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
  • H01R4/58—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
  • H01R35/00—Flexible or turnable line connectors, i.e. the rotation angle being limited
• • 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

Definitions

• the invention relates to an electrical contact connection between a stripped aluminum conductor and a contact element connected thereto.
• the invention further relates to a method for producing such a contact connection.
• the contact element is in this case designed in particular as a so-called cable lug, for example, in the manner of a screw contact element or a plug contact element or another contact element for a mechanically reversible detachable contact connection.
• the invention has for its object to provide a safe and long-term stable contact between an aluminum conductor and a contact element.
• the object is achieved by an electrical contact connection between a stripped aluminum conductor and a contact element connected thereto, wherein the aluminum conductor is integrally connected to an adapter element and the adapter element is mechanically connected to the contact element, so that the aluminum conductor indirectly via the adapter element with the contact element electrically is contacted.
• the adapter element On the one hand a secure and permanently reliable electrical contact between the adapter element and the aluminum conductor is given by the cohesive connection with the aluminum conductor.
• the adapter element in this case consists of a material other than aluminum and is in particular made of copper or a copper alloy. Therefore, a conventional copper conductor for the formation of the contact connection with the contact element is "simulated" via the adapter element, and therefore conventional contact elements and cable lugs as well as conventional types of attachment of the conductor in these contact elements can be used for the contact element a conventional mechanical contact connection to the contact element for a permanently secure electrical contact connection sufficient.
• the contact connection is a crimp connection and the contact element is a crimping element.
• Crimp connections are preferably used for smaller conductor cross sections with a conductor cross-sectional area smaller than 10 mm 2 and have proven to be particularly reliable and are easy to manufacture.
• a modified crimp connection is created, which ensures on the one hand a reliable and secure permanent contact connection and on the other hand allows the use of previous crimp contact systems.
• the construction of an aluminum electrical system with aluminum cables with small conductor cross-sections is possible, in which case - can be made of conventional technologies and contact elements - except for the use of the adapter element.
• crimping ie during the formation of the crimped connection, so-called crimpfs of the crimping element are generally deformed mechanically, so that the conductor in the crimping element is clamped by the crimped edges.
• crimp connection it is preferred to use standard crimping elements. These are or are in particular tinned, so that the electrical contact connection is made corrosion-resistant.
• the adapter element is a foil, in particular of copper or a copper alloy. Due to the thin and thus easily deformable design of the adapter element in the manner of a film, it can be easily introduced between the aluminum conductor and the contact element, so that conventional contact elements can be used. Due to the easy deformability, the adpater element is particularly suitable for use in a crimped connection.
• the film preferably has an anti-corrosion coating.
• an anticorrosion coating electrochemically related materials are added to aluminum, such as aluminum. Chromium, nickel and / or zinc or their alloys used.
• the cohesive connection between the aluminum conductor and the adapter element is a welded connection. It is thus made a non-detachable connection, which ensures a secure hold of the adapter element on the aluminum conductor.
• Preferred welding methods suitable for this Turn are suitable, for example, ultrasonic welding, laser welding and arc welding.
• the aluminum conductor is preferably a stranded conductor with a plurality of stranded wires.
• the aluminum conductor is expediently flattened in the contact region.
• the individual stranded wires are arranged adjacent to each other.
• Preferably, only a few layers of stranded wires are arranged one above the other. In particular, only one layer is formed, so that each or almost every stranded wire rests against the adapter element and is connected thereto.
• By flattening the stranded wires are thus arranged in the manner of a row next to each other and welded to the adapter element, so that the contact surface between the aluminum conductor and the adapter element is particularly large.
• the stranded wires in this case form an approximately U-shaped contour
• the stringing together of the stranded wires is therefore designed to be bent overall.
• the curved configuration therefore simulates, as it were, the outer contour of a conventionally used conductor for a crimped connection, so that the outer contour also adapts to the contour of the standard crimping element.
• the largest possible contact surface is formed between the adapter element and the contact element.
• the curved or U-shaped contour is preferably formed during the formation of the integral connection, in particular during welding of the stranded conductor to the film.
• the paint encloses a contact zone of the contact element, in which the electrical contact takes place and in which the aluminum conductor is located with the adapter element, so that no atmospheric oxygen can reach the electrical contact points.
• the object is further achieved according to the invention by a method for producing a contact connection between a stripped aluminum conductor and a contact element connected thereto, in which the aluminum conductor is connected conclusively to an adapter element, in particular a copper foil, and the adapter element is mechanically connected to the contact element, so that the aluminum conductor is electrically contacted indirectly via the adapter element with the contact element.
• first of all the aluminum conductor is adhesively bonded to the copper foil, in particular welded together.
• the aluminum conductor comprises a plurality of stranded wires, these are preferably flattened and arranged side by side on the adapter element, such that they are connected in particular in the manner of a U-shaped contour with the adapter element.
• the U-shaped contour is preferably realized by the shape of the welding electrodes, via which the stranded wire and the adapter foil are thus pressed into the U-shaped contour.
• the adapter element and the aluminum conductor are clamped in the contact zone in the contact element in the subsequent second production step, in particular by crimping.
• the position of the adapter element is - depending on the nature of the individual Crimpflanken the crimp - positioned at the bottom of the contact element or even above the head directly under the Crimpflanken.
• a complete enclosure of the stranded wires of the conductor is provided with the adapter element for increased stability of the holding forces in the contact zone.
• a lacquer is applied to the contact connection, if necessary, in such a way that the lacquer layer surrounds the contact connection in the contact zone.
• the method for producing such an electrical contact connection can be used in particular for aluminum conductors with small cross-sections and allows the use of crimp contact systems in an aluminum electrical system.
• Fig. 2 shows the components of the electrical contact connection according to
• Fig. 3 shows the finished contact connection.
• an electrical contact connection 2 essentially comprises the stripped end of an aluminum conductor 4, an adapter element 6 and a contact element 8.
• the aluminum conductor 4 here is a stranded conductor and has a plurality of stranded wires 10 that are intertwined with one another.
• the aluminum conductor 4 is formed as aluminum cable and further comprises outside of the contact area a (not shown) insulating jacket.
• the adapter element 6 is a copper foil which has an anticorrosion coating of chromium, nickel and / or zinc (not shown here).
• a crimping element is provided which comprises two Crimpflanken 12.
• the aluminum conductor 4 is joined in a materially bonded manner to the copper foil 6 by welding in a first step.
• Suitable welding methods for this application are, for example, ultrasonic welding, laser welding or arc welding.
• the individual stranded conductors 10 are adjacent to one another, so that preferably each of the stranded conductors 10 bears against the copper foil 6 and is welded directly to the latter.
• the originally substantially circular stranded conductor 4 is therefore pressed to form the integral connection with the copper foil 6 in a flat cross-sectional geometry.
• the individual stranded wires 10 preferably assume a contour which is adapted in particular to the curved contour of the contact element 8.
• the flattening of the aluminum conductor 4 and its contouring into a U-shape takes place directly during the welding process.
• the U-shaped contour is adjusted in particular by a corresponding contouring of the welding electrodes, which are pressed against the aluminum conductor 4 and the copper foil 6.
• the copper foil 6 likewise bears only U-shaped on the individual stranded wires 10.
• the copper foil 6 continues to surround the aluminum conductor 4 and, for example, completely or almost completely, so that the individual stranded wires are connected to the copper foil 6 on two sides, for example. If a plurality of rows-for example 2 rows / layers-are arranged one above the other on stranded wires 10, the encircling arrangement of the copper foil 6 increases at least the probability that each of the individual stranded wires 10 is welded to the copper foil 6.
• the welding takes place in a first method step outside the contact element 8.
• a conventional copper cable is virtually simulated.
• conventional contact elements and methods for forming the contact connection can be used.
• the formation of a crimp connection is provided.
• the prepared with the copper foil 6 aluminum conductor 4 is stripped with his and the copper foil 6 having end inserted into the contact element 8. This condition is shown in FIG.
• the crimped connection is prepared by the Crimpflanken 12 are bent by means of a crimping tool, not shown, inwardly toward the aluminum conductor 4, so that the copper foil 6 is clamped with the aluminum conductor 4 in the crimping element 8 and thereby a mechanical connection between the adapter element 6 and the crimping element 8 is formed.
• the copper foil 6 is oriented towards the rounded bottom of the crimping element 8.
• the copper foil 6 is arranged in the region of the Crimpflanken 12 or - as already mentioned above - that the copper foil 6 is placed around the stranded wires 10 so that both the bottom and the Crimpflanken 12 of the crimping element 8 with the copper foil 6 are contacted.
• the contact element 8 is in this case generally formed in the manner of a cable lug, in which generally at one end of a clamping attachment of the conductor takes place and the other end is designed for a screw or plug connection.
• the other end is formed, for example, as an eyelet or fork (screw) or in the manner of a flat connector.
• For clamping attachment of the conductor end can be provided in addition to a crimped connection and a crimp connection in which the conductor end is first inserted into a corresponding sleeve of the contact element and this sleeve is then deformed by means of a crimping pliers, so that a force and Positive fit with the stripped conductor end forms.
• a reliable and permanently secure contact connection between the aluminum conductor 4 and the contact element is described by the contact connection described here with the adapter element designed in particular as a foil.
• ment 8 is formed, which consists for example of copper or a copper alloy / brass.
• a conventional copper wire is virtually "simulated" by the adapter element 6, so that conventional contact elements, in particular crimp contact elements 8, can be used
• the contact connection described here is used in particular in a motor vehicle electrical system, preferably for smaller conductor cross sections of up to 10 mm 2 . Thanks to this special technology, a conventional copper crimp contact system within such a vehicle electrical system can be reliably and reliably replaced by a modified aluminum conductor crimp contact system.

Landscapes

• Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
• Processing Of Terminals (AREA)

Priority Applications (3)

Applications Claiming Priority (2)

Publications (1)

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Family Applications (1)

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Cited By (2)

Families Citing this family (8)

Citations (4)

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• 2008
  • 2008-12-09 DE DE200810061186 patent/DE102008061186B4/de not_active Expired - Fee Related
• 2009
  • 2009-12-04 WO PCT/EP2009/008645 patent/WO2010066376A1/de active Application Filing
  • 2009-12-04 EP EP09796944.8A patent/EP2371036B1/de not_active Not-in-force
  • 2009-12-04 CN CN200980149629.XA patent/CN102246353B/zh not_active Expired - Fee Related
  • 2009-12-04 RU RU2011127992/07A patent/RU2490763C2/ru not_active IP Right Cessation

Patent Citations (4)

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