EP2166546B1 - Reactor unit with an electric connector - Google Patents

Reactor unit with an electric connector Download PDF

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Publication number
EP2166546B1
EP2166546B1 EP09167731.0A EP09167731A EP2166546B1 EP 2166546 B1 EP2166546 B1 EP 2166546B1 EP 09167731 A EP09167731 A EP 09167731A EP 2166546 B1 EP2166546 B1 EP 2166546B1
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EP
European Patent Office
Prior art keywords
pressing
connecting part
aluminum
reactor unit
copper
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
Application number
EP09167731.0A
Other languages
German (de)
French (fr)
Other versions
EP2166546A3 (en
EP2166546A2 (en
Inventor
Shinsuke Yanagi
Shigeru Matsuo
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Panasonic Corp
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Panasonic Corp
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Filing date
Publication date
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Publication of EP2166546A2 publication Critical patent/EP2166546A2/en
Publication of EP2166546A3 publication Critical patent/EP2166546A3/en
Application granted granted Critical
Publication of EP2166546B1 publication Critical patent/EP2166546B1/en
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Classifications

    • 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

Definitions

  • the present invention relates to a reactor unit having electrical connecting means between winding coils and copper wires using aluminum wires such as a reactor used in electric and electronic appliances.
  • FIG. 5 is a front view of a conventional reactor having electrical connecting means between winding coils and copper wires.
  • iron core 2 made of iron is mounted on pedestal 1 made of iron.
  • Winding coil 4 wound with aluminum wires 3 having an enamel film baked on the surface is inserted in iron core 2. Then, the entire reactor is impregnated in varnish.
  • the material of winding coil 4 is composed of aluminum wires 3.
  • Aluminum wires 3 are less expensive than copper wires, and are used widely in reactors and other windings recently.
  • the enamel parts are removed from the beginning and end of winding of winding coil 4 of aluminum wires 3, and aluminum core 5 is soldered and connected to other electric terminal 6 made of copper by means of solder 7.
  • a power supply input into reactor 8 from outside is supplied by inserting a tab terminal or the like connected to a lead wire or the like into electric terminal 6.
  • Document EP 0 371 310 A2 discloses an electrically conductive connector for a flat conductor.
  • the conductor comprises a sleeve for a round conductor and a flat part to which the flat conductor is soldered.
  • the present invention is intended to solve the problems of the conventional means, and it is hence an object thereof to present a reactor unit having electrical connecting part between winding coils of aluminum wires and copper wires, and more specifically an inexpensive and highly reliable reactor unit capable of preventing faulty contact in spite of sudden changes in the environmental temperature of the connection part.
  • the reactor unit of the present invention includes a winding coil having aluminum wires wound around an iron core, and a copper-made electric terminal connected to end parts of the winding coil, in which the electric terminal has a pressing and connecting part for pressing and connecting aluminum wires of the winding coil at one end, and a welding part of a nearly flat shape at other end.
  • This configuration realizes an inexpensive and highly reliable reactor unit having electrical connecting means between winding coils and copper wires not causing faulty contact in spite of sudden changes in the environmental temperature.
  • FIG. 1 to FIG. 4 This preferred embodiment is explained in FIG. 1 to FIG. 4 , relating to a reactor unit having electrical connecting part between winding coils using aluminum wires and copper wires for power supply input for the purpose of suppression of harmonic currents from washing machine or the like of inverter control, or improvement of power factor. It must be noted, however, that the present invention is not limited to the illustrated preferred embodiment alone.
  • FIG. 1 is a sectional view of reactor unit in preferred embodiment 1 of the present invention.
  • thin electromagnetic steel plates blanked in a shape of letter E by a pressing die are laminated and welded to obtain E-core 9, to which winding coils 10 wound with aluminum wires having an enamel film baked on the surface are fitted from the upper part.
  • Thin electromagnetic steel plates blanked in a shape of letter I by a pressing die are laminated and welded to obtain I-core 11, which is mounted on E-core 9, and the contact side surface of outer circumference is welded and fixed by means of welding member 12.
  • E-core 9 is welded and fixed to iron-made pedestal 13 by means of welding member 12 so as to be tightened with screws to washing machine or other machine to be applied.
  • Insulation tape 15 for insulation is wound on the outer circumference of winding coils 10.
  • the entire reactor is impregnated in varnish after completion of all processes of welding and fixing.
  • the purpose of impregnation in varnish is rust prevention of iron cores of E-core 9 and I-core 11, suppression of magnetic distortion sound, and protection of coil insulation tape from moisture, among others.
  • FIG. 2 is a front view of the reactor unit. As shown in FIG. 2 , winding coils 10 wound with aluminum wires 18 are fitted to iron core 16 formed of E-core 9 and I-core 11. Enamel parts are removed from start and end of winding of winding coils 10 of aluminum wires 18, and aluminum core wires 19 of aluminum wires 18 are exposed by about 10 mm, and pressed, connected and fixed to pressing and connecting part 25 of copper-made electric terminal 17, thereby composing reactor unit 14.
  • the core wire of copper-made lead wire 21 with connector 22 for supplying power source to the reactor is welded and fixed to welding part 17c of a nearly flat shape of electric terminal 17 by spot welding.
  • junction part 20 between aluminum core wire 19 and copper-made electric terminal 17 produces a potential difference because dissimilar metals of aluminum and copper are connected. Therefore if water or moisture sticks, an electrolytic corrosion occurs, and the contact resistance may be increased. Therefore, by applying silicone resin 23 to cover at least the entire area of the connection part of dissimilar metals by using a brush or the like, an electric connection can be assured appropriately.
  • junction part 20 by coating the outer circumference of junction part 20 with heat shrink tube 24 which shrinks when exposed to high temperature, as insulation tape, the waterproof effect may be further heightened.
  • FIG. 3 shows the detail of the connection part.
  • FIG. 3A is a side magnified view of the connection part.
  • FIG. 3B is a front magnified view of the connection part.
  • FIG. 3C is a sectional view of part 3C-3C of FIG. 3A.
  • FIG. 3D is a sectional view of part 3D-3D of FIG. 3A .
  • section 3C-3C shows first pressing and connecting part 17a of low pressing height, and the pressing crimp height (pressing and connecting height) is ⁇ A
  • section 3D-3D shows second pressing and connecting part 17b of high pressing height
  • the pressing crimp height is ⁇ B. Therefore, terminal end part 30 is processed by changing the pressing height so that the crimp height relation may be ⁇ A ⁇ ⁇ B.
  • terminal end part 30 In first pressing and connecting part 17a of section 3C-3C, terminal end part 30 is bent and processed to such an extent that inside aluminum core wire 19 may be compressed and deformed.
  • second pressing and connecting part 17b of section 3D-3D terminal end part 30 is bent and processed to such an extent that inside aluminum core wire 19 may not be deformed plastically.
  • an aluminum wire is soft in surface hardness, and the aluminum itself is elongated by stress of pressing and connecting, and is deformed plastically. It is hence difficult to satisfy both the stability of contact resistance required in pressing and fixing and the assurance of tensile strength.
  • the pressing and connecting height is divided, and the contact resistance is stabilized in first pressing and connecting part 17a of section 3C-3C, and the tensile strength is assured in second pressing and connecting part 17b of section 3D-3D, and the required roles for connection are divided, and successive pressing and connecting may be achieved.
  • the opposite side of aluminum wire 18 of electric terminal 17 is welding part 17c for joining copper-made lead wire 21 and electric terminal 17 by spot welding.
  • This welding part 17c is welding between copper materials, and is free from difference in coefficient of thermal expansion, junction part 20 has a strong resistance to temperature changes.
  • FIG. 4 shows an electric characteristic graph of the reactor unit of the preferred embodiment.
  • the axis of abscissas denotes the pressing crimp height (pressing and connecting height) of the pressing and connecting part
  • the axis of ordinates represents the electric contact resistance value of the pressing and connecting part.
  • the contact resistance value is stable, about 0.2 m ⁇ or less, but the contact resistance increases gradually when the crimp height value is about 2.3 mm or more.
  • the aluminum core wire is low in contact resistance and is stable when compressed strongly and deformed plastically, but the tensile strength against pulling is lowered.
  • the tensile strength in the range of crimp height value of about 1.8 mm to about 2.3 mm, the tensile strength increases gradually, and in the range of crimp height value of about 2.3 mm to about 2.6 mm, the tensile strength is stable, about 300 N/m 2 or more.
  • first pressing and connecting part 17a is pressed and connected at a crimp height value of 1.9 mm to 2.1 mm, and in order to assure the tensile strength, second pressing and connecting part 17b is pressed and fixed at a crimp height value of 2.4 mm to 2.6 mm, so that both contact resistance and tensile strength can be satisfied.
  • reactor unit 14 is composed, and similar materials of copper wire 21 and copper-made electric terminal 17 are connected by spot welding, thereby realizing an inexpensive and highly reliable reactor unit having electrical connecting means between aluminum winding coils and copper wires capable of preventing faulty contact in spite of sudden changes in the environmental temperature.
  • both the tensile strength and the contact resistance of pressing and connecting part 25 can be stabilized at the same time. Therefore, a sufficient performance is assured in spite of aging effects, and the reliability may be further enhanced.
  • waterproof treatment with silicone resin on the contact surface of aluminum material and copper material, or by applying waterproof treatment by coating with a heat-shrink tube which shrinks when exposed to high temperature, electrolytic corrosion occurring between dissimilar metals can be prevented, and the reliability may be enhanced moreover.

Description

    TECHNICAL FIELD
  • The present invention relates to a reactor unit having electrical connecting means between winding coils and copper wires using aluminum wires such as a reactor used in electric and electronic appliances.
    • BACKGROUND ART
  • FIG. 5 is a front view of a conventional reactor having electrical connecting means between winding coils and copper wires.
  • As shown in FIG. 5, iron core 2 made of iron is mounted on pedestal 1 made of iron. Winding coil 4 wound with aluminum wires 3 having an enamel film baked on the surface is inserted in iron core 2. Then, the entire reactor is impregnated in varnish. The material of winding coil 4 is composed of aluminum wires 3. Aluminum wires 3 are less expensive than copper wires, and are used widely in reactors and other windings recently.
  • The enamel parts are removed from the beginning and end of winding of winding coil 4 of aluminum wires 3, and aluminum core 5 is soldered and connected to other electric terminal 6 made of copper by means of solder 7.
  • In this configuration, a power supply input into reactor 8 from outside is supplied by inserting a tab terminal or the like connected to a lead wire or the like into electric terminal 6.
  • However, in the conventional configuration of electrical connecting means between winding coils of aluminum material and copper wires, aluminum wires cannot be fixed to the copper-made electric terminal by ordinary solder. Therefore, a special solder for aluminum wires is needed. Hence, the cost is higher as compared with the ordinary solder, and the manufacturing process is difficult.
  • Still worse, heat generation from the winding coil is transmitted to the terminal, and if a thermal stress is applied to the electric terminal, the soldered part may be cracked and defective in connection due to difference in coefficient of thermal expansion of aluminum and copper. Therefore, the reliability is inferior.
    • Prior art document Patent document
    • Patent document 1: Unexamined Japanese Patent Application Publication No. H7-22258
  • Document US 2007/0285852 A1 discloses an iron core transformer with at least one primary binding made of aluminum wire. A terminal with slot is provided to be connected to the aluminum conductor.
  • Document EP 0 371 310 A2 discloses an electrically conductive connector for a flat conductor. The conductor comprises a sleeve for a round conductor and a flat part to which the flat conductor is soldered.
    • SUMMARY OF THE INVENTION
  • The present invention is intended to solve the problems of the conventional means, and it is hence an object thereof to present a reactor unit having electrical connecting part between winding coils of aluminum wires and copper wires, and more specifically an inexpensive and highly reliable reactor unit capable of preventing faulty contact in spite of sudden changes in the environmental temperature of the connection part.
  • To solve the problems of the conventional means, the reactor unit of the present invention includes a winding coil having aluminum wires wound around an iron core, and a copper-made electric terminal connected to end parts of the winding coil, in which the electric terminal has a pressing and connecting part for pressing and connecting aluminum wires of the winding coil at one end, and a welding part of a nearly flat shape at other end.
  • This configuration realizes an inexpensive and highly reliable reactor unit having electrical connecting means between winding coils and copper wires not causing faulty contact in spite of sudden changes in the environmental temperature.
    • BRIEF DESCRIPTION OF DRAWINGS
    • FIG. 1 is a sectional view of a reactor unit in a preferred embodiment of the present invention.
    • FIG. 2 is a front view of the reactor unit.
    • FIG. 3A is side magnified view of connection part of the reactor unit.
    • FIG. 3B is a front magnified view.
    • FIG. 3C is a magnified sectional view of part 3C-3C.
    • FIG. 3D is a magnified sectional view of part 3D-3D.
    • FIG. 4 is an electrical characteristic graph of the reactor unit.
    • FIG. 5 is a front view of a conventional reactor having electrical connecting means between winding coils and copper wires.
    PREFERRED EMBODIMENTS FOR CARRYING OUT THE INVENTION Preferred Embodiment 1
  • This preferred embodiment is explained in FIG. 1 to FIG. 4, relating to a reactor unit having electrical connecting part between winding coils using aluminum wires and copper wires for power supply input for the purpose of suppression of harmonic currents from washing machine or the like of inverter control, or improvement of power factor. It must be noted, however, that the present invention is not limited to the illustrated preferred embodiment alone.
  • FIG. 1 is a sectional view of reactor unit in preferred embodiment 1 of the present invention. As shown in FIG. 1, thin electromagnetic steel plates blanked in a shape of letter E by a pressing die are laminated and welded to obtain E-core 9, to which winding coils 10 wound with aluminum wires having an enamel film baked on the surface are fitted from the upper part. Thin electromagnetic steel plates blanked in a shape of letter I by a pressing die are laminated and welded to obtain I-core 11, which is mounted on E-core 9, and the contact side surface of outer circumference is welded and fixed by means of welding member 12.
  • E-core 9 is welded and fixed to iron-made pedestal 13 by means of welding member 12 so as to be tightened with screws to washing machine or other machine to be applied.
  • Insulation tape 15 for insulation is wound on the outer circumference of winding coils 10.
  • The entire reactor is impregnated in varnish after completion of all processes of welding and fixing. The purpose of impregnation in varnish is rust prevention of iron cores of E-core 9 and I-core 11, suppression of magnetic distortion sound, and protection of coil insulation tape from moisture, among others.
  • FIG. 2 is a front view of the reactor unit. As shown in FIG. 2, winding coils 10 wound with aluminum wires 18 are fitted to iron core 16 formed of E-core 9 and I-core 11. Enamel parts are removed from start and end of winding of winding coils 10 of aluminum wires 18, and aluminum core wires 19 of aluminum wires 18 are exposed by about 10 mm, and pressed, connected and fixed to pressing and connecting part 25 of copper-made electric terminal 17, thereby composing reactor unit 14.
  • At other opposite side of electric terminal 17, the core wire of copper-made lead wire 21 with connector 22 for supplying power source to the reactor is welded and fixed to welding part 17c of a nearly flat shape of electric terminal 17 by spot welding.
  • Junction part 20 between aluminum core wire 19 and copper-made electric terminal 17 produces a potential difference because dissimilar metals of aluminum and copper are connected. Therefore if water or moisture sticks, an electrolytic corrosion occurs, and the contact resistance may be increased. Therefore, by applying silicone resin 23 to cover at least the entire area of the connection part of dissimilar metals by using a brush or the like, an electric connection can be assured appropriately.
  • Further, by coating the outer circumference of junction part 20 with heat shrink tube 24 which shrinks when exposed to high temperature, as insulation tape, the waterproof effect may be further heightened.
  • FIG. 3 shows the detail of the connection part. FIG. 3A is a side magnified view of the connection part. FIG. 3B is a front magnified view of the connection part. FIG. 3C is a sectional view of part 3C-3C of FIG. 3A. FIG. 3D is a sectional view of part 3D-3D of FIG. 3A.
  • As shown in FIG. 3A and 3B, when pressing and connecting aluminum core wire 19 of aluminum wire 18 to electric terminal 17, first pressing and connecting part 17a of low pressing height, and second pressing and connecting part 17b of high pressing height are pressed and connected in two stages.
  • As shown in FIG. 3C and 3D, section 3C-3C shows first pressing and connecting part 17a of low pressing height, and the pressing crimp height (pressing and connecting height) is ΔA, and section 3D-3D shows second pressing and connecting part 17b of high pressing height, and the pressing crimp height is ΔB. Therefore, terminal end part 30 is processed by changing the pressing height so that the crimp height relation may be ΔA < Δ B.
  • In first pressing and connecting part 17a of section 3C-3C, terminal end part 30 is bent and processed to such an extent that inside aluminum core wire 19 may be compressed and deformed. By contrast, in second pressing and connecting part 17b of section 3D-3D, terminal end part 30 is bent and processed to such an extent that inside aluminum core wire 19 may not be deformed plastically.
  • Generally, unlike a copper wire, an aluminum wire is soft in surface hardness, and the aluminum itself is elongated by stress of pressing and connecting, and is deformed plastically. It is hence difficult to satisfy both the stability of contact resistance required in pressing and fixing and the assurance of tensile strength. To solve such problem, in the preferred embodiment, the pressing and connecting height is divided, and the contact resistance is stabilized in first pressing and connecting part 17a of section 3C-3C, and the tensile strength is assured in second pressing and connecting part 17b of section 3D-3D, and the required roles for connection are divided, and successive pressing and connecting may be achieved.
  • The opposite side of aluminum wire 18 of electric terminal 17 is welding part 17c for joining copper-made lead wire 21 and electric terminal 17 by spot welding.
  • This welding part 17c is welding between copper materials, and is free from difference in coefficient of thermal expansion, junction part 20 has a strong resistance to temperature changes.
  • FIG. 4 shows an electric characteristic graph of the reactor unit of the preferred embodiment. In the electric characteristic graph, the axis of abscissas denotes the pressing crimp height (pressing and connecting height) of the pressing and connecting part, and the axis of ordinates represents the electric contact resistance value of the pressing and connecting part. As shown in FIG. 4, when pressing and connecting an aluminum wire of, for example, 2.0 mm in diameter, in the range of crimp height value of about 1.8 mm to about 2.3 mm, the contact resistance value is stable, about 0.2 mΩ or less, but the contact resistance increases gradually when the crimp height value is about 2.3 mm or more.
  • In other words, the aluminum core wire is low in contact resistance and is stable when compressed strongly and deformed plastically, but the tensile strength against pulling is lowered.
  • Similarly, as for the tensile strength, in the range of crimp height value of about 1.8 mm to about 2.3 mm, the tensile strength increases gradually, and in the range of crimp height value of about 2.3 mm to about 2.6 mm, the tensile strength is stable, about 300 N/m2 or more.
  • Accordingly, in order to stabilize the contact resistance, first pressing and connecting part 17a is pressed and connected at a crimp height value of 1.9 mm to 2.1 mm, and in order to assure the tensile strength, second pressing and connecting part 17b is pressed and fixed at a crimp height value of 2.4 mm to 2.6 mm, so that both contact resistance and tensile strength can be satisfied.
  • Thus, in the preferred embodiment, dissimilar materials are fixed by pressing and connecting aluminum wire 18 of winding coil 10 to copper-made electric terminal 17, reactor unit 14 is composed, and similar materials of copper wire 21 and copper-made electric terminal 17 are connected by spot welding, thereby realizing an inexpensive and highly reliable reactor unit having electrical connecting means between aluminum winding coils and copper wires capable of preventing faulty contact in spite of sudden changes in the environmental temperature.
  • Further, by varying the crimp height when pressing and connecting first pressing and connecting part 17a and second pressing and connecting part 17b, both the tensile strength and the contact resistance of pressing and connecting part 25 can be stabilized at the same time. Therefore, a sufficient performance is assured in spite of aging effects, and the reliability may be further enhanced.
  • Moreover, by applying waterproof treatment with silicone resin on the contact surface of aluminum material and copper material, or by applying waterproof treatment by coating with a heat-shrink tube which shrinks when exposed to high temperature, electrolytic corrosion occurring between dissimilar metals can be prevented, and the reliability may be enhanced moreover.

Claims (3)

  1. A reactor unit comprising a winding coil (10) having aluminum wires (18) wound around an iron core (16), and a copper-made electric terminal (17) connected to end parts of the winding coil (10), wherein the electric terminal (17) has a pressing and connecting part (25) for pressing and connecting aluminum wires of the winding coil at one end, characterized by a welding part (17c) of a nearly flat shape at other end,wherein the electric terminal (17) has the pressing and connecting part (25) divided into a first pressing and connecting part (17a) and a second pressing and connecting part (17b) both pressing an aluminum core wire (19) of the aluminum wires (18), and the pressing and connecting height differs between the first pressing and connecting part (17a) and the second pressing and connecting part (17b).
  2. The reactor unit of claim 1, wherein the pressing and connecting part (25) is coated with a silicone resin for waterproof treatment.
  3. The reactor unit of claim 1, wherein the pressing and connecting part (25) is covered with a heat-shrink tube for waterproof treatment.
EP09167731.0A 2008-09-19 2009-08-12 Reactor unit with an electric connector Not-in-force EP2166546B1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP2008240483A JP4631951B2 (en) 2008-09-19 2008-09-19 Electrical connection means for washing machine between wound coil and copper wire

Publications (3)

Publication Number Publication Date
EP2166546A2 EP2166546A2 (en) 2010-03-24
EP2166546A3 EP2166546A3 (en) 2011-01-26
EP2166546B1 true EP2166546B1 (en) 2014-01-01

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP09167731.0A Not-in-force EP2166546B1 (en) 2008-09-19 2009-08-12 Reactor unit with an electric connector

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EP (1) EP2166546B1 (en)
JP (1) JP4631951B2 (en)
CN (2) CN101710534B (en)
RU (1) RU2422934C2 (en)
TW (1) TWI431647B (en)

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Also Published As

Publication number Publication date
JP2010073930A (en) 2010-04-02
EP2166546A3 (en) 2011-01-26
CN101710534A (en) 2010-05-19
CN201508754U (en) 2010-06-16
EP2166546A2 (en) 2010-03-24
TWI431647B (en) 2014-03-21
TW201013714A (en) 2010-04-01
JP4631951B2 (en) 2011-02-16
CN101710534B (en) 2012-05-30
RU2009134970A (en) 2011-03-27
RU2422934C2 (en) 2011-06-27

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