EP3419121B1 - Procédé de fabrication d'une liaison électrique et système de soudure par ultrasons - Google Patents

Procédé de fabrication d'une liaison électrique et système de soudure par ultrasons Download PDF

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Publication number
EP3419121B1
EP3419121B1 EP17305785.2A EP17305785A EP3419121B1 EP 3419121 B1 EP3419121 B1 EP 3419121B1 EP 17305785 A EP17305785 A EP 17305785A EP 3419121 B1 EP3419121 B1 EP 3419121B1
Authority
EP
European Patent Office
Prior art keywords
contact element
anvil
ultrasonic welding
surface structure
welding system
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP17305785.2A
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German (de)
English (en)
Other versions
EP3419121A1 (fr
Inventor
Andreas Pedimonte
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nexans SA
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Nexans SA
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Publication date
Application filed by Nexans SA filed Critical Nexans SA
Priority to EP17305785.2A priority Critical patent/EP3419121B1/fr
Publication of EP3419121A1 publication Critical patent/EP3419121A1/fr
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Publication of EP3419121B1 publication Critical patent/EP3419121B1/fr
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    • 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
    • H01R43/0207—Ultrasonic-, H.F.-, cold- or impact 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
    • H01R4/02—Soldered or welded connections
    • H01R4/023—Soldered or welded connections between cables or wires and terminals

Definitions

  • the invention relates to a method for producing an electrical connection and an ultrasonic welding system which is suitable for carrying out the method.
  • This method has prevailed particularly in electrical lines having a conductor which is made of stranded strands.
  • the contact element is pressed with a so-called side shifter on the anvil of the welding system.
  • the surface of the anvil is profiled, for example with projecting ribs, to improve the mechanical contact with the contact element and the anvil.
  • On the other side of the contact element of the stranded electrical conductor is pressed by means of the sonotrode on the contact element and set in vibration. The conductor is firmly welded to the contact element.
  • an electrical contact element with a connection region for the connection of an electrical conductor and a contact region is known.
  • the electrical conductor is connected by ultrasonic welding to the connection area, which has a surface structure.
  • the present invention is based on the general object to improve the quality of welded joints between electrical conductors and contact elements.
  • the method of the invention has the advantage that the inter-engaging surface structures on the contact element and the anvil prevent the contact element from vibrating upon welding to an extent that could compromise the quality of the weld. As a result, improved quality of the weld is achieved, especially with aluminum pipes.
  • the invention proposes an ultrasonic welding system with an ultrasonic welding system, which has a sonotrode and an anvil, and with a contact element for an electrical line.
  • the anvil and the contact element each have a surface structure that is complementary to each other. The surface structures improve the mechanical contact between the contact element and the anvil of the ultrasonic welding machine.
  • the anvil has at least one rib with a triangular cross-section. Accordingly, the contact element is provided with as many grooves with a triangular cross section as the anvil has ribs, wherein the included between the flanks of a groove angle is smaller than the included between the edges of a rib angle.
  • This embodiment has the advantage that the ribs rest only along two lines along the grooves, whereby play between anvil and contact element is avoided.
  • the locations of the ribs and grooves are reversed, i. the anvil has grooves while the contact element is provided with ribs. But even in this embodiment, the included between the flanks of a groove angle is smaller than the included between the edges of a rib angle.
  • the surface structures of the anvil and contact elements come into engagement with one another such that a positive connection between the anvil and the contact element is produced.
  • an electrical contact element with a connection region for the connection of an electrical conductor by ultrasonic welding and with a contact region in connection with the invention can be used.
  • the terminal region has a surface structure that allows for improved mechanical contact with the anvil of an ultrasonic welding machine.
  • the surface structure of the electrical contact element is designed to be complementary to a surface structure of an anvil of an ultrasonic welding system.
  • an exclusion between the anvil of the ultrasonic welding system and the contact element is achieved.
  • the positive engagement prevents vibration of the contact element during welding, which could be detrimental to the quality of the weld.
  • FIG. 1 schematically shows a contact element 10 in a perspective view.
  • the contact element 10 is divided into a connection region 11 and a contact region 12.
  • the connection region 11 is formed flat and provided for the connection of an electrical conductor.
  • the contact region 12 has a substantially round cross-section and is intended for connection to electrical components or devices, for example in an automobile.
  • the connection area 11 has two main surfaces, of which in FIG. 1 only the main surface 13 is visible. Both main surfaces have a smooth surface. On the non-visible main surface, an electrical conductor is welded in an ultrasonic welding device, while the main surface 13 is in contact with an anvil of a welding system during the welding process.
  • FIG. 2A shows in a perspective view from the side an anvil 20 of a welding system.
  • a belonging to the welding system sonotrode in FIG. 2A not shown, which serves to generate the vibrations necessary for welding.
  • On the anvil 20 a support surface 21 is visible, on which an electrical contact element 10 is placed and positioned by means of an insertion mask 22.
  • the support surface 21 of the anvil 20 is provided with a surface structure with respect to FIG. 2B will be explained in more detail.
  • the anvil including the surface structure is made in one piece.
  • the welding system on a side slide not shown, whose function will be explained below.
  • the anvil 20 is constructed in two parts and has a main body and a support plate 23 arranged thereon, which in FIG. 2B is shown.
  • the support plate 23 forms the support surface 21 FIG. 2A
  • the support plate 23 is provided with a bore 24 which receives a mounting screw for mounting the support plate 23 on the base body of the anvil.
  • the support plate 23 is provided in particular with a surface structure 26, which in the in FIG. 2B illustrated embodiment of ribs 27 is formed, which have a triangular cross-section.
  • the ribs, which are the in FIG. 2A form surface structure are similar to those in FIG. 2B illustrated ribs.
  • the side shifter is used during welding to keep the contact element 10 as quiet as possible, so that caused by the vibrations introduced by the sonotrode friction between the contact element and the conductor, whereby the welding between the contact element and the conductor is brought about.
  • the side shifter limits the movement of the (stranded) wires during welding when welding a stranded stranded conductor.
  • the profile or the surface structure 26 of the anvil 20 is impressed to a certain extent. It happens, however, that a reliable fixation of the contact element is not always guaranteed, especially when welding an aluminum line. The reason is that the contact element 10 begins to oscillate at the beginning of the welding process, when the surface structure 26 of the anvil 20 is not yet impressed in the smooth surface 41. The result is impermissible fluctuations in the quality of the weld.
  • FIG. 3 shown improved contact element 30 with a terminal portion 31 and a contact portion 32 before.
  • Contact element 10 shown is the connection region 31 of the contact element 30 on the in FIG. 3 provided on the upper side with grooves 33 which form a complementary to the surface structure 26 of the anvil 20 surface structure.
  • the contact region 32 corresponds to the contact region 12 of the contact element 10.
  • the surface structure is formed by grooves 33 having a triangular cross-section which extend transversely to a longitudinal axis 34 of the contact element 30.
  • grooves 33 In the in FIG. 1 illustrated embodiment, four grooves 33 are shown. In other embodiments, however, more or less grooves 33 may be provided.
  • the grooves 33 are also formed with a different cross-section, for example, with a rectangular cross section or a semicircular cross section. The grooves are different from the illustration in FIG. 1 Also not limited to a direction transverse to the longitudinal axis 34, but may also be parallel to the longitudinal axis 34 or in any other direction.
  • the surface structure can be formed not only by depressions in the connection region 31 of the contact element 30, but also by elevations.
  • the structural elements can also cross over one another, for example, to cross over at a right angle.
  • the dimensions of the grooves 33 are chosen so that they are complementary to the ribs 27 on the support plate 23. This means in particular that when placing the contact element 30 on the support surface of the anvil 20 of the ultrasonic welding system each one of the ribs 27 comes with a groove 33 into engagement. In this way, a positive connection between the anvil 20 and the contact element 30, which creates a Swinging of the contact element 10 during the welding process largely prevented or at least greatly reduced compared to a conventional contact element 10, which rests on the anvil 20 at the beginning of the welding process with a smooth surface.
  • the nature of the surface structures does not matter for the realization of the invention. It is crucial that the surface structures are formed so that a positive connection between the contact element and the anvil 20 of the welding system is possible. Concretely, this means, for example, that when the ribs 27 of the platen 23 have a rectangular cross section, the grooves 33 in the contact member 30 also have a rectangular cross section.
  • the geometry of the surface structure is otherwise adjusted to achieve the stated advantage.
  • the diameter of the ribs is made larger than the diameter of the grooves.
  • the difference in diameter is for example between 0.05 mm to 1.0 mm and in particular between 0.05 mm to 0.5 mm.
  • FIG. 4 a welded to the contact element 30 line 40 is shown.
  • the lead has an insulating jacket 41 and a conductor 42 made of a plurality of wires.
  • a stripped end of the Line 40 is welded to the contact element by ultrasonic welding.
  • step 51 a surface structure is produced on each contact element 30, which is adapted to a corresponding surface structure 26 on the anvil 20 of the ultrasonic welding system.
  • step 51 a sufficient number of appropriately prepared contact elements 30 is provided. That is, the contact elements 30 are not made individually for each electrical weld, although that is basically possible of course.
  • a contact element 30 is placed on the anvil 20 of the ultrasonic welding machine so that the surface structure of the contact element 30 engages with the surface structure 26 of the anvil 20 (step 52).
  • the electrical conductor 42 to be connected is placed on the connection region 31 of the contact element 30 and then pressed with the sonotrode and vibrated so that a welding of the electrical conductor 42 takes place with the contact element 30.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Claims (5)

  1. Procédé de fabrication d'une liaison électrique par soudure par ultrasons entre un conducteur électrique (42) et un élément de contact (30), dans lequel le procédé comprend les étapes suivantes :
    - production sur l'élément de contact d'une structure superficielle (33) qui est adaptée à une structure superficielle (26, 27) sur une enclume (20) d'une installation de soudure par ultrasons de telle sorte que l'enclume (20) et l'élément de contact (30) comportent respectivement une structure superficielle (26, 27, 33) qui sont constituées de façon complémentaire entre elles ;
    - pose de l'élément de contact (30) sur l'enclume de l'installation de soudure par ultrasons de telle sorte que la structure superficielle (33) de l'élément de contact (30) vient en prise avec la structure superficielle (26, 27) de l'enclume (20) ; et
    - soudage du conducteur électrique (42) sur l'élément de contact (30).
  2. Système de soudure par ultrasons avec une installation de soudure par ultrasons qui comporte une sonotrode et une enclume (20), ainsi qu'avec un élément de contact (30) pour une ligne électrique (40), caractérisé en ce que l'enclume (20) et l'élément de contact (30) comportent respectivement une structure superficielle (26, 27 ; 33) qui sont constituées de façon complémentaire entre elles.
  3. Système de soudure par ultrasons selon la revendication 2, caractérisé en ce que l'enclume (20) comporte au moins une nervure (27) dotée d'une section transversale de forme triangulaire, en ce que l'élément de contact (30) comporte autant de stries (33) dotées d'une section transversale de forme triangulaire que l'enclume (20) a de nervures (27), et en ce que l'angle formé entre les flancs d'une strie (33) est plus petit que l'angle formé entre les flancs d'une nervure (27).
  4. Système de soudure par ultrasons selon la revendication 2, caractérisé en ce que l'enclume (20) comporte au moins une strie dotée d'une section transversale de forme triangulaire, en ce que l'élément de contact (30) comporte autant de nervures dotées d'une section transversale de forme triangulaire que l'enclume (20) a de stries, et en ce que l'angle formé entre les flancs d'une strie est plus petit que l'angle formé entre les flancs d'une nervure.
  5. Système de soudure par ultrasons selon l'une des revendications 2 à 4, caractérisé en ce que les structures superficielles (26, 27 ; 33) de l'enclume (20) et de l'élément de contact (30) entrent en prise l'une avec l'autre de telle sorte qu'il est créé une liaison de forme entre l'enclume (20) et l'élément de contact (30).
EP17305785.2A 2017-06-23 2017-06-23 Procédé de fabrication d'une liaison électrique et système de soudure par ultrasons Active EP3419121B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP17305785.2A EP3419121B1 (fr) 2017-06-23 2017-06-23 Procédé de fabrication d'une liaison électrique et système de soudure par ultrasons

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Application Number Priority Date Filing Date Title
EP17305785.2A EP3419121B1 (fr) 2017-06-23 2017-06-23 Procédé de fabrication d'une liaison électrique et système de soudure par ultrasons

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EP3419121A1 EP3419121A1 (fr) 2018-12-26
EP3419121B1 true EP3419121B1 (fr) 2019-10-09

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DE102019134763B4 (de) * 2019-12-17 2021-08-19 Auto-Kabel Management Gmbh Schweißvorrichtung sowie Schweißverfahren zur Herstellung einer stoffschlüssigen Verbindung zwischen einem Leiter und einem Anschlussteil

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JP3295331B2 (ja) * 1997-01-09 2002-06-24 矢崎総業株式会社 電線接続構造及び接続方法
JP3300241B2 (ja) * 1997-01-09 2002-07-08 矢崎総業株式会社 被覆電線と端子の接続構造
JP2009087831A (ja) * 2007-10-02 2009-04-23 Furukawa Electric Co Ltd:The フラットケーブルの端子接続方法及びその端子接続装置
JP6056639B2 (ja) * 2013-05-07 2017-01-11 株式会社オートネットワーク技術研究所 端子、端子付き電線および端子付き電線の製造方法

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