WO2013092116A1

WO2013092116A1 - Contact element for connecting a cable line, method for producing said contact element, and method for connecting a contact element to a cable line

Info

Publication number: WO2013092116A1
Application number: PCT/EP2012/073580
Authority: WO
Inventors: Jürgen Herzig; Manuel Vilsmeier
Original assignee: Lisa Dräxlmaier GmbH
Priority date: 2011-12-19
Filing date: 2012-11-26
Publication date: 2013-06-27
Also published as: DE102011088989B4; DE102011088989A1

Abstract

The invention relates to a contact element (10) that is designed to connect a cable line at a connection, which cable line comprises several individual wires forming an end face of the cable line. The contact element (10) comprises a dome (12) for connecting the contact element (10) to the cable line by means of contact welding. The dome (12) is designed to be inserted into the cable line through the end face between the individual wires in order to connect.

Description

2073580

Contact element for connecting a cable line, method for its production and method for connecting a

Contact element with a cable line

TECHNICAL AREA

The present application relates to a contact element, which is designed for connecting a cable line to a terminal, which comprises a plurality of individual wires, which form an end face of the cable line. Furthermore, the present application relates to a system of such a contact element and a

Cable line, a method of making a

Contact element and a method for connecting a

Contact element with a cable line comprising a plurality of individual wires forming an end face of the cable line.

STATE OF THE ART

From DE 1 916 895 AI is a contact plug with a

Cylinder for receiving stranded wires out. The individual wires of the strand are inserted into the cylinder and

subsequently through a welding electrode on the front side

welded. In this way, a firm connection between the cylinder, which performs the function of a sleeve, and the cable line of the individual wires is made.

A disadvantage of this method of attachment of a cable line to a terminal is that the corresponding

Contact element for the end-side welding of the sleeve with the cable line must be specially designed and can not fall back on a standard contact plug.

Moreover, in the connection method shown in the prior art, the disadvantage arises that only a small part of the conductor wires of the cable line actually in direct contact with the sleeve and thus with the contact plug in

Contact comes, under what the wire features the

Terminal suffer. In addition, that requires

Contact welding in the mold, as in the prior art It is shown that a welding electrode frontally contacts both the sleeve and the lead wires to weld them together. This in turn requires a corresponding configuration of the contact plug in order to ensure the access of the weld for an electrode.

PRESENTATION OF THE INVENTION

The object of the present invention over the prior art is to provide a contact element for connecting a cable line to a terminal, which is for efficient connection between the cable line and the

Contact element is suitable and efficient and

can be produced cost-saving. In addition, there is the

Task to be able to produce the contact element by recourse to standardized elements, not only for the mentioned

Contact element to use selected special parts.

The object is achieved by a contact element according to claim 1, a system according to claim 10 and the method according to claim 9 or 11. Further advantageous features of the invention will become apparent from the dependent claims.

An inventive contact element, which is designed for connecting a cable line to a terminal, wherein the cable line comprises a plurality of individual wires whose front ends define an end face of the cable line, has a dome for connecting the contact element to the cable line by means of contact welding. Here is the dome to

configured to be introduced at least partially through the end face between the individual wires in the cable line for connection. This means that the dome is inserted into the front end of the cable line to the largest possible

Contact surface and thus to allow the lowest possible resistance between the contact element on the one hand and the cable line on the other.

The fact that a dome of the contact element is inserted into the cable line, is a particularly good conductive connection between the cable line and the contact element possible, because not only a peripheral contacting of the cable line by the contact element takes place, but the contact element from both sides, outside and inside, through the cable line

can be contacted. Under a "dome" is in this

Document understood, for example, a cylinder jacket-shaped element whose cylinder axis extends substantially parallel to the extension direction of the cable line in the longitudinal section to be contacted. On the other hand, it is

possible that the dome has the shape of one or more pins which are inserted into the cable line.

The contact welding between the dome and the cable line can in particular be realized in that the cable line and the contact element have different electrical potentials, which lead to a flow of current through the contact points between the contact element and the cable line. Depending on the contact resistance of this current leads to a heating of the contact point and at sufficiently large

Amperages to a softening and welding of the contact points with each other.

Advantageously, the dome essentially has a shape of a

Hollow cylinder jacket with a cylinder axis, which defines a hollow cross-sectional shape perpendicular to the cylinder axis. In this case, the cross-sectional shape is selected and dimensioned such that for each of the individual wires of the cable line a maximum distance between the single wire and the dome perpendicular to the

Cylinder axis can be maintained. This means that the cross-sectional shape of the dome depends on the size and shape of the dome

End face of the cable line is adjusted. It should be noted that the defined perpendicular to the cylinder axis maximum distance between the single wire and the dome is also a measure of the guided from the contact point to the respective individual wire heat. The greater the distance between the contact point and the respective individual wire, the less heat is transferred via heat conduction to the individual wire, so that distant individual wires can no longer be softened in the sense of a contact welding. Therefore, this should be T EP2012 / 073580

4

Maximum distance is not so great that a softening of the individual wires and therefore a contact welding is not possible, so that the maximum distance is preferably a contact weldable maximum distance. For example, the Ma imalabstand as a distance between an inner surface of the hollow cylinder jacket and an outer surface of a centrally located within the

Hollow cylinder lying lying single wire defined and determined so that a softening of this central single wire by contact welding is possible. As an example, the inner diameter of an example

hollow cylinder-shaped dome with a cross-sectional shape of a cloverleaf between 0.5 mm and 1 mm and the outer diameter of a central single wire to be surrounded less than 0.5 mm. At this size ratio becomes a sufficient

Ensured energy input through the dome in the cable line in the contact welding point to melt this maximum inside of the dome remote individual wire for contact welding can. Advantageously, the inner diameter of the hollow cylinder jacket is 1.75 times the outer diameter of the individual wires of the cable line or stranded conductor. Of the

Outer diameter of the hollow cylinder jacket of the dome one

Cross-sectional shape, for example, of a cloverleaf is preferably 0.3 mm less than an inner diameter of a

preferred to the cable line in the field of

Contact sweat connection inverted and / or pressed

Anti-buckling sleeve.

Under a hollow cylinder shell in the sense of this preferred

Embodiment is not only a closed, but also an open form to understand. The cross-sectional shape of the

Hollow cylinder can assume a variety of shapes. It is preferable that the cross-sectional shape forms a cloverleaf shape, a heart shape, an ellipse shape, a ring shape, or a polygonal shape. Set these cross-sectional shapes

in particular, the base of the cylinder, whose jacket is at least partially formed by the dome. Under a hollow cylinder is not only a hollow circular cylinder

but each body is understood by two essentially parallel planar surfaces and a lateral surface formed by parallel straight lines is limited.

In a preferred embodiment, the dome is formed from a formed, in particular bent sheet metal. This sheet is advantageously a metal, since this can be easily transformed. Incidentally, however, in principle, other current-conducting materials are suitable to form the dome. The preferred bending of the sheet to the dome has the advantage of being particularly easy to implement.

In a preferred embodiment, the contact element for connecting to a cable line with an end face of more than 2.5 mm ² , in particular with an end face of more than 4 mm ² , particularly preferably more than 6 mm ² configured. Such large cross sections of cable lines can be on the way of contact welding with good conductivity of the

Connection between the contact element and the cable line in the prior art is not so easy to realize, since the distance between each contact surface between a dome, a sleeve or other contact element and the inner individual wires for contact welding is too large.

In a preferred embodiment, the cable line has more than 10 individual wires. The preferred contact element

allows an efficient connection of the cable line with the corresponding contact element, even if the cable line consists of a plurality of individual wires.

Preferably, the contact element further comprises a sleeve

(Anti-buckling sleeve), which is used to enclose with the Dom

connected cable line in the area of the connection between the dome and the cable line is designed so that the

Cable line is at least partially disposed between the dome and the sleeve, wherein the sleeve is preferably a separate element.

Such a sleeve increases the strength of the contact between the cable line and the contact element, in particular in the With regard to shear forces and buckling loads of

Joint. The sleeve is preferred in this

Embodiment, however, mainly used to support the contact. This means that the sleeve can basically also be made of a non-conductive material. The fact that the sleeve can be configured as a separate element, it is unnecessary that this sleeve already on the contact element

is provided if this has not yet been connected to the cable line. In this way, the contact element can be simplified structurally. The outside diameter of the

Hollow cylinder jacket of the dome is preferably 0.3 mm less than an inner diameter of preferably around the

Cable line in the contact welded connection inverted or arranged sleeve.

In a preferred embodiment, the contact element further comprises a connection part for connecting the contact element to the terminal, wherein the dome is formed integrally with the connection part. The connecting part of the contact element forms that part which is connected to the terminal to which the cable line is to be connected. The

Contact element represents, for example, a plug, which makes it possible to easily, quickly and safely plug a cable line into a corresponding connection socket and connect to this. The connecting part is therefore tuned to the connection to be connected to the cable line.

Due to the one-piece design of the contact element including the connection part and the dome, the contact element

be particularly inexpensive, because no additional

Connecting steps of individual parts of the contact element

become necessary. In a particularly preferred embodiment, the contact element further comprises at least one

Welding terminal, which is designed for connecting a welding electrode to the contact element. Such a

Welding connection thereby enlarges the contact surface between the welding electrode and the contact element in order to realize the contact welding for connecting the cable line to the contact element. An example of such a welding connection are two radially outward to the cylinder axis of the dome outwardly extending wings of metal, where one of the

Welding electrodes can be easily attached.

In a method according to the invention for producing a contact element with a one-piece construction of the dome with the connection part, the dome is formed from the same piece of material which also forms the connection part. In this case, the dome is advantageously formed by bending the piece of material. This method allows a particularly efficient production of the contact element, without having to make concessions in the flexibility of its use. In principle, the dome can also be made of a separate material, which is different with regard to the contact element.

In a method according to the invention for connecting a

Contact element with a cable line comprising a plurality of individual wires whose end faces define an end face of the cable line, wherein the contact element has a dome for connecting the contact element to the cable line, the following steps are carried out.

First, an electrical potential is applied to the cable line and to the contact element. For example, the anode may be connected to the contact element and the cathode to the cable line. Then, the dome is at least partially inserted through the end face between the individual wires in the cable line, so that substantially all the individual wires are softened by at one or more contact points between each one or more of the individual wires and the contact element heat, at least in the vicinity of the contact points. This softening of the individual wires is a particularly strong and good conductive connection between the

Contact element and the cable line realized. After the potential of the contact element and / or the cable line is removed, no current flows through the contact point between the contact element and the connecting line, and the heating of the individual wires is stopped. As a result, the individual wires solidify again and go the firm connection with the Contact element. During cooling, a pressing of the contact element can take place.

When designing the cathedral, make sure that the

Inner diameter of the dome is not too small, otherwise the displaced volume causes a splashing of the material.

Furthermore, this could lead to excessive heating of the

lead within the cathedral located single wires.

On the other hand, it is also to be avoided that the inner diameter of the dome is too large, that is, not sufficient

Heat input takes place in the connection between the cable line and the contact element. This could then lead to the individual wires of the cable line are not melted, and allow only an insufficient conductive connection between the cable line and the contact element.

Therefore, it is preferable that the cross-sectional shape of the dome so too

select that a distance from the dome in the cable line (measured in a direction perpendicular to the cylinder axis of the dome) at a given distance, which depends on the welding current, to each of the

Individual wires of the cable line is adjusted and thus can be acted upon with a sufficient amount of heat without heating individual wires of the cable so strong that they spray out during insertion of the cathedral in the cable line. For this purpose, in particular the cloverleaf has proven, but also a heart shape or similar shapes can meet these requirements

correspond. For cable lines with a face of 2.5 mm ² , a reliable connection between contact element and cable line can also be achieved with a dome whose

Cross-sectional shape is circular. For larger end faces of the cable line, for example, in a cross-sectional area of 4 mm ² or 6 mm ² , however, instead of using a

circular cross-sectional shape of the cathedral a cloverleaf or heart shape preferred. Especially with lines with a

Cross sectional area of more than 6 mm ² , a rosette-like cross-sectional shape is preferred. Further advantages, features and effects of the invention will become apparent from the following description of the figures and the

Entity of the claims.

BRIEF FIGURE DESCRIPTION

Fig. 1 shows a perspective view of an exemplary contact element, which is designed for connecting a cable line to a terminal.

FIG. 2 shows an enlarged detail of the contact element from FIG. 1 in order to be able to represent some details of the dome in more detail.

Fig. 3 shows an enlarged view of a dome according to another embodiment with one of the first

Embodiment deviating preferred cross-sectional shape.

WAYS FOR CARRYING OUT THE INVENTION

Fig. 1 shows in a perspective view

Contact element 10, which is designed for connecting a cable line (not shown) to a connection (not shown). The contact element 10 is designed to be connected to such a cable line, the more

Single wires comprises, which form an end face of the cable line.

The contact element 10 comprises a dome 12, which is used to connect the contact element 10 to the cable line by means of

Contact welding is formed. The dome 12 is configured to connect at least partially through the

Face to be inserted between the individual wires in the (not shown) cable line.

The dome 12 is configured in the embodiment shown in Fig. 1 in a circular cylindrical shell mold. In other words, the dome 12 is by a to a circular cylinder shell

made of bent sheet metal. The shape of the dome 12 In the embodiment shown in FIG. 1, it defines a circular cylinder jacket, the cylinder axis Z belonging to this cylinder being indicated in FIG. The cylinder axis Z extends as it were in the preferred direction of insertion of the dome 12 in the cable line.

Furthermore, the contact element 10 comprises a connection part 14 for connecting the contact element 10 to a connection. The dome 12 and the terminal part 14 are in the one shown in FIG

Embodiment formed in one piece. In particular, the contact element 10 is made of a standard connector

provided, in addition to the connection part 14 a

Having crimp contact according to the invention to the dome 12th

was transformed to be introduced through the end face in the cable line. For this purpose, the crimp was bent to the circular cylinder jacket. Such a shaped contact element 10 can already in the manufacture of the

Kontakt1emen s 10 are formed.

Furthermore, the contact element 10 comprises a two-part welding connection 16 following the dome 12. The welding connection 16 is separated by two radially away from the cylinder axis Z

extending metal tongues formed, which can be connected for contact welding of the cable line to the contact element 10 with a welding electrode. This way you can talk about the

Welding terminal 16, the contact element 10, in particular the dome 12, are brought to the same potential as the electrode. Preferably, the welding terminal 16 becomes the anode

connected. This makes it possible to perform the contact welding efficiently and material-friendly, because the on the

Welding connection 16 attached electrode because of the large

Contact surface, which is made possible by the welding connection 16, only relatively little wears.

Fig. 2 shows an enlarged view of the dome 12 of Fig. 1. In this case, a sheet was, for example, as

Crimping may be provided, bent together to form a circular cylinder jacket. This means that the perpendicular to the

Cylinder axis Z extending cross-sectional shape of the dome 12 a Ring shape is. A portion of the individual wires of the cable line may enter the interior of the dome 12, ie, an area within the annular shape of the dome 12, when the dome is inserted into the end face of the cable line. The remaining individual wires of the cable line can be arranged around the dome 12 and at least partially in direct contact with the dome 12.

The configuration of the contact element 10 shown in Fig. 2 is chosen such that the contact element for a stranded wire having a nominal cross section of 2.5 mm2 is designed and an inner diameter _Ό τ of the dome 12 of 0, 6 mm to 0.9 mm,

preferably 0.7 mm. The outer diameter D _A is accordingly determined by the sum of the inner diameter and the double sheet thickness of the material from which the dome 12 is bent.

Fig. 2 further shows an interface 18, abutting the two parts of the dome forming the metal sheet 12 and thus the

Close cylinder jacket. Alternatively, it is also possible that the cylinder jacket open, so the cylinder jacket

is incomplete.

The embodiment of the contact element 10 shown in FIGS. 1 and 2 is intended for connection to a cable line whose end face does not exceed a size of 2.5 mm ² . In such a cable line, all individual wires can be heated sufficiently to realize a contact welding, so that the strands are welded together and with the contact element 10.

FIG. 3 shows a further embodiment of a contact element 10 in the enlarged view, which essentially shows the dome 12 and parts of the welding terminal 16. Unlike in the first embodiment described above, the

Cross-sectional shape of the mandrel 12 in that shown in Fig. 3

Embodiment cloverleaf-shaped. Under a cloverleaf is understood in this context, a cross-sectional shape, the more, in particular three circular arc-shaped bulges

(convex areas) and several, in particular three indentations (concave areas). The inner diameter Ό _χ of such a cloverleaf-shaped cross-sectional shape is defined by the vertices of the Einbuchten (concave areas) perpendicular to the cylinder axis Z. The outer diameter D _A is defined by the vertices of the bulges (convex portions) perpendicular to the cylinder axis Z.

Also in Fig. 3 can be seen where the parts of the dome 12th

collide with each other. This separation surface 18 can also be so wide in the embodiment shown in FIG. 3 that the dome 12 does not form a closed cylinder jacket surface, but rather an open cylinder jacket surface which thus

is incomplete.

Advantageously, the inner diameter D _x of

Hollow cylinder shell 1.75 times the outer diameter of the individual wires of the cable line. The outside diameter of the

Hollow cylinder jacket of the dome of a cross-sectional shape of a

Cloverleaf is preferably 0, 3 mm less than one

Inner diameter of a preferably placed around the cable line in the contact welded connection buckling sleeve.

In the embodiment shown in Fig. 3 is the

Inner diameter Di a dimension of 0.6 mm. The individual wires of the cable line in this case preferably have a diameter of about 0.4 mm. The outer diameter D _{A of} the dome 12 in this

Embodiment is 2.5 mm. A buckling protection sleeve to be put over the contact point then preferably has one

Inner diameter of 2.8 mm. The shown in Fig. 3

Embodiment is configured to connect a cable line of an end face of more than 2.5 mm ² , in particular of 4 mm ² or 6 mm ² , with the contact element 10.

In addition to the embodiments shown in the figures, it is also possible to further vary the cross-sectional shape of the mandrel 12, for example in a heart shape, elliptical shape or polygonal shape. The actual configuration of the mandrel 12 depends on the size of the end face of the cable duct as well as its cross-sectional shape and is always designed so that each the individual wires of the cable line a maximum distance to a part of the dome 12, which is used by the

Contact welding current and the materials involved may be dependent, does not exceed.

Claims

PATENTA SPEECHES

A contact element (10) adapted to connect a cable line to a terminal comprising a plurality of individual wires forming an end face of the cable line,

with a dome (12) for connecting the contact element (10) to the cable line by means of contact welding,

wherein the dome (12) is adapted for connection at least partially through the end face between the

Single wires to be inserted into the cable line.

2. Contact element (10) according to claim 1, wherein the dome (12) is substantially a form of a hollow cylinder jacket with a

Cylinder axis (Z) defining a hollow cross-sectional shape perpendicular to the cylinder axis (Z),

wherein the cross-sectional shape is selected and dimensioned such that for each of the individual wires of the cable line

Maximum distance between the single wire and the dome (12)

perpendicular to the cylinder axis (Z) can be maintained.

3. Contact element (10) according to claim 2, wherein the

Cross-sectional shape of a cloverleaf, a heart shape, a

Ellipse shape, a ring shape or a polygonal shape.

4. Contact element (10) according to one of the preceding claims, wherein the dome (12) is formed from a formed, in particular bent sheet metal.

5. Contact element (10) according to one of the preceding claims, which is designed for connection to a cable line with an end face of more than 2.5 mm ² , in particular with an end face of at least 4 mm ² or more than 6 mm ² .

6. contact element (10) according to any one of the preceding claims, further comprising a sleeve which is designed for enclosing connected to the dome (12) cable line in the region of the connection between the dome (12) and the cable line, so that the cable line at least partly between the cathedral (12) and the Sleeve is arranged, wherein the sleeve is preferably a separate element.

7. Contact element (10) according to one of the preceding claims, further comprising a connection part (14) for connecting the

Contact element (10) with a connection, wherein the dome (12) is formed integrally with the connection part (14).

8. contact element (10) according to any one of the preceding claims, further comprising at least one welding connection (16) which is designed for contacting a welding electrode to the contact element (10).

9. A method for producing a contact element (10) according to one of claims 1 to 8,

wherein the dome (12) is formed from the same piece of material that also forms the terminal part (14).

10. System of a contact element (10) according to one of

Claims 1 to 8 and a cable line, the more

Single wires comprises, which form an end face of the cable line.

11. A method for connecting a contact element (10) according to one of claims 1 to 8 with a cable line comprising a plurality of individual wires forming an end face of the cable line,

wherein the contact element (10) has a dome (12) for connecting the contact element (10) to the cable line,

comprising the following steps:

Applying an electrical potential to the cable line and the contact element (10) and

at least partially inserting the mandrel (12) through the

End face between the individual wires in the cable line,

so that essentially all the individual wires through

Contact points between each one of the individual wires and the contact element (10) resulting heat are softened at least in the vicinity of the contact points.