EP3451455B1 - Procédé de fabrication d'une liaison électrique et une ligne électrique - Google Patents

Procédé de fabrication d'une liaison électrique et une ligne électrique Download PDF

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Publication number
EP3451455B1
EP3451455B1 EP17306128.4A EP17306128A EP3451455B1 EP 3451455 B1 EP3451455 B1 EP 3451455B1 EP 17306128 A EP17306128 A EP 17306128A EP 3451455 B1 EP3451455 B1 EP 3451455B1
Authority
EP
European Patent Office
Prior art keywords
contact sleeve
conductor
mounting bracket
contact
sleeve
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
EP17306128.4A
Other languages
German (de)
English (en)
Other versions
EP3451455A1 (fr
Inventor
Rainer Huscher
Michael Singer
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.)
Nexans SA
Original Assignee
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 Nexans SA filed Critical Nexans SA
Priority to EP17306128.4A priority Critical patent/EP3451455B1/fr
Publication of EP3451455A1 publication Critical patent/EP3451455A1/fr
Application granted granted Critical
Publication of EP3451455B1 publication Critical patent/EP3451455B1/fr
Active legal-status Critical Current
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
    • 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
    • H01R4/02—Soldered or welded connections
    • H01R4/029—Welded connections
    • 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
    • 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
    • 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
    • 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
    • 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
    • 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

Definitions

  • the invention relates to a method for electrically conductive connection of a contact part based on copper or aluminum with an existing of a plurality of individual wires containing aluminum electrical conductor and a corresponding line.
  • Ladders made of aluminum are increasingly being used, in particular for reasons of weight and cost, as a replacement for copper conductors.
  • Main applications of such conductors are, for example, the automotive and aircraft technology.
  • the lower electrical conductivity of aluminum over copper is irrelevant for most applications.
  • problems arise when attaching contact parts to the conductors since aluminum conductors are surrounded by an electrically very poorly conductive oxide layer. This deficiency is particularly noticeable in existing from a variety of individual wires, also referred to as stranded conductors conductors noticeable.
  • the individual wires are surrounded by an unavoidable without special treatment oxide layer. This problem has long been known.
  • the contact part based on copper or aluminum is made of copper or of a copper alloy or of aluminum or an aluminum alloy. It may additionally have on its outer surface a layer of, for example, tin, zinc or nickel, which is, for example, electrodeposited.
  • the contact part is referred to below without material specification only as "contact part”.
  • the individual wires of the conductor consist of either aluminum or an aluminum alloy.
  • aluminum for the sake of simplicity, only the term “aluminum” will be used hereinafter to refer to both aluminum and alloys thereof.
  • the US Pat. No. 6,538,203 B1 relates to a connecting part for connecting a stranded aluminum line to a connecting part made of copper or a similar metal.
  • a support sleeve is placed on a stripped end of the line and attached, for example by crimping.
  • the connecting part is welded to the end face of the line and the support sleeve, in particular by friction welding.
  • the connecting part is set in rotation and pressed against the end face of the line.
  • the present invention has the object to provide a method to overcome or at least improve one or more of the problems mentioned above.
  • the contact sleeve is crimped or crimped to achieve a tight fit of the contact sleeve on the conductor.
  • the contact sleeve and the fastening tab together form a contact part.
  • the contact sleeve is rolled, for example, from a stamped sheet metal strip.
  • the fastening tab can also be a stamped and bent part.
  • Contact sleeve and mounting strap are thus easy and inexpensive to manufacture.
  • other methods for producing the contact sleeve and the fastening tab are also possible. Due to the fact that the contact part is formed in two parts in each case, regardless of the manufacturing method, the adaptation to different applications is simplified.
  • the step of materially connecting the individual wires of the conductor to one another and to the contact sleeve is carried out by means of a plasma arc.
  • the alumina, with which the individual wires are coated is at the cohesive connection of the individual wires of the surface displaces and no longer affects the electrical connection between the details and the contact sleeve.
  • the method according to the invention is within wide limits regardless of where the connection between the contact sleeve and mounting strap is made. As a result, the method can be used for a wide variety of applications.
  • the invention proposes an electrical line with a conductor having a plurality of individual wires containing aluminum and which is connected to a contact part, which is composed of a contact sleeve and a fastening tab.
  • the individual wires of the conductor are integrally connected with each other and with the plugged onto the conductor contact sleeve.
  • the contact sleeve is welded to the fastening tab.
  • the contact sleeve has on a front side on a projection which corresponds to a passage in the fastening tab, so that engages in the mounting position of the fastening tab of the projection of the contact sleeve in the passage of the fastening tab.
  • the fastening tab is integrally connected to an end face of the contact sleeve.
  • the contact sleeve and the fastening tab together form a contact part.
  • the contact sleeve may have four projections, but also a smaller or larger number. If the contact sleeve has more than one projection, then a corresponding number of passages are provided in the fastening tab. When mounting the electrical cable, the mounting tab can be easily put on the contact sleeve and is held there, because the projections engage in the passages.
  • the contact sleeve is formed as a rolled sleeve, which is made of a metal strip.
  • the fastening tab is a stamped and or bent part.
  • Contact sleeve and mounting strap are thus easy and inexpensive to manufacture and offer corresponding cost advantages in production.
  • a contact part which is made of such a contact sleeve and a fastening tab, cheaper than a comparable contact part which is made by deep drawing.
  • the electrical conductor according to the invention is not limited to a specific manufacturing method for the contact sleeve or the fastening tab.
  • Figure 1A schematically shows a line 10 having an electrical conductor 11 which is composed of a plurality of stranded individual wires 12 and which is surrounded by an insulation 13. In a section 14, the insulation 13 is removed from the conductor 11.
  • a contact sleeve 16 On the stripped region of the conductor 11, a contact sleeve 16 is pushed, which consists of copper, a copper alloy, aluminum or an aluminum alloy.
  • the contact sleeve 16 carries on its in FIG. 1 to the right-facing end face a number of projections 17, for example four pieces, of which in Figure 1A however, only two are visible.
  • the contact sleeve 16 Before assembly, the contact sleeve 16 has an inner diameter which is larger than the outer diameter of the conductor 11, to allow easy insertion of the contact sleeve 16 on the conductor, without bending individual wires 12 of the conductor 11. When the contact sleeve has reached its mounting position, it is pressed or crimped onto the conductor. The contact sleeve 16 is then firmly seated on the ladder 11.
  • FIG. 1B shows a side view of the line 10 from Figure 1A ,
  • four Projections 17 to recognize well.
  • fewer than four or more than four projections 17 may be provided.
  • the object of the present invention is independent of the concrete number of projections.
  • FIG. 2A the contact sleeve 16 is shown in a perspective view.
  • a metal strip 18 is punched out, at the same time the projections 17 arise.
  • the punched sheet metal strip 18 is in FIG. 2B shown.
  • the thus prepared sheet metal strip 18 is rolled to complete the contact sleeve 16.
  • a rolled contact sleeve 16 is simple and inexpensive to manufacture, the present invention is not limited to this type of manufacturing. In principle, the contact sleeve can also be produced, for example, by casting, deep-drawing or machining processes.
  • FIG. 3 shows the line 10 from Figure 1A after the individual wires 12 have been welded together and with the contact sleeve 16 in a plasma arc with each other. This creates a region 21, where no individual wires 12 longer exist and has a material connection with the contact sleeve 16.
  • the alumina is displaced.
  • the alumina may "float" to the surface of molten material. As a result, the alumina no longer affects the electrical conductivity between the conductor 11 and the contact sleeve 16.
  • FIG. 3 described welding of the individual wires 12 with the contact sleeve 16 does not take place.
  • the contact sleeve 16 is fixedly connected to the conductor 11 solely by pressing or crimping.
  • FIG. 4A is the line 10 off FIG. 3 shown with an attached attachment foot or a mounting strap 22.
  • the fastening tab is made of copper or aluminum.
  • the fastening tab 22 is formed as an angle section with two legs 23, 24.
  • the first leg 23 the fastening tab 22 is provided with a screw hole 26 for a fastening screw, while the second leg 24 has passages 27 which are dimensioned so that the projections 17 of the contact sleeve 16 are receivable therein, when the leg 24 of the fastening tab 22 has a mounting position on the end face the contact sleeve 16 occupies.
  • FIG. 4A is the line 10 off FIG. 3 shown with an attached attachment foot or a mounting strap 22.
  • the fastening tab is made of copper or aluminum.
  • the fastening tab 22 is formed as an angle section with two legs 23, 24.
  • the first leg 23 the fastening tab 22 is provided with a screw hole 26 for a fastening screw, while the second leg 24 has passages 27 which
  • a tool 28 is shown, with which the leg 24 of the fastening tab 22 is welded by friction stir welding with the contact sleeve 16.
  • the temperature required for welding contact sleeve 16 and fastening tab 22 is generated by friction.
  • the material of the contact sleeve 16 connects to that of the fastening tab 22 at a temperature below the melting temperature of the metals used cohesively or is welded together by diffusion.
  • the pressure applied by the tool 28 and the work done thereby also contribute to this.
  • the tool used in the method accordingly has a friction surface, with which it is pressed onto the leg 24 of the fastening tab 22, which is in FIG. 4 symbolized by an arrow P.
  • the tool 28 When the method is carried out, the tool 28 is rotated about its axis A, for example by an electric motor, and then moved in the direction of the arrow P. It is then pressed with continued pressure against the leg 24 of the fastening tab 22, so that the material thereof is heated by friction.
  • the fastening tab 22 is made as a simple stamped and bent part. Dimensions, shape, number of mounting holes, etc. are thereby easily adaptable to individual applications. However, the invention is not limited to a stamped and / or bent fastening tab 22. In principle, the invention is independent of how the fastening tab 22 is made.
  • FIG. 4B shows a further embodiment of a conduit 10, wherein the end of the conduit which carries the contact sleeve 16, is shown in cross section.
  • another fastening tab 29 is welded in this case, which, as stated above, can be designed almost arbitrarily.
  • FIG. 5A shows in a flow chart the individual manufacturing steps for a first method for producing an electrical connection according to the invention.
  • a contact sleeve 16 is pushed onto the conductor 11 in step S1 and then crimped on the conductor 11 in step S2.
  • the stranded wires 12 are connected to one another in a material-tight manner with one another and with the contact sleeve 16 in a plasma arc.
  • the fastening tab 22 is welded to the contact sleeve 16, in particular friction stir welded.
  • FIG. 5B shows in a further flowchart the individual manufacturing steps for a second method for producing an electrical connection according to the invention.
  • Steps S5 and S6 are identical to steps S1 and S2 in the first production mode.
  • the fastening tab 22 is welded to the contact sleeve 16, in particular friction stir welded, whereby at the same time the individual wires 12 of the conductor 11 are welded to the contact sleeve 16.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)

Claims (7)

  1. Procédé de liaison électro-conductrice d'une pièce de contact, constituée d'une douille de contact (16) et d'une patte de fixation (22), à base de cuivre ou d'aluminium, avec un conducteur (11) qui comprend une pluralité de fils individuels (12) contenant de l'aluminium, ce procédé comprenant les étapes suivantes :
    - emboîtement (S1, S5) de la douille de contact (16) sur le conducteur (11) et
    - liaison mécanique (S2, S6) de la douille de contact (16) avec le conducteur (11), le procédé étant caractérisé par les étapes suivantes :
    - pose de la patte de fixation (22), de façon à ce qu'une saillie (17) s'emboîte sur un côté frontal de la douille de contact (17), avec un passage correspondant (27) sur la patte de fixation (22) et maintienne la patte de fixation (22) sur la douille de contact (16),
    - liaison par liaison de matière des fils individuels (12) du conducteur (11) entre eux et avec la douille de contact (16) et
    - liaison par liaison de matière (S4, S7) de la patte de fixation (22) sur le côté frontal de la douille de contact (16).
  2. Procédé selon la revendication 1, caractérisé en ce que l'étape de liaison par liaison de matière (S3) des fils individuels (12) du conducteur (11) entre eux et avec la douille de contact (16) est réalisée au moyen d'un arc plasma.
  3. Procédé selon la revendication 1, caractérisé en ce que, dans l'étape de la liaison par liaison de matière (S7) de la patte de fixation (22) avec la douille de contact (16) les fils individuels (12) du conducteur (11) sont reliés par liaison de matière entre eux et avec la douille de contact (16) de manière simultanée.
  4. Procédé selon l'une des revendications précédentes, caractérisé en ce que la liaison par liaison de matière (S4, S7) entre la patte de fixation (22) et le côté frontal de la douille de contact (16) est réalisée par un procédé dans la liste suivante :
    - soudure par friction,
    - soudure aux ultrasons,
    - brasage tendre et
    - brasage dur.
  5. Conduite électrique avec un conducteur (11), qui comprend une pluralité de fils individuels (12) contenant de l'aluminium et qui est relié avec une pièce de contact à base de cuivre ou d'aluminium, qui est constituée d'une douille de contact (16) et d'une patte de fixation (22), les fils individuels (12) du conducteur étant reliés entre eux et avec la douille de contact emboîtée sur le conducteur (11) par liaison de matière, la douille de contact (16) étant reliée avec la patte de fixation (22) par liaison de matière, caractérisée en ce que la douille de contact (16) comprend, sur un côté frontal, une saillie (17), qui correspond avec un passage (27) dans la patte de fixation (22), de façon à ce que, dans la position de montage de la patte de fixation, la saillie (17) de la douille de contact s'emboîte dans le passage (27) de la patte de fixation, et à ce que la patte de fixation (22) soit reliée au côté frontal de la douille de contact (16) par liaison de matière.
  6. Conduite électrique selon la revendication 5, caractérisée en ce que la douille de contact (16) est une douille roulée.
  7. Conduite électrique selon l'une des revendications 5 ou 6, caractérisé en ce que la patte de fixation (22) est une pièce estampée ou pliée.
EP17306128.4A 2017-09-01 2017-09-01 Procédé de fabrication d'une liaison électrique et une ligne électrique Active EP3451455B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP17306128.4A EP3451455B1 (fr) 2017-09-01 2017-09-01 Procédé de fabrication d'une liaison électrique et une ligne électrique

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP17306128.4A EP3451455B1 (fr) 2017-09-01 2017-09-01 Procédé de fabrication d'une liaison électrique et une ligne électrique

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Publication Number Publication Date
EP3451455A1 EP3451455A1 (fr) 2019-03-06
EP3451455B1 true EP3451455B1 (fr) 2019-11-06

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP4002592A1 (fr) 2020-11-19 2022-05-25 Nexans Connecteur pour une conduite électrique et raccordement de conduite

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Publication number Priority date Publication date Assignee Title
DE102021129706A1 (de) * 2021-11-15 2023-05-17 Strunk Connect automated solutions GmbH & Co. KG Verfahren zum Verbinden einer elektrischen Leitung aus Aluminium mit einem Rohr aus Kupfer

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Publication number Priority date Publication date Assignee Title
DE19908031B4 (de) * 1999-02-24 2009-08-13 Auto-Kabel Management Gmbh Verbindung eines elektrischen Aluminiumkabels mit einem aus Kupfer oder dergleichen Metall bestehenden Anschlußteil
AT503774B1 (de) * 2006-06-02 2008-03-15 Gebauer & Griller Verfahren zum verbinden von zwei elektrisch leitenden bauteilen miteinander und elektrische leitung
DE102008059481A1 (de) * 2008-11-28 2010-06-02 Auto-Kabel Managementgesellschaft Mbh Torsionales Ultraschallschweißen
DE102011017070B4 (de) * 2011-04-14 2013-10-31 Auto-Kabel Management Gmbh Herstellung eines elektrischen Kabels sowie Verfahren zur Herstellung einer Verbindung
DE102011018353A1 (de) * 2011-04-20 2012-10-25 Auto-Kabel Managementgesellschaft Mbh Schweißhülse mit Kontaktteil
EP2735397B1 (fr) 2012-11-23 2018-01-17 Nexans Procédé de connection électrique d'une pièce de contact à un conducteur électrique
DE102014006244A1 (de) * 2014-04-28 2015-10-29 Rosenberger Hochfrequenztechnik Gmbh & Co. Kg Crimp-Schweißverbindung

Non-Patent Citations (1)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP4002592A1 (fr) 2020-11-19 2022-05-25 Nexans Connecteur pour une conduite électrique et raccordement de conduite

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