EP4199273A1 - Procédé de fabrication d'un conducteur plat - Google Patents

Procédé de fabrication d'un conducteur plat Download PDF

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Publication number
EP4199273A1
EP4199273A1 EP21215633.5A EP21215633A EP4199273A1 EP 4199273 A1 EP4199273 A1 EP 4199273A1 EP 21215633 A EP21215633 A EP 21215633A EP 4199273 A1 EP4199273 A1 EP 4199273A1
Authority
EP
European Patent Office
Prior art keywords
cross
flat
section
sectional shape
flat 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.)
Pending
Application number
EP21215633.5A
Other languages
German (de)
English (en)
Inventor
Tobias Heutger
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.)
Fischer and Kaufmann GmbH and Co KG
Original Assignee
Fischer and Kaufmann GmbH and Co KG
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 Fischer and Kaufmann GmbH and Co KG filed Critical Fischer and Kaufmann GmbH and Co KG
Priority to EP21215633.5A priority Critical patent/EP4199273A1/fr
Publication of EP4199273A1 publication Critical patent/EP4199273A1/fr
Pending legal-status Critical Current

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    • 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
    • H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21F—WORKING OR PROCESSING OF METAL WIRE
    • B21F45/00—Wire-working in the manufacture of other particular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21F—WORKING OR PROCESSING OF METAL WIRE
    • B21F5/00—Upsetting wire
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B5/00—Non-insulated conductors or conductive bodies characterised by their form
    • H01B5/02—Single bars, rods, wires, or strips
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/03—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the relationship between the connecting locations
    • H01R11/05—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the relationship between the connecting locations the connecting locations having different types of direct connections

Definitions

  • the invention relates to a method for producing a flat conductor with a non-rectilinear curved shape from a metallic wire with an essentially circular cross section, the wire being preformed by bending to form a curved intermediate shape and then the intermediate shape being pressed flat to form a flat conductor, according to the preamble of claim 1.
  • the invention further relates to a flat conductor which is produced without cutting from a piece of metal wire with an essentially circular cross-section, the wire being preformed by bending to form a curved intermediate shape and being finally formed into the flat conductor by pressing the intermediate shape flat, according to the preamble of claim 13.
  • Flat conductors are components made from an electrically conductive metal or a metal alloy, which have a solid flat cross-section. Flat conductors of this type are used, for example, in electrical drive systems, for example in motor vehicles, as electrical connecting elements for transmitting electrical currents, in particular in the two or three-digit ampere range. Such flat conductors are also referred to as busbars. In contrast to cables, which are usually flexible, flat conductors are designed to be dimensionally stable and have a planar or three-dimensional shape or structure adapted to the respective intended use.
  • a plastically deformable material in particular a metal, is used to produce the flat conductor, in which the circular initial cross section is flattened while reducing the initial diameter, the material displaced in the transverse direction being formed into the desired flat cross section.
  • the invention is based on the object of specifying a flat conductor and a method for its production, with which a particularly large variety of shapes for flat conductors can be made available in an efficient manner.
  • the method according to the invention is characterized in that during flat pressing the flat conductor is formed with at least two first sections with a first flat cross-sectional shape and at least one intermediate second section with a second cross-sectional shape which deviates from the first flat cross-sectional shape.
  • a basic idea of the invention is to move away from a simple process of flattening a wheel piece with a circular cross-section and to form a flat conductor by bending and then flattening a piece of wire, with a cross-sectional shape varying over the axial length being achieved.
  • the invention is based on the finding that, particularly in the case of non-cutting metal forming, a specific material flow can be set in different directions with a corresponding design of the press tools, so that different cross-sectional shapes can also be formed in a flat conductor during flat pressing.
  • a particularly preferred embodiment of the invention is that the second cross-sectional shape is provided as a substantially circular cross-sectional shape becomes.
  • a flat conductor can thus be produced which not only has sections with a flat cross-sectional shape, but also at least one section with a circular cross-sectional shape.
  • the at least one section with the circular cross section lies between two adjoining sections with a flat, preferably rectangular, cross section. Transition areas are preferably formed between the sections.
  • a receiving groove for a sealing ring can also be formed on the second section.
  • a preferred embodiment of the invention further consists in the fact that the circular cross-sectional shape corresponds to the circular cross-section of the wire or is designed with a smaller diameter than this.
  • a desired particularly smooth surface can also be set, which can be advantageous for sealing purposes.
  • the diameter of the cylindrical second section is larger than a height of the adjacent first sections with a flat, rectangular cross-section. With such a rectangular shape, the longer side of the rectangle can be larger than the diameter of the cylindrical section.
  • an axial stretching can be provided in the second section.
  • the second section with the circular cross-sectional shape can also be enlarged by material compression in the longitudinal direction by a corresponding material displacement in the longitudinal direction, such that the diameter is greater than both a height and a width of an adjacent flat-pressed section.
  • the flat cross-sectional shape can be approximately oval or polygonal. A square shape is also possible. According to a development of the invention, it is particularly preferred that the first flat cross-sectional shape is designed as a first rectangular cross-section with a first width and a first height. Such a rectangular cross section is particularly advantageous for connecting further electrical components.
  • the second cross-sectional shape with a second rectangular cross-section with a second width and a second Height is formed, wherein the second cross-sectional shape differs from the first cross-sectional shape in terms of width and/or height. It is thus possible for several or all sections of the flat conductor to be designed with a rectangular shape, although the first cross-sectional shape differs from the second cross-sectional shape.
  • the two cross-sectional shapes can preferably have the same surface area. Alternatively, it can also be provided that the cross-sectional areas of the different cross-sectional shapes have different sizes. This can be done by a targeted material displacement in the longitudinal direction, for example by compressing or stretching, during flat pressing.
  • a further advantageous embodiment of the invention is that the second section is formed with a defined length and that the second cross-sectional shape changes over the defined length of the second section.
  • a conical progression or a narrowing can be provided in the second section along the longitudinal direction.
  • a material displacement is effected not only in a transverse direction of the wire, but also a targeted material displacement in a longitudinal direction.
  • the press tools are to be provided with a correspondingly designed receiving space with a defined receiving volume and contouring for forming the flat conductor.
  • a longitudinal displacement and distribution of the material can already take place in the preceding bending step, stretching or compressing the starting wire in sections to produce a desired distribution of material at the points at which a corresponding change in cross section is then provided in the finished flat conductor.
  • the flat conductor After the flat conductor has been formed, it can optionally be processed further, for example by making fastening holes or by giving the free end sections a special design. According to a further development of the invention, it is particularly advantageous that at least one preferably two or more connecting mandrels are formed.
  • the connecting mandrels can be designed as cylindrical or angular mandrels.
  • the connecting mandrels can be formed by stamping or by machining. According to one embodiment variant of the invention, it is particularly gentle on the material if the at least one connecting mandrel is formed without cutting.
  • the connecting mandrel which is designed with a significantly smaller cross-sectional area than the adjoining flat conductor section, can be formed without cutting by longitudinal displacement of the material during the flat pressing process. In this way, material waste can be avoided, which is a considerable advantage, particularly when expensive metals and metal alloys are used.
  • a further expedient configuration of the flat conductor is achieved in that the second section is designed to accommodate a sealing ring, in particular an O-ring seal.
  • This second section which is shaped in particular as a cylinder, can be provided for the sealing ring in particular where the flat conductor is passed through a housing or another component.
  • the provision of a relatively inexpensive O-ring seal allows the flat conductor to be spaced apart from the adjacent component and a liquid-tight and/or gas-tight seal between the flat conductor and the surrounding component to be achieved with such a passage.
  • An annular groove may be formed in the section for secure positioning and receipt of the O-ring.
  • the flexible sealing rings can also easily be pushed over a partially larger section with a flat cross-sectional shape onto the preferably cylindrical second section for receiving the sealing ring.
  • the flat conductor can be arranged in a sealed manner in a closed housing, with the flat conductor then being able to emerge from the housing at two points.
  • the housing can in particular be a housing for connecting various electrical components, which are electrically connected to the flat conductor in the housing, protected from the external environment. This allows Avoid short circuits on the electrical connections caused by splashing water or dirt.
  • the invention is characterized in that the flat conductor is formed with at least two first sections with a first flat cross-sectional shape and at least one intermediate second section with a second cross-sectional shape that differs from the first flat cross-sectional shape.
  • the flat conductor according to the invention can be produced in particular by one of the methods described above. In this way, the advantages described above can be achieved with the flat conductor.
  • the flat conductor is preferably made from an electrically conductive metal or a metal alloy, in particular from copper or a copper alloy.
  • a possible process sequence for producing a flat conductor 20 from a wire 10 is shown in eight work steps.
  • a first step OP1 one end of the wire 10 is bent approximately at right angles by bending.
  • a second step OP2 the wire 10 is further bent to form an intermediate shape 16.
  • a further number of bends can be made on the wire 10 in one plane or in space.
  • the intermediate form 16 is then flattened in process steps OP3 and OP4, wherein a circular cross-section of the wire 10 is flattened.
  • two first sections 30 are formed at the end regions, which have a flat cross-sectional shape 32 .
  • a second section 40 with a gradual reduction in cross section is formed between the two first sections 30, it being possible for the cross section reduction to have a second cross section.
  • Two connecting mandrels 26 can be formed on an end section of the flat conductor 20 in two further steps OP5 and OP6.
  • the connecting mandrels 26 can either be formed in a material-protruding manner, for example by notching a central region between the two connecting mandrels 26, or without cutting by shifting the material in the longitudinal direction.
  • the flat conductor 20 can be end-formed, with an end section of the flat conductor 20, which in particular lies opposite the connecting spikes 26, being folded upwards approximately at right angles.
  • the entire process can be carried out on a press with a so-called transfer tool, one process step being carried out with each press stroke.
  • the workpiece can be transferred from one tool to the next by means of a corresponding transfer device, so that the flat conductor 20 can be produced efficiently from a wire 10.
  • the wire 10 can be unwound from a wire spool and cut to length, with the cutting to length also being able to be carried out on a press.
  • FIG. 2a to 2c Another possible embodiment of a flat conductor 20 according to the invention is shown with two first sections 30 with a rectangular cross section 34 at the end regions. A second section 40 with a cylindrical outer contour or a circular cross-sectional shape 42 is formed between the two first sections 30 .
  • the flat conductor 20 according to the Figures 2a to 2c be made in a manner similar to that described in 1 is shown.
  • the rod-shaped connecting mandrels 26 can be formed.
  • the flat conductor 20 can be designed in almost any spatial manner, with the individual sections 30, 40 being able to be provided with any desired cross-sections.
  • FIG 3 shows a further embodiment of a flat conductor 20 according to the invention or at least part of a flat conductor 20 according to the invention with two first sections 30 and a second section 40 arranged between them.
  • the first sections 30 are designed with a flat cross-sectional shape 32 and in particular with a first rectangular cross-section 34 .
  • the rectangular cross section 34 has a height H and a width B.
  • the rectangular shape can be the same or different in the two first sections 30 .
  • the second section 40 with a circular cross-sectional shape 42 is formed between the two first sections 30 with a flat cross-sectional shape 32 .
  • the diameter of the cylindrical second section 40 is greater than the height H and smaller than the width B of the first rectangular cross section 34.
  • the shape extends from the first rectangular cross section 34 via a transfer section 38 to the second section 40 with the circular cross-sectional shape 42.
  • An annular groove 48 for accommodating a sealing ring, in particular a so-called O-ring, can be introduced into the cylindrical second section 40 .
  • the introduction of the annular groove 48 can preferably also be done without cutting on the press in one of the press cuts.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Insulated Conductors (AREA)
EP21215633.5A 2021-12-17 2021-12-17 Procédé de fabrication d'un conducteur plat Pending EP4199273A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP21215633.5A EP4199273A1 (fr) 2021-12-17 2021-12-17 Procédé de fabrication d'un conducteur plat

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP21215633.5A EP4199273A1 (fr) 2021-12-17 2021-12-17 Procédé de fabrication d'un conducteur plat

Publications (1)

Publication Number Publication Date
EP4199273A1 true EP4199273A1 (fr) 2023-06-21

Family

ID=78957197

Family Applications (1)

Application Number Title Priority Date Filing Date
EP21215633.5A Pending EP4199273A1 (fr) 2021-12-17 2021-12-17 Procédé de fabrication d'un conducteur plat

Country Status (1)

Country Link
EP (1) EP4199273A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102024107752A1 (de) * 2024-03-19 2025-09-25 Schaeffler Technologies AG & Co. KG Herstellungsverfahren für einen elektrischen Hochvoltkontakt

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7530843B1 (en) * 2008-03-19 2009-05-12 Yazaki North America, Inc. Sealed electrical terminal
JP2010176893A (ja) * 2009-01-27 2010-08-12 Panasonic Electric Works Co Ltd 配線器具用導電部品の製造方法
JP2014090623A (ja) * 2012-10-31 2014-05-15 Saijo Inx Co Ltd バスバー材料及びその曲げ加工用治具
DE202016100869U1 (de) * 2015-10-28 2016-03-04 Eugen Forschner Gmbh Vorrichtung zum Verbinden von elektrischen Bauteilen mit einer Stromversorgung
EP3639945A1 (fr) 2018-10-17 2020-04-22 Volkswagen Aktiengesellschaft Procédé de fabrication d'un conducteur plat métallique à trois dimensions à partir d'un fil métallique rond

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7530843B1 (en) * 2008-03-19 2009-05-12 Yazaki North America, Inc. Sealed electrical terminal
JP2010176893A (ja) * 2009-01-27 2010-08-12 Panasonic Electric Works Co Ltd 配線器具用導電部品の製造方法
JP2014090623A (ja) * 2012-10-31 2014-05-15 Saijo Inx Co Ltd バスバー材料及びその曲げ加工用治具
DE202016100869U1 (de) * 2015-10-28 2016-03-04 Eugen Forschner Gmbh Vorrichtung zum Verbinden von elektrischen Bauteilen mit einer Stromversorgung
EP3639945A1 (fr) 2018-10-17 2020-04-22 Volkswagen Aktiengesellschaft Procédé de fabrication d'un conducteur plat métallique à trois dimensions à partir d'un fil métallique rond

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102024107752A1 (de) * 2024-03-19 2025-09-25 Schaeffler Technologies AG & Co. KG Herstellungsverfahren für einen elektrischen Hochvoltkontakt

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