• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    An insulating element (2) exhibiting, of individual conductors (3) such as wires or strands of light metal, preferably aluminum or aluminum alloys constructed cable (4) final connecting element (1) for the electrical connection between the cable (4) and a contact member of a consumer. It is provided that the connecting element (1) comprises a contact sleeve (7) in which the contact element side end portions (6) of the individual conductors (3) are accommodated and which contact sleeve (7) has a first region (8), in which the contact sleeve ( 7) with the end sections (6) is preferably pressed positively and a second, the end portions (6) projecting portion (9), which is formed into a connection portion (14), wherein the end portions (6) in their end regions by means of a solder ( 12), preferably a zinc solder are soldered.
    公开号:AT516232A1
    申请号:T50630/2014
    申请日:2014-09-10
    公开日:2016-03-15
    发明作者:Karl Ing Fröschl；Gottfried Dipl Ing Fleischer
    申请人:Gebauer & Griller；
    IPC主号:
    专利说明:

    CONNECTOR
    FIELD OF THE INVENTION
    The present invention relates to an insulation-comprising, from individual conductors such as wires or strands of light metal, preferably aluminum or aluminum alloys constructed Kabelabschließendes connecting element for the electrical connection between the cable and a contact member of a consumer.
    STATE OF THE ART
    In the field of vehicle technology, it has meanwhile become common, for reasons of cost and weight, to form electrical lines as light-metal lines, preferably of aluminum. The earlier used, relatively heavy and expensive copper pipes were now almost completely replaced by light metal cables, at least in the automotive industry.
    A challenge in the use of aluminum cables is to ensure the durable and powerful contacting of the aluminum wires. In the meantime, more and more copper connection elements are used in practice, whereby it must be ensured that the aluminum wires do not come into direct contact with the copper in order to avoid the otherwise occurring contact corrosion.
    The most different solutions for the production of such connecting elements are known from the prior art. However, these known solutions are characterized by relatively cumbersome or expensive production methods or are inflexible with regard to the connection to a contact element of a consumer.
    OBJECT OF THE INVENTION
    It is therefore the object of the present invention to obviate these drawbacks and to propose a connecting element for making an electrical connection between a cable having an insulation made of single conductors such as wires or strands of light metal, preferably aluminum or aluminum alloys, and a contact member of a consumer, which connecting members are easily manufactured can and is flexible, which relates to the connection to a contact element of a consumer.
    PRESENTATION OF THE INVENTION
    According to the invention this is achieved in that the
    Connecting element comprises a contact sleeve, in which contact-member-side end portions of the individual conductors are received and which contact sleeve has a first region in which the contact sleeve with the end portions is preferably pressed form-locking and a second, the end portions projecting portion which is formed into a terminal portion, wherein the end portions in their end regions by means of a solder , preferably a zinc solder are soldered.
    It is essential here that the core of the connection element according to the invention can be a simple contact sleeve which, on the one hand, is securely connected to the aluminum conductor by pressing and soldering, but at the same time forms by direct forming a corresponding connection section which serves to directly contact a consumer. Sleeves are easy and cheap to manufacture. The strength of the present invention can be seen in the fact that the sleeve is adapted accordingly only in the course of the manufacturing process for the connecting element.
    According to a preferred embodiment of the invention, it is provided that the connecting portion is formed by the forming flat, preferably at least a flat contact surface, whereby an easy to be used for the connection of a contact element surface is provided.
    According to a further preferred embodiment of the invention, it is provided that the contact sleeve is provided on its inside with a coating of nickel, whereby the above-described direct contact between light metal conductor and copper contact sleeve is avoided.
    An alternative embodiment of the invention provides that the coating of nickel on its inside has a coating of tin. The tin may be used in welding operations performed on the contact sleeve to produce gas-tight seals of the contact sleeve after forming.
    The embodiment of soldering the end portions as a resistance solder joint, according to another preferred embodiment of the invention, is characterized by low manufacturing costs, while maintaining good electrical conductivity between the individual conductors and the contact sleeve.
    According to a particularly preferred embodiment of the invention, it is provided that the soldering of the end portions comprises the end faces of the end portions, so that the end portions are cap-like covered by the solder.
    In order to allow the solder to penetrate into the interstices between the individual conductors, it is provided that the preferably positive-locking compression is formed such that there is sufficient space between the individual conductors of the end portions for receiving the solder, wherein the individual conductors outside the contact sleeve are not soldered. The force to be applied during compression must be adapted to the conditions such as the diameter of the individual conductors and the wall thickness of the sleeve, but must not be overly strong at any rate. It is preferable to avoid cold welding between the aluminum single conductors.
    A particularly secure and conductive connection between the aluminum conductors and the contact sleeve is then achieved, the end portions of the individual conductors completely pass through the first region of the contact sleeve in which the compression takes place, and the end faces of the end portions between the first region and the second region of the contact sleeve which is deformed. are arranged. Moreover, this also ensures that the end portions do not hinder the deformation of the contact sleeve, whereby an increased effort would be required.
    According to a further preferred embodiment of the invention it is provided that a contact element is arranged at the connection section. Such a contact element allows the connection to the contact member of the consumer. Particularly preferably, the contact element is designed as a plug-in contact element, so that the connection element according to the invention can be easily plugged onto the contact component of the consumer.
    In a particularly preferred embodiment of the invention, it is provided that the plug-in contact element is welded to the connection section, preferably hump-welded. The resulting compound is particularly stable and electrically highly conductive and has the advantage that the weld also allows any coatings incorporated into the contact sleeve to be melted and used as solder to produce a gas-tight seal.
    In order to propose a connection element which is particularly flexible in terms of installation, it is provided that the plug contact element has an opening for making contact with the contact element of the load, the axis of the contact sleeve and the plugging direction enclosing an angle not equal to 0, preferably an angle of 90 °. The delivery of the cable to the consumer can thereby be made more flexible than is the case with known systems. In particular, in connection with the newly formed connection portion, the
    Plug contact element are attached with the same effort in any Winkelam connection section.
    However, the above-described object of the invention is also achieved by a method of manufacturing a cable comprising an insulation and single conductors such as wires or strands of light metal, preferably aluminum or aluminum alloys, final connecting element for the electrical connection between the cable and a contact member of a consumer the method comprises the following method steps: - attaching a contact sleeve (7) onto the stripped end of the cable (4) such that the contact sleeve (7) receives the contact component-side end sections (6) of the individual conductors (3) - pressing the contact sleeve (7) with the contact-component-side end sections (6) of the individual conductors (3) in a first region (8) of the contact sleeve (7) - introduction of heat into the pressing position {n) of the compression while simultaneously feeding a solder through the contact-component-side end face of the contact sleeve (7) - melting of the solder and manufacturing ng a soldering between the contact member side end portions (6) of the individual conductors (3) and the inner surface of the contact sleeve (7) - forming the contact sleeve (7) in a second, the contact member side end portions (6) of the individual conductors (3) projecting portion
    The preparation of the soldering is carried out according to the invention by means of resistance soldering method, whereby the inventive
    Connecting element is inexpensive to produce.
    According to a preferred embodiment of the invention, during the soldering process, the electrodes used in the resistance soldering process are placed in the first region of the contact sleeve or, during the soldering operation, placed in that half of the first region which is closer to end faces of the end sections, the electrodes preferably being less than half the length of the cover first area. Thereby it can be ensured that no liquid solder flows beyond the contact sleeve into the cable and under the insulation, whereby it could be destroyed.
    BRIEF DESCRIPTION OF THE FIGURES
    The invention will now be explained in more detail with reference to exemplary embodiments. The drawings are exemplary and are intended to set forth the inventive idea, but in no way restrict it or, ultimately, reproduce it.
    Showing:
    Fig.l a axonometrisehe view of a first
    Variant of a connecting element
    A axonomterische view of a second variant of a
    connecting element
    3 is a sectional view of the first variant of
    connecting element
    4 to 8 individual process steps for producing a
    connecting element
    Fig.9 Cross section of the compressed portion of a cable
    WAYS FOR CARRYING OUT THE INVENTION
    FIG. 1 shows an overview of a connection element 1 according to the invention, which terminates a cable 4 having an insulation 2 and comprises a contact sleeve 7 which is pressed together with the individual conductors 3 of the cable 4 in a first region 8 and is formed in a second region 9 into a connection section 14. At the terminal portion 14, a contact member 16 is mounted in the form of a male contact element having an opening 17 which defines a plug-in direction 19 for contacting with the contact part of a consumer (not shown).
    2 shows a substantially identically constructed connecting element 1 according to the invention as shown in FIG. 1, but with the difference that the plug-in contact element 16 is aligned differently at the connecting section 14, namely that the axis 18 of the contact sleeve 7 and the predetermined direction 19 are at an angle 20 of substantially 90 °.
    Basically, the terminal portion 14 is arbitrarily deformable and ausgestitierbar so that differently shaped contact elements 16 are fastened thereto. The shape of the connection section 14 can be adapted to the shape of the contact element 16 or vice versa. The formation of the contact element 16 as a plug contact, as shown in the present embodiment, enables the rapid and secure production of an electrical connection with the unillustrated contact part of a consumer.
    FIG. 3 shows a connecting element 1 according to the invention in a longitudinal section along the axis 18.
    The cable 4 is provided with an insulation 2 surrounding a plurality of individual conductors 3. The individual conductors 3 are made as wires or strands and made of a light metal, in the present embodiment aluminum or an aluminum alloy. The right in Figure 3 end of the cable 4 is stripped, so that there end portions 6 of the individual conductors 3 protrude beyond the insulation 2 and are received by a contact sleeve 7.
    The contact sleeve 7 is made of copper or a copper alloy and is provided with a nickel layer 10 on its inner side to prevent direct contact between aluminum conductor 3 and contact sleeve 7 and thus to avoid contact corrosion.
    The contact sleeve 7 is pressed in the above-mentioned first region 8 with the end portions 6 of the individual conductors 3. Due to the concomitant constriction of the cross-section of the contact sleeve 7 in the hand regions 21 of the first region 8, a form closure between the contact sleeve 7 and the end sections 6.
    In addition, end portions 6 of the individual conductors 3 are soldered in their end regions and frontally with each other and with the contact sleeve 7. Here, the pressing force causing the pressing in the first region 8 is selected such that there is sufficient space between the individual conductors 3, so that the liquid solder 12 can penetrate into these intermediate spaces. At the same time, the gap is kept so small that the liquid solder 12 can not run the cable in the direction of insulation 2 or over the insulation 2. This results in a soldering which covers both the end faces of the individual conductors 3 and the spaces between the individual conductors 3 a portion of the end portions 6, and the inner surface of the contact sleeve 7 in this area.
    The portion of the contact sleeve 7 projecting beyond the end surfaces of the end sections 6 is reshaped into a connection section 14 in a second region 9 after the soldering has been completed. In the present exemplary embodiment, the deformation results in the formation of two planar contact surfaces 15a, 15b. Attached to one of these contact surfaces 15a, 15b is the further contact contact element 16 already described above, specifically, welded, by projection welding, with the projections provided for this purpose being marked 22. The deformation also results in that the soldering point inside the sleeve can be largely shielded from external influences, in particular when, in a preferred embodiment of the invention, the inner nickel coating 10 of the contact sleeve 7 is coated with a further layer of tin. In this case, the butt weld in the connection section 14 in the second region of the contact sleeve 7, ie where it is formed, would form a gas-tight barrier layer on the inside of the contact sleeve 7 by the welding operation.
    METHOD FOR PRODUCING A COMPOUND COMPOUNDS OF THE INVENTION
    4 to 8 show the individual method steps for producing a connecting element 1 according to the invention. Specifically, in FIG. 4 it is clear how the contact sleeve 7 is plugged onto the stripped end of the cable 4 and the end sections 6 of the individual conductors 3 are received therein.
    5 shows the already pressed state of the contact sleeve 7, wherein the compression in a first region 8 of the Kontakthülsestattfindet, which is somewhat shorter in the present embodiment than the insulating 2 protruding end portions 6 formed. In the course of the pressing, where the individual conductors 3 touch, a transformation of the initially round individual conductor cross-sections to honeycomb-shaped cross sections occurs, as shown in FIG. 9, whereby the interspaces between the individual conductors are reduced. The compression also causes the contact sleeve 7 and the individual conductors 3 are firmly connected to each other, which greatly simplifies the further production of the connecting element according to the invention, in particular the handling of cable 4 and contact sleeve 7, so that in a next process step on the front end still free in this stage of the process At the same time, a resistance welding device, specifically its electrodes 22, can be attached to the first region 8 of the contact sleeve 7 in order to introduce the frontally introduced solder by means of heat introduction via the contact sleeve 7 12, so that this one hand, the wetting surfaces of the end portions 6 of the individual conductors 3 wetting, as well as can penetrate into the interstices between the individual conductors 3, at least over a length corresponding to the length of the compression, ie the first region 8 maybe. The electrodes 22 preferably cover not the entire length of the first region 8 but only a portion thereof, preferably not more than half the length of the first region 8. The electrodes 22 are preferably arranged in that half of the first region 8, which is closer to end faces of the end portions 6 runs to ensure that the solder 12 in the closer to the insulation 2 extending portion of the first region 8 again becomes viscous and does not flow into the cable 4. In other words, by the implementation of the electrodes and their position on the contact sleeve 7 together with the soldering parameters, the penetration depth of the solder 12 can be influenced.
    Finally, FIG. 7 shows the contact sleeve 7 pressed and soldered to the end sections 6 of the individual conductors 3.
    Finally, in FIG. 8, the second region 9 of the contact sleeve 7 is also formed into a connection section 14. It should be explicitly mentioned again at this point that the type and nature of the deformation, in particular the resulting geometry of these connecting portion 14 of the contact sleeve 7 is flexibly selectable and can be turned off on the contact element 16 and its purpose or geometry. The formation of a planar connection section 14 with at least one, preferably two, planar contact surfaces 15a, 15b has, however, proved to be advantageous in practice, since a versatile reference surface can be formed which facilitates the welding process, in particular in combination with a butt weld.
    REFERENCE LIST 1 Connection element 2 Insulation 3 Single conductor 4 Cable 5 Contact component Consumers 6 End sections of individual conductors 7 Contact sleeve 8 First area of contact sleeve 9 Second area of contact sleeve 10 Nickel coating 11 End faces of end sections 12 Lot 13 Contact side end of contact sleeve 14 Connection section 15 Flat contact surface 16 Plug contact element 17 Opening of the plug-in contact element 18 axis of the contact sleeve 19 plug-in direction 20 angle 21 edge regions of the first component 8 22 resistance welding device / electrodes
    权利要求:
    Claims (16)
    [1]
    CLAIMS 1. A connector (1) comprising an insulation (2) made of individual conductors (3) such as wires or strands of light metal, preferably aluminum or aluminum alloys, for electrical connection between the cable (4) and a contact member of a consumer, characterized in that the connecting element (1) comprises a contact sleeve (7) in which contact-member-side end sections (6) of the individual conductors (3) are received and which contact sleeve (7) has a first region ¢ 8), in which the contact sleeve (7) Preferably, the end portions (6) is pressed form-fitting and a second, the Endabschnitte (6) projecting portion (9), which is formed into a connection portion (14), wherein the end portions {6} in their end regions by means of a solder {12}, preferably one Zinc solders are soldered.
    [2]
    Second connecting element (1) according to claim 1, characterized in that the connecting portion {14) is ebenausgebildet by the deformation, preferably at least one flat contact surface (15).
    [3]
    3. Connecting element (1) according to one of the preceding claims, characterized in that the contact sleeve (7) is provided on its inner side with a coating (10) made of nickel.
    [4]
    4. Connecting element (1) according to claim 3, characterized in that the coating (10) of nickel on its inside has a coating of tin.
    [5]
    5. Connecting element (1) according to one of the preceding claims, characterized in that the soldering of the end portions (6) is a Widerstandslötverbindung.
    [6]
    6. Connecting element (1) according to one of the preceding claims, characterized in that the soldering of the end portions (6) comprises the end faces of the end portions (6).
    [7]
    A connecting element (1) according to any one of the preceding claims, characterized in that the preferably positive-locking pressing is arranged such that there is sufficient space between the individual conductors (3) of the end sections (6) for receiving the solder (12), the individual conductors (3 ) are not soldered outside the contact sleeve (7).
    [8]
    A connecting element (1) according to any one of the preceding claims, characterized in that the end sections (6) completely pass through the first area (8) and the end faces of the end sections (6) are arranged between the first area (8) and the second area (9).
    [9]
    9. Connecting element (1) according to one of the preceding claims, characterized in that at the connection portion (14) a contact element (16) is preferably arranged in the form of a plug-in contact element.
    [10]
    10. Connecting element (1) according to claim 9, characterized in that the plug-in contact element (16) with the connection portion (14) is welded, is preferably hump welded.
    [11]
    11. Connecting element (1) according to claim 9 or 10, characterized in that the plug contact element (16) has a one direction (19) predetermining opening (17) for contacting with the contact member of the consumer, wherein the axis (18) of the contact sleeve (7) and the plug-in direction (19) enclose an angle (20) not equal to 0, preferably an angle (20) of 90 °.
    [12]
    A method of making a cable (4) comprising an insulation (2) and individual conductors (3) such as wires or strands of light metal, preferably aluminum or aluminum alloys, final connection element (1) for the electrical connection between the cable (4) and a contact member a consumer, characterized in that it comprises the following steps: - fitting a contact sleeve (7) on the stripped end of the cable (4) such that the contact sleeve (7) receives the contact member side end portions (6) of the individual conductors (3) - pressing the Contact sleeve (7) with the contact component-side end portions (6) of the individual conductors (3) in a first region (8) of the contact sleeve {7) - introducing heat into the pressing location (s) of the compression while simultaneously feeding a solder through the contact-component-side end face of the contact sleeve (FIG. 7) - melting the solder and producing a soldering between the contact component side end portions (6) of the single conductor (3) and the inner surface of the contact sleeve (7) - forming the contact sleeve (7) in a second, the contact member side end portions (6) of the single conductor {3} superior area
    [13]
    13. The method according to claim 12, characterized in that the production of the soldering by means of resistance soldering takes place.
    [14]
    14. The method according to claim 13, characterized in that the electrodes (22) used in the resistance soldering process during the soldering in the first region (8) of the contact sleeve (7) are placed.
    [15]
    A method according to claim 14, characterized in that during the soldering operation the electrodes (22) are placed in that half of the first region (8) which is closer to end faces of the end sections [6], the electrodes (22) preferably less than cover half the length of the first area (8).
    [16]
    16. The method according to any one of claims 12 to 15, characterized in that the forming of the contact sleeve (7) in the second region (9) by compressing the contact sleeve (7), for the purpose of producing at least one connection portion ¢ 14), preferably one at least one flat contact surface (15) having terminal portion (14).
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    同族专利:
    公开号 | 公开日
    EP2996200A1|2016-03-16|
    AT516232B1|2016-08-15|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    WO2004047227A1|2002-11-19|2004-06-03|Gebauer & Griller Kabelwerke Gesellschaft M.B.H.|Method for joining a connecting element to an electric cable|
    JP2006179369A|2004-12-24|2006-07-06|Mitsubishi Cable Ind Ltd|Connection method of aluminum wire and connection structure of aluminum wire|
    JP2010225529A|2009-03-25|2010-10-07|Autonetworks Technologies Ltd|Electric wire with terminal metal fitting|
    DE102010044241A1|2010-09-02|2012-03-08|Auto-Kabel Managementgesellschaft Mbh|Connector for connecting electrical aluminum cable with cable shoe for electrical system of motor car, has sleeve formed with cable shoe as single-piece, and provided as end of pipe, where end of cable is connected with sleeve|
    WO2014024938A1|2012-08-07|2014-02-13|古河電気工業株式会社|Crimping terminal, connection structure, connector, wire harness, crimping terminal manufacturing method, and connection structure manufacturing method|
    DE10346160B3|2002-05-25|2005-07-14|Feindrahtwerk Adolf Edelhoff Gmbh & Co.|Contacting cable with wires or braids of aluminum or aluminum alloy involves tinning metal terminal on end with individual conductors at end of cable by ultrasonic tinning with metal via opening|
    DE10357048A1|2003-12-04|2005-07-21|Leoni Bordnetz-Systeme Gmbh & Co Kg|Method for producing an electrical connection between an aluminum conductor and a contact element|
    KR20060129364A|2004-03-23|2006-12-15|게바우어 운트 그릴러 카벨베르케 게에에스엠베하|Method for joining a connecting element to an electric conductor made of aluminum and electric conductor produced according to said method|
    IT1403926B1|2011-02-09|2013-11-08|Cembre Spa|ELECTRICAL CONNECTOR FOR THE CONNECTION OF ELECTRIC CABLES TO ELECTRICAL TERMINALS.|
    DE102011011409B4|2011-02-16|2013-10-31|Auto-Kabel Management Gmbh|Connection part and connection for electrical systems|DE102018116599A1|2018-07-10|2020-01-16|Phoenix Contact E-Mobility Gmbh|Method for connecting an electrical conductor to a contact element|
    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    ATA50630/2014A|AT516232B1|2014-09-10|2014-09-10|Method for connecting a cable end to a connecting element|ATA50630/2014A| AT516232B1|2014-09-10|2014-09-10|Method for connecting a cable end to a connecting element|
    EP15184472.7A| EP2996200A1|2014-09-10|2015-09-09|Connecting element|
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