High voltage connector for an aluminum cable with a copper terminal

Abstract

The invention is directed to a connector (1), comprising an aluminum cable (2) and a copper terminal (4), further comprising a junction part (3), wherein said junction part (3) is made of aluminum and comprises a first end (5) able to be joined to the aluminum cable (2) and a second end (6) able to be joined to the copper terminal (4).

Description

Technical domain

[0001] The invention concerns a connector comprising an aluminum cable and a copper terminal.Background

[0002] It is known to make electrical connectors out of copper. Transport cables are also made of copper. Copper is a very good electrical conductor. Since both the connector and the cable are of the same matter, joining a connector to a cable, e.g. by welding is easy.

[0003] Now, there is a great need to replace the cable with aluminum. Aluminum is also a very good electrical conductor, but it is lighter and cheaper.

[0004] For compatibility reasons, with existing copper connectors and their copper terminals, the terminal must remain in copper.

[0005] Accordingly, there is a need for a connector joining an aluminum cable with a copper terminal.Summary of the invention

[0006] The invention is directed to a connector, comprising an aluminum cable, a copper terminal, and a junction part, wherein said junction part is made of aluminum and comprises a first end able to be joined to the aluminum cable and a second end able to be joined to the copper terminal.

[0007] Some specific features or embodiments, usable alone or in combination, are: the first end comprises an inner cylinder, along a connector's axis, set up to tightly welcome the aluminum cable, and the aluminum cable, inserted in said inner cylinder, and said inner cylinder of the first end, are joined by EMPT welding, the first end comprises an inner cylinder, along the connector's axis, set up to tightly welcome the aluminum cable, and the aluminum cable, inserted in said inner cylinder, and said inner cylinder of the first end, are joined by radial crimping, the second end comprises an inner cylinder, respectively an outer cylinder, along the connector's axis, the copper terminal comprises a corresponding outer cylinder, respectively an inner cylinder, along the connector's axis, both cylinders set up to tightly engage one another, and once engaged one another, are joined by EMPT welding, the second end comprises a first face perpendicular to the connector's axis, and the copper terminal comprises a corresponding second face perpendicular to the connector's axis, facing the first face, and the first face of the second end and the second face of the copper terminal are joined by friction welding, the second end comprises an inner cylinder, respectively an outer cylinder, along the connector's axis, the copper terminal comprises a corresponding outer cylinder, respectively an inner cylinder, along the connector's axis, both cylinders set up to tightly engage one another, and once engaged one another, are joined by longitudinal press fitting, the second end comprises an inner cylinder, respectively an outer cylinder, along the connector's axis, the copper terminal comprises a corresponding outer cylinder, respectively an inner cylinder, along the connector's axis, both cylinders set up to tightly engage one another, and once engaged one another, are joined by radial crimping, the second end comprises an inner cylinder, respectively an outer cylinder, along the connector's axis, the copper terminal comprises a corresponding outer cylinder, respectively an inner cylinder, along the connector's axis, both cylinders set up to tightly engage one another, and once engaged one another, are joined by longitudinal crimping, the connector further comprising an centerpin, the copper terminal and the second end of the junction part comprising an axial hole, along the connector's axis, set up to tightly welcome the centerpin, and the centerpin and the axial hole, once engaged one another, are joined by longitudinal crimping, the connector further comprising an centerpin, integral with the junction part, the copper terminal comprising an axial hole, along the connector's axis, set up to tightly welcome the centerpin, and the centerpin and the axial hole, once engaged one another, are joined by longitudinal crimping, the distal end of the centerpin is made of an insulating material.

[0008] The invention is further directed to a method of manufacturing such a connector, comprising the following steps: - joining the second end with the copper terminal, -joining the first end with the aluminum cable, said two steps being applied either in this order or simultaneously.Drawings

[0009] Others features, details and advantages of the invention will become more apparent from the detailed illustrating description given hereafter with respect to the drawings on which: [Fig. 1] shows, in perspective view, a connector, [Fig. 2] shows, in longitudinal cut view, the aluminum junction part and the copper terminal, before joining, [Fig. 3] shows, in longitudinal cut view, the junction part and the copper terminal, after joining, [Fig. 4] shows, in longitudinal cut view, the aluminum cable and the junction part, before joining, [Fig. 5] shows, in longitudinal cut view, the aluminum cable and the junction part, after joining, [Fig. 6] illustrates the EMPT welding joining, [Fig. 7] illustrates the friction welding joining, [Fig. 8] illustrates the press-fit joining, [Fig. 9] illustrates the radial crimping joining, [Fig. 10] illustrates the longitudinal crimping joining, [Fig. 11] shows a crossing centerpin, [Fig. 12] shows an centerpin integral to the junction part. Detailed description

[0010] One object of the invention is a connector 1. Said connector 1 comprises an aluminum cable 2 and a copper terminal 4. Since said two materials are not easy to bond one another, according to a feature, the connector 1 further comprises a junction part 3, to be inserted inbetween said aluminum cable 2 and said copper terminal 4, so as to join them while assuring the electrical continuity.

[0011] Accordingly, said junction part 3 is made of aluminum and comprises a first end 5 able to be joined to the aluminum cable 2 and a second end 6 able to be joined to the copper terminal 4.

[0012] By adding said junction part 3, the connector 1 allows to separate the joining of the aluminum cable 2 with the copper terminal 4 in two joints: a first joint between the first end 5 of the junction part 3 and the aluminum cable 2 and a second joint between the second end 6 of the junction part 3 and the copper terminal 4. This allows applying different methods of joining to the two ends 5, 6 and to distinguish two joining times.

[0013] Let us first focus on the first end 5 of the junction part 3. There is different ways to join the aluminum cable 2 to the first end 5 of the junction part 3.

[0014] Since the aluminum cable 2, be it massive or stranded, noticeably exhibits the shape of an outer cylinder, as illustrated on figures 4 and 5, the first end 5 is advantageously shaped to comprise an inner cylinder 7, along an axis A of the connector 1. Said inner cylinder 7 is preferentially set up to tightly accommodate the outer diameter of the aluminum cable 2. So the aluminum cable 2 can be inserted in said inner cylinder 7. Once inserted, according to another feature, the aluminum cable 2 and said inner cylinder 7 of the first end 5 of the junction part 3 can be joined by Electro Magnetic Pulse Technology welding or EMPT welding. Figure 4 shows the aluminum cable 2 inserted in the inner cylinder 7 before the EMPT welding operation. Figure 5 shows the same after the EMPT welding operation. The EMPT causes the inner cylinder 7 to shrink around the platinum cable 2.

[0015] EMPT welding is a technology that realizes a cold welding based on electromagnetic energies. This technology can be applied only to conductive materials. It has the advantage of being appliable to materials exhibiting different fusing points, contrary to other welding technology. This technology can thus be applied to the joining of a copper part with an aluminum part. It can also be applied to the joining of an aluminum part with an aluminum part.

[0016] Keeping the same outer cylinder shape of the aluminum cable 2 and the same inner cylinder 7 shape of the first end 5, according to another feature, illustrated on figure 4 and 5, the aluminum cable 2 and said inner cylinder 7 of the first end 5 of the junction part 3 can be joined by radial crimping. Figure 4 shows the aluminum cable 2 inserted in the inner cylinder 7 before the radial crimping operation. Figure 5 shows the same after the radial crimping operation. The radial crimping operation is applied by crimping tools, mechanically radially restraining the diameter of the inner cylinder 7 around the aluminum cable 2.

[0017] Let us now focus on the second end 6 of the junction part 3. There is different ways to join the second end 6 of the junction part 3 to the copper terminal 4.

[0018] According to another feature, as illustrated in figures 2, 3 and 6, the second end 6 may comprise an inner cylinder 8, along the connector's axis A, the copper terminal 4 may comprises a corresponding outer cylinder 9, along the connector's axis A. Both cylinders 8, 9 are set up to tightly engage to one another. Once engaged to one another, they can be joined by EMPT welding. As previously indicated, EMPT welding can positively accommodate the material difference and efficiently join aluminum junction part 3 with copper terminal 4. Figure 2 shows the outer cylinder 9 inserted in the inner cylinder 8 before the EMPT welding operation. Figure 3 shows the same after the EMPT welding operation.

[0019] Alternately, but not illustrated, the second end 6 may comprise an outer cylinder, along the connector's axis A, and the copper terminal 4 may comprise a corresponding inner cylinder, along the connector's axis A. Both cylinders are set up to tightly engage to one another. Once engaged to one another, they can be joined by EMPT welding

[0020] According to another feature, as illustrated in figure 7, the second end 6 may comprise a first face 10 perpendicular to the connector's axis A, and the copper terminal 4 may comprise a corresponding second face 11 perpendicular to the connector's axis A, facing the first face 10. Said disposition allows, using turning and pressing tools T, to join the first face 10 of the second end 6 with the second face 11 of the copper terminal 4 by friction welding. It is to be noted that friction welding allows the welding of different materials.

[0021] According to another feature, as illustrated in figure 8, the second end 6 may comprise an inner cylinder 12, along the connector's axis A, the copper terminal 4 may comprise a corresponding outer cylinder 13, along the connector's axis A, both cylinders 12, 13 set up to tightly engage to one another, and once engaged to one another, are joined by longitudinal press fitting.

[0022] Press fitting consists in conforming two corresponding shapes, tightly adjusted and comprising a complementary micro shape slightly reversibly deformable on both parts in order to obtain a "click" interlocking of both parts, when in the wished relative position. So, both cylinders 12, 13 are cylindrically engaged, to one another, and their corresponding micro shapes cooperate when they axially abut.

[0023] Alternately, but not illustrated, the second end 6 may comprise an outer cylinder, along the connector's axis A, and the copper terminal 4 may comprise a corresponding inner cylinder, along the connector's axis A. Both cylinders are set up to tightly engage to one another. Once engaged to one another, they can be joined by longitudinal press fitting.

[0024] According to another feature, as illustrated in figure 9, the second end 6 may comprise an inner cylinder 14, along the connector's axis A, the copper terminal 4 may comprise a corresponding outer cylinder 15, along the connector's axis A, both cylinders 14, 15 set up to tightly engage to one another. Once engaged to one another, they can be joined by radial crimping.

[0025] Radial crimping is a joining method based on applying a mechanical pressure to radially deform at least one of the parts to be joined. Here, deformations are applied radially, along the arrows.

[0026] Alternately, but not illustrated, the second end 6 may comprise an outer cylinder, along the connector's axis A, and the copper terminal 4 may comprise a corresponding inner cylinder, along the connector's axis A. Both cylinders are set up to tightly engage to one another. Once engaged to one another, they can be joined by radial crimping.

[0027] According to another feature, as illustrated in figure 10, the second end 6 may comprise an inner cylinder 16, along the connector's axis A, the copper terminal 4 may comprise a corresponding outer cylinder 17, along the connector's axis A, both cylinders 16, 17 set up to tightly engage to one another. Once engaged to one another, they can be joined by longitudinal crimping.

[0028] Longitudinal, here, is along the connector's axis A. Longitudinal crimping is a joining method based on applying a mechanical pressure to longitudinally deform at least one of the parts to be joined. Here, the deformation is applied longitudinally, along the connector's axis A, to the end of the outer cylinder 17. The aim is to shape the end of the inserted outer cylinder 17 of the copper terminal 4, protruding out of the inner cylinder 16, with a stop S, in order to forbid a retreat out of the inner cylinder 16.

[0029] Alternately, but not illustrated, the second end 6 may comprise an outer cylinder, along the connector's axis A, and the copper terminal 4 may comprise a corresponding inner cylinder, along the connector's axis A. Both cylinders are set up to tightly engage to one another. Once engaged to one another, they can be joined by longitudinal crimping.

[0030] In all the preceding embodiments, the copper terminal 4 can comprise at least one flexible lamella to help contact with a corresponding terminal of a counter connector and to help transferring electricity.

[0031] According to another feature, as illustrated in figures 8-12, the connector 1 further comprises a centerpin 18. Said centerpin 18 is aligned with the connector's axis A.

[0032] According to a first feature, the copper terminal 4 and the second end 6 of the junction part 3 comprise an axial hole 19, along the connector's axis A. Said axial hole 19 is set up to tightly welcome the centerpin 18, and the centerpin 18 and the axial hole 19, once engaged to one another, are joined by longitudinal crimping.

[0033] According to another feature, as illustrated in figures 12, the centerpin 18 is made integral with the junction part 3 and the copper terminal 4 comprises an axial hole 19, along the connector's axis A, set up to tightly welcome the centerpin 18. The centerpin 18 and the axial hole 19, once engaged to one another, are joined by longitudinal crimping.

[0034] According to another feature, more particularly illustrated in figure 8, the centerpin 18 comprises a distal end 20 made of an insulating material. The centerpin 18 is conductive and connected, through the junction part 3, to the aluminum cable 2. It can thus be at a high electrical potential. So, to avoid a possibly vulnerating contact between said high potential and an operator's digit, when the connector 1 is disconnected / open, the tip or distal end 20 of the centerpin 16 is insulated.

[0035] When it comes to manufacturing such a connector 1, the invention further consists of a manufacturing method. Said method comprises two steps. A first step consists in joining the second end 6 with the copper terminal 4. A further step consists in joining the first end 5 with the aluminum cable 2. In order not to too heavily deform the junction part 3, which could occur when joining the first end 5 with the aluminum cable 2, said two steps must be applied in this order.

[0036] Alternately, said two steps can be applied simultaneously.

[0037] While there is shown and described the present preferred embodiment of the invention, it is to be distinctly understood that this invention is not limited thereto but may be variously embodied to practice within the scope of the following claims.Reference sign list

[0038] 1: connector, 2: aluminum cable, 3: junction part, 4: copper terminal, 5: first end, 6: second end, 7: inner cylinder 8: inner cylinder, 9: outer cylinder, 10: first face, 11: second face, 12: inner cylinder, 13: outer cylinder, 14: inner cylinder, 15: outer cylinder, 16: inner cylinder, 17: outer cylinder, 18: centerpin, 19: axial hole, 20: distal end, A: connector's axis, S : stop, sd : stop.

Claims

1. A connector (1), comprising an aluminum cable (2) and a copper terminal (4), characterized in that it further comprises a junction part (3), wherein said junction part (3) is made of aluminum and comprises a first end (5) able to be joined to the aluminum cable (2) and a second end (6) able to be joined to the copper terminal (4).

2. The connector (1) according to claim 1, wherein the first end (5) comprises an inner cylinder (7), along a connector's axis (A), set up to tightly welcome the aluminum cable (2), and the aluminum cable (2), inserted in said inner cylinder (7), and said inner cylinder (7) of the first end (5), are joined by EMPT welding.

3. The connector (1) according to claim 1, wherein the first end (5) comprises an inner cylinder (7), along the connector's axis (A), set up to tightly welcome the aluminum cable (2), and the aluminum cable (2), inserted in said inner cylinder (7), and said inner cylinder (7) of the first end (5), are joined by radial crimping.

4. The connector (1) according to any one of claims 1 to 3, wherein the second end (6) comprises an inner cylinder (8), respectively an outer cylinder, along the connector's axis (A), the copper terminal (4) comprises a corresponding outer cylinder (9), respectively an inner cylinder, along the connector's axis (A), both cylinders (8, 9) set up to tightly engage one another, and once engaged one another, are joined by EMPT welding.

5. The connector (1) according to any one of claims 1 to 3, wherein the second end (6) comprises a first face (10) perpendicular to the connector's axis (A), and the copper terminal (4) comprises a corresponding second face (11) perpendicular to the connector's axis (A), facing the first face (10), and the first face (10) of the second end (6) and the second face (11) of the copper terminal (4) are joined by friction welding.

6. The connector (1) according to any one of claims 1 to 3, wherein the second end (6) comprises an inner cylinder (12), respectively an outer cylinder, along the connector's axis (A), the copper terminal (4) comprises a corresponding outer cylinder (13), respectively an inner cylinder, along the connector's axis (A), both cylinders (12, 13) set up to tightly engage one another, and once engaged one another, are joined by longitudinal press fitting.

7. The connector (1) according to any one of claims 1 to 3, wherein the second end (6) comprises an inner cylinder (14), respectively an outer cylinder, along the connector's axis (A), the copper terminal (4) comprises a corresponding outer cylinder (15), respectively an inner cylinder, along the connector's axis (A), both cylinders (14, 15) set up to tightly engage one another, and once engaged one another, are joined by radial crimping.

8. The connector (1) according to any one of claims 1 to 3, wherein the second end (6) comprises an inner cylinder (16), respectively an outer cylinder, along the connector's axis (A), the copper terminal (4) comprises a corresponding outer cylinder (17), respectively an inner cylinder, along the connector's axis (A), both cylinders (16, 17) set up to tightly engage one another, and once engaged one another, are joined by longitudinal crimping.

9. The connector (1) according to any one of claims 1 to 8, further comprising an centerpin (18), the copper terminal (4) and the second end (6) of the junction part (3) comprising an axial hole (19), along the connector's axis (A), set up to tightly welcome the centerpin (18), and the centerpin (18) and the axial hole (19), once engaged one another, are joined by longitudinal crimping.

10. The connector (1) according to any one of claims 1 to 8, further comprising an centerpin (18) integral with the junction part (3), the copper terminal (4) comprising an axial hole (19), along the connector's axis (A), set up to tightly welcome the centerpin (18), and the centerpin (18) and the axial hole (19), once engaged one another, are joined by longitudinal crimping.

11. The connector (1) according to any one of claims 9 to 10, wherein the distal end (20) of the centerpin (18) is made of an insulating material.

12. A method of manufacturing a connector (1) according to any one of claims 1 to 10, comprising the following steps: - joining the second end (6) with the copper terminal (4), - joining the first end (5) with the aluminum cable (2), said two steps being applied either in this order or simultaneously.

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