Method for the integrally bonded joining of an electric cable to an electrical contact part and electric cable arrangement
The present disclosure relates to a process for integrally joining an electrical line to an electric contact part by means of a material bond. An exposed end of the line is inserted into a receiving sleeve of the contact part. Then a friction welding tool is rotated on an open end face of the receiving sleeve for the cohesive connection of the line end with the receiving sleeve. According to the disclosure, a powdery metal filler material is introduced into the receiving sleeve before rotation in such a way that the metal filler material is at least partially arranged between the line end and/or the receiving sleeve and the friction welding tool. Furthermore, the disclosure also concerns an electrical line arrangement which is manufactured with the aid of the metal filler material.
1. A method for integrally joining an electrical line to an electrical contact part, the method comprising the steps:
inserting an exposed line end of the electrical line into a receiving sleeve of the contact part,
rotating a friction welding tool on an open-end face of the receiving sleeve for the cohesive connection of the line end with the receiving sleeve,
wherein
a powdery metal filler material is introduced into the receiving sleeve before rotation in such a way that the metal filler material is arranged at least partially between at least one of the line end and the receiving sleeve and the friction welding tool, and
the contact part includes a solder material depot in a heat input zone, from which the solder material is melted due to the rotation of the friction welding tool by at least one of heat input and a residual heat.
2. The method according to claim 1 , wherein the metal filler material is introduced into the receiving sleeve by means of an adjustable metering device before the friction welding tool is rotated.
3. That the method according to claim 1 , wherein the metal filler material is distributed inside the receiving sleeve after insertion by means of ultrasound.
4. The method according to claim 1 , wherein the metal filler material is selected with at least one of a grain size and a grain shape which increases the friction with the friction welding tool.
5. The method according to claim 1 , wherein the metal filler material is a mixture of at least one of different grain sizes and grain shapes.
6. The method according to claim 1 , wherein the metal filler material is selected or mixed from: brass, bronze, silver or nickel and alloys of brass, bronze, silver or nickel.
7. The method according to claim 1 , wherein the contact part is formed in two parts with the receiving sleeve and a connecting part for connection to an electrical counter-connection.
8. The method according to claim 1 , wherein a soldering material is additionally introduced for the integrally joining of the receiving sleeve with the connecting part.
9. The method according to claim 7 , wherein at least one of the receiving sleeve and the connecting part have a solder material depot which is arranged in such a way that due to the rotation of the friction welding tool by at least one of heat input and a residual heat resulting therefrom, the solder material is released for joining the receiving sleeve and connecting part.
10. The method according to claim 7 , wherein the receiving sleeve and the connecting part are pressed together before the line end is inserted.
11. The method according to claim 1 , wherein, before rotation, a powdery solder material is introduced into the receiving sleeve such that the solder material is arranged in a heat input zone for melting.
12. The method according to claim 1 , wherein the line comprises a conductor of an aluminum material.
13. The method according to claim 1 , wherein the line is a stranded conductor and the metal filler material is distributed between strands of the line.
14. The method according to claim 1 , wherein the contact part is made of a copper material at least in the region of the receiving sleeve.
15. An electrical line arrangement, comprising at least one electrical line and an electrical contact part which are integrally joined together by inserting an exposed line end of the electrical line into a receiving sleeve of the contact part and rotating a friction welding tool on an open end face of the receiving sleeve for the cohesive connection of the line end with the receiving sleeve, the electrical line arrangement further comprising a powdery metal filler material that is introduced into the receiving sleeve before rotation in such a way that the metal filler material is arranged at least partially between at least one of the line end and the receiving sleeve and the friction welding tool.