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EP1559172A1 - Method for electrically connecting a conductor to a contact - Google Patents

Method for electrically connecting a conductor to a contact

Info

Publication number
EP1559172A1
EP1559172A1 EP03758046A EP03758046A EP1559172A1 EP 1559172 A1 EP1559172 A1 EP 1559172A1 EP 03758046 A EP03758046 A EP 03758046A EP 03758046 A EP03758046 A EP 03758046A EP 1559172 A1 EP1559172 A1 EP 1559172A1
Authority
EP
European Patent Office
Prior art keywords
contact element
welding
conductor
legs
electrical conductor
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP03758046A
Other languages
German (de)
French (fr)
Inventor
Thomas Bernhard Pabst
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
FCI SA
Original Assignee
FCI SA
Framatome Connectors International SAS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by FCI SA, Framatome Connectors International SAS filed Critical FCI SA
Publication of EP1559172A1 publication Critical patent/EP1559172A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H01R4/029—Welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
    • H01R12/50—Fixed connections
    • H01R12/59—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0228—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections without preliminary removing of insulation before soldering or welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/10—Sockets for co-operation with pins or blades
    • H01R13/11—Resilient sockets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H01R4/023—Soldered or welded connections between cables or wires and terminals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0214—Resistance welding

Definitions

  • the present invention relates to a method for the electrical connection of an electrical conductor with a contact element and a plug connector with a conductor and a contact element, the connection between the conductor and the contact element being produced by the method.
  • the present invention relates in particular to a method for connecting a ribbon conductor to a contact element by resistance welding.
  • the invention is used, for example, in the automotive industry, where the installation of additional electrical components means that ribbon conductors are increasingly used in order to better conduct the increasing current flows over a larger conductor cross section
  • the invention can be used with all types of conductors, in particular ribbon conductors, which have been manufactured, for example, by laminating, printing, etching or extrusion.
  • Various contacting techniques such as crimp contacting, cohesive contacting or terminal contacting, are known for connecting a plug connector or contact element to a conductor.
  • cohesive contacts the connection can be established, for example, by soldering, gluing or welding, welding processes providing better mechanical and electrical properties for the contact point than soldering or gluing.
  • the welding can be carried out by resistance welding, laser welding or ultrasonic welding. Resistance welding is widely used in the field of plug contacts, since this can be carried out easily, quickly and inexpensively.
  • the object of the present invention is therefore to provide an easy to carry out, inexpensive and fast mechanically and electrically durable connection. This object is achieved by a method according to claim 1.
  • the electrical conductor sheathed with insulation is inserted between two legs of the contact element.
  • the welding device is then placed on the two legs and the welding process is carried out, the welding current being switched on.
  • the insulation of the electrical conductor is destroyed during the welding process by the welding current and the heat supplied thereby, which leads to a firm mechanical and electrical connection of the conductor to the contact element.
  • the method according to the invention means that it is no longer necessary to strip the electrical conductor before the welding process.
  • the electrical conductor can simply be inserted between the legs of the contact element in the non-stripped state.
  • the welding process can be shortened considerably, which considerably reduces the cost of producing connector components.
  • the welding process is carried out by resistance welding, where the heat supplied is generated by the current flowing during the welding process and the ohmic resistance of the conductor.
  • the method according to the invention is not limited to resistance welding; other fusion welding methods such as electric arc welding are also welding or gas welding or other pressure welding processes can be used.
  • the current flows over the two legs of the contact element, i.e. from the anode via one leg, then to the other leg via the cathode.
  • the current does not yet flow through the insulated conductor to the cathode. Since the heat supplied is very high, and the current seeks the shortest path, the insulation between the current legs of the contact element begins to melt, so that the current then directly from the anode, the first leg, to the electrical conductor the second leg flows to the cathode.
  • this must first flow in a "detour" via the two legs and the connection point between the two legs.
  • the welding device is preferably attached to the outer sides of the two legs opposite the conductor.
  • a welding stamp of the welding device is preferably attached to an outside of the contact element, so that the two welding stamps sandwich the two legs of the contact element and the electrical conductor inserted therein.
  • the contact element is also connected to a plug connector, which can be connected to a complementary plug connector in order to continue the current path of the electrical conductor.
  • the electrical conductor is preferably a ribbon conductor which is produced, for example, by lamination, printing, etching or extrusion.
  • the method according to the invention is not limited to the connection of ribbon conductors to contact elements.
  • the electrical conductor can have any shape.
  • the contact element is preferably bent in an S shape, the conductor being inserted into one of the two openings of the S shape.
  • the contact element can also be C-shaped, the conductor then being inserted into the C-shaped opening.
  • the contact element can also be clipped onto the side of the conductor. It is only advantageous for the embodiment of the invention that the electrical conductor is enclosed on two interconnected sides by the contact element. A U-shaped design of the contact element is also possible.
  • the invention also relates to a plug connector which has a contact element and an electrical conductor connected to the contact element, the connection between the contact element and the electrical conductor being produced by the method described above.
  • FIG. 3 shows an example of a flat conductor strip for connection to a plurality of contact elements
  • FIG. 6 shows a connector in which the conductor-contact element is connected according to the method according to the invention.
  • Fig. 7 the contact element shown in Fig. 5 with a housing.
  • FIG. 1 shows a schematic structure for carrying out the method according to the invention.
  • An electrical contact element 1 is shown with two legs 2 and 3, which receive an electrical conductor 4 between their legs.
  • the electrical conductor 4 is in the slot between the two legs 2 and 3 with the conductive core 5, for example Copper and insulation 6 introduced.
  • welding punches 7, 8 in the form of an anode and cathode of a welding device, not shown, are placed on the outer sides of the two legs 2, 3. At the beginning, the welding current cannot flow from the welding stamp 7 via leg 2 and the conductor 5 to the welding stamp 8, since there is an open circuit.
  • the current flows during the welding process from the welding stamp 7 over the leg 2 to the connection point 9 of the two legs and over the other leg 3 to the welding stamp 8, as shown by arrow A.
  • the currents flowing during the welding process heat the contact element selectively to such an extent that the insulation provided between the legs is destroyed, so that the legs now directly touch the conductor 5, so that a current flow directly from the welding stamp 7 via the conductor 5 to the welding step 8 without the detour via connection point 9 is possible (arrow B).
  • the mechanical strength of the welded connection is plotted over the conductor cross section.
  • the force required to loosen the welded connection increases proportionally with the wire diameter.
  • the tensile strength in resistance welding is slightly better than, for example, in laser welding, so that in summary it can be concluded that resistance Stand welding a stronger mechanical connection can be achieved than with laser welding.
  • a circuit board 10 is shown in detail with its conductor tracks 22, which are provided with insulation 6. Furthermore, several contact elements 1 are arranged, for example, to connect the conductor tracks with plug connectors (not shown).
  • the contact element 1 is equipped at its end receiving the electrical conductor with three legs, the upper leg 2 and two lower legs 3.
  • the printed circuit board 10 can, for example, be fed to the visual white device, so that the welding process according to the invention is performed executes on each contact element 1.
  • 4 a shows a plurality of plug connectors 11 which have been plugged onto the contact element 1 after the welding process has taken place, the contact element 1, as shown in FIG. 3, being C-shaped.
  • 4b shows how the electrical conductor 4 is inserted between the two legs 2, 3 of the contact element 1.
  • the contact element is bent in a C-shape.
  • the depression 12 can be seen in the form of a welding bead on which the welding process according to the invention was carried out.
  • 4c the contact element is bent in an S-shape, the electrical conductor 4 being inserted into the upper opening of the S-shape and then welded.
  • the contact element 1 soldered to the conductor track at one end is provided at its other end with the plug connector 11, which in the embodiment shown is designed as a socket.
  • the connector 11 has at its rear end inwardly bent tabs 25 on which u. a. Conductor elements of a mating connector can be attached.
  • the connector has an insulating housing 26, which has a raised side wall 27 for coding and a locking leg 28 which extends resiliently upwards from a bridge 29 against the direction of insertion, with which the connector 11 is fastened in a receptacle (not shown) can.
  • FIG 4d shows a further embodiment according to the invention, the contact element 1 consisting of two plates 14, 15 connected via webs 13, which were folded laterally over the electrical conductor 4.
  • FIG. 5 shows a further embodiment of the contact element 1, the two legs being molded onto the top or bottom of a housing 30.
  • the two legs 2, 3 and the front section of the housing 30 ensure the U-shaped configuration of the contact element 1.
  • the housing 30 is closed on all four sides.
  • the sides 31 and 32 of the housing 30 can also extend further in the direction of the legs 2 and 3, so that the legs 2, 3 would be enclosed on four sides at their end facing the housing 30, which would increase the rigidity of the legs 2, 3 ,
  • the contact element shown in FIG. 5 is also surrounded by the housing 26 shown in FIGS. 4a and 4b.
  • FIG. 6 shows a plug connector 16 which has the contact element 1 shown in FIG. 4c.
  • the connector 16 has a housing 17 made of insulating material, which has a latching element 18 at the front end.
  • the individual conductor tracks 22 are inserted into the connector from behind, a slide strain relief 19 being provided for the broadband conductor.
  • the conductor tracks end in the here S-shaped opening between the two legs 2 and 3 of the contact element 1, which has a conventional contact socket at its front end for receiving a contact pin (not shown).
  • FIG. 7 shows the U-shaped contact element shown in FIG. 5, the end opposite the legs 2, 3 being provided with the housing 26.
  • the housing has a web 33 behind the locking leg 28. Behind this web are the inwardly bent tabs 25, which are bent around the forwardly extended side walls 31, 32 of the housing 30 in order to fix the housing 26 to the contact element.
  • inventive method can be used to achieve a good electrical connection between an electrical conductor and a contact element in a simple and quick manner with a welding method.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)

Abstract

The invention relates to a method for electrically connecting a conductor to a contact, according to which the electrical conductor that is coated with an insulation is first inserted between two legs of the contact, whereupon a welding device is placed against both legs and the welding process is carried out by turning on the welding current. The insulation of the electrical conductor is destroyed due to the heat delivered during the welding process, resulting in a permanent mechanical and electrical connection between the conductor and the contact.

Description

Verfahren zur elektrischen Verbindung eines Leiters mit einem Kontaktelement Method for the electrical connection of a conductor to a contact element
Die vorliegende Erfindung betrifft ein Verfahren zur elektrischen Verbindung eines elektrischen Leiters mit einem Kontaktelement sowie einen Steckverbinder mit einem Leiter und einem Kontaktelement, wobei die Verbindung zwischen Leiter und Kontaktelement nach dem Verfahren hergestellt wurde. Die vorliegende Erfindung betrifft insbesondere ein Verfahren zur Verbindung eines Flachbandleiters mit einem Kontaktelement durch Widerstandsschweißen. Die Erfindung findet beispielsweise Anwendung in der Automobilindustrie, wo durch den Einbau zusätzlicher elektrischer Komponenten vermehrt Flachbandleiter eingesetzt werden, um die größer werdenden Stromflüsse über einen größeren Leiterquerschnitt besser leiten The present invention relates to a method for the electrical connection of an electrical conductor with a contact element and a plug connector with a conductor and a contact element, the connection between the conductor and the contact element being produced by the method. The present invention relates in particular to a method for connecting a ribbon conductor to a contact element by resistance welding. The invention is used, for example, in the automotive industry, where the installation of additional electrical components means that ribbon conductors are increasingly used in order to better conduct the increasing current flows over a larger conductor cross section
zu können. Die Erfindung kann bei allen Arten von Leitern, insbesondere Flachbandleitern eingesetzt werden, die beispielsweise laminiert, gedruckt, geätzt oder extrudiert hergestellt wurden.to be able to. The invention can be used with all types of conductors, in particular ribbon conductors, which have been manufactured, for example, by laminating, printing, etching or extrusion.
Zur Verbindung eines Steckverbinders bzw. Kontaktelements mit einem Leiter sind verschiedene Kontaktierungstechniken wie Crimp- kontaktierungen, stoffschlüssige Kontaktierungen oder Klemmkon- taktierungen bekannt. Bei stoffschlüssigen Kontaktierungen kann die Verbindung beispielsweise durch Löten, Kleben oder Schweißen hergestellt werden, wobei Schweißverfahren bessere mechanische und elektrische Eigenschaften für die Kontaktierungsstelle liefern als Löten oder Kleben. Beim Verschweißen der Leiterbahn mit dem Kontaktelement eines Steckverbinders kann die Verschweißung durch Widerstandsschweißen, Laserschweißen oder Ultraschallschweißen erfolgen. Auf dem vorliegenden Gebiet der Steckkontakte findet das Widerstandsschweißen eine breite Anwendung, da dieses einfach, schnell und kostengünstig durchgeführt werden kann.Various contacting techniques, such as crimp contacting, cohesive contacting or terminal contacting, are known for connecting a plug connector or contact element to a conductor. In the case of cohesive contacts, the connection can be established, for example, by soldering, gluing or welding, welding processes providing better mechanical and electrical properties for the contact point than soldering or gluing. When welding the conductor track to the contact element of a connector, the welding can be carried out by resistance welding, laser welding or ultrasonic welding. Resistance welding is widely used in the field of plug contacts, since this can be carried out easily, quickly and inexpensively.
Bisher war es jedoch vor dem Schweißvorgang notwendig, den elektrischen Leiter vor dem Schweißvorgang an dem Ende abzuisolieren, an dem es mit dem Kontaktelement verbunden wird. Dieser Abisolierschritt verkompliziert und verteuert das Herstellungsverfahren, was gerade für den kostensensitiven Automobilbereich ein besonderer Nachteil ist.Until now, however, it was necessary to strip the electrical conductor at the end at which it is connected to the contact element before the welding process. This stripping step complicates and increases the cost of the manufacturing process, which is a particular disadvantage for the cost-sensitive automotive sector.
Aufgabe der vorliegenden Erfindung ist somit die Bereitstellung einer einfach durchzuführenden, kostengünstigen und schnellen mechanisch und elektrisch haltbaren Verbindung. Diese Aufgabe wird erfindungsgemäß durch ein Verfahren gemäß Patentanspruch 1 gelöst.The object of the present invention is therefore to provide an easy to carry out, inexpensive and fast mechanically and electrically durable connection. This object is achieved by a method according to claim 1.
Erfindungsgemäß werden bei der Verbindung eines elektrischen Leiters mit einem Kontaktelement folgende Schritte durchgeführt:According to the invention, the following steps are carried out when connecting an electrical conductor to a contact element:
Zu Beginn wird der mit einer Isolierung ummantelte elektrische Leiter zwischen zwei Schenkel des Kontaktelements eingeführt. Anschließend wird die Schweiß Vorrichtung an die beiden Schenkel angelegt und der Schweiß Vorgang durchgeführt, wobei der Schweißstrom eingeschaltet wird. Durch den Schweißstrom und die dadurch zugeführte Wärme wird die Isolierung des elektrischen Leiters während des Schweißvorgangs zerstört, was zu einer festen mechanischen und elektrischen Verbindung des Leiters mit dem Kontaktelement führt.At the beginning, the electrical conductor sheathed with insulation is inserted between two legs of the contact element. The welding device is then placed on the two legs and the welding process is carried out, the welding current being switched on. The insulation of the electrical conductor is destroyed during the welding process by the welding current and the heat supplied thereby, which leads to a firm mechanical and electrical connection of the conductor to the contact element.
Durch das erfindungsgemäße Verfahren ist eine Abisolierung des elektrischen Leiters vor dem Schweißvorgang nicht mehr notwendig. Der elektrische Leiter kann im nicht abisolierten Zustand einfach zwischen die Schenkel des Kontaktelements eingelegt werden. Hierdurch kann der Schweißvorgang erheblich verkürzt werden, was die Herstellung von Steckverbinderkomponenten erheblich verbilligt.The method according to the invention means that it is no longer necessary to strip the electrical conductor before the welding process. The electrical conductor can simply be inserted between the legs of the contact element in the non-stripped state. As a result, the welding process can be shortened considerably, which considerably reduces the cost of producing connector components.
In einer bevorzugten Ausführungsform erfolgt der Schweißvorgang durch ein Widerstandsschweißen, wo die zugeführte Wärme durch den beim Schweißvorgang fließenden Strom und den Ohmschen Widerstand des Leiters erzeugt wird. Das erfindungsgemäße Verfahren ist jedoch nicht auf ein Widerstandsschweißen beschränkt, es sind auch andere Schmelzschweißverfahren wie elektrisches Lichtbogen- schweißen oder Gasschweißen oder auch andere Preß schweiß verfahren anwendbar.In a preferred embodiment, the welding process is carried out by resistance welding, where the heat supplied is generated by the current flowing during the welding process and the ohmic resistance of the conductor. However, the method according to the invention is not limited to resistance welding; other fusion welding methods such as electric arc welding are also welding or gas welding or other pressure welding processes can be used.
Zu Beginn des erfindungsgemäßen Verfahrens fließt beispielsweise bei einem Widerstandsschweißen der Strom über die beiden Schenkel des Kontaktelements, d.h. von der Anode über einen Schenkel, anschließend zum anderen Schenkel über die Kathode ab. Der Strom fließt noch nicht über den mit einer Isolierung versehenen Leiter zur Kathode. Da die zugeführte Wärme sehr hoch ist, und sich der Strom jeweils den kürzesten Weg sucht, beginnt die zwischen den Strom führenden Schenkeln des Kontaktelements liegende Isolation zu schmelzen, so daß der Strom anschließend direkt von der Anode, dem ersten Schenkel, dem elektrischen Leiter zu dem zweiten Schenkel zur Kathode fließt. Damit jedoch überhaupt ein Schweißstrom entsteht, muß dieser zuerst über die beiden Schenkel und den Verbindungspunkt der beiden Schenkel miteinander auf einem "Umweg" fließen.At the beginning of the method according to the invention, for example in the case of resistance welding, the current flows over the two legs of the contact element, i.e. from the anode via one leg, then to the other leg via the cathode. The current does not yet flow through the insulated conductor to the cathode. Since the heat supplied is very high, and the current seeks the shortest path, the insulation between the current legs of the contact element begins to melt, so that the current then directly from the anode, the first leg, to the electrical conductor the second leg flows to the cathode. However, in order for a welding current to arise at all, this must first flow in a "detour" via the two legs and the connection point between the two legs.
Vorzugsweise wird beim Schweißvorgang die Schweißvorrichtung an den dem Leiter gegenüberliegenden Außenseiten der beiden Schenkel angesetzt.During the welding process, the welding device is preferably attached to the outer sides of the two legs opposite the conductor.
Vorzugsweise wird hierbei jeweils ein Schweißstempel der Schweißvorrichtung an einer Außenseite des Kontaktelements angesetzt, so daß die beiden Schweißstempel die beiden Schenkel des Kontaktelements und den darin eingeführten elektrischen Leiter sandwichartig umschließen. In einer bevorzugten Ausführungsform ist das Kontaktelement weiterhin mit einem Steckverbinder verbunden, der zur Weiterführung der Strombahn des elektrischen Leiters mit einem komplementären Steckverbinder verbunden werden kann.In this case, a welding stamp of the welding device is preferably attached to an outside of the contact element, so that the two welding stamps sandwich the two legs of the contact element and the electrical conductor inserted therein. In a preferred embodiment, the contact element is also connected to a plug connector, which can be connected to a complementary plug connector in order to continue the current path of the electrical conductor.
Vorzugsweise ist der elektrische Leiter ein Flachbandleiter, der beispielsweise durch Laminieren, Drucken, Ätzen oder Extrudieren hergestellt wird. Das erfindungsgemäße Verfahren ist jedoch nicht auf die Verbindung von Flachbandleitern mit Kontaktelementen begrenzt. Der elektrische Leiter kann jegliche Form haben.The electrical conductor is preferably a ribbon conductor which is produced, for example, by lamination, printing, etching or extrusion. However, the method according to the invention is not limited to the connection of ribbon conductors to contact elements. The electrical conductor can have any shape.
Vorzugsweise ist das Kontaktelement S-förmig gebogen, wobei der Leiter in eine der beiden Öffnungen der S-Form eingeschoben wird. Ebenso kann das Kontaktelement auch C-förmig geformt sein, wobei der Leiter dann in die C-fδrmige Öffnung eingeschoben wird. Das Kontaktelement kann jedoch auch seitlich auf den Leiter aufgeklipst werden. Vorteilhaft für die Ausführung der Erfindung ist nur, daß der elektrische Leiter von auf zwei miteinander verbundenen Seiten von dem Kontaktelement umschlossen ist. Ebenso ist eine U-fδrmige Ausbildung des Kontaktelements möglich.The contact element is preferably bent in an S shape, the conductor being inserted into one of the two openings of the S shape. Likewise, the contact element can also be C-shaped, the conductor then being inserted into the C-shaped opening. However, the contact element can also be clipped onto the side of the conductor. It is only advantageous for the embodiment of the invention that the electrical conductor is enclosed on two interconnected sides by the contact element. A U-shaped design of the contact element is also possible.
Die Erfindung betrifft ebenso einen Steckverbinder, der ein Kontaktelement und einen an das Kontaktelement angeschlossenen elektrischen Leiter aufweist, wobei die Verbindung zwischen Kontaktelement und elektrischem Leiter nach dem oben beschriebenen Verfahren hergestellt wurde. Nachfolgend wird zum besseren Verständnis der Erfindung diese unter Bezugnahme auf die beiliegenden schematischen Zeichnungen näher beschrieben. Hierbei zeigen:The invention also relates to a plug connector which has a contact element and an electrical conductor connected to the contact element, the connection between the contact element and the electrical conductor being produced by the method described above. For a better understanding of the invention, this will be described in more detail below with reference to the accompanying schematic drawings. Here show:
Fig. 1 einen schematischen Aufbau zur Durchführung des erfindungsgemäßen Verfahrens,1 shows a schematic structure for carrying out the method according to the invention,
Fig. 2 den Zusammenhang zwischen Drahtdurchmesser und Reißfestigkeit für verschiedene Schweißarten,2 the relationship between wire diameter and tensile strength for different types of welding,
Fig. 3 ein Beispiel eines Flachleiterbandes zur Verbindung mit mehreren Kontaktelementen,3 shows an example of a flat conductor strip for connection to a plurality of contact elements,
die Fig. 4a - 4c verschiedene Ausführungsformen der Verbindung des elektrischen Leiters mit dem Kontaktelement,4a-4c different embodiments of the connection of the electrical conductor to the contact element,
Fig. 5 eine weitere Ausführungsform des Kontaktelements, und5 shows a further embodiment of the contact element, and
Fig. 6 einen Steckverbinder, bei dem die Verbindung Leiter-Kontaktelement nach dem erfϊndungsgemäßen Verfahren erfolgte.6 shows a connector in which the conductor-contact element is connected according to the method according to the invention.
Fig. 7 das in Fig. 5 gezeigte Kontaktelement mit einem Gehäuse.Fig. 7, the contact element shown in Fig. 5 with a housing.
In Fig. 1 ist ein schematischer Aufbau zur Durchführung des erfϊndungsgemäßen Verfahrens dargestellt. Ein elektrisches Kontaktelement 1 ist mit zwei Schenkeln 2 und 3 dargestellt, die zwischen ihren Schenkeln einen elektrischen Leiter 4 aufnehmen. Der elektrische Leiter 4 wird hierbei in den Schlitz zwischen den beiden Schenkeln 2 und 3 mit dem leitenden Kern 5, beispielsweise aus Kupfer und der Isolation 6 eingeführt. Zur Durchführung des Schweiß Verfahrens werden auf den Außenseiten der beiden Schenkel 2, 3 Schweißstempel 7, 8 in Form einer Anode und Kathode einer nicht näher gezeigten Schweißvorrichtung aufgesetzt. Zu Beginn kann der Schweißstrom vom Schweißstempel 7 über Schenkel 2 und den Leiter 5 zum Schweißstempel 8 nicht fließen, da ein nicht geschlossener Stromkreis vorliegt. Zu Beginn fließt der Strom beim Schweiß vorgang vom Schweiß Stempel 7 über den Schenkel 2 zum Verbindungspunkt 9 der beiden Schenkel und über den anderen Schenkel 3 zum Schweißstempel 8, wie es durch den Pfeil A dargestellt ist. Die beim Schweißvorgang fließenden Ströme erhitzen das Kontaktelement punktuell so sehr, daß die zwischen den Schenkeln vorgesehene Isolierung zerstört wird, so daß nun die Schenkel direkt den Leiter 5 berühren, so daß ein Stromfluß direkt vom Schweißstempel 7 über den Leiter 5 zum Schweißste pel 8 ohne den Umweg über den Verbindungspunkt 9 möglich ist (Pfeil B). Hierdurch erfolgt eine feste mechanische Schweißverbindung zwischen Kontaktelement 1 und dem elektrischen Leiter 4, ohne daß vorher die Isolierung 6 auf Höhe der Schenkel 2, 3 des Kontaktelements entfernt werden mußten.1 shows a schematic structure for carrying out the method according to the invention. An electrical contact element 1 is shown with two legs 2 and 3, which receive an electrical conductor 4 between their legs. The electrical conductor 4 is in the slot between the two legs 2 and 3 with the conductive core 5, for example Copper and insulation 6 introduced. To carry out the welding process, welding punches 7, 8 in the form of an anode and cathode of a welding device, not shown, are placed on the outer sides of the two legs 2, 3. At the beginning, the welding current cannot flow from the welding stamp 7 via leg 2 and the conductor 5 to the welding stamp 8, since there is an open circuit. At the beginning, the current flows during the welding process from the welding stamp 7 over the leg 2 to the connection point 9 of the two legs and over the other leg 3 to the welding stamp 8, as shown by arrow A. The currents flowing during the welding process heat the contact element selectively to such an extent that the insulation provided between the legs is destroyed, so that the legs now directly touch the conductor 5, so that a current flow directly from the welding stamp 7 via the conductor 5 to the welding step 8 without the detour via connection point 9 is possible (arrow B). This results in a firm mechanical welded connection between the contact element 1 and the electrical conductor 4 without the insulation 6 having to be removed beforehand at the legs 2, 3 of the contact element.
In Fig. 2 ist die mechanische Festigkeit der Schweißverbindung über dem Leiterquerschnitt aufgetragen. Bei einem theoretischen Leiter steigt die Kraft, die notwendig ist, um die geschweißte Verbindung wieder zu lösen, proportional mit dem Drahtdurchmesser an. Wie sich aus den von der Anmelderin durchgeführten Meßkurven weiterhin ergibt, ist die Reißfestigkeit bei einem Widerstandsschweißen geringfügig besser als beispielsweise bei einer Laserschweißung, so daß zusammenfassend gefolgert werden kann, daß durch Wider- Standsschweißen eine festere mechanische Verbindung erreicht werden kann als mit Laserschweißen.2, the mechanical strength of the welded connection is plotted over the conductor cross section. In the case of a theoretical conductor, the force required to loosen the welded connection increases proportionally with the wire diameter. As can also be seen from the measurement curves carried out by the applicant, the tensile strength in resistance welding is slightly better than, for example, in laser welding, so that in summary it can be concluded that resistance Stand welding a stronger mechanical connection can be achieved than with laser welding.
In Fig. 3 ist eine Leiterplatte 10 ausschnittsweise mit ihren Leiterbahnen 22 dargestellt, die mit einer Isolierung 6 versehen sind. Weiterhin sind mehrere Kontaktelemente 1 angeordnet, um beispielsweise die Leiterbahnen mit (nicht gezeigten) Steckverbindern zu verbinden. Im gezeigten Ausführungsbeispiel ist das Kontaktelement 1 an seinem den elektrischen Leiter aufnehmenden Ende mit drei Schenkeln ausgestattet, dem oberen Schenkel 2 und zwei unteren Schenkeln 3. In der dargestellten Ausführungsform kann die Leiterplatte 10 beispielsweise der Seh weiß Vorrichtung zugeführt werden, damit diese das erfindungsgemäße Schweißverfahren an jedem Kontaktelement 1 ausführt.In Fig. 3, a circuit board 10 is shown in detail with its conductor tracks 22, which are provided with insulation 6. Furthermore, several contact elements 1 are arranged, for example, to connect the conductor tracks with plug connectors (not shown). In the exemplary embodiment shown, the contact element 1 is equipped at its end receiving the electrical conductor with three legs, the upper leg 2 and two lower legs 3. In the embodiment shown, the printed circuit board 10 can, for example, be fed to the visual white device, so that the welding process according to the invention is performed executes on each contact element 1.
In Fig. 4 a sind mehrere Steckverbinder 11 dargestellt, die nach dem erfolgten Schweißvorgang auf das Kontaktelement 1 aufgesteckt wurden, wobei das Kontaktelement 1, wie in Fig. 3 dargestellt, C- förmig ausgebildet ist. In Fig. 4b ist dargestellt, wie der elektrische Leiter 4 zwischen die beiden Schenkel 2, 3 des Kontaktelements 1 eingeschoben ist. In diesem Fall ist das Kontaktelement C-förmig gebogen. Weiterhin ist die Vertiefung 12 in Form einer Schweißsicke zu erkennen, an der der erfindungsgemäße Schweißvorgang durchgeführt wurde. In Fig. 4c ist das Kontaktelement S-förmig gebogen, wobei der elektrische Leiter 4 in die obere Öffnung der S-Form eingeschoben und anschließend verschweißt wurde. Das an einem Ende mit der Leiterbahn verlötete Kontaktelement 1 ist an seinem anderen Ende mit dem Steckverbinder 11 versehen, der in der dargestellten Ausführungsform als Buchse ausgebildet ist.4 a shows a plurality of plug connectors 11 which have been plugged onto the contact element 1 after the welding process has taken place, the contact element 1, as shown in FIG. 3, being C-shaped. 4b shows how the electrical conductor 4 is inserted between the two legs 2, 3 of the contact element 1. In this case, the contact element is bent in a C-shape. Furthermore, the depression 12 can be seen in the form of a welding bead on which the welding process according to the invention was carried out. 4c, the contact element is bent in an S-shape, the electrical conductor 4 being inserted into the upper opening of the S-shape and then welded. The contact element 1 soldered to the conductor track at one end is provided at its other end with the plug connector 11, which in the embodiment shown is designed as a socket.
Der Steckverbinder 11 weist an seinem hinteren Ende nach innen umgebogene Laschen 25 auf, an denen u. a. Leiterelemente eines Gegensteckverbinders befestigt werden können. Der Steckverbinder weist ein isolierendes Gehäuse 26, das zur Kodierung eine erhöhte Seitenwand 27 und einen Verriegelungsschenkel 28 aufweist, der sich federnd von einer Brücke 29 entgegen der Emführrichtung nach schräg oben erstreckt, mit dem der Steckverbinder 11 in einer Aufnahme (nicht gezeigt) befestigt werden kann.The connector 11 has at its rear end inwardly bent tabs 25 on which u. a. Conductor elements of a mating connector can be attached. The connector has an insulating housing 26, which has a raised side wall 27 for coding and a locking leg 28 which extends resiliently upwards from a bridge 29 against the direction of insertion, with which the connector 11 is fastened in a receptacle (not shown) can.
In Fig. 4d ist eine weitere erfϊndungsgemäße Ausführungsform dargestellt, wobei das Kontaktelement 1 aus zwei über Stege 13 verbundenen Platten 14, 15 besteht, die seitlich über den elektrischen Leiter 4 geklappt wurden.4d shows a further embodiment according to the invention, the contact element 1 consisting of two plates 14, 15 connected via webs 13, which were folded laterally over the electrical conductor 4.
Fig. 5 zeigt eine weitere Ausführungsform des Kontaktelements 1 , wobei die beiden Schenkel an der Oberseite bzw. Unterseite eines Gehäuses 30 angeformt sind. Die beiden Schenkel 2, 3 und der vordere Abschnitt des Gehäuses 30 sorgen für die U-förmige Ausbildung des Kontaktelements 1. Das Gehäuse 30 ist auf allen vier Seiten geschlossen. Die Seiten 31 und 32 des Gehäuses 30 können auch weiter in Richtung der Schenkel 2 und 3 verlaufen, so daß die Schenkel 2, 3 an ihrem dem Gehäuse 30 zugewandten Ende an vier Seiten umschlossen wären, wodurch die Steifigkeit der Schenkel 2, 3 erhöht würde. Das in Figur 5 gezeigte Kontaktelement ist ebenso von dem in den Fig. 4a und 4b gezeigten Gehäuse 26 umgeben. Fig. 6 zeigt einen Steckverbinder 16, der das in Fig. 4c dargestellte Kontaktelement 1 aufweist. Der Steckverbinder 16 weist ein Gehäuse 17 aus isolierendem Material auf, das am vorderen Ende ein Ver- rastungselement 18 aufweist. Die einzelnen Leiterbahnen 22 werden von hinten in den Steckverbinder eingeführt, wobei eine Schieberzugentlastung 19 für den Breitbandleiter vorgesehen ist. Die Leiterbahnen enden in der hier S-förmig ausgebildeten Öffnung zwischen den beiden Schenkeln 2 und 3 des Kontaktelements 1 , der an seinem vorderen Ende eine konventionelle Kontaktbuchse zur Aufnahme eines (nicht gezeigten) Kontaktstifts aufweist.5 shows a further embodiment of the contact element 1, the two legs being molded onto the top or bottom of a housing 30. The two legs 2, 3 and the front section of the housing 30 ensure the U-shaped configuration of the contact element 1. The housing 30 is closed on all four sides. The sides 31 and 32 of the housing 30 can also extend further in the direction of the legs 2 and 3, so that the legs 2, 3 would be enclosed on four sides at their end facing the housing 30, which would increase the rigidity of the legs 2, 3 , The contact element shown in FIG. 5 is also surrounded by the housing 26 shown in FIGS. 4a and 4b. FIG. 6 shows a plug connector 16 which has the contact element 1 shown in FIG. 4c. The connector 16 has a housing 17 made of insulating material, which has a latching element 18 at the front end. The individual conductor tracks 22 are inserted into the connector from behind, a slide strain relief 19 being provided for the broadband conductor. The conductor tracks end in the here S-shaped opening between the two legs 2 and 3 of the contact element 1, which has a conventional contact socket at its front end for receiving a contact pin (not shown).
Fig. 7 zeigt das in Fig. 5 gezeigte U-förmige Kontaktelement , wobei das dem Schenkeln 2, 3 gegenüberliegende Ende mit dem Gehäuse 26 versehen ist. Das Gehäuse weist hinter dem Verriegelungsschenkel 28 einen Steg 33 auf. Hinter diesem Steg schließen sich die nach innen umgebogenen Laschen 25 an, die um die nach vorne verlängerten Seitenwände 31, 32 des Gehäuses 30 gebogen sind, um das Gehäuse 26 am Kontaktelement festzulegen.FIG. 7 shows the U-shaped contact element shown in FIG. 5, the end opposite the legs 2, 3 being provided with the housing 26. The housing has a web 33 behind the locking leg 28. Behind this web are the inwardly bent tabs 25, which are bent around the forwardly extended side walls 31, 32 of the housing 30 in order to fix the housing 26 to the contact element.
Zusammenfassend ist festzuhalten, daß durch das erfindungsgemäße Verfahren auf einfache und schnelle Weise mit einem Schweißverfahren eine gute elektrische Verbindung zwischen einem elektrischen Leiter und einem Kontaktelement erreicht werden kann. In summary, it should be noted that the inventive method can be used to achieve a good electrical connection between an electrical conductor and a contact element in a simple and quick manner with a welding method.

Claims

Ansprüche Expectations
1. Verfahren zur elektrischen Verbindung eines elektrischen Leiters (4) mit einem Kontaktelement (1) mit den folgenden Schritten:1. A method for the electrical connection of an electrical conductor (4) to a contact element (1) with the following steps:
- Einführen des mit einer Isolierung (6) ummantelten elektrischen Leiters (4) zwischen zwei Schenkel (2, 3) des Kontaktelements (1),- inserting the electrical conductor (4) sheathed with insulation (6) between two legs (2, 3) of the contact element (1),
- Ansetzen einer Schweißvorrichtung (7, 8) an beiden Schenkeln (2, 3),- attaching a welding device (7, 8) to both legs (2, 3),
- Durchführen des Schweißvorgangs mit Einschalten des Schweißstromes, wobei die zugeführte Wärme während des Schweißvorganges die Isolierung (6) des elektrischen Leiters (4) zerstört und zu einer festen mechanischen und elektrischen Verbindung des Leiters (4) mit dem Kontaktelement (1) führt.- Carrying out the welding process when the welding current is switched on, the heat supplied during the welding process destroying the insulation (6) of the electrical conductor (4) and leading to a firm mechanical and electrical connection of the conductor (4) to the contact element (1).
2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß der Schweißvorgang ein Widerstandsschweißen ist.2. The method according to claim 1, characterized in that the welding process is resistance welding.
3. Verfahren nach Anspruch 2, dadurch gekennzeichnet, daß zu Beginn des Schweißvorgangs der Schweißstrom über die beiden Schenkel (2, 3) des Kontaktelements und deren Verbindungspunkt (9) fließt.3. The method according to claim 2, characterized in that at the beginning of the welding process, the welding current flows over the two legs (2, 3) of the contact element and their connection point (9).
4. Verfahren nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, daß die Schweißvorrichtung (7, 8) an den dem Leiter gegenüberliegenden Außenseiten der beiden Schenkel (2, 3) angesetzt wird.4. The method according to any one of the preceding claims, characterized in that the welding device (7, 8) to the Head opposite outer sides of the two legs (2, 3) is attached.
5. Verfahren nach Anspruch 4, dadurch gekennzeichnet, daß jeweils ein Schweißstempel (7, 8) der Schweißvorrichtung an einer Außenseite des Kontaktelements (1) angesetzt wird.5. The method according to claim 4, characterized in that in each case a welding stamp (7, 8) of the welding device is attached to an outside of the contact element (1).
6. Verfahren nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, daß das Kontaktelement (1) mit einem Steckverbinder (11) verbunden ist.6. The method according to any one of the preceding claims, characterized in that the contact element (1) is connected to a connector (11).
7. Verfahren nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, daß der mit einer Isolierung (6) ummantelte Leiter (4) ein Flachbandleiter ist.7. The method according to any one of the preceding claims, characterized in that the conductor (4) coated with insulation (6) is a ribbon conductor.
8. Verfahren nach einem der vorstehenden Ansprüche, dadurch gekennzeichnet, daß das Kontaktelement (1) S-förmig gebogen ist.8. The method according to any one of the preceding claims, characterized in that the contact element (1) is bent in an S-shape.
9. Verfahren nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, daß das Kontaktelement (1) C-förmig gebogen ist.9. The method according to any one of claims 1 to 7, characterized in that the contact element (1) is bent in a C-shape.
10. Steckverbinder (11) mit einem Kontaktelement (1) und einem an das Kontaktelement angeschlossenen elektrischen Leiter (4), dadurch gekennzeichnet, daß die Verbindung zwischen Kontaktelement (1) und elektrischem Leiter (4) nach einem Verfahren nach einem der Ansprüche 1 bis 9 hergestellt wurde. 10. Connector (11) with a contact element (1) and an electrical conductor (4) connected to the contact element, characterized in that the connection between the contact element (1) and the electrical conductor (4) according to a method according to one of claims 1 to 9 was produced.
EP03758046A 2002-10-31 2003-10-23 Method for electrically connecting a conductor to a contact Withdrawn EP1559172A1 (en)

Applications Claiming Priority (3)

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DE10250930A DE10250930B3 (en) 2002-10-31 2002-10-31 Method for the electrical connection of a conductor to a contact element
DE10250930 2002-10-31
PCT/EP2003/011739 WO2004040702A1 (en) 2002-10-31 2003-10-23 Method for electrically connecting a conductor to a contact

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EP (1) EP1559172A1 (en)
JP (1) JP2006505103A (en)
KR (1) KR20050074513A (en)
CN (1) CN1708878A (en)
AU (1) AU2003274064A1 (en)
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WO (1) WO2004040702A1 (en)

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US7084346B2 (en) 2006-08-01
AU2003274064A1 (en) 2004-05-25
US20060060372A1 (en) 2006-03-23
KR20050074513A (en) 2005-07-18
CN1708878A (en) 2005-12-14
WO2004040702A1 (en) 2004-05-13
JP2006505103A (en) 2006-02-09

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