EP4462602B1 - Elektrisches kabel und kraftfahrzeug mit einem solchen kabel - Google Patents

Elektrisches kabel und kraftfahrzeug mit einem solchen kabel Download PDF

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Publication number
EP4462602B1
EP4462602B1 EP23290015.9A EP23290015A EP4462602B1 EP 4462602 B1 EP4462602 B1 EP 4462602B1 EP 23290015 A EP23290015 A EP 23290015A EP 4462602 B1 EP4462602 B1 EP 4462602B1
Authority
EP
European Patent Office
Prior art keywords
section
round conductor
connecting element
electrical
electrical cable
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
EP23290015.9A
Other languages
English (en)
French (fr)
Other versions
EP4462602A1 (de
Inventor
Hervé Rouland
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.)
Leoni Wiring Systems France SAS
Original Assignee
Leoni Wiring Systems France SAS
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 Leoni Wiring Systems France SAS filed Critical Leoni Wiring Systems France SAS
Priority to EP23290015.9A priority Critical patent/EP4462602B1/de
Publication of EP4462602A1 publication Critical patent/EP4462602A1/de
Application granted granted Critical
Publication of EP4462602B1 publication Critical patent/EP4462602B1/de
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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
    • H01R31/00—Coupling parts supported only by co-operation with counterpart
    • H01R31/06—Intermediate parts for linking two coupling parts, e.g. adapter
    • 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
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H01R4/029—Welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/60—Connections between or with tubular conductors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/03—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the relationship between the connecting locations
    • H01R11/09—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the relationship between the connecting locations the connecting locations being identical
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • 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

  • JP 2013 242991 A describes a joint between a stranded copper wire and a stranded aluminium wire, wherein the end of the copper wire is shaped to form a groove into which the aluminium wire is fitted and welded to the copper wire.
  • JP S54 34083 A describes a crimp terminal which is connected to a stranded wire.
  • the connecting element is both electrically contacted and mechanically connected to the round conductor exclusively by welding. Therefore, no additional measures are provided, for example for mechanical fastening. The effort for establishing the contact connection between the round conductor and the connecting element is therefore low.
  • the round conductor is in particular an inherently rigid round metal conductor with a diameter of at least 10 mm and preferably of at least 20 mm.
  • the round conductor and the connection element are made of metal.
  • the round conductor is an aluminium round conductor. It is therefore made of aluminium or an aluminium alloy typically with an aluminium content of more than 90 %.
  • the connecting element is preferably made of copper or a copper alloy.
  • the round conductor is used in particular as a so-called busbar, especially in a motor vehicle electrical system.
  • the cable preferably forms a main supply line and thus a so-called backbone or is part of such a backbone.
  • Such a backbone typically connects a front vehicle part with a rear vehicle part for power supply.
  • the round conductor, and thus also the cable typically has a length of at least 0.5 m and preferably of at least 1 m or also of at least 1.5 m.
  • the pre-assembled cable is preferably formed by the round conductor with the connecting element connected at least at one end.
  • connecting elements are attached on both sides.
  • the pre-assembled cable has additionally at one end and in particular at both ends an electrical component, in particular a plug, which is connected to the respective connecting element.
  • a pre-assembled electrical cable 8 according to FIG 1 and FIG 2 has, in the embodiment shown, a solid round conductor 2 which is surrounded by an insulation sheath 4.
  • a plug 6 is attached to each end of the round conductor 2 as an electrical component.
  • the round conductor 2 has a blank end part 9 at each of its two opposite ends, which has a round cross-section.
  • the cross-section of the round conductor 2 is preferably constant over its entire length. The round conductor 2 is therefore undeformed at the end parts 9.
  • the connecting element 10 is in particular a metallic one-piece element and in one embodiment a monolithic component.
  • the connecting element 10 is a (flexible) multilayer construction with a plurality (>3, especially >5) of thin metal layers 17.
  • the layers 17 are only illustrated in a very simplified way in FIG 2 and only in the intermediate section 14.
  • the layers 17 are welded together especially (only) at the end sides. Therefore, in a preferred embodiment, in the intermediate section 14 the layers 17 are not fixed to each other, for example they are not welded together. Therefore, the individual layers 17 can slide to some extent relative to each other. Due to this the flexibility of the intermediate section 14 is high
  • the connecting element 10 is therefore in particular a metal bent part, which is preferably produced by forming from a flat metal strip. This generally has two opposite flat sides which are connected to each other via two opposite narrow sides.
  • one end of the flat metal strip is preferably bent around a bending axis oriented parallel to the longitudinal direction L.
  • the shell-shaped section 12 extends in the circumferential direction, for example, over an angular range of less than 180° and in particular also of less than 120° or less than 90°.
  • the shell-shaped section 12 extends over an angular range of 30° to 60°.
  • the shell-shaped section 12 preferably has a radius of curvature which is adapted to the radius of the round conductor 2, so that the outer side of the round conductor 2, which is freed from the insulation sheath 4, lies with its cylindrical surface on an inner side of the shell-shaped section 12. This inner side forms a partially cylindrical surface.
  • the radius of curvature corresponds to the radius of the round conductor 2.
  • the shell-shaped section 12 extends in the longitudinal direction L over a comparatively short length, which in the embodiment example is for example shorter than a diameter of the round conductor 2.
  • the curved, shell-shaped section 12 merges into the intermediate section 14, which is formed by a section of the flat metal strip, wherein said section is bent.
  • the intermediate section 14, and thus the metal strip, are formed as a whole in a curved shape and therefore are undulated.
  • the intermediate section 14 has at least one arc section 18 and preferably a plurality of arc sections 18. In particular, two or three arc sections are formed.
  • the intermediate section 14 is flexible in the longitudinal direction and is specifically elastic. The flexible intermediate section 14 can therefore be compressed or stretched and thus serves to compensate for length.
  • a respective arc section 18 is bent around a bending axis which is oriented perpendicular to the longitudinal direction L and parallel to the flat sides of the flat metal strip.
  • the intermediate section 14 finally merges into the connecting section 16, which extends in particular in a straight line and in particular in the longitudinal direction L.
  • the connecting section 16 is electrically and mechanically connected to a respective plug 6 via a welded connection.
  • a respective plug 6 preferably has a connection piece 20, which in turn is designed in particular as a flat metal strip.
  • the respective plug 6 generally has an insulating housing in which a contact terminal not shown in more detail here is arranged, for example a socket or a plug pin, this contact terminal being electrically contacted on the connection piece 20.
  • the connection piece 20 emerges from the housing and is connected to the connecting element 10 at its emerging part.
  • the blank, round end part 9 is inserted into the shell-shaped section 12 and joined to it by welding.

Landscapes

  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)

Claims (10)

  1. Elektrisches Kabel (8), insbesondere für ein Kraftfahrzeug, das einen massiven elektrischen Rundleiter (2) und ein Verbindungselement (10) aufweist, das mit dem Rundleiter (2) verbunden ist und das einen Verbindungsabschnitt (16) zur elektrischen Verbindung mit einem elektrischen Bauteil (6) aufweist, wobei das Verbindungselement (10) weiter einen schalenförmigen Abschnitt (12) aufweist, wobei ein runder Endteil (9) des Rundleiters (2) an den schalenförmigen Abschnitt (12) des Verbindungselements (10) geschweißt ist, dadurch gekennzeichnet, dass ein flexibler Zwischenabschnitt (14) zum Längenausgleich zwischen dem schalenförmigen Abschnitt (12) und dem Verbindungsabschnitt (16) angeordnet ist und dass das Verbindungselement (10) einen mehrschichtigen Aufbau mit einer Vielzahl von Schichten aufweist, wobei die Schichten innerhalb des Zwischenabschnitts (14) nicht aneinander fixiert sind.
  2. Elektrisches Kabel (8) nach dem vorstehenden Anspruch, dadurch gekennzeichnet, dass der flexible Zwischenabschnitt (14) gewellt ist.
  3. Elektrisches Kabel (8) nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass der Verbindungsabschnitt (16) als mindestens ein flacher Metallstreifen gebildet ist.
  4. Elektrisches Kabel (8) nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass das Verbindungselement (10) mit dem Verbindungsabschnitt (16) an dem elektrischen Bauteil (6) durch Schweißen fixiert ist.
  5. Elektrisches Kabel (8) nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass der Verbindungsabschnitt (16) an einen Verbindungsteil (20) eines Steckers (6) geschweißt ist.
  6. Elektrisches Kabel (8) nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass das Verbindungselement (10) ausschließlich durch Schweißen mit dem Rundleiter (2) sowohl elektrisch kontaktiert als auch mechanisch verbunden ist.
  7. Elektrisches Kabel (8) nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass der Rundleiter (2) ein eigensteifer Rundleiter (2) mit einem Durchmesser von mindestens 10 mm, vorzugsweise mindestens 20 mm, ist.
  8. Elektrisches Kabel (8) nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass der Rundleiter (2) ein Aluminiumleiter ist.
  9. Elektrisches Kabel (8) nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, dass an runden Endteilen (9) an beiden Seiten des Rundleiters (2) Verbindungselemente (10) angebracht sind.
  10. Kraftfahrzeug mit einem elektrischen Kabel (8) nach einem der vorstehenden Ansprüche.
EP23290015.9A 2023-05-12 2023-05-12 Elektrisches kabel und kraftfahrzeug mit einem solchen kabel Active EP4462602B1 (de)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP23290015.9A EP4462602B1 (de) 2023-05-12 2023-05-12 Elektrisches kabel und kraftfahrzeug mit einem solchen kabel

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP23290015.9A EP4462602B1 (de) 2023-05-12 2023-05-12 Elektrisches kabel und kraftfahrzeug mit einem solchen kabel

Publications (2)

Publication Number Publication Date
EP4462602A1 EP4462602A1 (de) 2024-11-13
EP4462602B1 true EP4462602B1 (de) 2025-02-26

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP23290015.9A Active EP4462602B1 (de) 2023-05-12 2023-05-12 Elektrisches kabel und kraftfahrzeug mit einem solchen kabel

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Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5434083A (en) * 1978-04-06 1979-03-13 Furukawa Electric Co Ltd:The Joint for flexible conductor of twisted aluminium wires
DE102010005841B4 (de) 2010-01-26 2011-12-08 Auto-Kabel Managementgesellschaft Mbh Kabelschuh mit schalenförmiger Ausformung und Befestigungseinrichtung
JP2013242991A (ja) * 2012-05-18 2013-12-05 Auto Network Gijutsu Kenkyusho:Kk 電線の接合構造
CN113708172A (zh) * 2021-08-26 2021-11-26 长春捷翼汽车零部件有限公司 一种电能传输转接机构、充电插座和机动车辆
CN115411538A (zh) 2022-09-16 2022-11-29 欧托凯勃汽车线束（太仓）有限公司 一种曲面超声波焊接端子及配套使用的焊接组件

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