Cable lug comprising a nut or functional part, method for the production of such a cable lug, and nut

Abstract

A cable lug or functional part in combination with a nut is provided. The cable lug or functional part has a tubular receiving portion for a cable, an integrally formed flat part connecting portion connected to the tubular receiving portion, the flat part connecting portion having a hole therethrough defined by a wall said hole having a central axis. The nut includes a body having an undercut. The nut is held captively and rotatably on the flat part connecting portion. The nut does not pass through the flat part connecting portion is held by a reshaped holding material portion of the flat part connecting portion which projects into the undercut. The reshaped holding material portion is accommodated in the undercut, and an axial clearance is provided between the reshaped holding material and the wall which defines the hole.

Claims

1. A cable lug in combination with a functional part, comprising: the cable lug having a tubular receiving portion for a cable, an integrally formed flat part connecting portion connected to the tubular receiving portion, the flat part connecting portion having a hole therethrough defined by a wall, the hole defining a central axis, the wall including a cylindrical wall portion and a holding material portion extending inwardly from the cylindrical wall portion toward the central axis; and the functional part comprising a body which defines a centerline, a first bearing surface on a base of the body, a displacer unitary with the body located directly below the first bearing surface, the displacer having a first outer surface extending from the first bearing surface, the first outer surface being inwardly tapered along at least a portion of its outside surface relative to the centerline at an angle of any one of 20 to 50 degrees and having an outside diameter less than an outside diameter of the first bearing surface, a shank unitary with the body and extending from the displacer, the displacer having a second surface proximate to the shank, the second surface extending between the shank and the first outer surface, the second surface continuously encircles the body and is angled at a constant angle relative to the centerline of the body, wherein the second surface of the displacer and a surface of the shank form an undercut; and wherein the holding material portion is in the undercut and an axial clearance is provided between the holding material portion and the surfaces which forms the undercut such that the functional part is held captively and rotatably on the flat part connecting portion and the functional part does not pass through the flat part connecting portion.

2. The combination according to claim 1, wherein the holding material portion is seated in the undercut with radial play.

3. The combination according to claim 1, wherein the wall of the hole of the flat part connecting portion has a conical surface, and the holding material portion has a surface which extends from the conical surface.

4. The combination according to claim 3, wherein the conical surface is rotationally symmetrical.

5. The combination according to claim 1, wherein the holding material portion is rotationally symmetrical.

6. The combination according to claim 1, wherein the wall of the hole of the flat part connecting portion has two conical surfaces, and at least one of the conical surfaces extends at an acute angle to a horizontal or a vertical.

7. The combination according to claim 1, wherein the undercut is formed outside a thread of the functional part.

8. The combination according to claim 1, wherein the surface of the shank is cylindrical.

9. The combination according to claim 8, wherein the cylindrical surface of the shank merges into a thread root of the functional part.

10. The combination according to claim 1, wherein the second surface of the displacer defines an upper delimiting surface of the undercut and a portion of the surface of the shank forms a lower delimiting surface of the undercut, and wherein each of the upper and lower delimiting surfaces overlap the holding material portion in a radial direction extending outwardly from the central axis.

11. The combination according to claim 10, wherein the upper delimiting surface of the undercut extends radially outwardly from the central axis, and the lower delimiting surface of the undercut extends radially outwardly over more than half of the upper delimiting surface of the undercut.

12. The combination according to claim 1, wherein the hole is formed with a hole step.

13. The combination according to claim 12, wherein the hole step is formed in a lower region of the hole which faces away from the functional part.

14. The combination according to claim 12, wherein the hole step projects toward an interior of the hole.

15. The combination according to claim 12, wherein a radial extent of the hole step corresponds to a radial depth of the undercut.

16. The combination according to claim 12, wherein, in terms of depth, the hole step is formed outside a lower region of the functional part.

17. A cable lug in combination with a functional part, comprising: the cable lug having a tubular receiving portion for a cable, an integrally formed flat part connecting portion connected to the tubular receiving portion, the flat part connecting portion having a hole therethrough defined by a wall, the hole defining a central axis, the wall including a cylindrical wall portion and a holding material portion extending inwardly from the cylindrical wall portion toward the central axis; and a functional part comprising a body which defines a centerline, a first bearing surface on a base of the body, a displacer unitary with the body located directly below the first bearing surface, the displacer having a first outer surface extending from the first bearing surface, the first outer surface being inwardly tapered along at least a portion of its outside surface relative to the centerline at an angle of any one of 20 to 50 degrees and having an outside diameter less than an outside diameter of the first bearing surface, a shank unitary with the body and extending from the displacer, the displacer having a second surface proximate to the shank, the second surface extending between the shank and the first outer surface, the second surface continuously encircles the body and is angled at a constant angle relative to the centerline of the body, wherein the second surface of the displacer and a surface of the shank form an undercut; wherein the holding material portion is in the undercut such that the functional part is held captively and rotatable on the flat part connecting portion, the surfaces of the undercut having an axial extent which is equal to or less than an axial extent of the cylindrical wall portion of the flat part connecting portion.

18. The combination according to claim 17, wherein the holding material portion is seated in the undercut with radial play.

19. The combination according to claim 17, wherein the holding material portion is rotationally symmetrical.

20. The combination according to claim 17, wherein the second surface of the displacer is rotationally symmetrical.

21. The combination according to claim 17, wherein the wall of the hole of the flat part connecting portion has two conical surfaces, and at least one of the conical surfaces extends at an acute angle to a horizontal or a vertical.

22. The combination according to claim 17, wherein the undercut is formed outside a thread of the functional part.

23. The combination according to claim 17, wherein the second surface of the displacer defines an upper delimiting surface of the undercut and a portion of the surface of the shank forms a lower delimiting surface of the undercut, and wherein each of the upper and lower delimiting surfaces overlap the holding material portion in a radial direction extending outwardly from the central axis.

24. The combination according to claim 17, wherein the upper delimiting surface of the undercut extends radially outwardly from the central axis, and the lower delimiting surface of the undercut extends radially outwardly over more than half of the upper delimiting surface of the undercut.

25. The combination according to claim 17, wherein the hole is formed with a hole step.

26. The combination according to claim 25, wherein the hole step is formed in a lower region of the hole which faces away from the functional part.

27. The combination according to claim 25, wherein the hole step projects toward the interior of the hole.

28. The combination according to claim 25, wherein a radial extent of the hole step corresponds to a radial depth of the undercut.

29. The combination according to claim 25, wherein, in terms of depth, the hole step is formed outside a lower region of the functional part.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The organization and manner of the structure and operation of the invention, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in connection with the accompanying drawings, wherein like reference numerals identify like elements in which:

(2) FIG. 1 is a perspective view of a cable lug with a nut which is associated with the flat part, before pressing;

(3) FIG. 2 shows the item according to FIG. 1, sectioned in the region of the flat part;

(4) FIG. 2a shows an enlargement according to the detail IIa from FIG. 2;

(5) FIG. 3 shows the item according to FIG. 1 in position fitted onto the cable lug;

(6) FIG. 4 shows a cross-sectional illustration, which corresponds to FIG. 2, of the item according to FIG. 3;

(7) FIG. 5 shows the item according to FIG. 1 and FIG. 3 in a pressed position;

(8) FIG. 6 shows a sectional illustration, which corresponds to FIG. 2 and FIG. 4, of the item according to FIG. 5;

(9) FIG. 6a shows an enlargement according to the detail VIa from FIG. 6;

(10) FIG. 7 shows an illustration with a nut screwed onto a threaded connecting pin;

(11) FIG. 8 shows an illustration of a functional part in the form of a screw;

(12) FIG. 9 shows the item according to FIG. 8 with a screw seated on the flat part of the cable lug, before pressing;

(13) FIG. 10 shows an alternative embodiment of a nut which is connected to a cable lug, in perspective view;

(14) FIG. 11 shows a cross-section through the item according to FIG. 10 in the region of the flat part connecting portion;

(15) FIG. 11a shows an enlargement according to portion XIa from FIG. 11;

(16) FIG. 12 shows a cross-section through FIG. 11 in the pressed-in state of the nut;

(17) FIG. 13 shows a perspective view of a further embodiment of the functional part in the form of a nut fitted onto the cable lug;

(18) FIG. 14 shows a cross-section through the item according to FIG. 13, before the pressing;

(19) FIG. 15 shows an enlargement of the region XV in FIG. 14;

(20) FIG. 16 shows an illustration according to FIG. 13, following pressing;

(21) FIG. 17 shows a cross-section through the item of FIG. 16; and

(22) FIG. 18 shows an enlargement of the region XVIII in FIG. 17.

DETAILED DESCRIPTION

(23) A cable lug 1 with a functional part 3, which is in the form of a nut 2 in this case, is presented and described, in first instance with reference to FIGS. 1 to 7.

(24) For a connection between the nut 2 and the cable lug 1 which is secure against coming free, that is to say in a manner secured against becoming detached, but such that the connection is rotatable, the nut 2 is pressed to the cable lug 1, as is shown by FIGS. 5 to 6 in particular.

(25) Specifically, the cable lug 1 has a tubular receiving portion 4 and a flat part connecting portion 5. The cable 19 is introduced into the tubular portion 4 and then held therein, for example by a press fit, the intention being for electrically reliable connection to be achieved by means of the cable lug 1.

(26) The cable lug 1, which is formed from a solid material in the exemplary embodiment, also has a hole 6 in the already mentioned press-deformed flat part connecting portion 5. In the exemplary embodiment, the nut 2 is inserted into this hole 6 and then connected to the cable lug 1, that is to say specifically to the flat part connecting portion 5, in a captive but rotatable manner, by being pressed down in the manner still to be described.

(27) The nut 2 has a body 30 having an upper portion and a lower portion and a central passageway 32 that extends therethrough. The lower portion has a tubular shank 34 formed thereon. A centerline 36 extends through the center of the body 30. As can be seen in further detail from the illustrations of FIGS. 2, 4 and 6, the nut 2 has an internal thread 7 in the central passageway 32, in the exemplary embodiment with an upper plastic insert 8 in order to prevent the nut 2 from becoming detached. In this respect, there is in question a self-locking nut.

(28) An undercut 9 is integrally formed in the lower portion of the nut 2, at the lower end. In the exemplary embodiment, this undercut 9 is produced by turning on a lathe.

(29) The undercut 9 begins below the lower end of the internal thread 7. On the inner side, the undercut 9 has a cylindrical surface 10 which is axially flush with the root of the internal thread 7.

(30) Specifically, the undercut 9 is formed by a lower delimiting surface 11 and an upper delimiting surface or neck 12 and a generally vertical delimiting surface 38 which connects the lower delimiting surface 11 to the upper delimiting surface 12. The upper delimiting surface 12 is also part of a displacer or stepped area which is formed on the nut 2, at the lower end.

(31) The displacer stepped area of the nut 2, which is illustrated in detail on an enlarged scale in the magnified illustration, is as it were the negative of the stepped area which is positively formed in the flat part connecting portion 5, in the pressed state.

(32) More specifically, the stepped area comprises an outer, generally vertical surface 13 and the delimiting surface 12 which has already been discussed. Therefore, surface 13 forms a first surface and surface 12 forms a second surface of the displacer or stepped area. In the exemplary embodiments described here, the two surfaces, the delimiting surface 12 and the outer, generally vertical surface 13, extend at an acute angle α and β respectively in relation to a horizontal H and a vertical V respectively. The outer surface 13 is tapered. The vertical V is parallel to the centerline 36 of the body. The horizontal H is transverse to the centerline of the body 30. The acute angle α or β is preferably in the range of 1 to 60 degrees, more preferably between 10 degrees and 30 degrees for α, and between 20 degrees and 50 degrees for β. In the exemplary embodiment, the angle α is 15 degrees and the angle β is 30 degrees.

(33) The generally vertical surface 13 merges in a radially outward direction into a first bearing or horizontal surface 14 which, however, is formed with a varying radial extent over the circumference on account of the hexagonal form of the nut 2 in the exemplary embodiment.

(34) This varying radial extent of the horizontal surface 14 can be seen in the illustration according to FIG. 3, in which the nut 2 is illustrated in a position fitted onto the flat part connecting portion 5 before pressing. In this case, the hole 6 extends partly, still radially, beyond an associated vertical flat surface 15 of the nut 2.

(35) FIG. 4 illustrates a cross-section through FIG. 3, likewise correspondingly in the state before pressing.

(36) In contrast, FIGS. 5 and 6 illustrate the state following pressing.

(37) It is pertinent that a holding material portion 16 is formed from the flat part connecting portion 5, said holding material portion 16 extending into the undercut 9 of the nut 2. The holding material portion 16 is part of the stepped area which has already been mentioned and is positively formed in the flat part 5 during the pressing-in process of the nut 2 into the flat part connecting portion 5 but, in the same way, has the oblique orientation with respect to a horizontal H or vertical V, as already described. It is clear that upper delimiting surface 12 and generally vertical surface 13 act as a displacer to displace the material of the flat part connecting portion 5 into the undercut 9 during the pressing-in process to thereby form holding material portion 16.

(38) In this case, the holding material portion 16 clearly extends radially inward beyond the hole 6 of original diameter which remains in the lower region, seen over the thickness of the holding material portion 16. The step-like sunk-in region with the stop surfaces 17 and 18 which is created in the holding material portion 16 following pressing is formed such that it is rotationally symmetrical over the circumference of the hole 6. That is to say, the area is produced in a notional sense by rotation of a template. There are no undercuts in the area in relation to the direction of rotation of the notional template mentioned (this is naturally an example of shaping as it is used as required in casting molds; this is only mentioned here in order to make clear the nature of the rotationally symmetrical area).

(39) As can be seen, the holding material portion 16 is held in the undercut 9 both with axial and radial play. However, this play is comparatively small, as can be gathered, in terms of magnitude in the region of the thread depth of the internal thread 7 of the nut 2, that is to say in the millimeter range or in the range of tenths of a millimeter.

(40) The holding material portion 16 itself is also formed to be rotationally symmetrical. The undercut 9 completely laterally overlaps the holding material portion 16 in the pressed state.

(41) In FIG. 7, there is illustrated the connection state of the cable lug 1, with the pressed-in cable 19 located therein, to an (electrical) connection part 20. The connection part 20 has a screw pin 21 by means of which the nut 2, which is captively but rotatably press-connected to the cable lug 1, is screwed on. In this way, a desired pressure/butting connection is produced between the lower side of the flat part connecting portion 5 and the upper side of the connection part 20.

(42) The embodiment of FIGS. 8 and 9 shows a functional part 3 in the form of pin 22. Said pin 22 may possibly also be a screw on which a thread can also be formed at the lower end of the undercut 9.

(43) Substantially the same conditions are produced as for the nut 2 described in relation to FIGS. 1 to 7, only now the pin 22 of the functional part 3 passes through the hole 6. For pressing purposes, a counter holder which has a corresponding receptacle or hole 6 for the pin 22 is suitably used here.

(44) It can be gathered with reference to FIGS. 10 and 11, in particular in comparison with FIG. 3 for example, that the nut 2 has an upper shaped portion 23 with an annularly circumferential planar pressing area 24. The required compressive force can be applied to the nut 2 by means of this pressing area 24 using a suitable pressure-exerting tool, in order to form the holding material portion 16 out of the flat part connecting portion 5 of the cable lug 1 in the course of the pressing. The nut 2 is merely pushed into the flat part connecting portion 5 from above, as has also already been described previously. The pressing area 24 is substantially smaller than the projected full surface of the nut 2. It corresponds at least to less than half of this projected complete surface.

(45) The already mentioned plastic part 8 is accommodated within the structure 23, said plastic part being aligned, in a manner corresponding to a self-locking nut and as can also be seen from the cross-sectional illustration according to FIG. 11, with the internal thread line of the screw thread 7 on an inner wall, which wall has a cylindrical shape.

(46) It is also material to the embodiment of FIG. 11, as can also be seen from the detailed illustration of FIG. 11a, that the angle α is chosen to be 0 degrees whereas the angle β is chosen to be 45 degrees in this case.

(47) Furthermore, it is pertinent that, as shown in FIG. 12 of this embodiment, the bearing or horizontal surface 14 does not rest on the flat part connecting portion 5 in the compressed state. Instead, it hovers as it were over the flat part connecting portion 5 when the pressing-in is correct. In other words, the pressing force is selected such that, with the given configuration of the stepped area, a pressing-in process is performed only to the extent that the surface 14 does not come to rest on the flat part connecting portion 5, and preferably also without taking into account the elastic recovery which results after the nut is relieved of the pressing force, that is to say in such a way that the surface 14 does not come into contact with the upper surface of the flat part connecting portion 5 at any time in the pressing process.

(48) In first instance, it is pertinent to the embodiment of FIGS. 13 to 18 that the hole 6 is stepped in the axial direction. Starting from a relatively large diameter at the top, which is associated with the functional part, specifically with the nut 3, the diameter of the hole 6 changes to a smaller diameter toward the bottom by way of a hole step 25. The hole step 25 is formed symmetrically with respect to the center of a longitudinal axis of the hole 6.

(49) The hole step 25 serves to increase the area on the lower end of the flat part connecting portion 5 in the vicinity of the hole 6, this because, in one application, the flat part connecting portion 5, together with the nut 3, is fitted and screwed onto a stepped pin which has a thread at its upper end. The flat part connecting portion 5 accordingly has to sit on a relatively narrow, annularly circumferential area of the pin. This seating and therefore contact area can advantageously be increased in size by the described hole step 25.

(50) In terms of production, the procedure followed may be, for example, that the upper portion of the hole 6 is pressed in and then, in a second working step, the lower region of the hole is cut or punched out, leaving the hole step 25. Accordingly, a cut edge can be established in the cable lug 1 in the lower region of the hole 6 and, in contrast, plastic deformation in the upper region.

(51) A radial extent r, compare FIG. 15, of the hole step 25 preferably corresponds to the radial depth T, compare FIG. 11a for example, of the undercut 9. Furthermore, said radial depth T of 5 the undercut 9 can also correspond to the vertical height of the vertical surface or the stepped area 13, 17 in this case.

(52) It is also important in the embodiment described here that, in the case of the illustrated nut 3, a circumferential compression flange 26 is integrally formed at the lower end of the nut. This compression flange 26 extends from the lower horizontal surface 14 over a height which corresponds to approximately one third of the vertical height of the head of the functional part, here the nut 3, this height being measured from the horizontal surface 14 up to the pressing area 24.

(53) If a horizontal flange 26, as described here, is provided for the functional part or the nut, the pressing area 24 is no longer of primary importance. Said pressing area 24 may also be dispensed with or formed in the manner illustrated in FIGS. 1 to 7 for example.

(54) The compression flange 26 serves the purpose of enabling a pressure-exerting tool to be fitted. Relatively high compression forces for press-connecting the functional part or the nut 3 to the cable lug 1 can then be applied by means of this compression flange 26.

(55) Since this produces a substantially larger lower horizontal surface 14 than corresponds to the polygonal contour of the nut 3, this is also advantageous in terms of the described pressing process, which can be controlled, specifically as a function of force, up until there is a sharp rise in the pressing force, which signals engagement of the horizontal surface 14 on the flat part connecting portion 5 of the cable lug 1.

(56) The radial extent of the compression flange 26 in relation to a flat face of the polygonal portion of the nut 3 corresponds, in the smallest radial extent, to one twentieth to one fifth of the diameter of the screw 3, as measured in the region of the polygonal portion and centrally with respect to a flattened portion.

(57) The surface, on which the pressure-exerting tool can sit, of the compression flange 26 can run downward in a slightly inclined manner, but can also run horizontally.

(58) The vertical height of the hole 6 in the region of the relatively small diameter, that is to say below the hole step 25 as seen from above, is selected such that the lower termination of the undercut 9 of the functional part does not rest on the step in the pressed state either. In the exemplary embodiment, the screw including the undercut 9 ends, as shown, above the hole step in the pressed state also.

(59) The functional part, specifically the nut 3 of the last-described embodiment, can also be combined with a hole as is further described above. On the other hand, the functional parts as are further described above can also be combined with a hole as is explained in relation to the last described exemplary embodiment.

(60) All disclosed features are (in themselves) pertinent to the invention. The disclosure content of the associated/accompanying priority documents (copy of the prior application) is also hereby incorporated in its entirety in the disclosure of the application, including for the purpose of incorporating features of these documents in claims of the present application.