EP3324493A1 - A method for producing a contact element at the end of an electrical conductor - Google Patents

A method for producing a contact element at the end of an electrical conductor Download PDF

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Publication number
EP3324493A1
EP3324493A1 EP16306498.3A EP16306498A EP3324493A1 EP 3324493 A1 EP3324493 A1 EP 3324493A1 EP 16306498 A EP16306498 A EP 16306498A EP 3324493 A1 EP3324493 A1 EP 3324493A1
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EP
European Patent Office
Prior art keywords
conductor
contact element
electrically conductive
particles
conductive material
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP16306498.3A
Other languages
German (de)
French (fr)
Other versions
EP3324493B1 (en
Inventor
Helmut Steinberg
Rudolf Derntl
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.)
HERMLE MASCHINENBAU GmbH
Nexans SA
Original Assignee
HERMLE MASCHINENBAU GmbH
Nexans SA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by HERMLE MASCHINENBAU GmbH, Nexans SA filed Critical HERMLE MASCHINENBAU GmbH
Priority to EP16306498.3A priority Critical patent/EP3324493B1/en
Priority to PT163064983T priority patent/PT3324493T/en
Priority to US15/813,805 priority patent/US10944228B2/en
Priority to CN201711145972.XA priority patent/CN108075340B/en
Publication of EP3324493A1 publication Critical patent/EP3324493A1/en
Application granted granted Critical
Publication of EP3324493B1 publication Critical patent/EP3324493B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric 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
    • H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/08—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/02—Coating starting from inorganic powder by application of pressure only
    • C23C24/04—Impact or kinetic deposition of particles
    • 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
    • H01R13/025—Contact members formed by the conductors of a cable end
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive 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
    • 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

Definitions

  • the invention relates to a method for attaching a contact element at the end of an electrical conductor, with which at the end of the conductor existing, firmly connected to the conductor electrically conductive material is deformed into a contact element with a variable shape ( DE 2 325 294 A ).
  • the lump is then mechanically deformed into a contact element, which can be designed differently in any way.
  • the material of the conductor itself is used for the formation of a contact element.
  • the method is thereby limited to the material of the conductor.
  • the invention has the object of developing the initially described method so that it can be used for any materials of conductor and contact element.
  • This structure referred to below as a "composite body" is thereby electrically conductively connected to the material of the conductor, so that the entire conductive cross section of the conductor is detected.
  • This is essential, for example, if the conductor is a stranded conductor consisting of several wires, for example made of aluminum or an aluminum alloy.
  • particles continue to impinge on the composite body, gradually depositing a metal body leading away from the conductor on the composite body. The process is terminated when the metal body has sufficient material to form an electrical contact element.
  • the conductor is advantageously arranged vertically for carrying out the method so that its front side is accessible from above.
  • the particles then hit the surface of the conductor with surface normal with advantage. In this case, small angular deviations from the surface normal may be permissible. Particles that do not hit the face of the conductor but are moved past the conductor in its axial direction do not adhere to the surface of the conductor.
  • a tube acting as a nozzle is advantageously used, as already mentioned.
  • a tube may have a constriction in its course, through which the gas stream loaded with the particles receives the required high speed.
  • a basically known "Laval nozzle" is used as the tube.
  • the method can be used for all metallic materials that are suitable as electrical conductors on the one hand and as electrical contact elements on the other hand. It is particularly advantageous that different metals can be used for the conductor and the contact element to be generated, which are metallurgically firmly connected to form a unit. Influences of corrosion on a contact point can be excluded when using this method. The electrical contact resistance between conductor and contact element is negligible, even if different metals are used for both parts.
  • the conductor can be made of aluminum, for example, and the contact element of copper or vice versa. This also applies to alloys of these two materials. For example, brass can also be used with Advantage especially for the contact element. But it is also possible to use the same material for the conductor and the contact element.
  • Fig. 1 the end of an insulated electrical conductor L is shown, which is designed in the illustrated embodiment as consisting of a plurality of individual wires 1 stranded conductor.
  • the conductor can also be a solid conductor.
  • the conductor L is freed from an insulation 2 surrounding it.
  • particles of electrically conductive material are applied in its axial direction according to the arrow 3 at high speed, which is advantageously higher than the speed of sound. The corresponding procedure is based on Fig. 3 explained in more detail below.
  • a compact structure is first produced at the end of the conductor L, which in Fig. 2 indicated and shown as a hatched drawn composite body 4, which consists of the material of the conductor L on the one hand and from the metal applied with the particles on the other hand, which is metallurgically firmly connected in the composite body 4 with the material of the conductor L.
  • the metal body 5 is in Fig. 2 drawn with respect to the composite body 4 of other hatching.
  • the method according to the invention is carried out, for example, as follows: For supplying, for example and advantageously made of copper particles - hereinafter also referred to as "particles" - to an existing example of aluminum conductor L serving as a nozzle tube 6 is used in the axial direction of the arranged conductor L vertically over the same is arranged.
  • a gas source 7 advantageously an inert gas
  • gas stream 6 particles are given before entering the tube, which are contained in a supply 8 of particles.
  • the gas stream can be passed through the particles.
  • the particles are however arranged in any case so that they are taken away and transported by the gas stream.
  • the conductor L is advantageously arranged in a tool 9 so that only its tip protrudes from the same.
  • the tool 9 on the one hand the wires 1 of the conductor L, when the same is designed as a stranded conductor, held together and the insulation 2 of the conductor L is on the other hand protected against the particles.
  • the tool 9 can advantageously be made in several parts.
  • the laden with the particles gas stream 10 emerges from the same at the free end of the tube 6 at high speed, which is advantageously higher than the speed of sound. He encounters the front of the conductor L.
  • the gas stream 10 thus has the function of a carrier for the particles, which thereby impinge on the front side of the conductor L at the same speed as the gas.
  • the composite body 4 is generated with a comprehensive metal body 5.
  • the tube 6 is corresponding Fig. 3 positioned at a distance from the end face of the conductor L. This distance is changeable. It depends on the material of the particles and is for example between 20 mm and 150 mm.
  • the total of a circular cross-section having tube 6 may in its course according to the purely schematic representation in Fig. 4 have a constriction 11 of its clear cross section, whereby the required velocity of the gas flow and thus the required speed of the particles can be achieved according to the function of the mentioned Laval nozzle.
  • the conductor L is metallurgically fixed at its end to the metal body 5 in the transition area with the compact structure referred to above as "composite body 4".
  • the metal body 5, which also comprises the composite body 4 can then be mechanically converted to a contact element K of any shape for different applications.
  • a contact element K of any shape for different applications.
  • six examples of possible contact elements K are shown schematically.
  • the contact element K after Fig. 5a For example, it can be used as a connection to the pole of a battery as a so-called battery terminal.
  • Fig. 5d For example, a designed as a pin contact element K is reproduced.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Composite Materials (AREA)
  • Conductive Materials (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

Es wird ein Verfahren zum Anbringen eines Kontaktelements (K) am Ende eines elektrischen Leiters (L) angegeben, mitwelchem am Ende des Leiters (L) vorhandenes, mitdem Leiterfest verbundenes elektrisch leitendes Material zu einem Kontaktelement (K) mit variabler Form verformt wird. Zunächst wird das Ende des blanken Leiters (L) in eine zumindest an nähernd vertikale Position gebracht. Danach werden auf das nach oben ragende, stirnseitige Ende des Leiters (L) in axialer Richtung desselben Partikel (8) eines elektrisch leitenden Materials mit einer so hohen Geschwindigkeit aufgebracht, dass sich das Material des Leiters mit dem elektrisch leitenden Material zu einem kompakten Gebilde (4) verbindet, das mechanisch fest und elektrisch leitend mit dem Material des Leiters (L) verbunden ist. Anschließend werden zur Bildung eines Metallkörpers (5) ohne Unterbrechung des Verfahrens weitere Partikel (8) des elektrisch leitenden Materials auf das kompakte Gebilde (4) aufgebracht und der Metallkörper (5) wird abschließend mechanisch zu dem Kontaktelement (K) umgeformt.The invention relates to a method for attaching a contact element (K) to the end of an electrical conductor (L), with which the electrically conductive material present at the end of the conductor (L) and being connected to the conductor is deformed into a contact element (K) of variable shape. First, the end of the bare conductor (L) is brought into an at least approximately vertical position. Thereafter, on the upwardly projecting, end-side end of the conductor (L) in the axial direction of the same particles (8) of an electrically conductive material applied at such a high speed that the material of the conductor with the electrically conductive material to a compact structure ( 4), which is mechanically fixed and electrically conductive with the material of the conductor (L) is connected. Subsequently, to form a metal body (5) without interrupting the process, further particles (8) of the electrically conductive material are applied to the compact structure (4) and the metal body (5) is finally mechanically converted to the contact element (K).

Description

Die Erfindung bezieht sich auf ein Verfahren zum Anbringen eines Kontaktelements am Ende eines elektrischen Leiters, mit welchem am Ende des Leiters vorhandenes, mit dem Leiter fest verbundenes elektrisch leitendes Material zu einem Kontaktelement mit variabler Form verformt wird ( DE 2 325 294 A ).The invention relates to a method for attaching a contact element at the end of an electrical conductor, with which at the end of the conductor existing, firmly connected to the conductor electrically conductive material is deformed into a contact element with a variable shape ( DE 2 325 294 A ).

Verfahren zum Anbringen von Kontaktelementen an den Enden von elektrischen Leitern bzw. Leitungen sind seit langer Zeit bekannt. Zur Herstellung einer wirksamen elektrischen Verbindung zwischen einem Kontaktelement und einem Leiter wird zunächst der Leiter von denselben umgebenden isolierenden Schichten befreit. Danach kann ein Kontaktelement in bekannter Technik beispielsweise mittels Schrauben bzw. Klemmen oder durch Schweißen bzw. Löten oder durch Crimpen mit dem Leiter verbunden werden. In der Verbindungsstelle ist ein möglichst niedriger elektrischer Übertragungswiderstand zwischen dem Kontaktelement und dem Leiter von Bedeutung. Außerdem soll ein fester Sitz des Kontaktelements auf dem Leiter auf Dauer sichergestellt sein.Methods of attaching contact elements to the ends of electrical conductors have been known for a long time. To produce an effective electrical connection between a contact element and a conductor, the conductor is first freed from the same surrounding insulating layers. Thereafter, a contact element in a known technique, for example by means of screws or clamps or by welding or soldering or by crimping be connected to the conductor. In the connection point, the lowest possible electrical transmission resistance between the contact element and the conductor is important. In addition, a tight fit of the contact element on the conductor to be ensured in the long term.

Aus der eingangs erwähnten DE 2 325 294 A geht ein Verfahren zur Erzeugung eines Kontaktelements am Ende eines elektrischen Leiters hervor, das ohne mechanische Befestigungselemente auskommt. Mit diesem Verfahren wird das Ende eines elektrischen Leiters derart erwärmt, dass das Material desselben schmilzt. Dabei wird mit entsprechender Anordnung des Leiters verhindert, dass das geschmolzene Metall des Leiters von demselben abtropft. Es wird dadurch eine birnenförmige, als "Klümpchen" bezeichnete Masse gebildet, die fester Bestandteil des Leiters ist.From the above-mentioned DE 2 325 294 A goes out a method for producing a contact element at the end of an electrical conductor, which manages without mechanical fasteners. With this method, the end of an electrical conductor is heated so that the material of the same melts. It is prevented with appropriate arrangement of the conductor that the molten metal of the conductor drips from the same. It is thereby formed a pear-shaped, referred to as "lumps" mass, which is an integral part of the conductor.

Das Klümpchen wird anschließend mechanisch zu einem Kontaktelement verformt, das in beliebiger Art und Weise unterschiedlich ausgeführt sein kann. Bei diesem bekannten Verfahren wird also das Material des Leiters selbst für die Bildung eines Kontaktelements verwendet. Das Verfahren ist dadurch auf das Material des Leiters beschränkt.The lump is then mechanically deformed into a contact element, which can be designed differently in any way. In this known method, therefore, the material of the conductor itself is used for the formation of a contact element. The method is thereby limited to the material of the conductor.

Der Erfindung liegt die Aufgabe zugrunde, das eingangs geschilderte Verfahren so weiterzubilden, dass es für beliebige Materialien von Leiter und Kontaktelement einsetzbar ist.The invention has the object of developing the initially described method so that it can be used for any materials of conductor and contact element.

Diese Aufgabe wird gemäß der Erfindung dadurch gelöst,

  • dass zunächst das Ende des blanken Leiters in eine zumindest annähernd vertikale Position gebracht wird,
  • dass danach auf das nach oben ragende, stirnseitige Ende des Leiters in axialer Richtung desselben Partikel eines elektrisch leitenden Materials mit einer so hohen Geschwindigkeit aufgebracht werden, dass sich das Material des Leiters mit dem elektrisch leitenden Material zu einem kompakten Gebilde verbindet, das mechanisch fest und elektrisch leitend mit dem Material des Leiters verbunden ist,
  • dass anschließend zur Bildung eines Metallkörpers ohne Unterbrechung des Verfahrens weitere Partikel des elektrisch leitenden Materials auf das kompakte Gebilde aufgebracht werden und
  • dass der Metallkörper abschließend mechanisch zu dem Kontaktelement umgeformt wird.
This object is achieved according to the invention characterized
  • that first the end of the bare conductor is brought into an at least approximately vertical position,
  • that thereafter be applied to the upwardly projecting, end-side end of the conductor in the axial direction of the same particles of an electrically conductive material at such a high speed that connects the material of the conductor with the electrically conductive material into a compact structure, the mechanically fixed and electrically conductively connected to the material of the conductor,
  • that subsequently to the formation of a metal body without interrupting the process, further particles of the electrically conductive material are applied to the compact structure and
  • that the metal body is finally mechanically converted to the contact element.

Dieses Verfahren, das in der Fachwelt auch als "Kaltgasspritzen" bezeichnet wird, arbeitet rein mechanisch, ohne Zuführung von Wärme an den Leiter. Die Partikel des elektrisch leitenden Materials - im Folgenden nur noch kurz "Partikel" genannt - werden der Stirnseite des Leiters mit Vorteil über ein als Düse wirkendes Rohr zugeführt, und zwar mittels eines als Träger dienenden Gasstroms, der zusammen mit den darin enthaltenen Partikeln mit hoher Geschwindigkeit auf die Stirnseite des Leiters auftrifft. Als Gas wird vorzugsweise ein inertes Gas eingesetzt. Die beispielsweise aus Kupfer bestehenden Partikel dringen wegen der hohen Geschwindigkeit, die mit Vorteil über der Schallgeschwindigkeit liegen kann, in das Material des Leiters ein und verbinden sich mit demselben metallurgisch zu einem kompakten Gebilde, in dem das Material des Leiters und das Material der Partikel enthalten ist. Dieses im Folgenden als "Verbundkörper" bezeichnete Gebilde ist dadurch elektrisch leitend mit dem Material des Leiters verbunden, so dass der gesamte leitende Querschnitt des Leiters erfaßt ist. Das ist beispielsweise dann von wesentlicher Bedeutung, wenn es sich bei dem Leiter um einen aus mehreren Drähten bestehenden Litzenleiter handelt, die beispielsweise aus Aluminium oder einer Aluminiumlegierung bestehen. Da das Verfahren ohne Unterbrechung weitergeführt wird, treffen auf den Verbundkörper weiter Partikel auf, wodurch auf dem Verbundkörper nach und nach ein vom Leiter wegweisender Metallkörper aufgetragen wird. Das Verfahren wird dann beendet, wenn der Metallkörper genügend Material zur Formung eines elektrischen Kontaktelements aufweist.This process, which is also referred to in the art as "cold gas spraying", works purely mechanically, without supplying heat to the conductor. The particles of the electrically conductive material - hereinafter referred to as "particles" for short - are fed to the end face of the conductor with advantage via a tube acting as a nozzle, by means of a gas stream serving as a carrier, which together with the particles contained therein with high Velocity impinges on the face of the conductor. The gas used is preferably an inert gas. The existing example of copper particles penetrate because of the high speed, which can be advantageous over the speed of sound, in the material of the conductor and connect to the same metallurgically to a compact structure in which the material of the conductor and the material of the particles is. This structure, referred to below as a "composite body", is thereby electrically conductively connected to the material of the conductor, so that the entire conductive cross section of the conductor is detected. This is essential, for example, if the conductor is a stranded conductor consisting of several wires, for example made of aluminum or an aluminum alloy. As the process continues uninterrupted, particles continue to impinge on the composite body, gradually depositing a metal body leading away from the conductor on the composite body. The process is terminated when the metal body has sufficient material to form an electrical contact element.

Der Leiter wird zur Durchführung des Verfahrens mit Vorteil vertikal angeordnet, so dass seine Stirnseite von oben zugänglich ist. Die Partikel treffen dann mit Vorteil flächennormal auf die Stirnseite des Leiters auf. Dabei können geringe Winkelabweichungen von der Flächennormalen zulässig sein. Partikel, die nicht auf die Stirnseite des Leiters auftreffen, sondern in dessen Achsrichtung am Leiter vorbei bewegt werden, haften nicht an der Oberfläche des Leiters.The conductor is advantageously arranged vertically for carrying out the method so that its front side is accessible from above. The particles then hit the surface of the conductor with surface normal with advantage. In this case, small angular deviations from the surface normal may be permissible. Particles that do not hit the face of the conductor but are moved past the conductor in its axial direction do not adhere to the surface of the conductor.

Zum Zuführen der Partikel, die auch Pulverpartikel sein können, wird - wie bereits erwähnt - mit Vorteil ein als Düse wirkendes Rohr verwendet. Ein solches Rohr kann in seinem Verlauf eine Verengung haben, durch welche der mit den Partikeln beladene Gasstrom die erforderliche hohe Geschwindigkeit erhält. In bevorzugter Ausführungsform wird als Rohr eine grundsätzlich bekannte "Lavaldüse" eingesetzt.For supplying the particles, which may also be powder particles, a tube acting as a nozzle is advantageously used, as already mentioned. Such a tube may have a constriction in its course, through which the gas stream loaded with the particles receives the required high speed. In a preferred embodiment, a basically known "Laval nozzle" is used as the tube.

Das Verfahren kann für alle metallischen Materialien eingesetzt werden, die als elektrische Leiter einerseits und als elektrische Kontaktelemente andererseits geeignet sind. Von besonderem Vorteil ist dabei, dass für den Leiter und das zu erzeugende Kontaktelement auch unterschiedliche Metalle eingesetzt werden können, die metallurgisch fest zu einer Einheit verbunden werden. Einflüsse von Korrosion auf eine Kontaktstelle können bei Einsatz dieses Verfahrens ausgeschlossen werden. Der elektrische Übergangswiderstand zwischen Leiter und Kontaktelement ist vernachlässigbar, auch wenn unterschiedliche Metalle für beide Teile eingesetzt werden.The method can be used for all metallic materials that are suitable as electrical conductors on the one hand and as electrical contact elements on the other hand. It is particularly advantageous that different metals can be used for the conductor and the contact element to be generated, which are metallurgically firmly connected to form a unit. Influences of corrosion on a contact point can be excluded when using this method. The electrical contact resistance between conductor and contact element is negligible, even if different metals are used for both parts.

Im geschilderten Sinne können der Leiter beispielsweise aus Aluminium und das Kontaktelement aus Kupfer bestehen oder umgekehrt. Das gilt auch für Legierungen dieser beiden Materialien. Auch Messing kann beispielsweise verwendet werden, mit Vorteil besonders für das Kontaktelement. Es ist aber auch möglich, für den Leiter und das Kontaktelement jeweils das gleiche Material einzusetzen.In the sense described, the conductor can be made of aluminum, for example, and the contact element of copper or vice versa. This also applies to alloys of these two materials. For example, brass can also be used with Advantage especially for the contact element. But it is also possible to use the same material for the conductor and the contact element.

Das Verfahren nach der Erfindung wird anhand der Zeichnungen als Ausführungsbeispiel erläutert.The method according to the invention will be explained with reference to the drawings as an exemplary embodiment.

Es zeigen:

  • Fig. 1 das Ende eines abisolierten elektrischen Leiters.
  • Fig. 2 das Ende des Leiters nach Fig. 1 nach einer Bearbeitung mit dem Verfahren nach der Erfindung.
  • Fig. 3 in schematischer Darstellung eine Anordnung zur Durchführung des Verfahrens nach der Erfindung.
  • Fig. 4 ein bei dem Verfahren nach der Erfindung einsetzbares Rohr.
  • Fig. 5 unterschiedliche, mit dem Verfahren nach der Erfindung herstellbare Kontaktelemente.
Show it:
  • Fig. 1 the end of a stripped electrical conductor.
  • Fig. 2 the end of the conductor after Fig. 1 after processing with the method according to the invention.
  • Fig. 3 a schematic representation of an arrangement for carrying out the method according to the invention.
  • Fig. 4 a usable in the method according to the invention tube.
  • Fig. 5 different, with the method according to the invention producible contact elements.

In Fig. 1 ist das Ende eines isolierten elektrischen Leiters L dargestellt, der im dargestellten Ausführungsbeispiel als aus einer Vielzahl von Einzeldrähten 1 bestehender Litzenleiter ausgeführt ist. Der Leiter kann aber auch ein Massivleiter sein. An seinem Ende ist der Leiter L von einer denselben umgebenden Isolierung 2 befreit. Auf die Stirnseite des Leiters L werden in seiner Achsrichtung entsprechend dem Pfeil 3 Partikel aus elektrisch leitendem Material mit hoher Geschwindigkeit aufgebracht, die mit Vorteil höher als die Schallgeschwindigkeit ist. Das entsprechende Verfahren wird anhand von Fig. 3 weiter unten genauer erläutert.In Fig. 1 the end of an insulated electrical conductor L is shown, which is designed in the illustrated embodiment as consisting of a plurality of individual wires 1 stranded conductor. The conductor can also be a solid conductor. At its end, the conductor L is freed from an insulation 2 surrounding it. On the front side of the conductor L particles of electrically conductive material are applied in its axial direction according to the arrow 3 at high speed, which is advantageously higher than the speed of sound. The corresponding procedure is based on Fig. 3 explained in more detail below.

Mit dem Verfahren nach der Erfindung wird am Ende des Leiters L zunächst ein kompaktes Gebilde erzeugt, das in Fig. 2 angedeutet und als schraffiert eingezeichneter Verbundkörper 4 dargestellt ist, der aus dem Material des Leiters L einerseits und aus dem mit den Partikeln aufgebrachten Metall andererseits besteht, das in dem Verbundkörper 4 metallurgisch fest mit dem Material des Leiters L verbunden ist.With the method according to the invention, a compact structure is first produced at the end of the conductor L, which in Fig. 2 indicated and shown as a hatched drawn composite body 4, which consists of the material of the conductor L on the one hand and from the metal applied with the particles on the other hand, which is metallurgically firmly connected in the composite body 4 with the material of the conductor L.

Auf dem Verbundkörper 4 wird durch die weiter auf denselben auftreffenden Partikel aus dem elektrisch leitenden Material zusätzlich ein nur aus dem Material der Partikel bestehender Metallkörper 5 erzeugt. Er ist metallurgisch fest mit dem Verbundkörper 4 verbunden. Der Metallkörper 5 ist in Fig. 2 mit gegenüber dem Verbundkörper 4 anderer Schraffur eingezeichnet.On the composite body 4 is additionally generated by the further incident on the same particles of the electrically conductive material consisting only of the material of the particles metal body 5. It is metallurgically firmly connected to the composite body 4. The metal body 5 is in Fig. 2 drawn with respect to the composite body 4 of other hatching.

Das Verfahren nach der Erfindung wird beispielsweise wie folgt durchgeführt:
Zum Zuführen von beispielsweise und mit Vorteil aus Kupfer bestehenden Partikeln - im Folgenden weiter kurz als "Partikel" bezeichnet - zu einem beispielsweise aus Aluminium bestehenden Leiter L wird ein als Düse wirkendes Rohr 6 verwendet, das in Achsrichtung des mit vertikalem Verlauf angeordneten Leiters L über demselben angeordnet wird. In das Rohr 6 wird an seinem einen Ende aus einer Gasquelle 7 kommendes Gas, mit Vorteil ein inertes Gas, als Gasstrom eingeblasen. Dem Gasstrom werden vor dem Eintritt in das Rohr 6 Partikel aufgegeben, die in einem Vorrat 8 von Partikeln enthalten sind. Der Gasstrom kann durch die Partikel hindurchgeleitet werden. Die Partikel werden aber auf jeden Fall so angeordnet, dass sie vom Gasstrom mitgenommen und transportiert werden.The method according to the invention is carried out, for example, as follows:
For supplying, for example and advantageously made of copper particles - hereinafter also referred to as "particles" - to an existing example of aluminum conductor L serving as a nozzle tube 6 is used in the axial direction of the arranged conductor L vertically over the same is arranged. Into the tube 6, at its one end, gas coming from a gas source 7, advantageously an inert gas, is blown in as a gas stream. The gas stream 6 particles are given before entering the tube, which are contained in a supply 8 of particles. The gas stream can be passed through the particles. The particles are however arranged in any case so that they are taken away and transported by the gas stream.

Der Leiter L ist mit Vorteil in einem Werkzeug 9 so angeordnet, dass nur seine Spitze aus demselben herausragt. Durch das Werkzeug 9 sind einerseits die Drähte 1 des Leiters L, wenn derselbe als Litzenleiter ausgeführt ist, zusammengehalten und die Isolierung 2 des Leiters L ist andererseits gegenüber den Partikeln geschützt. Das Werkzeug 9 kann mit Vorteil mehrteilig ausgeführt sein. Der mit den Partikeln beladene Gasstrom 10 tritt am freien Ende des Rohres 6 mit hoher Geschwindigkeit, die mit Vorteil höher als die Schallgeschwindigkeit ist, aus demselben aus. Er trifft auf die Stirnseite des Leiters L auf. Der Gasstrom 10 hat damit die Funktion eines Trägers für die Partikel, die dadurch mit der gleichen Geschwindigkeit wie das Gas auf die Stirnseite des Leiters L auftreffen. Durch die Partikel wird der bereits beschriebene, den Verbundkörper 4 mit umfassende Metallkörper 5 erzeugt.The conductor L is advantageously arranged in a tool 9 so that only its tip protrudes from the same. By the tool 9, on the one hand the wires 1 of the conductor L, when the same is designed as a stranded conductor, held together and the insulation 2 of the conductor L is on the other hand protected against the particles. The tool 9 can advantageously be made in several parts. The laden with the particles gas stream 10 emerges from the same at the free end of the tube 6 at high speed, which is advantageously higher than the speed of sound. He encounters the front of the conductor L. The gas stream 10 thus has the function of a carrier for the particles, which thereby impinge on the front side of the conductor L at the same speed as the gas. By the particles of the already described, the composite body 4 is generated with a comprehensive metal body 5.

Das Rohr 6 wird entsprechend Fig. 3 mit Abstand zur Stirnseite des Leiters L positioniert. Dieser Abstand ist veränderbar. Er hängt vom Material der Partikel ab und liegt beispielsweise zwischen 20 mm und 150 mm.The tube 6 is corresponding Fig. 3 positioned at a distance from the end face of the conductor L. This distance is changeable. It depends on the material of the particles and is for example between 20 mm and 150 mm.

Das insgesamt einen kreisrunden Querschnitt aufweisende Rohr 6 kann in seinem Verlauf entsprechend der rein schematischen Darstellung in Fig. 4 eine Einengung 11 seines lichten Querschnitts haben, wodurch entsprechend der Funktion der erwähnten Lavaldüse die benötigte Geschwindigkeit des Gasstroms und damit die benötigte Geschwindigkeit der Partikel erreicht werden kann.The total of a circular cross-section having tube 6 may in its course according to the purely schematic representation in Fig. 4 have a constriction 11 of its clear cross section, whereby the required velocity of the gas flow and thus the required speed of the particles can be achieved according to the function of the mentioned Laval nozzle.

Nach Beendigung des Verfahrens ist der Leiter L an seinem Ende metallurgisch fest mit dem Metallkörper 5 verbunden, und zwar in dem Übergangsbereich mit dem kompakten Gebilde, das im Vorangehenden als "Verbundkörper 4" bezeichnet ist. Der auch den Verbundkörper 4 umfassende Metallkörper 5 kann danach mechanisch zu einem Kontaktelement K mit beliebiger Form für unterschiedliche Anwendungen umgeformt werden. In den Fig. 5a bis 5d sind sechs Beispiele für mögliche Kontaktelemente K schematisch dargestellt. Das Kontaktelement K nach Fig. 5a kann beispielsweise als Anschluß an den Pol einer Batterie als sogenannte Batterieklemme eingesetzt werden. In Fig. 5d ist beispielsweise ein als Steckerstift ausgeführtes Kontaktelement K wiedergegeben.Upon completion of the process, the conductor L is metallurgically fixed at its end to the metal body 5 in the transition area with the compact structure referred to above as "composite body 4". The metal body 5, which also comprises the composite body 4, can then be mechanically converted to a contact element K of any shape for different applications. In the Fig. 5a to 5d six examples of possible contact elements K are shown schematically. The contact element K after Fig. 5a For example, it can be used as a connection to the pole of a battery as a so-called battery terminal. In Fig. 5d For example, a designed as a pin contact element K is reproduced.

Claims (4)

Verfahren zum Anbringen eines Kontaktelements am Ende eines elektrischen Leiters, mit welchem am Ende des Leiters vorhandenes, mit dem Leiter fest verbundenes elektrisch leitendes Material zu einem Kontaktelement mit variabler Form verformt wird, dadurch gekennzeichnet, - dass zunächst das Ende des blanken Leiters (L) in eine zumindest annähernd vertikale Position gebracht wird, - dass danach auf das nach oben ragende, stirnseitige Ende des Leiters (L) in axialer Richtung desselben Partikel eines elektrisch leitenden Materials mit einer so hohen Geschwindigkeit aufgebracht werden, dass sich das Material des Leiters (L) mit dem elektrisch leitenden Material zu einem kompakten Gebilde (4) verbindet, das mechanisch fest und elektrisch leitend mit dem Material des Leiters (L) verbunden ist, - dass anschließend zur Bildung eines Metallkörpers (5) ohne Unterbrechung des Verfahrens weitere Partikel des elektrisch leitenden Materials auf das kompakte Gebilde (4) aufgebracht werden und - dass der Metallkörper (5) abschließend mechanisch zu dem Kontaktelement (K) umgeformt wird. Method for attaching a contact element at the end of an electrical conductor, with which at the end of the conductor existing, firmly connected to the conductor electrically conductive material is deformed to a contact element with a variable shape, characterized in that first the end of the bare conductor (L) is brought into an at least approximately vertical position, - That thereafter be applied to the upwardly projecting, frontal end of the conductor (L) in the same direction of the same particles of an electrically conductive material at such a high speed that the material of the conductor (L) with the electrically conductive material to a compact Structure (4) connects, which is mechanically fixed and electrically conductive connected to the material of the conductor (L), - That subsequently to the formation of a metal body (5) without interrupting the process, further particles of the electrically conductive material are applied to the compact structure (4) and - That the metal body (5) is finally transformed mechanically to the contact element (K). Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass der blanke Leiter (L) mit vertikaler Position angeordnet wird.A method according to claim 1, characterized in that the bare conductor (L) is arranged with a vertical position. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass ein Leiter (L) verwendet wird, der aus einer Vielzahl von zu einer Einheit zusammengefaßten Drähten aufgebaut ist, welche aus Aluminium oder einer Aluminiumlegierung bestehen.A method according to claim 1, characterized in that a conductor (L) is used which is constructed from a plurality of wires combined into a single unit, which consist of aluminum or an aluminum alloy. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass als Material für die Partikel Kupfer oder eine Kupferlegierung eingesetzt wird.A method according to claim 1, characterized in that is used as the material for the particles of copper or a copper alloy.
EP16306498.3A 2016-11-17 2016-11-17 A method for producing a contact element at the end of an electrical conductor Active EP3324493B1 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
EP16306498.3A EP3324493B1 (en) 2016-11-17 2016-11-17 A method for producing a contact element at the end of an electrical conductor
PT163064983T PT3324493T (en) 2016-11-17 2016-11-17 A method for producing a contact element at the end of an electrical conductor
US15/813,805 US10944228B2 (en) 2016-11-17 2017-11-15 Method for attaching a contact element to the end of an electrical conductor
CN201711145972.XA CN108075340B (en) 2016-11-17 2017-11-17 Method for attaching a contact element to an end of an electrical conductor

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EP16306498.3A EP3324493B1 (en) 2016-11-17 2016-11-17 A method for producing a contact element at the end of an electrical conductor

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US20230369788A1 (en) * 2022-05-11 2023-11-16 Hamilton Sundstrand Corporation Method of terminating a wire bundle and a bundled wire electrical connector

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DE2325294A1 (en) 1972-05-18 1973-11-29 Essex International Inc METHOD OF MAKING A CONTACT OF AT LEAST ONE METALLIC ELECTRIC CONDUCTOR
US4775337A (en) * 1986-12-02 1988-10-04 Universal Manufacturing Corporation Conductive wire with integral electrical terminal
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US20180138648A1 (en) 2018-05-17
CN108075340B (en) 2021-02-02
PT3324493T (en) 2023-03-29
US10944228B2 (en) 2021-03-09
CN108075340A (en) 2018-05-25

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