EP1658662B1 - Electric contact crimping method and contact obtained according to said method - Google Patents

Electric contact crimping method and contact obtained according to said method Download PDF

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Publication number
EP1658662B1
EP1658662B1 EP04720635.4A EP04720635A EP1658662B1 EP 1658662 B1 EP1658662 B1 EP 1658662B1 EP 04720635 A EP04720635 A EP 04720635A EP 1658662 B1 EP1658662 B1 EP 1658662B1
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EP
European Patent Office
Prior art keywords
crimping
wire
wings
zones
section
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
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EP04720635.4A
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German (de)
French (fr)
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EP1658662A1 (en
Inventor
Thierry Courtin
El Mostafa Zindine
Flavio Fantini
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Delphi International Operations Luxembourg SARL
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Delphi International Operations Luxembourg SARL
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Publication of EP1658662A1 publication Critical patent/EP1658662A1/en
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048—Crimping apparatus or processes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048—Crimping apparatus or processes
    • H01R43/0488—Crimping apparatus or processes with crimp height adjusting means
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool

Definitions

  • the present invention relates to a method of crimping electrical contact and the contact obtained by this method.
  • the crimped contacts have reliability problems for low current and low voltage applications and more particularly micro-cuts appear over time. It has been demonstrated that the crimping could lose its effectiveness due to a phenomenon of elastic return of the crimping fins which causes a decrease in the contact pressure between the fins and the strands of the crimped wires and can lead to increases or instabilities of contact resistance or even loss of electrical contact.
  • FR 242 7 702 discloses a method according to the preamble of claim 1.
  • the present invention aims to improve the crimped electrical contacts and remedy the problem of elastic return to maintain a significant contact pressure throughout the life of the contact.
  • the present invention relates to a process according to claim 1.
  • the first crimping step folds a first surface of the fins to said first height. on the wire and the second crimping step folds a localized area of the fins at said second height, less than the first.
  • the second crimping can be performed on two disjoint areas of the fins. More particularly, the second crimping can in particular be performed on the end zones of the fins.
  • the second crimping can be performed on a central area of the fins.
  • the first crimping step can be performed on all the fins so as to close the fins on the wire.
  • the second crimping step is performed on a portion of the surface of the fins having undergone the first crimping step.
  • the method can be such that the crimping tool comprises a common anvil and separable punch elements.
  • the drum can in particular be deformed during the first crimping step and retain its shape during the second crimping step.
  • the invention further relates to an electrical contact element having a crimping section provided with an open barrel provided with crimping fins on an electric wire, the crimping section being crimped onto the wire by the method described above such that, after crimping, the crimping section comprises three successive zones of crimping of the fins on the wire, two of the three zones being of reduced thickness relative to the third zone so that the wire exerts an elastic stress on the fins at the level of the third zone.
  • one of the three zones is of reduced thickness compared to the other two zones so that the wire exerts an elastic stress on the fins in the other two zones.
  • crimping is performed on electrical contacts open drum.
  • Such contacts comprise a front part A, in particular of connection to a conventionally known complementary contact, and comprise, in an intermediate part, for the crimping connection a crimping section provided with an open shaft 3 provided with fins 4,
  • the crimping section is intended to be crimped onto the wire to make an electrical contact between the wire 2 and the contact element 1.
  • the contact 1 comprises an end section 31 forming a force recovery zone provided with wings 10, 11 intended to close on the insulator 13 of the wire 2.
  • the front part A of the contact element may be of any type and may even possibly be constituted by a second crimping connection section for producing for example a splice.
  • Such contact elements are made by cutting and folding a metal strip of small thickness of the order of 0.2 mm to a few millimeters thick.
  • the wire generally copper-based, has a low elastic return capability and in particular lower than that of alloys such as cuproberyllium often used for contact elements.
  • the invention tends to modify the mechanical behavior of crimping in order to use the physical phenomenon of springback in a favorable direction on a particular zone of the contact.
  • the method of crimping a crimping section of an element 1 of electrical contact on an electrical wire 2 comprises a first crimping step of the crimping section 30 on the stripped portion 12 of the wire at a first height h1 by folding the fins 4, 5 on the wire 2 by a crimping tool comprising a punch 6 and an anvil 7.
  • a crimping tool comprising a punch 6 and an anvil 7.
  • the punch 6 formed according to the example of three parts 6a, 6b, 6c, bears with its three parts on all of the fins 4 and 5 and the anvil presses under the shaft 3, the fins 4 and 5 being fins continuous.
  • the crimping height h1 is obtained as a function of the dimensions of the contact and the wire by conventional crimping so that a minimum compression ratio of the order of 5% is obtained so as to close the fins on the wire.
  • This first step of crimping is performed on a major part of the surface of the fins 4, 5 see all of these fins by the punch 6 and on a major part see the entire barrel 3 by the anvil 7.
  • the method comprises a second step or crimping operation, this operation is performed at a second height h2, less than the first on a localized area of the fins. This step is carried out so that a compression ratio greater than 15% and typically of the order of 25 to 30% is obtained under the crimping tool.
  • This second step is schematically represented in figures 4 and 5b representing a first embodiment for which only the elements 6a, 6c of the punch 6 rest on the ends 4a, 4c, 5a, 5c of the fins, the element 6b remaining in recess and not coming into contact with the fins and, the figure 5a for a second embodiment for which only the punch element 6b presses on the fin parts 4b and 5b, the punching elements 6a and 6c remaining recessed and not coming into contact with the fins.
  • the second crimping step is performed on a portion of the surface of the fins having undergone the first crimping step.
  • the crimped contact comprises three successive zones of crushing of the fins on the wire, two of the three zones being of reduced thickness relative to the third zone so that the wire exerts an elastic stress on the fins at the level of the third zone .
  • the crimped contact comprises three successive zones of crushing of the fins on the wire, one of the three zones being of reduced thickness relative to the other two zones so that the wire exerts an elastic stress on the fins at the two other areas.
  • the double crimping reverses the springback to make it play a positive role that is to say create a contact pressure between the barrel and the strands.
  • the strands swell locally in the zone 20b between the two tools 6a and 6c performing the second crimping step. Consequently, whereas for the zones of the fins under the tools 6a and 6c, the elastic return of the fins remains greater than that of the strands of the wire, in the zone 20b, it is the wire which deforms the wing by the effect of swelling.
  • the elasticity of the fins then has in this part 20b a positive effect because it tends to compress the wire which implies a mechanical contact pressure and therefore good electrical conduction even under mechanical or thermal stresses.
  • the crimping tool represented in figure 1 and adapted to the method according to the invention comprises an anvil 7 and common elements 6a, 6b, 6c dissociable punch. Such a tool can operate on a traditional automatic press with a separate command of the punch elements.
  • the interest of the common anvil is that the barrel 3 is deformed during the first crimping step and retains its shape during the second crimping step The barrel thus retains good mechanical rigidity and good resistance to mechanical stresses in case traction on the wire.
  • Such a method is applicable to crimp contacts with open barrel for bent cut electrical contacts but also to contacts with closed barrels such as rolled cut contacts based on a metal strip.
  • the first crimping step can be performed by means of the single element 6b of the punch. (for a final second stage result of the type shown in figure 3a ) or by means of the only elements 6a and 6c of this punch (for a final second-stage result of the type shown in figure 3b ), this means that the elements 6a and 6c, respectively the element 6b, remain (s) during this first step in a high position without themselves come to press force on the fins 4 and 5 of the barrel placed on the anvil.
  • the fins 4 and 5 will nevertheless undergo a more or less marked bending / crimping operation over all or a very significant part of their length beyond the sole area (s) of fin (s) on the where (s) the element 6b, respectively, the elements 6a / 6c of the punch have come to bear.
  • the first crimping height defines the crimping height on the central area of the fins respectively the crimping height on the end zones of the fins.
  • the second crimping step which follows the first step is then carried out by means of the elements 6a, 6c, respectively of the element 6b, according to the invention, the element 6b of the punch, respectively the elements 6a and 6c of this punch remaining in a first-stage end-of-course position to keep the keg in the shape that it has at the end of the first stage.
  • the first crimping step crimped at least a first zone of each fin 4 and 5 of the barrel to a first crimping height, by more or less sharply folding the fins on a surface extending beyond said at least a first zone, and the second crimping step crimps at the second crimping height at least a second zone of each fin 4 and 5, said localized region of the crimping section, complementary (s) of said at least a first zoned.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Manufacture Of Switches (AREA)

Description

La présente invention concerne un procédé de sertissage de contact électrique et le contact obtenu par ce procédé.The present invention relates to a method of crimping electrical contact and the contact obtained by this method.

Il est connu de réaliser un contact électrique entre un fil électrique notamment multibrins et un élément de contact métallique par une opération de sertissage pour laquelle des ailettes découpées dans l'élément de contact métallique sont repliées autour du fil électrique dénudé par un outil de sertissage, de type poinçon-enclume. Cette technique est appliquée pour des contacts réalisés à partir d'un flan métallique découpé plié.It is known to make electrical contact between a particularly multi-strand electrical wire and a metal contact element by a crimping operation for which fins cut in the metal contact element are folded around the stripped electric wire by a crimping tool, punch-anvil type. This technique is applied for contacts made from a folded cut metal blank.

Le document US 5 561 267 concerne par exemple un contact à sertir comportant des ailettes de taille différente permettant un recouvrement d'une ailette de sertissage sur une autre et un procédé de sertissage avec poinçonenclume adaptés.The document US 5,561,267 For example, a crimp contact having fins of different size for covering one crimping vane on another and a crimping method with an appropriate binder.

Les contacts sertis rencontrent des problèmes de fiabilité pour des applications faibles courants et faibles tensions et plus particulièrement des micro-coupures apparaissent dans le temps. Il a été mis en évidence que le sertissage pouvait perdre de son efficacité en raison d'un phénomène de retour élastique des ailettes de sertissage ce qui cause une diminution de la pression de contact entre les ailettes et les brins des fils sertis et peut conduire à des augmentations ou des instabilités de résistance de contact, voire à des pertes de contact électrique.The crimped contacts have reliability problems for low current and low voltage applications and more particularly micro-cuts appear over time. It has been demonstrated that the crimping could lose its effectiveness due to a phenomenon of elastic return of the crimping fins which causes a decrease in the contact pressure between the fins and the strands of the crimped wires and can lead to increases or instabilities of contact resistance or even loss of electrical contact.

Le document US 5 025 554 pour sa part concerne un sertissage auquel de la pâte à souder a été ajoutée afin d'améliorer la conduction électrique. Le problème d'une telle combinaison est la difficulté de localiser une petite quantité de pâte à souder dans un procédé de sertissage automatisé sur une chaîne de production de faisceaux automobiles et aux cadences associées. FR 242 7 702 décrit un procédé selon le préambule de la revendication 1.The document US 5,025,554 for its part is a crimping to which solder paste has been added to improve the electrical conduction. The problem with such a combination is the difficulty of locating a small amount of soldering in an automated crimping process on an automobile beam production line and at associated speeds. FR 242 7 702 discloses a method according to the preamble of claim 1.

La présente invention vise à perfectionner les contacts électriques sertis et à remédier au problème de retour élastique afin de conserver une pression de contact importante au long de la vie du contact.The present invention aims to improve the crimped electrical contacts and remedy the problem of elastic return to maintain a significant contact pressure throughout the life of the contact.

Plus particulièrement, la présente invention concerne un procédé selon la revendication 1.More particularly, the present invention relates to a process according to claim 1.

Plus particulièrement, dans le cas où la section de sertissage comporte un fût ouvert de réception du fil électrique et des ailettes de sertissage dépassant du fût et destinées à enserrer le fil, la première étape de sertissage replie une première surface des ailettes à ladite première hauteur sur le fil et la seconde étape de sertissage replie une zone localisée des ailettes à ladite seconde hauteur, inférieure à la première.More particularly, in the case where the crimping section comprises an open drum for receiving the electrical wire and crimping fins projecting from the barrel and intended to grip the wire, the first crimping step folds a first surface of the fins to said first height. on the wire and the second crimping step folds a localized area of the fins at said second height, less than the first.

En mode de réalisation particulier, le second sertissage peut être réalisé sur deux zones disjointes des ailettes. Plus particulièrement, le second sertissage peut notamment être réalisé sur des zones extrêmes des ailettes.In a particular embodiment, the second crimping can be performed on two disjoint areas of the fins. More particularly, the second crimping can in particular be performed on the end zones of the fins.

En mode de réalisation alternatif, le second sertissage peut être réalisé sur une zone centrale des ailettes.In alternative embodiment, the second crimping can be performed on a central area of the fins.

Avantageusement, la première étape de sertissage peut être effectuée sur la totalité des ailettes de manière à refermer les ailettes sur le fil.Advantageously, the first crimping step can be performed on all the fins so as to close the fins on the wire.

Selon un mode de réalisation préférentiel de l'invention, la seconde étape de sertissage est effectuée sur une partie de la surface des ailettes ayant subi la première étape de sertissage.According to a preferred embodiment of the invention, the second crimping step is performed on a portion of the surface of the fins having undergone the first crimping step.

Le procédé peut être notamment tel que l'outil de sertissage comporte une enclume commune et des éléments de poinçon dissociables. Le fût peut en particulier être déformé lors de la première étape de sertissage et conserver sa forme lors de la seconde étape de sertissage.The method can be such that the crimping tool comprises a common anvil and separable punch elements. The drum can in particular be deformed during the first crimping step and retain its shape during the second crimping step.

L'invention concerne en outre un élément de contact électrique comportant une section de sertissage pourvue d'un fût ouvert muni d'ailettes de sertissage sur un fil électrique, la section de sertissage étant sertie sur le fil par le procédé décrit précédemment tel que, après sertissage, la section de sertissage comporte trois zones successives d'écrasement des ailettes sur le fil, deux des trois zones étant d'épaisseur réduite par rapport à la troisième zone de sorte que le fil exerce une contrainte élastique sur les ailettes au niveau de la troisième zone. En alternative, l'une des trois zones est d'épaisseur réduite par rapport aux deux autres zones de sorte que le fil exerce une contrainte élastique sur les ailettes au niveau des deux autres zones.The invention further relates to an electrical contact element having a crimping section provided with an open barrel provided with crimping fins on an electric wire, the crimping section being crimped onto the wire by the method described above such that, after crimping, the crimping section comprises three successive zones of crimping of the fins on the wire, two of the three zones being of reduced thickness relative to the third zone so that the wire exerts an elastic stress on the fins at the level of the third zone. Alternatively, one of the three zones is of reduced thickness compared to the other two zones so that the wire exerts an elastic stress on the fins in the other two zones.

D'autres avantages et caractéristiques seront mieux comprises à la lecture de la description qui va suivre d'un mode de réalisation particulier de l'invention donné à titre d'exemple non limitatif en référence aux figures qui représentent:

  • En figure 1: Un outil de sertissage selon un aspect de l'invention;
  • En figure 2: Un élément de contact électrique et un fil à sertir selon le procédé de l'invention;
  • En figures 3a et 3b: un contact serti à l'aide du procédé selon l'invention;
  • En figure 4: Une vue schématique en coupe d'un sertissage de fil électrique obtenu par un procédé selon l'invention;
  • En figures 5a et 5b: deux versions de la seconde étape de sertissage du procédé selon l'invention;
  • En figure 6: Une représentation schématique de la première étape de sertissage du procédé selon l'invention.
Other advantages and features will be better understood on reading the following description of a particular embodiment of the invention given by way of non-limiting example with reference to the figures which represent:
  • In figure 1 : A crimping tool according to one aspect of the invention;
  • In figure 2 : An electrical contact element and a crimp wire according to the method of the invention;
  • In Figures 3a and 3b a contact crimped using the method according to the invention;
  • In figure 4 : A schematic sectional view of a crimping of electric wire obtained by a method according to the invention;
  • In Figures 5a and 5b two versions of the second crimping step of the method according to the invention;
  • In figure 6 : A schematic representation of the first crimping step of the method according to the invention.

Selon l'exemple d'application représenté en figure 2 le sertissage est réalisé sur des contacts électriques à fût ouvert. De tels contacts comportent une partie avant A, notamment de raccordement à un contact complémentaire traditionnellement connue, et comportent, dans une partie intermédiaire, pour le raccordement par sertissage une section 30 de sertissage pourvue d'un fût 3 ouvert muni d'ailettes 4, 5 de sertissage sur un la partie dénudée 12 d'un fil 2 électrique, la section de sertissage étant destinée à être sertie sur le fil pour réaliser un contact électrique entre le fil 2 et l'élément de contact 1.According to the application example represented in figure 2 crimping is performed on electrical contacts open drum. Such contacts comprise a front part A, in particular of connection to a conventionally known complementary contact, and comprise, in an intermediate part, for the crimping connection a crimping section provided with an open shaft 3 provided with fins 4, The crimping section is intended to be crimped onto the wire to make an electrical contact between the wire 2 and the contact element 1.

Selon l'exemple, le contact 1 comporte une section terminale 31 formant une zone de reprise d'efforts pourvue d'ailes 10, 11 destinées à se refermer sur l'isolant 13 du fil 2.According to the example, the contact 1 comprises an end section 31 forming a force recovery zone provided with wings 10, 11 intended to close on the insulator 13 of the wire 2.

La partie avant A de l'élément de contact peut être de tout type et peut même éventuellement être constituée d'une seconde section de raccordement par sertissage pour réaliser par exemple une épissure.The front part A of the contact element may be of any type and may even possibly be constituted by a second crimping connection section for producing for example a splice.

De tels éléments de contact sont réalisés par découpe et pliage d'une bande métallique d'épaisseur faible de l'ordre de 0,2 mm à quelques millimètres d'épaisseur.Such contact elements are made by cutting and folding a metal strip of small thickness of the order of 0.2 mm to a few millimeters thick.

Du fait de la nécessité pour ces contacts de posséder une bonne rigidité et, dans le cas de contacts à lames de contact ressort, une bonne élasticité, le matériau employé est très peu ductile et est sujet à retour élastique lors d'opérations de pliage ou formage.Because of the need for these contacts to have good rigidity and, in the case of spring contact contact spring, good elasticity, the material used is very ductile and is subject to elastic return during folding operations or forming.

Il a été montré que ce retour élastique existe au niveau des ailettes 4, 5 de sertissage et que même si les variations de dimensions ne sont que de l'ordre de quelques microns, ce retour élastique peut causer des pertes de contact intermittentes entre les brins et l'élément de contact notamment pour des applications à faibles courant et tension comme les procédures d'auto diagnostic des dispositifs embarqués sur véhicules automobiles.It has been shown that this elastic return exists at the crimping fins 4, 5 and that even if the dimensional variations are only of the order of a few microns, this elastic return can cause intermittent contact losses between the strands. and the contact element in particular for low current and voltage applications such as auto diagnostic procedures for devices on motor vehicles.

De plus, le fil, généralement à base de cuivre, possède une faible capacité de retour élastique et notamment inférieure à celle d'alliages tels qu'un cuprobéryllium souvent employé pour les éléments de contacts.In addition, the wire, generally copper-based, has a low elastic return capability and in particular lower than that of alloys such as cuproberyllium often used for contact elements.

L'invention tend à modifier le comportement mécanique du sertissage afin d'utiliser le phénomène physique du retour élastique dans un sens favorable sur une zone particulière du contact.The invention tends to modify the mechanical behavior of crimping in order to use the physical phenomenon of springback in a favorable direction on a particular zone of the contact.

Pour ce faire, le procédé de sertissage d'une section de sertissage d'un élément 1 de contact électrique sur un fil 2 électrique selon l'invention comporte une première étape de sertissage de la section de sertissage 30 sur la partie dénudée 12 du fil à une première hauteur h1 en repliant les ailettes 4, 5 sur le fil 2 par un outil de sertissage comportant un poinçon 6 et une enclume 7. Pour cette première étape dont le début est décrit en figure 6, le poinçon 6, constitué selon l'exemple de trois parties 6a, 6b, 6c, appuie avec ses trois parties sur la totalité des ailettes 4 et 5 et l'enclume appuie sous le fût 3, les ailettes 4 et 5 étant des ailettes continues.To do this, the method of crimping a crimping section of an element 1 of electrical contact on an electrical wire 2 according to the invention comprises a first crimping step of the crimping section 30 on the stripped portion 12 of the wire at a first height h1 by folding the fins 4, 5 on the wire 2 by a crimping tool comprising a punch 6 and an anvil 7. For this first step, the beginning of which is described in FIG. figure 6 , the punch 6, formed according to the example of three parts 6a, 6b, 6c, bears with its three parts on all of the fins 4 and 5 and the anvil presses under the shaft 3, the fins 4 and 5 being fins continuous.

La hauteur de sertissage h1 est obtenue en fonction des dimensions du contact et du fil par un sertissage classique de telle sorte que l'on obtienne un taux de compression minimal de l'ordre de 5% de façon à refermer les ailettes sur le fil. Cette première étape de sertissage est effectuée sur une majeure partie de la surface des ailettes 4, 5 voir sur la totalité de ces ailettes par le poinçon 6 et sur une majeure partie voir la totalité du fût 3 par l'enclume 7.The crimping height h1 is obtained as a function of the dimensions of the contact and the wire by conventional crimping so that a minimum compression ratio of the order of 5% is obtained so as to close the fins on the wire. This first step of crimping is performed on a major part of the surface of the fins 4, 5 see all of these fins by the punch 6 and on a major part see the entire barrel 3 by the anvil 7.

Le procédé comporte une seconde étape ou opération de sertissage, cette opération est effectuée à une seconde hauteur h2, inférieure à la première sur une zone localisée des ailettes. Cette étape est réalisée de telle sorte qu'un taux de compression supérieur à 15% et typiquement de l'ordre de 25 à 30% soit obtenu sous l'outil de sertissage. Cette seconde étape est représentée schématiquement aux figures 4 et 5b représentant un premier mode de réalisation pour lequel seuls les éléments 6a, 6c du poinçon 6 appuient sur les extrémités 4a, 4c, 5a, 5c des ailettes, l'élément 6b restant en retrait et ne venant pas en contact avec les ailettes et, à la figure 5a pour un second mode de réalisation pour lequel seul l'élément de poinçon 6b appuie sur les parties d'ailettes 4b et 5b, les éléments de poinçon 6a et 6c restant en retrait et ne venant pas en contact avec les ailettes.
dans les deux modes de réalisation, la seconde étape de sertissage est effectuée sur une partie de la surface des ailettes ayant subi la première étape de sertissage.The method comprises a second step or crimping operation, this operation is performed at a second height h2, less than the first on a localized area of the fins. This step is carried out so that a compression ratio greater than 15% and typically of the order of 25 to 30% is obtained under the crimping tool. This second step is schematically represented in figures 4 and 5b representing a first embodiment for which only the elements 6a, 6c of the punch 6 rest on the ends 4a, 4c, 5a, 5c of the fins, the element 6b remaining in recess and not coming into contact with the fins and, the figure 5a for a second embodiment for which only the punch element 6b presses on the fin parts 4b and 5b, the punching elements 6a and 6c remaining recessed and not coming into contact with the fins.
in both embodiments, the second crimping step is performed on a portion of the surface of the fins having undergone the first crimping step.

Ces deux modes de réalisation du second sertissage conduisent pour le contact à deux variantes, l'une pour laquelle les zones extrêmes longitudinales 4a 4c, 5a, 5c des ailettes comme représenté en figure 3a sont plus écrasées, la hauteur h2 correspondant pour le contact résultant à une épaisseur e2, que la zone centrale d'épaisseur e1 résultant de la hauteur de sertissage h1 effectuée sur ces ailettes, l'autre pour laquelle le second sertissage est réalisé sur la zone centrale 4b, 5b des ailettes comme représenté en figure 3b, les épaisseurs e1 et e2 correspondant ici aussi respectivement aux hauteurs de sertissage h1 et h2.These two embodiments of the second crimping lead to the two-variant contact, one for which the longitudinal end regions 4a 4c, 5a, 5c of the fins as shown in FIG. figure 3a are more crushed, the height h2 corresponding to the resulting contact at a thickness e2, the central zone of thickness e1 resulting from the crimping height h1 performed on these fins, the other for which the second crimping is performed on the zone 4b, 5b of the fins as shown in FIG. figure 3b , the thicknesses e1 and e2 here also corresponding respectively to crimping heights h1 and h2.

Selon l'exemple de la figure 3a, le contact serti comporte trois zones successives d'écrasement des ailettes sur le fil, deux des trois zones étant d'épaisseur réduite par rapport à la troisième zone de sorte que le fil exerce une contrainte élastique sur les ailettes au niveau de la troisième zone.According to the example of the figure 3a , the crimped contact comprises three successive zones of crushing of the fins on the wire, two of the three zones being of reduced thickness relative to the third zone so that the wire exerts an elastic stress on the fins at the level of the third zone .

Selon l'exemple de la figure 3b, le contact serti comporte trois zones successives d'écrasement des ailettes sur le fil, l'une des trois zones étant d'épaisseur réduite par rapport aux deux autres zones de sorte que le fil exerce une contrainte élastique sur les ailettes au niveau des deux autres zones.According to the example of the figure 3b , the crimped contact comprises three successive zones of crushing of the fins on the wire, one of the three zones being of reduced thickness relative to the other two zones so that the wire exerts an elastic stress on the fins at the two other areas.

Le double sertissage inverse le retour élastique pour lui faire jouer un rôle positif c'est à dire créer une pression de contact entre le fût et les brins. Selon le procédé et, comme décrit en figure 4, en fin de la seconde opération de sertissage, pour le mode de réalisation de la figure 3a, les brins gonflent localement dans la zone 20b entre les deux outils 6a et 6c réalisant la seconde étape de sertissage. En conséquence, alors que pour les zones des ailettes sous les outils 6a et 6c, le retour élastique des ailettes reste supérieur à celui des brins du fil, dans la zone 20b, c'est le fil qui vient déformer l'aile par effet de gonflement.The double crimping reverses the springback to make it play a positive role that is to say create a contact pressure between the barrel and the strands. According to the method and, as described in figure 4 at the end of the second crimping operation, for the embodiment of the figure 3a , the strands swell locally in the zone 20b between the two tools 6a and 6c performing the second crimping step. Consequently, whereas for the zones of the fins under the tools 6a and 6c, the elastic return of the fins remains greater than that of the strands of the wire, in the zone 20b, it is the wire which deforms the wing by the effect of swelling.

L'élasticité des ailettes a alors dans cette partie 20b un effet positif car elle tend à comprimer le fil ce qui implique une pression de contact mécanique et donc une bonne conduction électrique même sous des sollicitations mécaniques ou thermiques.The elasticity of the fins then has in this part 20b a positive effect because it tends to compress the wire which implies a mechanical contact pressure and therefore good electrical conduction even under mechanical or thermal stresses.

L'outil de sertissage représenté en figure 1 et adapté au procédé selon l'invention comporte une enclume 7 commune et des éléments 6a, 6b, 6c de poinçon dissociables. Un tel outil peut fonctionner sur une presse automatique traditionnelle moyennant une commande dissociée des éléments de poinçon.The crimping tool represented in figure 1 and adapted to the method according to the invention comprises an anvil 7 and common elements 6a, 6b, 6c dissociable punch. Such a tool can operate on a traditional automatic press with a separate command of the punch elements.

Il est bien sûr possible de réaliser les opérations de sertissage sur deux postes séparés, un premier poste comportant un premier poinçon effectuant le premier sertissage et un second poste comportant un poinçon adapté à effectuer le second sertissage sur une zone particulière du contact. Il reste que le mode de réalisation pour lequel le poinçon 6 se divise en éléments de poinçons mobiles pouvant être actionnés séparément permet de conserver un parfait alignement de l'élément de contact avec les poinçons et de réaliser successivement les deux opérations sur la même presse.It is of course possible to perform the crimping operations on two separate stations, a first station having a first punch performing the first crimping and a second station having a punch adapted to perform the second crimping on a particular area of the contact. It remains that the embodiment for which the punch 6 is divided into movable punch elements that can be actuated separately keeps a perfect alignment of the contact element with the punches and perform successively both operations on the same press.

L'intérêt de l'enclume commune est que le fût 3 est déformé lors de la première étape de sertissage et conserve sa forme lors de la seconde étape de sertissage Le fût garde ainsi une bonne rigidité mécanique et une bonne résistance aux contraintes mécaniques en cas de traction sur le fil.The interest of the common anvil is that the barrel 3 is deformed during the first crimping step and retains its shape during the second crimping step The barrel thus retains good mechanical rigidity and good resistance to mechanical stresses in case traction on the wire.

Un tel procédé est applicable aux contacts à sertir à fût ouvert pour contacts électriques découpés pliés mais aussi à des contacts à fût fermés tels que contacts découpés roulés à base d'un feuillard métallique.Such a method is applicable to crimp contacts with open barrel for bent cut electrical contacts but also to contacts with closed barrels such as rolled cut contacts based on a metal strip.

Il est à noter que selon l'invention pour laquelle le poinçon se divise en éléments de poinçons mobiles pouvant être actionnés séparément, la première étape de sertissage peut être effectuée au moyen du seul élément 6b du poinçon (pour un résultat final de seconde étape du type montré à la figure 3a) ou au moyen des seuls éléments 6a et 6c de ce poinçon (pour un résultat final de seconde étape du type montré à la figure 3b), cela signifiant que les éléments 6a et 6c, respectivement l'élément 6b, reste(nt) lors de cette première étape dans une position haute sans venir eux-mêmes appuyer en force sur les ailettes 4 et 5 du fût placé sur l'enclume. Les ailettes 4 et 5 subiront néanmoins une opération de pliage/sertissage plus ou moins marquée sur toute ou une partie très significative de leur longueur au-delà de la/des seule(s) zone(s) d'ailette(s) sur la/lesquelle(s) l'élément 6b, respectivement, les éléments 6a/6c du poinçon sont venus s'appuyer. Dans ce cas, la première hauteur de sertissage définit la hauteur de sertissage sur la zone centrale des ailettes respectivement la hauteur de sertissage sur les zones d'extrémité des ailettes. La seconde étape de sertissage qui suit la première étape est alors effectuée au moyen des éléments 6a, 6c, respectivement de l'élément 6b, selon l'invention, l'élément 6b du poinçon, respectivement les éléments 6a et 6c de ce poinçon restant dans une position de fin de parcours de première étape pour conserver le fût dans la forme qu'il a à l'issue de la première étape. Ainsi donc, la première étape de sertissage sertit au moins une première zone de chaque ailette 4 et 5 du fût à une première hauteur de sertissage, en repliant de manière plus ou moins marquée les ailettes sur une surface s'étendant au-delà de ladite au moins une première zone, et la seconde étape de sertissage sertit à la seconde hauteur de sertissage au moins une seconde zone de chaque ailette 4 et 5, dite région localisée de la section de sertissage, complémentaire(s) de ladite au moins une première zone.It should be noted that according to the invention for which the punch is divided into movable punch elements that can be actuated separately, the first crimping step can be performed by means of the single element 6b of the punch. (for a final second stage result of the type shown in figure 3a ) or by means of the only elements 6a and 6c of this punch (for a final second-stage result of the type shown in figure 3b ), this means that the elements 6a and 6c, respectively the element 6b, remain (s) during this first step in a high position without themselves come to press force on the fins 4 and 5 of the barrel placed on the anvil. The fins 4 and 5 will nevertheless undergo a more or less marked bending / crimping operation over all or a very significant part of their length beyond the sole area (s) of fin (s) on the where (s) the element 6b, respectively, the elements 6a / 6c of the punch have come to bear. In this case, the first crimping height defines the crimping height on the central area of the fins respectively the crimping height on the end zones of the fins. The second crimping step which follows the first step is then carried out by means of the elements 6a, 6c, respectively of the element 6b, according to the invention, the element 6b of the punch, respectively the elements 6a and 6c of this punch remaining in a first-stage end-of-course position to keep the keg in the shape that it has at the end of the first stage. Thus, the first crimping step crimped at least a first zone of each fin 4 and 5 of the barrel to a first crimping height, by more or less sharply folding the fins on a surface extending beyond said at least a first zone, and the second crimping step crimps at the second crimping height at least a second zone of each fin 4 and 5, said localized region of the crimping section, complementary (s) of said at least a first zoned.

Claims (18)

  1. Method for crimping electric contact (1) onto an electric wire (2), the contact having a crimping section (30) provided with a barrel (3) for receiving electric wire (2), the barrel comprising a part designed to clasp the wire by deformation, characterized in that it comprises a first crimping step at a first crimping height (h1) by compressing a first surface of the crimping section over wire (2) by means of a crimping tool comprising a stamping element (6) and an anvil (7) and a second crimping step at a second crimping height (h2), lower than the first, in a localized region (4a, 4b, 4c, 5a, 5b, 5c) of the crimping section, one of the crimping steps deforming, by expanding effect, the wire in an already crimped part of the crimping section.
  2. Method for crimping electric contact (1) according to claim 1, further characterized in that crimping section (30) has an open barrel (3) for receiving electric wire (2) and crimping wings (4, 5), those wings extending beyond the barrel and being designed to clasp the wire, and in that the first crimping step folds a first surface of wings (4, 5) at said first height (h1) onto wire (2) and the second crimping step folds a localized region (4a, 4b, 4c, 5a, 5b, 5c) of the wings at a second crimping height (h2), lower than the first.
  3. Method according to claim 2, further characterized in that the second crimping is conducted over two disjoint zones (4b, 4c, 5b, 5c) of the wings.
  4. Method according to claim 3, further characterized in that the second crimping is conducted over two end zones (4b, 4c, 5b, 5c) of the wings.
  5. The method according to claim 2, further characterized in that the second crimping is conducted on a central zone (4a, 5a) of the wings.
  6. The method according to one of the preceding claims, further characterized in that the first crimping step is conducted over the entire surface of wings (4, 5).
  7. The method according to claim 6, further characterized in that the second crimping step is conducted over a part (4a, 4b, 4c, 5a, 5b, 5c) of the surface of the wings having undergone the first crimping step.
  8. The method according to one of the preceding claims, further characterized in that the crimping tool has a common anvil (7) and separable stamping element parts (6a, 6b, 6c).
  9. Method according to one of the preceding claims, further characterized in that barrel (3) is deformed during the first crimping step and keeps its form during the second crimping step.
  10. Method according to one of the preceding claims further characterized in that the crimping step at a second height is performed after the crimping step at a first height.
  11. Method according to one of the preceding claims, wherein the crimping section comprises a first part and a second part and wherein the first crimping step is performed on at least the first part of the crimping section and wherein the second crimping step is performed on the second part of the crimping section deforming, by expanding effect of the wire, the first part of the crimping section.
  12. Electric contact element comprising a crimping section (30) provided with an open barrel (3) equipped with wings (4, 5) for crimping onto an electric wire (2), said crimping section being crimped onto the wire by a method according to one of claims 1 to 9, characterized in that after crimping, crimping section (30) has three successive zones for crushing the wings onto the wire, at least one of the three zones being of reduced thickness with regard to at least one other zone so that the wire exerts an elastic force on the wings at the level of at least one of the zones.
  13. Electric contact element according to claim 12, wherein two of the three zones being of reduced thickness with regard to the third zone so that the wire exerts an elastic force on the wings at the level of the third zone.
  14. Electric contact element according to claim 12, wherein one of the three zones is of reduced thickness with regard to the two other zones so that the wire exerts an elastic force on the wings at the level of the other two zones.
  15. Electrical wire assembly comprising a stripped portion and an electric contact element according to claim 13, the three successive zones for crushing the wire being located on the stripped portion of the wire so that the stripped portion of the wire exerts an elastic force on the wings at the level of the third zone.
  16. Electrical wire assembly comprising a stripped portion and an electric contact element according to claim 14, the three successive zones for crushing the wire being located on the stripped portion of the wire so that the stripped portion of the wire exerts an elastic force on the wings at the level of the other two zones.
  17. Tool for crimping of an electric contact (1) onto an electric wire (2), the contact having a crimping section (30) provided with a barrel (3) for receiving electric wire (2), the barrel comprising a part designed to clasp the wire by deformation, characterized in that it comprises a common anvil (7) for receiving the barrel, separable stamp element parts (6a, 6b, 6c), and a control system adapted to control separately the stamping element parts in order to conduct a first crimping step at a first crimping height (h1) by folding a first surface of the crimping section over wire (2) and a second crimping step at a second crimping height (h2), lower than the first, in a localized region (4a, 4b, 4c, 5a, 5b, 5c) of the crimping section, in a manner adapted for deforming , by expanding effect of the wire, an already crimped part of the crimping section.
  18. Tool for crimping according to claim 17, wherein the crimping section comprise a first part (4b, 5b ; 4a, 4c, 5a, 5c) and a second part (4a, 4c, 5a, 5c ; 4b, 5b), and wherein the control system is adapted to control the first crimping step on at least the first part (4b, 5b ; 4a, 4c, 5a, 5c) of the crimping section and the second crimping step on the second part (4a, 4c, 5a, 5c ; 4b, 5b) of the crimping section, deforming, by expanding effect of the wire, the first part (4b, 5b ; 4a, 4c, 5a, 5c) of the crimping section.
EP04720635.4A 2003-08-19 2004-03-15 Electric contact crimping method and contact obtained according to said method Expired - Lifetime EP1658662B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR0310011A FR2859047A1 (en) 2003-08-19 2003-08-19 Improved electrical wire contact crimping method having outer shaft two stages deformed using die stamps with second crimping stage forming smaller localised gap size.
PCT/FR2004/000631 WO2005029653A1 (en) 2003-08-19 2004-03-15 Electric contact crimping method and contact obtained according to said method

Publications (2)

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EP1658662A1 EP1658662A1 (en) 2006-05-24
EP1658662B1 true EP1658662B1 (en) 2016-07-27

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EP04720635.4A Expired - Lifetime EP1658662B1 (en) 2003-08-19 2004-03-15 Electric contact crimping method and contact obtained according to said method

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US (1) US20070054565A1 (en)
EP (1) EP1658662B1 (en)
JP (1) JP4413926B2 (en)
KR (2) KR101273881B1 (en)
CN (1) CN100452566C (en)
BR (1) BRPI0412982A (en)
CA (1) CA2534403C (en)
FR (1) FR2859047A1 (en)
MX (1) MXPA06001829A (en)
WO (1) WO2005029653A1 (en)

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EP3439111B1 (en) * 2017-08-01 2021-12-22 VM Industries Optimised crimping of two electrical connectors

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JP5164819B2 (en) * 2008-12-12 2013-03-21 矢崎総業株式会社 Crimping method of crimping barrel, crimping barrel and crimping device
KR200456773Y1 (en) * 2009-10-22 2011-11-21 주식회사 유라코퍼레이션 Unit of terminal cable
JP5953590B2 (en) * 2012-03-21 2016-07-20 矢崎総業株式会社 Electric wire with crimp terminal and method for crimping crimp terminal to electric wire
CN103458542A (en) * 2012-12-18 2013-12-18 上海华族实业有限公司 Ceramic PTC heater with corrugate heat radiating fins
JP2015076238A (en) * 2013-10-08 2015-04-20 矢崎総業株式会社 Crimping terminal and caulking jig of crimping terminal
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EP1658662A1 (en) 2006-05-24
MXPA06001829A (en) 2006-05-31
WO2005029653A1 (en) 2005-03-31
JP2007503083A (en) 2007-02-15
CA2534403A1 (en) 2005-03-31
KR20110063582A (en) 2011-06-10
CN100452566C (en) 2009-01-14
KR101273881B1 (en) 2013-06-17
FR2859047A1 (en) 2005-02-25
BRPI0412982A (en) 2006-10-03
CA2534403C (en) 2013-05-07
JP4413926B2 (en) 2010-02-10
KR20060065696A (en) 2006-06-14
US20070054565A1 (en) 2007-03-08
CN1836354A (en) 2006-09-20

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