Crimp connection system for electrical cables comprising a fastening sleeve

Abstract

A crimp connection system for electrical cables, including an electrical cable having a stripped cable end and a fastening sleeve. The stripped cable end is arranged at least partially within the fastening sleeve. The fastening sleeve has a number of fastening protrusions extending from the interior and/or outer surfaces of the fastening sleeve. The fastening protrusions are distributed over the interior and/or outer surfaces of the fastening sleeve. The crimp connection system also includes a contact terminal having a crimp portion. The fastening sleeve is arranged at least partially within the crimp portion.

Claims

1. A crimp connection system for electrical cables, comprising: an electrical cable having a stripped cable end; a fastening sleeve, wherein the stripped cable end is arranged at least partially within the fastening sleeve, wherein the fastening sleeve comprises a plurality of fastening protrusions extending from an interior surface and an outer surface of the fastening sleeve, wherein the plurality of fastening protrusions of the fastening sleeve is formed as an embossment, a louver, or a combination thereof and wherein the plurality of fastening protrusions are distributed over the interior surface and the outer surface of the fastening sleeve; and a contact terminal comprising a crimp portion, wherein the fastening sleeve is arranged at least partially within the crimp portion.

2. The crimp connection system of claim 1, wherein the electrical cable is formed from aluminum and the contact terminal is formed of copper or a copper based alloy.

3. The crimp connection system of claim 2, wherein the plurality of fastening protrusions has a rigidity that is higher than the rigidity of the electrical cable and the contact terminal, so that the plurality of fastening protrusions can carve into the electrical cable and the contact terminal during crimping.

4. The crimp connection of claim 1, wherein the fastening sleeve is a substantially flat metal sheet or foil in an initial state, and is in an substantially cylindrical form, in an installed state.

5. The crimp connection system of claim 4, wherein the fastening sleeve has a first opposing edge and a second opposing edge, wherein the first opposing edge and the second opposing edge are each provided with an engaging contour, and wherein the engaging contour of the first opposing edge engages with the engaging contour of the second opposing edge in the installed state.

6. The crimp connection of claim 4, wherein the fastening sleeve has a longitudinal length in the installed state of at least 8 mm.

7. The crimp connection system of claim 1, wherein the fastening sleeve is formed from a material comprising copper or a copper based alloy and wherein the fastening sleeve is coated with an overcoat comprising zinc, tin, silver, or gold.

8. The crimp connection system of claim 1, wherein a sheet thickness of the fastening sleeve is between 0.2 mm and 0.8 mm.

9. The crimp connection system of claim 1, wherein the plurality of fastening protrusions define a frustoconical shape.

10. A method to assemble a crimp connection system, comprising the following steps: a) arranging a fastening sleeve circumferentially around a stripped end of an electrical cable, wherein the fastening sleeve is crimped on the stripped end of the electrical cable, with a crimping tool having a crimp surface provided with recesses that correspond to a plurality of fastening protrusions of the fastening sleeve; b) arranging the fastening sleeve and the stripped end of the electrical cable within a crimp portion of a contact terminal; and c) crimping the contact terminal to affix the electrical cable to the contact terminal.

11. The method of claim 10, wherein the fastening sleeve is formed from a substantially flat metal sheet, and wherein the fastening sleeve has a first opposing edge and a second opposing edge, wherein the first opposing edge and the second opposing edge are each provided with an engaging contour, and wherein the method further comprises the step of forming the fastening sleeve in a substantially cylindrical form such that the engaging contour of the first opposing edge engages with the engaging contour of the second opposing edge.

12. The method of claim 10, wherein the plurality of fastening protrusions extends from the interior and outer surfaces of the fastening sleeve, wherein the plurality of fastening protrusions of the fastening sleeve is formed as an embossment, a louver, or a combination thereof, and wherein the plurality of fastening protrusions is distributed over the interior and outer surfaces of the fastening sleeve.

13. The crimp connection system of claim 12, wherein the plurality of fastening protrusions has a substantially round cross section having a diameter of no more than 3 mm.

14. The crimp connection system of claim 12, wherein the fastening sleeve comprises at least four fastening protrusions.

15. The method of claim 12, wherein the plurality of fastening protrusions define a frustoconical shape.

16. The method of claim 15, wherein the recesses define a frustoconical shape.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

(1) Other characteristics and advantages of the invention shall appear upon reading the detailed description and the appended drawings, in which:

(2) FIGS. 1A-1D show different assembly steps of a crimp connection system according to one embodiment;

(3) FIG. 2 shows an exploded view of the crimp connection system according to one embodiment;

(4) FIGS. 3A-3C show different embodiments of a fastening sleeve of the crimp connection system in an initial state according to one embodiment;

(5) FIG. 4 shows the fastening sleeve of FIG. 3A in a side view according to one embodiment, and

(6) FIG. 5 shows the fastening sleeve of FIG. 4 in a final state according to one embodiment.

DETAILED DESCRIPTION OF THE INVENTION

(7) FIG. 1A shows the electrical cable 10 having a stripped cable end 11. In FIG. 1B the fastening sleeve 20 is arranged circumferential around the stripped cable end 11 of the electrical cable 10. The fastening sleeve 20 has fastening protrusions 23 and opposing edges 21, 22 provided with an engaging contour, wherein the engaging contour of the first edge 21 is engaged with the engaging contour of the second edge 22. The skilled person will recognize that the fastening sleeve 20 is essentially formed from a sheet metal that is rolled to an essentially cylindrical sleeve-like form. The assembly shown in FIG. 1B can be arranged within a crimping portion 31 of a contact terminal 30 as shown in FIG. 1C. The contact terminal 30 has a screwing portion that can be used to screw the contact terminal, for example on a screw contact of a battery or the like.

(8) Further, the contact terminal 30 provides an outer surface 32 that will be deformed during crimping. FIG. 1D shows the crimp connection system in a crimped state. The outer surface 32 of the contact terminal 30 was crimped in a hexagonal form, resulting in the hexagonal outer surface 33 of the contact terminal 30. Thus, a crimp connection between the electrical cable 10 and the contact terminal 30 can be provided, comprising a fastening sleeve 20 that prevents the stripped cable end 11 and the crimping portion 31 of the contact terminal 30 from micro movement. Thus fretting corrosion is prevented.

(9) FIG. 2 shows the crimp connection 1 in an exploded view. The electrical cable 10 provides a stripped cable end 11 that can be arranged within the fastening sleeve 20. The fastening sleeve 20 has an inner surface 25 and an outer surface 26 (the fastening protrusions are not shown in the schematic illustration of FIG. 2). Further, the fastening sleeve can be arranged within the crimping portion 31 of the contact terminal 30. The contact terminal 30 provides an outer surface 32 that can be deformed during crimping to a hexagonal surface, or the like, as shown in FIG. 1D.

(10) FIGS. 3A-3C show different embodiments of the fastening sleeves 20a, 20b, 20c in an initial respectively intermediate state. The fastening sleeves 20a, 20b, 20c, are formed from a substantially flat metal sheet or foil, preferably comprising copper or a copper-based alloy. These metal sheets can be formed by stamping methods such as punching, blanking, embossing, bending, piercing or flanging or the like. The fastening sleeves 20a, 20b, 20c provide opposing edges 21a, 22a, 21b, 22b, 21c, 22c wherein the opposing edges are provided with an engaging contour. The engaging contour shown in the fastening sleeves 20a, 20b, 20c are to be understood as exemplary contours. The contours can be formed in any suitable form that can be engaged with each other.

(11) Fastening sleeve 20a is provided with an engaging contour having a triangular form. The engaging contour of edge 21a has a recessing contour whereas the engaging contour of edge 22a has a protruding contour. The engaging contours of fastening sleeve 20b are similar, however, certain protruding and recessing triangles are provided. The engaging contour of fastening sleeve 20c provides puzzle-piece-like protrusions and recesses that can engage with each other. Differently formed protrusions and recesses are also possible.

(12) Further, the fastening sleeve 20a provides fastening protrusions 23a that are distributed in rows on a first surface of the fastening sleeve. Fastening sleeve 20b also provides fastening protrusions 23b that are distributed in form of rows that are offset from each other. As can be seen, the fastening protrusions 23a and 23b have a substantially round cross section. The number of fastening protrusions provided can vary. Preferably, at least eight or even more preferably at least 24 fastening protrusions are provided. Fastening sleeve 20c is provided with fastening protrusions 23c. These fastening protrusions 23c have a substantially rectangular cross section. These fastening protrusions 23c are displaced from each other. As can be best seen in FIG. 4, the fastening protrusions 23a can protrude from an inner surface and/or an outer surface of the fastening sleeve. These protrusions are preferably formed by stamping methods such as punching, blanking, embossing, bending, piercing or flanging or the like.

(13) As FIG. 4 shows the fastening sleeve 20a in an initial or intermediate state, where the fastening sleeve is not yet formed to a substantially cylindrical form. Therefore, the fastening protrusions 23a can be formed by conventional stamping technique in a substantially flat metal sheet or metal foil. When the fastening sleeve 20a, shown in FIG. 4, is formed from the intermediate state to the final state as shown in FIG. 5, the inner surface 25a will be the inner most surface of the fastening sleeve 20a and the outer surface 26a will be the outer surface of the fastening sleeve 20a.

(14) The final or installed state of the fastening sleeve 20a is shown in FIG. 5. As can be seen, the engaging contour of the opposing edges 21a and 22a engage with each other to prevent a deformation of the fastening sleeve in axial direction. Further, the fastening protrusions 23a protrude from the inner surface 25a (as shown by circles) and from the outer surface 26a of the fastening sleeve 20a. It has to be understood that also the fastening protrusions 23b and 23c can protrude from the inner and/or outer surface of the fastening sleeves.