Method for connecting at least one wire to a contact element

• US 7,823,282 B2
• Filed: 06/24/2005
• Issued: 11/02/2010
• Est. Priority Date: 07/07/2004
• Status: Expired due to Fees

• Current Assignee: Aliaxis Deutschland GmbH (Aliaxis SA)
• Original Assignee: Friatec AG (Aliaxis SA)
• Inventors: Hojenski, Andreas, Heinzel, Andre
• Primary Examiner(s): Banks; Derris H
• Assistant Examiner(s): CARLEY, JEFFREY T.
• Application Number:
  US11/631,591
• Publication Number:
  US 20080155823A1
• Time in Patent Office: 1,957 Days
• Field of Search: 298/57, 298/60, 298/63, 298/42, 298/76, 298/77, 298/67
• US Class Current: 29/867
• CPC Class Codes: H01R 4/023 between cables or wires and terminals
• CPC Class Codes: H01R 43/0207 Ultrasonic-, H.F.-, cold- or impact welding
• CPC Class Codes: H01R 43/0228 without preliminary removing of insulation before soldering or welding
• CPC Class Codes: H01R 43/04 for forming connections by deformation, e.g. crimping tool
• CPC Class Codes: Y10T 29/49147 Assembling terminal to base
• CPC Class Codes: Y10T 29/49192 with insulation removal

Abstract

A method for connecting at least one wire to a contact element to facilitate connection of the wire to a power source comprising the following steps: a) preparation of the contact element which is fitted with a groove for receiving at least one wire; b) insertion of the wire into the groove of the contact element; c) lowering an electrode onto the contact element; and d) heating of the area around the groove by means of the electrode while simultaneously deforming the area around the groove thereby embedding the wire lying in said groove.

Claims

1. A method for connecting at least one wire to a contact element for connecting the wire to a power source, comprising the steps of:

(a) providing a contact element having a groove for receiving at least one wire, said groove having two fork studs, one on either side of the groove;

(b) placing the wire in the groove of the contact element;

(c) lowering an electrode onto the contact element to establish two line contacts between the contact element and the electrode, one line contact on each of the two fork studs;

(d) heating the fork studs on either side of the groove by flowing current through the electrode and through the fork studs,

wherein only the fork studs have been reduced in strength by being heated, and wherein the fork studs are mechanically deformed, so that the wire lying in the groove is pressed into electrical contact with the contact element and is completely enclosed by the deformed fork studs which become welded to each other while its cross-section remains essentially intact.

2. The method according to claim 1, further comprising after step (d):

e) cooling the deformed contact element.

3. The method according to claim 1, wherein the groove is deeper than the diameter of the wire.

4. The method according to claim 1, wherein two or more wires or wire ends are placed in the groove to establish an electric contact between the wires or wire ends.

5. The method according to claim 1, wherein the groove has a rectangular, semi-circular, or V-shaped cross-section.

6. The method according to claim 5, wherein the inner surfaces of the groove are smooth, scalloped, corrugated, or fitted with serrations.

7. The method according to claim 5, wherein the groove is convex or linear in a longitudinal direction and is either horizontal, slanted, or concave in a transverse direction.

8. The method according to claim 1, wherein the fork studs of a pair are essentially parallel to each other.

9. The method according to claim 1, wherein the fork studs are at an angle to each other.

10. The method according to claim 5, wherein the contact element comprises a plug-shaped body, at a free end of which the groove is formed.

11. The method according to claim 10, wherein a flange is fitted circumferentially around the plug-shaped body, said flange comprising one or more parts.

12. The method according to claim 1, wherein the contact element comprises a base body that is at least partially coated with a metallic coating that has a low melting point or improved electric conductivity or both a low melting point and improved electric conductivity.

13. The method of claim 1, wherein the electrode has a concave surface for resting on the contact element.

14. The method according to claim 12, wherein the metallic coating is one of zinc, tin, copper or alloy thereof.

15. The method according to claim 14, wherein the metallic coating is a eutectic.