EP3266068B1 - Verfahren zum crimpen eines elektrischen kontakts auf ein kabel und werkzeug zur durchführung des verfahrens - Google Patents

Verfahren zum crimpen eines elektrischen kontakts auf ein kabel und werkzeug zur durchführung des verfahrens Download PDF

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Publication number
EP3266068B1
EP3266068B1 EP16708183.5A EP16708183A EP3266068B1 EP 3266068 B1 EP3266068 B1 EP 3266068B1 EP 16708183 A EP16708183 A EP 16708183A EP 3266068 B1 EP3266068 B1 EP 3266068B1
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EP
European Patent Office
Prior art keywords
crimping
contact
cable
electrical
electrical conduction
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Active
Application number
EP16708183.5A
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English (en)
French (fr)
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EP3266068A1 (de
Inventor
Laurent DELESCLUSE
Laurent Tristani
Benoît BEAUR
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Aptiv Technologies Ltd
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Aptiv Technologies Ltd
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Publication of EP3266068A1 publication Critical patent/EP3266068A1/de
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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048—Crimping apparatus or processes
    • H01R43/0488—Crimping apparatus or processes with crimp height adjusting means
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H01R4/184—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H01R4/184—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
    • H01R4/185—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion combined with a U-shaped insulation-receiving portion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048—Crimping apparatus or processes

Definitions

  • the invention relates to the field of electrical connectors.
  • the invention relates in particular to a method of crimping an electrical contact on an electrical cable, an electrical contact crimped with this method, as well as a tool for implementing this method.
  • male and female electrical contacts are used to make an electrical connection between cable connectors or between a cable connector and an electrical or electronic device for example.
  • male or female contacts are electrically connected, by soldering, crimping or the like, to a cable comprising one or more strands.
  • contacts are often made by stamping and bending a sheet of copper.
  • the cables are generally also made of copper.
  • a crimping of the crimping zone is also carried out on the cable, by folding and compressing the fins on the cable.
  • a tool comprising a punch comprising two different crimping heights is used.
  • a crimping zone is then obtained, which after crimping, itself comprises a portion of mechanical retention and a portion of electrical conduction.
  • the mechanical retention and electrical conduction portions are in continuity of material with each other. In other words, starting from a contact with a single fin on each side of the cable, without cutting these fins or slitting separating them into several portions, a barrel for continuous crimping in the longitudinal direction is obtained.
  • the mechanical retention and electrical conduction portions have different final crimp heights, the final crimp height of the mechanical retention portion being higher than the final crimp height of the electrical conduction portion.
  • the strands of the cable are less compressed (the compression ratio is for example between 20 and 30%), the integrity of their mechanical properties is therefore essentially preserved and the retention of the cable in the crimp barrel meets specifications. For example, for a 1.5mm 2 copper wire, this retention force must be greater than 155N.
  • the strands of the cable are more compressed (the compression ratio is for example between 50 and 65%), the mechanical properties are therefore degraded compared to the mechanical retention zone.
  • the electrical resistivity in the electrical conduction zone is lower than in the mechanical retention zone.
  • An object of the invention is to at least partially overcome this drawback.
  • the deformations of the contact in the transition zone between the mechanical retention portion and the electrical conduction portion are limited and the contact does not have a crack or tear.
  • the copper contact is coated with a protective layer, for example tin, the integrity thereof remains. This avoids electrolytic corrosion problems due to the differences in electrochemical potentials between the cable and the contact.
  • the invention relates to a contact according to claim 2, crimped with the method according to claim 1.
  • This contact comprises a step between the mechanical retention portion and the electrical conduction portion whose height is between 0 , 4 and 0.7mm, or even less and between 0.5 and 0.6mm in some cases.
  • the method according to the invention also involves a tool comprising a crimping punch for the implementation of a crimping method of an electrical contact.
  • This punch comprises a groove having essentially a shape of W in section in a plane perpendicular to the longitudinal direction.
  • This groove has two successive segments in the longitudinal direction, a deeper segment for compressing the fins at the level of the mechanical retention portion and a shallower segment for compressing the fins at the level of the electrical conduction portion, the difference in height between these two segments being between 0.4 and 0.7mm, or even less and between 0.5 and 0.6mm in certain cases.
  • the figure 1 shows an electrical contact 100 intended to be mounted in a connector cavity (not shown) of a motor vehicle.
  • the contact 100 is made for example by stamping and bending a copper sheet.
  • the thickness of this copper sheet is for example between 0.2 and 0.5 mm.
  • it is a female contact 100, straight, extending in a longitudinal direction L which also corresponds to the coupling direction.
  • the contact 100 can be a right angle contact for example.
  • the contact 100 is shown here attached to a carrier strip 101 whose contact 100 will be separated at a later stage, after possible tinning.
  • the contact 100 has a coupling portion 110, a crimping zone 120 on the conductive strands 210 of a cable 200 and a crimping end 130 on the insulator 220 of this cable (see figure 2 ).
  • the coupling portion 110, the crimping zone 120 and the crimping end 130 follow one another along the longitudinal direction L which also corresponds to the coupling direction.
  • the coupling portion 110 may be perpendicular to the crimping zone 120 and to the crimping end 130 which themselves extend along the longitudinal direction L. But if the description which follows relates to a right contact, a person skilled in the art will easily know how to transpose it for a contact at right angle or other.
  • the crimping zone 120 is in the form of a gutter with two fins 122, 124 each extending on one side of a base 126.
  • the two fins 122, 124 and the base 126 therefore form, before crimping, a groove having essentially a U shape in section in a plane perpendicular to the longitudinal direction L.
  • Each fin 122 or 124 is continuous over its entire length. In other words, a fin 122 or 124 has neither a slot nor a cutout.
  • the contact 100 undergoes a crimping operation on a cable 200 during which the fins 122, 124 are folded and compressed on a stripped part of the cable 200.
  • This crimping operation is carried out by inserting the end of the cable 200 in the respective grooves of the crimping zone 120 and of the crimping end 130 and striking the contact 100, at the crimping zone 120 between an anvil (not shown) of a type known to those skilled in the art and a punch 300 which will be described later.
  • the crimping zone 120 has a mechanical retention portion 140, an electrical conduction portion 150 and a transition zone 160 between the two.
  • the mechanical retention portions 140, electrical conduction portions 150 and the transition zone 160 are in continuity of material with one another, without slit or cut in the longitudinal direction L.
  • the mechanical retention portions 140 and electrical conduction portions 150 have different final crimp heights in a direction perpendicular to the longitudinal direction L and corresponding to the direction D of movement of the punch 300 towards the anvil and vice versa.
  • the final crimp height of the mechanical retention portion 140 (see also figure 3B ) is lower than the final crimp height of the electrical conduction portion 150 (see also figure 3A ).
  • the heights of the mechanical retention portions 140 and electrical conduction portions 150 are essentially constant each over their respective length.
  • the difference in height is therefore essentially fixed and can be between 0.5mm and 0.6mm, for a thickness of copper sheet between 0.20 and 0.39mm and for an aluminum cable whose diameter is between 1.25 and 4 mm, or even between 0.75 and 6 mm.
  • This difference in height is sufficient to obtain very different compression rates respectively in the electrical conduction portion 150 and in the mechanical retention portion 140, while avoiding creating a crack or a tear in the sheet metal forming the contact 100. This is particularly important when copper is tinned.
  • a tear or a crack in the tinned copper layer would cause the underlying copper to be exposed and therefore in the long term, electrochemical corrosion phenomena mechanically weakening the contact and degrading its conduction, in particular at the level of the contact-cable interface.
  • the compression ratio is defined as the ratio of the section of cable 200 after crimping to the section of cable 200 before crimping. We can then see, by comparing the sections of the contact 100, and therefore the sections of the cable 200, respectively represented on the Figures 3A and 3B , that the compression ratio of the cable 200 is higher at the level of the electrical conduction portion 150 ( figure 3B ), that at the level of the mechanical retention portion 140 ( figure 3A ).
  • the compression ratio at the level of the electrical conduction portion 150 is advantageously of the order of 50% or more (up to 65%) and the rate compression at the mechanical retention portion 140 is between 20 and 30%.
  • the length I ce (that is to say in the longitudinal direction L) of the electrical conduction portion 150 is greater than 1.5 mm. It has been found by the inventors, that with a length I ce ⁇ 1.4 mm, the electrical resistance of the crimping is greater than 0.3 m ⁇ and changes over time, regardless of the compression ratio at the level of the electrical conduction portion 150. It has also been found by the inventors that with a compression ratio at the electrical conduction portion 150 of less than 50%, the electrical resistance of the crimping is greater than 0.3 m ⁇ and evolves in time, regardless of length l ce . On the other hand, with a length l ce > 1.4mm and a compression ratio in the electrical conduction portion 150 greater than 50%, a resistance is obtained at the electrical conduction portion of less than 0.3m ⁇ and stable in the time.
  • the dimension of the transition zone 160, in the longitudinal direction L is between 0.3mm and 0.6mm. In this case, it is 0.3mm.
  • the difference in height between the electrical conduction portion 150 and the mechanical retention portion 140 forms a step with an internal fold 162 and an external fold 164.
  • the internal folds 162 and external 164 are rounded with a radius of curvature between 0 , 1mm and 0.5mm.
  • the radius of curvature of the internal fold 162 is 0.1mm and that of the external fold 164 is 0.2mm.
  • the sum of the radii of curvature of the internal 162 and external 164 folds is therefore 0.3 mm.
  • Contact 100 illustrated on Figures 2, 3A and 3B is crimped using a tool comprising a punch 300 illustrated on the Figures 4, 5 and 6 .
  • This punch 300 essentially has the shape of an elongated parallelepiped plate between a high end 310 and a low end 320, in the direction D of movement of the punch 300 during crimping (see figure 4 ).
  • This plate has a thickness E in the direction corresponding to the longitudinal direction L during crimping.
  • the lower end 320 has two teeth 330 separated by a notch 340.
  • the notch 340 corresponds to the part of the punch 300 which makes it possible to shape the fins 122, 124, during crimping.
  • the notch 340 has a V-shaped mouth 342 which makes it possible to bring the fins 122, 124 towards one another to a position in which they are substantially parallel, then a channel 344, with walls which are essentially parallel to receive the fins 122, 124 when they are parallel, and finally, a groove 346 which makes it possible to gradually bring the fins 122, 124 successively above the cable 200, towards the latter and finally therein.
  • This groove 346 has essentially a shape of W in section in a plane perpendicular to the longitudinal direction L.
  • the groove 346 has two successive segments 348, 350 in the longitudinal direction L.
  • the deepest segment 348 corresponds to that which compresses the fins 122, 124 at the level of the mechanical retention portion 140.
  • the shallowest segment 350 corresponds to that which compresses the fins 122, 124 at the level of the electrical conduction portion 150.
  • the difference in height h between these two segments can be between 0.5 and 0.6mm. In the example described here, this difference in height h is 0.55 mm.
  • the length of the segment 350 compressing the fins 122, 124 at the level of the electrical conduction portion 150 has a dimension, in the longitudinal direction, is greater than or equal to 1.4mm. In the example described here, it is 1.5mm.
  • the height difference h between the segments 348, 350 forms a step with a step edge 352 and a step bottom 354.
  • the step edge 352 can have a radius of curvature for example between 0.1mm and 0.5mm . In the case described here, it is 0.1mm.
  • the bottom 354 of the step is also rounded. It can have a radius of curvature for example between 0.1mm and 0.5mm. In the case described here, it is 0.2mm.
  • the edge 356 of the groove is also rounded with a radius of curvature for example between 0.15 and 0.4 mm .

Landscapes

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

Claims (6)

  1. Verfahren zum Crimpen eines elektrischen Kontakts (100), wobei
    - bereitgestellt werden:
    • ein elektrisches Kabel (200), das mehrere leitende Adern (210) aus Aluminium aufweist,
    • ein elektrischer Kontakt (100) aus Kupfer mit einem Crimpbereich (120), der sich in einer Längsrichtung (L) erstreckt und einen Unterteil (126) und zwei sich jeweils von einer Seite des Unterteils (126) aus erstreckende Schenkel (122, 124) umfasst, um eine Rille zu bilden, die im Schnitt in einer zur Längsrichtung (L) senkrechten Ebene im Wesentlichen eine U-Form aufweist,
    • ein Crimpwerkzeug, das einen Stempel (300) umfasst, wobei dieser Stempel eine Rille (346) aufweist, die, wenn er in dem Crimpwerkzeug positioniert ist, im Schnitt in einer zur Längsrichtung (L) des elektrischen Kontakts (100) senkrechten Ebene im Wesentlichen eine W-Form aufweist, wobei diese Rille (346) zwei in der Längsrichtung (L) aufeinanderfolgende Segmente (348, 350) aufweist, ein tieferes Segment (348) zum Zusammendrücken der Schenkel (122, 124) des elektrischen Kontakts (100) an einem Abschnitt zur mechanischen Halterung (140) und ein weniger tiefes Segment (350) zum Zusammendrücken der Schenkel (122, 124) an einem Abschnitt zur elektrischen Leitung (150), wobei der Höhenunterschied (h) zwischen diesen zwei Segmenten (348, 350) zwischen 0,4 und 0,7 mm beträgt,
    - ein Crimpen des Crimpbereichs (120) auf dem Kabel (200) durchgeführt wird, indem die Schenkel (122, 124) auf dem Kabel (200) umgebogen und zusammengedrückt werden, wobei der Crimpbereich (120) nach dem Crimpen seinerseits den Abschnitt zur mechanischen Halterung (140) und den Abschnitt zur elektrischen Leitung (150) umfasst, wobei die Abschnitte zur mechanischen Halterung (140) und zur elektrischen Leitung (150) stoffschlüssig miteinander verbunden sind und die Abschnitte zur mechanischen Halterung (140) und zur elektrischen Leitung (150) unterschiedliche endgültige Crimphöhen aufweisen, wobei die endgültige Crimphöhe des Abschnitts zur mechanischen Halterung (140) größer als die endgültige Crimphöhe des Abschnitts zur elektrischen Leitung (150) ist,
    wobei die Differenz zwischen den endgültigen Crimphöhen des Abschnitts zur mechanischen Halterung (140) und des Abschnitts zur elektrischen Leitung (150) zwischen 0,4 und 0,7 mm beträgt.
  2. Elektrischer Kontakt aus Kupfer, welcher mit dem Verfahren nach Anspruch 1 auf ein mehrere leitende Adern (210) aus Aluminium aufweisendes Kabel aufgecrimpt wird und eine Stufe zwischen dem Abschnitt zur mechanischen Halterung (140) und dem Abschnitt zur elektrischen Leitung (150) aufweist, deren Höhe zwischen 0,4 und 0,7 mm beträgt.
  3. Kontakt nach Anspruch 2, wobei die Stufe eine abgerundete innere Biegung (162) mit einem Krümmungsradius zwischen 0,1 mm und 0,5 mm aufweist.
  4. Kontakt nach Anspruch 2 oder 3, wobei die Stufe eine abgerundete äußere Biegung (164) mit einem Krümmungsradius zwischen 0,1 mm und 0,5 mm aufweist.
  5. Kontakt nach den Ansprüchen 3 und 4, wobei die Summe der Krümmungsradien der inneren (162) und äußeren Biegung (164) zwischen 0,3 mm und 0,5 mm beträgt.
  6. Kontakt nach den Ansprüchen 3 und 4, wobei der Krümmungsradius der inneren Biegung (162) gleich 0,1 mm ist und derjenige der äußeren Biegung (164) gleich 0,2 mm ist.
EP16708183.5A 2015-03-06 2016-03-07 Verfahren zum crimpen eines elektrischen kontakts auf ein kabel und werkzeug zur durchführung des verfahrens Active EP3266068B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR1551916A FR3033450B1 (fr) 2015-03-06 2015-03-06 Procede de sertissage d'un contact electrique sur un cable et outil pour la mise en oeuvre de ce procede
PCT/EP2016/054804 WO2016142345A1 (fr) 2015-03-06 2016-03-07 Procédé de sertissage d'un contact électrique sur un câble et outil pour la mise en œuvre de ce procédé

Publications (2)

Publication Number Publication Date
EP3266068A1 EP3266068A1 (de) 2018-01-10
EP3266068B1 true EP3266068B1 (de) 2020-03-04

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EP16708183.5A Active EP3266068B1 (de) 2015-03-06 2016-03-07 Verfahren zum crimpen eines elektrischen kontakts auf ein kabel und werkzeug zur durchführung des verfahrens

Country Status (6)

Country Link
US (1) US10886686B2 (de)
EP (1) EP3266068B1 (de)
KR (1) KR102521413B1 (de)
CN (1) CN107408765B (de)
FR (1) FR3033450B1 (de)
WO (1) WO2016142345A1 (de)

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JP1711775S (ja) * 2021-10-21 2022-04-05 キャリア付き端子

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AU2013314647B2 (en) * 2012-09-14 2016-12-15 Saint-Gobain Glass France Pane having an electrical connection element
JP2014199721A (ja) * 2013-03-29 2014-10-23 日本碍子株式会社 圧着端子，圧着体及び圧着体の製造方法。

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FR3033450B1 (fr) 2017-02-17
US20180241167A1 (en) 2018-08-23
FR3033450A1 (fr) 2016-09-09
KR20170132765A (ko) 2017-12-04
CN107408765B (zh) 2020-08-11
US10886686B2 (en) 2021-01-05
WO2016142345A1 (fr) 2016-09-15
CN107408765A (zh) 2017-11-28
KR102521413B1 (ko) 2023-04-14
EP3266068A1 (de) 2018-01-10

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