METHOD FOR MANUFACTURING ELECTRICAL CONNECTION DEVICE AND ELECTRICAL CONNECTION DEVICE - Patent application

Abstract

The subject of the present invention is a method for manufacturing an electrical connection device (100), comprising the method steps of providing at least one connection device (110) having an insulating material housing (112) with a receiving area (115) for receiving a marking plate (111), providing at least one marking plate (111), inserting the at least one marking plate (111) into the receiving area (115) of the insulating material housing (112) of the at least one connection device (110), and forming at least one integral joint connection (119) between the at least one marking plate (111) and the insulating material housing (112) of the at least one connection device (110) by laser beam welding.

Description

[Technical field]

[0001] The present invention relates to a method for manufacturing an electrical connection device The present invention further relates to such an electrical connection device. [Background technology]

[0002] In control cabinets, marking plates are used to indicate the connections of, for example, connection terminals, terminal blocks, plug connectors, etc., which are hereinafter referred to collectively as connection devices. The marking plates themselves are, for example, attached directly to the connection devices, in particular to the insulating material housings of the connection devices. For this purpose, the marking plates usually have a clamping geometry in the region of their feet in order to be received by form-fitting and / or press-fitting into recesses in the insulating material housings of the connection devices.

[0003] It has been shown that simply pressing the marking plate into a recess in the insulating material housing is only suitable to a limited extent for automated production. Vibrations, shocks or other dynamic effects during automated handling of the connection device may therefore cause the marking plate to loosen or slip out of the desired position, making subsequent automated labelling of the marking plate impossible. Thus, up until now, it has not been possible to use such clampable marking plates for the automated production of connection devices. Summary of the Invention [Problem to be solved by the invention]

[0004] Based on this background, it is an object of the present invention to provide a method for manufacturing an electrical connection device that allows reliable automated production, as well as an electrical connection device. [Means for solving the problem]

[0005] This object is achieved according to the invention by means of the features of the independent claims. Exemplary embodiments and advantageous developments of the invention are set out in the dependent claims.

[0006] The method for manufacturing an electrical connection device according to the invention is characterized in that it comprises the method steps of providing at least one connection device having an insulating material housing with a receiving area for receiving a marking plate, providing at least one marking plate, inserting the at least one marking plate into the receiving area of ​​the insulating material housing of the at least one connection device, and forming at least one integral joint connection between the at least one marking plate and the insulating material housing by laser beam welding.

[0007] By forming an integral joint connection between the marking plate inserted in the receiving area and the insulating material housing by laser beam welding, a reliable fixation of the marking plate on the insulating material housing can be achieved, which also does not come loose due to transport-related vibrations or shocks during automated production. For example, a connection device such as a terminal block can thus be equipped with one or more marking plates that are initially mounted on a support rail in connection with an automated control cabinet production, and the one or more marking plates accommodated in the insulating material housing of the connection device are then labelled without risk of loss of the one or more marking plates throughout the entire process. The integral joint connection between the marking plate and the insulating material housing ensures a positionally correct or positionally stable arrangement of the marking plate on the insulating material housing, which prevents errors during the subsequent labelling of any marking plate, particularly in the case of an automated labelling of the marking plate. The integral joint connection can be formed by a point-like or line-like weld seam between the marking plate and the insulating material housing. The receiving area is preferably formed on the outer surface of the insulating material housing. The receiving area may for example take the form of a recess, a notch, an opening, a groove, etc. in the insulating material housing. The receiving area allows a defined positioning of the marking plate on the insulating material housing of the connecting device.

[0008] The connection device may be a connection terminal, a terminal block, a plug connector, etc. The connection device preferably has at least one connection element inside an insulating material housing, via which e.g. a cable or a conductor or a mating plug connector can be contacted. The connection element may take the form of a spring-force terminal connection, a screw connection, an insulation-piercing connection, etc.

[0009] Laser beam welding is specifically performed in such a way that starting from a laser beam source, a laser beam is directed towards a predefined region of the insulating material housing and towards a predefined region of the marking plate. Both this region of the insulating material housing and this region of the marking plate are melted by the laser beam, whereby melts are formed in this melted region of the insulating material housing and in this melted region of the marking plate, which melts can at least partially mix to form an integral joint connection. The regions of the insulating material housing and the marking plate that are melted by the energy of the laser beam are preferably arranged directly adjacent to each other or adjacent to each other when the marking plate is inserted into the receiving area. The region of the insulating material housing that is melted by the laser beam can be, for example, a wall of the insulating material housing that defines the boundary of the receiving area. Furthermore, this region may also be formed in a region of the outer surface of the insulating material housing.

[0010] The insulating material housing may comprise, at least in the region of the integral joint connection to be formed, one of the following plastics: acrylonitrile butadiene styrene copolymer (ABS), polystyrene (PS), polycarbonate (PC), styrene acrylonitrile copolymer (SAN) or polymethylmethacrylate (PMMA), for example polypropylene (PP), polyamide (PA), polyimide (PI) polyoxymethylene (POM) or polyethylene (PE), polyarylsulfone (PSU, PPSU), polyetheretherketone (PEEK), polyester (PES), polyethyleneterephthalate (PET), silicone. A region of the receiving area is preferably a region in which the insulating material housing is melted by the energy of the laser beam to form the integral joint connection. It has been found to be particularly advantageous if the insulating material housing, at least in the region of the integral joint connection to be formed, comprises or consists of polyamide, in particular polyamide 6.6.

[0011] The marking plate may comprise or consist of one of the following plastics: acrylonitrile butadiene styrene copolymer (ABS), polystyrene (PS), polycarbonate (PC), styrene acrylonitrile copolymer (SAN) or polymethylmethacrylate (PMMA), for example polypropylene (PP), polyamide (PA), polyimide (PI), polyoxymethylene (POM) or polyethylene (PE), polyarylsulfone (PSU, PPSU), polyetheretherketone (PEEK), polyester (PES), polyethylene terephthalate (PET), silicone. It has proven to be particularly advantageous if the marking plate comprises or consists of polyamide, in particular polyamide 6.6.

[0012] The plastic material of the marking plate and the plastic material of the insulating material housing are selected such that they can be welded together by laser beam welding or are meltable or are meltable at least in partial regions. In order to be able to achieve good weldability and / or meltability, the plastic material of the marking plate and the plastic material of the insulating material housing are preferably selected to have similar melting points, in particular identical melting points. For the marking plate and the insulating material housing, the plastic materials are preferably selected to be of similar type, so as to have at least very similar properties, in particular very similar melting behavior.

[0013] After the laser beam welding, and thus after the integral joint connection between the insulating material housing and the marking plate is formed, the labeling and / or marking of the marking plate can be performed. The labeling and / or marking can be performed, for example, by laser labeling using a UV laser or a CO2 laser. The labeling and / or marking of the marking plate can be performed automatically, so that both the fixing of the marking plate to the insulating material housing and the labeling and / or marking of the fixed marking plate can be performed automatically.

[0014] Alternatively, however, it is also possible to label the marking plate before the laser beam welding and thus before an integral joint connection with the insulating material housing is formed, so that an already labeled marking plate may be connected to the insulating material housing.

[0015] Instead of laser marking, other labelling or marking methods may be used for labelling and / or marking the marking plate, such as inkjet printing, pad printing, etc.

[0016] The marking plate preferably has a labeling part and a foot part, and the marking plate can be integrally joined to the insulating material housing in the region of the labeling part of the marking plate by laser beam welding and / or the marking plate can be integrally connected to the insulating material housing in the region of the foot part of the marking plate by laser beam welding. The foot part is the part where the marking plate is inserted into the receiving area. In the inserted state of the marking plate in the receiving area, the labeling part of the marking plate can at least partially project from the receiving area, in particular when the receiving area takes the form of a recess. The foot part can have two tabs, in particular two protruding tabs, whereby an integral connection with the insulating material housing, and therefore a weld, can be formed in the region of these tabs.

[0017] To pre-fix the marking plate on the insulating material housing, the marking plate can be fixed in a receiving area of ​​the insulating material housing by form-fitting and / or press-fitting before the laser beam welding. In particular, the foot of the marking plate, for example the tab of the foot of the marking plate, can be engaged in an undercut or latch groove of the receiving area of ​​the insulating material housing and / or can be clamped in the receiving area of ​​the insulating material housing for the connection of the marking plate to the insulating material housing by form-fitting and / or press-fitting. In addition to the integral joint connection by laser beam welding, the marking plate can thus be connected by form-fitting and / or press-fitting to the insulating material housing of the connection device. Instead of the tab, the foot can have, for example, one or more latch lugs or latch hooks for forming a pre-fixing by form-fitting and / or press-fitting on the insulating material housing.

[0018] According to an alternative embodiment, the foot of the marking plate can take the form of a planar surface, in which case it does not include tabs or the like, so that no form-fit or press-fit connection of the marking plate to the insulating material housing has to be made in the area of ​​the receiving area, in which case the marking plate can be connected to the insulating material housing only by an integral joint by laser beam welding.

[0019] In particular, the joining of the marking plate to the insulating material housing is provided to take place without the aid of adhesive, so that an additional adhesive is preferably omitted entirely.

[0020] In particular, during laser beam welding, the adjacent plastic materials of the marking plate and the insulating material housing are homogeneously melted together.

[0021] The strength of the integral joint connection formed between the marking plate and the insulating material housing can be set by the welding parameters of the laser beam welding. For example, the strength of the welded connection can be set such that a mechanical break of the integral joint connection between the marking plate and the insulating material housing can be performed without tools, in order to enable replacement of the marking plate in a quick and simple manner. Alternatively, the strength of the welded connection can be set such that a mechanical break of the integral joint connection between the marking plate and the insulating material housing can be performed with the aid of a tool, such as a screwdriver, in order to enable replacement of the marking plate.

[0022] Furthermore, at least two connecting devices arranged in a row can be provided, and a marking plate can be inserted into a receiving area of ​​the respective insulating material housing of the at least two connecting devices, respectively, and a laser beam can be moved along the at least two connecting devices in order to form a laser beam weld and connect the marking plate to the respective insulating material housing by an integral joint. The welding of the marking plate to the respective insulating material housing of the two or more connecting devices can thus be performed directly one after the other and thus substantially simultaneously. The laser beam can be moved along the connecting devices arranged in a row or the connecting devices arranged in a row can be placed on a carrier through which a stationary laser beam can pass.

[0023] The object according to the invention is further achieved by an electrical connecting device comprising at least one connecting device having an insulating material housing with a receiving area for receiving a marking plate and at least one marking plate, wherein the marking plate is inserted into a receiving area of ​​the insulating material housing of the at least one connecting device, and the at least one marking plate inserted into the receiving area and the insulating material housing are integrally connected to one another by laser beam welding.

[0024] As a result, a cost-effective electrical connection device is presented that is optimized for automated assembly methods, and the integral bonded connection between the marking plate and the insulating material housing can reliably avoid loss of the marking plate due to transport-related shocks or vibrations.

[0025] The marking plate may have a labeling part and a foot part, and the marking plate may be joined to the insulating material housing in the region of the labeling part of the marking plate by laser beam welding and / or the marking plate may be integrally connected to the insulating material housing in the region of the foot part of the marking plate by laser beam welding. The labeling part preferably takes the form of a flat or planar surface. The inscription of the marking plate may be applied or applied onto the labeling part. The foot part preferably adjoins the labeling part directly. The foot part and the labeling part are preferably formed integrally with one another. The positioning of the marking plate in the receiving area of ​​the insulating material housing is preferably performed by the foot part. The foot part may have, for example, two tabs, in particular two protruding tabs. In the region of these tabs, in particular at the free ends of the tabs, an integral joint connection of the marking plate to the insulating material housing may be formed.

[0026] In order to be able to form a particularly firm connection between the marking plate and the insulating material housing, the marking plate can be connected to the insulating material housing by form-fitting and / or press-fitting in addition to the integral joint connection. This can be formed, for example, by feet of the marking plate, for example tabs on the feet, which engage in undercuts or grooves provided in the receiving area and / or are clamped, in particular resiliently clamped, in the receiving area itself.

[0027] Furthermore, at least two connection devices arranged in a row can be provided, and one marking plate can be inserted into a receiving area of ​​each insulating material housing of the at least two connection devices, and each marking plate can be connected to each insulating material housing by laser beam welding.

[0028] For example, two or more connection devices may be provided in the form of terminal blocks, such that the electrical connection apparatus comprises a plurality of terminal blocks arranged in a row, each terminal block being fitted with an associated marking plate such that the marking plates can be automatically labelled after integral joint connection of the respective connection device to the insulating material housing.

[0029] The invention will now be described in more detail below on the basis of preferred embodiments with reference to the accompanying drawings. [Brief description of the drawings]

[0030] [Figure 1] FIG. 1 is a schematic diagram of an electrical connection device including a connection device and a marking plate inserted into a recess in an insulating material housing of the connection device, where an integral joint connection with the insulating material housing is formed in the area of ​​the labeling portion of the marking plate. [Diagram 2] 2 is a schematic diagram of a connection arrangement consisting of a number of connection devices shown in FIG. 1 arranged in a row. [Diagram 3] FIG. 1 is a schematic diagram of an electrical connection device including a connection device and a marking plate inserted into a recess in an insulating material housing of the connection device, where an integral joint connection with the insulating material housing is formed in the area of ​​the foot of the marking plate. [Figure 4] 4 is a schematic diagram of the connection device shown in FIG. 3 during laser beam welding. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] FIG. 1 shows a connection apparatus 100 including a connection device 110 and a marking plate 111 arranged on the connection device 110 for labeling or marking the connection device 110 .

[0032] The connection device 110 here takes the form of a terminal block. The connection device 110 further comprises an insulating material housing 112. The insulating material housing 112 here has two openings 113 through which conductors can be inserted into the insulating material housing 112 for connecting the conductors. A connection element such as a spring force terminal connection is arranged in the insulating material housing 112 for making electrical contact with the conductors inserted through the openings 113.

[0033] To fix the marking plate 111 in the insulating material housing 112, a receiving area 115 is formed on the outer surface 114 of the insulating material housing 112, in or on which the marking plate 111 is received. The receiving area 115 here takes the form of a recess in the insulating material housing 112. The marking plate 111 is inserted into this recess such that at least a part of the marking plate 111 enters the recess and thus the receiving area 115.

[0034] The marking plate 111 has a labeling portion 116 and a foot portion 117 .

[0035] The labelling or marking is applied onto the marking plate 111 or to a labelling portion 116 on the marking plate 111. The labelling portion 116 takes the form of a flat or planar surface.

[0036] The foot 117 is directly connected to the labeling part 116. The foot 117 is integrally formed with the labeling part 116 so that the entire marking plate 111 is formed in one piece. By means of the foot 117, the marking plate 111 enters the recess and thus the receiving area 115. In the embodiment shown here, the foot 117 has two tabs 118a, 118b that extend away from the labeling part 116. The tabs 118a, 118b are arranged at an angle to each other so as to form a V-shape. By using the tabs 118a, 118b, the marking plate 111 is clamped or braced in the receiving area 115 via the foot 117, so that a kind of pre-assembly of the marking plate 111 on the insulating material housing 112 can be performed.

[0037] Once the marking plate 111 is inserted into the receiving area 115, laser beam welding is performed to fix the marking plate 111 to the insulating material housing 112, so that an integral joint connection 119 is formed between the marking plate 111 and the insulating material housing 112. The laser beam welding is performed by a laser beam 210 emitted by a laser source 200. The laser beam 210 directly impinges on areas of the marking plate 111 and areas of the insulating material housing 112, so that the integral joint connection 119 is formed in these areas. With the laser beam 210, a predetermined area of ​​the marking plate 111 and a predetermined area of ​​the insulating material housing 112 are melted, respectively, to form the integral joint connection 119 in these areas. In a cooled state, the integral joint connection 119 takes the form of a weld seam. This weld seam can be a dot-like or line-like pattern.

[0038] 1, the integral joint connection 119 with the insulating material housing 112 is made in the area of ​​the labeling portion 116 of the marking plate 111. The integral joint connection 119 is formed on two opposite end faces 120a, 120b of the labeling portion 116 of the marking plate 111. The area of ​​the insulating material housing 112 where the integral joint connection 119 is formed is in the area of ​​the outer surface 114 of the insulating material housing 112.

[0039] 2 shows a connection arrangement 100 comprising a number of connection devices 110 arranged in a row as shown in FIG. 1 and each of which has an integrally joined marking plate 111. The integrally joined connection portion 119 extends linearly along the connection device 110 into the area of ​​the labeling portion 116 of the marking plate 111. Now, when the connection devices 110 are already arranged in a row, the laser beam 210 may be moved along the connection devices 110 so that simultaneous welding of the individual marking plates 111 to the respective insulating material housings 112 of the individual connection devices 110 can take place. This allows in particular a fast and reliable fastening of the marking plates 111 to the multiple connection devices 110.

[0040] 3 and 4 respectively show a connecting apparatus 110 in which the connecting device 110 and the marking plate 111 are of the same design as shown in FIG.

[0041] In the embodiment shown in Figures 3 and 4, the integral joint connection 119 between the marking plate 111 and the insulating material housing 112 is formed between the foot 117 of the marking plate 111 and the insulating material housing 112. The areas of the marking plate 111 melted by the laser beam 210 are the free ends of the two tabs 118a, 118b of the foot 117 of the marking plate 111, respectively. The areas of the insulating material housing 112 melted by the laser beam 210 are within the receiving area 115 of the insulating material housing 112. In this embodiment, the integral joint connection 119 is formed on each connecting device 110 individually.

[0042] 1-4, the insulating material housing 112 and the marking plate 111 are made from the same type of material, at least in the area of ​​formation of the integral joint connection 119. For example, both the insulating material housing 112 and the marking plate 111 may be made from polyamide, specifically polyamide 6.6.

[0043] 1 to 4, in order to manufacture the electrical connecting arrangement 100, firstly the connecting device 110 is prepared in one method step. The marking plate 111 is inserted into the receiving area 115 of the insulating material housing 112 of the connecting device 110. In this state, the marking plate 111 is pre-fixed in the receiving area 115, since the marking plate 111 is held in the receiving area 115 by the tabs 118a, 118b of the feet 117 with a form-fit and a press-fit.

[0044] The welding of the marking plate 111 to the insulating material housing 112 begins with a laser source 200, with a laser beam 210 directed toward the marking plate 111 and the insulating material housing 112. In the embodiment shown in Figures 1 and 2, the laser beam 210 is directed toward an area of ​​the fastening portion 116 of the marking plate 111. In the embodiment shown in Figures 3 and 4, the laser beam 210 is directed toward a predetermined area of ​​the foot portion 117 of the marking plate 111. The laser beam 210 causes localized melting, which fuses the plastic material of the marking plate 111 and the plastic material of the insulating material housing 112, forming an integral joint connection 119 between the insulating material housing 112 and the marking plate 111.

[0045] The labeling portion 116 of the marking plate 111 may be stamped or marked either before or after the integral joint connection of the marking plate 111 to the insulating material housing 112 . [Explanation of symbols]

[0046] 100 Connection Device 110 Connected Devices 111 Marking Plate 112 Insulating material housing 113 Aperture 114 Exterior 115 Reception Area 116 Fixed part 117 Foot Tabs 118a and 118b 119 Integral joint connection 120a, 120b end face 200 Laser Source 210 Laser Beam

Claims

1. A method of manufacturing an electrical connection device (100), comprising the steps of: - providing at least one connection device (110) having an insulating material housing (112) with a receiving area (115) for partially receiving a marking plate (111); - a method step of providing at least one marking plate (111); - a method step of inserting said at least one marking plate (111) into said receiving area (115) of said insulating material housing (112) of said at least one connecting device (110), wherein a part of said at least one marking plate (111) is located within said receiving area (115) and a part of said at least one marking plate (111) adjoins said insulating material housing (112) outside said receiving area (115); - forming at least one integral joint connection (119) between said at least one marking plate (111) and said insulating material housing (112) of said at least one connecting device (110) outside said receiving area (115) by laser beam welding; A method comprising:

2. 2. The method of claim 1, characterized in that when the laser beam welding is performed, a laser beam (210) is directed towards a predetermined area of ​​the marking plate (111) and towards a predetermined area of ​​the insulating material housing (112) where the integral joint connection (119) is formed.

3. 3. The method according to claim 1 or 2, characterized in that the insulating material housing (112) comprises or consists of polyamide, at least in the area where the integral joint connection (119) is formed.

4. 4. The method according to claim 1, wherein the marking plate (111) comprises or is made of polyamide.

5. 5. The method according to claim 1, characterized in that the labelling and / or marking of the marking plate (111) inserted in the receiving area (115) takes place after laser beam welding.

6. 6. The method according to claim 1, wherein the marking plate (111) comprises a labeling portion (116) and a foot portion (117), and wherein the marking plate (111) is integrally joined to the insulating material housing (112) in the area of ​​the labeling portion (116) of the marking plate (111) by laser beam welding and / or the marking plate (111) is integrally joined to the insulating material housing (112) in the area of ​​the foot portion (117) of the marking plate (111) by laser beam welding.

7. 7. The method according to claim 1, characterized in that prior to the laser beam welding, the marking plate (111) is fixed in the receiving area (115) by form-fitting and / or press-fitting.

8. 8. The method according to claim 1, characterized in that at least two connecting devices (110) arranged in a row are provided, a marking plate (111) is inserted into the receiving area (115) of the insulating material housing (112) of each of the at least two connecting devices (110), and a laser beam (210) is moved along the at least two connecting devices (110) to bring about the laser beam welding to connect the marking plate (111) to the respective insulating material housing (112) by an integral joint.

9. 1. An electrical connection apparatus (100) comprising at least one connection device (110) having an insulating material housing (112) having a receiving area (115) for partially receiving a marking plate (111), and at least one marking plate (111), wherein the at least one marking plate (111) is inserted into the receiving area (115) of the insulating material housing (112) of the at least one connection device (110), a portion of the at least one marking plate (111) is located within the receiving area (115), a portion of the at least one marking plate (111) is adjacent to the insulating material housing (112) outside the receiving area (115), and the at least one marking plate (111) inserted into the receiving area (115) and the insulating material housing (112) have a weld portion welded together to each other outside the receiving area (115).

10. 10. The electrical connection device (100) according to claim 9, characterized in that the marking plate (111) comprises a labeling portion (116) and a foot portion (117), and the marking plate (111) is integrally joined to the insulating material housing (112) in the region of the labeling portion (116) of the marking plate (111) and / or the marking plate (111) is integrally joined to the insulating material housing (112) in the region of the foot portion (117) of the marking plate (111).

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