CN201508754U - 电抗器单元 - Google Patents

电抗器单元 Download PDF

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CN201508754U
CN201508754U CN2009201777708U CN200920177770U CN201508754U CN 201508754 U CN201508754 U CN 201508754U CN 2009201777708 U CN2009201777708 U CN 2009201777708U CN 200920177770 U CN200920177770 U CN 200920177770U CN 201508754 U CN201508754 U CN 201508754U
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reactor unit
pressure contact
contact portion
electric terminal
winding coil
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柳真介
松尾繁
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Panasonic Holdings Corp
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Matsushita Electric Industrial Co Ltd
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2823—Wires
    • H01F27/2828—Construction of conductive connections, of leads
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00—Fixed inductances not covered by group H01F17/00
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual 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
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H01R11/16—End pieces terminating in a soldering tip or socket
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-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
    • H01R4/02—Soldered or welded connections
    • H01R4/023—Soldered or welded connections between cables or wires and terminals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-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
    • H01R4/02—Soldered or welded connections
    • H01R4/029—Welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-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
    • H01R4/10—Electrically-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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/183—Electrically-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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H01R4/184—Electrically-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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-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
    • H01R4/58—Electrically-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 characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-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
    • H01R4/70—Insulation of connections
    • H01R4/72—Insulation of connections using a heat shrinking insulating sleeve
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/29—Terminals; Tapping arrangements for signal inductances
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-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
    • H01R4/10—Electrically-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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/187—Electrically-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 effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping combined with soldering or welding

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Coils Of Transformers For General Uses (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)

Abstract

本实用新型的电抗器单元具有：将铝线卷绕在铁制铁芯上而形成的绕组线圈、和与绕组线圈的端部相连接的铜制电气端子。电气端子的一端具有用于与绕组线圈的铝线进行压接接触的压接部，另一端具有呈略平面状的焊接部。这样，可以以很低的制造成本实现不同材质材料之间的电连接，提供一种可靠性高的电抗器单元。

Description

电抗器单元
技术领域
本实用新型涉及一种使用在电气电子机器中的电抗器，更具体地说，涉及一种在具有铝线卷绕成的绕组线圈与铜线之间设有电气连接装置的电抗器单元。
背景技术
日本专利公开公报1995-22258号中示出了一种在绕组线圈与铜线之间设有电气连接装置的现有电抗器，图5为该现有电抗器的主视图。
如图5所示，在铁制底座1上装有铁制的铁芯2，铁芯2上装有绕组线圈4，绕组线圈4用表面烧结有漆膜的铝线3卷绕而成，整个电抗器还要进行浸漆处理。绕组线圈4由材质为铝的铝线3构成的原因是铝线3比铜线成本比，近年来铝线被广泛使用于电抗器等的绕组中。
连接时，先将位于绕组线圈4的绕组起点和终点处的铝线3上的漆层部分除去，将铝芯线5用焊锡7焊接到另外设置的铜制电气端子6上。
在上述结构中，从外部到电抗器8的电源输入可以通过将与导线连接的连接端子插到电气端子6上来进行。
但是，在现有的铝质绕组线圈与铜线之间的电气连接装置中，用通常的焊锡无法将铝线固定在铜制的电气端子上，故需要使用铝线专用的焊锡材料，会产生比通常的焊锡成本高、操作困难等问题。
另外，绕组线圈的热量传到端子上、给电气端子施加热应力时，由于铝和铜的热膨胀系数不同，在焊锡部位就容易出现裂纹，造成接触不良，故还存在着可靠性方面的问题。
实用新型内容
本实用新型旨在解决现有技术中存在的上述问题，其目的在于提供一种在用铝线卷绕而成的绕组线圈与铜线之间设有电气连接部的电抗器单元，该电抗器单元的接触部在环境温度急剧变化的情况下也不会造成接触不良，并且制造成本低，可靠性高。
为了解决上述问题，本实用新型的电抗器单元包括：将铝线卷绕在铁制铁芯上形成的绕组线圈、和与所述绕组线圈的端部相连接的铜制电气端子。其中，所述电气端子的一端具有与所述绕组线圈的铝线进行压紧连接的压接部，另一端具有呈略平面状的焊接部。
这样，可以以低廉的制造成本实现一种即使环境温度急剧变化也不会造成接触不良且可靠性高的电抗器单元。
附图说明
图1为本实用新型的一个实施例中的电抗器单元的截面图，
图2为该电抗器单元的主视图，
图3A为该电抗器单元中的连接部的侧面放大图，
图3B为该电抗器单元中的连接部的正面放大图，
图3C为该电抗器单元中的连接部的3C-3C截面图，
图3D为该电抗器单元中的连接部的3D-3D截面图，
图4为该电抗器单元的电气特性表，
图5为在绕组线圈和铜线之间设有电气连接部的现有电抗器的主视图。
具体实施方式
下面参照附图对本实用新型的一个实施例进行详细说明。同时需要指出的是，本实用新型的实施例不具有限定本实用新型范围的作用。
(实施例)
下面参照图1～图4对本实施例的电抗器单元进行说明。本实施例的电抗器单元用来抑制进行变频控制的洗衣机等中的高频电流，改善功率因数，其中的绕组线圈使用了铝线，电源输入部分采用铜线，在绕组线圈和铜线之间设有电气连接部。
图1为本实施例中的电抗器单元的截面图。如图1所示，将电磁薄钢板由冲压加工模具冲压成英文字母“E”字状后经层叠/焊接后形成E形铁芯9，由表面烧结有漆膜的铝线卷绕成的绕组线圈10从上方嵌入到E形铁芯9中。然后，将电磁薄钢板由冲压加工模具冲压成字母“I”状后经层叠/焊接后形成的I形铁芯11设置到E形铁芯9之上，再将外周的接触侧面用焊接材料12进行焊接、固定。
另外，为了使E形铁芯9可以用螺丝固定在洗衣机等产品上，E形铁芯9通过焊接材料12被焊接、固定在铁制的底座13上。
并且，绕组线圈10的外周部还卷绕上用于实现绝缘的绝缘胶带15。
当全部的焊接固定工序结束后，还要将电抗器整体进行浸漆处理。浸漆处理的目的是为了防止E形铁芯9及I形铁芯11的铁芯生锈、抑制电磁噪声、防止线圈绝缘胶带受潮等。
图2是该电抗器单元的主视图。如图2所示，在E形铁芯9及I形铁芯11构成的铁制铁芯16上安装由铝线18卷绕成的绕组线圈10，而且，在铝线18卷绕成的绕组线圈10的起始部分和终点部分上的漆层除去，使铝线18的铝芯线19大约露出10mm后，压接(即压紧式连接，下同)固定在铜制的电气端子17的压接部25上，以此构成电抗器单元14。
另外，在电气端子17的另一侧(对面一侧)，设有用来给电抗器供电并带有连接器22的铜制导线21，铜制导线21的芯线通过点焊焊接方式固定在电气端子17中呈略平面状的焊接部17c上。
在铝芯线19和铜制电气端子17的焊接连接部20处，由于是铝和铜这两种不同的金属相互连接而成，会产生电位差。因而，附着上水或潮气时会引起电蚀现象，造成接触电阻增大。所以，至少在不同金属的接触部要通过刷子等涂敷上硅胶树脂23，使接触部被完全遮盖，从而可以保持适当的电气连接。
另外，在焊接连接部20的外周再套上能在高温照射时发生收缩的热收缩管24来起到绝缘胶带的作用的话，可以进一步提高防水效果。
图3是连接部的详细示意图。其中，图3A是连接部的侧视放大图，图3B是连接部的正视放大图，图3C是图3A的3C-3C截面图，图3D是图3A的3D-3D截面图。
如图3A及图3B所示，将铝线18的铝芯线19压接在电气端子17上时，形成有压接高度较低的第一压接部17a和压接高度较高的第二压接部17b，呈两段式压接。
如图3C及图3D所示，截面3C-3C中显示出了压接高度较低的第一压接部17a，其压接高度为ΔA；截面3D-3D中显示出了压接高度较高的第二压接部分17b，其压接高度为ΔB。为了使压接高度形成ΔA＜ΔB的关系，需要在加工过程中改变端子的端部30的压接高度。
在截面3C-3C处的第一压接部17a中，端子端部30被弯曲至内部铝芯线19发生压缩变形的程度。与此相对，在截面3D-3D处的第二压接部17b中，端子端部30被弯曲至内部铝芯线19不产生塑性变形的程度。
一般来说，铝线与铜线不同，表面硬度较为柔软，压接时受应力作用后铝材本身会发生延伸，造成塑性变形，因此压接固定时既要保持接触电阻的稳定又要确保抗拉强度非常困难。为了解决此问题，本实施例中将压接高度分开不同的种类，通过截面3C-3C处的第一压接部17a保持接触电阻稳定，同时通过截面3D-3D处的第二压接部17b来保证抗拉强度，按照在连接中发生的不同作用进行不同的压接。
电气端子17中与铝线18处于相反的一侧设有焊接部17c，焊接部17c用来通过点焊将铜制导线21焊接到电气端子17上。
由于在焊接部17c中都是铜质材料进行焊接，没有热膨胀系数差，所以焊接连接部20耐温度变化的性能很高。
图4是实施例中显示出的电抗器单元的电气特性图。这一电气特性图中的横轴表示压接部的压接高度，纵轴表示压接部的接触电阻值。如图4所示，在对例如φ2.0mm的铝线进行压接的情况下，在压接高度为1.8mm到2.3mm的范围内，接触电阻值稳定在大约0.2mΩ以下；当压接高度达到2.3mm以上时，接触电阻将慢慢地增大。
换句话说，当铝芯线被严重压缩、产生塑性变形时，虽然接触电阻稳定在较低值，但是抗拉强度也低。
另外，在压接高度为1.8mm到2.3mm的范围内，抗拉强度慢慢地变强；在压接高度为2.3mm到2.6mm的范围内，抗拉强度逐渐上升并稳定在300N/m2以上。
因此，为了稳定接触电阻，对于第一压接部17a采用1.9mm至2.1mm的压接高度进行压接，同时，为了确保抗拉强度，对于第二压接部17b采用2.4mm至2.6mm的压接高度进行压接固定。通过此方法，可以同时满足接触电阻和抗拉强度两方面的要求。
如上所述，在本实施例的电抗器单元14中，通过将绕组线圈10的铝线18压接在铜质材料制成的电气端子17上将不同的材质加以固定，并将铜线21通过点焊焊接在同样也是铜质的电气端子17上，实现了一种制造成本低且即使环境温度急剧变化也不会发生接触不良的、可靠性高的电抗器单元。
另外，通过在对第一压接部17a和第二压接部17b进行压接时将压接高度加以改变，可以使压接部25的抗拉强度和接触电阻同时保持稳定。因此，在长期使用的过程中也能保持良好的性能，进一步提高其可靠性。
再者，通过在铝质和铜质材料的接触面上用硅胶树脂进行防水处理，或套上经高温照射后会发生收缩的热收缩管进行防水处理，可以防止不同种金属之间产生电蚀，进一步提高其可靠性。

Claims (4)

1.一种电抗器单元，其特征在于包括：将铝线卷绕在铁制铁芯上形成的绕组线圈、和与所述绕组线圈的端部相连接的铜制电气端子，
其中，所述电气端子的一端具有与所述绕组线圈的铝线进行压紧连接的压接部，另一端具有呈略平面状的焊接部。
2.如权利要求1所述的电抗器单元，其特征在于：
所述电气端子中的压接部具有第一压接部和第二压接部，且所述第一压接部分和所述第二压接部分的压接高度不同。
3.如权利要求1或2中任一项所述的电抗器单元，其特征在于：
上述压接部通过硅胶树脂进行防水处理。
4.如权利要求1或2中任一项所述的电抗器单元，其特征在于：
上述压接部被热收缩管覆盖而进行防水处理。
CN2009201777708U 2008-09-19 2009-09-16 电抗器单元 Expired - Fee Related CN201508754U (zh)

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JP2008240483A JP4631951B2 (ja) 2008-09-19 2008-09-19 巻線コイルと銅線との洗濯機用電気接続手段

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TWI431647B (zh) 2014-03-21
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EP2166546A3 (en) 2011-01-26
CN101710534A (zh) 2010-05-19
RU2422934C2 (ru) 2011-06-27
TW201013714A (en) 2010-04-01
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JP4631951B2 (ja) 2011-02-16

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