EP3206258A1 - Système de fabrication d'un raccordement électrique, raccordement électrique et son procédé de fabrication - Google Patents

Système de fabrication d'un raccordement électrique, raccordement électrique et son procédé de fabrication Download PDF

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Publication number
EP3206258A1
EP3206258A1 EP16199039.5A EP16199039A EP3206258A1 EP 3206258 A1 EP3206258 A1 EP 3206258A1 EP 16199039 A EP16199039 A EP 16199039A EP 3206258 A1 EP3206258 A1 EP 3206258A1
Authority
EP
European Patent Office
Prior art keywords
flat conductor
aluminum flat
metal clip
electrical connection
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.)
Granted
Application number
EP16199039.5A
Other languages
German (de)
English (en)
Other versions
EP3206258B1 (fr
Inventor
Dipl.-Ing. Frank GRONWALD
Dipl.-Ing. Wacim TAZARINE
Dipl.-Ing. Martin Schloms
Dipl.-Ing. Sebastian Martens
Franz-Heinz Kaszubowski
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.)
Auto Kabel Management GmbH
Original Assignee
Auto Kabel Management GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Auto Kabel Management GmbH filed Critical Auto Kabel Management GmbH
Publication of EP3206258A1 publication Critical patent/EP3206258A1/fr
Application granted granted Critical
Publication of EP3206258B1 publication Critical patent/EP3206258B1/fr
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
    • H01R4/28—Clamped connections, spring connections
    • H01R4/48—Clamped connections, spring connections utilising a spring, clip, or other resilient member
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R25/00—Coupling parts adapted for simultaneous co-operation with two or more identical counterparts, e.g. for distributing energy to two or more circuits
    • H01R25/14—Rails or bus-bars constructed so that the counterparts can be connected thereto at any point along their length
    • H01R25/145—Details, e.g. end pieces or joints
    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2201/00—Connectors or connections adapted for particular applications
    • H01R2201/26—Connectors or connections adapted for particular applications for vehicles

Definitions

  • the invention relates to a system for producing an electrical connection with an aluminum flat conductor designed as a motor vehicle energy conductor, in particular a motor vehicle battery conductor, and having an electrical connection element which is designed to be connected to the aluminum flat conductor. Furthermore, the invention relates to an electrical connection produced using such a system, in particular for use in motor vehicles, and to a method for producing an electrical connection.
  • Bordnetze of motor vehicles are provided for many years by a classic harness structure.
  • this classic harness structure will in future be replaced by a so-called energy backbone structure.
  • an energy main backbone is provided in the vehicle, which leads from front to back through the entire vehicle.
  • the energy backbone may be formed, for example, as an aluminum flat conductor and possibly several layers for different voltage levels, such as 0 volts (ground), 12 volts or 48 volts.
  • a threaded bolt welded by means of friction welding on the aluminum flat conductor
  • a Reibsch spauge by the Aluminum flat conductor welded or welded a so-called pigtail to the line.
  • connection element which is adapted to be connected to the aluminum flat conductor such that an electrical connection is established between the aluminum flat conductor and the connection element
  • the connection element comprises a metal clip, which is adapted to be laterally attached to the aluminum flat conductor, that between the aluminum flat conductor and the metal clip, an electrical connection is made.
  • an electrical connection in particular for use in motor vehicles, manufactured using the system described above, wherein the metal clip of the electrical connection element is mounted laterally on the aluminum flat conductor, that the aluminum flat conductor and the metal clip electrically are connected.
  • the above object is achieved according to the invention at least partially by a method for producing the electrical connection described above using the system described above, comprising the following steps: stripping the aluminum flat conductor in a connection area, if necessary, and laterally attaching the metal clip on the Aluminum flat conductor in the connection area such that an electrical connection between the aluminum flat conductor and the electrical connection element is produced.
  • the metal clip is adapted to be laterally attached to the aluminum flat conductor.
  • the size of the metal clip is adapted to the cross-sectional size of the aluminum flat conductor.
  • the height of the metal clip is adapted to the height of the aluminum flat conductor.
  • a metal clip is to be understood in particular as meaning a metal element having at least two opposite side regions, so that a Aluminum flat conductor is arranged after the attachment of the metal element between the two opposite side parts.
  • the metal clip is plugged in the course of aluminum flat conductor at a desired location from the side of the aluminum flat conductor. In this way, the position of the contact in the course of aluminum flat conductor can be selected as needed.
  • a plurality of connection elements can be plugged with corresponding metal brackets at different positions on the aluminum flat conductor, so that a multiple power tap is made possible by the aluminum flat conductor to supply, for example, arranged in different areas of the motor vehicle components.
  • the metal clip is adapted to be laterally fitted over a narrow side of the aluminum flat conductor on the aluminum flat conductor, that between the aluminum flat conductor and the metal clip, an electrical connection is made.
  • the metal clip is thus plugged from a narrow side of the aluminum flat conductor. In this way, a particularly small space for the electrical connection is achieved.
  • the metal clip is formed of copper or a copper alloy. In this way, an electrical connection with low electrical resistance can be produced.
  • the aluminum flat conductor is provided with a conductive coating at least in a connection region provided for connection of the electrical connection element, wherein the coating is preferably nobler than the aluminum alloy of the aluminum flat conductor.
  • the aluminum flat conductor can be provided over the entire length with such a coating.
  • the coating can be applied, for example, during the production of the aluminum flat conductor in a continuous process, in particular before the application of the insulating material to the aluminum flat conductor.
  • the coating can also be subsequently applied to the aluminum flat conductor, for example in the assembly of the aluminum flat conductor for a motor vehicle.
  • the coating can be single or multi-layered.
  • the conductive coating is based on copper, tin, zinc, nickel, silver, gold or alloys of one or more of these metals.
  • the coating can be applied mechanically, for example by plating, but also electrochemically, by spraying or by physical vapor phase separation (PVD).
  • the metal clip is U-shaped. In this way, the metal clip can be pushed onto the aluminum flat conductor in such a way that it protrudes on two opposite sides on the flat conductor rests and so has a firm hold on the aluminum flat conductor and allows reliable contact.
  • the metal clip comprises a spring element, which is designed to hold the metal clip non-positively on the aluminum flat conductor.
  • a firm connection of the electrical connection element with the aluminum flat conductor can already be achieved by plugging, so that an electrical contact is reliably ensured.
  • the metal clip is for example U-shaped, then one or both legs of the U-shape can be formed as a spring element or have a spring element. In this way, the metal clip can pinch the flat conductor between them.
  • the distance between the two legs of the U-shaped metal clip in the relaxed state is less than the thickness of the aluminum flat conductor.
  • the metal clip is widened when attaching the metal clip on the aluminum flat conductor, so that it exerts a clamping force on the aluminum flat conductor and is fixed to this.
  • the metal clip by means of a pressing and / or crimping with the aluminum flat conductor.
  • the metal clip is non-positively and / or positively connected to the aluminum flat conductor, preferably by means of a pressing and / or crimping connection.
  • this comprises a positive and / or positive connection of the metal clip to the aluminum flat conductor, preferably to produce a press and / or crimp connection. In this way, a permanent electrical connection can be achieved.
  • the metal clip is materially connected to the aluminum flat conductor, preferably welded, in particular by ultrasonic welding, laser welding or Friction spot welding. In this way, a secure and permanent connection between the metal clip and the aluminum flat conductor is ensured.
  • this comprises a material-locking connection of the metal clip to the aluminum flat conductor, preferably welding, in particular by ultrasonic welding, laser welding or friction spot welding.
  • the metal clip is additionally provided with a spring element in order to frictionally hold the metal clip on the aluminum flat conductor, this has the advantage that the metal clip can initially be frictionally positioned at the desired position of the aluminum flat conductor so that the subsequent cohesive joining is facilitated.
  • the metal clip has a first leg with a first contact surface and a second leg with a second contact surface opposite the first contact surface, wherein the distance between the first and the second contact surface is adapted to the thickness of the aluminum flat conductor, so that the metal clip with the first and the second leg on the aluminum flat conductor can be plugged.
  • the legs are in particular designed so that the first and / or second contact surface in the plugged state lies flat against the broad sides of the aluminum flat conductor.
  • the metal clip can simply be plugged or pushed onto the aluminum flat conductor, so that the aluminum flat conductor is arranged between the two legs.
  • the contact surfaces also provide a frictional connection between the metal bracket and the aluminum flat conductor to provisionally position the metal bracket on the aluminum flat conductor before making a permanent connection between the metal bracket and the aluminum flat conductor.
  • the provisional frictional connection is in particular by adjusting the distance of the first and second contact surface to the Aluminum flat conductor thickness reinforced.
  • the first and second contact surfaces are preferably plane-parallel.
  • the distance of the first and second contact surface is adapted to the thickness of the aluminum flat conductor, that after pushing the metal clip on the aluminum flat conductor both contact surfaces are in contact with the aluminum flat conductor.
  • the distance of the first and second contact surface is adapted to the thickness of the aluminum flat conductor, that after pushing the metal clip on the aluminum flat conductor both contact surfaces are in contact with the aluminum flat conductor.
  • the metal clip can also be plugged at different angles on the aluminum flat conductor, for example, perpendicular or obliquely to the course of the aluminum flat conductor.
  • the metal clip is slotted accordingly obliquely to the course of the aluminum flat conductor on the aluminum flat conductor, for example at an angle to the course of the aluminum flat conductor between 10 ° and 80 °.
  • the metal clip which is plugged onto the flat conductor is preferably welded thereto, in particular by spot welding, preferably resistance spot welding.
  • the welding can be carried out in particular by contacting the two limbs of the metal clamp with two welding electrodes, so that a welding current flows through the two limbs and the flat conductor arranged therebetween, whereby, on the one hand, breaking up of oxide layers on the flat conductor and, on the other hand, welding of the limbs the flat conductor is effected.
  • the so-called delta spot welding method has been found in which electrode bands are arranged between the welding electrodes and the legs, so that the welding electrodes do not come into direct mechanical contact with the thighs. For each spot welding process, the electrode bands are each moved a small distance, so that a clean area of the electrode band is always applied to the welding electrodes. In this way, consistently good and clean spot welds can be achieved.
  • the metal clip and the aluminum flat conductor can also be connected to one another by a non-positive and / or positive connection, for example by a screw or rivet connection.
  • the metal clip may be a profile part.
  • the metal clip can be produced by first extruding an aluminum profile with a corresponding, in particular U- or Y-shaped cross-section, and then sawing it into individual metal clamps.
  • the metal clip may also be a milled part
  • the metal clip preferably has a connection surface for connecting a further electrical component to the metal clip.
  • the connection surface can be provided, for example, by a sheet-metal-shaped section of the metal clip, which attaches to the junction of the two legs and forms a Y-shape in cross-section with them.
  • connection element may have, in addition to the metal clip, a further electrical component connected to the metal clip, so that the connection element for the system forms a prefabricated unit of metal clip and one or more further components.
  • the further electrical component is connected in particular to the connection surface with the metal clip.
  • connection element may comprise a connecting bolt which is connected to the metal clamp, in particular welded, and which facilitates the connection of another electrical component, such as a cable, to the connection element.
  • connection element may also comprise a cable, which is optionally electrically conductively connected to the metal clip by means of a socket, in particular welded.
  • connection element for the system can be made available as a prefabricated component which comprises a cable with a metal clamp, in particular welded metal clamp, connected thereto for connection to a flat conductor.
  • the metal clip may be manufactured as a one-piece component.
  • the two legs and one for the connection surface at the junction of the two Schnekel appending sheet-like section can be made in one piece.
  • the metal clip may also be composed of several parts.
  • the metal clip has two interconnected metal clip parts, wherein the one metal clip part comprises the first and the other metal clip part the second leg.
  • the two metal clip parts are preferably non-positively and / or positively connected with each other, for example by a press connection or by latching means, such as a clip connection.
  • the production of the metal clip is simplified, since the individual metal clip parts have a simpler shape than the composite metal clip and therefore can be correspondingly easier to manufacture.
  • the individual metal clip parts can be produced not only as a milling or profile part, but alternatively as a stamped part or bent part.
  • the metal clip is preferably made of an aluminum alloy. In this way, contact corrosion is prevented to aluminum flat conductor.
  • the metal clip is at least partially coated, in particular with a nickel-phosphorus and / or tin coating. In this way a very good corrosion protection is achieved.
  • the metal clip is preferably coated in the region of the connection surface, in particular on a sheet-metal-shaped section provided for this purpose.
  • connection element comprises a housing in which a contacting space is provided, wherein the aluminum flat conductor is guided through the housing such that a portion of the aluminum flat conductor extends through the contacting space and the metal clip is arranged such that it laterally on the through Contacting space extending portion of the aluminum flat conductor is attachable.
  • the electrical connection element comprises a housing in which a contacting space is provided, the aluminum flat conductor is passed through the housing such that a portion of the aluminum flat conductor passes through the contacting space, and the metal clip is laterally on the through the contacting space running portion of the aluminum flat conductor plugged.
  • the contacting of the aluminum flat conductor within a housing such as a power distribution box or fuse box done.
  • the housing protects the electrical connection and / or the aluminum flat conductor stripped in the connection region from, for example, moisture or chemical and / or thermal influences from the environment.
  • the transition between copper / aluminum between the metal clip and the aluminum flat conductor can be protected by the housing from corrosion.
  • the housing is preferably the housing of a power distributor and / or a fuse box. In this way, the contacting of the power distributor and / or the fuse box with the aluminum flat conductor can be done directly in the power distributor or in the fuse box.
  • the power distributor preferably comprises a plurality of electrical connections for connecting electrical components, wherein the electrical connections via the metal bracket are electrically connectable to the aluminum flat conductor.
  • the fuse box preferably comprises one or more fuses, for example fuses or semiconductor fuses, with which one or more electrical connections can be secured.
  • the housing is preferably opened laterally such that the housing can be slid laterally onto the aluminum flat conductor so that the connection region of the aluminum flat conductor is arranged in the contacting space. This facilitates the assembly of the housing.
  • the electrical connection in particular the transition between the metal clamp and the aluminum conductor, can also be protected against corrosion by other measures, for example by applying a coating such as, for example, a lacquer or by means of a heat-shrinkable tube.
  • connection profile has a stepped shape, wherein a contact region with the contact surface for connection to the flat conductor by a step of a portion with a
  • the connecting element has the further advantage that it can be produced very simply and inexpensively, for example as a profile part and in particular as a stamped or bent part. Accordingly, the above object according to this alternative aspect is also achieved by an electrical connection made with such a system.
  • the systems, methods and electrical connections described above, according to an alternative teaching, may be used not only for aluminum flat conductors but also for flat conductors of other materials, such as copper. Accordingly, further advantageous teachings result from the previously described systems, methods and electrical connections or their embodiments in that instead of the aluminum flat conductor, a flat conductor made of a different material, in particular of a different metal, is used. In this case, the material of the metal clip or the connecting element is preferably adapted to the material of the flat conductor. Thus, in a copper flat conductor, a metal brace made of copper is preferably used.
  • FIGS. 1a-b show a schematic plan view of an embodiment of a system 2 with an aluminum flat conductor designed as a motor vehicle power conductor 4, which is arranged as a so-called energy backbone in a motor vehicle 6, and with at least one or more electrical connection elements 8, 8 '.
  • connection elements 8, 8' are arranged at the desired position on the motor vehicle energy conductor 4 (FIG. Fig. 1a ) and the metal clip 10, 10 'is pushed laterally onto the motor vehicle energy conductor 4. If the motor vehicle energy conductor 4 has an insulation 14, the motor vehicle energy conductor 4 is stripped in the area 16, 16 'provided for the electrical connection 12, 12' (terminal area) before the metal clip 10, 10 'is plugged on.
  • the motor vehicle power conductor 4 may have a metallic coating 18 in the connection region, which is more noble than the aluminum flat conductor alloy. In this way, oxidation of the surface of the motor vehicle power conductor 4 in the connection region 16, 16 'is avoided, so that a low-resistance electrical connection 12, 12' can be produced.
  • the coating 18 may also extend over the entire length of the motor vehicle power conductor 4.
  • the aluminum flat conductor 4 can in principle be contacted at any point with an electrical connection element 8, 8 'in order to supply the components of a motor vehicle with electrical energy.
  • FIG. 1b show in schematic representation various embodiments of electrical connections 20, 20 ', 20 "in sectional view.
  • the electrical connections 12, 12' from FIG. 1b be formed according to one of the electrical connections 20, 20 ', 20 ".
  • the electrical connection 20 in Fig. 2a comprises an aluminum flat conductor 22 with an aluminum core 24 made of an aluminum alloy and a coating 26 applied thereto made of a nobler alloy, for example a tin alloy. Furthermore, the electrical connection 20 comprises an electrical connection element 28 with a U-shaped metal bracket 30, whose two legs are each formed as a spring element 32, 32 '.
  • the spring elements 32, 32 ' are widened and therefore exert a force on the opposite broad sides of the aluminum flat conductor 22, so that the metal clip 30 clamps the aluminum flat conductor 22 between them and is thereby held on the aluminum flat conductor 22 ,
  • FIG. 2b shows an alternative electrical connection 20 '.
  • the electrical connection 20 ' differs from the electrical connection 20 FIG. 2a in that the metal clip 30 is welded to the aluminum flat conductor 22 at a welding point 34, for example by means of friction welding or ultrasonic welding. In this way, a permanent electrical connection between the metal bracket 30 and the aluminum flat conductor 22 is ensured.
  • the metal clip 30 can first be slid laterally onto the aluminum flat conductor 22 at the desired position and can be prefixed with the spring elements 32, 32' in a force-fitting manner (corresponding to FIG FIG. 2a ). Subsequently, the weld point 34 can be generated in a simple manner without requiring additional positioning of the metal clip 30 on the aluminum flat conductor 22.
  • Figure 2c shows an alternative electrical connection 20 ".
  • the electrical connection 20" differs from the electrical connection 20 FIG. 2a in that the metal clip 30 is pressed with the aluminum flat conductor 22, so that the metal clip 30 and the aluminum flat conductor 22 are permanently connected to one another by a press connection 36.
  • FIGS. 3a-b show a schematic representation of another embodiment of a system 38 for producing an electrical connection 40th
  • Fig. 3a shows a sectional view according to the in Fig. 3b with IIIa designated cutting plane.
  • Fig. 3a shows a sectional view according to the in Fig. 3a Section plane designated IIIb.
  • the system 38 includes an aluminum flat conductor 42 having an aluminum core 44, a zinc alloy coating 46, and insulation 48 disposed thereon.
  • the system 38 further includes an electrical connector 50 having a U-shaped metal bracket 52 and a housing 54, the metal bracket in FIG a contacting space 56 is arranged in the housing 54.
  • the aluminum flat conductor 42 is stripped in the desired connection region 57 and guided into the housing 54, so that the connection region 57 is positioned in the contacting space 56 and the metal clip 52 is laterally attached to the aluminum flat conductor 42.
  • the housing 54 is laterally opened at the contacting space 56, so that the housing 54 for contacting the aluminum flat conductor 42 can simply be attached laterally to the aluminum flat conductor 42.
  • attaching the housing 54 on the aluminum flat conductor 42 then it comes to attaching the metal clip 52 on the aluminum flat conductor 42nd
  • the two legs of the U-shaped metal bracket 52 are formed as spring elements 58, 58 'and clamp the aluminum flat conductor 42 between them, so that a reliable electrical connection 40 between the aluminum flat conductor 42 and the connection element 50 is ensured.
  • the housing 54 is preferably a Stromverteilerbox having a plurality of electrical taps 60 for connecting electrical consumers.
  • the housing 54 can furthermore be designed, in particular, as a fuse box and comprise fuses 62 for the individual taps 60.
  • the electrical connection 40 is protected from moisture and other environmental influences from the environment, so that the life of the electrical connection 40 is increased.
  • the aluminum flat conductor 42 can in particular be protected against corrosion, that it is stripped only within the housing 54, in particular within the contacting space 56.
  • the Fig. 4a-d show another embodiment of the system and the connection.
  • the system 70 comprises an aluminum flat conductor 72 with an insulation 74 and a connection element 76 with a metal clip 78.
  • the metal clip 78 has a first leg 80 with a first contact surface 82 and a second leg 84 with a second contact surface 86, wherein the two contact surfaces 82 , 86 lie opposite each other and are preferably plane-parallel to each other.
  • the distance between the two contact surfaces 82, 86 is adapted to the thickness of the flat conductor 72, so that the metal clip 78 can be pushed onto a stripped connection region 88 of the flat conductor 72, as shown in FIG Fig. 4b is shown.
  • the stripped connection region 88 can optionally be positioned at one end of the flat conductor 72 or at another position in the course of the flat conductor 72.
  • the space between the two legs 80, 82 is widened at the end of the two legs, for example by means provided at the ends of the legs 80,84 bevels 90th
  • the metal clip 78 is spot-welded to the flat conductor 72 in the region of the legs 80, 84 after being pushed onto the flat conductor 72.
  • the legs 80, 84 positioned on opposite sides of the flat conductor 72 are each contacted with a welding electrode 92, 94, through which a welding current is then conducted through the legs 80, 84 and the flat conductor 72, so that the legs 80, 84 and the flat conductor 72 are welded together.
  • the welding current also makes possible oxide layers on the flat conductor 72 broken, so that it comes to a good electrical connection 95 between the flat conductor 72 and the legs 80, 84 of the metal clip 78.
  • delta spot welding method proved to be particularly suitable.
  • one electrode strip 96, 98 is arranged between the electrodes 92, 94 and the components to be electrically contacted, in this case the legs 80, 84 of the metal clip 78, so that the electrodes 92, 94 are not in direct mechanical Contact with the legs 80, 84 to be contacted electrically.
  • the electrode belt 96, 98 is transported further by one piece after each spot welding (compare arrows 100 in FIG Fig. 4c ) so that a "fresh" electrode tape surface is used for each spot weld.
  • the metal clip 78 is then as in Fig. 4d represented by a welded joint 102 with the flat conductor 72 fixed and electrically conductive connected.
  • the metal clip 78 and the flat conductor 72 can also be positively and / or non-positively connected to each other, for example by a rivet connection 104, as in the in Fig. 5 illustrated alternative embodiment of the system is the case.
  • a rivet connection 104 for example, a rivet connection 104
  • corresponding bores 106, 108 may be provided in the legs 80, 84.
  • the legs 80, 84 and the flat conductor 72 can also be pierced together when the metal clip 78 is attached to the flat conductor 72.
  • connection element 76 can be used in particular as a connection piece or cable lug in order to connect a further electrical component to the flat conductor 72.
  • the metal clip 78 preferably has a pad 109 for connecting the metal clip 78 to another electrical component, such as a cable.
  • the terminal surface 109 of the metal clip 78 is formed by a sheet-like portion 110 which attaches to the junction of the two legs 80, 84 and forms a Y-shape in cross-section with these.
  • an electrical component such as a cable may be welded.
  • the sheet-like portion 110 of the metal bracket 78 may be as shown in FIG Fig. 5 shown a bore 112, so that, for example, a cable with the sheet-metal section 110 can be screwed or riveted.
  • the connection element 76 may comprise, in addition to the metal clip 78, a cable connected thereto and thus form a prefabricated connection element 76.
  • Fig. 6a-c show further embodiments of the connecting element 76 and in particular the connection region of the metal clip 78. Corresponding parts are in turn provided with the same reference numerals.
  • connection element 76 'in Fig. 6a comprises a flexible cable 114 which is electrically connected to the metal bracket 78 by welding one end of the cable 114 or a bushing 116 provided at the end of the cable 114 onto the connection surface 109, for example by ultrasonic welding.
  • the metal clip 78 and the welded cable 114 may be provided to the system as a pre-terminated connector 76 '.
  • connection element 76 "in Fig. 6b includes a terminal bolt 118 which is welded to the terminal surface 109 of the metal bracket 78, for example by Friction welding. In this way, various cables or components can be connected to the bolt 118.
  • the connecting element 76 '' in Fig. 6c includes a metal clip 78 'with two legs 80, 84 and a cable 120 with plugged socket 122, which is welded to a arranged on the connection of the two legs 80, 84 pad 124, in particular by friction welding.
  • the metal bracket 78 'and the cable 120 welded thereto may be provided to the system as a pre-terminated connector 76 "'.
  • the metal clip 78 or 78 ' can also be designed in several parts.
  • the Fig. 7a-b show an exemplary embodiment of such a multipart metal clip 78 ".
  • the metal clip 78 is formed in two parts with a first metal clip part 126 and a second metal clip part 128, wherein the first metal clip part 126 comprises the first leg 80 and the second metal clip part 128 comprises the second leg 84.
  • the metal clip parts 126, 128 each have connecting means 130 corresponding to one another to be able to connect the two metal clasp parts, which then as in Fig. 7b as illustrated in Fig. 15, the metal brackets 78 " Fig. 7a illustrated as mutually corresponding pins and recesses be formed with a press fit, so that the two metal clip parts can be connected to each other by pressing the pins in the recesses.
  • clip or locking connections are conceivable.
  • the metal clip parts 126, 128 can be produced, for example, as a stamped part and therefore particularly inexpensively.
  • connection element 134 is like that in FIG Fig. 4a illustrated connection element 76 formed with an additional bore 112 in the sheet-metal portion 110 of the metal clip 78 in order to screw or rivet the metal clip 78 with another component can.
  • Connection element 136 is like that in FIG Fig. 6c illustrated connection element 76 "'formed with a welded to the metal bracket 78' cable 120.
  • Connection element 138 is like the connection element 76" out Fig. 6b formed with a welded on the sheet-metal portion 110 of the metal clip 78 bolt 118 for connection to another component.
  • Connection element 140 is like that in FIG Fig. 6a illustrated connection element 76 'formed with a welded to the sheet-metal portion 110 of the metal bracket 78 flexible cable 114th
  • connection elements 140 can be connected to one end of the flat conductor or, as shown using the example of the connection elements 134, 136 and 138, in the course of the flat conductor. Furthermore, the connection elements can be plugged at different angles on the flat conductor, for example, vertically (as in connection element 134 or 136) or at an oblique angle to the course of the flat conductor 132 (as in connection element 138 or 140).
  • connection elements 134, 136, 138 or 140 may be after welding, screwing or riveting with a heat-shrinkable tube or a housing be surrounded (as it is in Fig. 8 for the connection element 136 is shown by the dotted lines 142).
  • a contact protection and on the other a corrosion protection can be achieved.
  • a pile fat may additionally or alternatively also be applied to the respective electrical connection, for example to the flat conductor 132 or the respective metal clip, before the metal clip is pushed onto the flat conductor.
  • terminal element described here or its embodiments and the system comprising this extremely flexible connection options for a flat conductor are described here or its embodiments and the system comprising this extremely flexible connection options for a flat conductor.
  • the Fig. 9a-b show an alternative system 200 for making an electrical connection with an aluminum flat conductor 202 and an electrical connection element 204, which has a connection profile 206 with a flat contact surface 208, which is contacted flat with the aluminum flat conductor 202 and then as in Fig. 9a represented by a welded joint 210 or alternatively as in Fig. 9b represented with a mechanical connection, in particular a rivet connection 212 with the aluminum flat conductor 202 is firmly and electrically conductively connected.
  • the welded connection 210 can be produced, for example, by spot welding, in particular by the DeltaSpot welding method.
  • the connection profile 206 preferably has, as in Fig.
  • FIG. 9a-b 12 illustrates a stepped shape wherein a contact region 214 with the contact surface 208 for connection to the lead 202 is separated by a step 216 from a portion 218 having a pad for connection to another electrical component. In this way, a flatter construction is possible.
  • Section 218 may also be as in Fig. 6a-c be formed shown for the metal clip.
  • the system 200 and the connection made thereby each represent independent inventive teachings.
  • the exemplary embodiments described with reference to the figures furthermore represent exemplary embodiments of a system and an electrical connection according to an alternative teaching, when the aluminum flat conductors according to the exemplary embodiments are replaced by a flat conductor made of a different material, in particular another metal such as copper.
EP16199039.5A 2016-02-10 2016-11-16 Système de fabrication d'un raccordement électrique, raccordement électrique et son procédé de fabrication Active EP3206258B1 (fr)

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CN109326931A (zh) * 2017-11-03 2019-02-12 利萨·德雷克塞迈尔有限责任公司 分布式小型配电器、导线系统和制造方法
CN113851866A (zh) * 2021-08-26 2021-12-28 智新科技股份有限公司 铜排与接线端子柔性连接卡夹及控制器三相铜排连接结构
FR3118541A1 (fr) * 2020-12-30 2022-07-01 Tyco Electronics (Shanghai) Co., Ltd. Corps de borne, borne de connexion et materiau en feuille destine a la fabrication d'un corps de borne

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US4351583A (en) * 1980-06-19 1982-09-28 Gte Products Corporation Electrical terminal
US4886468A (en) * 1988-06-08 1989-12-12 General Electric Company Insulated electrical power distribution busway tabs
US5011421A (en) * 1990-03-05 1991-04-30 Westinghouse Electric Corp. Plane change connector assembly
DE4342269A1 (de) * 1992-12-10 1994-06-16 Yazaki Corp Verfahren zum Herstellen einer Verbindungsanschlußklemme für eine Sammelschiene und eine so hergestellte Verbindungsanschlußklemme
EP1018783A2 (fr) * 1999-01-04 2000-07-12 Sumitomo Wiring Systems, Ltd. Boíte de jonction électrique avec une barre omnibus
US6280216B1 (en) * 1999-11-09 2001-08-28 General Electric Company Lug adapter assembly having reduced force clips
DE20108348U1 (de) * 2000-05-17 2001-08-30 Professional General Elect Stromschiene
EP1240968A1 (fr) * 2001-02-16 2002-09-18 Hirschmann Austria GmbH Procédé pour réaliser une connexion électrique au moyen d'un brasage par induction
EP1313175A1 (fr) * 2001-11-20 2003-05-21 Fci Connection semi-permanente entre une barre omnibus et un contact d'un connecteur électrique
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EP2806499A1 (fr) * 2013-05-21 2014-11-26 Tyco Electronics Corporation Connecteur de puissance comportant des ressorts de contact

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CN109326931A (zh) * 2017-11-03 2019-02-12 利萨·德雷克塞迈尔有限责任公司 分布式小型配电器、导线系统和制造方法
FR3118541A1 (fr) * 2020-12-30 2022-07-01 Tyco Electronics (Shanghai) Co., Ltd. Corps de borne, borne de connexion et materiau en feuille destine a la fabrication d'un corps de borne
CN113851866A (zh) * 2021-08-26 2021-12-28 智新科技股份有限公司 铜排与接线端子柔性连接卡夹及控制器三相铜排连接结构

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ES2848980T3 (es) 2021-08-13
EP3206258B1 (fr) 2021-01-20

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