EP3270464A1 - Method for connecting a contact element to an electrical conductor - Google Patents

Method for connecting a contact element to an electrical conductor Download PDF

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Publication number
EP3270464A1
EP3270464A1 EP16305913.2A EP16305913A EP3270464A1 EP 3270464 A1 EP3270464 A1 EP 3270464A1 EP 16305913 A EP16305913 A EP 16305913A EP 3270464 A1 EP3270464 A1 EP 3270464A1
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EP
European Patent Office
Prior art keywords
contact element
stranded conductor
electrically conductive
tab
conductor
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Granted
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EP16305913.2A
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German (de)
French (fr)
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EP3270464B1 (en
Inventor
Helmut Steinberg
Roy Karchs
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Nexans SA
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Nexans SA
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Priority to EP16305913.2A priority Critical patent/EP3270464B1/en
Priority to ES16305913T priority patent/ES2699917T3/en
Publication of EP3270464A1 publication Critical patent/EP3270464A1/en
Application granted granted Critical
Publication of EP3270464B1 publication Critical patent/EP3270464B1/en
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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
    • H01R4/58—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
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/28—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
    • 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

Definitions

  • the invention relates to a method for electrically conductive connection of an electrically conductive material contact element to an aluminum-containing electrical stranded wire having a plurality of combined into one unit wires, with which to the stranded conductor, leaving his front side in the region of its end one piece with the contact element connected fastener is molded mechanically tight ( EP 2 747 205 A ).
  • Aluminum-containing conductors are being used more and more frequently as a replacement for copper conductors, for example in the automotive and aerospace industries.
  • the aluminum-containing conductors used therein are made of either aluminum or an aluminum alloy. In the following, for the sake of simplicity, only aluminum is mentioned.
  • a significant advantage of such electrical conductors is compared to copper lighter weight.
  • the lower electrical conductivity of the aluminum compared to copper, however, is of minor importance for most applications.
  • a disadvantage of these conductors is the fact that aluminum reacts with oxygen, forming an electrically insulating oxide layer surrounding the conductor and in particular each of the wires of a corresponding stranded conductor.
  • EP 2 001 085 B1 is a method for producing an electrically conductive connection between an aluminum-containing electrical stranded conductor and a contact portion of an electrical or electronic device described.
  • a contact element is fixed in an electrically conductive manner by crimping.
  • the contact element is then connected to the contact part of the device.
  • the oxide layers of the stranded conductor are broken, so that there is an effective electrically conductive connection between the contact element and conductor.
  • This method has proven itself in practice.
  • the corresponding connection can be unfavorable Cases are affected by major shocks, such as occur during operation of a motor vehicle.
  • EP 2 747 205 A1 shows a method in which an aluminum-containing, consisting of wires electrical stranded conductor at its end by destroying the wires thereof optionally surrounding oxide layers by ultrasonic welding is electrically connected to a contact element.
  • An integrally connected to the contact element fastener is crimped around the stranded conductor in addition to the electrical contact point between the stranded conductor and the contact element.
  • the electrically conductive connection between the contact element and the conductor and the mechanical discharge of the contact point using the one-piece contact element are separated.
  • the electrically conductive connection is made by ultrasonic welding so that any existing oxide layers are broken, so that the electrically conductive material of the conductor is connected directly to the contact element.
  • This method has proven itself in practice. The welding of the stranded conductor with the contact element is relatively expensive.
  • the invention has for its object to make the initially described method so that the contact element can be attached to the electrical conductor with reduced effort.
  • Sprung electrically conductive material is advantageously an electrically good conductive metal, such as stainless steel.
  • a corresponding contact element can be coated, at least on the side intended for contact with the stranded conductor, with a metal which is highly conductive, in particular copper.
  • the electrically conductive material may also be a plastic, such as polyamide, which is rendered electrically conductive by the addition of metallic particles and / or carbon black.
  • An existing plastic contact element may also be coated with a highly electrically conductive material, in particular copper, at least on its surface, which is intended to rest on the stranded conductor.
  • an electrical contact surface is initially generated on the end face, the total of the aluminum of the conductor, ie in particular with the aluminum of the wires thereof, is connected.
  • different methods are known which work almost exclusively with the supply of heat in order to melt the aluminum of the conductor.
  • This process step is the only one with which heat is supplied to the conductor. It serves to prepare the conductor end for the electrically effective attachment of the contact element to the same.
  • a corresponding method is for example in the DE 10 2011 089 207 A1 described. In this method, the material of the conductor is melted at its end by means of ultrasound.
  • the contact element is fixed purely mechanically fixed and immovable and electrically conductively connected to the contact surface of the conductor.
  • the approximately or substantially strip-shaped contact element consists entirely of resilient metal.
  • metal can be used with advantage stainless steel.
  • the contact element can be combined with a be coated electrically good conductive material, for example with copper.
  • the surfaces of the contact element are coated with the highly conductive material, which rest in the assembled state on the conductor or on its contact surface.
  • obliquely projecting from the same tab consists of the same resilient material as the contact element.
  • the angle at which the tab protrudes from the contact element is between 84 ° and 87 °. It is essential that the slope of the tab has in the direction of the fastening part of the contact element.
  • the same is arranged parallel to the conductor, in such a way that it lies with its end against the conductor on which the fastening part is located.
  • the tab is still relatively loose at the contact surface of the conductor.
  • the contact element is then displaced in the axial direction of the conductor, in the direction away from the front side of the conductor direction, whereby the tab is bent by the conductor against its spring force and thereby pressed with increased force to the contact surface of the conductor.
  • the fastening part of the contact element is firmly and immovably formed around the conductor. This end position of the contact element is thereby maintained in the long term and the tab is pressed permanently against the contact surface of the conductor.
  • the fastening part can be fixed, for example, and advantageously by crimping on the conductor.
  • the contact element may also have a second attachment part attached adjacent to the first attachment part.
  • the second attachment member may be wrapped around and secured to a portion of the conductor which is provided with insulation.
  • Fig. 1 schematically the end of an aluminum-containing electrical conductor 1 is shown, which has a number of combined into one unit wires 2.
  • the wires 2 are stranded together, for example.
  • the conductor 1 is surrounded by an insulation 3, which is at the end of the same removed.
  • On the front side of the conductor 1 is an electrically conductive, indicated by a cross-hatching contact surface 4 is present, which is electrically conductively connected to the aluminum of all wires 2 of the conductor 1.
  • the contact surface 4 is generated in a known technique by supplying heat, for example in an ultrasonic system.
  • Fig. 3 shows an electrical contact element 5, which is designed substantially or strip-shaped.
  • the contact element 5 is made of a resilient metal, for example made of stainless steel. It has a fastening part at one end 6, which is executed according to the drawing representation wider than the remaining part of the contact element 5 and for fixing the contact element 5 on the conductor 1 is used.
  • a tab 7 is cut out so far, for example by punching, that a transverse edge 8 is maintained.
  • the end 9 of the contact element 5 is used to connect secondary contacts or conductors.
  • the tab 7 is bent around the edge 8, so that it protrudes at an angle ⁇ from the contact element 5, which is between 80 ° and 89 °.
  • the angle ⁇ is in a preferred embodiment between 84 ° and 87 °.
  • the tab 7 is in the corresponding inclination due to their resilient material under spring tension.
  • the slope of the tab 7 points in the direction of the fastening part 6 of the contact element 5.
  • the size of the angle ⁇ also depends on the resilient material used for the contact element 5.
  • the contact element 5 can according to Fig. 4 also have a second fastening part 10 which is mounted adjacent to the fastening part 6. It can be used with advantage for additional definition of the contact element 5 on the conductor 1 in its provided with the insulation 3 area.

Abstract

Es wird ein Verfahren zum elektrisch leitenden Anschliessen eines aus elektrisch leitendem Material bestehenden Kontaktelements (5) an einen Aluminium enthaltenden elektrischen Litzenleiter (1) angegeben, der eine Vielzahl von zu einer Einheit zusammengefassten Drähten aufweist. Um den Litzenleiter (1) wird unter Freilassung seiner Stirnseite im Bereich seines Endes ein einteilig mit dem Kontaktelement (5) verbundenes Befestigungsteil (6) mechanisch fest herumgeformt. Es wird ein aus federndem, elektrisch leitfähigem Material bestehendes, etwa streifenförmiges Kontaktelement (5) verwendet, das in seinem Verlauf eine unter einem zwischen 80° und 89° liegenden Winkel schräg von demselben abstehende (9), unter Federspannung stehende (9) Lasche (7) hat. Die Schräge der Lasche (7) weist in Richtung des Befestigungsteils (6) des Kontaktelements (5). Vor der Befestigung des Kontaktelements (5) am Litzenleiter (1) wird zunächst an der Stirnseite desselben eine elektrisch leitende (9) Kontaktfläche erzeugt, die elektrisch leitend mit dem Aluminium der Drähte des Litzenleiters (1) verbunden wird. Danach wird das Kontaktelement (5) mit zur Achsrichtung des Litzenleiters (1) parallelem Verlauf mittels des Befestigungsteils (6) in einer solchen Lage fest und unverrückbar mit dem Litzenleiter (1) verbunden, dass die vom Kontaktelement (5) abstehende (9) Lasche (7) aufgrund ihrer Federspannung elektrisch leitend und mechanisch fest an die Kontaktfläche angedrückt wird.The invention relates to a method for the electrically conductive connection of a contact element (5) made of electrically conductive material to an aluminum-containing electrical stranded conductor (1) which has a large number of wires combined to form a unit. To the stranded conductor (1), releasing its end face in the region of its end a one-piece with the contact element (5) connected to the fastening part (6) formed around mechanically tight. It is an existing of resilient, electrically conductive material, approximately strip-shaped contact element (5) is used, which in its course at an angle lying between 80 ° and 89 ° angle of the same projecting (9), spring-loaded (9) tab ( 7) has. The slope of the tab (7) points in the direction of the fastening part (6) of the contact element (5). Before the attachment of the contact element (5) to the stranded conductor (1), an electrically conductive (9) contact surface is initially produced on the end face thereof, which is electrically conductively connected to the aluminum of the wires of the stranded conductor (1). Thereafter, the contact element (5) with the axial direction of the stranded conductor (1) parallel course by means of the fastening part (6) in such a position firmly and immovably connected to the stranded conductor (1), that of the contact element (5) protruding (9) tab (7) is pressed electrically conductive and mechanically fixed to the contact surface due to their spring tension.

Description

Die Erfindung bezieht sich auf ein Verfahren zum elektrisch leitenden Anschließen eines aus elektrisch leitendem Material bestehenden Kontaktelements an einen Aluminium enthaltenden elektrischen Litzenleiter, der eine Vielzahl von zu einer Einheit zusammengefaßten Drähten aufweist, mit welchem um den Litzenleiter unter Freilassung seiner Stirnseite im Bereich seines Endes ein einteilig mit dem Kontaktelement verbundenes Befestigungsteil mechanisch fest herumgeformt wird ( EP 2 747 205 A ).The invention relates to a method for electrically conductive connection of an electrically conductive material contact element to an aluminum-containing electrical stranded wire having a plurality of combined into one unit wires, with which to the stranded conductor, leaving his front side in the region of its end one piece with the contact element connected fastener is molded mechanically tight ( EP 2 747 205 A ).

Aluminium enthaltende Leiter werden als Ersatz für Kupferleiter immer öfter eingesetzt, beispielsweise in der Automobil- und Flugzeugtechnik. Die darin verwendeten, Aluminium enthaltenden Leiter bestehen entweder aus Aluminium oder aus einer Aluminiumlegierung. Im Folgenden wird der Einfachheit halber nur noch Aluminium erwähnt. Ein wesentlicher Vorteil von derartigen elektrischen Leitern ist ihr gegenüber Kupfer geringeres Gewicht. Die geringere elektrische Leitfähigkeit des Aluminiums gegenüber Kupfer ist für die meisten Anwendungen hingegen von untergeordneter Bedeutung. Ein Nachteil dieser Leiter ist die Tatsache, dass Aluminium mit Sauerstoff reagiert, wodurch eine elektrisch isolierende Oxidschicht gebildet wird, welche den Leiter und insbesondere jeden der Drähte eines entsprechenden Litzenleiters umgibt.Aluminum-containing conductors are being used more and more frequently as a replacement for copper conductors, for example in the automotive and aerospace industries. The aluminum-containing conductors used therein are made of either aluminum or an aluminum alloy. In the following, for the sake of simplicity, only aluminum is mentioned. A significant advantage of such electrical conductors is compared to copper lighter weight. The lower electrical conductivity of the aluminum compared to copper, however, is of minor importance for most applications. A disadvantage of these conductors is the fact that aluminum reacts with oxygen, forming an electrically insulating oxide layer surrounding the conductor and in particular each of the wires of a corresponding stranded conductor.

In der EP 2 001 085 B1 ist ein Verfahren zur Herstellung einer elektrisch leitenden Verbindung zwischen einem Aluminium enthaltenden elektrischen Litzenleiter und einem Kontaktteil eines elektrischen bzw. elektronischen Geräts beschrieben. An dem von seiner Isolierung befreiten Ende des Leiters wird ein Kontaktelement durch Crimpen elektrisch leitend befestigt. Das Kontaktelement wird danach mit dem Kontaktteil des Geräts verbunden. Beim Crimpen des Kontaktelements werden die Oxidschichten des Litzenleiters durchbrochen, so dass sich eine wirksame elektrisch leitende Verbindung zwischen Kontaktelement und Leiter ergibt. Dieses Verfahren hat sich in der Praxis bewährt. Die entsprechende Verbindung kann aber in ungünstigen Fällen bei größeren Erschütterungen beeinträchtigt werden, wie sie beispielsweise beim Betrieb eines Kraftfahrzeugs auftreten.In the EP 2 001 085 B1 is a method for producing an electrically conductive connection between an aluminum-containing electrical stranded conductor and a contact portion of an electrical or electronic device described. At the end of the conductor which has been freed from its insulation, a contact element is fixed in an electrically conductive manner by crimping. The contact element is then connected to the contact part of the device. When crimping the contact element, the oxide layers of the stranded conductor are broken, so that there is an effective electrically conductive connection between the contact element and conductor. This method has proven itself in practice. The corresponding connection can be unfavorable Cases are affected by major shocks, such as occur during operation of a motor vehicle.

Aus der eingangs erwähnten EP 2 747 205 A1 geht ein Verfahren hervor, bei dem ein Aluminium enthaltender, aus Drähten bestehender elektrischer Litzenleiter an seinem Ende unter Zerstörung von die Drähte desselben gegebenenfalls umgebenden Oxidschichten durch Ultraschallschweißen elektrisch leitend an ein Kontaktelement angeschlossen wird. Ein einstückig mit dem Kontaktelement verbundenes Befestigungselement wird neben der elektrischen Kontaktstelle zwischen dem Litzenleiter und dem Kontaktelement um den Litzenleiter herumgecrimpt. Bei diesem Verfahren sind die elektrisch leitende Verbindung zwischen dem Kontaktelement und dem Leiter sowie die mechanische Entlastung der Kontaktstelle unter Einsatz des einstückigen Kontaktelements voneinander getrennt. Die elektrisch leitende Verbindung wird durch Ultraschallschweißung so hergestellt, dass gegebenenfalls vorhandene Oxidschichten aufgebrochen werden, so dass das elektrisch leitende Material des Leiters direkt mit dem Kontaktelement verbunden wird. Auch dieses Verfahren hat sich in der Praxis bewährt. Die Verschweißung des Litzenleiters mit dem Kontaktelement ist aber relativ aufwendig.From the above-mentioned EP 2 747 205 A1 shows a method in which an aluminum-containing, consisting of wires electrical stranded conductor at its end by destroying the wires thereof optionally surrounding oxide layers by ultrasonic welding is electrically connected to a contact element. An integrally connected to the contact element fastener is crimped around the stranded conductor in addition to the electrical contact point between the stranded conductor and the contact element. In this method, the electrically conductive connection between the contact element and the conductor and the mechanical discharge of the contact point using the one-piece contact element are separated. The electrically conductive connection is made by ultrasonic welding so that any existing oxide layers are broken, so that the electrically conductive material of the conductor is connected directly to the contact element. This method has proven itself in practice. The welding of the stranded conductor with the contact element is relatively expensive.

Der Erfindung liegt die Aufgabe zugrunde, das eingangs geschilderte Verfahren so zu gestalten, dass das Kontaktelement mit vermindertem Aufwand am elektrischen Leiter angebracht werden kann.The invention has for its object to make the initially described method so that the contact element can be attached to the electrical conductor with reduced effort.

Diese Aufgabe wird gemäß der Erfindung dadurch gelöst,

  • dass ein aus federndem, elektrisch leitfähigem Material bestehendes, etwa streifenförmiges Kontaktelement verwendet wird, das in seinem Verlauf eine unter einem zwischen 80° und 89° liegenden Winkel schräg von demselben abstehende, unter Federspannung stehende Lasche hat, wobei die Schräge der Lasche in Richtung des Befestigungsteils des Kontaktelements weist,
  • dass vor der Befestigung des Kontaktelements am Litzenleiter zunächst an der Stirnseite desselben eine elektrisch leitende Kontaktfläche erzeugt wird, die elektrisch leitend mit dem Aluminium des Litzenleiters verbunden wird, und
  • dass danach das Kontaktelement mit zur Achsrichtung des Litzenleiters parallelem Verlauf mittels des Befestigungsteils in einer solchen Lage fest und unverrückbar mit dem Litzenleiter verbunden wird, dass die vom Kontaktelement abstehende Lasche aufgrund ihrer Federspannung elektrisch leitend und mechanisch fest an die Kontaktfläche angedrückt wird.
This object is achieved according to the invention characterized
  • in that a strip-like contact element consisting of resilient, electrically conductive material is used which, in its course, has an angle at an angle lying between 80 ° and 89 ° and is spring-loaded, the slope of the flap being in the direction of Fastening part of the contact element has,
  • that before the attachment of the contact element on the stranded conductor first on the end side of the same an electrically conductive contact surface is generated, which is electrically conductively connected to the aluminum of the stranded conductor, and
  • that thereafter the contact element with the axial direction of the stranded conductor parallel course by means of the fastening part in such a position is firmly and immovably connected to the stranded conductor, that the projecting tab of the contact element is electrically conductive and mechanically pressed firmly against the contact surface due to their spring tension.

Federndes elektrisch leitfähiges Material ist mit Vorteil ein elektrisch gut leitendes Metall, wie beispielsweise Edelstahl. Ein entsprechendes Kontaktelement kann zumindest auf der zur Anlage am Litzenleiter bestimmten Seite mit einem elektrisch gut leitenden Metall, wie insbesondere Kupfer, beschichtet sein. Das elektrisch leitfähige Material kann aber auch ein Kunststoff sein, wie beispielsweise Polyamid, der durch Zugabe von metallischen Partikeln und/oder Ruß elektrisch leitfähig gemacht ist. Ein aus Kunststoff bestehendes Kontaktelement kann auch mit einem elektrisch gut leitenden Material, wie insbesondere Kupfer, beschichtet sein, und zwar zumindest auf seiner Oberfläche, die zur Anlage am Litzenleiter bestimmt ist.Sprung electrically conductive material is advantageously an electrically good conductive metal, such as stainless steel. A corresponding contact element can be coated, at least on the side intended for contact with the stranded conductor, with a metal which is highly conductive, in particular copper. The electrically conductive material may also be a plastic, such as polyamide, which is rendered electrically conductive by the addition of metallic particles and / or carbon black. An existing plastic contact element may also be coated with a highly electrically conductive material, in particular copper, at least on its surface, which is intended to rest on the stranded conductor.

Zum Anbringen des Kontaktelements am Ende des Litzenleiters - im Folgenden nur noch als "Leiter" bezeichnet - wird an dessen Stirnseite zunächst eine elektrische Kontaktfläche erzeugt, die insgesamt mit dem Aluminium des Leiters, also insbesondere mit dem Aluminium der Drähte desselben, verbunden ist. Dafür sind unterschiedliche Verfahren bekannt, die nahezu ausschließlich mit Wärmezufuhr arbeiten, um das Aluminium des Leiters aufzuschmelzen. Dieser Verfahrensschritt ist der einzige, mit welchem dem Leiter Wärme zugeführt wird. Er dient zur Vorbereitung des Leiterendes zur elektrisch wirksamen Befestigung des Kontaktelements an demselben. Ein entsprechendes Verfahren ist beispielsweise in der DE 10 2011 089 207 A1 beschrieben. Bei diesem Verfahren wird das Material des Leiters an seinem Ende mittels Ultraschalls geschmolzen.For attaching the contact element at the end of the stranded conductor - hereinafter referred to only as "conductor" - an electrical contact surface is initially generated on the end face, the total of the aluminum of the conductor, ie in particular with the aluminum of the wires thereof, is connected. For this purpose, different methods are known which work almost exclusively with the supply of heat in order to melt the aluminum of the conductor. This process step is the only one with which heat is supplied to the conductor. It serves to prepare the conductor end for the electrically effective attachment of the contact element to the same. A corresponding method is for example in the DE 10 2011 089 207 A1 described. In this method, the material of the conductor is melted at its end by means of ultrasound.

An dem mit der Kontaktfläche versehenen Leiter wird das Kontaktelement rein mechanisch fest und unverrückbar festgelegt und elektrisch leitend mit der Kontaktfläche des Leiters verbunden. Das etwa bzw. im Wesentlichen streifenförmige Kontaktelement besteht insgesamt aus federndem Metall. Als Metall kann mit Vorteil Edelstahl eingesetzt werden. Das Kontaktelement kann insgesamt mit einem elektrisch gut leitenden Material beschichtet sein, beispielsweise mit Kupfer. In bevorzugter Ausführungsform sind insbesondere die Flächen des Kontaktelements mit dem gut leitenden Material beschichtet, die im Montagezustand am Leiter bzw. an seiner Kontaktfläche anliegen.At the conductor provided with the contact surface, the contact element is fixed purely mechanically fixed and immovable and electrically conductively connected to the contact surface of the conductor. The approximately or substantially strip-shaped contact element consists entirely of resilient metal. As metal can be used with advantage stainless steel. The contact element can be combined with a be coated electrically good conductive material, for example with copper. In a preferred embodiment, in particular the surfaces of the contact element are coated with the highly conductive material, which rest in the assembled state on the conductor or on its contact surface.

Die im Verlauf des Kontaktelements unter einem Winkel, der zwischen 80° und 89° liegt, also der kleiner als 90° ist, schräg von demselben abstehende Lasche besteht aus dem gleichen federnden Material wie das Kontaktelement. In bevorzugter Ausführungsform liegt der Winkel, unter dem die Lasche vom Kontaktelement absteht, zwischen 84° und 87°. Dabei ist wesentlich, dass die Schräge der Lasche in Richtung des Befestigungsteils des Kontaktelements weist. Beim Anlegen des Kontaktelements an den Leiter wird dasselbe in Richtung von der Stirnseite desselben fortweisend mit Druck bewegt, so dass die Lasche entgegen ihrer Federwirkung bzw. Vorspannung an die Kontaktfläche gedrückt wird. Die Lasche ist mit Vorteil durch Stanzen teilweise aus dem Kontaktelement herausgeschnitten und anschließend um eine im Kontaktelement verbleibende Kante in ihre Position abgebogen. In dieser Position steht sie - wie bereits erwähnt - unter Federspannung, so dass sie bei einer Druckbelastung und einer damit verbundenen Auslenkung aus ihrer Position ständig in diese zurück gelangen will.In the course of the contact element at an angle which is between 80 ° and 89 °, that is less than 90 °, obliquely projecting from the same tab consists of the same resilient material as the contact element. In a preferred embodiment, the angle at which the tab protrudes from the contact element is between 84 ° and 87 °. It is essential that the slope of the tab has in the direction of the fastening part of the contact element. When the contact element is applied to the conductor, the same is forcibly moved with pressure in the direction of the end face thereof, so that the tab is pressed against the contact surface against its spring action or pretension. The tab is advantageously cut out by punching partially out of the contact element and then bent around an edge remaining in the contact element in their position. In this position, it is - as already mentioned - under spring tension, so they want to come back at a pressure load and an associated deflection from its position constantly in this.

Zur Befestigung des Kontaktelements am Leiter wird dasselbe parallel zum Leiter angeordnet, und zwar derart, dass es mit seinem Ende am Leiter anliegt, an dem sich das Befestigungsteil befindet. In dieser Position liegt die Lasche noch relativ lose an der Kontaktfläche des Leiters an. Das Kontaktelement wird dann in Achsrichtung des Leiters verschoben, und zwar in der von der Stirnseite des Leiters wegweisenden Richtung, wodurch die Lasche durch den Leiter entgegen ihrer Federkraft gebogen und dadurch mit erhöhter Kraft an die Kontaktfläche des Leiters angedrückt wird. In dieser Position, die dabei stabil gehalten wird, wird das Befestigungsteil des Kontaktelements fest und unverrückbar um den Leiter herumgeformt. Diese Endposition des Kontaktelements wird dadurch auf Dauer beibehalten und die Lasche wird auf Dauer gegen die Kontaktfläche des Leiters gedrückt. Das Befestigungsteil kann beispielsweise und mit Vorteil durch Crimpen am Leiter festgelegt werden.To attach the contact element to the conductor, the same is arranged parallel to the conductor, in such a way that it lies with its end against the conductor on which the fastening part is located. In this position, the tab is still relatively loose at the contact surface of the conductor. The contact element is then displaced in the axial direction of the conductor, in the direction away from the front side of the conductor direction, whereby the tab is bent by the conductor against its spring force and thereby pressed with increased force to the contact surface of the conductor. In this position, which is kept stable, the fastening part of the contact element is firmly and immovably formed around the conductor. This end position of the contact element is thereby maintained in the long term and the tab is pressed permanently against the contact surface of the conductor. The fastening part can be fixed, for example, and advantageously by crimping on the conductor.

Das Kontaktelement kann auch ein zweites Befestigungsteil aufweisen, das neben dem ersten Befestigungsteil angebracht ist. Das zweite Befestigungsteil kann um einen Bereich des Leiters herumgelegt und dort befestigt werden, der mit einer Isolierung versehen ist.The contact element may also have a second attachment part attached adjacent to the first attachment part. The second attachment member may be wrapped around and secured to a portion of the conductor which is provided with insulation.

Das Verfahren nach der Erfindung wird anhand der Zeichnungen in Form von Ausführungsbeispielen erläutert.The method according to the invention will be explained with reference to the drawings in the form of embodiments.

Es zeigen:

  • Fig. 1 das Ende eines elektrischen Leiters.
  • Fig. 2 einen Schnitt durch Fig. 1 längs der Linie II - II in vergrößerter Darstellung.
  • Fig. 3 ein bei dem Verfahren nach der Erfindung einsetzbares Kontaktelement.
  • Fig. 4 ein gegenüber Fig. 3 ergänztes Kontaktelement in schematischer und verkleinerter Darstellung.
  • Fig. 5 eine Seitenansicht eines Abschnitts des Kontaktelements nach Fig. 3 in vergrößerter Darstellung.
  • Fig. 6 das Ende des Leiters nach Fig. 1 mit daran angelegtem Kontaktelement vor seiner Befestigung.
  • Fig. 7 das Ende des Leiters nach Fig. 6 mit daran befestigtem Kontaktelement.
Show it:
  • Fig. 1 the end of an electrical conductor.
  • Fig. 2 a cut through Fig. 1 along the line II - II in an enlarged view.
  • Fig. 3 a usable in the method according to the invention contact element.
  • Fig. 4 one opposite Fig. 3 supplemented contact element in a schematic and reduced representation.
  • Fig. 5 a side view of a portion of the contact element after Fig. 3 in an enlarged view.
  • Fig. 6 the end of the conductor after Fig. 1 with attached contact element before its attachment.
  • Fig. 7 the end of the conductor after Fig. 6 with attached contact element.

In Fig. 1 ist schematisch das Ende eines Aluminium enthaltenden elektrischen Leiters 1 dargestellt, der eine Anzahl von zu einer Einheit zusammengefaßten Drähten 2 aufweist. Die Drähte 2 sind beispielsweise miteinander verseilt. Der Leiter 1 ist von einer Isolierung 3 umgeben, die am Ende desselben entfernt ist. An der Stirnseite des Leiters 1 ist eine elektrisch leitende, durch eine Kreuzschraffur angedeutete Kontaktfläche 4 vorhanden, die mit dem Aluminium aller Drähte 2 des Leiters 1 elektrisch leitend verbunden ist. Die Kontaktfläche 4 ist in bekannter Technik durch Wärmezufuhr erzeugt, beispielweise in einer Ultraschallanlage.In Fig. 1 schematically the end of an aluminum-containing electrical conductor 1 is shown, which has a number of combined into one unit wires 2. The wires 2 are stranded together, for example. The conductor 1 is surrounded by an insulation 3, which is at the end of the same removed. On the front side of the conductor 1 is an electrically conductive, indicated by a cross-hatching contact surface 4 is present, which is electrically conductively connected to the aluminum of all wires 2 of the conductor 1. The contact surface 4 is generated in a known technique by supplying heat, for example in an ultrasonic system.

Fig. 3 zeigt ein elektrisches Kontaktelement 5, das etwa bzw. im Wesentlichen streifenförmig ausgeführt ist. Das Kontaktelement 5 besteht aus einem federnden Metall, beispielsweise aus Edelstahl. Es hat an seinem einen Ende ein Befestigungsteil 6, das entsprechend der zeichnerischen Darstellung breiter als der restliche Teil des Kontaktelements 5 ausgeführt ist und zur Festlegung des Kontaktelements 5 am Leiter 1 dient. Im Verlauf des Kontaktelements 5 ist eine Lasche 7 beispielsweise durch Stanzen so weit herausgeschnitten, dass eine quer verlaufende Kante 8 erhalten bleibt. Das Ende 9 des Kontaktelements 5 dient zum Anschluß weiterführender Kontakte oder Leiter. Fig. 3 shows an electrical contact element 5, which is designed substantially or strip-shaped. The contact element 5 is made of a resilient metal, for example made of stainless steel. It has a fastening part at one end 6, which is executed according to the drawing representation wider than the remaining part of the contact element 5 and for fixing the contact element 5 on the conductor 1 is used. In the course of the contact element 5, a tab 7 is cut out so far, for example by punching, that a transverse edge 8 is maintained. The end 9 of the contact element 5 is used to connect secondary contacts or conductors.

Zur Fertigstellung eines einsatzbereiten Kontaktelements 5 wird die Lasche 7 um die Kante 8 gebogen, so dass sie unter einem Winkel α vom Kontaktelement 5 absteht, der zwischen 80° und 89° liegt. Der Winkel α liegt in bevorzugter Ausführungsform zwischen 84° und 87°. Die Lasche 7 steht in der entsprechenden Schrägstellung aufgrund ihres federnden Materials unter Federspannung. Die Schräge der Lasche 7 weist in Richtung des Befestigungsteils 6 des Kontaktelements 5. Die Größe des Winkels α hängt auch von dem federnden Material ab, das für das Kontaktelement 5 verwendet wird.To complete a ready-to-use contact element 5, the tab 7 is bent around the edge 8, so that it protrudes at an angle α from the contact element 5, which is between 80 ° and 89 °. The angle α is in a preferred embodiment between 84 ° and 87 °. The tab 7 is in the corresponding inclination due to their resilient material under spring tension. The slope of the tab 7 points in the direction of the fastening part 6 of the contact element 5. The size of the angle α also depends on the resilient material used for the contact element 5.

Das Kontaktelement 5 kann gemäß Fig. 4 auch ein zweites Befestigungsteil 10 haben, das neben dem Befestigungsteil 6 angebracht ist. Es kann mit Vorteil zur zusätzlichen Festlegung des Kontaktelements 5 am Leiter 1 in dessen mit der Isolierung 3 versehenem Bereich eingesetzt werden.The contact element 5 can according to Fig. 4 also have a second fastening part 10 which is mounted adjacent to the fastening part 6. It can be used with advantage for additional definition of the contact element 5 on the conductor 1 in its provided with the insulation 3 area.

Zur Montage des Kontaktelements 5 am Leiter 1 wird beispielsweise wie folgt vorgegangen:

  • Das Kontaktelement 5 wird entsprechend Fig. 6 mit parallelem Verlauf zum Leiter 1 an denselben angelegt. Die Lasche 7 liegt dann an der Kontaktfläche 4 an, welche sich an der Stirnseite des Leiters 1 befindet. Der schräge Verlauf der Lasche 7 ist in Fig. 6 etwas übertrieben dargestellt, um die entsprechende Ausgangsposition des Kontaktelements 5 deutlich zu zeigen. Danach wird das Kontaktelement 5 in Achsrichtung des Leiters 1 unter weiterer Anlage an demselben mit Druck verschoben, und zwar in Richtung des Pfeiles P von der Kontaktfläche 4 fortweisend. Dadurch wird die Lasche 7 entgegen ihrer Federspannung um die Kante 8 gebogen, so dass sie mit erhöhter Kraft an die Kontaktfläche 4 angedrückt wird. In dieser Position wird das Befestigungsteil 6 um den Leiter 1 so herumgeformt, dass das Kontaktelement 5 fest und unverrückbar am Leiter 1 befestigt ist, so wie es in Fig. 7 dargestellt ist. Das kann beispielsweise durch Crimpen erfolgen. Das gegebenenfalls vorhandene zweite Befestigungsteil 10 kann in analoger Weise zusätzlich im Bereich der Isolierung 3 am Leiter 1 festgelegt werden. Die Positionen des Kontaktelements 5 am Leiter 1 und insbesondere der Lasche 7 an der Kontaktfläche 4 sind dadurch insgesamt auf Dauer sichergestellt.
For mounting the contact element 5 on the conductor 1, for example, proceed as follows:
  • The contact element 5 is corresponding Fig. 6 with parallel course to the conductor 1 is applied to the same. The tab 7 then abuts the contact surface 4, which is located on the front side of the conductor 1. The oblique course of the tab 7 is in Fig. 6 slightly exaggerated to clearly show the corresponding starting position of the contact element 5. Thereafter, the contact element 5 is displaced in the axial direction of the conductor 1 under further contact with the same with pressure, in the direction of the arrow P of the contact surface 4 hinweisend. As a result, the tab 7 is bent against its spring tension around the edge 8 so that it is pressed against the contact surface 4 with increased force. In this position the fastening part 6 is formed around the conductor 1 so that the contact element 5 is firmly and immovably fixed to the conductor 1, as it is in Fig. 7 is shown. This can be done for example by crimping. The possibly existing second fastening part 10 can be set in an analogous manner in addition to the insulation 3 on the conductor 1. The positions of the contact element 5 on the conductor 1 and in particular the tab 7 on the contact surface 4 are thus ensured in total over time.

Claims (8)

Verfahren zum elektrisch leitenden Anschließen eines aus elektrisch leitendem Material bestehenden Kontaktelements an einen Aluminium enthaltenden elektrischen Litzenleiter, der eine Vielzahl von zu einer Einheit zusammengefaßten Drähten aufweist, mit welchem um den Litzenleiter unter Freilassung seiner Stirnseite im Bereich seines Endes ein einteilig mit dem Kontaktelement verbundenes Befestigungsteil mechanisch fest herumgeformt wird, dadurch gekennzeichnet, - dass ein aus federndem, elektrisch leitfähigem Material bestehendes, etwa streifenförmiges Kontaktelement (5) verwendet wird, das in seinem Verlauf eine unter einem zwischen 80° und 89° liegenden Winkel (α) schräg von demselben abstehende, unter Federspannung stehende Lasche (7) hat, wobei die Schräge der Lasche (7) in Richtung des Befestigungsteils (6) des Kontaktelements (5) weist, - dass vor der Befestigung des Kontaktelements (5) am Litzenleiter (1) zunächst an der Stirnseite desselben eine elektrisch leitende Kontaktfläche (4) erzeugt wird, die elektrisch leitend mit dem Aluminium der Drähte (2) des Litzenleiters (1) verbunden wird, und - dass danach das Kontaktelement (5) mit zur Achsrichtung des Litzenleiters (1) parallelem Verlauf mittels des Befestigungsteils (6) in einer solchen Lage fest und unverrückbar mit dem Litzenleiter (1) verbunden wird, dass die vom Kontaktelement (5) abstehende Lasche (7) aufgrund ihrer Federspannung elektrisch leitend und mechanisch fest an die Kontaktfläche (4) angedrückt wird. A method for electrically conductive connection of a contact element made of electrically conductive material to an aluminum-containing electrical stranded conductor having a plurality of combined into one unit wires, with which around the stranded conductor, leaving its end face in the region of its end integrally connected to the contact element fastening part mechanically firmly formed around, characterized that an existing of resilient, electrically conductive material, such as strip-shaped contact element (5) is used, in its course at an angle of between 80 ° and 89 ° angle (α) obliquely projecting from the same, spring-loaded tab (7) has, wherein the slope of the tab (7) in the direction of the fastening part (6) of the contact element (5), - That before the attachment of the contact element (5) on the stranded conductor (1) first on the end side of the same an electrically conductive contact surface (4) is generated, which is electrically connected to the aluminum of the wires (2) of the stranded conductor (1), and - That thereafter the contact element (5) with the axial direction of the stranded conductor (1) parallel course by means of the fastening part (6) in such a position fixed and immovable to the stranded conductor (1) is connected, that the contact element (5) projecting tab ( 7) is pressed electrically conductive and mechanically fixed to the contact surface (4) due to their spring tension. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass die Lasche (7) unter einem Winkel (α) vom Kontaktelement (5) abgebogen wird, der zwischen 84° und 87° liegt.A method according to claim 1, characterized in that the tab (7) is bent at an angle (α) from the contact element (5), which lies between 84 ° and 87 °. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass ein aus elektrisch gut leitendem Metall bestehendes Kontaktelement (5) eingesetzt wird.Method according to Claim 1, characterized in that a contact element (5) consisting of electrically good conducting metal is used. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass ein aus Edelstahl mit federnden Eigenschaften bestehendes Kontaktelement (5) eingesetzt wird.A method according to claim 1, characterized in that a stainless steel with resilient properties existing contact element (5) is used. Verfahren nach Anspruch 4, dadurch gekennzeichnet, dass das Kontaktelement (5) zumindest auf seiner zur Anlage am Litzenleiter (1) bestimmten Oberfläche mit einem elektrisch gut leitenden Material beschichtet wird, insbesondere mit Kupfer.A method according to claim 4, characterized in that the contact element (5) is coated at least on its intended to rest on the stranded conductor (1) surface with a highly electrically conductive material, in particular copper. Verfahren nach Anspruch 1, dadurch gekennzeichnet, - dass das Kontaktelement (5) an den Litzenleiter (1) in einer Position angelegt wird, in welcher die Lasche (7) an der Kontaktfläche (4) anliegt, - dass das Kontaktelement (5) danach in Achsrichtung des Litzenleiters (1) derart gedrückt wird, dass die Lasche (7) durch die Kontaktfläche (4) entgegen ihrer Federspannung verformt wird, und - dass abschließend das Befestigungsteil (6) des Kontaktelements (5) unter stabiler Beibehaltung desselben um den Litzenleiter (1) herumgecrimpt wird. Method according to claim 1, characterized in that - That the contact element (5) is applied to the stranded conductor (1) in a position in which the tab (7) against the contact surface (4), - That the contact element (5) is then pressed in the axial direction of the stranded conductor (1) such that the tab (7) is deformed by the contact surface (4) against its spring tension, and - That finally the fastening part (6) of the contact element (5) is crimped around the stranded conductor (1) with stable retention thereof. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass ein aus elektrisch leitfähig gemachtem Kunststoff bestehendes Kontaktelement (5) eingesetzt wird.A method according to claim 1, characterized in that a made of electrically conductive plastic made existing contact element (5) is used. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass ein aus Kunststoff bestehendes Kontaktelement (5) eingesetzt wird, das zumindest auf seiner zur Anlage am Litzenleiter bestimmten Oberfläche mit einem elektrisch gut leitenden Material beschichtet wird, insbesondere mit Kupfer.A method according to claim 1, characterized in that an existing plastic contact element (5) is used, which is coated at least on its intended to rest on the stranded conductor surface with a highly electrically conductive material, in particular copper.
EP16305913.2A 2016-07-13 2016-07-13 Method for connecting a contact element to an electrical conductor Active EP3270464B1 (en)

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EP16305913.2A EP3270464B1 (en) 2016-07-13 2016-07-13 Method for connecting a contact element to an electrical conductor
ES16305913T ES2699917T3 (en) 2016-07-13 2016-07-13 Procedure for connecting a contact element in an electrical conductor

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CN110556635A (en) * 2018-06-04 2019-12-10 矢崎总业株式会社 Terminal-equipped electric wire and method for manufacturing terminal-equipped electric wire

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DE102011089207A1 (en) 2011-12-20 2013-06-20 Lisa Dräxlmaier GmbH Method for contacting strand spacer with contact e.g. plug, in motor car, involves compacting and welding individual wires, positioning contacting section on contact portion of contact, and welding contacting section with contact portion
WO2013151185A1 (en) * 2012-04-04 2013-10-10 Yazaki Corporation Terminal-attached electric wire
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EP2747205A1 (en) 2012-12-18 2014-06-25 Nexans Method for the electrically conductive connection of a stranded conductor with a contact element

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US4650723A (en) * 1985-06-26 1987-03-17 Daiichi Denshi Kogyo Kabushiki Kaisha Material for electric contacts
EP2001085B1 (en) 2007-06-06 2010-05-19 Nexans Method for manufacturing an electrically conducting connection
JP2009231079A (en) * 2008-03-24 2009-10-08 Yazaki Corp Method of crimping terminal on electric wire
DE102011089207A1 (en) 2011-12-20 2013-06-20 Lisa Dräxlmaier GmbH Method for contacting strand spacer with contact e.g. plug, in motor car, involves compacting and welding individual wires, positioning contacting section on contact portion of contact, and welding contacting section with contact portion
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CN110556635A (en) * 2018-06-04 2019-12-10 矢崎总业株式会社 Terminal-equipped electric wire and method for manufacturing terminal-equipped electric wire
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ES2699917T3 (en) 2019-02-13

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