Crimping device, method for producing crimped connection, and composite of electrical conductor and electrical connector

Abstract

The invention relates to a crimping device (1) for crimping a crimping sleeve (2) to an electrical conductor (3), the crimping device (1) comprising a first mould (4) and a second mould (5) such that the crimping device (1) is designed for single-axis pressing, the first mould (4) having a first cross-sectional mould contour (6) and the second mould (5) having a second cross-sectional mould contour (7), the first cross-sectional mould contour (6) being designed to be substantially parallel to the first cross-sectional mould contour (6), and the second cross-sectional mould contour (7) being designed to be parallel to the second cross-sectional mould contour (7), the second cross-sectional mould contour (7) being designed to be parallel to the first cross-sectional mould contour (6). The first cross-sectional mold profile (6) and the second cross-sectional mold profile (7) together form a crimping profile (8). The aim of the invention is to provide a crimping device which has a mechanically simple design and also ensures advantageous compression, essentially in that the first cross-sectional mold contour (6) has at least one ridge (9) and the second cross-sectional mold contour (7) has at least one ridge (9), the crimping contour having at least three ridges (9).

Description

Technical Field

[0001] The present invention relates to a crimping device for crimping a crimp sleeve onto an electrical conductor, wherein the crimping device includes a first mold and a second mold, such that the crimping device is configured for uniaxial crimping, wherein the first mold has a first cross-sectional mold profile, and wherein the second mold has a second cross-sectional mold profile, wherein the first cross-sectional mold profile and the second cross-sectional mold profile together constitute a crimping profile.

[0002] Therefore, in the sense of the invention, the crimp profile is a cross-sectional profile derived from the first cross-sectional mold profile and the second cross-sectional mold profile when the first and second molds are closed. The cross-sectional mold profile is the side of the crimping device facing the crimping sleeve, which contacts the crimping sleeve during crimping.

[0003] The crimping device according to the invention can be part of a manually operated crimping pliers or a crank press, or it can be part of an electrically operated automatic crimping device, wherein the electrically operated automatic crimping device can be either semi-automatic or fully automatic.

[0004] An electrical conductor (to which a crimp sleeve is secured or crimped by means of a crimping device) may have one or more strands. A conductor with multiple strands is also called a stranded wire, while a conductor with only one strand is also called a solid conductor. Within the scope of this invention, an electrical conductor can be either a stranded wire or a solid conductor.

[0005] Furthermore, the present invention also relates to a method for establishing a crimp connection between an electrical conductor and an electrical connector, wherein the electrical connector includes a crimp sleeve.

[0006] Furthermore, the present invention also relates to a composite consisting of an electrical conductor and an electrical connector, wherein the electrical connector includes a crimp sleeve. Background Technology

[0007] Crimping (where an electrical conductor is pressed together with an electrical connector at one end to create a fixed unit) is well known in the art. In particular, different crimp geometries are known, such as quadruple-hump geometry, B-shaped crimp geometry, hexagonal crimp geometry, or WM-shaped crimp geometry.

[0008] A common drawback of the aforementioned crimp geometry is that the area of ​​the crimp sleeve located near the crimp region on the end side along the conductor direction also exhibits a lack of smoothness due to uneven compression. This can be disadvantageous because it typically requires more space in both the longitudinal and radial directions. Furthermore, the corresponding deformation may be detrimental to continued use of the composite.

[0009] In particular, the crimping contact and crimping geometry of multi-axis pressing are known from the documents WO 2022 / 073743 A1, DE10 2018 199 440 A1, EP 2 685 573 A2 and EP 3 984 702 A1. Summary of the Invention

[0010] Based on the aforementioned prior art, the object of the present invention is to provide a crimping device that is not only mechanically simple to construct but also ensures advantageous compression. Furthermore, the object of the present invention is to provide a method for establishing a crimped connection between an electrical conductor and an electrical connector, and a composite consisting of an electrical conductor and an electrical connector.

[0011] According to the first teaching of the present invention, the above-mentioned task is achieved by the crimping device having the features of claim 1 described at the beginning, wherein the first cross-sectional mold profile has at least one protrusion, and the second cross-sectional mold profile has at least one protrusion, wherein the crimping profile has at least three protrusions. According to the present invention, at least one of the two cross-sectional mold profiles has at least two protrusions.

[0012] According to the present invention, a crimping profile having at least three, preferably at least four, protrusions can be achieved using two molds, thereby achieving compression along a single axis. Therefore, the crimping device can be constructed with particular simplicity. Furthermore, the mechanically simple construction can be combined with the advantageous deformation of the conductor for connection, resulting in a particularly advantageous connection overall.

[0013] In particular, the crimp sleeve can be constructed to be shorter than usual, ensuring a reliable crimp connection. Even with a large conductor cross-section, multiple crimping points are unnecessary, resulting in shorter processing time for the user. Higher processing reliability is also achieved because multiple crimping operations are eliminated. The crimping device according to the invention is particularly suitable for crimping sleeves onto electrical conductors with large conductor cross-sections. Because the composite according to the invention is a mass-produced product, the shorter design of the crimp sleeve ensures a significant cost advantage through material savings.

[0014] According to an advantageous design, the first cross-sectional mold profile has at least two protrusions, and the second cross-sectional mold profile has at least two protrusions, such that the crimping profile has at least four protrusions. This profile ensures sufficient deformation of the electrical conductor, thereby ensuring reliable contact between the conductor and the crimping sleeve. Particularly preferred is that the four protrusions of the crimping profile are arranged at approximately 45° angles relative to the crimping direction.

[0015] According to another advantageous design, the pressing profile is constructed symmetrically with respect to a separation axis located at the connection point between the first and second molds when the second mold is placed on top of the first mold. The symmetrical design of the pressing profile determines an even number of protrusions, such as four or six protrusions. Simultaneously, the number of protrusions on the first mold corresponds to the number of protrusions on the second mold.

[0016] Similarly, it is also possible to consider a pressing profile constructed asymmetrically relative to the separation axis, which is located at the junction of the first and second molds when the second mold is placed on top of the first mold. According to this design, the number of protrusions on the first mold differs from the number of protrusions on the second mold. In particular, the total number of protrusions is odd.

[0017] According to another advantageous design of the crimping device, the first and second molds have a longitudinal axis, wherein the shape of the first cross-sectional mold profile and / or the shape of the second cross-sectional mold profile varies along the longitudinal axis. Here, at least one mold has such a cross-sectional mold profile at its end side, which, during crimping, applies less force to the crimping sleeve compared to the cross-sectional mold profile arranged at the center of the mold, preferably without causing the crimping sleeve to be crimped.

[0018] Particularly preferably, the first and second dies have a cross-sectional die profile at their ends facing the electrical conductor, which, during clamping, applies less force to the crimp sleeve compared to a cross-sectional die profile arranged at the center of the die, preferably preventing the crimp sleeve from being clamped. This design has the advantage that a region already exists at the end side of the crimping device that applies only a small force or no force to the crimp sleeve, thus maintaining the circular shape of the crimp sleeve. Particularly preferably, the crimp profile arranged at the end side corresponds to the external shape of the crimp sleeve.

[0019] The orientation of the longitudinal axis corresponds to the orientation of the longitudinal axis of the crimp sleeve when the crimp sleeve is arranged in the first mold.

[0020] According to the preferred design, the crimping device has a crimping area in which the crimping sleeve is pressed against the electrical conductor, and an exit area in which the force on the crimping sleeve is reduced, or in which no force is applied to the crimping sleeve even when the mold is closed.

[0021] According to another preferred design, in at least one die, the transition from the crimping area to the end-side cross-sectional die profile of the crimp sleeve is constructed to be continuous, rather than stepped. This design has the advantage that the stress in the conductor strands increases continuously, and the absence of steps or edges significantly reduces the risk of individual strands being sheared or otherwise damaged.

[0022] According to another design of the crimping device, the first and second dies have longitudinal axes, wherein the first and / or second dies have exit regions along the longitudinal axis and at least along the electrical conductor direction, which have sliding ramps. Due to the presence of the exit regions, the cross-section of the crimp profile increases along the electrical conductor direction. Particularly preferably, the crimp profile arranged on the end sides substantially corresponds to the external shape of the crimp sleeve.

[0023] Particularly preferred is that the export area occupies at most 1 / 3, 1 / 4, or 1 / 5 of the mold's longitudinal length.

[0024] According to one design, only at least one protrusion of the first mold and / or at least one protrusion of the second mold have a sliding ramp. According to this design, the radius of the mold profile at each end cross-section, or the radius of the end-side crimping profile, can be smaller than the radius of the outer crimping sleeve. In this case, force is still applied to the crimping sleeve at the end.

[0025] Alternatively, the radius of the mold profile or the radius of the end-side crimp profile of each end-side cross section can correspond to the radius of the external crimp sleeve.

[0026] Another advantage is that compression is achieved through the entire compression profile in the compression area, meaning compression is not limited to the dowels. In this case, the radius of the compression profile in the location where the dowels are not located is smaller than the radius of the outer compression sleeve. According to this design, the first cross-sectional mold profile and / or the second cross-sectional mold profile can have sliding ramps that extend fully along each cross-sectional mold profile.

[0027] A particular advantage is that the crimp profile is constructed to be substantially circular on the side facing the electrical conductor. This design ensures that the area of ​​the crimp sleeve facing and surrounding the conductor is circularly constructed, and in this respect, the area remains undeformed.

[0028] According to another advantageous design, the first mold and / or the second mold have two exit areas, wherein the two exit areas are respectively arranged on the first mold and / or the second mold on the end side in the direction of the electrical conductor and in the direction of the electrical connection element.

[0029] This design offers several advantages: it allows for a continuous transition of the electrical conductor into the crimp region and avoids burrs on the ends facing the electrical connection elements. Furthermore, it ensures that the crimp sleeve maintains its circular shape in both end regions, which is particularly advantageous in other applications, such as connections to other components.

[0030] According to a second teaching of the present invention, the task described at the beginning is achieved by the method described at the beginning for establishing a crimp connection between an electrical conductor and an electrical connector, wherein the method is performed using one of the crimping devices described above, and the method includes the following steps: In the preparation step: the end of the electrical conductor is introduced into the crimp sleeve, and the crimp sleeve is placed into the first mold. In the connection step: the second mold and the first mold are closed, so that the crimp sleeve and the stripped end of the conductor are pressed together in the crimping area. In the opening step: open the first mold and the second mold.

[0031] The preparation steps do not include a fixed order of the defined steps. Therefore, it is not important whether the stripped end of the electrical conductor is first introduced into the crimp sleeve or the crimp sleeve is first placed into the first mold.

[0032] This method has the advantage that it can be implemented particularly simply through uniaxial clamping, i.e., clamping along one clamping direction, while the geometry of the crimp profile enables the electrical conductor and connector to establish a favorable connection through the crimp sleeve. Here, uniaxial clamping is achieved by the opposing movement of two dies, wherein the direction of die movement can be perpendicular to the longitudinal axis of the crimp sleeve, but is not mandatory. Uniaxial clamping can also be achieved, for example, by a clamping motion in which two dies move toward each other on an arc track. This method can be performed manually, for example, with crimping pliers or a crank press, or it can be performed using an electrically automatic crimping device.

[0033] According to the third teaching of the present invention, the task described at the beginning is achieved by means of the composite consisting of the electrical conductor and the electrical connector described at the beginning, in that the crimp sleeve is pressed against the end of the electrical conductor using the crimping device and the aforementioned method.

[0034] According to an advantageous design, the electrical connector is constructed as a cable lug, a plug connector, or a wire end sleeve.

[0035] Furthermore, it is advantageous that the conductor has multiple strands, which are pressed against the crimp sleeve in the crimping region, and that there is a sloping transition region on at least one side between the crimped and non-crimped regions. This design of the composite ensures that, on the one hand, the load on the conductor strands increases only continuously, and there are no steps or edges that could damage the strands. On the other hand, the shape of the crimp sleeve can also be maintained in the non-crimped region, thus preventing uneven deformation of the sleeve outside the crimped region. The roundness of the crimp sleeve in the non-crimped region is advantageous, for example, in ensuring a specific safety level (IP safety level).

[0036] For details on the various design schemes for the composite, please refer to the descriptions of the different design schemes for the crimping device. Attached Figure Description

[0037] The crimping device according to the invention, the method according to the invention, and the composite according to the invention have various design and modification possibilities. Reference is made to the claims, which are dependent on the independent claims, and to the following embodiments in conjunction with the accompanying drawings. The drawings show: Figure 1 An embodiment of the crimping device in the open position is shown. Figure 2 An embodiment of the crimping device in the closed position is shown. Figure 3 An embodiment of the crimping device is shown in a longitudinal sectional view. Figure 4 An embodiment of a crimping device with a crimping sleeve inserted is shown. Figure 5 The longitudinal sectional view shows the results according to Figure 4 Implementation examples, Figure 6 Embodiments of the first and second molds are shown. Figure 7 Another embodiment of the crimping device is shown. Figure 8 It shows along Figure 7 Another embodiment of the cutting surface CC of the crimping device. Figure 9 An embodiment of a composite consisting of an electrical conductor and an electrical connector is shown. Figure 10 An embodiment of a method for establishing a crimped connection is shown. Detailed Implementation

[0038] Figure 1An embodiment of a crimping device 1 is shown in front view for crimping a crimping sleeve 2 onto an electrical conductor 3, and the crimping device has a first mold 4 and a second mold 5. In the illustrated embodiment, both molds 4 and 5 are open.

[0039] For crimping, conductor 3 is introduced into crimping sleeve 2 with its stripped end, and crimping sleeve 2 is placed into first mold 4. Conductor 3 preferably has multiple strands, which are stripped in the area of ​​crimping sleeve 2. Next, second mold 5 moves toward first mold 4 in the direction of the arrow until molds 4 and 5 are in direct contact with each other.

[0040] The first mold 4 has a first cross-sectional mold profile 6, and the second mold has a second cross-sectional mold profile 7, such that the first cross-sectional mold profile 6 and the second cross-sectional mold profile 7 together constitute the pressing profile 8.

[0041] During the crimping process, the individual strands of conductor 3 are squeezed and deformed in this way, causing the insulation surface to crack and thus enabling electrical contact to be established with the crimping sleeve 2. In addition, the strands (or single strands of solid conductors) of crimping sleeve 2 and conductor 3 are plastically deformed together, so that the two form a strong composite under the compressed state.

[0042] In the illustrated embodiment, the first cross-sectional mold profile 6 has two protrusions 9, and the second cross-sectional mold profile 7 also has two protrusions 9. Therefore, the crimp profile 8 has a total of four protrusions 9, which cause the electrical conductor 3 and the crimp sleeve 2 to be plastically deformed together.

[0043] In this regard, the advantage of the illustrated embodiment is that the four-convex-dot crimp profile can be applied to the conductor using a two-piece mold. Therefore, the crimping process occurs along a single axis, i.e., along the pressing direction. This has the advantage that the crimping device 1 can be constructed in a mechanically particularly simple and cost-effective manner. Furthermore, the crimping process is thus simpler to construct compared to cases using more than one axis. With the illustrated geometry, even when the conductor cross-section is large, crimping in more than one crimping region can be omitted.

[0044] Figure 2 Another view of the crimping device 1 is shown, which has a first mold 4 and a second mold 5, wherein the molds 4 and 5 are arranged opposite each other in the closed position. In this embodiment, the crimping profile 8 also has a total of four protrusions 9.

[0045] Figure 3 It shows a section cut along the defined section plane AA. Figure 2The figure shows a longitudinal sectional view of an embodiment. As can be seen from this figure, the dies 4 and 5 have an exit area 10 at their ends, in which a continuous transition from a crimping profile including four protrusions 9 to a circular crimping profile is constructed. In this way, in practice, the strands of wire compressed by the protrusions 9 can be slowly and continuously unloaded from high loads. Furthermore, damage to the strands at (non-existent) edges is avoided.

[0046] Figure 4 and Figure 5 The crimping device 1 and the crimping sleeve 2 are shown in a front view. Figure 4 ( ) is shown once, along the cross-section BB defined by the longitudinal axis 20 of the crimping device 1. Figure 5 The longitudinal cross-sectional view of the section is shown once, but the electrical conductor is not shown. The section plane BB is located exactly between the two protrusions.

[0047] Figure 5 The longitudinal sectional view shows the region of the crimp sleeve 2 with minimal deformation. The protrusions 9 are arranged on dies 4 and 5, offset approximately 45° from the intersection of axis BB and the crimp sleeve 2. At the conductor-facing ends of dies 4 and 5, it can be seen that dies 4 and 5 have exit regions 10 through which the crimp profile 8 continuously transitions into a circular cross-section. In the illustrated embodiment, the exit region 10 is also arranged in the region of the crimp profile 8 without the protrusions 9.

[0048] Figure 6 Separate views of the first mold 4 and the second mold 5 are shown. Both the first mold 4 and the second mold 5 have two protrusions 9 that transition into the exit region 10 at the end. In the illustrated embodiment, the exit region 10 has a continuously decreasing height of each of the protrusions 9. In addition to reducing the height of the protrusions 9, the radius of the remaining area of ​​the crimp profile 8 is also increased, such that the substantially circular cross-section of the crimp profile at the conductor-facing end substantially corresponds to the external shape of the crimp sleeve 2. This arrangement has the advantage that there are no sharp edges or steps in the exit region that could otherwise cause damage to the strands, such as shearing or bending. Furthermore, the crimp sleeve 2 does not undergo uneven deformation in the area near the crimping device 1.

[0049] Figure 7 Another embodiment of the crimping device 1 is shown, which includes a first mold 4 and a second mold 5 in a closed position.

[0050] also, Figure 8 It shows along Figure 7 The figure shows a view of the crimping device 1 cut open by the defined cross-section CC. The figure particularly shows the outlet region 10, which is arranged on the end side in the region of the protrusion 9.

[0051] Figure 9 An embodiment of a composite 19 consisting of an electrical conductor 3 and an electrical connector 11 is shown. The electrical connector 11 has a crimp sleeve 2 and a mating connector joint 12. The crimp sleeve 2 and the strands 13 of the electrical conductor 3 are crimped together as a unit. Exit areas 10 are arranged at the ends of the crimping regions 14, through which the crimp profile 8 continuously transitions into a circular cross-section, eliminating any edges that could damage the strands 13. Furthermore, the exit areas 10 prevent uneven deformation of the crimp sleeve 2 near the crimping regions 14. In the illustrated embodiment, exit areas 10 are present both in the direction of the electrical conductor 3 and in the direction of the mating connector joint 12. Additionally, the end of a sheath 15 is shown in the figure, which is removed at the end of the conductor 3 (where it is introduced into the crimp sleeve 2).

[0052] Figure 10 An embodiment of a method for establishing a crimped connection between an electrical conductor 3 and an electrical connector 11 is shown, wherein the electrical conductor 3 may have one or more strands 13. The electrical connector 11 specifically includes a crimp sleeve 2. If the electrical conductor 3 has a sheath 15, then the sheath must be removed from the end of the conductor 3 or cable before the crimping process, so that only the stripped end of the cable, i.e., the actual conductor 3, is introduced into the crimp sleeve 2.

[0053] This method utilizes Figure 1 The crimping device 1 shown is used to achieve this, and includes the following steps: In preparation step 16, the end of the electrical conductor 3 is introduced into the crimp sleeve 2, and the crimp sleeve 2 is placed into the first mold 4. Whether the conductor 3 is introduced into the crimp sleeve 2 first or the crimp sleeve 2 is placed into the first mold 4 first is not important for the method described here.

[0054] In connection step 17, the second mold 5 and the first mold 4 are closed or moved toward each other, so that the stripped ends of the crimp sleeve 2 and the conductor 3 are pressed against each other in the crimping area 14.

[0055] In step 18, the first mold 4 and the second mold 5 are opened again.

[0056] The method shown has the advantages of being particularly simple to implement due to the use of only two molds 4 and 5, and also provides an advantageous connection between the electrical conductor and the electrical connector due to the geometry of the crimp profile 8. In particular, the method is advantageous when the conductor has a large cross-section.

[0057] Explanation of reference numerals in the attached figures

[0058] 1. Crimping device

[0059] 2 Crimped sleeve

[0060] 3 electrical conductors

[0061] 4. First mold

[0062] 5. Second mold

[0063] 6. First cross-section mold profile

[0064] 7. Second cross-section mold profile

[0065] 8. Press-fit profile

[0066] 9 protrusions

[0067] 10 Export Zones

[0068] 11 electrical connectors

[0069] 12-pin connector

[0070] 13-strand line

[0071] 14 Crimping Area

[0072] 15 sheath

[0073] 16 Preparation Steps

[0074] 17 Connection Steps

[0075] 18 Opening Steps

[0076] 19. A composite consisting of electrical conductors and electrical connectors.

[0077] 20 longitudinal axis

Claims

1. A crimping device (1) for crimping a crimping sleeve (2) onto an electrical conductor (3), wherein, The crimping device (1) includes a first mold (4) and a second mold (5), such that the crimping device (1) is configured for uniaxial crimping. The first mold (4) has a first cross-sectional mold profile (6), and the second mold (5) has a second cross-sectional mold profile (7). The first cross-sectional mold profile (6) and the second cross-sectional mold profile (7) together constitute the pressing profile (8). Its features are, The first cross-sectional mold profile (6) has at least one protrusion (9), and the second cross-sectional mold profile (7) has at least one protrusion (9). The crimping profile (8) has at least three protrusions (9).

2. The crimping device (1) according to claim 1, characterized in that, The first cross-sectional mold profile (6) has at least two protrusions (9), and the second cross-sectional mold profile (7) has at least two protrusions (9), such that the pressing profile (8) has at least four protrusions (9).

3. The crimping device (1) according to claim 1 or 2, characterized in that, The pressing profile (8) is constructed symmetrically relative to the separation axis, which is constructed at the connection position between the first mold (4) and the second mold (5) when the second mold (5) is placed on the first mold (4).

4. The crimping device (1) according to any one of claims 1 to 3, characterized in that, The first mold (4) and the second mold (5) have a longitudinal axis (20), and the shape of the first cross-sectional mold profile (6) and / or the shape of the second cross-sectional mold profile (7) varies along the longitudinal axis (20), wherein at least one mold (4, 5) has such a cross-sectional mold profile (6, 7) at the end side, which exerts a smaller force on the crimp sleeve (2) during pressing compared to the cross-sectional mold profile arranged at the center of the mold (4, 5), preferably without causing the crimp sleeve (2) to be pressed.

5. The crimping device according to claim 4, characterized in that, In at least one mold (4, 5), the transition of the cross-sectional mold profile (6, 7) from the crimping area (14) to the end side of the crimping sleeve (2) is constructed to be continuous, i.e. not stepped.

6. The crimping device (1) according to any one of claims 1 to 5, characterized in that, The first mold (4) and the second mold (5) have a longitudinal axis (20), and the first mold (4) and / or the second mold (5) have at least one exit area (10) along the longitudinal axis (20) toward the direction of the electrical conductor (3), the exit area having a sliding ramp.

7. The crimping device (1) according to any one of claims 1 to 6, characterized in that, The crimp profile (8) is constructed to be substantially circular on the side facing the electrical conductor (3).

8. The crimping device (1) according to any one of claims 1 to 7, characterized in that, The first mold (4) and / or the second mold (5) have two exit areas (10), which are respectively arranged on the first mold (4) and / or the second mold (5) in the direction of the electrical conductor (3) and the direction of the electrical connector (11) on the end side.

9. A method for establishing a crimp connection between an electrical conductor (3) and an electrical connector (11), wherein, The electrical connector (11) includes a crimp sleeve (2). Its features are, The method is performed using the apparatus (1) according to any one of claims 1 to 8, and the method includes the following steps: In preparation step (16): the end of the electrical conductor (3) is introduced into the crimp sleeve (2), and the crimp sleeve (2) is placed into the first mold (4). In the connection step (17): the second mold (5) and the first mold (4) are closed, so that the stripped ends of the crimp sleeve (2) and the conductor (3) are pressed against each other in the crimping area (14). In the opening step (18): the first mold (4) and the second mold (5) are opened.

10. A composite (19) comprising an electrical conductor (3) and an electrical connector (11), wherein, The electrical connector (11) includes a crimp sleeve (2). Its features are, Using the crimping device (1) according to any one of claims 1 to 8 and the method according to claim 9, the crimping sleeve (2) is pressed against the end of the electrical conductor (3).

11. The composite (19) according to claim 10, characterized in that, The electrical connector (11) is constructed as a cable lug or a plug connector (12) or a wire end sleeve.

12. The composite (19) according to claim 10 or 11, characterized in that, The electrical conductor (3) has multiple strands (13) which are pressed against the crimp sleeve (2) in the crimping region (14) and wherein there is an inclined transition region on at least one side between the crimping region and the non-crimped region.

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