EP3474391B1 - Method for joining at least two multi-strand leads by means of ultrasound - Google Patents

Method for joining at least two multi-strand leads by means of ultrasound Download PDF

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Publication number
EP3474391B1
EP3474391B1 EP17197426.4A EP17197426A EP3474391B1 EP 3474391 B1 EP3474391 B1 EP 3474391B1 EP 17197426 A EP17197426 A EP 17197426A EP 3474391 B1 EP3474391 B1 EP 3474391B1
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Prior art keywords
wires
fanning
strands
strand
ultrasound
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German (de)
French (fr)
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EP3474391A1 (en
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Peter Solenthaler
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Telsonic Holding AG
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Telsonic Holding AG
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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
    • H01R4/021—Soldered or welded connections between two or more cables or wires

Definitions

  • the invention Method for connecting, in particular welding and / or soldering, at least two multi-stranded strands by means of ultrasound.
  • a generic method is for example in the DE 197 23 215 A1 described which discloses connection methods and connection arrangements for insulated lines or cables.
  • two insulated cables are crossed at an intersection angle, clamped between two resin plates and then subjected to ultrasound. This is intended to excellently loosen or loosen the core wires, gradually widen the loosened or loosened core wires into a flat shape, and to lead the wire parts of both insulated wires to be in contact with each other at several places, thereby establishing a connection state with excellent electrical conductivity and a low contact resistance should be obtained.
  • Similar procedures are also in DE 197 23 242 A1 and DE 198 39 220 A1 disclosed.
  • connection node is electrically insulated due to the resin platelets surrounding it, and can therefore no longer be electrically connected to further electrical conductors.
  • the WO 2015/007619 A1 discloses a method for producing a knot by welding first strand comprising at least one individual wire with second strand comprising different materials comprising at least one individual wire in a compression space of an ultrasonic welding device which is adjustable in height and width.
  • the at least one first strand is inserted into the compression space and its individual wires then welded to a partial node.
  • the compression space is then opened, the at least one second strand is placed in the compression space on the partial node and then, after the compression space is closed, the at least one second strand is welded to the partial node.
  • a first strand is inserted into the compression space without any special pretreatment and then its width is set, as a result of which the first strand is compressed in the horizontal direction.
  • this horizontal compression reduces the connection surface, which is also essentially horizontal, at which the two strands come into contact with one another and are welded to one another.
  • the first strand may uncontrollably fray in the vertical direction during the horizontal compression, as a result of which the welding energy cannot be reliably introduced homogeneously.
  • the result is connections with pulling and peeling forces that are low and also subject to significant fluctuations. Overall, this method is therefore prone to errors.
  • the connecting knot that arises between the strands should not be electrically insulated and / or pull-off forces and peeling forces should be achieved which are as large as possible and are also subject to only the smallest possible fluctuations. This should be possible in particular for the largest possible strand cross sections.
  • Fanning out a strand in step a) is understood here and below to mean that a width of the strand cross section of the strand extending parallel to the fanning-out plane is increased, for example by at least 10%, preferably at least 20%, particularly preferably at least 25%.
  • step a) Due to the fanning out in step a) is in contrast to the above WO 2015/007619 A1 an enlarged connection area is reached, at which the at least two strands come into contact with one another and can be connected to one another in the later step c).
  • the positioning of the strands in the compression space is simpler and more defined than is possible, for example, with strands which have an essentially circular cross section and are stacked one above the other in the compression space.
  • the individual wires of the fanned-out strands can interlock when connecting in step c), which additionally contributes to increasing the stability of the connection.
  • the strands are inserted into a compression space of an ultrasound connection device, so that at least two of the strands essentially are in contact with each other along the fanning plane.
  • the ultrasonic connection device can be an ultrasonic welding device.
  • the strands are first inserted into the compression space and then fanned out. A tool can be used for this, which can be inserted directly into the compression chamber. It is conceivable that initially only a first strand is inserted into the compression space and then fanned out there, and then a second strand is placed in the compression space and on the first strand already fanned out and then also fanned out.
  • the strands are first fanned out and then inserted into the compression space.
  • a first strand is fanned out after insertion into the compression space and a second strand is fanned out before insertion into the compression space.
  • the strands can be connected with a very homogeneous distribution of the connection energy, in particular the welding energy and / or the soldering energy.
  • connection energy in particular the welding energy and / or the soldering energy.
  • the pull-off forces could be increased by up to 30% in some experiments with the method according to the invention. The process is therefore less prone to errors overall.
  • the connection obtained is also of high quality optically.
  • connection force and connection energy required for the connection can be reduced due to the fanning out, since part of the deformation work was already introduced into the strands during the fanning out.
  • a reduction in the connection force and connection energy required for connection is particularly advantageous for strands with large strand cross sections.
  • at least one of the strands, preferably all strands can have a strand cross section of more than 1 mm 2 , preferably more than 10 mm 2 , particularly preferably more than 25 mm 2 .
  • the total strand cross section of the strands can be more than 4 mm 2 , preferably more than 40 mm 2 , particularly preferably more than 100 mm 2 .
  • the process duration can be reduced while maintaining the connection energy, in particular the welding energy.
  • At least one of the strands is additionally compressed in step a).
  • Compression of the strand here and below means that a height of the strand cross-section of the strand running perpendicular to the fanning-out plane is reduced, for example by at least 10%, preferably at least 20%, particularly preferably at least 25%.
  • This compression gives the strands a shape that is subject to even smaller tolerances, which means that even more homogeneous properties of the connecting nodes can be achieved.
  • the compression can be perpendicular or oblique to the fanning out plane.
  • a tool known per se such as, for example, a press, which can optionally contain a suitable tool attachment, can be used for fanning out and optionally for compressing in step a).
  • the press can be a pneumatically driven pressing tongs.
  • the tool can be installed on or in the ultrasonic connection device. But it can also be a separate tool.
  • At least one of the strands can consist of aluminum or copper or another non-ferrous metal.
  • at least one first strand can be made of copper and at least one second strand can be made of aluminum.
  • the compression space is delimited by a work surface of a sonotrode that can be excited to ultrasonic vibrations, a work surface an anvil and side surfaces of two side delimiting elements.
  • the strands are particularly preferably inserted into the compression space in such a way that the fanning-out plane runs parallel to the working surface of the sonotrode and to the working surface of the anvil. If the sonotrode and the anvil are pressed against one another in step c) with a connecting force that runs perpendicular to their working surfaces, the connecting force also runs perpendicular to the fanning out plane. This results in a particularly stable connection.
  • a particularly stable connection also results if, at least in step c), all of the strands are arranged along a direction perpendicular to the fanning-out plane. Thus, for example, no two strands are adjacent in a direction running parallel to the fanning-out plane.
  • the strands can be arranged and connected to one another at an angle which is less than 30 °, preferably less than 15 °, particularly preferably less than 5 °.
  • the strands 30 are shown on the left and right, each of which is arranged along a direction and has parallel longitudinal axes, that is to say arranged at an angle of 0 ° to one another.
  • the strands 30 can consist, for example, of aluminum or copper or another non-ferrous metal and have a strand cross section of 25 mm 2 , so that a total strand cross section of 100 mm 2 results in each case.
  • a known ultrasonic welding device 10 for welding the strands 30 is shown.
  • This contains a compression space 11 which is delimited by the working surface 13 of a sonotrode 12, the working surface 15 of an anvil 14 and by side surfaces 18 of two side delimiting elements 16, 17.
  • the left side delimitation element 16 is in the horizontal direction relative to the sonotrode 12 slidably arranged, while the right side delimitation element 17 is slidably arranged in the vertical direction relative to the sonotrode 12.
  • the anvil 14 is arranged to be displaceable in the horizontal direction relative to the right side delimitation element 17.
  • step b) the strands 30 were placed on the working surface 13 of the sonotrode 12 in such a way that the fanning-out plane E runs parallel to the working surface 13 of the sonotrode 12 and to the working surface 15 of the anvil 14.
  • step c) the sonotrode 12 and the anvil 14 are pressed against one another with a connecting force that runs perpendicular to their working surfaces 13, 15, so that the connecting force also runs perpendicular to the fanning-out planes E. All four strands 30 are arranged along this direction of the connecting force.
  • the connecting surface at which the strands 30 come into contact with one another and are welded to one another is significantly larger if the strands 30 are as in FIG Figure 2b were fanned out beforehand.
  • the ultrasonic vibrations introduced by the sonotrode 12 can thus penetrate and penetrate the composite of the strands 30 more efficiently and homogeneously.
  • the strands 30 can be connected to a very homogeneous distribution of the welding energy. This results in high and evenly high peel and peel forces, as can be determined in an optional, subsequent quality assessment. The process is therefore less prone to errors overall.
  • the connecting force and welding energy required for the welding can be reduced, which is particularly advantageous for strands 30 with large strand cross sections.
  • the connection obtained is also of high quality optically.
  • FIG 3 Four strands 30 are shown in a second arrangement, in which two lower strands 30 are arranged side by side and above that two upper strands 30 are arranged side by side.
  • Analog to the Figures 1 left and 2a were the four in the Figures 3 and 4 strands 30 shown are not fanned out beforehand according to a conventional method and therefore still have their original, essentially circular strand cross section.
  • strands 30 shown side by side are only insufficiently connected to one another, since their connecting surfaces run parallel to the direction of the connecting force in which the sonotrode 12 and the anvil 14 are pressed against one another.
  • there is a gap 31 between the strands 30 At this point, the weld connection can become particularly unstable.
  • a tool 50 suitable for fanning out and compressing according to the invention is shown.
  • This includes a stand 51 with a support surface 52 for one or more strands 30 and a press ram 53 with a press surface 54 arranged parallel to the support surface 52.
  • the press ram 53 can be moved pneumatically relative to the stand 51 in a direction R, which is at an angle ⁇ to Support surface 52 and the pressing surface 54.
  • process step a) according to the invention, the strand 30 is clamped between the support surface 52 and the press surface 54 and thus fanned out in a fanning-out plane E defined by the support surface 52 and the press surface 54 and compressed at an angle ⁇ thereto.

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

Description

Die Erfindung Verfahren zum Verbinden, insbesondere Verschweissen und/oder Verlöten, mindestens zweier mehrdrähtiger Litzen mittels Ultraschalls.The invention Method for connecting, in particular welding and / or soldering, at least two multi-stranded strands by means of ultrasound.

Ein gattungsgemässes Verfahren ist beispielsweise in der DE 197 23 215 A1 beschrieben, die Verbindungsverfahren und Verbindungsanordnungen für isolierte Leitungen oder Kabel offenbart. Hierbei werden zwei isolierte Leitungen unter einem Kreuzungswinkel gekreuzt, zwischen zwei Harzplättchen eingeklemmt und anschliessend mit Ultraschall beaufschlagt. Hierdurch sollen die Kerndrähte ausgezeichnet voneinander gelöst oder aufgelockert und die voneinander gelösten oder aufgelockerten Kerndrähte allmählich in eine flache Form aufgespreizt werden, und die Leitungsdrahtteile von beiden isolierten Leitungen sollen an mehreren Stellen in Kontakt miteinander sein, wodurch ein Verbindungszustand mit einer ausgezeichneten elektrischen Stromleiteigenschaft und mit einem niedrigen Kontaktwiderstand erhalten werden sollen. Ähnliche Verfahren sind auch in DE 197 23 242 A1 und DE 198 39 220 A1 offenbart.A generic method is for example in the DE 197 23 215 A1 described which discloses connection methods and connection arrangements for insulated lines or cables. Here, two insulated cables are crossed at an intersection angle, clamped between two resin plates and then subjected to ultrasound. This is intended to excellently loosen or loosen the core wires, gradually widen the loosened or loosened core wires into a flat shape, and to lead the wire parts of both insulated wires to be in contact with each other at several places, thereby establishing a connection state with excellent electrical conductivity and a low contact resistance should be obtained. Similar procedures are also in DE 197 23 242 A1 and DE 198 39 220 A1 disclosed.

Die in den genannten Dokumenten beschriebenen Verfahren resultieren zwar in einer Verbindung zweier Litzen an einem Verbindungsknoten. Dieser Verbindungsknoten ist jedoch aufgrund der ihn umschliessenden Harzplättchen elektrisch isoliert, kann also nicht mehr mit weiteren elektrischen Leitern elektrisch verbunden werden.The methods described in the cited documents result in a connection of two strands at a connection node. However, this connection node is electrically insulated due to the resin platelets surrounding it, and can therefore no longer be electrically connected to further electrical conductors.

Die WO 2015/007619 A1 offenbart ein Verfahren zum Herstellen eines Knotens durch Schweissen von zumindest einer Einzeldrähte umfassenden ersten Litze mit zumindest einer Einzeldrähte umfassenden zweiten Litze unterschiedlicher Materialien in einem in Höhe und Breite verstellbaren Verdichtungsraum einer Ultraschallschweissvorrichtung. Die zumindest eine erste Litze wird in den Verdichtungsraum eingelegt und deren Einzeldrähte sodann zu einem Teilknoten verschweisst. Anschliessend wird der Verdichtungsraum geöffnet, die zumindest eine zweite Litze in den Verdichtungsraum auf den Teilknoten gelegt und sodann nach Schliessen des Verdichtungsraums die zumindest eine zweite Litze mit dem Teilknoten verschweisst.The WO 2015/007619 A1 discloses a method for producing a knot by welding first strand comprising at least one individual wire with second strand comprising different materials comprising at least one individual wire in a compression space of an ultrasonic welding device which is adjustable in height and width. The at least one first strand is inserted into the compression space and its individual wires then welded to a partial node. The compression space is then opened, the at least one second strand is placed in the compression space on the partial node and then, after the compression space is closed, the at least one second strand is welded to the partial node.

In einem in WO 2015/007619 A1 beschriebenen Ausführungsbeispiel wird eine erste Litze ohne besondere Vorbehandlung in den Verdichtungsraum eingelegt und dann dessen Breite eingestellt, wodurch die erste Litze in horizontaler Richtung komprimiert wird. Durch diese horizontale Kompression wird jedoch die ebenfalls im Wesentlichen horizontale Verbindungsfläche reduziert, an der die beiden Litzen in Kontakt miteinander geraten und miteinander verschweisst werden. Zudem kann es passieren, dass die erste Litze bei der horizontalen Kompression in unkontrollierter Weise in vertikaler Richtung ausfranst, wodurch die Schweissenergie nicht zuverlässig homogen eingeleitet werden kann. Die Folge sind Verbindungen mit Abzugskräften und Schälkräften, die niedrig sind und zudem deutlichen Schwankungen unterliegen. Insgesamt ist dieses Verfahren daher auch fehleranfällig.In one in WO 2015/007619 A1 In the embodiment described, a first strand is inserted into the compression space without any special pretreatment and then its width is set, as a result of which the first strand is compressed in the horizontal direction. However, this horizontal compression reduces the connection surface, which is also essentially horizontal, at which the two strands come into contact with one another and are welded to one another. In addition, the first strand may uncontrollably fray in the vertical direction during the horizontal compression, as a result of which the welding energy cannot be reliably introduced homogeneously. The result is connections with pulling and peeling forces that are low and also subject to significant fluctuations. Overall, this method is therefore prone to errors.

Es ist daher eine Aufgabe der vorliegenden Erfindung, ein Verfahren zum Verbinden mindestens zweier mehrdrähtiger Litzen mittels Ultraschalls bereitzustellen, durch das die oben genannten Nachteile zumindest teilweise ausgeräumt werden. Insbesondere sollen der zwischen den Litzen entstehende Verbindungsknoten nicht elektrisch isoliert werden und/oder Abzugskräfte und Schälkräfte erreicht werden, die möglichst gross sind und zudem nur möglichst kleinen Schwankungen unterliegen. Dies soll insbesondere für möglichst grosse Litzenquerschnitte möglich sein.It is therefore an object of the present invention to provide a method for connecting at least two multi-stranded strands by means of ultrasound, by means of which the disadvantages mentioned above are at least partially eliminated. In particular, the connecting knot that arises between the strands should not be electrically insulated and / or pull-off forces and peeling forces should be achieved which are as large as possible and are also subject to only the smallest possible fluctuations. This should be possible in particular for the largest possible strand cross sections.

Diese und weitere Aufgaben werden durch ein erfindungsgemässes Verfahren zum Verbinden mindestens zweier mehrdrähtiger Litzen mittels Ultraschalls gelöst, welches die folgenden Schritte enthält:

  1. a) Auffächern mindestens einer der Litzen, bevorzugt sämtlicher Litzen, in einer Auffächerungsebene,
  2. b) vor, während und/oder nach Schritt a): Einlegen der Litzen in einen Verdichtungsraum einer Ultraschallverbindungsvorrichtung, so dass mindestens zwei der Litzen im Wesentlichen entlang der Auffächerungsebene in Kontakt miteinander sind,
  3. c) Verbinden, insbesondere Verschweissen und/oder Verlöten, der aufgefächerten Litzen mittels Ultraschalls.
These and other tasks are achieved by a method according to the invention for connecting at least two multi-stranded strands solved by means of ultrasound, which contains the following steps:
  1. a) fanning out at least one of the strands, preferably all strands, in a fanning-out plane,
  2. b) before, during and / or after step a): inserting the strands into a compression space of an ultrasound connection device so that at least two of the strands are in contact with one another essentially along the fanning-out plane,
  3. c) connecting, in particular welding and / or soldering, the fanned strands by means of ultrasound.

Unter einem Auffächern einer Litze im Schritt a) wird hier und im Folgenden verstanden, dass eine parallel zur Auffächerungsebene verlaufende Breite des Litzenquerschnitts der Litze vergrössert wird, beispielsweise um mindestens 10 %, bevorzugt mindestens 20 %, besonders bevorzugt mindestens 25 %.Fanning out a strand in step a) is understood here and below to mean that a width of the strand cross section of the strand extending parallel to the fanning-out plane is increased, for example by at least 10%, preferably at least 20%, particularly preferably at least 25%.

Aufgrund des Auffächerns im Schritt a) wird im Gegensatz zur oben erwähnten WO 2015/007619 A1 eine vergrösserte Verbindungsfläche erreicht, an der die mindestens zwei Litzen in Kontakt miteinander geraten und im späteren Schritt c) miteinander verbunden werden können. Ausserdem gestaltet sich die Positionierung der Litzen im Verdichtungsraum einfacher und definierter, als es beispielsweise bei Litzen möglich ist, die einen im Wesentlichen kreisförmigen Querschnitt aufweisen und im Verdichtungsraum übereinander gestapelt werden. Zudem können sich die Einzeldrähte der aufgefächerten Litzen beim Verbinden im Schritt c) miteinander verzahnen, was zusätzlich zur Erhöhung der Stabilität der Verbindung beiträgt.Due to the fanning out in step a) is in contrast to the above WO 2015/007619 A1 an enlarged connection area is reached, at which the at least two strands come into contact with one another and can be connected to one another in the later step c). In addition, the positioning of the strands in the compression space is simpler and more defined than is possible, for example, with strands which have an essentially circular cross section and are stacked one above the other in the compression space. In addition, the individual wires of the fanned-out strands can interlock when connecting in step c), which additionally contributes to increasing the stability of the connection.

Vor, während oder nach Schritt a) werden die Litzen in einen Verdichtungsraum einer Ultraschallverbindungsvorrichtung eingelegt, so dass mindestens zwei der Litzen im Wesentlichen entlang der Auffächerungsebene in Kontakt miteinander sind. Die Ultraschallverbindungsvorrichtung kann eine Ultraschallschweissvorrichtung sein. In einer Variante werden die Litzen zunächst in den Verdichtungsraum eingelegt und dann aufgefächert. Hierzu kann ein Werkzeug verwendet werden, welches direkt in den Verdichtungsraum eingeführt werden kann. Dabei ist es denkbar, dass zunächst nur eine erste Litze in den Verdichtungsraum eingelegt wird und dann dort aufgefächert wird und anschliessend eine zweite Litze in den Verdichtungsraum und auf die erste bereits aufgefächerte Litze gelegt und sodann ebenfalls aufgefächert wird. In einer anderen Variante werden die Litzen zunächst aufgefächert und dann in den Verdichtungsraum eingelegt. Ausserdem liegt es im Rahmen der Erfindung, dass eine erste Litze nach dem Einlegen in den Verdichtungsraum aufgefächert wird und eine zweite Litze bereits vor dem Einlegen in den Verdichtungsraum aufgefächert wird.Before, during or after step a), the strands are inserted into a compression space of an ultrasound connection device, so that at least two of the strands essentially are in contact with each other along the fanning plane. The ultrasonic connection device can be an ultrasonic welding device. In a variant, the strands are first inserted into the compression space and then fanned out. A tool can be used for this, which can be inserted directly into the compression chamber. It is conceivable that initially only a first strand is inserted into the compression space and then fanned out there, and then a second strand is placed in the compression space and on the first strand already fanned out and then also fanned out. In another variant, the strands are first fanned out and then inserted into the compression space. In addition, it is within the scope of the invention that a first strand is fanned out after insertion into the compression space and a second strand is fanned out before insertion into the compression space.

Durch dieses erfindungsgemässe Verfahren können die Litzen mit einer sehr homogenen Verteilung der Verbindungsenergie, insbesondere der Schweissenergie und/oder der Lötenergie, verbunden werden. Hierdurch ergeben sich hohe und auch gleichmässig hohe Abzugskräfte und Schälkräfte, wie in einer optionalen, nachfolgenden Qualitätsbeurteilung festgestellt werden kann. Beispielsweise konnten in einigen Versuchen mit dem erfindungsgemässen Verfahren die Abzugskräfte um bis zu 30 % erhöht werden. Das Verfahren ist damit insgesamt weniger fehleranfällig. Auch optisch hat die erzielte Verbindung eine hohe Qualität.By means of this method according to the invention, the strands can be connected with a very homogeneous distribution of the connection energy, in particular the welding energy and / or the soldering energy. This results in high and evenly high peeling forces and peeling forces, as can be determined in an optional, subsequent quality assessment. For example, the pull-off forces could be increased by up to 30% in some experiments with the method according to the invention. The process is therefore less prone to errors overall. The connection obtained is also of high quality optically.

Weiterhin können aufgrund des Auffächerns die für das Verbinden benötigte Verbindungskraft und Verbindungsenergie reduziert werden, da während des Auffächerns bereits ein Teil der Deformationsarbeit in die Litzen eingetragen wurde. Eine Reduktion der zum Verbinden benötigten Verbindungskraft und Verbindungsenergie ist insbesondere für Litzen mit grossen Litzenquerschnitten von Vorteil. Beispielsweise kann mindestens eine der Litzen, bevorzugt sämtliche Litzen einen Litzenquerschnitt von mehr als 1 mm2, bevorzugt mehr als 10 mm2, besonders bevorzugt mehr als 25 mm2 aufweisen. Der Gesamtlitzenquerschnitt der Litzen kann mehr als 4 mm2, bevorzugt mehr als 40 mm2, besonders bevorzugt mehr als 100 mm2 betragen. Alternativ kann bei Beibehaltung der Verbindungsenergie, insbesondere der Schweissenergie, die Verfahrensdauer reduziert werden.Furthermore, the connection force and connection energy required for the connection can be reduced due to the fanning out, since part of the deformation work was already introduced into the strands during the fanning out. A reduction in the connection force and connection energy required for connection is particularly advantageous for strands with large strand cross sections. For example, at least one of the strands, preferably all strands, can have a strand cross section of more than 1 mm 2 , preferably more than 10 mm 2 , particularly preferably more than 25 mm 2 . The total strand cross section of the strands can be more than 4 mm 2 , preferably more than 40 mm 2 , particularly preferably more than 100 mm 2 . Alternatively, the process duration can be reduced while maintaining the connection energy, in particular the welding energy.

Vorteilhafterweise wird im Schritt a) mindestens eine der Litzen, bevorzugt sämtliche Litzen zusätzlich komprimiert. Unter einem Komprimieren der Litze wird hier und im Folgenden verstanden, dass eine senkrecht zur Auffächerungsebene verlaufende Höhe des Litzenquerschnitts der Litze reduziert wird, beispielweise um mindestens 10 %, bevorzugt mindestens 20 %, besonders bevorzugt mindestens 25 %. Durch dieses Komprimieren erhalten die Litzen eine Form, die noch kleineren Toleranzen unterliegt, wodurch noch homogenere Eigenschaften der entstehenden Verbindungsknoten erreicht werden können. Die Kompression kann senkrecht oder schräg zur Auffächerungsebene erfolgen.Advantageously, at least one of the strands, preferably all strands, is additionally compressed in step a). Compression of the strand here and below means that a height of the strand cross-section of the strand running perpendicular to the fanning-out plane is reduced, for example by at least 10%, preferably at least 20%, particularly preferably at least 25%. This compression gives the strands a shape that is subject to even smaller tolerances, which means that even more homogeneous properties of the connecting nodes can be achieved. The compression can be perpendicular or oblique to the fanning out plane.

Zum Auffächern und optional zum Komprimieren im Schritt a) kann ein an sich bekanntes Werkzeug verwendet werden, wie beispielsweise eine Presse, die gegebenenfalls einen geeigneten Werkzeugaufsatz enthalten kann. Bei der Presse kann es sich um eine pneumatisch angetriebene Presszange handeln. Das Werkzeug kann an oder in der Ultraschallverbindungsvorrichtung installiert sein. Es kann sich aber auch um ein separates Werkzeug handeln.A tool known per se, such as, for example, a press, which can optionally contain a suitable tool attachment, can be used for fanning out and optionally for compressing in step a). The press can be a pneumatically driven pressing tongs. The tool can be installed on or in the ultrasonic connection device. But it can also be a separate tool.

Mindestens eine der Litzen, bevorzugt sämtliche Litzen können aus Aluminium oder Kupfer oder einem anderen Buntmetall bestehen. Insbesondere kann mindestens eine erste Litzen aus Kupfer bestehen und mindestens eine zweite Litze aus Aluminium.At least one of the strands, preferably all strands, can consist of aluminum or copper or another non-ferrous metal. In particular, at least one first strand can be made of copper and at least one second strand can be made of aluminum.

In einer baulich einfachen und effektiven Ausführungsform wird der Verdichtungsraum begrenzt durch eine Arbeitsfläche einer zu Ultraschallschwingungen anregbaren Sonotrode, eine Arbeitsfläche eines Ambosses und Seitenflächen zweier Seitenbegrenzungselemente. Besonders bevorzugt werden die Litzen derart in den Verdichtungsraum eingelegt, dass die Auffächerungsebene parallel zur Arbeitsfläche der Sonotrode und zur Arbeitsfläche des Ambosses verläuft. Wenn die Sonotrode und der Amboss im Schritt c) mit einer Verbindungskraft gegeneinander gepresst werden, die senkrecht zu ihren Arbeitsflächen verläuft, so verläuft die Verbindungskraft auch senkrecht zur Auffächerungsebene. Hierdurch ergibt sich eine besonders stabile Verbindung. Eine besonders stabile Verbindung ergibt sich weiterhin, wenn zumindest im Schritt c) sämtliche Litzen entlang einer senkrecht zur Auffächerungsebene verlaufenden Richtung angeordnet sind. Somit sind also beispielsweise keine zwei Litzen in einer parallel zur Auffächerungsebene verlaufenden Richtung benachbart.In a structurally simple and effective embodiment, the compression space is delimited by a work surface of a sonotrode that can be excited to ultrasonic vibrations, a work surface an anvil and side surfaces of two side delimiting elements. The strands are particularly preferably inserted into the compression space in such a way that the fanning-out plane runs parallel to the working surface of the sonotrode and to the working surface of the anvil. If the sonotrode and the anvil are pressed against one another in step c) with a connecting force that runs perpendicular to their working surfaces, the connecting force also runs perpendicular to the fanning out plane. This results in a particularly stable connection. A particularly stable connection also results if, at least in step c), all of the strands are arranged along a direction perpendicular to the fanning-out plane. Thus, for example, no two strands are adjacent in a direction running parallel to the fanning-out plane.

Besonders effizient ist es, wenn vor Schritt c) keine der Litzen geschweisst oder gelötet wird. Die Litzen werden also ausschliesslich im Schritt c) miteinander verschweisst und/oder verlötet, was zu kürzeren Verfahrensdauern führt.It is particularly efficient if none of the strands is welded or soldered before step c). The strands are therefore welded and / or soldered to one another exclusively in step c), which leads to shorter processing times.

Die Litzen können zumindest im Schritt c) unter einem Winkel angeordnet und miteinander verbunden werden, der kleiner als 30°, bevorzugt kleiner als 15°, besonders bevorzugt kleiner als 5° ist.At least in step c), the strands can be arranged and connected to one another at an angle which is less than 30 °, preferably less than 15 °, particularly preferably less than 5 °.

Nachfolgende wird die Erfindung anhand von Ausführungsbeispielen und Zeichnungen näher erläutert. Dabei zeigen

Figur 1:
vier ohne erfindungsgemässes vorheriges Auffächern verbundene Litzen sowie vier nach erfindungsgemässem vorherigem Auffächern verbundene Litzen, jeweils in einer ersten Anordnung, in einer perspektivischen Ansicht;
Figur 2a:
die vier ohne erfindungsgemässes vorheriges Auffächern verbundene Litzen gemäss Figur 1 in einer Schnittansicht durch einen Verbindungsknoten;
Figur 2b:
die vier nach erfindungsgemässem vorherigem Auffächern verbundene Litzen gemäss Figur 1 in einer Schnittansicht durch einen Verbindungsknoten;
Figur 3:
vier ohne erfindungsgemässes vorheriges Auffächern verbundene Litzen in einer zweiten Anordnung, in einer perspektivischen Ansicht;
Figur 4:
die vier ohne erfindungsgemässes vorheriges Auffächern verbundenen Litzen gemäss Figur 3 in einer Schnittansicht durch einen Verbindungsknoten;
Figur 5:
ein Werkzeug zum erfindungsgemässen Auffächern einer darin eingelegten Litze vor dem Auffächern;
Figur 6:
das Werkzeug mit der darin eingelegten Litze nach dem Auffächern.
The invention is explained in more detail below on the basis of exemplary embodiments and drawings. Show
Figure 1:
four strands connected without prior fanning out according to the invention and four strands connected according to the previous fanning out according to the invention, each in a first arrangement, in a perspective view;
Figure 2a:
the four strands connected without prior fanning out according to the invention Figure 1 in a sectional view through a connecting node;
Figure 2b:
the four strands connected according to the previous fanning out according to the invention Figure 1 in a sectional view through a connecting node;
Figure 3:
four strands connected without prior fanning out according to the invention in a second arrangement, in a perspective view;
Figure 4:
the four strands connected without prior fanning out according to the invention Figure 3 in a sectional view through a connecting node;
Figure 5:
a tool for fanning a stranded wire according to the invention before fanning out;
Figure 6:
the tool with the wire inserted in it after fanning out.

In Figur 1 sind links und rechts jeweils vier Litzen 30 dargestellt, die jeweils alle entlang einer Richtung angeordnet sind und parallele Längsachsen aufweisen, also unter einem Winkel von 0° zueinander angeordnet sind. Die Litzen 30 können beispielsweise aus Aluminium oder Kupfer oder einem anderen Buntmetall bestehen und einen Litzenquerschnitt von 25 mm2 aufweisen, so dass sich jeweils ein Gesamtlitzenquerschnitt von 100 mm2 ergibt.In Figure 1 four strands 30 are shown on the left and right, each of which is arranged along a direction and has parallel longitudinal axes, that is to say arranged at an angle of 0 ° to one another. The strands 30 can consist, for example, of aluminum or copper or another non-ferrous metal and have a strand cross section of 25 mm 2 , so that a total strand cross section of 100 mm 2 results in each case.

In den Figuren 2a, 2b und 4 ist eine an sich bekannte Ultraschallschweissvorrichtung 10 zum Schweissen der Litzen 30 dargestellt. Diese enthält einen Verdichtungsraum 11, der von der Arbeitsfläche 13 einer Sonotrode 12, der Arbeitsfläche 15 eines Ambosses 14 sowie von Seitenflächen 18 zweier Seitenbegrenzungselemente 16, 17 begrenzt ist. Das linke Seitenbegrenzungselement 16 ist in horizontaler Richtung relativ zur Sonotrode 12 verschiebbar angeordnet, während das rechte Seitenbegrenzungselement 17 in vertikaler Richtung relativ zur Sonotrode 12 verschiebbar angeordnet ist. Der Amboss 14 ist in horizontaler Richtung relativ zum rechten Seitenbegrenzungselement 17 verschiebbar angeordnet. Hierdurch können in an sich bekannter Weise eine Breite und eine Höhe des Verdichtungsraums 11 eingestellt werden.In the Figures 2a, 2b and 4 A known ultrasonic welding device 10 for welding the strands 30 is shown. This contains a compression space 11 which is delimited by the working surface 13 of a sonotrode 12, the working surface 15 of an anvil 14 and by side surfaces 18 of two side delimiting elements 16, 17. The left side delimitation element 16 is in the horizontal direction relative to the sonotrode 12 slidably arranged, while the right side delimitation element 17 is slidably arranged in the vertical direction relative to the sonotrode 12. The anvil 14 is arranged to be displaceable in the horizontal direction relative to the right side delimitation element 17. As a result, a width and a height of the compression space 11 can be set in a manner known per se.

Die vier in Figur 1 links und in Figur 2a gezeigten Litzen 30 wurden gemäss einem herkömmlichen Verfahren nicht zuvor aufgefächert und haben daher noch ihren ursprünglichen, im Wesentlichen kreisförmigen Litzenquerschnitt. In dieser Form und Anordnung sind die Litzen nur schwierig, jedenfalls aber nicht zuverlässig in definierter Weise im Verdichtungsraum 11 positionierbar. Zudem ist die Verbindungsfläche, an der die Litzen 30 in Kontakt miteinander geraten und miteinander verschweisst werden, nur sehr klein.The four in Figure 1 left and in Figure 2a The strands 30 shown were not fanned out beforehand according to a conventional method and therefore still have their original, essentially circular strand cross section. In this form and arrangement, the strands are difficult to position, but in any case not reliably positioned in the compression space 11. In addition, the connection area at which the strands 30 come into contact with one another and are welded to one another is only very small.

Hingegen wurden die vier in Figur 1 rechts und in Figur 2b zu sehenden Litzen 30 gemäss dem erfindungsgemässen Verfahren in einem Schritt a) zuvor in einer hier vertikal angeordneten Auffächerungsebene E aufgefächert und komprimiert, beispielsweise mit einem in den Figuren 5 und 6 gezeigten Werkzeug 50; d. h. eine parallel zur Auffächerungsebene E verlaufende Breite b des Litzenquerschnitts der Litze 30 wurde vergrössert, und eine senkrecht zur Auffächerungsebene E verlaufende Höhe h des Litzenquerschnitts der Litzen 30 wurde reduziert. Die Litzen 30 wurden in einem Schritt b) derart auf die Arbeitsfläche 13 der Sonotrode 12 aufgelegt, dass die Auffächerungsebene E parallel zur Arbeitsfläche 13 der Sonotrode 12 und zur Arbeitsfläche 15 des Ambosses 14 verläuft. Die Sonotrode 12 und der Amboss 14 werden im Schritt c) mit einer Verbindungskraft gegeneinander gepresst, die senkrecht zu ihren Arbeitsflächen 13, 15 verläuft, sodass die Verbindungskraft auch senkrecht zu den Auffächerungsebenen E verläuft. Sämtliche vier Litzen 30 sind entlang dieser Richtung der Verbindungskraft angeordnet.In contrast, the four in Figure 1 right and in Figure 2b to be seen strands 30 according to the inventive method in a step a) previously fanned out and compressed in a fanning plane E arranged vertically here, for example with a Figures 5 and 6 tool 50 shown; ie a width b of the strand cross-section of the strand 30 running parallel to the fanning-out plane E has been increased, and a height h of the strand cross-section of the strands 30 running perpendicular to the fanning-out plane E has been reduced. In a step b), the strands 30 were placed on the working surface 13 of the sonotrode 12 in such a way that the fanning-out plane E runs parallel to the working surface 13 of the sonotrode 12 and to the working surface 15 of the anvil 14. In step c), the sonotrode 12 and the anvil 14 are pressed against one another with a connecting force that runs perpendicular to their working surfaces 13, 15, so that the connecting force also runs perpendicular to the fanning-out planes E. All four strands 30 are arranged along this direction of the connecting force.

Wie durch Vergleich der Figuren 2a und 2b zu entnehmen ist, ist die Verbindungsfläche, an der die Litzen 30 in Kontakt miteinander geraten und miteinander verschweisst werden, deutlich grösser, wenn die Litzen 30 wie in Figur 2b vorher aufgefächert wurden. Die von der Sonotrode 12 eingebrachten Ultraschallschwingungen können somit effizienter und homogener in den Verbund der Litzen 30 eindringen und diesen durchdringen. Hierdurch können die Litzen 30 mit einer sehr homogenen Verteilung der Schweissenergie verbunden werden. Folglich ergeben sich hohe und auch gleichmässig hohe Abzugskräfte und Schälkräfte, wie in einer optionalen, nachfolgenden Qualitätsbeurteilung festgestellt werden kann. Das Verfahren ist damit insgesamt weniger fehleranfällig. Weiterhin können aufgrund des Auffächerns die für das Verschweissen benötigte Verbindungskraft und Schweissenergie reduziert werden, was insbesondere für Litzen 30 mit grossen Litzenquerschnitten von Vorteil ist. Auch optisch hat die erzielte Verbindung eine hohe Qualität.As by comparing the Figures 2a and 2b it can be seen that the connecting surface at which the strands 30 come into contact with one another and are welded to one another is significantly larger if the strands 30 are as in FIG Figure 2b were fanned out beforehand. The ultrasonic vibrations introduced by the sonotrode 12 can thus penetrate and penetrate the composite of the strands 30 more efficiently and homogeneously. As a result, the strands 30 can be connected to a very homogeneous distribution of the welding energy. This results in high and evenly high peel and peel forces, as can be determined in an optional, subsequent quality assessment. The process is therefore less prone to errors overall. Furthermore, due to the fanning out, the connecting force and welding energy required for the welding can be reduced, which is particularly advantageous for strands 30 with large strand cross sections. The connection obtained is also of high quality optically.

In Figur 3 sind vier Litzen 30 in einer zweiten Anordnung dargestellt, in der zwei untere Litzen 30 nebeneinander und darüber zwei obere Litzen 30 nebeneinander angeordnet sind. Analog zu den Figuren 1 links und 2a wurden die vier in den Figuren 3 und 4 gezeigten Litzen 30 gemäss einem herkömmlichen Verfahren nicht zuvor aufgefächert und haben daher noch ihren ursprünglichen, im Wesentlichen kreisförmigen Litzenquerschnitt. Die in Figur 4 jeweils nebeneinander dargestellten Litzen 30 werden nur unzureichend miteinander verbunden, da ihre Verbindungsflächen parallel zur Richtung der Verbindungskraft verlaufen, in der die Sonotrode 12 und der Amboss 14 gegeneinander gepresst werden. Zudem befindet sich zwischen den Litzen 30 eine Lücke 31. An dieser Stelle kann die Schweissverbindung besonders instabil werden.In Figure 3 Four strands 30 are shown in a second arrangement, in which two lower strands 30 are arranged side by side and above that two upper strands 30 are arranged side by side. Analog to the Figures 1 left and 2a were the four in the Figures 3 and 4 strands 30 shown are not fanned out beforehand according to a conventional method and therefore still have their original, essentially circular strand cross section. In the Figure 4 strands 30 shown side by side are only insufficiently connected to one another, since their connecting surfaces run parallel to the direction of the connecting force in which the sonotrode 12 and the anvil 14 are pressed against one another. In addition, there is a gap 31 between the strands 30. At this point, the weld connection can become particularly unstable.

In den Figuren 5 und 6 ist ein zum erfindungsgemässen Auffächern und Komprimieren geeignetes Werkzeug 50 dargestellt. Dieses enthält ein Stativ 51 mit einer Auflagefläche 52 für eine oder mehrere Litzen 30 und einen Pressstempel 53 mit einer parallel zur Auflagefläche 52 angeordneten Pressfläche 54. Der Pressstempel 53 ist pneumatisch relativ zum Stativ 51 in einer Richtung R verfahrbar, die unter einem Winkel β zur Auflagefläche 52 und zur Pressfläche 54 verläuft. Hierdurch wird im erfindungsgemässen Verfahrensschritt a) die Litze 30 zwischen der Auflagefläche 52 und der Pressfläche 54 eingeklemmt und somit in einer durch die Auflagefläche 52 und die Pressfläche 54 definierten Auffächerungsebene E aufgefächert und unter einem Winkel β dazu komprimiert.In the Figures 5 and 6 A tool 50 suitable for fanning out and compressing according to the invention is shown. This includes a stand 51 with a support surface 52 for one or more strands 30 and a press ram 53 with a press surface 54 arranged parallel to the support surface 52. The press ram 53 can be moved pneumatically relative to the stand 51 in a direction R, which is at an angle β to Support surface 52 and the pressing surface 54. As a result, in process step a) according to the invention, the strand 30 is clamped between the support surface 52 and the press surface 54 and thus fanned out in a fanning-out plane E defined by the support surface 52 and the press surface 54 and compressed at an angle β thereto.

Claims (11)

  1. Method for joining at least two multi-strand wires (30) by means of ultrasound, comprising the steps of:
    a) fanning out at least one of the wires (30), preferably all of the wires (30) in a fanning-out plane (E),
    b) before, during and/or after step a): placing the wires (30) into a compression chamber (11) of an ultrasound joining device (10), so that at least two of the wires (30) are in contact with one another substantially along the fanning-out plane (E),
    c) joining, in particular welding and/or soldering, the fanned-out wires (30) by means of ultrasound.
  2. Method according to Claim 1,
    wherein, in step a), at least one of the wires (30), preferably all of the wires (30), is/are additionally compressed.
  3. Method according to one of the preceding claims,
    wherein, in step a), a height (h), extending perpendicularly to the fanning-out plane (E), of the wire cross section of at least one of the wires (30), preferably all of the wires (30), is reduced by at least 10%, preferably at least 20%, particularly preferably at least 25%.
  4. Method according to one of the preceding claims,
    wherein, in step a), a width (b), extending parallel to the fanning-out plane (E), of the wire cross section of at least one of the wires (30), preferably all of the wires (30), is increased by at least 10%, preferably at least 20%, particularly preferably at least 25%.
  5. Method according to one of the preceding claims,
    wherein at least one of the wires (30), preferably all of the wires (30), has/have a wire cross section of more than 1 mm2, preferably more than 10 mm2, particularly preferably more than 25 mm2.
  6. Method according to one of the preceding claims,
    wherein at least one of the wires (30), preferably all of the wires (30), consists/consist of aluminium or copper or another nonferrous metal.
  7. Method according to one of the preceding claims,
    wherein the compression chamber (11) is delimited by a working face (13) of a sonotrode (12), which can be induced to perform ultrasonic vibrations, a working face (15) of an anvil (14) and side faces (18) of two side delimiting elements (16, 17).
  8. Method according to Claim 7,
    wherein the fanning-out plane (E) extends parallel to the working face (13) of the sonotrode (12) and to the working face (15) of the anvil (14).
  9. Method according to one of the preceding claims,
    wherein, at least in step c), all of the wires (30) are arranged along a direction extending perpendicularly to the fanning-out plane (E).
  10. Method according to one of the preceding claims,
    wherein, before step c), none of the wires (30) is welded or soldered.
  11. Method according to one of the preceding claims,
    wherein, at least in step c), the wires (30) are arranged and joined to one another at an angle which is less than 30°, preferably less than 10°, particularly preferably less than 5°.
EP17197426.4A 2017-10-20 2017-10-20 Method for joining at least two multi-strand leads by means of ultrasound Active EP3474391B1 (en)

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WO2023006210A1 (en) * 2021-07-29 2023-02-02 Schunk Sonosystems Gmbh Ultrasonic welding method and ultrasonic welding part

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JP3131384B2 (en) 1996-06-04 2001-01-31 矢崎総業株式会社 Insulated wire joint structure
JP3311604B2 (en) 1996-06-04 2002-08-05 矢崎総業株式会社 Insulated wire joint structure
JP3435036B2 (en) 1997-08-29 2003-08-11 矢崎総業株式会社 Connection structure and processing method of shielded electric wire
JP4778369B2 (en) * 2005-07-19 2011-09-21 矢崎総業株式会社 Wire connection method
JP2007149421A (en) * 2005-11-25 2007-06-14 Yazaki Corp Ultrasonic joining method, device therefor and electric wire bundle
JP2010044887A (en) * 2008-08-11 2010-02-25 Autonetworks Technologies Ltd Wire harness and method of manufacturing the same, and method of connecting insulation wire
JP5660458B2 (en) * 2010-02-16 2015-01-28 日立金属株式会社 Electric wire with terminal and manufacturing method thereof
DE102013107637A1 (en) 2013-07-18 2015-01-22 Schunk Sonosystems Gmbh Method for producing a knot by welding

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