WO2008014981A1 - Connector cable with lugs - Google Patents
Connector cable with lugs Download PDFInfo
- Publication number
- WO2008014981A1 WO2008014981A1 PCT/EP2007/006775 EP2007006775W WO2008014981A1 WO 2008014981 A1 WO2008014981 A1 WO 2008014981A1 EP 2007006775 W EP2007006775 W EP 2007006775W WO 2008014981 A1 WO2008014981 A1 WO 2008014981A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- cable
- lug
- iron
- thermite
- welding
- Prior art date
Links
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
- H01R4/02—Soldered or welded connections
- H01R4/023—Soldered or welded connections between cables or wires and terminals
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60M—POWER SUPPLY LINES, AND DEVICES ALONG RAILS, FOR ELECTRICALLY- PROPELLED VEHICLES
- B60M5/00—Arrangements along running rails or at joints thereof for current conduction or insulation, e.g. safety devices for reducing earth currents
-
- 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
- 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
- H01R11/16—End pieces terminating in a soldering tip or socket
-
- 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
- H01R4/203—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 having an uneven wire-receiving surface to improve the contact
- H01R4/206—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 having an uneven wire-receiving surface to improve the contact with transversal grooves or threads
Definitions
- the stresses will reside in the crimped portion of the copper lug due to the properties of the material.
- vibrations due to the passage of railway cars can cause cracks to form in the crimped portion, thus leading to damage to the copper lug itself if crimped portions exist other than the welded portion in the sleeve portion of the copper lug, or the vibrations may reach the bonding cable itself and cause it to be severed at the crimped portion.
- the crimped portion exists inside the welded portion, then the heat of welding during thermite welding can cause the crimped portion to melt, resulting in a state of disconnection.
- FIG. 3 A perspective view of the connector cable of the present invention after thermite welding.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing Of Electrical Connectors (AREA)
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
Abstract
A connector cable comprising a conductor cable; and an iron lug for thermite welding inside which the conductor cable is inserted, and press-formed to a predetermined shape; wherein one or more groove portions are formed on an outer surface of the iron lug so as to make the inner surface of the iron lug press against the conductor cable; and at least one groove portion is positioned outside the welded portion after thermite welding. The connector cable for thermite welding is easier to inspect and has a larger welding area than conventional cables.
Description
CONNECTOR CABLE WITH LUGS
TECHNICAL FIELD The present invention relates to a cable with attached lugs, specifically a connector cable with lugs for thermite welding to a base metal.
BACKGROUND ART
Thermite welding is a welding technique in which a mixed powder of aluminum and copper oxide (or iron oxide) is ignited and burned near the surface of a base metal, wherein the heat generated by the chemical reaction causes the copper (or iron) and a portion of the base metal to melt and fuse together. This welding technique is particularly often used in the field of railroads, such as to electrically connect separated railway rails by weld together a cable formed by attaching copper lugs on both ends of a conductor cable known as a bonding cable, with the surface of a railway rail by means of a welded portion composed of thermite material.
The bonding cable and copper lug on a cable as described above could be connected by inserting the bonding cable into a sleeve portion of a copper lug and crimping a portion of the copper lug, or inserting the bonding cable into the lug and forming together with the lug to result in a designated shape.
In the case of connection by crimping, the stresses will reside in the crimped portion of the copper lug due to the properties of the material. For example, when thermite welding a cable and a railway rail, vibrations due to the passage of railway cars can cause cracks to form in the crimped portion, thus leading to damage to the copper lug itself if crimped portions exist other than the welded portion in the sleeve portion of the copper lug, or the vibrations may reach the bonding cable itself and cause it to be severed at the crimped portion. Furthermore, if the crimped portion exists inside the welded portion, then the heat of welding during thermite welding can cause the crimped portion to melt, resulting in a state of disconnection. The above problems can cause damage to the copper lug itself, or make it impossible to inspect for contact problems between the bonding cable and the copper lug occurring inside the thermite welded portion.
Additionally, in the case of connection by forming, the ductile and malleable properties of copper lugs enable the bonding cable and inner surface of the lug to be fit closely together without any space in between, thus allowing molten copper in the thermite material to melt into the copper lug during thermite welding to achieve a good electrical connection. However, when thermite welding the cable and a railway rail for example, vibrations due to passage of railway cars can cause cracks or damage in the boundary portion between the thermite welded portion and the lug where the copper has entered, in which case the copper lug can come loose from the thermite welded portion together with the bonding cable. One might consider solving the above-described problems of copper terminals by using high-strength iron lugs. In that case, the iron lugs will usually be connected by press-forming since they are not suited to crimping, but the hardness of iron makes it difficult to form while retaining close contact with the bonding cable inside, so that spaces tend to be formed between the bonding cable and the inside surface of the iron lug. As a result, contact defects may occur between the bonding cable and the iron lug, but these portions occur inside the iron lug and are therefore not visible from outside, which makes it difficult to inspect the state of electrical contact between the bonding cable and the iron lug.
An example of the conventional art is described in JP 2005-14008A.
DISCLOSURE OF THE INVENTION
Therefore, the present invention has the object of offering a connector cable for thermite welding enabling the wear conditions of the bonding cable to be easily confirmed, by forming a groove portion in the iron lug so as to press against the bonding cable on an inner surface, wherein the groove portion is present outside the welded portion after thermite welding, making it possible to identify portions of the bonding cable that are susceptible to rupture.
(1) In order to achieve the above-described purpose, the connector cable according to the present invention is characterized by comprising a conductor cable; and an iron lug for thermite weding inside which the conductor cable is inserted, and press-formed to a predetermined shape; wherein one or more groove portions are formed on an outer surface of the iron lug so as to make the inner surface of the iron lug press against the
conductor cable; and at least one groove portion is positioned outside the welded portion after thermite welding.
(2) Additionally, the connector cable of the present invention preferably has at least two groove portions, each near an end of the iron lug. (3) Additionally, the connector cable of the present invention is preferably such that the predetermined shape which has been press-formed has an outer surface consisting of a flat surface and a curved surface.
(4) Additionally, the connector cable of the present invention preferably has a groove portion formed on the curved surface. (5) Additionally, the connector cable of the present invention is preferably such that the conductor cable passes through the iron lug.
(1) Since the connector cable of the present invention has at least one groove portion provided outside the welding portion after thermite welding, the pressed portion can be viewed by the groove portion. As a result, if for example, thermite welding is performed using a railway rail as a base metal, then the condition of the bonding cable when worn down due to rubbing against the end portions of the iron lug due to vibrations from the passage of railway cars can be easily confirmed.
Additionally, since the connector cable of the present invention has at least one groove portion formed on the outer surface of the iron lug so as to make the inner surface of the iron lug press against the conductor cable, there is a contact portion that reliably holds the conductor cable and the iron lug even when a gap is formed between the conductor cable and the iron lug at the time of formation, thus preventing contact problems.
(2) Since the connector cable of the present invention has at least two groove portions, each near an end of the iron lug, one of the groove portions will be positioned inside the welded portion after thermite welding, so that the weld metal will fill the inside of the groove portion and increase the welded area, while also forming a welded portion so as to detain the iron lug, thereby relieving stress to the welding boundary and improving the welding strength. (3) Since the connector cable of the present invention is such that the predetermined shape which has been press-formed has an outer surface consisting of a flat surface and a curved surface, the surface of the base metal such as a railway rail or
the like can be brought into contact with the flat surface portion of the iron lug, thereby enabling thermite welding to be performed with the connector cable in a stable condition, while the outer surface can be formed with a curve, such as by being dome-shaped or waved to form an arbitrary outer surface in accordance with the shape of the conductor cable inside.
(4) Since the connector cable of the present invention has a groove portion formed on the curved surface, if the groove portion is inside the welded portion after thermite welding, the welding area can be increased, and if it is outside the welded portion, the wear conditions of the bonding cable can be viewed from outside. Additionally, by forming a plurality of groove portions, the welding area can be further increased.
(5) Since the connector cable of the present invention is such that the conductor cable passes through the iron lug, the welding area can be increased by formation of a portion that is welded by the weld metal of the welded portion in not only the surface of the iron lug inside the welded portion that has been thermite welded, but also the conductor cable portion, thereby increasing the conductivity between the conductor cable and the railway rail.
BRIEF DESCRIPTION OF THE DRAWINGS
[Fig. 1] A perspective view of a connector cable for thermite welding according to the present invention.
[Fig. 2] A section viewed from X-X direction.
[Fig. 3] A perspective view of the connector cable of the present invention after thermite welding.
[Fig. 4] A section view of an iron lug of the connector cable plated with a zinc-iron alloy.
BEST MODES FOR CARRYING OUT THE INVENTION
An example of a preferred embodiment of the present invention shall be explained below with reference to the drawings. In the drawings, the same constituents shall be designated by the same reference numbers, and their explanations shall be skipped where appropriate.
Embodiment 1
Fig. 1 shows a perspective view of a connector cable for thermite welding according to the present invention. This connector cable 1 comprises a copper conductor cable 2 and an iron lug 3 for thermite welding into which the conductor cable 2 is inserted, press-formed to have the external shape of a tube of semicircular cross section. The conductor cable 2 inside the iron lug 3 is also formed to have the same shape.
The iron lug 3 has two groove portions 4' and 4", each formed on a circumferential curved surface near an end portion thereof. Even if stresses generated by formation of the groove portion are present, the properties of the materials will prevent cracking or rupturing due to vibration from the passage of railway cars.
Fig. 2 shows a section view from X-X direction in the groove portion 4'. In the groove portion 4', the depression causes the inside surface of the iron lug 3 to press against the conductor cable 2. This pressing portion enables the conductor cable 2 to be held to maintain a portion of contact between the conductor cable 2 and the iron lug 3, while compensating for contact problems due to spaces between the inside surface of the iron lug 3 and the conductor cable 2 during press forming of the connector cable 1.
Additionally, during thermite welding, molten metal flows into the groove portion 4', thus uniting the surface of the iron lug 3 and the thermite weld metal, so that the welding area between the thermite material and the iron lug 3 can be increased to achieve high welding strength.
Fig. 3 is a perspective view showing the state after thermite welding the connector cable 1 of the present invention and a base metal such as a railway rail (not shown). The connector cable 1 together with the groove portion 4' is covered by the welded portion 5 near its tip, and thermite welded to the surface of the base metal (not shown). Additionally, the groove portion 4" of the iron lug 3 is not covered by the welded portion 5 and is exposed, but like the groove portion 4', grips the conductor cable 2 due to the pressure from its depression. Therefore, the groove portion 4" receives external forces acting on the conductor cable 2. As a result, when external stresses such as vibrations from railway cars act on the conductor cable 2, the conductor cable 2 is first worn or ruptured at the groove portion 4". Thus, the ruptured portion of the conductor cable 2 is exposed and can be checked from outside, so that the state of deterioration of the conductor cable 2 can be easily understood, making it easy to inspect the connector
cable 1.
While the iron lug of the connector cable is normally plated with zinc in order to prevent corrosion, it is also possible to plate the iron lug with a zinc-iron alloy. Fig. 4 shows a cross section of an iron lug plated with a zinc-iron alloy. In the case of thermite welding, the extremely high temperature of the molten metal of the thermite material may cause the zinc plating to melt, so anti-corrosion effects may be lost. Therefore, an alloy plating 6 may be formed by thermal diffusion of zinc on the surface of the iron lug 3 in order to form an alloy of iron and zinc (Zn-Fe layer) on the surface of the iron lug 3.
Due to this alloy plating treatment, the invention of the present embodiment offers a connector cable with exceptional heat resistance and corrosion resistance at the time of welding.
Claims
1. A connector cable characterized by comprising: a conductor cable; an iron lug for thermite welding inside which the conductor cable is inserted, and press-formed to a predetermined shape; wherein one or more groove portions are formed on an outer surface of the iron lug so as to make the inner surface of the iron lug press against the conductor cable; and at least one groove portion is positioned outside the welded portion after thermite welding.
2. A connector cable as recited in claim 1, characterized in that at least two groove portions are formed, each near an end of the iron lug.
3. A connector cable as recited in claim 1 or 2, characterized in that said predetermined shape which has been press-formed has an outer surface consisting of a flat surface and a curved surface.
4. A connector cable as recited in claim 3, characterized in that a groove portion is formed on said curved surface.
5. A connector cable as recited in any one of claims 1-4, characterized in that said conductor cable passes through said iron lug.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2009522166A JP5158888B2 (en) | 2006-08-02 | 2007-07-31 | A structure in which the connecting cable with terminal is welded to the rail material by thermite. |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2006-210563 | 2006-08-02 | ||
| JP2006210563 | 2006-08-02 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2008014981A1 true WO2008014981A1 (en) | 2008-02-07 |
Family
ID=38581971
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/EP2007/006775 WO2008014981A1 (en) | 2006-08-02 | 2007-07-31 | Connector cable with lugs |
Country Status (3)
| Country | Link |
|---|---|
| JP (1) | JP5158888B2 (en) |
| CN (1) | CN101500843A (en) |
| WO (1) | WO2008014981A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2014114672A1 (en) * | 2013-01-24 | 2014-07-31 | Elringklinger Ag | Method for producing an electrically conductive connection between an electrical line and an electrically conductive component, and module produced according to the method |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP7394100B2 (en) | 2021-09-30 | 2023-12-07 | 古河電工パワーシステムズ株式会社 | Rail bond structure and method of forming rail bond structure |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US1865719A (en) * | 1926-12-30 | 1932-07-05 | Ohio Brass Co | Attachable welding terminal |
| US1933564A (en) * | 1927-10-24 | 1933-11-07 | Electric Railway Improvement Co | Bonding rail |
| GB1013317A (en) * | 1963-06-27 | 1965-12-15 | Amp Inc | Electrical connector for steel members |
| JP2005007461A (en) * | 2003-06-20 | 2005-01-13 | Fci Asia Technology Pte Ltd | Welded terminal |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH09253871A (en) * | 1996-03-22 | 1997-09-30 | Nippon Koki Co Ltd | Ignitor for welding to ignite thermite mixture |
| JP4629302B2 (en) * | 2002-08-26 | 2011-02-09 | 日油技研工業株式会社 | Rail welding terminal welding method |
| JP2006334644A (en) * | 2005-06-02 | 2006-12-14 | Shingo Kizai Kk | Method for forming rail bond |
-
2007
- 2007-07-31 WO PCT/EP2007/006775 patent/WO2008014981A1/en active Application Filing
- 2007-07-31 CN CNA2007800285729A patent/CN101500843A/en active Pending
- 2007-07-31 JP JP2009522166A patent/JP5158888B2/en active Active
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US1865719A (en) * | 1926-12-30 | 1932-07-05 | Ohio Brass Co | Attachable welding terminal |
| US1933564A (en) * | 1927-10-24 | 1933-11-07 | Electric Railway Improvement Co | Bonding rail |
| GB1013317A (en) * | 1963-06-27 | 1965-12-15 | Amp Inc | Electrical connector for steel members |
| JP2005007461A (en) * | 2003-06-20 | 2005-01-13 | Fci Asia Technology Pte Ltd | Welded terminal |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2014114672A1 (en) * | 2013-01-24 | 2014-07-31 | Elringklinger Ag | Method for producing an electrically conductive connection between an electrical line and an electrically conductive component, and module produced according to the method |
| CN104823329A (en) * | 2013-01-24 | 2015-08-05 | 爱尔铃克铃尔股份公司 | Method for producing electrically conductive connection between electrical line and electrically conductive component, and module produced according to method |
| US10833426B2 (en) | 2013-01-24 | 2020-11-10 | Elringklinger Ag | Method for producing an electrically conductive bond between an electrical line and an electrically conductive component and assembly produced using the method |
Also Published As
| Publication number | Publication date |
|---|---|
| JP2009545446A (en) | 2009-12-24 |
| JP5158888B2 (en) | 2013-03-06 |
| CN101500843A (en) | 2009-08-05 |
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