Wire contact for an electrical component and method for producing a wire contact

Description

[0001] Electrical component with a stranded wire contact and method for producing a stranded wire contact of an electrical component.

[0002] The present invention relates to a stranded wire contact for an electrical component, i.e., a contact region of the component comprising a section of a stranded wire, in particular a stranded wire end. The component is, in particular, an inductive component. The stranded wire forms, for example, a functional element of the component. For example, the stranded wire forms a winding, in particular a coil of the component. In particular, it is a high-frequency stranded wire.

[0003] The stranded wire contact serves to electrically connect the stranded wire, for example, to a component's connecting piece, in particular a contact pin. The stranded wire contact can also be designed for direct contact with a circuit board.

[0004] When manufacturing the stranded wire contact, the insulation of the stranded wire must also be removed. For example, each individual wire of the stranded wire has insulation in the form of a coating. In addition, the entire stranded wire can have a sheath. The individual wires can be twisted together. Furthermore, the individual wires can be wound around a connecting piece. This makes it difficult to reliably remove the insulation of the individual wires and the outer insulation of the stranded wire. A stranded wire contact is usually manufactured by soldering, with the temperature being set so high that the insulation is removed at the same time as the stranded wire contact is manufactured. For example, such soldering processes are carried out by immersion in a solder bath or by wave soldering with liquid tin or tin alloy.When using a varnish insulation containing polyurethane in the temperature class of 155 °C to 180 °C, temperatures of the solder bath or solder wave of around 400 °C are often required to reliably remove the insulation.

[0005] In some cases, the insulation has even higher temperature ratings. This is the case, for example, with insulation made of polyesterimide or polyimide. In this case, a two-step manufacturing process for the stranded wire contact is often required. In a first step, the insulation is removed, for example, mechanically, by burning off, or by chemical processes. In a second step, a soldering process is performed to create a mechanical and electrical connection.

[0006] The disadvantage of such soldering processes is that the heated air above the soldering fluid comes into direct contact with a functional element of the component, such as a winding. Furthermore, the hot soldering fluid can leak along the stranded wire toward a functional element. This leads to undesirable damage to the insulation and an increased risk of failure. Furthermore, the evaporation of the insulation creates unwanted solder balls. Furthermore, such processes are costly and time-consuming.

[0007] JP 3 140817 U, JP 3 174350 U, and JP 2003 234218 A each describe a coil in which wire ends are connected to terminal elements by diffusion bonding, the terminal elements being designed as terminals. WO 2015 / 014647 A1 describes a method for producing a hot-crimp connection of a conductor to a cable lug. JP 2003 145274 A discloses a stranded wire connected to a cable lug by thermocompression bonding. JP 2012 084472 discloses a stranded wire connected to an element for further contacting by crimping.

[0008] It is an object of the present invention to provide an improved stranded wire contact for an electrical component.

[0009] An electrical component according to claim 1 is disclosed.

[0010] The stranded wire contact comprises a section of stranded wire. The stranded wire comprises a plurality of individual wires. The stranded wire forms, for example, a winding of the component, in particular a coil. The electrical component is designed, for example, as an inductive component. For example, each individual wire within the winding is surrounded by separate insulation. For example, this is varnish insulation. In addition, the stranded wire can be surrounded by outer insulation, in particular a sheath. However, the stranded wire can also be free of any additional outer sheath. In particular, it is a high-frequency stranded wire.

[0011] The stranded wire contact is designed to electrically contact the stranded wire. The stranded wire contact comprises one end of the stranded wire that protrudes from the winding. The stranded wire contact can be arranged at a short distance from a winding of the stranded wire, for example, at a distance of a few mm.

[0012] The stranded wire contact also has a contact piece that at least partially surrounds the stranded wire section. The contact piece is connected to the stranded wire by thermal diffusion bonding. According to the invention, the stranded wire and the contact piece each have a free end, with the free ends arranged flush.

[0013] The thermal diffusion bonding connection is visible on the finished component. In diffusion bonding, the individual wires are bonded to the contact piece under pressure and at elevated temperatures. The temperature is lower than the melting point of the contact piece material and the material of the individual wires. In diffusion bonding, two-way diffusion occurs at the atomic level across the interfaces of the parts to be joined, creating an intimate connection between the parts. In stranded wire contact, both the contact piece and the individual wires can be bonded to each other using diffusion bonding.

[0014] The stranded wire contact may contain insulation residue, for example, in the form of clumped particles. For example, during diffusion bonding, the insulation of the individual wires and / or the outer insulation of the stranded wire are melted. This allows the stranded wire to be connected to the contact piece without removing the insulation separately.

[0015] The stranded wire contact is manufactured without soldering, meaning it is solderless. This eliminates the undesirable side effects that occur during soldering, such as damage to the adjacent winding due to heat development or disruptive solder balls. The stranded wire contact is also free of any solder material used during soldering, as well as any other connecting material, such as a conductive adhesive.

[0016] The contact piece is electrically conductive and, in particular, comprises a metal. The contact piece is in electrical contact with the stranded wire. The contact piece can serve as a current carrier for removing the insulation from the stranded wire during the manufacture of the stranded wire contact.

[0017] The contact piece can also provide mechanical fixation for the stranded wire. For example, the contact piece can fix the stranded wire to a connection piece of the component or be designed as a connection piece.

[0018] The connecting piece is arranged, for example, on a support element of the component. The support element can be designed to support a winding of the stranded wire. The support element can alternatively or additionally be designed to support the connecting piece or other elements. The support element can also be a housing part of the component. The support element is made, for example, of an electrically insulating material.

[0019] The stranded wire and the connecting piece can each have a free end. The free ends of the stranded wire and the connecting piece can, for example, point in the same direction of the component. In particular, the free ends can be flush with each other.

[0020] The connecting piece comprises a conductive material, in particular a metallic material. For example, the connecting piece is designed as a contact pin. The connecting piece can be in the form of a single contact finger. The connecting piece can also have multiple regions between which the stranded wire is arranged. For example, the connecting piece is designed in the form of a fork with two prongs. The connecting piece can also have a different shape.

[0021] The component can have multiple connection pieces. For example, the component has multiple connection pieces arranged side by side. The component can also have connection pieces on two opposite sides. The component can have multiple stranded wires, each connected to a connection piece.

[0022] In one embodiment, the component has a connection piece for electrically connecting the component. The connection piece can be designed in particular for connection to a printed circuit board. For example, the connection piece is designed for PTH (pin through hole) mounting. Alternatively, the connection piece can also be designed for SMD (surface mountable device), i.e. for surface mounting. The connection piece is designed, for example, as a connection pin. The component can have a plurality of connection pieces. For example, a connection piece is provided for each connection piece. The connection piece is electrically connected to the stranded wire contact. The connection piece can be electrically connected to the contact piece and / or the connection piece.

[0023] For example, the connecting piece and a connected connecting piece point in different directions. For example, the connecting piece is oriented laterally, while the connecting piece points downwards. For example, the connecting piece protrudes laterally from the support element, while the connecting piece protrudes downwards from the support element. The connecting piece and the connecting piece can also run parallel to each other.

[0024] The connector and the connecting piece can be formed as a single piece. For example, the connector and the connecting piece are different ends of an angle.

[0025] According to the invention, the contact piece is designed as a sheathing element that at least partially surrounds the stranded wire. The sheathing element is, in particular, a so-called "splice crimp." The sheathing element is designed as a piece of metallic tape bent around the conductors.

[0026] In one embodiment, the sheathing element configured as a contact piece is present in addition to a connecting piece to which the stranded wire is arranged. The sheathing element can, on the one hand, serve the function of a current carrier during thermal diffusion bonding. On the other hand, the sheathing element can ensure reliable fixation of the contact piece to the connecting piece. The sheathing element can be completely wrapped around the stranded wire and the connecting piece.

[0027] In the present case, in an embodiment in which the stranded wire contact is formed solely by a connecting piece and the section of stranded wire, the connecting piece is referred to as the contact piece. In an embodiment in which the stranded wire contact is formed by a sheath element, a stranded wire, and a connecting piece, the sheath element is referred to as the contact piece.

[0028] In an alternative embodiment, the stranded wire contact has no connecting piece and is thus formed solely by the sheathing element and a section of the stranded wire. The stranded wire contact thus serves for direct connection to a circuit board without an additional connecting piece. The component can have a holding device for securing the stranded wire contact or be free of a holding device.

[0029] When the contact piece is designed as a sheathing element, a piece of metallic strip is provided, for example, in a flat form and bent around the adjacent conductors. The sheathing element thus only takes on its shape, particularly a sleeve shape, when it is arranged around the conductors.

[0030] After the forming process, the lateral sections of the strip overlap. This overlap of the lateral sections distinguishes this type of sheathing element from a prefabricated sleeve, such as a cable lug.

[0031] According to claim 9, a method for producing a stranded wire contact of an electrical component is disclosed. The stranded wire contact comprises a section of stranded wire and a contact piece. In particular, it can be the stranded wire contact and the component described above.

[0032] A stranded wire comprising a plurality of individual wires is provided. For example, the individual wires each have insulation in the form of a lacquer layer. The stranded wire can also have outer insulation, for example, in the form of a sleeve.

[0033] An arrangement of the stranded wire is formed with a contact piece of the electrical component. According to the invention, the contact piece is a sheathing element in the form of a metallic strip piece ("splice crimp"). The stranded wire can be arranged on a connecting piece, and then an arrangement of the stranded wire arranged on the connecting piece with the sheathing element designed as a contact piece is formed. Alternatively, the connecting piece can be omitted, and only an arrangement of the sheathing element and the stranded wire is formed.

[0034] In a comparative example not claimed, the contact piece is a connecting piece, for example in the form of a rigid contact pin. The connecting piece is arranged, for example, on a carrier element, in particular an insulating carrier element of the component.

[0035] The stranded wire is connected to the contact piece by thermal diffusion bonding. This involves applying mechanical pressure to the stranded wire-contact piece assembly. Specifically, the stranded wire is pressed against the contact piece. At the same time, the assembly is heated. This heating can also at least partially remove the insulation.

[0036] Heating occurs, for example, through current flow. In particular, heating occurs due to the electrical resistance of the insulation.

[0037] After the connection is made, one free end of the stranded wire is cut off. A free end of the contact piece can also be cut off at the same time. The free ends are flush with each other.

[0038] The present disclosure describes several aspects of an invention. All features disclosed with respect to the stranded wire contact, the component, or the method are also disclosed correspondingly with respect to the other aspects, even if the respective feature is not explicitly mentioned in the context of the other aspects.

[0039] Furthermore, the description of the subject matter specified here is not limited to the individual specific embodiments. Rather, the features of the individual embodiments can be combined with one another – as far as technically feasible.

[0040] In the following, the objects described here are explained in more detail using schematic embodiments.

[0041] They show: Figure 1A shows an illustrative example of a stranded wire contact of a component which is not part of the invention, in a schematic sectional view, Figure 1B shows an illustrative example of a stranded wire contact similar to the stranded wire contact of Figure 1A in an actually manufactured component in sectional view, Figure 2the stranded wire contact according to the Figures 1A and 1B , as well as a section of a component in perspective view, Figures 3A to 3CProcess steps in the production of the stranded wire contact of the Figures 1A, 1B and 2 , Figure 4A shows an embodiment of a stranded wire contact in a schematic sectional view, Figure 4B shows an embodiment of a stranded wire contact similar to the stranded wire contact from Figure 4A in an actually manufactured component in sectional view, Figure 5 the stranded wire contact according to the Figures 4A and 4B , as well as a component in perspective view, Figures 6A to 6EProcess steps in the production of the stranded wire contact of the Figures 4A, 4B and 5, Figure 7 shows a further embodiment of a component with a stranded wire contact in a perspective view, Figure 8 shows a further embodiment of a stranded wire contact in a component in a sectional view, Figure 9 shows an embodiment of a component with the stranded wire contact from Figure 8 .

[0042] Preferably, in the following figures, like reference numerals refer to functionally or structurally corresponding parts of the various embodiments.

[0043] Figure 1 shows a stranded wire contact 1 comprising a stranded wire 2 and a contact piece 100 in a schematic sectional view. The contact piece 100 contacts the stranded wire 2 directly and enables an electrical connection of the stranded wire 2. The Figure 1 shows the contact piece 100 in a sectional view across the stranded wire 2.

[0044] The stranded wire 2 comprises a plurality of individual wires 4. The individual wires 4 are electrically and mechanically connected to each other and to the contact piece 100. The contact piece 100 and / or the stranded wire 2 are part of an electrical component, in particular an inductive component.

[0045] The stranded wire 2 forms a winding (see e.g. winding 18 from Figure 5 ) of an electrical component.

[0046] In Figure 1 One end of the stranded wire 2 can be seen protruding from the winding. The individual wires 4 are each surrounded by insulation, at least within the winding. Each individual wire 4 has separate insulation. The insulation is, in particular, enamel insulation. In this case, the strands are enameled wire strands. The stranded wire 2 is, in particular, a high-frequency stranded wire.

[0047] An outer periphery of the stranded wire 2 can also be surrounded by insulation within the winding, e.g., a silk covering. This outer sheathing can, but does not have to, be present.

[0048] The contact piece 100 has two sections 5, 6, between which the stranded wire 2 is accommodated. During the production of the conductor connection 1, the sections 5, 6 are pressed together. The resulting deformation of the contact piece 100 remains. Thus, the sections 5, 6 are permanently plastically deformed. The sections 5, 6 are each formed, for example, in the shape of a leg. The contact piece 100 can also have a different shape.

[0049] The contact piece 100 is designed in particular as a connecting piece 3, wherein the connecting piece 3 connects the stranded wire 2 to a connecting piece (see connecting piece 10 from Figure 2 ) of the component.

[0050] The contact piece 100 is connected to the stranded wire 2 by thermal diffusion bonding. For this purpose, the parts to be connected, i.e., the stranded wire 2 and the contact piece 100, are pressed together and simultaneously heated.

[0051] The heating temperature is below the melting temperature of the parts to be joined.

[0052] Immediately before diffusion bonding, the individual wires 4 are still surrounded by insulation. The insulation melts during diffusion bonding, allowing an electrical connection between the individual wires 4. If the stranded wire 2 is sheathed, this insulation can also melt during diffusion bonding, enabling an electrical connection between the stranded wire 2 and the contact piece 3.

[0053] In the stranded wire contact 1, it can be seen from the presence of remnants of the insulation, e.g. clumped particles 7, that the insulation was initially still present during diffusion bonding. In conventional processes, the insulation is removed before the stranded wire contact 1 is produced. This is a complex process step that is not necessary here. In other conventional processes, the insulation is removed by applying a solder material. This means that solder balls can be present on the stranded wire contact and that damage to the component can occur during soldering due to the high temperature. Damage can occur in particular if a winding of the stranded wire is arranged very close to the stranded wire contact, for example within a range of a few mm.

[0054] Figure 1B shows a stranded wire contact 1, corresponding to the stranded wire contact 1 from Figure 1A in a real-life version. The multitude of individual wires 4 is particularly clearly visible.

[0055] The individual wires 4 virtually completely fill the interior of the contact piece 100. The degree of filling can be adjusted by suitable dimensions of the contact piece 100 and appropriate pressure application during thermal diffusion bonding.

[0056] Figure 2 shows a perspective view of a section of a component 8 comprising a stranded wire contact 1 of a stranded wire 2 with a contact piece 100 designed as a connecting piece 3. The stranded wire contact 1 is in particular as shown in the Figure 1A or 1B. The component 8 is, for example, an inductive component. The component 8 has, in particular, a winding (not shown) of the stranded wire 2. The winding can be arranged very close to the stranded wire contact 1, in particular within a range of a few mm, for example, at a distance of 1 to 10 mm.

[0057] The stranded wire 2 extends out of the winding and has insulation 9 within the winding and also in the area directly adjacent to the winding. The insulation 9 is formed, for example, by an insulating sleeve or other sheathing in which the individual wires 4 are accommodated. The insulation 9 may also be absent. The individual wires 4 may also be surrounded by further insulation, for example, by a layer of varnish.

[0058] In the area of ​​conductor connection 1, the insulation 9 of the stranded wire 2 and the further insulation of the individual wires 4 are removed, thus establishing electrical contact with the connecting piece 3. The insulation 9 is removed in the area of ​​conductor connection 1, i.e., in the area where the stranded wire 2 is arranged within the connecting piece 3. The insulation 9 is present in the area where the stranded wire 2 exits the connecting piece 3.

[0059] The connecting piece 3 is designed, for example, in the form of a fork, clamp, eyelet or sleeve. The connecting piece 3 already has Figure 1 shown has two partial areas 5, 6, which lie on opposite sides of the stranded wire 2. The connecting piece 3 can also have other shapes, in particular shapes that allow the stranded wire 2 to be received between two partial areas 5, 6 and then the partial areas 5, 6 to be pressed together, with the stranded wire 2 arranged therebetween.

[0060] The connecting piece 3 comprises a conductive material, in particular a metal. The connecting piece 3 is arranged, for example, on one side of the component 8. The connecting piece 3 is electrically connected to a connection piece 10, for example a connection pin. The connection pin can be designed, in particular, for PTH mounting, in which the connection pin is inserted through a hole in the printed circuit board. Alternatively, the connecting piece 10 can also be designed for SMD mounting. In this case, the connecting piece 10 extends, for example, in the lateral direction of the component 8. For example, the connecting piece 10 of the Figure 2 bent outwards or inwards.

[0061] In addition, the end of the stranded wire 2 is also mechanically fixed by the connecting piece 3.

[0062] The connecting piece 3 can be formed integrally with the connecting piece 10. In particular, it can be a metal angle. One end of the metal angle can form the connecting piece 3 and the other end the connecting piece 10. The middle part of the metal angle can pass through the carrier element 22, for example, be overmolded with the carrier material.

[0063] The component 8 comprises, for example, a plurality of stranded wires 2, connecting pieces 3, and connecting pieces 10. The connecting pieces 3 are arranged, for example, next to one another, and the connecting pieces 10 are arranged below the connecting pieces 3. The connecting pieces 3 are arranged, for example, on a support element 22 of the component 8. The connecting pieces 10 can also be arranged on the support element 22.

[0064] In the Figures 3A to 3CProcess steps in the production of a conductor connection 1 of a stranded wire 2 with a connecting piece 3 are shown. The process is suitable, for example, for the production of the Figure 1 and 2 shown conductor connection 1.

[0065] Figure 3A shows a first method step in which a stranded wire 2 is inserted into a contact piece 100, in particular into a contact piece 100 designed as a connecting piece 3. This is, for example, one end of a stranded wire 2 wound into a coil. The contact piece 100 has the shape of a fork with two opposing partial regions 5, 6 and a connecting region 11.

[0066] The stranded wire 2 comprises a plurality of individual wires 4, for example, 4 to 3000 individual wires 4. The stranded wire 2 is surrounded by an outer insulation 9. The insulation 9 is designed, in particular, as an insulating sleeve in which all individual wires 4 are arranged. The stranded wire 2 can also have no outer insulation 9. Each individual wire 4 is surrounded by an inner insulation 12, which is designed, for example, as a layer of varnish. The individual wires 4 comprise copper, for example. The individual wires 4 have, for example, thicknesses between 0.02 and 0.5 mm.

[0067] Figure 3B shows a further process step. The partial areas 5, 6 are pressed together. For example, a tool, in particular a crimping tool, is used for this purpose. This is, for example, a crimping pliers. The pressure exerted from both sides is indicated by arrows.

[0068] During compression, the stranded wire 2 is heated. For example, electrodes 13, 14 are applied to the sections 5, 6, resulting in a current flow through the stranded wire 2, particularly through the insulation 9, 12 of the stranded wire 2. The electrodes 13, 14 can be integrated into the tool. Due to the ohmic resistance, the stranded wire 2 heats up, causing the insulation 9, 12 to melt. In the process, the insulation 9, 12 evaporates at least partially. However, molten residues of the insulation 9, 12 remain in the stranded wire 2.

[0069] The exposed individual wires 4 are permanently electrically and mechanically connected to each other and to the contact piece 100 when the pressure and the elevated temperature are applied.

[0070] The pressure also at least partially closes gaps created by the evaporation of the insulation layers 9, 12. In particular, the individual wires 4 and the contact piece 100 are connected by diffusion bonding. This process can also be referred to as hot crimping or diffusion welding.

[0071] Figure 3C shows the stranded wire contact 1 after the connection process. Remains of the insulation 9, 12 are visible in the form of clumped particles 7. The individual wires 4 are firmly connected to each other and to the contact piece 100. The described process allows for good electrical conductivity with a high mechanical connection strength.

[0072] Furthermore, the described method makes it possible to concentrate the heating for removing the insulation 9, 12 on a small area of ​​the contact piece 100. This is difficult to achieve with conventional soldering processes. If necessary, additional insulating tapes are used to protect the winding. Such protective devices are not necessary in this case.

[0073] The hot crimping process is a well-controlled and simple process, allowing a reliable electrical and mechanical connection to be created at low cost. For example, it eliminates the formation of solder balls, the size and expansion of which are often difficult to control.

[0074] Figure 4A shows a further embodiment of a conductor connection 1 comprising a stranded wire 2 and a contact piece 100 in a sectional view across the stranded wire 2 in a schematic view.

[0075] In contrast to the design of the Figure 1The contact piece 100 is formed by a sheathing element 15, which is present in addition to a connecting piece 3. The sheathing element 15 encloses the stranded wire 2 and the connecting piece 3.

[0076] Furthermore, the connecting piece 3 is not designed in the shape of a fork, but rather has a simple rectangular cross-section. The connecting piece 3 is, for example, rigid. The connecting piece 3 has, for example, a pin shape. The stranded wire 2 is arranged on the connecting piece 3. The stranded wire 2 can also be guided around the connecting piece 3.

[0077] The enveloping element 15 is formed as a metallic strip. The enveloping element 15 is bent around a longitudinal axis of the connecting piece 3. Edge regions 16, 17 of the enveloping element 15 overlap. The enveloping element has two opposing partial regions 5, 6.

[0078] The sheathing element 15, the stranded wire 2, and the connecting piece 3 are mechanically and electrically connected to each other. Remains of insulation 9, 12 may also be present here in the form of particles 7 or similar. The stranded wire contact 1 can be manufactured by diffusion bonding.

[0079] Figure 4B shows a stranded wire contact 1, corresponding to the stranded wire contact 1 from Figure 4A in a real-life version. In particular, the winding of the stranded wire 2 around the connecting piece 3, as well as the high filling level of the interior of the sheathing element 15, can be seen here.

[0080] Figure 5 shows in perspective view a section of a component 8 comprising a stranded wire contact 1, which is formed by one end of a stranded wire 2, a contact piece 100 and a connecting piece 3 according to the Figures 4A and 4B The component 8 is made of Figure 2can be designed similarly. Component 8 is an inductive component. Component 8 has one or more windings 18 and one or more stranded wires 2.

[0081] The ends of the stranded wires 2 are each connected to connecting pieces 3. The connecting pieces 3 are arranged, for example, in rows on two opposite sides of the component 8.

[0082] The connecting pieces 3 are connected to a support element 22 of the component 8. The winding 18 is arranged on the support element 22. The support element 22 can also extend partially or completely into the winding 18.

[0083] In the Figures 6A to 6EProcess steps in the production of a stranded wire contact 1 comprising one end of a stranded wire 2 and a connecting piece 3 are shown, in which an additional sheathing element 15 is used as the contact piece 100. The process is suitable, for example, for the production of the Figure 4 and 5 shown conductor connections 1.

[0084] Figure 6A shows a first method step in which a stranded wire 2 is arranged on a connecting piece 3. This is, for example, one end of a stranded wire 2 wound into a coil. The stranded wire 2 is, for example, placed on the connecting piece 3 or wound around the connecting piece 3.

[0085] The connecting piece 3 has a simple rectangular shape. The connecting piece 3 can also have a different shape that is suitable for connection to the stranded wire 2. The stranded wire 2 and / or the connecting piece 3 are, for example, part of an inductive component 8, in particular of the same component 8. The connecting piece 3 can be as in Figure 2 be connected to a connecting piece 10. The connecting piece 3 must, in contrast to Figure 1 have no opposing sub-areas 5, 6.

[0086] The stranded wire 2 is provided with a sheathing insulation 9 and comprises a plurality of individual wires 4, each of which is provided with insulation 12. Alternatively, the sheathing insulation 9 may also be absent.

[0087] To produce the enveloping element 15, a flat strip piece 19 is cut from a metallic strip. The enveloping element 15 is made of, for example, copper, brass, bronze, or other copper alloys.

[0088] The strip piece 19 is bent around the assembly of stranded wire 2 and connecting piece 3. For this purpose, the assembly is placed, for example, in a bending device, the strip piece 19 is brought forward, and wrapped around the assembly by applying force (see arrows). In this process, the edge regions 16, 17 of the strip piece 19 overlap.

[0089] Such a sheathing element 15 is commonly referred to as a "splice crimp." The sheathing element 15 differs from a prefabricated sleeve into which one or more conductors are inserted. The present sheathing element 15 only acquires its sleeve shape during its arrangement around the stranded wire 2 and the connecting piece 3. The stranded wire 2 and the connecting piece 3 are therefore not inserted into the sheathing element 15. The sheathing element 15 is not formed integrally with either the stranded wire 2 or the connecting piece 3.

[0090] Figure 6B shows a further process step, analogous to the process step according to Figure 3B The contact piece 100, designed as a sheathing element 15, has two partial regions 5, 6, between which the stranded wire 2 is arranged. In the process, force is exerted from two opposite sides on the arrangement of the sheathing element 15, the connecting piece 3, and the stranded wire 2.

[0091] For this purpose, a tool with two punches 20, 21 is used, for example. A first punch 20 is flat, for example, and is pressed against the enveloping element 15 from below. A second punch 21, for example, has a curved shape and is pressed against the enveloping element 15 from above. The first punch 20 can also only apply a counterforce to the force exerted by the second punch 21.

[0092] The curved shape of the second stamp 21 serves in particular to limit the width of the conductor connection 1. This is advantageous, for example, when several conductor connections 1 are arranged next to one another.

[0093] During compression, the stranded wire 2 is heated. For example, electrodes 13, 14 are applied to the dies 20, 21. The electrodes 13, 14 can be integrated into the tool. The contact piece 100, in particular the opposing sections 5, 6, are brought into contact with the electrodes 13, 14. The stranded wire 2 is heated by the current flow, causing the insulation 9, 12 to melt.

[0094] Under the applied pressure and elevated temperature, the exposed individual wires 4 permanently electrically and mechanically bond to each other, to the connecting piece 3, and to the encasing element 15 through diffusion bonding. Likewise, the connecting piece 3 bonds to the encasing element 15.

[0095] Figure 6Cshows the resulting stranded wire contact 1. Due to the shape of the dies 20, 21, the stranded wire contact 1 has a curved shape on one side and a flat shape on the opposite side. Due to the process used, particles 7 of the insulation 9, 12 are present.

[0096] The stranded wire contact 1 can be completely or almost completely filled with the material of the stranded wire 2 and the connecting piece 3 within the sheathing element 15. The gaps shown in the figure are, for example, filled with the stranded wire 2 in the case of a stranded wire 2 that is wound around the connecting piece 3, analogous to Figure 1B .

[0097] Figure 6D shows the stranded wire contact 1 using the example of component 8 from Figure 5 after the diffusion bonding process step.

[0098] The free ends 23, 24 of the connecting piece 3 and the stranded wire 2 protrude from the sheathing element 15. The free ends 23, 24 will be cut off in a subsequent step.

[0099] Figure 6E shows the stranded wire contact 1 with cut ends. The stranded wire 2, the connecting piece 3, and the sheathing element 15 are thus flush at the ends. The component 8 can now be mounted on a printed circuit board, for example, with its connecting pieces 10.

[0100] Figure 7 shows a further embodiment of a component 8 comprising a stranded wire contact 1 in a perspective view. In contrast to Figure 5 Component 8 is designed for SMD mounting. For assembly, component 8 can be placed on a circuit board, and the connection pieces 10 can be soldered to the circuit board.

[0101] The connecting pieces 10 extend in the lateral direction of the component 8. In particular, the connecting pieces 10 run horizontally relative to a mounting surface of the component 8. In this case, the connecting pieces 10 run parallel to the connecting pieces 3. The connecting pieces 10, like the connecting pieces 3, are directed outward. Alternatively, the connecting pieces 10 can also be directed inward.

[0102] When manufacturing component 8, for example, component 8 is first produced according to Figure 5 manufactured and then the connecting pieces 10 are bent.

[0103] Accordingly, the embodiment of component 8 can also be Figure 2 be trained for SMD assembly.

[0104] Figure 8 shows a further embodiment of a stranded wire contact 1 comprising one end of a stranded wire 2 and a contact piece 100. The contact piece 100 is formed by a sheath element 15 which, as in the Figures 4A and 4BThe stranded wire 2 can also be designed according to the Figures 4A and 4B be trained.

[0105] In contrast to the stranded wire contact 1 of the Figures 4A and 4B There is no connecting piece 3, so that the sheathing element 15 only surrounds the stranded wire 2. The stranded wire contact 1 is otherwise in accordance with the Figures 6A to 6D The contact piece 100 is connected to the stranded wire 2 by thermal diffusion bonding.

[0106] In this embodiment, the connector 10 for connection to a printed circuit board can be formed directly from the stranded wire contact 1.

[0107] Figure 9 shows an embodiment of a component 8 with a stranded wire contact 1 according to Figure 8 The component 8 has two stranded contacts 1. The stranded contacts 1 form the terminals 10 for connection to a printed circuit board.

[0108] The stranded contacts 1 are aligned vertically with a mounting plane of the component 8. The component 8 is designed in particular for PTH mounting, with the stranded contacts 1 being guided through the circuit board. An embodiment for SMD mounting is also conceivable.

[0109] The free ends of the stranded wire 2, in particular the stranded wire contacts 1, are accommodated in a holder 25 for mechanical fixation. Thus, the stranded wire 2 is fixed to the carrier element 22 of the component 8. The holder 25 is electrically insulating and can be formed as a component of the carrier element 22. List of reference symbols

[0110] 1 Stranded wire contact 2 Stranded wire 3 Connecting piece 4 Single wire 5 Partial area 6 Partial area 7 Particle 8 Component 9 Insulation 10 Connection piece 11 Connection area 12 Insulation 13 Electrode 14 Electrode 15 Sheath element 16 Edge area 17 Edge area 18 Winding 19 Strip piece 20 Stamp 21 Stamp 22 Carrier element 23 Free end 24 Free end 25 Holder 100 Contact piece

Claims

1. Electrical component, comprising a winding (18) of a stranded wire (2), wherein the stranded wire (2) has a large number of individual wires (4), wherein each individual wire (4) is surrounded by a separate insulation (12) within the winding (18), and comprising a strand contact (1), which comprises a portion of the stranded wire (2) and comprises a contact piece (100) which at least partially surrounds the portion of the stranded wire (2), wherein the contact piece (100) is connected to the stranded wire (2) by thermal diffusion bonding, characterized in that the contact piece (100) is formed from a metal strip piece (19) bent around the stranded wire (2), wherein lateral regions of the metal strip piece (19) overlap, in which component the stranded wire (2) and the contact piece (100) each comprise a free end (23, 24), wherein the free ends (23, 24) are arranged flush.

2. Electrical component according to Claim 1, comprising a connection piece (10) for electrical connection of the component (8), wherein the connection piece (10) is electrically connected to the strand contact (1).

3. Electrical component according to either of Claims 1 and 2, wherein the connection piece (10) is electrically connected to a connecting piece (3), wherein the contact piece (100) surrounds the stranded wire (2) and the connecting piece (3).

4. Electrical component according to Claim 3, wherein the connecting piece (3) is arranged on a carrier element (22) of the component.

5. Electrical component according to Claim 4, wherein the connecting piece (3) is in the form of a contact pin.

6. Electrical component according to any of the preceding claims, wherein the strand contact (1) is designed to be directly connected to a printed circuit board.

7. Electrical component according to any of the preceding claims, wherein the strand contact (1) is free of solder.

8. Electrical component according to any of the preceding claims, wherein the winding (18) is arranged on a carrier element (22) of the component (8).

9. Method for producing the strand contact of the electrical component according to any of the preceding claims, comprising the steps of: A) providing a winding (18) of a stranded wire (2), wherein the stranded wire (2) comprises a large number of individual wires (4), wherein each individual wire (4) is surrounded by a separate insulation (12) within the winding (18), B) forming an arrangement of the stranded wire (2) with a contact piece (100), wherein the contact piece (100) is formed from a metal strip piece, and bending the contact piece (100) around the stranded wire (2), so that lateral regions of the metal strip piece (19) overlap, C) connecting the stranded wire (2) to the contact piece (100) by thermal diffusion bonding and thereby forming the strand contact (1), wherein the stranded wire (2) and the contact piece (100) both have a free end (23, 24), wherein the free ends (23, 24) are arranged flush.

10. Method according to Claim 9, in which the end of the stranded wire (2) is cut off after step C).

11. Method according to either of Claims 9 and 10, in which the stranded wire (2) is arranged on a connecting piece (3) before step B) and the contact piece (100) is arranged around the stranded wire (2) and the connecting piece (3) in step B).