EP3342008B1 - Method for producing a plug connector, method for amplifying a plug connector and device - Google Patents

Description

The invention relates to a method for producing a plug connection and a device produced therewith. In use, plug connections are often exposed to loads such as vibrations, temperature changes or other influences, in which a connection zone between two connections can be damaged.

Previous solutions are based in particular on conventional plug connections, which are typically no longer accessible after they have been produced and sheathed. For example, splice, solder, weld or adhesive connections are used for the connection in an area that has not yet been closed. In the latter variant, a connection point is protected in a separate step by a sealing process, for example by potting.

For procedures according to the state of the art - see EP1278277 -, it has been shown that the load capacity is too low for numerous applications. In addition, an alternative connection process or a subsequent protection of the connection point requires a complex process flow.

It is therefore an object of the invention to provide a method for producing a plug connection, as well as a device produced therewith, an alternative, in particular more reliable and / or easier connection being produced. This is achieved according to the invention by a method according to claim 1 and a device according to claim 13. Advantageous configurations can be found in the respective subclaims, for example.

The content of the claims is made part of the description by express reference.

By means of this method according to the invention, a plug connection can be produced which is particularly reliable and long-lasting due to the laser beam welding. By using an at least partially transparent plastic material, the laser beam welding can be carried out when the connection zone has already been encased. Separate process steps are therefore not necessary.

The laser beam welding can in particular form a weld which connects the first terminal to the second terminal. This welding point can absorb and absorb forces that typically act on the plug connection, so that there are no harmful influences.

The laser beam welding can in particular form a plurality of weld points, in particular two weld points can be formed. These connect the first terminal to the second terminal.

By using several welding points, the effect of the laser beam welding can be increased, since the forces are introduced or transmitted at several points.

The first terminal can in particular be a male terminal. The second terminal can in particular be a female terminal. Such male and female terminals typically fit into one another. The terminals can in particular be designed to be complementary to one another.

The first terminal and / or the second terminal can also have a flat tongue-like structure. In this case in particular, the first terminal and / or the second terminal can have a slide-on aid. This makes it easier to join the two terminals.

• Ermitteln eines optimalen Fokuspunkts, auf welchen der Laserstrahl dann fokussiert wird.

According to one embodiment, the method can furthermore have the following step:

• Determining an optimal focal point on which the laser beam is then focused.

In this way, it can be determined before the laser beam welding at which point the laser beam welding is advantageously carried out. In particular, it can be determined on which Place a cavity in the connection zone. The optimal focal point is then preferably outside this cavity, since typically only a poorer weld would be possible in the cavity.

The method can also advantageously have a step of checking the connection zone, in particular of formed weld points. In this way, welds can be checked so that any errors in their manufacture are detected before a manufactured component is delivered and an error may not occur until it is in use.

The determination and / or the checking can in particular be carried out by means of an x-ray device. This has proven itself for typical purposes.

The laser beam can be radiated onto the connecting zone from circumferential directions. This enables punctual heating of a very small area in the connection zone, with excessive heating of the surrounding material being avoided. The laser beam can also be divided into a plurality of partial beams which are radiated onto the connecting zone from different directions at the same time. This also enables the same effect, so that a relevant heat development occurs only at a certain point.

The laser beam can in particular have a wavelength between 520 nm and 565 nm. This corresponds to a green area. Such a wavelength range has proven to be advantageous for typical applications.

The plastic material can be, for example, polybutylene terephthalate (PBT) or polyamide (PA). These plastics have advantageous properties for sheathing a connection zone and, moreover, at least in some designs, the desired transparency.

The first terminal and / or the second terminal can be made of copper and / or bronze. This allows good electrical conduction and the production of good and reliable welds.

The invention further relates to a device according to claim 13, which has a plug connection which was produced by means of a method as described herein. With regard to the method, all embodiments and variants described herein can be used. Explained advantages apply accordingly.

The device according to the invention allows the implementation of the advantages described with reference to the method according to the invention with regard to the plug connection.

• Fig. 1a und 1b: eine Steckverbindung vor Durchführung einer Laserstrahlschweißung mit Gehäuse,
• Fig. 2: die Steckverbindung von Fig. 1 ohne Gehäuse,
• Fig. 3a, 3b, 3c: typische Kräfte auf die Steckverbindung von Fig. 2,
• Fig. 4: die Steckverbindung von Fig. 1a und 1b nach Laserstrahlschweißung,
• Fig. 5a, 5b, 5c: Wirkungen von Kräften auf die Steckverbindung von Fig. 4.

The person skilled in the art will learn further features and advantages from the exemplary embodiment described below with reference to the accompanying drawings. Show:

• Figures 1a and 1b : a plug connection prior to laser beam welding with the housing,
• Fig. 2 : the connector from Fig. 1 without housing,
• Figures 3a, 3b, 3c : typical forces on the connector of Fig. 2 ,
• Fig. 4 : the connector from Figures 1a and 1b after laser beam welding,
• Figures 5a, 5b, 5c : Effects of forces on the connector of Fig. 4 .

The Figures 1a and 1b show a plug connection which is formed from a first terminal 10 and a second terminal 20. Fig. 1a shows a side view while Figure 1b shows a plan view.

The two terminals 10, 20 overlap in a connection zone 30. They are thus electrically contacted.

The connection zone 30 together with the adjacent parts of the terminals 10, 20 is surrounded by a housing 40. The housing 40 consists of a plastic material which is transparent in the green wavelength range.

Although the two terminals 10, 20 are mechanically connected to one another at the connection zone 30 and are also protected by the housing 40, it has been shown that with prolonged stress in situations such as in motor vehicles, in which strong vibrations can occur, due to the resulting associated forces damage to the connection zone 30 can occur. This can lead to poorer or even lost contact between the terminals 10, 20.

Fig. 2 FIG. 8 shows the terminals 10, 20 with the connection zone 30 of FIG Fig. 1a but without the housing 40.

The Figures 3a, 3b and 3c show different force loads which can typically act on the connection zone 30. In Fig. 3a a first force 50 and a second force 55 are shown, which cause a load in the same direction at different intensities. In the Figures 3b and 3c act the two forces 50, 55 in opposite directions, with Figure 3b the forces 50, 55 are directed towards one another while they are at Figure 3c are directed away from each other.

The situations that occur in the Figures 3a, 3b and 3c are shown, are typical stress situations which can act on the connection zone 30 during use and which can lead to various types of damage, especially over long periods of time.

Fig. 4 shows the terminals 10, 20 after laser beam welding has been carried out. The laser beam welding formed a first weld 32 and a second weld 34 in the connection zone 30, which connect the first terminal 10 to the second terminal 20. In this way, the connection at the connection zone 30 is significantly strengthened and there is a much higher resistance to forces reached. In particular, it has been shown that such a laser beam welding significantly increases the resistance to vibrations and similar stresses which typically occur in motor vehicles.

The laser beam welding was carried out through the housing 40, which, as already mentioned above, is transparent in the green wavelength range. Accordingly, a green laser was used for the laser beam welding, which can thus penetrate through the housing 40.

The Figures 5a, 5b and 5c show those already in the Figures 3a, 3b and 3c load situations shown with a connection zone 30 reinforced by the welds 32, 34. Regarding the forces 50, 55 that act, refer to the above description of FIG Figures 3a, 3b and 3c referenced. As from the Figures 5a, 5b and 5c As can easily be seen, the welds 32, 34 increase the resistance of the connection zone 30 to such loads, which overall leads to a significantly longer durability.

Mentioned steps of the method according to the invention can be carried out in the order given. The method according to the invention can, in one of its embodiments, for example with a specific combination of steps, be carried out in such a way that no further steps are carried out. In principle, however, further steps can also be carried out, including those which are not mentioned.

The claims belonging to the registration do not represent a waiver of the achievement of further protection.

If it turns out in the course of the procedure that a feature or a group of features is not absolutely necessary, the applicant is already striving to formulate at least one independent claim which no longer has the feature or the group of features. Here can it is, for example, a sub-combination of a claim available on the filing date or a sub-combination, restricted by further features, of a claim available on the filing date. Such new claims or combinations of features are to be understood as being covered by the disclosure of this application.

It should also be noted that configurations, features and variants of the invention, which are described in the various embodiments or exemplary embodiments and / or shown in the figures, can be combined with one another as desired. Individual or multiple features can be interchanged as required. Combinations of features resulting therefrom are to be understood as being covered by the disclosure of this application.

References in dependent claims are not to be understood as a waiver of the achievement of an independent, objective protection for the features of the dependent claims. These features can also be combined with other features as required.

Features that are only disclosed in the description or features that are only disclosed in the description or in a claim in connection with other features can in principle be of independent importance for the invention. They can therefore also be included in claims individually to distinguish them from the prior art.

Claims (13)

1. Method for establishing a plug connection formed of a first terminal (10) and a second terminal (20), which method comprises the following steps:

   - bringing together the first terminal (10) and the second terminal (20), so that they overlap in a connecting zone (30) formed between them, then

   - sheathing the connecting zone (30) with a plastic material which is transparent in at least one wavelength range, and then

   - irradiating the connecting zone (30) with a laser beam, the wavelength of said laser beam lying in the wavelength range, for the purpose of carrying out laser beam welding.
2. Method according to Claim 1,
   wherein a welding point (32, 34) which connects the first terminal (10) to the second terminal (20) is formed by the laser beam welding.
3. Method according to Claim 1 or 2,
   wherein a plurality of welding points (32, 34), in particular two welding points (32, 34), which connect the first terminal (10) to the second terminal (20), are formed by the laser beam welding.
4. Method according to one of the preceding claims,
   wherein the first terminal (10) is a male terminal.
5. Method according to one of the preceding claims,
   wherein the second terminal (20) is a female terminal.
6. Method according to one of the preceding claims,
   wherein the first terminal (10) and/or the second terminal (20) have/has a flat tongue-like structure.
7. Method according to Claim 6,
   wherein the first terminal (10) and/or the second terminal (20) have/has a slide-on aid.
8. Method according to one of the preceding claims, which further comprises the following step:

   - ascertaining an optimal focal point onto which the laser beam is then focused.
9. Method according to one of the preceding claims, which further comprises the following step:

   - checking the connecting zone (30), in particular welding points (32, 34) which are formed.
10. Method according to either of Claims 8 and 9,
    wherein the ascertaining process and/or the checking process are/is carried out by means of an x-ray device.
11. Method according to one of the preceding claims,

    - wherein the laser beam is shone onto the connecting zone (30) from circumferential directions,
    and/or

    - wherein the laser beam is split into a plurality of beam elements which are shone onto the connecting zone (30) from different directions at the same time.
12. Method according to one of the preceding claims,

    - wherein the first terminal (10) and/or the second terminal (20) are/is formed from copper and/or bronze.
13. Apparatus which comprises a plug connection which was established by means of a method according to one of the preceding claims and which comprises the following:

    - the first and second terminal (10, 20), which overlap in the connecting zone (30), which are connected by the laser beam welding and which form the plug connection;

    - a housing (40) consisting of the plastic material, which is transparent in the at least one wavelength range, wherein the housing sheathes the plug connection.

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