, copper is used according to the invention as the material for the contact area. In an advantageous embodiment, the contact area is additionally at least partially coated, for example silver-plated or gold-plated, and thus permanently protected against corrosion. Furthermore, a permanently low-resistance plug connection with other copper contacts and above with corresponding copper lines is thereby advantageously also possible, since the problematic transition between copper and aluminum is laid according to the invention in the interior of the crimp contact.
Von besonderem Vorteil ist es, dass der als Aluminium bestehende Crimpbereich mit dem aus Kupfer bestehenden Kontaktbereich durch einen Reibschweißvorgang verbunden ist, weil auf diese Weise das Entstehen einer Elektrokorrosion verhindert ist. Schließlich befindet sich die Kontaktfläche so im Inneren des Kontakts und kommt auf diese Weise nicht mit Sauerstoff in Berührung. Dadurch ist eine gute Leitfähigkeit auch nachhaltig, d.h. auch über einen langen Zeitraum, gewährleistet.It is particularly advantageous that the crimping area, which is made of aluminum, is connected to the contact area, which is made of copper, by means of a friction welding process, because in this way the occurrence of electrical corrosion is prevented. After all, the contact surface is located inside the contact and does not come into contact with oxygen in this way. As a result, good conductivity is also sustainable, i.e. also over a long period of time.
Weiterhin sorgt das Verschweißen, insbesondere das Reibschweißen, für eine besonders stabile Verbindung, so dass der Crimpkontakt auch mechanisch stabil ist.Furthermore, the welding, in particular the friction welding, ensures a particularly stable connection, so that the crimp contact is also mechanically stable.
Bei der Herstellung bietet sich gemäß dem zweiten Aspekt der Erfindung die Verwendung zylinderförmiger Kupfer- und Aluminiumrohlinge an, welche in axialer Richtung aneinander, erfindungsgemäß durch Reibschweißen, verschweißt werden. Für den Reibschweißvorgang erscheint dementsprechend zunächst das Rotationsschweißen sinnvoll. Vorteilhafterweise kann der Crimpbereich mit dem Kontaktbereich aber auch durch Vibrationsschweißen verbunden sein. In der Praxis hat sich eine Kombination aus Rotationsschweißen und Vibrationsschweißen als besonders vorteilhaft erwiesen, da beim reinen Rotationsschweißen der Nachteil besteht, dass die inneren Bereiche der Kontaktfläche eine geringere Reibung erfahren als die äußeren Bereiche, so dass die Elemente zumindest im Kontaktbereich ein zentrales sogenannte "Sackloch" aufweisen müssten. Beim etwas aufwändigeren Vibrationsschweißen erfahren dagegen sämtliche Bereiche die gleiche Reibenergie, so dass auch die inneren Bereiche der Kontaktfläche verschweißt werden können. In der Kombination können sich die Vorteile beider Verfahren sinnvoll ergänzen.According to the second aspect of the invention, the use of cylindrical copper and aluminum blanks, which are attached to one another in the axial direction, according to the invention by friction welding, be welded. For the friction welding process, rotation welding appears to be sensible at first. The crimping area can advantageously also be connected to the contact area by vibration welding. In practice, a combination of rotation welding and vibration welding has proven to be particularly advantageous, since pure rotation welding has the disadvantage that the inner areas of the contact surface experience less friction than the outer areas, so that the elements at least in the contact area have a central so-called " Blind hole "would have to have. With somewhat more complex vibration welding, however, all areas experience the same frictional energy, so that the inner areas of the contact surface can also be welded. When combined, the advantages of both processes can complement each other.
Durch Drehen und Bohren kann der Kontaktbereich zum Stift- oder Buchsenkontakt ausgebildet werden und in den Crimpbereich kann der Hohlraum mit der Kabeleinführöffnung gebohrt werden. Erfindungsgemäß wird in den Hohlraum das zusätzliche Innengewinde geschnitten, das der Erhöhung der auf den Litzenleiter wirkenden Reibkraft dient.The contact area can be made into a pin or socket contact by turning and drilling, and the cavity with the cable insertion opening can be drilled into the crimping area. According to the invention, the additional internal thread, which serves to increase the frictional force acting on the stranded conductor, is cut into the cavity.
Ein Ausführungsbeispiel der Erfindung ist in den Zeichnungen dargestellt und wird im Folgenden näher erläutert. Es zeigen:
- Fig. 1a,b
- einen Querschnitt und eine perspektivische Darstellung eines als Stiftkontakt ausgebildeten Crimpkontaktes;
- Fig. 2a,b
- einen Querschnitt und eine perspektivische Darstellung eines als Buchsenkontakt ausgebildeten Crimpkontaktes;
- Fig. 3a,b
- einen Querschnitt und eine perspektivische Darstellung des Stiftkontakts mit einem Innengewinde;
- Fig. 3c
- eine vergrößerte Darstellung des Innengewindes;
- Fig. 4a,b
- einen Querschnitt und eine perspektivische Darstellung des Buchsenkontakts mit einem Innengewinde;
- Fig. 4c
- eine vergrößerte Darstellung des Innengewindes;
- Fig. 5a,b
- ein 3D-Querschnitt des Stift- und Buchsenkontaktes mit dem zusätzlichen Innengewinde;
- Fig. 6a,b
- ein 3D-Querschnitt des Stift- und Buchsenkontaktes mit dem zusätzlichen Innengewinde und einem Dorn;
- Fig. 7
- einen Schwerlaststeckverbinder in einer Explosionsdarstellung.
- Fig. 1a, b
- a cross section and a perspective illustration of a crimp contact designed as a pin contact;
- Fig. 2a, b
- a cross section and a perspective illustration of a crimp contact designed as a socket contact;
- Fig. 3a, b
- a cross section and a perspective view of the pin contact with an internal thread;
- Figure 3c
- an enlarged view of the internal thread;
- Figures 4a, b
- a cross section and a perspective view of the socket contact with an internal thread;
- Figure 4c
- an enlarged view of the internal thread;
- Fig. 5a, b
- a 3D cross-section of the pin and socket contact with the additional internal thread;
- Fig. 6a, b
- a 3D cross-section of the pin and socket contact with the additional internal thread and a mandrel;
- Fig. 7
- a heavy duty connector in an exploded view.
Die Figuren enthalten teilweise vereinfachte, schematische Darstellungen. Zum Teil werden für gleiche, aber gegebenenfalls nicht identische Elemente identische Bezugszeichen verwendet. Verschiedene Ansichten gleicher Elemente könnten unterschiedlich skaliert sein.The figures contain partially simplified, schematic representations. In some cases, identical reference symbols are used for identical, but possibly not identical elements. Different views of the same elements could be scaled differently.
Die
In den aus Aluminium bestehenden ersten Crimpbereich 11 kann ein erster Hohlraum 111 hineingebohrt werden. Der erste Crimpbereich 11 besitzt dadurch an seinem freistehenden Ende angrenzend an den Hohlraum eine erste Kabeleinführöffnung 110.A
Die
In den aus Aluminium bestehenden zweiten Crimpbereich 21 kann weiterhin ein Hohlraum 211 hineingebohrt werden. Der zweite Crimpbereich 21 besitzt dadurch an seinem freistehenden Ende angrenzend an den zweiten Hohlraum 211 eine zweite Kabeleinführöffnung 210.A
Die
Weiterhin besitzt der erste Crimpbereich 11 in dieser modifizierten Ausführung in seinem ersten Hohlraum 111 ein erstes zusätzliches Innengewinde 112, das bei der Herstellung des Stiftkontakts 1 von innen in den ersten Crimpbereich 11 hineingeschnitten wird. Dieses erste zusätzliche Innengewinde 112 dient dazu, einen in den ersten Hohlraum 111 eingeführten Litzenleiter in diesem durch eine erhöhte Reibkraft zu halten, auch wenn der Dorn 113 in den ersten Hohlraum 111 in Richtung der ersten Kabeleinführöffnung 110, also entgegen der Einführrichtung des Litzenleiters, hineingeschraubt wird.Furthermore, in this modified embodiment, the first crimping
Eine vorteilhafte Ausführung des ersten zusätzlichen Innengewindes 112 ist in der
Mit anderen Worten wird bei der Herstellung nur der äußere Teil des theoretischen Innengewindes in den ersten Crimpbereich 11 geschnitten und das dadurch gebildete, real existierende, zusätzliche Innengewinde 112 besitzt somit eine besonders abgeflachte Form.In other words, during production, only the outer part of the theoretical internal thread is cut into the first crimping
Die
Weiterhin besitzt der zweite Crimpbereich 21 im zweiten Hohlraum 211 ein zweites zusätzliches Innengewinde 212, das bei der Herstellung von innen in den Crimpbereich 21 des Buchsenkontaktes 2 hineingeschnitten wird. Dieses zweite zusätzliche Innengewinde 212 dient dazu, einen in den zweiten Hohlraum 211 eingeführten Litzenleiter in diesem durch eine erhöhte Reibkraft zu halten, auch wenn der Dorn 213 in den zweiten Hohlraum 211 in Richtung der zweiten Kabeleinführöffnung 210, also entgegen der Einführrichtung des Litzenleiters, hineingeschraubt wird.Furthermore, the second crimping
Eine vorteilhafte Ausführung des zweiten zusätzlichen Innengewindes 212 ist in der
Mit anderen Worten wird bei der Herstellung nur der äußere Teil des theoretischen Innengewindes in den zweiten Crimpbereich 21 geschnitten und das dadurch gebildete, real existierende, zusätzliche Innengewinde 212 besitzt somit eine besonders abgeflachte Form.In other words, only the outer part of the theoretical internal thread is cut into the second crimping
In den
Die
Die
Weiterhin ist ein Isolierkörper 3 dargestellt, der dazu vorgesehen ist, den Stiftkontakt 1 aufzunehmen. Dieser Isolierköper 3 kann seinerseits über Befestigungselemente 31 in dem Steckverbindergehäuse 4 befestigt werden.Furthermore, an insulating
- 11
- StiftkontaktPin contact
- 1010
- erster Übergangsbereichfirst transition area
- 101101
- erste Durchgangsöffnungfirst through opening
- 103103
- Innengewindeinner thread
- 1111
- erster Crimpbereichfirst crimping area
- 110110
- erste Kabeleinführöffnungfirst cable entry opening
- 111111
- erster Hohlraumfirst cavity
- 112112
- erstes zusätzliches Innengewindefirst additional internal thread
- 1212
- erster Kontaktbereichfirst contact area
- 121121
- KontaktstiftContact pin
- 12111211
- StifthohlraumPen cavity
- 113113
- erster Dornfirst thorn
- 11311131
- Schraubkopf des ersten DornsScrew head of the first mandrel
- 11321132
- Außengewinde des DornsExternal thread of the mandrel
- 22
- BuchsenkontaktSocket contact
- 2020th
- zweiter Übergangsbereichsecond transition area
- 201201
- zweite Durchgangsöffnungsecond through opening
- 203203
- Innengewindeinner thread
- 2121st
- zweiter Crimpbereichsecond crimping area
- 210210
- zweite Kabeleinführöffnungsecond cable entry opening
- 211211
- zweiter Hohlraumsecond cavity
- 212212
- zweites zusätzliches Innengewindesecond additional internal thread
- 2222nd
- zweiter Kontaktbereichsecond contact area
- 221221
- KontaktbuchseContact socket
- 22112211
- BuchsenhohlraumSocket cavity
- 213213
- zweiter Dornsecond thorn
- 21312131
- Schraubkopf des zweiten DornsScrew head of the second mandrel
- 21322132
- Außengewinde des zweiten DornsExternal thread of the second mandrel
- 33
- IsolierkörperInsulating body
- 3131
- BefestigungselementeFasteners
- 44th
- SteckverbindergehäuseConnector housing
- DR D R
- Realer Innendurchmesser des ersten / zweiten HohlraumsReal inner diameter of the first / second cavity
- DT D T
- Theoretischer Innendurchmesser des zusätzlichen InnengewindesTheoretical inside diameter of the additional internal thread
- TR T R
- Theoretische Tiefe des weiteren InnenggewindesTheoretical depth of the further internal thread
- TT T T
- Reale Tiefe des zusätzlichen InnengewindesReal depth of the additional internal thread
Claims (9)
- Crimp contact (1, 2) for a heavy load plug connector, wherein the crimp contact (1, 2) is embodied at least in regions in a rotationally symmetrical manner, wherein the corresponding symmetrical axis extends in the plugging direction,
wherein the crimp contact (1, 2) comprises a crimp region (11, 21) that is embodied from aluminum or an aluminum alloy,
wherein the crimp contact (1, 2) comprises a contact region (12, 22) that adjoins the crimp region (11, 21), said contact region being embodied from copper or a copper alloy, wherein the crimp region (11, 21) is welded to the contact region (12, 22), wherein the crimp contact (1, 2) comprises in its crimp region (11, 21) a cylindrical hollow chamber (111, 211) having a cable insertion opening (110, 210) for receiving an aluminum stranded conductor, characterized in that the crimp contact (1, 2) comprises in its cylindrical hollow chamber (111, 211) an additional inner thread (112, 212), wherein the actual inner diameter (DR) of the cylindrical hollow chamber (111, 211) is greater than the theoretical inner diameter (DT) of the additional inner thread (112, 212) so that the additional inner thread (112, 212) is flattened off, wherein the crimp contact (1, 2) comprises within its hollow chamber (111, 211) a spike (113, 213) that points in the direction of the cable insertion opening (110, 210), wherein the crimp contact (1, 2) comprises a through-going opening (101, 201) having an inner thread (103, 203) that is tailored to said through-going opening so that the spike (113, 213) can be screwed by way of the through-going opening (101, 201) into the hollow chamber (111, 211). - Crimp Contact (1, 2) as claimed in claim 1, characterized in that the spike (113, 213) comprises a screw head (1131, 2131), by way of example a slot or a cross slot so that said spike can be screwed with the aid of a screwdriver into the hollow chamber (111, 211).
- Crimp Contact (1, 2) as claimed in any one of the preceding claims, characterized in that the surface of the contact region (12, 22) is at least in part coated with silver.
- A heavy load plug connector comprising a plug connector housing (4), an insulating body (3) and at least one crimp contact (1, 2) as claimed in one of the preceding claims.
- A method for producing a crimp contact according to claim 3, wherein the method comprises the following steps:1) welding together a cylindrical copper rod and a cylindrical aluminum rod by means of frictional welding to form a common cylindrical rod having an aluminum part and a copper part,2) producing by means of turning and/or drilling an aluminum part a crimp region (11, 21) having a hollow chamber (111, 211) for receiving an aluminum stranded conductor and producing the contact region (12, 22) from the copper part, wherein the hollow chamber (111, 211) is drilled with an actual inner diameter (DR) in the crimp region (11, 21), wherein the additional inner thread (112, 212) is cut with a theoretical inner diameter (DT) in the crimp region (111, 211) on the hollow chamber side, wherein the theoretical inner diameter (DT) of the additional inner thread (112, 212) is smaller than the actual diameter (DR) of the hollow chamber (111, 211), wherein
an additional through-going hole (101, 201) can be subsequently drilled in the crimp contact (1, 2) to the hollow chamber (111, 211)and an inner thread (103, 203) can be cut in said through-going opening (101, 201), so that the spike (113, 213) can be screwed into the hollow chamber (111, 211) through the through-going hole (191, 301).3) coating the surface of the contact region (12, 22) at least in part with silver. - The method as claimed in claim 5, wherein the frictional welding in the first method step comprises rotational welding and/or vibration welding.
- A method for using a crimp contact (1, 2) as calimed in one of the claims 1 to 3, whereinA.) initially a stranded conductor is inserted through the cable insertion opening (110, 210) into a cylindrical hollow chamber (111, 211) of a crimp region (11, 21) of the crimp contact (1, 2) and wherein in a later method step theB.) spike (113, 213) is screwed into the hollow chamber (111, 211) of the crimp region (11, 21) opposite the direction of insertion of the stranded conductor and wherein in a later method stepC.) the crimp region (11, 21) is pressed together using a crimping tool
- The method as claimed in claim 7, wherein the stranded conductor is held when screwing the spike (113, 213) by means of the additional inner thread (112, 212) of the hollow chamber (111, 211) using a particularly strong frictional force in the hollow chamber (111, 211).
- The method as claimed in any one of the claims 8 to 9, wherein
the stranded wires of the stranded conductor are pressed together by means of screwing in the spike (113, 213) and are pressed from the interior against the crimp region (11, 21), and that as a consequence furthermore oxide layers of the stranded conductors are broken open, as a result of which the cross conductivity is increased.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102014112701.3A DE102014112701A1 (en) | 2014-09-03 | 2014-09-03 | crimp contact |
PCT/DE2015/100330 WO2016034166A2 (en) | 2014-09-03 | 2015-08-05 | Crimp contact |
Publications (2)
Publication Number | Publication Date |
---|---|
EP3189561A2 EP3189561A2 (en) | 2017-07-12 |
EP3189561B1 true EP3189561B1 (en) | 2020-10-07 |
Family
ID=54148301
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP15766384.0A Active EP3189561B1 (en) | 2014-09-03 | 2015-08-05 | Crimp contact |
Country Status (9)
Country | Link |
---|---|
US (1) | US20170229793A1 (en) |
EP (1) | EP3189561B1 (en) |
JP (1) | JP2017526147A (en) |
KR (1) | KR20170044738A (en) |
CN (1) | CN106797076A (en) |
CA (1) | CA2958509A1 (en) |
DE (1) | DE102014112701A1 (en) |
RU (1) | RU2670955C9 (en) |
WO (1) | WO2016034166A2 (en) |
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- 2015-08-05 KR KR1020177008517A patent/KR20170044738A/en not_active Application Discontinuation
- 2015-08-05 CN CN201580047356.3A patent/CN106797076A/en active Pending
- 2015-08-05 CA CA2958509A patent/CA2958509A1/en not_active Abandoned
- 2015-08-05 EP EP15766384.0A patent/EP3189561B1/en active Active
- 2015-08-05 JP JP2017512710A patent/JP2017526147A/en not_active Withdrawn
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- 2015-08-05 WO PCT/DE2015/100330 patent/WO2016034166A2/en active Application Filing
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Also Published As
Publication number | Publication date |
---|---|
RU2670955C9 (en) | 2018-11-21 |
RU2670955C2 (en) | 2018-10-26 |
CA2958509A1 (en) | 2016-03-10 |
WO2016034166A3 (en) | 2016-07-21 |
US20170229793A1 (en) | 2017-08-10 |
RU2017110793A3 (en) | 2018-10-03 |
JP2017526147A (en) | 2017-09-07 |
DE102014112701A1 (en) | 2016-03-03 |
EP3189561A2 (en) | 2017-07-12 |
WO2016034166A2 (en) | 2016-03-10 |
KR20170044738A (en) | 2017-04-25 |
CN106797076A (en) | 2017-05-31 |
RU2017110793A (en) | 2018-10-03 |
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