WO2011029717A1 - Conductor connector for electrically connecting at least two electrical conductors and method for electrically connecting two electrical conductors - Google Patents

Abstract

The present invention relates to connecting two electrical conductors made of different metals or different metal alloys, for which purpose a conductor connector is provided, the connector body thereof being a plated sheet metal part having two outer coatings, the materials of which are selected to correspond to the material of the electrical conductors to be connected, thereby ensuring a homogeneous connection between the electrical conductor and the connector body and preventing the problem of electrochemical corrosion.

Description

 LINEAR CONNECTOR FOR ELECTRICAL CONNECTION AT LEAST TWO ELECTRICAL CONDUCTORS AND METHOD FOR ELECTRIC CONNECTION OF TWO ELECTRICAL CONDUCTORS

The present invention bet rifft the connection of two elec tric ladder made of different metals or

 Alloys. In particular, the present invention is concerned with a line connector and a method for

 elec- tical connection of two such electrical conductors and an elec- trical line, in which two electrical conductors are connected via a line connector.

A line connector with the features in the preamble of claim 1 is known in the art and shown in Figure 1.

The lead connector includes a connector body 106 that includes at opposite ends a first sleeve 106a and a second sleeve 106b. The sleeves 106a, 106b are connected by a web 106c at a distance from each other. Of the

 Connecting body 106 is formed of brass and

 completely nickel plated. For connecting a first line of aluminum and a second line of copper, the aluminum line is welded by plasma welding the front side in the first sleeve 106a. The copper wire is

 however, crimped in the second sleeve 106b.

Has problematic in such a line connectors and the associated method for connecting the

 elec tric lines exposed to each other that the use of brass as a material for the line connector leads to an expensive component and beyond

different processing methods for connecting the two lines to the line connector must be used (plasma welding and crimping). In addition, during the welding process, the electrochemical corrosion under Influence of a Elekt rolyten proved problematic, which, inter alia, the compound of various types

Materials results. Furthermore, the second sleeve 106b cracks during crimping. In order to reduce cracking, the cable cross-section of the copper line in the region of the crimp has a small tolerance range, whereby the line connector can only be used for a specific application.

Finally, brass has a comparatively high

electric resistance.

The object of the present invention is therefore to provide a cable connector and a method for electrically connecting two electrical conductors of different metals or alloys, which reduce or eliminate the problem of electrochemical corrosion.

This object is achieved by a line connector with the features of claim 1 and a method with the

Characteristics of claim 10 solved. advantageous

Embodiments of the present invention can be found in the subclaims.

The present invention is based on the idea of constructing the line connector from a (preferably only) two-layered sheet, the materials of the layers being respectively predetermined by the material of the electrical conductor to be connected to the respective layer or

These correspond, so that a pure connection between elec tric line and the respective layer of the line connector is possible.

Accordingly, the line connector for

Electrically connecting at least one first electrical conductor made of a first metal or a first alloy and at least one second electrical conductor made of a second metal and a second alloy

Connecting body with which the first and second electrical conductors are to be connected. This is inventively characterized in that it comprises a sheet, in particular a plat tated sheet having a first outer layer and a second outer layer. Preferably, the sheet consists of only these two layers. The first layer is formed from the first metal or the first alloy and the second outer layer from the second metal or the second alloy. Preferably, the material is selected from the first and the second layer so that the material is identical to that of the first electrical conductor and the second electrical conductor, which are to be connected to each of the first and second outer layer. Through this

Design, it is possible to contain the elekt rochemical corrosion or even rule out, especially if the electrical conductors with the outer layers to

are welded.

According to a particularly preferred embodiment, the connecting body is a roll-coated sheet in which on a base material, which forms one of the outer layers, another ^' material (plating material) in a

Rolling process is plated, wherein the plated material forms the other outer layer. This is

especially useful if the formation of

Oxide layers on one or the other layer can lead to increased resistance of the compound and possibly consuming to remove chemically or mechanically and to prevent the re-formation of this oxide layer. In a roll-plating process, the two

Material layers substantially without inclusions of air or oxygen, ie gas-tight, are interconnected. During the rolling process, no oxide layer _{f is formed} so that the resistance in the joint between the two layers does not change as a result of the rolling process. Preferably, it is in the

Base material around an aluminum sheet, which with copper or another material (plating material) is plated {see also below).

Particularly preferred is the above variant, when the first outer layer of aluminum or a

Aluminum alloy and the second outer layer of a different material, eg. As copper or a copper alloy is formed. Especially with aluminum pipes, the high resistance of the oxide layer and the effort required to remove them chemically or mechanically and to prevent the re-formation is a problem. The choice of aluminum or aluminum alloy and z. As copper or a copper alloy also leads to the

Line connector compared to the production of brass is significantly cheaper. In addition, in the case of an Al / Cu composite, a significantly lower electrical resistance than brass is achievable.

In particular, an axial line course of the

To ensure the resulting electrical line of line connector and the elec tric ladders, it is preferred according to an embodiment that the connecting body

at least over a partial length of a preferably twisted by about 180 ° torsion about its longitudinal axis. Thereby, one end of the line connector for connection to the first line may point in the same direction as the one

opposite end to connect with the other

electrical conductor. Another advantage of the twisted twist is that angular departures in almost all directions and without additional parts is possible only by rotating the sheet in the region of the twist or the helix, so that the line connector can be used very variable.

Ie. the electrical conductors may be flush with each other or connected at an angle to each other outgoing. Furthermore, the line connector as well Potential distributors are used, including the electrical lines, in particular copper and aluminum cables are welded to the respective outer layer.

Alternatively, it is also conceivable that the connecting body between its respective ends, which serve the connection with the respective elec- trical ladders, at least in a partial length has a gradation or bending, the

equally ensures an axial line course. According to a preferred embodiment, this step is formed in a section in the longitudinal direction between the ends of the line connector Z- or S-shaped.

The line connector is regardless of the design, preferably in the form of St ripe or other shapes cut or punched. The deformation or bending to form the gradation and / or twisting can during or after the. Punching or cutting process done. Furthermore, other transformations can take place, such as. B, the formation of cup-shaped receptacles for the electrical conductors or similar.

An electrical lead according to the present invention comprises first and second electrical conductors as described above, respectively connected to the first and second outer layers. This connection preferably takes place via the same

Connection method and ^' in particular a welding method, particularly preferably an ultrasonic welding method. As a result, different processing methods for connecting the electrical conductors to the line connector can be avoided and thus the method can be optimized. In the event that the connection point comes into contact with an electrolyte, it is preferred that the weld is opposite the

Seal electrolytes with a gasket. According to a particularly preferred embodiment, this can be achieved by a Klebsrumpfschlauch done. But there are also other isolation options conceivable.

In addition to the line connector described above betages the present invention consequently also an elec- tric line from at least two elec- tric ladders

different material and such

Cable connector and a method for electrically connecting two elec trical ladder.

Furthermore, those skilled in the art will further appreciate further features and advantages of the present invention which can be implemented individually and in combination with one or more of the above aspects of the following description

preferred embodiments. The description of these exemplary embodiments makes reference to the accompanying drawings, in which:

Figure 1 is a perspective view of a

Line connector of the prior art shows;

Figure 2 shows a line connector according to a first

Embodiment of the present invention and connected to two electrical conductors shows; and

3 shows a line connector according to a second

 Embodiment of the present invention and connected to two electrical conductors shows.

Figure 2 shows an electrical line with a

Line connector according to a first embodiment of the present invention.

The electrical line comprises a first electrical conductor 2 consisting of an insulation 2a, preferably made of plastic, and a strand 2b. The strand 2b, which forms the first electric ladder 2, consists in the illustrated embodiment of aluminum or a

Aluminum alloy.

Furthermore, a second elec- trical conductor 3 is provided.

This consists equally of an insulation 3a and a strand 3b. The strand 3b in this embodiment is made of copper or a copper alloy.

To connect the two elec- trical conductors 2, 3 is a line connector. The cable connector has a

Connecting body 6 on. The connecting body 6 is constructed by a metal sheet with a first outer layer 6a and a second outer layer 6b. It consists in the illustrated embodiment only of these two

Outer layers, which are in direct and surface contact with each other. On the other hand, however, it is also conceivable to provide any intermediate layers, although this is not considered to be preferred.

In the illustrated embodiment, the sheet is preferably a plated sheet and, more particularly, produced by a roll cladding method. In this case, an aluminum or aluminum alloy sheet is plated with copper or a copper alloy. The Plat tation forms the second outer layer 6b, while the aluminum or aluminum alloy sheet forms the first outer layer 6a. However, it is also conceivable to plate a copper sheet with aluminum.

To connect the elec trical conductors 2 and 3, the strand 2b of the electrical conductor 2 is connected to the first outer layer 6a, in particular welded and cold welded in particular in a Ult ultrasound welding process "The strand 3b of the elec- trical conductor 3 is connected to the second outer layer 6b and preferably in the same method as the strand 2b with the first outer layer 6a, that is, a Ultallallallschweißverfahren, Thus, the longitudinal course of electric line can be maintained, for. B. the

Central axes of the electrical ladder 2 and 3 are aligned, as indicated in Figure 2 by the axis M, the connecting body 6 has a gradation 7. The gradation 7 is between the Abschnit th or ends of

Connecting body of the respective electric

Ladders 2, 3 is connected. In the illustrated in Figure 2

Longitudinal section, the connecting body 6 has an S-shaped profile. This could also be Z-shaped with a correspondingly mirror-image arrangement.

The Walzplattierverfahren can be a gas-tight

Connection between the materials aluminum resp.

Aluminum alloy and copper or copper alloy can be achieved. By the gas-tight connection, the formation of an oxide layer on the aluminum sheet is avoided, which is not present before the rolling process. As a result, a high resistance at the joint between the layers 6a and 6b can be avoided.

In addition, by the same possible choice of material (identity) of the outer layer 6a with respect to the elec- trical conductor 2 or its strand 2b and the second outer layer 6b and the electrical conductor 3 and its strand 3b made a sorted connection, so that the problem of elekt rochemical corrosion, especially when using a welding process reduced, if not impossible. Furthermore, apart from the only Z- or S-shaped bend to maintain a longitudinal course through various bending, folding and punching possibilities of the sheet, a variable connector can be created in the variable outlets of each elec- electric ladder 2, 3 in

different directions and at an angle to each other are possible. This eliminates additional angles or distribution components. The choice of materials copper and aluminum is the

Line connector beyond the use of Brass cheaper. Also, a weight reduction can be achieved.

Finally, the connection method of the elec- trical ladder 2, 3 with the connecting body 6 are the same, z. B. a welding process, whereby the manufacturing costs are reduced overall.

As a variant of this embodiment and with the same or comparable advantages, it is also conceivable stat t the gradation 7 or additionally one

helical twist or helix or twisting 8 (Figure 3) provided, which is realized in the representation in Figure 3 as a twisting by about 180 °. Again, it is possible to maintain the longitudinal course, wherein on the side to be connected to the electrical conductor 2, the first

Outer layer 6a in the same direction as the second outer layer 6b on the side to be connected to the second electrical conductor 3. In addition, it is also conceivable here by various bending and folding as well as

Punching possibilities to create an angled arrangement of the electrical conductors to each other or a distributor.

Otherwise, the embodiment of the second embodiment in FIG. 3 does not differ from that in FIG. 2, so that reference is made to the above description

Avoid repetitions.

It should be understood that the described embodiments are to be understood as examples only of practicing the present invention. Of course, it is conceivable to use other metals or metal alloys for the elec- trical ladder than the described or other shaped bends or gradations 7 or

Tordierungen 8 to meet the corresponding requirements for the electrical line or to be connected

Electrician enough to do. In addition, it is too conceivable to choose other methods for connecting the respective electrical conductors to the connector body, but preferred is the same

 Selecting processing methods to realize the above advantages. Also, that can

 Walzplattierverfahren, especially for those materials are used, in which the formation of an oxide layer leads to a high resistance, as was explained purely by way of example with reference to the aluminum. Accordingly, a definition of the present invention can be found in the following claims.

Claims

claims A line connector for electrically connecting at least one first electrical conductor (2) made of a first metal or a first alloy and at least one second electrical conductor (3) made of a second metal or a second alloy, comprising a connector body {6) characterized in that the connecting body (6) is a metal sheet having a first outer layer (6a) which is formed to be connected to the first conductor of the first metal or the first alloy and a second outer layer (6b) to be connected to the second one Ladder is formed of the second metal or the second alloy comprises. 2. Line connector according to claim 1, characterized characterized in that the connecting body (6) a Roll-plated sheet metal is. 3. Line connector according to one of the preceding Claims, characterized in that the first Outer layer (6a) made of aluminum or an aluminum alloy and the second outer layer (6b) made of copper or a Copper alloy is formed. 4. Line connector according to one of the preceding Claims, characterized in that the connecting body (6) at least over a partial length, preferably by about 180 °, twisted torsion (8) about its longitudinal axis. 5. Cable connector according to one of the preceding Claims, characterized in that the connecting body (6) at least in a partial length a gradation (6c) or bending. 6. Cable connector according to claim 5, characterized in that the gradation (6c) is formed in a longitudinal section Z-shaped or S-shaped. 7. Elekt rische line comprising at least a first electrical conductor (2) made of a first metal or a first alloy, at least a second electrical Ladder (3) made of a second metal or a second Alloy and a line connector according to one of preceding claims, wherein the first outer layer (6a) is connected to the at least one first electrical conductor (2) and the second outer layer (6b) is connected to the at least one second electrical conductor (3). 8. Electrical line according to claim 7, characterized in that the first electrical conductor (2) is an aluminum line (2), preferably an aluminum strand, and the second electrical conductor is a copper line {3), preferably a copper strand. 9. Electrical line according to claim 8, characterized in that the first conductor (2) is made of aluminum or a first outer layer (6a) Aluminum alloy, cold-welded, preferably Rapidly cold-welded, and the second conductor (3) with the second outer layer (6b) made of copper or a Copper alloy welded, preferably Ult raschallverschweißt. 10. A method for elec trically connecting at least two electrical conductors (2,3) made of different metals or alloys, comprising providing a Connecting body (6) with a sheet having a first outer layer (6a) and a second outer layer (6b), the placing of the connecting body (6) between the electrical conductors (2,3), that the first outer layer (6a) with the at least a first electric ladder (2) and the second outer layer (6b) is in contact with the at least one second electrical conductor (3) and the electrical conductors (2,3) are connected to the respective ones Auföenschichten (6a, 6b) of the connecting body (6). 11. The method according to claim 10, characterized in that the connecting body (6) made of a plated, preferably walzplat advantage, sheet metal is produced. 12. The method according to claim 11, characterized in that that of the connecting body (6) by Walzplat animals a first outer layer (6a) made of aluminum or a Aluminum alloy having a second outer layer (6b) made of copper or a copper alloy. 13. The method according to claim 12, characterized in that at least one aluminum line (2) as a first conductor to the first outer layer (6a) connected, preferably cold-welded, and that at least one copper line (3) as a second conductor with the second outer layer ( 6b) is connected, preferably welded 14. The method according to any one of claims 10 to 13, characterized in that the connecting body (6) before the Connection with the electrical ladders (2,3) formed, preferably bent, is. 15. The method according to any one of claims 10 to 13, characterized in that the connecting body (6) before the Reshaped connection with the electrical conductors (2,3), preferably at least twisted about its longitudinal axis, is.