EP0576666B1 - Anschlussverfahren eines elektrischen kabels mit einem kern aus leichtmetall auf ein standardisiertes endstück; und endstück zur durchführung dieses verfahrens - Google Patents

Anschlussverfahren eines elektrischen kabels mit einem kern aus leichtmetall auf ein standardisiertes endstück; und endstück zur durchführung dieses verfahrens Download PDF

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Publication number
EP0576666B1
EP0576666B1 EP93904100A EP93904100A EP0576666B1 EP 0576666 B1 EP0576666 B1 EP 0576666B1 EP 93904100 A EP93904100 A EP 93904100A EP 93904100 A EP93904100 A EP 93904100A EP 0576666 B1 EP0576666 B1 EP 0576666B1
Authority
EP
European Patent Office
Prior art keywords
cable
connecting part
blind hole
around
bottom portion
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP93904100A
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English (en)
French (fr)
Other versions
EP0576666A1 (de
Inventor
Gilles Tournier
Jean-Luc Ballenghien
Serge Roques
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Airbus Group SAS
Original Assignee
Airbus Group SAS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Airbus Group SAS filed Critical Airbus Group SAS
Publication of EP0576666A1 publication Critical patent/EP0576666A1/de
Application granted granted Critical
Publication of EP0576666B1 publication Critical patent/EP0576666B1/de
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49174—Assembling terminal to elongated conductor
    • Y10T29/49181—Assembling terminal to elongated conductor by deforming
    • Y10T29/49185—Assembling terminal to elongated conductor by deforming of terminal

Definitions

  • the invention relates to a method for connecting an electric cable comprising a core of a light metal such as aluminum, coated with an insulating sheath, to a standardized end element such as a connector contact.
  • the invention also relates to a connecting piece usable in the implementation of this method.
  • the invention applies to all industries using long lengths of electric cables and for which financial and / or weight savings are desired.
  • the aeronautical industry is one of these industries.
  • the sensitivity of aluminum to chemical attack requires, unlike copper, to make the connection between the aluminum cable and the copper contact tight, in order to isolate the aluminum from the ambient environment.
  • document EP-A-0 018 863 proposes to interpose a tubular sleeve between a bare wire and an electrical connection end-piece.
  • the invention specifically relates to a method for connecting an electric cable comprising a light metal core such as aluminum on a standardized end element such as an electrical contact ensuring a stable and reliable electrical connection, a additional mechanical strength on the insulating sheath and a seal vis-à-vis the external environment, without complicating the implementation, without making obsolete the standardized connectors currently used and preserving as much as possible the use of existing tools.
  • compaction makes it possible to introduce the end of the cable on which the connection piece has been fixed into the standard end element and to crimp this end in this element, in the same way as if the electric cable were directly mounted in the standard end element.
  • connection piece may be formed directly by the end element, so that no subsequent crimping is necessary.
  • a connecting piece which has at least one frustoconical outer surface around the bottom part and around the entry part of the blind hole.
  • connection piece which comprises, between the bottom part and the entry part of the blind hole, a frustoconical tubular part of constant thickness, the surface tapered outer surface forming a single tapered surface with the outer surface of the tapered tubular part.
  • connection piece When the core of the cable is formed of strands assembled into strands and delimiting inter-strand spaces between them, a connection piece is preferably used, the frustoconical tubular part of which has a section substantially equal to that of said inter-strand spaces.
  • the radial compaction of the connecting piece can be carried out in different ways, this compaction is advantageously carried out by force passage through a calibrated tool. For this purpose, it is possible to pull on a rod-shaped part formed beyond the blind hole in the connection piece. This rod-shaped part is then cut before the connecting piece is introduced and crimped into the end element.
  • the subject of the invention is also a connecting piece as defined by the characteristics of claim 9.
  • FIG. 1 there is shown a connecting piece 10 in the state it initially occupies before mounting at the end of an electrical cable 12 formed of a core 14 of a light metal such as aluminum and an insulating sheath 16 covering the core 14, with the exception of its stripped end illustrated in FIG. 1.
  • the mounting of the connecting piece 10 at the end of the cable 12 is intended to allow the connection of the latter on a standardized end element such as a contact of a standardized connector.
  • this connection must be such that it provides a mechanical traction connection between the standard end element and the cable core as well as between the standard end element and the sheath.
  • this connection must be sealed, in order to protect the exposed part of the light metal core 14 from the environment.
  • the connecting piece 10 is made of an electrically conductive material and having good cold deformation capabilities, such as annealed brass covered with a protective layer of tin or silver which is very malleable and electrically conductive.
  • the connecting piece 10 has a symmetry of revolution about a longitudinal axis and it has a recessed part 10a adapted to receive the partially stripped end of the electric cable 12 and a solid part 10b, in the form of a cylindrical rod, designed to allow pulling this part through calibrated tools such as dies. It should be noted that if the compaction is carried out by other means, the solid part 10b can be eliminated.
  • the hollowed out part 10a of the connecting piece 10, which constitutes the essential part thereof, is turned upwards in FIG. 1.
  • This hollowed out part has an outer surface 18 of frustoconical shape, the diameter of which increases progressively from the solid part 10b to its end.
  • the external surface 18 can for example form an angle of approximately 3 ° with the longitudinal axis of the connecting piece 10.
  • a stepped blind hole 20 is formed coaxially in the recessed part 10a of the part 10, so as to be able to receive the partially stripped end of the electric cable 12.
  • the stepped blind hole 20 comprises, starting from the bottom, a cylindrical bottom portion 22, a frustoconical intermediate portion 24 and a cylindrical inlet portion 26 of larger diameter than the bottom portion 22.
  • the frustoconical portion 24 is separated of the bottom part 22 by a shoulder 27 and it forms with the longitudinal axis of the part an angle equal to the angle formed with this same axis by the outer surface 18. In the example considered, this angle is therefore substantially equal to 3 °.
  • the frustoconical tubular part 28 formed in the part 10 around the frustoconical part 24 of the blind hole 20 has a constant thickness.
  • the inlet portion 26 is located in the immediate extension of the frustoconical portion 24 and has a diameter equal to the largest diameter of this frustoconical portion.
  • the diameter of the bottom portion 22 of the blind hole 20 is substantially equal to the outside diameter of the core 14 of the electrical cable 12 and the diameter of the inlet portion 26 is substantially equal to the outside diameter of the insulating sheath. 16 of the cable. This characteristic makes it possible to engage the non-stripped portion of the cable 12 adjacent to the stripped end portion of this cable in the inlet portion 26 of the blind hole 20 and to penetrate the end of the stripped end portion of the cable 12 into the bottom portion 22 of the blind hole 20, as illustrated in FIG. 2B.
  • the stripped end portion of the cable 12 passes through the frustoconical portion 24 and partially penetrates the bottom part 22, so that its end is located at a certain distance from the bottom of the blind hole 20.
  • the core 14 of the electric cable 12 is formed by a set of strands 30 assembled in a strand and whose initial section is illustrated 5 in FIG. 3A. As this figure shows, each individual strands 30 of the core 14 then have a circular shape in section and inter-strand spaces 31 exist between the adjacent strands of the strand.
  • this piece is placed in a tool formed by two juxtaposed dies 32 and 34. More precisely , the solid rod-shaped part of the connecting piece 10 is successively introduced into the dies 34 and 32, so that the die 34 which has the largest internal diameter is turned towards the hollow part of the piece 10.
  • the inside diameter of the die 34 is substantially equal to the outside diameter of the insulating sheath 16 of the cable 12, while the inside diameter of the die 32, of smaller section, is substantially equal to the initial outside diameter of the core 14 of the cable electric.
  • the inverted cone 22a which is thus formed in the bottom part of the blind hole 20 of the part 10 achieves an effective mechanical connection between the core 14 of the cable 12 and the connecting piece 10.
  • the connection mechanical obtained between the core of the cable 14 and the connecting piece 10, allows the cable to be trapped during the operating process of compacting the core and the insulated cable.
  • the frustoconical tubular part 28 of the piece 10 passes through the die 34.
  • This part of the piece 10 is thus given the shape of a cylindrical tube 28a (FIGS. 2E and 2F) whose outside diameter is substantially equal to the initial outside diameter of the core 14 of the electric cable and whose inside diameter depends on the thickness initially presented by the part 10 in this zoned.
  • This thickness is advantageously chosen so that the section of the frustoconical tubular part 28 is substantially equal to the initial section of all the inter-strand spaces 31.
  • FIG. 3B illustrates a section of the core 14 of the cable 12 produced in this zone after the compaction has been carried out.
  • the traction exerted on the solid part 10b in the form of a rod of the connecting piece 10 continues until the open end of this piece arrives at the level of the larger die 34 diameter.
  • the die 32 of smaller diameter is then slightly beyond the end of the sheath 16 adjacent to the stripped part of the cable.
  • the radial compaction of the connecting piece 10 is continued by the die 32 around the frustoconical part 24 of the hole 20 and by the die 34 around the cylindrical part 26 of this hole.
  • the end of the frustoconical surface 18 initially surrounding the entry portion 26 takes a cylindrical shape and a diameter is substantially equal to the outside diameter of the sheath 16.
  • the cone initially present on the external surface of the part 10 is reversed and transferred to the internal surface of this part, that is to say that the initially cylindrical part 26 takes a frustoconical shape 26a whose diameter decreases progressively to the end of part 10, as illustrated in FIG. 2F.
  • a mechanical connection is thus created between the connecting piece 10 and the insulating sheath 16. Thanks to this mechanical connection, any tensile force exerted on the insulating sheath is automatically transmitted to the connecting piece 10.
  • the solid rod-shaped part of the connecting piece 10 is cut slightly beyond the bottom of the blind hole 20, as illustrated in FIG. 2G.
  • a cable 12 is then available, the end of which is embedded in a closed tubular piece 10 and crimped in a sealed manner on the end of the sheath 16, so that the stripped end of the core 14 of the cable, made of a light metal easily oxidizable, not in direct contact with the outside atmosphere.
  • this piece 10 both on the sheath 16 and on the core 14 ensures an effective mechanical connection which uses both the mechanical resistance of the core and that of the cable sheath when a tensile force is exerted on the latter.
  • the dimensions of the end of the cable are identical to those of a partially stripped cable which would not be embedded in the part 10, which makes it possible to envisage the connection of this cable to an end element such as '' a standardized contact, using existing tools. It should be noted that this essential characteristic is obtained without the effective cross-section of the cable being appreciably reduced in the connection zone, since the radial compaction of the core of the cable inside the part 10 is carried out so that the shape presented in section by each of the strands 30 of the cable is modified (FIG. 3B) and the spaces 31 initially present between these strands are practically eliminated, without the section of each of the strands being really modified.
  • the compaction of the core 14 of the cable allows, taking into account the constituent and protective materials of the part 10, to overcome the constraints of differential expansion.
  • FIG. 2H there is illustrated the introduction of the end of a cable 12 embedded in accordance with the invention in a part 10, inside the female part 36 of a standardized contact 40.
  • the end of the part 10 appears opposite an insertion control hole 42 passing through the female part 36.
  • a standard crimping pliers can then be used in a conventional manner in order to crimp the female part 36 of the contact 40 on the part 10, as illustrated in FIG. 2I.
  • connection method according to the invention can be used for standard end elements different from the contacts 40 of connectors illustrated in FIGS. 2H and 2I.
  • These standardized end elements can in particular be constituted by lugs of different types, contacts of relay sockets, contacts of module modules, contacts of ground modules, etc.
  • the radial compaction obtained in the embodiment represented by force passage through calibrated tools such as dies can be replaced by any equivalent process such as methods of rolling by balls or rolls, methods of magnetoforming or compaction methods in tools with movable jaws. Consequently, the solid rod-shaped part 10b of the part 10 can, in certain cases, be eliminated. The cutting step of this part then disappears.
  • connection method according to the invention it is also possible to use the connection method according to the invention to directly fix the standard end element to the end of the cable.
  • shapes comparable to those which have been described for the hollowed out part 10a of the part 10 are provided directly on the end element to which the cable is to be fixed.

Landscapes

  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Mechanical Coupling Of Light Guides (AREA)
  • Connector Housings Or Holding Contact Members (AREA)

Claims (11)

  1. Verfahren zur Verbindung eines elektrischen Kabels (12) mit einer Seele (14) aus Leichtmetall, die mit einem Isolierbezug (16) beschichtet ist, auf einem normierten Endelement (40), umfassend die folgenden Schritte:
    mindestens teilweise Einführung eines freigelegten Endteiles in einen Grundteil (22) eines Sacklochs (20), das in einem Verbindungsstück (10) gebildet ist, welches aus einem deformierbaren und elektrisch leitenden Material gefertigt ist, und eines benachbarten nicht-freigelegten Teils des Kabels in einen Eingangsteil (26) des Sackloches mit größerem Durchmesser als der Grundteil;
    Einführung des freigelegten Endteiles des Kabels (12), das in dem Verbindungsstück (10) aufgenommen ist, in das Innere des normierten Endelementes (40); und
    Einfassen des normierten Endelementes (40) auf dem Verbindungsstück (10);
    dadurch gekennzeichnet, daß das Verbindungsstück eine Dicke aufweist, die mindestens teilweise um das Grundteil (22) und um den Eingangsteil des Sackloches (20) gegen ein offenes Ende des letzteren zunimmt, und daß der Einführung des freigelegten Endteiles des Kabels (12), das in dem Verbindungsstück (10) aufgenommen ist, in das Innere des normierten Endelementes (40) eine radiale Verdichtung des Verbindungsstückes (10) vorausgeht, um damit ihm um den Eingangsteil des Sackloches (20) herum einen ersten äußeren Durchmessers im wesentlichen gleich dem äußeren anfänglichen Durchmesser der Seele des Kabels zu geben und auf dem Rest seiner Länge einen zweiten äußeren Durchmesser im wesentlichen gleich zum anfänglichen äußeren Durchmesser der Seele des Kabels zu geben.
  2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß ein Verbindungsstück (10) verwendet wird, das mindestens eine kegelstumpfförmige äußere Fläche (18) um den Grundteil (22) und um den Eingangsteil (24) des Sacklochs (20) aufweist.
  3. Verfahren nach Anspruch 2, dadurch gekennzeichnet, daß ein Verbindungsstück verwendet wird, das einen kegelstumpfförmigen Röhrenteil (28) verwendet mit konstanter Dicke zwischen dem Grundteil und dem Eingangsteil des Sackloches, wobei die äußere kegelstumpfförmige Fläche (18) sich auf diesem Röhrenteil fortsetzt.
  4. Verfahren nach Anspruch 3, angewendet auf die Verbindung eines Kabels (12), dessen Seele (14) aus Drähten (30) gebildet ist, die als Litze zusammengefügt sind und wobei die Räume zwischen den Drähten (31) begrenzt sind, dadurch gekennzeichnet, daß ein Verbindungsstück (10) verwendet wird, dessen kegelstumpfförmiges Röhrenteil einen Querschnitt aufweist, der im wesentlichen gleich ist zu demjenigen der Räumen zwischen den Drähten (31).
  5. Verfahren nach einem der vorangegangenen Ansprüche, dadurch gekennzeichnet, daß eine radiale Verdichtung des Verbindungsstückes (10) durch Durchlaufen eines kalibrierten Werkzeuges (32, 34) unter Zwang ausgeführt ist.
  6. Verfahren nach Anspruch 5, dadurch gekennzeichnet, daß das Durchlaufen unter Zwang ausgeführt wird durch Ziehen eines Teiles in Form eines Bolzens, der über dem Sackloch (20) in dem Verbindungsstück gebildet ist.
  7. Verfahren nach Anspruch 6, dadurch gekennzeichnet, daß nach der radialen Verdichtung des Verbindungsstückes (10) der Teil in Form eines Bolzens abgetrennt wird.
  8. Verfahren nach einem der vorangegangenen Ansprüche 1 bis 5, dadurch gekennzeichnet, daß als Verbindungsstück direkt das Endelement (40) verwendet wird.
  9. Verbindungsstück (10) aus einem deformierbaren und elektrisch leitenden Material, das rotationssymmetrisch um eine Längsachse ist und entlang dieser Achse ein abgestuftes Sackloch (20) aufweist, das einen Grundteil (22) und einen Eingangsteil (26) mit größerem Durchmesser als das Grundteil (10) umfaßt, wobei das Verbindungsstück vorgesehen ist, um durch radiale Verdichtung am teilweise freigelegten Ende eines elektrischen Kabels (12) mit einer Seele (14) aus Leichtmetall und beschichtet mit einem Isolierbezug (16) angebracht zu werden, um eine Verbindung des Kabels mit einem normierten Endelement (40) zu ermöglichen, dadurch gekennzeichnet, daß das Verbindungsstück (10) eine Dicke aufweist, die mindestens teilweise um das Grundteil (22) und um den Eingangsteil des Sackloches (20) gegen das offene Ende des letzteren zunimmt.
  10. Verbindungsteil nach Anspruch 9, dadurch gekennzeichnet, daß es mindestens eine äußere kegelstumpfförmige Fläche (18) um den Grundteil (22) und um den Eingangsteil (26) des Sackloches (22) aufweist.
  11. Vrbindungsteil nach Anspruch 10, dadurch gekennzeichnet, daß es einen kegelstumpfförmigen Röhrenteil (28) aufweist mit einer konstanten Dicke zwischen dem Grundteil und dem Eingangsteil des Sackloches (20), wobei die kegelstumpfförmige äußere Fläche (18) sich auf diesem Röhrenteil fortsetzt.
EP93904100A 1992-01-21 1993-01-20 Anschlussverfahren eines elektrischen kabels mit einem kern aus leichtmetall auf ein standardisiertes endstück; und endstück zur durchführung dieses verfahrens Expired - Lifetime EP0576666B1 (de)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
FR9200589A FR2686459B1 (fr) 1992-01-21 1992-01-21 Procede de raccordement d'un cable electrique comportant une ame en metal leger sur un element d'extremite normalise, et piece de raccordement pour la mise en óoeuvre de ce procede.
FR9200589 1992-01-21
PCT/FR1993/000055 WO1993014535A1 (fr) 1992-01-21 1993-01-20 Procede de raccordement d'un cable electrique comportant une ame en metal leger sur un element d'extremite normalise, et piece de raccordement pour la mise en ×uvre de ce procede

Publications (2)

Publication Number Publication Date
EP0576666A1 EP0576666A1 (de) 1994-01-05
EP0576666B1 true EP0576666B1 (de) 1996-05-08

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EP93904100A Expired - Lifetime EP0576666B1 (de) 1992-01-21 1993-01-20 Anschlussverfahren eines elektrischen kabels mit einem kern aus leichtmetall auf ein standardisiertes endstück; und endstück zur durchführung dieses verfahrens

Country Status (7)

Country Link
US (1) US5408743A (de)
EP (1) EP0576666B1 (de)
CA (1) CA2106297C (de)
DE (1) DE69302525T2 (de)
ES (1) ES2089796T3 (de)
FR (1) FR2686459B1 (de)
WO (1) WO1993014535A1 (de)

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Also Published As

Publication number Publication date
ES2089796T3 (es) 1996-10-01
US5408743A (en) 1995-04-25
FR2686459A1 (fr) 1993-07-23
EP0576666A1 (de) 1994-01-05
WO1993014535A1 (fr) 1993-07-22
CA2106297C (fr) 2002-10-22
FR2686459B1 (fr) 1996-07-05
DE69302525D1 (de) 1996-06-13
CA2106297A1 (fr) 1993-07-22
DE69302525T2 (de) 1996-09-26

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