METHOD FOR WELDING A CABLE TO A TERMINAL AND THE TERMINAL OBTAINED THEREFROM

• US 20140182127A1
• Filed: 06/29/2012
• Published: 07/03/2014
• Est. Priority Date: 07/01/2011
• Status: Active Grant

• Current Assignee: Aptiv Technologies AG
• Original Assignee: Aptiv Technologies Limited (BorgWarner Incorporated)
• Inventors: Nagy, Peter, Kovacs, Tamas
• Granted Patent: US 9,728,927 B2
• Time in Patent Office: Days
• US Class Current: 29/860
• CPC Class Codes: B23K 2103/12 Copper or alloys thereof
• CPC Class Codes: B23K 26/32 taking account of the properties of the material involved
• CPC Class Codes: H01R 13/65912 for shielded multiconductor cable coaxial cables with one conductor surrounded by shield H01R9/05; flat shielded cables H01R12/594
• CPC Class Codes: H01R 43/0221 Laser welding H01R43/0228 takes precedence
• CPC Class Codes: H01R 43/0263 for positioning or holding parts during soldering or welding process
• CPC Class Codes: Y10T 29/49179 by metal fusion bonding

Abstract

The invention is a welding method for welding a cable to a terminal, the cable comprising multiple strands and an insulating sheath around the multiple strands, the method comprising the steps of removing the insulating sheath from an end section of the cable, pressing the multiple strands to the terminal with a pressing mechanism, and making at least one welding connection between the multiple strands and the terminal by applying at least one pulse of a laser onto the end section of the cable, and removing the pressing mechanism.

Claims

1. A welding method for welding a cable to a terminal, wherein the cable comprises multiple strands, the method comprising the steps of:

pressing the multiple strands to the terminal with a pressing mechanism,

making at least one welding connection between the multiple strands and the terminal by applying at least one pulse of a laser onto the end section of the cable; and

removing the pressing mechanism.

2. The method according to claim 1, wherein a first pulse of the laser is applied, and wherein the diameter of an impact area of the first pulse of the laser is larger than the overall width of the pressed down multiple strands.

3. The method according to claim 2, wherein the impact area of the first pulse of the laser covers the end of the cable.

4. The method according to claim 2, wherein the first pulse of the laser is applied with such a power, that all of the multiple strands in the end section of the cable and maximum 50% of a cross section of the terminal are melted.

5. The method according to claim 2, wherein a second pulse of the laser is applied onto the end section of the cable, wherein the diameter of an impact area of the second pulse of the laser is larger than the overall width of the pressed down multiple strands.

6. The method according to claim 5, wherein the impact area of the second pulse of the laser has no overlap with the impact area of the first pulse of the laser.

7. The method according to claim 5, wherein the impact area of the second pulse of the laser has an overlap with the impact area of the first pulse of the laser.

8. The method according to claim 7, wherein the power of the second pulse of the laser is higher than the power of the first pulse of the laser.

9. The method according to claim 5, wherein the second pulse of the laser is applied with such a power, that all of the multiple strands in the end section of the cable and maximum 50% of a cross section of the terminal are melted.

10. The method according to claim 1, wherein a terminal with a flat welding surface is applied.

11. The method according to claim 1, wherein a terminal with a welding surface of a U-shaped cross section is applied.

12. The method according to claim 1, wherein the terminal and/or all of the multiple strands are made of copper.

13. The method according to claim 1, wherein during welding an inert gas is applied around the terminal and the multiple strands.