EP3270464B1 - Method for connecting a contact element to an electrical conductor - Google Patents

Method for connecting a contact element to an electrical conductor Download PDF

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Publication number
EP3270464B1
EP3270464B1 EP16305913.2A EP16305913A EP3270464B1 EP 3270464 B1 EP3270464 B1 EP 3270464B1 EP 16305913 A EP16305913 A EP 16305913A EP 3270464 B1 EP3270464 B1 EP 3270464B1
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EP
European Patent Office
Prior art keywords
contact element
conductor
stranded conductor
tab
contact
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EP16305913.2A
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German (de)
French (fr)
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EP3270464A1 (en
Inventor
Helmut Steinberg
Roy Karchs
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Nexans SA
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Nexans SA
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Priority to ES16305913T priority Critical patent/ES2699917T3/en
Priority to EP16305913.2A priority patent/EP3270464B1/en
Publication of EP3270464A1 publication Critical patent/EP3270464A1/en
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Publication of EP3270464B1 publication Critical patent/EP3270464B1/en
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    • 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
    • H01R43/28—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26
    • 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
    • H01R4/10—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
    • H01R4/183—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 for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H01R4/184—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 for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion

Definitions

  • the invention relates to a method for the electrically conductive connection of a contact element to an electrical conductor according to the preamble of patent claim 1.
  • Such a method is for example from the EP 2 747 205 A1 out.
  • Aluminum-containing conductors are being used more and more frequently as a replacement for copper conductors, for example in the automotive and aerospace industries.
  • the aluminum-containing conductors used therein are made of either aluminum or an aluminum alloy. In the following, for the sake of simplicity, only aluminum is mentioned.
  • a significant advantage of such electrical conductors is compared to copper lighter weight.
  • the lower electrical conductivity of the aluminum compared to copper, however, is of minor importance for most applications.
  • a disadvantage of these conductors is the fact that aluminum reacts with oxygen, forming an electrically insulating oxide layer surrounding the conductor and in particular each of the wires of a corresponding stranded conductor.
  • EP 2 001 085 B1 is a method for producing an electrically conductive connection between an aluminum-containing electrical stranded conductor and a contact portion of an electrical or electronic device described.
  • a contact element is fixed in an electrically conductive manner by crimping.
  • the contact element is then connected to the contact part of the device.
  • the oxide layers of the stranded conductor are broken, so that an effective electrically conductive connection between the contact element and conductor results.
  • This method has proven itself in practice. However, the corresponding compound can be affected in unfavorable cases with larger shocks, such as occur during operation of a motor vehicle.
  • the WO 2013/151185 A1 describes a contact element which is attached to the end of an electrical conductor freed from its insulation.
  • the contact element has a contact zone serving the electrical connection and two attachment regions.
  • the contact element is crimped onto the conductor with one fastening region, while the second fastening region is wrapped around the insulation still present on the conductor. Finally, a material serving as corrosion protection is formed around the crimp area.
  • the material has two layers of electrically conductive material, between which a layer of insulating material or plastic is attached.
  • the one metallic layer has resilient properties. It serves to press a pin, which is made of the material, firmly against the wall of a socket.
  • the other metallic layer is made of good conductive material.
  • JP 2009 231079 A a method is described, with which a contact element designed as a cable lug, which has a fastening part, is crimped with this fastening part to an aluminum wire consisting of electrical conductors. Oxide layers surrounding the aluminum wires are destroyed by ultrasound, and the attachment part of the contact element is then crimped around the conductor reduced in diameter at its end.
  • the US 2013/0309903 A1 describes a method by which a contact element can be attached by crimping to an electrical conductor. It consists of conventional electrically conductive material.
  • the contact element has a for the Crimping provided fastening part and provided for example with a through hole connecting part. Between the fastening part and the connecting part, the contact element has a projection which is approximately V-shaped and projects on one side from the contact element. The projection serves to limit the conductor, which rests in the mounting position below the projection.
  • EP 2 747 205 A1 shows a method in which an aluminum-containing, consisting of wires electrical stranded conductor at its end by destroying the wires thereof optionally surrounding oxide layers by ultrasonic welding is electrically connected to a contact element.
  • An integrally connected to the contact element fastener is crimped around the stranded conductor in addition to the electrical contact point between the stranded conductor and the contact element.
  • the electrically conductive connection between the contact element and the conductor and the mechanical discharge of the contact point using the one-piece contact element are separated.
  • the electrically conductive connection is made by ultrasonic welding so that any existing oxide layers are broken, so that the electrically conductive material of the conductor is connected directly to the contact element.
  • This method has proven itself in practice. The welding of the stranded conductor with the contact element is relatively expensive.
  • the invention has for its object to make the initially described method so that the contact element can be attached to the electrical conductor with reduced effort.
  • Sprung electrically conductive material is advantageously an electrically good conductive metal, such as stainless steel.
  • a corresponding contact element can be coated, at least on the side intended for contact with the stranded conductor, with a metal which is highly conductive, in particular copper.
  • conductor For attaching the contact element at the end of the stranded conductor - hereinafter referred to only as "conductor” - an electrical contact surface is initially generated on the end face, the total of the aluminum of the conductor, ie in particular with the aluminum of the wires thereof, is connected.
  • different methods are known which work almost exclusively with the supply of heat in order to melt the aluminum of the conductor. This process step is the only one with which heat is supplied to the conductor. It serves to prepare the conductor end for the electrically effective attachment of the contact element to the same.
  • a corresponding method is for example in the DE 10 2011 089 207 A1 described. In this method, the material of the conductor is melted at its end by means of ultrasound.
  • the contact element is fixed purely mechanically fixed and immovable and electrically conductively connected to the contact surface of the conductor.
  • the approximately or substantially strip-shaped contact element consists entirely of resilient metal.
  • metal can be used with advantage stainless steel.
  • the contact element may be coated overall with an electrically highly conductive material, for example with copper.
  • the surfaces of the contact element are coated with the highly conductive material, which rest in the assembled state on the conductor or on its contact surface.
  • obliquely projecting from the same tab consists of the same resilient material as the contact element.
  • the angle at which the tab protrudes from the contact element is between 84 ° and 87 °. It is essential that the slope of the tab has in the direction of the fastening part of the contact element.
  • the contact element To attach the contact element to the conductor, the same is arranged parallel to the conductor, in such a way that it lies with its end against the conductor on which the fastening part is located. In this position, the tab is still relatively loose at the contact surface of the conductor. The contact element is then displaced in the axial direction of the conductor, whereby the tab is bent by the conductor against its spring force and thereby pressed with increased force to the contact surface of the conductor. In this position, which is kept stable, the fastening part of the contact element is firmly and immovably formed around the conductor. This end position of the contact element is maintained in the long run and the tab is permanently pressed against the contact surface of the conductor. The fastening part will be fixed by crimping on the conductor.
  • the contact element may also have a second attachment part attached adjacent to the first attachment part.
  • the second attachment member may be wrapped around and secured to a portion of the conductor which is provided with insulation.
  • Fig. 1 schematically the end of an aluminum-containing electrical conductor 1 is shown, which has a number of combined into one unit wires 2.
  • the wires 2 are stranded together, for example.
  • the conductor 1 is surrounded by an insulation 3, which is at the end of the same removed.
  • On the front side of the conductor 1 is an electrically conductive, indicated by a cross-hatching contact surface 4 is present, which is electrically conductively connected to the aluminum of all wires 2 of the conductor 1.
  • the contact surface 4 is generated in a known technique by supplying heat, for example in an ultrasonic system.
  • Fig. 3 shows an electrical contact element 5, which is designed substantially or strip-shaped.
  • the contact element 5 is made of a resilient metal, for example made of stainless steel. It has at its one end a fastening part 6, which is designed according to the drawing representation wider than the remaining part of the contact element 5 and serves to fix the contact element 5 on the conductor 1.
  • a tab 7 is cut out so far, for example by punching, that a transverse edge 8 is maintained.
  • the end 9 of the contact element 5 is used to connect secondary contacts or conductors.
  • the tab 7 is bent around the edge 8, so that it protrudes at an angle ⁇ from the contact element 5, which is between 80 ° and 89 °.
  • the angle ⁇ is more preferable Embodiment between 84 ° and 87 °.
  • the tab 7 is in the corresponding inclination due to their resilient material under spring tension.
  • the slope of the tab 7 points in the direction of the fastening part 6 of the contact element 5.
  • the size of the angle a also depends on the resilient material used for the contact element 5.
  • the contact element 5 can according to Fig. 4 also have a second fastening part 10 which is mounted adjacent to the fastening part 6. It can be used with advantage for additional definition of the contact element 5 on the conductor 1 in its provided with the insulation 3 area.
  • the contact element 5 For mounting the contact element 5 on the conductor 1, for example, proceed as follows: The contact element 5 is corresponding Fig. 6 with parallel course to the conductor 1 is applied to the same. The tab 7 then abuts the contact surface 4, which is located on the front side of the conductor 1. The oblique course of the tab 7 is in Fig. 6 slightly exaggerated to clearly show the corresponding starting position of the contact element 5. Thereafter, the contact element 5 is displaced in the axial direction of the conductor 1 under further contact with the same with pressure. As a result, the tab 7 is bent against its spring tension around the edge 8 so that it is pressed against the contact surface 4 with increased force.
  • the fastening part 6 is formed around the conductor 1 so that the contact element 5 is firmly and immovably fixed to the conductor 1, as it is in Fig. 7 is shown. This can be done for example by crimping.
  • the possibly existing second fastening part 10 can be set in an analogous manner in addition to the insulation 3 on the conductor 1. The positions of the contact element 5 on the conductor 1 and in particular the tab 7 on the contact surface 4 are thus ensured in total over time.

Description

Die Erfindung bezieht sich auf ein Verfahren zum elektrisch leitenden Anschließen eines Kontaktelements an einen elektrischen Leiter gemäß dem Oberbegriff des Patentanspruchs 1.The invention relates to a method for the electrically conductive connection of a contact element to an electrical conductor according to the preamble of patent claim 1.

Ein solches Verfahren geht beispielweise aus der EP 2 747 205 A1 hervor.Such a method is for example from the EP 2 747 205 A1 out.

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. Im Folgenden wird der Einfachheit halber nur noch Aluminium erwähnt. 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 eine elektrisch isolierende Oxidschicht gebildet wird, welche den Leiter und insbesondere jeden der Drähte eines entsprechenden Litzenleiters umgibt.Aluminum-containing conductors are being used more and more frequently as a replacement for copper conductors, for example in the automotive and aerospace industries. The aluminum-containing conductors used therein are made of either aluminum or an aluminum alloy. In the following, for the sake of simplicity, only aluminum is mentioned. A significant advantage of such electrical conductors is compared to copper lighter weight. The lower electrical conductivity of the aluminum compared to copper, however, is of minor importance for most applications. A disadvantage of these conductors is the fact that aluminum reacts with oxygen, forming an electrically insulating oxide layer surrounding the conductor and in particular each of the wires of a corresponding stranded conductor.

In der 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 beschrieben. 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 wirksame elektrisch leitende Verbindung zwischen Kontaktelement und Leiter ergibt. Dieses Verfahren hat sich in der Praxis bewährt. Die entsprechende Verbindung kann aber in ungünstigen Fällen bei größeren Erschütterungen beeinträchtigt werden, wie sie beispielsweise beim Betrieb eines Kraftfahrzeugs auftreten.In the EP 2 001 085 B1 is a method for producing an electrically conductive connection between an aluminum-containing electrical stranded conductor and a contact portion of an electrical or electronic device described. At the end of the conductor which has been freed from its insulation, a contact element is fixed in an electrically conductive manner by crimping. The contact element is then connected to the contact part of the device. When crimping the contact element, the oxide layers of the stranded conductor are broken, so that an effective electrically conductive connection between the contact element and conductor results. This method has proven itself in practice. However, the corresponding compound can be affected in unfavorable cases with larger shocks, such as occur during operation of a motor vehicle.

Die WO 2013/151185 A1 beschreibt ein Kontaktelement, das am Ende eines von seiner Isolierung befreiten elektrischen Leiters befestigt wird. Das Kontaktelement hat eine dem elektrischen Anschluß dienende Kontaktzone und zwei Befestigungsbereiche. Mit dem einen Befestigungsbereich wird das Kontaktelement an den Leiter angecrimpt, während der zweite Befestigungsbereich um die noch auf dem Leiter vorhandene Isolierung herumgelegt wird. Um den Crimpbereich wird abschließend ein als Korrosionsschutz dienendes Material herumgeformt.The WO 2013/151185 A1 describes a contact element which is attached to the end of an electrical conductor freed from its insulation. The contact element has a contact zone serving the electrical connection and two attachment regions. The contact element is crimped onto the conductor with one fastening region, while the second fastening region is wrapped around the insulation still present on the conductor. Finally, a material serving as corrosion protection is formed around the crimp area.

Aus der US 4,650,723 geht ein Material zur Herstellung von in Verbindern verwendbaren Kontakten hervor. Das Material hat zwei Schichten aus elektrisch leitendem Material, zwischen denen eine Schicht aus Isoliermaterial bzw. Kunststoff angebracht ist. Die eine metallische Schicht hat federnde Eigenschaften. Sie dient dazu, einen Steckerstift, der aus dem Material hergestellt ist, fest an die Wandung einer Steckbuchse zu drücken. Die andere metallische Schicht besteht aus gut leitendem Material.From the US 4,650,723 there is a material for making contacts usable in connectors. The material has two layers of electrically conductive material, between which a layer of insulating material or plastic is attached. The one metallic layer has resilient properties. It serves to press a pin, which is made of the material, firmly against the wall of a socket. The other metallic layer is made of good conductive material.

In der JP 2009 231079 A ist ein Verfahren beschrieben, mit dem ein als Kabelschuh ausgeführtes Kontaktelement, das einen Befestigungsteil aufweist, mit diesem Befestigungsteil an einen aus Aluminiumdrähten bestehenden elektrischen Leiter angecrimpt wird. Oxidschichten, welche die Aluminiumdrähte umgeben, werden durch Ultraschall zerstört und das Befestigungsteil des Kontaktelements wird dann um den an seinem Ende im Durchmesser reduzierten Leiter herumgecrimpt.In the JP 2009 231079 A a method is described, with which a contact element designed as a cable lug, which has a fastening part, is crimped with this fastening part to an aluminum wire consisting of electrical conductors. Oxide layers surrounding the aluminum wires are destroyed by ultrasound, and the attachment part of the contact element is then crimped around the conductor reduced in diameter at its end.

Die US 2013/0309903 A1 beschreibt ein Verfahren, mit dem ein Kontaktelement durch Crimpen an einem elektrischen Leiter befestigt werden kann. Es besteht aus üblichem elektrisch leitendem Material. Das Kontaktelement hat einen für den Crimpvorgang vorgesehenen Befestigungsteil und einen beispielsweise mit einem Durchgangsloch versehenen Anschlußteil. Zwischen Befestigungsteil und Anschlußteil hat das Kontaktelement einen Vorsprung, der etwa V-förmig ausgebildet ist und auf einer Seite von dem Kontaktelement absteht. Der Vorsprung dient zur Begrenzung für den Leiter, der in Montageposition unten am Vorsprung anliegt.The US 2013/0309903 A1 describes a method by which a contact element can be attached by crimping to an electrical conductor. It consists of conventional electrically conductive material. The contact element has a for the Crimping provided fastening part and provided for example with a through hole connecting part. Between the fastening part and the connecting part, the contact element has a projection which is approximately V-shaped and projects on one side from the contact element. The projection serves to limit the conductor, which rests in the mounting position below the projection.

Aus der eingangs erwähnten EP 2 747 205 A1 geht ein Verfahren hervor, bei dem ein Aluminium enthaltender, aus Drähten bestehender elektrischer Litzenleiter an seinem Ende unter Zerstörung von die Drähte desselben gegebenenfalls umgebenden Oxidschichten durch Ultraschallschweißen elektrisch leitend an ein Kontaktelement angeschlossen wird. Ein einstückig mit dem Kontaktelement verbundenes Befestigungselement wird neben der elektrischen Kontaktstelle zwischen dem Litzenleiter und dem Kontaktelement um den Litzenleiter herumgecrimpt. Bei diesem Verfahren sind die elektrisch leitende Verbindung zwischen dem Kontaktelement und dem Leiter sowie die mechanische Entlastung der Kontaktstelle unter Einsatz des einstückigen Kontaktelements voneinander getrennt. Die elektrisch leitende Verbindung wird durch Ultraschallschweißung so hergestellt, dass gegebenenfalls vorhandene Oxidschichten aufgebrochen werden, so dass das elektrisch leitende Material des Leiters direkt mit dem Kontaktelement verbunden wird. Auch dieses Verfahren hat sich in der Praxis bewährt. Die Verschweißung des Litzenleiters mit dem Kontaktelement ist aber relativ aufwendig.From the above-mentioned EP 2 747 205 A1 shows a method in which an aluminum-containing, consisting of wires electrical stranded conductor at its end by destroying the wires thereof optionally surrounding oxide layers by ultrasonic welding is electrically connected to a contact element. An integrally connected to the contact element fastener is crimped around the stranded conductor in addition to the electrical contact point between the stranded conductor and the contact element. In this method, the electrically conductive connection between the contact element and the conductor and the mechanical discharge of the contact point using the one-piece contact element are separated. The electrically conductive connection is made by ultrasonic welding so that any existing oxide layers are broken, so that the electrically conductive material of the conductor is connected directly to the contact element. This method has proven itself in practice. The welding of the stranded conductor with the contact element is relatively expensive.

Der Erfindung liegt die Aufgabe zugrunde, das eingangs geschilderte Verfahren so zu gestalten, dass das Kontaktelement mit vermindertem Aufwand am elektrischen Leiter angebracht werden kann.The invention has for its object to make the initially described method so that the contact element can be attached to the electrical conductor with reduced effort.

Diese Aufgabe wird entsprechend den kennzeichnenden Merkmalen des Patentanspruchs 1 gelöst.This object is achieved according to the characterizing features of claim 1.

Federndes elektrisch leitfähiges Material ist mit Vorteil ein elektrisch gut leitendes Metall, wie beispielsweise Edelstahl. Ein entsprechendes Kontaktelement kann zumindest auf der zur Anlage am Litzenleiter bestimmten Seite mit einem elektrisch gut leitenden Metall, wie insbesondere Kupfer, beschichtet sein. Zum Anbringen des Kontaktelements am Ende des Litzenleiters - im Folgenden nur noch als "Leiter" bezeichnet - wird an dessen Stirnseite zunächst eine elektrische Kontaktfläche erzeugt, die insgesamt mit dem Aluminium des Leiters, also insbesondere mit dem Aluminium der Drähte desselben, verbunden ist. Dafür sind unterschiedliche Verfahren bekannt, die nahezu ausschließlich mit Wärmezufuhr arbeiten, um das Aluminium des Leiters aufzuschmelzen. Dieser Verfahrensschritt ist der einzige, mit welchem dem Leiter Wärme zugeführt wird. Er dient zur Vorbereitung des Leiterendes zur elektrisch wirksamen Befestigung des Kontaktelements an demselben. Ein entsprechendes Verfahren ist beispielsweise in der DE 10 2011 089 207 A1 beschrieben. Bei diesem Verfahren wird das Material des Leiters an seinem Ende mittels Ultraschalls geschmolzen.Sprung electrically conductive material is advantageously an electrically good conductive metal, such as stainless steel. A corresponding contact element can be coated, at least on the side intended for contact with the stranded conductor, with a metal which is highly conductive, in particular copper. For attaching the contact element at the end of the stranded conductor - hereinafter referred to only as "conductor" - an electrical contact surface is initially generated on the end face, the total of the aluminum of the conductor, ie in particular with the aluminum of the wires thereof, is connected. For this purpose, different methods are known which work almost exclusively with the supply of heat in order to melt the aluminum of the conductor. This process step is the only one with which heat is supplied to the conductor. It serves to prepare the conductor end for the electrically effective attachment of the contact element to the same. A corresponding method is for example in the DE 10 2011 089 207 A1 described. In this method, the material of the conductor is melted at its end by means of ultrasound.

An dem mit der Kontaktfläche versehenen Leiter wird das Kontaktelement rein mechanisch fest und unverrückbar festgelegt und elektrisch leitend mit der Kontaktfläche des Leiters verbunden. Das etwa bzw. im Wesentlichen streifenförmige Kontaktelement besteht insgesamt aus federndem Metall. Als Metall kann mit Vorteil Edelstahl eingesetzt werden. Das Kontaktelement kann insgesamt mit einem elektrisch gut leitenden Material beschichtet sein, beispielsweise mit Kupfer. In bevorzugter Ausführungsform sind insbesondere die Flächen des Kontaktelements mit dem gut leitenden Material beschichtet, die im Montagezustand am Leiter bzw. an seiner Kontaktfläche anliegen.At the conductor provided with the contact surface, the contact element is fixed purely mechanically fixed and immovable and electrically conductively connected to the contact surface of the conductor. The approximately or substantially strip-shaped contact element consists entirely of resilient metal. As metal can be used with advantage stainless steel. The contact element may be coated overall with an electrically highly conductive material, for example with copper. In a preferred embodiment, in particular the surfaces of the contact element are coated with the highly conductive material, which rest in the assembled state on the conductor or on its contact surface.

Die im Verlauf des Kontaktelements unter einem Winkel, der zwischen 80° und 89° liegt, also der kleiner als 90° ist, schräg von demselben abstehende Lasche besteht aus dem gleichen federnden Material wie das Kontaktelement. In bevorzugter Ausführungsform liegt der Winkel, unter dem die Lasche vom Kontaktelement absteht, zwischen 84° und 87°. Dabei ist wesentlich, dass die Schräge der Lasche in Richtung des Befestigungsteils des Kontaktelements weist. Beim Anlegen des Kontaktelements an den Leiter wird dasselbe in Richtung von der Stirnseite desselben fortweisend mit Druck bewegt, so dass die Lasche entgegen ihrer Federwirkung bzw. Vorspannung an die Kontaktfläche gedrückt wird. Die Lasche ist mit Vorteil durch Stanzen teilweise aus dem Kontaktelement herausgeschnitten und anschließend um eine im Kontaktelement verbleibende Kante in ihre Position abgebogen. In dieser Position steht sie - wie bereits erwähnt - unter Federspannung, so dass sie bei einer Druckbelastung und einer damit verbundenen Auslenkung aus ihrer Position ständig in diese zurück gelangen will.In the course of the contact element at an angle which is between 80 ° and 89 °, that is less than 90 °, obliquely projecting from the same tab consists of the same resilient material as the contact element. In a preferred embodiment, the angle at which the tab protrudes from the contact element is between 84 ° and 87 °. It is essential that the slope of the tab has in the direction of the fastening part of the contact element. When creating the Contact element to the conductor is the same in the direction of the end side of the same progressively moved with pressure, so that the tab is pressed against its spring action or bias to the contact surface. The tab is advantageously cut out by punching partially out of the contact element and then bent around an edge remaining in the contact element in their position. In this position, it is - as already mentioned - under spring tension, so they want to come back at a pressure load and an associated deflection from its position constantly in this.

Zur Befestigung des Kontaktelements am Leiter wird dasselbe parallel zum Leiter angeordnet, und zwar derart, dass es mit seinem Ende am Leiter anliegt, an dem sich das Befestigungsteil befindet. In dieser Position liegt die Lasche noch relativ lose an der Kontaktfläche des Leiters an. Das Kontaktelement wird dann in Achsrichtung des Leiters verschoben, wodurch die Lasche durch den Leiter entgegen ihrer Federkraft gebogen und dadurch mit erhöhter Kraft an die Kontaktfläche des Leiters angedrückt wird. In dieser Position, die dabei stabil gehalten wird, wird das Befestigungsteil des Kontaktelements fest und unverrückbar um den Leiter herumgeformt. Diese Endposition des Kontaktelements wird dadurch auf Dauer beibehalten und die Lasche wird auf Dauer gegen die Kontaktfläche des Leiters gedrückt. Das Befestigungsteil wird durch Crimpen am Leiter festgelegt werden.To attach the contact element to the conductor, the same is arranged parallel to the conductor, in such a way that it lies with its end against the conductor on which the fastening part is located. In this position, the tab is still relatively loose at the contact surface of the conductor. The contact element is then displaced in the axial direction of the conductor, whereby the tab is bent by the conductor against its spring force and thereby pressed with increased force to the contact surface of the conductor. In this position, which is kept stable, the fastening part of the contact element is firmly and immovably formed around the conductor. This end position of the contact element is maintained in the long run and the tab is permanently pressed against the contact surface of the conductor. The fastening part will be fixed by crimping on the conductor.

Das Kontaktelement kann auch ein zweites Befestigungsteil aufweisen, das neben dem ersten Befestigungsteil angebracht ist. Das zweite Befestigungsteil kann um einen Bereich des Leiters herumgelegt und dort befestigt werden, der mit einer Isolierung versehen ist.The contact element may also have a second attachment part attached adjacent to the first attachment part. The second attachment member may be wrapped around and secured to a portion of the conductor which is provided with insulation.

Das Verfahren nach der Erfindung wird anhand der Zeichnungen in Form von Ausführungsbeispielen erläutert.The method according to the invention will be explained with reference to the drawings in the form of embodiments.

Es zeigen:

  • Fig. 1 das Ende eines elektrischen Leiters.
  • Fig. 2 einen Schnitt durch Fig. 1 längs der Linie II - II in vergrößerter Darstellung.
  • Fig. 3 ein bei dem Verfahren nach der Erfindung einsetzbares Kontaktelement.
  • Fig. 4 ein gegenüber Fig. 3 ergänztes Kontaktelement in schematischer und verkleinerter Darstellung.
  • Fig. 5 eine Seitenansicht eines Abschnitts des Kontaktelements nach Fig. 3 in vergrößerter Darstellung.
  • Fig. 6 das Ende des Leiters nach Fig. 1 mit daran angelegtem Kontaktelement vor seiner Befestigung.
  • Fig. 7 das Ende des Leiters nach Fig. 6 mit daran befestigtem Kontaktelement.
Show it:
  • Fig. 1 the end of an electrical conductor.
  • Fig. 2 a cut through Fig. 1 along the line II - II in an enlarged view.
  • Fig. 3 a usable in the method according to the invention contact element.
  • Fig. 4 one opposite Fig. 3 supplemented contact element in a schematic and reduced representation.
  • Fig. 5 a side view of a portion of the contact element after Fig. 3 in an enlarged view.
  • Fig. 6 the end of the conductor after Fig. 1 with attached contact element before its attachment.
  • Fig. 7 the end of the conductor after Fig. 6 with attached contact element.

In Fig. 1 ist schematisch das Ende eines Aluminium enthaltenden elektrischen Leiters 1 dargestellt, der eine Anzahl von zu einer Einheit zusammengefaßten Drähten 2 aufweist. Die Drähte 2 sind beispielsweise miteinander verseilt. Der Leiter 1 ist von einer Isolierung 3 umgeben, die am Ende desselben entfernt ist. An der Stirnseite des Leiters 1 ist eine elektrisch leitende, durch eine Kreuzschraffur angedeutete Kontaktfläche 4 vorhanden, die mit dem Aluminium aller Drähte 2 des Leiters 1 elektrisch leitend verbunden ist. Die Kontaktfläche 4 ist in bekannter Technik durch Wärmezufuhr erzeugt, beispielweise in einer Ultraschallanlage.In Fig. 1 schematically the end of an aluminum-containing electrical conductor 1 is shown, which has a number of combined into one unit wires 2. The wires 2 are stranded together, for example. The conductor 1 is surrounded by an insulation 3, which is at the end of the same removed. On the front side of the conductor 1 is an electrically conductive, indicated by a cross-hatching contact surface 4 is present, which is electrically conductively connected to the aluminum of all wires 2 of the conductor 1. The contact surface 4 is generated in a known technique by supplying heat, for example in an ultrasonic system.

Fig. 3 zeigt ein elektrisches Kontaktelement 5, das etwa bzw. im Wesentlichen streifenförmig ausgeführt ist. Das Kontaktelement 5 besteht aus einem federnden Metall, beispielsweise aus Edelstahl. Es hat an seinem einen Ende ein Befestigungsteil 6, das entsprechend der zeichnerischen Darstellung breiter als der restliche Teil des Kontaktelements 5 ausgeführt ist und zur Festlegung des Kontaktelements 5 am Leiter 1 dient. Im Verlauf des Kontaktelements 5 ist eine Lasche 7 beispielsweise durch Stanzen so weit herausgeschnitten, dass eine quer verlaufende Kante 8 erhalten bleibt. Das Ende 9 des Kontaktelements 5 dient zum Anschluß weiterführender Kontakte oder Leiter. Fig. 3 shows an electrical contact element 5, which is designed substantially or strip-shaped. The contact element 5 is made of a resilient metal, for example made of stainless steel. It has at its one end a fastening part 6, which is designed according to the drawing representation wider than the remaining part of the contact element 5 and serves to fix the contact element 5 on the conductor 1. In the course of the contact element 5, a tab 7 is cut out so far, for example by punching, that a transverse edge 8 is maintained. The end 9 of the contact element 5 is used to connect secondary contacts or conductors.

Zur Fertigstellung eines einsatzbereiten Kontaktelements 5 wird die Lasche 7 um die Kante 8 gebogen, so dass sie unter einem Winkel α vom Kontaktelement 5 absteht, der zwischen 80° und 89° liegt. Der Winkel α liegt in bevorzugter Ausführungsform zwischen 84° und 87°. Die Lasche 7 steht in der entsprechenden Schrägstellung aufgrund ihres federnden Materials unter Federspannung. Die Schräge der Lasche 7 weist in Richtung des Befestigungsteils 6 des Kontaktelements 5. Die Größe des Winkels a hängt auch von dem federnden Material ab, das für das Kontaktelement 5 verwendet wird.To complete a ready-to-use contact element 5, the tab 7 is bent around the edge 8, so that it protrudes at an angle α from the contact element 5, which is between 80 ° and 89 °. The angle α is more preferable Embodiment between 84 ° and 87 °. The tab 7 is in the corresponding inclination due to their resilient material under spring tension. The slope of the tab 7 points in the direction of the fastening part 6 of the contact element 5. The size of the angle a also depends on the resilient material used for the contact element 5.

Das Kontaktelement 5 kann gemäß Fig. 4 auch ein zweites Befestigungsteil 10 haben, das neben dem Befestigungsteil 6 angebracht ist. Es kann mit Vorteil zur zusätzlichen Festlegung des Kontaktelements 5 am Leiter 1 in dessen mit der Isolierung 3 versehenem Bereich eingesetzt werden.The contact element 5 can according to Fig. 4 also have a second fastening part 10 which is mounted adjacent to the fastening part 6. It can be used with advantage for additional definition of the contact element 5 on the conductor 1 in its provided with the insulation 3 area.

Zur Montage des Kontaktelements 5 am Leiter 1 wird beispielsweise wie folgt vorgegangen:
Das Kontaktelement 5 wird entsprechend Fig. 6 mit parallelem Verlauf zum Leiter 1 an denselben angelegt. Die Lasche 7 liegt dann an der Kontaktfläche 4 an, welche sich an der Stirnseite des Leiters 1 befindet. Der schräge Verlauf der Lasche 7 ist in Fig. 6 etwas übertrieben dargestellt, um die entsprechende Ausgangsposition des Kontaktelements 5 deutlich zu zeigen. Danach wird das Kontaktelement 5 in Achsrichtung des Leiters 1 unter weiterer Anlage an demselben mit Druck verschoben. Dadurch wird die Lasche 7 entgegen ihrer Federspannung um die Kante 8 gebogen, so dass sie mit erhöhter Kraft an die Kontaktfläche 4 angedrückt wird. In dieser Position wird das Befestigungsteil 6 um den Leiter 1 so herumgeformt, dass das Kontaktelement 5 fest und unverrückbar am Leiter 1 befestigt ist, so wie es in Fig. 7 dargestellt ist. Das kann beispielsweise durch Crimpen erfolgen. Das gegebenenfalls vorhandene zweite Befestigungsteil 10 kann in analoger Weise zusätzlich im Bereich der Isolierung 3 am Leiter 1 festgelegt werden. Die Positionen des Kontaktelements 5 am Leiter 1 und insbesondere der Lasche 7 an der Kontaktfläche 4 sind dadurch insgesamt auf Dauer sichergestellt.For mounting the contact element 5 on the conductor 1, for example, proceed as follows:
The contact element 5 is corresponding Fig. 6 with parallel course to the conductor 1 is applied to the same. The tab 7 then abuts the contact surface 4, which is located on the front side of the conductor 1. The oblique course of the tab 7 is in Fig. 6 slightly exaggerated to clearly show the corresponding starting position of the contact element 5. Thereafter, the contact element 5 is displaced in the axial direction of the conductor 1 under further contact with the same with pressure. As a result, the tab 7 is bent against its spring tension around the edge 8 so that it is pressed against the contact surface 4 with increased force. In this position, the fastening part 6 is formed around the conductor 1 so that the contact element 5 is firmly and immovably fixed to the conductor 1, as it is in Fig. 7 is shown. This can be done for example by crimping. The possibly existing second fastening part 10 can be set in an analogous manner in addition to the insulation 3 on the conductor 1. The positions of the contact element 5 on the conductor 1 and in particular the tab 7 on the contact surface 4 are thus ensured in total over time.

Claims (4)

  1. A method for the electrically conductive connection of a, for example, strip-shaped contact element (5) consisting of electrically conductive material to an electrical stranded conductor (1) containing aluminum, which has a plurality of wires combined into one unit, with which a fastening part connected in one piece with the contact element (5) is mechanically firmly crimped around the stranded conductor (1) while leaving its end face free in the area of its end, characterized in
    - that a contact element (5) consisting of a resilient material is used, which in its path has a spring-loaded tab (7), projecting at an angle (α) between 80° and 89° obliquely from the same, wherein the inclination of the tab (7) points in the direction of the fastening part (6) of the contact element (5),
    - that before the fastening of the contact element (5) on the stranded conductor (1) initially an electrically conductive contact surface (4) is generated on the end face of the same, which contact surface is connected electrically conductively to the aluminum of the wires (2) of the stranded conductor (1),
    - that subsequently the contact element (5) is applied to the stranded conductor (1) in a position, in which the tab (7) abuts against the contact surface (4) of the same,
    - that the contact element (5) is then pressed in the axial direction of the stranded conductor (1) in such a manner that the tab (7) is deformed by the contact surface (4) contrary to its spring effect, and
    - that finally the contact element (5) is firmly and immovably crimped around the stranded conductor (1) with the path parallel to the axial direction of the stranded conductor (1) by means of the fastening part (6) in such a position, that the tab (7) projecting from the contact element (5) is pressed electrically conductively and mechanically firmly against the contact surface (4) due to its spring tension.
  2. A method according to Claim 1, characterized in that the tab (7) is positioned projecting from the contact element (5) at an angle (α), which is between 84° and 87°.
  3. A method according to Claim 1, characterized in that a contact element (5) is used consisting of stainless steel with resilient properties.
  4. A method according to Claim 3, characterized in that the contact element (5) is coated at least on its surface designated for abutting against the stranded conductor (1) with an electrically highly conductive material, in particular with copper.
EP16305913.2A 2016-07-13 2016-07-13 Method for connecting a contact element to an electrical conductor Active EP3270464B1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
ES16305913T ES2699917T3 (en) 2016-07-13 2016-07-13 Procedure for connecting a contact element in an electrical conductor
EP16305913.2A EP3270464B1 (en) 2016-07-13 2016-07-13 Method for connecting a contact element to an electrical conductor

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP16305913.2A EP3270464B1 (en) 2016-07-13 2016-07-13 Method for connecting a contact element to an electrical conductor

Publications (2)

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EP3270464A1 EP3270464A1 (en) 2018-01-17
EP3270464B1 true EP3270464B1 (en) 2018-09-12

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Families Citing this family (1)

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Publication number Priority date Publication date Assignee Title
JP6768742B2 (en) * 2018-06-04 2020-10-14 矢崎総業株式会社 Manufacturing method of electric wire with terminal and electric wire with terminal

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Publication number Priority date Publication date Assignee Title
US4650723A (en) * 1985-06-26 1987-03-17 Daiichi Denshi Kogyo Kabushiki Kaisha Material for electric contacts
DE502007003854D1 (en) 2007-06-06 2010-07-01 Nexans Process for the preparation of an electrically conductive compound
JP5017156B2 (en) * 2008-03-24 2012-09-05 矢崎総業株式会社 Crimping method of terminal to electric wire
DE102011089207B4 (en) 2011-12-20 2021-02-04 Lisa Dräxlmaier GmbH Method for contacting a stranded wire with a contact
EP2834886A1 (en) * 2012-04-04 2015-02-11 Yazaki Corporation Terminal-attached electric wire
JP5880849B2 (en) * 2012-05-15 2016-03-09 住友電装株式会社 Crimp terminal
EP2747205B1 (en) 2012-12-18 2021-04-14 Nexans Method for the electrically conductive connection of a stranded conductor with a contact element

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EP3270464A1 (en) 2018-01-17

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