EP3736920B1 - Borne de contact et son procédé de fabrication - Google Patents

Borne de contact et son procédé de fabrication Download PDF

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Publication number
EP3736920B1
EP3736920B1 EP19305575.3A EP19305575A EP3736920B1 EP 3736920 B1 EP3736920 B1 EP 3736920B1 EP 19305575 A EP19305575 A EP 19305575A EP 3736920 B1 EP3736920 B1 EP 3736920B1
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EP
European Patent Office
Prior art keywords
connection
contact area
contact
conductor part
conductor
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Active
Application number
EP19305575.3A
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German (de)
English (en)
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EP3736920A1 (fr
Inventor
Helmut Steinberg
Frank Schröer
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Nexans SA
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Nexans SA
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Filing date
Publication date
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Priority to EP19305575.3A priority Critical patent/EP3736920B1/fr
Publication of EP3736920A1 publication Critical patent/EP3736920A1/fr
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Publication of EP3736920B1 publication Critical patent/EP3736920B1/fr
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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
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/76—Making machine elements elements not mentioned in one of the preceding groups
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K21/00—Making hollow articles not covered by a single preceding sub-group
    • B21K21/16—Remodelling hollow bodies with respect to the shape of the cross-section

Definitions

  • the invention relates to an electrical contact terminal and a method for its production.
  • a power source e.g. a battery or a generator
  • a current-carrying cable and contact means are required.
  • plugs and matching sockets are available for contacting.
  • Detachable power supply connections for high currents require large, electrically conductive contact surfaces, among other things to keep the temperature increase due to the current flowing through the contact resistance between the contact surfaces to a minimum.
  • the power supply connections must also have a sufficiently large conductor cross-section in the parts leading to the respective contact surfaces in order to be able to carry the high current without the material becoming excessively hot.
  • the power supply connection of the device is firmly connected to the corresponding connection part in a detachable manner, for example to prevent accidental loosening due to vibrations or other movements.
  • this is often done by fastening the connection part with one or more screws.
  • the corresponding connector In order to contact electrical contact surfaces located beneath the surface of a device, the corresponding connector must have a corresponding protruding area.
  • This can be designed, for example, as a sleeve, which creates the electrical contact between the connector and the power supply connection located beneath the surface of the device.
  • the components can be connected with a screw, for example.
  • Such a power supply connection with a captive sleeve is, for example, in the EN 10 2018 004 217 disclosed.
  • connection parts made up of several components can have an undesirably high contact resistance, especially at high currents, because there are several pairs of contact surfaces arranged one after the other in series. Therefore, the aim is usually to keep the number of pairs of contact surfaces as small as possible. In addition, multi-part solutions are usually more complex and therefore more expensive.
  • the EP 2 653 244 A1 shows the forming of a sleeve from a thin sheet using a stamp.
  • material is moved from the areas of the sheet surrounding the sleeve to the punching edge using a forming roller. This reduces the thickness of the sheet in the areas surrounding the sleeve, which rules out the use of a sleeve produced in this way for the transmission of large currents.
  • the present invention has the object of creating a connection part for power supply connections of devices in order to overcome or at least improve one or more of the problems mentioned above.
  • a method for producing such a connection part is proposed.
  • the one-piece connection part has a contact area with an electrical contact surface that is formed in a defined manner from a solid, electrically conductive conductor part by forming, which protrudes like a collar from a surface of the conductor part facing a device to be connected. In the contact area or in its immediate vicinity there is also a through hole that goes through the connection part, which can be used to attach the connection part to a device to be supplied.
  • the contact area of the contact area and the cross section of the contact area connecting the conductor part and the contact surface are at least as large as the smallest cross section of the conductor part.
  • the through hole can be made using a machining or non-machining process. Examples of possible methods include drilling, milling, erosion or punching. Eroding can be helpful, for example, to create special contours of the through hole that cannot be created or are difficult to create using other processes.
  • the contact region protruding from the conductor part has the shape of a substantially annular wall.
  • annular wall is chosen for all possible shapes of the contact region, including oval or polygonal shapes, and regardless of whether the contact region has a closed shape or is perforated in a crenellated manner at one or more points.
  • a wall that is not circular or perforated at at least one point may require a specific alignment of the connection part with respect to the power supply connection, which may be desirable in certain applications.
  • the annular wall may therefore have at least one first surface lying in a plane that is substantially parallel to a surface of the conductor part from which the contact region protrudes.
  • the at least one first surface lying in a plane The first surface can form the electrical contact surface. If the wall is perforated in one or more places like a battlement, a second level below the first level can also form an electrical contact surface if the power supply connection has the appropriate shape.
  • the wall can have an outer wall that is substantially perpendicular to the surface of the conductor part.
  • the outer wall of the wall can be inclined towards the interior of the wall, for example tapering from the surface of the conductor part towards the first plane, which can, among other things, make it easier to bring the connection part and the power supply connection together.
  • the outer wall of the wall can represent an alternative or additional electrical contact surface that, when connected, is in contact with a corresponding electrical contact surface of the power supply connection of the device to be supplied. Regardless of the position of the electrical contact surface, its surface that can be electrically connected to the contact surface of the power supply connection is at least as large as the electrically effective cross-section of the conductor part.
  • connection part which are not part of the invention
  • the outer wall of the annular wall has an inclination which differs slightly from an inclination of a recess of the corresponding power supply connection.
  • materials of the connection part and the power supply connection have different strengths, so that one of the two parts adapts to the shape of the other part when they are connected. This makes it possible to achieve particularly good contact between the contact surfaces without compromising the ability of the parts to be separated from one another.
  • connection area for an electrical conductor is provided in an area of the conductor part that is not in the area of the contact area formed by forming.
  • the connection area can, for example, have a clamping or crimping device for the electrical conductor, or a Connection point to which the electrical conductor can be soldered or welded.
  • connection part which are not part of the invention
  • two contact areas produced by forming are provided at different locations on the conductor part, for example in order to electrically connect two devices or terminals of a device to one another directly via the connection part.
  • connection part which are not part of the invention, at least part of the surface of the contact area is covered with an electrically conductive layer.
  • This layer can be applied, for example, by means of galvanic or chemical processes, or by mechanical processes, such as spraying or immersion in liquefied material that is electrically conductive at least in the solidified state. Other, equally conceivable processes will not be discussed in detail here.
  • At least part of the surface of the contact area is coated with a corrosion-inhibiting or anti-corrosive layer.
  • This layer can itself be electrically conductive or can be removed before or during assembly. Removal can also occur by displacing the material of the layer during assembly, for example when the contact surfaces of the contact area of the connector and a power supply connection of a device are pressed against each other flat and free of gaps.
  • a blank of a conductor part is first positioned in a first die, which has a depression or recess corresponding to the contact area.
  • the conductor part is then formed at least in the area of the depression or recess by means of a stamp or by the pressure of an incompressible active medium, with material of the conductor part displaced by the stamp or the active medium entering the depression and filling it.
  • Suitable forming processes include ironing and, in particular, extrusion. In principle, however, any forming process that can achieve a defined wall thickness in the collar-like protruding contact area is suitable.
  • the forming processes can take place cold, i.e. at ambient temperature, but also semi-warm or warm, i.e. after the temperature of the workpiece has been increased above the ambient temperature. The choice of temperature depends, among other things, on the material used for the conductor part and the dimensions of the formed area.
  • Materials that are well suited for forming include copper and aluminum or alloys thereof, which have good flowability and good electrical conductivity.
  • material of the conductor part in the area of the depression or recess is removed before forming, for example by drilling or punching.
  • the volume of the removed material preferably corresponds to the volume of the stamp minus the volume of the contact area defined by the depression or recess of the die and the stamp, which protrudes from the surface like a collar.
  • the edge of the hole can deviate from a cylindrical shape.
  • a hole can taper conically or parabolically towards its end to accommodate the shape of the die and the flow behavior of the material.
  • a hole that widens towards the die is also conceivable; this can be done, for example, before forming from the side that is in contact with the die during forming.
  • the workpiece must be turned over accordingly before forming.
  • the shape of the punch can also deviate from a general cylindrical shape to improve the flow of material during the forming process.
  • the punch can, for example, have transitions to different diameters that come into effect one after the other during the forming process.
  • material can be removed in such a way that the blank of the conductor part is not completely drilled through, so that a cavity is created which is deformed by the active medium.
  • the conductor part can be drilled through in the contact area afterwards, for example by drilling or punching.
  • processes such as deep drawing with active media, internal high-pressure forming or hydroforming can be used.
  • a defined contour is created on the surface of the connecting part that is remote from the die. This can be done, for example, by preventing the workpiece from expanding in a direction away from the die, at least in the area of the contact area to be created by forming, by means of an additional die through which the punch can pass freely.
  • the additional die can either be positioned against the workpiece by the punch before forming, or can be pressed against the workpiece like a second punch after forming the workpiece.
  • the punch can also have an appropriately shaped part that prevents the workpiece from expanding in the final position of the punch during forming.
  • More complex shapes of the contact area formed by forming can be achieved by multi-part matrices that are radially removed from the contact area after forming.
  • the shape of the punch can be adapted to the shape of the die and, if necessary, to the shape of the hole in the conductor part in order to optimize the flow of the material.
  • connection part presented above has precisely defined dimensions with narrow tolerances in the contact area due to the manufacturing process, so that reworking can be largely dispensed with.
  • the formation of the collar-like contact area protruding from the conductor part from the material of the conductor part itself reduces the number of electrical contact surfaces that are in contact with one another compared to known solutions in which sleeves or the like are used.
  • the further shape of the conductor part outside the contact area is irrelevant and can be adapted to the respective application-specific requirements.
  • the one-piece design advantageously reduces the number of parts that have to be aligned with one another during assembly or that can get into hard-to-reach or inaccessible areas of the assembly site or get lost during disassembly.
  • Manufacturing by forming can be done in a single step using a single tool, allowing significant savings. Depending on the size of the connector and the machine used to manufacture it, multiple connectors can be manufactured in parallel using a single operation, allowing further savings.
  • Figure 1 shows a first schematic example of a connection part 100 according to the invention at different steps of production according to a first variant.
  • part a) of the figure only the as yet unprocessed conductor part 102 of the connection part 100 is shown.
  • a side view is shown on the left-hand side and, if available, a top view on the right-hand side.
  • the conductor part 102 has a cross-section dimensioned for the desired current-carrying capacity.
  • the dimensions and shape of the exemplary connection part 100 shown in the figure can vary depending on the application. Among other things, the conductor part 102 can also follow a contour of a device or the like (not shown in the figure).
  • a connection for an electrical line or another contact area is not shown in the figure. Connections for electrical lines can be designed in the conventional way, e.g. as clamp, crimp, solder or weld connections or the like.
  • the conductor part 102 is placed on a die 104 in such a way that the point at which the contact area 106 is to be created by forming the conductor part 102 is placed over a depression or recess 108 in the die.
  • the depression 108 represents a negative form of the later contact area 102, into which the material of the conductor part 102 is pressed or flows during forming.
  • material has been removed in the contact area to be created, shown in the figure by a conical bore 110.
  • the shape of the bore 110 depends on various factors, including the volume of the material to be displaced, the shape of the contact area 106 to be created, the diameter of a bore remaining after forming that passes through the contact area, and the flowability of the material.
  • the bore 110 therefore does not necessarily have to be conical, but can have a general parabolic shape, a stepped course, or the like.
  • the bore 110 does not have to drill completely through the conductor part 102 either; a blind bore can also be provided.
  • an opening made in another way can also be used, which is not made by drilling but by another machining or non-machining process, for example by milling or punching. For the sake of simplicity, only drilling is mentioned below, although in principle other methods for creating the opening may also be suitable.
  • Part c) of the figure shows the connection part 100 immediately after a stamp 112 has been pressed into the hole 110.
  • Stamp 112 has displaced material from the conductor part 102 into the recess 108 so that the upper region, which determines the shape of the later contact region 106 of the connection part 100, is completely filled except for the volume used by the stamp 112.
  • the lower region of the recess 108 receives the tip of the stamp 112 and also remains largely free of displaced material from the conductor part 102.
  • the lower region of the die 104 can also be open at the bottom to prevent an accumulation of displaced material (not shown in the figure).
  • the shape of the stamp 112 can deviate from the cylindrical shape shown in the figure.
  • Part d) of the figure shows the finished connection part 100 after it has been removed from the die 104.
  • the contact area 106 formed from the material of the conductor part 102 is clearly visible on the underside of the connection part 100.
  • a through hole 114 remains, which is used to attach the Connection part 100 can be used on a power supply connection of a device.
  • the electrical contact is made via the flat underside of the contact area 106, or whether the side walls are used for the electrical contact, or both, is irrelevant and depends on the design of the power supply connection. The same applies to the through hole 114, or whether this is present at all or not.
  • the forming process can also produce a pot-shaped depression with a closed base.
  • connection part could contact the power connection with its entire base, and it could be attached using a clip or clamp which exerts a force acting essentially perpendicularly on the connection part.
  • a base of the pot-shaped depression could also be connected to a complementary contact surface by means of a bayonet catch, i.e. without a screw connection.
  • Figure 2 shows schematic examples of the first connection part 100 according to the invention in different steps of production according to a second and third variant.
  • Part a) of the figure shows the initial situation as it relates to part b) of the Figure 1 is described, that is, the conductor part 102 is already placed on the die 104 and positioned so that the point at which the contact region 106 is to be created by forming the conductor part 102 is placed above the recess 108 of the die.
  • Part b) of the Figure 2 shows a similar situation to that described in part c) of the Figure 1 is described, ie immediately after pressing the punch 112 into the bore 110 of the conductor part 102.
  • an upper die 116 is placed on the conductor part 102 so that the conductor part 102 is clamped between the die 104 and the upper die 116.
  • the upper die 116 has a corresponding opening at the point where the punch 112 is pressed into the bore 110 of the conductor part 102, which opening is not shown in more detail in the figure.
  • Part c) of the Figure 2 shows an alternative to the embodiment described with reference to part b) of the figure, which does not use a separate upper die 116.
  • Material that has been displaced upwards against the direction of movement of the punch 112 during the pressing of the punch 112 into the bore 110 of the conductor part 102 is pressed back in the opposite direction at the end of the movement of the punch 112 by an enlarged diameter of the punch 112, so that the surface of the conductor part 102 has the desired, defined contour.
  • the stamp 112 can also be designed in two parts, wherein the part of the stamp 112 with the enlarged diameter is pressed against the conductor part 102 at the end of the forming process in order to give the surface of the conductor part 102 the desired, defined contour (not shown in the figure).
  • Figure 3 shows a second schematic example of a connecting part 100 according to the invention in different steps of production according to the second and third variant.
  • the parts a) to c) of the Figure 3 essentially correspond to the corresponding parts a) to c) of the Figure 2 .
  • the difference between the Figures 2 and 3 shown connection parts 100 is in the form of the contact area 106. While the Figures 1 and 2 illustrated connecting part 100 has essentially vertical side walls, the side walls of the Figure 3 shown connection part 100 is inclined towards the bore 114, so that the contact area 106 protrudes conically from the conductor part 102.
  • the inclined side walls of the contact area 106 can be advantageous when releasing the connection part 100 from the die 104, and the conical shape can also make it easier to position the connection part 100 in relation to the power connection of the device to be supplied with energy.
  • the conical shape of the contact area 106 can be clearly seen in part d) of the figure.
  • the recess 108 of the die 104 shown in parts a) to c) of the figure has a corresponding shape.
  • Figure 4 shows exemplary schematic examples of connection parts 100 according to the invention connected to corresponding power supply connections 120 of a device.
  • Part a) of the Figure 4 shows the connection part 100 comprising the conductor part 102 and the contact area 106 according to a first embodiment, as it is connected by means of a screw 122 to the power supply connection 120 of a device to be supplied with electrical energy.
  • the power supply connection 120 is located below the surface of the device and can only be contacted through an opening in the housing 124.
  • the contact area 106 protruding from the conductor part 102 penetrates through the opening into the housing 124 and is in surface electrical contact with the power supply connection 120.
  • the screw 122 passing through the through hole 114 of the connection part 100 engages in a thread of the power supply connection 120.
  • a washer 126 can be arranged between the head of the screw 122 and the top of the connection part 100.
  • a spring ring or the like can be provided to secure the screw.
  • Part b) of the Figure 4 corresponds except for the shape of the connection area 106 to part a) of the Figure 4
  • the advantages of the conical shape of the contact area 106 protruding from the conductor part 102 are also easily recognizable in the schematic representation of the figure.
  • the hole 114 of the connection part 100 can be automatically centered with the thread of the power supply connection 120.
  • connection area 106 In order to at least partially use the side walls of the connection area 106 as contact surfaces, as shown in the figure, correspondingly tight tolerances must be observed so that the conical side walls of the connection area lie flat against the correspondingly shaped side walls of the power supply connection 120.
  • shape of the power supply connection 120 or the connection area 106 can be designed in such a way that at least during the first assembly of the parts together, a further deformation of at least one of the two elements takes place, after which the plane running perpendicular to the screw axis lying contact surface and the side walls lie flat against each other. At least one of the materials of the connection part 200 and the power supply connection 120 must be deformable by the forces occurring during the connection.
  • Part c) of the Figure 4 corresponds essentially to the connection of connection part 100 and power supply connection 120 shown in part b).
  • a seal 128 is additionally provided between the underside of connection part 100 and the top of housing 124, which prevents the ingress of foreign bodies or fluids.
  • Seal 124 can, for example, comprise a sealing ring made of an elastic material.
  • Figure 6 shows a flow chart of an exemplary manufacturing method 200 for a connection part 100 according to the invention.
  • step 202 the - still unprocessed - conductor part 102 is positioned to the die 104, if necessary after material of the conductor part 102 has been removed in an area in an optional step 201 that is in the contact area 106 at least after forming.
  • step 204 the conductor part 102 is then formed at least in the area of a recess 108 of the die by means of a stamp 112 or by the pressure of an incompressible active medium. Material of the conductor part 102 displaced by the stamp or the active medium enters the recess 108 and fills it.
  • the surface of the conductor part 102 that is remote from the die is then brought into a desired contour, e.g. smoothed. This can be done at the same time as the forming or by further forming. Alternatively, uncontrolled demolding, i.e. loss of the original surface contour, can be prevented by suitable measures.
  • the formed connection part 100 is removed from the die and subjected to further processing steps or use, for example an optional step 210 in which at least part of the surface of the contact area is coated with an electrically conductive and/or anti-corrosive layer.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacturing Of Electrical Connectors (AREA)

Claims (7)

  1. Pièce de raccordement (100) réalisée d'une seule pièce pour un raccordement d'alimentation électrique (120) avec au moins une zone de contact (106) façonnée de manière définie par formage à partir d'une partie conductrice (102), qui dépasse comme un col d'une surface de la partie conductrice (102) et avec un trou de passage (114) se trouvant dans ou sur la zone de contact (106) et traversant la pièce de raccordement (100), caractérisée en ce qu'une première surface de contact électrique de la zone de contact (106), qui peut être mise en contact, grâce à une force agissant parallèlement à l'axe du trou de passage (114), de manière plane avec une deuxième surface de contact correspondante du raccordement d'alimentation électrique (120) et la section transversale de la zone de contact (106) dépassant comme un col est au moins exactement aussi grande que la section transversale la plus petite de la partie conductrice (102).
  2. Pièce de raccordement (100) selon la revendication 1, dans laquelle, sur la partie conductrice (102), est prévue une zone de raccordement pour un conducteur électrique.
  3. Pièce de raccordement (100) selon l'une des revendications précédentes, dans laquelle au moins une partie de la surface de la zone de contact (106) est recouverte d'une couche électroconductrice et/ou d'une couche de protection contre la corrosion.
  4. Procédé de fabrication (200) pour des pièces de raccordement électriques (100) réalisées d'une seule pièce selon l'une des revendications 1 à 3, avec une zone de contact (106) dépassant comme un col d'une surface de la pièce de raccordement (100) avec une première surface de contact électrique, comprenant :
    - le positionnement (202) d'une ébauche de la pièce conductrice (102) par rapport à une première matrice (104), qui comprend un renfoncement ou un évidement (108) correspondant à la zone de contact (106),
    - le formage (204) de l'ébauche de la pièce conductrice (102) au moins au niveau du renfoncement ou de l'évidement (108) au moyen d'un poinçon (112) ou de la pression d'un fluide incompressible, dans laquelle le matériau, comprimé par le poinçon (112) ou par le fluide sous pression, de la pièce conductrice (102) arrive dans le renfoncement ou l'évidement (108) et remplit celui-ci,
    - retrait (201) du matériau de la pièce conductrice (102) au niveau du renfoncement ou de l'évidement (108), avant le formage (204),
    caractérisé en ce que le volume de matériau retiré correspond au volume du poinçon (112) moins le volume de la zone de contact (106) dépassant de la surface, défini par le renfoncement ou l'évidement (108) de la matrice (104) et le poinçon (112).
  5. Procédé de fabrication (200) selon la revendication 4 ou 5, comprenant en outre :
    - la fabrication (206) d'un contour de surface défini dans la zone de contact, sur la surface, se trouvant loin de la matrice (104), de la pièce de raccordement (100), à l'aide d'une autre matrice, à travers laquelle passe le poinçon, ou à l'aide d'une partie, de forme correspondante, du poinçon.
  6. Procédé de fabrication (200) selon la revendication 4, 5 ou 6, comprenant en outre :
    - le revêtement (210) d'au moins une partie de la surface de la zone de contact (106) avec une couche électroconductrice et/ou de protection contre la corrosion.
  7. Conduite d'alimentation en énergie électrique avec une pièce de raccordement selon l'une des revendications 1 - 3.
EP19305575.3A 2019-05-06 2019-05-06 Borne de contact et son procédé de fabrication Active EP3736920B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP19305575.3A EP3736920B1 (fr) 2019-05-06 2019-05-06 Borne de contact et son procédé de fabrication

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Application Number Priority Date Filing Date Title
EP19305575.3A EP3736920B1 (fr) 2019-05-06 2019-05-06 Borne de contact et son procédé de fabrication

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EP3736920A1 EP3736920A1 (fr) 2020-11-11
EP3736920B1 true EP3736920B1 (fr) 2024-04-17

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Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2653244B1 (fr) * 2012-04-20 2014-12-17 Leifeld Metal Spinning AG Procédé et dispositif pour le formage d'une pièce

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102018004257B4 (de) 2017-08-28 2023-07-27 Spectrolytic Ltd. Mikromechanikstruktur und Verfahren zum Herstellen der Mikromechanikstruktur

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2653244B1 (fr) * 2012-04-20 2014-12-17 Leifeld Metal Spinning AG Procédé et dispositif pour le formage d'une pièce

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