Method for producing an electrically conductive connection and a contact element provided with an electric connection so produced

• US 7,568,268 B2
• Filed: 05/05/2006
• Issued: 08/04/2009
• Est. Priority Date: 11/06/2003
• Status: Expired due to Fees

• Current Assignee: Bayerische Motoren Werke AG
• Original Assignee: Bayerische Motoren Werke AG
• Inventors: Dinkel, Dieter, Fahrnbauer, Bernhard, Roloff, Hartmut, Albiez, Robert
• Primary Examiner(s): Bryant; David P
• Assistant Examiner(s): GATES, ERIC ANDREW
• Application Number:
  US11/418,266
• Publication Number:
  US 20060289195A1
• Time in Patent Office: 1,187 Days
• Field of Search: 29/33.B, 29/34.R, 29/34.D, 295/644, 295/643, 295/642, 295/05, 295/14, 298/60, 298/61, 298/62, 298/63, 298/64, 298/65, 298/66, 298/67, 174/74.R, 174/84.C, 174/90, 174/93, 174/128.1, 174/129.R, 174/133.R, 174/75.C, 174/78, 129/85.16, 129/56.22, 219/56.1, 219/91.2, 219/85.16, 219/56.22
• US Class Current: 29/33.00B
• CPC Class Codes: H01R 43/0214 Resistance welding H01R43/0228 takes precedence
• CPC Class Codes: H01R 43/0249 for simultaneous welding or soldering of a plurality of wires to contact elements
• CPC Class Codes: H01R 43/28 for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26
• CPC Class Codes: Y10T 29/49179 by metal fusion bonding
• CPC Class Codes: Y10T 29/49908 Joining by deforming
• CPC Class Codes: Y10T 29/49924 of parallel side-by-side elongated members
• CPC Class Codes: Y10T 29/5121 Wire working
• CPC Class Codes: Y10T 29/5183 Welding strip ends

Abstract

A method is provided for producing an electrically conductive connection between a contact element interacting with a corresponding counter-contact and several electric lines, each of which consists of several wires. The method consists of placing the lines on a contact element supporting surface, controlling the lines integrity, and fixing the lines to the contact elements by resistance welding. In particular, the contact element is provided with crimping elements which surround and/or form a ground cable terminal screwed to a mass bolt.

Claims

1. A method of producing an electrically conductive connection between a contact element, which interacts with a corresponding counter-contact element, and several electric lines, each of which includes several stranded wires, the method comprising the acts of:

depositing on a plane supporting surface of the contact element the several electrical lines;

determining whether to carry out a welding of the several electric lines by checking for a completeness of the several lines deposited on the plane supporting surface of the contact element, to verify that all the several electric lines are present by determining a cross-section formed by the stranded wires using a current flow of an electrically driven forming element; and

subsequently, if the several lines are present, resistance welding the several lines to fix the lines in a contact-making manner on the contact element.

2. The method according to claim 1, wherein the several lines are changed to a rectangular cross-section shape.

3. The method according to claim 2, wherein the rectangular cross-section shape is produced by use of two forming elements laterally applied to the lines.

4. The method according to claim 3, wherein the act of checking to verify that all the several electric lines are present further comprises the act of determining a cross-section formed by the stranded wires.

5. The method according to claim 2, wherein the act of checking to verify that all the several electric lines are present further comprises the act of determining a cross-section formed by the stranded wires.

6. The method according to claim 1, wherein the act of determining the cross-section is also performed optically.

7. A contact element formed according to the method of claim 1, wherein the plane supporting surface further comprises two crimping elements which surround the several lines.

8. A contact element formed according to the method of claim 1, wherein the contact element is a ground cable socket operably configured to be held on a ground bolt via a screwed connection.