FRICTION WELDING CONNECTOR AND ITS METHOD OF PRODUCTION

Abstract

A method of making an electrical connection is here proposed. The method includes the steps of joining a first contact member to a second contact member in a material-to-material contact. The method steps for the same include: providing the first contact part, which towards the second contact part has a male, first joining section as a solid component with an at least substantially rotationally symmetrical profile, providing the second contact part having towards the first contact part a female second joining portion with a hollow profile, inserting the first joining section into the second joining section, applying a friction welding tool (400) to or in an opening of the second joining section (121), and moving the friction welding tool relative to the first contact part and/or the second contact part to generate welding energy for at least partially plasticizing a part of the first joining portion and/or second joining portion facing the other contact part.

Claims

1. A method for making an electrical connection by joining a first contact part to a second contact part in a material-to-material contact, the method comprising the steps of: Providing the first contact part, comprising a male first joining section arranged towards the second contact part and being a solid component with an at least substantially rotationally symmetrical profile, Providing the second contact part comprising a female second joining section arranged towards the first contact part and comprising a hollow profile, Inserting the first joining section into the second joining section, applying a friction welding tool to or in an opening of the second joining section, and Moving the friction welding tool relative to at least one of the first contact part and the second contact part so as to generate welding energy for at least partially plasticizing at least one of a part of the first joining section and the second joining section facing an other contact part.

2. The method according to claim 1, wherein a material of the first contact part has a lower mechanical strength or lower yield point than a material of the second contact part.

3. The method according to claim 1, wherein the first contact part comprises at least one material recess formed in the first joining section.

4. The method according to claim 1, wherein the at least one material recess is formed by a machining manufacturing process.

5. The method according to claim 3, wherein the material recess extends along an axis of rotation of the first joining section.

6. The method according to claim 3, wherein the material recess is arranged on a lateral surface of the first joining section.

7. The method according to claim 1, wherein at least one of the first contact part and the second contact part comprises an electrical connection section in addition to the joining section and is configured to attach a further contact partner or contact part.

8. The method according to claim 1, further comprising the step of: attaching at least one further contact partner to an electrical connection section of at least one of the first contact part and second contact part.

9. The method according to claim 1, further comprising the step of: coating at least one of the first joining section and second joining section with an insulating material after melting of the same.

10. An electrical connection assembly, comprising: a first contact part comprising a solid component male first joining section having an at least substantially rotationally symmetrical profile, a second contact comprising a female second joining portion with a hollow profile, wherein the first joining section is arranged in the second joining section and is materially connected thereto.

11. The method according to claim 10, wherein the first contact part comprises a material having a lower mechanical strength or lower yield point than a material of the second contact part.

12. The electrical connection assembly according to claim 10, wherein the first contact part comprises at least one material recess formed in the first joining section.

13. The electrical connection assembly according to claim 10, wherein the at least one material recess is formed by a machining manufacturing process.

14. The electrical connection assembly according to claim 13, wherein the material recess extends along an axis of rotation of the first joining section.

15. The electrical connection assembly according to claim 13, wherein the material recess is arranged on a lateral surface of the first joining section.

16. The electrical connection assembly according to claim 10, wherein at least one of the first contact part and the second contact part comprises an electrical connection section in addition to the joining section and is configured to attach a further contact partner or contact part.

17. The electrical connection assembly according to claim 10, further comprising at least one further contact partner configured to be attached to an electrical connection section of at least one of the first contact part and second contact part.

18. The electrical connection assembly according to claim 10, further comprising and insulating material coating at least one of the first joining section and second joining section with an insulating material after melting of the same.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0030] Further advantages, features, and details of the various embodiments of this disclosure will become apparent from the ensuing description of a preferred exemplary embodiment and with the aid of the drawings. The features and combinations of features recited below in the description, as well as the features and feature combination shown after that in the drawing description or in the drawings alone, may be used not only in the particular combination recited, but also in other combinations on their own, without departing from the scope of the disclosure. An advantageous embodiment of the present invention is set out below with reference to the accompanying figures, wherein:

[0031] FIG. 1 depicts a perspective view of an electrical connection arrangement according to one embodiment of the invention,

[0032] FIG. 2 depicts a perspective view of an electrical connection arrangement according to one embodiment of the invention,

[0033] FIG. 3 depicts a perspective view of an electrical connection arrangement with insulation according to one embodiment of the invention,

[0034] FIG. 4 depicts a perspective view of an electrical connection arrangement with insulation according to one embodiment of the invention,

[0035] FIG. 5 depicts in each case a perspective view of different first contact parts with a material recess according to embodiments of the invention,

[0036] FIG. 6 depicts a sectional view of a first and a second contact part according to an embodiment of the invention before a joining process,

[0037] FIG. 7 depicts a sectional view of a first and a second contact part according to an embodiment of the invention during a friction welding process; and

[0038] FIG. 8 depicts a sectional view of a first and a second contact part according to an embodiment of the invention after a joining process.

[0039] The figures are merely schematic representations and serve only to explain the invention. Identical or similarly acting elements are marked throughout with the same reference signs.

DETAILED DESCRIPTION OF THE INVENTION

[0040] As used throughout the present disclosure, unless specifically stated otherwise, the term “or” encompasses all possible combinations, except where infeasible. For example, the expression “A or B” shall mean A alone, B alone, or A and B together. If it is stated that a component includes “A, B, or C”, then, unless specifically stated otherwise or infeasible, the component may include A, or B, or C, or A and B, or A and C, or B and C, or A and B and C. Expressions such as “at least one of” do not necessarily modify an entirety of the following list and do not necessarily modify each member of the list, such that “at least one of “A, B, and C” should be understood as including only one of A, only one of B, only one of C, or any combination of A, B, and C.

[0041] FIG. 1 shows a perspective view of an electrical connection arrangement 100 which is particularly suitable for use in a motor vehicle. The line arrangement 100 has a first contact part 110 and a second contact part 120, which in turn can each be connected to one or more electrical contact partners. For better illustration, the first contact part 110 is here connected to a contact partner 200, which is here exemplarily a type of bus bar. That is, the first contact part 110 is connected on the one hand to the second contact part 120 and on the other hand to the contact partner 200, so that a continuous current path can be formed between a plurality of contact partners via the line arrangement 100. FIG. 1 shows that the second contact part 120 can also be connected to a further contact partner (not shown here).

[0042] The first contact part 110 and the second contact part 120 are made of materials that are different from each other, with the second contact part 120 being mechanically stronger than the first contact part 110. Similarly, the first contact part 110 may have a higher ductility than the second contact part 120. In particular, the first contact part 110 may be made of an aluminum material, for example. The second contact part 120 may be made of a copper or steel material, for example.

[0043] According to FIG. 1, the first contact part 110 and the second contact part 120 are connected to each other in a section 130, forming a material bond. In section 130, the first contact part 110 and the second contact part 120 may also be pressed together. The first contact part 110 has a male first joining section 111, which is formed as a solid component, for example a solid material, and has a rotationally symmetrical profile, which in this example has a cylindrical shape. The second contact part 120 has a female second joining section 121 which is complementary to the first joining section and is accordingly formed as a hollow profile for receiving the first joining section. The second joining section can therefore also be understood as a type of sleeve.

[0044] The first contact part 110 and the second contact part 120 each have an electrical connection section 112 and 122, respectively, additional to the joining section 111 and 121, respectively, for attaching a further contact partner, such as here the contact partner 200. The first connection section 122 of the first contact part 110 is here exemplarily designed as a welding lug, but may also be designed as a screw lug, etc. The second connection section 122 of the first contact part 110 is here exemplarily formed as a screw tab, but may also be formed as a weld tab, etc. According to FIG. 1, the first contact part 110 and/or the second contact part 120 may have a bend formed between the respective joining section 111, 121 and the respective connection section 112, 122. Alternatively or in addition thereto, the respective joining portion 111, 121 and the respective connection portion 112, 122 may be rotated relative to each other, in particular about their longitudinal axis.

[0045] FIG. 2 shows a further exemplary embodiment of the line arrangement 100, wherein here the first contact part 110 has a different connection section 112. In contrast to the embodiment described above, the connection section 112 is not designed as a welded tab here, but is suitable for connection by means of a positive and/or non-positive connection, for example for a tox connection.

[0046] In FIGS. 3 and 4, the conduit arrangement 100 is in each case sheathed with an insulating material 140, which is at least electrically insulating, but may also have a sealing function.

[0047] FIG. 5 comprises three partial FIGS. 5A, 5B and 5C, each showing the first contact part 110 as a single component. Common to these three exemplary embodiments is that the first joining portion 111 has a material recess 113. This is formed, for example, by a machining manufacturing process, such as drilling, milling or the like. In FIG. 5A, the first joining section 111 has as material recess 113, by way of example, a central bore, which is formed here as a blind hole, which extends at least in sections along a longitudinal extent or an axis of rotation of the first joining section 111. In FIG. 5B, as an example, three holes are provided as material recess 113, which may, for example, have a smaller cross-section than the central hole of FIG. 5A. In FIG. 5C, a number of material recesses 113 are provided, which are formed on an outer surface of the first joining section 111.

[0048] Referring now to FIGS. 6, 7, and 8, a method of fabricating the electrical lead assembly 100 by joining the first contact member 110 to the second contact member 120 will be explained below.

[0049] First, as indicated in FIG. 6, the two contact parts 110, 120 are inserted into each other by inserting the first joining section 111 into the second joining section 121.

[0050] As indicated in FIG. 7, in an optional step a pressing tool 300 is applied to the outside of section 130 from the radial direction and a pressing force F is applied to it, as indicated by two arrows in FIG. 7. In this process, a deformation of the first joining section 111 can be favored by the material recess 113 (see also FIGS. 5 and 6).

[0051] Referring further to FIG. 7, a friction welding tool 400 is then moved to the section 130, as indicated by a double arrow. The friction welding tool is here a kind of mandrel which can be moved, for example, but also turned or rotated. For example, the friction welding tool 400 is guided at or partially into the second joining area 121, which is open on both sides for this purpose, so that the first contact part 110 can be approached from a first side and the friction welding tool 400 from a second side. The friction welding tool 400 is then moved, in particular rotated or rotated, relative to the first contact part 110 and/or the second contact part 120 for generating welding energy, for at least partially plasticizing a part of the first joining section 111 and/or second joining section 121 facing the other contact part.

[0052] FIG. 8 shows a sectional view of the finished connection arrangement 110. A welded joint 131 is now formed in section 130.

[0053] In a further optional step, the insulation material 140 (see FIGS. 3 and 4) can then be applied in the section 130, possibly also with an overlap with another section, for example by overmolding with a suitable plastic, or by a similar manufacturing process.

[0054] Finally, the interconnect assembly 100 may be connected to the one or more contact partners 200, for example, by bolting, welding, toxing, etc., as appropriate.

[0055] Since the devices and methods described in detail above are examples of embodiments, they can be modified to a wide extent by the skilled person in the usual manner without leaving the scope of the invention. In particular, the mechanical arrangements and the proportions of the individual elements with respect to each other are merely exemplary. Some preferred embodiments of apparatus according to the invention have been disclosed above. The invention is not limited to the solutions explained above, but the innovative solutions can be applied in different ways within the limits set by the claims.