WO2004047227A1 - Method for joining a connecting element to an electric cable - Google Patents

Method for joining a connecting element to an electric cable Download PDF

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Publication number
WO2004047227A1
WO2004047227A1 PCT/AT2003/000288 AT0300288W WO2004047227A1 WO 2004047227 A1 WO2004047227 A1 WO 2004047227A1 AT 0300288 W AT0300288 W AT 0300288W WO 2004047227 A1 WO2004047227 A1 WO 2004047227A1
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WO
WIPO (PCT)
Prior art keywords
aluminum
copper
conductor
sleeve
nickel
Prior art date
Application number
PCT/AT2003/000288
Other languages
German (de)
French (fr)
Inventor
Karl Franz FRÖSCHL
Original Assignee
Gebauer & Griller Kabelwerke Gesellschaft M.B.H.
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 Gebauer & Griller Kabelwerke Gesellschaft M.B.H. filed Critical Gebauer & Griller Kabelwerke Gesellschaft M.B.H.
Priority to AU2003269572A priority Critical patent/AU2003269572A1/en
Publication of WO2004047227A1 publication Critical patent/WO2004047227A1/en

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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
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • 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
    • H01R4/20—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 using a crimping sleeve
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • H01R4/625—Soldered or welded connections

Definitions

  • the present invention relates to a method for connecting a connecting element made of copper or a copper alloy for a cable, in particular a cable lug, to an electrical cable which has a conductor consisting of aluminum.
  • connection elements in particular cable lugs
  • glue them together using an electrically conductive plastic material, to solder or weld them together, or to connect them to one another in a form-fitting manner by deformation or compression.
  • electrically conductive plastic material to solder or weld them together
  • connect them to one another in a form-fitting manner by deformation or compression.
  • existing connecting elements are not in direct contact, since otherwise, if a liquid acting as an electrolyte acts on these connections, an electrochemical process occurs, by which the aluminum nium existing conductors are destroyed, whereby the electrical and mechanical connection is destroyed.
  • the object of the present invention is therefore to provide a method by which an aluminum conductor can be permanently connected to a connection element made of copper or a copper alloy. This is achieved according to the invention in that a layer of a metal lying in the electrochemical series between aluminum and copper, in particular nickel or a nickel alloy, is provided between the electrical conductor made of aluminum and the connecting element made of copper or a copper alloy.
  • the position of the metal lying in the electrochemical voltage series between aluminum and copper is preferably applied, in particular welded, to the end face of the electrical conductor.
  • the weld can be produced in particular by means of a powder welding process.
  • a plate of a metal lying in the electrochemical series between aluminum and copper, in particular nickel or a nickel alloy, can be applied, in particular welded, to the aluminum conductor.
  • connection element can be formed by a flat plate made of copper or a copper alloy, which is connected, in particular welded, to the aluminum conductor with the interposition of a layer of a metal which lies in the electrochemical series between aluminum and copper.
  • the plate can then be bent into an elbow, with the connection point for the aluminum conductor on one leg and a connection point for making an electrical connection, e.g. a hole.
  • a sleeve made of a metal lying in the electrochemical series between aluminum and copper can be applied to the aluminum conductor, the connection part can be placed on this sleeve and these components can be welded together, Soldering and / or mechanical deformation are firmly connected.
  • the sleeve applied to the conductor is made of steel.
  • a sleeve or clamp made of copper or a copper alloy is formed on the conductor made of aluminum, which is provided at least on its side facing the conductor with a coating consisting of metal, in particular nickel, in the electrochemical series between aluminum and copper , whereupon the sleeve or clamp and the conductor are connected to one another by deformation and / or by soldering.
  • the sleeve or clamp can be connected to the aluminum conductor by soldering the end face of the conductor to the sleeve.
  • the subject invention further relates to an electrical cable with an electrical conductor, which is formed with at least one connection part, in particular a cable clamp, wherein according to the invention the electrical conductor is made of aluminum and the connection part is made of copper or a copper alloy, and between which electrical conductor and the connection part is a layer of a metal lying in the electrochemical series between aluminum and copper, in particular nickel.
  • the electrical conductor and the connecting part can be connected to one another by mechanical deformation and / or soldering or welding with the interposition of the layer of a metal lying in the electrochemical series between copper and aluminum.
  • FIG. 1 shows a cable with an electrical conductor made of aluminum and a cable lug, which are connected to one another according to a first embodiment of the method according to the invention, in a side view, partially in section,
  • FIG. 2 shows a cable with an electrical conductor made of aluminum and a cable lug, which according to a second embodiment form of the method according to the invention are connected to one another, partially cut,
  • FIG. 4 shows a cable with a conductor made of aluminum and a cable lug, which are connected to one another according to a fourth embodiment of the method according to the invention, partially cut, and
  • FIG. 5 shows a cable with a conductor made of aluminum and a cable lug, which are connected to one another in accordance with a fifth embodiment, partially cut.
  • an electrical cable 1 which consists of a conductor 11 made of aluminum, which is surrounded by insulation 12. The stripped free end of the conductor 11 is tightly enclosed by a sleeve 13 made of aluminum.
  • the cable 1 is assigned a pole piece 2 made of brass, which is to be attached to the conductor 11.
  • the pole piece 2 consists of an L-shaped angled plate with two legs 21 and 22, wherein there is a bore 23 in the leg 21 with which it can be placed on the pole pin of a battery.
  • the leg 22 projecting from the leg 21 at a right angle serves to be connected to the conductor 11.
  • a powdery layer 3 of a metal which is in the electrochemical series between aluminum and copper, in particular nickel, is applied to the end face of the conductor 11 and this layer is applied to the conductor 11 welded. Subsequently, the layer 3 and the leg 22 of the pole piece 2 are brought into contact with one another and they are welded together.
  • the conductor 11 is also surrounded by a sleeve 13 made of aluminum.
  • a plate 3a made of nickel is welded onto the end face of the conductor 11. The connection surface for the welding process is enlarged by the sleeve 13 made of aluminum. Subsequently, this plate 3a is welded to the pole shoe 2 made of brass.
  • the pole piece 2 can also be designed as a flat plate which is welded to the end face of the conductor 11, this plate then being bent into the angled pole piece 2.
  • the layer 3, 3a of the metal, in particular nickel can initially be applied to the pole piece 2, which is then connected to the conductor 1.
  • a sleeve 3b made of a metal lying in the electrochemical series between aluminum and copper is placed on the free end of the aluminum conductor 11 and a sleeve-shaped part 24a of a cable lug 2a is pushed over this sleeve 3b. whereupon these two sleeves 3b and 24a are mechanically and electrically connected to one another by compression and deformation.
  • This cable lug 2a is also formed with a bore 23.
  • the sleeve 3b is e.g. made of steel.
  • the sleeve 24b of a pole piece 2b is placed on the conductor 11 made of aluminum, which has at least on its inside assigned to the conductor 11 a coating 3c made of a metal lying in the electrochemical series between aluminum and copper, in particular made of nickel, the sleeve 24b and the conductor 11 being mechanically and electrically connected by deformation.
  • the end face of the conductor 11 is also formed with the sleeve 24b with a soldering 4.
  • the aluminum conductor 11 of the cable 1 is not directly connected to the connection element 2, 2a, 2b, which is made of copper or a copper alloy, but that there is a layer 3, 3a, 3b between these two components , 3c, which consists of such a metal, which lies in the electrochemical series between aluminum and copper, whereby the risk of decomposition of the conductor 11 made of aluminum is very much reduced.
  • the decisive factor for the desired effect is that aluminum has a standard potential of -1,676 volts and copper has a standard potential of at least 0.337 volts, each measured against a normal hydrogen electrode.
  • the potential frequency between these two metals causes the aluminum to decompose in the presence of an electrolyte.
  • the standard potential of which is between that of aluminum and copper
  • the metals in the electrochemical series between aluminum and copper are manganese, zinc, chromium, iron, cobalt, nickel, tin, lead and tungsten.
  • the desired effect can be achieved by means of all of these metals or also by means of alloys or mixtures of these metals. Nickel and zinc are particularly suitable for this purpose, since their standard potentials are in the middle range between those of aluminum and copper.

Landscapes

  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Connection Of Batteries Or Terminals (AREA)

Abstract

Disclosed is a method for joining a connecting element (2), especially a cable lug, to an electric cable (1) comprising an aluminum conductor (11), said connecting element (2) being made of copper or a copper alloy. According to the inventive method, a layer (3c) of a metal, particularly nickel or a nickel alloy, which is located between aluminum and copper in the electrochemical series, is provided between the electrical conductor (11) made of aluminum and the connecting element (2b) made of copper or a copper alloy.

Description

Verfahren zur Verbindung eines Anschlußelementes mit einem elektrischen Kabel Method for connecting a connection element with an electrical cable
Die gegenständliche Erfindung betrifft ein Verfahren zur Verbindung eines aus Kupfer oder aus einer Kupferlegierung bestehenden Anschlußelementes für ein Kabel, insbesondere eines Kabelschuhs, mit einem elektrischen Kabel, welches einen aus Aluminium bestehenden Leiter aufweist.The present invention relates to a method for connecting a connecting element made of copper or a copper alloy for a cable, in particular a cable lug, to an electrical cable which has a conductor consisting of aluminum.
Es ist bekannt, elektrische Leiter, insbesondere solche, welche in Kraftfahrzeugen verwendet werden, aus Aluminium herzustellen. Die Vorteile von aus Aluminium hergestellten elektrischen Leitern bestehen darin, daß Aluminium gegenüber anderen Metallen, insbesondere Kupfer, aus welchen gleichfalls elektrische Leiter hergestellt werden, wesentlich billiger ist, daß es ein geringes Gewicht aufweist, daß es leicht verarbeitbar ist und daß es sehr korrosionsbeständig ist. Der Grund dafür allerdings, daß ungeachtet seiner besonderen Vorteile Aluminium für die Herstellung von elektrischen Leitern nicht allgemein verwendet wird, liegt darin, daß es gegenüber anderen Metallen eine wesentlich geringere Festigkeit aufweist, weswegen die Anschlußelemente, insbesondere Kabelschuhe, aus anderen Metallen, insbesondere Kupferlegierungen, wie Messing, hergestellt werden müssen. Dabei besteht jedoch das Erfordernis, die insbesondere aus Kupferlegierungen hergestellten Anschlußelemente mit den Leitern aus Aluminium dauerhaft zu verbinden.It is known to produce electrical conductors, in particular those used in motor vehicles, from aluminum. The advantages of electrical conductors made of aluminum are that aluminum is much cheaper than other metals, in particular copper, from which electrical conductors are also made, that it is light in weight, that it is easy to process and that it is very corrosion-resistant , However, the reason why, despite its particular advantages, aluminum is not generally used for the production of electrical conductors is that it has a considerably lower strength than other metals, which is why the connecting elements, in particular cable lugs, made of other metals, in particular copper alloys, like brass. However, there is a need to permanently connect the connecting elements, which are made in particular from copper alloys, to the conductors made of aluminum.
Um aus Aluminium hergestellte Leiter mit Anschlußelementen, insbesondere Kabelschuhen, zu verbinden, ist es bekannt, diese mittels eines elektrisch leitenden Kunststoffmaterials zu verkleben, diese miteinander zu verlöten oder zu verschweißen oder diese durch Verformung bzw. Verpressung miteinander formschlüssig zu verbinden. Dabei besteht jedoch weiters das Erfordernis zu gewährleisten, daß die aus Aluminium hergestellten Leiter mit den aus Kupfer oder einer Kupferlegierung od.dgl. bestehenden Anschlußelementen nicht in direktem Kontakt stehen, da andernfalls dann, soferne an diesen Verbindungen eine als Elektrolyt wirkende Flüssigkeit zur Wirkung kommt, ein elektrochemischer Prozeß auftritt, durch welchen die aus Alumi- nium bestehenden Leiter zersetzt werden, wodurch die elektrische und mechanische Verbindung zerstört wird.In order to connect conductors made of aluminum to connection elements, in particular cable lugs, it is known to glue them together using an electrically conductive plastic material, to solder or weld them together, or to connect them to one another in a form-fitting manner by deformation or compression. However, there is also the need to ensure that the conductor made of aluminum or the like made of copper or a copper alloy. existing connecting elements are not in direct contact, since otherwise, if a liquid acting as an electrolyte acts on these connections, an electrochemical process occurs, by which the aluminum nium existing conductors are destroyed, whereby the electrical and mechanical connection is destroyed.
Der gegenständlichen Erfindung liegt somit die Aufgabe zugrunde, ein Verfahren zu schaffen, durch welches ein aus Aluminium bestehender Leiter mit einem aus Kupfer oder einer Kupferlegierung bestehenden Anschlußelement in dauerhafter Weise verbunden werden kann. Dies wird erfindungsgemäß dadurch erzielt, daß zwischen dem aus Aluminium hergestellten elektrischen Leiter und dem aus Kupfer oder einer Kupferlegierung hergestellten Anschlußelement eine Lage eines in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer liegenden Metalles, insbesondere Nickel oder einer Nickellegierung, vorgesehen wird.The object of the present invention is therefore to provide a method by which an aluminum conductor can be permanently connected to a connection element made of copper or a copper alloy. This is achieved according to the invention in that a layer of a metal lying in the electrochemical series between aluminum and copper, in particular nickel or a nickel alloy, is provided between the electrical conductor made of aluminum and the connecting element made of copper or a copper alloy.
Vorzugsweise wird die Lage des in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer liegenden Metalles auf die Stirnfläche des elektrischen Leiters aufgebracht, insbesondere angeschweißt. Die Verschweißung kann insbesondere mittels eines Pulverschweißverfahrens hergestellt werden. Dabei kann an den Leiter aus Aluminium ein Plättchen eines in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer liegenden Metalles, insbesondere Nickel oder eine Nickellegierung, aufgebracht, insbesondere angeschweißt, werden.The position of the metal lying in the electrochemical voltage series between aluminum and copper is preferably applied, in particular welded, to the end face of the electrical conductor. The weld can be produced in particular by means of a powder welding process. A plate of a metal lying in the electrochemical series between aluminum and copper, in particular nickel or a nickel alloy, can be applied, in particular welded, to the aluminum conductor.
Das Anschlußelement kann durch ein ebenflächiges Plättchen aus Kupfer oder einer Kupferlegierung gebildet sein, welches unter Zwischenlage einer Schichte eines Metalles, welches in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer liegt, mit dem Leiter aus Aluminium verbunden, insbesondere verschweißt, wird. Hierauf kann das Plättchen in ein Winkelstück verbogen werden, wobei sich auf dem einen Schenkel die Anschlußstelle für den Leiter aus Aluminium und am anderen Schenkel eine Anschlußstelle für die Herstellung einer elektrischen Verbindung, z.B. eine Bohrung, befinden.The connection element can be formed by a flat plate made of copper or a copper alloy, which is connected, in particular welded, to the aluminum conductor with the interposition of a layer of a metal which lies in the electrochemical series between aluminum and copper. The plate can then be bent into an elbow, with the connection point for the aluminum conductor on one leg and a connection point for making an electrical connection, e.g. a hole.
Weiters kann auf den Leiter aus Aluminium eine Hülse aus einem in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer liegenden Metall aufgebracht werden, kann auf diese Hülse der Anschlußteil aufgesetzt werden und können diese Bauteile miteinander durch Schweißung, Lötung und bzw. oder mechanische Verformung fest verbunden werden. Insbesondere ist die auf dem Leiter aufgebrachte Hülse aus Stahl hergestellt.Furthermore, a sleeve made of a metal lying in the electrochemical series between aluminum and copper can be applied to the aluminum conductor, the connection part can be placed on this sleeve and these components can be welded together, Soldering and / or mechanical deformation are firmly connected. In particular, the sleeve applied to the conductor is made of steel.
Vorzugsweise wird auf den Leiter aus Aluminium eine mit einem Anschlußteil ausgebildete Hülse oder Klemme aus Kupfer oder einer Kupferlegierung aufgesetzt, welche zumindest an ihrer dem Leiter zugewandten Seite mit einer in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer liegenden Metall, insbesondere Nickel, bestehenden Beschichtung versehen ist, worauf die Hülse oder Klemme und der Leiter durch Verformung und bzw. oder durch Verlötung miteinander verbunden werden. Dabei kann die Hülse oder Klemme mit dem Leiter aus Aluminium durch Verlötung der Stirnfläche des Leiters mit der Hülse verbunden werden.Preferably, a sleeve or clamp made of copper or a copper alloy is formed on the conductor made of aluminum, which is provided at least on its side facing the conductor with a coating consisting of metal, in particular nickel, in the electrochemical series between aluminum and copper , whereupon the sleeve or clamp and the conductor are connected to one another by deformation and / or by soldering. The sleeve or clamp can be connected to the aluminum conductor by soldering the end face of the conductor to the sleeve.
Die gegenständliche Erfindung betrifft weiters ein elektrisches Kabel mit einem elektrischen Leiter, welches mit mindestens einem Anschlußteil, insbesondere einer Kabelklemme, ausgebildet ist, wobei erfindungsgemäß der elektrische Leiter aus Aluminium hergestellt ist und der Anschlußteil aus Kupfer oder einer Kupferlegierung hergestellt ist und wobei sich zwischen dem elektrischen Leiter und dem Anschlußteil eine Lage eines in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer liegenden Metalls, insbesondere Nickel, befindet. Dabei können der elektrische Leiter und der Anschlußteil unter Zwischenlage der Schichte eines in der elektrochemischen Spannungsreihe zwischen Kupfer und Aluminium liegenden Metalls miteinander durch mechanische Verformung und bzw. oder Verlötung bzw. Verschweißung verbunden sein.The subject invention further relates to an electrical cable with an electrical conductor, which is formed with at least one connection part, in particular a cable clamp, wherein according to the invention the electrical conductor is made of aluminum and the connection part is made of copper or a copper alloy, and between which electrical conductor and the connection part is a layer of a metal lying in the electrochemical series between aluminum and copper, in particular nickel. The electrical conductor and the connecting part can be connected to one another by mechanical deformation and / or soldering or welding with the interposition of the layer of a metal lying in the electrochemical series between copper and aluminum.
Das erfindungsgemäße Verfahren ist nachstehend anhand von fünf in der Zeichnung dargestellten Ausführungsbeispielen näher erläutert. Es zeigen:The method according to the invention is explained in more detail below with reference to five exemplary embodiments shown in the drawing. Show it:
Fig.1 ein Kabel mit einem aus Aluminium hergestellten elektrischen Leiter und einen Kabelschuh, welche gemäß einer ersten Ausführungsform des erfindungsgemäßen Verfahrens miteinander verbunden werden, in Seitenansicht, teilweise geschnitten,1 shows a cable with an electrical conductor made of aluminum and a cable lug, which are connected to one another according to a first embodiment of the method according to the invention, in a side view, partially in section,
Fig.2 ein Kabel mit einem aus Aluminium hergestellten elektrischen Leiter und einen Kabelschuh, welche gemäß einer zweiten Ausführungs- form des erfindungsgemäßen Verfahrens miteinander verbunden werden, teilweise geschnitten,2 shows a cable with an electrical conductor made of aluminum and a cable lug, which according to a second embodiment form of the method according to the invention are connected to one another, partially cut,
Fig.3 ein Kabel mit einem aus Aluminium hergestellten elektrischen Leiter und einen Kabelschuh, welche gemäß einer dritten Ausführungsform des erfindungsgemäßen Verfahrens miteinander verbunden sind, teilweise geschnitten,3 a cable with an electrical conductor made of aluminum and a cable lug which are connected to one another in accordance with a third embodiment of the method according to the invention, partially cut,
Fig.4 ein Kabel mit einem aus Aluminium hergestellten Leiter und einem Kabelschuh, welche gemäß einer vierten Ausführungsform des erfindungsgemäßen Verfahrens miteinander verbunden sind, teilweise geschnitten, und4 shows a cable with a conductor made of aluminum and a cable lug, which are connected to one another according to a fourth embodiment of the method according to the invention, partially cut, and
Fig.5 ein Kabel mit einem aus Aluminium hergestellten Leiter und einem Kabelschuh, welche gemäß einer fünften Ausführungsform miteinander verbunden sind, teilweise geschnitten.5 shows a cable with a conductor made of aluminum and a cable lug, which are connected to one another in accordance with a fifth embodiment, partially cut.
In Fig.l ist ein elektrisches Kabel 1 dargestellt, welches aus einem aus Aluminium hergestellten Leiter 11 , der von einer Isolierung 12 umgeben ist, besteht. Dabei ist das abisolierte freie Ende des Leiters 11 von einer Hülse 13 aus Aluminium fest umschlossen. Dem Kabel 1 ist ein aus Messing hergestellter Polschuh 2 zugeordnet, welcher am Leiter 11 befestigt werden soll. Der Polschuh 2 besteht aus einem L-förmig abgewinkelten Plättchen mit zwei Schenkeln 21 und 22, wobei sich im Schenkel 21 eine Bohrung 23 befindet, mit welcher es auf den Polzapfen einer Batterie aufgesetzt werden kann. Der vom Schenkel 21 im rechten Winkel abragende Schenkel 22 dient dazu, um mit dem Leiter 11 verbunden zu werden.In Fig.l an electrical cable 1 is shown, which consists of a conductor 11 made of aluminum, which is surrounded by insulation 12. The stripped free end of the conductor 11 is tightly enclosed by a sleeve 13 made of aluminum. The cable 1 is assigned a pole piece 2 made of brass, which is to be attached to the conductor 11. The pole piece 2 consists of an L-shaped angled plate with two legs 21 and 22, wherein there is a bore 23 in the leg 21 with which it can be placed on the pole pin of a battery. The leg 22 projecting from the leg 21 at a right angle serves to be connected to the conductor 11.
Um diese Verbindung des Kabels 1 mit dem Polschuh 2 zu bewirken, wird auf die Stirnfläche des Leiters 11 eine pulverförmige Lage 3 eines Metalles, welches sich in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer befindet, insbesondere Nickel, aufgetragen und wird diese Lage mit dem Leiter 11 verschweißt. In weiterer Folge werden die Lage 3 und der Schenkel 22 des Polschuhs 2 aneinander zur Anlage gebracht und werden sie miteinander verschweißt.In order to effect this connection of the cable 1 with the pole shoe 2, a powdery layer 3 of a metal, which is in the electrochemical series between aluminum and copper, in particular nickel, is applied to the end face of the conductor 11 and this layer is applied to the conductor 11 welded. Subsequently, the layer 3 and the leg 22 of the pole piece 2 are brought into contact with one another and they are welded together.
Durch die Anordnung der aus Nickel bestehenden Lage 3 zwischen dem aus Aluminium bestehenden Leiter 11 und dem aus Messing bestehenden Polschuh 2 wird eine elektrochemisch bedingte Zersetzung des Leiters 11 wei- testgehend verhindert. Bei der in Fig.2 dargestellten zweiten Ausführungsform ist der Leiter 11 gleichfalls von einer Hülse 13 aus Aluminium umgeben. Dabei wird auf die Stirnfläche des Leiters 11 ein Plättchen 3a aus Nickel aufgeschweißt. Durch die Hülse 13 aus Aluminium wird die Anschlußfläche für den Schweißvorgang vergrößert. In der Folge wird dieses Plättchen 3a mit dem aus Messing bestehenden Polschuh 2 verschweißt.By arranging the layer 3 made of nickel between the conductor 11 made of aluminum and the pole shoe 2 made of brass, electrochemically caused decomposition of the conductor 11 is largely prevented. In the second embodiment shown in Figure 2, the conductor 11 is also surrounded by a sleeve 13 made of aluminum. A plate 3a made of nickel is welded onto the end face of the conductor 11. The connection surface for the welding process is enlarged by the sleeve 13 made of aluminum. Subsequently, this plate 3a is welded to the pole shoe 2 made of brass.
Bei beiden Varianten kann der Polschuh 2 auch als ebenflächiges Plättchen ausgebildet sein, welches mit der Stirnfläche des Leiters 11 verschweißt wird, wobei in der Folge dieses Plättchen in den abgewinkelten Polschuh 2 verbogen wird.In both variants, the pole piece 2 can also be designed as a flat plate which is welded to the end face of the conductor 11, this plate then being bent into the angled pole piece 2.
In analoger Weise kann die Lage 3, 3a des Metalles, insbesondere Nickel, vorerst auf den Polschuh 2 aufgebracht werden, welcher dann mit dem Leiter 1 verbunden wird.In an analogous manner, the layer 3, 3a of the metal, in particular nickel, can initially be applied to the pole piece 2, which is then connected to the conductor 1.
Bei der in Fig.3 dargestellten dritten Ausführungsform wird auf das freie Ende des Leiters 11 aus Aluminium eine Hülse 3b aus einem in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer liegenden Metalles aufgesetzt und wird über diese Hülse 3b ein hülsenförmiger Teil 24a eines Kabelschuhs 2a aufgeschoben, worauf diese beiden Hülsen 3b und 24a durch Verpressung und Verformung miteinander mechanisch und elektrisch verbunden werden. Auch dieser Kabelschuh 2a ist mit eine Bohrung 23 ausgebildet. Die Hülse 3b ist dabei z.B. aus Stahl hergestellt.In the third embodiment shown in FIG. 3, a sleeve 3b made of a metal lying in the electrochemical series between aluminum and copper is placed on the free end of the aluminum conductor 11 and a sleeve-shaped part 24a of a cable lug 2a is pushed over this sleeve 3b. whereupon these two sleeves 3b and 24a are mechanically and electrically connected to one another by compression and deformation. This cable lug 2a is also formed with a bore 23. The sleeve 3b is e.g. made of steel.
Bei der in Fig.4 dargestellten vierten Ausführungsform wird auf den Leiter 11 aus Aluminium die Hülse 24b eines Polschuhs 2b aufgesetzt, welche zumindest an ihrer dem Leiter 11 zugeordneten Innenseite mit einer Beschichtung 3c aus einem in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer liegenden Metalls, insbesondere aus Nickel, versehen ist, wobei die Hülse 24b und der Leiter 11 durch Verformung mechanisch und elektrisch verbunden sind.In the fourth embodiment shown in FIG. 4, the sleeve 24b of a pole piece 2b is placed on the conductor 11 made of aluminum, which has at least on its inside assigned to the conductor 11 a coating 3c made of a metal lying in the electrochemical series between aluminum and copper, in particular made of nickel, the sleeve 24b and the conductor 11 being mechanically and electrically connected by deformation.
Bei der in Fig.5 dargestellten fünften Ausführungsform ist zudem die Stirnfläche des Leiters 11 mit der Hülse 24b mit einer Verlötung 4 ausgebildet. Bei allen Ausführungsformen ist es maßgeblich, daß der aus Aluminium bestehende Leiter 11 des Kabels 1 mit dem aus Kupfer oder einer Kupferlegierung bestehenden Anschlußelement 2,2a,2b nicht unmittelbar verbunden ist, sondern daß sich zwischen diesen beiden Bauteilen eine Lage 3,3a,3b,3c befindet, welche aus einem solchen Metall besteht, welches in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer liegt, wodurch die Gefahr einer Zersetzung des aus Aluminium bestehenden Leiters 11 sehr stark verringert wird.In the fifth embodiment shown in FIG. 5, the end face of the conductor 11 is also formed with the sleeve 24b with a soldering 4. In all embodiments, it is important that the aluminum conductor 11 of the cable 1 is not directly connected to the connection element 2, 2a, 2b, which is made of copper or a copper alloy, but that there is a layer 3, 3a, 3b between these two components , 3c, which consists of such a metal, which lies in the electrochemical series between aluminum and copper, whereby the risk of decomposition of the conductor 11 made of aluminum is very much reduced.
Maßgeblich für den angestrebten Effekt ist, daß Aluminium ein Normpotential von -1.676 Volt und Kupfer ein Normpotential von zumindest 0.337 Volt, jeweils gemessen gegen eine Wasserstoff-Normalelektrode, aufweisen. Die zwischen diesen beiden Metallen bestehende Potentialfrequenz verursacht bei Vorhandensein eines Elektrolyten eine Zersetzung des Aluminiums. Soferne sich jedoch zwischen diesen beiden Metallen ein solches Metall befindet, dessen Normpotential zwischen demjenigen von Aluminium und Kupfer liegt, tritt eine Verminderung der jeweils zwischen den Metallen auftretenden Potentialdifferenzen auf, wodurch die Gefahr einer elektrochemischen Zersetzung stark herabgesetzt wird. Die in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer liegenden Metalle sind Mangan, Zink, Chrom, Eisen, Kobalt, Nickel, Zinn, Blei und Wolfram. Der angestrebte Effekt kann mittels sämtlicher dieser Metalle bzw. auch mittels Legierungen oder Mischungen dieser Metalle erzielt werden. Insbesondere geeignet hierfür sind Nickel und Zink, da sich deren Normpotentiale im mittleren Bereich zwischen denjenigen von Aluminium und Kupfer befinden. The decisive factor for the desired effect is that aluminum has a standard potential of -1,676 volts and copper has a standard potential of at least 0.337 volts, each measured against a normal hydrogen electrode. The potential frequency between these two metals causes the aluminum to decompose in the presence of an electrolyte. However, if there is such a metal between these two metals, the standard potential of which is between that of aluminum and copper, there is a reduction in the potential differences that occur between the metals, thereby greatly reducing the risk of electrochemical decomposition. The metals in the electrochemical series between aluminum and copper are manganese, zinc, chromium, iron, cobalt, nickel, tin, lead and tungsten. The desired effect can be achieved by means of all of these metals or also by means of alloys or mixtures of these metals. Nickel and zinc are particularly suitable for this purpose, since their standard potentials are in the middle range between those of aluminum and copper.

Claims

ANSPRUCHE EXPECTATIONS
1. Verfahren zur Verbindung eines aus Kupfer oder aus einer Kupferlegierung bestehenden Anschlußelementes (2] für ein Kabel (1), insbesondere eines Kabelschuhs, mit einem elektrischen Kabel (1), welches einen aus Aluminium bestehenden Leiter (11) aufweist, dadurch gekennzeichnet, daß zwischen dem aus Aluminium bestehenden elektrischen Leiter (11) und dem aus Kupfer oder einer Kupferlegierung bestehenden Anschlußelement (2) eine Lage eines in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer liegenden Metalles, insbesondere Nickel oder eine Nickellegierung, vorgesehen wird.1. A method for connecting a connection element (2) made of copper or a copper alloy for a cable (1), in particular a cable lug, to an electrical cable (1) which has a conductor (11) made of aluminum, characterized in that that a layer of a metal lying in the electrochemical series between aluminum and copper, in particular nickel or a nickel alloy, is provided between the electrical conductor (11) made of aluminum and the connection element (2) made of copper or a copper alloy.
2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß die Lage (3) des in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer liegenden Metalles auf die Stirnfläche des elektrischen Leiters (11) aufgebracht, insbesondere angeschweißt, wird.2. The method according to claim 1, characterized in that the layer (3) of the metal lying in the electrochemical series between aluminum and copper on the end face of the electrical conductor (11) is applied, in particular welded.
3. Verfahren nach einem der Ansprüche 1 und 2, dadurch gekennzeichnet, daß die Lage (3) des in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer liegenden des Metalles, insbesondere Nickel oder eine Nickellegierung, am Leiter (11) mittels eines Pulverschweiß Verfahrens befestigt wird.3. The method according to any one of claims 1 and 2, characterized in that the layer (3) in the electrochemical series between aluminum and copper of the metal, in particular nickel or a nickel alloy, is attached to the conductor (11) by means of a powder welding process ,
4. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß an den Leiter (11) ein Plättchen (3a) eines in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer liegenden Metalles, insbesondere Nickel oder eine Nickellegierung, aufgebracht, insbesondere angeschweißt, wird.4. The method according to claim 1, characterized in that on the conductor (11) a plate (3a) of a lying in the electrochemical series between aluminum and copper metal, in particular nickel or a nickel alloy, is applied, in particular welded.
5. Verfahren nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, daß das Anschlußelement (2) durch ein ebenflächiges Plättchen aus Kupfer oder einer Kupferlegierung gebildet ist, welches unter Zwischenlage einer Schichte aus Metall, welches in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer liegt, mit dem Leiter (11) aus Aluminium verbunden, insbesondere verschweißt, wird. 5. The method according to any one of claims 1 to 4, characterized in that the connecting element (2) is formed by a flat plate made of copper or a copper alloy, which is interposed with a layer of metal, which is in the electrochemical series between aluminum and copper , connected to the conductor (11) made of aluminum, in particular welded.
6. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß auf den Leiter (11) aus Aluminium eine Hülse (3b) aus einem in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer liegenden Metall, insbesondere Nickel, aufgebracht wird und daß auf diese Hülse (3b) der Anschlußteil (2a) aufgesetzt wird und daß der Leiter (1), die Hülse (3b) und der Anschlußteil (2a) durch Schweißung, Lötung und bzw. oder mechanische Verformung miteinander fest verbunden werden.6. The method according to claim 1, characterized in that on the conductor (11) made of aluminum, a sleeve (3b) made of a metal in the electrochemical series between aluminum and copper, in particular nickel, is applied, and that on this sleeve (3b) the connecting part (2a) is placed and that the conductor (1), the sleeve (3b) and the connecting part (2a) are firmly connected to one another by welding, soldering and / or mechanical deformation.
7. Verfahren nach Anspruch 1 , dadurch gekennzeichnet, daß auf den Leiter (11) aus Aluminium eine mit einem Anschlußteil (23) ausgebildete Hülse (24b) oder Klemme aus Kupfer oder einer Kupferlegierung aufgesetzt wird, welche zumindest an ihrer dem Leiter (11) zugewandten Seite mit einer in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer liegenden Metall, insbesondere Nickel, bestehenden Beschichtung (30) versehen ist, worauf die Hülse (24b) oder Klemme und der Leiter (11) durch mechanische Verformung und bzw. oder dessen Verlötung miteinander verbunden werden.7. The method according to claim 1, characterized in that on the conductor (11) made of aluminum with a connecting part (23) formed sleeve (24b) or clamp made of copper or a copper alloy is placed, which at least on the conductor (11) facing side is provided with a coating (30) existing in the electrochemical series of voltages between aluminum and copper, in particular nickel, whereupon the sleeve (24b) or clamp and the conductor (11) by mechanical deformation and / or their soldering to one another get connected.
8. Verfahren nach Anspruch 7, dadurch gekennzeichnet, daß die Hülse (24b) oder Klemme und der Leiter (11) aus Aluminium miteinander durch Verlötung der Stirnfläche des Leiters (11) mit der Hülse (24b) verbunden werden.8. The method according to claim 7, characterized in that the sleeve (24b) or clamp and the conductor (11) made of aluminum are connected to each other by soldering the end face of the conductor (11) to the sleeve (24b).
9. Elektrisches Kabel mit einem elektrischen Leiter (11), welches mit mindestens einem Anschlußteil (2,2a,2b), insbesondere einer Kabelklemme, ausgebildet ist, dadurch gekennzeichnet, daß der elektrische Leiter (11) aus Aluminium hergestellt ist und daß der Anschlußteil (2,2a,2b) aus Kupfer oder einer Kupferlegierung hergestellt ist, wobei sich zwischen dem elektrischen Leiter (11) und dem Anschlußteil (2,2a,2b) eine Lage (3,3a,3b) eines in der elektrochemischen Spannungsreihe zwischen Aluminium und Kupfer liegenden Metalls, insbesondere Nickel, befindet.9. Electrical cable with an electrical conductor (11) which is formed with at least one connecting part (2,2a, 2b), in particular a cable clamp, characterized in that the electrical conductor (11) is made of aluminum and that the connecting part (2,2a, 2b) is made of copper or a copper alloy, with a layer (3,3a, 3b) between the electrical conductor (11) and the connecting part (2,2a, 2b) in the electrochemical series between aluminum and copper-lying metal, in particular nickel.
10. Elektrisches Kabel nach Anspruch 9, dadurch gekennzeichnet, daß der elektrische Leiter (11) und der Anschlußteil (2,2a,2b) unter Zwischenlage der Schichte (3,3a,3b) eines in der elektrochemischen Spannungsreihe zwischen Kupfer und Aluminium liegenden Metalls, insbesonder Nickel, miteinander durch mechanische Verformung und bzw. oder Verlötung bzw. Verschweißung verbunden sind. 10. Electrical cable according to claim 9, characterized in that the electrical conductor (11) and the connecting part (2,2a, 2b) with the interposition of the layer (3,3a, 3b) of a metal lying in the electrochemical series between copper and aluminum , in particular nickel, are connected to one another by mechanical deformation and / or soldering or welding.
PCT/AT2003/000288 2002-11-19 2003-09-29 Method for joining a connecting element to an electric cable WO2004047227A1 (en)

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