EP3379652B1 - Arrangement for contacting an electrical conductor and method therefor - Google Patents

Arrangement for contacting an electrical conductor and method therefor Download PDF

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Publication number
EP3379652B1
EP3379652B1 EP17305336.4A EP17305336A EP3379652B1 EP 3379652 B1 EP3379652 B1 EP 3379652B1 EP 17305336 A EP17305336 A EP 17305336A EP 3379652 B1 EP3379652 B1 EP 3379652B1
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EP
European Patent Office
Prior art keywords
conductor
container
insulation
cable lug
stripped
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EP17305336.4A
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German (de)
French (fr)
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EP3379652A1 (en
Inventor
Roy Karchs
Helmut Steinberg
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Nexans SA
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Nexans SA
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Publication of EP3379652A1 publication Critical patent/EP3379652A1/en
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Publication of EP3379652B1 publication Critical patent/EP3379652B1/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
    • 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
    • H01R4/625—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
    • 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
    • H01R13/46—Bases; Cases
    • H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
    • H01R13/5205—Sealing means between cable and housing, e.g. grommet
    • 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
    • H01R4/187—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 combined with soldering or welding
    • 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

Definitions

  • the invention relates to an arrangement for contacting an electrical conductor according to the preamble of patent claim 1 and to a method for contacting an electrical conductor according to claim 2.
  • a large number of electrical conductors for example stranded conductors, and contact elements made of electrically conductive material connected to them are used. Electrical connections must be made between the voltage source, for example a battery, and actuators, sensors, control elements, etc.
  • the voltage source for example a battery
  • contact elements are elements made of metal, for example cable lugs, which are designed in such a way that they can be crimped onto or welded to a stripped conductor end.
  • the conductor and the contact element are non-positively and / or cohesively connected to one another.
  • Electrical conductors made of copper are increasingly being replaced by conductors made of aluminum or an aluminum alloy, especially in the automotive industry.
  • aluminum is a lighter and cheaper material with good electrical properties.
  • the contact elements mostly consist of copper or a copper alloy.
  • the metals are also to be named representative of their alloys.
  • the stripped aluminum conductor In order to establish a perfect electrically conductive connection between a contact element made of copper and an aluminum conductor, the stripped aluminum conductor must be freed from the non-conductive oxide layer, which forms when aluminum comes into contact with oxygen, before electrical connection. This can be achieved, for example, by welding the aluminum conductor to the contact element.
  • the Welding also has the advantage that the conductor and the contact element are materially connected to one another, so that any cold flow of the aluminum has no effect on the quality of the connection.
  • shrink tubing is often brought around the connection point, as is the case for example in DE 3 319 880 A1 is described.
  • the inside of the shrink tube is provided with a hot-melt adhesive, for example, and then contracts around the connection point by heating.
  • the material connection between the shrink tube and the adhesive is not optimally resistant to strong temperature fluctuations to which the conductors and contact elements can be exposed.
  • the shrink tubing process also has the disadvantage that it is relatively time-consuming and expensive.
  • connection In addition to media tightness, the mechanical stability of the connection with the contact element is particularly important for stranded conductors or battery cables with large cross-sections.
  • the connection must be resistant to vibrations and a possible cold flow of the aluminum.
  • the EP 2 662 934 A2 describes a connection between an electrical cable, which has an aluminum conductor, and a contact part made of copper.
  • an aluminum connection cap is first pushed onto the stripped end of the conductor, and one end is pressed with the conductor.
  • the connection cap has a sleeve and an end wall.
  • the contact part has a protrusion with a contact surface with a three-dimensional shape.
  • To establish the connection between the contact part and the conductor of the cable the contact part is placed with its contact surface on the end wall of the connection cap.
  • An electrical voltage is then applied to the contact part and the connection cap. Both parts are heated as a result. They are pressed against each other at the same time. Because of the different materials of the contact part and connection cap and conductor, the sleeve having the contact surface is pressed through the end wall of the sleeve into the conductor and welded to the same.
  • From the DE 10 2004 050 676 A1 shows a cable lug which has a hollow cylinder part with two sections with different diameters.
  • the cable lug is connected to an insulated electrical conductor in that the stripped conductor is inserted into the section of the hollow cylinder part with the smaller diameter and that a single conductor seal surrounding the insulated line is arranged in the section with the larger diameter.
  • the section of the hollow cylinder part surrounding the conductor is crimped on the conductor. Then the section of the hollow cylinder part surrounding the single conductor seal is also crimped on the enclosed parts.
  • the invention is based on the object of providing an arrangement for contacting an electrical conductor and a corresponding method which meet the above-mentioned requirements.
  • both the stripped end of the conductor and the end of the insulation of the conductor are advantageously crimped with one and the same cable lug in a non-positive manner. This prevents a relative movement between the insulation of the conductor and the cable lug. Any vibrations of the system in which the electrical conductor is attached, for example an engine compartment of a motor vehicle, are absorbed by the insulation crimp. Further cares the insulation crimp for strain relief of the electrical conductor.
  • the connection between the end of the line and the cable lug is accordingly protected from mechanical loads that can occur during use and is particularly durable.
  • the connection between the cable lug and the insulation is also completely sealed against moisture, oxygen, etc. by the sealing element pressed in between the wall of the container and the insulation of the conductor by the crimp wings of the insulation crimp. The electrical conductor and the contact point between the conductor and the contact element are protected against corrosion from environmental influences.
  • the arrangement according to the invention can advantageously be used for conductors with large cross-sections, which must be contacted reliably and consistently.
  • the object of the invention is also achieved by a method according to claim 2.
  • a cable lug 1 of the arrangement according to the invention is shown in the unassembled state in Fig. 1 shown.
  • the cable lug 1 has a pot-like, essentially cylindrical container 2, which is closed at its bottom 2a.
  • the container 2 represents a receptacle for an electrical conductor to be connected to the cable lug 1.
  • the container 2 can also have a conical shape narrowing towards the bottom 2a, or have other shapes suitable for holding the ladder.
  • the cable lug 1 consists for example of copper.
  • the container 2 is open on one side, opposite the bottom 2a.
  • the edge 2b forms a trumpet-shaped opening.
  • a flat contact end 3 is attached to the edge 2b.
  • the cable lug 1 can be connected to an electrical element, for example a battery terminal or the body of a motor vehicle.
  • the cable lug 1 can be screwed onto the electrical element, for which purpose a screw can be inserted through a bore or a hole 4 in the contact end 3.
  • the tab 5 with the crimping wings 6 and 7 represents an insulation crimp.
  • the transition between the edge 2b of the container 2 and the tab 5 is designed to be relatively narrow, so that the tab 5 can be bent away in the direction of the bottom 2a of the container 2, as indicated by the arrow 5a.
  • Fig. 2 is an embodiment of the arrangement according to the invention with an electrical conductor 10 and a cable lug 1 attached to it Fig. 1 shown.
  • the electrical conductor 10 is, for example, a stranded conductor made of aluminum.
  • the arrangement can, however, also have other types of electrical conductors, for example individual conductors.
  • Fig. 3 an embodiment of the arrangement according to the invention is shown in the assembled state with a conductor 10, the cable lug 1 being shown in section for a better overview.
  • the stranded conductor 10 consists of a large number of individual electrical conductors 11 and is surrounded by insulation 12.
  • the individual conductors 11 consist, for example, of aluminum.
  • the insulation 12 consists, for example, of silicone or polyvinyl chloride.
  • the conductor 10 is freed from the insulation 12 at its end.
  • the stripped end of the conductor 10 is inserted into the container 2 of the cable lug 1.
  • the end of the insulation 12 also extends a little way into the container 2.
  • the stripped part of the conductor 10 is completely covered by the cable lug 1.
  • the container 2 is crimped onto the stripped end of the conductor 10.
  • the end face 13 of the conductor 10 is welded to the bottom 2a of the container 2 of the cable lug 1.
  • the tab 5 of the cable lug 1 is bent approximately parallel to the longitudinal axis of the electrical conductor 10, so that the tab 5 points away from the stripped end of the conductor 10.
  • the two crimping wings 6 and 7 of the tab 5 are crimped around the electrical conductor 10 in the region of the end of the insulation 12.
  • the crimping wings 6 and 7 can extend somewhat into the container 2, as in FIG Fig. 3 shown.
  • the crimping wings 6 and 7 are accordingly partially located between the wall of the container 2 and the insulation 12 of the conductor 10.
  • a rotationally symmetrical sealing element 14 is arranged, which seals the stripped end of the conductor 10 from the environment.
  • the sealing element 14 is firmly pressed into the intermediate space by means of the two crimping wings 6 and 7 of the tab 5 and held there.
  • the method according to the invention for producing the arrangement shown above for sealing the connection between the contact element and the electrical conductor can be carried out, for example, as follows: First, a sealing element 14 is pushed onto the insulation 12 of the conductor 10. The end of the conductor 10 is stripped and inserted into the container 2 of the cable lug 1. The end face 13 of the conductor 10 is led to the bottom 2a of the container 2. The conductor 10 is stripped so far that the end of the insulation extends into the container 2. The cable lug 1 is then frictionally connected to the stripped conductor end by crimping the container 2. For example, the container 2 are pressed into a hexagon in its lower area close to the ground.
  • the upper area of the container 2 close to the edge is left rotationally symmetrical. Then the end face 13 of the conductor 10, or the end faces 13 of the individual conductors 11 of the stranded conductor 10, are welded to the bottom 2a of the container 2. This can take place, for example, in that a weld nugget is first produced thermally on the face of the conductor and then the conductor 10 is connected to the bottom 2a of the container 2 in a materially bonded manner, for example by friction stir welding.
  • the welded area is indicated by reference number 15 in Fig. 3 indicated.
  • the conductor 10 is now materially and non-positively connected to the cable lug 1.
  • the sealing element 14 is then pushed into the container 2 between its wall and the insulation 12 of the conductor 10, so that it rests in a rotationally symmetrical manner in the trumpet-shaped area of the container 2. Finally, the tab 5 of the cable lug 1 is bent in the direction of the insulation 12 of the conductor 10, so that the tab 5 continues the wall of the container 2 continuously.
  • the crimping wings 6 and 7 of the tab 5 are crimped around the insulation 12.
  • the space between the wall of the container 2 and the insulation 12 of the conductor 10 is closed to the outside by the crimping wings 6 and 7.
  • the crimping wings 6 and 7 are partially inserted into the space between them.
  • the sealing element 14 is pressed firmly into the space so that the stripped conductor end is completely sealed off from the environment.
  • the method shown for producing the contact can advantageously take place in an automated production process or be integrated therein.

Landscapes

  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)

Description

Die Erfindung bezieht sich auf eine Anordnung zur Kontaktierung eines elektrischen Leiters gemäß dem Obergriff des Patentanspruchs 1 sowie auf ein Verfahren zur Kontaktierung eines elektrischen Leiters gemäß Patentanspruch 2.The invention relates to an arrangement for contacting an electrical conductor according to the preamble of patent claim 1 and to a method for contacting an electrical conductor according to claim 2.

Insbesondere in der Automobilelektronik kommt eine Vielzahl von elektrischen Leitern, beispielsweise Litzenleitern, und mit diesen verbundenen Kontaktelementen aus elektrisch leitendem Material zum Einsatz. Elektrische Verbindungen müssen zwischen der Spannungsquelle, beispielsweise einer Batterie, und Aktuatoren, Sensoren, Steuerelementen usw. hergestellt werden. Beispielsweise in Fahrzeugen mit elektrischem Antrieb oder Hybridantrieb gibt es eine zunehmende Anzahl von Kontaktelementen, an welche elektrische Leiter angeschlossen werden müssen. In den meisten Fällen handelt es sich dabei um flexible isolierte Litzenleiter. Die Kontaktelemente sind Elemente aus Metall, beispielsweise Kabelschuhe, welche so beschaffen sind, dass sie an ein abisoliertes Leiterende gecrimpt oder mit diesem verschweißt werden können. Der Leiter und das Kontaktelement werden dabei kraft- und/oder stoffschlüssig miteinander verbunden.In particular in automotive electronics, a large number of electrical conductors, for example stranded conductors, and contact elements made of electrically conductive material connected to them are used. Electrical connections must be made between the voltage source, for example a battery, and actuators, sensors, control elements, etc. For example, in vehicles with an electric drive or hybrid drive, there is an increasing number of contact elements to which electrical conductors have to be connected. In most cases these are flexible, insulated stranded conductors. The contact elements are elements made of metal, for example cable lugs, which are designed in such a way that they can be crimped onto or welded to a stripped conductor end. The conductor and the contact element are non-positively and / or cohesively connected to one another.

Elektrische Leiter aus Kupfer werden heute, insbesondere in der Automobilindustrie, zunehmend durch Leiter aus Aluminium oder einer Aluminium-Legierung ersetzt. Aluminium ist gegenüber Kupfer ein leichteres und preiswerteres Material mit guten elektrischen Eigenschaften. Die Kontaktelemente bestehen zumeist aus Kupfer oder einer Kupferlegierung. Im Folgenden sollen die Metalle auch stellvertretend für ihre Legierungen genannt werden. Um eine einwandfreie elektrisch leitende Verbindung zwischen einem Kontaktelement aus Kupfer und einem Aluminiumleiter herzustellen, muß der abisolierte Aluminiumleiter vor dem elektrischen Verbinden von der nichtleitenden Oxidschicht befreit werden, die sich beim Kontakt von Aluminium mit Sauerstoff bildet. Dies kann beispielsweise durch Verschweißen des Aluminiumleiters mit dem Kontaktelement bewirkt werden. Das Verschweißen hat weiterhin den Vorteil, dass der Leiter und das Kontaktelement stofflich miteinander verbunden sind, sodass ein eventuelles Kaltfließen des Aluminiums keinen Einfluß auf die Qualität der Verbindung hat.Electrical conductors made of copper are increasingly being replaced by conductors made of aluminum or an aluminum alloy, especially in the automotive industry. Compared to copper, aluminum is a lighter and cheaper material with good electrical properties. The contact elements mostly consist of copper or a copper alloy. In the following, the metals are also to be named representative of their alloys. In order to establish a perfect electrically conductive connection between a contact element made of copper and an aluminum conductor, the stripped aluminum conductor must be freed from the non-conductive oxide layer, which forms when aluminum comes into contact with oxygen, before electrical connection. This can be achieved, for example, by welding the aluminum conductor to the contact element. The Welding also has the advantage that the conductor and the contact element are materially connected to one another, so that any cold flow of the aluminum has no effect on the quality of the connection.

Um Korrosion an dem abisolierten Leiterende bzw. Kontaktkorrosion an der Verbindung zwischen Kontaktelement und Leiter zu vermeiden, dürfen weder Sauerstoff noch Feuchtigkeit an den Leiter gelangen. Korrosion hat einen erhöhten Übergangswiderstand zwischen Leiter und Kontaktelement zur Folge und kann außerdem die Festigkeit der metallischen Verbindung beeinträchtigen. Weiterhin ist es möglich, dass Feuchtigkeit durch den Spalt zwischen dem Leiter und der Isolierung aufgrund von Kapillarwirkung in Leitungsrichtung vordringt. Die Verbindungsstelle um das Ende der Isolierung und das Kontaktelement muss deshalb mediendicht abgedichtet werden.In order to avoid corrosion on the stripped end of the conductor or contact corrosion on the connection between contact element and conductor, neither oxygen nor moisture must reach the conductor. Corrosion results in increased contact resistance between the conductor and the contact element and can also impair the strength of the metallic connection. Furthermore, it is possible that moisture penetrates through the gap between the conductor and the insulation due to capillary action in the direction of the line. The connection point around the end of the insulation and the contact element must therefore be sealed media-tight.

Insbesondere bei gecrimpten Kabelschuhen wird oft ein Schrumpfschlauch um die Verbindungsstelle gebracht, wie es beispielsweise in der DE 3 319 880 A1 beschrieben ist. Der Schrumpfschlauch wird dabei an seiner Innenseite beispielsweise mit einem Heißklebstoff versehen und zieht sich anschließend durch Erhitzen um die Verbindungsstelle zusammen. Die Materialverbindung von Schrumpfschlauch und Klebstoff ist jedoch gegenüber starken Temperaturschwankungen, denen die Leiter und Kontaktelemente ausgesetzt sein können, nicht optimal beständig. Das Schrumpfschlauchverfahren hat außerdem den Nachteil, dass es relativ zeitaufwendig und kostspielig ist.In the case of crimped cable lugs in particular, shrink tubing is often brought around the connection point, as is the case for example in DE 3 319 880 A1 is described. The inside of the shrink tube is provided with a hot-melt adhesive, for example, and then contracts around the connection point by heating. However, the material connection between the shrink tube and the adhesive is not optimally resistant to strong temperature fluctuations to which the conductors and contact elements can be exposed. The shrink tubing process also has the disadvantage that it is relatively time-consuming and expensive.

Insbesondere für Litzenleiter oder Batterieleitungen mit großen Querschnitten ist neben der Mediendichtigkeit die mechanische Stabilität der Verbindung mit dem Kontaktelement von Bedeutung. Die Verbindung muß widerstandsfähig gegenüber Schwingungen und einem eventuellen Kaltfließen des Aluminiums sein.In addition to media tightness, the mechanical stability of the connection with the contact element is particularly important for stranded conductors or battery cables with large cross-sections. The connection must be resistant to vibrations and a possible cold flow of the aluminum.

Die EP 2 662 934 A2 beschreibt eine Verbindung zwischen einem elektrischen Kabel, das einen Leiter aus Aluminium hat, und einem Kontaktteil aus Kupfer. Für diese Verbindung wird zunächst auf das abisolierte Ende des Leiters eine Verbindungskappe aus Aluminium aufgeschoben, die an einem Ende mit dem Leiter verpreßt wird. Die Verbindungskappe hat eine Hülse und eine Stirnwand. Das Kontaktteil hat einen Vorsprung mit einer Kontaktfläche mit einer dreidimensionalen Form. Zur Herstellung der Verbindung von Kontaktteil und Leiter des Kabels wird das Kontaktteil mit seiner Kontaktfläche an die Stirnwand der Verbindungskappe angelegt. Es wird dann eine elektrische Spannung an das Kontaktteil und die Verbindungskappe gelegt. Beide Teile werden dadurch erwärmt. Sie werden gleichzeitig gegeneinander gedrückt. Wegen der unterschiedlichen Materialien von Kontaktteil und Verbindungskappe sowie Leiter wird die die Kontaktfläche aufweisende Hülse durch die Stirnwand der Hülse hindurch bis in den Leiter gedrückt und mit demselben verschweißt.The EP 2 662 934 A2 describes a connection between an electrical cable, which has an aluminum conductor, and a contact part made of copper. For this connection, an aluminum connection cap is first pushed onto the stripped end of the conductor, and one end is pressed with the conductor. The connection cap has a sleeve and an end wall. The contact part has a protrusion with a contact surface with a three-dimensional shape. To establish the connection between the contact part and the conductor of the cable, the contact part is placed with its contact surface on the end wall of the connection cap. An electrical voltage is then applied to the contact part and the connection cap. Both parts are heated as a result. They are pressed against each other at the same time. Because of the different materials of the contact part and connection cap and conductor, the sleeve having the contact surface is pressed through the end wall of the sleeve into the conductor and welded to the same.

Aus der DE 10 2004 050 676 A1 geht ein Kabelschuh hervor, der einen Hohlzylinderteil mit zwei Abschnitten mit unterschiedlichen Durchmessern aufweist. Der Kabelschuh wird dadurch mit einem isolierten elektrischen Leiter verbunden, dass der abisolierte Leiter in den Abschnitt des Hohlzylinderteils mit dem kleineren Durchmesser eingeführt wird und dass in dem Abschnitt mit dem größeren Durchmesser eine die isolierte Leitung umgebende Einzelleiterdichtung angeordnet wird. Der den Leiter umgebende Abschnitt des Hohlzylinderteils wird auf dem Leiter quetschverbunden. Danach wird der die Einzelleiterdichtung umgebende Abschnitt des Hohlzylinderteils auf den umschlossenen Teilen ebenfalls quetschverbunden.From the DE 10 2004 050 676 A1 shows a cable lug which has a hollow cylinder part with two sections with different diameters. The cable lug is connected to an insulated electrical conductor in that the stripped conductor is inserted into the section of the hollow cylinder part with the smaller diameter and that a single conductor seal surrounding the insulated line is arranged in the section with the larger diameter. The section of the hollow cylinder part surrounding the conductor is crimped on the conductor. Then the section of the hollow cylinder part surrounding the single conductor seal is also crimped on the enclosed parts.

Der Erfindung liegt die Aufgabe zugrunde, eine Anordnung zum Kontaktieren eines elektrischen Leiters sowie ein entsprechendes Verfahren bereitzustellen, welche die oben genannten Anforderungen erfüllen.The invention is based on the object of providing an arrangement for contacting an electrical conductor and a corresponding method which meet the above-mentioned requirements.

Diese Aufgabe wird entsprechend den kennzeichnenden Merkmalen der Patentansprüchen und gelöst.This object is achieved according to the characterizing features of the patent claims and.

Bei der erfindungsgemäßen Anordnung sind mit Vorteil sowohl das abisolierte Leiterende als auch das Ende der Isolierung des Leiters kraftschlüssig mit ein und demselben Kabelschuh vercrimpt. Dadurch ist eine Relativbewegung zwischen der Isolierung des Leiters und dem Kabelschuh ausgeschlossen. Eventuelle Schwingungen der Anlage, in welcher der elektrische Leiter angebracht ist, beispielsweise eines Motorraums eines Kraftfahrzeugs, werden von dem Isolationscrimp absorbiert. Weiterhin sorgt der Isolationscrimp für eine Zugentlastung des elektrischen Leiters. Die Verbindung zwischen dem Leitungsende und dem Kabelschuh ist demnach vor mechanischen Belastungen, welche im Einsatz derselben auftreten können, geschützt und besonders haltbar. Durch das zwischen der Wandung des Behälters und der Isolierung des Leiters von den Crimpflügeln des Isolationscrimps eingepreßte Dichtelement ist die Verbindung zwischen dem Kabelschuh und der Isolierung außerdem vollständig gegen Feuchtigkeit, Sauerstoff, etc. abgedichtet. Der elektrische Leiter sowie die Kontaktstelle zwischen dem Leiter und dem Kontaktelement sind gegen Korrosion durch Umwelteinflüsse geschützt.In the arrangement according to the invention, both the stripped end of the conductor and the end of the insulation of the conductor are advantageously crimped with one and the same cable lug in a non-positive manner. This prevents a relative movement between the insulation of the conductor and the cable lug. Any vibrations of the system in which the electrical conductor is attached, for example an engine compartment of a motor vehicle, are absorbed by the insulation crimp. Further cares the insulation crimp for strain relief of the electrical conductor. The connection between the end of the line and the cable lug is accordingly protected from mechanical loads that can occur during use and is particularly durable. The connection between the cable lug and the insulation is also completely sealed against moisture, oxygen, etc. by the sealing element pressed in between the wall of the container and the insulation of the conductor by the crimp wings of the insulation crimp. The electrical conductor and the contact point between the conductor and the contact element are protected against corrosion from environmental influences.

Die erfindungsgemäße Anordnung kann mit Vorteil für Leiter mit großen Querschnitten eingesetzt werden, welche sicher und beständig kontaktiert werden müssen.The arrangement according to the invention can advantageously be used for conductors with large cross-sections, which must be contacted reliably and consistently.

Die Aufgabe der Erfindung wird weiterhin durch ein Verfahren nach Patentanspruch 2 gelöst.The object of the invention is also achieved by a method according to claim 2.

Ein Ausführungsbeispiel des Erfindungsgegenstandes ist in den Zeichnungen dargestellt. Es zeigen:

  • Fig. 1 einen Kabelschuh in unmontiertem Zustand nach einem Ausführungsbeispiel der Anordnung nach der Erfindung.
  • Fig. 2 ein Ausführungsbeispiel der Anordnung mit dem Kabelschuh in montiertem Zustand.
  • Fig. 3 die Anordnung nach Fig. 2 in einem Längsschnitt.
An exemplary embodiment of the subject matter of the invention is shown in the drawings. Show it:
  • Fig. 1 a cable lug in the unassembled state according to an embodiment of the arrangement according to the invention.
  • Fig. 2 an embodiment of the arrangement with the cable lug in the assembled state.
  • Fig. 3 the arrangement according to Fig. 2 in a longitudinal section.

In den Zeichnungen beziehen sich gleiche Bezugszeichen auf gleiche technische Merkmale.In the drawings, the same reference symbols relate to the same technical features.

Ein Kabelschuh 1 der erfindungsgemäßen Anordnung ist in unmontiertem Zustand in Fig. 1 gezeigt. Der Kabelschuh 1 weist einen topfartigen, im Wesentlichen zylindrischen Behälter 2 auf, welcher an seinem Boden 2a geschlossen ist. Der Behälter 2 stellt eine Aufnahme für einen mit dem Kabelschuh 1 zu verbindenden elektrischen Leiter dar. Der Behälter 2 kann auch eine konische, sich zum Boden 2a hin verengende Form, oder andere, zur Leiteraufnahme geeignete Formen haben. Der Kabelschuh 1 besteht beispielsweise aus Kupfer.A cable lug 1 of the arrangement according to the invention is shown in the unassembled state in Fig. 1 shown. The cable lug 1 has a pot-like, essentially cylindrical container 2, which is closed at its bottom 2a. The container 2 represents a receptacle for an electrical conductor to be connected to the cable lug 1. The container 2 can also have a conical shape narrowing towards the bottom 2a, or have other shapes suitable for holding the ladder. The cable lug 1 consists for example of copper.

Der Behälter 2 ist nach einer Seite, dem Boden 2a gegenüberliegend, offen. Der Rand 2b bildet eine trompetenförmige Öffnung. Am Rand 2b ist ein flaches Kontaktende 3 angebracht. Mittels des Kontaktendes 3 kann der Kabelschuh 1 mit einem elektrischen Element, beispielsweise einer Batterieklemme oder der Karosserie eines Kraftfahrzeugs, verbunden werden. Beispielsweise kann der Kabelschuh 1 an das elektrische Element geschraubt werden, wozu eine Schraube durch eine Bohrung bzw. ein Loch 4 in dem Kontaktende 3 gesteckt werden kann.The container 2 is open on one side, opposite the bottom 2a. The edge 2b forms a trumpet-shaped opening. A flat contact end 3 is attached to the edge 2b. By means of the contact end 3, the cable lug 1 can be connected to an electrical element, for example a battery terminal or the body of a motor vehicle. For example, the cable lug 1 can be screwed onto the electrical element, for which purpose a screw can be inserted through a bore or a hole 4 in the contact end 3.

Dem Kontaktende 3 gegenüber ist an dem offenen Rand 2b des Behälters 2 eine Lasche 5 angebracht, welche zwei Crimpflügel 6 und 7 aufweist. Die Lasche 5 mit den Crimpflügeln 6 und 7 stellt einen Isolationscrimp dar. Der Übergang zwischen dem Rand 2b des Behälters 2 und der Lasche 5 ist relativ schmal gestaltet, sodass die Lasche 5 in Richtung vom Boden 2a des Behälters 2 weg gebogen werden kann, wie mit dem Pfeil 5a angedeutet.A tab 5, which has two crimping wings 6 and 7, is attached to the open edge 2b of the container 2 opposite the contact end 3. The tab 5 with the crimping wings 6 and 7 represents an insulation crimp. The transition between the edge 2b of the container 2 and the tab 5 is designed to be relatively narrow, so that the tab 5 can be bent away in the direction of the bottom 2a of the container 2, as indicated by the arrow 5a.

In Fig. 2 ist ein Ausführungsbeispiel der erfindungsgemäßen Anordnung mit einem elektrischen Leiter 10 und einem daran angebrachten Kabelschuh 1 nach Fig. 1 gezeigt. Der elektrische Leiter 10 ist beispielsweise ein Litzenleiter aus Aluminium. Die Anordnung kann allerdings auch andere Arten von elektrischen Leitern, beispielsweise Einzelleiter, aufweisen.In Fig. 2 is an embodiment of the arrangement according to the invention with an electrical conductor 10 and a cable lug 1 attached to it Fig. 1 shown. The electrical conductor 10 is, for example, a stranded conductor made of aluminum. The arrangement can, however, also have other types of electrical conductors, for example individual conductors.

In Fig. 3 ist ein Ausführungsbeispiel der erfindungsgemäßen Anordnung in montiertem Zustand mit einem Leiter 10 gezeigt, wobei der Kabelschuh 1 zur besseren Übersicht im Schnitt dargestellt ist. Der Litzenleiter 10 besteht aus einer Vielzahl von elektrischen Einzelleitern 11 und ist von einer Isolierung 12 umgeben. Die Einzelleiter 11 bestehen beispielsweise aus Aluminium. Die Isolierung 12 besteht beispielsweise aus Silikon oder Polyvinylchlorid. Der Leiter 10 ist an seinem Ende von der Isolierung 12 befreit.In Fig. 3 an embodiment of the arrangement according to the invention is shown in the assembled state with a conductor 10, the cable lug 1 being shown in section for a better overview. The stranded conductor 10 consists of a large number of individual electrical conductors 11 and is surrounded by insulation 12. The individual conductors 11 consist, for example, of aluminum. The insulation 12 consists, for example, of silicone or polyvinyl chloride. The conductor 10 is freed from the insulation 12 at its end.

Das abisolierte Ende des Leiters 10 ist in den Behälter 2 des Kabelschuhs 1 eingesteckt. Das Ende der Isolierung 12 reicht ebenfalls ein Stück weit in den Behälter 2 hinein. Der abisolierte Teil des Leiters 10 ist vollständig von dem Kabelschuh 1 bedeckt. Der Behälter 2 ist an das abisolierte Ende des Leiters 10 gecrimpt. Die Stirnseite 13 des Leiters 10 ist am Boden 2a des Behälters 2 des Kabelschuhs 1 angeschweißt.The stripped end of the conductor 10 is inserted into the container 2 of the cable lug 1. The end of the insulation 12 also extends a little way into the container 2. The stripped part of the conductor 10 is completely covered by the cable lug 1. The container 2 is crimped onto the stripped end of the conductor 10. The end face 13 of the conductor 10 is welded to the bottom 2a of the container 2 of the cable lug 1.

Die Lasche 5 des Kabelschuhs 1 ist etwa parallel zur longitudinalen Achse des elektrischen Leiters 10 gebogen, sodass die Lasche 5 vom abisolierten Ende des Leiters 10 weg zeigt. Die beiden Crimpflügel 6 und 7 der Lasche 5 sind um den elektrischen Leiter 10 im Bereich des Endes der Isolierung 12 gecrimpt. Die Crimpflügel 6 und 7 können dabei etwas in den Behälter 2 hineinreichen, wie in Fig. 3 dargestellt. Die Crimpflügel 6 und 7 befinden sich demnach teilweise zwischen der Wandung des Behälters 2 und der Isolierung 12 des Leiters 10.The tab 5 of the cable lug 1 is bent approximately parallel to the longitudinal axis of the electrical conductor 10, so that the tab 5 points away from the stripped end of the conductor 10. The two crimping wings 6 and 7 of the tab 5 are crimped around the electrical conductor 10 in the region of the end of the insulation 12. The crimping wings 6 and 7 can extend somewhat into the container 2, as in FIG Fig. 3 shown. The crimping wings 6 and 7 are accordingly partially located between the wall of the container 2 and the insulation 12 of the conductor 10.

In einem Zwischenraum zwischen der Wandung des Behälters 2 und der Isolierung 12 des Leiters 10 ist ein rotationssymmetrisches Dichtelement 14 angeordnet, welches das abisolierte Ende des Leiters 10 gegenüber der Umgebung abdichtet. Das Dichtelement 14 ist mittels der beiden Crimpflügel 6 und 7 der Lasche 5 fest in den Zwischenraum eingepreßt und dort gehalten.In an intermediate space between the wall of the container 2 and the insulation 12 of the conductor 10, a rotationally symmetrical sealing element 14 is arranged, which seals the stripped end of the conductor 10 from the environment. The sealing element 14 is firmly pressed into the intermediate space by means of the two crimping wings 6 and 7 of the tab 5 and held there.

Das erfindungsgemäße Verfahren zur Herstellung der oben dargestellten Anordnung zur Abdichtung der Verbindung zwischen dem Kontaktelement und dem elektrischen Leiter kann beispielsweise wie folgt durchgeführt werden:
Zunächst wird ein Dichtelement 14 auf die Isolierung 12 des Leiters 10 geschoben. Das Ende des Leiters 10 wird abisoliert und in den Behälter 2 des Kabelschuhs 1 eingeführt. Die Stirnseite 13 des Leiters 10 wird bis an den Boden 2a des Behälters 2 geführt. Der Leiter 10 wird dabei so weit abisoliert, dass das Ende der Isolierung bis in den Behälter 2 hineinreicht. Der Kabelschuh 1 wird anschließend kraftschlüssig durch Crimpen des Behälters 2 mit dem abisolierten Leiterende verbunden. Beispielsweise kann der Behälter 2 in seinem unteren, bodennahen Bereich zu einem Sechskant verpreßt werden.The method according to the invention for producing the arrangement shown above for sealing the connection between the contact element and the electrical conductor can be carried out, for example, as follows:
First, a sealing element 14 is pushed onto the insulation 12 of the conductor 10. The end of the conductor 10 is stripped and inserted into the container 2 of the cable lug 1. The end face 13 of the conductor 10 is led to the bottom 2a of the container 2. The conductor 10 is stripped so far that the end of the insulation extends into the container 2. The cable lug 1 is then frictionally connected to the stripped conductor end by crimping the container 2. For example, the container 2 are pressed into a hexagon in its lower area close to the ground.

Der obere, randnahe Bereich des Behälters 2 wird rotationssymmetrisch belassen. Anschließend wird die Stirnseite 13 des Leiters 10, bzw. werden die Stirnseiten 13 der einzelnen Leiter 11 des Litzenleiters 10, mit dem Boden 2a des Behälters 2 verschweißt. Dies kann beispielsweise dadurch erfolgen, dass zunächst thermisch eine Schweißlinse auf der Leiterstirnseite erzeugt und danach der Leiter 10 stoffschlüssig, beispielsweise durch Rührreibschweißen, mit dem Boden 2a des Behälters 2 verbunden wird. Der verschweißte Bereich ist mittels der Bezugsnummer 15 in Fig. 3 angedeutet. Der Leiter 10 ist nun stoff- und kraftschlüssig mit dem Kabelschuh 1 verbunden.The upper area of the container 2 close to the edge is left rotationally symmetrical. Then the end face 13 of the conductor 10, or the end faces 13 of the individual conductors 11 of the stranded conductor 10, are welded to the bottom 2a of the container 2. This can take place, for example, in that a weld nugget is first produced thermally on the face of the conductor and then the conductor 10 is connected to the bottom 2a of the container 2 in a materially bonded manner, for example by friction stir welding. The welded area is indicated by reference number 15 in Fig. 3 indicated. The conductor 10 is now materially and non-positively connected to the cable lug 1.

Danach wird das Dichtelement 14 in den Behälter 2 zwischen dessen Wandung und die Isolierung 12 des Leiters 10 geschoben, sodass dieser in dem trompetenförmigen Bereich des Behälters 2 rotationssymmetrisch anliegt. Abschließend wird die Lasche 5 des Kabelschuhs 1 in Richtung der Isolierung 12 des Leiters 10 verbogen, sodass die Lasche 5 die Wandung des Behälters 2 stetig weiterführt. Die Crimpflügel 6 und 7 der Lasche 5 werden um die Isolierung 12 gecrimpt. Dabei wird der Zwischenraum zwischen der Wandung des Behälters 2 und der Isolierung 12 des Leiters 10 nach außen hin von den Crimpflügeln 6 und 7 verschlossen. Die Crimpflügel 6 und 7 werden dafür teilweise in den Zwischenraum eingeführt. Das Dichtelement 14 wird dadurch fest in den Zwischenraum eingepreßt, sodass das abisolierte Leiterende vollständig gegenüber der Umwelt abgedichtet ist.The sealing element 14 is then pushed into the container 2 between its wall and the insulation 12 of the conductor 10, so that it rests in a rotationally symmetrical manner in the trumpet-shaped area of the container 2. Finally, the tab 5 of the cable lug 1 is bent in the direction of the insulation 12 of the conductor 10, so that the tab 5 continues the wall of the container 2 continuously. The crimping wings 6 and 7 of the tab 5 are crimped around the insulation 12. The space between the wall of the container 2 and the insulation 12 of the conductor 10 is closed to the outside by the crimping wings 6 and 7. For this purpose, the crimping wings 6 and 7 are partially inserted into the space between them. The sealing element 14 is pressed firmly into the space so that the stripped conductor end is completely sealed off from the environment.

Das dargestellte Verfahren zur Herstellung der Kontaktierung kann mit Vorteil in einem automatisierten Fertigungsablauf erfolgen oder darin integriert werden.The method shown for producing the contact can advantageously take place in an automated production process or be integrated therein.

Claims (2)

  1. An arrangement for contacting an electrical conductor (10), which has an insulation (12), wherein a cable lug (1) is crimped around a stripped end of the conductor (10) and an end face (13) of the conductor (10) is welded to the cable lug (1), wherein the cable lug (1) has a cup-like container (2), which is closed on a bottom (2a) of the container (2) and open on a side opposite the bottom (2a) at an edge (2b), in which a flat contact end (3) is attached to the edge (2b), characterized in that a tab (5) serving as an insulation crimp is attached opposite the edge (2b), which has two crimping wings (6,7),
    - that the stripped end of the conductor (10) is fixed in the container (2) by crimping and welding, wherein an end of the insulation (12) extends into the container (2),
    - that the crimping wings (6,7) of the tab (5) are crimped around the end of the insulation (12) of the conductor (10), and
    - that an annular sealing element (14) is arranged in a space between a wall of the container (2) and the insulation (12) of the stripped end of the conductor (10) and is pressed into the space by the crimping wings (6, 7) of the tab (5), so that the container (2) is tightly closed.
  2. A method for contacting an electrical conductor (10), which has an insulation (12), in which a cable lug (1) is crimped around a stripped end of the conductor (10) and an end face (13) of the conductor (10) is welded to the cable lug (1),
    - wherein an annular sealing element (14) is slid onto the insulation (12) of the conductor (10),
    - wherein the stripped end of the conductor (10) is inserted into a cup-like container (2) of the cable lug (1), which is closed on a bottom (2a) and is open on its side opposite the bottom (2a) at an edge (2b), such that an end of the insulation (12) of the conductor (10) extends into the container (2), and in which the stripped end of the conductor (10) is fixed by crimping and welding,
    - wherein the annular sealing element (14) is slid into a space between a wall of the container (2) and the stripped end of the conductor (10) and
    - that a flat contact end (3) and opposite the same a tab (5) serving as an insulation crimp are attached to the edge (2b), which tab has two crimping wings (6, 7), which are crimped around the end of the insulation (12) of the conductor (10), wherein the annular sealing element (14) is pressed by the crimping wings (6, 7) of the tab between the wall of the container (2) and the stripped conductor end, so that the container (2) is tightly closed.
EP17305336.4A 2017-03-24 2017-03-24 Arrangement for contacting an electrical conductor and method therefor Active EP3379652B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP17305336.4A EP3379652B1 (en) 2017-03-24 2017-03-24 Arrangement for contacting an electrical conductor and method therefor

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP17305336.4A EP3379652B1 (en) 2017-03-24 2017-03-24 Arrangement for contacting an electrical conductor and method therefor

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EP3379652A1 EP3379652A1 (en) 2018-09-26
EP3379652B1 true EP3379652B1 (en) 2021-04-28

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Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3656092A (en) * 1970-08-07 1972-04-11 Amp Inc Terminal device for welded termination of electrical leads
DE3319880A1 (en) 1983-06-01 1984-12-06 Compakta Werke Baustoff-GmbH, 8225 Traunreut Elastic, liquid-tight connection of metal cable insulation to the metallic connecting clamp
DE29806778U1 (en) * 1998-04-15 1999-09-02 Grote & Hartmann Screw connection
JP2002216862A (en) * 2001-01-19 2002-08-02 Yazaki Corp Waterproof structure of connection part of electric wire and terminal, and waterproofing method
JP4326797B2 (en) * 2002-12-26 2009-09-09 株式会社オートネットワーク技術研究所 Connection structure between wires and terminal fittings
DE102004050676A1 (en) * 2004-10-18 2006-04-20 Volkswagen Ag Cable socket for bulk screw connection in motor vehicle, has cylinder part with sections of different diameters, where one section is closed at turned away part of section with larger diameter and cylinder part drawn out of sheet metal
DE102011017070B4 (en) * 2011-04-14 2013-10-31 Auto-Kabel Management Gmbh Production of an electric cable and method for producing a connection
EP2621021A1 (en) * 2012-01-25 2013-07-31 Intercable GmbH Cable lug for connecting a conductive element with an aluminium cable
AT512881B1 (en) * 2012-05-11 2014-03-15 Gebauer & Griller Connection of an electrical cable to a contact part and method of making this connection

Non-Patent Citations (1)

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Title
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