EP3312936B1 - Borne de puissance avec ailettes de sertissage et zone de soudure - Google Patents

Borne de puissance avec ailettes de sertissage et zone de soudure Download PDF

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Publication number
EP3312936B1
EP3312936B1 EP16194696.7A EP16194696A EP3312936B1 EP 3312936 B1 EP3312936 B1 EP 3312936B1 EP 16194696 A EP16194696 A EP 16194696A EP 3312936 B1 EP3312936 B1 EP 3312936B1
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EP
European Patent Office
Prior art keywords
terminal
power
flat
insulation
wings
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.)
Active
Application number
EP16194696.7A
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German (de)
English (en)
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EP3312936A1 (fr
Inventor
Michael Kasser
Swindhard Packebusch
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Aptiv Technologies Ltd
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Aptiv Technologies Ltd
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Priority to EP16194696.7A priority Critical patent/EP3312936B1/fr
Priority to PCT/EP2017/075467 priority patent/WO2018073022A1/fr
Publication of EP3312936A1 publication Critical patent/EP3312936A1/fr
Application granted granted Critical
Publication of EP3312936B1 publication Critical patent/EP3312936B1/fr
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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
    • H01R4/10—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
    • H01R4/185—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 combined with a U-shaped insulation-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
    • H01R4/10—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
    • H01R4/187—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 combined with 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
    • H01R2201/00—Connectors or connections adapted for particular applications
    • H01R2201/26—Connectors or connections adapted for particular applications for vehicles
    • 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
    • H01R4/188—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 having an uneven wire-receiving surface to improve the contact

Definitions

  • the invention relates to a power terminal and a method for crimping and welding said terminal to an insulated electrical wire.
  • a power terminal with a first end that is typically crimped or welded to an end of an insulated electrical wire.
  • the other end of the power terminal often comprises a ring terminal.
  • the ring terminal is subsequently attached to a pin on the power supply.
  • An example of a power supply is a starter/alternator battery.
  • a first power terminal is used to connect a first insulated electrical wire to a male pin on the starter/alternator battery.
  • a second power terminal is used to connect a second insulated electrical wire to the same male pin on the starter/alternator.
  • Drawback of such power terminals is that two power terminals are needed to connect two different wires to a single male pin.
  • Document JP H09 92348 discloses an example of power terminal comprising two pairs of insulation crimping wings and a weld area between the two pairs.
  • the object of the invention is to solve above drawback or at least provide an alternative.
  • the object of the invention is to provide a faster way of connecting two wires to a power supply.
  • the present invention solves the above problem by providing a power terminal according to claim 1.
  • a power terminal having a weld area in between two pairs of insulation crimping wings allows for welding the terminal to a lead of an insulated electrical wire that is in between the ends of this single wire.
  • One power terminal can be used to provide power towards ends of the wire.
  • the power terminal provides an electrical junction between the power supply and two ends of a single wire. This avoids the need of using two power terminals and thereby having to perform two electrical welding steps.
  • the power terminal according to the invention improves existing power terminals and/or at least provides an alternative.
  • the first pair of insulation crimping wings, the second pair of insulation crimping wings and the weld area are longitudinally arranged.
  • longitudinally is meant that said pairs of crimping wings and the weld area are arranged and aligned along a longitudinal axis of the terminal. The longitudinal axis of the terminal is then parallel with the insulated wire when the wire is crimped and welded to the terminal.
  • the lead of the wire in between the pair of insulation crimping wings may be free from bends. This may result in a better weld between lead and weld area as the lead is straight, i.e. aligned with the longitudinal axis.
  • the power connector at least partly extends transversely from the longitudinal axis of the power terminal.
  • the power connector extending transversely is that it allows the power connector to be provides next to the electrical wire when the electrical wire is welded and crimped to the power terminal.
  • the power connector may be spaced or offset from the electrical wire. This may result in more space for connecting the power connector with for example a male pin of the power supply.
  • the power connector is a ring terminal for receiving an electrical pin. This allows the power terminal to be electrically and mechanically connected to a male pin on the power supply.
  • the power connector comprises a flat connector surface and the weld area comprises a flat weld surface, wherein the flat connector surface is parallel with the flat weld surface.
  • the power terminal is made from a single sheet of metal resulting in a power terminal having substantially a same thickness.
  • the crimping wings, the weld area and the power connector all have substantially the same thickness.
  • the flat weld surface is offset from the flat connector surface.
  • the flat connector surface is below the insulated electrical wire.
  • a plane spanned by the flat connector surface is free from an intersection with the insulated electrical wire when the insulated electrical wire is crimped and welded to the power terminal.
  • the flat connector surface is spaced away from the flat weld surface in an opposite direction with respect to the direction in which ends of the insulation crimping wings are pointing when the power terminal is in a pre-weld state.
  • the lead of the insulated electrical conductor may be firmly in contact with the flat weld surface after welding. Due to a thickness of the insulation of the insulated electrical wire bending moments may occur after the lead is welded to the flat surface as there is a transition area between end of the insulation and beginning of the lead. Having the flat connector surface spaced away from the flat weld surface allows reduction of such unwanted bending moments.
  • the flat connector surface is level with the flat weld surface.
  • the power terminal comprises a first flat bridge portion between the wings of the first pair of insulation wings.
  • a first step is provided between the weld area and the first flat bridge portion.
  • the weld area preferably a flat weld surface, is spaced away from the first flat bridge portion.
  • the first step may compensate for a transition area between the end of the insulation and the beginning of the lead. This may reduce unwanted bending moments.
  • the power terminal comprises a second flat bridge portion between the wings of the second pair of insulation wings.
  • a second step is provided between the weld area and the second flat bridge portion.
  • the weld area preferably a flat weld surface, is spaced away from the second flat bridge portion and is level with the first flat bridge portion.
  • the second step may compensate for a transition area between the end of the insulation and the beginning of the lead.
  • the height of the second step between weld area and second bridge portion is preferably equal to the height of the first step between weld area and first bridge portion. This may minimize unwanted bending moments when there are two transition areas in an insulated electrical wire where a lead is in between ends of the insulated electrical wire.
  • the length of the insulation wings is substantially equal to the length of the weld area.
  • the electrical connection may not be sufficient as there is too little contact area between lead and weld area.
  • the terminal is made of aluminum.
  • the terminal is made of copper.
  • the invention further relates to a wire terminal assembly.
  • the wire terminal assembly comprises a power terminal according to one of the preceding embodiments and an insulated electrical wire.
  • the insulated electrical wire is crimped and welded to the terminal.
  • the insulated electrical wire comprises a copper conductor.
  • the insulated electrical wire comprises an aluminum conductor.
  • Figure 1 shows a power terminal 1 comprising a first of insulation crimping wings 4 and a second pair of insulation crimping wings 5.
  • the power terminal 1 is shown in a pre-weld state prior to be welded and crimped to an insulated electrical wire 6 as shown in figure 2 .
  • the pairs of crimping wings 4, 5 extend substantially transverse with respect to a longitudinal axis (X) of the power terminal 1.
  • the insulation crimping wings are suitable for crimping to insulation 3 of the insulated electrical wire 6.
  • the first pair and second pair of insulation crimping wings 4, 5 are suitable to be crimped to insulation of the same insulated electrical wire 6.
  • a weld area 7 is provided in between the first pair and second pair of insulation crimping wings 4, 5 .
  • the weld area 7 is suitable for welding to a lead 9 of the insulated electrical wire 6.
  • the length LW of the weld area 7 is substantially equal to the length LL of the lead 9.
  • the power terminal 1 further comprises a power connector 10 that is in conductive contact with the weld area 7.
  • the power connector 10 is suitable to be connected to a terminal of a power supply (not shown).
  • Figure 2 shows the power terminal 1 in a welded state, i.e. crimped and welded to the insulated electrical wire 6.
  • the first pair of insulation crimping wings 4, the second pair of insulation crimping wings 5 and the weld area 7 are arranged longitudinally along the longitudinal axis X of the terminal 1.
  • the power terminal 1 is arranged with the first pair of insulation crimping wings 4, the weld area 7, the second pair of insulation crimping wings 5 and the power connector 10.
  • the longitudinal axis X of the terminal 1 is parallel, i.e. aligned, with the insulated wire 6.
  • the power connector 10 extends transversely from the longitudinal axis X of the terminal 1. This way the power connector is spaced away from the insulated electrical wire 6 such that it allows for connection to a power supply.
  • the power connector 10 is a ring terminal comprising a flat connector surface 12. The ring terminal is suitable for receiving an electrical pin of the power supply.
  • the power terminal comprises an intermediate longitudinal ridge 15 provided between the power connector 10 and the second pair of insulation crimping wings 5.
  • the intermediate longitudinal ridge 15 provides support to the insulation of the insulated electrical wire 6.
  • the ridge 15 is longitudinal and thus parallel with the longitudinal axis X of the power terminal 1 and with the insulated electrical wire.
  • the longitudinal ridge 15 supports and extends along the insulated electrical wire 6 when said wire is crimped and welded to the power terminal.
  • the intermediate longitudinal ridge 15 is provided between the power connector 10 and an angled portion 17.
  • the angled portion 17 is a flat portion between the power connector 10 and the second pair of insulated crimping wings 5.
  • the intermediate longitudinal ridge 15 protrudes from the angled flat portion 17 and the flat connector surface 12. This allows a better support of the insulated electrical wire 6.
  • the weld area 7 comprises a flat weld surface 14.
  • the flat connector surface 12 is parallel with the flat weld surface 14.
  • the flat connector surface 12 is offset with respect to the flat weld surface 14.
  • the power terminal 1 comprises a first flat bridge portion 27 between the wings of the first pair of insulation wings 4.
  • a first step 30 is provided between the weld area 7 and the first flat bridge portion 27.
  • the flat weld surface 14 is parallel with the first flat bridge portion 27. Due to the first step 30, the flat weld surface 14 is offset or spaced away from the first flat bridge portion 27.
  • the power terminal 1 comprises a second flat bridge portion 28 between the wings of the second pair of insulation wings 5.
  • a second step 31 is provided between the weld area 7 and the second flat bridge portion 28.
  • the flat weld surface 14 is parallel with the second flat bridge portion 28. Due to the second step 31, the flat weld surface 14 is offset or spaced away from the second flat bridge portion 28.
  • first flat bridge portion 27 and the second flat bridge portion 28 are parallel and level.
  • the flat bridge portions 27, 28 are in a same plane.
  • the flat weld surface 14 is spaced away from this same plane in a direction equal to the direction in which the wings extend in the pre-weld state.
  • the height of the first step and the second step are substantially equal.
  • the length of the insulation crimping wings LI is substantially equal to the length of the weld area LW.
  • the power terminal 1 may be made from aluminum or copper.
  • Figure 2 shows a power connection assembly 20, comprising the terminal 1 and the insulated electrical wire 6.
  • the wire 6 is crimped and welded to the terminal 1.
  • the insulated electrical wire 6 comprises a copper electrical conductor or an aluminum electrical conductor.
  • the lead 9 is made of the same material as the electrical conductor.
  • an insulation of the insulated electrical wire 6 is at least partly removed.
  • the insulation that is removed is in an area in between ends of the insulated electrical wire 6.
  • lead 9 of the insulated electrical wire 6 is uncovered.
  • lead 9 may sometimes be understood as being a portion in an end of an electrical wire.
  • lead 9 is to be understood as an uncovered portion of the electrical conductor inside an insulated electrical wire 6. Therefore, here, the lead 9 is not at ends of the insulated electrical wire but in between ends of the insulated electrical wire 6, e.g. in a middle of the insulated electrical wire 6.
  • the uncovered lead 9 is aligned with the weld area 7 of the power terminal 1.
  • the aligning results that both lengths are parallel with each other and have a beginning and end that are aligned.
  • the lead 9 is welded to the weld area 7, preferably by ultrasonic welding.
  • first pair of insulation crimping wings and the second pair of insulation crimping wings are crimped to the insulation of the insulated electrical wire. There is no preference in which order the first pair and second pair are crimped.
  • power connector assembly 20 and method improve existing power terminals, power connector assemblies and methods for connecting a power terminal to an insulated electrical wire.
  • only one power terminals may be used to connect to an insulated electrical wire wherein both ends of the wire may be provided with its own terminal for distributing power.
  • the power terminal 1 allows a robust and secure mechanical and electrical connection to a lead 9 of the insulated electrical wire 6, where the lead is located between ends of the insulated electrical wire. For that purpose insulation is removed locally in between ends of the insulated electrical wire which results in the lead 9 being uncovered.

Landscapes

  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Manufacturing Of Electrical Connectors (AREA)

Claims (10)

  1. Borne de puissance (1) comprenant :
    - une première paire d'ailettes de sertissage sur isolation (4) pour le sertissage sur une isolation (3) d'un fil électrique isolé (6) ;
    - une seconde paire d'ailettes de sertissage sur isolation (5) pour le sertissage sur une isolation (3) du même fil électrique isolé (6) ;
    - une zone de soudage (7) prévue entre la première paire d'ailettes de sertissage sur isolation (4) et la seconde paire d'ailettes de sertissage sur isolation (5) pour le soudage sur un conducteur (9) du fil électrique isolé (6), dans laquelle la longueur (LW) de la zone de soudage (7) est sensiblement égale à la longueur (LL) du fil (9) ;
    - un connecteur de puissance (10) en contact conducteur avec la zone de soudage (7) ;
    dans laquelle la première paire d'ailettes de sertissage sur isolation (4), la seconde paire d'ailettes de sertissage sur isolation (5) et la zone de soudage (7) sont agencées longitudinalement le long d'un axe longitudinal (X) de la borne (1), ledit axe longitudinal (X) de la borne (1) parallèle au fil isolé (6) quand le fil (6) est serti et soudé sur la borne (1) ;
    dans laquelle le connecteur de puissance (10) s'étend au moins partiellement transversalement depuis l'axe longitudinal (X) de la borne (1),
    caractérisée en ce qu'un rebord longitudinal intermédiaire (15) est prévu entre le connecteur de puissance (10) et la seconde paire d'ailettes de sertissage sur isolation (5), dans laquelle le rebord longitudinal (15) supporte et s'étend le long du fil électrique isolé (6) lorsque ledit fil (6) est serti et soudé sur la borne de puissance (1), et en ce que le rebord longitudinal intermédiaire (15) est prévu entre le connecteur de puissance (10) et une portion en angle (17), ladite portion en angle (17) étant une portion plane entre le connecteur de puissance (10) et ladite seconde paire d'ailettes de sertissage sur isolation (5).
  2. Borne de puissance (1) selon la revendication précédente, dans laquelle le connecteur de puissance (10) est une borne annulaire pour recevoir une broche électrique.
  3. Borne de puissance (1) selon l'une des revendications précédentes, dans laquelle le connecteur de puissance (10) comprend une surface de connecteur plane (12) et la zone de soudage comprend une surface de soudage plane (14), telles que la surface de connecteur plane (12) est parallèle à la surface de soudage plane (14).
  4. Borne de puissance (1) selon l'une des revendications précédentes, dans laquelle la surface de connecteur plane (12) est décalée par rapport à la surface de soudage plane (14).
  5. Borne de puissance (1) selon l'une des revendications précédentes, comprenant une première portion de pontage plane (27) entre les ailettes de la première paire d'ailettes sur isolation (4), dans laquelle un premier gradin (30) est prévu entre la zone de soudage (7) et la première portion de pontage plane (27).
  6. Borne de puissance (1) selon l'une des revendications précédentes, comprenant une seconde portion de pontage plane (28) entre les ailettes de la seconde paire d'ailettes sur isolation (5), dans laquelle un second gradin (31) est prévu entre la zone de soudage (7) et la seconde portion de soudage plane (28).
  7. Borne de puissance (1) selon l'une des revendications précédentes, dans laquelle la longueur des ailettes sur isolation (LI) est sensiblement égale à la longueur de la zone de soudage (LW).
  8. Borne de puissance (1) selon l'une des revendications précédentes, dans laquelle la borne est réalisée en aluminium ou en cuivre.
  9. Ensemble de connexion de puissance (20), comprenant une borne (1) selon l'une des revendications précédentes, et le fil électrique isolé (6), ledit fil (6) étant serti et soudé sur la borne (1).
  10. Ensemble de connexion de puissance (20) selon la revendication précédente, dans lequel le fil électrique isolé (6) comprend un conducteur électrique en cuivre ou un conducteur électrique en aluminium.
EP16194696.7A 2016-10-19 2016-10-19 Borne de puissance avec ailettes de sertissage et zone de soudure Active EP3312936B1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP16194696.7A EP3312936B1 (fr) 2016-10-19 2016-10-19 Borne de puissance avec ailettes de sertissage et zone de soudure
PCT/EP2017/075467 WO2018073022A1 (fr) 2016-10-19 2017-10-06 Borne d'alimentation à oreilles de sertissage et région de soudure

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP16194696.7A EP3312936B1 (fr) 2016-10-19 2016-10-19 Borne de puissance avec ailettes de sertissage et zone de soudure

Publications (2)

Publication Number Publication Date
EP3312936A1 EP3312936A1 (fr) 2018-04-25
EP3312936B1 true EP3312936B1 (fr) 2019-08-14

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EP16194696.7A Active EP3312936B1 (fr) 2016-10-19 2016-10-19 Borne de puissance avec ailettes de sertissage et zone de soudure

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EP (1) EP3312936B1 (fr)
WO (1) WO2018073022A1 (fr)

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5567187A (en) * 1994-06-16 1996-10-22 Belden Wire & Cable Company Reverse insulation grip blade
JP3156833B2 (ja) * 1995-09-22 2001-04-16 矢崎総業株式会社 ブスバーへの電線接続方法

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
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EP3312936A1 (fr) 2018-04-25

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