EP3994767B1 - Raccordement électrique entre un conducteur électrique et un élément de contact, procédé et dispositif pour sa fabrication - Google Patents

Raccordement électrique entre un conducteur électrique et un élément de contact, procédé et dispositif pour sa fabrication Download PDF

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Publication number
EP3994767B1
EP3994767B1 EP20734768.3A EP20734768A EP3994767B1 EP 3994767 B1 EP3994767 B1 EP 3994767B1 EP 20734768 A EP20734768 A EP 20734768A EP 3994767 B1 EP3994767 B1 EP 3994767B1
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EP
European Patent Office
Prior art keywords
electrical conductor
contact portion
contact
irradiated
region
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP20734768.3A
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German (de)
English (en)
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EP3994767A1 (fr
Inventor
Karl Fröschl
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Gebauer and Griller Kabelwerke GmbH
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Gebauer and Griller Kabelwerke GmbH
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Publication of EP3994767A1 publication Critical patent/EP3994767A1/fr
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Publication of EP3994767B1 publication Critical patent/EP3994767B1/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
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/187—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping combined with soldering or welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H01R4/029—Welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H01R4/184—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
    • 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
    • H01R43/0221—Laser 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
    • H01R43/0249—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 for simultaneous welding or soldering of a plurality of wires to contact elements
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048—Crimping apparatus or processes

Definitions

  • the invention relates to a method for producing an electrical connection between an electrical conductor comprising a plurality of individual wires and a contact element, the electrical conductor being arranged in a contact section of the contact element and the contact section and the electrical conductor then being pressed together so that the contact section presses the electrical conductor embraces.
  • the invention also relates to a corresponding device for establishing an electrical connection and a unit made from an electrical conductor comprising a plurality of individual wires and a contact element.
  • the contact element is formed, for example, by a cable lug, such as a crimp cable lug, or a cable sleeve, such as a crimp sleeve.
  • connection methods for electrically connecting an electric wire to a contact member in which a wire crimping portion provided on the contact member is press-contacted to an electric conductor of the electric wire.
  • a pressure-contact connection when the conductor of the electric wire is composed of a plurality of strands, the conductor wires located on the outer periphery are brought into direct contact with the contact member, and current conduction is easy for them to achieve.
  • the individual wires, which are arranged in the center of the conductor, can be Contact element are brought into conductive contact only via the individual wires that are located on the outer circumference.
  • DE 10358153 A1 proposed, in addition to the crimping, to weld the individual wires to one another and to the contact element by means of a laser. It is provided there that several areas of the conductor are welded one after the other and overlapping. During the first welding step, rapid heating occurs from the application of the laser beam, explosively dispersing material within the conductor. Each subsequently welded area covers the first welded area and uses the resulting increased temperature condition, in that there is no rapid heating by the laser beam during the second and subsequent welding steps. The material melts gradually so that explosive scattering can be prevented.
  • the disadvantage of this method is that explosive distribution can still occur during the first welding step.
  • the DE 10 2013 010981 B3 shows a method and a device for connecting an electrical conductor to a contact part, one or more openings being provided in the device for pressing, through which a laser beam of a laser welding device can pass.
  • a specific arrangement or mode of operation of laser beams is in the DE 10 2013 010981 B3 not disclosed.
  • a crimped contact element which encloses a bundle of aluminum wires.
  • tabs of the contact element are connected to one another by means of spot laser welding, which, however, is intended to prevent liquid from entering the contact element and not the production of an electrical one Connection between the individual wires of an electrical conductor and the contact element is used.
  • the starting point for this is a method for producing an electrical connection between an electrical conductor comprising several individual wires and a contact element, the electrical conductor being arranged in a contact section of the contact element and the contact section and the electrical conductor then being pressed together so that the contact section presses the electrical conductor embraces.
  • the contact section by means of laser irradiation of the contact section, or by means of laser irradiation of the electrical conductor through an opening in the contact section, several spaced-apart elongate welded joints are produced between the contact section and the electrical conductor, with the elongate welded joints each extending from one irradiated area of the contact section, or from an irradiated area of the electrical conductor, through an entire cross-section of the pressed electrical conductor to an area of the contact section which is opposite to the irradiated area, so that the electrical conductor is connected to this area of the contact section is connected, wherein the irradiated areas are arranged in a grid pattern.
  • the invention therefore provides that the laser irradiation is carried out in such a way that the elongate welded joint extends in the irradiation direction through the entire cross section of the pressed electrical conductor.
  • the elongate welded joints thus extend in their longitudinal direction from the irradiated area of the contact section through the conductor to that area of the contact section guided around the conductor that is opposite the irradiated area. The individual wires covered by this welded connection are then even connected to the contact section at two points.
  • the elongate welds extend from the irradiated area of the electrical conductor through the conductor to that area of the contact portion wrapped around the conductor which is opposite the irradiated area.
  • the individual wires covered by this welded connection are then connected to the contact section at at least one point.
  • the depth of penetration of the laser into the material can be adjusted by varying the energy introduced into the material by the laser and/or by the duration of the laser irradiation.
  • Elongated welded joints according to the present invention have a greater extent in their longitudinal direction, ie in the irradiation direction, than in the width direction.
  • the length is preferably a multiple of the average width or its diameter, in particular the elongate welded joints can be rod-shaped, ie have an approximately constant diameter over their length.
  • Such elongate, in particular rod-shaped, welded joints can be produced by deep laser welding, where a vapor capillary forms in the depth of the workpiece due to high beam intensities in the melt in the direction of radiation. As a result, the material is also melted in depth; the melting zone is usually more deep than it is wide.
  • the energy of the laser beam is metered according to the desired penetration depth of the laser beam in the area of the contact section that is opposite the irradiated area.
  • the laser beam should not completely penetrate this opposite area of the contact section and exit to the outside, as this would represent a quality defect.
  • a typical output of a laser for the method according to the invention is 1-15 kW.
  • the power requirement depends on the material of the electrical conductor and the contact section.
  • the power requirement also depends on the diameter of the elongate welded connection, the length of the elongate welded connection, ie the penetration depth, and the penetration speed.
  • the irradiated area is visible after the laser irradiation in the first variant of the invention on the surface of the contact section, or in the second variant of the invention on the surface of the electrical conductor, usually as an approximately round area, corresponding to the diameter of the laser beam and the material melted all around the contact area or the electrical conductor.
  • the irradiated areas are therefore located on the surface of the contact section in the first variant of the invention and on the surface of the electrical conductor in the second variant. Since the electrical conductor comprises a number of individual wires, the irradiated areas are on the surface of the individual wires.
  • a plurality of elongated welded joints are produced simultaneously, in particular by the same source of laser radiation.
  • the laser beam can be distributed to all desired irradiated areas by appropriate optical deflections.
  • Examples of a grid-like arrangement of the irradiated areas are several irradiated areas that lie in a line and thus form a row, with two or more such rows being arranged transversely, in particular perpendicularly, to the longitudinal direction of the individual wires of the electrical conductor and in the longitudinal direction of the individual wires in are arranged at a constant distance from one another. Adjacent rows have, for example, the same number of irradiated areas or differ by one irradiated area.
  • one irradiated area is offset from another irradiated area normal to the longitudinal direction of the individual wires, so that the projection of all elongated welded joints onto a cross-sectional area of the electrical conductor that lies in the region of the elongated welded joints result in a continuous welded surface in the transverse direction of the electrical conductor.
  • the laser beam generally strikes the contact section normal to the surface of the contact section, or in the second variant of the invention normal to the surface of the electrical conductor, specifically normal to the surface of its individual wires, on the electrical conductor.
  • the irradiated areas are simultaneously offset from one another normal to the direction of irradiation.
  • a possible grid-like arrangement with irradiated areas offset from one another consists, for example, of several rows of irradiated areas, the rows running transversely, in particular perpendicularly, to the longitudinal direction of the individual wires and adjacent rows being offset transversely, in particular perpendicularly, to the longitudinal direction of the individual wires.
  • the irradiated areas of the first, third, etc. row can then be aligned with one another viewed in the longitudinal direction of the individual wires, as can the irradiated areas of the second, fourth, etc. row.
  • Adjacent rows, which are offset from one another can also overlap one another, viewed in the longitudinal direction of the individual wires.
  • the degree of compression of the individual wires is lower in a longitudinal area of the contact element in which there are no irradiated areas than in a longitudinal area of the contact element where there are irradiated areas.
  • the degree of compression indicates the ratio of the conductor cross-section after compression (or crimping) to the conductor cross-section before compression (or crimping).
  • a degree of compression of 100% means that the conductor cross-section has not been reduced at all by the compression (or crimping), but has remained the same.
  • a degree of compression of 80% means that the conductor cross-section has been reduced to 80% of the original conductor cross-section as a result of the pressing (or crimping).
  • the contact section can now be made into two longitudinal regions transversely to the longitudinal direction of the individual wires.
  • the conductor In one longitudinal area the conductor is only pressed, in the other longitudinal area the conductor is pressed and additionally irradiated with the laser according to the invention.
  • the longitudinal area where the laser is also used it is advantageous if there are as many gaps as possible between the individual wires, i.e. an open cable structure is ensured, which acts as a ventilation channel when melt pressure builds up during the laser welding process. This measure stabilizes the laser welding process, which means, for example, if there is an emulsion residue between the pressed wires, this emulsion can evaporate when the energy is introduced, which has a negative effect on the laser welding result. If you now ensure that the loose rope structure gives a kind of chimney effect, then the evaporation has this Emulsion residue has no negative impact on the result.
  • Another possibility for producing a different degree of compression is that the different degree of compression is produced by a contact section with cable lug claws of different lengths in the transverse direction. That longitudinal section which is to be compressed more then has longer cable lug claws, i.e. more material that is pressed in the direction of the conductor during compression. In this way, a different height or compression of the conductor can be achieved even if the contact surface of the compression tool is level.
  • the degree of compression of the individual wires is greater than 70% in a longitudinal area of the contact element where irradiated areas are located.
  • the position of the pressed electrical conductor is not changed between pressing and laser irradiation.
  • the pressed electrical conductor thus remains in the tool after pressing and is also welded there with the laser.
  • the contact section is provided with a nickel coating at least in the area where it touches the electrical conductor.
  • the nickel layer protects against corrosion between the conductor and the contact section and, on the other hand, increases the energy absorption during laser welding.
  • the diameter of an irradiated area is between 0.4 and 0.8 mm, in particular between 0.5 and 0.7 mm, preferably 0.6 mm.
  • the grid constant of the irradiated areas is between 0.8 and 1.2 mm, in particular between 0.9 and 1.1 mm, preferably 1 mm.
  • the grid constant specifies the constant distance between two irradiated areas in a certain direction of the grid.
  • the pitch constant will therefore be greater than a diameter of an irradiated area in order to space the elongate welds from one another.
  • the diameter of an elongated weld joint is usually slightly larger than the diameter of the irradiated one area.
  • the largest diameter of an elongate welded connection is 0.7 to 0.9 mm, in particular around 0.8 mm.
  • a device for carrying out the method according to the invention i.e. for producing an electrical connection between an electrical conductor comprising several individual wires and a contact element, comprises a pressing tool with which the electrical conductor arranged in a contact section of the contact element can be pressed with the contact element, so that the contact section surrounds the electrical conductor, and is characterized in that a device for laser irradiation is provided, which is designed to produce a plurality of spaced-apart elongate welded joints between the contact section and the electrical conductor, with the elongate welded joints in an irradiation direction each extending from an irradiated area of the Contact section, or from an irradiated area of the electrical conductor in an opening in the contact section, to an area of the contact section which is the irradiated area opposite, extend so that the electrical conductor is connected to this area of the contact portion, wherein the irradiated areas are arranged in a grid.
  • the device can be designed in such a way that one or more embodiment variants of the method according to the invention can be carried out with it.
  • the device can be designed in such a way that the position of the pressed electrical conductor is not changed between pressing and laser irradiation.
  • the invention also includes a unit produced according to the method according to the invention or with the device according to the invention and consisting of an electrical conductor comprising a plurality of individual wires and a contact element, the electrical conductor being arranged in a contact section of the contact element and the contact section and the electrical conductors are pressed together so that the contact section surrounds the electrical conductor and there is an electrical connection between the electrical conductor and the contact element.
  • the unit is characterized in that there are a plurality of spaced-apart elongate welds between the contact portion and the electrical conductor, the elongate welds extending in a direction of irradiation from an irradiated area of the contact section, or from an irradiated area of the electrical conductor in an opening in the contact section , extend up to an area of the contact section which is opposite the irradiated area, so that the electrical conductor is connected to this area of the contact section, the irradiated areas being arranged in a grid pattern.
  • the unit can be designed in such a way that the elongate welded joints are spaced apart from one another over a large part of their length normal to the irradiation direction.
  • the unit can be designed in such a way that at least one irradiated area is offset from another irradiated area normal to the longitudinal direction of the individual wires, so that the projection of all elongate welded joints onto a cross-sectional area of the electrical conductor that is in the area of the elongate welded joints, result in a continuous welded surface in the transverse direction of the electrical conductor.
  • the unit can be designed in such a way that the grid constant of the irradiated areas is between 0.8 and 1.2 mm, in particular between 0.9 and 1.1 mm, preferably 1 mm.
  • the unit can be designed in such a way that the largest diameter of an elongate welded joint is 0.7 to 0.9 mm, in particular around 0.8 mm.
  • the invention can be used to make a so-called B-crimp die or heart crimp die, as is known in the art.
  • the invention can of course also be used for other types of crimping mold or pressing mold.
  • the invention makes it possible to use individual wires made of aluminum or an aluminum alloy.
  • the use of aluminum for the individual wires results in an oxide layer forming on the surface of the individual wires and thus in stable resistance conditions over the service life of the conductor.
  • the elongate welded connections according to the invention produce a material connection and thus an electrical contact between the individual wires and the contact section of the contact element, which contact does not oxidize and therefore guarantees constant resistance ratios.
  • the individual wires made of aluminum or an aluminum alloy are advantageously pressed with a contact section or a contact element (e.g. crimp cable lug, crimp sleeve) made of copper or a copper alloy, e.g. bronze, brass.
  • a contact element e.g. crimp cable lug, crimp sleeve
  • copper or a copper alloy e.g. bronze, brass.
  • the unit according to the invention can be used for high-voltage plug-in systems.
  • Fig. 1a-d show a first variant of a device for pressing and laser welding, this device being designed for contact elements with contact sections with cable lug claws of different lengths in the transverse direction.
  • Fig. 1a a longitudinal section through the opened device is shown.
  • a contact element 2 (cable lug) is inserted in a lower part 1 of the pressing tool.
  • the contact section 4 of the contact element 2 which contact section 4 surrounds the electrical conductor 5 , is pressed downwards, with the ends of the cable lug claws 6 , 7 being pressed inwards into the conductor 5 .
  • the press or crimp connection is made in the form of a B crimp.
  • the longer cable lug claw 7 surrounds an area of the conductor 5 which is further away from the connection section 8 and which is not welded with the laser. There is therefore a lower degree of compression within the cable lug claw 7, for example less than 80%. There are fewer gaps between the individual wires 9 here. this is in 1c recognizable, which is a cross-section along line CC in Fig. 1a indicates. It can be seen below that the individual wires 9 are so strongly pressed together that they already have a rather hexagonal cross section.
  • the bearing surface 10 (see Fig. 1a ) of the lower part 1 is straight here and therefore designed the same for both cable lug claws 6.7.
  • a laser part 11 is embedded in the upper part 3 so that it can be lowered.
  • Fig. 3a-b show the device Fig. 1a-c in a sectional view during laser welding, according to the illustrations in Figures 1a and 1b .
  • the laser part 11 contains or is connected to a laser as a source of radiation.
  • the laser part can use optics containing lenses, mirrors, etc., to emit a laser beam in the irradiation direction, here the vertical, and to move this laser beam horizontally along a grid, with the vertical orientation of the laser beam being retained. In this way, the laser beam can be directed to different, approximately punctiform, irradiated areas in succession in time.
  • the laser beams 12 are shown here as thin lines. Alternatively, the laser beam can be divided into a plurality of laser beams 12 by means of optics, which impinge on the irradiated areas at the same time.
  • FIG 3a two laser beams 12 are shown, each impinging on an irradiated area and forming an elongate welded connection 14 downwards into the conductor 5 and up to the cable lug claw 6 on the opposite side.
  • Figure 3b correspondingly, six laser beams 12 are shown, each impinging on an irradiated area and forming an elongate welded joint 14 downwards into the conductor 5 and up to the cable lug claw 6 on the opposite side.
  • the elongate welded joints 14 run essentially in the direction of irradiation, that is to say vertically in this case. They do not overlap or touch each other.
  • figure 5 shows a top view of the contact element 2 after laser welding, where the entry points of the laser beam 12 can be seen as the irradiated area 13.
  • the irradiated areas 13 are regularly spaced from one another and here form a grid with rows running in the transverse direction of the contact element 2 , ie normal to the longitudinal direction of the individual wires 9 of the electrical conductor 5 of alternately six and five irradiated areas 13. Successive rows in the longitudinal direction of the individual wires 9 or in the longitudinal direction of the contact element 2 are offset from one another in the transverse direction, specifically by half a grid constant.
  • Fig. 7a-e show a second variant of a device for pressing and laser welding, wherein the pressing tool has a stepped contact surface.
  • Figure 7a largely corresponds Fig. 1a except for the fact that the bearing surface 10 of the lower part 1 for the contact section 4 has a different height here corresponding to the two longitudinal areas of the contact section 4, thus forming two steps 15,16.
  • the lug claws 6.7 can, but do not have to be of the same length.
  • Figures 7d and 7e show the contact element 2 in the pressed state.
  • the cable lug claw 6 surrounds an area of the conductor 5 which is closer to the connecting section 8 and which is additionally welded with the laser. Within the cable lug claw 6 there is a higher degree of compression, for example higher than 70%, in particular higher than 80% or higher than 90%, due to the step 15 lying further down.
  • a higher degree of compression for example higher than 70%, in particular higher than 80% or higher than 90%, due to the step 15 lying further down.
  • the individual wires 9 point as in Fig. 1b another circular cross-section.
  • the cable lug claw 7 again surrounds an area of the conductor 5 which is further away from the connection section 8 and which is not welded with the laser. Within the cable lug claw 7, therefore, there is a lower Degree of compression, eg less than 80%. Here there are fewer gaps between the individual wires 9, the same as in FIG 1c below, where the individual wires 9 are pressed together so strongly that they already have a rather hexagonal cross-section.
  • the Figures 8-15 show a third embodiment variant of the invention, the pressing tool not having a stepped contact surface here.
  • the two cable lug claws 6.7 of the contact element 2 are the same length here.
  • the contact element 2 in 8 again has a contact section 4 and a connecting section 8 .
  • the contact section 4 comprises two cable lug claws 6,7 of equal length here, which are separated from one another by a slot which forms an opening 17 in the pressed state of the contact element, through which the surface of the pressed electrical conductor 5 remains accessible.
  • a corrugation between the two cable lug claws 7, which are further away from the end of the electrical conductor 5 than the cable lug claws 6, serves to secure the electrical conductor 5 from being pulled out of the contact element 2 in the longitudinal direction of the electrical conductor 5.
  • the cable lug claws 6.7 could also according to the variants in the Figures 1 to 7 be of different lengths.
  • the cable lug claws 6.7 are already bent towards one another, so that an electrical conductor 5 can be inserted between them, as in 10 shown.
  • the insulation of the electrical conductor 5 is removed in the cable lug claws 6.7.
  • the cable lug claws 6.7 are bent relative to the connecting section 8 upwards.
  • the ends of the Cable lug claws 6.7 are then pressed from above into the electrical conductor 5 during pressing, see 11-13 .
  • the cable lug claws 6.7 are pressed into the electrical conductor 5 from below.
  • electrical conductor 5 and contact element 2 are inserted into the lower part 1 of a pressing tool.
  • the contact section 4 of the contact element 2 more precisely its cable lug claws 6.7, is pressed inwards and then downwards, with the ends of the cable lug claws 6.7 being pressed inwards into the conductor 5.
  • the press or crimp connection is made in the form of a B crimp.
  • the upper part 3 has a recess 18 running transversely to the longitudinal direction of the electrical conductor 5, which is aligned with the slot, which later forms the opening 17 of the contact section 4, so that laser beams 12 hit the surface from above through this recess 18 and the opening 17 of the electrical conductor 5 can be sent.
  • the laser beams 12 hit the side with the ends of the cable lug claws 6.7 on the contact element 2, while in the embodiment variants according to Figures 1-7 the laser beams 12 hit the opposite side of the contact element 2.
  • the opening 17 is closer to the connecting section 8 than to the end of the contact section 4 which faces away from the connecting section 8 , seen in the longitudinal direction of the individual wires 9 .
  • the opening 17 extends in the transverse direction of the contact element 4, ie normal to the longitudinal direction of the individual wires 9 over the entire width of the pressed electrical conductor 5. This ensures that each individual wire 9 is covered by an elongate welded joint 14.
  • the process of laser irradiation on the pressed electrical conductor 5 is over 14 shown. This process takes place in the pressing tool 1.3, following the pressing of the electrical conductor 5, the position of which does not change in the process.
  • the laser beams 12 are arranged in a grid pattern and impinge normally on the surface of the individual wires 9 exposed in the opening 17 .
  • the grid-like arrangement of the laser beams 12 here comprises three parallel rows that run normal to the longitudinal direction of the individual wires 9, with the middle row being offset by half a grid constant relative to the two outer rows.
  • the outer rows include eight laser beams, for example, and the middle row seven laser beams.
  • the irradiated areas 13 here have a diameter D of 0.6 mm, the grid constant R is 1 mm.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)

Claims (15)

  1. Procédé pour réaliser une liaison électrique entre un conducteur électrique (5) comprenant plusieurs fils individuels (9) et un élément de contact (2), le conducteur électrique (5) étant disposé dans une partie de contact (4) de l'élément de contact (2) et la partie de contact (4) et le conducteur électrique (5) étant ensuite sertis l'un avec l'autre, de sorte que la partie de contact (4) enserre le conducteur électrique (5),
    caractérisé en ce qu'au moyen d'une irradiation par laser de la partie de contact (4), ou au moyen d'une irradiation par laser du conducteur électrique (5) à travers une ouverture (17) dans la partie de contact (4), plusieurs soudures allongées (14) espacées les unes des autres sont réalisées entre la partie de contact (4) et le conducteur électrique (5), les soudures allongées (14) s'étendant chacune dans une direction d'irradiation depuis une zone irradiée (13) de la partie de contact (4), ou depuis une zone irradiée (13) du conducteur électrique (5), à travers toute une section transversale du conducteur électrique serti (5) jusqu'à une zone de la partie de contact (4) qui fait face à la zone irradiée (13), de sorte que le conducteur électrique (5) est relié à cette zone de la partie de contact (4), les zones irradiées (13) étant disposées en forme de réseau.
  2. Procédé selon la revendication 1, caractérisé en ce que les soudures allongées (14) sont espacés les unes des autres sur une grande partie de leur longueur, normalement à la direction d'irradiation.
  3. Procédé selon l'une des revendications 1 à 2, caractérisé en ce que plusieurs soudures allongées (14) sont réalisés en même temps, en particulier par la même source (11) d'irradiation par laser.
  4. Procédé selon l'une des revendications précédentes, caractérisé en ce qu'au moins une zone irradiée (13) est décalée par rapport à une autre zone irradiée (13) perpendiculairement à la direction longitudinale des fils individuels (9), de sorte que la projection de toutes les soudures allongées (14) sur une surface de section transversale du conducteur électrique (5) qui se situe dans la zone des soudures allongées (14) donne une surface soudée continue dans la direction transversale du conducteur électrique (5).
  5. Procédé selon l'une des revendications précédentes, caractérisé en ce que le degré de sertissage des fils individuels (9) est plus faible dans une zone longitudinale de l'élément de contact (2) dans laquelle ne se trouvent pas de zones irradiées que dans une zone longitudinale de l'élément de contact (2) dans laquelle se trouvent des zones irradiées (13).
  6. Procédé selon la revendication 5, caractérisé en ce que le degré de sertissage différent est réalisé par un outil de sertissage (1) possédant une surface d'appui étagée (10, 15, 16) .
  7. Procédé selon la revendication 5 ou 6, caractérisé en ce que le degré de sertissage différent est réalisé par une partie de contact (4) possédant des griffes de cosse de câble (6, 7) de longueurs différentes dans la direction transversale.
  8. Procédé selon l'une des revendications précédentes, caractérisé en ce que le degré de sertissage des fils individuels (9) est supérieur à 70 % dans une zone longitudinale de l'élément de contact (2) où se trouvent des zones irradiées (13).
  9. Procédé selon l'une des revendications précédentes, caractérisé en ce que l'irradiation par laser est effectuée dans l'outil (1, 3) dans lequel le sertissage est effectué.
  10. Procédé selon la revendication 9, caractérisé en ce que la position du conducteur électrique serti (5) n'est pas modifiée entre le sertissage et l'irradiation par laser.
  11. Procédé selon l'une des revendications précédentes, caractérisé en ce que la réalisation d'une soudure allongée (14) dure moins de 100 ms, en particulier moins de 80 ms, par exemple autour de 60 ms.
  12. Procédé selon l'une des revendications précédentes, caractérisé en ce que le diamètre (D) d'une zone irradiée (13) est compris entre 0,4 et 0,8 mm, en particulier entre 0,5 et 0,7 mm, de préférence égal à 0,6 mm.
  13. Procédé selon l'une des revendications précédentes, caractérisé en ce que le pas de réseau (R) des zones irradiées (13) est compris entre 0,8 et 1,2 mm, en particulier entre 0,9 et 1,1 mm, de préférence égale à 1 mm.
  14. Dispositif pour réaliser une liaison électrique entre un conducteur électrique (5) comprenant plusieurs fils individuels (9) et un élément de contact (2), le dispositif comprenant un outil de sertissage (1, 3) avec lequel le conducteur électrique (5) disposé dans une partie de contact (4) de l'élément de contact (2) peut être serti avec l'élément de contact (2), de sorte que la partie de contact (4) enserre le conducteur électrique (5),
    caractérisé en ce qu'il est prévu un moyen (11) pour une irradiation par laser, qui est conçu pour réaliser plusieurs soudures allongées (14) espacées les unes des autres entre la partie de contact (4) et le conducteur électrique (5), les soudures allongées (14) s'étendant chacune dans une direction d'irradiation depuis une zone irradiée (13) de la partie de contact (4), ou d'une zone irradiée (13) du conducteur électrique (5) dans une ouverture (17) dans la partie de contact (4), jusqu'à une zone de la partie de contact (4) qui fait face à la zone irradiée (13), de sorte que le conducteur électrique (5) est relié à cette zone de la partie de contact (4), les zones irradiées (13) étant disposées en forme de réseau.
  15. Unité composée d'un conducteur électrique (5) comprenant plusieurs fils individuels (9) et d'un élément de contact (2), le conducteur électrique (5) étant disposé dans une partie de contact (4) de l'élément de contact (2) et la partie de contact (4) et le conducteur électrique (5) étant sertis l'un avec l'autre, de sorte que la partie de contact (4) enserre le conducteur électrique (5) et qu'il existe une liaison électrique entre le conducteur électrique (5) et l'élément de contact (2),
    caractérisée en ce qu'il existe plusieurs soudures allongées (14) espacées les unes des autres entre la partie de contact (4) et le conducteur électrique (5), les soudures allongées (14) s'étendant chacune dans une direction d'irradiation depuis une zone irradiée (13) de la partie de contact (4), ou depuis une zone irradiée (13) du conducteur électrique (5) dans une ouverture (17) dans la partie de contact (4), jusqu'à une zone de la partie de contact (4) qui fait face à la zone irradiée (13), de sorte que le conducteur électrique (5) est relié à cette zone de la partie de contact (4), les zones irradiées (13) étant disposées en forme de réseau.
EP20734768.3A 2019-07-03 2020-07-01 Raccordement électrique entre un conducteur électrique et un élément de contact, procédé et dispositif pour sa fabrication Active EP3994767B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP19184264.0A EP3761452A1 (fr) 2019-07-03 2019-07-03 Raccordement électrique entre un conducteur électrique et un élément de contact
PCT/EP2020/068540 WO2021001434A1 (fr) 2019-07-03 2020-07-01 Connexion électrique entre un conducteur électrique et un élément de contact

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EP3994767B1 true EP3994767B1 (fr) 2023-01-25

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JP7225166B2 (ja) * 2020-07-22 2023-02-20 矢崎総業株式会社 電線の製造方法および電線製造装置

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JP2511123B2 (ja) * 1988-10-13 1996-06-26 矢崎総業株式会社 圧着端子、及び圧着端子と電線の接続方法
DE19749909C2 (de) 1996-12-10 2000-08-31 Fraunhofer Ges Forschung Vorrichtung zum Herstellen von Verbindungen zwischen jeweils zwei Kontaktelementen mittels Laserenergie
JP2000231944A (ja) 1999-02-12 2000-08-22 Sumitomo Wiring Syst Ltd 接続端子と電線の接続部の構造及び接続装置
JP4413491B2 (ja) 2002-12-11 2010-02-10 矢崎総業株式会社 電線と接続端子との接続方法
DE102010035424A1 (de) * 2010-08-26 2012-03-01 Audi Ag Verfahren zum Verbinden eines elektrischen Leiters mit einem elektrischen Kontaktteil
AT510475B1 (de) 2010-10-13 2013-02-15 Gebauer & Griller Anschlussteil für einen elektrischen leiter
JP5466194B2 (ja) 2011-03-15 2014-04-09 日本航空電子工業株式会社 電線対導電性金属板のレーザ溶接構造
DE102012007846B4 (de) * 2012-04-19 2023-06-15 Audi Ag Crimpvorrichtung zum Verbinden eines elektrischen Leiters mit einem elektrischen Kontaktteil, das verformbare Schenkel aufweist
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EP2830158B1 (fr) * 2013-02-23 2017-12-27 Furukawa Electric Co., Ltd. Borne, structure de connexion de fil, et procédé pour fabriquer une borne
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DE102013010981B3 (de) 2013-07-01 2014-08-28 Audi Ag Verfahren und Vorrichtung zum Verbinden eines elektrischen Leiters mit einem elektrischen Kontaktteil

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US12015230B2 (en) 2024-06-18
WO2021001434A1 (fr) 2021-01-07
US20220328985A1 (en) 2022-10-13
EP3761452A1 (fr) 2021-01-06
CN114080737A (zh) 2022-02-22
EP3994767A1 (fr) 2022-05-11
JP7508493B2 (ja) 2024-07-01
JP2022540058A (ja) 2022-09-14
CN114080737B (zh) 2024-05-28

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