Abstract:
In order to provide a method for establishing an electrically conductive connection between an electrical line which includes a plurality of individual conductors and an electrically conductive component which is easily realizable but nevertheless leads to a corrosion resistant connection between the individual conductors of the electrical line and the electrically conductive component, it is proposed that the method includes producing a crimping element that surrounds the individual conductors sectionally from a crimping element preform by means of a crimping tool, and connecting at least a portion of the individual conductors to the electrically conductive component by an ultrasonic welding process by means of a sonotrode.

Description:
RELATED APPLICATION 
       [0001]    This application is a continuation application of PCT/EP2014/070256 filed on Sep. 23, 2014, which claims priority to German patent application no. 10 2013 219 150.2 filed on Sep. 24, 2013, each of which is incorporated herein by reference. 
     
    
     FIELD OF DISCLOSURE 
       [0002]    The present invention relates to a method for establishing an electrically conductive connection between an electrical line which comprises a plurality of individual conductors and an electrically conductive component. 
       BACKGROUND 
       [0003]    In the case of one known method of this type, aluminum strands of an electrical line are connected to a nickel-plated and silvered copper blade by ultrasonic welding. 
         [0004]    The problem thereby is that the connection between the aluminum strands and the copper blade corrodes under the influence of air humidity and/or an NaCl solution so that the tensile strength of the connection drops considerably due to corrosion. 
       SUMMARY OF THE INVENTION 
       [0005]    The object of the present invention is to provide a method for establishing an electrically conductive connection between an electrical line which comprises a plurality of individual conductors and an electrically conductive component which is easily realizable and is preferably effected without the use of any additional corrosion protection but nevertheless leads to a corrosion resistant connection between the individual conductors of the electrical line and the electrically conductive component. 
         [0006]    This object is achieved by a method for establishing an electrically conductive connection between an electrical line which comprises a plurality of individual conductors and an electrically conductive component, which comprises the following:
       producing a crimping element that surrounds the individual conductors sectionally from a crimping element preform by means of a crimping tool;   connecting at least a portion of the individual conductors to the electrically conductive component by an ultrasonic welding process by means of a sonotrode.       
 
         [0009]    The concept underlying the present invention is to combine mechanical fixing of the individual conductors by the crimping process with improved compacting of the individual conductors due to the crimping action and by use of the ultrasonic welding process. 
         [0010]    The individual conductors are compacted to such an extent by the crimping process and the following ultrasonic welding process that the whole assembly of individual conductors approximates to a solid material. Corrosion cannot find a sufficiently large corrodible surface on the compacted individual conductors as to crucially damage the joint. 
         [0011]    The additional mechanical securing and/or fixing of the individual conductors by the crimping process additionally prevents the individual conductors from becoming separated from the connection to the electrically conductive component even if corrosion should nevertheless occur. 
         [0012]    In the crimping process, i.e., when producing the crimping element that surrounds the individual conductors sectionally, the individual conductors are preferably completely surrounded by the crimping element before the ultrasonic welding process. 
         [0013]    Uneven distribution of the individual conductors and hence uneven compression during the ultrasonic welding process are thereby prevented. 
         [0014]    The crimping process, which is preferably carried out before the ultrasonic welding process, causes the individual conductors to adopt a defined shape, this thereby leading to greater reliability of the subsequent ultrasonic welding process. 
         [0015]    Due to the improved compacting of the individual conductors and the significantly improved mechanical fixing produced by the crimping process, the effect can be achieved that the connection between the electrical line and the electrically conductive component has greater strength and will not be broken by loosening of the ultrasonically welded connection but only in the event of material failure of the individual conductors. Thus, the individual conductors behind the weld are more likely to break away before the connection separates at the welded joint. 
         [0016]    The initial values for the tensile strength of the connection between the electrical line and the electrically conductive component are already significantly higher immediately after the establishment of the electrically conductive connection than was the case in the known connecting process. Since the tensile strength of the connection is no longer determined by the failure of the welded joint, but rather, by a failure in the material of the individual conductors, the reliability of the process is significantly increased due to the fact that the individual conductors will always sever at similar values of the tensile load. 
         [0017]    The individual conductors are protected due to being surrounded by the crimping element and by virtue of the process of welding at least a portion of the individual conductors to the crimping element. Furthermore, contraction of the individual conductors which could lead to the individual conductors severing more readily is prevented during the ultrasonic welding process. Consequently, in the method in accordance with the invention, predetermined breaking points are not produced in the individual conductors. 
         [0018]    Due to the greater degree of compaction and the complete enclosure of the welded joint by the material of the crimping element, the corrodible surface available for the formation of corrosion is significantly reduced, this thereby significantly increasing the corrosion resistance of the resultant connection. 
         [0019]    In particular, a junction point between the electrical line and the electrically conductive component that has been established by the method in accordance with the invention can be employed without the application of a corrosion protection medium to the junction point. 
         [0020]    In a preferred embodiment of the method in accordance with the invention, provision is made for the sonotrode to be different from the crimping tool. 
         [0021]    Thus, the crimping process and the ultrasonic welding process are preferably carried out successively in different tools. 
         [0022]    Preferably, the ultrasonic welding process is only begun after the production of the crimping element. 
         [0023]    In one preferred embodiment of the invention, provision is made for the individual conductors to be compacted both by means of the crimping tool and also by means of the sonotrode of the ultrasonic welding tool. 
         [0024]    The spatial volume between the individual conductors of the electrical line that remains in the region of the crimping element is thus reduced by the crimping process and is reduced still further by the ultrasonic welding process. 
         [0025]    Good compaction of the individual conductors is obtained, in particular, if the welding pressure of the sonotrode amounts at least intermittently to at least approximately 3 bar, in particular, to at least approximately 4 bar, to at least approximately 5 bar for example. 
         [0026]    In tests, a welding pressure of approximately 5 bar has proved to be particularly expedient. 
         [0027]    Furthermore, it has proved to be expedient for the process of compacting the individual conductors if the welding time of the ultrasonic welding process amounts to at least approximately 1.0 seconds, preferably to at least approximately 1.5 seconds, and in particular to at least approximately 3 seconds. 
         [0028]    In particular, the welding time of the ultrasonic welding process is the time which is needed for the crimping element that surrounds the individual conductors to deform to a given final height (the so-called final node height) (for example, a final node height of 7.5 mm). 
         [0029]    In principle, provision could be made for the crimping element preform to be a structural element that is manufactured separately from the electrically conductive component. 
         [0030]    In a preferred embodiment of the invention however, provision is made for the crimping element preform to be formed in one piece with the electrically conductive component. 
         [0031]    The crimping element preform and/or the crimping element that is formed therefrom preferably have a material thickness of at least approximately 1 mm and in particular of at least approximately 1.5 mm, of at least approximately 1.8 mm for example. 
         [0032]    For example, the crimping element preform and/or the crimping element that is formed therefrom may comprise a preferably coated copper material having a material thickness of approximately 1.8 mm. 
         [0033]    In order to prevent unwanted bending of the crimping element, it is expedient if the crimping element preform and/or the electrically conductive component comprise a metallic material having a tensile strength R m , of more than 250 N/mm 2 , preferably of more than 300 N/mm 2 , and in particular of more than 350 N/mm 2 . 
         [0034]    For example, the crimping element preform and/or the electrically conductive component may comprise a copper material having a tensile strength of at least approximately 360 N/mm 2 . 
         [0035]    In a preferred embodiment of the invention, provision is made for the crimping element preform and/or the electrically conductive component to comprise copper, preferably as the main constituent. 
         [0036]    Hereby, the main constituent of a material is considered to be that constituent which has the highest part by weight of the material. 
         [0037]    In particular, provision may be made for the crimping element preform and/or the electrically conductive component to be formed of copper or a copper alloy. 
         [0038]    Furthermore, it has proved to be expedient for the crimping element preform and/or the electrically conductive component to have a coating which comprises nickel and/or silver. 
         [0039]    In principle, the individual conductors can be formed from any material that has sufficiently high electrical conductivity. 
         [0040]    In a preferred embodiment of the invention, provision is made for the individual conductors to comprise aluminum, in particular, as the main constituent. 
         [0041]    For example, provision may be made for the individual conductors to be formed of aluminum or an aluminum alloy. 
         [0042]    It is expedient if the crimping element preform is formed from a material which is of greater mechanical strength than the material from which at least a portion of the individual conductors that are crimped by means of the crimping element is formed. Thereby in particular, one can achieve the effect that a sufficiently large amount of welding energy is introducible into the material of the individual conductors during the ultrasonic welding process. 
         [0043]    For example, provision may be made for the material from which the crimping element preform is formed to have a greater tensile strength, a higher yield point and/or a higher modulus of elasticity than the material from which at least a portion of the individual conductors is formed. 
         [0044]    Preferably, the tensile strength of the material from which the crimping element preform is formed amounts to at least double and in particular to at least three-times the tensile strength of the material from which at least a portion of the individual conductors is formed. 
         [0045]    Furthermore, the yield point of the material from which the crimping element preform is formed preferably amounts to at least double and in particular to at least five-times, and particularly preferred to at least ten-times the yield strength of the material from which at least a portion of the individual conductors is formed. 
         [0046]    The material from which the crimping element preform is formed can, for example, be the copper material bearing the designation Cu R360 in accord with EN 13599 which has a tensile strength of 360 MPa and a yield point of 320 MPa. 
         [0047]    The material from which at least a portion of the individual conductors that is crimped by means of the crimping element is formed and in particular all the individual conductors that are crimped by means of the crimping element can, for example, be the aluminum material bearing the designation AW-AI 99.5 in accord with EN 573/485 which has a tensile strength of from 65 to 95 MPa and a yield point of 20 MPa. 
         [0048]    The method in accordance with the invention is suitable, in particular, for establishing an electrically conductive connection between an electrical line of relatively large cross sectional area and an electrically conductive component. 
         [0049]    In particular, provision may be made for the entire cross-sectional area of the individual conductors of the electrical line in the region of the crimping element, in particular after the establishment of the electrically conductive connection, to amount to more than 50 mm 2  and in particular to more than 55 mm 2 , to approximately 59 mm 2  for example. 
         [0050]    For particularly good compactment of the individual conductors during the ultrasonic welding process, it has proved to be expedient for the sonotrode to comprise a contact area having a longitudinal direction, wherein the longitudinal direction of the contact area includes an angle with the free edges of the crimping element of more than 45°, preferably an angle of more than 60° and in particular an angle of approximately 90° during the ultrasonic welding process. 
         [0051]    Furthermore, it is expedient if the electrically conductive component comprises a welding region, to which at least a portion of the individual conductors of the electrical line is fixed, and a contact region, wherein the contact region is connected to the welding region by a bent region. 
         [0052]    In particular, provision may be made for the contact region to be connected to the welding region by means of a bent section through an angle of more than 45°, preferably through an angle of more than 60°, for example, through an angle of approximately 90°. 
         [0053]    The bent region can extend along a bending line which is directed substantially parallel to a transverse direction of the crimping element. 
         [0054]    As an alternative thereto, provision may also be made for the bent region to extend along a bending line which is directed transverse to the transverse direction of the crimping element. 
         [0055]    In particular, provision may be made for the bending line to include an angle of at least approximately 10° and in particular of at least approximately 20° with the transverse direction of the crimping element. 
         [0056]    Furthermore, provision is preferably made for the bending line to include an angle of at most approximately 60° and in particular of at most approximately 45° with the transverse direction of the crimping element. 
         [0057]    In a special embodiment of the invention, provision is made for not just one electrical line, but rather, a plurality of electrical lines and in particular two electrical lines to be connected to the electrically conductive component in electrically conductive manner, wherein a crimping element that is produced from a crimping element preform surrounds the individual conductors of a plurality of electrical lines sectionally. 
         [0058]    Furthermore, provision may be made for the electrically conductive component to which one or more electrical lines are connected in electrically conductive manner to comprise an electrical line element which itself comprises a plurality of individual conductors or strands. 
         [0059]    Provision is preferably made thereby for the crimping element to surround the individual conductors of the electrical line element sectionally. 
         [0060]    In particular in this case, the crimping element thus surrounds both the individual conductors of the one electrical line or the plurality of electrical lines and also the individual conductors of the electrical line element. 
         [0061]    Provision is preferably made thereby for the individual conductors of the one electrical line or the plurality of electrical lines on the one hand and the individual conductors of the electrical line element on the other to overlap each other in the longitudinal direction of the crimping element. 
         [0062]    In a special embodiment of the invention, provision may be made for the individual conductors of the electrical line element to be formed from a material which is different from the material of the individual conductors of the one electrical line or the plurality of electrical lines. 
         [0063]    Thus, for example, provision may be made for the individual conductors of the electrical line element to comprise aluminum and for the individual conductors of the one electrical line or the plurality of electrical lines to comprise copper. 
         [0064]    As an alternative thereto, provision may also be made for the contact region to merge into the welding region without a bent section. 
         [0065]    The electrically conductive component can be formed, in particular, as a module connector of an electro-chemical device. 
         [0066]    The electro-chemical device can, in particular, be in the form of an accumulator and in particular a lithium ion accumulator. 
         [0067]    Furthermore, the present invention relates to an assembly which comprises an electrical line that comprises a plurality of individual conductors and an electrically conductive component connected to the electrical line. 
         [0068]    The further object of the present invention is to construct such an assembly in such a way that it can be assembled in a simple manner but nevertheless have a high corrosion resistance. 
         [0069]    This object is achieved by an assembly which comprises an electrical line that comprises a plurality of individual conductors, a crimping element which surrounds the individual conductors sectionally and an electrically conductive component which is connected to at least a portion of the individual conductors by an ultrasonic welding process. 
         [0070]    Such an assembly can, in particular, be manufactured by the previously described methods in accordance with the invention. 
         [0071]    Further features and advantages of the invention form the subject matter of the following description and the graphical illustration of an exemplary embodiment. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0072]      FIG. 1  shows a schematic perspective illustration of an assembly which comprises an electrical line having a plurality of individual conductors, a crimping element that surrounds the individual conductors sectionally and an electrically conductive component that is connected by ultrasonic welding to at least a portion of the individual conductors; 
           [0073]      FIG. 2  a structural element preform that has been detached from a flat raw material; 
           [0074]      FIG. 3  a perspective illustration of the electrically conductive component with a crimping element preform; 
           [0075]      FIG. 4  a side view of the electrically conductive component with the crimping element preform; 
           [0076]      FIG. 5  a front view of the electrically conductive component with the crimping element preform, as viewed in the direction of the arrow  5  in  FIG. 4 ; 
           [0077]      FIG. 6  a perspective illustration of a crimping tool which comprises a tool upper part, a tool lower part and a positioning element; 
           [0078]      FIG. 7  an illustration of the crimping tool and the crimping element preform of the electrically conductive component before a crimping process for producing a crimping element from the crimping element preform; 
           [0079]      FIG. 8  an illustration corresponding to  FIG. 7  of the crimping tool and the crimping element after the crimping process by means of which the crimping element has been produced from the crimping element preform; 
           [0080]      FIG. 9  a perspective illustration of the electrically conductive component with the crimping element; 
           [0081]      FIG. 10  a side view of the electrically conductive component with the crimping element; 
           [0082]      FIG. 11  a front view of the electrically conductive component with the crimping element as viewed in the direction of the arrow  11  in  FIG. 10 ; 
           [0083]      FIG. 12  a perspective illustration of a sonotrode, an anvil and the electrical line having a plurality of individual conductors that are surrounded sectionally by the crimping element of the electrically conductive component; 
           [0084]      FIG. 13  a schematic perspective illustration of a second embodiment of an assembly which comprises an electrical line having a plurality of individual conductors, a crimping element that surrounds the individual conductors sectionally and an electrically conductive component that is connected by ultrasonic welding to at least a portion of the individual conductors, wherein the electrically conductive component comprises a welding region to which at least a portion of the individual conductors of the electrical lines is fixed, and a contact region which is connected to the welding region by a bent region, and wherein the bent region extends along a bending line which is directed transverse to a transverse direction of the crimping element; 
           [0085]      FIG. 14  a structural element preform of the second embodiment of the assembly that has been detached from a flat raw material; 
           [0086]      FIG. 15  a perspective illustration of the electrically conductive component with a crimping element preform in the second embodiment of the assembly; 
           [0087]      FIG. 16  a plan view from above of the electrically conductive component with the crimping element preform in the second embodiment of the assembly; 
           [0088]      FIG. 17  a schematic perspective illustration of a third embodiment of an assembly which comprises two electrical lines each of which incorporates a plurality of individual conductors, an electrical line element having a plurality of individual conductors in the form of an electrically conductive component and a crimping element that surrounds both the individual conductors of the electrical lines and also the individual conductors of the electrical line element sectionally, wherein at least a portion of the individual conductors of the electrical lines is connected to at least a portion of the individual conductors of the electrical line element by ultrasonic welding; 
           [0089]      FIG. 18  a side view of the assembly depicted in  FIG. 17  as viewed in the direction of the arrow  18  in  FIG. 17 ; 
           [0090]      FIG. 19  a cross section through the crimping element of the assembly depicted in  FIG. 18  and the individual conductors of the electrical lines and the electrical line element that are surrounded sectionally by the crimping element, along the line  19 - 19  in  FIG. 18 ; 
           [0091]      FIG. 20  a crimping element starter blank that has been detached from a flat raw material; 
           [0092]      FIG. 21  a perspective illustration of a crimping element preform of the third embodiment of the assembly which has been produced from the substantially flat crimping element starter blank illustrated in  FIG. 20  by bending out the edge regions of the eventual crimping element from the plane of the closed side of the crimping element; and 
           [0093]      FIG. 22  a front view of the crimping element preform depicted in  FIG. 21  as viewed in the direction of the arrow  22  in  FIG. 21 . 
       
    
    
       [0094]    Similar or functionally equivalent elements are designated by the same reference symbols in all of the Figures. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0095]    An assembly bearing the general reference  100  that is illustrated in  FIG. 1  comprises an electrical line  102  in the form of a cable  104  which comprises a plurality of strands or individual conductors  106  and an electrically insulating sheath  108  and also an electrically conductive component  110  which comprises a substantially plate-like contact region  112  and a welding region  114  which are preferably connected to one another in one piece manner by a curved or bent-up region  116 . 
         [0096]    At least a portion of the individual conductors  106  of the electrical line  102  is connected to the electrically conductive component  110  in electrically conductive manner in the welding region  114  by an ultrasonic welding process. 
         [0097]    The welding region  114  comprises a crimping element  118  which surrounds the individual conductors  106  sectionally. In particular, the crimping element  118  surrounds the end sections  196  of the individual conductors  106  that are not provided with the sheath  108 . 
         [0098]    The crimping element  118  has a closed side  120  having a continuous, substantially flat bearing surface  122  and a side referred to hereinafter as the open side  124  which is located opposite the closed side  120  and incorporates mutually opposite curved edge regions  126   a  and  126   b  of the crimping element  118 . 
         [0099]    Provision is preferably made thereby for the free edges  128   a  and  128   b  of the respective edge regions  126   a  and  126   b  of the crimping element  118  to end at a small spacing way from one another or for them to touch one another (see  FIGS. 9 to 11 , in which the electrically conductive component  110  is illustrated with the crimping element  118 , but without the individual conductors  106  of the electrical line  102  that are surrounded by the crimping element  118 ). 
         [0100]    The crests  130   a ,  130   b  (see  FIG. 11 ) of the respective edge regions  126   a  and  126   b  remote from the closed side  120  of the crimping element  118  are spaced apart by an intermediate recess  134  in a transverse direction  132  of the crimping element  118 . 
         [0101]    The free edges  128   a ,  128   b  of the respective edge regions  126   a  and  126   b  of the crimping element  118  form the bottom of the recess  134  for example. 
         [0102]    The transverse direction  132  of the crimping element  118  is oriented perpendicularly to a longitudinal direction  136  of the crimping element  118  which runs substantially parallel to the longitudinal direction of the electrical line  102  and substantially parallel to the free edges  128   a  and  128   b  of the crimping element  118 . 
         [0103]    The lateral free edges  128   a ,  128   b  of the crimping element  118  connect a front edge  138  with a rear edge  140  of the crimping element  118 . 
         [0104]    The electrically conductive component  110  including the crimping element  118  is formed from an electrically conductive metallic material. 
         [0105]    Preferably, the electrically conductive component  110  including the crimping element  118  consists of a metallic material having a tensile strength R m  of more than 250 N/mm 2  and in particular of more than 300 N/mm 2 , of more than 350 N/mm 2  for example. 
         [0106]    Furthermore, provision is preferably made for the electrically conductive component  110  including the crimping element  118  to comprise copper, preferably as the main constituent. 
         [0107]    Hereby, the main constituent of a component is considered to be that material which has the largest part by weight in the component concerned. 
         [0108]    In particular, the electrically conductive component  110  including the crimping element  118  may comprise a copper material having a tensile strength of at least approximately 360 N/mm 2 . 
         [0109]    The electrically conductive component  110  including the crimping element  118  preferably comprises a coating. 
         [0110]    In particular, such a coating may comprise nickel and/or silver. 
         [0111]    The individual conductors  106  of the electrical line  102  can, in principle, be formed from any material that has adequate electrical conductivity. 
         [0112]    In particular, provision may be made for the individual conductors  106  to comprise aluminum and in particular to be formed of aluminum or an aluminum alloy. 
         [0113]    The electrically conductive component  110  can, for example, be in the form of a contact shoe of a module connector of an electro-chemical device. 
         [0114]    The contact region  112  of the electrically conductive component  110  preferably extends in a longitudinal direction  142  which is oriented, in particular, substantially perpendicularly to the longitudinal direction  136  of the crimping element  118  and/or substantially perpendicularly to the transverse direction  132  of the crimping element  118 . 
         [0115]    A preferably substantially flat bearing surface  144  of the contact region  112  preferably includes an angle α with the flat bearing surface  122  of the crimping element  118  of more than 45° and in particular of more than 60°, of approximately 90° for example. 
         [0116]    As an alternative thereto, the bearing surface  144  of the contact region  112  could also be oriented substantially parallel to the bearing surface  122  of the crimping element  118  and in particular, substantially flush with the bearing surface  122  of the crimping element  118 . 
         [0117]    In the graphically illustrated embodiment of the electrically conductive component  110 , a transverse direction  143  of the contact region  112  running perpendicularly to the longitudinal direction  142  of the contact region  112  and parallel to the bearing surface  144  of the contact region  112  is oriented substantially parallel to the transverse direction  132  of the crimping element  118 . 
         [0118]    As an alternative thereto however, provision could also be made for an intermediate region to be arranged between the contact region  112  and the welding region  114  of the electrically conductive component  110 , a first edge of said intermediate region adjoining the welding region  114  and a second edge thereof adjoining the contact region  112 , wherein the first edge and the second edge do not run in parallel with each other, but include an angle therebetween, preferably an acute angle. In this case then, the transverse direction  143  of the contact region  112  is also twisted through this angle with respect to the transverse direction  132  of the crimping element  118 . 
         [0119]    For the purposes of producing the previously described assembly  100  that is illustrated in  FIG. 1  and also  FIGS. 9 to 11 , one proceeds as follows. 
         [0120]    A structural element preform  146  that is illustrated in  FIG. 2  is detached by being cut out, preferably by means of a laser for example, or stamped out, from a suitable raw material such as a metal sheet for example which is preferably flat. 
         [0121]    The closed side  120  and also the edge regions  126   a  and  126   b  of the eventual crimping element  118  are located in this structural element preform  146  in substantially the same plane, wherein the two edge regions  126   a  and  126   b  extend in mutually opposite directions along the transverse direction  132  of the crimping element  118  away from the closed side  120 . 
         [0122]    From this substantially flat structural element preform  146  that is illustrated in  FIG. 2 , the electrically conductive component  110  with the crimping element preform  148  that is illustrated in  FIGS. 3 to 5  is produced by bending out the edge regions  126   a  and  126   b  as well as the contact region  112  from the plane of the closed side  120  in such a way that they extend substantially parallel to the longitudinal direction  142  of the contact region  112  and substantially perpendicularly to the bearing surface  122  of the closed side  120 . 
         [0123]    The edge regions  126   a  and  126   b  are connected by respective curved regions  150   a  and  150   b  to the closed side  120  of the crimping element preform  148  in this crimping element preform  148 . 
         [0124]    The contact region  112  is already connected in this state by means of the bent region  116  to the closed side  120  of the crimping element preform  148 . 
         [0125]    For the purposes of connecting the individual conductors  106  of the electrical line  102  to the electrically conductive component  110  by a crimping process, the crimping tool  152  illustrated in  FIG. 6  is used for example. 
         [0126]    This crimping tool  152  comprises a tool upper part  154 , a tool lower part  156  and a positioning element  158 . 
         [0127]    The positioning element  158  comprises a base  160  having an upper side  162  from which a rear supporting element  164  and two lateral supporting elements  166  extend upwardly. 
         [0128]    The rear supporting element  164  has a front guide surface  168  facing the lateral supporting elements  166  upon which the bearing surface  144  of the contact region  112  of the electrically conductive component  110  is placeable, preferably substantially flatly, for the crimping process. 
         [0129]    The lateral supporting elements  166  have a respective lateral guide surface  170  on their mutually facing sides upon which the contact region  112  of the electrically conducting element  110  is laterally supported during the crimping process. 
         [0130]    Apart from the rear supporting element  164  and the lateral supporting elements  166 , the remaining portion of the upper side  162  of the base  160  of the positioning element  158  forms a seating surface  172  on which a part of the bearing surface  122  of the crimping element preform  148  of the electrically conductive component  110  abuts, preferably substantially flatly, during the crimping process. 
         [0131]    The tool upper part  154  of the crimping tool  152  comprises a substantially parallelepipedal block  174  for example which has a recess  176  on the side thereof facing the tool lower part  156  during the crimping process, the margin of the upper edge of said recess having a crimping profile  178  which is complementary to the open side  124  of the finished crimping element  118 . 
         [0132]    In particular, the crimping profile  178  can thus comprise two substantially semi-circular or segments of semi-circular profile sections  180  that are arranged next to each other in a transverse direction  182  of the crimping tool  152  which coincides with the transverse direction  132  of the crimping element  118  that is to be produced. 
         [0133]    The tool upper part  154  is moveable relative to the tool lower part  156  along a pressing direction  184  which runs substantially perpendicularly to the transverse direction  182  and substantially perpendicularly to the longitudinal direction  142  of the crimping element  118  that is to be produced. 
         [0134]    Inclined bounding surfaces  186  of the recess  176  in the tool upper part  154  extend from the mutually remote edges of the profile sections  180  in the direction of the tool lower part  156 . 
         [0135]    The inclined bounding surfaces  186  are inclined at an acute angle with respect to the pressing direction  184  of the crimping tool  152 . 
         [0136]    The tool lower part  156  comprises a base  188  from which an anvil  190  extends in the direction of the tool upper part  154 . 
         [0137]    The anvil has two lateral inclined bounding surfaces  192  which are preferably inclined at substantially the same angle with respect to the pressing direction  184  of the crimping tool  152  as the inclined bounding surfaces  186  of the recess  176  of the tool upper part  154 , and also a seating surface  194  which faces the crimping profile  178  of the tool upper part  154  and matches the shape of the bearing surface  122  of the finished crimping element  118 . 
         [0138]    In particular, the seating surface  194  can then be substantially flat. 
         [0139]    For the purposes of the crimping process by means of which the individual conductors  106  of the electrical line  102  are connected to the electrically conductive component  110  by the crimping action when forming the crimping element  118 , the electrically conductive component  110  with the crimping element preform  148  that is illustrated in  FIGS. 3 to 5  is inserted into the crimping tool  152  in such a way that the bearing surface  144  of the contact region  112  abuts on the front guide surface  168  of the positioning element  158  and the bearing surface  122  of the crimping element preform  148  abuts on the seating surface  172  of the positioning element  158  and on the seating surface  194  of the tool lower part  156 . The crimping element preform  148  thereby comes to be located in the space between the tool lower part  156  and the tool upper part  154  in the region of the recess  176  of the tool upper part  154  (see  FIG. 7 ). 
         [0140]    The end sections  196  of the individual conductors  106  of the electrical line  102  that are not provided with the sheath  108  are inserted into the crimping element preform  148  between the upturned edge regions  126   a  and  126   b  (for reasons of clarity, the individual conductors  106  are not illustrated in  FIGS. 7 and 8 ). 
         [0141]    Thereafter, the tool upper part  154 , which was initially spaced from the tool lower part  156  in the pressing direction  184  (see  FIG. 7 ), is moved along the pressing direction  184  towards the tool lower part  156 , wherein a deformation pressure is transmitted to the crimping element preform  148  by the inclined bounding surfaces  186  of the recess  176  and the crimping profile  178 . 
         [0142]    Due to this deformation pressure, the crimping element preform  148  is deformed in plastic manner in such a way that the crimping element  118 , which is illustrated in  FIG. 8  and has an e.g. substantially B-shaped cross section that is complementary to the crimping profile  178 , is formed from the crimping element preform  148 . 
         [0143]    During the process of producing the crimping element  118  from the crimping element preform  148 , the edge regions  126   a ,  126   b  of the crimping element  118  are bent around the end sections  196  of the individual conductors  106  that are not provided with the sheath  108  and are pressed against the individual conductors  106  in such a way that the end sections  196  of the individual conductors  106  surrounded by the crimping element  118  are compacted and pressed against one another in force-locking manner. 
         [0144]    Due to the compacting action occurring during the crimping process, the spatial volume of the electrical line  102  remaining between the individual conductors  106  is reduced in the region of the crimping element  118 . 
         [0145]    When the final state illustrated in  FIG. 8  is reached, wherein the inclined bounding surfaces  186  of the tool upper part  154  abut on the inclined bounding surfaces  192  of the tool lower part  156 , the crimping process is finished. 
         [0146]    The crimping tool  152  is now opened by moving the tool upper part  154  relative to the tool lower part  156  along the pressing direction  184  away from the tool lower part  156 , and the assembly  100  incorporating the electrically conductive component  110  and the electrical line  102  of which the individual conductors  106  thereof are connected to the electrically conductive component  110  by the crimping element  118  is removed from the crimping tool  152  and inserted into the ultrasonic welding tool  198  that is illustrated schematically in  FIG. 12 . 
         [0147]    The ultrasonic welding tool  198  comprises a sonotrode  200  and an anvil  202  located opposite the sonotrode  200 . 
         [0148]    The assembly  100  is placed on the anvil  202  in such a way that the bearing surface  122  of the crimping element  118  comes to rest on a seating surface  204  of the anvil  202 . 
         [0149]    Thereafter, the sonotrode  200  is advanced towards the assembly  100  in such a way that a contact area  208  of the sonotrode  200  extending in a longitudinal direction  206  of the sonotrode  200  comes into contact with the open side  124  of the crimping element  118 . 
         [0150]    Hereby, the longitudinal direction  206  of the contact area  208  of the sonotrode  200  is preferably oriented substantially parallel to the transverse direction  132  of the crimping element  118  so that the sonotrode  200  extends transversely over the recess  134  between the edge regions  126   a  and  126   b  of the crimping element  118 . 
         [0151]    The ultrasonic welding process is carried out on the assembly  100  by means of the sonotrode  200  so that the individual conductors  106  of the electrical line  102  are welded together and also to the inner side of the crimping element  118  on the electrically conductive component  110  by a friction welding process and are thus connected by a substance-to-substance bond. 
         [0152]    During the ultrasonic welding process, the direction of excitation of the sonotrode  200  is preferably oriented substantially parallel to the transverse direction  132  of the crimping element  118  and/or substantially parallel to the longitudinal direction  206  of the sonotrode  200 . 
         [0153]    The crimping element  118  and the individual conductors  106  are subjected to a welding pressure by the sonotrode  200  during the ultrasonic welding process. 
         [0154]    The welding pressure preferably amounts, at least intermittently, to at least approximately 3 bar and in particular to at least approximately 4 bar, to at least approximately 5 bar for example. 
         [0155]    A welding pressure of approximately 5 bar has proved to be particularly expedient in trials. 
         [0156]    The welding time during which the ultrasonic welding process takes place preferably amounts to at least approximately 1.0 seconds and in particular to at least approximately 1.5 seconds, to at least approximately 3 seconds for example. 
         [0157]    Preferably, the target size for the ultrasonic welding process is the final node height, i.e., the final height of the crimping element  118  in the present case. 
         [0158]    The sonotrode  200  penetrates into the crimping element  118  in the course of the ultrasonic welding process and deforms it. The ultrasonic welding process is continued until such time as a predetermined final height of the crimping element  118  (for example a final height of 7.5 mm starting from a height of 9.8 mm) is reached. 
         [0159]    It is thereby ensured that the process of compacting the individual conductors  106  and hence too the corrosion resistance are always equally good. 
         [0160]    The welding energy transmitted by the sonotrode  200  into the assembly  100  during the ultrasonic welding process preferably amounts to at least approximately 3,000 Ws and in particular to at least approximately 4,000 Ws, to at least approximately 5,000 Ws for example and to at most approximately 7,000 Ws for example. 
         [0161]    If the target size of the ultrasonic welding process is the final node height, the energy being introduced is a resulting factor. 
         [0162]    A portion of the excitation energy from an ultrasonic process may be lost since the assembly  100  vibrates in unison. 
         [0163]    The individual conductors  106  in the region of the crimping element  118  are further compacted by the ultrasonic welding process i.e., the spatial volume of the electrical line  102  remaining between the individual conductors  106  is reduced still more by the ultrasonic welding process. 
         [0164]    After the termination of the ultrasonic welding process, the ultrasonic welding tool  198  is opened and the finished assembly  100 , in which the individual conductors  106  of the electrical line  102  are connected to the electrically conductive component  110  by the crimping process by means of the crimping element  118  and also by virtue of the ultrasonic welding process, is removed from the ultrasonic welding tool  198 . 
         [0165]    A second embodiment of an assembly  100  that is illustrated in  FIGS. 13 to 16  differs from the previously described embodiment illustrated in  FIGS. 1 to 12  in that the bent region  116  by means of which the contact region  112  of the electrically conductive component  110  is connected to the welding region  114  extends along a bending line  210  which is not oriented substantially parallel to the transverse direction  132  of the crimping element  118  as in the first embodiment, but rather, extends transverse to the transverse direction  132  of the crimping element  118 . 
         [0166]    Hereby, the bending line  210  and the transverse direction  132  of the crimping element  118  preferably include an angle of more than approximately 10° and in particular of more than approximately 20°. 
         [0167]    Furthermore, the bending line  210  and the transverse direction  132  of the crimping element  118  preferably include an angle of less than approximately 60° and in particular of less than approximately 45°. 
         [0168]    For example, the angle included between the bending line  210  and the transverse direction  132  of the crimping element  118  may amount to approximately 25°. 
         [0169]    In this embodiment, the welding region  114  of the electrically conductive component  110  is thus formed asymmetrically with respect to a longitudinal mid plane  212  of the crimping element  118  which runs substantially perpendicularly to the bearing surface  122  of the crimping element  118  and substantially parallel to the longitudinal direction  136  of the crimping element  118  (see  FIG. 16 ). 
         [0170]    It is thereby possible to select the orientation of the contact region  112  of the electrically conductive component  110  independently of the orientation of the crimping element  118 . 
         [0171]    For the purposes of producing the second embodiment of the assembly  100 , one proceeds as follows. 
         [0172]    A structural element preform  146  that is illustrated in  FIG. 14  is detached by being cut out preferably by means of a laser for example, or stamped out, from a suitable raw material such as a metal sheet for example which is preferably flat. 
         [0173]    The electrically conductive component  110  with the crimping element preform  148  that is illustrated in  FIGS. 15 and 16  is produced from the substantially flat structural element preform  146  that is illustrated in  FIG. 14  by curving up the edge regions  126   a  and  126   b  as well as the contact region  112  from the plane of the closed side  120  in such a way that they extend substantially parallel to the longitudinal direction  136  of the eventual crimping element  118  and substantially perpendicularly to the bearing surface  122  of the closed side  120 . 
         [0174]    In this state, the contact region  112  is connected by the bent region  116  which extends along the bending line  210  to the asymmetrically formed welding region  114 . 
         [0175]    The process of connecting the individual conductors  106  of the electrical line  102  to the electrically conductive component  110  by a crimping process and the process of connecting the individual conductors  106  of the electrical line  102  to one another and to the inner side of the crimping element  118  on the electrically conductive component  110  by an ultrasonic welding process can be effected in the manner described above in connection with the first embodiment of the assembly  100 . 
         [0176]    The result of the crimping process and the subsequent ultrasonic welding process is the finished assembly  100  that is illustrated in  FIG. 13 . 
         [0177]    In all other respects, the second embodiment of the assembly  100  that is illustrated in  FIGS. 13 to 16  corresponds in regard to the construction, functioning, manner of production and choice of materials with the first embodiment that is illustrated in  FIGS. 1 to 12  and so to this extent, reference should be made to the preceding description. 
         [0178]    A third embodiment of an assembly  100  that is illustrated in  FIGS. 17 to 22  differs from the first embodiment illustrated in  FIGS. 1 to 12  in that not just one but a plurality and in particular two electrical lines  102 , namely a first electrical line  102   a  and a second electrical line  102   b , are connected to the electrically conductive component  110  in electrically conductive manner by means of the crimping element  118 . 
         [0179]    Hereby, the electrical lines  102   a  and  102   b  may, for example, be constructed in the same manner as the single electrical line  102  in the previously described first embodiment of the assembly  100 . 
         [0180]    In particular, the electrical lines  102   a  and  102   b  may each comprise a plurality of strands or individual conductors  106  and an electrically insulating sheath  108 . 
         [0181]    The electrically conductive component  110  to which the electrical lines  102   a  and  102   b  are connected in electrically conductive manner could, just as in the first embodiment, be formed in one piece with the crimping element  118  and be designed in substantially the same way as was previously described in connection with the first embodiment of the assembly  100 . 
         [0182]    In the embodiment illustrated in  FIGS. 17 to 22  however, the electrically conductive component  110  is produced separately from the crimping element  118  and in particular, it is in the form of an electrical line element  214  which comprises a plurality of strands or individual conductors  216  and an electrically insulating sheath  218  (see in particular  FIG. 18 ). 
         [0183]    As can be gathered from the cross sectional view of  FIG. 19 , the crimping element  118  here surrounds both the individual conductors  106  of the electrical lines  102   a  and  102   b  and also the individual conductors  216  of the electrical line element  214 . 
         [0184]    Herein, the stripped end regions of the individual conductors  106  of the electrical lines  102   a  and  102   b  on the one hand and the stripped end regions of the individual conductors  216  of the electrical line element  214  on the other overlap in the longitudinal direction  136  of the crimping element  118 . 
         [0185]    The crimping element  118  may be formed in substantially the same manner as was previously described in connection with the first embodiment of the assembly  100  but without being formed in one piece with the electrically conductive component  110 . 
         [0186]    The individual conductors  106  of the electrical lines  102   a ,  102   b  on the one hand and the individual conductors  216  of the electrical line element  214  on the other can, in principle, be formed from substantially the same electrically conductive material and in particular from a metallic material such as aluminum, an aluminum alloy, copper or a copper alloy for example. 
         [0187]    In a special arrangement of this embodiment of the assembly  100  however, provision is made for the individual conductors  216  of the electrical line element  214  to be formed from a material which is different from the material of the individual conductors  106  of the electrical lines  102   a ,  102   b.    
         [0188]    For example, provision may be made for the individual conductors  106  of the electrical lines  102   a ,  102   b  to be formed of copper or a copper alloy, whilst the individual conductors  216  of the electrical line element  214  are formed of aluminum or an aluminum alloy. 
         [0189]    Conversely, the individual conductors  106  of the electrical lines  102   a ,  102   b  could be made of aluminum or an aluminum alloy and the individual conductors  216  of the electrical line element  214  made of copper or a copper alloy. 
         [0190]    Furthermore, provision could also be made for the individual conductors  106  of the two electrical lines  102   a  and  102   b  not to be formed from the same electrically conductive material, but rather, from mutually differing electrically conductive materials. 
         [0191]    For the purposes of producing the previously described assembly  100  that is illustrated in  FIGS. 17 to 19 , one proceeds as follows. 
         [0192]    A crimping element starting blank  220  that is illustrated in  FIG. 20  is detached by being cut out, preferably by means of a laser for example, or stamped out, from a suitable raw material such as a metal sheet for example which is preferably flat. 
         [0193]    The closed side  120  and also the edge regions  126   a  and  126   b  of the eventual crimping element  118  lie in substantially the same plane in this crimping element starting blank  220  wherein the two edge regions  126   a  and  126   b  extend away from the closed side  120  in mutually opposite directions along the transverse direction  132  of the crimping element  118 . 
         [0194]    The crimping element preform  148  that is illustrated in  FIGS. 21 and 22  is produced from the substantially flat crimping element starting blank  220  that is illustrated in  FIG. 20  by bending out the edge regions  126   a  and  126   b  from the plane of the closed side  120  in such a way that they extend substantially parallel to the longitudinal direction  136  and substantially perpendicularly to the bearing surface  122  of the closed side  120  of the crimping element  118 . 
         [0195]    The edge regions  126   a  and  126   b  are connected to the closed side  120  of the crimping element preform  148  by curved regions  150   a ,  150   b  in this crimping element preform  148 . 
         [0196]    The crimping tool  152  illustrated in  FIG. 6  for example is used for the purposes of connecting the individual conductors  106  of the electrical lines  102   a ,  102   b  and the individual conductors  216  of the electrical line element  214  by means of a crimping process. 
         [0197]    For the purposes of the crimping process during which the crimping element  118  is formed and by means of which the individual conductors  106  of the electrical lines  102   a ,  102   b  are connected by the crimping action to the individual conductors  216  of the electrical line element  214  that form a constituent of the electrically conductive component  110 , the end sections  196  of the individual conductors  106  of the electrical lines  102   a ,  102   b  that are not provided with the sheath  108  are inserted into the crimping element preform  148  between the upright edge regions  126   a  and  126   b  from the one side of the crimping element preform  148 , and the end sections  222  of the individual conductors  216  of the electrical line element  214  that are not provided with the sheath  218  are inserted into the crimping element preform  148  between the upright edge regions  126   a  and  126   b  from the other side of the crimping element preform  148 . 
         [0198]    Thereby for example, provision may be made for the individual conductors  106  of the electrical lines  102   a  and  102   b  to be arranged on the side of the individual conductors  216  of the electrical line element  214  that is remote from the closed side  120  of the crimping element  118  as can be gathered from the cross sectional view of  FIG. 19 . 
         [0199]    The crimping element preform  148  is deformed in plastic manner by means of the crimping tool  152  in such a way that the crimping element  118  which is illustrated in  FIGS. 17 to 19  and has a substantially B-shaped cross section for example is obtained from the crimping element preform  148 . 
         [0200]    During the process of producing the crimping element  118  from the crimping element preform  148 , the edge regions  126   a ,  126   b  of the crimping element  118  are curved around the end sections  196  of the individual conductors  106  of the electrical lines  102   a ,  102   b  that are not provided with the sheath  108  and thereby pressed against the individual conductors  106  such that the end sections  196  of the individual conductors  106  that are surrounded by the crimping element  118  are pressed together in force-locking manner. 
         [0201]    At the same time in the process of producing the crimping element  118  from the crimping element preform  148 , the end sections  222  of the individual conductors  216  of the electrical line element  214  that are not provided with the sheath  218  are pressed against the individual conductors  106  of the electrical lines  102   a ,  102   b  in such a way that the end sections  222  of the individual conductors  216  that are surrounded by the crimping element  118  are compacted and are pressed against one another and the individual conductors  106  of the electrical lines  102   a ,  102   b  in force-locking manner. 
         [0202]    The spatial volume of the electrical lines  102   a ,  102   b  remaining between the individual conductors  106  and the spatial volume of the electrical line element  214  remaining between the individual conductors  216  are reduced in the region of the crimping element  118  by the compacting action during the crimping process. 
         [0203]    Subsequently, the assembly  100  consisting of the electrical lines  102   a  and  102   b , the crimping element  118  and the electrical line element  214  is removed from the crimping tool  152  and inserted into an ultrasonic welding tool  198  such as the one illustrated in  FIG. 12  for example. 
         [0204]    The assembly  100  is placed on the anvil  202  in such a way that the bearing surface  122  of the crimping element  118  comes to lie on the seating surface  204  of the anvil  202 . 
         [0205]    Thereafter, the sonotrode  200  is advanced towards the assembly  100  in such a way that the contact area  208  of the sonotrode  200  extending in the longitudinal direction  206  of the sonotrode  200  comes into contact with the open side  124  of the crimping element  118 . 
         [0206]    The ultrasonic welding process is carried out on the assembly  100  by means of the sonotrode  200  so that the individual conductors  106  of the electrical lines  102   a ,  102   b  are welded together and to the individual conductors  216  of the electrical line element  214  as well as to the inner side of the crimping element  118  and the individual conductors  216  of the electrical line element  214  are welded together, to the individual conductors  106  of the electrical lines  102   a ,  102   b  and to the inner side of the crimping element  118  by a friction welding process and are thus connected by a substance-to-substance bond. 
         [0207]    After termination of the ultrasonic welding process, the ultrasonic welding tool  198  is opened and the finished assembly  100  in which the individual conductors  106  of the electrical lines  102   a ,  102   b  are connected to the individual conductors  216  of the electrical line element  214  by both the crimping process by means of the crimping element  118  and by the ultrasonic welding process is removed from the ultrasonic welding tool  198 . 
         [0208]    In all other respects the third embodiment of an assembly  100  that is illustrated in  FIGS. 17 to 22  corresponds in regard to the construction, functioning, manner of production and choice of materials to the first embodiment illustrated in  FIGS. 1 to 12  so that to this extent, reference is made to the previous description thereof.