EP3206258B1 - 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
EP3206258B1
EP3206258B1 EP16199039.5A EP16199039A EP3206258B1 EP 3206258 B1 EP3206258 B1 EP 3206258B1 EP 16199039 A EP16199039 A EP 16199039A EP 3206258 B1 EP3206258 B1 EP 3206258B1
Authority
EP
European Patent Office
Prior art keywords
flat conductor
metal clip
aluminium flat
connection
electrical
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP16199039.5A
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German (de)
English (en)
Other versions
EP3206258A1 (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
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Publication date
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Publication of EP3206258A1 publication Critical patent/EP3206258A1/fr
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Publication of EP3206258B1 publication Critical patent/EP3206258B1/fr
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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
    • H01R4/28—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 establishing an electrical connection with an aluminum flat conductor designed as a motor vehicle energy conductor, in particular a motor vehicle battery conductor, and with an electrical connection element designed to be connected to the aluminum flat conductor.
  • the invention further relates to an electrical connection produced using such a system, in particular for use in motor vehicles, and a method for producing an electrical connection.
  • the energy backbone can, for example, be designed as a flat aluminum cable and, if necessary, have several layers for different voltage levels, such as 0 volts (ground), 12 volts or 48 volts.
  • Outlets or interfaces must now be provided along the entire course of the aluminum flat cable in order to be able to supply the various electrical components in a motor vehicle with power. To do this, the aluminum flat cable must be contacted with power distributors or fuse boxes.
  • a threaded bolt can be friction-welded onto the aluminum flat conductor, a friction-welded eye through the Aluminum flat conductors are welded through or a so-called pigtail can be welded to the cable.
  • a plug connection is known with which the end faces, ie the ends of a motor vehicle energy conductor, can be contacted.
  • a connector contact for semi-permanent connection to a flat tongue of a busbar is known.
  • an electrical junction box with a busbar is known which has a web and a plurality of connection parts.
  • a method of manufacturing a connection terminal for a bus bar is known. From the U.S.
  • connection element comprises a metal clip which is designed to be plugged laterally onto the aluminum flat conductor in such a way that an electrical connection is established between the aluminum flat conductor and the metal clip
  • connection element comprises a housing, in which a contacting space is provided that the aluminum flat conductor can be passed through the housing in such a way that a section of the aluminum flat conductor runs through the contacting space ft that the metal clip is arranged in such a way that it can be plugged laterally onto the section of the aluminum flat conductor running through the contacting space
  • the housing is the housing of a power distributor with a plurality of electrical connections for connecting electrical components Connections can be electrical
  • an electrical connection according to claim 9 in particular for use in motor vehicles, produced using the system described above, the metal clip of the electrical connection element being attached to the side of the aluminum flat conductor in such a way that the aluminum flat conductor and the metal bracket are electrically connected.
  • the above-mentioned object is at least partially achieved according to the invention by a method according to claim 13 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 attaching the side of the Metal clip on the aluminum flat conductor in the connection area in such a way that an electrical connection is established between the aluminum flat conductor and the electrical connection element.
  • the metal clip is set up to be attached to the side of 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 preferably adapted to the height of the aluminum flat conductor.
  • a metal clip is understood to mean, in particular, a metal element with at least two opposing side areas, so that a Aluminum flat conductor is arranged between the two opposite side parts after attaching the metal element.
  • Lateral attachment is understood in particular to mean that the metal clip is attached to the aluminum flat conductor at a desired point in the course of the aluminum flat conductor. In this way, the position of the contact in the course of the aluminum flat conductor can be selected as required.
  • several connection elements with corresponding metal clamps can be plugged onto the aluminum flat conductor at different positions, so that multiple current taps are made possible from the aluminum flat conductor, for example to supply components arranged in different areas of the motor vehicle.
  • the metal clip is set up to be plugged laterally onto the aluminum flat conductor via a narrow side of the aluminum flat conductor in such a way that an electrical connection is established between the aluminum flat conductor and the metal clip.
  • the metal clip is therefore preferably plugged onto the aluminum flat conductor from a narrow side. In this way, a particularly small installation space for the electrical connection is achieved.
  • the metal clip is made from copper or a copper alloy. In this way, an electrical connection with low electrical resistance can be established.
  • the aluminum flat conductor is provided with a conductive coating at least in a connection area provided for connecting the electrical connection element, the coating preferably being more noble than the aluminum alloy of the aluminum flat conductor.
  • oxide layers often form, which prevent electrical contact with the aluminum flat conductor by attaching a metal clip. It was found that this problem can be solved by providing the aluminum flat conductor with a coating at the intended contact point (the connection area), which prevents the formation of an oxide layer at this point and thus allows a low-resistance contact with the metal clip.
  • the aluminum flat conductor can be provided with such a coating over the entire length.
  • 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 insulation material to the aluminum flat conductor.
  • the coating can also be applied subsequently to the aluminum flat conductor, for example when assembling the aluminum flat conductor for a motor vehicle.
  • the coating can have one or more layers.
  • the conductive coating is preferably 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 plated on, but also electrochemically, by spraying or by physical vapor phase deposition (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 is on two opposite sides of the flat conductor and thus has a firm hold on the aluminum flat conductor and enables reliable contact.
  • the metal clip comprises a spring element which is designed to hold the metal clip in a non-positive manner on the aluminum flat conductor. In this way, a firm connection between the electrical connection element and the aluminum flat conductor can be achieved by simply plugging it in, so that electrical contact is reliably ensured.
  • the metal clip is, for example, U-shaped, one or both legs of the U-shape can be designed as a spring element or have a spring element. In this way, the metal clip can clamp the flat conductor between them.
  • the distance between the two legs of the U-shaped metal clip in the relaxed state is preferably less than the thickness of the aluminum flat conductor.
  • the metal clip is widened when the metal clip is attached to the aluminum flat conductor so that it exerts a clamping force on the aluminum flat conductor and is thus fixed to it.
  • the metal clip is also possible to connect the metal clip to the aluminum flat conductor by means of a press and / or crimped connection.
  • the metal clip is non-positively and / or positively connected to the aluminum flat conductor, preferably by means of a press and / or crimped connection.
  • this includes a force-fitting and / or form-fitting connection of the metal clip to the aluminum flat conductor, preferably with the production of a press and / or crimped 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 guaranteed.
  • this includes a material 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 hold the metal clip frictionally on the aluminum flat conductor, this has the advantage that the metal clip can first be positively positioned at the desired position of the aluminum flat conductor, so that the subsequent material connection 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, the distance between the first and the second contact surface being adapted to the thickness of the aluminum flat conductor, so that the metal clip with the first and the second leg can be plugged onto the aluminum flat conductor.
  • the legs are designed in particular such that the first and / or second contact surface rests flat against the broad sides of the aluminum flat conductor in the attached state.
  • 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 create a frictional connection between the metal clip and the aluminum flat conductor in order to temporarily position the metal clip on the aluminum flat conductor before a permanent connection is established between the metal clip and the aluminum flat conductor.
  • the provisional frictional connection is in particular also by adapting the distance between the first and second contact surface to the Reinforced aluminum flat conductor thickness.
  • the first and the second contact surface are preferably plane-parallel.
  • the distance between the first and second contact surfaces is preferably adapted to the thickness of the aluminum flat conductor in such a way that after the metal clip has been pushed onto the aluminum flat conductor, both contact surfaces are in contact with the aluminum flat conductor. In this way a secure provisional fixation of the metal clamp on the aluminum flat conductor is achieved. Furthermore, a reliable electrical connection can be ensured in this way.
  • the metal clip can also be attached to the aluminum flat conductor at different angles, for example perpendicularly or at an angle to the course of the aluminum flat conductor.
  • the metal clip is slipped onto the aluminum flat conductor at an angle corresponding to the course of the aluminum flat conductor, for example at an angle to the course of the aluminum flat conductor between 10 ° and 80 °.
  • the metal clip attached to the flat conductor is preferably welded to the latter, in particular by spot, preferably resistance spot welding.
  • the welding can in particular take place in that the two legs of the metal clip are contacted with two welding electrodes, so that a welding current flows through the two legs and the flat conductor arranged between them, which on the one hand breaks the oxide layers on the flat conductor and on the other hand welds the legs together the flat conductor is effected.
  • the so-called DeltaSpot welding process has proven to be a particularly suitable welding process for such a connection, in which electrode strips are arranged between the welding electrodes and the legs, so that the welding electrodes do not come into direct mechanical contact with the legs. For each spot welding process, the electrode strips are moved a little further, so that a clean area of the electrode strip is always in contact with the welding electrodes. In this way, consistently good and clean spot welds can be achieved.
  • the metal clamp and the aluminum flat conductor can also be connected to one another by a force-fitting and / or form-fitting connection, for example by a screw or rivet connection.
  • the metal clip can 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 clips.
  • the metal clip can 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 section of the metal clip which attaches to the connection point of the two legs and forms a Y-shape with them in cross section.
  • connection element in addition to the metal clip, can have a further electrical component connected to the metal clip, so that the connection element for the system forms a pre-assembled unit made of a metal clip and one or more other components.
  • the further electrical component is connected to the metal clip, in particular at the connection surface.
  • connection element can comprise a connection bolt connected, in particular welded, to the metal clip, which facilitates the connection of another electrical component, such as a cable, to the connection element.
  • connection element can also comprise a cable which, if necessary, is electrically conductively connected to the metal clip, in particular welded, by means of a socket.
  • connection element for the system can be made available as a pre-assembled component which comprises a cable with a metal clip connected to it, in particular a welded one, for connection to a flat conductor.
  • the metal clip can be manufactured as a one-piece component.
  • the two legs and a sheet-metal section that attaches to the connection point of the two screws can be made in one piece.
  • the metal clip can also be composed of several parts.
  • the metal clip has two metal clip parts connected to one another, one metal clip part comprising the first leg and the other metal clip part comprising the second leg.
  • the two metal clip parts are preferably connected to one another in a force-fitting and / or form-fitting manner, 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 metal clip composed of them and can therefore be manufactured correspondingly more easily.
  • the individual metal clip parts can be manufactured not only as a milled or profile part, but alternatively also as a stamped part or bent part.
  • the metal clip is preferably made of an aluminum alloy. This prevents contact corrosion to the aluminum flat conductor.
  • the metal clip is coated at least in certain areas, in particular with a nickel-phosphorus and / or tin coating. In this way, very good corrosion protection is achieved.
  • the metal clip is preferably coated in the area of the connection surface, in particular on a sheet-metal section provided for this purpose.
  • the connection element comprises a housing in which a contacting space is provided, wherein the aluminum flat conductor can be passed through the housing in such a way that a section of the aluminum flat conductor runs through the contacting space and the metal clip is arranged such that it is laterally onto the section running through the contacting space of the aluminum flat conductor can be attached.
  • the electrical connection element comprises a housing in which a contacting space is provided, the aluminum flat conductor is passed through the housing in such a way that a section of the aluminum flat conductor runs through the contacting space, and the metal clip is laterally on the section of the Aluminum flat conductor attached.
  • the aluminum flat conductor can be contacted within a housing, for example a power distribution box or fuse box.
  • the housing protects the electrical connection and / or the aluminum flat conductor stripped in the connection area, for example, from moisture or chemical and / or thermal influences from the environment.
  • the copper / aluminum transition between the metal clip and the aluminum flat conductor can be protected from corrosion by the housing.
  • the housing is the housing of a power distributor and / or a fuse box.
  • the power distributor and / or the fuse box can be contacted with the aluminum flat conductor directly in the power distributor or in the fuse box.
  • the power distributor comprises a plurality of electrical connections for connecting electrical components, wherein the electrical connections can be electrically connected to the aluminum flat conductor via the metal clamp.
  • the fuse box comprises one or more fuses, for example fuses or semiconductor fuses, with which one or more electrical connections can be protected.
  • the housing is preferably opened laterally in such a way that the housing can be pushed laterally onto the aluminum flat conductor, so that the connection area 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 clip and the aluminum conductor, can also be protected from corrosion by other measures, for example by applying a coating such as a lacquer or by a shrink tube.
  • the above-mentioned object is further achieved by a system for establishing an electrical connection with an aluminum flat conductor and an electrical connection element which has a connection profile with a flat contact surface in order to connect the connection profile to the aluminum flat conductor on one side, especially to be welded or riveted.
  • a connection profile Preferably that has Connection profile on a stepped shape, a contact area with the contact surface for connection to the flat conductor by a step of a section with a Connection surface is separated for connection to a further electrical component.
  • the connection element also has the 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.
  • the above-mentioned object is also achieved according to this alternative aspect by an electrical connection established with such a system.
  • the systems, methods and electrical connections described above can be used not only for aluminum flat conductors, but also for flat conductors made of other materials, such as copper.
  • further advantageous teachings result from the systems, methods and electrical connections described above or their embodiments, in that a flat conductor made of a different material, in particular a different metal, is used instead of the aluminum flat conductor.
  • the material of the metal clip or of the connection element is preferably adapted to the material of the flat conductor.
  • a metal clip made of copper is preferably used.
  • Figures 1a-b show a schematic representation in plan view of an embodiment of a system 2 with a motor vehicle energy conductor 4 designed as an aluminum flat conductor, 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. 1a ) and the metal clip 10, 10 'is pushed onto the motor vehicle energy conductor 4 from the side. If the motor vehicle energy conductor 4 has insulation 14, the motor vehicle energy conductor 4 is stripped in the area 16, 16 '(connection area) provided for the electrical connection 12, 12', before the metal clip 10, 10 'is attached.
  • the motor vehicle energy conductor 4 can have a metallic coating 18 in the connection area, which is more noble than the alloy of the aluminum flat conductor. In this way, oxidation of the surface of the motor vehicle energy conductor 4 in the connection area 16, 16 'is avoided, so that a low-resistance electrical connection 12, 12' can be established.
  • the coating 18 can also extend over the entire length of the motor vehicle energy 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.
  • FIGS. 2a-c show various exemplary embodiments of electrical connections 20, 20 ′, 20 ′′ in a schematic representation in sectional view.
  • the electrical connections 12, 12 ′ from Figure 1b be designed 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 made of a more noble alloy, for example a tin alloy, applied thereon. Furthermore, the electrical connection 20 comprises an electrical connection element 28 with a U-shaped metal clip 30, the two legs of which are each designed as a spring element 32, 32 '.
  • the spring elements 32, 32 ' are expanded 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 Figure 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 clip 30 and the aluminum flat conductor 22 is ensured.
  • the metal clip 30 can first be pushed laterally onto the aluminum flat conductor 22 in the desired position and pre-fixed there with the spring elements 32, 32' (corresponding to FIG Figure 2a ).
  • the welding point 34 can then be produced in a simple manner without additional positioning of the metal clamp 30 on the aluminum flat conductor 22 being necessary.
  • Figure 2c 12 shows an alternative electrical connection 20 ′′.
  • Electrical connection 20 ′′ differs from electrical connection 20 Figure 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.
  • FIG. 3a-b show a schematic representation of a further exemplary embodiment of a system 38 for establishing an electrical connection 40.
  • FIG. 3a shows a sectional view corresponding to FIG Figure 3b section plane designated IIIa.
  • Fig. 3a shows a sectional view corresponding to FIG Fig. 3a with Illb designated cutting plane.
  • the system 38 comprises an aluminum flat conductor 42 with an aluminum core 44, a coating 46 made of a zinc alloy and an insulation 48 applied thereon.
  • the system 38 also comprises an electrical connection element 50 with a U-shaped metal bracket 52 and a housing 54, the metal bracket in a contacting space 56 is arranged in the housing 54.
  • connection area 57 is stripped in the desired connection area 57 and guided into the housing 54, so that the connection area 57 is positioned in the contacting space 56 and the metal clip 52 is attached to the side of the aluminum flat conductor 42.
  • the housing 54 is opened laterally in the contacting space 56, so that the housing 54 for contacting the aluminum flat conductor 42 can simply be plugged laterally onto the aluminum flat conductor 42.
  • the metal clip 52 is then plugged onto the aluminum flat conductor 42.
  • the two legs of the U-shaped metal clip 52 are designed 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 power distribution box that has a plurality of electrical taps 60 for connecting electrical consumers.
  • the housing 54 can also 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 by the housing 54, so that the service life of the electrical connection 40 is increased.
  • the aluminum flat conductor 42 can be protected from corrosion in particular by the fact that it is stripped only within the housing 54, in particular within the contacting space 56.
  • the Figures 4a-d show another embodiment of the system and connection.
  • the system 70 comprises an aluminum flat conductor 72 with insulation 74 and a connection element 76 with a metal bracket 78.
  • the metal bracket 78 has a first leg 80 with a first contact surface 82 and a second leg 84 with a second contact surface 86, the two contact surfaces 82 , 86 lie opposite one another and are preferably plane-parallel to one another.
  • 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 area 88 of the flat conductor 72, as shown in FIG Figure 4b is shown.
  • the stripped connection area 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 of chamfers 90 provided at the ends of the legs 80, 84.
  • the metal clip 78 is spot-welded to the flat conductor 72 in the region of the legs 80, 84 after it has been 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 passed 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 creates possible oxide layers on the flat conductor 72 broken open, so that there is a good electrical connection 95 between the flat conductor 72 and the legs 80, 84 of the metal clip 78.
  • the method in Figure 4c The illustrated, so-called DeltaSpot welding process has proven to be particularly suitable.
  • an electrode strip 96, 98 is arranged between the electrodes 92, 94 and the components to be electrically contacted with them, in this case the legs 80, 84 of the metal clamp 78, so that the electrodes 92, 94 are not in direct mechanical contact Come into contact with the legs 80, 84 to be electrically contacted therewith.
  • the electrode strip 96, 98 is transported a little further after each spot weld (cf. arrows 100 in Figure 4c ), so that a "fresh" electrode strip surface is used for each spot weld.
  • the metal clip 78 is then as in FIG Figure 4d shown firmly and electrically conductively connected to the flat conductor 72 by a welded connection 102.
  • the metal clamp 78 and the flat conductor 72 can also be connected to one another in a form-fitting and / or force-fitting manner, for example by a rivet connection 104, as is the case with the one in FIG Fig. 5 illustrated alternative embodiment of the system is the case.
  • a rivet connection 104 for example by a rivet connection 104.
  • Corresponding components are used in Fig. 5 the same reference numerals as in Figures 4a-d used.
  • Corresponding bores 106, 108 can be provided in the legs 80, 84 for the rivet connection (or also for a screw connection).
  • the legs 80, 84 and the flat conductor 72 can also be drilled through together if the metal clip 78 is slipped onto the flat conductor 72.
  • connection element 76 can in particular be used 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 connection surface 109 in order to be able to connect the metal clip 78 to a further electrical component, such as a cable, for example.
  • the connection surface 109 of the metal clip 78 is formed by a sheet-like section 110 which attaches to the connection point of the two legs 80, 84 and forms a Y-shape with these in cross section.
  • An electrical component, such as a cable can be welded to the connection surface 109 of the section 110.
  • the sheet-like portion 110 of the metal bracket 78 can be as shown in FIG Fig. 5 shown have a bore 112 so that, for example, a cable can be screwed or riveted to the sheet-metal section 110.
  • the connection element 76 in addition to the metal clip 78, can comprise a cable connected thereto and thus form a pre-assembled connection element 76.
  • connection element 76 shows further configurations of the connection element 76 and in particular of the connection area of the metal clip 78. Corresponding parts are again provided with the same reference symbols.
  • connection element 76 'in Figure 6a comprises a flexible cable 114, which is electrically connected to the metal clamp 78 by welding one end of the cable 114 or a socket or cable lug 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-on cable 114 can be provided for the system as a pre-assembled connection element 76 '.
  • connection element 76 "in Figure 6b comprises a connecting bolt 118 which is welded onto the connecting surface 109 of the metal clip 78, for example through Friction welding. In this way, various cables or components can be connected to the bolt 118.
  • connection element 76 '''in Figure 6c comprises a metal clip 78 'with two legs 80, 84 and a cable 120 with an attached socket 122, which is welded to a connection surface 124 arranged at the connection of the two legs 80, 84, in particular by friction welding.
  • the metal clip 78 'and the cable 120 welded to it can be made available for the system as a pre-assembled connection element 76'''.
  • the metal clip 78 or 78 ' can also be made in several parts.
  • the Figures 7a-b show an embodiment of such a multi-part metal clip 78 ′′.
  • the metal clip 78 ′′ is designed in two parts with a first metal clip part 126 and a second metal clip part 128, the first metal clip part 126 comprising the first leg 80 and the second metal clip part 128 the second leg 84.
  • the metal clip parts 126, 128 each have connecting means 130 corresponding to one another in order to be able to connect the two metal clamp parts together, which are then as in Figure 7b shown form the metal bracket 78 ".
  • the connecting means 130 can as in FIG Figure 7a shown as mutually corresponding pegs and recesses with a press fit, so that the two metal clip parts can be connected to one another by pressing the pegs into the recesses.
  • clip or latching connections are also conceivable.
  • the metal clip parts 126, 128 can be produced, for example, as a stamped part and thus particularly inexpensively.
  • Fig. 8 shows an aluminum flat conductor 132 to which various connection elements 134, 136, 138, 140 are connected by way of example.
  • Connector 134 is like that in FIG Figure 4a
  • the connection element 76 shown is designed with an additional bore 112 in the sheet-metal section 110 of the metal clip 78 in order to be able to screw or rivet the metal clip 78 to a further component.
  • Connector 136 is like that in FIG Figure 6c
  • Connection element 138 is made like connection element 76 " Figure 6b formed with a bolt 118 welded onto the sheet-like section 110 of the metal clip 78 for connection to a further component.
  • Connection element 140 is like that in FIG Figure 6a
  • the connection element 76 ′ shown is formed with a flexible cable 114 welded onto the sheet-metal section 110 of the metal clip 78.
  • connection elements To connect the respective connection elements, the flat conductor 132 is stripped in the corresponding areas. The respective metal clip is then pushed onto the flat conductor and then welded to the flat conductor 132, for example to the in Figure 4c illustrated DeltaSpot spot welding process, or screwed or riveted.
  • the connection elements can, as shown in the example of connection elements 140, be connected to one end of the flat conductor or as shown in the example of connection elements 134, 136 and 138, in the course of the flat conductor. Furthermore, the connection elements can be plugged onto the flat conductor at different angles, for example vertically (as with connection element 134 or 136) or at an inclined angle to the course of the flat conductor 132 (as with connection element 138 or 140).
  • connection elements 134, 136, 138 or 140 can after welding, screwing or riveting with a shrink tube or a housing be surrounded (as it is in Fig. 8 for the connection element 136 is shown by the dash-dotted lines 142).
  • a pole grease can additionally or alternatively 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.
  • connection element described in the present case or its embodiments and this comprehensive system thus allow extremely flexible connection options for a flat conductor.
  • FIGS 9a-b show an alternative system 200 for establishing 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 flatly contacted with the aluminum flat conductor 202 and then as in FIG Figure 9a shown by means of a weld joint 210 or alternatively as in FIG Figure 9b is shown with a mechanical connection, in particular a rivet connection 212 with the aluminum flat conductor 202 firmly and electrically conductively connected.
  • the welded connection 210 can be produced, for example, by means of spot welding, in particular with the DeltaSpot welding process.
  • connection profile 206 preferably has as in FIG Figures 9a-b shown has a stepped shape, wherein a contact area 214 with the contact surface 208 for connection to the flat conductor 202 is separated by a step 216 from a section 218 with a connection surface for connection to a further electrical component. In this way, a flatter construction is possible.
  • Section 218 can also be used as in Figures 6a-c be designed for the metal bracket shown.
  • the system 200 and the connection brought about by it each represent independent inventive teachings.
  • the exemplary embodiments described with reference to the figures also represent exemplary embodiments for 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 a different metal such as copper.

Landscapes

  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Connection Of Batteries Or Terminals (AREA)

Claims (15)

  1. Système (2, 38, 70) de fabrication d'un raccordement électrique (12, 12', 20, 20', 20", 40, 95), comportant:
    - un conducteur plat en aluminium (4, 22, 42, 72, 132) conçu en tant que conducteur d'énergie de véhicule automobile, notamment en tant que conducteur de batterie de véhicule automobile, et
    - un élément de connexion électrique (8, 8', 28, 46, 50, 76, 76', 76", 76''', 134, 136, 138, 140) qui est conçu de sorte à être connecté au conducteur plat en aluminium (4, 22, 42, 72, 132) afin de fabriquer, entre le conducteur plat en aluminium (4, 22, 42, 72, 132) et l'élément de connexion (8, 8', 28, 46, 50, 76, 76', 76", 76''', 134, 136, 138, 140), un raccordement électrique (12, 12', 20, 20', 20", 40, 95),
    - l'élément de connexion (8, 8', 28,46, 50, 76, 76', 76", 76''', 134, 136, 138, 140) comportant un collier métallique (10, 10', 30, 52, 78, 78', 78") qui est conçu de sorte à être monté latéralement sur le conducteur plat en aluminium (4, 22, 42, 72,132) afin de fabriquer, entre le conducteur plat en aluminium (4, 22, 42, 72, 132) et le collier métallique (10, 10', 30, 52, 78, 78', 78"), un raccordement électrique, et
    - l'élément de connexion (16, 16', 57) comportant un boîtier (54) dans lequel l'on prévoit un espace de mise en contact (56),
    caractérisé
    - en ce que le conducteur plat en aluminium (4, 22, 42) est susceptible d'être introduit de telle sorte à travers le boîtier (54) qu'une section du conducteur plat en aluminium (4, 22, 42) passe à travers l'espace de mise en contact (56),
    - en ce que le collier métallique (10, 10', 30, 52) est agencé de sorte à pouvoir être monté latéralement sur la section du conducteur plat en aluminium (4, 22, 42) passant à travers l'espace de mise en contact (56), et
    - en ce que le boîtier (54) est un boîtier d'un distributeur de courant avec une multitude de connexions électriques pour le branchement de composants électriques, les connexions électriques étant susceptibles d'être reliées électriquement, par l'intermédiaire du collier métallique, avec le conducteur plat en aluminium, ou en ce que le boîtier (54) estun boîtier d'une boîte à fusibles, la boîte à fusibles comportant un ou plusieurs fusibles avec lesquels une ou plusieurs connexions électriques peuvent être protégées par fusibles.
  2. Système selon la revendication 1,
    caractérisé en ce que le collier métallique (10, 10', 30, 52, 78, 78', 78") est conçu de sorte à être monté, par un côté étroit du conducteur plat en aluminium (4, 22,42, 72, 132), latéralement sur le conducteur plat en aluminium (4, 22, 42, 72, 132) afin de fabriquer, entre le conducteur plat en aluminium (4, 22, 42, 72, 132) et le collier métallique (10, 10', 30, 52, 78, 78', 78"), un raccordement électrique.
  3. Système selon la revendication 1 ou 2,
    caractérisé en ce que le collier métallique (10, 10', 30, 52, 78, 78', 78") est conçu en cuivre ou en alliage de cuivre ou en ce que le collier métallique (10, 10', 30, 52, 78, 78', 78") est conçu en aluminium ou en alliage d'aluminium.
  4. Système selon l'une des revendications 1 à 3,
    caractérisé en ce que le conducteur plat en aluminium (4, 22, 42, 72, 132) est pourvu, au moins dans une zone de connexion (16, 16', 57, 88) prévue pour le branchement de l'élément de connexion électrique (8, 8', 28, 46, 50, 76, 76', 76", 76''', 134, 136, 138, 140), d'un revêtement conducteur (18, 26, 46), le revêtement (18, 26, 46) étant, de préférence, plus noble que l'alliage d'aluminium du conducteur plat en aluminium (4, 22, 42, 72, 132).
  5. Système selon l'une des revendications 1 à 4,
    caractérisé en ce que le collier métallique (10, 10', 30, 52, 78, 78', 78") est conçu en forme de U ou de Y.
  6. Système selon l'une des revendications 1 à 5,
    caractérisé en ce que le collier métallique (10, 10', 30, 52, 78, 78', 78") comporte un élément à ressort (32, 32', 58, 58') qui est conçu de sorte à maintenir, par liaison de force, le collier métallique (10, 10', 30, 52, 78, 78', 78") sur le conducteur plat en aluminium (4, 22, 42, 72, 132).
  7. Système selon l'une des revendications 1 à 6,
    caractérisé en ce que le collier métallique (10, 10', 30, 52, 78, 78', 78") présente une première branche (80) avec une première surface de contact (82) et une deuxième branche (84) avec une deuxième surface de contact (82) à l'opposé de la première surface de contact (86), la distance entre la première et la deuxième surface de contact (82, 86) étant adaptée à l'épaisseur du conducteur plat en aluminium (4, 22, 42, 72, 132), de sorte que le collier métallique (10, 10', 30, 52, 78, 78', 78") est susceptible de pouvoir être monté, avec la première et la deuxième branche (80, 84), sur le conducteur plat en aluminium (4, 22, 42, 72, 132), les branches (80, 84) étant notamment conçues de sorte que la première et/ou la deuxième surface de contact (82, 86), à l'état monté, reposent à plat sur les côtés larges du conducteur plat en aluminium (4, 22, 42, 72, 132).
  8. Système selon la revendication 7,
    caractérisé en ce que le collier métallique (10, 10', 30, 52, 78, 78', 78") présente deux parties de collier métallique (126, 128), reliées l'une à l'autre, de préférence reliées entre elles par liaison de forme et/ou de force, une partie de collier métallique (126) comportant la première branche (80) et l'autre partie de collier métallique (128) comportant la deuxième branche (84).
  9. Raccordement électrique (12, 12', 20, 20', 20", 40, 95) destiné à être utilisé dans des véhicules automobiles (6), fabriqué en utilisant un système (2, 38, 70) de fabrication d'un raccordement électrique (12, 12', 20, 20', 20", 40, 95),
    - le système (2, 38, 70) comportant un conducteur plat en aluminium (4, 22, 42, 72, 132), conçu en tant que conducteur d'énergie de véhicule automobile, notamment en tant que conducteur de batterie de véhicule automobile, et un élément de connexion électrique (8, 8', 28, 46, 50, 76, 76', 76", 76''', 134, 136, 138, 140) qui est conçu de sorte à être connecté au conducteur plat en aluminium (4, 22, 42, 72, 132) du système (2, 38, 70) afin de fabriquer, entre le conducteur plat en aluminium (4, 22, 42, 72, 132) et l'élément de connexion (8, 8', 28, 46, 50, 76, 76', 76", 76''', 134, 136, 138, 140), un raccordement électrique (12,12', 20, 20', 20", 40, 95),
    - l'élément de connexion (8, 8', 28, 46, 50, 76, 76', 76", 76''', 134, 136, 138, 140) du système (2, 38, 70) comportant un collier métallique (10, 10', 30, 52, 78, 78', 78") qui est conçu de sorte à être monté latéralement sur le conducteur plat en aluminium (4, 22, 42, 72, 132) du système (2, 38, 70) afin de fabriquer, entre le conducteur plat en aluminium (4, 22, 42, 72, 132) et le collier métallique (10, 10', 30, 52, 78, 78', 78"), un raccordement électrique, et
    - l'élément de connexion (16, 16', 57) comportant un boîtier (54) dans lequel l'on prévoit un espace de mise en contact (56), et
    - le collier métallique (10, 10', 30, 52, 78, 78', 78") de l'élément de connexion électrique (8, 28, 50, 76, 76', 76", 76''', 134, 136, 138, 140) étant monté de telle sorte latéralement sur le conducteur plat en aluminium (4, 22, 42, 72, 132) que le conducteur plat en aluminium (4, 22, 42, 72,132) et le collier métallique (10, 10', 30, 52, 78, 78', 78") sont reliés électriquement,
    caractérisé
    - en ce que le conducteur plat en aluminium (4, 22, 42) est susceptible d'être introduit de telle sorte à travers le boîtier (54) qu'une section du conducteur plat en aluminium (4, 22, 42) passe à travers l'espace de mise en contact (56),
    - en ce que le collier métallique (10, 10', 30, 52) est monté latéralement sur la section du conducteur plat en aluminium (4, 22, 42) passant à travers l'espace de mise en contact (56), et
    - en ce que le boîtier (54) de l'élément de connexion (16, 16', 57) du système (2, 38, 70) est un boîtier d'un distributeur de courant avec une multitude de connexions électriques pour le branchement de composants électriques, les connexions électriques étant susceptibles d'être reliées électriquement, par l'intermédiaire du collier métallique, avec le conducteur plat en aluminium du système (2, 38, 70), ou en ce que le boîtier (54) est un boîtier d'une boîte à fusibles, la boîte à fusibles comportant un ou plusieurs fusibles avec lesquels une ou plusieurs connexions électriques peuvent être protégées par fusibles.
  10. Raccordement électrique selon la revendication 9
    caractérisé en ce que le collier métallique (10, 10', 30, 52, 78, 78', 78") est relié par liaison de forme et/ou de force au conducteur plat en aluminium (4, 22, 42, 72, 132), de préférence au moyen d'un assemblage serti et/ou d'un sertissage.
  11. Raccordement électrique selon la revendication 9 ou 10,
    caractérisé en ce que le collier métallique (10, 10', 30, 52, 78, 78', 78") est relié par liaison par la matière au conducteur plat en aluminium (4, 22, 42, 72, 132), est, de préférence, soudé, notamment par un soudage par ultrasons, un soudage au laser, un soudage par points et par résistance ou un soudage par points de friction.
  12. Raccordement électrique selon l'une des revendications 9 à 11,
    caractérisé en ce que le collier métallique (10, 10', 30, 52, 78, 78', 78") est monté obliquement par rapport au parcours du conducteur plat en aluminium (4, 22, 42, 72, 132) sur le conducteur plat en aluminium (4, 22, 42, 72, 132).
  13. Procédé de fabrication d'un raccordement électrique (12, 12', 20, 20', 20", 40) selon l'une des revendications 9 à 12 en utilisant un système (2, 38, 70) pour la fabrication d'un raccordement électrique (12, 12', 20, 20', 20", 40, 95):
    - le système (2, 38, 70) présentant un conducteur plat en aluminium (4, 22, 42, 72, 132), conçu en tant que conducteur d'énergie de véhicule automobile, notamment en tant que conducteur de batterie de véhicule automobile, et un élément de connexion électrique (8, 8', 28, 46, 50, 76, 76', 76", 76''', 134, 136, 138,140) qui est conçu de sorte à être connecté au conducteur plat en aluminium (4, 22, 42, 72, 132) afin de fabriquer, entre le conducteur plat en aluminium (4, 22, 42, 72, 132) et l'élément de connexion (8, 8', 28, 46, 50, 76, 76', 76", 76''', 134, 136, 138, 140), un raccordement électrique (12, 12', 20, 20', 20", 40, 95),
    - l'élément de connexion (8, 8', 28, 46, 50, 76, 76', 76", 76''', 134, 136, 138, 140) du système (2, 38, 70) comportant un collier métallique (10, 10', 30, 52, 78, 78', 78") qui est conçu de sorte à être monté latéralement sur le conducteur plat en aluminium (4, 22, 42, 72, 132) du système (2, 38, 70) afin de fabriquer, entre le conducteur plat en aluminium (4, 22, 42, 72, 132) et le collier métallique (10, 10', 30, 52, 78, 78', 78"), un raccordement électrique, et
    - l'élément de connexion (16, 16', 57) du système (2, 38, 70) comportant un boîtier (54) dans lequel l'on prévoit un espace de mise en contact (56),
    - le conducteur plat en aluminium (4, 22, 42) du système (2, 38, 70) étant susceptible d'être introduit de telle sorte à travers le boîtier (54) qu'une section du conducteur plat en aluminium (4, 22, 42) du système (2, 38, 70) passe à travers l'espace de mise en contact (56),
    - le collier métallique (10, 10', 30, 52) du système (2, 38, 70) étant agencé de sorte à être monté latéralement sur la section du conducteur plat en aluminium (4, 22, 42) du système (2, 38, 70) passant à travers l'espace de mise en contact (56), et
    - le boîtier (54) est un boîtier d'un distributeur de courant avec une multitude de connexions électriques pour le branchement de composants électriques, les connexions électriques étant susceptibles d'être reliées électriquement, par l'intermédiaire du collier métallique, avec le conducteur plat en aluminium du système (2, 38, 70), ou le boîtier (54) est un boîtier d'une boîte à fusibles, la boîte à fusibles comportant un ou plusieurs fusibles avec lesquels une ou plusieurs connexions électriques peuvent être protégées par fusibles
    le procédé comportant les étapes de travail suivantes:
    - dénudage du conducteur plat en aluminium (4, 22, 42, 72, 132) du système dans une zone de connexion (16, 16', 57, 88), et
    - montage latérale du collier métallique du système (10, 10', 30, 52, 78, 78', 78") sur le conducteur plat en aluminium (4, 22, 42, 72, 132) dans la zone de connexion (16, 16', 57, 88) de sorte à fabriquer un raccordement électrique (12, 12', 20, 20', 20", 40, 95) entre le conducteur plat en aluminium du système (4, 22, 42, 72,132) et le collier métallique du système (10, 10', 30, 52, 78, 78', 78").
  14. Procédé selon la revendication 13, comportant en outre:
    - raccordement par liaison de force et/ou de forme du collier métallique (10, 10', 30, 52, 78, 78', 78") au conducteur plat en aluminium (4, 22, 42, 72, 132), de préférence en fabriquant un assemblage serti et/ou un sertissage.
  15. Procédé selon la revendication 13 ou 14, comportant en outre:
    - raccordement par liaison par la matière du collier métallique (10, 10', 30, 52, 78, 78', 78") au conducteur plat en aluminium (4, 22, 42, 72, 132), de préférence soudage, notamment par un soudage par ultrasons, un soudage au laser, un soudage par points et par résistance ou un soudage par points de friction.
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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CN214797803U (zh) * 2020-12-30 2021-11-19 泰科电子(上海)有限公司 端子本体、连接端子及用于制作端子本体的片料
CN113851866B (zh) * 2021-08-26 2024-06-04 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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