Method for electrically connecting a conductor to a contact

• US 7,084,346 B2
• Filed: 10/23/2003
• Issued: 08/01/2006
• Est. Priority Date: 10/31/2002
• Status: Expired due to Fees

• Current Assignee: FCI
• Original Assignee: FCI
• Inventors: Pabst, Thomas Bernhard
• Primary Examiner(s): Mayo, III, William H.
• Application Number:
  US10/531,955
• Publication Number:
  US 20060060372A1
• Time in Patent Office: 1,013 Days
• Field of Search: 174/36, 174/74.R, 174/75.C, 174/78, 174/84.R, 174/84.C, 439/424, 439/882, 439/98, 439/99, 219/56.22, 219/56.21, 219/56.1
• US Class Current: 174/74.00R
• CPC Class Codes: H01R 12/59 for flexible printed circuits, flat or ribbon cables or like structures
• CPC Class Codes: H01R 13/11 Resilient sockets carrying separate resilient parts H01R13/15
• CPC Class Codes: H01R 4/023 between cables or wires and terminals
• CPC Class Codes: H01R 4/029 Welded connections H01R4/021 - H01R4/028 take precedence
• CPC Class Codes: H01R 43/0214 Resistance welding H01R43/0228 takes precedence
• CPC Class Codes: H01R 43/0228 without preliminary removing of insulation before soldering or welding

Abstract

The invention relates to a method for electrically connecting a conductor to a contact, according to which the electrical conductor that is coated with an insulation is first inserted between two legs of the contact, whereupon a welding device is placed against both legs and the welding process is carried out by turning on the welding current. The insulation of the electrical conductor is destroyed due to the heat delivered during the welding process, resulting in a permanent mechanical and electrical connection between the conductor and the contact.

Claims

1. A method for the electrical connection of an electrical conductor to a contact element with the following steps:

introduction of the electrical conductor ensheathed with an insulation between two legs of the contact element,

application of a welding device to both legs,

conducting the welding process by switching on the welding current, wherein the heat introduced during the welding process breaks down the insulation of the electrical conductor and leads to a solid mechanical and electrical connection of the conductor with the contact element, wherein the two legs of the contact element are located on respective opposite sides of the electrical conductor, and wherein each leg is welded to the electrical conductor only on its respective opposite side of the electrical conductor.

2. The method according to claim 1, further characterized in that the welding process is a resistance welding.

3. The method according to claim 2, further characterized in that at the beginning of the welding process, the welding current flows over the two legs of the contact element and its connection point.

4. The method according to claim 1, further characterized in that the welding device is applied to the outer sides of the two legs lying opposite the conductor.

5. The method according to claim 4, further characterized in that a welding stamp of the welding device is applied in each case to one outer side of contact element.

6. The method according to claim 1, further characterized in that the contact element is connected to a plug connector.

7. The method according to claim 1, further characterized in that the conductor ensheathed with an insulation is a flat flex conductor.

8. The method according to claim 1, further characterized in that the contact element is bent in an S-shape.

9. The method according to claim 1, further characterized in that the contact element is bent in a C-shape.

10. A plug connector with a contact element and an electrical conductor, which is connected to the contact element, is hereby characterized in that the connection between contact element and electrical conductor was produced according to a method according to claim 1.

11. The method according to claim 2, wherein the electrical conductor comprises an electrically conductive substantially flat core and substantially flat sheets of the insulation on opposite sides of the core.

12. The method according to claim 1 wherein the legs comprise two substantially flat, substantially parallel legs.

13. The method according to claim 12 wherein the legs are substantially flat, substantially parallel both before and after conducting the welding process.

14. The method according to claim 1 wherein the welding device comprises substantially flat electrode tips.

15. The method according to claim 1 wherein a distant between electrode tips of the welding device at a start of the welding process is smaller than a length of the legs.

16. A method of connecting an electrical conductor to a contact element comprising;

inserting the electrical conductor into the contact element, wherein the contact element comprises two substantially parallel legs, wherein the electrical conductor comprises an electrically conductive substantially flat core and insulating material surrounding the core, and wherein the electrical conductor is inserted between the legs; and

applying a welding process to the legs to melt at least a portion of the insulating material between the legs and directly attach the legs to opposite respective sides of the flat core.

17. A method of connecting an electrical conductor to a contact element comprising:

inserting the electrical conductor into the contact element, wherein the contact element comprises two legs, wherein the electrical conductor comprises an electrically conductive core and insulating material surrounding the core, and wherein the electrical conductor is inserted between the legs; and

applying a welding process to the legs by a welding device to melt at least a portion of the insulating material between the legs and directly attach the legs to opposite respective sides of the core, wherein a distance between furthest portions of opposing electrode tips of the welding device at a start of the welding process is smaller than a length of insertion of the core along the legs.

18. A method as in claim 17 wherein the core comprises a substantially flat core and the insulating material comprises substantially flat sheets on opposite sides of the core, and wherein the legs comprise substantially flat legs such that the welding of the legs to the core forms a substantially flat sandwich structure.

19. A method as in claim 17 wherein the legs are directly electrically and mechanically connected to each other by the core.