CN1031161C - Electrical connector - Google Patents

Abstract

A device 1 for forming an electrical connection between a plurality of electrical conductors comprises an electrically insulating sleeve (3), a metallic connecting element (4) located within the sleeve and a quantity of solder (8) for forming a permanent electrical connection between the conductors. The connecting element (4) has an external surface that is uneven so that a significant proportion of any radiation that is radially inwardly directed onto the external surface of the element will be reflected at least twice by the external surface of the element. This uneveness enables the response of the device to heating by infrared radiation to be significantly improved. The connecting element may be formed for example by coiling a wire having a polygonal, e.g. square, cross-section into a frusto-conical helix.

Description

Electrical connector

The present invention relates to electrical connector, particularly the connector of each the lead soldering point in the device of formation such as car electric distribution.

The electric wiring device, the sort of electric wiring device of for example making in the auto industry, often quite complicated.In some cases, this class distribution block will be equipped with the assembly of two or more leads, terminal, electric wire connecting junction and any other element earlier when making, then each assembly is coupled together on electric.In this case, the assembling process of distribution block can be by computer control, and like this, the assembly manipulation personnel just can see the wiring situation from picture by means of monitor, and check the distribution block manufacture process in each stage the assembling of each assembly unit whether correct.In order to carry out this control, can couple together by means of the conductor wire end of spring contact for example each assembly, and in the assembly unit galvanization or signal so that whether examine distribution correct.Have only after so examining and each binding clip could be removed, form the permanent electrical wiring.

Introduced among the patent application PCJ/GB91/01016 of our while pending trial and in this distribution, carried out the device (Fig. 1 to 6) that electrical wiring is used, also the disclosure of this application has been included here, for your guidance.This device has a metal connection element and a certain amount of solder, and the metal connection element is the cone-type spiral coil of metal wire coiled, is placed in can recover in the full-sized sleeve pipe after being heated.This device can be screwed to it on each lead, forms interim electrical wiring, after electric wiring is through test, again with device heats, forms nonvolatil electrical wiring.

According to one aspect of the present invention, the invention provides a kind of device that many conductor wires are coupled together on electric, this device comprises that an electric insulation sleeve pipe, one are arranged in the metal connection element of sleeve pipe and a certain amount of each lead are connected into the solder of permanent wiring, and the outer surface of wiring element is coarse as to be enough to make it will radially inwardly be radiated twice of the minimum reflection of most of any radiation on it.

Device of the present invention has such advantage: can make wiring element, thereby each soldering point, if it is they are thermo-contacts, more responsive than the infrared radiation that the device described in the above-mentioned international patent application is used heater element; This is because wiring element increases the cause that has absorbed most of radiation because of order of reflection.

Above-mentioned device preferably has such wiring element, and the inner surface of element band screw thread is tapered, thereby stubborn being set on the lead of wiring element just can be formed interim electrical wiring.

Therefore, according to another aspect of the present invention, the invention provides a kind of method that is electrically connected many conductor wires, this method comprises the following steps:

(i) around all leads such device is set, this device comprises an electric insulation sleeve pipe, a metal connection element and an a certain amount of solder that is arranged in sleeve pipe, and the inner surface of wiring element band thread is tapered, and outer surface is coarse;

(ii) device is twisted and be set on all leads, make all lead fixed on wiring element, then

(iii),, thereby make the solder fusing, make to form permanent the connection between each lead device heats radially to the internal radiation infrared radiation;

Wherein the outer surface of wiring element is with twice of the minimum reflection of most of radiation.

Wiring element is desirable any form usually, but preferably makes like this: a wires is rolled into the taper coil, makes coil form thread.The preferably minimum part of the inner surface of wiring element is tapered, for example can be taper or frustoconical.When wiring element was made by metal wire, because metal wire tool elasticity, and wiring element to a certain extent can radial expansion when bundle conductor is introduced wherein, thereby wiring element can clamp introducing bundle conductor wherein.But this device has a kind of extremely beneficial form, and the device of this form is to make it from its relaxed state radial expansion in its manufacture process, thus make its can be when forming permanent wiring radial contraction or have the tendency of radial contraction.Therefore, for example, the resilience force that sleeve pipe or solder can resist spring makes spring keep straining at state, and like this, spring just can restore during softening or solder fusing when sleeve pipe.For example, can on the outer surface of the inner surface of sleeve pipe or solder, form a lug boss (boss) that just disappears during with device heats.The degree of expansion needn't be too big, for example is not more than 5%, or not even greater than 2% because coil when device heats preferably and soldering element (solder element) keep in touch.

The cross section of metal wire is preferably got polygonal, and is particularly square, does beneficial like this.Metal wire can be made by any proper metal or metal alloy, but preferably is made of copper, particularly purity basically with common as the same copper of conductor wire.

But wiring element also can adopt other structure.For example, wiring element can be made inner surface and attack the solid metal block that thread, outer surface are attacked another thread or be cut with groove.

Outer surface preferably can reach such degree of roughness, outer surface can be reflected any major part (50%) radiation that radially inwardly shines on it twice at least at least, under the better situation, can make at least 70% particularly any radiation of at least 90% by twice of the minimum reflection of outer surface.

Finding out through us, is under the situation of hard tempering copper at metal wire, and when the infrared radiation of heater element was on shining the surface, its energy of about 60% was absorbed, and about 40% energy is reflected back.Its wiring element of device of the present invention by the thread situation of the metal of square cross section under, then depend on the design (for example tapering of the orientation of metal wire and wiring element) of wiring element in geometric aspects, the most of radiation that radially inwardly shines the wiring element outer surface was the outer surface reflection twice of metal wire before being scattered from wiring element, a part of radiation then only reflected once before being scattered.But if change the cross section of metal wire, angle between the adjacent surface that adjoins on each circle is reduced to below 90 degree, then radiation only reflects part minimizing (reducing to zero usually) once, radiation with angle reduce and the part that increases then reflects three times or even more than three times, thereby further reduced the radiant energy of wiring element institute scattering.Angle between the adjacent surface of each groove (no matter these grooves be form by tapping, milling or respectively adjoin between the circle at metal wire form) preferably be not more than 90 degree.In some cases, preferably make and will respectively adjoin the angle that forms between the winding less than 80 degree, for example less than 70 degree, particularly at 40 degree to the scopes of 65 degree.For example, be under 60 the situation at each surperficial angle of wiring element, nearly 80% reflection of incident radiation line three times, 20% reflection twice, thus make absorbed incident ray reach about 92%.

Usually, the cross section of metal wire is got square or rhombus, and designs to such an extent that make metal wire form the each several part formation thread of wiring element inner surface.Wiring element can be screwed on all leads that will couple together with that, make it for example before forming permanent wiring, form interim electrical wiring for the usefulness of test.

Aspect from the broad sense of the present invention, device of the present invention has a such wiring element, the single inner surface of this wiring element is tapered, thereby for example can form the twist joint of cutting back between a branch of lead that inserts sleeve pipe one end, and the other end of sleeve pipe then for example is closed.But also can make device of the present invention that some such wiring element are arranged, this wiring has two ends, and the cone-type spiral coil of metal wire is made in one of them or two ends, thereby, for example can between the couple of conductor bundle, form a row twist joint.Can adopt an end not have the wiring element of thread, at this moment as long as bundle conductor is pushed in the wiring element.When thread all was with in the wiring element two ends, the screw thread at two ends can be got same direction of rotation, and perhaps an end is got the dextrorotation screw thread, and the other end is got left-handed screw thread.Do not need in view of will form patch usually the time to twist sleeve pipe to such an extent that surpass 1/4 to 1/2 circle, thereby the selection that screw thread turns to can't produce any specific question so that it is set on all leads.But each end of wiring element can relatively rotate with respect to each other.For example, can by with in the cannelure of the part metals coil of wire in going into wiring element and the end portion supports that metal wire is formed on columniform little wiring element.

When each end of wiring element can relatively rotate with respect to each other, often total hope was made two parts with sleeve pipe, and each part is placed on one of them end of wiring element.Like this, be placed in wherein part each end of wiring element is rotated by turning sleeve pipe.

Usually, sleeve pipe is revertible dimensionally, can return to original size after particularly being heated, and in other words, can make its shape on varying sized when sleeve pipe is heated basically.

Usually, returned to the previous original form of distortion thus during the heating of these sleeve pipes, but " be heated and can recover life size " used herein is even a speech comprises that also those originally not have to be out of shape but get the sleeve pipe of new profile when being heated.

This class sleeve pipe of common version is a kind of for example United States Patent (USP) 2,027,962 that has; 3,086,242 and 3,597, hot shortness's sleeve pipe that the polymeric material of elasticity described in 372 or plastic memory performance is made.For example, United States Patent (USP) 2,027, just clearly illustrated more like this in 962: heat-staple the sort of form can be that for example extruded tube expand into a kind of interim form of the continuous process of thermally labile form on the size under hot state on original size, but in other purposes, heat-staple sleeve pipe prefabricated component is the unsettled form of size when becoming to be heated that distorts under individual states on the size.

When making the sleeve pipe of heated recoverable, can polymeric material be carried out crosslinking Treatment in any stage in making the sleeve pipe process that improves needed size restorability.A kind of method of making the sleeve pipe of heated recoverable is earlier polymeric material to be processed into desired heat-stable form, then polymeric material is carried out crosslinking Treatment, again sleeve pipe is heated to above the temperature of the crystalline melt point of polymer, or if polymer is higher than the temperature (being determined on a case-by-case basis) of the softening point of polymer when being the noncrystalline material, make casing deformation, then sleeve pipe is cooled off under it is in deformation state, make sleeve pipe keep its deformation state.During use,, thereby make sleeve pipe recover its original thermally-stabilised shape once heating because the deformation state of sleeve pipe is unsettled to heat.

All its any materials with size recoverability energy that can make all can be in order to make sleeve pipe.Comparatively ideal material has low-density, middle density or high density polyethylene (HDPE), ethene and for example ethylene copolymer of following material composition; For example, the alhpa olefin of 1-butylene or 1-hexene and so on, or vinylacetate, polyamide or fluoropolymer, for example polytetrafluoroethylene, vinylidene fluoride or ethylene-tetrafluoroethylene copolymer.

The end portion encloses of each lead is in wiring element, and any heart yearn that can also lower lead pierces through the risk of sleeve pipe in the restorable process of sleeve pipe.In addition, conducting element can also play radiator, thereby prevents that device is overheated in the process that sleeve pipe restores.

As mentioned above, device comprises a certain amount of solder, is with for the purpose of the spelter solder difference, and the soft solder of some is for the usefulness that forms permanent soldered fitting.This solder can be for example only to be Sn ₆₃Pb ₃₇The form of low-melting constituent, this composition can melt when device heats and sleeve pipe restore, and perhaps also can adopt the different solder composition of more than one fusing points, as described in the International Patent Application WO 88/O9068.In the device of this form, the higher composition of fusing point (Sn for example _96.5Ag _3.5When low temperature eutectic) melting, just can know that from outward appearance device has heated to such an extent that be enough to melt the lower composition of fusing point, and form gratifying soldered fitting.In case of necessity, the solder that fusing point is lower can be the composition of non-low temperature eutectic, and for example as described in the International Patent Application WO 90/09255, can be by fusing point the higher and lower braze composition of fusing point form the low temperature eutectic mixture together.For example, non-low temperature eutectic Sn that can fusing point is lower ₆₀Pb ₄₀Composition uses with the fusing point higher composition of being made up of pure tin of relative quantity, makes Sn ₆₃P6 ₃₇The low-temperature eutectic material.Here also the disclosure of above-mentioned two patent applications is included, for your guidance.Adopt solder, particularly tin and the Sn of two kinds of components ₆₀Pb ₄₀Mixture, such benefit is arranged, promptly can reduce the possibility of " solder seepage ", promptly solder flows along lead because of the capillarity of stranded conductor, and departs from the weld zone; Director's heating time of device, this phenomenon will take place.

Solder can be placed in and can flow into any position that forms soldering point in the wiring element.Solder can be got form or any other form of ring-type, for example, and sphere, and can be symmetrical in casing axis or depart from the configuration of casing axis ground.The solder element can, for example, be placed in the less end of wiring element diameter, in this case, the form of desirable sphere of solder element or wedge perhaps for example is placed in the bigger end region of wiring element diameter with the form of annular.Solder axially adjoins wiring element such benefit: the absorption process of infrared radiation can be carried out along the whole length of wiring element; But it has such shortcoming: the thermo-contact between solder and the wiring element has reduced.In view of this, solder preferably is placed in the wiring element external surface peripheral with the form of annular.The benefit of doing like this is to have improved the thermo-contact situation (each circle of solder wiring element in case fusing just can be flowed through) between solder and the wiring element.But the flat surface that solder is orientated outwardly can make infrared radiation only reflect once at the position that the solder ring is covered wiring element.Because of than, cover the degree of wiring element for the restriction solder, keep height thermo-contact between the two simultaneously, preferably adopt the solder ring that (diametrically) is thicker and axial dimension is less.For example, the axial length of solder ring preferably is not more than 3 times of radial thickness, particularly in 1 to 2 times scope of radial thickness.Can adopt the solder of amount more than, for example, the occasion that forms an above cone-shaped inner surface of twist joint in wiring element just can be done like this.

Referring now to accompanying drawing, illustrates a kind of form of device of the present invention and the method for installing this device.In the accompanying drawing:

Fig. 1 is the cutaway view of device;

Fig. 2 and 3 is this device end view and end-views when being placed in the infrared heater;

Fig. 4 shows and shines the geometric path of device by the radiation on the thread wiring element of square-section metal;

Fig. 5 shows the geometric path that shines the radiation on the device diamond-shaped cross-section wiring element.

Referring to accompanying drawing. In order to a series of electric insulation wires at the electric device that couples together, comprise a sleeve pipe 3 and a wiring element 4, when being heated, sleeve pipe 3 can recover life size, by making through crosslinked and Kynoar that expanded, wiring element is made spring or the coil of frustoconical by hard tempered metal line. The desirable square form shown in Figure 4 of the cross section of copper cash, the also form of desirable rhombus shown in Figure 5 is wherein adjoined the limit and is become about 60 degree angles with one on limit that metal wire forms each face, adjoins the limit with another and becomes about 120 to spend angles. As shown in Figure 5, the metal linear system is reeled to such an extent that make formed each edge of each face each other in 60 degree be positioned at the inside and outside of wiring element, inward flange forms thread, for fixing wire to be connected. That end that metal wire is placed in the less end of wiring element 4 diameters is crookedly must make its Axis Extension that crosses coil, thereby avoids wire to be connected to insert head. In some cases, can launch each end of copper cash 5, and they are remained on the reposition, come the diameter of spread loop 4 with this, do so beneficial.

Sn ₆₃Pb ₃₇The outer surface that meltable solder ring 8 is solderless wrapped connection kind of thread elements 4 between itself and heat-shrinkable sleeve pipe 3 arranges. The solder ring is thicker and short, and its axial length only is about 2 times of its radial thickness, thus wiring element as far as possible major part be in open state.

Sleeve pipe makes it reset on the spherical sealing component 10 of being made by meltable polymeric material (for example polyethylene) at an end of the less end portion of wiring element diameter in advance, and another ringwise potted component then is placed in the sleeve pipe that adjoins wiring element 4 other ends.

In the time of bunched conductor will being electrically connected, with their end strip off, then insert the open end of device 1, the end that play the block effect until they are crooked near metal wire 5 cross span coil axis. Then each wire and device are axially placed in the infrared heater, shown in the schematic diagram of Fig. 2 and 3.

Infrared heater mainly is comprised of a quartz ampoule 20, is wound with heat-resistant component 21 and ceramic gasket 22 on the quartz ampoule 20. Heating element heater 21 is guided to terminal part 23, and insulation board is housed around the heating element heater 21. With in device 1 Inserting Tube 20 and when connecting heater, the infrared radiation that heating element heater comes radially inwardly shines on the device, makes solder 8 fusings and flows in the wiring element by coil, thereby recoverable sleeve pipe 3 is shunk around all wires.

Figure 4 and 5 are profiles of some coils of wiring element. Fig. 4 shows device of the present invention by the thread circle processed of leading of square cross section, and Fig. 5 shows the device lozenge shape cross-section and leads thread coil. Four faces 31,32,33 and 34 flatten in the copper cash system that makes wiring element, and dispose to such an extent that make the edge that adjoins formation between face 31 and 32 form the internal thread button of wiring element. Because wiring element tapered (tapering is about 10 degree) and slightly distortion, thereby in vertical direction slightly skew of wire coil. As can be seen from Figure 4, incide most of infrared radiation on the wiring element outer surface after an outer surface (for example surface 34) reflexes to the adjacent surface 33 that adjoins coil, radially outward reflect back. " 2 class district " shows the position that above-mentioned phenomenon occurs wiring element. In addition, also have a little position that is called " 1 class district ", wiring element only makes the radiation reflection once in this position. Under this layout, there is 93.7% surface to belong to 2 class districts, 6.3% surface belongs to 1 class district. If the power of incident radiation line has 60% to be absorbed. Have 40% to be reflected, then absorbed incident radiation power percent of total is not difficult to calculate, and its value is 82.5%. In device shown in Fig. 5, the angle between each surface of metal wire 5 is reduced to 60 degree by 90 degree, and in this case, all incident radiation line reflections twice have three times (as shown in " 3 class district ") of 80% reflection. This layout can confirm that the total percentage of absorbed incident power is 91.7% by same calculating.

Example

It is different but frustum identical in quality comes the firing rate of determination test element with this with the method for machining wiring element to be made outer surface.The outer surface of one of them element is flat cone, and the outer surface of second element is processed into a series of V-shaped grooves, and each surface in the groove is 90 degrees to each other, and the processing mode of the 3rd element is the same with second element, and just the angle between each groove face is 50 degree.Put into baking oven after the thermocouple of dress hard in each element.Write down the temperature that each element heating was reached afterwards in a minute.The result is as shown in the table.As can be seen from the table, the element of the angle between each edge surface little (50 degree), its firing rate is more faster than other element.

Table

Element

	1 ℃ of temperature after 1 minute
		50 ° of edges, 90 ° of edges of smooth surface	100 130 170

Claims (10)

1. device in order to many conductor wires are coupled together on electric, it is characterized in that, comprise an electric insulation sleeve pipe, one be placed in metal connection element in the sleeve pipe with a certain amount of in order to each lead is connected into the permanent solder that is connected on electric, the outer surface of described wiring element is coarse as to be enough to make most of footpath and inwardly to shine twice of the minimum reflection of any radiation on it.

2. device as claimed in claim 1 is characterized in that, the outer surface of described wiring element is coarse as to make twice of the minimum reflection of its major part with any radiation to internal radiation.

3. device as claimed in claim 1 or 2 is characterized in that described outer surface has one or more groove, and the angle in the groove between the adjacently situated surfaces is not more than 90 degree.

4. device as claimed in claim 3 is characterized in that, described angle is less than 70 degree.

5. device as claimed in claim 4 is characterized in that, described angle is spent to the scopes of 65 degree 40.

6. as each described device of claim 1 to 5, it is characterized in that described wiring element is made by the cone-type spiral coil of metal wire.

7. device as claimed in claim 6 is characterized in that the cross section of described metal wire is square or rhombus, and designs to such an extent that make the described metal wire each several part that forms described wiring element inner surface limit thread.

8. device as claimed in claim 7 is characterized in that, can recover life size when described sleeve pipe is heated.

9. device as claimed in claim 8 is characterized in that, described wiring element has two ends, and the cone-type spiral coil of metal wire is made in one of them or two ends.

10. a method that is electrically connected many conductor wires is characterized in that it comprises the following steps:

(i) such device is being set around all leads, this device comprises an electric insulation sleeve pipe, a metal connection element and an a certain amount of solder that is arranged in described sleeve pipe, and the inner surface of described wiring element band thread is tapered, and outer surface is coarse;

(ii) described device is twisted and be set on described all leads, make described all lead fixed in described wiring element; Then

(iii),, thereby make the solder fusing, make to form permanent the connection between described each lead described device heats radially to the internal radiation infrared radiation;

The outer surface of wherein said wiring element is with twice of the minimum reflection of most of radiation.

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