GB2052891A - Method of attaching a contact element to an electric line - Google Patents
Method of attaching a contact element to an electric line Download PDFInfo
- Publication number
- GB2052891A GB2052891A GB8017399A GB8017399A GB2052891A GB 2052891 A GB2052891 A GB 2052891A GB 8017399 A GB8017399 A GB 8017399A GB 8017399 A GB8017399 A GB 8017399A GB 2052891 A GB2052891 A GB 2052891A
- Authority
- GB
- United Kingdom
- Prior art keywords
- contact element
- conductor
- tube
- copper
- line
- 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- Withdrawn
Links
- 238000000034 method Methods 0.000 title claims description 18
- 239000004020 conductor Substances 0.000 claims abstract description 37
- 229910052802 copper Inorganic materials 0.000 claims abstract description 23
- 239000010949 copper Substances 0.000 claims abstract description 23
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 22
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical group [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 claims abstract description 15
- 229910052751 metal Inorganic materials 0.000 claims description 5
- 239000002184 metal Substances 0.000 claims description 5
- 230000007797 corrosion Effects 0.000 abstract description 6
- 238000005260 corrosion Methods 0.000 abstract description 6
- 230000006378 damage Effects 0.000 abstract description 3
- 230000000694 effects Effects 0.000 description 4
- 238000009413 insulation Methods 0.000 description 3
- 239000004411 aluminium Substances 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 238000002788 crimping Methods 0.000 description 2
- 241001424392 Lucia limbaria Species 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 238000005476 soldering Methods 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
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
- H01R4/10—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/20—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve
-
- 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
- H01R4/10—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/183—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
- H01R4/184—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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
-
- 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
- H01R4/58—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 characterised by the form or material of the contacting members
- H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
Landscapes
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
- Manufacturing Of Electrical Connectors (AREA)
- Cable Accessories (AREA)
Abstract
A stranded conductor (2), comprising individual wires (4) which consist of an aluminium core (5) covered with a relatively thin copper layer (6), is provided with a contact element in such a manner that the relatively thin copper layers (6) are not damaged by pushing a tube (7) closed at one end over the end of the conductor (2), and thereafter firmly joining a contact element (9) to the stranded conductor (2) by being struck or crimped on. This prevents destruction of the conductor (2) by corrosion. A conductor (2) with such a contact element can be used, for example, as a battery cable in a motor vehicle. <IMAGE>
Description
SPECIFICATION
Method of attaching a contact element to an electric line
The invention relates to a method of attaching a contact element (as herein defined) to an electric line (as herein defined) provided with one or more stranded conductors consisting a multiplicity of individual wires, in which each individual wire consists of an aluminium core and a copper sheath covering it which is thin in relation to the diameter of the aluminium core, and which is metallurgically bonded to it.
The term "line" in the present description and claims embraces all electric lines, leads and cables which have one or more insulated conductors. The term "line", which is used for the sake of simplicity, is thus representative of all types of construction. The term "contact element" in the present description and claims embraces all metallic contact means which can be used for providing an electrical through-connection, e.g. the pins of plugs or cable lugs.
Lines comprising insulated conductors consisting of an aluminium core with a copper sheath are preferably used where the high conductivity of copper is not absolutely necessary, and where conductors consisting only of copper are in fact to be avoided for weight and cost reasons. Such an area of use is, for example, that of battery cables for motor vehicles, particularly if the cables must be especially long in order to bridge increased distances. Lines employing the aluminiumand-copper conductors mentioned, however, can also be used for high-frequency purposes if only a relatively small copper cross-section is needed with given line dimensions.
Independently of this conductor construction, the lines under consideration can be manufactured by familiar methods. For connecting the conductors, or providing them with contacts, one can, in principle, again use all the ordinary techniques. However, if a striking or crimping technique, which is a more and more usual and cost-effective method today, is used for firmly attaching contact elements, the danger arises that the thin copper layer of the conductor may be destroyed, leading to corrosion effects and the gradual destruction of the joint during the service of the line concerned. For this reason, lines with an aluminium core and a copper sheath have hitherto been connected, or provided with contacts, almost exclusively by soldering or welding.
It is an object of the present invention to provide a method by means of which it is possible to strike or crimp a contact element on to an electric line having one or more stranded conductors comprising individual wires which consist of an aluminium core having a covering in the form of a thin copper sheath, which method will at the same time ensure that the joint is not affected by corrosion.
According to the invention, we provide a method of attaching a contact element (as herein defined) to an electric line (as herein defined) provided with one or more stranded conductors consisting of a multiplicity of individual wires, in which each individual wire consists of an aluminium core and a copper sheath covering it which is thin in relation to the diameter of the aluminium core, and which is metallurgically bonded to it, characterised in that: the line is stripped at the end to which the contact element is to be attached; a metal tube, closed at one end by a bottom, is therafter pushed on to the stripped stranded conductor until the end of the conductor abuts against the bottom of the tube; and the contact element is thereafter struck or crimped on to the conductor in the area of the tube.
The above-mentioned metal tube closed at one end is desirably of good electrical conductivity, and may accordingly be of copper.
An advantage of the present method is that the individual wires mentioned are covered, by the tube pushed over them, in such a manner that, although they are squeezed together when the contact element is struck or when the crimp connection is being made, they are not damaged. As the tube is desirably of a metal with good electrical conductivity, e.g. copper, a connection with sufficiently good conductivity and with contact resistances which are not unacceptably high can be guaranteed. Since the thin copper layers of the individual wires are not damaged, corrosion effects at the joint can be eliminated.A further advantage of the present method is that the ends of the individual wires, at which the aluminium core and the copper sheath could be freely exposed, are actually covered by the tube closed at one end, so that, even here, any corrosion caused by atmospheric effects can be prevented.
The method of the invention is more fully explained in the description which follows, with reference to the accompanying diagrammatic drawing, in which:
Figure 1 is a fragmentary side view of an electric line in the case of which some insulation has been removed from its stranded conductor;
Figure 2 is a section through Fig. 1 on line Il-Il; Figure 3 is a cross-section through an individual wire, on an enlarged scale;
Figure 4 is a fragmentary side view which shows the end of the line with a piece of tube pushed on to it; and
Figure 5 is a fragmentary side view which shows the end of the line with a struck-on contact element.
Figs. 1, 4 and 5 show, at 1, an electric line comprising only a single conductor, this being a stranded conductor 2. Such a line can be used, for example, as a connecting line for batteries of motor vehicles. The stranded conductor 2 is covered by an insulation 3, preferably of a heat-resistant insulating material. To permit a contact element to be attached to the end of the line, insulation has been removed from this end, as shown in Fig. 1, exposing the stranded conductor 2 consisting of a plurality of individual wires; these wires 4 can be stranded or twisted together in the stranded conductor 2.
As shown in Fig. 3, each individual wire 4 of the stranded conductor consists of an aluminium core 5 and a copper sheath 6 covering it, which is metallurgically firmly joined to the aluminium core. The wires 4 can be produced in a continuous operation from a copper band run in longitudinally beside, and formed into a slit tube around, an aluminium strand, the edges of the slit tube being welded together along a longitudinal seam, and the resulting structure drawn down until it is adjacent to the aluminium strand. The desired dimensions of the wire 4 are then obtained by further drawing-down, with additional heat treatment. In relation to the diameter of the aluminium core 5, the copper sheath 6 of the finished individual wire is thin, the ratio of the thickness of the copper sheath to the diameter of the aluminium core being about 1:10.An individual wire 4 for a line as shown in Fig. 1 may for example have a total diameter of 2 mm, so that the copper sheath may be less than 0.2 mm thick. Such a thin layer is highly susceptible to mechanical damage.
In order to protect the stripped stranded conductor 2, we push on to its end, as shown in Fig. 4, a metal tube 7, preferably of copper and having a bottom 8 at one end, that is to say being closed at one end. This tube 7, therefore, represents a type of cup. It is pushed over the conductor 2 until the end of the latter abuts against the bottom 8. Compared to the outside diameter of the conductor 2, the inside diameter of the tube 7 can be slightly reduced, so that the former is slightly compressed when the tube 7 is pushed on.
After the tube 7 has been pushed on, nearly all of the exposed surface of the conductor 2, and particularly its end, is covered by the tube 7, so that no corrosion caused by atmospheric effects can occur on the conductor 2.
After the tube 7 has been pushed on to the conductor 2, a contact element 9, shown in
Fig. 5 as a cable lug, can be attached to the end of the line 1 by being struck on or crimped on. During the process of striking or crimping, the conductor 2 and the tube 7 covering it are squeezed together by the crimp section 10 of the contact element 9; there is no danger of the thin copper sheaths 6 of the individual wires 4 of the conductor 2 being damaged.
Claims (4)
1. Method of attaching a contact element (as herein defined) to an electric line (as herein defined) provided with one or more stranded conductors consisting of a multiplicity of individual wires, in which each individual wire consists of an aluminium core and a copper sheath covering it which is thin in relation to the diameter of the aluminium core, and which is metallurgically bonded to it, characterised in that: the line (1) is stripped at the end to which the contact element (9) is to be attached; a metal tube (7), closed at one end by a bottom (8), is thereafter pushed on to the stripped stranded conductor (2) until the end of the conductor (2) abuts against the bottom (8) of the tube (7); and the contact element (9) is thereafter struck or crimped on to the conductor (2) in the area of the tube (7).
2. Method according to claim 1, characterised in that the tube (7) used is of copper.
3. Method according to claim 1, substantially as described with reference to the accompanying diagrammatic drawing.
4. An electric line (as herein defined) to which a contact element has been attached by a method according to claim 1, 2 or 3.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE19792925852 DE2925852A1 (en) | 1979-06-27 | 1979-06-27 | METHOD FOR ATTACHING A CONTACT PART TO AN ELECTRICAL LINE |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| GB2052891A true GB2052891A (en) | 1981-01-28 |
Family
ID=6074242
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB8017399A Withdrawn GB2052891A (en) | 1979-06-27 | 1980-05-28 | Method of attaching a contact element to an electric line |
Country Status (6)
| Country | Link |
|---|---|
| JP (1) | JPS567366A (en) |
| DE (1) | DE2925852A1 (en) |
| FR (1) | FR2460056A1 (en) |
| GB (1) | GB2052891A (en) |
| IT (1) | IT8048045A0 (en) |
| SE (1) | SE8004715L (en) |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2138199A (en) * | 1983-03-09 | 1984-10-17 | Icore Int Ltd | An electrical cable |
| US7048562B2 (en) | 2004-07-13 | 2006-05-23 | Yazaki Europe Ltd. | Connection between a cable end piece and a cable end |
| EP1926177A1 (en) * | 2006-11-22 | 2008-05-28 | Nexans | System for contacting an electric conductor |
| CN102246353B (en) * | 2008-12-09 | 2013-12-25 | 莱尼电气系统有限公司 | Electrical contact connection and method for producing electrical contact connection |
| CN111162388A (en) * | 2018-11-07 | 2020-05-15 | 东京Cosmos电机株式会社 | Relay wire |
| EP3633689A4 (en) * | 2017-05-29 | 2020-09-16 | Japan Aviation Electronics Industry, Ltd. | ELECTRICAL CABLE, ELECTRICAL CABLE WITH CONNECTOR, WIRING HARNESS AND METHOD FOR MANUFACTURING AN ELECTRICAL CABLE |
Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7954235B2 (en) * | 2009-09-18 | 2011-06-07 | Delphi Technologies, Inc. | Method of making a seal about a copper-based terminal |
| JP2011192586A (en) * | 2010-03-16 | 2011-09-29 | Autonetworks Technologies Ltd | Cable having terminal fitting, and manufacturing method for same |
| JP5418332B2 (en) * | 2010-03-17 | 2014-02-19 | 株式会社オートネットワーク技術研究所 | Electric wire with terminal bracket |
| CN114744463B (en) * | 2022-05-12 | 2023-12-15 | 江苏通光强能输电线科技有限公司 | A manufacturing process for high tensile strength copper-aluminum transition terminals |
-
1979
- 1979-06-27 DE DE19792925852 patent/DE2925852A1/en not_active Withdrawn
-
1980
- 1980-02-29 IT IT8048045A patent/IT8048045A0/en unknown
- 1980-03-10 FR FR8005333A patent/FR2460056A1/en not_active Withdrawn
- 1980-05-28 GB GB8017399A patent/GB2052891A/en not_active Withdrawn
- 1980-06-25 JP JP8526580A patent/JPS567366A/en active Pending
- 1980-06-26 SE SE8004715A patent/SE8004715L/en unknown
Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2138199A (en) * | 1983-03-09 | 1984-10-17 | Icore Int Ltd | An electrical cable |
| US7048562B2 (en) | 2004-07-13 | 2006-05-23 | Yazaki Europe Ltd. | Connection between a cable end piece and a cable end |
| EP1926177A1 (en) * | 2006-11-22 | 2008-05-28 | Nexans | System for contacting an electric conductor |
| CN102246353B (en) * | 2008-12-09 | 2013-12-25 | 莱尼电气系统有限公司 | Electrical contact connection and method for producing electrical contact connection |
| EP3633689A4 (en) * | 2017-05-29 | 2020-09-16 | Japan Aviation Electronics Industry, Ltd. | ELECTRICAL CABLE, ELECTRICAL CABLE WITH CONNECTOR, WIRING HARNESS AND METHOD FOR MANUFACTURING AN ELECTRICAL CABLE |
| CN111162388A (en) * | 2018-11-07 | 2020-05-15 | 东京Cosmos电机株式会社 | Relay wire |
| CN111162388B (en) * | 2018-11-07 | 2021-07-06 | 东京Cosmos电机株式会社 | relay wire |
Also Published As
| Publication number | Publication date |
|---|---|
| SE8004715L (en) | 1980-12-28 |
| FR2460056A1 (en) | 1981-01-16 |
| IT8048045A0 (en) | 1980-02-29 |
| JPS567366A (en) | 1981-01-26 |
| DE2925852A1 (en) | 1981-01-22 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |