# US 10,873,171 B2 · Method for the integrally bonded joining of an electric cable to an electrical contact part and electric cable arrangement > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,873,171 B2 - Document ID: US10873171B2 - Status: Granted - Kind: B2 - Application number: 16/758,105 - Filed: 2018-10-08 - Published: 2020-09-03 - Granted: 2020-12-22 - Earliest claimed: 2017-10-23 - Assignees: Lisa Dräxlmaier GmbH - Applicants: Lisa Dräxlmaier GmbH - Inventors: Christoph Forstmeier - Web page: https://patentgrep.com/patent/US10873171B2 ## CPC - H01R 43/0214: {Resistance welding (H01R43/0228 takes precedence)} - H01R 43/0235: {for applying solder (H01R43/0228 takes precedence)} - B23K 20/129: {specially adapted for particular articles or work} - B23K 20/16: with interposition of special material to facilitate connection of the parts, e.g. material for absorbing or producing gas - H01R 4/023: {between cables or wires and terminals} - B23K 2101/38: Conductors - H01R 4/024: {comprising preapplied solder} - H01R 11/12: End pieces terminating in an eye, hook, or fork - H01R 43/0207: {Ultrasonic-, H.F.-, cold- or impact welding} - H01R: ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM ## Abstract 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. ## Claims ### Claim 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. ### Claim 2 (depends on 1) 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. ### Claim 3 (depends on 1) That the method according to claim 1, wherein the metal filler material is distributed inside the receiving sleeve after insertion by means of ultrasound. ### Claim 4 (depends on 1) 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. ### Claim 5 (depends on 1) 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. ### Claim 6 (depends on 1) 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. ### Claim 7 (depends on 1) 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. ### Claim 8 (depends on 1) 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. ### Claim 9 (depends on 7) 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. ### Claim 10 (depends on 7) The method according to claim 7, wherein the receiving sleeve and the connecting part are pressed together before the line end is inserted. ### Claim 11 (depends on 1) 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. ### Claim 12 (depends on 1) The method according to claim 1, wherein the line comprises a conductor of an aluminum material. ### Claim 13 (depends on 1) 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. ### Claim 14 (depends on 1) 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. ### Claim 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.