EP3324493B1 - 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
EP3324493B1
EP3324493B1 EP16306498.3A EP16306498A EP3324493B1 EP 3324493 B1 EP3324493 B1 EP 3324493B1 EP 16306498 A EP16306498 A EP 16306498A EP 3324493 B1 EP3324493 B1 EP 3324493B1
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EP
European Patent Office
Prior art keywords
conductor
particles
contact element
composite body
electrically conductive
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP16306498.3A
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German (de)
French (fr)
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EP3324493A1 (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
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HERMLE MASCHINENBAU GmbH
Nexans SA
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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
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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 to the end of an electrical conductor according to the preamble of patent claim 1.
  • Such a method is, for example, in DE 2 325 294 A described.
  • DE 2 325 294 A describes a method for producing a contact element at the end of an electrical conductor that does not require mechanical fastening elements.
  • the end of an electrical conductor is heated in such a way that the material of the same melts.
  • the molten metal of the conductor is prevented from dripping off the same. This forms a pear-shaped mass known as a "lump", which is an integral part of the conductor.
  • the nugget is then mechanically deformed into a contact element that can be designed in any number of different ways.
  • the material of the conductor itself is used to form a contact element. The method is thus limited to the material of the conductor.
  • the invention is based on the object of further developing the method described at the outset in such a way that it can be used for any materials of conductor and contact element.
  • composite body is thus electrically conductively connected to the material of the conductor, so that the entire conductive Cross-section of the conductor is detected.
  • the conductor is a multi-wire stranded conductor made, for example, of aluminum or an aluminum alloy.
  • particles continue to impinge on the composite body, gradually depositing a metal body on the composite body pointing away from the conductor. The method is terminated when the metal body has sufficient material to form an electrical contact element.
  • the conductor is advantageously arranged vertically, so that its end face is accessible from above.
  • the particles then advantageously hit the end face of the conductor normal to the surface. Small angular deviations from the surface normal can be permissible. Particles that do not hit the end 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 used to supply the particles, which can also be powder particles.
  • the tube has a constriction in its course, through which the gas flow 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. It is of particular advantage that different metals can also be used for the conductor and the contact element to be produced, which metals are firmly connected to form a unit. Influences of corrosion on a contact point can be ruled out 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 can be made of copper, or vice versa. This also applies to alloys these two materials. Brass can also be used, for example, with particular advantage for the contact element. However, it is also possible to use the same material for the conductor and the contact element.
  • In 1 shows the end of an insulated electrical conductor L, which is designed as a stranded conductor consisting of a large number of individual wires 1 .
  • the conductor L has no insulation 2 surrounding it.
  • particles of electrically conductive material are applied at high speed in its axial direction according to the arrow 3, which is higher than the speed of sound. The corresponding procedure is based on 3 explained in more detail below.
  • a compact structure is first produced at the end of the conductor L, which 2 indicated and shown as a shaded composite body 4, which consists of the material of the conductor L on the one hand and the metal applied with the particles on the other hand, which is metallurgically firmly connected to the material of the conductor L in the composite body 4.
  • metal body 5 On the composite body 4, due to the particles made of the electrically conductive material that continue to impinge on the same, an additional layer made only of the material of the particles is formed existing metal body 5 generated. It is metallurgically connected to the composite body 4 . The metal body 5 is in 2 drawn with compared to the composite body 4 different hatching.
  • the method according to the invention is carried out, for example, as follows: To feed particles, for example and advantageously made of copper - hereinafter referred to as "particles" for short - to a conductor L made of aluminum, for example, a tube 6 acting as a nozzle is used, which extends in the axial direction of the conductor L arranged with a vertical course the same is ordered. Gas coming from a gas source 7, advantageously an inert gas, is blown as a gas stream into the tube 6 at its end. Particles, which are contained in a supply 8 of particles, are added to the gas stream before it enters the pipe 6 . The gas stream can be passed through the particles. In any case, the particles are arranged in such a way that they are taken along and transported by the gas flow.
  • the conductor L is arranged in a tool 9 in such a way that only its tip protrudes from the same.
  • the individual wires 1 of the conductor L are held together by the tool 9 and, on the other hand, the insulation 2 of the conductor L is protected from the particles.
  • the tool 9 can advantageously be made in several parts.
  • the gas stream 10 loaded with the particles exits the free end of the tube 6 at a high speed, which is higher than the speed of sound. It hits the face of the conductor L.
  • the gas stream 10 thus has the function of a carrier for the particles, which thereby impinge on the end face of the conductor L at the same speed as the gas.
  • the metal body 5 that has already been described and encompasses the composite body 4 is produced by the particles.
  • the tube 6 is accordingly 3 positioned at a distance from the face of the conductor L. This distance can be changed. It depends on the material of the particles and is between 20 mm and 150 mm, for example.
  • the conductor L is metallurgically bonded at its end to the metal body 5, specifically in the transition area to the compact structure previously referred to as "composite body 4".
  • the metal body 5, which also includes the composite body 4 can then be mechanically formed into a contact element K with any shape for different applications.
  • six examples of possible contact elements K are shown schematically.
  • the contact element K after Figure 5a can be used, for example, as a connection to the pole of a battery as a so-called battery terminal.
  • a contact element K designed as a plug pin is shown.

Description

Die Erfindung bezieht sich auf ein Verfahren zum Anbringen eines Kontaktelements am Ende eines elektrischen Leiters gemäß dem Oberbegriff des Patentanspruchs 1.The invention relates to a method for attaching a contact element to the end of an electrical conductor according to the preamble of patent claim 1.

Ein solches Verfahren ist beispielsweise in der DE 2 325 294 A beschrieben.Such a method is, for example, in DE 2 325 294 A described.

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 Übergangswiderstand zwischen dem Kontaktelement und dem Leiter von Bedeutung. Außerdem soll ein fester Sitz des Kontaktelements auf dem Leiter auf Dauer sichergestellt sein.Methods for attaching contact elements to the ends of electrical conductors or lines have been known for a long time. In order to produce an effective electrical connection between a contact element and a conductor, the conductor is first freed from the insulating layers surrounding it. A contact element can then be connected to the conductor using known technology, for example by means of screws or clamps or by welding or soldering or by crimping. The lowest possible electrical transition resistance between the contact element and the conductor is important at the connection point. In addition, a firm seat of the contact element on the conductor should be ensured over the long term.

In der US 2013/0072075 A1 ist ein Verfahren beschrieben, mit dem mittels einer Düse erhitztes Pulver auf eine Unterlage aufgetragen wird, und zwar mit einer über der Schallgeschwindigkeit liegenden Geschwindigkeit. Die Düse wird bei diesem Verfahren horizontal angeordnet. Sie ist als Trichter ausgeführt, der sich in Richtung des zu beschichtenden Werkstücks erweitert. Es soll mit dem Verfahren eine dünne, als Film bezeichnete Schicht auf dem Werkstück aufgebracht werden. Dabei wird das Werkstück durch das Pulver erodiert und plastisch verformt, so dass das Pulver aufgrund seiner kinetischen oder thermischen Energie als Film an demselben haften bleibt. Wenn das zu beschichtende Werkstück ein elektrischer Draht ist, auf dessen Stirnseite eine Schicht mittels des Pulvers aufgetragen werden soll, dann wird zusätzlich eine Blende mit einer Öffnung eingesetzt, durch welche sichergestellt ist, dass das Pulver tatsächlich auf die Stirnseite des Leiters auftrifft.In the U.S. 2013/0072075 A1 describes a method by which heated powder is applied to a substrate by means of a nozzle at a speed exceeding the speed of sound. In this process, the nozzle is positioned horizontally. It is designed as a funnel that widens in the direction of the workpiece to be coated. The aim of the process is to apply a thin layer, known as a film, to the workpiece. The workpiece is eroded by the powder and plastically deformed, so that the powder adheres to it as a film due to its kinetic or thermal energy. If the workpiece to be coated is an electrical wire, on the end of which a layer is to be applied using the powder, then a screen with an opening is also used, through which it is ensured that the powder actually hits the end of the conductor.

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 one mentioned above DE 2 325 294 A describes a method for producing a contact element at the end of an electrical conductor that does not require mechanical fastening elements. With this method, the end of an electrical conductor is heated in such a way that the material of the same melts. With a corresponding arrangement of the conductor, the molten metal of the conductor is prevented from dripping off the same. This forms a pear-shaped mass known as a "lump", 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 nugget is then mechanically deformed into a contact element that can be designed in any number of different ways. In this known method, the material of the conductor itself is used to form a contact element. The method is thus 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 is based on the object of further developing the method described at the outset in such a way that it can be used for any materials of conductor and contact element.

Diese Aufgabe wird entsprechend den kennzeichnenden Merkmalen des Patentanspruchs 1 gelöst.This object is achieved according to the characterizing features of patent claim 1.

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 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 über der Schallgeschwindigkeit liegt, 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 sind.This method, which is also referred to as "cold gas spraying" in the technical world, 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 via a tube acting as a nozzle, namely by means of a gas stream serving as a carrier, which, together with the particles contained therein, is emitted at high speed strikes the face of the conductor. An inert gas is preferably used as the gas. Because of the high speed, which is above the speed of sound, the particles consisting of copper, for example, penetrate the material of the conductor and combine with it metallurgically to form a compact structure in which the material of the conductor and the material of the particles are contained.

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 von wesentlicher Bedeutung, weil 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 structure, referred to below as "composite body", is thus electrically conductively connected to the material of the conductor, so that the entire conductive Cross-section of the conductor is detected. This is essential because the conductor is a multi-wire stranded conductor made, for example, of aluminum or an aluminum alloy. As the process continues without interruption, particles continue to impinge on the composite body, gradually depositing a metal body on the composite body pointing away from the conductor. The method 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.To carry out the method, the conductor is advantageously arranged vertically, so that its end face is accessible from above. The particles then advantageously hit the end face of the conductor normal to the surface. Small angular deviations from the surface normal can be permissible. Particles that do not hit the end 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 - ein als Düse wirkendes Rohr verwendet. Das Rohr hat in seinem Verlauf eine Verengung, durch welche der mit den Partikeln beladene Gasstrom die erforderliche hohe Geschwindigkeit erhält. In bevorzugter Ausführungsform wird als Rohr eine grundsätzlich bekannte "Lavaldüse" eingesetzt.As already mentioned, a tube acting as a nozzle is used to supply the particles, which can also be powder particles. The tube has a constriction in its course, through which the gas flow 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 verwendet 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. It is of particular advantage that different metals can also be used for the conductor and the contact element to be produced, which metals are firmly connected to form a unit. Influences of corrosion on a contact point can be ruled out 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 can be made of copper, or vice versa. This also applies to alloys these two materials. Brass can also be used, for example, with particular advantage for the contact element. However, 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 is 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:
  • 1 the end of a stripped electrical conductor.
  • 2 the end of the conductor 1 after processing with the method according to the invention.
  • 3 a schematic representation of an arrangement for carrying out the method according to the invention.
  • 4 a pipe usable in the method according to the invention.
  • figure 5 different contact elements that can be produced with the method according to the invention.

In Fig. 1 ist das Ende eines isolierten elektrischen Leiters L dargestellt, der als aus einer Vielzahl von Einzeldrähten 1 bestehender Litzenleiter ausgeführt ist. 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 höher als die Schallgeschwindigkeit ist. Das entsprechende Verfahren wird anhand von Fig. 3 weiter unten genauer erläutert.In 1 shows the end of an insulated electrical conductor L, which is designed as a stranded conductor consisting of a large number of individual wires 1 . At its end, the conductor L has no insulation 2 surrounding it. On the end face of the conductor L, particles of electrically conductive material are applied at high speed in its axial direction according to the arrow 3, which is higher than the speed of sound. The corresponding procedure is based on 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 2 indicated and shown as a shaded composite body 4, which consists of the material of the conductor L on the one hand and the metal applied with the particles on the other hand, which is metallurgically firmly connected to the material of the conductor L in the composite body 4.

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, due to the particles made of the electrically conductive material that continue to impinge on the same, an additional layer made only of the material of the particles is formed existing metal body 5 generated. It is metallurgically connected to the composite body 4 . The metal body 5 is in 2 drawn with compared to the composite body 4 different 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 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:
To feed particles, for example and advantageously made of copper - hereinafter referred to as "particles" for short - to a conductor L made of aluminum, for example, a tube 6 acting as a nozzle is used, which extends in the axial direction of the conductor L arranged with a vertical course the same is ordered. Gas coming from a gas source 7, advantageously an inert gas, is blown as a gas stream into the tube 6 at its end. Particles, which are contained in a supply 8 of particles, are added to the gas stream before it enters the pipe 6 . The gas stream can be passed through the particles. In any case, the particles are arranged in such a way that they are taken along and transported by the gas flow.

Der Leiter L ist in einem Werkzeug 9 so angeordnet, dass nur seine Spitze aus demselben herausragt. Durch das Werkzeug 9 sind einerseits die Einzeldrähte 1 des Leiters L, 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 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 arranged in a tool 9 in such a way that only its tip protrudes from the same. On the one hand, the individual wires 1 of the conductor L are held together by the tool 9 and, on the other hand, the insulation 2 of the conductor L is protected from the particles. The tool 9 can advantageously be made in several parts. The gas stream 10 loaded with the particles exits the free end of the tube 6 at a high speed, which is higher than the speed of sound. It hits the face of the conductor L. The gas stream 10 thus has the function of a carrier for the particles, which thereby impinge on the end face of the conductor L at the same speed as the gas. The metal body 5 that has already been described and encompasses the composite body 4 is produced by the particles.

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 accordingly 3 positioned at a distance from the face of the conductor L. This distance can be changed. It depends on the material of the particles and is between 20 mm and 150 mm, for example.

Das insgesamt einen kreisrunden Querschnitt aufweisende Rohr 6 hat in seinem Verlauf entsprechend der rein schematischen Darstellung in Fig. 4 eine Einengung 11 seines lichten Querschnitts, wodurch entsprechend der Funktion der erwähnten Lavaldüse die benötigte Geschwindigkeit des Gasstroms und damit die benötigte Geschwindigkeit der Partikel erreicht wird.The course of the tube 6, which has a circular cross section overall, has in accordance with the purely schematic representation in 4 a narrowing 11 of his clear cross-section, whereby the required speed of the gas flow and thus the required speed of the particles is 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.At the end of the process, the conductor L is metallurgically bonded at its end to the metal body 5, specifically in the transition area to the compact structure previously referred to as "composite body 4". The metal body 5, which also includes the composite body 4, can then be mechanically formed into a contact element K with any shape for different applications. In the Figures 5a to 5d six examples of possible contact elements K are shown schematically. The contact element K after Figure 5a can be used, for example, as a connection to the pole of a battery as a so-called battery terminal. In Figure 5d For example, a contact element K designed as a plug pin is shown.

Claims (4)

  1. A method for producing a contact element at the end of an electrical conductor, which is designed as a stranded conductor consisting of a plurality of individual wires, with which electrically conductive material existing at the end of the conductor and fixedly connected to the conductor is deformed to form a contact element with a variable form, characterized in
    - that initially the end of the bare conductor (L) is brought into an at least approximately vertical position, in which it is arranged in a tool (9) holding the individual wires together,
    - that particles of an electrically conductive material with a velocity above the speed of sound are then applied to the upwardly projecting end face of the conductor (L) in the axial direction thereof by means of a tube which is provided with a constriction in its course and acts as a nozzle and which is arranged above the conductor, whereby the material of the conductor (L) bonds with the electrically conductive material applied to its end face of the conductor to form a compact composite body (4), which is connected mechanically fixedly and electrically conductively to the material of the conductor (L),
    - that without interruption of the process further particles of the electrically conductive material are then applied to the compact composite body (4), whereby a metal body (5) consisting only of the material of the particles is generated, which is connected metallurgically fixedly to the composite body (4) and
    - that the metal body (5), which also comprises the composite body (4) is finally mechanically formed into the contact element (K).
  2. The method according to claim 1, characterized in that the bare conductor (L) is arranged in a vertical position.
  3. The method according to claim 1, characterized in that a conductor (L) is used, which is constructed from a plurality of wires combined into one unit, which consists of aluminum or an aluminum alloy.
  4. The method according to claim 1, characterized in that copper or a copper alloy is used as material for the particles.
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)

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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
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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US4038743A (en) 1972-05-18 1977-08-02 Essex International, Inc. Terminating and splicing electrical conductors
US4775337A (en) * 1986-12-02 1988-10-04 Universal Manufacturing Corporation Conductive wire with integral electrical terminal
JPH04249875A (en) * 1991-01-08 1992-09-04 Yazaki Corp Formation electrode for providing wire with end functioning as terminal and wire with terminal function
US5960540A (en) * 1996-11-08 1999-10-05 The Whitaker Corporation Insulated wire with integral terminals
JP2005216827A (en) * 2004-02-02 2005-08-11 Yazaki Corp Wire end terminal and its manufacturing method
JP5186528B2 (en) * 2010-04-23 2013-04-17 日本発條株式会社 Conductive member and manufacturing method thereof
CH707565A2 (en) * 2013-02-14 2014-08-15 Brugg Cables Industry Ag Electrical conductor e.g. signal cable, has electrical conductor wire that is formed in end portion of compact element, and is provided with strands
JP6114632B2 (en) * 2013-05-29 2017-04-12 矢崎総業株式会社 Terminalized wire
JP6581331B2 (en) * 2013-07-29 2019-09-25 デクセリアルズ株式会社 Method for producing conductive adhesive film, method for producing connector
JP6170956B2 (en) * 2015-03-12 2017-07-26 矢崎総業株式会社 Mold for terminalized wire

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PT3324493T (en) 2023-03-29
US20180138648A1 (en) 2018-05-17
CN108075340B (en) 2021-02-02
US10944228B2 (en) 2021-03-09
EP3324493A1 (en) 2018-05-23

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