Connection of a Connection Part to a Stranded Wire

Abstract

Connection of a connection wire to a stranded wire, in which a connecting part has a first metallic surface made of a first metal material and a second metallic surface made of a second metal material which is different from the first metal material, the stranded wire is formed from a metal material, the connecting part sheathing the stranded wire is laid with the first metallic surface adjacent to the stranded wire around the stranded wire, and the connecting part is connected to the stranded wire at least in a positive-locking manner.

Claims

1-19. (canceled)

20. Connection of a connection wire with a stranded wire, where a connecting part has a first metallic surface of a first metal material and a second metallic surface of a second metal material different from the first metal material, the stranded wire is made of a metal material, the connecting part is laid around the stranded wire to sheath the stranded wire, with the first metallic surface adjacent to the stranded wire, and the connecting part is at least positively connected to the stranded wire, wherein the connecting part with the second metallic surface facing away from the stranded wire is connected to the connection wire in a material-locking manner wherein the connecting part is laid around the stranded wire as a cut-to-length strip, or in that the connecting part is laid around the stranded wire from an endless belt and is then cut to length.

21. Connection according to claim 20, wherein the amount of the standard potential difference between the first metal material and the second metal material is greater than 1V, preferably greater than 1.5V, and in particular in that the amount of the standard potential difference between the first metal material and the second metal material is less than 2V.

22. Connection according to claim 20, wherein one of the metal materials has a positive standard potential with respect to a normal hydrogen electrode and the other metal material has a negative standard potential with respect to a normal hydrogen electrode.

23. Connection according to claim 20, wherein the amount of the standard potential difference between the metal material of the connecting line and the second metal material is less than 1.5 V, preferably less than 1 V.

24. Connection according to claim 20, wherein the connecting part is coated bimetallically or in that the connecting part is roll clad bimetallically or in that the connecting part is formed as a bimetallic sheet metal part.

25. Connection according to claim 20, wherein the first metal material is formed from a metallic carrier material and the second metal material is formed from a metallic coating material or the first metal material is formed from a metallic coating material and the second metal material is formed from a metallic carrier material.

26. Connection according to claim 20, wherein the first metal material is copper, a copper alloy, aluminium, an aluminium alloy or stainless steel and/or the second metal material is copper, a copper alloy, aluminium, an aluminium alloy or nickel and/or in that the connection wire is formed from copper, a copper alloy, aluminium or an aluminium alloy.

27. Connection according to claim 20, wherein the conductor cross-section of the stranded wire is greater than 50 mm.sup.2 and less than 200 mm.sup.2.

28. Connection according to claim 20, wherein the stranded wire is an energy conductor in a motor vehicle, in particular a battery conductor.

29. Connection according to claim 20, wherein the stranded wire is guided in a cable with insulation, and in that the connection between the stranded wire and the connecting part is formed in the region of an uninsulated region of the cable which is surrounded on both sides by the insulation, or in that the connection between the stranded wire and the connecting part is formed in the region of a stripped end of the cable.

30. Connection according to claim 20, wherein the connecting part is crimped around the stranded wire, in particular in that the connecting part in the region of an insulation has an inner circumference corresponding to the outer circumference of the insulation, in particular in that the connecting part is arranged gas-tight on the insulation and/or in that the connecting part in the region of the stranded wire has at least one flat surface region pointing outwards, a seam of the connecting part in particular being arranged in at least one flat surface region.

31. Connection according to claim 20, wherein the connecting part is wrapped around the stranded wire in a positive fit and in that the connecting part is welded to the stranded wire, in particular ultrasonically welded or resistance welded.

32. Connection according to claim 20, wherein the connecting part has a polygonal outer circumference, at least two outer edges being formed as welding faces for a material-locking connection between the connecting part and the connecting line.

33. Connection according to claim 29, wherein that the connection wire is arranged in the region of the joint with the connecting part parallel to the stranded wire on the insulation of the cable comprising the stranded wire.

34. Method of connecting a connecting part to a stranded wire, the method comprising: laying the connecting part with a first metallic surface made of a first metal material around the stranded wire in a positive fit, wherein the connecting part is laid around the stranded wire as a cut-to-length strip, or in that the connecting part is laid around the stranded wire from an endless belt and is then cut to length to form a cut-to-length strip; welding the connecting part to the stranded wire in a material-locking manner; and connecting a connection wire in a material-locking manner to a second metallic surface of the connecting part, wherein the second metallic surface is made of a second metal material which faces away from the first metallic surface.

35. Method according to claim 34, wherein the connecting part and the stranded wire are plastically deformed before or during the material-locking connection.

36. Method according to claim 34, wherein the connecting part is welded to the stranded wire in the region of a butt joint or an overlap joint.

37. Method according to claim 34, wherein the welding comprises ultrasonic welding.

38. Method according to claim 34, wherein the welding comprises resistance welding.

Description

[0045] In the following, the subject matter is explained in more detail by means of a drawing showing embodiments. In drawing show:

[0046] FIG. 1a-f various embodiments of connection parts;

[0047] FIG. 2a-d various embodiments of a connection part with a cable comprising a stranded wire;

[0048] FIG. 3a, b a cross section through a stranded wire joined with a connecting part;

[0049] FIG. 4a-d embodiments for welding the connecting part to the stranded wire;

[0050] FIG. 5a-c embodiments for welding the connecting part to a connection wire.

[0051] FIG. 1a shows a connecting part 2 in a cross-section. The connection part 2 has two surfaces 2a and 2b, which are made of different metal materials. The connecting part 2 according to FIG. 1a is, for example, a bimetallic sheet metal strip with a carrier material 4 and a coating material 6. The transition between the carrier material 4 and the coating material 6 is characterised by a standard potential difference. This is preferably larger than one volt.

[0052] The carrier material 4 can, for example, be an aluminium material or a copper material. All alloys of aluminium and copper can be used as carrier material. The coating material 6 can also be a copper material or an aluminium material as well as all alloys belonging to it. Also the coating material can be 6 nickel.

[0053] FIG. 1b shows another embodiment of a connection part 2, where carrier material 4 and coating material 6 are coated on all sides with a further material 8. In particular, material 8 may be a nickel material.

[0054] FIG. 1c shows another embodiment of a connection part 2, where the carrier material 4 can be formed as a sheet and the coating material 6 can be, for example, a nickel coating in particular. The coating can be a galvanic coating.

[0055] FIG. 1d shows another embodiment of a connection part 2, where a carrier material 4 can be coated on all sides with a coating material 6. Here, the coating material 6 can preferably be a nickel layer.

[0056] FIG. 1e shows another embodiment of a connection part 2. Here a carrier material 4 can be provided with a coating material 6 arranged on it or embedded therein, in particular roll clad coating material 6. A transition between the carrier material 4 and the coating material 6 can, for example, be coated with a coating 8, which is, for example, nickel. The coating material 6 may be free of the coating 8 at a distance from the transition between the substrate 4 and the coating material 6.

[0057] FIG. 1f shows another embodiment of a connection part 2. This is formed as a two-part sleeve in which carrier material 4 and coating material 6 are provided on both sleeve parts. It is not shown that the sleeve can also be fully coated, e.g. with nickel.

[0058] The above statements for the material combinations for carrier material 4 and coating material 6 apply to all conceivable connecting parts. In particular, further material combinations are possible, in particular by using stainless steel or similar materials. A joining between the connecting part 2 and a stranded wire 10 of a cable 12 is shown as an example in FIG. 2a.

[0059] Depending on the application and the material of the stranded wire 10, a connecting part according to FIG. 1a-f can be placed either with the surface 2a or the surface 2b on the stranded wire 10 or with the carrier material 4 or the coating material 6 on the stranded wire 10.

[0060] Here it is possible that the cable 12 is spliced so that the stranded wire 10 is exposed between two insulated areas of the cable 12. The connecting part 2 is now placed around such an area. In this case, connection part 2 with one of the surfaces 2a, b is placed on the stranded wire 10 and then turned over. Connection part 2 can be cut to length before the cover is turned over, or it can be cut to length after the cover is turned over.

[0061] FIG. 2b shows an embodiment in which the connection part 2 is laid around the stranded wire 10 at one end of the cable 12 which is stripped at the end face. Here, too, it depends on which material the stranded wire 10 is made of, which of the surfaces 2a, b of connection part 2 is laid on the stranded wire 10. Copper materials or aluminium materials are particularly suitable for stranded wire 10.

[0062] FIG. 2c shows how a sleeve 2 is pushed on or put on, for example according to FIG. 1f on a front end of a cable 12 in which the stranded wire 10 is stripped.

[0063] According to FIG. 2d, cable 12 is spliced so that sleeve 2 is exposed between two insulated areas of cable 12. The sleeve 2 is now pushed onto such an area or, in the case of a multi-part sleeve, placed onto it. The sleeve with one of the surfaces 2a, b is placed on the stranded wire 10 and then pressed.

[0064] After connecting part 2 to the stranded wire 10, it is plastically deformed and laid around the stranded wire. A cross-section of such an at least mechanically joined connection between the connecting part 2 and the stranded wire 10 is shown in FIG. 3a. Here the coating material 6 is on the side of connection part 2 facing the stranded wire 10 and the carrier material 4 is on the side of connection part 2 facing away from the stranded wire 10. Plastic deformation of connection part 2 produces a positive connection at the transition between the coating material 6 and the stranded wire 10. Connection part 2 is laid in a butt joint around the stranded wire 10 and a seam 14 is formed.

[0065] FIG. 3b shows another embodiment in which, for example, the carrier material 4 is arranged on the side of connection part 2 facing the stranded wire 10 and the coating material 6 on the side of connection part 2 facing away from the stranded wire 10.

[0066] The connection part 2, for example, has been laid around the stranded wire 10 and then cut to length. The seam 14, for example, is shaped as an overlap joint.

[0067] FIG. 4a shows the joining of the connection part 2 to the cable 12. FIG. 4a shows two press jaws 16a, 16b as examples with which the connection part 2 can be joined to the cable 12 plastically deforming. To do this, the press jaws 16a, b move in the direction of connection part 2 and deform it in the process. The cross-section I-I is shown in FIG. 4a on the right. As can be seen, a contour of the connecting part 2, for example, is given with the aid of the press jaws 16a, b. In the example shown, the connecting part 2 has a multi-edged outer contour after being pressed through the pressing jaws 16a, b. In addition, connection part 2 is directly connected to the stranded wire 10.

[0068] Furthermore it can be seen in FIG. 4a that connection part 2 is also pressed against cable 12 in the area of the insulation of cable 12. The pressing jaws 16a, b can be shaped in such a way that a positive and preferably gas-tight connection is formed between the connecting part and the insulation of the cable 12.

[0069] The seam 14 of connection part 2 can also be seen in FIG. 4a. Seam 14 is located in the area of a flat surface of the outer circumference of connector 2. In particular, seam 14 is located in the area of a welding plane with which connector 2 is welded to the stranded wire line 10. The pressing jaws 16a, b can also be formed as ultrasonic tools, in particular as anvils and sonotrodes, and enable the connection part 2 to be welded to the stranded wire 10 as well as along the seam 14 immediately during the pressing described in FIG. 4a.

[0070] FIG. 4b shows another example in which a sonotrode 18a and an anvil 18b work in a similar manner to the press jaws 16a, b according to FIG. 4a. The contour of sonotrode 18a and anvil 18b can also be such that the cross-section along the section plane I-I of connector 2 is angular after deformation. Here, too, it can be seen that the seam 14 is in the area of a flat welding surface. With the help of the sonotrode 18a and the anvil 18b it is possible to first form the connection part 2 around the stranded wire 10 and then or in the same working step weld it to the stranded wire 10. This allows simultaneous welding along the seam 14.

[0071] FIG. 4c shows another example. Pressing jaws 16a, b or sonotrode 18a and anvil 18b can be used to press connection part 2 onto the stranded wire 10 and, if necessary, weld it simultaneously or afterwards. The pressing jaws 16a, b shape the cross-section along the section I-I as shown in FIG. 4c. Here, too, flat welding surfaces are formed. Seam 14 can be provided within one of these welding surfaces.

[0072] FIG. 4d shows another example in which the connecting part 2 is pressed against the stranded wire 10 and the insulation of the cable 12. At section I-I is shown, outer circumference e.g. can be square and especially seam 14 can be build as overlap-joint.

[0073] After joining the connecting part 2 to the stranded wire 10 with positive and material locking, in particular by means of ultrasonic welding or resistance welding, and if necessary to the insulation of the cable 12 with positive locking, it is possible to lay connecting lines 20a, b on the preferably flat welding surfaces on the outer circumference of the connecting part 2. This connection wire 20a, 20b can be welded with their exposed ends or their stranded wires to a surface 2a, b of the connection part 2 as shown in FIG. 5a.

[0074] The stranded wire 10 is preferably made of a different metal material than the connection wires 20a, b.

[0075] By the fact that the connecting part 2 is formed from a carrier material 4 and a coating material 6, which are formed from different materials, a smaller standard potential difference results at the transition between the outwardly facing surface of the connecting part 2 to the connecting line 20a, b than a direct connection of the connecting lines 20a, b to the stranded wire 10.

[0076] FIG. 5b shows another embodiment in which the connecting part 2 is laid sleeve-shaped around one end of a cable 12 or the stranded wire. Here, too, the connection wires 20a, b preferably by means of a sonotrode 18a and an anvil 18b are welded to the outer surface of the connecting part 2. Here, too, connection part 2 has a first surface that faces the stranded wire 10 and a second surface that faces the connection wires 20a, b. The first surface faces the stranded wire 10. These surfaces are made of different materials, in particular carrier material 4 on the one hand and coating material 6 on the other.

[0077] The largest standard potential difference is preferably formed within the connecting part 2 at the transition between the carrier material 4 and the coating material 6, whereas the potential differences between on the one hand the stranded wire 10 and the carrier 4 or the coating material 6 and on the other hand the material of the stranded wire of the connection wire 20a, b and the material of the carrier material 4 or the coating material 6 are smaller.

[0078] FIG. 5c shows another example where the stranded wire 10 is connected to a flat cable 20c via the connection part 2. The cable of the connection wire 20c is free of its insulation in a central area. In this exposed area, the connecting part can be connected to the connection wire 20c with one of the surfaces 2a, b with material connection. The connection part 2 encloses the stranded wire 10 and is connected to it by a material connection.

[0079] At least two or more exposed areas can be provided along the 20c flat cable. At these areas, the stranded wires 10 can be connected in substance in the various configurations described above. Thus, a first stranded wire 10 can be spliced and in the area of the splice, connection part 2 can establish the connection with the flat cable, as shown on the left. The stranded wire 10 can also be provided with a sleeve as connection part 2 at the end face, for example, and a connection can be made to the flat cable 20c via this, as shown on the right.

[0080] With the help of the joining process shown, contact corrosion-proof joining by means of ultrasonic welding or resistance welding is possible. Cables made of different materials can be joined in a particularly simple way using a bimetal connection part.