Electrical conductor and method for producing an electrical conductor

Abstract

The invention relates to an electrical conductor, in particular a flat conductor, comprising at least one through-opening and a contact part which is integrally connected to the conductor at the through-opening, wherein the contact part has an axially extending first portion and a radially extending second portion, characterised in that the second portion is formed as a flange and is welded to the conductor, and a side of the flange facing the conductor has a surface which has at least one recess and / or at least one projection.

Description

[0001] One Mobility Autokabel GmbH

[0002] Electrical conductor and method for manufacturing an electrical conductor

[0003] The subject matter relates to an electrical conductor and a method for manufacturing an electrical conductor, in particular a battery conductor, especially in the form of a flat conductor, particularly for automotive applications.

[0004] In the automotive industry, flat cables (also known as ribbon cables) are increasingly being used instead of round cables. Flat cables have proven particularly advantageous for battery cables, especially the B+ cable, which carries high currents. Due to their compact form factor, flat cables allow for large conductor cross-sections in small installation spaces, particularly in tight, inaccessible areas, thus improving the current-carrying capacity of the battery cables. Flat cables are also increasingly used in electric vehicles, where voltages of several hundred volts are drawn via the battery cables. Here, too, the power cables must meet high demands in terms of current-carrying capacity and performance.

[0005] However, round conductors are still used for connecting electrical devices. This is primarily because electrical devices usually require contact via flexible cables. When installing the connecting cables between rigid battery cables and electrical devices, it is often necessary to thread the cables into tight spaces, which is easier with round conductors than with rigid flat conductors. Therefore, when using flat conductors as the main strand for the battery cable, contact between the flat conductor and the round conductor is essential. Such contact can be achieved, for example, via a terminal bolt. A round conductor can then be electrically connected to the terminal bolt, for example, by friction welding. Branches to electrical devices can be arranged at various points along the flat conductor.The resulting cable harness can be installed in a vehicle, and the electrical consumers are connected to the battery harness via the round conductors.

[0006] However, it has been shown that attaching connection bolts to flat ribbon conductors is problematic in many cases. Such connections must be electrically stable and protected from environmental influences. When using aluminum as the conductor material of the flat ribbon conductor, it must also be ensured that it does not deform when the connection bolt is attached. In particular, when tightening the connection bolt, the screw can press into the aluminum. Due to the high viscosity of aluminum compared to other metals, there is the problem that tightening torques for the screw connections of the connection bolts may not be able to be maintained. Furthermore, the screw connections can loosen under mechanical stress because the aluminum of the flat ribbon conductor can deform beneath the screw connections.Furthermore, interfaces between aluminum and more noble metals, such as copper, are susceptible to contact corrosion. Direct connection points must be protected from environmental influences.

[0007] From DE 10 2006 050 708 A1, a weld sleeve is known that is welded into an opening of a flat conductor. The weld sleeve is also known as a weld eye. The weld sleeve is welded to the flat conductor by means of a pressure welding process. The weld sleeve itself has a through-opening into which a contact element can be inserted and mechanically fixed there, e.g., by screwing. The pressure welding keeps the contact resistance of the corresponding contact low and reduces electrical losses. The weld sleeve is made of a mechanically less viscous material than the flat conductor, e.g., copper. The weld sleeve is manufactured from solid material, e.g., by cold forming or by machining.

[0008] 2403WO One Mobility Autokabel GmbH A problematic aspect of the weld between the weld eye and the flat conductor is the material of the flat conductor that is displaced during the pressure welding process. During welding, at least the material of the flat conductor plasticizes in a surface area. When we subsequently refer to plasticization or plasticized material, we are always referring to this flow behavior caused by the welding process or the plasticized material itself.

[0009] The plasticized material is displaced by the portion of the weld bead penetrating the flat conductor. This forms a weld bead in the area of ​​the distal end faces of the weld bead. This weld bead can protrude beyond the plane of the respective end faces. If a connecting component, such as a screw head or washer, is then screwed in, it no longer rests fully on the end face of the weld bead, but at least partially on the weld bead as well. This leads to significantly higher contact resistances, as the contact area is considerably reduced. Furthermore, in such a case, a defined tightening force may not be possible, as the burr formed by the weld bead may yield under subsequent load, thus rendering the connection mechanically unstable.

[0010] The object was therefore based on the task of improving the electrical and mechanical properties of the connection between a conductor and a contact part by means of welding.

[0011] This task is solved by a conductor according to claim 1, a contact part according to claim 15 and a method according to claim 16.

[0012] Especially when using a conductor in automotive applications, for example as an electrical power conductor, a battery conductor (e.g., B+ or B- conductor), a conductor in a cable with at least two layers, a battery cell connector, or a 2403WO One Mobility Autokabel GmbH battery module connector, the challenge always lies in providing electrical connections on the conductor. Particularly in automotive applications, electrical conductors are exposed to demanding operating and environmental conditions. These environmental conditions can vary considerably, meaning that connection points on the electrical conductor are exposed to widely fluctuating temperatures, humidity, electrolytes, and the like. These environmental conditions, which can lead to thermal expansion or accelerate contact corrosion, necessitate the most secure possible fastening of the bolt to the electrical conductor.On the other hand, an electrical conductor, especially in automotive applications, is subject to dynamic loads. An electrical connection formed by a bolt must also withstand these dynamic loads and always be securely and electrically conductively attached to the electrical conductor.

[0013] The subject matter is a conductor, in particular a flat conductor (flat ribbon conductor), with a through-hole. The through-hole is preferably a bore. The through-hole is preferably substantially cylindrical. The through-hole can also be punched.

[0014] To enable a connection between an electrical conductor and a terminal, for example a bolt, especially a screw or the like, it is proposed that a contact element be provided that is friction-welded to or within the through-hole. The material-bonded connection of the contact element to the conductor ensures reliable contact with the conductor.

[0015] The contact part can be formed as a sleeve or a weld eye with a through-hole. The term "hole" is used here to distinguish the passage through the contact part from the opening of the conductor. It is understood that the through-hole does not necessarily have to be produced by drilling, but can also be formed by forging, pressing, or other shaping processes.

[0016] 2403WO One Mobility Autokabel GmbH An axial extension can be understood as a longitudinal extension or extension in the longitudinal direction. The contact part extends axially with a first section and a second section. The two sections can lie directly adjacent to each other in the longitudinal direction. The contact part is preferably formed in one piece, particularly preferably as a forged, turned, or cold-formed part. The contact part is formed from at least two sections. The two sections extend in the axial direction of the contact part.

[0017] The first section is inserted into the through-hole along its axial extent. This first section is inserted into the through-hole during the welding of the contact part to the conductor. During welding, at least the conductor material plasticizes at least at one interface or contact surface between the conductor and the contact part. The materials chosen for the conductor typically exhibit high conductivity and low hardness, while high-strength materials with lower conductivity are often selected for the contact part. Therefore, at least the conductor material plasticizes, while the contact part material remains solid. This plasticization allows the first section, which has areas with different circumferences, to be inserted into the through-hole. When circumferences or perimeters are mentioned below, this refers to the size of a cross-section through the contact part.It could also refer to a diameter. The point is that the contact element in the first section has a larger clear opening at least at one point than the through-hole. This is generally the case when the circumference of the contact element is larger than the circumference of the through-hole. However, there can also be geometries of the contact element where, although it has a smaller circumference than the through-hole in the first section, the diameter of the flange in the second section is larger than the clear opening of the conductor, thus allowing the flange to weld to the conductor-facing surface of the second section. Preferably, however, the first section 2403WO One Mobility Autokabel GmbH also has, at least partially, a diameter that does not fit within the clear opening of the through-hole. This is particularly the case with angular cross-sectional shapes.It is particularly preferred that, when the first section is inserted into the through-hole, at least a portion of the contact part's outer surface rests against the inner outer surface of the through-hole in such a way that contact is established and welding can also occur in the region of the first section. The contact can be located over a larger circumference or additionally over a smaller circumference within the first section.

[0018] The opening can have a clear width, in particular an opening cross-section, which is congruent to a cross-section of the first section in an area with a smaller circumference. The opening can have a clear width, in particular an opening cross-section, which is smaller than a cross-section of the first section in an area with a smaller circumference. The opening can have a clear width, in particular an opening cross-section, which is larger than a cross-section of the first section in an area with a smaller circumference. The opening can have a clear width, in particular an opening cross-section, which is larger than a cross-section of the first section in an area with a smaller circumference and smaller than a cross-section of the first section in an area with a smaller circumference.The opening can have a clear width, in particular an opening cross-section, which is congruent to a cross-section of the first section in an area with a larger perimeter.

[0019] In particular, the cross-sectional area of ​​the opening lies between the smallest and largest circumferences of the first section. Preferably, the cross-sectional area is slightly larger than the smallest circumference of the first section, but smaller than the largest circumference of the first section.

[0020] 2403WO One Mobility Autokabel GmbH During joining, plasticized material from the conductor can flow into the annular space between the contact part and the outer surface of the through-hole. When the second section of the contact part is welded to the conductor, plasticized material is displaced and flows into the cavities provided in the area of ​​the outer surface of the contact element. This creates, at least in sections, a positive connection between the contact part in the area of ​​the first section, which, due to its variable diameter, forms the aforementioned cavities.

[0021] The second section is formed as a flange and serves both as a contact surface for the conductor and as an enlarged bearing surface for a connecting bolt or a consumer connection. The contact surface is the surface facing the conductor. The bearing surface is the opposite end face of the contact part. A connecting bolt head, a nut screwed onto the connecting bolt, or a washer can rest on the surface of the flange facing away from the conductor (bearing surface). A consumer connection can preferably be arranged on the bearing surface. The bearing surface can be round, rectangular, square, polygonal, or the like.

[0022] Along its circumference, the second section can have radially extending areas and radially less extended areas. The second section can have a one-, two-, three-, or multi-axis geometry. This contour gives the contact part in the second section an external polygon, allowing it to be positively engaged by a corresponding tool. The contact part can then be moved, rotated, vibrated, and / or pressed relative to the flat part during the welding process.

[0023] The first section has a first outer circumference, and the second section has a second, larger outer circumference than the first. The second section can thus project radially outwards, collar-like, relative to the first section. When attaching the contact part to the through-hole of the conductor (2403WO One Mobility Autokabel GmbH), the contact part is inserted into the through-hole of the conductor along with the first section. The second section limits the insertion depth of the contact part into the through-hole of the conductor, as it acts as a stop.

[0024] To increase the pull-out strength of the contact section from the flat conductor and to create spaces into which the material plasticized during welding can flow, preventing a weld bead from protruding beyond the planes of the end faces of the first and second sections, it is proposed that the first section have a concave or convex cross-sectional profile along the axial extent of the contact section. This cross-sectional profile can be referred to as the longitudinal cross-sectional profile. The longitudinal section is preferably made along a central axis of the contact section. The contact section is preferably rotationally symmetrical about this central axis.

[0025] The diameter in the area of ​​the outer surface of the first section is variable and changes at least once, preferably at least twice, between the contact surface and the end face of the first section. A convex profile is defined as having a bulge in the area of ​​the first section, while a concave profile has a tapered shape. The slope in the area of ​​the outer surface between the contact surface and the end face in the first section can be continuous in sections, or it can include steps with sections running parallel to the main direction of the flat conductor and / or arc-shaped sections. In the case of a convex profile, the envelope adjacent to the outer surface has a convex shape, whereas in the case of a concave profile, the envelope assumes a concave shape.

[0026] While the contact element is being inserted into the conductor's through-hole, the welding process is already underway, specifically pressure welding and / or friction welding, particularly rotary friction welding and / or ultrasonic welding. During the welding process, the contact element is moved relative to the 2403WO One Mobility Autokabel GmbH conductor, in particular rotated. As the first section penetrates the through-hole, the frictional heat plasticizes at least the conductor material in the area of ​​the contact element's contact surface. The plasticized material flows into so-called bead chambers. A bead chamber is formed by the longitudinal profile of the first section. The first section is not cylindrical but has areas with different diameters / circumferences / cross-sections. A bead chamber is formed in the areas with the smaller diameters / circumferences / cross-sections.

[0027] It has been found that it is particularly advantageous if the first and second sections are formed in one piece. In particular, the contact part can be formed as a stamped or turned part. The one-piece construction prevents damage to the contact part during the welding process, especially the breaking of the connection between the first and second sections.

[0028] On the other hand, it ensures that the contact part can withstand dynamic environmental conditions permanently.

[0029] According to one embodiment, it is proposed that the first section is positively fitted into the through-opening after welding. During welding, material of the conductor on the inner surface of the through-opening, and possibly also material on the outer surface of the first section, plastically degrades. Since the first section is convex or concave, there are areas with a smaller circumference than other areas. These areas are filled with cooled material after welding.

[0030] It is proposed that the largest clear width of the passage opening, in particular the inner circumference of the passage opening, is smaller than the clear width of a region of the first section with the largest circumference / diameter / cross-section.

[0031] 2403WO One Mobility Autokabel GmbH When the term "circumference" is used here, it can also refer to the diameter or the cross-section. For a second section with a point-symmetric shape about its central axis, this is the same; for non-point-symmetric shapes, the circumference may be described by the envelope, and a diameter can describe the greatest distance between two points on the outer surface in a cross-sectional plane. It is also meant that a maximum radius of the first section in the area with the larger circumference is larger than a maximum radius of the first section in the area with the smaller circumference.

[0032] According to one embodiment, it is proposed that the first section comprises at least a first region with a first circumference and at least a second region with a second circumference smaller than the first, and that during welding, plasticized material is displaced into the second region and hardens there. During welding, material plasticizes at least in the volume of the larger circumference. The plasticized material can flow into the volume (bead chamber) located in the second region. After the material cools, a positive fit is created in the axial direction, as the plasticized material fills the volume between the inner surface of the through-hole and the outer surface of the first section in the region with the smaller circumference.

[0033] According to one embodiment, it is proposed that during welding, plasticized material does not project axially beyond any plane of an end face of the contact part, and in particular not beyond an end face of the first section and / or an end face of the second section. The bead chamber that forms in the area with the smaller diameter allows the plasticized material to flow into this volume and prevents it from escaping, or only a small portion of it does, through the outer edges of the through-hole. This ensures that any weld bead that may form at the outer edge of the through-hole is small and, in particular, does not extend beyond the plane of the two end faces.

[0034] The 2403WO One Mobility Autokabel GmbH contact part protrudes. This ensures that a connection part rests flat on one of the end faces and not on the weld bead.

[0035] According to one embodiment, it is proposed that the cross-sectional profile of the first section is stepped, with at least one stepped transition between the first area with the first perimeter and the second area with the smaller perimeter compared to the first perimeter.

[0036] The concave or convex shape can be formed by step-like transitions between areas with different circumferences. This is particularly advantageous for a turned part. The second area can be a free-cut along the circumference of the first section.

[0037] According to one embodiment, it is proposed that the cross-sectional profile of the first section is continuous, with at least one continuous transition, in particular with an arc-shaped contour, between a first area with a first perimeter and a second area with a perimeter smaller than the first perimeter.

[0038] The concave or convex shape can be formed by continuous, arc-shaped transitions between areas of different circumferences. This is particularly advantageous for a forged part.

[0039] The second region can, in particular, lie between two first regions or between the second region and a first region. The first region can adjoin the end face of the first region. In this case, a concave cross-sectional profile is formed. The second region can adjoin the end face of the first region, and the first region can lie between the second region and the second region. In this case, a convex cross-sectional profile is formed.

[0040] 2403WO One Mobility Autokabel GmbH According to one embodiment, it is proposed that the first region is arranged axially between two second regions. One second region can directly adjoin the second section, and another second region can directly adjoin the end face of the first section. It is also proposed that the first region is arranged axially between the second section and a second region. The second region can directly adjoin the end face of the first section. In this case, a convex cross-sectional profile is obtained.

[0041] According to one embodiment, it is proposed that the second section has a radially outwardly projecting collar, wherein the second section has an end face facing away from the first section and a contact surface facing the first section, the contact surface being frustoconically tapered towards the first section and having an opening angle between 1° and 10°, particularly between 3° and 7°, preferably 5°. The opening angle of a frustocone can be understood as the angle enclosed between a base and a generatrix of the cone. In this case, the base of the contact surface can be a plane perpendicular to the longitudinal axis of the contact part. The generatrix is ​​formed by the outer surface of the contact surface. The tapered shape ensures that the contact surface also penetrates the conductor surface during welding.A volume can also be formed along an outer circumference into which plasticized material can flow.

[0042] According to one embodiment, it is proposed that the second section, at a transition between the second and first sections, has a collar projecting radially outwards towards the end face of the first section. The collar is frustoconical in shape, tapering towards the second section, and in particular has an opening angle between 1° and 10°, more specifically between 3° and 7°, preferably 5°. The opening angle of a frustocone can be understood as the angle enclosed between a base and a generatrix of the cone. The base can, in this case, be a plane perpendicular to the longitudinal axis of the contact part. The generatrix is ​​formed by the outer surface of the collar facing the second section. The tapered shape ensures that molten material can flow radially outwards.

[0043] According to one embodiment, it is proposed that a lateral surface of a region of the first section, which directly adjoins an end face of the first section facing away from the second section, tapers in a frustoconical shape towards the end face. The base can be a plane perpendicular to the longitudinal axis of the contact part. The generatrix is ​​formed by the outer lateral surface of the contact part of the second section, particularly in the region adjacent to the end face. This lateral surface, which tapers towards the end face of the first section, facilitates the initial penetration of the first section into the through-hole. The end face of the first section is opposite the end face of the second section, also referred to as the bearing surface.

[0044] According to one embodiment, it is proposed that the axial extent of the first section and the axial extent of the second section are essentially the same.

[0045] According to one embodiment, it is proposed that a transition between the first section and the second section and / or between a first region and a second region has a fillet, wherein the inner radius of the fillet is between 0.2 mm and 0.8 mm, in particular between 0.4 mm and 0.6 mm, preferably 0.5 mm. The fillet ensures that the plasticized material can fill the entire volume and come into contact with the contact part. Air inclusions between the contact part and the plasticized material are avoided.

[0046] According to one embodiment, it is proposed that the through-hole in the contact part has a frustoconical opening cross-section that widens towards the end face of the second section (2403WO One Mobility Autokabel GmbH) with an opening angle of 35° and 55°, in particular between 40° and 50°, preferably 45°. This facilitates the insertion of a connecting bolt or screw into the through-hole.

[0047] According to one embodiment, it is proposed that the longitudinal extent of the first section be greater than the longitudinal extent of the through-opening, so that the first section projects beyond a surface of the conductor facing away from the second section, and a weld bead does not protrude beyond the projecting portion. The slightly greater longitudinal extent of the first section ensures that its end face projects from the plane of the conductor. Excess plasticized material may protrude from the edge of the through-opening, but remains below the plane of the end face and thus does not impede the contact of a terminal part with the end face.

[0048] According to one embodiment, it is proposed that the contact part be metallically coated. A metallic coating can, in particular, be tinning, silver plating, or nickel plating. In particular, a coating can also be multilayered, especially silver plating with an underlayer of nickel plating.

[0049] As previously mentioned, it is proposed that the contact element be formed as a weld eye with a through-hole. Such a weld eye is particularly suitable for subsequent bolting to a stud on which the round conductor can be attached. The cross-sectional profile of the through-hole can be round, rectangular, square, polygonal, or the like. Along its inner circumference, the through-hole can have radially outward-projecting areas and radially less outward-projecting areas. The inner circumference of the through-hole can have a one-, two-, three-, or multi-axis geometry. Due to this contour, the contact element at the through-hole has an internal polygon, and a corresponding tool can engage positively in the through-hole. The 2403WO One Mobility Autokabel GmbH contact element can then be moved, rotated, vibrated, and / or pressed relative to the flat part during the welding process.

[0050] In rotary friction welding, the contact part must be pressed against the conductor with sufficient pressure and simultaneously set into rotation. A friction welding tool must, while rotating and setting the contact part in rotation, also simultaneously press the contact part against the conductor.

[0051] It has been found that the electrical contact of an electrical output on the contact part is sufficiently good even if the necessary bolt does not directly abut the inner circumference of the sleeve-shaped contact part. It is sufficient if the bolt head abuts the end face of the contact part. In this case, a sufficiently good electrical contact is possible. On the other hand, this means that neither a positive fit nor complementary cross-sections are necessary between the through-hole in the contact part or the inner surface of the through-hole in the contact part and the outer surface of the bolt. Rather, it has been found that it is advantageous for the manufacturing process if the contact part has a through-hole formed as an internal polygon. The inner circumference of the through-hole is preferably polygonal.On the other hand, the outer circumference of the contact part is preferably essentially round or angular.

[0052] In this context, it should be mentioned that the term internal polygon or external polygon can also refer to a polycircular shape.

[0053] In particular, the through-bore or the second section is formed as a drive profile, with sections of smaller radius and sections of larger radius, the sections alternating with each other.

[0054] As mentioned previously, the problem of contacting the flat cable and the round cable arises particularly when the flat cable is made of 2403WO One Mobility Autokabel GmbH aluminum. Using an aluminum alloy for the flat cable offers significant advantages in terms of material costs and weight, making it preferable for the flat cable to be made of an aluminum alloy or an alloy thereof.

[0055] The contact element can be made of a transition metal material or an alloy thereof. The use of aluminum, stainless steel, copper, brass, and / or alloys thereof is preferred. If the contact elements are made of aluminum, the aluminum alloys used for their manufacture exhibit higher strength than the aluminum alloy used for the flat conductor. For example, aluminum alloys of the 6000 series are used for contact elements. By using a material with higher strength than the conductor material, the mechanical strength of the connection between the flat conductor and the terminal bolt can be increased. Using the aforementioned materials ensures that the mechanical stress during tightening of the terminal bolt through the contact element does not cause significant deformation of the contact element.Even under continuous mechanical stress, it is ensured that the end faces of the contact part do not deform significantly, thus guaranteeing a permanently secure connection between the terminal bolt and the sleeve. The contact part can also be metallically coated, with the coating being made of nickel, silver, tin, or alloys thereof. The coating of the contact part can be matched to the material of a terminal bolt, screw, consumer connection, or the like.

[0056] Another aspect is a contact part for contacting an electrical conductor in the manner described above.

[0057] According to a further aspect, a method for manufacturing an electrical conductor is proposed. In this method, a previously described electrical conductor is connected to a previously described contact part (2403WO One Mobility Autokabel GmbH) in such a way that the contact part is welded to the conductor by means of resistance welding, in particular projection welding, friction welding, in particular rotary friction welding, pressure welding, in particular magnetic pulse welding.

[0058] The subject matter is explained in more detail below with reference to a drawing showing an exemplary embodiment. The drawing shows:

[0059] Fig. 1 shows a truncated cone with base, lateral surface and generatrix;

[0060] Fig. 2 shows a cross-section through a contact part according to exemplary embodiments;

[0061] Fig. 3a-b Views of contact parts according to exemplary embodiments;

[0062] Fig. 4a-b Cross-sections through a contact part according to exemplary embodiments;

[0063] Fig. 5a-b Cross-sections through a contact part according to exemplary embodiments;

[0064] Fig. 6a-b shows a cross-section through contact parts according to exemplary embodiments;

[0065] Fig. 7 shows a conductor with a contact part according to exemplary embodiments;

[0066] Figs. 8-10 show a conductor welded to a contact part according to exemplary embodiments;

[0067] Fig. 11a-c Outer contours of a contact part according to exemplary embodiments;

[0068] Fig. 12a-c Internal contours of a through hole according to exemplary embodiments;

[0069] 2403WO One Mobility Autokabel GmbH To clarify the term opening angle used here, a truncated cone 2 is shown in Fig. 1. The truncated cone 2 has a base 2a with a radius 2b. Extending from the base 2a is a lateral surface 2c, which, in longitudinal section along a longitudinal axis 2d, has a generatrix 2c'. An angle 4 enclosed between the radius 2b and the generatrix 2c' can be understood as the opening angle of the truncated cone.

[0070] Fig. 2 shows a contact part 6. The contact part 6 has a first section 8 and a second section 10. The contact part 6 terminates in the first section 8 with an end face 8a. Distally opposite the end face 8a, the contact part terminates in the second section 10 with an end face 10a. The end face 10a can also be understood as a bearing surface. A surface 10b of the second section 10 facing the first section 8 can be understood as a contact surface. A through-hole 12 extends along a longitudinal axis 6a of the contact part 6.

[0071] Fig. 3a shows a view of a contact part 6 with a convex cross-sectional profile of the first section 8. It can be seen that the first section 8 has two second regions 16. One second region 16 borders directly on the second section 10, and another second region 16 borders directly on the end face 8a. A first region 14 lies between the second regions 16. It can also be seen that the circumference of the first region 14 is larger than the circumference of the second regions 16.

[0072] Fig. 3b shows a view of a contact part 6 with a concave cross-sectional profile of the first section 8. It can be seen that the first section 8 has two first regions 14. One first region 14 borders directly on the second section 10, and another first region 14 borders directly on the end face 8a. A second region 16 lies between the first regions 14. It can also be seen that the circumference of the second region 16 is smaller than the circumference of the first regions 14.

[0073] 2403WO One Mobility Autokabel GmbH Fig. 4a shows a contact part 6 in a longitudinal section along the longitudinal axis 6a. The first section 8 is divided into two areas 14, 16, as shown in Fig.

[0074] 3a, b. The transition between areas 14 and 16 is arc-shaped. The perimeter of area 16 is smaller than that of area 14.

[0075] Fig. 4b shows a contact part corresponding to Fig. 4a with the difference that the transition between areas 14, 16 is step-like.

[0076] Figures 5a and 5b show, corresponding to Figures 4a and 4b, a contact part 8 with an arcuate or step-shaped transition. In Figures 5a and 5b, the circumference of the first region 14 is larger than that of the second region 14.

[0077] Fig. 6a shows a cross-section through a contact part 6. Starting from the end face 10a, the second section 10 extends towards the contact surface 10b. The contact surface 10b extends towards the first section 8. The contact surface 10b is formed by a lateral surface of a frustoconical region of the second section 10. The frustocone tapers towards the first section 8. An opening angle 18 of the frustocone lies between 1° and 10°, as described above, particularly at 5°.

[0078] It can also be seen that the transitions between the second section 10 and the second area 16, as well as between the second area 16 and the first area 14, are formed as a concave shape, with a radius 20, as described above, being in particular 0.5mm.

[0079] The second region 16 extends from the second section 10 to the first region 14. A circumferential collar forms at the transition between the second region 16 and the first region 14. This collar is frustoconical with an opening angle 22b of preferably 1° to 20°, for example 10°. Other opening angles between 5° and 15° are also possible.

[0080] 2403WO One Mobility Autokabel GmbH The first region 14 extends towards the end face 8a. The first region 14 is frustoconical and tapers towards the end face 8a. An angle 22a is preferably between 0° and 10°, particularly preferably at 0°.

[0081] The through-hole 12 extends within the contact part 8. It can be seen that the through-hole 12 opens in a trumpet shape towards the end face 10a. The flanks of the widening through-hole 12 form an angle 12a between 80° and 100°, preferably 90°.

[0082] Fig. 6b shows a cross-section through another contact part 6. Unless otherwise described below, the contact part 6 of Fig. 6b preferably corresponds to the contact part 6 of Fig. 6a. According to Fig. 6b, the contact part has rounded contours within the second section 10 at a radius 20, where the radius 20 is, for example, 0.5 mm. The radius 20 can also assume different values ​​in different sections of the contact part 6. The opening angle 18 of the truncated cone is preferably 5°, while the opening angle 22b is preferably 10° and the angle 22a (not shown in Fig. 6b) is 0°. The diameter 34 of the through-hole 12 is preferably between 7 mm and 15 mm, for example, 10.5 mm. The diameter 35 in the second region 16 is preferably 10 mm to 20 mm, for example 14 mm, and the diameter 36 in the first region 14 is preferably 12 mm to 22 mm, for example 16 mm.The diameter of the through-hole 12 can be constant along the bore or vary, for example by providing an offset 33.

[0083] Fig. 7 shows a flat conductor 24 with a through-hole 26. The contact part 6 is inserted into the through-hole 26 by means of welding.

[0084] Fig. 8 shows a schematic cross-section through a joined conductor. It can be seen that the contact surface 10b of the contact part 6 is welded to the flat conductor (hatched). Plasticized material (dotted) can flow into a volume 28 between the outer surface of the contact part 8 and the inner surface of the through-hole 26, which is formed in the concave area 16. This volume 28, also called the bead chamber, prevents excess plasticized material from escaping over the edges 26a of the through-hole. It can also be seen that a small bead 30 can form between an edge 26a and the end face 8a. This bead 30 does not project beyond the end face 8a. The same applies to a bead 32, which does not project beyond the end face 10a.

[0085] Fig. 9 shows another welded contact part 6. Here too, plasticized material can flow into a volume 28.

[0086] Fig. 10 shows another example. In the example shown, the first section 14 is convex. The bead chambers form in the second area 16.

[0087] Figs. 11a-c show different outer contours of the second section 10, as a multi-round shape (Fig. 11a), polygonal (Fig. 11b) or round (Fig. 11c).

[0088] Figs. 12a-c show different internal contours of the through bore 12, as a multi-round shape (Fig. 12a), triangular (Fig. 12b) or hexagonal (Fig. 12c).

[0089] 2403WO One Mobility Autokabel GmbH Reference number

[0090] 2 frustum of a cone

[0091] 2a Basis

[0092] 2b Radius

[0093] 2c lateral surface area

[0094] 2c' Mantle line

[0095] 2D Longitudinal axis

[0096] 4 included angle

[0097] 6 Contact part

[0098] 6a Longitudinal axis of the contact part

[0099] 8 first section

[0100] 8a Front surface of the first section

[0101] 10 second section

[0102] 10a Front surface of the second section

[0103] 10b Site area of ​​the second section

[0104] 12 Through-hole of the contact part 12

[0105] 12a Angle

[0106] 14 first area

[0107] 16 second area

[0108] 18 opening angles

[0109] 20 radius

[0110] 22a Angle

[0111] 22b Opening angle

[0112] 24 ladders

[0113] 26. Passage opening of the conductor 24

[0114] 26a Edges of the passage opening 26

[0115] 28 volumes

[0116] 30, 32 bulge

[0117] 33 Offset

[0118] 34 Diameter of the through-hole on end face 10a

[0119] 35 diameter in the second area 16

[0120] 2403WO One Mobility Autokabel GmbH 36 Diameter in the first area 14

[0121] 2403WO One Mobility Autokabel GmbH

Claims

One Mobility Autokabel GmbH Patent claims 1. Electrical conductor (24), in particular flat conductor, comprising at least one through-opening (26), and a contact part (6) which is materially connected to the conductor at least in the through-opening (26), wherein the contact part (6) has a first section (8) and a second section (10) in its axial extension, wherein the first section (8) is inserted into the through-hole (26) along its axial extent and the second section (10) is formed as a flange and a side of the flange facing the conductor (24) is formed as a contact surface (10b) and is friction welded to the conductor (24), characterized by that the first section (8) has a concave or convex cross-sectional profile in a section along the axial extent of the contact part (6).

2. Electrical conductor (24) according to claim 1, characterized by that the first section (8) is arranged in the through-opening (26) at least section by section in a form-fitting manner after welding.

3. Electrical conductor (24) according to one of the preceding claims, characterized in that, that the first section (8) has at least a first area (14) with a first perimeter and at least a second area (16) with a perimeter smaller than the first perimeter and that during welding, plasticized material is displaced into the second area (16) and hardened there.

4. Electrical conductor (24) according to one of the preceding claims, characterized in that, that a material that has become plasticized during welding does not project in the axial direction beyond a plane of an end face of the contact part (6), in particular not beyond an end face of the first section (8) and / or an end face of the second section (10).

5. Electrical conductor (24) according to one of the preceding claims, characterized in that that the cross-sectional profile of the first section (8) is stepped, with at least one stepped transition between the first area (14) with the first perimeter and the second area (16) with the smaller perimeter than the first perimeter.

6. Electrical conductor (24) according to one of the preceding claims, characterized in that, that the cross-sectional profile of the first section (8) is continuous, with at least one continuous transition, in particular with an arc-shaped contour, between the first area (14) with the first perimeter and the second area (16) with the perimeter smaller than the first perimeter.

7. Electrical conductor (24) according to one of the preceding claims, characterized in that, that the second area (16) is arranged in the axial direction between two first areas (14) or that the second area (16) is arranged in the axial direction between the second section (10) and the first area (14) or that the first area (14) is arranged in the axial direction between two second areas (16) or that the first region (14) is arranged in the axial direction between the second section (10) and the second region (16). 2403WO One Mobility Autokabel GmbH 8. Electrical conductor (24) according to one of the preceding claims, characterized in that that the first section (8) has a collar extending radially outwards, wherein the second section (10) has an end face (10a) facing away from the first section (8) and a contact surface (10b) facing the first section, wherein the contact surface is tapered in a frustoconical shape towards the second section (10) and in particular has an opening angle between 1° and 10°, in particular between 3° and 7°, preferably 5°.

9. Electrical conductor (24) according to one of the preceding claims, characterized in that, that the axial extent of the first section (8) and the axial extent of the second section (10) are essentially the same.

10. Electrical conductor (24) according to one of the preceding claims, characterized in that that a transition between the first section (8) and the second section (10) and / or between a first area (14) and a second area (16) has a fillet, wherein an inner radius of the fillet measures between 0.2mm and 0.8mm, in particular between 0.4mm and 0.6mm, preferably 0.5mm.

11. Electrical conductor (24) according to one of the preceding claims, characterized in that that the through-bore (12) has a frustoconical opening cross-section widening towards the end face of the second section with an opening angle between 35° and 55°, in particular between 40° and 50°, preferably 45°.

12. Electrical conductor (24) according to any one of the preceding claims, 2403WO One Mobility Autokabel GmbH characterized by that a longitudinal extent of the first section (8) is greater than a longitudinal extent of the passage opening (26), so that the first section (8) extends beyond a surface of the conductor (24) facing away from the second section (10).

13. Electrical conductor (24) according to one of the preceding claims, characterized in that that the first section (8) is materially bonded to the inner diameter of the through-hole (26), in particular friction welded.

14. Electrical conductor (24) according to one of the preceding claims, characterized in that, that the contact part (6) is made of a different metallic material than the conductor (24), in particular that the conductor (24) is made of an aluminium material and the contact part (6) is made of a copper material.

15. Contact part (6) for contacting an electrical conductor (24), in particular according to one of the preceding claims, comprising a first section (8) and a second section (10), wherein the first section (8) is inserted into the through-hole (26) along an axial extension and is welded with its outer surface to an inner surface of the through-hole (26) and the second section (10) is formed as a flange and a side of the flange facing the conductor (24) is formed as a contact surface (10b), characterized by that the first section (8) has a concave or convex cross-sectional profile in a section along the axial extent of the contact part (6). 2403WO One Mobility Autokabel GmbH 16. Method for producing an electrical conductor (24) according to any one of the preceding claims, characterized by that the contact part (6) is welded to the conductor (24) by means of friction welding, in particular rotary friction welding. 2403WO One Mobility Autokabel GmbH

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