WO2015165572A1 - Crimp-schweissverbindung - Google Patents
Crimp-schweissverbindung Download PDFInfo
- Publication number
- WO2015165572A1 WO2015165572A1 PCT/EP2015/000800 EP2015000800W WO2015165572A1 WO 2015165572 A1 WO2015165572 A1 WO 2015165572A1 EP 2015000800 W EP2015000800 W EP 2015000800W WO 2015165572 A1 WO2015165572 A1 WO 2015165572A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- connection
- crimp
- welded
- stranded
- stranded wire
- 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
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/187—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping combined with soldering or welding
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- 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
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
- H01R43/0207—Ultrasonic-, H.F.-, cold- or impact welding
Definitions
- the invention relates to a method for producing a permanent mechanical and electrical connection between a stranded conductor and a connection element. In this case, one end of the stranded wire is welded to the connection element. Furthermore, the invention relates to a connection between a connection element and a stranded conductor produced according to the method according to the invention.
- a stranded conductor or strand is a conductor consisting of a plurality of thin individual wires.
- the individual wires can be coaxially circulated by a common insulating sleeve and possibly additionally by a common outer conductor.
- Several such stranded wires can run side by side in a cable.
- Litz wires generally have the advantage of a particularly high degree of flexibility and only a low susceptibility to conductor breaks, even under mechanical loads such as vibrations or shearing and bending forces acting on the stranded conductor.
- connection element such as a connector or a terminal
- a connection element such as a connector or a terminal
- a connection element such as a connector or a terminal
- ferrule can, for example, be crimped with the end of the stranded wire.
- solder the strand it is known to solder the strand to a connection element.
- Litz wires or strands that are used for high current transmission for example, in automobiles, however, regularly have a large line cross-section and a large number of individual wires, whereby the connection of the strand to the connection element is difficult. Furthermore, the joints are regularly exposed to high force effects such as vibrations, so that a particularly stable and durable attachment of the strand to the connection element is required.
- connection element a durable cohesive connection can be made quickly and comparatively inexpensive.
- the strand is placed on a flat contact surface of the connection element, flattened so that as many individual wires of the strand are in direct contact with the contact surface, and then the individual wires are welded to the contact surface.
- welds are not produced with consistent resistance and durability due to the partially disordered aligned individual wires during welding, so that welded joints not always withstand the vibrations that may be exposed to the joint, permanently.
- connection element is crimped both with the stranded wire and also welded to the stranded wire.
- the connecting element has a Crimpverianaung, in which one end of the stranded wire is introduced before crimping or before welding.
- the stranded conductor is not welded to a flat contact surface, but is attached to a circumferential circumferential side wall of the crimping recess.
- the invention is based on the knowledge that in the case of a single-sided installation of the stranded conductor to a contact surface of the connection element numerous individual wires are not connected directly to the connection element during welding, which affects the attachment strength.
- the stranded conductor according to the invention circumferential side wall of the crimping recess, the fastening strength can be improved.
- the contact resistance can be reduced by the comparatively large-scale system.
- the fact that the stranded wire is received during welding in a crimp prevents unwanted flow of conductive material to the contact surface before the individual wires of the stranded wire sufficiently adhere to the contact surface.
- the invention is based on the knowledge that for a purely frictional connection such as a crimp on a large number of individual wires of the stranded wire to be crimped considerable pressing forces are spent in order to achieve a desired plastic deformation of the individual wires over the entire pipe diameter. For this reason, pure crimp connections in stranded conductors with a large cross section are expensive to produce and not sufficiently reliable.
- the frictionally acting crimp connection and the cohesive welded connection complement each other in an optimal manner, since the individual wires already pressed against each other after the crimping process merge without considerable welding effort with only short welding time to provide a material connection without line material emerging from the crimping recess during welding.
- the stranded conductor has a diameter of more than 0.5 cm, in particular 1 cm or more and / or a strand cross-sectional area of more than 20 mm 2 , preferably more than 40 mm 2 , in particular 50 mm 2 or more.
- the stranded wire is not necessarily round and can also be formed as an oval or flat stranded wire.
- the stranded conductor can have more than 100, preferably more than 200, in particular 250 or more individual wires running side by side.
- Such a stranded wire can be designed for currents of more than 50 A, in particular 100 A or more, as they occur in automotive applications.
- the Crimpverianaung is preferably substantially circular cylindrical and adapted to the diameter of the Litzen Arthur. It may be surrounded by a thin, preferably substantially circular cylindrical jacket-shaped side wall, so that molding of the side wall onto the individual wires of the stranded conductor arranged in the recess is possible by a pressing force from outside.
- the connecting element is crimped to provide a crimp connection with the stranded line and then the finished crimp connection is welded to provide a crimp welded connection.
- the crimped connection is welded by means of ultrasound.
- the energy required for welding is generated by a high-frequency mechanical vibration, which is formed by friction between the components to be welded. This friction simultaneously breaks up an oxide layer on the surfaces of the components to be joined.
- Ultrasonic welding is characterized by a comparatively shorter welding time. Furthermore, the ultrasonic waves can be applied in a simple manner from the outside to the connection element and thus introduced into the Crimpvertiefung.
- the connecting element is crimped gas-tight with the stranded wire.
- the stranded wire is crimped so firmly with the connecting element that neither a liquid nor a gaseous medium can penetrate from the outside into the crimp, so that an oxidation between the pressed individual wires and an associated increase in the contact resistance can be imposed.
- the remaining between the crimped strands individual cavities are therefore not in fluid communication with the environment.
- a gas-tight crimp can be ensured by a sufficiently high pressing force acting on the cylindrical side wall of the crimping recess from many sides from the outside. As a result, the individual wires are uniformly pressed against each other and compacted.
- the end of the stranded wire is preferably stripped and then inserted into a preferably substantially cylindrical blind hole of the connecting element.
- the stranded wire is inserted so far into the blind hole that strike the front ends of the individual wires at the bottom of the blind hole.
- the blind hole has only one opening when using a blind hole.
- the junction can also be sealed off from environmental influences.
- the invention relates to a crimp welded connection produced according to the method according to the invention.
- Such a crimp welded joint is characterized by an end of a stranded wire engaging in a crimping recess of a connecting element, such as a connector, wherein the stranded wire and the connecting element are crimped together and welded together.
- the crimp welded joint according to the invention is first crimped during its manufacture and then welded.
- Such a crimp welded joint is characterized by virtually no voids between the individual wires and a particularly uniform compression.
- the stranded conductor is arranged for transmitting high currents and may have a cross-sectional area of more than 20 mm 2 , preferably more than 40 mm 2 , in particular 50 mm 2 or more and / or more than 100, in particular 200 or more individual wires ,
- the individual wires of the stranded wire are preferably formed of aluminum.
- the connection element in particular the side wall of the crimping recess, against which the stranded conductor rests, is formed at least partially from copper.
- connection can be sealed by means of an (optionally additional) insulation crimp in the input region of the crimping recess (liquid-tight and / or gastight).
- insulation crimp in the input region of the crimping recess (liquid-tight and / or gastight).
- at least a part of a jacket of the stranded conductor and / or a different sealing element attached to the stranded conductor may be introduced in sections into the crimping recess and crimped together.
- connection element may be formed as a connector for electrically connecting the stranded conductor with a mating connector, wherein the connector on one side of the Crimpvertiefung and / or on the opposite side has a preferred socket-shaped insertion geometry.
- the crimp-welded connection according to the invention is characterized in particular by the following properties: uniform strand compaction, gas-tight connection preferably without cavities in the crimp, improved contact resistance and / or improved surface structure of the contact.
- Fig. 2a is a perspective view of a crimp before the
- 2b is a sectional view of a stranded wire after crimping, but before welding
- Fig. 3a is a side view of a crimp welded joint according to the invention.
- 3b shows a sectional view through a crimp welded connection produced according to the method according to the invention.
- a substantially rotationally symmetrical formed connecting element 100 is shown in the form of a connector, wherein the connecting element 100 has a Crimpverianaung 22, in which engages an end 12 of a stranded wire 10.
- the crimp recess 22 is formed on a side facing the stranded conductor 10 in the form of a substantially cylindrical blind hole 24 in the connection element 100.
- the connection element 100 On the side facing away from the blind hole 24, the connection element 100 has a socket-shaped plug-in geometry 28 for connecting the connection element 100 to a mating connector (not shown).
- the blind hole 24 is surrounded by a relatively thin side wall 26, on the at Crimping radially inwardly acting pressing forces F can be applied.
- a thin side wall offers the further advantage that a better vibration introduction into the blind hole 24 is possible during welding.
- the Crimpvertiefung is not necessarily formed as a cylindrical blind hole, and it may alternatively not be rotationally symmetrical and / or formed as a through hole.
- a round cross-sectional geometry facilitates the crimping process and leads to a particularly uniform compaction of the stranded conductor. Unlike a through hole, leakage of molten conduit material during welding is prevented in a blind hole.
- An outer boundary surface of the connection element 100 may be shaped crimp-optimized.
- the outer boundary surface has a subsequent to the side wall 26 of the blind hole 24 and flared intermediate portion which merges into a transition region 29 with an enlarged diameter.
- the transition region 29 provides sufficient volume of material to permit deformation of the sidewall 26 when crimping radially inwardly.
- the conical intermediate section minimizes cracks and other damage to the material during crimping and / or welding.
- the plug-in geometry 28 is shown by way of example only as a socket.
- the plug geometry can also be formed in the form of a plug.
- the connection element may not be formed as a connector, but represent a part of a housing or another contact element.
- the stranded conductor 10 shown in FIG. 1 has a large number of conducting individual wires 14, which are surrounded by a common jacket.
- the jacket is stripped, so that the individual wires abut against the inner surface of the side wall 26 of the blind hole 24.
- at least some of the jacket and / or another sealing element can be introduced at least in sections into the blind hole and crimped in, so that an insulation crimp is formed.
- the insulation crimp can also be used in an additional crimping process additional cable-side crimp connection can be created. As a result, the connection is sealed on the cable side by the crimp and at the front end by the blind hole.
- the stranded wire 10 has about 250 individual wires.
- the cross-sectional area formed jointly by the individual wires (referred to herein as the cross-section of the stranded conductor) is approximately 50 mm 2 .
- the stranded conductor can be surrounded by a common shield and / or an outer sheath.
- the individual wires can each have an insulating coating.
- connection element 20 consists essentially of copper.
- Other, not necessarily different conductive materials are also conceivable.
- the exposed end 12 of the stranded wire 10 is inserted into the blind hole 24 until the front ends of the individual wires abut against the bottom of the blind hole 24.
- a pressing force F is radially applied from outside to the side wall 26 of the blind hole.
- the pressing force F acts on the side wall 26 from several sides, in particular peripherally, in order to achieve the most uniform possible compression of the individual wires 14 and pressing against the side wall 26.
- the individual wires 14 are deformed such that only a few cavities between the individual wires within the blind hole 24 are present.
- the pressing force F is dimensioned such that a gas-tight crimp is formed.
- FIG. 2 b particularly clearly shows the single wires 14 of the stranded conductor 10 pressed together closely.
- ultrasonic waves are introduced from the outside into the finished crimp connection.
- the individual wires 14 already close to one another merge with each other and with the inner surface of the side wall 26 of the blind hole.
- a positive connection practically without cavities between the individual wires 14 of the stranded conductor is formed, as shown in cross section in Fig. 3b and in a side view in Fig. 3a.
- a comparatively low welding energy is sufficient for this because the connection is already "pre-compressed" by the crimping.
- FIGS. 2b and 3b show particularly clearly that a mere crimp connection differs significantly from the crimp welded connection according to the invention.
- a welding method other than ultrasonic welding may be used.
- connection can easily absorb tensile forces on the stranded wire of 3 kN, while conventional welded joints are designed regularly to a maximum tensile force of about 1, 8 kN.
- the crimp weld approximately reaches the tensile strength of the remainder of the stranded wire or cable. In a pure welded joint, the pull-out force is significantly lower. LIST OF REFERENCE NUMBERS
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
- Manufacturing Of Electrical Connectors (AREA)
Abstract
Description
Claims
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/307,412 US10396472B2 (en) | 2014-04-28 | 2015-04-16 | Crimped and welded connection |
CA2944234A CA2944234C (en) | 2014-04-28 | 2015-04-16 | Crimped and welded connection |
CN201580022884.3A CN106463846B (zh) | 2014-04-28 | 2015-04-16 | 压接熔接连接结构 |
EP15718771.7A EP3138160B1 (de) | 2014-04-28 | 2015-04-16 | Crimp-schweissverbindung |
JP2016564614A JP2017514286A (ja) | 2014-04-28 | 2015-04-16 | 圧着溶接接続 |
KR1020167029395A KR102189414B1 (ko) | 2014-04-28 | 2015-04-16 | 크림프되고 용접된 연결조인트 |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102014006244.9A DE102014006244A1 (de) | 2014-04-28 | 2014-04-28 | Crimp-Schweißverbindung |
DE102014006244.9 | 2014-04-28 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2015165572A1 true WO2015165572A1 (de) | 2015-11-05 |
Family
ID=53008434
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/EP2015/000800 WO2015165572A1 (de) | 2014-04-28 | 2015-04-16 | Crimp-schweissverbindung |
Country Status (9)
Country | Link |
---|---|
US (1) | US10396472B2 (de) |
EP (1) | EP3138160B1 (de) |
JP (1) | JP2017514286A (de) |
KR (1) | KR102189414B1 (de) |
CN (1) | CN106463846B (de) |
CA (1) | CA2944234C (de) |
DE (1) | DE102014006244A1 (de) |
TW (1) | TWI676326B (de) |
WO (1) | WO2015165572A1 (de) |
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JP6066609B2 (ja) | 2012-07-30 | 2017-01-25 | 矢崎総業株式会社 | 圧着端子付きアルミ電線 |
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2014
- 2014-04-28 DE DE102014006244.9A patent/DE102014006244A1/de active Pending
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2015
- 2015-04-09 TW TW104111416A patent/TWI676326B/zh active
- 2015-04-16 US US15/307,412 patent/US10396472B2/en active Active
- 2015-04-16 KR KR1020167029395A patent/KR102189414B1/ko active IP Right Grant
- 2015-04-16 CA CA2944234A patent/CA2944234C/en active Active
- 2015-04-16 JP JP2016564614A patent/JP2017514286A/ja active Pending
- 2015-04-16 EP EP15718771.7A patent/EP3138160B1/de active Active
- 2015-04-16 CN CN201580022884.3A patent/CN106463846B/zh active Active
- 2015-04-16 WO PCT/EP2015/000800 patent/WO2015165572A1/de active Application Filing
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US3717842A (en) * | 1971-02-26 | 1973-02-20 | Perfection Electrical Prod Inc | Method of connecting aluminum wire to electrical terminals |
EP2362491A1 (de) * | 2010-02-26 | 2011-08-31 | Delphi Technologies, Inc. | Verfahren zum Verbinden einer elektrischen Leitung mit einem elektrischen Anschlusselement |
DE102013105669A1 (de) * | 2012-06-06 | 2013-12-12 | Gebauer & Griller Kabelwerke Gesellschaft M.B.H. | Verbindung eines elektrischen Kabels mit einem Kontaktteil |
Also Published As
Publication number | Publication date |
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EP3138160A1 (de) | 2017-03-08 |
CA2944234C (en) | 2020-06-23 |
TWI676326B (zh) | 2019-11-01 |
DE102014006244A1 (de) | 2015-10-29 |
CA2944234A1 (en) | 2020-03-17 |
KR20160147754A (ko) | 2016-12-23 |
EP3138160B1 (de) | 2023-07-12 |
KR102189414B1 (ko) | 2020-12-14 |
US20170069975A1 (en) | 2017-03-09 |
CN106463846A (zh) | 2017-02-22 |
CN106463846B (zh) | 2020-07-07 |
JP2017514286A (ja) | 2017-06-01 |
TW201541766A (zh) | 2015-11-01 |
US10396472B2 (en) | 2019-08-27 |
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