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
  • H01R43/28—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26
• • 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
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
  • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
  • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
  • B23K20/106—Features related to sonotrodes
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
  • B23K20/22—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded
  • B23K20/227—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded with ferrous layer
  • B23K20/2275—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded with ferrous layer the other layer being aluminium
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
  • B23K20/22—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded
  • B23K20/233—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer
  • B23K20/2333—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer one layer being aluminium, magnesium or beryllium
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
  • B23K20/22—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded
  • B23K20/233—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer
  • B23K20/2336—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer both layers being aluminium
• • 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
  • H01R11/26—End pieces terminating in a screw clamp, screw or nut
• • 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
  • H01R11/28—End pieces consisting of a ferrule or sleeve
  • H01R11/281—End pieces consisting of a ferrule or sleeve for connections to batteries
• • 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
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K2101/00—Articles made by soldering, welding or cutting
  • B23K2101/006—Vehicles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K2101/00—Articles made by soldering, welding or cutting
  • B23K2101/32—Wires
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K2101/00—Articles made by soldering, welding or cutting
  • B23K2101/36—Electric or electronic devices
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K2101/00—Articles made by soldering, welding or cutting
  • B23K2101/36—Electric or electronic devices
  • B23K2101/38—Conductors
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K2103/00—Materials to be soldered, welded or cut
  • B23K2103/02—Iron or ferrous alloys
  • B23K2103/04—Steel or steel alloys
  • B23K2103/05—Stainless steel
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K2103/00—Materials to be soldered, welded or cut
  • B23K2103/08—Non-ferrous metals or alloys
  • B23K2103/10—Aluminium or alloys thereof
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K2103/00—Materials to be soldered, welded or cut
  • B23K2103/08—Non-ferrous metals or alloys
  • B23K2103/12—Copper or alloys thereof
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K2103/00—Materials to be soldered, welded or cut
  • B23K2103/18—Dissimilar materials
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
  • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
  • B23K2103/00—Materials to be soldered, welded or cut
  • B23K2103/18—Dissimilar materials
  • B23K2103/20—Ferrous alloys and aluminium or alloys thereof
• • 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
  • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
  • H01R13/02—Contact members
  • H01R13/025—Contact members formed by the conductors of a cable end
• • 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
  • H01R4/58—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
• • 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
  • H01R43/02—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
  • H01R43/0214—Resistance welding

Definitions

• Main power line which is directly connected to the positive pole of the battery to realize electrical outlets to consume. Due to the large number of electrical consumers to be connected in a vehicle electrical system is a wide
• the tap of electrical energy from the main energy line is not readily possible.
• such a tap is each connected to a transition resistance and thus ohmic losses and on the other hand there is an increased risk of corrosion at the taps.
• Partial elements are required on which the bolts can be welded, so that ultimately a contact element (such as a cable lug) can connect.
• the object was the object of providing a method available with which a tap on a stranded conductor is particularly easy to implement.
• the main battery line runs from the rear to the front of the vehicle. This can be done by an underground installation of the battery cable or by an interior installation of the battery cable.
• Battery string can be realized with the help of the subject terminal console a plurality of electrical outlets in a particularly simple manner.
• connection consoles on such conductors.
• the cable is provided with a metallic stranded conductor.
• the cable may be provided with an insulation or not.
• the isolation can be removed first.
• the non-insulated region of the cable that is to say the bare strands of the stranded conductor, which forms the core of the cable, can be led to a compression device.
• the metallic stranded conductor is mechanically compacted.
• the strands of the stranded conductor are pressed together.
• the strands are bonded together during compression.
• the result is preferably a material bond on the outer lateral surfaces of the strands.
• By compacting a flat area is formed.
• the area can also be considered as a connection area.
• the strands are connected to each other by means of material connection. It forms a compact area in which the stiffness of the stranded wire compared to the non-compacted stranded wire is substantially increased.
• Connecting element can thereby another cable, e.g. a flat conductor or a
• Round conductor each made of solid material or stranded wire, a connecting bolt, a tap, a contact eye or sleeve or the like.
• the connection element can be materially connected to the areal area.
• the base material of the connecting element for example, aluminum can be used.
• a harder material e.g., aluminum
• connection element Copper alloy
• connection element Copper alloy
• the use of aluminum as a base material has the advantage that the corrosion resistance of the component and thus the interface between the strands and the connection element and ultimately the entire system increases significantly. Corrosion resistance can be further enhanced by additional coating of the terminal (e.g., nickel).
• the areal area be compacted with a degree of compaction of between 70% and 100%, in particular with a degree of compaction of between 85% and 95%.
• a degree of compaction of between 70% and 100% in particular with a degree of compaction of between 85% and 95%.
• the strands form a nearly flat contact surface in this compacted state.
• the areal area is compressed by welding the strands of the stranded conductor, in particular that the areal area is compacted by means of ultrasonic welding or by means of resistance welding.
• welding the strands with each other is achieved that they do not move against each other during subsequent connection with the connection element and absorb welding energy.
• resistance welding and concomitant compaction the surfaces which are attached to the
• the surface used for welding of the welding tool used during compaction is profiled in a relief-like manner. As a result, areas are formed in the planar area, which are highly compacted and areas that are less compacted. The profile ensures that, at least in the higher compacted areas, the strands are welded together sufficiently well.
• a relief-shaped profile embossed in the planar area when welding takes place at an angle to the longitudinal axis of the strands of the stranded conductor. Due to the angled course, in particular substantially perpendicular to the longitudinal axis of the strands or of the cable, it is achieved that the areal area is sufficiently compacted over its entire width. It is also achieved that external strands are included in the step of compacting and not protrude as loose strands of the flat area and are not connected to the area. A fraying of the area is thus avoided.
• the profile is strip-shaped or latticed. Both forms offer the advantage of connecting all the strands with the flat area.
• the profile be introduced on both sides of the area.
• a particularly good compaction is achieved in the areas in which the profile protrudes into the planar area.
• the strands are equally compressed on both sides of the flat area.
• connection element is arranged in the recess.
• connection element can be arranged in the recess.
• the recess may e.g. be formed by punching correspondingly large holes in the area.
• the connection element is annular.
• Another object is a cable with a metallic stranded conductor produced by a method described herein.
• the cable has an insulation of the stranded conductor, that the planar region is arranged in a stripped region arranged between two insulation sections of the insulation and that the connection element is connected in a materially bonded manner to the conductor in the planar region. Then, a tap can be realized in a central region of the cable. It is understood that the
• Isolation can also be removed at a front end and the area lies in the end region of the stranded conductor.
• the stranded conductor is a round conductor and / or that the stranded conductor is formed from aluminum or an alloy thereof or from copper or an alloy thereof.
• connection element made of copper or alloys thereof, steel or stainless steel is formed and / or that the connection element made of copper or alloys thereof, steel or stainless steel is formed and / or that the connection element made of copper or alloys thereof, steel or stainless steel is formed and / or that the connection element made of copper or alloys thereof, steel or stainless steel is formed and / or that the
• the connecting element is annular sleeve-shaped and is connected on both sides of the planar region of radially outwardly facing collar with the flat region cohesively.
• the collar can be materially connected to the surface region facing the area with the flat area.
• connection element and the stranded conductor are sheathed with insulation, in particular over the insulation of the stranded conductor also, are preferably encapsulated.
• the areal area preferably lies between the ends of the cable and is preferably arranged in a middle area of the cable. In particular, the area lies away from the distal ends of the cable. Due to the cohesive arrangement of the connection element on the conductor, a high current flow with low electrical losses is possible.
• the conductor of the electric cable is insulated and in the area of the area the conductor is free of the insulation.
• the area between two isolated areas of the conductor If a plurality of stripped regions are provided, one or more connection elements can be provided along the path of the cable, via which electrical taps are possible.
• the cable is one of the main battery string, thus a variety of electrical taps on the battery string can be made possible without affecting the conductance of the battery line as such by otherwise necessary interruptions negative.
• the Taps do not lead to increased electrical power loss along the cable, since the cable is not interrupted by the taps.
• connection element Due to the material connection with the connection element, the cable remains intact and its conductance is essentially unaffected. So it is possible to lead a one- or two- or multi-piece cable from the battery to the engine compartment, in particular to the starter or the electric motor in the engine compartment, which is not or only marginally affected by taps in its electrical conductivity of each section.
• the insulation of the cable is such that it completely encloses the conductor in the insulation sections. The isolation is
• a non-conductor in particular a plastic, such as
• PVC or silicone formed.
• the cable is rigid and thus not plastically deformable due in particular to its own weight.
• the conductor is formed of aluminum or an alloy thereof.
• E aluminum, such as aluminum 99.5 can be used for the conductor.
• the connecting element is preferably formed from an electrically similar, in particular the same metallic material.
• the terminal may also be formed of copper.
• connection element A particularly good connection between the connection element and the conductor is possible if this is produced by means of ultrasonic welding.
• Ultrasonic welding breaks up any existing aluminum oxide layer on the conductor and the resulting welding knot is largely free of aluminum oxide.
• the contact resistance is in the range of
• the connecting element by means of friction welding, in particular rotational friction welding or
• connection element to the conductor can also break up any existing aluminum oxide layer on the strands of the conductor and the contact resistance between the flat part and the
• Fig. La a cross section of a cable
• Fig. Lb is a view of a stripped cable
• Figure lc is a view of a stripped, compressed cable.
• FIG. 2 is a view of a cable according to FIG. 1;
• FIG. 2 is a view of a cable according to FIG. 1;
• FIG. 3a shows a view of a connecting bolt according to an embodiment
• Fig. 3b is a view of a connecting bolt according to another
• Fig. 3c is a view of a connecting bolt according to another
• FIG. 4 shows a view of a bolt according to FIG. 3b;
• Fig. 5a -c plan views according to embodiments;
• FIG. 6a, b views according to an embodiment
• Fig. 7a, b views according to an embodiment
• FIG. 1 a shows an electrical cable 2 with a metallic stranded conductor 4 and an insulation 6.
• the metallic conductor 4 is preferably a stranded conductor and in particular resistant to bending.
• the conductor 4 is preferably a round conductor.
• the material of the strands of the conductor 4 is preferably aluminum, in particular aluminum 99.5. The bending stiffness of the cable 2 arises when the cable 2 due to its own
• the insulation 6 is preferably made of PVC or silicone.
• the cable 2 may be stripped in a central region, that is, away from its respective distal ends, so that a stripped region 8 is formed.
• the conductor 4 is free of the insulation 6.
• the flat area 10 can be formed by a corresponding tool.
• the areal area 10 preferably has a width that is greater than the diameter of the conductor 4 by a factor of at least 2, preferably between 2 and 5, and at least by the factor 2, preferably the factor 5 to 10, is smaller than the diameter of the conductor 4.
• the height is shown in Fig. Lc. In Fig. Lc, the area 10 is shown.
• FIG. 2 shows a view of a cable 2 according to FIG. 1c. It can be seen that the conductor 4 is a round conductor and is flat in the area 10.
• the flat area 10 is located in the stripped area 8, which is remote from the distal ends of the cable 2.
• the pressing tool can simultaneously be a welding tool, in particular an ultrasonic tool.
• Terminal bolt 12 is cylindrical and formed of a solid material.
• the connecting bolt 12 may be formed of stainless steel.
• the terminal bolt 12 can be formed by turning or cutting a rod.
• FIG. 3b shows a connecting bolt 12, which has a terminal at its one end
• Terminal lug 14 to which, for example, a clamping element of an electrical connection can be clamped.
• a clamping element of an electrical connection can be clamped.
• Terminal lug 14 are clamped.
• FIG. 3 c shows a connection bolt 12, in which one end is provided with a thread 16.
• an electrical connection can be screwed.
• FIG. 3d shows a further connecting bolt 12, which has an opening 18, in particular in the form of a bore, at its end. Through this opening 18, for example, a screw connection can be made with an electrical connection in which a screw is pushed through an opening 18 and / or bolted there.
• FIG. 5a shows a top view of a cable 2. It can be seen that in the area 10 a relief-shaped profile 20 is embossed. In this case, the regions of the profile 20 extend with an increased compression substantially perpendicular to the longitudinal axis 2a of the cable 2.
• the profile 20 can be provided on both sides on the flat region 10 and be uniform.
• FIG. 5 c shows a cable 2 in which the profile 20 has been embossed as a lattice structure in the region 10.
• the strands of the line 4 are highly compressed and it comes to a material connection at least in the region of the profile. This makes it possible, directly on the line 4 and its strands after the compression to weld a connecting bolt 12 or another connection element.
• FIGS. 6 a, b show a connection bolt 12, which is welded directly onto the flat area 10 in the areal area 10. Due to the profile of the area is suitable for this and sufficiently compacted that the connecting bolt, for example. can be applied by rotary friction welding or ultrasonic welding.
• Figs. 7a, b show a flat region 10 in which an opening 22 has been introduced during compaction or thereafter, in particular punched.
• a sleeve 12b can be inserted as another possible connection element.
• the outer flanges of the sleeve 12 b can then be welded to the strands of the conductor 4 in the area 10.
• the sleeve 12b may also have a flange on only one side so that it can only be welded to the flange on one surface of the flat region 10.

Landscapes

• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
• Pressure Welding/Diffusion-Bonding (AREA)
• Motor Or Generator Frames (AREA)

Applications Claiming Priority (3)

Publications (1)

Family

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