Profile element for producing a cable lug

Abstract

The disclosure comprises a profile element (1) for manufacturing a cable lug (60) for connecting a cable (50), comprising: a cuboid and hollow profile body (2), wherein the profile body (2) has inside it at least two cable receiving chambers (3, 4) arranged side by side and extending along a longitudinal axis (5) of the profile body (2), wherein the at least two cable receiving chambers (3, 4) are separated from each other by a separating element (6) which extends inside the profile body (2) along the longitudinal axis (5).

Description

TECHNICAL AREA

[0001] The present invention relates to a profile element for manufacturing a cable lug and to a cable lug. BACKGROUND OF THE INVENTION

[0002] In the prior art, cable lugs are a common device for connecting electrical conductors, especially flat conductors. An example of such a cable lug is described in DE 10 200 701 5696 A. A cable lug is generally manufactured from an extruded profile or from a standard profile tube or profile element.

[0003] To create an electrical connection, the conductor to be connected, i.e., the stranded ends of the stripped conductor, is inserted into a chamber with an opening in a receiving area of ​​the profile element. The receiving area is then crimped or pressed to create a positive-locking connection between the conductor and the profile element of the cable lug in this known manner.

[0004] However, particularly with electrical conductors or electrical connectors designed as flat cables or flat conductors and having a relatively large and rectangular conductor cross-section, for example 500 to approximately 2000 mm², there is a risk that the cable lug would spring back due to its elastic material properties with this crimped flat conductor.

[0005] This kind of springiness prevents sufficient contact force from forming between the cable lug and the individual strands of the flat conductor. As a result, oxygen can reach the strands of the flat conductor, increasing the contact resistance and thus reducing the quality of the electrical connection.

[0006] It is therefore the object of the present invention to provide a solution for an improved cable lug that enables a high-quality and reliable electrical connection of a cable with low contact resistance. SUMMARY OF THE INVENTION

[0007] This problem is solved by a profile element for manufacturing a cable lug for connecting a cable, in particular a flat cable, with the features of the independent claim.

[0008] According to a first aspect, the disclosure relates to a profile element for manufacturing a cable lug, which has the following features: a cuboid and hollow profile body, wherein the profile body has inside it at least two cable receiving chambers arranged next to each other and extending along a longitudinal axis of the profile body, wherein the at least two cable receiving chambers are separated from each other by a separating element which extends inside the profile body along the longitudinal axis.

[0009] A fundamental concept of the present invention is that the cable lug, manufactured from a profile element, has at least two cable receiving chambers separated from each other by a separating element or a stiffening rib running between the two cable receiving chambers. The separating element ensures that the entire cable lug is mechanically stiffened after crimping, so that the resulting electrical connection between the conductor and the cable lug has a consistent quality.

[0010] The present invention has the advantage that the cable lug formed from the profile element according to the invention for connecting a cable, in particular a flat cable with a rectangular cross-section, has a low contact resistance and enables a high-quality and reliable electrical connection between the conductor and the cable lug produced or formed from the profile element.

[0011] Furthermore, due to the inserted separating element between the cable receiving chambers of the profile element, oxidation of the cable strands is prevented, since when the profile element is crimped to form a cable lug, the material of the separating element bonds with the cable strands.

[0012] Furthermore, the profile element according to the invention allows for the simple and efficient production of cable lugs for so-called parallel connectors, the length of which can be easily and repeatedly extended as required. This simply requires mechanically and electrically connecting a collection of conductors in series using a corresponding number of profile elements according to the invention as connecting elements.

[0013] One possible embodiment of the present invention consists in the profile body having a material recess on at least one outer surface, which is arranged in the longitudinal direction of the profile element, and wherein the material recess is furthermore arranged in a region of the profile body that separates the at least two cable receiving chambers from one another. This achieves the advantage that, when the profile element is crimped to form a cable lug, the material of the separating element can move into the material recess and the electrical conductivity of the cable lug is at least maintained.

[0014] One possible embodiment of the present invention consists in the first wall thickness of the separating element being less than or equal to the second wall thickness of the profile body. This enables the efficient production of a stable cable lug with good electrical conductivity properties from the profile element.

[0015] One possible embodiment of the present invention consists in the fact that the at least two cable receiving chambers each have identical dimensions. This enables simple and cost-effective manufacturing of a cable lug.

[0016] One possible embodiment of the present invention consists in the profile body having an insertion phase which is attached to the end face of at least one end section in an inner region of the at least two cable receiving chambers of the profile body. This facilitates the insertion of a conductor into the profile body.

[0017] One possible embodiment of the present invention consists in the profile element being made of copper or aluminum. This enables the efficient and cost-effective production of a cable lug from the profile element according to the invention.

[0018] According to a second aspect, the present disclosure relates to a cable lug for receiving an electrical flat conductor with a profile element according to one of the preceding embodiments, comprising a contact area and a receiving area, wherein the receiving area is configured to receive the electrical (flat) conductor, and wherein the receiving area consists of a first end section of the profile element and the contact area consists of a second end section of the profile element opposite the first end section, wherein the contact area is configured such that, after a crimping process of this area, the material of the separating element fills the material recess on the outside of the profile body flush with the surface.

[0019] According to a third aspect, the present disclosure relates to a parallel connector with a profile element according to one of the preceding embodiments for electrically connecting a first conductor string and a second conductor string via the profile element, wherein the first conductor string is arranged at a first end section of the profile element and the second conductor string is arranged at a second end section of the profile element opposite the first end section. BRIEF DESCRIPTION OF THE FIGURES

[0020] Further measures improving the invention are described in more detail below, together with a description of preferred embodiments of the invention, with reference to the figures. The figures show: Figure 1 Profile element according to an embodiment of the present invention; Figure 2 Profile element according to an embodiment of the present invention; Figure 3-1 Profile element according to an embodiment of the present invention; Figure 3-2 Profile element in top view according to an embodiment of the present invention; Figure 3-3 Profile element from the front according to an embodiment of the present invention; Figure 4-1 Cable lug made of a profile element according to an embodiment of the present invention; Figure 4-2 Cable lug made of a profile element according to an embodiment of the present invention; Figure 4-3 Cable lug made from a profile element in top view according to an embodiment of the present invention; Figure 5 Cable lug made of a profile element according to an embodiment of the present invention with inserted flat conductor cable; Figure 6 Cable lug made of a profile element according to an embodiment of the present invention with an inserted flat conductor cable; and Figure 7 Parallel connector made of a profile element according to an embodiment of the present invention with two inserted flat conductor cables. DETAILED DESCRIPTION OF THE INVENTION

[0021] The Figure 1 Figure 1 shows a profile element 1 for manufacturing a cable lug 60 for connecting a cable 50 according to an embodiment of the present invention. The profile element 1 is to be regarded as the semi-finished product from which a cable lug is manufactured. The profile element 1 can be produced from an extruded profile or from a flow-formed part.

[0022] The profile element 1 has a cuboid and hollow profile body 2, wherein the profile body 2 has two cable receiving chambers 3, 4 arranged side by side and extending along a longitudinal axis 5 of the profile body 2. The two cable receiving chambers 3, 4 are separated from each other by a separating element 6, which extends within the profile body 2 along the longitudinal axis 5. However, the present invention is not limited to a profile body 2 with two cable receiving chambers. Depending on the application, the profile body 2 can have any number of adjacent cable receiving chambers 3, 4.

[0023] Optionally, and not shown in the figures, the profile element can also have a so-called capillary stopper. This is to be regarded as a separating element formed transversely to the longitudinal axis 5 of the profile element 1, which limits the depth or length of the respective cable receiving chambers 3, 4.

[0024] The Figure 2 Figure 1 shows a profile element 1 according to an embodiment of the present invention. The profile body 2 has a material recess 9, 10 on at least one outer surface 7, 8. The outer surface 7 is, according to the Figure 2 to be regarded as the upper outer side and the outer side 8 as the lower outer side opposite the upper outer side 7 of the profile element 1.

[0025] The material recess, which can be designed as a groove-shaped material indentation or depression, for example a few millimeters deep, is arranged in the longitudinal direction or longitudinal axis 5 of the profile element 1. Furthermore, the material recess 9, 10 is arranged in a region of the profile body 2 that separates the two cable receiving chambers 3, 4 from each other. Figure 2 The profile element 1 has a first material recess 9, which is located on a top side of the profile body 2, and a second material recess 10, which is located on a bottom side, the underside of the profile body 2 opposite the top side.

[0026] In profile element 1 of the Figure 2It can be seen that the first wall thickness 12 of the separating element 6 is less than or equal to the second wall thickness 13 of the profile body 2. This is advantageous because it simplifies the manufacture of the profile element 1 and, furthermore, ensures optimal mechanical stiffening of the profile body 2.

[0027] Furthermore, in profile element 1 the Figure 2 It can be seen that the two cable receiving chambers 3, 4, which are arranged symmetrically to each other, each have the same dimensions with respect to their length, height, and depth. This is also advantageous, as it facilitates the quick and cost-effective production of the profile element 1 and furthermore ensures optimal mechanical stiffening of the profile body 2.

[0028] The profile element 1 is made of metal, preferably copper or aluminum, to ensure cost-effective and simple manufacturing of the profile element and the cable lug produced from it. Other metals may be used as material for the profile element 1 depending on the application.

[0029] The Figure 3-1 Figure 1 shows a profile element 1 according to a further embodiment of the present invention, wherein the profile body 2 has an insertion phase 15. This insertion phase 15 is attached to the end face of at least one end section 16, 17 in an inner region 3-1, 4-1 of the two cable receiving chambers 3, 4 of the profile body 2.

[0030] The insertion phase or insertion element 15 can optionally also be designed as a sloping or flattened material reinforcement or one bent outwards from the inner area 3-1, 4-1 on an outer side of at least one end section 16, 17 of the profile body 2, as shown in the Figure 3-1 as also shown. In principle, an insertion phase or chamfer facilitates the insertion of the strands of the flat conductor into the profile element 1.

[0031] The Figure 3-2 Figure 1 shows a profile element 1 in top view according to an embodiment of the present invention, as already described in detail in the preceding figures.

[0032] The Figure 3-3 Figure 1 shows a profile element 1 from the front according to an embodiment of the present invention, as already described in detail in the preceding figures. In this embodiment, the profile element 1 has no material recess.

[0033] The Figure 4-1 Figure 1 shows a cable lug 60 made from a profile element 1 according to an embodiment of the present invention. The cable lug 60 is designed to receive an electrical flat conductor 50 (not shown) with a profile element 1. The cable lug 60 has a contact area 62 and a receiving area 64. The receiving area 64 is designed to receive the electrical (flat) conductor 50. The receiving area 64 is formed by a first end section 65 of the profile element 1, and the contact area 62 by a second end section 66 of the profile element 1 opposite the first end section 65. The contact area 62 is formed by the material of the separating element 6 filling the material recess 9, 10 on the respective outer surface 7, 8 of the profile body 2 of the profile element 1 flush with the surface of this area after a crimping or pressing process, for example with a hydraulic press.

[0034] The Figure 4-2shows a cable lug 60 made from a profile element 1 according to an embodiment of the present invention and is comparable to the cable lug made of Figure 4-1 The receiving area 64 and the contact area 62 are connected to each other via a connecting bridge 67, which is created during a pressing or crimping process of the profile element 1 to produce the cable lug.

[0035] The Figure 4-3 Figure 1 shows a cable lug 60 made from a profile element 1 in a top view according to an embodiment of the present invention and is comparable to the cable lug made of Figure 4-1 .

[0036] The Figure 5 shows an application for a cable lug 60 made from a profile element 1 according to an embodiment of the present invention with an inserted flat conductor cable 50.

[0037] The Figure 6shows a cable lug 60 made from a profile element 1 according to an embodiment of the present invention with an inserted conductor string or flat conductor cable 76 in a further application.

[0038] The Figure 7 Figure 1 shows a parallel connector 80 made of a profile element 1 according to an embodiment of the present invention with two inserted flat conductor cables 76 for electrically connecting a first conductor strand 72 and a second conductor strand 74 via the profile element 1. The first conductor strand 72 is arranged at a first end section 73 of the profile element 1 and the second conductor strand 74 is arranged at a second end section 75 of the profile element 1 opposite the first end section 73.

[0039] A material recess as in the Figure 2 Is the cable lug 60 the Figure 6 as well as the parallel connector 80 from the Figure 7Not required, as neither is crimped. Here, the electrical connection of the flat conductor cable to the profile element is achieved by a simple plug-in process into the respective chambers of the profile element.

Claims

1. Profile element (1) for manufacturing a cable lug (60) for connecting a cable (50), comprising: a cuboid and hollow profile body (2), wherein the profile body (2) has inside it at least two cable receiving chambers (3, 4) arranged next to each other and extending along a longitudinal axis (5) of the profile body (2), wherein the at least two cable receiving chambers (3, 4) are separated from each other by a separating element (6) which extends inside the profile body (2) along the longitudinal axis (5).

2. Profile element (1) according to claim 1, wherein the profile body (2) has a material recess (9, 10) on at least one outer side (7, 8) which is arranged in the longitudinal direction (5) of the profile element (1) and wherein the material recess (9, 10) is further arranged in a region of the profile body (2) which separates the at least two cable receiving chambers (3, 4) from each other.

3. Profile element (1 according to one of the preceding claims, wherein a first wall thickness (12) of the separating element (6) is less than or equal to a second wall thickness (13) of the profile body (2).

4. Profile element (1) according to one of the preceding claims, wherein the at least two cable receiving chambers (3, 4) each have the same dimensions.

5. Profile element (1) according to one of the preceding claims, wherein the profile body (2) has an insertion phase (15) which is attached to the end face of at least one end section (16, 17) in an inner area (3-1, 4-1) of the at least two cable receiving chambers (3, 4) of the profile body (2).

6. Profile element (1) according to any of the preceding claims, wherein the profile element (1) is made of copper or aluminium.

7. Cable lug (60) for receiving an electrical flat conductor (50) with a profile element (1) according to one of the preceding claims, comprising a contact area (62) and a receiving area (64), wherein the receiving area (64) is configured to receive the electrical (flat) conductor (50), and wherein the receiving area (64) consists of a first end section (65) of the profile element (1) and the contact area (62) consists of a second end section (66) of the profile element (1) opposite the first end section (65), wherein the contact area (62) is configured such that, after a crimping process of this area, the material of the separating element (6) fills the material recess (9, 10) on the outside (7, 8) of the profile body (2) flush with the surface.

8. Parallel connector (80) with a profile element (1) according to one of the preceding claims for electrically connecting a first conductor string (72) and a second conductor string (74) via the profile element (1), wherein the first conductor string (72) is arranged at a first end section (73) of the profile element (1) and the second conductor string (74) is arranged at a second end section (75) of the profile element (1) opposite the first end section (73).

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