EP4216371A1 - Verfahren zum verbinden eines elektrischen kabels mit einem kontaktstück - Google Patents

Verfahren zum verbinden eines elektrischen kabels mit einem kontaktstück Download PDF

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Publication number
EP4216371A1
EP4216371A1 EP22152340.0A EP22152340A EP4216371A1 EP 4216371 A1 EP4216371 A1 EP 4216371A1 EP 22152340 A EP22152340 A EP 22152340A EP 4216371 A1 EP4216371 A1 EP 4216371A1
Authority
EP
European Patent Office
Prior art keywords
strands
face
cable
crimping
recess
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.)
Pending
Application number
EP22152340.0A
Other languages
German (de)
English (en)
French (fr)
Inventor
Peter Khu
Andreas Zelzer
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Komax Holding AG
Original Assignee
Komax Holding AG
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Komax Holding AG filed Critical Komax Holding AG
Priority to EP22152340.0A priority Critical patent/EP4216371A1/de
Priority to JP2022200213A priority patent/JP2023106302A/ja
Priority to CN202310023146.7A priority patent/CN116470363A/zh
Priority to MX2023000838A priority patent/MX2023000838A/es
Priority to US18/157,284 priority patent/US12658608B2/en
Publication of EP4216371A1 publication Critical patent/EP4216371A1/de
Pending legal-status Critical Current

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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
    • 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
    • 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
    • H01R4/023—Soldered or welded connections between cables or wires and terminals
    • 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
    • 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

Definitions

  • the present invention relates to a method for connecting an electrical cable with a plurality of electrical strands to a contact piece, with a crimping area having a central recess which is at least partially surrounded by a crimping tab being formed on the contact piece, and the axial ends of the plurality of electrical strands being inserted into the recess and being pressed with the crimping tab to produce an electrical connection.
  • a contact piece such as a cable lug or a contact pin
  • a contact piece is often attached to one end of the cable, with which an electrical connection can be established between the cable and a cable connection when the cable is used.
  • crimp connections are often used, with which the electrical cable (or its electrical conductor) is pressed into a crimp section of the contact piece.
  • the cable and the contact piece can also be welded after crimping, for example by means of laser welding.
  • connection methods are from DE 103 58 153 A1 or the DE 10 2009 056 799 A1 known.
  • connection methods are complex in terms of process technology and associated with difficulties. Electrical insulation of the cable must first be removed in order to expose the electrical conductors of the cable without damaging the conductors. Thereafter, the exposed conductor section must be arranged in the crimping section and pressed therein. Care must be taken to ensure that a good electrical connection is made without damaging the electrical conductors. Welding can result in weld spatter, oxidation or traces of smoke, which can also affect the cable. If electrical conductors made of aluminum are used, then there is the additional problem that an electrically insulating oxide layer quickly forms on the surface of aluminum, which can impair the electrical conductivity and can also lead to impairments when welding.
  • This object is achieved in that the axial ends of the plurality of electrical strands are fixed in the recess with a clamping tool before insertion, so that the axial ends of the plurality of electrical strands a length axially from the clamping tool and the ends of the plurality of stranded wires protruding axially out of the clamping tool are sheared off in the transverse direction with a cutting tool, so that a closed end face is formed at the axial end of the stranded wires, that the axial end of the plurality of electrical stranded wires is inserted into the recess and that the plurality of stranded wires are welded to the contact piece by the closed end face arranged in the recess being melted by radiant energy of a radiation directed onto the end face.
  • a closed front surface is created at the axial end of the cable, which on the one hand facilitates the insertion of the cable into the crimping area and on the other hand also improves the welding on the front side after crimping. Both increase the process stability of the connection method and also the quality of the connection produced.
  • the front-side welding can be improved if the closed front face is arranged in the recess axially set back from an end edge of the crimping region facing away from the cable.
  • the ends of the plurality of strands protruding axially from the crimping tool may be sheared normal to the longitudinal axis of the cable such that the face is oriented normal to the longitudinal axis of the cable, or sheared at an angle to the longitudinal axis of the cable such that the face is oriented at an angle to the longitudinal axis of the cable.
  • a sloping end face has certain advantages.
  • radiation such as a laser beam, which is intended to impinge essentially normally on the end face, is aligned in a direction deviating from the longitudinal axis of the cable.
  • This can increase safety during welding because radiation cannot escape from a lock of a welding chamber into which the cable is inserted in the longitudinal direction of the cable.
  • contact pieces can also be welded where the radiation cannot be directed in the longitudinal direction of the cable through a functional part of the contact piece.
  • an inclined end face also improves the tensile strength and also the electrical conductivity of the connection.
  • a cutout is provided in the crimping lug in the region of the end edge.
  • Shadowing can also be avoided if the end edge is beveled at an angle to the longitudinal axis of the cable and the end face is beveled at a steeper angle than the angle of the end edge. In this case, an area of the end face is closer to the end edge arranged than the rest of the end face. This means that a larger area of the end face is accessible to the radiation.
  • the axial end of the strands is advantageously pressed in the radial direction prior to shearing, preferably in a gas-tight manner.
  • the resulting area which is compacted by pressing and has fewer cavities between the strands, can improve electrical conductivity on the one hand.
  • the welding can also be improved because the radiant energy of the radiation can penetrate better into the axial end.
  • a coating for example a nickel layer, is often present on the surface of the contact piece.
  • Such a coating on the surface of the contact piece can be removed at least in certain areas in the crimping area before crimping in order to improve the electrical connection.
  • Such a coating on the surface of the contact piece can also be removed at least in regions in the welding area and/or in the area in front of the end face in the recess before welding in order to improve the welding quality.
  • the coating is removed with the radiation that is also used for the welding.
  • FIG. 1a and 1b a ready-made electrical conductor according to the invention is shown.
  • An electrical cable 1 with an outer electrical insulation 2 has been stripped at one axial end by removing the outer insulation so that the electrical strands 3 of the cable 1 are exposed.
  • the exposed strands 3 were introduced into a crimping area 6 of a contact piece 5 .
  • the crimping area 6 is in Fig.1a shown in section to show the strands 3.
  • the crimping area 6 is formed by a crimping tab 7 which at least partially surrounds a recess 8 , the electrical strands 3 being arranged in the recess 8 .
  • the strands 3 in the recess 8 are pressed with the crimping tab 7 in a known manner using a crimping tool. After the pressing, the strands 3 and the contact piece 5 are welded to one another in the area of the crimp lug 7 .
  • the welding takes place on the end face 9 of the strands 3 arranged in the recess 8 .
  • the end face 9 of the stranded wires 3 is preferably arranged set back axially from the end edge 10 of the crimping area 6 facing away from the cable 1 .
  • the welding takes place by radiant energy, preferably with a laser beam, which is directed onto the end face 9 in order to melt the strands 3 in the area of the end face 9 . Due to the adhesive forces, the melted and also the finished end face 9 of the strands can form a concave surface, as shown in Fig.1a shown.
  • the cable 1 is provided with an outer insulation 2 which, in order to establish an electrical connection between the strands 3 of the cable 1 and the contact piece 5 in the region of the axial end of the cable 1, must first be removed in order to expose the strands 3.
  • a cable 1 without insulation 2 can also be used, which means that the stripping step can also be omitted.
  • the cable can already be stripped of insulation at the axial end, so that the stripping step can also be omitted in this case.
  • the contact piece 5 has a crimping lug 7 on one axial end, which Fig.2a have already been bent upwards.
  • the crimping area 6 is formed with a forming tool 11 and a mandrel 12 in that the crimping tab 7 is deformed around the mandrel 12 in the desired manner.
  • the crimping area 6 has a recess 8 with a conically converging inlet area, which merges into a cylindrical pressing area.
  • the strands 3 of the cable 1 are inserted into the recess 8 via the inlet area, with the cone facilitating the insertion.
  • the end face 9 of the strands 3 is in Compression of the crimping area 6 arranged.
  • the recess 8 can also have any other suitable shape and geometry.
  • the crimping tab 7 After the deformation on the peripheral surface, the crimping tab 7 usually rests on a crimping tab joint 4 ( Fig.1b ) to each other.
  • the crimping tab 7 can also be shaped in such a way that it forms a crimping lock on the outer peripheral surface at the crimping tab joint 4 , which can cause the crimping tab 7 to hold together better.
  • the steps after Figures 2a and 2b are therefore to be considered optional.
  • step Fig.2d the strands 3 are pressed in the recess 8 of the crimping area 6 with the crimping tabs 7 by means of a crimping tool 13 in a known manner (indicated by arrows).
  • the recess is preferably 0.2 - 0.5mm larger than the finished pressed size.
  • the cable 1 with the crimped contact piece 5 is then brought into a welding chamber 20, in which the stranded wire 3 is welded to the crimping tab 7 ( Fig.2e ).
  • radiation preferably electromagnetic radiation such as a laser beam 21 is directed onto the end face 9, preferably essentially normal to the end face 9, in order to heat and melt the strands 3 in the area of the end face 9 by the radiation energy.
  • the crimping tab 7 is preferably not actively heated by the radiation.
  • the heating of the end face 9 by the radiation preferably takes place in such a way that first the edge area of the pressed strands 3 and then the inner area of the pressed strands 3 is heated.
  • Fig.2f shows the fully welded conductor consisting of the cable 1 and the contact piece 5.
  • Fig.2f also shows a concave surface of the finished end face 9 formed by the adhesive forces of the melted end face 9 of the strands.
  • the axial end of the strands 3 is fixed in a clamping tool 33, for example in the form of two clamping jaws 30, 31 movable relative to one another, the axial end of the strands 3 protruding freely from the clamping tool 33 by a certain axial length L.
  • the axial end of the strands 3 protruding from the clamping tool 33 is sheared off in the transverse direction Q (transverse to the longitudinal direction of the strands 3) with a cutting tool 32 .
  • the shearing in the transverse direction Q not only produces a clean end face 9, but also a closed cut surface, since the ends of the strands 3 are compressed at the cutting point by the deformation during shearing, or are even cold-welded.
  • the finished cut surface forms the end face 9 of the strands 3 .
  • the cutting edge 34 of the cutting tool 32 is preferably obtuse-angled because this supports the production of the closed end face 9 .
  • the cutting edge 32 can be concave or convex, as required, as in Figure 3a indicated by dashed lines.
  • the strands 3 can not only be fixed by the clamping tool 33, but the axial end of the strands 3 can also be simultaneously pressed in the radial direction, preferably pressed in a gas-tight manner.
  • the strands 3 are pressed together in the radial direction, for example by the clamping jaws 31, 32, in order to reduce cavities between the individual strands 3 in the pressing area.
  • gas-tight pressing With gas-tight pressing, the cavities in the pressing area are eliminated.
  • Such a pressing can improve the electrical conductivity at the transition between the stranded wires 3 and the contact piece 5 .
  • a corresponding radial pressure is exerted on the strands 3 for pressing.
  • Such pressing can also be designed as a separate process step.
  • the axial end is pressed with a clamping tool in a separate device before it is sheared off.
  • the clamping jaws 31, 32 advantageously have a non-circular, such as an elliptical or oval, inner shape for the pressing. Above all, the gas-tight pressing can be realized more easily in a non-circular shape.
  • the axial end of the strands 3 can also be shaped in the axial direction during pressing, preferably according to the shape of the crimping area 6.
  • a cylindrical area is formed at the axial end during pressing, which merges into a conical area and then optionally can also merge into a rounded entry area.
  • Such a shape in the axial direction can advantageously be used in a crimping area 6 as in Fig.1a shown to be used. If the axial end of the strands 3 is analogous or opposite, formed into the crimping area 6, less forming work has to be applied during crimping due to the preforming. In the case of gas-tight pressing, the strands 3 are pressed gas-tight in the area of the cylindrical area, i.e. at the axial end of the strands 3.
  • the end of the strands 3 does not necessarily have to be sheared off at right angles to the longitudinal axis of the strands 3 or the cable 1, but the end face 9 can also be formed at a certain angle ⁇ to the longitudinal axis, as in Figures 4a and 4b is shown.
  • the closed end face 9 produced by the shearing has advantages in particular when the strands 3 are welded to the crimping lug 7 at the end. On the one hand, this allows the axial end of the strands 3 to be inserted more easily and securely into the recess 8 because individual strands 3 cannot bend. On the other hand, as a result, the end face 9 can be better heated with the radiation, preferably the laser beam 21 . Both lead to higher process stability. If the axial end of the strands 3 is additionally pressed, the front area can be heated even better for welding.
  • the shearing can also be easily integrated into the overall process of producing the electrical connection. Shearing takes only a short time and can be carried out just before welding. This is particularly advantageous where the strands 3 are made of a material that oxidizes rapidly in the ambient atmosphere, such as in ambient air, such as aluminum. The shearing creates a bright, oxide-free surface, which improves welding in particular, but also increases the quality of the electrical connection made.
  • Fig.5 shows a possible configuration of a welding chamber 20 for welding the strands 3 to the contact piece 5 by means of a laser 22, in which case any other suitable radiation source could also be used to generate radiation.
  • the cable 1 with the crimped contact piece 5 is introduced into the welding chamber 20 via a lock 23 .
  • the lock 23 can be closed around the cable 1 in order to prevent the laser beam 21 from exiting the welding chamber 20 unintentionally.
  • the cable 1 can also be angled in the welding chamber 20 at an angle to the longitudinal axis of the cable 1 so that the direction of the laser beam 21 deviates from the longitudinal axis.
  • a suitable device 25 can be provided in the welding chamber 20 in order to bend the cable 1, for example by lifting the end of the cable.
  • a holding device 28 can also be provided in the welding chamber 20 in order to hold the contact element 5, preferably in the area of the crimping area 6, at least during the welding.
  • the laser beam 21 can be generated by a laser 22 and coupled into the welding chamber 20 via a window 24 .
  • the laser 22 can also be arranged in the welding chamber 20 .
  • the laser 22 comprises known devices in order to direct the laser beam 21 to different points of a certain area, for example the end face 9 .
  • a protective gas nozzle 27 can also be provided in the welding chamber 20 in order to supply protective gas to the welding point during welding. The quality of the welded connection can thus be increased.
  • An extraction system 26 can also be provided in the welding chamber 20, preferably in the vicinity of the welding point, in order to extract welding fumes and, if necessary, protective gas. This can improve the welding quality.
  • An air flow can be generated by suction 26 and/or supply of protective gas to the welding point, which can reduce disadvantageous welding effects such as oxidation, welding spatter, traces of smoke etc.
  • the advantage of such a sloping end face 9 is that the radiation, for example the laser beam 21, which is intended to impinge essentially normally on the end face 9, is originally aligned in a direction deviating from the longitudinal axis of the cable 1. This can prevent the radiation from escaping through the lock 23 of the welding chamber 20 without having to bend the cable 1 in the welding chamber 20, as in FIG Fig.7 evident.
  • a sloping end face 9 allows processing of contact pieces 5 whose functional part does not offer a passage for the radiation, for example the laser beam 21, as for example with a full contact pin.
  • a sloping end face 9 also improves the tensile strength and the electrical conductivity of the connection.
  • Such a recess 14 can be produced after crimping by machining, such as milling or grinding, or it can already be prefabricated on the crimp tabs 7, for example when the contact piece 5 is stamped out of sheet metal. It is also possible to use the radiation, such as the laser beam 21, to burn away that part of the crimping tab 7 which interferes with the welding. For this purpose, the radiation could be generated with different powers, for example. In a further alternative, the angles of the end edge 10 and the end face 9 could be chosen to be different. In the area of radiation shielding, the end face 9 could be arranged less far from the end edge 10 and the end face 9 could be arranged at a steeper angle than the end edge 10.
  • Fig.8 shows a welding chamber 20 with a laser 22 as a radiation source, for example, in which a cable 1 with an inclined end face 9 is welded to a contact piece on the end face.
  • the laser beam 21 which is intended to impinge essentially normally on the end face, points in a direction other than the longitudinal axis of the cable 1 and therefore cannot exit from the lock 23 . Furthermore, no device 25 for bending the cable 1 is required in such an embodiment.
  • the contact pieces 5 are often stamped from a strip material and bent into the desired shape.
  • the strip material is often given a protective coating, such as a layer of nickel, on the surface.
  • a protective coating such as a layer of nickel
  • Such a nickel layer can impair both the electrical conductivity and the welding quality. It is therefore advantageous to remove a coating, if present, before crimping, at least at points on the contact piece 5 at which an electrical connection is made or at which welding is carried out.
  • the (partial) removal of the coating can be carried out mechanically, thermally or chemically.
  • the inner surface of the crimping tab 7 can be processed with a grinding brush, for example. Etching pens or spray nozzles can be used for chemical removal.
  • the thermal distance can be vaporized in the intended area by means of radiation, such as by means of a laser.
  • the coating on the inside of the crimping tab 7 is removed in the welding station 20 by means of the laser beam 21 immediately before the end face 9 in the recess 8 after the crimping and before the welding.
  • the stranded wires 3 and the contact piece 5 can also only be crimped inside the welding chamber 20 .
  • the radiation such as the laser beam 21 can also be used to remove a coating of the contact part at least in certain areas in the crimping area.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
EP22152340.0A 2022-01-20 2022-01-20 Verfahren zum verbinden eines elektrischen kabels mit einem kontaktstück Pending EP4216371A1 (de)

Priority Applications (5)

Application Number Priority Date Filing Date Title
EP22152340.0A EP4216371A1 (de) 2022-01-20 2022-01-20 Verfahren zum verbinden eines elektrischen kabels mit einem kontaktstück
JP2022200213A JP2023106302A (ja) 2022-01-20 2022-12-15 接点部片との電気的なケーブルの結合のための方法
CN202310023146.7A CN116470363A (zh) 2022-01-20 2023-01-09 用于将电缆与接触件连接的方法
MX2023000838A MX2023000838A (es) 2022-01-20 2023-01-18 Metodo para conectar un cable electrico a una pieza de contacto.
US18/157,284 US12658608B2 (en) 2022-01-20 2023-01-20 Method for connecting an electrical cable to a contact piece

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP22152340.0A EP4216371A1 (de) 2022-01-20 2022-01-20 Verfahren zum verbinden eines elektrischen kabels mit einem kontaktstück

Publications (1)

Publication Number Publication Date
EP4216371A1 true EP4216371A1 (de) 2023-07-26

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP22152340.0A Pending EP4216371A1 (de) 2022-01-20 2022-01-20 Verfahren zum verbinden eines elektrischen kabels mit einem kontaktstück

Country Status (5)

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US (1) US12658608B2 (enExample)
EP (1) EP4216371A1 (enExample)
JP (1) JP2023106302A (enExample)
CN (1) CN116470363A (enExample)
MX (1) MX2023000838A (enExample)

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JP7111784B2 (ja) * 2020-09-11 2022-08-02 矢崎総業株式会社 雌端子の製造方法
JP2025108968A (ja) * 2024-01-11 2025-07-24 株式会社オートネットワーク技術研究所 端子付配線部材および端子付配線部材の製造方法

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