CN108336622A - 一种基于铜基体插孔连接汇流方法 - Google Patents

一种基于铜基体插孔连接汇流方法 Download PDF

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CN108336622A
CN108336622A CN201711325270.XA CN201711325270A CN108336622A CN 108336622 A CN108336622 A CN 108336622A CN 201711325270 A CN201711325270 A CN 201711325270A CN 108336622 A CN108336622 A CN 108336622A
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socket
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苟俊锋
谭磊
王楚婷
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Tianjin Jinhang Computing Technology Research Institute
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    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/01Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the form or arrangement of the conductive interconnection between the connecting locations
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/03Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the relationship between the connecting locations
    • H01R11/07Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the relationship between the connecting locations the connecting locations being of the same type but different sizes
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/03Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the relationship between the connecting locations
    • H01R11/09Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts characterised by the relationship between the connecting locations the connecting locations being identical
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/28Clamped connections, spring connections
    • H01R4/48Clamped connections, spring connections utilising a spring, clip, or other resilient member
    • H01R4/4809Clamped connections, spring connections utilising a spring, clip, or other resilient member using a leaf spring
    • H01R4/4818Clamped connections, spring connections utilising a spring, clip, or other resilient member using a leaf spring adapted for axial insertion of a wire end
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/28Clamped connections, spring connections
    • H01R4/48Clamped connections, spring connections utilising a spring, clip, or other resilient member
    • H01R4/4854Clamped connections, spring connections utilising a spring, clip, or other resilient member using a wire spring
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/007Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for elastomeric connecting elements
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048Crimping apparatus or processes
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/16Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending

Abstract

本发明公开一种基于铜基体插孔连接汇流方法,该方法首先根据应用需要选用合适的压接插针,然后根据压接插针设计出匹配的汇流插座,再将该汇流插座应用到工况电路中,即可实现汇流。该方法的优点在于采用压接的方式实现大电流的汇流,所使用的汇流插座设计、制造周期短,具有使用简单、维修方便的特点,避免了“一点多线的限用工艺”和助焊剂残留带来的隐患,同时,较手工焊接短接模式少了绞合、搪锡、清洗等辅助工序,提高了生产效率和加工可靠性。同时,所设计的汇流插座具有可自由组合的特点,可实现快速应用。

Description

一种基于铜基体插孔连接汇流方法
技术领域
[0001] 本发明涉及电路设计技术领域,具体是一种基于铜基体插孔连接汇流方法,是通 过接插件弹性插孔实现多导线的短接,可以替代采用焊接实现多导线短接的方法,适用于 导线数量多、空间狭小军工产品,可避免军工产品中“限制使用一点多线焊接”带来的虚焊 缺陷的发生。
背景技术
[0002] 随着军工产品小型化、多功能化的发展需要,电子电气产品空间越来越小,对于有 大电流控制的产品,限于电气功能分配和载流能力要求,经常需要将多个电流进行汇流和 分流,为配合功能实现。
[0003] 目前在军工产品中,明确规定“每个接线端子上一般不应超过三根导线”。为避免 该限用工艺,大多使用压接端子反复转接缩减导线数量,但对于多大20根以上的汇流端子 而言,仅压接端子的空间就已经不能满足产品装配要求。因此,为实现产品功能,大多数厂 家采用多根导线绞合、搪锡后直接焊接的方法进行短接,此方法对操作人员技术、工具、过 程控制要求非常高,必须保证搪锡到位、熔融充分、焊接中无应力扰动等,否则极易带来虚 焊,同时绞合中助焊剂残留无法清洗干净,长期使用中存在接点被腐蚀的隐患。
发明内容
[0004] 针对现有技术的不足,本发明拟解决的技术问题是,提供一种能够通过与压接针 弹性连接的汇流连接方法,实现密集接点、可靠汇流。
[0005] 本发明解决所述技术问题的技术方案是,设计一种基于铜基体插孔连接汇流方 法,其特征在于,该方法具体步骤如下:
[0006] 第一步:根据需汇流导线的截面积尺寸,确定匹配的标准压接插针型号,进而确定 压接插针直径及相匹配插孔;
[0007] 第二步:根据第一步确定的压接插针直径及相匹配插孔,确定对应弹性接触体的 内径,以及与其匹配的弹性接触体安装孔孔径;
[0008] 第三步:根据第二步确定的弹性接触体的内径d及间距P和孔深度H数据制造汇流 插座,汇流插座采用铜基体;弹性接触体的内径d、间距P和孔深度H选用参数与压接插针接 触端长度L、直径d'、导线外径D相关,其中为实现一孔双线压接提高接线密度而确保可安 装,建议P不小于2D;经试验和考虑元器件外形公差范围,相关尺寸通过下述关系式进行计 算:
[0009] H彡 L (1)
[0010] P 彡 2D (2)
[0011] d = d, (3);
[0012] 第四步:对工况电路按照汇流插座位置进行线束布局,使出线位置与汇流插座位 置对应;
[0013] 第五步:将所选用的压接插针与导线压接,并将所需数量压接插针的接触端安装 到对应的设置有弹性接触体的汇流插座中;通过固定螺纹孔将汇流插座固定在所需位置, 接通电源,即可完成汇流。
[0014] 与现有技术相比,本发明有益效果在于:本发明的优点在于设计、制造周期短,具 有使用简单、维修方便的特点,避免了“一点多线的限用工艺”和助焊剂残留带来的隐患,同 时,较手工焊接短接模式少了绞合、搪锡、清洗等辅助工序,提高了生产效率和加工可靠性。 同时,具有可自由组合的特点,可实现快速应用。项目成果形成的产品具有系列化特点,使 用自由组合不能满足时可以根据产品特点快速开展定制设计。
附图说明
[0015] 图1为本发明一种实施例的俯视图。
[0016] 图2为本发明一种实施例的压接插针与导线连接示意图。
[0017] 图3为本发明一种实施例的仰视图。
[0018] 图4为本发明一种实施例的左视纵向剖视图。
[0019] 图5为本发明一种实施例的主视纵向剖视图。
具体实施方式
[0020] 以下将结合附图对本发明做进一步的说明,但不应以此来限制本发明的保护范 围。
[0021] 本发明一种基于铜基体插孔连接汇流方法,该方法具体步骤如下:
[0022] 第一步:根据需汇流导线的截面积尺寸,确定匹配的标准压接插针型号(表1),进 而确定压接插针直径及相匹配插孔;
[0023] 表1常用标准压接插针尺寸及对应电流情况
[0024]
Figure CN108336622AD00041
[0025] 第二步:根据第一步确定的压接插针直径及相匹配插孔,确定对应弹性接触体的 内径,以及与其匹配的弹性接触体安装孔孔径;所述弹性接触体为四爪或六爪铍铜卡爪、线 黄、惯黄等;
[0026] 第三步:根据第二步确定的弹性接触体的内径d及间距P和孔深度H数据制造汇流 插座,汇流插座采用铜基体;弹性接触体的内径d、间距P和孔深度H选用参数与压接插针接 触端长度L、直径d'、导线外径D相关,其中为实现一孔双线压接提高接线密度而确保可安 装,建议P不小于2D;经试验和考虑元器件外形公差范围,相关尺寸通过下述关系式进行计 算:
[0027] H彡 L (1)
[0028] P 彡 2D (2)
[0029] d = d, (3)
[0030] 其中,!1、1^、?、0、(1、(1/取值参见表1;汇流插座底部设置有固定螺纹孔,其按照标准 紧固件进行设计,深度不小于3_;
[0031] 第四步:对工况电路按照汇流插座位置进行线束布局,使出线位置与汇流插座位 置对应;
[0032] 第五步:将所选用的压接插针与导线压接,并将所需数量压接插针的接触端安装 到对应的设置有弹性接触体的汇流插座中;通过固定螺纹孔将汇流插座固定在所需位置, 接通电源,即可完成汇流。
[0033] 所述汇流插座的个数为单个或多个,单个使用时,直接安装在绝缘体上实现多个 导线的汇流和分流;多个汇流插座组合应用时,需要根据汇流座螺纹孔位设计相应的安装 孔,并利用导通金属片以实现电流导通,汇流插座间可采用无间距设计。
[0034] 实施例1
[0035] 本实施例提供一种基于铜基体插孔连接汇流方法,该汇流方法采用的汇流插座如 图1-5所示,该插座包括基座1、弹性接触体2,所述基座1为铜铸造而成,其上表面并排设置 有12个上孔,分两排整齐布置。
[0036] 所述上孔内安装有弹性接触体2,所述弹性接触体2的内孔为21。所述基座1的底面 上设置一个固定螺纹孔11,用于插座的定位固定。
[0037] 压接插针3的一端与导线4连接,其另一端为接触端,安装于弹性接触体2的内孔21 内。
[0038] 固定螺纹孔11选择M4的螺纹孔,深度不小于4mm。
[0039] 所述弹性接触体为镀金材质,可以根据需要与厂家进行沟通选择,弹性接触体与 导线压接之后直接插入汇流底座中,靠适配的弹性卡簧进行固定,必要时可以使用一些环 氧胶。
[0040] 本发明插座可直接螺钉安装在绝缘体上单体使用,需要更大电流汇流时,还可通 过安装在金属结构件上或采用短路铜片并联使用。还能够与插孔连接的插针通过坑压式压 接与导线连接,可以快速连接,实现密集接点、可靠汇流。
[0041] 本发明的工作原理是用压接的方式实现大电流的汇流,其工作流程是将导线与压 接针固定,再将连有导线的压接针放入汇流底座中,必要时可以使用一些环氧胶进行固定 (如erg〇5881、erg〇1690等),然后将整个汇流底座用螺钉固定在玻璃布板或其他绝缘体上, 以实现汇流功能。
[0042] 本发明主要通过采用整体铜材为基体,实现大电流汇流,并一侧精准钻孔后在孔 内装入适配的弹性卡簧,方便与导线压接针实现可靠连接,从而达到可靠汇流的目的,具有 使用、维修方便的特点,回避了“一点多线的限用工艺”和助焊剂残留带来的隐患,提高了生 产效率和加工可靠性。
[0043] 本发明未述及之处适用于现有技术。

Claims (3)

  1. CN 108336622 A 权利要求书 1/1页
    1. 一种基于铜基体插孔连接汇流方法,其特征在于,该方法具体步骤如下: 第一步:根据需汇流导线的截面积尺寸,确定匹配的标准压接插针型号,进而确定压接 插针直径及相匹配插孔; 第二步:根据第一步确定的压接插针直径及相匹配插孔,确定对应弹性接触体的内径, 以及与其匹配的弹性接触体安装孔孔径; 第三步:根据第二步确定的弹性接触体的内径d及间距P和孔深度H数据制造汇流插座, 汇流插座采用铜基体;弹性接触体的内径d、间距P和孔深度H选用参数与压接插针接触端长 度L、直径d'、导线外径D相关;经试验和考虑元器件外形公差范围,相关尺寸通过下述关系 式进行计算: H^L (1) P ^ 2D (2) d = d' (3); 第四步:对工况电路按照汇流插座位置进行线束布局,使出线位置与汇流插座位置对 应; 第五步:将所选用的压接插针与导线压接,并将所需数量压接插针的接触端安装到对 应的设置有弹性接触体的汇流插座中;通过固定螺纹孔将汇流插座固定在所需位置,接通 电源,即可完成汇流。 2 ·根据权利要求1所述的一种基于铜基体插孔连接汇流方法,其特征在于,所述弹性接 触体为四爪或六爪铍铜卡爪、线簧、惯簧中的一种。
  2. 3.根据权利要求1所述的一种基于铜基体插孔连接汇流方法,其特征在于,所述汇流插 座底部设置有固定螺纹孔,其按照标准紧固件进行设计,深度不小于3mm。 2
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Cited By (1)

* Cited by examiner, † Cited by third party
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WO2020181828A1 (zh) * 2019-03-12 2020-09-17 烟台台芯电子科技有限公司 一种插针焊接工装及插针固定方法

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