EP2673843B1 - Connecteur électrique pour connecter des câbles électriques à des terminaux électriques - Google Patents

Connecteur électrique pour connecter des câbles électriques à des terminaux électriques Download PDF

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Publication number
EP2673843B1
EP2673843B1 EP12707920.0A EP12707920A EP2673843B1 EP 2673843 B1 EP2673843 B1 EP 2673843B1 EP 12707920 A EP12707920 A EP 12707920A EP 2673843 B1 EP2673843 B1 EP 2673843B1
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EP
European Patent Office
Prior art keywords
connector
layer
tubular body
connection portion
terminal
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.)
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Application number
EP12707920.0A
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German (de)
English (en)
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EP2673843A1 (fr
Inventor
Giovanni Rosani
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Cembre SpA
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Cembre SpA
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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
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/20—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H01R11/12—End pieces terminating in an eye, hook, or fork
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
    • 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
    • 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
    • H01R4/64—Connections between or with conductive parts having primarily a non-electric function, e.g. frame, casing, rail
    • H01R4/646—Connections between or with conductive parts having primarily a non-electric function, e.g. frame, casing, rail for cables or flexible cylindrical bodies

Definitions

  • the object of the present invention is an electrical connector for connecting electrical cables to electrical terminals.
  • DE102007005810A1 indicates a state of the art for such connectors.
  • WO 2004/047 227 A1 indicates a connector according to the preamble of claim 1.
  • Single piece electrical connectors made of copper are known, which form a cable connection portion, for example a tubular or C-shaped seat suitable for receiving one end of an electric cable and for being compressed around such an end so as to obtain, a press-fit connection, as well as a terminal connection portion suitable for being connected in pressing contact, for example through a bolt, against an electrical terminal of a use.
  • a cable connection portion for example a tubular or C-shaped seat suitable for receiving one end of an electric cable and for being compressed around such an end so as to obtain, a press-fit connection, as well as a terminal connection portion suitable for being connected in pressing contact, for example through a bolt, against an electrical terminal of a use.
  • This known type of electrical connector can be applied to make electrical contacts in the civil, industrial and rail fields.
  • the electric conductors made of aluminium must be connected to the pre-existing terminals made of copper and also to the more common recently installed terminals which are still now very frequently made of copper.
  • Analogous requirements have arisen for connecting cables made of copper to terminals made of aluminium, for connecting cables of steel to terminals made of copper and vice versa, as well as for connecting cables made of steel to terminals made of aluminium and vice versa .
  • connectors so called cable terminal connectors
  • bi-metal connectors are currently sold on the market having a cable seat in aluminium that is suitable for being compressed onto the conductor, as well as a terminal connection portion made of copper that is suitable for being connected in contact with a terminal, in which the cable seat and the terminal connection portion are welded to one another.
  • the manufacturing process of the single parts made of aluminium and copper and their subsequent joining through welding is, on one hand, complex and costly and, on the other hand, is not able to obtain a copper-aluminium connection that is sufficiently reliable and resistant for applications in which the connectors undergo vibrations.
  • One example of electrical connections exposed to the external environment and undergoing vibrations and cyclical mechanical stress is the connection between electrical cables and train rails.
  • the purpose of the present invention is therefore that of proposing an electrical connector (so called cable terminal) for the connection of electrical cables made of a first metal (for example aluminium) to terminals made of a second metal (for example copper), having characteristics such as to withstand mechanical stress, in particular vibrations, and avoid the phenomenon of galvanic crevice corrosion.
  • a first metal for example aluminium
  • a second metal for example copper
  • a connector (cable terminal) for connecting an electric cable to a terminal, comprising a tubular body that forms a cable connection portion that is suitable for receiving one end of an electric cable and a terminal connection portion suitable for being connected in contact with a terminal, in which the tubular body comprises one inner layer that is substantially made of a first conductive metal that forms an inner surface of the tubular body and one outer layer that is substantially made of a second conductive metal that is different from the first conductive metal and that forms an outer surface of the tubular body, in which the outer surface forms a terminal contact surface of the terminal connection portion and the inner surface forms a cable contact surface of the cable connection portion, in which said inner layer and said outer layer are metallurgically bonded.
  • the connection between the two layers can be made through melting of the material in the transition area between the outer layer and the inner layer, for example through the manufacture of the bi-layer or multi-layer tubular body through drawing or co-extrusion.
  • the cable terminal thus configured makes it possible to obtain the specific advantages of a bi-metal cable terminal (no difference of galvanic potential in the area of contact between the cable terminal and the terminal) with low costs and with mechanical resistance that is suitable for applications undergoing vibrations.
  • the terms “substantially made of a first metal” and “substantially made of a second metal” or, more specifically “substantially made of copper” and “substantially made of aluminium” do not exclude alloys of such metals as long as the metals indicated form the main portion of the alloy itself.
  • the expressions “substantially made of copper” and “substantially made of aluminium” refer to the two metals as usually found on the market and used as conductors for the electrical and electro-technical industry.
  • the tubular body 8 comprises an inner layer 9 that is substantially made of a first conductive metal (for example aluminium, alternatively steel, copper) that forms an inner surface 17 of the tubular body 8 and an outer layer 10 substantially made of a second conductive metal (for example copper, alternatively aluminium, steel) that is different from the first conductive metal and that forms an outer surface 18 of the tubular body 8, in which the outer surface 18 forms a terminal contact surface of the terminal connection portion 6 and the inner surface 17 forms a cable contact surface of the cable connection portion 4.
  • a first conductive metal for example aluminium, alternatively steel, copper
  • a second conductive metal for example copper, alternatively aluminium, steel
  • the inner layer 9 and the outer layer 10 are connected to one another with continuity of material substantially over the entire surface, for example through melting of the material in the interface or transition area 19 between the outer layer and the inner layer. Consequently the inner layer is to all effects welded to the outer layer. This can be obtained for example through the manufacture of the bi-layer or multi-layer tubular body 8 through drawing or co-extrusion.
  • the latter are metallurgically bonded.
  • a metallurgical bond between the two metal layers can be obtained for example through the manufacture of the bi-layer or multi-layer tubular body through drawing.
  • a bi-layer or multi-layer tube previously preassembled is equipped with an inner floating mandrel and is cold drawn through one or a series of outer matrices so that the high pressure between the tube layers generates the aforementioned metallurgical bond.
  • the metallurgical bond between the two metal layers can be obtained by manufacturing the bi-layer or multi-layer tubular body through co-extrusion or, in other words, through co-extrusion welding (CEW) in which the two different metals are, for example, extruded simultaneously and together through the same matrix so that the high pressure and the high temperature generate the metallurgical bond in the transition area 19 between the two adjacent layers of the tube.
  • CEW co-extrusion welding
  • the metallurgical bond between the two metal layers can be obtained through the manufacture of the bi-layer or multi-layer tubular body through roll welding (ROW) in which the different metals are joined during their forced passage between the lamination rollers so that the high pressure and, if foreseen, the high temperature generate the metallurgical bond between the layers of the tube.
  • ROW roll welding
  • connection between the two layers thus obtained that is to say the metallurgical bond of the two different metal materials, is sometimes called "metallurgical cladding".
  • This connection is obtained through layers having preferably uniform thicknesses and not too thin and provides, together with minimum thicknesses of the metal layers involved of at least 0.5 mm, preferably from 0.5 mm to 10 mm, the most favourable mechanical and galvanic characteristics for the electrical connector.
  • the tubular body 8 is a two-layer tubular body with the inner layer 9 made of aluminium and the outer layer 10 made of copper, in which the inner layer 9 has a thickness ranging from 0.5 mm to 10 mm and the outer layer 10 has a thickness ranging from 0.5 mm to 2 mm.
  • metal bond we mean that the lattice structure of the two metals is forced in mutual conformance with sharing of electrons in the interface between the two layers which generates a bond at the atomic level.
  • the latter are metallurgically bonded and locally interpenetrated.
  • the transition area 19 with metallurgical bond extends continuously and uninterruptedly for the entire extension of the interface between the two layers.
  • both metal layers and also the interface between them substantially extend on the entire extension of the tubular body, the wall of which is therefore multi-layer all over and substantially without monolayer portions.
  • the cable terminal thus configured makes it possible to obtain the specific advantages of a bi-metal cable terminal (no difference of galvanic potential in the contact area between the cable terminal and the terminal) with low costs and with mechanical resistance that is suitable for applications undergoing vibration.
  • the terminal connection portion 5 is formed by a flattened end, for example through cold plastic deformation, of the multi-layer tubular body 8 and can be equipped with a through hole 11 that is suitable for receiving a bolt 12 or a connection screw.
  • the cable connection portion 4 is formed by one open end portion (tubular, for example cylindrical) of the tubular body 8, opposite to the flattened end, and suitable for receiving an end of the electric cable 2 as well as for being compressed around it so as to make a press-fit and shape connection ( Figures 3, 4 ).
  • the outer layer 10 extends beyond the inner layer 9, so that only the outer layer 10 is exposed to the external environment.
  • Such a configuration of the free edges of the tubular body 8 can be made for example through boring or milling of the ends of the tubular body 8 so as to eliminate an end section of the inner layer 9.
  • the end section of the outer layer above the inner layer can be folded towards the inside of the tubular body 8 to prevent exposure of the inner layer to the environment.
  • the flattened terminal connection portion is substantially symmetrical with respect to the cable connection portion.
  • the flattened terminal connection portion 6 defines a contact plane 16 that is substantially tangent to the outer surface 18 of the cable connection portion 4 or radially outside of it or inclined with respect to it, so that said contact plane 16 does not intersect the cable connection portion 4.

Landscapes

  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Coupling Device And Connection With Printed Circuit (AREA)

Claims (12)

  1. Connecteur (1) pour connecter un câble électrique (2) à un terminal (3), ledit connecteur (1) comprenant un corps tubulaire (8) qui forme une partie de connexion pour câble (4) adaptée pour recevoir le câble électrique (2) et une partie de connexion pour terminal (6) adaptée pour être connectée au terminal (3),
    dans lequel le corps tubulaire (8) est un corps tubulaire multicouches ayant une couche interne (9) d'un premier métal conducteur qui forme une surface interne (17) du corps tubulaire (8) et une couche externe (10) d'un second métal conducteur différent du premier métal conducteur et qui forme une surface externe (18) du corps tubulaire (8),
    dans lequel la surface externe (18) forme une surface de contact de terminal de la partie de connexion au terminal (6) et la surface interne (17) forme une surface de contact de câble de la partie de connexion au câble (4),
    caractérisé en ce que le corps tubulaire (8) est un tube multicouches sélectionné dans le groupe constitué par:
    des tubes multicouches tréfilés,
    des tubes multicouches co-extrudés,
    des tubes multicouches laminés,
    et lesdites couches externe (10) et interne (9) sont en liaison métallurgique.
  2. Connecteur (1) selon la revendication 1, dans lequel la couche interne (9) et la couche externe (10) s'étendent substantiellement sur la totalité du corps tubulaire (8).
  3. Connecteur (1) selon la revendication 1 ou 2, dans lequel ladite couche externe (10) et ladite couche interne (9) sont en liaison métallurgique et s'interpénètrent localement.
  4. Connecteur (1) selon l'une des revendications précédentes, dans lequel la partie de connexion au terminal (5) est formée à partir d'une extrémité aplatie du corps tubulaire (8).
  5. Connecteur (1) selon l'une quelconque des revendications précédentes, dans lequel la partie de connexion au terminal (5) définit un trou traversant (11) adapté pour recevoir un boulon (12) ou une vis de connexion, ledit trou traversant (11) s'étendant à travers les couches externe et interne (10, 9).
  6. Connecteur (1) selon l'une quelconque des revendications précédentes, dans lequel la partie de connexion au câble (4) est formée à partir d'une extrémité ouverte du corps tubulaire (8), à l'opposé de l'extrémité aplatie, et adaptée pour recevoir une extrémité du câble électrique (2) ainsi que pour être compressée autour d'elle, de manière à former un ajustement à pression.
  7. Connecteur (1) selon l'une quelconque des revendications précédentes, dans lequel au moins une extrémité libre (14, 15) du corps tubulaire (8) la couche externe (10) s'étend au-delà de la couche interne (9), de sorte que seule la couche externe (10) est exposée à l'environnement extérieur.
  8. Connecteur (1) selon l'une quelconque des revendications précédentes, dans lequel une section terminale de la couche externe (10) au-dessus de la couche interne est recourbée vers l'intérieur du corps tubulaire (8).
  9. Connecteur (1) selon l'une quelconque des revendications précédentes, dans lequel la partie de connexion au terminal (6) est aplatie et définit un plan de contact (16) orienté de manière à ne pas créer d'intersection avec la partie de connexion au câble (4).
  10. Connecteur (1) selon l'une quelconque des revendications précédentes, dans lequel ledit premier métal conducteur est sélectionné dans le groupe constitué par l'aluminium, le cuivre, l'acier, et ledit second métal conducteur est sélectionné dans le groupe constitué par le cuivre, l'acier, l'aluminium.
  11. Connecteur (1) selon l'une quelconque des revendications précédentes, dans lequel l'épaisseur de la couche interne (9) est foncièrement uniforme et supérieure ou égale à 0,5 mm et l'épaisseur de la couche externe (10) est foncièrement uniforme et supérieure ou égale à 0,5 mm.
  12. Connecteur (1) selon la revendication 11, dans lequel le corps tubulaire (8) est un corps tubulaire à deux couches, la couche interne (9) étant faite d'aluminium et la couche externe (10) étant faite de cuivre, dans lequel la couche interne (9) a une épaisseur allant de 0,5 mm à 10 mm et la couche externe (10) a une épaisseur allant de 0,5 mm à 2 mm.
EP12707920.0A 2011-02-09 2012-02-07 Connecteur électrique pour connecter des câbles électriques à des terminaux électriques Active EP2673843B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITMI2011A000192A IT1403926B1 (it) 2011-02-09 2011-02-09 Connettore elettrico per la connessione di cavi elettrici a terminali elettrici.
PCT/IB2012/050540 WO2012107873A1 (fr) 2011-02-09 2012-02-07 Connecteur électrique servant à connecter des câbles électriques à des bornes électriques

Publications (2)

Publication Number Publication Date
EP2673843A1 EP2673843A1 (fr) 2013-12-18
EP2673843B1 true EP2673843B1 (fr) 2016-03-23

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP12707920.0A Active EP2673843B1 (fr) 2011-02-09 2012-02-07 Connecteur électrique pour connecter des câbles électriques à des terminaux électriques

Country Status (3)

Country Link
EP (1) EP2673843B1 (fr)
IT (1) IT1403926B1 (fr)
WO (1) WO2012107873A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10971827B2 (en) 2017-10-06 2021-04-06 Tdk Electronics Ag Crimp interconnect device, crimped arrangement and method for making a crimped arrangement

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP5578592B1 (ja) * 2013-02-23 2014-08-27 古河電気工業株式会社 端子、電線接続構造体及び端子の製造方法
ES2505915B1 (es) * 2013-04-09 2015-08-11 Relats, S. A. Tejido trenzado para conector, a un conector que comprende a dicho tejido y a un conjunto de elemento a conectar a tierra
AT516232B1 (de) * 2014-09-10 2016-08-15 Gebauer & Griller Kabelwerke Ges M B H Verfahren zur Verbindung eines Kabelendes mit einem Verbindungselement
DE102018127729A1 (de) * 2018-11-07 2020-05-07 Auto-Kabel Management Gmbh Verfahren zur Herstellung eines Anschlussteils für elektrische Anlagen, Anschlussteil sowie Verbindung eines Anschlussteils mit einem Kabel

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GB1164100A (en) * 1967-09-13 1969-09-10 Amp Inc Terminal for Connection to Aluminium Wire
US3717839A (en) * 1971-01-08 1973-02-20 Amp Inc Threaded electrical connections
US5307562A (en) * 1992-11-06 1994-05-03 The Whitaker Corporation Method for making contact
JPH10134869A (ja) * 1996-10-30 1998-05-22 Yazaki Corp 端子材料および端子
WO2004047227A1 (fr) * 2002-11-19 2004-06-03 Gebauer & Griller Kabelwerke Gesellschaft M.B.H. Procede pour connecter un element de raccordement a un cable electrique
DE102007005810A1 (de) * 2007-01-17 2008-07-24 Gustav Klauke Gmbh Verfahren zur Herstellung eines Kabelschuhs und Kabelschuh
US7695331B2 (en) * 2007-05-01 2010-04-13 Tri-Star Technology Electrical contact assembly including a sleeve member
JP2009283287A (ja) * 2008-05-22 2009-12-03 Yazaki Corp アルミ電線用圧着端子

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10971827B2 (en) 2017-10-06 2021-04-06 Tdk Electronics Ag Crimp interconnect device, crimped arrangement and method for making a crimped arrangement

Also Published As

Publication number Publication date
ITMI20110192A1 (it) 2012-08-10
IT1403926B1 (it) 2013-11-08
WO2012107873A1 (fr) 2012-08-16
EP2673843A1 (fr) 2013-12-18

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