EP2747205B1 - Method for the electrically conductive connection of a stranded conductor with a contact element - Google Patents

Method for the electrically conductive connection of a stranded conductor with a contact element Download PDF

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Publication number
EP2747205B1
EP2747205B1 EP12306605.2A EP12306605A EP2747205B1 EP 2747205 B1 EP2747205 B1 EP 2747205B1 EP 12306605 A EP12306605 A EP 12306605A EP 2747205 B1 EP2747205 B1 EP 2747205B1
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EP
European Patent Office
Prior art keywords
contact element
stranded conductor
conductor
contact
electrically conductive
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
EP12306605.2A
Other languages
German (de)
French (fr)
Other versions
EP2747205A1 (en
Inventor
Helmut Dr. Steinberg
Udo Dr. Mayer
Johannes Denteler
Sunhilde Fleischer
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.)
Bayerische Motoren Werke AG
Nexans SA
Original Assignee
Bayerische Motoren Werke AG
Nexans SA
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 Bayerische Motoren Werke AG, Nexans SA filed Critical Bayerische Motoren Werke AG
Priority to EP12306605.2A priority Critical patent/EP2747205B1/en
Priority to US14/102,863 priority patent/US20140165394A1/en
Priority to BRBR102013032275-0A priority patent/BR102013032275A2/en
Publication of EP2747205A1 publication Critical patent/EP2747205A1/en
Application granted granted Critical
Publication of EP2747205B1 publication Critical patent/EP2747205B1/en
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Anticipated expiration legal-status Critical

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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
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048—Crimping apparatus or processes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/187—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping combined with soldering or welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—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
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0207—Ultrasonic-, H.F.-, cold- or impact welding
    • 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
    • Y10T29/49174—Assembling terminal to elongated conductor
    • Y10T29/49179—Assembling terminal to elongated conductor by metal fusion bonding
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49174—Assembling terminal to elongated conductor
    • Y10T29/49181—Assembling terminal to elongated conductor by deforming
    • Y10T29/49185—Assembling terminal to elongated conductor by deforming of terminal

Definitions

  • the invention relates to a method for the electrically conductive connection of a stranded conductor to an electrical contact element.
  • Conductors containing aluminum are increasingly used as a replacement for copper conductors, for example in automotive and aircraft technology.
  • the aluminum-containing conductors used therein are either made of aluminum or an aluminum alloy.
  • a major advantage of such electrical conductors is their lower weight compared to copper.
  • the lower electrical conductivity of aluminum compared to copper is of minor importance for most applications.
  • a disadvantage of these conductors is the fact that aluminum reacts with oxygen, whereby electrically insulating oxide layers are formed which surround the wires of a corresponding conductor.
  • the invention is based on the object of developing the method described at the outset in such a way that the contact point between the conductor and the contact element is effectively protected against vibrations.
  • the electrically conductive connection between the contact element and the conductor and the mechanical relief of the contact point are separated from one another, but using a one-piece component.
  • the electrically conductive connection is produced, for example by ultrasonic welding, in such a way that any oxide layers that may be present are broken up, so that the electrically conductive material of the conductor is connected directly to the contact element. Oxide layers that may form after completion of the contact point have no effect.
  • the mechanical relief of the contact point is achieved by the crimped holding part, which surrounds the conductor in the immediate vicinity of the contact point sufficiently tightly so that neither bending loads nor tensile loads and in particular coarser vibrations do not affect the long term Contact point can affect. It is important that the holding part only serves to fix the conductor in a mechanically stable manner, while the electrical connection is established directly between the conductor and the contact element.
  • contact element 1 consists for example of copper. However, it can also consist of another metal with good electrical conductivity.
  • the contact element 1 is intended to be used in motor vehicles, for example. In the case of assembly, it is connected to electrical contact parts that are attached, for example, to a starter, an electric motor or other electrical current carrying devices. The connection can be made, for example, by plugging on, screwing or welding.
  • the contact element 1 is according to Fig. 1 a flat component with an approximately rectangular cross-section. But it can also have a different geometric shape.
  • a holding part 2 suitable for a crimping process is connected in one piece to the contact element 1.
  • FIG Fig. 2 An electrical conductor to be connected both electrically and mechanically to the contact element 1 is shown in FIG Fig. 2 a stranded conductor 3 - hereinafter referred to as "conductor 3" for short - which consists of a large number of wires 4 combined to form a unit.
  • the wires 4 can be stranded with one another, for example. In the present case, they consist of aluminum or an aluminum alloy.
  • the conductor 3, which is easily bendable due to its structure as a stranded conductor, is surrounded by an insulation 5 which is removed from the end of the conductor 3 in order to carry out the method according to the invention.
  • an arrangement which ensures that oxide layers which surround the individual wires 4 of the conductor 3 are broken up. This ensures that the electrically conductive material of the conductor 3 or the wires 4 of the same is electrically conductively connected to the contact element 1 after the method has been completed.
  • such an arrangement is an ultrasonic welding system.
  • an electric welding system could also be used, for example, the current strength of which is high enough to destroy the oxide layers or which is coupled to a mechanical system by means of which the mentioned oxide layers are broken up.
  • the method according to the invention is carried out, for example, as follows: According to Fig. 2 The end of the prepared conductor 3 is placed on the contact element 1. The corresponding position can be mechanically stabilized by the holding part 2, which is crimped around the conductor 3. Then the conductor 3 or the wires 4 are placed on the contact element 1 and electrically conductively welded to the same by means of an ultrasonic welding system.
  • the illustrated geometric shape of the contact element 1 as a flat component an approximately rectangular, in Fig. 4 Contact point 6 bordered by dashed lines.
  • the surface of the sonotrode of the ultrasonic welding system facing the conductor 3 is expediently always adapted in its geometric shape so that it completely covers the conductor 3. This also applies in particular if the contact element 1 is not correspondingly a flat component Figs. 1 to 3 is executed, but has a different geometric shape.
  • the conductor 3 - as described - can initially be connected to the contact element 1 without actuating the holding part 2. After completion of the electrically conductive connection between conductor 3 and contact element 1, the holding part 2 is then crimped around the conductor 3 to relieve the mechanical stress on the contact point 6.

Description

Die Erfindung bezieht sich auf ein Verfahren zum elektrisch leitenden Verbinden eines Litzenleiters mit einem elektrischen Kontaktelement.The invention relates to a method for the electrically conductive connection of a stranded conductor to an electrical contact element.

Ein solches Verfahren geht aus der EP 2 001 085 B1 hervor.Such a procedure is based on the EP 2 001 085 B1 emerged.

Aluminium enthaltende Leiter werden als Ersatz für Kupferleiter immer öfter eingesetzt, beispielsweise in der Automobil- und Flugzeugtechnik. Die darin verwendeten, Aluminium enthaltenden Leiter bestehen entweder aus Aluminium oder aus einer Aluminiumlegierung. Ein wesentlicher Vorteil von derartigen elektrischen Leitern ist ihr gegenüber Kupfer geringeres Gewicht. Die geringere elektrische Leitfähigkeit des Aluminiums gegenüber Kupfer ist für die meisten Anwendungen hingegen von untergeordneter Bedeutung. Ein Nachteil dieser Leiter ist die Tatsache, daß Aluminium mit Sauerstoff reagiert, wodurch elektrisch isolierende Oxidschichten gebildet werden, welche die Drähte eines entsprechenden Leiters umgeben.Conductors containing aluminum are increasingly used as a replacement for copper conductors, for example in automotive and aircraft technology. The aluminum-containing conductors used therein are either made of aluminum or an aluminum alloy. A major advantage of such electrical conductors is their lower weight compared to copper. In contrast, the lower electrical conductivity of aluminum compared to copper is of minor importance for most applications. A disadvantage of these conductors is the fact that aluminum reacts with oxygen, whereby electrically insulating oxide layers are formed which surround the wires of a corresponding conductor.

In der US 3,717,842 A ist ein Verfahren beschrieben, mit welchem ein metallisches Kontaktelement an einen aus Aluminiumdrähten bestehenden Litzenleiter angecrimpt wird. Das Kontaktelement hat an seinem einen Ende Teile, welche um den Litzenleiter herumgecrimpt werden. An seinem anderen Ende ist das Kontaktelement so gebogen, daß es auf einen anderen elektrischen Kontakt aufgesteckt werden kann. Die Crimpverbindung wird zusätzlich mit Ultraschall beaufschlagt, wodurch die elektrische Verbindung zwischen Leiter und Kontaktelement verbessert wird und Oxidschichten, welche die Aluminiumdrähte gegebenenfalls umgeben, aufgebrochen werden.In the U.S. 3,717,842 A describes a method with which a metallic contact element is crimped onto a stranded conductor made of aluminum wires. The contact element has parts at one end which are crimped around the stranded conductor. At its other end, the contact element is bent so that it can be plugged onto another electrical contact. The crimp connection is additionally acted upon with ultrasound, whereby the electrical Connection between conductor and contact element is improved and oxide layers which may surround the aluminum wires are broken up.

Aus der eingangs erwähnten EP 2 001 085 B1 ist ein Verfahren zur Herstellung einer elektrisch leitenden Verbindung zwischen einem Aluminium enthaltenden elektrischen Litzenleiter und einem Kontaktteil eines elektrischen bzw. elektronischen Geräts bekannt. An dem von seiner Isolierung befreiten Ende des Leiters wird ein Kontaktelement durch Crimpen elektrisch leitend befestigt. Das Kontaktelement wird danach mit dem Kontaktteil des Geräts verbunden. Beim Crimpen des Kontaktelements werden die Oxidschichten des Litzenleiters durchbrochen, so daß sich eine elektrisch leitende Verbindung zwischen Kontaktelement und Leiter ergibt. Diese Verbindung hat sich in der Praxis bewährt. Sie kann aber in ungünstigen Fällen bei größeren Erschütterungen beeinträchtigt werden, wie sie beispielsweise beim Betrieb eines Kraftfahrzeugs auftreten.From the aforementioned EP 2 001 085 B1 a method for producing an electrically conductive connection between an electrical stranded conductor containing aluminum and a contact part of an electrical or electronic device is known. A contact element is attached in an electrically conductive manner by crimping to the end of the conductor that has been stripped of its insulation. The contact element is then connected to the contact part of the device. When the contact element is crimped, the oxide layers of the stranded conductor are broken through, so that an electrically conductive connection results between the contact element and the conductor. This connection has proven itself in practice. In unfavorable cases, however, it can be adversely affected by major vibrations, such as those that occur, for example, when operating a motor vehicle.

Der Erfindung liegt die Aufgabe zugrunde, das eingangs geschilderte Verfahren so weiterzubilden, daß die Kontaktstelle zwischen dem Leiter und dem Kontaktelement wirksam gegen Erschütterungen geschützt ist.The invention is based on the object of developing the method described at the outset in such a way that the contact point between the conductor and the contact element is effectively protected against vibrations.

Diese Aufgabe wird mit einem Verfahren mit den Merkmalen des Patentanspruchs 1 gelöst.This object is achieved with a method having the features of claim 1.

Bei diesem Verfahren sind die elektrisch leitende Verbindung zwischen dem Kontaktelement und dem Leiter sowie die mechanische Entlastung der Kontaktstelle voneinander getrennt, allerdings unter Einsatz eines einstückigen Bauteils. Die elektrisch leitende Verbindung wird, beispielsweise durch Ultraschallschweißung, so hergestellt, daß gegebenenfalls vorhandene Oxidschichten aufgebrochen werden, so daß das elektrisch leitende Material des Leiters direkt mit dem Kontaktelement verbunden wird. Oxidschichten, die sich nach Fertigstellung der Kontaktstelle gegebenenfalls bilden, bleiben ohne Einfluß. Die mechanische Entlastung der Kontaktstelle wird durch das gecrimpte Halteteil erreicht, welches den Leiter in unmittelbarer Nähe der Kontaktstelle ausreichend fest umgibt, so daß weder Biegebelastungen noch Zugbelastungen und insbesondere auch gröbere Erschütterungen sich auch auf Dauer nicht auf die Kontaktstelle auswirken können. Dabei ist von Bedeutung, daß das Halteteil nur der mechanisch stabilen Festlegung des Leiters dient, während die elektrische Verbindung direkt zwischen dem Leiter und dem Kontaktelement hergestellt wird.In this method, the electrically conductive connection between the contact element and the conductor and the mechanical relief of the contact point are separated from one another, but using a one-piece component. The electrically conductive connection is produced, for example by ultrasonic welding, in such a way that any oxide layers that may be present are broken up, so that the electrically conductive material of the conductor is connected directly to the contact element. Oxide layers that may form after completion of the contact point have no effect. The mechanical relief of the contact point is achieved by the crimped holding part, which surrounds the conductor in the immediate vicinity of the contact point sufficiently tightly so that neither bending loads nor tensile loads and in particular coarser vibrations do not affect the long term Contact point can affect. It is important that the holding part only serves to fix the conductor in a mechanically stable manner, while the electrical connection is established directly between the conductor and the contact element.

Das Verfahren nach der Erfindung wird anhand der Zeichnungen in einem Ausführungsbeispiel erläutert.The method according to the invention is explained in an exemplary embodiment with reference to the drawings.

Es zeigen:

  • Fig. 1 in schematischer Darstellung ein bei dem Verfahren nach der Erfindung einsetzbares Kontaktelement.
  • Fig. 2 das Ende eines elektrischen Leiters.
  • Fig. 3 und 4 zwei unterschiedliche Ansichten einer Verbindungsstelle zwischen einem Leiter und dem Kontaktelement nach Fig. 1.
Show it:
  • Fig. 1 a schematic representation of a contact element which can be used in the method according to the invention.
  • Fig. 2 the end of an electrical conductor.
  • Figures 3 and 4 two different views of a connection point between a conductor and the contact element Fig. 1 .

Das in Fig. 1 schematisch dargestellte Kontaktelement 1 besteht beispielsweise aus Kupfer. Es kann aber auch aus einem anderen elektrisch gut leitenden Metall bestehen. Das Kontaktelement 1 soll beispielsweise in Kraftfahrzeugen eingesetzt werden. Es wird im Montagefall mit elektrischen Kontaktteilen verbunden, die beispielsweise an einem Anlasser, einem Elektromotor oder anderen, elektrischen Strom führenden Geräten angebracht sind. Die Verbindung kann beispielsweise durch Aufstecken, Verschrauben oder Schweißen erfolgen. Das Kontaktelement 1 ist gemäß Fig. 1 ein flaches Bauteil mit einem etwa rechteckigen Querschnitt. Es kann aber auch eine andere geometrische Form haben. Einstückig mit dem Kontaktelement 1 ist ein für einen Crimpvorgang geeignetes Halteteil 2 verbunden.This in Fig. 1 schematically shown contact element 1 consists for example of copper. However, it can also consist of another metal with good electrical conductivity. The contact element 1 is intended to be used in motor vehicles, for example. In the case of assembly, it is connected to electrical contact parts that are attached, for example, to a starter, an electric motor or other electrical current carrying devices. The connection can be made, for example, by plugging on, screwing or welding. The contact element 1 is according to Fig. 1 a flat component with an approximately rectangular cross-section. But it can also have a different geometric shape. A holding part 2 suitable for a crimping process is connected in one piece to the contact element 1.

Ein mit dem Kontaktelement 1 sowohl elektrisch als auch mechanisch zu verbindender elektrischer Leiter ist gemäß Fig. 2 ein Litzenleiter 3 - im folgenden kurz "Leiter 3" genannt -, der aus einer Vielzahl von zu einer Einheit zusammengefaßten Drähten 4 besteht. Die Drähte 4 können beispielsweise miteinander verseilt sein. Sie bestehen im vorliegenden Fall aus Aluminium oder einer Aluminiumlegierung. Der durch den Aufbau als Litzenleiter gut biegbare Leiter 3 ist von einer Isolierung 5 umgeben, die zur Durchführung des Verfahrens nach der Erfindung vom Ende des Leiters 3 entfernt ist. Zum elektrisch leitenden Verbinden des Leiters 3 mit dem Kontaktelement 1 wird eine Anordnung eingesetzt, die sicherstellt, daß Oxidschichten aufgebrochen werden, welche die einzelnen Drähte 4 des Leiters 3 umgeben. Dadurch ist erreicht, daß das elektrisch leitende Material des Leiters 3 bzw. der Drähte 4 desselben nach Abschluß des Verfahrens mit dem Kontaktelement 1 elektrisch leitend verbunden ist. Eine solche Anordnung ist in bevorzugter Ausführungsform eine Ultraschallschweißanlage. Es könnte aber auch beispielsweise eine Elektro-Schweißanlage eingesetzt werden, deren Stromstärke zur Zerstörung der Oxidschichten hoch genug ist oder die mit einer mechanischen Anlage gekoppelt ist, durch welche die erwähnten Oxidschichten aufgebrochen werden.An electrical conductor to be connected both electrically and mechanically to the contact element 1 is shown in FIG Fig. 2 a stranded conductor 3 - hereinafter referred to as "conductor 3" for short - which consists of a large number of wires 4 combined to form a unit. The wires 4 can be stranded with one another, for example. In the present case, they consist of aluminum or an aluminum alloy. The conductor 3, which is easily bendable due to its structure as a stranded conductor, is surrounded by an insulation 5 which is removed from the end of the conductor 3 in order to carry out the method according to the invention. For the electrically conductive connection of the conductor 3 to the contact element 1, an arrangement is used which ensures that oxide layers which surround the individual wires 4 of the conductor 3 are broken up. This ensures that the electrically conductive material of the conductor 3 or the wires 4 of the same is electrically conductively connected to the contact element 1 after the method has been completed. In a preferred embodiment, such an arrangement is an ultrasonic welding system. However, an electric welding system could also be used, for example, the current strength of which is high enough to destroy the oxide layers or which is coupled to a mechanical system by means of which the mentioned oxide layers are broken up.

Das Verfahren nach der Erfindung wird beispielsweise wie folgt durchgeführt:
Der gemäß Fig. 2 vorbereitete Leiter 3 wird mit seinem Ende auf das Kontaktelement 1 aufgelegt. Die entsprechende Position kann durch das Halteteil 2 mechanisch stabilisiert werden, welches um den Leiter 3 herumgecrimpt wird. Danach werden der Leiter 3 bzw. die Drähte 4 auf das Kontaktelement 1 aufgelegt und mittels einer Ultraschallschweißanlage elektrisch leitend mit demselben verschweißt. Es ergibt sich bei der dargestellten geometrischen Form des Kontaktelements 1 als flaches Bauteil eine etwa rechteckige, in Fig. 4 gestrichelt umrandete Kontaktstelle 6. Die dem Leiter 3 zugewandte Oberfläche der Sonotrode der Ultraschallschweißanlage wird zweckmäßig stets in ihrer geometrischen Form so angepaßt, daß sie den Leiter 3 vollständig abdeckt. Das gilt insbesondere auch dann, wenn das Kontaktelement 1 nicht als flaches Bauteil entsprechend Fig. 1 bis 3 ausgeführt ist, sondern eine andere geometrische Form hat.The method according to the invention is carried out, for example, as follows:
According to Fig. 2 The end of the prepared conductor 3 is placed on the contact element 1. The corresponding position can be mechanically stabilized by the holding part 2, which is crimped around the conductor 3. Then the conductor 3 or the wires 4 are placed on the contact element 1 and electrically conductively welded to the same by means of an ultrasonic welding system. In the illustrated geometric shape of the contact element 1 as a flat component, an approximately rectangular, in Fig. 4 Contact point 6 bordered by dashed lines. The surface of the sonotrode of the ultrasonic welding system facing the conductor 3 is expediently always adapted in its geometric shape so that it completely covers the conductor 3. This also applies in particular if the contact element 1 is not correspondingly a flat component Figs. 1 to 3 is executed, but has a different geometric shape.

In einer anderen Ausführungsform des Verfahrens kann der Leiter 3 - so wie beschrieben - zunächst ohne Betätigung des Halteteils 2 mit dem Kontaktelement 1 verbunden werden. Das Halteteil 2 wird dann nach Fertigstellung der elektrisch leitenden Verbindung zwischen Leiter 3 und Kontaktelement 1 zur mechanischen Entlastung der Kontaktstelle 6 um den Leiter 3 herumgecrimpt.In another embodiment of the method, the conductor 3 - as described - can initially be connected to the contact element 1 without actuating the holding part 2. After completion of the electrically conductive connection between conductor 3 and contact element 1, the holding part 2 is then crimped around the conductor 3 to relieve the mechanical stress on the contact point 6.

Claims (4)

  1. A method for the electrically conductive connection of a stranded conductor (3) surrounded by an insulation (5), which has a plurality of wires containing aluminum, having an electrical contact element (1), wherein the contact element (1) designed as a flat component with an approximately rectangular cross section has an approximately rectangular contact point (6) for the electrically conductive connection between the contact element and the stranded conductor (3) and a mechanical holding part (2) integrally connected to the contact element (1) for the mechanical relief of the contact point, wherein the contact point (6) and the holding part (2) are separated from one another on the one-piece component, wherein the stripped stranded conductor is placed with its end on the contact element (1), wherein the stranded conductor (3) is connected electrically conductively to the contact element at its end under destruction of the oxide layers of the wires (4) at the contact point (6) located on the contact element (1) and wherein the holding part (2) integrally connected to the contact element (1) is crimped around the stripped stranded conductor (3).
  2. The method according to claim 1, characterized in that first the stranded conductor (3) and the contact element (1) are electrically conductively connected to each other at the contact point (6) and then the holding part (2) is crimped around the stranded conductor (3).
  3. The method according to claim 1, characterized in that first the holding part (2) is crimped around the stranded conductor (3) and the stranded conductor (3) is then electrically conductively connected to the contact element (1) at the contact point (6).
  4. The method according to claims 1 to 3, characterized in that the stranded conductor (3) and the contact element (1) are electrically conductively connected to one another at the contact point (6) by means of an ultrasonic welding system.
EP12306605.2A 2012-12-18 2012-12-18 Method for the electrically conductive connection of a stranded conductor with a contact element Active EP2747205B1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
EP12306605.2A EP2747205B1 (en) 2012-12-18 2012-12-18 Method for the electrically conductive connection of a stranded conductor with a contact element
US14/102,863 US20140165394A1 (en) 2012-12-18 2013-12-11 Method for electrically conductively connecting a stranded conductor to a contact element
BRBR102013032275-0A BR102013032275A2 (en) 2012-12-18 2013-12-16 METHOD FOR ELECTRICAL CONNECTION OF A WIRE CONDUCTOR WITH A CONTACT ELEMENT

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP12306605.2A EP2747205B1 (en) 2012-12-18 2012-12-18 Method for the electrically conductive connection of a stranded conductor with a contact element

Publications (2)

Publication Number Publication Date
EP2747205A1 EP2747205A1 (en) 2014-06-25
EP2747205B1 true EP2747205B1 (en) 2021-04-14

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EP12306605.2A Active EP2747205B1 (en) 2012-12-18 2012-12-18 Method for the electrically conductive connection of a stranded conductor with a contact element

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US (1) US20140165394A1 (en)
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BR (1) BR102013032275A2 (en)

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EP3270464B1 (en) 2016-07-13 2018-09-12 Nexans Method for connecting a contact element to an electrical conductor
JP6989560B2 (en) * 2019-04-22 2022-01-05 矢崎総業株式会社 Manufacturing method of electric wire with terminal and vibration damping method of electric wire

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JP2011165618A (en) * 2010-02-15 2011-08-25 Hitachi Cable Ltd Wire with terminal
JP2011060778A (en) * 2010-11-30 2011-03-24 Hitachi Cable Ltd Connection terminal and aluminum cable with the same

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BR102013032275A2 (en) 2014-09-02
EP2747205A1 (en) 2014-06-25

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