(19)
(11)EP 1 796 215 B1

(12)EUROPEAN PATENT SPECIFICATION

(45)Mention of the grant of the patent:
25.02.2009 Bulletin 2009/09

(21)Application number: 06123278.1

(22)Date of filing:  31.10.2006
(51)International Patent Classification (IPC): 
H01R 4/62(2006.01)
H01R 4/02(2006.01)
H01R 4/12(2006.01)

(54)

Method for interconnecting electric cables

Verfahren zur Verbindung von elektrischen Kabeln

Procédé pour connecter des câbles électriques


(84)Designated Contracting States:
AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HU IE IS IT LI LT LU LV MC NL PL PT RO SE SI SK TR

(30)Priority: 07.12.2005 IT TV20050192

(43)Date of publication of application:
13.06.2007 Bulletin 2007/24

(73)Proprietors:
  • Tonello, Gino
    31031 Caerano San Marco TV (IT)
  • Tonello, Mirko
    31031 Caerano San Marco TV (IT)

(72)Inventors:
  • Tonello, Gino
    31031 Caerano San Marco TV (IT)
  • Tonello, Mirko
    31031 Caerano San Marco TV (IT)

(74)Representative: Modiano, Micaela Nadia 
Dr. Modiano & Associati SpA Via Meravigli 16
20123 Milano
20123 Milano (IT)


(56)References cited: : 
EP-A1- 1 076 341
JP-A- 2004 087 446
GB-A- 171 317
  
      
    Note: Within nine months from the publication of the mention of the grant of the European patent, any person may give notice to the European Patent Office of opposition to the European patent granted. Notice of opposition shall be filed in a written reasoned statement. It shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention).


    Description


    [0001] The present invention relates to a method for the interconnection of electric cables and in particular of a first carbon fibre electric cable with a second metallic conductor electric cable.

    [0002] There are currently in use electric cables constituted by a bundle of carbon fibres enveloped in a sheath provided by an electrically insulating material, for example a silicon resin; since the carbon has an elevated resistance to heat, such carbon fibre cables have an optimal application as heating electrical resistors, for example in the area of thermocouples.

    [0003] In order to provide the electrical current to such carbon fibre cables, they must be connected, at their ends, to metallic conductors, typically made of copper or aluminium, connected, directly or by means of appropriate circuits, to a power source.

    [0004] It is known to provide the electrical connection between one end of the carbon fibre bundle to one end of the metallic conductor by means of a connection method, known as "crimping", that provides for the insertion of the two ends in an appropriate metallic ring, that is then pressed so as to press therein the carbon fibres and the metallic conductor, providing the electrical contact therebetween.

    [0005] Such known connection method has however a great drawback: due to the very reduced mechanical resistance, in particular of tensile resistance, of the carbon fibres, only modest mechanical stresses on one or both of the cables may cause the breakage of such carbon fibres, with the consequent interruption of the electrical connection between the two cables.

    [0006] In order to limit the possibility of rupture of the carbon fibres, the compression of the metallic ring should not be too elevated, which however compromises the quality of the electrical contact between the metallic conductor and the carbon fibres.

    [0007] Moreover, it is not possible to connect a metallic conductor to a bundle of carbon fibres by means of soldering, since the carbon, due to its physical/chemical properties, is not adapted to be soldered.

    [0008] Due to the above-mentioned drawbacks the use of such carbon fibre cables is therefore very reduced.

    [0009] EP-A-1076341 discloses an operation of connecting an insulated wire and a pin terminal, that includes: removing an insulation at an end of the insulated wire to expose a conductor; winding the exposed conductor into a spiral part, and then inserting the pin terminal into the central opening of the spiral part; and fixing the spiral part and the pin terminal with a fixing material such as solder.

    [0010] GB-A-171317 discloses a terminal for use with high-tension electric cables, comprising a single piece of springy wire which at one end is formed into coils fit about the end of a piece of cable. The wire is led off centrally from the coils approximately linearly and then formes a transverse loop about the conducting wires of the cable. The wire further extends from such transverse loop to form a free end expandable loop for attachment to a spark plug electrode or the like.

    [0011] JP-A-2004087446 discloses a method of joining carbon fibre bundles including inserting two carbon fibre bundles into opposite ends of a casing and then filling the casing with a conductive material to integrate the carbon fibres with each other.

    [0012] The aim of the present invention is to solve the described technical problems, eliminating the drawbacks of the cited prior art, by providing a method that allows to obtain an optimal electrical connection between a carbon fibre cable and a metallic conductor cable.

    [0013] Within this aim, an object of the present invention is to provide a method that permits to interconnect a carbon fibre cable with a metallic conductor cable, reducing the risk of separation of the two cables even under the action of mechanical stress.

    [0014] A not least object is to provide a method for interconnecting a carbon fibre cable with a metallic conductor cable that has reduced costs with respect to the known art.

    [0015] In accordance with the invention, there is provided a method for interconnecting a first electric cable, constituted by a carbon fibre bundle enveloped in a first insulating sheath, with a second cable constituted by a metallic conductor enveloped in a second insulating sheath, as defined in the appended claims.

    [0016] Further characteristics and advantages of the invention will become better apparent from the following detailed description of a preferred but not exclusive embodiment thereof, illustrated only by way of non-limiting example in the accompanying drawings, in which:

    Figure 1 is a perspective view of a carbon fibre cable and a metallic conductor cable in the first step of the interconnection method according to the invention;

    Figures 2, 3 and 4 are perspective views of three winding steps of the metallic conductor cable on the carbon fibre cable;

    Figure 5 is a perspective view of the step of pouring of a layer of tin;

    Figure 6 is a perspective view of the two cables of the preceding figures after their mutual interconnection.



    [0017] In the following embodiments, single characteristics, given in relation to specific examples, in reality may be interchanged with other different characteristics of other embodiments.

    [0018] Moreover, it is to be noted that everything found to be known during the patenting procedure is not intended to be claimed and subject to a disclaimer from the claims.

    [0019] With reference to the figures, a method according to the present invention allows to obtain the interconnection of a first cable 1, constituted by a carbon fibre bundle 2 enveloped in a first sheath 3 provided in an electrically insulating material, with a second cable 4, constituted by a metallic conductor 5, for example copper or aluminium, covered by a second sheath 6, provided also in an electrically insulating material.

    [0020] Advantageously, at least the material that constitutes the first sheath 3 must provide, in addition to good electrical insulating characteristics, also a good mechanical resistance.

    [0021] Advantageously, the first and the second sheaths may be provided in two different electrically insulating materials.

    [0022] With reference to Figure 1, the method according to the invention provides a first step in which a first portion of the first sheath 3 and a second portion of the second sheath 6, that cover respectively a first end 7 of the bundle 2 and a second end 8 of the metallic conductor 5, are partially removed, so as to leave uncovered such first and second ends.

    [0023] Advantageously, the second portion of the second sheath 6 is removed for an extension that is greater than the first portion of the first sheath 3, so that the length of the uncovered portion of the metallic conductor 5 is greater than that of the uncovered portion of the bundle 2.

    [0024] The second end 8 of the metallic conductor 5 is then wound in a spiral-like manner on the first cable 1, starting from the first end 7 of the bundle 2, until the metallic conductor 5 affects the first sheath 3.

    [0025] At this point, with reference to Figure 3, the direction of advancement of the spiral defined by the second end 8 of the metallic conductor 5 is inverted, so as to provide at least one loop 9 that winds about the first sheath 3 to constitute a binding means of the metallic conductor 5 to the latter; as described previously, the sheath 3 may have a good mechanical resistance, so as to allow the maintenance of the connection between the first and the second cables even in the presence of mechanical stresses subjected thereto.

    [0026] With reference to Figures 3 and 4, the metallic conductor 5 is then wound further in a spiral-like manner, advancing in the direction of the first end 7 of the bundle 2 and thereby going to cover substantially entirely such first end 7.

    [0027] As illustrated in Figure 4, the second cable 4 is therefore aligned with the first cable 1.

    [0028] At this point, with reference to Figure 5, at least one layer 10 of tin or other metallic conductor or covering element is arranged to cover completely the second end 8 of the metallic conductor 5, which is wound about substantially entirely the first end 7 of the bundle 2.

    [0029] In the example shown in Figure 5, the second end 8 of the metallic conductor 5 is covered with a layer 10 of tin in the liquid state.

    [0030] The layer 10 does not affect, even if perhaps only slightly, the bundle 2 of carbon fibres, but instead covers completely the second end 8 of the metallic conductor 5, incorporating the same in the condition of winding of the first end 7 of the bundle 2, and guaranteeing in this manner the maintenance of the electrical connection between the latter and the metallic conductor 5.

    [0031] The layer 10 is then in case closed in a heat-shrinking sheath 11, provided in an electrically insulating material, whose ends partially cover respectively the first and the second sheaths of the first and second cables, thereby electrically insulating the joining region between such cables from the external environment.

    [0032] Any mechanical stresses that occur on the first cable and/or on the second cable are absorbed by the metallic conductor 5 and by the first sheath 3, that have high mechanical resistance, while the bundle 2 is not affected or only slightly affected.

    [0033] It is seen therefore how the invention has achieved the proposed aim and objects, there being provided a method that allows the optimum connection, both electrical and mechanical, of a first carbon fibre cable with a second metallic conductor cable.

    [0034] Moreover, the method according to the invention, delegating the mechanical hold in the connection between the two cables only to the first sheath and to the metallic conductor, and therefore not to the carbon fibres, guarantees the maintenance of the electrical connection between the two cables even in the case in which the same are subjected to mechanical stresses.

    [0035] Of course the invention is susceptible to numerous modifications and variations all of which fall within the scope of the appended claims.

    [0036] Naturally, the materials employed as well as the dimensions constituting the singular components of the invention may be more pertinent according to specific requirements.

    [0037] The different means for carrying out certain different functions certainly do not have to exist only in the illustrated embodiment, but may be per se present in many embodiments, also not illustrated.

    [0038] The characteristics indicated as advantageous, opportune or similar, may also be not present or substituted by equivalents.

    [0039] Where technical features mentioned in any claim are followed by reference signs, those reference signs have been included for the sole purpose of increasing the intelligibility of the claims and accordingly, such reference signs do not have any limiting effect on the interpretation of each element identified by way of example by such reference signs.


    Claims

    1. A method for interconnecting a first electric cable (1), constituted by a carbon fibre bundle (2) enveloped in a first insulating sheath (3), with a second cable (4) constituted by a metallic conductor (5) enveloped in a second insulating sheath , (6), comprising the steps of:

    a) removing a first portion of said first sheath (3) that covers a first end (7) of said bundle (2), and removing a second portion of said second sheath (6) that covers a second end (8) of said metallic conductor (5) for an extension greater than that of said first portion;

    b) spiral-like winding said second end (8) of said metallic conductor (5) about said carbon fibre bundle (2) starting from said first end (7) of said first cable (1) in a first direction until said metallic conductor (5) affects said first sheath (3);

    c) changing the direction of advancement of the spiral defined by said second end (8) of said metallic conductor (5) to provide at least one loop (9) that covers said first sheath (3);

    d) spiral-like winding said metallic conductor (5) in a second direction opposite said first direction back toward said first end (7) of said bundle (2) and mutually aligning said first and second cables (1,4);

    e) adding at least one layer (10) of tin or other conductor or covering element to totally cover said second end (8) of said metallic conductor (5).


     
    2. The method according to claim 1, characterized in that said at least one layer (10) is closed in a heat-shrinking sheath (11), provided in an electrically insulating material, whose ends partially cover respectively said first and second sheaths (3,6).
     
    3. The method according to one or more of the preceding claims, characterized in that said first sheath (3) is provided in silicon resin having good electrically insulating properties and a good mechanical resistance.
     
    4. The method according to one or more of the preceding claims, characterized in that said layer (10) completely covers said second end (8) of said metallic conductor (5) incorporating the same in the winding condition of said first end (7) of said bundle (2).
     
    5. A composite electrical cable comprising a first electric cable (1), constituted by a carbon fibre bundle (2) enveloped in a first insulating sheath (3), and a second cable (4), constituted by a metallic conductor (5) enveloped in a second insulating sheath (6), said first and second sheaths (3,6) being partially removed at a first and at a second end (7,8) respectively of said first and second cables (1,4), said second sheath (6) being removed by a portion of length greater than that of said first sheath (3), said second end (8) being wound in a first direction in a spiral-like manner to substantially completely cover said first end (7) of said carbon fibre bundle (2), and defining at least one loop (9) that wraps around said first sheath (3) to constitute a coupling means therefor, and said second end (8) being wound, after said loop (9), in a second direction opposite said first direction about said first end (7), said second end (8) being substantially completely covered by at least one layer (10) of tin or other metal or other covering element.
     


    Ansprüche

    1. Verfahren zur Verbindung eines ersten elektrischen Kabels (1), das durch ein von einer ersten Isolierhülle (3) umhülltes Kohlefaserbündel (2) gebildet ist, mit einem zweiten Kabel (4), das durch einen von einer zweiten Isolierhülle (6) umhüllten metallischen Leiter (5) gebildet ist, umfassend die Schritte:

    a) Entfernen eines ersten Abschnittes der ersten Hülle (3), die ein erstes Ende (7) des Bündels (2) bedeckt, und Entfernen eines zweiten Abschnittes der zweiten Hülle (6), die ein zweites Ende (8) des metallischen Leiters (5) bedeckt, entlang einer Strecke, die größer ist als die des ersten Abschnittes;

    b) spiralartiges Wickeln des zweiten Endes (8) des metallischen Leiters (5) um das Kohlefaserbündel (2), wobei von dem ersten Ende (7) des ersten Kabels (1) in einer ersten Richtung begonnen wird, bis der metallische Leiter (5) an der ersten Hülle (3) angreift;

    c) Ändern der Richtung des Fortschreitens der Spirale, die durch das zweite Ende (8) des metallischen Leiters (5) definiert ist, um zumindest eine Schleife (9) zu schaffen, die die erste Hülle (3) umgibt;

    d) spiralartiges Wickeln des metallischen Leiters (5) in einer zweiten, der ersten Richtung entgegengesetzten Richtung zurück in Richtung des ersten Endes (7) des Bündels (2) und gegenseitiges Ausrichten des ersten und zweiten Kabels (1, 4);

    e) Hinzufügen zumindest einer Schicht (10) aus Zinn oder einem anderen Leiter oder Abdeckelement, um das zweite Ende (8) des metallischen Leiters (5) vollständig zu bedecken.


     
    2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß zumindest eine Schicht (10) in einer bei Hitze schrumpfenden Hülle (11) eingeschlossen ist, welche aus einem elektrisch isolierenden Material gebildet ist und deren Enden teilweise die entsprechende erste und zweite Hülle (3, 6) bedecken.
     
    3. Verfahren nach einem oder mehreren der vorhergehenden Ansprüche, dadurch gekennzeichnet, daß die erste Hülle (3) aus einem gute elektrisch Isoliereigenschaften und gute mechanische Festigkeit aufweisenden Silikonharz gebildet ist.
     
    4. Verfahren nach einem oder mehreren der vorhergehenden Ansprüche, dadurch gekennzeichnet, daß die Schicht (10) das zweite Ende (8) des metallischen Leiters (5) vollständig bedeckt, wobei es diesen in der Wicklungslage des ersten Endes (7) des Bündels (2) einschließt.
     
    5. Elektrisches Kompositkabel, umfassend ein erstes elektrisches Kabel (1), das aus einem von einer Isolierhülle (3) umhüllten Kohlefaserbündel (2) gebildet ist, und ein zweites Kabel (4), das durch einen in einer zweiten Isolierhülle (6) umhüllten metallischen Leiter (5) gebildet ist, wobei die erste und zweite Hülle (3, 6) teilweise an einem ersten und an einem zweiten Ende (7, 8) entsprechend dem ersten und zweiten Kabel (1, 4) entfernt ist, wobei die zweite Hülle (6) auf einem Abschnitt von größerer Länge als der der ersten Hülle (3) entfernt ist, wobei das zweite Ende (8) in einer ersten Richtung in einer spiralartigen Weise gewickelt ist, um im wesentlichen das erste Ende (7) des Kohlefaserbündels (2) vollständig zu bedecken, und zumindest eine Schleife (9) zu definieren, die um die erste Hülle (3) gewickelt ist, um dort ein Verbindungsmittel zu bilden, und wobei das zweite Ende (8) nach der Schleife (9) in einer der ersten Richtung entgegengesetzten zweiten Richtung um das erste Ende (7) gewickelt ist, wobei das zweite Ende (8) im wesentlichen vollständig durch zumindest eine Schicht (10) aus Zinn oder einem anderen Metall oder anderen Abdeckelement bedeckt ist.
     


    Revendications

    1. Procédé pour interconnecter un premier câble électrique (1), constitué par un faisceau de fibres de carbone (2) enveloppé dans une première gaine isolante (3), avec un deuxième câble (4) constitué par un conducteur métallique (5) enveloppé dans une deuxième gaine isolante (6), comprenant les étapes consistant à :

    a) retirer une première partie de ladite première gaine (3) qui recouvre une première extrémité (7) dudit faisceau (2), et retirer une deuxième partie de ladite deuxième gaine (6) qui recouvre une deuxième extrémité (8) dudit conducteur métallique (5) sur une longueur supérieure à celle de ladite première partie ;

    b) enrouler en spirale ladite deuxième extrémité (8) dudit conducteur métallique (5) autour dudit faisceau de fibres de carbone (2) en commençant par ladite première extrémité (7) dudit premier câble (1) dans une première direction jusqu'à ce que ledit conducteur métallique (5) atteigne ladite première gaine (3) ;

    c) changer la direction d'avance de la spirale définie par ladite deuxième extrémité (8) dudit conducteur métallique (5) pour réaliser au moins une boucle (9) qui recouvre ladite première gaine (3) ;

    d) enrouler en spirale ledit conducteur métallique (5) dans une deuxième direction opposée à ladite première direction de retour vers ladite première extrémité (7) dudit faisceau (2) et aligner mutuellement lesdits premier et deuxième câbles (1, 4) ;

    e) ajouter au moins une couche (10) d'étain ou d'un autre conducteur ou élément de recouvrement pour recouvrir totalement ladite deuxième extrémité (8) dudit conducteur métallique (5).


     
    2. Procédé selon la revendication 1, caractérisé en ce que ladite au moins une couche (10) est enfermée dans une gaine thermorétractable (11), réalisée en un matériau électriquement isolant, dont les extrémités recouvrent partiellement respectivement lesdites première et deuxième gaines (3, 6).
     
    3. Procédé selon une ou plusieurs des revendications précédentes, caractérisé en ce que ladite première gaine (3) est réalisée en une résine de silicium ayant de bonnes propriétés d'isolement électrique et une bonne résistance mécanique.
     
    4. Procédé selon une ou plusieurs des revendications précédentes, caractérisé en ce que ladite couche (10) recouvre complètement ladite deuxième extrémité (8) dudit conducteur métallique (5) incorporant le susdit dans la condition d'enroulement de ladite première extrémité (7) dudit faisceau (2).
     
    5. Câble électrique composite comprenant un premier câble électrique (1), constitué par un faisceau de fibres de carbone (2) enveloppé dans une première gaine isolante (3), et un deuxième câble (4), constitué par un conducteur métallique (5) enveloppé dans une deuxième gaine isolante (6), lesdites première et deuxième gaines (3, 6) étant partiellement retirées à des première et deuxième extrémités (7, 8), respectivement, desdits premier et deuxième câbles (1, 4), ladite deuxième gaine (6) étant retirée sur une partie de longueur supérieure à celle de ladite première gaine (3), ladite deuxième extrémité (8) étant enroulée dans une première direction en spirale pour recouvrir sensiblement complètement ladite première extrémité (7) dudit faisceau de fibres de carbone (2), et définissant au moins une boucle (9) que s'enroule autour de ladite première gaine (3) pour constituer des moyens d'accouplement pour celui-ci, et ladite deuxième extrémité (8) étant enroulée, après ladite boucle (9), dans une deuxième direction opposée à ladite première direction autour de ladite première extrémité (7), ladite deuxième extrémité (8) étant sensiblement complètement recouverte d'au moins une couche (10) d'étain ou d'un autre métal ou d'un autre élément de recouvrement.
     




    Drawing











    Cited references

    REFERENCES CITED IN THE DESCRIPTION



    This list of references cited by the applicant is for the reader's convenience only. It does not form part of the European patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be excluded and the EPO disclaims all liability in this regard.

    Patent documents cited in the description