Electric connection for motor vehicle line

Abstract

The connection comprises a terminal part, a sleeve which is bonded to the terminal part and which has a passage opening running in the longitudinal direction, and a pin which is connected to the sleeve and has a pin shaft and a pin head, wherein the pin shaft of the pin is compressed in the passage opening of the sleeve in the longitudinal direction, and the pin head of the pin is arranged in a recess arranged on the end-face end of the sleeve. The invention is characterized in that the sleeve end face lying at the end-face end is bonded to the terminal part.

Description

[0001] The subject matter concerns an electrical connection, in particular a connection between a terminal part and a flat part.

[0002] In electrical connection technology, particularly in automotive applications, it is common to create detachable connections between two electrical conductors using a stud attached to one of the conductors. This stud is positioned on a flat surface of one of the conductors and serves to be screwed to the other conductor. The stud can be attached to a conductor either as a through-bolt through a hole in the conductor or as a weld stud. A weld stud is welded to a flat surface of a conductor, for example, by friction welding, especially rotary friction welding. The second conductor can then be slipped onto the welded stud and screwed to the first conductor using a nut attached to the stud.The conductors are pressed against each other by the clamping force of the nut, and an electrically conductive path between the conductors is formed primarily via their immediate contact surface as well as via the bolt.

[0003] The conductor to which the bolt is welded is typically a flat component, especially a flat wire or an electrical component with a flat surface. Copper conductors are generally used in power lines. Aluminum conductors are also possible. To prevent contact corrosion at the interface between the conductor and the bolt, and thus ensure a durable and stable connection, the bolt is usually made of the same material as the conductor. For aluminum connections, the joint must be protected from environmental influences to prevent contact corrosion. This is typically achieved with copper, so both the bolt and the conductor are made of copper or a copper alloy.

[0004] While copper has very good electrical and thermal conductivity, which is advantageous for the connection itself, copper is relatively ductile. This means that when screwing the second conductor to the first conductor via the bolt, the tightening torque of the nut must not be too high. If a high tightening torque is required, there is always a risk of the bolt thread shearing. Such shear forces can also occur at the thread under dynamic loads during continuous operation, causing it to shear off. This is particularly problematic when using copper.

[0005] WO 2009 / 098412 A2 discloses a prior art compound according to the preamble of claim 1.

[0006] The object was therefore based on the task of providing an electrical connection which meets increased mechanical requirements while maintaining the same electrical quality.

[0007] This problem is solved by a connection according to claim 1.

[0008] The connection includes at least one connecting part. Such a connecting part can be in the form of a strip or sheet metal. The connecting part is, in particular, a flat conductor or a flat section of a round conductor. For example, a round conductor may be flattened at one end or along its length. The flattening can be achieved, for example, by forging, upsetting, or similar processes.

[0009] It is also possible that the connecting element is not made of a solid material, in particular a single strand of a conductor, but also of a braid, fabric, or multi-strand conductor. In this case, a flat area can be formed into the braid, fabric, or strands by appropriate forming processes such as upsetting, pressing, welding, or the like. On a fabric strip, for example, a substantially inclusion-free area can be formed by welding and / or compacting, which can then be processed like a solid material, in particular one onto which a sleeve can be applied.

[0010] For an electrical connection of the terminal part to another terminal part, for example a conductor or the like, it is proposed that an electrically conductive, in particular metallic, sleeve be provided. The sleeve is bonded to the terminal part by a material bond. The sleeve has a through-opening extending in its longitudinal direction. The sleeve is connected to the terminal part in such a way that the longitudinal direction of the sleeve runs transversely to the longitudinal direction of the terminal part. In particular, the longitudinal direction of the sleeve runs parallel to the surface normal of the surface of the terminal part on which the sleeve is mounted.

[0011] For a mechanical connection between the connecting part and the other connecting part, for example, a conductor, a bolt is provided next to the sleeve. The bolt is connected to the sleeve and has a bolt shank and a bolt head. While the sleeve is bonded to the connecting part by a material bond, the bolt shank is pressed longitudinally into the through-opening of the sleeve. According to the invention, the outer surface of the bolt shank is in direct contact with the inner surface of the through-opening. In this way, a force-fit or form-fit is created when the bolt is inserted into the through-opening. In particular, the bolt can also be driven into the through-opening in such a way that the cross-section of the through-opening changes compared to its original state. The bolt plastically deforms the inner surface of the through-opening.

[0012] The sleeve has a recess at one of its end faces, which is designed to receive the bolt head. When the bolt is inserted into the sleeve, i.e., with its shank inserted into the through-hole, the bolt head rests in the recess at the end face. The recess extends longitudinally into the sleeve, preferably extending further than the bolt head itself. Thus, the bolt head is completely enclosed within the recess.

[0013] The sleeve is then metallurgically bonded to the connecting part via its end face. The recessed design ensures the bolt is fully received within the sleeve, allowing the end face to be flat. The plane formed by this end face serves as the connection surface for the metallurgical bond with the connecting part.

[0014] The bolt, thus inserted into the sleeve, serves to absorb the tightening force when clamping the second connector between the end face of the sleeve opposite the recess and a nut screwed onto the bolt. An electrical path between the then screwed-together connectors runs from the connector in question, through the sleeve, to the second connector clamped to the sleeve. The second connector can be formed according to the above descriptions of the first connector, with a through-hole provided in the flattened or flat area into which the bolt, with its shank, can be inserted.

[0015] The bolt together with the sleeve thus forms a fastening means for a second connecting part to the first connecting part.

[0016] According to one embodiment, it is proposed that the bolt, with its collar-shaped bolt head projecting radially outwards, is supported at least partially circumferentially by a circumferential shoulder in the recess of the sleeve. The shoulder is formed in the recess of the sleeve in the manner of a fold. The bolt head projects radially outwards to the longitudinal direction of the bolt, particularly circumferentially. The cross-section of the bolt head is preferably round, but can also be polygonal, particularly hexagonal or octagonal. The cross-section of the recess can be adapted to the cross-section of the bolt. Particularly with a polygonal bolt head, this can secure the bolt in the sleeve against a torque acting about the longitudinal axis. This can simplify the screwing of a connecting part to the sleeve via the bolt.

[0017] The recess located at the end face of the sleeve preferably completely encloses the through-hole. This allows the bolt head to be fully inserted into the recess, and the bolt head no longer protrudes beyond the end face of the sleeve.

[0018] According to one embodiment, it is proposed that the bolt shank protrudes from the through-hole at an end of the sleeve distal to the recess. This protruding end serves to attach a second connecting part to the sleeve and thus to the first connecting part. The bolt shank can have a uniform cross-section along its longitudinal axis or different cross-sections. For example, the bolt shank can have areas with different radial projections in the region where it is inserted into the through-hole. The through-hole can correspond to these projections and, in particular, have a corresponding opening cross-section. Thus, the bolt shank can be positively engaged in the region of the through-hole.

[0019] According to one embodiment, it is proposed that one end of the bolt shaft has a thread, in particular that the thread extends into the through-hole. The bolt can be screwed to a second connecting part via this thread. Specifically, the second connecting part can be pressed against the end face of the sleeve by means of a nut.

[0020] As already mentioned, the bolt shank can be positively engaged in the through-hole. For this purpose, the bolt is knurled, at least in sections, according to one embodiment. The knurled portion has projections and recesses extending longitudinally along the bolt shank. Preferably, the knurled portion of the bolt shank is pressed into the through-hole by means of an interference fit. This can result in plastic deformation of the inner surface of the through-hole.

[0021] As already explained, it is preferable if the bolt is mounted in the sleeve in a rotationally secure manner. This can be achieved in particular by pressing the bolt shank into the through-hole.

[0022] According to one embodiment, it is proposed that the bolt head be arranged longitudinally at a distance from the end face in the recess. This ensures that, on the one hand, the end face can be welded flush with the connecting part, and on the other hand, that the bolt head is not in direct contact with the connecting part when welded.

[0023] The sleeve is preferably made of a copper alloy, and the bolt of a steel alloy. Preferably, the sleeve is made of a material that is more ductile than the bolt. However, the combination of copper and steel has proven advantageous. Because the bolt is less ductile than the sleeve, its thread offers greater resistance to thread shear during tightening than if the bolt were made of the same material as the sleeve. The bolt can therefore be tightened with a higher torque; in particular, a nut screwed onto the bolt's thread can be tightened with a higher torque than if the bolt were made of the same material as the sleeve.

[0024] According to one embodiment, it is proposed that the sleeve be friction-welded, and in particular completely friction-welded, to the connecting part at its end face. Rotary friction welding can be used for this purpose. The sleeve can preferably have a region with different radial dimensions. In particular, the outer cross-section can be polygonal, so that a friction welding tool with high torque enables friction welding. The sleeve does not need to be held in the friction welding tool by means of radially inward-directed contact forces; rather, the energy can be introduced to the outer surface of the sleeve via the positive locking between the sleeve and the friction welding tool.

[0025] According to the invention, it is proposed that a connecting element with an opening is placed over the bolt shaft. This connecting element has previously been described as a second connecting element. The connecting element can be formed according to the above description of the first connecting element. In particular, the connecting element has a flat area or a flattened section with the opening. The connecting element is clamped to the sleeve by a nut mounted on the bolt shaft. The nut can be screwed onto the bolt shaft with a tightening torque. The connecting element is clamped to the sleeve via the nut. The connecting element is in direct contact with the distal end of the sleeve, towards the retraction. An electrical path between the connecting element and the connecting element is ensured directly via the sleeve.

[0026] According to the invention, it is proposed that the connecting part, the sleeve and the bolt as well as the connecting part are encapsulated in a common housing, wherein the connecting part and the connecting part are led out of the housing in a moisture-proof manner.

[0027] The subject matter is explained in more detail below with reference to a drawing showing an exemplary embodiment. The drawing shows: Figs. 1a-d various connecting parts according to exemplary embodiments; Figs. 2a, b views of sleeves according to exemplary embodiments; Figs. 3a-c top views of end-face sleeves with recesses according to exemplary embodiments; Fig. 4 a view of a bolt according to an exemplary embodiment; Figs. 5a, b top views of bolt heads according to exemplary embodiments; Figs. 6a-c cross-sections of bolt shanks according to exemplary embodiments; Figs. 7a-c the production of a connection according to an exemplary embodiment.

[0028] Fig. 1a Figure 1 shows a first connection part according to an exemplary embodiment. Connection part 2 is a flat conductor in the example shown. The connection part in all variants presented here can be made of a copper alloy or an aluminum alloy.

[0029] The connecting part 2 has a longitudinal axis 4, a vertical axis 6 and a transverse axis 8. The connecting part 2 can have one or more flat connecting surfaces, which in particular run parallel to a plane spanned by two of the axes 4-8.

[0030] The connection part 2 according to the Fig. 1b The conductor can be shaped as a round conductor. A connection area 10 can be provided at one end or along the conductor. The connection area 10 can be formed as a flattened section. In particular, the connection area 10 is formed from the round conductor by upsetting or pressing.

[0031] Fig. 1c A connection part 2 is shown as a stranded conductor, with a connection area 10 also formed at the end face. The strands can be compacted in the connection area 10 and, in particular, welded or soldered together.

[0032] Fig. 1d Figure 2 shows a connecting part 2 as a braided band. The connecting area 10 can be formed along the braided band or at an end face. The strands of the braid can be joined together in the connecting area 10, in particular by means of a material bond, for example by ultrasonic welding or resistance welding. The embodiments shown in Figure 10 are described in Figure 1. Fig. 1a-d The described configurations can be combined as desired for different connection parts 2.

[0033] A sleeve is now proposed for connecting a connecting part 2 to a connecting part.

[0034] Fig. 2a Figure 1 shows a sleeve 12. The sleeve 12 has a longitudinal axis 14. The sleeve 12 has a through-opening 16. The through-opening 16 extends from a first end face 18a to a second end face 18b. The longitudinal axis 14 extends between the two end faces 18a and 18b. In the region of one end face 18a, the sleeve 12 has a recess 20. The recess 20 is preferably surrounded by the outer surface of the sleeve 12. The through-opening 16 is provided in the region of the recess 20, particularly centrally within the recess 20.

[0035] Fig. 2b Figure 1 shows the sleeve 12 in a longitudinal section. The recess 20 is visible. It is also evident that the sleeve 12 completely surrounds the recess 20. The through-opening 16 extends from the recess 20 to the end face 18b.

[0036] The sleeve 12 is preferably made of a copper or aluminum alloy. In particular, the sleeve 12 is made of the same material as the connecting part 2. Materials can be alloys, such as brass as a copper alloy.

[0037] The outer surface of the lateral surface as well as the cross-section of the recess 20 and the passage opening 16 can be round or angular, in particular circular, elliptical or polygonal.

[0038] The Fig. 3a-c The diagram shows various embodiments of the sleeve in a top view. Fig. 3a The outer surface of the sleeve 12 is octagonal. The recess 20 is adapted to this in its cross-section and is also octagonal. The through-opening 16 with a round cross-section is arranged within the recess 20.

[0039] Fig. 3b Figure 1 shows another embodiment in which the outer surface of the sleeve 12 and the recess 20 are round, in particular circular. The through-opening 16 within the recess 20, however, is hexagonal.

[0040] Fig. 3c shows in contrast to the Fig. 3b The through-opening 16 has a star-shaped cross-section. A wide variety of shapes can be combined with one another.

[0041] Fig. 4 Figure 1 shows a bolt 22. The bolt 22 has a longitudinal axis 24. The bolt 22 has a bolt head 26 and a bolt shank 28. The bolt shank 28 extends along the longitudinal axis 24. The bolt shank 28 can have a first region 28a and a second region 28b. The first region 28a is preferably inserted into the through-opening 16, and the second region 28b projects beyond the end face 18b. In region 28a, the bolt shank 28 can be knurled in the direction of the longitudinal axis 24, whereas region 28b of the bolt shank 28 can be threaded.

[0042] The bolt head 26 can be described in its cross-section as shown in the Fig. 5a und b As shown, it should be adapted to a cross-section of the setback 20. Thus, it shows Fig. 5a a bolt head 26 with an octagonal cross-section, whereas Fig. 5b Figure 26 shows a bolt head 26 with a star-shaped cross-section. This and other cross-sections are conceivable. The cross-sections of the bolt head 26 and the recess 20 can be congruent with each other, so that the bolt head 26 can be positively engaged in the recess 20. This positive engagement prevents the bolt 22 from rotating in the through-opening 16, so that the bolt 22 can be screwed onto the sleeve 12 via the thread in area 28b.

[0043] In addition to various cross-sections of the bolt head according to the Fig. 5a, b The bolt shaft 28, particularly in region 28a, can also have a cross-section that is not circular. This is shown in the figure below. Fig. 6a a bolt shaft 22 in area 28a, which is oval. Fig. 6b shows a bolt shaft 22 in a cross-section in the area 28a, which is triangular and Fig. 6c shows a corresponding square cross-section.

[0044] The through-hole 16 and the cross-section of the bolt shank 22 in region 28a can be congruent to each other. It is also possible that the knurling in region 28a is such that its maximum diameter is slightly larger than the diameter of the through-hole 16, so that when the bolt 22 is inserted into the through-hole 16, an interference fit is formed between the bolt 26 in region 28a and the through-hole 16. In this case, the knurling can lead to plastic deformation of the inner surface of the through-hole 16.

[0045] The Fig. 7a-c demonstrate the creation of a tangible connection. First ( Fig. 7a The bolt 22 is inserted into the sleeve 12 so that the bolt head 26 is recessed in the recess 20. The bolt shank 28 is within the through-opening 16 with its section 28a, whereas the bolt shank 28 protrudes from the end face 18b of the sleeve 12 in its section 28b.

[0046] After the bolt 22 has been inserted into the through-opening 16, the sleeve 12 is joined to the connecting part 2 in the area of ​​the end face 18a by a material bond, in particular by welding ( Fig 7b In this process, a welding tool can press the sleeve 12 against the connection area 10 by means of friction welding, and the introduced rotational energy can cause the joining partners to melt. Resistance welding can also be performed.

[0047] After the sleeve 12 has been welded onto the connecting part 2, a connecting part 30, which may be shaped according to a connecting part described herein or in a different form, can be attached to the bolt 22, in particular by screwing it on. The connecting part 30 is in particular a cable, especially as described in the Fig. 1a-d is described.

[0048] The connecting part 30 has a through-opening 32. The connecting part 30 is placed onto the bolt 22, specifically the bolt shaft 28 in area 28b, via the through-opening 32. A nut 34 is then screwed onto the bolt 22. When tightened, the nut 34 presses the connecting part 30 against the end face 18b of the sleeve 12.

[0049] The bolt 22 is preferably made of a harder material than the sleeve 12. This allows the nut 34 to be tightened with a higher torque than if the bolt 22 were made of the same material as the sleeve 12. The sleeve 12 is preferably made of a copper or aluminum alloy, and the bolt 22 of a steel alloy.

[0050] An electrical connection between the connecting part 30 and the terminal part 2 is made in particular via the sleeve 12. The bolt 22 preferably serves for the mechanical fixing of the connecting part 30 to the sleeve 12, which in turn is joined to the terminal part 2 in the area of ​​the end face 18a by a material bond. Reference symbol list

[0051] 2 Connection part 4 Longitudinal axis 6 Vertical axis 8 Transverse axis 10 Connection area 12 Sleeve 14 Longitudinal axis 16 Through opening 18a, end face 20 Recess 22 Bolt 24 Longitudinal axis 26 Bolt head 28 Bolt shank 28a, b area 30 Connecting part 32 Through opening 34 Nut

Claims

1. Connection comprising - a connecting part (2), - a sleeve (12) connected to the connecting part (2) in a material-locking manner and having a through-opening (16) extending in the longitudinal direction (4), and - a bolt (22) connected to the sleeve (12) and having a bolt shank (28) and a bolt head (26), wherein - the bolt (22) is pressed with its bolt shank (28) in the longitudinal direction (4) into the through-opening (16) of the sleeve (12), - the bolt (22) being arranged with its bolt head (26) in a recess arranged at an end face of the sleeve (12), wherein - the sleeve (12) is connected in a material-locking manner to the connecting part (2) with its end face, wherein - a connection part (30) with an opening is placed over the bolt shank (28) and is clamped to the sleeve (12) with a nut mounted on the bolt shank (28), so that the connection part (30) is in direct contact with the end of the sleeve (12) distal to the recess, - characterised in that - the connecting part (2), the sleeve (12), the bolt (22) and the connection part (30) are encapsulated in a common housing, wherein the connecting part (2) and the connecting part (30) are led out of the housing in a moisture-tight manner.

2. Connection according to claim 1, characterised in that - the bolt (22) with its collar-shaped bolt head (26) projecting radially outwards is at least partially supported circumferentially on a circumferential shoulder in the recess of the sleeve (12).

3. Connection according to claim 1 or 2, characterised in that - the recess arranged at the front end of the sleeve (12) surrounds the through-opening (16) of the sleeve (12).

4. Connection according to one of the preceding claims, characterised in that - the bolt shank (28) protrudes with its shaft end out of the through-opening (16) at a distal end of the sleeve (12) relative to the recess.

5. Connection according to one of the preceding claims, characterised in that - a shaft end of the bolt (22) has a thread, in particular that the thread protrudes into the through-opening (16).

6. Connection according to one of the preceding claims, characterised in that - the bolt shank (28) is knurled at least in sections and the knurled part is pressed into the through-opening (16) in a press fit.

7. Connection according to one of the preceding claims, characterised in that - the bolt (22) is pressed into the through-opening (16) in a manner that prevents it from turning.

8. Connection according to one of the preceding claims, characterised in that - the bolt head (26) is arranged in the longitudinal direction (4) at a distance from the end face in the recess.

9. Connection according to one of the preceding claims, characterised in that - the sleeve (12) is made of a copper material and / or the bolt (22) is made of steel.

10. Connection according to one of the preceding claims, characterised in that - the sleeve is rotationally friction welded to the connecting part with the end face.

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