EP3451455B1 - Method for making an electrical connection and an electrical line - Google Patents

Method for making an electrical connection and an electrical line Download PDF

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Publication number
EP3451455B1
EP3451455B1 EP17306128.4A EP17306128A EP3451455B1 EP 3451455 B1 EP3451455 B1 EP 3451455B1 EP 17306128 A EP17306128 A EP 17306128A EP 3451455 B1 EP3451455 B1 EP 3451455B1
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EP
European Patent Office
Prior art keywords
contact sleeve
conductor
mounting bracket
contact
sleeve
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
EP17306128.4A
Other languages
German (de)
French (fr)
Other versions
EP3451455A1 (en
Inventor
Rainer Huscher
Michael Singer
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
Original Assignee
Nexans SA
Priority date (The priority date 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 date listed.)
Filing date
Publication date
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Priority to EP17306128.4A priority Critical patent/EP3451455B1/en
Publication of EP3451455A1 publication Critical patent/EP3451455A1/en
Application granted granted Critical
Publication of EP3451455B1 publication Critical patent/EP3451455B1/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
    • H01R4/02—Soldered or welded connections
    • H01R4/029—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
    • 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
    • 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
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • 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
    • H01R11/12—End pieces terminating in an eye, hook, or fork
    • 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
    • H01R4/58—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

Definitions

  • the invention relates to a method for electrically conductive connection of a contact part based on copper or aluminum with an existing of a plurality of individual wires containing aluminum electrical conductor and a corresponding line.
  • 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 aluminum over copper is irrelevant for most applications.
  • 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 noticeable.
  • the individual wires are surrounded by an unavoidable without special treatment oxide layer. This problem has long been known.
  • the contact part based on copper or aluminum is made of copper or of a copper alloy or of aluminum or an aluminum alloy. It may additionally have on its outer surface a layer of, for example, tin, zinc or nickel, which is, for example, electrodeposited.
  • the contact part is referred to below without material specification only as "contact part”.
  • the individual wires of the conductor consist of either aluminum or an aluminum alloy.
  • aluminum for the sake of simplicity, only the term “aluminum” will be used hereinafter to refer to both aluminum and alloys thereof.
  • the US Pat. No. 6,538,203 B1 relates to a connecting part for connecting a stranded aluminum line to a connecting part made of copper or a similar metal.
  • a support sleeve is placed on a stripped end of the line and attached, for example by crimping.
  • the connecting part is welded to the end face of the line and the support sleeve, in particular by friction welding.
  • the connecting part is set in rotation and pressed against the end face of the line.
  • the present invention has the object to provide a method to overcome or at least improve one or more of the problems mentioned above.
  • the contact sleeve is crimped or crimped to achieve a tight fit of the contact sleeve on the conductor.
  • the contact sleeve and the fastening tab together form a contact part.
  • the contact sleeve is rolled, for example, from a stamped sheet metal strip.
  • the fastening tab can also be a stamped and bent part.
  • Contact sleeve and mounting strap are thus easy and inexpensive to manufacture.
  • other methods for producing the contact sleeve and the fastening tab are also possible. Due to the fact that the contact part is formed in two parts in each case, regardless of the manufacturing method, the adaptation to different applications is simplified.
  • the step of materially connecting the individual wires of the conductor to one another and to the contact sleeve is carried out by means of a plasma arc.
  • the alumina, with which the individual wires are coated is at the cohesive connection of the individual wires of the surface displaces and no longer affects the electrical connection between the details and the contact sleeve.
  • the method according to the invention is within wide limits regardless of where the connection between the contact sleeve and mounting strap is made. As a result, the method can be used for a wide variety of applications.
  • the invention proposes an electrical line with a conductor having a plurality of individual wires containing aluminum and which is connected to a contact part, which is composed of a contact sleeve and a fastening tab.
  • the individual wires of the conductor are integrally connected with each other and with the plugged onto the conductor contact sleeve.
  • the contact sleeve is welded to the fastening tab.
  • the contact sleeve has on a front side on a projection which corresponds to a passage in the fastening tab, so that engages in the mounting position of the fastening tab of the projection of the contact sleeve in the passage of the fastening tab.
  • the fastening tab is integrally connected to an end face of the contact sleeve.
  • the contact sleeve and the fastening tab together form a contact part.
  • the contact sleeve may have four projections, but also a smaller or larger number. If the contact sleeve has more than one projection, then a corresponding number of passages are provided in the fastening tab. When mounting the electrical cable, the mounting tab can be easily put on the contact sleeve and is held there, because the projections engage in the passages.
  • the contact sleeve is formed as a rolled sleeve, which is made of a metal strip.
  • the fastening tab is a stamped and or bent part.
  • Contact sleeve and mounting strap are thus easy and inexpensive to manufacture and offer corresponding cost advantages in production.
  • a contact part which is made of such a contact sleeve and a fastening tab, cheaper than a comparable contact part which is made by deep drawing.
  • the electrical conductor according to the invention is not limited to a specific manufacturing method for the contact sleeve or the fastening tab.
  • Figure 1A schematically shows a line 10 having an electrical conductor 11 which is composed of a plurality of stranded individual wires 12 and which is surrounded by an insulation 13. In a section 14, the insulation 13 is removed from the conductor 11.
  • a contact sleeve 16 On the stripped region of the conductor 11, a contact sleeve 16 is pushed, which consists of copper, a copper alloy, aluminum or an aluminum alloy.
  • the contact sleeve 16 carries on its in FIG. 1 to the right-facing end face a number of projections 17, for example four pieces, of which in Figure 1A however, only two are visible.
  • the contact sleeve 16 Before assembly, the contact sleeve 16 has an inner diameter which is larger than the outer diameter of the conductor 11, to allow easy insertion of the contact sleeve 16 on the conductor, without bending individual wires 12 of the conductor 11. When the contact sleeve has reached its mounting position, it is pressed or crimped onto the conductor. The contact sleeve 16 is then firmly seated on the ladder 11.
  • FIG. 1B shows a side view of the line 10 from Figure 1A ,
  • four Projections 17 to recognize well.
  • fewer than four or more than four projections 17 may be provided.
  • the object of the present invention is independent of the concrete number of projections.
  • FIG. 2A the contact sleeve 16 is shown in a perspective view.
  • a metal strip 18 is punched out, at the same time the projections 17 arise.
  • the punched sheet metal strip 18 is in FIG. 2B shown.
  • the thus prepared sheet metal strip 18 is rolled to complete the contact sleeve 16.
  • a rolled contact sleeve 16 is simple and inexpensive to manufacture, the present invention is not limited to this type of manufacturing. In principle, the contact sleeve can also be produced, for example, by casting, deep-drawing or machining processes.
  • FIG. 3 shows the line 10 from Figure 1A after the individual wires 12 have been welded together and with the contact sleeve 16 in a plasma arc with each other. This creates a region 21, where no individual wires 12 longer exist and has a material connection with the contact sleeve 16.
  • the alumina is displaced.
  • the alumina may "float" to the surface of molten material. As a result, the alumina no longer affects the electrical conductivity between the conductor 11 and the contact sleeve 16.
  • FIG. 3 described welding of the individual wires 12 with the contact sleeve 16 does not take place.
  • the contact sleeve 16 is fixedly connected to the conductor 11 solely by pressing or crimping.
  • FIG. 4A is the line 10 off FIG. 3 shown with an attached attachment foot or a mounting strap 22.
  • the fastening tab is made of copper or aluminum.
  • the fastening tab 22 is formed as an angle section with two legs 23, 24.
  • the first leg 23 the fastening tab 22 is provided with a screw hole 26 for a fastening screw, while the second leg 24 has passages 27 which are dimensioned so that the projections 17 of the contact sleeve 16 are receivable therein, when the leg 24 of the fastening tab 22 has a mounting position on the end face the contact sleeve 16 occupies.
  • FIG. 4A is the line 10 off FIG. 3 shown with an attached attachment foot or a mounting strap 22.
  • the fastening tab is made of copper or aluminum.
  • the fastening tab 22 is formed as an angle section with two legs 23, 24.
  • the first leg 23 the fastening tab 22 is provided with a screw hole 26 for a fastening screw, while the second leg 24 has passages 27 which
  • a tool 28 is shown, with which the leg 24 of the fastening tab 22 is welded by friction stir welding with the contact sleeve 16.
  • the temperature required for welding contact sleeve 16 and fastening tab 22 is generated by friction.
  • the material of the contact sleeve 16 connects to that of the fastening tab 22 at a temperature below the melting temperature of the metals used cohesively or is welded together by diffusion.
  • the pressure applied by the tool 28 and the work done thereby also contribute to this.
  • the tool used in the method accordingly has a friction surface, with which it is pressed onto the leg 24 of the fastening tab 22, which is in FIG. 4 symbolized by an arrow P.
  • the tool 28 When the method is carried out, the tool 28 is rotated about its axis A, for example by an electric motor, and then moved in the direction of the arrow P. It is then pressed with continued pressure against the leg 24 of the fastening tab 22, so that the material thereof is heated by friction.
  • the fastening tab 22 is made as a simple stamped and bent part. Dimensions, shape, number of mounting holes, etc. are thereby easily adaptable to individual applications. However, the invention is not limited to a stamped and / or bent fastening tab 22. In principle, the invention is independent of how the fastening tab 22 is made.
  • FIG. 4B shows a further embodiment of a conduit 10, wherein the end of the conduit which carries the contact sleeve 16, is shown in cross section.
  • another fastening tab 29 is welded in this case, which, as stated above, can be designed almost arbitrarily.
  • FIG. 5A shows in a flow chart the individual manufacturing steps for a first method for producing an electrical connection according to the invention.
  • a contact sleeve 16 is pushed onto the conductor 11 in step S1 and then crimped on the conductor 11 in step S2.
  • the stranded wires 12 are connected to one another in a material-tight manner with one another and with the contact sleeve 16 in a plasma arc.
  • the fastening tab 22 is welded to the contact sleeve 16, in particular friction stir welded.
  • FIG. 5B shows in a further flowchart the individual manufacturing steps for a second method for producing an electrical connection according to the invention.
  • Steps S5 and S6 are identical to steps S1 and S2 in the first production mode.
  • the fastening tab 22 is welded to the contact sleeve 16, in particular friction stir welded, whereby at the same time the individual wires 12 of the conductor 11 are welded to the contact sleeve 16.

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

Description

Gebietarea

Die Erfindung betrifft ein Verfahren zum elektrisch leitenden Verbinden eines Kontaktteils auf Kupfer- oder Aluminiumbasis mit einem aus einer Vielzahl von Aluminium enthaltenden Einzeldrähten bestehenden elektrischen Leiter sowie eine entsprechende Leitung.The invention relates to a method for electrically conductive connection of a contact part based on copper or aluminum with an existing of a plurality of individual wires containing aluminum electrical conductor and a corresponding line.

Hintergrundbackground

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. 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. Die Einzeldrähte sind von einer ohne Sonderbehandlung nicht zu vermeidenden Oxidschicht umgeben. Diese Problematik ist seit langem bekannt. Elektrische Leitungen mit einem solchen Leiter, der zweckmäßigerweise von einem Mantel aus Isoliermaterial umgeben ist, werden vielfach im Fahrzeugbereich verbaut. Um solche Leitungen in der Produktion effektiv und zeitsparend verbauen zu können, werden die Leitungen an ihren Enden mit elektrischen Kontaktteilen versehen, die auch als "Terminal" bezeichnet werden.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 aluminum over copper is irrelevant for most applications. 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 noticeable. The individual wires are surrounded by an unavoidable without special treatment oxide layer. This problem has long been known. Electrical lines with such a conductor, which is suitably surrounded by a jacket made of insulating material, are often installed in the vehicle area. In order to be able to install such lines in production effectively and in a time-saving manner, the lines are provided at their ends with electrical contact parts, which are also referred to as "terminals".

Das Kontaktteil auf Kupfer- oder Aluminiumbasis besteht aus Kupfer oder aus einer Kupferlegierung bzw. aus Aluminium oder einer Aluminiumlegierung. Es kann auf seiner äußeren Oberfläche zusätzlich eine Schicht aus beispielsweise zum Zinn, Zink oder Nickel aufweisen, die beispielsweise galvanisch abgeschieden ist. Das Kontaktteil wird im Folgenden ohne Materialangabe nur als "Kontaktteil" bezeichnet.The contact part based on copper or aluminum is made of copper or of a copper alloy or of aluminum or an aluminum alloy. It may additionally have on its outer surface a layer of, for example, tin, zinc or nickel, which is, for example, electrodeposited. The contact part is referred to below without material specification only as "contact part".

Die Einzeldrähte des Leiters bestehen entweder aus Aluminium oder aus einer Aluminiumlegierung. Der Einfachheit halber wird im Folgenden nur der Begriff "Aluminium" verwendet, um sowohl Aluminium als auch Legierungen daraus zu bezeichnen.The individual wires of the conductor consist of either aluminum or an aluminum alloy. For the sake of simplicity, only the term "aluminum" will be used hereinafter to refer to both aluminum and alloys thereof.

Aus der EP 2 735 397 A1 ist beispielsweise ein Verfahren bekannt, bei dem ein topfförmiges Kontaktteil auf einen Litzenleiter aufgeschoben wird. Das Kontaktteil ist je nach Anwendungsfall mit unterschiedlichen Anschlusselementen versehen. Das Kontaktteil wird als einstückiges Bauteil durch Tiefziehen hergestellt und durch Rührreibschweißen mit dem Leiter stoffschlüssig verbunden. Gemäß dem bekannten Verfahren ist es allerdings erforderlich, für jeden Anwendungsfall ein Kontaktteil herzustellen, das an den jeweiligen Leiterquerschnitt angepasst und mit einem geeigneten Anschlusselement versehen ist. Für jede Art von Kontaktteil müssen entsprechende Werkzeuge bereitgestellt werden, was die Herstellungskosten nach oben treibt.From the EP 2 735 397 A1 For example, a method is known in which a pot-shaped contact part is pushed onto a stranded conductor. The contact part is provided depending on the application with different connection elements. The contact part is produced as a one-piece component by deep drawing and bonded cohesively by friction stir welding with the conductor. According to the known method, however, it is necessary to produce a contact part for each application, which is adapted to the respective conductor cross-section and provided with a suitable connection element. For each type of contact part corresponding tools must be provided, which drives up the production costs.

Die US 6 538 203 B1 betrifft ein Verbindungsteil, um eine vieldrähtige Aluminiumleitung mit einem Verbindungsteil aus Kupfer oder einem ähnlichen Metall zu verbinden. Eine Stützhülse wird auf ein abisoliertes Ende der Leitung gesteckt und zum Beispiel durch Crimpen befestigt. Das Verbindungsteil wird auf die Stirnseite der Leitung und der Stützhülse geschweißt, insbesondere durch Reibschweißen. Zu diesem Zweck wird das Anschlussteil in Rotation versetzt und gegen die Stirnseite der Leitung gedrückt.The US Pat. No. 6,538,203 B1 relates to a connecting part for connecting a stranded aluminum line to a connecting part made of copper or a similar metal. A support sleeve is placed on a stripped end of the line and attached, for example by crimping. The connecting part is welded to the end face of the line and the support sleeve, in particular by friction welding. For this purpose, the connecting part is set in rotation and pressed against the end face of the line.

Hiervon ausgehend hat die vorliegende Erfindung die Aufgabe, ein Verfahren zu schaffen, um eines oder mehrere der eingangs genannten Probleme zu überwinden oder zumindest zu verbessern.On this basis, the present invention has the object to provide a method to overcome or at least improve one or more of the problems mentioned above.

Zusammenfassung der ErfindungSummary of the invention

Zur Lösung dieser Aufgabe schlägt die Erfindung nach einem ersten Aspekt ein Verfahren zum elektrisch leitenden Verbinden eines aus einer Kontakthülse und einer Befestigungslasche bestehenden Kontaktteiles auf Kupfer- oder Aluminiumbasis mit einem Leiter, der eine Vielzahl von Aluminium enthaltenden Einzeldrähten aufweist. Das Verfahren umfasst die folgenden Schritte:

  • Aufstecken der Kontakthülse auf den Leiter,
  • mechanisches Verbinden der Kontakthülse auf dem Leiter,
  • Aufsetzen einer Befestigungslasche, so dass ein Vorsprung an einer Stirnseite der Kontakthülse mit einem korrespondierenden Durchlass an der Befestigungslasche in Eingriff kommt und die Befestigungslasche auf der Kontakthülse hält,
  • -stoffschlüssiges Verbinden der Einzeldrähte des Leiters untereinander und mit der Kontakthülse, und
  • stoffschlüssiges Verbinden einer Befestigungslasche an der Stirnseite der Kontakthülse.
To achieve this object, the invention proposes, according to a first aspect, a method of electrically connecting a copper or aluminum contact piece consisting of a contact sleeve and a fastening tab to a conductor having a plurality of individual wires containing aluminum. The method comprises the following steps:
  • Attaching the contact sleeve to the conductor,
  • mechanical connection of the contact sleeve on the conductor,
  • Placing a fastening tab such that a projection on an end face of the contact sleeve engages a corresponding passage on the fastening tab and holds the fastening tab on the contact sleeve,
  • - Substantially connecting the individual wires of the conductor with each other and with the contact sleeve, and
  • integral connection of a fastening tab on the front side of the contact sleeve.

Bei der mechanischen Verbindung der Kontakthülse mit dem Leiter wird die Kontakthülse beispielsweise gequetscht oder gecrimpt, um einen festen Sitz der Kontakthülse auf dem Leiter zu erzielen. Die Kontakthülse und die Befestigungslasche bilden gemeinsam ein Kontaktteil. Die Kontakthülse wird beispielsweise aus einem gestanzten Blechstreifen gerollt. Die Befestigungslasche kann ebenso ein Stanz- und Biegeteil sein. Kontakthülse und Befestigungslasche sind somit einfach und kostengünstig herzustellen. Andere Verfahren zur Herstellung der Kontakthülse und der Befestigungslasche kommen jedoch ebenfalls in Betracht. Dadurch, dass das Kontaktteil unabhängig von der Herstellungsart in jedem Fall zweiteilig ausgebildet ist, ist die Anpassung an unterschiedliche Anwendungsfälle vereinfacht. Für jeden Leiterquerschnitt muss nur eine Art von Kontakthülse vorgehalten werden, an die dann die benötigte Kontaktlasche angeschweißt wird. Es ist also nicht mehr wie bisher erforderlich für jeden Anwendungsfall ein Kontaktteil vorzuhalten. Bei dem erfindungsgemäßen Verfahren zur Herstellung einer elektrischen Verbindung ist es insbesondere nicht mehr erforderlich für jeden Typ von Kontaktteil ein eigenes Tiefziehwerkzeug bereit zu halten wie bei dem Verfahren nach der EP 2 735 397 A1 .For example, in the mechanical connection of the contact sleeve to the conductor, the contact sleeve is crimped or crimped to achieve a tight fit of the contact sleeve on the conductor. The contact sleeve and the fastening tab together form a contact part. The contact sleeve is rolled, for example, from a stamped sheet metal strip. The fastening tab can also be a stamped and bent part. Contact sleeve and mounting strap are thus easy and inexpensive to manufacture. However, other methods for producing the contact sleeve and the fastening tab are also possible. Due to the fact that the contact part is formed in two parts in each case, regardless of the manufacturing method, the adaptation to different applications is simplified. For each conductor cross section, only one type of contact sleeve has to be provided, to which the required contact tab is then welded. It is therefore no longer necessary to hold a contact part for each application. In the method according to the invention for producing an electrical connection, in particular, it is no longer necessary for each type of contact part to have its own deep-drawing tool ready as in the method according to FIG EP 2 735 397 A1 ,

Bei einer vorteilhaften Ausführungsform des Verfahrens wird der Schritt des stoffschlüssigen Verbindens der Einzeldrähte des Leiters untereinander und mit der Kontakthülse mittels eines Plasmalichtbogens ausgeführt. Das Aluminiumoxid, mit dem die Einzeldrähte überzogen sind, wird bei der stoffschlüssigen Verbindung der Einzeldrähte von deren Oberfläche verdrängt und beeinträchtigt die elektrische Verbindung zwischen den Einzelheiten und zu der Kontakthülse nicht mehr.In an advantageous embodiment of the method, the step of materially connecting the individual wires of the conductor to one another and to the contact sleeve is carried out by means of a plasma arc. The alumina, with which the individual wires are coated, is at the cohesive connection of the individual wires of the surface displaces and no longer affects the electrical connection between the details and the contact sleeve.

Mit Vorteil wird die stoffschlüssige Verbindung zwischen der Befestigungslasche und der Kontakthülse durch ein Verfahren aus der folgenden Liste hergestellt wird:

  • Rührreibschweißen,
  • Ultraschallschweißen,
  • Weichlöten, und
  • Hartlöten.
Advantageously, the cohesive connection between the fastening tab and the contact sleeve is produced by a method from the following list:
  • Friction stir welding,
  • Ultrasonic welding,
  • Soft soldering, and
  • Brazing.

Grundsätzlich ist das erfindungsgemäße Verfahren innerhalb weiter Grenzen unabhängig davon, an welcher Stelle die Verbindung zwischen Kontakthülse und Befestigungslasche hergestellt wird. Dadurch ist das Verfahren für die unterschiedlichsten Anwendungsfälle einsetzbar.Basically, the method according to the invention is within wide limits regardless of where the connection between the contact sleeve and mounting strap is made. As a result, the method can be used for a wide variety of applications.

Nach einem zweiten Aspekt schlägt die Erfindung eine elektrische Leitung mit einem Leiter vor, der eine Vielzahl von Aluminium enthaltenden Einzeldrähte aufweist und der mit einem Kontaktteil verbunden ist, das aus einer Kontakthülse und einer Befestigungslasche aufgebaut ist. Die Einzeldrähte des Leiters sind untereinander und mit der auf den Leiter aufgesteckten Kontakthülse stoffschlüssig verbunden. Die Kontakthülse ist mit der Befestigungslasche verschweißt. Die Kontakthülse weist an einer Stirnseite einen Vorsprung auf, der mit einem Durchlass in der Befestigungslasche korrespondiert, so dass in Montagestellung der Befestigungslasche der Vorsprung der Kontakthülse in den Durchlass der Befestigungslasche eingreift. Die Befestigungslasche ist an einer Stirnseite der Kontakthülse stoffschlüssig verbunden.According to a second aspect, the invention proposes an electrical line with a conductor having a plurality of individual wires containing aluminum and which is connected to a contact part, which is composed of a contact sleeve and a fastening tab. The individual wires of the conductor are integrally connected with each other and with the plugged onto the conductor contact sleeve. The contact sleeve is welded to the fastening tab. The contact sleeve has on a front side on a projection which corresponds to a passage in the fastening tab, so that engages in the mounting position of the fastening tab of the projection of the contact sleeve in the passage of the fastening tab. The fastening tab is integrally connected to an end face of the contact sleeve.

Die Kontakthülse und die Befestigungslasche bilden gemeinsam ein Kontaktteil. Dadurch dass das Kontaktteil zweiteilig ausgebildet ist, ist die Anpassung an unterschiedliche Anwendungsfälle vereinfacht. Für jeden Leiterquerschnitt muss er nur eine Art von Kontakthülse vorgehalten werden, an die dann die benötigte Kontaktlasche angeschweißt wird. Es ist also nicht mehr wie bisher erforderlich für jeden Anwendungsfall ein Kontaktteil vorzuhalten.The contact sleeve and the fastening tab together form a contact part. The fact that the contact part is formed in two parts, the adaptation to different applications is simplified. For each conductor cross-section, he must be kept only a kind of contact sleeve, to which then the required contact tab is welded. It is therefore no longer necessary to hold a contact part for each application.

Bei einer vorteilhaften Weiterbildung der elektrischen Leitung kann die Kontakthülse vier Vorsprünge aufweisen, aber auch eine geringere oder größere Anzahl. Wenn die Kontakthülse mehr als einen Vorsprung aufweist, dann sind in der Befestigungslasche eine entsprechende Anzahl von Durchlässen vorgesehen. Bei der Montage der elektrischen Leitung lässt sich die Befestigungslasche einfach auf die Kontakthülse aufsetzen und wird dort gehalten, weil die Vorsprünge in die Durchlässe eingreifen.In an advantageous development of the electrical line, the contact sleeve may have four projections, but also a smaller or larger number. If the contact sleeve has more than one projection, then a corresponding number of passages are provided in the fastening tab. When mounting the electrical cable, the mounting tab can be easily put on the contact sleeve and is held there, because the projections engage in the passages.

Mit Vorteil ist die Kontakthülse als eine gerollte Hülse ausgebildet, die aus einem Blechstreifen hergestellt ist.Advantageously, the contact sleeve is formed as a rolled sleeve, which is made of a metal strip.

Vorteilhafterweise ist auch die Befestigungslasche ein Stanz- und oder Biegeteil.Advantageously, the fastening tab is a stamped and or bent part.

Kontakthülse und Befestigungslasche sind somit einfach und kostengünstig herzustellen und bieten dementsprechende Kostenvorteile in der Produktion. Insbesondere ist ein Kontaktteil, das aus einer solchen Kontakthülse und einer Befestigungslasche hergestellt ist, kostengünstiger als ein vergleichbares Kontaktteil das durch Tiefziehen hergestellt ist. Der erfindungsgemäße elektrische Leiter ist jedoch nicht auf ein bestimmtes Herstellungsverfahren für die Kontakthülse bzw. die Befestigungslasche beschränkt.Contact sleeve and mounting strap are thus easy and inexpensive to manufacture and offer corresponding cost advantages in production. In particular, a contact part, which is made of such a contact sleeve and a fastening tab, cheaper than a comparable contact part which is made by deep drawing. However, the electrical conductor according to the invention is not limited to a specific manufacturing method for the contact sleeve or the fastening tab.

Kurze Beschreibung der ZeichnungShort description of the drawing

Nachfolgend wird die Erfindung anhand einer Ausführungsform unter Bezugnahme auf die begleitenden Figuren exemplarisch näher erläutert. Alle Figuren sind rein schematisch und nicht maßstäblich. Es zeigen:

Fig. 1A
eine Ansicht einer Leitung mit einem Leiter aus einer Vielzahl von Einzeldrähten, teilweise im Querschnitt;
Fig. 1B
eine Ansicht auf eine Stirnseite des Leiters aus Figur 1A;
Fig. 2A
eine perspektivische Ansicht einer Kontakthülse;
Fig. 2B
ein Blechstreifen aus dem die Kontakthülse aus Figur 2A gerollt wird;
Fig. 3
den Leiter aus Figur 1A in einem späteren Fertigungszustand, teilweise im Querschnitt;
Fig. 4A
eine elektrische Leitung mit einem Kontaktteil in einer perspektivischen Ansicht;
Fig. 4B
eine elektrische Leitung mit einem Kontaktteil, teilweise im Querschnitt;
Fig. 5A
ein Flussdiagramm mit den Einzelschritten einer ersten Herstellungsart für eine erfindungsgemäße Verbindung; und
Fig. 5B
ein Flussdiagramm mit den Einzelschritten einer zweiten Herstellungsart für eine erfindungsgemäßen Verbindung.
The invention will be explained in more detail by way of example with reference to an embodiment with reference to the accompanying figures. All figures are purely schematic and not to scale. Show it:
Fig. 1A
a view of a line with a conductor of a plurality of individual wires, partially in cross section;
Fig. 1B
a view of an end face of the head Figure 1A ;
Fig. 2A
a perspective view of a contact sleeve;
Fig. 2B
a metal strip from the contact sleeve FIG. 2A is rolled;
Fig. 3
the ladder Figure 1A in a later state of manufacture, partly in cross section;
Fig. 4A
an electrical line with a contact part in a perspective view;
Fig. 4B
an electrical line with a contact part, partially in cross section;
Fig. 5A
a flow chart with the individual steps of a first production method for a compound according to the invention; and
Fig. 5B
a flow chart with the individual steps of a second production method for a compound according to the invention.

Gleiche oder ähnliche Elemente sind in den Figuren mit gleichen oder ähnlichen Bezugszeichen versehen.The same or similar elements are provided in the figures with the same or similar reference numerals.

Ausführungsbeispielembodiment

Figur 1A zeigt schematisch eine Leitung 10, die einen elektrischen Leiter 11 aufweist, der aus einer Vielzahl von miteinander verseilten Einzeldrähten 12 aufgebaut ist und der von einer Isolierung 13 umgeben ist. In einem Abschnitt 14 ist die Isolierung 13 von dem Leiter 11 entfernt. Figure 1A schematically shows a line 10 having an electrical conductor 11 which is composed of a plurality of stranded individual wires 12 and which is surrounded by an insulation 13. In a section 14, the insulation 13 is removed from the conductor 11.

Auf den abisolierten Bereich des Leiters 11 ist eine Kontakthülse 16 aufgeschoben, die aus Kupfer, einer Kupferlegierung, Aluminium oder einer Aluminiumlegierung besteht. Die Kontakthülse 16 trägt auf ihrer in Figur 1 nach rechts weisenden Stirnseite eine Anzahl von Vorsprüngen 17, beispielsweise vier Stück, von denen in Figur 1A jedoch nur zwei sichtbar sind.On the stripped region of the conductor 11, a contact sleeve 16 is pushed, which consists of copper, a copper alloy, aluminum or an aluminum alloy. The contact sleeve 16 carries on its in FIG. 1 to the right-facing end face a number of projections 17, for example four pieces, of which in Figure 1A however, only two are visible.

Vor der Montage weist die Kontakthülse 16 einen Innendurchmesser auf, der größer ist als der Außendurchmesser des Leiters 11, um ein problemloses Aufschieben der Kontakthülse 16 auf den Leiter zu ermöglichen, ohne dabei Einzeldrähte 12 des Leiters 11 zu verbiegen. Wenn die Kontakthülse ihre Montageposition erreicht hat, wird sie auf den Leiter gepresst oder gecrimpt. Die Kontakthülse 16 sitzt dann fest auf dem Leiter 11.Before assembly, the contact sleeve 16 has an inner diameter which is larger than the outer diameter of the conductor 11, to allow easy insertion of the contact sleeve 16 on the conductor, without bending individual wires 12 of the conductor 11. When the contact sleeve has reached its mounting position, it is pressed or crimped onto the conductor. The contact sleeve 16 is then firmly seated on the ladder 11.

Figur 1B zeigt eine Seitenansicht der Leitung 10 aus Figur 1A. In Figur 1B sind die auf der Stirnfläche der Kontakthülse 16 angeordneten vier Vorsprünge 17 gut zu erkennen. Bei anderen Ausführungsbeispielen können jedoch weniger als vier oder mehr als vier Vorsprünge 17 vorgesehen sein. Der Gegenstand der vorliegenden Erfindung ist unabhängig von der konkreten Anzahl der Vorsprünge. FIG. 1B shows a side view of the line 10 from Figure 1A , In FIG. 1B are arranged on the end face of the contact sleeve 16 four Projections 17 to recognize well. In other embodiments, however, fewer than four or more than four projections 17 may be provided. The object of the present invention is independent of the concrete number of projections.

In Figur 2A ist die Kontakthülse 16 in einer perspektivischen Ansicht dargestellt. Zur Herstellung der Kontakthülse 16 wird ein Blechstreifen 18 ausgestanzt, wobei gleichzeitig die Vorsprünge 17 entstehen. Der ausgestanzte Blechstreifen 18 ist in Figur 2B gezeigt. Der so vorbereitete Blechstreifen 18 wird gerollt, um die Kontakthülse 16 fertigzustellen. Eine gerollte Kontakthülse 16 ist zwar einfach und kostengünstig herzustellen, aber die vorliegende Erfindung ist nicht auf diese Herstellungsart beschränkt. Grundsätzlich kann die Kontakthülse auch zum Beispiel durch Gießen, Tiefziehen oder spanabhebende Verfahren herstellt sein.In FIG. 2A the contact sleeve 16 is shown in a perspective view. To produce the contact sleeve 16, a metal strip 18 is punched out, at the same time the projections 17 arise. The punched sheet metal strip 18 is in FIG. 2B shown. The thus prepared sheet metal strip 18 is rolled to complete the contact sleeve 16. Although a rolled contact sleeve 16 is simple and inexpensive to manufacture, the present invention is not limited to this type of manufacturing. In principle, the contact sleeve can also be produced, for example, by casting, deep-drawing or machining processes.

Figur 3 zeigt die Leitung 10 aus Figur 1A nachdem die Einzeldrähte 12 miteinander sowie mit der Kontakthülse 16 in einem Plasmalichtbogen miteinander verschweißt wurden. Dabei entsteht ein Bereich 21, wo keine Einzeldrähte 12 mehr vorliegen und der eine stoffschlüssige Verbindung mit der Kontakthülse 16 hat. Bei diesem Schweißvorgang wird das Aluminiumoxid verdrängt. Insbesondere kann das Aluminiumoxid an die Oberfläche von geschmolzenem Material "aufschwimmen". Im Ergebnis beeinträchtigt das Aluminiumoxid die elektrische Leitfähigkeit zwischen dem Leiter 11 und der Kontakthülse 16 nicht mehr. FIG. 3 shows the line 10 from Figure 1A after the individual wires 12 have been welded together and with the contact sleeve 16 in a plasma arc with each other. This creates a region 21, where no individual wires 12 longer exist and has a material connection with the contact sleeve 16. In this welding process, the alumina is displaced. In particular, the alumina may "float" to the surface of molten material. As a result, the alumina no longer affects the electrical conductivity between the conductor 11 and the contact sleeve 16.

Bei einer alternativen Ausführungsform findet die mit Bezug auf Figur 3 beschriebene Verschweißung der Einzeldrähte 12 mit der Kontakthülse 16 nicht statt. Die Kontakthülse 16 ist alleine durch Pressen oder Crimpen fest mit dem Leiter 11 verbunden.In an alternative embodiment, reference is made to FIG FIG. 3 described welding of the individual wires 12 with the contact sleeve 16 does not take place. The contact sleeve 16 is fixedly connected to the conductor 11 solely by pressing or crimping.

In Figur 4A ist die Leitung 10 aus Figur 3 mit einem daran angesetzten Befestigungsfuß oder einer Befestigungslasche 22 dargestellt. Die Befestigungslasche ist auf Kupfer- oder Aluminiumbasis hergestellt. Bei dem in Figur 4A dargestellten Ausführungsbeispiel ist die Befestigungslasche 22 als ein Winkelprofil mit zwei Schenkeln 23, 24 ausgebildet. Der erste Schenkel 23 der Befestigungslasche 22 ist mit einem Schraubenloch 26 für eine Befestigungsschraube versehen, während der zweite Schenkel 24 Durchlässe 27 ausweist, die so bemessen sind, dass die Vorsprünge 17 der Kontakthülse 16 darin aufnehmbar sind, wenn der Schenkel 24 der Befestigungslasche 22 eine Montageposition auf der Stirnfläche der Kontakthülse 16 einnimmt. In Figur 4A ist weiterhin ein Werkzeug 28 dargestellt, mit welchem der Schenkel 24 der Befestigungslasche 22 durch Rührreibschweißen mit der Kontakthülse 16 verschweißt wird. Bei diesem Schweißverfahren wird die für eine Verschweißung von Kontakthülse 16 und Befestigungslasche 22 benötigte Temperatur durch Reibung erzeugt. Dabei verbindet sich das Material der Kontakthülse 16 mit dem der Befestigungslasche 22 bei einer Temperatur unterhalb der Schmelztemperatur der verwendeten Metalle stoffschlüssig bzw. wird durch Diffusion miteinander verschweißt. Dazu tragen auch der durch das Werkzeug 28 aufgebrachte Druck und die dadurch verrichtete Umformarbeit bei. Das bei dem Verfahren eingesetzte Werkzeug hat dementsprechend eine Reibfläche, mit der es auf den Schenkel 24 der Befestigungslasche 22 aufgedrückt wird, was in Figur 4 durch einen Pfeil P symbolisiert ist. Beim Anlegen des Werkzeugs an das Kontaktteil ist dasselbe mit Vorteil bereits in Rotation versetzt. Es kann aber auch erst nach dem Anlegen an das Kontaktteil in Rotation versetzt werden.In FIG. 4A is the line 10 off FIG. 3 shown with an attached attachment foot or a mounting strap 22. The fastening tab is made of copper or aluminum. At the in FIG. 4A illustrated embodiment, the fastening tab 22 is formed as an angle section with two legs 23, 24. The first leg 23 the fastening tab 22 is provided with a screw hole 26 for a fastening screw, while the second leg 24 has passages 27 which are dimensioned so that the projections 17 of the contact sleeve 16 are receivable therein, when the leg 24 of the fastening tab 22 has a mounting position on the end face the contact sleeve 16 occupies. In FIG. 4A Furthermore, a tool 28 is shown, with which the leg 24 of the fastening tab 22 is welded by friction stir welding with the contact sleeve 16. In this welding process, the temperature required for welding contact sleeve 16 and fastening tab 22 is generated by friction. In this case, the material of the contact sleeve 16 connects to that of the fastening tab 22 at a temperature below the melting temperature of the metals used cohesively or is welded together by diffusion. The pressure applied by the tool 28 and the work done thereby also contribute to this. The tool used in the method accordingly has a friction surface, with which it is pressed onto the leg 24 of the fastening tab 22, which is in FIG. 4 symbolized by an arrow P. When applying the tool to the contact part, the same is advantageously already set in rotation. However, it can also be set in rotation only after it has been attached to the contact part.

Das Werkzeug 28 wird bei Durchführung des Verfahrens beispielsweise durch einen Elektromotor um seine Achse A in Drehung versetzt und danach in Richtung des Pfeiles P bewegt. Es wird dann mit anhaltendem Druck gegen den Schenkel 24 der Befestigungslasche 22 gedrückt, so dass das Material desselben durch Reibung erwärmt wird.When the method is carried out, the tool 28 is rotated about its axis A, for example by an electric motor, and then moved in the direction of the arrow P. It is then pressed with continued pressure against the leg 24 of the fastening tab 22, so that the material thereof is heated by friction.

Bei dem Ausführungsbeispiel bei dem die Kontakthülse 16 zunächst nur auf den Leiter 11 gepresst ist, findet eine Verschweißung der Einzeldrähte 12 mit der Kontakthülse 16 während des Rührreibschweißens statt. D.h. während die Befestigungslasche 22 mit der Kontakthülse verscheißt wird, werden gleichzeitig die Einzeldrähte 12 mit der Kontakthülse verschweißt.In the embodiment in which the contact sleeve 16 is initially pressed only on the conductor 11, a welding of the individual wires 12 takes place with the contact sleeve 16 during friction stir welding. That while the fastening tab 22 is slipped off with the contact sleeve, at the same time the individual wires 12 are welded to the contact sleeve.

Die Befestigungslasche 22 ist als einfaches Stanz- und Biegeteil hergestellt. Abmessungen, Form, Anzahl von Befestigungsöffnungen usw. sind dadurch auf einfache Weise an einzelne Anwendungsfälle anpassbar. Allerdings ist die Erfindung nicht auf eine gestanzte und/oder gebogene Befestigungslasche 22 eingeschränkt. Grundsätzlich ist die Erfindung unabhängig davon, wie die Befestigungslasche 22 hergestellt ist.The fastening tab 22 is made as a simple stamped and bent part. Dimensions, shape, number of mounting holes, etc. are thereby easily adaptable to individual applications. However, the invention is not limited to a stamped and / or bent fastening tab 22. In principle, the invention is independent of how the fastening tab 22 is made.

Figur 4B zeigt ein weiteres Ausführungsbeispiel einer Leitung 10, wobei das Ende der Leitung, welche die Kontakthülse 16 trägt, im Querschnitt dargestellt ist. An die Kontakthülse ist in diesem Fall eine andere Befestigungslasche 29 angeschweißt, die, wie oben ausgeführt, nahezu beliebig gestaltet sein kann. FIG. 4B shows a further embodiment of a conduit 10, wherein the end of the conduit which carries the contact sleeve 16, is shown in cross section. To the contact sleeve another fastening tab 29 is welded in this case, which, as stated above, can be designed almost arbitrarily.

Figur 5A zeigt in einem Flussdiagramm die einzelnen Herstellungsschritte für ein erstes Verfahren zur Herstellung einer erfindungsgemäßen elektrischen Verbindung. Zu Beginn wird im Schritt S1 eine Kontakthülse 16 auf den Leiter 11 aufgeschoben und danach in Schritt S2 auf dem Leiter 11 gecrimpt. Anschließend werden in Schritt S3 die Litzendrähte 12 miteinander und mit der Kontakthülse 16 in einem Plasmalichtbogen stoffschlüssig verbunden. Abschließend wird die Befestigungslasche 22 mit der Kontakthülse 16 verschweißt, insbesondere rührreibgeschweißt. FIG. 5A shows in a flow chart the individual manufacturing steps for a first method for producing an electrical connection according to the invention. Initially, a contact sleeve 16 is pushed onto the conductor 11 in step S1 and then crimped on the conductor 11 in step S2. Subsequently, in step S3, the stranded wires 12 are connected to one another in a material-tight manner with one another and with the contact sleeve 16 in a plasma arc. Finally, the fastening tab 22 is welded to the contact sleeve 16, in particular friction stir welded.

Figur 5B zeigt in einem weiteren Flussdiagramm die einzelnen Herstellungsschritte für ein zweites Verfahren zur Herstellung einer erfindungsgemäßen elektrischen Verbindung. Die Schritte S5 und S6 sind identisch mit den Schritten S1 und S2 bei der ersten Herstellungsart. Dann wird jedoch bereits in einem dritten Schritt S7 die Befestigungslasche 22 mit der Kontakthülse 16 verschweißt, insbesondere rührreibgeschweißt, wodurch gleichzeitig die Einzeldrähte 12 des Leiters 11 mit der Kontakthülse 16 verschweißt werden. FIG. 5B shows in a further flowchart the individual manufacturing steps for a second method for producing an electrical connection according to the invention. Steps S5 and S6 are identical to steps S1 and S2 in the first production mode. Then, however, in a third step S7, the fastening tab 22 is welded to the contact sleeve 16, in particular friction stir welded, whereby at the same time the individual wires 12 of the conductor 11 are welded to the contact sleeve 16.

BezugszeichenlisteLIST OF REFERENCE NUMBERS

AA
Achseaxis
PP
Pfeilearrows
1010
Leitungmanagement
1111
Leiterladder
1212
Einzeldrähteindividual wires
1313
Isolationisolation
1414
Abschnittsection
1616
Kontakthülsecontact sleeve
1717
Vorsprüngeprojections
1818
Blechstreifenmetal strip
2121
(kompaktierter) Bereich(compacted) area
2222
Befestigungslaschemounting tab
23,2423.24
Schenkelleg
2626
Schraubenlochscrew hole
2727
Durchlässepassages
2828
WerkzeugTool

Claims (7)

  1. A method for electrically conductively connecting a contact part consisting of a contact sleeve (16) and a mounting bracket (22) based on copper- or aluminum to a conductor (11), which has a plurality of aluminum-containing individual wires (12), wherein the method comprises the steps:
    - Placement (S1, S5) of the contact sleeve (16) on the conductor (11), and
    - mechanical connection (S2, S6) of the contact sleeve (16) to the conductor (11), wherein the method is characterized by the steps:
    - Placement of the mounting bracket (22), so that a projection (17) on an end face of the contact sleeve (17) comes into engagement with a corresponding feed-through (27) on the mounting bracket (22) and holds the mounting bracket (22) on the contact sleeve (16),
    - integral connection of the individual wires (12) of the conductor (11) with one another and with the contact sleeve (16), and
    - integral connection (S4, S7) of the mounting bracket (22) on the end face of the contact sleeve (16).
  2. The method according to Claim 1, characterized in that the step of the integral connection (S3) of the individual wires (12) of the conductor (11) with one another and with the contact sleeve (16) is carried out by means of a plasma arc.
  3. The method according to Claim 1, characterized in that in the step of the integral connection (S7) of the mounting bracket (22) with the contact sleeve (16) the individual wires (12) of the conductor (11) are simultaneously integrally connected with one another and with the contact sleeve (16).
  4. The method according to any one of the preceding claims, characterized in that the integral connection (S4, S7) between the mounting bracket (22) and the face end of the contact sleeve (16) is produced by a method from the following list:
    - friction stir welding,
    - ultrasonic welding,
    - soft soldering, and
    - hard soldering.
  5. An electrical line with a conductor (11), which has a plurality of aluminum-containing individual wires (12) and which is connected to a contact part based on copper or aluminum, which is composed of a contact sleeve (16) and a mounting bracket (22), wherein the individual wires (12) of the conductor are integrally connected with one another and with the contact sleeve placed on the conductor (11), wherein the contact sleeve (16) is integrally connected with the mounting bracket (22), characterized in that the contact sleeve (16) has a projection (17) on an end face, which corresponds with a feed-through (27) in the mounting bracket (22), so that in the mounting position of the mounting bracket of the projection (17) the contact sleeve engages in the feed-through (27) of the mounting bracket, and that the mounting bracket (22) is integrally connected on the end face of the contact sleeve (16).
  6. The electrical line according to Claim 5, characterized in that the contact sleeve (16) is a rolled sleeve.
  7. The electrical line according to any one of Claims 5 or 6, characterized in that the mounting bracket (22) is a stamped- and/or bent part.
EP17306128.4A 2017-09-01 2017-09-01 Method for making an electrical connection and an electrical line Active EP3451455B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP17306128.4A EP3451455B1 (en) 2017-09-01 2017-09-01 Method for making an electrical connection and an electrical line

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP17306128.4A EP3451455B1 (en) 2017-09-01 2017-09-01 Method for making an electrical connection and an electrical line

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EP4002592A1 (en) 2020-11-19 2022-05-25 Nexans Connector for electrical line and line connection

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