EP4002591B1 - Leistungsklemme mit verbessertem crimp-abschnitt und crimpverfahren dafür - Google Patents

Leistungsklemme mit verbessertem crimp-abschnitt und crimpverfahren dafür Download PDF

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Publication number
EP4002591B1
EP4002591B1 EP21210040.8A EP21210040A EP4002591B1 EP 4002591 B1 EP4002591 B1 EP 4002591B1 EP 21210040 A EP21210040 A EP 21210040A EP 4002591 B1 EP4002591 B1 EP 4002591B1
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EP
European Patent Office
Prior art keywords
crimping
terminal
tab
legs
extends
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EP21210040.8A
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English (en)
French (fr)
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EP4002591A1 (de
Inventor
Abdelaaziz Elmanfalouti
Sylvain Bossuyt
Quentin CORDIER
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Aptiv Technologies Ltd
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Aptiv Technologies Ltd
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Publication of EP4002591A1 publication Critical patent/EP4002591A1/de
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • 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
    • 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
    • H01R4/188—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 having an uneven wire-receiving surface to improve the contact
    • 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
    • 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
    • H01R13/10—Sockets for co-operation with pins or blades
    • H01R13/11—Resilient sockets
    • H01R13/111—Resilient sockets co-operating with pins having a circular transverse section
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2201/00—Connectors or connections adapted for particular applications
    • H01R2201/26—Connectors or connections adapted for particular applications for vehicles

Definitions

  • the invention relates to the field of automotive connectivity and more particularly the field of power connectivity for motor vehicles.
  • the terminals of current power connectors are generally machined, for example, by bar-turning from solid copper bars (or a copper alloy) and/or cut out and formed from relatively thick metal sheets (the document EP2919324 A1 discloses the general form of a cut-out terminal, the terminal further not being necessarily adapted to the power connectivity).
  • Some zones of the terminals are where applicable covered with a metal, such as silver and/or gold, in order to limit the heating actions, particularly at the points of contact between male and female terminals.
  • a power terminal which is formed by cutting out and forming a blank from a metal sheet of electrically conductive material.
  • This terminal comprises a contact portion and a crimping portion.
  • the crimping portion extends in a longitudinal direction between a front end located towards the contact portion and a rear end.
  • the crimping portion has, before crimping on a multi-strand electrical wire and in cross section, a U-shape.
  • Each of the legs of this U-shape corresponding to a crimping tab.
  • Each crimping tab comprises a front edge directed towards the front end. This front edge comprises at least one leg or tongue which extends from it, substantially parallel with the longitudinal direction.
  • At least one of these legs is intended to be inserted between the strands of the multi-strand wire, on which the terminal is crimped.
  • this leg which is inserted between the strands of the multi-strand wire increases the electric contact surface between the terminal and the wire and/or allows better compaction of the clamped and compacted strands by each of the crimping tabs.
  • the contact surface substantially comprises the internal surface of the crimping tabs, to which the external surface of each of the legs inserted between the strands is added, these two surfaces being in contact with the wire.
  • each leg extends from a front edge of a crimping tab, the material which forms this leg is not taken from a portion of the terminal (in particular, it is not taken from the bottom of the channel which forms the U-shape and in which the wire is placed).
  • the lines of current are distributed over an optimised volume of material; which is particularly advantageous in order to limit occurrences of heating in the case of applications for powerful electric currents.
  • the formation of the legs does not add any complexity to the process for producing the terminal, the legs being able to be cut out from a metal sheet of conductive material (for example, copper, aluminium or an alloy comprising at least one of these metals) at the same time as the crimping tabs.
  • Each of the legs extends over a first portion from a front edge towards the contact portion, this first portion having continuity of material with a second curved portion which continues over a third portion, which extends from the second portion backwards, this third portion corresponding to an internal portion which extends between the crimping tabs.
  • the terminal also comprises where applicable one and/or other of the following features which are considered independently of each other or as combination of one or several other features:
  • This assembly also comprises where applicable one and/or other of the following features which are considered independently of each other or as a combination of one or several other features:
  • This method also comprises where applicable the following feature, considered independently or as a combination of one or several other features:
  • the invention substantially relates to the crimping portion of a power terminal, for the purpose of conciseness only one example of a female terminal is described below among a number of other possible examples of power terminals, whether male terminals or female terminals.
  • the terminal 1 described below is, for example, used as a power terminal for a charging plug for an electric vehicle or for a plug-in hybrid vehicle. In other words, it is intended to be electrically connected to an electrical wire 100 and mounted in a charging plug casing (not illustrated). However, a terminal 1 of this type can be used in applications other than the application corresponding to a charging plug.
  • This terminal 1 described below with reference to Figure 1 is formed by cutting out and forming a blank from a metal sheet made from a copper alloy.
  • this metal sheet is 1.4 mm thick.
  • the terminal 1 is thus substantially monobloc.
  • the terminal 1 comprises a front end 2 and a rear end 3 ("front” and “rear” refer to the connection direction, the front end 2 corresponding to the end via which the pin of a male terminal is introduced into this female terminal).
  • This terminal 1 thus comprises, in the direction from the front end 2 towards the rear end 3, a contact portion 4 and a crimping portion 5.
  • the contact portion 4 is intended to establish an electrical connection with a male terminal.
  • the crimping portion 5 is intended to receive the free end of an electrical wire 100 and to establish an electrical connection therewith.
  • the crimping portion 5 extends in a longitudinal direction L between a front end 2 which is located towards the contact portion 4 and a rear end 3.
  • the crimping portion 5 comprises two crimping tabs 6.
  • Each crimping tab 6 comprises a front edge 7 towards the front end 2, a rear edge 8 towards the rear end 3 and a longitudinal edge 9.
  • Each front edge 7 or rear edge 8 is substantially perpendicular to the longitudinal direction L.
  • Each longitudinal edge 9 is substantially parallel with the longitudinal direction L.
  • Each front edge 7 comprises two legs 10.
  • the number of legs 10 may naturally be different from the number illustrated in Figures 1 and 3 .
  • the front edge 7 of each crimping tab 6 is provided with two legs 10, for example, in the case of crimping on a wire which has a cross section of 70 square millimetres.
  • each front edge 7 may comprise only one leg 10.
  • the front edge 7 of each crimping tab 6 is provided with a single leg 10, for example, in the case of crimping on a wire which has a cross section of 35 square millimetres.
  • the front edge 7 of each crimping tab 6 is where applicable provided with three legs 10, for example, in the case of crimping on a wire which has a cross section of 95 square millimetres.
  • each of the legs 10 extends towards the front end 2 in a manner parallel with the longitudinal direction L, from this front edge 7.
  • the legs 10 are subsequently folded back towards the rear end 3, above the internal surface 11 of the crimping tabs 6.
  • This internal surface 11 is intended to move into contact with the wire 100, on which the crimping portion 5 will be crimped.
  • Marks, ribs, indentations, etc. may be formed on the internal surface 11 of the crimping tabs 6, which surface is intended to come into contact with the wire 100.
  • each of the legs 10 thus extends over a first portion from a front edge 7 towards the contact portion 4.
  • This first portion 12 has continuity of material with a second portion 13 which is curved (for example, with a radius of curvature of approximately 3 millimetres).
  • the second portion 13 has continuity of material with a third portion or internal portion 14 which extends from the second portion 13 towards the rear end 3.
  • This internal portion 14 extends between the crimping tabs 6.
  • This internal portion 14 has a length, for example, between 20% and 40% of the length of a crimping tab 6 (that is to say, substantially the length of the longitudinal edge 9) parallel with the longitudinal direction L.
  • the internal portion 14 has a length of approximately 5 millimetres for a length of the crimping tab 6 of approximately 15 millimetres, that is to say, approximately 30% of the length of a crimping tab 6.
  • a cambering operation of the crimping tabs 6 is subsequently carried out, at the end of which the crimping portion 5 has a groove-like shape which is symmetrical relative to a plane P of symmetry parallel with the longitudinal direction L.
  • the crimping portion 5 has, at the end of this crimping operation of the crimping tabs 6, but before being crimped on a wire 100, a U-shape in cross section. Each of the branches of this U-shape then corresponds to a crimping tab 6.
  • a wire 100 is placed in the crimping portion 5 while the crimping tabs 6 are not yet folded.
  • the wire 100 is a multi-strand wire which is formed by a plurality of strands 110 which are constituted by a conductive material (for example, made of copper, aluminium or an alloy of one or other of these metals).
  • the wire 100 is covered by a sheath 120 of insulating material.
  • the free end of the wire 100 is exposed before being introduced into the crimping portion 5.
  • the free and exposed end of the wire 100 is inserted into the crimping portion 5, via the rear end 3, substantially parallel with the longitudinal direction L, in such a manner that the legs 10 are inserted more readily between the strands 110 parallel with the longitudinal direction L thereof.
  • the free end of the legs 10 is advantageously chamfered.
  • the free end of the wire 100 is previously formed in a preform, the cavity of which corresponds to the position and form of the legs 10.
  • the crimping portion 5, with the exposed end of the wire 100 introduced therein, is subjected to a deformation between an anvil and a punch which are suitable, in order to bring the longitudinal edge 9 of each crimping tab 6 towards the interior and towards the bottom of the groove of the crimping portion 5.
  • a deformation between an anvil and a punch which are suitable, in order to bring the longitudinal edge 9 of each crimping tab 6 towards the interior and towards the bottom of the groove of the crimping portion 5.
  • the longitudinal edge 9 is introduced inside the strands 110. This operation is advantageously facilitated by providing chamfered longitudinal edges 9.
  • the crimping portion 5 has a cross section in the region of the internal portion with two lobes 15.
  • the crimping portion 5 is schematically illustrated as a cross-section at a level of the crimping portion 5, in which the internal portion 14 of the legs 10 is located.
  • a terminal 1 as illustrated in Figure 4 is involved, with the internal portion 14 of a single leg 10 being introduced into each lobe 15.
  • Each internal portion 14 is inserted in a region of a lobe 15 which is substantially delimited, on the one hand, by a crimping tab 6 and, on the other hand, by a plane P' which is perpendicular to the plane P of symmetry parallel with the longitudinal direction L and tangent to a longitudinal edge 9 of each crimping tab 6.
  • Each internal portion 14 is thus surrounded by strands 110 in a flattened zone of the crimping portion 5 in which the strands 110 are compressed by 15% more in relation to the flattened zone of the crimping portion 5 in which the internal portion 14 of the legs 10 does not extend.
  • the compression rate of the strands 110 is 20%, in the zone where there is an internal portion, the compression rate of the strands 110 is 35%.
  • the compression rate is relatively homogeneous. The compression rate is also over the whole of the strands 110 on which the terminal 1 is crimped.
  • a plurality of groups of strands 110 are defined (for example, one group for each lobe 15 and one group in the median zone under the longitudinal edges 9 of the folded crimping tabs 6), the fact of introducing the internal portion 14 of one or more legs 10 within each group allows the internal resistance of each group to be reduced, not only as a result of the greater compacting of the strands 110 relative to each other, but also as a result of the fact that each leg 10 provides an additional conduction path with little resistance as far as the crimping tab 6 which carries this leg 10.
  • the internal contact resistance can thus be reduced by 7 microOhms, changing, for example, from 20 microOhms to 13 microOhms, for example.
  • the terminal 1 described above may have a number of variants which differ from the one described above as a result of different dimensions, different materials, different forms and/or a different number of legs 10.

Landscapes

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

Claims (12)

  1. Leistungsklemme (1), die durch Ausschneiden und Bilden eines Rohlings aus einem Blech aus elektrisch leitendem Material gebildet wird, wobei diese Klemme (1) einen Kontaktabschnitt (4) und einen Crimpabschnitt (5) umfasst, der sich in einer Längsrichtung (L) zwischen einem vorderen Ende (2), das zum Kontaktabschnitt (4) hin liegt, und einem hinteren Ende (3) erstreckt, wobei der Crimpabschnitt (5) vor dem Crimpen an einem elektrischen Mehrlitzendraht (100) und im Querschnitt eine U-Form aufweist, wobei jeder der Schenkel dieser U-Form einer Crimpzunge (6) entspricht, wobei jede Crimpzunge (6) eine Vorderkante (7) aufweist, die zum vorderen Ende (2) gerichtet ist, wobei die Vorderkante (7) jeder Crimpzunge (6) mindestens einen Schenkel (10) aufweist, der sich von ihr aus im Wesentlichen parallel zur Längsrichtung (L) erstreckt,
    dadurch gekennzeichnet, dass jeder der Schenkel (10) sich über einen ersten Abschnitt (12) von einer Vorderkante (7) zum Kontaktabschnitt (4) hin erstreckt, wobei dieser erste Abschnitt (12) eine Materialkontinuität mit einem zweiten gekrümmten Abschnitt (13) aufweist, der sich über einen dritten Abschnitt fortsetzt, der seinerseits eine Materialkontinuität mit dem zweiten Abschnitt (13) aufweist und der sich von dem zweiten Abschnitt (13) zum hinteren Ende (3) hin erstreckt, wobei dieser dritte Abschnitt einem inneren Abschnitt (14) entspricht, der sich zwischen den Crimpzungen (6) erstreckt.
  2. Klemme (1) gemäß Anspruch 1, wobei der innere Abschnitt (14) eine Länge zwischen 20 und 40 % der Länge einer Crimpzunge (6) parallel zur Längsrichtung (L) aufweist.
  3. Klemme (1) gemäß einem der Ansprüche 1 oder 2, wobei jede Crimpzunge (6) zwei Schenkel (10) aufweist, die sich von der Vorderkante (7) aus erstrecken, wobei jeder dieser beiden Schenkel (10) so gestaltet ist, dass er zum hinteren Ende (3) hingebogen werden kann.
  4. Klemme (1) gemäß einem der Ansprüche 1 oder 2, wobei der Crimpabschnitt (5) so gestaltet ist, dass er einen elektrischen Draht (100) aufnehmen kann, der einen Querschnitt von mindestens 35 Quadratmillimetern aufweist, und jede Crimpzunge (6) mindestens einen Schenkel (10) aufweist, der sich von der Vorderkante (7) erstreckt.
  5. Klemme (1) gemäß einem der Ansprüche 1 oder 2, wobei der Crimpabschnitt (5) so gestaltet ist, dass er einen elektrischen Draht (100) aufnehmen kann, der einen Querschnitt von mindestens 70 Quadratmillimetern aufweist, und jede Crimpzunge (6) mindestens zwei Schenkel (10) aufweist, die sich von der Vorderkante (7) erstrecken.
  6. Klemme (1) gemäß einem der Ansprüche 1 oder 2, wobei der Crimpabschnitt (5) so gestaltet ist, dass er einen elektrischen Draht (100) aufnehmen kann, der einen Querschnitt von mindestens 90 Quadratmillimetern aufweist, und jede Crimpzunge (6) mindestens drei Schenkel (10) aufweist, die sich von der Vorderkante (7) erstrecken.
  7. Anordnung, die einen leitenden elektrischen Mehrlitzendraht (100) umfasst, an dessen einem Ende eine Klemme (1) gemäß einem der vorhergehenden Ansprüche gecrimpt ist, wobei jede Crimpzunge (6) mindestens teilweise um jeden der inneren Abschnitte (14) der Schenkel (10) gefaltet ist.
  8. Anordnung gemäß Anspruch 7, wobei jede Crimpzunge (6) einen Kanal bildet, in dem einige der Litzen (110) des leitenden elektrischen Mehrlitzendrahtes (100) um mindestens einen Schenkel (10) herum angeordnet sind.
  9. Anordnung gemäß Anspruch 7 oder 8, wobei der nicht verdichtete elektrische Mehrlitzendraht (100) einen Querschnitt von größer oder gleich 35 Quadratmillimetern aufweist.
  10. 1 Anordnung gemäß einem der Ansprüche 7 bis 9, wobei der nicht verdichtete elektrische Mehrlitzendraht (100) einen Querschnitt von größer oder gleich 70 Quadratmillimetern aufweist.
  11. Crimpverfahren, umfassend die folgenden Arbeitsgänge:
    - Bereitstellen einer Klemme (1) gemäß Anspruch 1, wobei jeder der Schenkel (10) so geformt ist, dass er sich über einen ersten Abschnitt (12) von einer Vorderkante (7) in Richtung des Kontaktabschnitts (4) erstreckt, wobei dieser erste Abschnitt (12) eine Materialkontinuität mit einem zweiten gekrümmten Abschnitt (13) aufweist, der sich über einen dritten Abschnitt fortsetzt, der seinerseits eine Materialkontinuität mit dem zweiten Abschnitt (13) aufweist und der sich von dem zweiten Abschnitt (13) zum hinteren Ende (3) hin erstreckt, wobei dieser dritte Abschnitt einem inneren Abschnitt (14) entspricht, der sich zwischen den Crimpzungen (6) erstreckt,
    - Bereitstellen eines leitenden elektrischen Mehrlitzendrahtes (100) und Einführen eines freiliegenden Endes des Mehrlitzendrahtes (100) zwischen die Crimpzungen (6), und
    - Formen der Crimpzungen (6) zwischen einem Amboss und einem Stempel, um die Litzen (110) des Mehrlitzendrahtes (100) um den Innenabschnitt (14) jedes Schenkels (10) zu verdichten, wobei der Amboss und der Stempel jeweils geeignete Formen für den Crimpabschnitt (5) aufweisen, nach dem Ausbilden der Crimpzungen (6) durch Biegen derselben einen Querschnitt im Bereich des inneren Abschnitts (14) mit zwei Zipfeln (15) und mindestens einem inneren Abschnitt (14) aufweist, der in jeden Zipfel (15) eingeführt wird.
  12. Crimpverfahren gemäß Anspruch 11, dadurch gekennzeichnet, dass die Crimpzungen (6) während des Formvorgangs symmetrisch auf der einen und der anderen Seite einer zur Längsrichtung (L) parallelen Symmetrieebene (P) aneinander gebracht werden, wobei jeder innere Abschnitt (14) in einen Bereich eines Zipfels (15) eingefügt wird, der im Wesentlichen einerseits durch eine Crimpzunge (6) und andererseits durch eine Ebene (P') rechtwinklig zur Symmetrieebene (P), parallel zur Längsrichtung (L) und tangential zu einer Längskante (9) jeder Crimpzunge (6) begrenzt ist.
EP21210040.8A 2020-11-24 2021-11-23 Leistungsklemme mit verbessertem crimp-abschnitt und crimpverfahren dafür Active EP4002591B1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
FR2012092A FR3116667B1 (fr) 2020-11-24 2020-11-24 Contact de puissance à portion de sertissage améliorée

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EP4002591A1 EP4002591A1 (de) 2022-05-25
EP4002591B1 true EP4002591B1 (de) 2023-07-12

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Publication number Priority date Publication date Assignee Title
DE102014204358A1 (de) * 2014-03-10 2015-09-10 Te Connectivity Germany Gmbh Kontaktelement und Kontaktanordnung mit Frontschutz sowie Verfahren zu deren Herstellung
DE102015224219A1 (de) * 2015-12-03 2017-06-08 Te Connectivity Germany Gmbh Crimpkontakt mit verbesserter Kontaktierung und Crimpverbindung

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FR3116667A1 (fr) 2022-05-27
FR3116667B1 (fr) 2023-09-01

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