Electrical connection console for a motor-vehicle electrical system conductor

Abstract

Electrical connection console for a motor vehicle board net comprising a cable 2 with a metallic stranded conductor 4, and an electrical tap electrically and mechanically connected to the stranded conductor 4, characterized in that the tap is formed from a metallic sleeve 10, in that the sleeve 10 is connected to the stranded conductor 4 in a connection region 8 of the stranded conductor 4, and in that the sleeve 10 has a longitudinal extent in a longitudinal axis parallel to a longitudinal axis of the stranded conductor 4, in that the sleeve 10 has a recess 26 whose longitudinal axis runs transversely with respect to the longitudinal axis of the sleeve 10, and in that a contact sleeve 28 is arranged in the recess 26.

Claims

1. Electrical connection terminal for a motor vehicle wiring comprising: a cable with a metallic stranded conductor, and an electrical tap electrically and mechanically connected with the stranded conductor, wherein the tap is formed from a metallic sleeve, the sleeve is connected with the stranded conductor in a connection region of the stranded conductor and the sleeve has a longitudinal extension in a longitudinal axis parallel to a longitudinal axis of the stranded conductor, the sleeve has a recess, of which the longitudinal axis is oriented transversely to the longitudinal axis of the sleeve, and a contact sleeve is arranged in the recess, and the sleeve is welded to the stranded conductor in a material bond, wherein the contact sleeve is formed from at least two sections wherein a first section is made from a first metal and a second section made from a second metal, different than the first metal, wherein the second section is in contact with the stranded conductor and the second metal is equal to the metal of the stranded conductor and the contact sleeve has a through-opening, and wherein the contact sleeve is welded to the stranded conductor and the sleeve.

2. Electrical connection terminal according to claim 1, wherein the sleeve is pressed in the connection region in such a way that the sleeve has two contact surfaces running essentially parallel to one another and the recess extends between the contact surfaces.

3. Electrical connection terminal according to claim 2, wherein at least one edge length of the pressed sleeve is greater than the diameter of the conductor, in particular greater than the diameter of the cable.

4. Electrical connection terminal according to claim 2, wherein the pressed sleeve has a square or rectangular shape.

5. Electrical connection terminal according to claim 1, wherein a connecting bolt is arranged in the through-opening.

6. Electrical connection terminal according to claim 1, wherein the contact sleeve is formed from at least two sections which are arranged next to one another in the axial direction of the contact sleeve, wherein a first section has a first outer circumference and a second section has a second outer circumference which is larger than the first outer circumference.

7. Electrical connection terminal according to claim 6, wherein the second section is formed as a flange, in particular with a radially projecting collar, the flange lies against a contact surface of the sleeve, in particular wherein the flange is welded to the sleeve in a material bond.

8. Electrical connection terminal according to claim 6, wherein the first section is connected to the strands of the stranded conductor in a material bond, in particular friction-welded.

9. Electrical connection terminal according to claim 1, wherein the cable has an insulation of the stranded conductor, the connection region is arranged in a stripped region arranged between two insulation sections of the insulation, and the sleeve is connected to the stranded conductor in the connection region in a material bond.

10. Electrical connection terminal according to claim 9, wherein the insulation completely encloses the stranded conductor in the insulation sections.

11. Electrical connection terminal according to claim 1, wherein the stranded conductor is a round conductor and/or the stranded conductor is formed from aluminium or an alloy thereof.

12. Electrical connection terminal according to claim 1, wherein the sleeve, in parts a connecting bolt and the stranded conductor are sheathed with an insulation material, wherein the insulation material extends over the insulation of the stranded conductor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the following, the subject matter will be explained in more detail with reference to a drawings showing exemplary embodiments. The drawings show:

(2) FIG. 1a a cross-section of a cable;

(3) FIG. 1b a view of a stripped cable;

(4) FIG. 1c a view of another stripped cable;

(5) FIG. 2a a cable with a sleeve not yet applied;

(6) FIG. 2b a cable with a sleeve not yet applied;

(7) FIG. 2c a cable with a sleeve not yet applied;

(8) FIG. 2d a cable with a sleeve applied;

(9) FIG. 3a-f sleeves according to embodiments;

(10) FIG. 4a,b a connection between a sleeve and a stranded conductor according to embodiments;

(11) FIG. 5a-c a connection between a sleeve and a stranded conductor according to embodiments;

(12) FIG. 6 joining a sleeve to a stranded conductor;

(13) FIG. 7 a sleeve with a recess;

(14) FIG. 8a-c contact sleeves according to embodiments;

(15) FIG. 9a-d contact sleeves according to embodiments;

(16) FIG. 10 a connection between a contact sleeve and a sleeve with conductor;

(17) FIG. 11a-b joining of a contract sleeve in a recess of a sleeve;

(18) FIG. 12 a connection console with a fuse box.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

(19) FIG. 1a shows an electrical cable 2 with a metallic conductor 4 and an insulation 6.

(20) The metallic conductor 4 is preferably a stranded conductor and is in particular bend-resistant. The conductor 4 is preferably a round conductor. The material of the conductor 4 is preferably aluminium, in particular aluminium 99.5. The bending resistance of the cable 2 results when the cable 2 cannot be plastically deformed due to its own weight force. A force greater than the weight force is necessary to cause plastic deformation of the cable 2.

(21) The insulation 6 is preferably made of PVC or silicone.

(22) As shown in FIG. 1b, in a present connection console, the cable 2 may be stripped in a central area, i.e. away from its respective distal ends, so that a stripped area 8 is formed. In the stripped area 8, the conductor 4 is free from the insulation 6.

(23) As shown in FIG. 1c, in a connection console according to the subject matter, the cable 2 may be stripped in an end region, that is at a front end, so that a stripped area 8 is formed. In the stripped are 8, the conductor 4 is free of the insulation 6.

(24) A joint between the sleeve 10 and the stranded conductor 4 of the cable 2 is shown by way of example in FIG. 2.

(25) A metal sheet as described in FIGS. 3a-f may, depending on the application and the material of the stranded conductor 4, either be placed on the stranded conductor 2 with the surface 40a or the surface 40 or be placed on the stranded conductor 4 with the carrier material 10c or the coating material 10d.

(26) Here, it is possible that the cable 2 is spliced so that the stranded conductor 4 is exposed between two insulated regions of the cable 2. The sleeve 10 is placed around such an area. Here, the sleeve 10 is placed with one of the surfaces 10a, b on the stranded conductor 4 and then folded over. The sleeve 10 may be cut to length before being folded over, or it may be cut to length after being folded over.

(27) FIG. 2b shows an embodiment in which the sleeve is placed around the stranded conductor 4 at a stripped end of the cable 2. Here, too, it depends on which material the stranded conductor 4 is made of which of the surfaces 10a, b of the sleeve 10 is placed on the stranded conductor 4. Copper materials or aluminium materials are particularly suitable for the stranded conductor 4.

(28) FIG. 2c shows the sliding or placing of a sleeve 10, for example according to FIG. 3f, onto a front end of a cable 2 on which the stranded conductor 4 is stripped.

(29) According to FIG. 2d, the cable 2 is spliced so that the stranded conductor 4 is exposed between two insulated areas of the cable 2. The sleeve 10 is now pushed onto such an area or, in the case of a multi-part sleeve, placed on top. In this case, the sleeve 10 is placed with one of the surfaces 10a, b on the stranded conductor 4 and then pressed.

(30) After the sleeve 10 has been placed on the stranded conductor 4, it is plastically deformed and laid around the stranded conductor. A cross-section of such an at least mechanically joined connection between the sleeve 10 and the stranded conductor 4 is shown in FIG. 4a.

(31) FIG. 3a-f show the sleeve 10 in the not yet formed state, and in particular a transverse or longitudinal section through the sleeve 10.

(32) FIG. 3a shows a sleeve 10 in a cross-section. The sleeve 10 has two surfaces 10a and 10b which are formed from different metal materials. The sleeve 10 according to FIG. 3a is for example a bimetallic sheet metal strip, with a carrier material 10c and a coating material 10d. The junction between the carrier material 10c and the coating material 10d is characterised by a standard potential difference. This is preferably greater than one Volt.

(33) The substrate material 10c may be, for example, an aluminium material or a copper material. All alloys of aluminium and copper may be used as a carrier material. The coating material 10d may also be a copper material or an aluminium material as well as all alloys belonging thereto. Also, the coating material 10d may also be nickel.

(34) FIG. 3b shows a further example of a sleeve 10 in which the carrier material 10c and the coating material 10d are coated on all sides with a further material 12. The material 12 may in particular be a nickel material.

(35) FIG. 3c shows a further embodiment of a sleeve 10. Here, the carrier material 10c may be formed as a sheet and the coating material 10d may be, for example, a coating, in particular with nickel. The coating may be an electroplated coating.

(36) FIG. 3d shows a further embodiment of a sleeve 10. Here, a carrier material 10c may be coated on all sides with a coating material 10d. Preferably, the coating material 10d may be a nickel layer.

(37) FIG. 3e shows a further embodiment of a sleeve 10. Here, a carrier material 10c may be provided with a coating material 10d arranged thereon or embedded, in particular roll-cladded, therein. A transition between the carrier material 10c and the coating material 10d may be coated, for example, by a coating 12 which is nickel, for example. The coating material 10d may be free of the coating 1 remote from the transition between the carrier material 10c and the coating material 10d.

(38) FIG. 3f shows a further embodiment of a sleeve 10, which is formed as a two-part sleeve 10 in which carrier material 10c and coating material 10d are provided on both sleeve parts. It is not shown that the sleeve may also be fully coated, e.g. with nickel.

(39) The explanations regarding the material combinations for carrier material 10c and coating material 10d apply to all conceivable sleeves 10. In particular, further material combinations are possible, especially using stainless steel or the like.

(40) FIG. 4a shows a cross-section of a connection between a sleeve 10 and a stranded conductor 4. Here, the coating material 10d is on the side of the sleeve 10 facing the stranded conductor 4 and the carrier material 10c is on the side of the sleeve 10 facing away from the stranded conductor 10. By plastic deformation of the sleeve 10, initially a form-fit connection at the junction between the coating material 10d and the stranded conductor 4 is produced. The sleeve 10 is placed in a butt joint around the stranded conductor 4 and a seam 14 is formed.

(41) FIG. 4b shows a further embodiment in which, for example, the carrier material 10c is arranged on the side of the sleeve 10 facing the stranded conductor 4 and the coating material 10d is arranged on the side of the sleeve 10 facing away from the stranded conductor 10.

(42) The sleeve 10 has been placed around the stranded conductor 4, for example, and then cut to length. The seam 14 is formed, for example, as an overlap joint.

(43) After the sleeve has been placed against the stranded conductor 4, the latter is plastically deformed.

(44) FIG. 5a shows the pressing of the sleeve 10 at the stranded conductor 4. FIG. 5a shows, by way of example, two pressing jaws 16a, 16b with which the sleeve 10 may be formed onto the conductor 4 in a plastically forming fashion. For this purpose, the pressing jaws 16a, b move in the direction of the sleeve 10 and deform it in the process. The cross-section I-I is shown on the right in FIG. 5a. As may be seen, the pressing jaws 16a, b are used to define a contour of the sleeve 10, for example. In the example shown, after being pressed by the pressing jaws 16a, b, the sleeve 10 has a rectangular outer contour with two opposing surfaces 18a, b. The surfaces 18a,b preferably run parallel to each other. Furthermore, the sleeve 10 lies directly against the stranded conductor 4.

(45) Furthermore, it may be seen in FIG. 5a that the sleeve 10 is optionally also pressed against the cable 1 in the area of the insulation of the cable 2. The pressing jaws 16a, b may be shaped in such a way that a form-fitting and preferably also gas-tight connection is formed between the sleeve 10 and the insulation of the cable 2.

(46) In FIG. 5a the seam 14 of the sleeve 10 may also be seen. The seam 14 is located in the region of a flat surface 18a,b of the outer circumference of the sleeve 10. In particular, the seam 14 is in the region of a welding plane with which the sleeve 10 is welded to the stranded conductor 4. The pressing jaws 16a, b may also be formed as ultrasonic tools, in particular as an anvil and sonotrode, and may enable welding of the sleeve 10 to the stranded conductor 4 as well as along the seam 14 directly during the pressing described according to FIG. Sa.

(47) The pressing jaws 16a, b may function as a sonotrode and an anvil. The contour of the sonotrode 16a and anvil 16b may be such that the cross-section along the cutting plane I-I of the sleeve 10 is angular after deformation. With the aid of the sonotrode 18a and the anvil 18b, it is possible to first place the sleeve 10 around the stranded conductor 4 in a shaping manner and then weld it to the stranded conductor 4 afterwards or in the same work step. In this case, welding may take place simultaneously along the seam 14.

(48) FIG. 5b shows a further embodiment. Here, pressing jaws 16a, b or sonotrode 16a and anvil 16b may be provided to press the sleeve 10 onto the stranded conductor 4 and, if necessary, to weld it simultaneously or subsequently. The pressing jaws 16a, b are used to shape the cross-section along section I-I as shown in FIG. Sb. Here as well, flat welding surfaces are formed. The seam 14 may be provided within one of these welding surfaces.

(49) FIG. Sc shows another embodiment in which the sleeve 10 is pressed against the stranded conductor 4 and the insulation of the cable 4. Section I-I shows that the outer circumference may be, for example, tetragonal and, in particular, the seam 14 may also be formed as an overlap joint.

(50) The pressing jaws 16a, 16b may be formed as a crimping jaw 16a and a crimping jaw 16b, as shown in FIG. 6a. The crimping jaw 16b is coupled to an ultrasonic converter 22 via a booster 20.

(51) For crimping, the sleeve 10 with the conductor 4 is first placed on the crimping jaw 16b.

(52) Then the crimping jaw 16a is pressed against the crimping jaw 16b with a force so that the sleeve 10 is pressed.

(53) At the same time, the converter 20 is activated and the crimp die 16b is excited via the booster 10 with a high-frequency vibration, in particular an ultrasonic vibration. The direction of vibration is in particular perpendicular to the direction of movement 24. The direction of vibration may also be essentially parallel to the longitudinal direction of the line 2.

(54) During the lowering of the jaw 16a onto the jaw 16b, both the sleeve 10 and the conductor 4 are excited with the high-frequency vibration. This leads to an easier deformation of the sleeve 10 and the conductor 4. The high frequency vibration causes a welding between the strands of the conductor 4 among themselves in the stripped area 8. The energy applied may be less than necessary to cause welding between the metal of the strands 4 on and the metal of the sleeve 10.

(55) After crimping, the crimping jaws 16a, 12 are lifted from the sleeve in the opposite direction 24. The crimp connection formed is superior over previous ones because the conductivity of the contact is improved. The reason for this is the high-frequency vibration applied during the crimping process. In particular, this high-frequency vibration breaks up an insulation layer on the strands of the conductor 4. Furthermore, a welding between the strands is produced in the stripped area 8 of the conductor 4. A preferably void-free bundle of strands is created.

(56) While the crimping jaw 16a is moved onto the sleeve 10, in particular after the crimping jaw 16a has plastically deformed the sleeve 10, a solder may be brought to the area of the sleeve 10. Due to the vibrational energy applied by the jaw 16a, the conductor 4 as well as the sleeve 10 have heated up such that the solder melts.

(57) It is also possible, especially with small cross sections that after the joining process the crimping jaw 16a is first lifted a little from the sleeve 10 so that the contact pressure is reduced compared to the crimping process. Furthermore, the vibration energy may be reduced, but still be applied to the contact position between conductor 2 and sleeve 10. This allows the conductor 4 as well as the sleeve 10 to be heated so far that the solder melts and penetrates into the crimp connection.

(58) The high-frequency vibration creates a capillary effect for the solder and it flows very well into cavities that may still exist.

(59) After joining the sleeve 10 to the stranded conductor 4 in a form fit as well as a material bond, in particular by means of ultrasonic welding or resistance welding, and possibly to the insulation of the cable 2, it is possible to insert a contact sleeve into the sleeve 10.

(60) For this purpose, a recess 26, as exemplarily shown in FIG. 7, is produced in the sleeve 10 and the stranded conductor 4. The stranded conductor 4 has a longitudinal axis 4a, and the sleeve 10 extends parallel to this longitudinal axis 4a. The axis 26a of the recess 26 runs transversely to this longitudinal axis 4a.

(61) The recess 26 may be produced in the sleeve 10 and the cable 4 by punching or drilling. A contact sleeve may then be inserted into the recess, as will be shown in the following.

(62) FIG. 8a shows a contact sleeve 28. The contact sleeve 28 is formed from two sections 28a, 28b. The sections 28a, b are arranged side by side in the direction of the longitudinal axis X of the contact sleeve 28.

(63) The two sections 28a, b may also be one piece and formed from the solid material of the contact sleeve 28.

(64) It may be seen that the section 28a has a smaller diameter d than the section 28b, which has the diameter D. The larger diameter D means that the section 28b is arranged at the section 28a in a flange-like fashion.

(65) The section 28a preferably has a height h which corresponds to the length of the recess 26 in the direction 26.

(66) FIG. 8b shows a further contact sleeve 28 in which the first section 28a tapers along the axis X starting from the second section 28b. In particular, the first section 28a is frustoconical.

(67) FIG. 8c shows another contact sleeve 28 in which the second portion 28a is formed in sections from a cylindrical region, a frustoconical central region and a cylindrical end region.

(68) The shape of each of the first sections 28a is preferably such that their profiles correspond to the recess 26.

(69) For process-safe welding of the contact sleeve 28 in the recess 26, it is proposed that a through opening 30 is formed in the contact sleeve 28 with different diameters. Such different diameters result in different profiles of the through opening 30 as shown in FIGS. 9a-d.

(70) FIG. 9a-d show top views of contact sleeves 2 on the respective first section 28a.

(71) FIG. 9a shows a contact sleeve 28 with a through-opening 30, which is formed as a polygonal shape.

(72) The through opening 30 passes through the first section 28a and the second section 28b. Furthermore, it may be seen in FIG. 9, as well as in FIGS. 9b-d, that the second section 28b is arranged in a flange-like fashion on the first section 28a and forms a bearing surface facing in the direction of the first section 28a. With this contact surface, the contact sleeve 28 may be placed against the sleeve 10 in the area of the recess 26.

(73) FIG. 9b shows an embodiment in which the through opening 30 is tetragonal.

(74) FIG. 9c shows an embodiment in which the through-opening 30 is octagonal.

(75) FIG. 9d shows an embodiment in which the through-opening 30 is hexagonal.

(76) The through openings 30 are such that they each have a clear diameter that is smaller than the largest possible diameter. The offset of the diameters results in a particularly good torque transmission from a friction welding tool to the contact sleeve 28.

(77) A welded contact sleeve 28 at the sleeve 10 is shown in FIG. 10. It may be seen that the contact sleeve 28 is inserted into the recess 26. It is further shown that a weld seam 34 is formed at least in the area of the contact surface between the second portion 28 b and the surface of the sleeve 10. However, the weld seam 34 may also extend into the region of the contact surface 32 between the lateral surfaces of the first section 28a and the recess 26. In this case, a material bond may be formed between the material of the contact sleeve 28 in the section 28a with the strands of the stranded conductor 4.

(78) To join the contact sleeve 28 into the recess 26, the contact sleeve 28 is first pushed with its through opening 30 onto a friction welding mandrel 38a. FIG. 11 shows how the friction welding mandrel 38a is pushed into the through-opening 30 along the X-axis. Optional holding means 40 exert a holding force on the contact sleeve 28 so that it cannot slip off the friction welding mandrel 38 by its own gravity force.

(79) Subsequently, the friction welding mandrel 38a or the friction welding tool 38 is moved with a translatory movement in the direction of the recess 26. In the process, the contact sleeve 28 is inserted into the recess 26.

(80) Because of the flange formed by the second section 28b, the contact sleeve 28 comes to an end position at a certain insertion depth in the recess 26. In this end position, the flange of the section 28b rests against the surface of the sleeve 10.

(81) Subsequently, the friction welding mandrel 38a is set into rotation, whereby at the same time a contact pressure force is exerted on the surface of the sleeve 10 in the direction of the axis X. By the rotation and the contact force the contact sleeve 28 is welded to the sleeve 10. This is shown in FIG. 11b.

(82) Subsequently, a contact part, e.g. a connecting bolt, may be pushed through the through-opening 30 and connected to the contact sleeve. The contact part may be screwed into the through-opening 30, fixed in the through-opening 30 in a clamping manner or connected to the contact sleeve 28 in the through-opening 30 in a material bond.

(83) FIG. 12 shows a view of such a connection. A connecting bolt 42 is connected to the sleeve 10 and the conductor 4 via the contact sleeve 28. In addition to the connecting bolt 42, a fuse box 44 is shown in FIG. 12. The fuse box 44 is connected to the bolt 42 via an electrical conductor. The electrical conductor is screwed or clamped to the bolt 42, for example, and thus provides an electrical connection to the conductor 4. The electrical potential of the conductor 4 may thus be tapped in the fuse box 30 and outlets to the loads may branch off from there.

(84) With the help of the connection console shown, a particularly simple electrical tap of an energy line is possible. The power line as such is merely influenced electrically and its line resistance remains essentially unaffected by the number of connection consoles. Furthermore, the connection consoles may be provided at the desired positions along the line, so that a decentralised distribution of the energy in the on-board network is possible. Several fuse boxes and outlets may be connected to the power cable at different points within the vehicle in a particularly easy manner, depending on what is required. The cable may thus be individually adapted to suit a particular type of vehicle.