EP1688966B1 - Electrical flat cable for motor vehicles - Google Patents

Electrical flat cable for motor vehicles Download PDF

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Publication number
EP1688966B1
EP1688966B1 EP05012641.6A EP05012641A EP1688966B1 EP 1688966 B1 EP1688966 B1 EP 1688966B1 EP 05012641 A EP05012641 A EP 05012641A EP 1688966 B1 EP1688966 B1 EP 1688966B1
Authority
EP
European Patent Office
Prior art keywords
conductor
aluminium
flat strip
aluminum
strip conductor
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.)
Active
Application number
EP05012641.6A
Other languages
German (de)
French (fr)
Other versions
EP1688966A1 (en
Inventor
Rolf Stracke
Heinz-Georg Gottschlich
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.)
Auto Kabel Management GmbH
Original Assignee
Auto Kabel Management GmbH
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 Auto Kabel Management GmbH filed Critical Auto Kabel Management GmbH
Priority to EP11168031.0A priority Critical patent/EP2383840B1/en
Priority to EP05012641.6A priority patent/EP1688966B1/en
Priority to US11/815,145 priority patent/US20080194127A1/en
Priority to CN2006800039024A priority patent/CN101128888B/en
Priority to PCT/EP2006/050187 priority patent/WO2006051121A1/en
Priority to ES06708011T priority patent/ES2421156T3/en
Priority to CN201510674402.4A priority patent/CN105355294A/en
Priority to AT06708004T priority patent/ATE456177T1/en
Priority to PCT/EP2006/050648 priority patent/WO2006082231A2/en
Priority to ES13167659.5T priority patent/ES2568486T3/en
Priority to US11/813,711 priority patent/US7598456B2/en
Priority to EP06708011.9A priority patent/EP1844478B9/en
Priority to PCT/EP2006/050659 priority patent/WO2006082238A1/en
Priority to DE502006005976T priority patent/DE502006005976D1/en
Priority to EP06708004A priority patent/EP1844532B1/en
Priority to US11/815,144 priority patent/US7687721B2/en
Priority to EP13167659.5A priority patent/EP2662866B1/en
Publication of EP1688966A1 publication Critical patent/EP1688966A1/en
Application granted granted Critical
Publication of EP1688966B1 publication Critical patent/EP1688966B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/08—Flat or ribbon cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H01B13/14—Insulating conductors or cables by extrusion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/0009—Details relating to the conductive cores
    • H01B7/0018—Strip or foil conductors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/02—Disposition of insulation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/08—Flat or ribbon cables
    • H01B7/0823—Parallel wires, incorporated in a flat insulating profile
    • 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
    • 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
    • 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
    • Y10T29/49204—Contact or terminal manufacturing

Definitions

  • the invention relates generally to a flat electrical conductor for motor vehicles comprising at least one extruded aluminum conductor of aluminum and of profiled cross-section, wherein the aluminum conductor is made of Al 99.5% or pure or alloys thereof.
  • the invention generally also relates to a method for producing such a flat electrical conductor for motor vehicles and to the use of such a flat electrical conductor in a motor vehicle.
  • ribbon cable As a battery cable in motor vehicles. So shows, for example, the DE 4 210 202 A1 a ribbon cable for use as a battery cable.
  • This ribbon cable is formed by extruding a battery cable made of a stranded wire.
  • the ribbon cable described is a copper cable and has the above-mentioned disadvantages.
  • This ribbon cable for use in vehicle construction is also known.
  • This ribbon cable can be formed from a plurality of juxtaposed bands. These bands can be made of copper or of e-aluminum.
  • the sheath is made of laminated aluminum polyethylene with an aluminum tape and an insulator such as polyethylene terephthalate. Further, fasteners are provided to secure the ribbon conductor to the vehicle.
  • the ribbon cables shown use only aluminum.
  • the conductors are made of extruded aluminum wires. During extrusion, however, warps in the flat strip, so that subsequent processing steps can be automated only with considerable effort. Also, conventional aluminum cables with a cross section greater than 80mm 2 can no longer be wound onto a coil after they have been machined because the aluminum used is not soft enough.
  • the aluminum conductor is annealed so that it allows an elongation of at least 30%.
  • Both aluminum bands and aluminum sheets can be used. In the production of aluminum this is mostly, after it has been rolled or extruded, wound on a coil (reel, reel). It has now been recognized that the aluminum strip wound on the coil can then be easily processed into a ribbon conductor if the aluminum strip has previously been annealed. After the aluminum strip has been annealed, it can simply be unwound from the coil and processed further with little effort. Due to the fact that the soft annealed aluminum can easily be wound up and unwound on coils, the flat conductor can be manufactured by the meter.
  • an aluminum sheet After an aluminum sheet has been rolled, it preferably has widths between 50 cm and several meters. These wide aluminum sheets are wound up on coils and thus transported. For ribbon conductors in motor vehicles bandwidths of preferably 10 to 40 mm are needed. Therefore, it is proposed that the aluminum conductor is formed of a coil wound aluminum sheet divided into individual conductors.
  • the wide aluminum sheet is unwound from the coil and cut in a subsequent processing step. After cutting, the individual narrow individual conductors can be reeled on reels.
  • the cutting can be carried out by means of cutting, sawing, welding, laser cutting, water jet cutting or other chip-removing or non-cutting methods of separation. Here are particularly advantageous cutting with knives, laser or water jets.
  • the aluminum conductor is produced from an annealed aluminum semi-finished product, for example a cable, a strand or a profile, by means of extrusion molding.
  • the step of dividing the flat strip is omitted.
  • the ribbon conductors can be profiled as desired. Preference is given to rectangular, square or U profiles
  • the partial use of AL is 99.5% or pure, e.g. AL 99.7%, AL or alloys thereof is advantageous for use as a ribbon conductor.
  • the aluminum conductor has a production state of 0.
  • This is the manufacturing state of the soft annealed semi-finished aluminum. This state allows movement of the ribbon conductor in all directions. The ribbon conductor thus formed can thus be easily bent, and a virtually arbitrarily shaped cable harness can be made with it.
  • the state 0 also causes a good conductivity of the material. State 0 is the mechanical properties of the semifinished product described in DIN EN 485-2.
  • the aluminum used in the ribbon conductor has a conductivity of 30 to 37 m / (ohm * mm 2 ).
  • the winding and unwinding of the aluminum strip on a coil, the coiling of the cut or extruded ribbon conductor on a reel and the subsequent unwinding of the reel for feeding to an extruder is preferably simplified in that the ribbon conductor according to the invention allows an elongation of at least 30% , This elongation, which is preferably more than 35%, allows on the one hand the easy winding and unwinding and on the other hand the shaping of cable strands in any spatial directions.
  • the aluminum conductor has a tensile strength of about 60 to 80 N / mm 2 +/- 50%. This tensile strength allows for an automatic processing, in particular the extrusion with an insulator and on the other hand a simple bending to form a cable harness with bends in all directions.
  • connection bolts can be arranged at any point along the ribbon conductor.
  • the connection bolts allow easy tapping of the electrical potential along the ribbon conductor for connection of electrical loads or measuring points within the motor vehicle.
  • a center support point may be formed as a foreign start support point. It can be realized at any point in the vehicle, a foreign launch base.
  • the connecting bolt is at least partially formed of brass or alloys thereof.
  • copper, aluminum, steel or other conductive materials for the connection bolt are possible.
  • the connecting bolt is contacted by means of a friction welding process with the ribbon conductor. It is preferred that torsional friction welding or multi-orbital friction welding be used. Friction heat and pressure are generated by friction welding, so that the aluminum oxide layer of the ribbon conductor is broken, and the contact resistance of the electrical contact between the connection pin and the ribbon conductor is reduced. In friction welding, a penetration depth of less than 3 mm, preferably 1 mm, is preferably achieved.
  • connection bolt Since the material of the ribbon conductor is very soft, friction welding must be carried out with a suitable pressure, so that the connection bolt is not driven directly through the ribbon conductor.
  • the connecting bolt is preferably provided with a polygon, preferably with a square, which serves on the one hand as a tool holder for the friction welding and on the other hand allows a secure attachment of this in a later encapsulation.
  • connection bolt is arranged between the ends of the flat conductor.
  • a connecting bolt for tapping the potential for electrical consumers or for attaching a measuring point can be arranged anywhere along the ribbon conductor at any point.
  • the connection bolts can be arranged on any surface of the ribbon conductor.
  • the terminal bolts are arranged on the wide surfaces of the ribbon conductor. This also allows the realization as a foreign launch base.
  • the cross section of the ribbon conductor is at least 16 mm 2 .
  • a ratio of 1 to 5 between height and width for example, a height of 4 mm and a width of 20 mm is particularly advantageous.
  • the aluminum flat strip conductors known from DIN 43670 are formed from an aluminum core and a cladding made of copper and therefore have the known disadvantages of copper cables. To obtain the copper cladding, the aluminum ribbon conductors must be subjected to a further electrochemical processing step.
  • the invention proposes a method in which at least one previously annealed aluminum semi-finished product is unwound from a coil in which from the unwound aluminum semi-finished by dividing the aluminum semi-finished an aluminum conductor is formed, the aluminum conductor allows an elongation of at least 30%, in which after cutting the aluminum conductors on one Coil is wound and wherein the aluminum conductor is unwound from the coil and coated with an insulator.
  • the aluminum semi-finished product may be an aluminum sheet or strip. These are supplied by an aluminum manufacturer in widths between 50 cm and several meters. The wide aluminum sheet is already annealed and is provided wound on a coil.
  • the aluminum sheet is unwound and cut into flat ribbon conductors with the appropriate width.
  • cutting cutting with knives, a laser or a water jet is preferred.
  • the aluminum semi-finished product may be an aluminum cable or a stranded wire. This is extruded, so that forms a flat conductor.
  • the divided aluminum conductor is wound onto a coil. This winding is particularly easy with the soft annealed aluminum and affects only slightly the further processability of the ribbon conductor.
  • the aluminum conductor wound on the coil is unwound and coated with an insulator. This can be done by extruding, painting, laminating, overmolding or other methods of insulating conductors.
  • the ribbon conductor is first introduced by means of rollers via a guide bead to the extruder.
  • the ribbon conductor is cut to length after isolation. It is also possible that the ribbon conductor is rewound after isolation. As a result, a transport of the conductor is facilitated after isolation.
  • a cable harness according to another advantageous embodiment can be formed by bending the ribbon conductor in all directions. Bending is particularly easy due to the low hardness and high elongation achieved by soft annealing. It is possible to produce almost any desired shapes of cable strands with the flat-band conductor according to the invention.
  • connecting bolts be applied to the ribbon conductor by means of material joining after cutting to length.
  • the insulator be separated by means of suitable methods, such as cutting, lasers, etc. and attached to the stripped points of the connecting bolt.
  • Joining techniques may preferably be welding, in particular rotational friction welding, multi-orbital welding, torsional ultrasonic welding or laser welding.
  • Another object of the invention is the use of a soft annealed aluminum conductor as a ribbon conductor in a motor vehicle.
  • a ribbon conductor produced by a method described above or a ribbon conductor having the properties described above is proposed.
  • Figure 1A shows a cross section of a flat electrical conductor 1 which is formed of an aluminum conductor 2 and 4 an insulation.
  • the aluminum conductor 2 is made of a soft-annealed aluminum strip.
  • the aluminum preferably has a state of 0. This property gives the aluminum a good conductance and also good properties for absorbing vibrations in vehicle crashes and for bending the ribbon conductor in the assembly of cable strands. A conductance of 34 to 36 m / ohm mm 2 is preferred here.
  • the aluminum is further processed to have a tensile strength of 60 to 80 N / mm 2 , more preferably 75 N / mm 2 . Furthermore, the elongation is preferably more than 30%, particularly preferably 35%, resulting in good processability.
  • the aluminum core 2 preferably has a cross section of 80mm 2 .
  • the height H is preferably 4 mm and the width B is preferably 20 mm. Also preferred is a ratio of 1: 5 between height and width.
  • the insulator material 4 is preferably a polyethylene or other conventional insulator material, for example PVC, PUR, laminate or lacquer.
  • This insulator material 4 can be applied to the aluminum conductor 2, for example by means of extrusion, preferably by means of tube extrusion. Other isolation methods are also possible.
  • the aluminum conductor 2 has no torsions, resulting in a good processability. Furthermore, the elongation due to the soft annealing of the aluminum conductor 2 is above a strain value of 25%.
  • FIG. 1B shows a cross section of a ribbon conductor 1 with two aluminum conductors 2.
  • the aluminum conductors 2 have a U-profile and a rectangular profile.
  • Figure 1C shows a further cross section of a ribbon conductor 1.
  • a ribbon conductor 1 In a U-profile of a first aluminum conductor 2, two layered rectangular aluminum conductors 2 are arranged.
  • FIG. 2 shows a first manufacturing step in the manufacture of a flat strip conductor 1 according to the invention. Shown is a wound on a coil 6 aluminum sheet 8. This aluminum sheet 8 preferably has a thickness of 2 to 10 mm, more preferably 4 mm. The aluminum sheet 8 is factory annealed, resulting in the above-mentioned properties. The unwound from the coil 6 aluminum sheet 8 preferably has a width of 2 m. The aluminum sheet 8 is fed to a dicing device 10. In the dicing device 10, the aluminum sheet 8 is divided into the aluminum conductors 2. Here, the cutting can be done by knives. It is also possible to divide the aluminum sheet 8 by laser or by water jet cutting or sawing. All other non-cutting or span separating methods are also possible.
  • the aluminum conductors 2 are each reeled on reels 12. Due to the high extensibility of this coiling is readily possible. The uncoiling of the reels 12 is then also easily possible. The individual reels 12 can be easily transported and allow easy handling in the manufacturing process.
  • FIG. 3 shows the extrusion of the individual aluminum conductors 2 in a compact ribbon conductor 1.
  • each individual aluminum conductor 2 can first be isolated and then joined with the others to form a single ribbon conductor 2.
  • the aluminum conductor 2 is unwound from the reel 12, fed to the extruder 16 via at least one bead 14. It is also possible to supply a plurality of aluminum conductors 2 to the extruder 16 and to add them in one step to an insulated ribbon conductor 1.
  • the ribbon conductor 1 is recharged onto a reel 18.
  • the bead 14 bends caused by the reeling in the aluminum conductor 2 are compensated, and a uniform feed to the extruder 16 is made possible.
  • the extruder 16 is brought by suitable guides the aluminum conductor 2 to the extrusion head.
  • an insulator material can be extruded onto the aluminum conductor 2.
  • the flat conductor 1 is either reeled after extrusion on another reel 18 or assembled directly. The assembly can be done by cutting to length, bending, contacting or other processing steps.
  • the ribbon conductor 1 can be rewound and assembled again. Here it can first be cut to the desired length and then bent with suitable bending devices in a harness.
  • the soft aluminum bending is associated with relatively little effort.
  • FIG. 4 shows a connection pin 20 as a flat conductor support point.
  • the bolt 20 is preferably made of brass, steel, copper or other conductive materials.
  • the connecting bolt 20 has at its end an edged formation 24, preferably four-edged.
  • the molding 24 can be used as a tool base, in particular as a stop of a friction welding tool.
  • FIG. 5 shows a connection bolt 20 which is applied to a ribbon conductor 1.
  • the connecting bolt 20 is welded onto the flat conductor 1 by means of a welding or soldering process.
  • the penetration depth of the connecting bolt 20 in the flat conductor 1 when contacting is preferably at most 1 mm.
  • the polygonal shape 24 may serve as a holding element for subsequent encapsulation or potting after welding or soldering.
  • the arrangement of the connecting bolt 20 on the ribbon conductor 1 can at any point take place and is not necessarily only at the end of the ribbon conductor 1. A center tap, especially in the form of a Fremdstartstützengs is possible.
  • the connecting bolt When using thin sheets or strips, it can be problematic to weld the connecting bolt onto the end face.
  • the end face can be compressed with the aid of a plunger. The face can then be adjusted round or square to a shape. It is also possible to enclose the end face by means of a sleeve in order thereby to provide an enlarged contact surface for the connecting bolt.
  • connection of the connecting bolt in the region of the end face according to Fig. 6 possible.
  • the ribbon conductor 1 is bent for this purpose in the region of the end face. Any angular position is possible. In the present case, the bend is such that the broad area of the flat-band conductor 1 in the area of the end face is substantially perpendicular to the course of the flat-band conductor 1 in the region lying in front of it.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Windings For Motors And Generators (AREA)
  • Insulated Conductors (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Cable Accessories (AREA)
  • Coupling Device And Connection With Printed Circuit (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)
  • Processing Of Terminals (AREA)

Abstract

The ribbon conductor is made of aluminum with a profiled cross-section. The conductor is formed from soft-annealed aluminum tape that is unwound from at least one coil. The tape may be unwound from one coil and divided into individual conductors. Extrusion presses may be used to form the ribbon conductor. An independent claim is included for a method of manufacturing a ribbon conductor.

Description

Die Erfindung betrifft allgemein einen elektrischen Flachbandleiter für Kraftfahrzeuge umfassend wenigstens einen mittels Strangpressen gebildeten Aluminiumleiter aus Aluminium und mit profiliertem Querschnitt, wobei der Aluminiumleiter aus Al 99,5% oder reiner oder Legierungen davon gebildet ist. Die Erfindung betrifft im Allgemeinen auch ein Verfahren zur Herstellung eines solchen elektrischen Flachbandleiters für Kraftfahrzeuge und die Verwendung eines solchen elektrischen Flachbandleiters in einem Kraftfahrzeug.The invention relates generally to a flat electrical conductor for motor vehicles comprising at least one extruded aluminum conductor of aluminum and of profiled cross-section, wherein the aluminum conductor is made of Al 99.5% or pure or alloys thereof. The invention generally also relates to a method for producing such a flat electrical conductor for motor vehicles and to the use of such a flat electrical conductor in a motor vehicle.

Heutzutage ist es üblich, elektrische Flachbandleiter aus Kupfer oder E-Aluminium, beziehungsweise AlMgSi 0,5 herzustellen. So wird im Aluminium Taschenbuch, Band 3, 15. Auflage, Aluminium Verlag, Seite 632 die Verwendung dieser Materialien vorgeschlagen.Nowadays, it is common to produce electrical ribbon conductors made of copper or E-aluminum, or AlMgSi 0.5. So is in the Aluminum Paperback, Volume 3, 15th Edition, Aluminum Verlag, page 632 proposed the use of these materials.

Im Kraftfahrzeugbau, beispielsweise im PKW-Bau, LKW-Bau, Schiffsbau, Eisenbahnbau, wird herkömmlicherweise für die elektrische Beschaltung innerhalb der Fahrzeuge Kupfer aufgrund seiner hohen Leitfähigkeit verwendet. Jedoch ergibt sich der Nachteil, dass Kupferkabel aufgrund der hohen Rohstoffpreise teuer sind. Vor allem bei Leitern mit großem Querschnitt und großen Längen ist Kupfer auch aufgrund seines hohen Gewichtes nachteilig.In motor vehicle construction, for example in passenger car construction, truck construction, shipbuilding, railway construction, copper is conventionally used for the electrical wiring within the vehicles because of its high conductivity. However, there is the disadvantage that copper cables are expensive due to the high cost of raw materials. Especially for ladders with a large cross-section and long lengths copper is also disadvantageous because of its high weight.

Sowohl im PKW-Bau, als auch im LKW-Bau wird seit langem versucht, das Gewicht der Fahrzeuge zu reduzieren, um hierdurch u.a. Kraftstoff sparen zu können. Bei der Verwendung von Kupferkabeln ist eine Gewichtsreduzierung jedoch nur durch Verkleinerung der Kabelquerschnitte möglich, was zu Problemen bei der Stromtragfähigkeit der Kabel führt.Both in car construction, as well as in truck construction has been trying for a long time to reduce the weight of the vehicles in order to thereby save fuel, among other things. When using copper cables, however, weight reduction is only possible by reducing the cable cross-sections, which leads to problems with the current carrying capacity of the cables.

Es ist bereits bekannt, Flachbandkabel als Batteriekabel in Kraftfahrzeugen einzubauen. So zeigt zum Beispiel die DE 4 210 202 A1 ein Flachbandkabel für den Einsatz als Batteriekabel. Dieses Flachbandkabel wird gebildet durch Strangpressen eines aus einer Litze bestehenden Batteriekabels. Das beschriebene Flachbandkabel ist ein Kupferkabel und weist die oben genannten Nachteile auf.It is already known to install ribbon cable as a battery cable in motor vehicles. So shows, for example, the DE 4 210 202 A1 a ribbon cable for use as a battery cable. This ribbon cable is formed by extruding a battery cable made of a stranded wire. The ribbon cable described is a copper cable and has the above-mentioned disadvantages.

Aus der JP P2001-291433A ist ein Flachbandkabel zur Verwendung im Fahrzeugbau ebenfalls bekannt. Dieses Flachbandkabel kann aus mehreren nebeneinander angeordneten Bändern gebildet sein. Diese Bänder können aus Kupfer oder aus E-Aluminium hergestellt sein. Die Ummantelung ist aus laminiertem Aluminiumpolyethylen mit einem Aluminiumband und einem Isolator, wie Polyethylenterephthalate. Ferner werden Verbindungselemente vorgesehen, um den Flachbandleiter an dem Kfz zu befestigen.From the JP P2001-291433A a ribbon cable for use in vehicle construction is also known. This ribbon cable can be formed from a plurality of juxtaposed bands. These bands can be made of copper or of e-aluminum. The sheath is made of laminated aluminum polyethylene with an aluminum tape and an insulator such as polyethylene terephthalate. Further, fasteners are provided to secure the ribbon conductor to the vehicle.

Bei den gezeigten Flachbandkabeln wird ausschließlich E-Aluminium verwendet. Die Leiter werden aus stranggepressten Aluminiumdrähten hergestellt. Bei der Strangpressung ergeben sich jedoch Verwindungen in dem Flachband, so dass nachfolgende Bearbeitungsschritte nur mit erheblichem Aufwand automatisiert werden können. Auch können herkömmliche Aluminiumkabel mit einem Querschnitt von mehr als 80mm2 nicht mehr auf ein Coil aufgewickelt werden, nachdem sie bearbeitet wurden, da das verwendete Aluminium nicht weich genug ist.The ribbon cables shown use only aluminum. The conductors are made of extruded aluminum wires. During extrusion, however, warps in the flat strip, so that subsequent processing steps can be automated only with considerable effort. Also, conventional aluminum cables with a cross section greater than 80mm 2 can no longer be wound onto a coil after they have been machined because the aluminum used is not soft enough.

Die zuvor aufgezeigten Nachteile ergeben das technische Problem, einen elektrischen Flachbandleiter für Kraftfahrzeuge zur Verfügung zu stellen, der sich in einfacher Weise verarbeiten lässt.The above-mentioned disadvantages result in the technical problem of providing a flat electrical conductor for motor vehicles, which can be processed in a simple manner.

Dieses technische Problem wird erfindungsgemäß dadurch gelöst, dass der Aluminiumleiter derart weichgeglüht ist, dass er eine Dehnung von zumindest 30% ermöglicht. Es können sowohl Aluminiumbänder als auch Aluminiumbleche verwendet werden. Bei der Herstellung von Aluminium wird dieses zumeist, nachdem es gewalzt oder stranggepresst worden ist, auf ein Coil (Spule, Haspel) aufgewickelt. Es ist nun erkannt worden, dass das auf das Coil aufgewickelte Aluminiumband dann einfach zu einem Flachbandleiter verarbeitet werden kann, wenn das Aluminiumband zuvor weichgeglüht wurde. Nachdem das Aluminiumband weichgeglüht wurde, kann es einfach von dem Coil abgewickelt und mit geringem Aufwand weiterverarbeitet werden. Dadurch, dass sich das weichgeglühte Aluminium leicht auf Spulen auf- und abwickeln lässt, kann der Flachbandleiter als Meterware hergestellt werden.This technical problem is inventively achieved in that the aluminum conductor is annealed so that it allows an elongation of at least 30%. Both aluminum bands and aluminum sheets can be used. In the production of aluminum this is mostly, after it has been rolled or extruded, wound on a coil (reel, reel). It has now been recognized that the aluminum strip wound on the coil can then be easily processed into a ribbon conductor if the aluminum strip has previously been annealed. After the aluminum strip has been annealed, it can simply be unwound from the coil and processed further with little effort. Due to the fact that the soft annealed aluminum can easily be wound up and unwound on coils, the flat conductor can be manufactured by the meter.

Nachdem ein Aluminiumblech gewalzt worden ist, hat es vorzugsweise Breiten zwischen 50 cm und einigen Metern. Diese breiten Aluminiumbleche werden aufgewickelt auf Coils und so transportiert. Für Flachbandleiter in Kfz werden Bandbreiten von vorzugsweise 10 bis 40 mm benötigt. Daher wird vorgeschlagen, dass der Aluminiumleiter aus einem von einem Coil abgewickelten Aluminiumblech zerteilt in Einzelleiter gebildet ist. Somit wird gemäß dieses Ausführungsbeispieles das breite Aluminiumblech von dem Coil abgewickelt und in einem folgenden Bearbeitungsschritt zerteilt. Nach dem Zerteilen können die einzelnen schmalen Einzelleiter auf Haspeln aufgehaspelt werden. Das Zerteilen kann mittels Schneiden, Sägen, Schweißen, Laserschneiden, Wasserstrahlschneiden oder sonstiger spanhebender oder spanloser Trennverfahren durchgeführt werden. Hierbei sind besonders vorteilhaft das Schneiden mit Messern, Laser oder Wasserstrahlen.After an aluminum sheet has been rolled, it preferably has widths between 50 cm and several meters. These wide aluminum sheets are wound up on coils and thus transported. For ribbon conductors in motor vehicles bandwidths of preferably 10 to 40 mm are needed. Therefore, it is proposed that the aluminum conductor is formed of a coil wound aluminum sheet divided into individual conductors. Thus, according to this embodiment, the wide aluminum sheet is unwound from the coil and cut in a subsequent processing step. After cutting, the individual narrow individual conductors can be reeled on reels. The cutting can be carried out by means of cutting, sawing, welding, laser cutting, water jet cutting or other chip-removing or non-cutting methods of separation. Here are particularly advantageous cutting with knives, laser or water jets.

Erfindungsgemäß ist auch vorgesehen, dass aus einem weichgeglühten Aluminiumhalbzeug, beispielsweise einem Kabel, einer Litze oder einem Profil, mittels Strangpressen der Aluminiumleiter hergestellt wird. In diesem Fall entfällt der Schritt des Zerteilens des Flachbandes.According to the invention, it is also provided that the aluminum conductor is produced from an annealed aluminum semi-finished product, for example a cable, a strand or a profile, by means of extrusion molding. In this case, the step of dividing the flat strip is omitted.

Durch die Verwendung von Aluminiumbändern können die Flachbandleiter beliebig profiliert werden. Bevorzugt sind rechteckige-, quadratische- oder U-ProfileThrough the use of aluminum strips, the ribbon conductors can be profiled as desired. Preference is given to rectangular, square or U profiles

Es hat sich ferner erfindungsgemäß gezeigt, dass die teilweise Verwendung von AL 99,5% oder reiner, z.B. AL 99,7%, AL oder Legierungen davon vorteilhaft für den Einsatz als Flachbandleiter ist.It has further been found according to the invention that the partial use of AL is 99.5% or pure, e.g. AL 99.7%, AL or alloys thereof is advantageous for use as a ribbon conductor.

Gemäß vorteilhafter Ausgestaltung wird vorgeschlagen, dass der Aluminiumleiter einen Herstellungszustand von 0 hat. Dies ist der Herstellungszustand des weichgeglühten Halbzeugs aus Aluminium. Dieser Zustand ermöglicht eine Bewegung des Flachbandleiters in alle Raumrichtungen. Der so gebildete Flachbandleiter lässt sich somit einfach verbiegen, und ein nahezu beliebig geformter Kabelstrang kann damit gefertigt werden. Der Zustand 0 bewirkt auch eine gute Leitfähigkeit des Materials. Der Zustand 0 ist die mechanischen Eigenschaften des Halbzeugs betreffend in DIN EN 485-2 beschrieben.According to an advantageous embodiment, it is proposed that the aluminum conductor has a production state of 0. This is the manufacturing state of the soft annealed semi-finished aluminum. This state allows movement of the ribbon conductor in all directions. The ribbon conductor thus formed can thus be easily bent, and a virtually arbitrarily shaped cable harness can be made with it. The state 0 also causes a good conductivity of the material. State 0 is the mechanical properties of the semifinished product described in DIN EN 485-2.

Durch das Weichglühen des Aluminiumbandes werden die elektrischen Eigenschaften positiv beeinflusst. Daher wird gemäß vorteilhafter Ausführungsbeispiele vorgeschlagen, dass das verwendete Aluminium in dem Flachbandleiter eine Leitfähigkeit von 30 bis 37 m/(Ohm*mm2) hat. Das Auf- und Abwickeln des Aluminiumbandes auf einen Coil, das Aufhaspeln des geschnittenen oder stranggepressten Flachbandleiters auf eine Haspel und das nachfolgende Abwickeln von der Haspel für die Zuführung zu einem Extruder wird bevorzugt dadurch vereinfacht, dass der Flachbandleiter erfindungsgemäß eine Dehnung von zumindest 30% ermöglicht. Diese Dehnung, die vorzugsweise über 35% liegt, ermöglicht zum einen das einfache Auf- und Abwickeln und zum anderen das Formen von Kabelsträngen in beliebigen Raumrichtungen.The soft annealing of the aluminum strip positively influences the electrical properties. Therefore, according to advantageous embodiments, it is proposed that the aluminum used in the ribbon conductor has a conductivity of 30 to 37 m / (ohm * mm 2 ). The winding and unwinding of the aluminum strip on a coil, the coiling of the cut or extruded ribbon conductor on a reel and the subsequent unwinding of the reel for feeding to an extruder is preferably simplified in that the ribbon conductor according to the invention allows an elongation of at least 30% , This elongation, which is preferably more than 35%, allows on the one hand the easy winding and unwinding and on the other hand the shaping of cable strands in any spatial directions.

Darüber hinaus wird gemäß eines weiteren vorteilhaften Ausführungsbeispieles vorgeschlagen, dass der Aluminiumleiter eine Zugfestigkeit von in etwa 60 bis 80 N/mm2 +/- 50% hat. Diese Zugfestigkeit erlaubt zum einen eine automatische Bearbeitung, insbesondere das Extrudieren mit einem Isolator und auf der anderen Seite ein einfaches Verbiegen zur Bildung eines Kabelstranges mit Biegungen in alle Raumrichtungen.In addition, it is proposed according to a further advantageous embodiment that the aluminum conductor has a tensile strength of about 60 to 80 N / mm 2 +/- 50%. This tensile strength allows for an automatic processing, in particular the extrusion with an insulator and on the other hand a simple bending to form a cable harness with bends in all directions.

Auf den Flachbandleiter können gemäß eines weiteren vorteilhaften Ausführungsbeispieles Anschlussbolzen auf der Oberfläche als elektrische Kontaktpunkte aufgebracht sein. Die Anschlussbolzen lassen sich an beliebigen Punkten entlang des Flachbandleiters anordnen. Die Anschlussbolzen erlauben einen einfachen Abgriff des elektrischen Potenzials entlang des Flachbandleiters zum Anschluss von elektrischen Verbrauchern oder von Messpunkten innerhalb des Kraftfahrzeuges. Bevorzugt kann ein Mittenstützpunkt als Fremdstartstützpunkt gebildet sein. Es kann an beliebiger Stelle im Fahrzeug ein Fremdstartstützpunkt realisiert werden.On the ribbon conductor can be applied on the surface as electrical contact points according to a further advantageous embodiment terminal bolts. The connection bolts can be arranged at any point along the ribbon conductor. The connection bolts allow easy tapping of the electrical potential along the ribbon conductor for connection of electrical loads or measuring points within the motor vehicle. Preferably, a center support point may be formed as a foreign start support point. It can be realized at any point in the vehicle, a foreign launch base.

Ein besonders einfaches Kontaktieren wird gemäß eines vorteilhaften Ausführungsbeispieles dadurch ermöglicht, dass der Anschlussbolzen zumindest teilweise aus Messing oder Legierungen davon gebildet ist. Darüber hinaus sind Kupfer, Aluminium, Stahl oder sonstige leitfähige Materialien für den Anschlussbolzen möglich. Ferner wird vorgeschlagen, dass der Anschlussbolzen mittels eines Reibschweißverfahrens mit dem Flachbandleiter kontaktiert ist. Es ist bevorzugt, dass ein Torsionsreibschweißen oder ein Multi-Orbital-Reibschweißen verwendet wird. Durch das Reibschweißen wird Reibwärme und Druck erzeugt, do dass die Aluminiumoxidschicht des Flachbandleiters aufgebrochen wird, und sich der Übergangswiderstand des elektrischen Kontaktes zwischen Anschlussbolzen und Flachbandleiter verringert. Beim Reibschweißen wird vorzugsweise eine Eindringtiefe von weniger als 3 mm, bevorzugt 1 mm erreicht. Da das Material des Flachbandleiters sehr weich ist, muss beim Reibschweißen mit einem geeigneten Druck gearbeitet werden, so dass der Anschlussbolzen nicht unmittelbar durch den Flachbandleiter getrieben wird. Der Anschlussbolzen ist vorzugsweise mit einem Mehrkant, bevorzugt mit einem Vierkant versehen, der einerseits als Werkzeughalter für das Reibschweißen dient und zum anderen bei einer späteren Umspritzung eine sichere Befestigung dieser ermöglicht.A particularly simple contact is made possible according to an advantageous embodiment in that the connecting bolt is at least partially formed of brass or alloys thereof. In addition, copper, aluminum, steel or other conductive materials for the connection bolt are possible. It is also proposed that the connecting bolt is contacted by means of a friction welding process with the ribbon conductor. It is preferred that torsional friction welding or multi-orbital friction welding be used. Friction heat and pressure are generated by friction welding, so that the aluminum oxide layer of the ribbon conductor is broken, and the contact resistance of the electrical contact between the connection pin and the ribbon conductor is reduced. In friction welding, a penetration depth of less than 3 mm, preferably 1 mm, is preferably achieved. Since the material of the ribbon conductor is very soft, friction welding must be carried out with a suitable pressure, so that the connection bolt is not driven directly through the ribbon conductor. The connecting bolt is preferably provided with a polygon, preferably with a square, which serves on the one hand as a tool holder for the friction welding and on the other hand allows a secure attachment of this in a later encapsulation.

Es wird ferner vorgeschlagen, dass zumindest ein Anschlussbolzen zwischen den Enden des Flachbandleiters angeordnet ist. Dies bedeutet, dass entlang des Flachbandleiters an einer beliebigen Stelle ein Anschlussbolzen zum Abgriff des Potenzials für elektrische Verbraucher oder zum Anbringen eines Messpunktes angeordnet werden kann. Die Anschlussbolzen können an einer beliebigen Fläche des Flachbandleiters angeordnet werden. Vorzugsweise werden die Anschlussbolzen auf den breiten Flächen des Flachbandleiters angeordnet. Dies ermöglicht ebenfalls die Realisierung als Fremdstartstützpunkt.It is also proposed that at least one connection bolt is arranged between the ends of the flat conductor. This means that a connecting bolt for tapping the potential for electrical consumers or for attaching a measuring point can be arranged anywhere along the ribbon conductor at any point. The connection bolts can be arranged on any surface of the ribbon conductor. Preferably, the terminal bolts are arranged on the wide surfaces of the ribbon conductor. This also allows the realization as a foreign launch base.

Gemäß eines vorteilhaften Ausführungsbeispieles wird vorgeschlagen, dass der Querschnitt des Flachbandleiters zumindest 16 mm2 ist. Hierbei ist besonders vorteilhaft ein Verhältnis von 1 zu 5 zwischen Höhe und Breite, beispielsweise eine Höhe von 4 mm und eine Breite von 20 mm.According to an advantageous embodiment, it is proposed that the cross section of the ribbon conductor is at least 16 mm 2 . In this case, a ratio of 1 to 5 between height and width, for example, a height of 4 mm and a width of 20 mm is particularly advantageous.

Bekannte Aluminiumflachbandleiter sind allesamt mittels Strangpressen hergestellt und haben eine Dehnung von in etwa 25%. Diese stranggepressten Flachbandleiter sind zum einen nicht geeignet für eine automatische Weiterverarbeitung, da sich durch das Strangpressen Verwindungen im Material ergeben und zum anderen können diese auch nicht ohne weiteres auf Coils aufgewickelt werden.Known aluminum flat strip conductors are all made by extrusion and have an elongation of about 25%. These extruded ribbon conductors are not suitable for an automatic further processing, as resulting from the extrusions twisting in the material and on the other hand, these can not be readily wound on coils.

Die aus DIN 43670 bekannten Aluminiumflachbandleiter sind gebildet aus einem Aluminiumkern und einer Umhüllung aus Kupfer und weisen daher die bekannten Nachteile der Kupferkabel auf. Zur Erlangung der Kupferumhüllung müssen die Aluminiumflachbandleiter einem weiteren elektrochemischen Verarbeitungsschritt unterzogen werden.The aluminum flat strip conductors known from DIN 43670 are formed from an aluminum core and a cladding made of copper and therefore have the known disadvantages of copper cables. To obtain the copper cladding, the aluminum ribbon conductors must be subjected to a further electrochemical processing step.

Demgegenüber schlägt die Erfindung ein Verfahren vor, bei dem zumindest ein zuvor weichgeglühtes Aluminiumhalbzeug von einem Coil abgewickelt wird, bei dem aus dem abgewickelten Aluminiumhalbzeug durch Zerteilen des Aluminiumhalbzeugs ein Aluminiumleiter gebildet wird, wobei der Aluminiumleiter eine Dehnung von zumindest 30% ermöglicht, bei dem nach dem Zerteilen der Aluminiumleiter auf ein Coil aufgewickelt wird und bei dem der Aluminiumleiter von dem Coil abgewickelt wird und mit einem Isolator beschichtet wird. Das Aluminiumhalbzeug kann ein Aluminiumblech oder -band sein. Diese werden von einem Aluminiumhersteller in Breiten zwischen 50 cm und mehreren Metern geliefert. Das breite Aluminiumblech ist bereits weichgeglüht und wird auf einem Coil aufgewickelt zur Verfügung gestellt. Zur Herstellung der Flachbandleiter, die sich zum Einsatz in Kfz eignen, wird das Aluminiumblech abgewickelt und in Flachbandleiter mit entsprechender Breite zerteilt. Beim Zerteilen wird ein Schneiden mit Messern, einem Laser oder mit einem Wasserstrahl bevorzugt. Ferner ist es möglich, das Zerteilen mittels Sägen oder Schweißen oder sonstiger spanhebender oder spanloser Verfahren durchzuführen. Auch kann das Aluminiumhalbzeug ein Aluminiumkabel oder eine Litze sein. Diese wird stranggepresst, so dass sich ein Flachleiter bildet.In contrast, the invention proposes a method in which at least one previously annealed aluminum semi-finished product is unwound from a coil in which from the unwound aluminum semi-finished by dividing the aluminum semi-finished an aluminum conductor is formed, the aluminum conductor allows an elongation of at least 30%, in which after cutting the aluminum conductors on one Coil is wound and wherein the aluminum conductor is unwound from the coil and coated with an insulator. The aluminum semi-finished product may be an aluminum sheet or strip. These are supplied by an aluminum manufacturer in widths between 50 cm and several meters. The wide aluminum sheet is already annealed and is provided wound on a coil. For the production of the flat strip conductors, which are suitable for use in motor vehicles, the aluminum sheet is unwound and cut into flat ribbon conductors with the appropriate width. When cutting, cutting with knives, a laser or a water jet is preferred. Furthermore, it is possible to carry out the cutting by means of sawing or welding or other chip-removing or non-cutting methods. Also, the aluminum semi-finished product may be an aluminum cable or a stranded wire. This is extruded, so that forms a flat conductor.

Nachdem das Aluminiumblech in die einzelnen Flachbandleiter zerteilt worden ist, wird gemäß der Erfindung der zerteilte Aluminiumleiter auf ein Coil aufgewickelt. Dieses Aufwickeln ist mit dem weichgeglühten Aluminium besonders einfach und beeinträchtigt nur unwesentlich die weitere Verarbeitbarkeit des Flachbandleiters.After the aluminum sheet has been divided into the individual ribbon conductors, according to the invention, the divided aluminum conductor is wound onto a coil. This winding is particularly easy with the soft annealed aluminum and affects only slightly the further processability of the ribbon conductor.

Zum Aufbringen eines Isolators wird gemäß der Erfindung vorgeschlagen, dass der auf den Coil aufgewickelte Aluminiumleiter abgewickelt wird und mit einem Isolator beschichtet wird. Dies kann durch Extrudieren, Lackieren, Laminieren, Umspritzen oder sonstige Verfahren zur Isolation von Leitern geschehen.For applying an insulator, it is proposed according to the invention that the aluminum conductor wound on the coil is unwound and coated with an insulator. This can be done by extruding, painting, laminating, overmolding or other methods of insulating conductors.

Beim Extrudieren wird auch vorgeschlagen, dass der Flachbandleiter zunächst mittels Rollen über eine Führungsraupe an den Extruder herangeführt wird.When extruding it is also proposed that the ribbon conductor is first introduced by means of rollers via a guide bead to the extruder.

Zum Konfektionieren der isolierten Flachbandleiter wird gemäß eines vorteilhaften Ausführungsbeispieles vorgeschlagen, dass der Flachbandleiter nach dem Isolieren abgelängt wird. Auch ist es möglich, dass der Flachbandleiter nach dem Isolieren erneut aufgewicklet wird. Hierdurch wird ein Transport des Leiters nach dem Isolieren erleichtert. Nach dem Ablängen kann ein Kabelstrang gemäß eines weiteren vorteilhaften Ausführungsbeispieles durch Biegen des Flachbandleiters in alle Raumrichtungen gebildet werden. Das Biegen ist aufgrund der geringen Härte und der hohen Dehnung, die durch das Weichglühen erreicht wird, besonders einfach. Es lassen sich nahezu beliebige Formen von Kabelsträngen mit dem erfindungsgemäßen Flachbandleiter herstellen.For assembling the insulated ribbon conductors is proposed according to an advantageous embodiment that the ribbon conductor is cut to length after isolation. It is also possible that the ribbon conductor is rewound after isolation. As a result, a transport of the conductor is facilitated after isolation. After cutting to length, a cable harness according to another advantageous embodiment can be formed by bending the ribbon conductor in all directions. Bending is particularly easy due to the low hardness and high elongation achieved by soft annealing. It is possible to produce almost any desired shapes of cable strands with the flat-band conductor according to the invention.

Um Abgriffpunkte für elektrische Verbraucher oder Messeinrichtungen entlang des Flachbandleiters zur Verfügung zu stellen, wird vorgeschlagen, dass Anschlussbolzen mittels materialschlüssigen Fügens nach dem Ablängen an den Flachbandleiter aufgebracht werden. Hierzu wird vorgeschlagen, dass der Isolator mittels geeigneter Verfahren, wie beispielsweise Schneiden, Lasern, etc. aufgetrennt wird und an den abisolierten Stellen der Anschlussbolzen angebracht wird. Fügetechniken können bevorzugt Schweißen, insbesondere Rotationsreibschweißen, Multi-Orbital-Schweißen, torsionales Ultraschallschweißen oder Laserschweißen sein.In order to provide tapping points for electrical consumers or measuring devices along the ribbon conductor, it is proposed that connecting bolts be applied to the ribbon conductor by means of material joining after cutting to length. For this purpose, it is proposed that the insulator be separated by means of suitable methods, such as cutting, lasers, etc. and attached to the stripped points of the connecting bolt. Joining techniques may preferably be welding, in particular rotational friction welding, multi-orbital welding, torsional ultrasonic welding or laser welding.

Ein weiterer Gegenstand der Erfindung ist die Verwendung eines weichgeglühten Aluminiumleiters als Flachbandleiter in einem Kraftfahrzeug. Insbesondere die Verwendung eines nach einem zuvor beschriebenen Verfahren hergestellten Flachbandleiters bzw. eines Flachbandleiters mit den zuvor beschriebenen Eigenschaften wird vorgeschlagen.Another object of the invention is the use of a soft annealed aluminum conductor as a ribbon conductor in a motor vehicle. In particular, the use of a ribbon conductor produced by a method described above or a ribbon conductor having the properties described above is proposed.

Die Erfindung wird nachfolgend anhand einer Ausführungsbeispiele zeigenden Zeichnung näher erläutert. In der Zeichnung zeigen:

Fig. 1 A-C
Querschnitte eines erfindungsgemäßen Flachbandleiters;
Fig. 2
einen ersten Verfahrensschritt zur Herstellung von Flachbandleitern aus einem Aluminiumband;
Fig. 3
einen zweiten Herstellungsschritt zum Extrudieren des Flachbandleiters;
Fig. 4
einen Anschlussbolzen;
Fig. 5
einen auf einem Flachbandleiter aufgeschweißten Anschlussbolzen;
Fig. 6
einen stirnseitig aufgeschweißten Anschlussbolzen.
The invention will be explained in more detail with reference to an exemplary embodiments showing drawing. In the drawing show:
Fig. 1 AC
Cross sections of a ribbon conductor according to the invention;
Fig. 2
a first process step for the production of ribbon conductors made of an aluminum strip;
Fig. 3
a second manufacturing step of extruding the ribbon conductor;
Fig. 4
a connecting bolt;
Fig. 5
a connection bolt welded onto a ribbon conductor;
Fig. 6
a front-side welded connection pin.

Figur 1A zeigt einen Querschnitt eines elektrischen Flachbandleiters 1 der aus einem Aluminiumleiter 2 und einer Isolierung 4 gebildet ist. Der Aluminiumleiter 2 ist hergestellt aus einem weichgeglühten Aluminiumband. Das Aluminium hat vorzugsweise einen Zustand von 0. Diese Eigenschaft verleiht dem Aluminium einen guten Leitwert und darüber hinaus gute Eigenschaften zur Aufnahme von Schwingungen bei Fahrzeugcrashs und zum Biegen des Flachbandleiters bei der Konfektionierung von Kabelsträngen. Ein Leitwert von 34 bis 36 m/Ohm mm2 ist hierbei bevorzugt. Das Aluminium ist ferner derart bearbeitet, dass es eine Zugfestigkeit von 60 bis 80 N/mm2, besonders bevorzugt 75 N/mm2 aufweist. Ferner ist die Dehnung bevorzugt über 30%, besonders bevorzugt 35%, wodurch sich eine gute Verarbeitbarkeit ergibt. Der Aluminiumkern 2 hat vorzugsweise einen Querschnitt von 80mm2. Die Höhe H ist vorzugsweise 4 mm und die Breite B ist vorzugsweise 20 mm. Auch bevorzugt ist ein Verhältnis von 1:5 zwischen Höhe und Breite. Figure 1A shows a cross section of a flat electrical conductor 1 which is formed of an aluminum conductor 2 and 4 an insulation. The aluminum conductor 2 is made of a soft-annealed aluminum strip. The aluminum preferably has a state of 0. This property gives the aluminum a good conductance and also good properties for absorbing vibrations in vehicle crashes and for bending the ribbon conductor in the assembly of cable strands. A conductance of 34 to 36 m / ohm mm 2 is preferred here. The aluminum is further processed to have a tensile strength of 60 to 80 N / mm 2 , more preferably 75 N / mm 2 . Furthermore, the elongation is preferably more than 30%, particularly preferably 35%, resulting in good processability. The aluminum core 2 preferably has a cross section of 80mm 2 . The height H is preferably 4 mm and the width B is preferably 20 mm. Also preferred is a ratio of 1: 5 between height and width.

Das Isolatormaterial 4 ist vorzugsweise ein Polyethylen oder ein sonstiges, herkömmliches Isolatormaterial, Beispielsweise PVC, PUR, Laminat oder Lack. Dieses Isolatormaterial 4 kann beispielsweise mittels Extrudieren, vorzugsweise mittels Schlauchextrudieren, auf den Aluminiumleiter 2 aufgebracht werden. Andere Isolationsverfahren sind ebenfalls möglich. Der Aluminiumleiter 2 weist keine Verwindungen auf, wodurch sich eine gute Verarbeitbarkeit ergibt. Ferner liegt die Dehnung durch das Weichglühen des Aluminiumleiters 2 über einem Dehnungswert von 25%.The insulator material 4 is preferably a polyethylene or other conventional insulator material, for example PVC, PUR, laminate or lacquer. This insulator material 4 can be applied to the aluminum conductor 2, for example by means of extrusion, preferably by means of tube extrusion. Other isolation methods are also possible. The aluminum conductor 2 has no torsions, resulting in a good processability. Furthermore, the elongation due to the soft annealing of the aluminum conductor 2 is above a strain value of 25%.

Figur 1B zeigt einen Querschnitt eines Flachbandleiters 1 mit zwei Aluminiumleitern 2. Die Aluminiumleiter 2 haben ein U-Profil und ein rechteckiges Profil. FIG. 1B shows a cross section of a ribbon conductor 1 with two aluminum conductors 2. The aluminum conductors 2 have a U-profile and a rectangular profile.

Figur 1C zeigt einen weiteren Querschnitt eines Flachbandleiters 1. In einem U-Profil eines ersten Aluminiumleiters 2 sind zwei geschichtete rechteckige Aluminiumleiter 2 angeordnet. Figure 1C shows a further cross section of a ribbon conductor 1. In a U-profile of a first aluminum conductor 2, two layered rectangular aluminum conductors 2 are arranged.

Figur 2 zeigt einen ersten Herstellungsschritt bei der Herstellung eines erfindungsgemäßen Flachbandleiters 1. Gezeigt ist ein auf ein Coil 6 aufgewickeltes Aluminiumblech 8. Dieses Aluminiumblech 8 hat vorzugsweise eine Stärke von 2 bis 10 mm, besonders bevorzugt 4 mm. Das Aluminiumblech 8 ist werkseitig weichgeglüht, so dass sich die oben erwähnten Eigenschaften ergeben. Das von dem Coil 6 abgewickelte Aluminiumblech 8 hat vorzugsweise eine Breite von 2 m. Das Aluminiumblech 8 wird einer Zerteilvorrichtung 10 zugeführt. In der Zerteilvorrichtung 10 wird das Aluminiumblech 8 in die Aluminiumleiter 2 zerteilt. Hierbei kann das Zerteilen mittels Messern erfolgen. Auch ist es möglich, das Aluminiumblech 8 durch Lasern oder durch Wasserstrahlschneiden oder Sägen zu zerteilen. Alle weiteren spanlosen oder spanhebenden Trennverfahren sind ebenfalls möglich. Die Aluminiumleiter 2 werden jeweils auf Haspeln 12 aufgehaspelt. Durch die hohe Dehnbarkeit ist dieses Aufhaspeln ohne weiteres möglich. Das Abhaspeln von den Haspeln 12 ist dann ebenfalls problemlos möglich. Die einzelnen Haspeln 12 können leicht transportiert werden und ermöglichen eine einfache Handhabung im Herstellungsverfahren. FIG. 2 shows a first manufacturing step in the manufacture of a flat strip conductor 1 according to the invention. Shown is a wound on a coil 6 aluminum sheet 8. This aluminum sheet 8 preferably has a thickness of 2 to 10 mm, more preferably 4 mm. The aluminum sheet 8 is factory annealed, resulting in the above-mentioned properties. The unwound from the coil 6 aluminum sheet 8 preferably has a width of 2 m. The aluminum sheet 8 is fed to a dicing device 10. In the dicing device 10, the aluminum sheet 8 is divided into the aluminum conductors 2. Here, the cutting can be done by knives. It is also possible to divide the aluminum sheet 8 by laser or by water jet cutting or sawing. All other non-cutting or span separating methods are also possible. The aluminum conductors 2 are each reeled on reels 12. Due to the high extensibility of this coiling is readily possible. The uncoiling of the reels 12 is then also easily possible. The individual reels 12 can be easily transported and allow easy handling in the manufacturing process.

Figur 3 zeigt das Extrudieren der einzelnen Aluminiumleiter 2 in einen kompakten Flachbandleiter 1. Bei geschichteten Flachbandleitern 1, wie in FIG. 1B und 1C gezeigt, kann jeder einzelne Aluminiumleiter 2 zunächst isoliert werden und dann mit den anderen zu einem einzigen Flachbandleiter 2 gefügt werden. Hierbei wird der Aluminiumleiter 2 von der Haspel 12 abgehaspelt, über zumindest eine Raupe 14 dem Extruder 16 zugeführt. Auch ist es möglich, mehrere Aluminiumleiter 2 dem Extruder 16 zuzuführen und in einem Schritt zu einem isolierten Flachbandleiter 1 zu fügen. FIG. 3 shows the extrusion of the individual aluminum conductors 2 in a compact ribbon conductor 1. In layered ribbon conductors 1, as in FIG. 1B and 1C shown, each individual aluminum conductor 2 can first be isolated and then joined with the others to form a single ribbon conductor 2. In this case, the aluminum conductor 2 is unwound from the reel 12, fed to the extruder 16 via at least one bead 14. It is also possible to supply a plurality of aluminum conductors 2 to the extruder 16 and to add them in one step to an insulated ribbon conductor 1.

Nach dem Extrudieren wird der Flachbandleiter 1 erneut auf eine Haspel 18 aufgecoilt. Mittels der Raupe 14 werden durch das Haspeln verursachte Biegungen in dem Aluminiumleiter 2 ausgeglichen, und eine gleichmäßige Zuführung zum Extruder 16 wird ermöglicht. Im Extruder 16 wird durch geeignete Führungen der Aluminiumleiter 2 an den Extrudierkopf herangeführt.After extrusion, the ribbon conductor 1 is recharged onto a reel 18. By means of the bead 14 bends caused by the reeling in the aluminum conductor 2 are compensated, and a uniform feed to the extruder 16 is made possible. In the extruder 16 is brought by suitable guides the aluminum conductor 2 to the extrusion head.

Aufgrund des weichen Materials sind geeignete Führungsmittel notwendig. In dem Extruder 16 kann ein Isolatormaterial auf den Aluminiumleiter 2 aufextrudiert werden. Der Flachbandleiter 1 wird nach dem Extrudieren entweder auf eine weitere Haspel 18 aufgehaspelt oder direkt konfektioniert. Das Konfektionieren kann mittels Ablängen, Biegen, Kontaktieren oder sonstiger Verarbeitungsschritte erfolgen.Due to the soft material suitable guidance means are necessary. In the extruder 16, an insulator material can be extruded onto the aluminum conductor 2. The flat conductor 1 is either reeled after extrusion on another reel 18 or assembled directly. The assembly can be done by cutting to length, bending, contacting or other processing steps.

Von der Haspel 18 kann der Flachbandleiter 1 erneut abgehaspelt und konfektioniert werden. Hierbei kann es zunächst in die gewünschte Länge geschnitten und danach mit geeigneten Biegevorrichtungen in einen Kabelstrang gebogen werden. Durch das weiche Aluminium ist das Verbiegen mit relativ geringem Aufwand verbunden.From the reel 18, the ribbon conductor 1 can be rewound and assembled again. Here it can first be cut to the desired length and then bent with suitable bending devices in a harness. The soft aluminum bending is associated with relatively little effort.

Figur 4 zeigt einen Anschlussbolzen 20 als Flachleiterstützpunkt. Der Bolzen 20 ist vorzugsweise aus Messing, Stahl, Kupfer oder sonstigen leitfähigen Materialien hergestellt. Der Anschlussbolzen 20 hat an seinem Ende eine kantige Ausformung 24, bevorzugt vierkantig. Die Ausformung 24 kann als Werkzeugstützpunkt verwendet werden, insbesondere als Halt eines Reibschweißwerkzeugs. FIG. 4 shows a connection pin 20 as a flat conductor support point. The bolt 20 is preferably made of brass, steel, copper or other conductive materials. The connecting bolt 20 has at its end an edged formation 24, preferably four-edged. The molding 24 can be used as a tool base, in particular as a stop of a friction welding tool.

Figur 5 zeigt einen Anschlussbolzen 20, der auf einen Flachbandleiter 1 aufgebracht ist. Hierbei ist der Anschlussbolzen 20 mittels eines Schweiß- oder Lötverfahrens auf den Flachbandleiter 1 aufgeschweißt. Die Eindringtiefe des Anschlussbolzens 20 in den Flachbandleiter 1 beim Kontaktieren ist bevorzugt maximal 1 mm. Die mehrkantige Ausformung 24 kann nach dem Schweißen oder Löten als Halteelement für eine nachfolgende Umspritzung oder Verguss dienen. Die Anordnung des Anschlussbolzens 20 auf den Flachbandleiter 1 kann an einer beliebigen Stelle erfolgen und ist nicht notwendigerweise nur am Ende des Flachbandleiters 1. Auch ein Mittenabgriff, insbesondere in Form eines Fremdstartstützpunktes, ist möglich. FIG. 5 shows a connection bolt 20 which is applied to a ribbon conductor 1. In this case, the connecting bolt 20 is welded onto the flat conductor 1 by means of a welding or soldering process. The penetration depth of the connecting bolt 20 in the flat conductor 1 when contacting is preferably at most 1 mm. The polygonal shape 24 may serve as a holding element for subsequent encapsulation or potting after welding or soldering. The arrangement of the connecting bolt 20 on the ribbon conductor 1 can at any point take place and is not necessarily only at the end of the ribbon conductor 1. A center tap, especially in the form of a Fremdstartstützpunktes is possible.

Beim Einsatz von dünnem Blechen oder Bändern kann es problematisch sein, den Anschlussbolzen auf die Stirnfläche aufzuschweißen. Es wir einerseits vorgeschlagen, die Stirnfläche durch Stanzen derart umzuformen, dass die Stirnfläche eine vergrößerte Auflagefläche hat. So kann beispielsweise die Stirnfläche mit Hilfe eines Stößels gestaucht werden. Die Stirnfläche kann dann rund oder eckig an eine Form angepasst werden. Auch ist es möglich, die Stirnfläche mit Hilfe einer Hülse einzufassen um dadurch eine vergrößerte Auflagefläche für den Anschlussbolzen zur Verfügung zu stellen.When using thin sheets or strips, it can be problematic to weld the connecting bolt onto the end face. On the one hand, it is proposed to reshape the end face by punching in such a way that the end face has an enlarged bearing surface. For example, the end face can be compressed with the aid of a plunger. The face can then be adjusted round or square to a shape. It is also possible to enclose the end face by means of a sleeve in order thereby to provide an enlarged contact surface for the connecting bolt.

Ferner ist ein Anschluss des Anschlussbolzens im Bereich der Stirnfläche gemäß Fig. 6 möglich. Der Flachbandleiter 1 wird hierzu im Bereich der Stirnfläche verbogen. Jegliche Winkellage ist dabei möglich. Die Biegung ist vorliegend derart, dass die breite Fläche des Flachbandleiters 1 im Bereich der Stirnfläche im Wesentlichen senkrecht zum Verlauf des Flachbandleiters 1 im davor liegenden Bereich ist.Furthermore, a connection of the connecting bolt in the region of the end face according to Fig. 6 possible. The ribbon conductor 1 is bent for this purpose in the region of the end face. Any angular position is possible. In the present case, the bend is such that the broad area of the flat-band conductor 1 in the area of the end face is substantially perpendicular to the course of the flat-band conductor 1 in the region lying in front of it.

Auf die breite Fläche kann dann der Ring 22 des Anschlussbolzens 20 aufgeschweißt oder gelötet werden.On the wide surface of the ring 22 of the connecting bolt 20 can then be welded or soldered.

Claims (15)

  1. Electrical flat strip conductor for motor vehicles comprising at least one aluminium conductor (2) of aluminium and of profiled cross-section produced by extrusion, wherein the aluminium conductor (2) is made of Al 99.5%, or a purer grade, or of alloys thereof, characterised in that the aluminium conductor (2) is soft-annealed in such a way that it allows a stretch of at least 30%.
  2. Electrical flat strip conductor according to Claim 1, characterised in that the aluminium conductor (2) is produced from aluminium strip which is unwound from a coil (6) and divided into single conductors.
  3. Electrical flat strip conductor according to Claim 1 or 2, characterised in that, with regard to its mechanical properties, the aluminium conductor (2) is in an as-produced state of 0.
  4. Electrical flat strip conductor according to any one of Claims 1 to 3, characterised in that the aluminium conductor (2) has a tensile strength of approximately 60 to 80 N/mm2 +/- 50%.
  5. Electrical flat strip conductor according to any one of Claims 1 to 4, characterised in that the flat strip conductor has a conductivity of approximately 30 to 37 m/(ohm*mm2).
  6. Electrical flat strip conductor according to any one of Claims 1 to 5, characterised in that at least one connecting pin (20) is applied to the surface of the flat strip conductor (1) as a point for electrical contact.
  7. Electrical flat strip conductor according to Claim 6, characterised in that the connecting pin (20) is at least partly formed from brass, copper or alloys thereof.
  8. Electrical flat strip conductor according to Claims 6 or 7, characterised in that the connecting pin (20) is connected to the aluminium conductor by material connection.
  9. Electrical flat strip conductor according to any one of Claims 6 to 8, characterised in that at least one connecting pin (20) is arranged between the ends of the flat strip conductor (1).
  10. Method of producing an electrical flat strip conductor (1) for motor vehicles, comprising at least one aluminium conductor (2) produced by extrusion, wherein the aluminium conductor (2) is made of Al 99.5%, or a purer grade, or of alloys thereof,
    - in which at least one previously soft-annealed aluminium semi-finished product is unwound from a coil (6),
    - in which an aluminium conductor (2) is formed from the unwound aluminium semi-finished product by dividing the aluminium semi-finished product, wherein the aluminium conductor (2) allows a stretch of at least 30%,
    - in which the aluminium conductor (2) is wound into a coil (12) after the dividing, and
    - in which the aluminium conductor (2) is unwound from the coil (12) and coated with an insulator.
  11. Method according to Claim 10, characterised in that the aluminium conductor (2) is formed by extrusion of the aluminium semi-finished product and in that the aluminium conductor is wound into a coil (6) after the extrusion.
  12. Method according to Claim 11, characterised in that, before or after being insulated, the flat strip conductor (1) is cut to length.
  13. Method according to Claim 12, characterised in that, after the cutting to length, the flat strip conductor (1) is bent in such a way that a cable loom is formed for a motor vehicle.
  14. Method according to Claims 12 or 13, characterised in that a connecting pin (20) is applied to the flat strip conductor (1), after it has been cut to length, by joining by material connection.
  15. Use of an electrical flat strip conductor according to a method according to any one of Claims 10 to 14 or according to any one of claims 1 to 9, in a motor vehicle.
EP05012641.6A 2005-02-03 2005-06-13 Electrical flat cable for motor vehicles Active EP1688966B1 (en)

Priority Applications (17)

Application Number Priority Date Filing Date Title
EP11168031.0A EP2383840B1 (en) 2005-02-03 2005-06-13 Electrical flat ribbon conductor for motor vehicles
EP05012641.6A EP1688966B1 (en) 2005-02-03 2005-06-13 Electrical flat cable for motor vehicles
CN2006800039024A CN101128888B (en) 2005-02-03 2006-01-12 Belt type electrical wire for motor vehicles and its manufacture method and uses
PCT/EP2006/050187 WO2006051121A1 (en) 2005-02-03 2006-01-12 Electrical ribbon conductor for a motor vehicle
US11/815,145 US20080194127A1 (en) 2005-02-03 2006-01-12 Electrical Flat Strip Conductor For Motor Vehicles
EP06708004A EP1844532B1 (en) 2005-02-03 2006-02-03 Connection of electrical cables
AT06708004T ATE456177T1 (en) 2005-02-03 2006-02-03 CONNECTING ELECTRICAL CABLES
PCT/EP2006/050648 WO2006082231A2 (en) 2005-02-03 2006-02-03 Connection of electrical cables
ES06708011T ES2421156T3 (en) 2005-02-03 2006-02-03 Multi-layer electric flat ribbon conductor
US11/813,711 US7598456B2 (en) 2005-02-03 2006-02-03 Connection of electrical cables
EP06708011.9A EP1844478B9 (en) 2005-02-03 2006-02-03 Multilayered electrical flat conductor
PCT/EP2006/050659 WO2006082238A1 (en) 2005-02-03 2006-02-03 Multilayered electrical flat conductor
DE502006005976T DE502006005976D1 (en) 2005-02-03 2006-02-03 CONNECTION OF ELECTRIC CABLES
CN201510674402.4A CN105355294A (en) 2005-02-03 2006-02-03 Multilayered electrical flat conductor
US11/815,144 US7687721B2 (en) 2005-02-03 2006-02-03 Multi-layered electrical flat strip conductor
EP13167659.5A EP2662866B1 (en) 2005-02-03 2006-02-03 Multilayered electrical flat conductor
ES13167659.5T ES2568486T3 (en) 2005-02-03 2006-02-03 Multi-layer flat ribbon electrical conductor

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP05002211 2005-02-03
EP05012641.6A EP1688966B1 (en) 2005-02-03 2005-06-13 Electrical flat cable for motor vehicles

Related Child Applications (2)

Application Number Title Priority Date Filing Date
EP11168031.0A Division-Into EP2383840B1 (en) 2005-02-03 2005-06-13 Electrical flat ribbon conductor for motor vehicles
EP11168031.0A Division EP2383840B1 (en) 2005-02-03 2005-06-13 Electrical flat ribbon conductor for motor vehicles

Publications (2)

Publication Number Publication Date
EP1688966A1 EP1688966A1 (en) 2006-08-09
EP1688966B1 true EP1688966B1 (en) 2014-03-26

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EP05012641.6A Active EP1688966B1 (en) 2005-02-03 2005-06-13 Electrical flat cable for motor vehicles
EP11168031.0A Active EP2383840B1 (en) 2005-02-03 2005-06-13 Electrical flat ribbon conductor for motor vehicles

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Application Number Title Priority Date Filing Date
EP11168031.0A Active EP2383840B1 (en) 2005-02-03 2005-06-13 Electrical flat ribbon conductor for motor vehicles

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US (2) US20080194127A1 (en)
EP (2) EP1688966B1 (en)
CN (1) CN105355294A (en)
AT (1) ATE456177T1 (en)
DE (1) DE502006005976D1 (en)
ES (2) ES2421156T3 (en)
WO (1) WO2006051121A1 (en)

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US20080190641A1 (en) 2008-08-14
EP2383840A3 (en) 2014-06-11
ES2421156T3 (en) 2013-08-29
ES2568486T3 (en) 2016-04-29
CN105355294A (en) 2016-02-24
EP2383840B1 (en) 2016-04-13
EP2383840A2 (en) 2011-11-02
ATE456177T1 (en) 2010-02-15
US7598456B2 (en) 2009-10-06
DE502006005976D1 (en) 2010-03-11
US20080194127A1 (en) 2008-08-14
WO2006051121A1 (en) 2006-05-18
EP1688966A1 (en) 2006-08-09

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