EP3340397B1 - Method for fixing a contact element at the end of an electrical conductor - Google Patents

Method for fixing a contact element at the end of an electrical conductor Download PDF

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Publication number
EP3340397B1
EP3340397B1 EP16306778.8A EP16306778A EP3340397B1 EP 3340397 B1 EP3340397 B1 EP 3340397B1 EP 16306778 A EP16306778 A EP 16306778A EP 3340397 B1 EP3340397 B1 EP 3340397B1
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EP
European Patent Office
Prior art keywords
conductor
sleeve
contact element
soldered
layer
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EP16306778.8A
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German (de)
French (fr)
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EP3340397A1 (en
Inventor
Michael Singer
Udo Mayer
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Nexans SA
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Nexans SA
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Priority to EP16306778.8A priority Critical patent/EP3340397B1/en
Priority to ES16306778T priority patent/ES2732905T3/en
Publication of EP3340397A1 publication Critical patent/EP3340397A1/en
Application granted granted Critical
Publication of EP3340397B1 publication Critical patent/EP3340397B1/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
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • 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
    • H01R11/28—End pieces consisting of a ferrule or sleeve
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2201/00—Connectors or connections adapted for particular applications
    • H01R2201/26—Connectors or connections adapted for particular applications for vehicles
    • 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
    • H01R4/02—Soldered or welded connections
    • H01R4/023—Soldered or welded connections between cables or wires and terminals
    • H01R4/024—Soldered or welded connections between cables or wires and terminals comprising preapplied solder
    • 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
    • H01R4/20—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 using a crimping sleeve
    • 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
    • H01R4/22—End caps, i.e. of insulating or conductive material for covering or maintaining connections between wires entering the cap from the same end

Definitions

  • the invention relates to a method for fastening a contact element at the end of an electrical conductor according to the preamble of patent claim 1.
  • Such a method is for example from the DE 199 08 031 B4 out.
  • the sleeve may be made of aluminum-based metal, either aluminum or an aluminum alloy. This also applies to the individual wires of the conductor. In the following, only the material "aluminum" is considered.
  • Ladders made of aluminum are increasingly being used, in particular for reasons of weight and cost, as a replacement for copper conductors.
  • Main applications of such conductors are, for example, the automotive and aircraft technology.
  • the lower electrical conductivity of the aluminum over copper is irrelevant for most applications, as it may be compensated for by cross-sectional matching.
  • problems arise when attaching contact parts to the conductors since aluminum conductors are surrounded by an electrically very poorly conductive oxide layer. This deficiency is particularly noticeable in existing from a variety of individual wires, also referred to as stranded conductors conductors, each of which is surrounded by an unavoidable without special treatment oxide layer. This problem has long been known and described in numerous publications, of which three documents are mentioned below.
  • the US 5,517,755 A relates to a method for producing a connector for a stranded conductor.
  • the individual wires of the stranded conductor are made of copper.
  • the stranded conductor should be firmly connected to a component called a conductive surface.
  • a ring is wrapped around the end of the stranded conductor, through which the composite of the individual wires is compressed to a smaller diameter.
  • the individual wires, which protrude from the front end of the ring from the same, are separated at the level of the ring, so that they lie with the same in a plane.
  • the stranded conductor is finally inserted into a supply of soldering material on the surface and soldered to the surface.
  • a contact element is to be mounted electrically good conduction on a stranded wire of aluminum wires.
  • a tin-plated on the inside of metallic sleeve is first pushed onto the end of the stranded conductor.
  • the individual wires are then tinned or welded at their ends with each other and with the sleeve by means of ultrasound or inert gas welding.
  • the oxide layers surrounding the individual conductors should be broken up. This results in a cover-like tinning or welding at the end of the stranded conductor.
  • the contact element is pushed and pressed with the end of the stranded conductor.
  • the lid-like tinning or welding is excluded from the pressing.
  • the DE 103 46 160 B3 describes a method for contacting an aluminum conductor designed as a stranded conductor, in which a tinned on the inside, for example made of copper contact terminal is pushed onto the end of the aluminum conductor.
  • the tube-shaped contact terminal is tinned on the front side of the aluminum conductor by means of ultrasonic tinning together with the same or welded by means of a known welding process metallically with the same.
  • a supply of a contacting agent is applied to the end of a stranded conductor made of aluminum and heated at least to the region of its melting temperature.
  • a material connection between the stranded conductor and a simultaneously or subsequently deferred, pot-like contact element is to be produced via the contacting means for forming an electrical contact.
  • the contacting agent of the stranded conductor can be immersed in a tin bath. In this case, a part of the stranded conductor can be separated or cut off in the tin bath to form a fresh separating or cutting surface.
  • the contact element is pressed with zugentlastender effect around the stranded conductor.
  • the invention has for its object to simplify the initially described method.
  • solderable material used is, in particular and advantageously, tin.
  • the word “tin” is therefore used below, representing all usable solderable materials. Due to the mechanical processing of the end face of the conductor existing oxide layers are removed there, so that the tin applied to the end face is connected to the conductive material of all the individual wires of the conductor.
  • the mechanical processing of the end face of the conductor, for example by means of a milling cutter, and the coating of the same with the tin are carried out under protective gas. It may then be before coating the face with the tin will not form a new oxide layer on the face of the conductor. In this case, the tin can be applied for example by immersing the processed conductor end in a tin bath.
  • tin By the dipping process of the conductor end in a tin bath, tin likewise simultaneously adheres to the peripheral surface of the contact element or the sleeve.
  • the contact with an electrical contact to be attached to the contact element or the sleeve can be further improved.
  • Fig. 1 the end of an electrical line 1 is shown, which has an electrical conductor 3 surrounded by an insulation 2.
  • the conductor 3 is constructed from a plurality of individual wires 4, which are made of aluminum and are preferably stranded together. Such a conductor is also referred to as a stranded conductor.
  • the insulation 2 is removed at the end of the line 1, so that the conductor 3 is exposed.
  • a contact element sleeve 5 made of aluminum.
  • the sleeve 5 is pressed around the conductor 3 by mechanical processing, so that the individual wires 4 of the same are pressed together and the sleeve 5, the conductor 3 tightly and completely surrounds.
  • the pressing process is indicated by arrows 6. It is carried out so that the peripheral surface of the sleeve 5 is at least approximately cylindrical even after being pressed with the conductor 3.
  • the mechanical treatment of the conductor end with the described removal of a layer is carried out under a protective gas, so that no new oxide layer can form on the plane generated end face.
  • the conductor end thus treated is then placed in a tin bath 8 (keeping the protective gas atmosphere).
  • FIGS. 5 and 6 immersed). It is characterized on the flat end face of the conductor 3, a tin layer 9 is generated, which, as shown in FIG Fig. 4 extends beyond the peripheral surface of the sleeve 5.
  • the tin layer 9 has metallic and therefore electrically conductive contact with the aluminum of all individual conductors 4 of the conductor 3.

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

Description

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

Ein solches Verfahren geht beispielsweise aus der DE 199 08 031 B4 hervor.Such a method is for example from the DE 199 08 031 B4 out.

Die Hülse kann aus einem Metall auf Aluminiumbasis bestehen, und zwar entweder aus Aluminium oder aus einer Aluminiumlegierung. Das gilt auch für die Einzeldrähte des Leiters. Im Folgenden wird nur das Material "Aluminium" berücksichtigt.The sleeve may be made of aluminum-based metal, either aluminum or an aluminum alloy. This also applies to the individual wires of the conductor. In the following, only the material "aluminum" is considered.

Leiter aus Aluminium werden insbesondere aus Gewichts- und Kostengründen vermehrt als Ersatz für Kupferleiter verwendet. Haupteinsatzgebiete derartiger Leiter sind beispielsweise die Automobil- und die Flugzeugtechnik. Die geringere elektrische Leitfähigkeit des Aluminiums gegenüber Kupfer spielt für die meisten Anwendungen keine Rolle, da sie gegebenenfalls durch eine Querschnittsanpassung kompensiert werden kann. Probleme ergeben sich aber beim Anbringen von Kontaktteilen an den Leitern, da Aluminiumleiter von einer elektrisch sehr schlecht leitenden Oxidschicht umgeben sind. Dieser Mangel macht sich besonders bei aus einer Vielzahl von Einzeldrähten bestehenden, auch als Litzenleiter bezeichneten Leitern bemerkbar, von denen jeder von einer ohne Sonderbehandlung nicht zu vermeidenden Oxidschicht umgeben ist. Diese Problematik ist seit langem bekannt und in zahlreichen Druckschriften beschrieben, von denen im Folgenden drei Schriften erwähnt sind.Ladders made of aluminum are increasingly being used, in particular for reasons of weight and cost, as a replacement for copper conductors. Main applications of such conductors are, for example, the automotive and aircraft technology. The lower electrical conductivity of the aluminum over copper is irrelevant for most applications, as it may be compensated for by cross-sectional matching. However, problems arise when attaching contact parts to the conductors, since aluminum conductors are surrounded by an electrically very poorly conductive oxide layer. This deficiency is particularly noticeable in existing from a variety of individual wires, also referred to as stranded conductors conductors, each of which is surrounded by an unavoidable without special treatment oxide layer. This problem has long been known and described in numerous publications, of which three documents are mentioned below.

Die US 5,517,755 A betrifft ein Verfahren zur Herstellung eines Verbinders für einen Litzenleiter. Die Einzeldrähte des Litzenleiters bestehen aus Kupfer. Der Litzenleiter soll fest mit einem als leitende Oberfläche bezeichneten Bauteil verbunden werden. Dazu wird um das Ende des Litzenleiters ein Ring herumgelegt, durch welchen der Verbund der Einzeldrähte auf einen kleineren Durchmesser zusammengedrückt wird. Die Einzeldrähte, die am stirnseitigen Ende des Rings aus demselben herausragen, werden in Höhe des Rings abgetrennt, so dass sie mit demselben in einer Ebene liegen. Der Litzenleiter wird abschließend in einen auf der Oberfläche vorhandenen Vorrat an Lötmaterial gesteckt und mit der Oberfläche verlötet.The US 5,517,755 A relates to a method for producing a connector for a stranded conductor. The individual wires of the stranded conductor are made of copper. The stranded conductor should be firmly connected to a component called a conductive surface. For this purpose, a ring is wrapped around the end of the stranded conductor, through which the composite of the individual wires is compressed to a smaller diameter. The individual wires, which protrude from the front end of the ring from the same, are separated at the level of the ring, so that they lie with the same in a plane. The The stranded conductor is finally inserted into a supply of soldering material on the surface and soldered to the surface.

Aus der DE 102 23 397 B4 geht ein Verfahren hervor, mit dem ein Kontaktelement elektrisch gut leitend an einem Litzenleiter aus Aluminiumdrähten angebracht werden soll. Dazu wird auf das Ende des Litzenleiters zunächst eine an der Innenseite verzinnte metallische Hülse aufgeschoben. Die Einzeldrähte werden dann an ihren Stirnseiten untereinander und mit der Hülse mittels Ultraschalls oder Schutzgasschweißens verzinnt oder verschweißt. Die die Einzelleiter umgebenden Oxidschichten sollen dabei aufgebrochen werden. Es ergibt sich eine deckelartige Verzinnung bzw. Verschweißung am Ende des Litzenleiters. Abschließend wird das Kontaktelement aufgeschoben und mit dem Ende des Litzenleiters verpreßt. Die deckelartige Verzinnung bzw. Verschweißung wird vom Verpressen ausgenommen.From the DE 102 23 397 B4 goes out a method by which a contact element is to be mounted electrically good conduction on a stranded wire of aluminum wires. For this purpose, a tin-plated on the inside of metallic sleeve is first pushed onto the end of the stranded conductor. The individual wires are then tinned or welded at their ends with each other and with the sleeve by means of ultrasound or inert gas welding. The oxide layers surrounding the individual conductors should be broken up. This results in a cover-like tinning or welding at the end of the stranded conductor. Finally, the contact element is pushed and pressed with the end of the stranded conductor. The lid-like tinning or welding is excluded from the pressing.

Die DE 103 46 160 B3 beschreibt ein Verfahren zur Kontaktierung eines als Litzenleiter ausgeführten Aluminiumleiters, bei welchem auf das Ende des Aluminiumleiters eine an der Innenseite verzinnte, beispielsweise aus Kupfer bestehende Kontaktklemme aufgeschoben wird. Die rohrförmig ausgeführte Kontaktklemme wird an der Stirnseite des Aluminiumleiters mittels Ultraschall-Verzinnung gemeinsam mit demselben verzinnt oder mittels eines bekannten Schweißverfahrens metallisch mit demselben verschweißt.The DE 103 46 160 B3 describes a method for contacting an aluminum conductor designed as a stranded conductor, in which a tinned on the inside, for example made of copper contact terminal is pushed onto the end of the aluminum conductor. The tube-shaped contact terminal is tinned on the front side of the aluminum conductor by means of ultrasonic tinning together with the same or welded by means of a known welding process metallically with the same.

Bei dem Verfahren nach der DE 103 57 048 A1 wird auf das Ende eines aus Aluminium bestehenden Litzenleiters ein Vorrat eines Kontaktierungsmittels aufgebracht und zumindest bis in den Bereich seiner Schmelztemperatur erwärmt. Dabei soll über das Kontaktierungsmittel zur Ausbildung einer elektrischen Kontaktierung eine stoffliche Verbindung zwischen dem Litzenleiter und einem gleichzeitig oder anschließend aufgeschobenen, topfartigen Kontaktelement hergestellt werden. Zum Aufbringen des Kontaktierungsmittels kann der Litzenleiter in ein Zinnbad eingetaucht werden. Dabei kann ein Teil des Litzenleiters zur Bildung einer frischen Trenn- oder Schneidfläche im Zinnbad abgetrennt oder abgeschnitten werden. Das Kontaktelement wird mit zugentlastender Wirkung um den Litzenleiter herumgepreßt.In the method of the DE 103 57 048 A1 A supply of a contacting agent is applied to the end of a stranded conductor made of aluminum and heated at least to the region of its melting temperature. In this case, a material connection between the stranded conductor and a simultaneously or subsequently deferred, pot-like contact element is to be produced via the contacting means for forming an electrical contact. For applying the contacting agent of the stranded conductor can be immersed in a tin bath. In this case, a part of the stranded conductor can be separated or cut off in the tin bath to form a fresh separating or cutting surface. The contact element is pressed with zugentlastender effect around the stranded conductor.

Auch aus der eingangs erwähnten DE 199 08 031 B4 geht ein Verfahren hervor, mit dem ein Kontaktelement am Ende eines aus Einzeldrähten aus Aluminium bestehenden elektrischen Leiters angebracht wird. Dazu wird zunächst eine beispielsweise aus Kupfer bestehende Stützhülse um das Ende des Leiters herumgelegt und mit demselben verpreßt. Danach wird ein Kontaktelement mit der Stirnseite des Leiters so verschweißt, dass auch die Stützhülse mit erfaßt ist. Das Verschweißen kann durch einen Reibschweißvorgang realisiert werden, in welchem das Kontaktelement mit hoher Geschwindigkeit um seine Achse gedreht und gegen die Stirnseite des Leiters gedrückt wird. Dieses Verfahren erfordert für das Verschweißen von Leiter und Kontaktelement einen hohen apparativen Aufwand.Also from the aforementioned DE 199 08 031 B4 shows a method by which a contact element is attached to the end of an individual wires made of aluminum electrical conductor. For this purpose, an existing example of copper support sleeve is first placed around the end of the conductor and pressed with the same. Thereafter, a contact element with the end face of the conductor is welded so that the support sleeve is detected with. The welding can be realized by a friction welding process in which the contact element is rotated at high speed about its axis and pressed against the end face of the conductor. This method requires for the welding of conductor and contact element a high expenditure on equipment.

Der Erfindung liegt die Aufgabe zugrunde, das eingangs geschilderte Verfahren zu vereinfachen.The invention has for its object to simplify the initially described method.

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

Bei Einsatz dieses Verfahrens wird am Ende des Leiters nach der Festlegung des als Hülse ausgeführten Kontaktelements in einem einfachen Arbeitsschritt zunächst eine plane Fläche an der Stirnseite erzeugt, in welcher auch die Hülse erfaßt ist, welche eine glatte, ebene Grundlage für das Aufbringen einer Schicht aus lötfähigem Material darstellt. Als lötfähiges Material wird insbesondere und mit Vorteil Zinn verwendet. Statt der Worte "lötfähiges Material" wird daher im Folgenden das Wort "Zinn" verwendet, stellvertretend für alle verwendbaren lötfähigen Materialien. Durch die mechanische Bearbeitung der Stirnfläche des Leiters werden dort vorhandene Oxidschichten abgetragen, so dass das auf die Stirnfläche aufgebrachte Zinn mit dem leitfähigen Material aller Einzeldrähte des Leiters verbunden wird. Ein an dem Kontaktelement und insbesondere an der Schicht aus Zinn angebrachter elektrischer Kontakt, der mit dem Zinn durch Wärmezufuhr verbunden wird, hat dementsprechend einen elektrisch leitfähigen Kontakt zum Gesamtquerschnitt des Leiters.
Die mechanische Bearbeitung der Stirnfläche des Leiters, beispielsweise mittels eines Fräsers, und die Beschichtung derselben mit dem Zinn werden unter Schutzgas durchgeführt. Es kann sich dann vor dem Beschichten der Stirnfläche mit dem Zinn werden keine neue Oxidschicht auf der Stirnfläche des Leiters bilden. Dabei kann das Zinn beispielsweise durch Eintauchen des bearbeiteten Leiterendes in ein Zinnbad aufgebracht werden.When using this method, at the end of the conductor after the definition of the contact element designed as a sleeve in a simple step initially produces a flat surface on the front side, in which also the sleeve is detected, which is a smooth, flat basis for the application of a layer represents solderable material. The solderable material used is, in particular and advantageously, tin. Instead of the words "solderable material", the word "tin" is therefore used below, representing all usable solderable materials. Due to the mechanical processing of the end face of the conductor existing oxide layers are removed there, so that the tin applied to the end face is connected to the conductive material of all the individual wires of the conductor. An electrical contact attached to the contact element and in particular to the layer of tin, which is connected to the tin by supplying heat, accordingly has an electrically conductive contact with the overall cross section of the conductor.
The mechanical processing of the end face of the conductor, for example by means of a milling cutter, and the coating of the same with the tin are carried out under protective gas. It may then be before coating the face with the tin will not form a new oxide layer on the face of the conductor. In this case, the tin can be applied for example by immersing the processed conductor end in a tin bath.

Durch den Tauchvorgang des Leiterendes in ein Zinnbad bleibt gleichzeitig an der Umfangsfläche des Kontaktelements bzw. der Hülse ebenfalls Zinn haften. Durch die so erweiterte Zinnschicht kann der Kontakt zu einem an dem Kontaktelement bzw. der Hülse anzubringenden elektrischen Kontakt weiter verbessert werden.By the dipping process of the conductor end in a tin bath, tin likewise simultaneously adheres to the peripheral surface of the contact element or the sleeve. By the tin layer thus expanded, the contact with an electrical contact to be attached to the contact element or the sleeve can be further improved.

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

Es zeigen:

  • Fig. 1 das Ende einer elektrischen Leitung.
  • Fig. 2 die Leitung nach Fig. 1 mit auf deren Leiter angebrachtem Kontaktelement.
  • Fig. 3 schematisch eine Bearbeitung des Leiterendes.
  • Fig. 4 das Leiterende mit einer zusätzlichen Schicht.
  • Fig. 5 und 6 schematisch zwei Anordnungen zur Beschichtung des Leiterendes.
Show it:
  • Fig. 1 the end of an electrical line.
  • Fig. 2 the line after Fig. 1 with attached to the conductor contact element.
  • Fig. 3 schematically a processing of the conductor end.
  • Fig. 4 the conductor end with an additional layer.
  • FIGS. 5 and 6 schematically two arrangements for coating the conductor end.

In Fig. 1 ist das Ende einer elektrischen Leitung 1 dargestellt, die einen von einer Isolierung 2 umgebenen elektrischen Leiter 3 aufweist. Der Leiter 3 ist aus einer Vielzahl von Einzeldrähten 4 aufgebaut, die aus Aluminium bestehen und vorzugsweise miteinander verseilt sind. Ein solcher Leiter wird auch als Litzenleiter bezeichnet. Die Isolierung 2 ist am Ende der Leitung 1 entfernt, so dass der Leiter 3 freiliegt.In Fig. 1 the end of an electrical line 1 is shown, which has an electrical conductor 3 surrounded by an insulation 2. The conductor 3 is constructed from a plurality of individual wires 4, which are made of aluminum and are preferably stranded together. Such a conductor is also referred to as a stranded conductor. The insulation 2 is removed at the end of the line 1, so that the conductor 3 is exposed.

Auf dem Ende des Leiters 3 ist eine als Kontaktelement vorgesehene Hülse 5 aus Aluminium angebracht. Die Hülse 5 wird durch mechanische Bearbeitung um den Leiter 3 herumgepreßt, so dass die Einzeldrähte 4 desselben fest zusammengedrückt werden und die Hülse 5 den Leiter 3 fest und lückenlos umgibt. Der Preßvorgang ist durch Pfeile 6 angedeutet. Er wird so durchgeführt, dass die Umfangsfläche der Hülse 5 auch nach dem Verpressen mit dem Leiter 3 zumindest annähernd zylindrisch ist.On the end of the conductor 3 is provided as a contact element sleeve 5 made of aluminum. The sleeve 5 is pressed around the conductor 3 by mechanical processing, so that the individual wires 4 of the same are pressed together and the sleeve 5, the conductor 3 tightly and completely surrounds. The pressing process is indicated by arrows 6. It is carried out so that the peripheral surface of the sleeve 5 is at least approximately cylindrical even after being pressed with the conductor 3.

Nach dem Verpressen der Hülse 5 mit dem Leiter 3 wird dessen Stirnfläche mechanisch bearbeitet. Das ist in Fig. 3 durch Pfeile 7 angedeutet. Dabei wird beispielsweise mittels eines Fräsers eine Schicht vom Leiterende und von der dasselbe umgebenden Hülse 5 abgetragen, so dass sich eine plane Stirnfläche ergibt. Bei diesem Vorgang werden auch Oxidschichten vom Leiterende entfernt, so dass das Aluminium der Einzeldrähte 4 metallisch blank vorliegt.After pressing the sleeve 5 with the conductor 3 whose end face is machined. Is in Fig. 3 indicated by arrows 7. In this case, for example, by means of a milling cutter, a layer is removed from the conductor end and from the sleeve 5 surrounding the same, so that a planar end surface results. In this process, oxide layers are removed from the conductor end, so that the aluminum of the individual wires 4 is present bright metallic.

Die mechanische Behandlung des Leiterendes mit dem geschilderten Abtragen einer Schicht wird unter Schutzgas durchgeführt, so dass sich auf der erzeugten planen Stirnfläche keine neue Oxidschicht bilden kann. Das so behandelte Leiterende wird danach unter Beibehalt der Schutzgasatmoshäre in ein Zinnbad 8 (Fig. 5 und 6) eingetaucht. Es wird dadurch auf der planen Stirnfläche des Leiters 3 eine Zinnschicht 9 erzeugt, die sich entsprechend der Darstellung in Fig. 4 bis über die Umfangsfläche der Hülse 5 erstreckt. Die Zinnschicht 9 hat metallischen und damit elektrisch leitenden Kontakt zum Aluminium aller Einzelleiter 4 des Leiters 3.The mechanical treatment of the conductor end with the described removal of a layer is carried out under a protective gas, so that no new oxide layer can form on the plane generated end face. The conductor end thus treated is then placed in a tin bath 8 (keeping the protective gas atmosphere). FIGS. 5 and 6 immersed). It is characterized on the flat end face of the conductor 3, a tin layer 9 is generated, which, as shown in FIG Fig. 4 extends beyond the peripheral surface of the sleeve 5. The tin layer 9 has metallic and therefore electrically conductive contact with the aluminum of all individual conductors 4 of the conductor 3.

Claims (4)

  1. A method for fixing a contact element (5) at the end of an electrical conductor (3), which consists of a plurality of individual wires (4) stranded together made from a material containing aluminum, with which a tubular sleeve (5) serving as a contact element and consisting of a metal is wrapped around the end of the conductor and is pressed with the conductor (3),
    characterized in
    - that after fixing the sleeve (5) consisting of an aluminum-based metal on the conductor (3) the end face of the same and the end of the sleeve (5) are mechanically processed such that a continuous plane surface arises,
    - that immediately after the mechanical processing a closed layer (9) made of a material capable of being soldered is applied to the plane surface, to which an electrical contact is attached, which is connected with the layer (9) by supplying heat in such a manner that it has electrically conductive contact to the overall cross section of the conductor, and
    - that the generation of the plane surface and the application of the layer (9) made of material capable of being soldered are carried out under protective gas.
  2. A method according to Claim 1, characterized in that after the generation of the plane surface the end of the conductor is immersed in a bath (8) with material capable of being soldered.
  3. A method according to Claim 2, characterized in that the end of the conductor (3) is treated by means of ultra-sound in the bath (8) with material capable of being soldered.
  4. A method according to Claim 1, characterized in that the layer (9) made of the material capable of being soldered is extended to over the circumferential surface of the sleeve (5).
EP16306778.8A 2016-12-22 2016-12-22 Method for fixing a contact element at the end of an electrical conductor Active EP3340397B1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP16306778.8A EP3340397B1 (en) 2016-12-22 2016-12-22 Method for fixing a contact element at the end of an electrical conductor
ES16306778T ES2732905T3 (en) 2016-12-22 2016-12-22 Procedure for fixing a contact element at the end of an electrical conductor

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP16306778.8A EP3340397B1 (en) 2016-12-22 2016-12-22 Method for fixing a contact element at the end of an electrical conductor

Publications (2)

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EP3340397A1 EP3340397A1 (en) 2018-06-27
EP3340397B1 true EP3340397B1 (en) 2019-04-03

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Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5517755A (en) * 1994-04-08 1996-05-21 Reltec Corporation Method for making a litz wire connection
DE19908031B4 (en) 1999-02-24 2009-08-13 Auto-Kabel Management Gmbh Connection of an electrical aluminum cable with a connector made of copper or the like metal
DE10346160B3 (en) 2002-05-25 2005-07-14 Feindrahtwerk Adolf Edelhoff Gmbh & Co. Contacting cable with wires or braids of aluminum or aluminum alloy involves tinning metal terminal on end with individual conductors at end of cable by ultrasonic tinning with metal via opening
DE10223397B4 (en) 2003-10-04 2004-05-06 Feindrahtwerk Adolf Edelhoff Gmbh & Co Method and connection for contacting an aluminum cable with a metallic, tin-plated contact terminal
DE10357048A1 (en) 2003-12-04 2005-07-21 Leoni Bordnetz-Systeme Gmbh & Co Kg Method for producing an electrical connection between an aluminum conductor and a contact element

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
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EP3340397A1 (en) 2018-06-27

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