Electrical conductor assembly, method for producing an electrical conductor assembly

Abstract

An electrical conductor assembly (100) is shown comprising a wire section (20) having a plurality of conductive wires (21) made of a first electrically conductive material, and a contact section (30) in which the conductive wires (21) are pressed to form a contact unit (31), wherein the electrical conductor assembly (100) comprises a layer (40) made of a second electrically conductive material on a contact surface (32) of the contact unit (31). Furthermore, the present document discloses a method comprising a pressing step in which a plurality of conductive wires (21) made of a first electrically conductive material are partially pressed to form a contact unit (31), wherein the method comprises a step of attaching a layer (40) made of a second electrically conductive material to a contact surface (32) of the contact unit (31).

Description

Technical Field

[0001] This invention relates to electrical conductor assemblies and methods for producing electrical conductor assemblies. Background Technology

[0002] For example, a known electrical conductor assembly includes a wire segment and a contact segment. The wire segment has multiple wires made of a first conductive material, and in the contact segment, the wires are pressed together to form contact units. These contact units allow for easy connection to other components. This pressing can be accomplished, for example, by ultrasonic welding.

[0003] The disadvantage of this type of conductor assembly is that the contact unit is typically only associated with high contact resistance. Summary of the Invention

[0004] The purpose of this invention is to provide a solution that allows for contact with low contact resistance.

[0005] According to the present invention, this is achieved when the electrical conductor assembly has a layer made of a second conductive material on the contact surface of the contact unit.

[0006] This method is achieved because it includes the step of attaching or applying a second conductive material layer to the contact surface of the contact unit.

[0007] This layer can reduce contact resistance.

[0008] The invention can be further improved through the following developments and configurations, which are advantageous in themselves and can be arbitrarily combined with each other. These further developments and configurations can also be independent of the layered solution and represent their own invention.

[0009] To achieve a high degree of flexibility, the conductors can be separated within the wire segments. Specifically, they cannot be connected to each other in a form-fitting manner. The conductors within the wire segments do not need to be compressed.

[0010] Pressing should be understood specifically as establishing a connection between individual conductors in a form-fit manner. The gap between the conductors is reduced or almost zero. This can be accomplished, for example, by ultrasonic welding or melting. The conductors can be shaped into the desired form by mechanical pressure. The pressed contact unit can be composed primarily of conductive material and has few or no cavities.

[0011] The layer can be integrally attached to the contact unit or the rest of the contact unit to achieve particularly reliable contact. The layer can be attached to the rest of the contact unit, for example, in a form-fit manner.

[0012] The layer can be welded to the contact unit or the rest of the contact unit to achieve a particularly tight connection.

[0013] Layers can be attached to the contact unit or the rest of the contact unit by pressing. Specifically, during the pressing step of manufacturing the contact unit, layers can be attached to the rest of the contact unit. This can reduce the number of manufacturing steps.

[0014] In an advantageous configuration, the contact unit may include a through-hole. This through-hole facilitates attachment to a mating element. For this purpose, an attachment element, such as a screw, can be inserted through the through-hole. The attachment element can then apply force along the direction of the through-hole. For example, the head of a screw can apply force to the contact unit and press it against the mating contact element.

[0015] The conductors in the line segment can extend along the longitudinal direction, and the through-holes can extend perpendicular to the longitudinal direction. Due to the vertical arrangement, the attachment can be particularly strong because the attachment force will not cause the conductors to deform along the longitudinal direction.

[0016] In a further advantageous configuration, through-holes can penetrate the contact surface. This allows the force applied by the attachment element to act directly on the contact surface, thus significantly improving electrical contact.

[0017] The conductors in the line segment can be braided together. Individual conductors can be braided together, or they can be bundled together and then braided together. Braiding results in a structure that, firstly, provides a degree of stability, but secondly, also allows for desired flexibility.

[0018] In an alternative configuration, the conductors can extend parallel to each other within the line segments. This increases flexibility.

[0019] Other constructions of the conductors within the line segment are also possible. For example, the conductors may extend in a disordered manner or may be intertwined.

[0020] The contact element can be constructed in a plate shape. This allows for reliable contact while maintaining a compact construction. A plate shape can specifically mean that the contact element is approximately cuboid, where the extension in one direction is significantly smaller than the extensions in the two directions perpendicular to that direction, for example, by a factor of three.

[0021] In a particularly mechanically stable embodiment, the wires can extend continuously around the through-hole. Specifically, all the wires can extend around the through-hole. As a result, no wire is cut off by the through-hole. This through-hole can be obtained by keeping it open during the pressing process using appropriate elements (e.g., punches). Before pressing, elements can be inserted between the wires to laterally displace them.

[0022] In an alternative configuration, through-holes can be formed after the pressing step, for example, by drilling or by another method of removing material.

[0023] The layer can be part of a stabilizing sleeve that at least partially surrounds the contact unit. Such a layer can then serve a dual function, as it facilitates contact and contributes to the stabilization of the contact unit. The stabilizing sleeve can be at least partially attached to the contact unit in a form-fit manner. In other configurations, the stabilizing sleeve is separate and can be detached from the contact unit.

[0024] The stabilizing sleeve may surround or engage around the contact unit on at least two oppositely positioned sides. This prevents the contact unit from expanding on the oppositely positioned sides, as may occur under mechanical loads, such as during pressing, attachment, or contact.

[0025] According to an advantageous configuration, the electrical conductor assembly may include a guide member for attaching elements. The guide member can define the desired orientation of the attach element. Furthermore, the guide member can have smooth walls, which allows for easy guidance of the attach element. Conversely, without a guide member, inserting the attach element into a through-hole would be more difficult because the sidewalls of the through-hole would have a rough structure due to the pressed wire. Additionally, the gap between the attach element and the contact unit can be bridged by the guide member, enabling force flow between them.

[0026] The guiding member can be a sleeve or include a sleeve. In particular, the sleeve can be configured as cylindrical, especially cylindrical.

[0027] The guide member can be arranged in the through hole.

[0028] To keep the structure simple, the guiding component can be integrally formed with the stabilizing sleeve.

[0029] In a further advantageous construction, the guiding member can be integrally formed with the layer. The structure in that case is also very simple.

[0030] To increase safety, the conductor assembly may include a touch shield made of an electrically insulating material that at least partially surrounds the contact section.

[0031] In the online section, the cable sheath can be arranged around multiple conductors to prevent contact. The cable sheath and touch guards can work together to continuously prevent contact. Contact surfaces in the unassembled state can remain open. In the assembled state, contact surfaces can abut against corresponding mating contact surfaces, and the conductor assembly can have touch guards on all sides, which are in particular closed on all sides.

[0032] According to an advantageous configuration, the touch protector can at least partially surround the stabilizing sleeve. The touch protector can abut against and / or support the stabilizing sleeve. As a result, the conductor assembly can be further stabilized. In particular, the touch protector can be part of a stabilizing assembly that includes the stabilizing sleeve.

[0033] The invention also includes an electrical contact assembly comprising an electrical conductor assembly according to the invention and a mating contact element, wherein a layer of the electrical conductor assembly abuts against a mating contact surface of the mating contact element.

[0034] In the connected state, the layers can be respectively disposed in the remaining part of the contact unit or between the contact unit and the mating contact element.

[0035] Electrical contact components can advantageously be attached to mating contact elements via removable attachment elements. The attachment element can be a screw. Furthermore, the attachment element can be provided with touch protection elements, such as touch protection caps.

[0036] In an advantageous configuration of this method, individual elements can be arranged adjacent to multiple wires prior to the pressing step, and during the pressing step, the individual elements can be attached at least partially as layers. The individual elements can be films, plates, sheets, or elements formed from films, plates, or sheets. Attached Figure Description

[0037] In the following description, the invention will be explained in more detail by way of example, with reference to the accompanying drawings and based on advantageous configurations. The advantageous further developments and configurations shown therein are independent of each other and can be arbitrarily combined with each other as needed for the application.

[0038] in,

[0039] Figure 1 A schematic side cross-sectional view of an embodiment of a contact assembly having a conductor component is shown;

[0040] Figure 2 It shows Figure 1 A schematic perspective view of the conductor assembly;

[0041] Figure 3 Showing from Figure 1 and Figure 2 A schematic partial cross-sectional perspective view of the conductor assembly;

[0042] Figure 4 It shows Figures 1 to 3 A schematic cross-sectional view of the conductor assembly;

[0043] Figure 5 It shows Figures 1 to 4 A schematic partial cross-sectional perspective view of the conductor assembly;

[0044] Figure 6 A schematic perspective view showing another embodiment of the conductor assembly is shown;

[0045] Figures 7A to 7D A schematic perspective view showing further embodiments of the conductor assembly; and

[0046] Figure 8 A schematic perspective view of another embodiment of the contact component is shown. Detailed Implementation

[0047] The accompanying drawings illustrate various configurations of the electrical conductor assembly 100. The electrical conductor assembly 100 includes corresponding wire segments 20 in which multiple conductors 21 made of a first conductive material are present. For example, the conductors 21 can be combined to form different bundles 23, and the bundles 23 can be braided together. This provides good stability while maintaining flexibility. For example, they can be braided together in a flat or tubular manner. In other configurations, the conductors 21 may also extend parallel to each other or be braided together individually. For example, copper or a copper-containing material can be used as the first conductive material.

[0048] In the contact section 30 of the electrical conductor assembly 100, the wire 21 is pressed to form a contact unit 31. Thus, the wire 21 is formed there as a compact component, for example, in the form of a plate 39. This contact unit 31 can be easily connected to other elements, such as mating contact elements 210. For this purpose, contact surfaces 32, such as mating contact surfaces 212, can contact the mating contact elements 210. Pressing can be achieved in various ways, such as by pressing and welding, particularly cold welding such as ultrasonic welding, or by melting. By applying mechanical pressure simultaneously, the wire 21 can be shaped into a desired form.

[0049] A layer 40 made of a second conductive material is disposed on the contact surface 32 to maintain the lowest possible contact resistance when contacting the mating contact element 210. Layer 40 may be integrally formed with the rest of the contact unit 31 and may be arranged as a separate element, for example, adjacent to multiple wires 21, prior to the pressing step, and attached as layer 40 during the pressing step. In the attached state, layer 40 may form the contact surface 32. In other configurations, layer 40 is separate from the contact unit 31.

[0050] Materials that can be used for layer 40 are particularly those that reduce contact resistance or prevent oxidation. These can be, in particular, tin, zinc, silver, gold, or mixtures of these materials. Layer 40 may also contain copper.

[0051] The conductor assembly 100 may be part of the cable 80. The inner conductor 81 of the cable 80 may partially form the wire segment 20. The cable 80 may also include an insulation layer 82 on the inner conductor 81, an outer conductor 83 disposed thereon, and an outer cable sheath 85. The outer conductor 83 may serve as a grounding element or a shielding element.

[0052] The contact unit 31 has a through-hole 35 extending along a channel direction D that passes through the contact unit 31 and, in particular, through the contact surface 32. The channel direction D is perpendicular to the longitudinal direction L, along which the wire 21 extends in the line segment 20. Furthermore, both the channel direction D and the longitudinal direction L are perpendicular to the transverse direction Q. Therefore, the wire 21 is not cut off by the through-hole 35, but rather extends around it. This can be achieved during production by inserting a corresponding tool between the wires 21 before or during the pressing step, which is then removed after pressing. Such a tool may have, for example, a tapered tip to facilitate the insertion of multiple wires 21.

[0053] In the pressing step, the tool is positioned in the section between the conductors 21, and it can have a cylindrical, for example, cross-section. As a result, a cylindrical through-hole 35 can be created, which allows attachment in various rotational positions. In order to also allow the electrical conductor assembly 100 to be attached in certain defined directions, the through-hole 35 and the corresponding tool can have different cross-sections, such as rectangular, square, or triangular cross-sections.

[0054] The electrical conductor assembly 100 may include a stabilizing sleeve 50 for a stabilizing contact unit 31. The stabilizing sleeve 50 may at least partially surround the contact unit 31, thereby forming a counter-support that reduces or prevents outward deformation, for example, during pressing, during attachment, or during contact. In particular, the stabilizing sleeve 50 may surround or encircle the contact unit 31 on at least two oppositely disposed sides 51, 52.

[0055] In the example shown, the two sides 51, 52 are arranged at different ends of the contact unit 31 relative to the lateral direction Q. Measured in the channel direction D, the stabilizing sleeve 50 extends almost along the entire height of the contact unit 31. The stabilizing sleeve 50 may also surround the contact unit 31 on other sides, such as the front side. If the front wall 58 connects the side walls 56, 57 arranged on the sides 51 and 52 to each other, the front wall 58 can have an additional reinforcing effect.

[0056] The stabilizing sleeve 50 can be formed into a receiving portion for the contact section and can be configured in the shape of, for example, a channel, groove, or trench.

[0057] Layer 40 is advantageously part of the stabilizing sleeve 50. It is formed on or at the base of the contact surface 32.

[0058] The stabilizing sleeve 50 can be made of a metal sheet 59, for example by stamping and bending. This component can even be attached to the wire 21 before the pressing step, or it can already be used for stabilization during the pressing process.

[0059] The electrical conductor assembly 100 may also include a guide member 60 for guiding the attachment element 90. The guide member 60 can provide a smooth surface for easy insertion of the attachment element 90. In the example shown, the guide member 60 is configured as a sleeve 61. The sleeve 61 is disposed in the through-hole 35. Furthermore, the sleeve 61 is integrally formed with the layer 40 and the stabilizing sleeve 50. In this example, the sleeve 61 is configured as a cylinder, wherein the axis of the cylinder extends parallel to the channel direction D.

[0060] The sleeve 61, together with the stabilizing sleeve 50, can further stabilize the contact section 30. The contact unit 31 can be held and stabilized, in particular, between the sleeve 61, the front wall 58, and the side walls 56, 57.

[0061] To prevent accidental contact with conductive parts by a user, the electrical conductor assembly 100 may include a touch guard 70 that at least partially surrounds the contact section 30. It is made of an electrically insulating material, such as plastic. In the inline section 20, electrical insulation is provided by a cable sheath 85, which typically extends to the touch guard 70, and then the cable sheath 85 is seamlessly connected to the touch guard 70. This prevents user contact.

[0062] Touch protection element 70 may be part of touch protection assembly 75, which, in addition to touch protection element 70, includes touch protection caps 93 and 97 on screw 91, which serves as attachment element 90. Touch protection caps 93 and 97 are attached to screw head 92 or one end of screw 91 and surround screw 91 there.

[0063] When the electrical conductor assembly 100 is connected to the corresponding mating contact element 210, the touch protection assembly 75 forms a full-enclosure protection to prevent unwanted contact by the user. In the non-connected state, only the contact surface 32 is exposed and can make electrical contact with the mating contact element 210.

[0064] Screw 91 is removable. The external thread 96 of screw 91 interacts with the internal thread 216 arranged in the through hole 215 of mating contact element 210.

[0065] The mating contact element 210 can be electrically connected to the bus 220, or it can be part of the bus 220.

[0066] The touch guard 70 surrounds a portion of the stabilizing sleeve 50, thus forming part of the stabilizing assembly 55 that further stabilizes the contact unit 31. There, the sidewalls 76, 77 of the touch guard 70 abut against and support the sidewalls 56, 57 of the stabilizing sleeve 50 outwards. Unlike the stabilizing sleeve 50, where the sidewalls 56, 57 are connected on the lower side, the sidewalls 76, 77 of the touch guard 70 are connected on the upper side. The stabilizing assembly 55, including the touch guard 70 and the stabilizing sleeve 50, thus surrounds the contact unit 31 on all sides, particularly along the circumference, thereby achieving a high level of stability.

[0067] Figure 6 The pressed contact unit 31 is shown. The contact unit 31 forms a cuboid plate 39, the size of which in the channel direction D is significantly smaller than its size in the longitudinal direction L and the transverse direction Q, at least a factor of 10 in the example shown. Other shapes and dimensions are of course possible.

[0068] exist Figures 7A to 7D Various configurations are shown, in which certain elements may or may not be present. For example, in accordance with... Figure 7A In one embodiment, a touch protection element 70 is present that is not present in other configurations.

[0069] according to Figures 7A to 7C Each configuration includes a guide member 60 in the form of a sleeve 61 in a through-hole 35, and it is based on... Figure 7D It is not present in the configuration.

[0070] According to Figure 7C In the configuration, there is no attachment element 90, but according to Figure 7A , 7B In the embodiment of 7D, it exists in the form of a screw. This attachment element 90 may also exist on the mating contact element 210, or the attachment may be implemented in different ways.

[0071] The configuration without layer 40 is also possible. Other aspects, such as stabilizing sleeve 50, touch protection 70, or guiding member 60, can represent independent inventions.

[0072] Figure 8 A configuration in which two electrical conductor assemblies 100 form a contact assembly 200 is shown. Each electrical conductor assembly 100 can be considered as a mating contact element 210 of the other electrical conductor assembly 100. At least one of the electrical conductor assemblies 100 includes a layer 40 for reducing contact resistance. The two electrical conductor assemblies 100 can be attached to each other by an attachment element 90, which is, for example, in the form of a screw 91 having a nut 94.

[0073] Figure Labels

[0074] 20-line section

[0075] 21 conductors

[0076] 23 bundles

[0077] 30 contact section

[0078] 31 contact units

[0079] 32 contact surfaces

[0080] 35 through hole

[0081] 39 boards

[0082] 40 floors

[0083] 50 stable bushing

[0084] 51 First side

[0085] 52 Second side

[0086] 55 Stable Components

[0087] 56 sidewalls

[0088] 57 sidewalls

[0089] 58 Anterior Wall

[0090] 59 metal sheet

[0091] 60 guiding components

[0092] 61 casings

[0093] 70 Touch Protection

[0094] 75 Touch Protection Components

[0095] 80 cable

[0096] 81 Inner Conductor

[0097] 82 insulation layers

[0098] 83 outer conductor

[0099] 85 cable sheath

[0100] 90 Attachment Components

[0101] 91 screws

[0102] 92 screw head

[0103] 93 Touch Protective Cap

[0104] 94 nuts

[0105] 96 external thread

[0106] 97 Touch Protective Cap

[0107] 100 electrical conductor assembly

[0108] 200 contact components

[0109] 210 mating contact element

[0110] 212 mating contact surface

[0111] 215 through hole

[0112] 216 internal thread

[0113] 220 power rail

[0114] D-channel direction

[0115] L longitudinal direction

[0116] Q horizontal direction

Claims

1. An electrical conductor assembly (100) comprising a wire segment (20) and a contact segment (30), the wire segment (20) having a plurality of wires (21) made of a first conductive material, wherein the wires (21) are pressed in the contact segment (30) to form contact units (31), wherein, The electrical conductor assembly (100) includes a layer (40) made of a second conductive material on the contact surface (32) of the contact unit (31), the layer (40) being part of a stabilizing sleeve (50) that at least partially surrounds the contact unit (31), the stabilizing sleeve (50) being configured to stabilize the contact unit (31) and form a counter-support to reduce or prevent outward deformation of the contact unit (31), the stabilizing sleeve (50) surrounding or engaging the contact unit (31) on at least two opposing sides (51, 52), the two opposing sides (51, 52) being arranged relative to a lateral direction perpendicular to the extension direction of the plurality of wires (21).

2. The electrical conductor assembly (100) according to claim 1, wherein, The layer (40) is integrally connected to the rest of the contact unit (31).

3. The electrical conductor assembly (100) according to claim 1 or 2, wherein, The contact unit (31) includes a through hole (35).

4. The electrical conductor assembly (100) according to claim 3, wherein, The conductor (21) extends continuously around the through hole (35).

5. The electrical conductor assembly (100) according to claim 3, wherein, The electrical conductor assembly (100) includes a guide member (60) for attaching the element (90).

6. The electrical conductor assembly (100) according to claim 5, wherein, The guide member (60) is integrally formed with the stabilizing sleeve (50).

7. The electrical conductor assembly (100) according to claim 5, wherein, The guide member (60) is arranged in the through hole (35).

8. The electrical conductor assembly (100) according to claim 1 or 2, wherein, The electrical conductor assembly (100) includes a touch protector (70) made of an electrically insulating material, which at least partially surrounds the contact segment (30).

9. The electrical conductor assembly (100) according to claim 8, wherein, The touch protection element (70) at least partially surrounds the stabilizing sleeve (50).

10. An electrical contact assembly (200) comprising an electrical conductor assembly (100) according to any one of claims 1 to 9 and a mating contact element (210), wherein, The layer (40) of the electrical conductor assembly (100) abuts against the mating contact surface (212) of the mating contact element (210).

11. The electrical contact assembly (200) according to claim 10, wherein, The electrical conductor assembly (100) is attached to the mating contact element (210) via a removable attachment element (90).

12. A method for pressing an electrical conductor assembly (100) according to any one of claims 1 to 9, the method comprising a pressing step in which a plurality of wires (21) made of a first conductive material are partially pressed to form contact units (31), wherein, The method includes the step of attaching or applying a layer (40) made of a second conductive material to or onto the contact surface (32) of the contact unit (31).

13. The method according to claim 12, wherein, Prior to the pressing step, individual elements are arranged adjacent to the plurality of wires (21), and during the pressing step, the individual elements are attached at least partially as the layer (40).

14. The method according to claim 12 or 13, wherein, During the pressing step, the through holes (35) between the wires (21) remain open.

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