JP2004063260A

JP2004063260A - Connection structure and connection method of of conductor

Info

Publication number: JP2004063260A
Application number: JP2002219860A
Authority: JP
Inventors: Katsuaki Terada; 寺田　克明; Mitsuji Kubota; 久保田　満治
Original assignee: Yazaki Corp
Current assignee: Yazaki Corp
Priority date: 2002-07-29
Filing date: 2002-07-29
Publication date: 2004-02-26

Abstract

<P>PROBLEM TO BE SOLVED: To provide an inexpensive connection structure and a connection method of a conductor capable of providing sufficient junction strength of a connection part while eliminating a process for preliminary formation for bringing a conductor part into contact. <P>SOLUTION: This connection structure of a conductor is used for electrically connecting a plurality of conductors by using a conductive injection material. The plurality of conductors each comprise a bus bar 11 and a soft copper wire 12. The bus bar 11 is intercrossed with the copper wire 12 in a non-contact form. The bus bar 11 is electrically connected to the copper wire 12 by the conductive injection material 15 injected into the part where they are intercrossed with each other. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は、複数の導電体を電気的に接続する導電体の接続構造、および導電体の接続方法に関する。
【０００２】
【従来の技術】
この種の導電体の接続には、従来から図７に示されるような抵抗溶接を利用した接続構造が用いられている。この抵抗溶接を利用した接続構造は、ブスバー２と軟銅線３を電気的に接続する際に、ブスバー２の接続部分に軟銅線３の芯線３ａを配索し（図８（ａ））、接続部分であるブスバー２と芯線３の間に隙間ができないように予備成形を行い（図８（ｂ））、接続部分に機械的圧力を加えつつ、電流を流し、電流が流れる際に発生する熱を利用して、ブスバー２と芯線３ａを溶接することで、ブスバー２と軟銅線３ａが電気的に接続されるものである。
【０００３】
【発明が解決しようとする課題】
しかしながら、前記従来の抵抗溶接による導電体の接続構造では、上述のように予備成形の作業工程が必要であるため、作業工数が増大すると共に、必要な寸法精度がでないという問題があった。また、ブスバー２と芯線３ａとの間に隙間がある状態で抵抗溶接を行うと、溶接部分が爆飛してブスバー２が欠損してしまうため、溶接後の入念な製品検査が必要であった。さらに、爆飛により欠損した製品は廃棄しなければならず、製品の歩留りを悪化させ、製品コストを引上げていた。
【０００４】
そこで、本発明は、導体部分を接触させるための予備成形の工程を削減しつつ、接続部分の十分な接合強度を備えると共に、安価な導電体の接続構造、および接続方法の提供を目的とする。
【０００５】
【課題を解決するための手段】
上記目的を達成するため、請求項１の発明は、複数の導電体が導電射出材を用いて電気的に接続される導電体の接続構造であって、前記複数の導電体がブスバーと軟銅線から成り、これらブスバーと軟銅線の芯線が非接触状態で交差された部分に前記導電射出材が注入されて前記交差した部分が電気的に接続されたことを特徴とする。
【０００６】
この導電体の接続構造では、ブスバーと軟銅線を非接触状態に配索したままで導電射出材によって電気的に接続するので予備成形の工程を削減できると共に、要求された寸法精度を提供することができる。また、ブスバーと軟銅線を交差させることで接続部分が明確になり、ブスバーと軟導線を接続する際に導電射出材の無駄を無くし、コストの削減ができる。
【０００７】
請求項２の発明は、請求項１記載の導電体の接続構造において、前記ブスバーと軟銅線の芯線が非接触状態で交差された状態で金型の内部に配索され、この金型の内部に前記導電射出材が注入されて前記交差された部分が電気的に接続されたことを特徴とする。
【０００８】
この導電体の接続構造では、請求項１記載の発明の効果に加えて、複数の導電体の接続部分を接続部分の周辺部を含めて導電射出材で固定できるため、接続部分の機械的強度を向上させることができる。
【０００９】
請求項３の発明は、複数の導電体を導電射出材を用いて電気的に接続する導電体の接続方法であって、前記複数の導電体としてのブスバーと軟銅線の芯線を非接触状態で交差させ、次に、この交差した部分を除いた前記ブスバーと軟銅線の所定の部位を絶縁体で一体に成形し、次に、前記交差した部分とその周辺に導電射出材を注入して前記交差した部分を電気的に接続することを特徴とする。
【００１０】
この導電体の接続方法では、ブスバーと軟銅線を非接触状態に配索したままで導電射出材によって電気的に接続するので予備成形の工程を削減できると共に、要求された寸法精度を提供することができる。また、ブスバーと軟銅線を交差させることで接続部分が明確になり、ブスバーと軟導線を接続する際に導電射出材の無駄を無くし、コストの削減ができる。
【００１１】
請求項４の発明は、複数の導電体を導電射出材を用いて電気的に接続する導電体の接続方法であって、前記複数の導電体としてのブスバーと軟銅線の芯線を非接触状態で交差させ、次に、この交差した部分に導電射出材を注入し、次に、前記ブスバーと軟導線の所定の部位を絶縁体で一体に成形して前記交差した部分を電気的に接続することを特徴とする。
【００１２】
この導電体の接続方法では、ブスバーと軟銅線を非接触状態に配索したままで導電射出材によって電気的に接続するので予備成形の工程を削減できると共に、要求された寸法精度を提供することができる。また、ブスバーと軟銅線を交差させることで接続部分が明確になり、ブスバーと軟導線を接続する際に導電射出材の無駄を無くし、コストの削減ができる。
【００１３】
請求項５の発明は、複数の導電体を導電射出材を用いて電気的に接続する導電体の接続構造であって、前記複数の導電体が複数の軟銅線から成り、これら軟銅線の芯線が非接触状態で交差され、前記軟銅線の交差した部分に注入された前記導電射出材によって電気的に接続されたことを特徴とする。
【００１４】
この導電体の接続構造では、軟銅線を非接触状態に配索したままで導電射出材によって電気的に接続するので予備成形の工程を削減できると共に、要求された寸法精度を提供することができる。また、軟銅線を交差させることで接続部分が明確になり、軟導線を接続する際に導電射出材の無駄を無くし、コストの削減ができる。
【００１５】
請求項６の発明は、請求項５記載の導電体の接続構造において、前記複数の軟銅線の芯線が非接触状態で交差された状態で金型の内部に配索され、この金型の内部に前記導電射出材が注入されて前記交差された部分が電気的に接続されたことを特徴とする。
【００１６】
この導電体の接続構造では、請求項５記載の発明の効果に加えて、複数の導電体の接続部分を接続部分の周辺部を含めて導電射出材で固定できるため、接続部分の機械的強度を向上させることができる。
【００１７】
請求項７の発明は、複数の導電体を導電射出材を用いて電気的に接続する導電体の接続方法であって、前記複数の導電体としての複数の軟銅線の芯線を非接触状態で交差させ、次に、この交差した部分を除いた前記複数の軟銅線の所定の部位を絶縁体で一体に成形し、次に、前記交差した部分とその周辺に導電射出材を注入して前記交差した部分を電気的に接続することを特徴とする。
【００１８】
この導電体の接続方法では、ブスバーと軟銅線を非接触状態に配索したままで導電射出材によって電気的に接続するので予備成形の工程を削減できると共に、要求された寸法精度を提供することができる。また、ブスバーと軟銅線を交差させることで接続部分が明確になり、ブスバーと軟導線を接続する際に導電射出材の無駄を無くし、コストの削減ができる。
【００１９】
請求項８の発明は、複数の導電体を導電射出材を用いて電気的に接続する導電体の接続方法であって、前記複数の導電体としての前記複数の軟銅線の芯線を非接触状態で交差させ、次に、この交差した部分に導電射出材を注入し、次に、前記複数の軟導線の所定の部位を絶縁体で一体に成形して前記交差した部分を電気的に接続することを特徴とする。
【００２０】
この導電体の接続方法では、ブスバーと軟銅線を非接触状態に配索したままで導電射出材によって電気的に接続するので予備成形の工程を削減できると共に、要求された寸法精度を提供することができる。また、ブスバーと軟銅線を交差させることで接続部分が明確になり、ブスバーと軟導線を接続する際に導電射出材の無駄を無くし、コストの削減ができる。
【００２１】
【発明の実施の形態】
以下、本発明に係る導電体の接続構造の実施形態について説明する。
【００２２】
図１（ａ）、（ｂ）に示す、本発明に係る第１実施形態は、絶縁体の内部に配索されたブスバーと軟銅線を接続する導電体の接続構造である。
【００２３】
まず、図１（ａ）に示すように、金型（不図示）の内部にブスバー１１と軟銅線１２を非接触状態で交差させて配索し、金型内部に絶縁体１３を射出し、一次成形を行う。このとき、ブスバー１１と軟銅線１２とが交差している接続部分が絶縁体１３で埋らないように絶縁体１３を射出する。また、ブスバー１１と軟銅線１２は非接触状態で配設されているので、ブスバー１１と軟銅線１２は導通していない。
【００２４】
次に、図１（ｂ）に示すように、ブスバー１１と軟銅線１２の接続部分に導電射出材１５を注入し、二次成形を行う。これによって、ブスバー１１と軟銅線１２は電気的に接続される。
【００２５】
本実施形態の導電体の接続構造では、ブスバー１１と軟銅線１２を非接触状態に配索したままで導電射出材１５によって電気的に接続するので予備成形の工程を削減できると共に、要求された寸法精度を提供することができる。
【００２６】
また、導電射出材１５は通電中に熱がほとんど発生しないため、接続部分に問題となるような熱応力が発生せず、長期間にわたって十分な接合強度を備えると共に、検査工程を簡略化することで製品コストの削減ができる。
【００２７】
さらに、ブスバー１１と軟銅線１２を交差させることで接続部分が明確になり、ブスバー１１と軟導線１２を接続する際に導電射出材１５の無駄を無くし、コストの削減ができる。
【００２８】
さらにまた、ブスバー１１と軟銅線１２の接続部分を空間１４を含めて導電射出材１５で固定するため、接続部分の機械的強度を向上させることができる。
【００２９】
図２〜図５に示す、本発明に係る第２実施形態は、複数のブスバーと軟銅線を接続し、より複雑な回路体としてのインサート成形品を製造する場合の導電体の接続構造である。
【００３０】
まず、図２に示すように、ブスバー２１、２１、２１を下型（不図示）に配設し、軟銅線２２、２２、２２をブスバー２１、２１、２１のそれぞれと非接触状態で交差するよう配索する。
【００３１】
なお、本実施形態では、ブスバー２１、２１、２１を同一平面上に配設すると共に、軟銅線２２、２２、２２を同一平面上に配索しつつ、ブスバー２１、２１、２１を配設した平面と平行な平面に配索している。
【００３２】
また、軟銅線２２を配索する際に、軟銅線２２の一端側２２ａの先端部２２ｂをチャック（不図示）を用いて所定の位置に固定している。
【００３３】
次に、図３（ａ）に示すように、所望のブスバー２１と軟銅線２２の隙間に導電射出材２３を注入し、ブスバー２１と軟銅線２２を電気的に接続する。なお、図３（ｂ）は、図３（ａ）のＡ−Ａ線に沿った断面図で、ブスバー２１と軟銅線２２が導電射出材２３で電気的に接続されている様子を示している。
【００３４】
次に、上型（不図示）を下型に合わせ、上型と下型が形成する内部空間に絶縁体を注入し回路体のインサート成形体２０ａを成形したものが、図４に示される。　なお、本実施形態では、軟銅線２２、２２、２２の他端側の先端部も図２〜図４と同様の工程で回路体のインサート成形体２０ｂを成形する。
【００３５】
次に、図４のＢの方向にインサート成形体２０ｂを回転させて、インサート成形体２０ａとインサート成形体２０ｂを重ね合せたものが、図５に示されるインサート成形品２０である。
【００３６】
本実施形態の導電体の接続構造では、ブスバー２１と軟銅線２２を非接触状態に配索したままで導電射出材２３によって電気的に接続するので予備成形の工程を削減できると共に、要求された寸法精度を提供することができる。
【００３７】
また、導電射出材２３は通電中に熱がほとんど発生しないため、接続部分に問題となるような熱応力が発生せず、長期間にわたって十分な接合強度を備えると共に、検査工程を簡略化することで製品コストの削減ができる。
【００３８】
さらに、ブスバー２１と軟銅２２線を交差させることで接続部分が明確になり、ブスバー２１と軟導線２２を接続する際に導電射出材２３の無駄を無くし、コストの削減ができる。
【００３９】
さらにまた、ブスバー２１と軟銅線２２の接続部分を接続部分の周辺部を含めて導電射出材２３で固定するため、接続部分の機械的強度を向上させることができる。
【００４０】
そのうえ、絶縁体でインサート成形されているため、回路体の機械的強度が向上すると共に、通電中に回路体に手を触れても感電することがない。
【００４１】
図６（ａ）、（ｂ）に示す、本発明に係る第３実施形態は、非接触状態に配索された絶縁被覆を備えた２本の軟銅線の芯線を接続する導電体の接続構造である。
【００４２】
まず、図６（ａ）に示すように、軟銅線３１、３１′の接続したい部分の絶縁被覆を取除いて、芯線３１ａ、３１ａ′を露出させて、非接触状態で交差させて配索する。このとき、軟銅線３１、３１′は非接触状態に配索されているので、芯線３１ａ、３１ａ′は導通していない。
【００４３】
次に、導電射出材３２を芯線３１ａ、３１ａ′の隙間に注入する。これによって、芯線３１ａ、３１ａ′は電気的に接続される。
【００４４】
本実施形態の導電体の接続構造では、軟銅線３１、３１′を非接触状態に配索したままで導電射出材３２によって電気的に接続するので予備成形の工程を削減できると共に、要求された寸法精度を提供することができる。
【００４５】
また、導電射出材３２は通電中に熱がほとんど発生しないため、接続部分に問題となるような熱応力が発生せず、長期間にわたって十分な接合強度を備えると共に、検査工程を簡略化することで製品コストの削減ができる。
【００４６】
さらに、軟銅線３１、３１′を交差させることで接続部分が明確になり、軟導線３１、３１′を接続する際に導電射出材の無駄を無くし、コストの削減ができる。
【００４７】
さらにまた、軟銅線３１、３１′の接続部分を接続部分の周辺部を含めて導電射出材３２で固定できるため、接続部分の機械的強度を向上させることができる。
【００４８】
【発明の効果】
以上説明したように請求項１の発明によれば、ブスバーと軟銅線を非接触状態に配索したままで導電射出材によって電気的に接続するので予備成形の工程を削減できると共に、要求された寸法精度を提供することができる。また、ブスバーと軟銅線を交差させることで接続部分が明確になり、ブスバーと軟導線を接続する際に導電射出材の無駄を無くし、コストの削減ができる。
【００４９】
請求項２の発明によれば、請求項１記載の発明の効果に加えて、複数の導電体の接続部分を接続部分の周辺部を含めて導電射出材で固定できるため、接続部分の機械的強度を向上させることができる。
【００５０】
請求項３の発明によれば、ブスバーと軟銅線を非接触状態に配索したままで導電射出材によって電気的に接続するので予備成形の工程を削減できると共に、要求された寸法精度を提供することができる。また、ブスバーと軟銅線を交差させることで接続部分が明確になり、ブスバーと軟導線を接続する際に導電射出材の無駄を無くし、コストの削減ができる。
【００５１】
請求項４の発明によれば、ブスバーと軟銅線を非接触状態に配索したままで導電射出材によって電気的に接続するので予備成形の工程を削減できると共に、要求された寸法精度を提供することができる。また、ブスバーと軟銅線を交差させることで接続部分が明確になり、ブスバーと軟導線を接続する際に導電射出材の無駄を無くし、コストの削減ができる。
【００５２】
請求項５の発明によれば、軟銅線を非接触状態に配索したままで導電射出材によって電気的に接続するので予備成形の工程を削減できると共に、要求された寸法精度を提供することができる。また、軟銅線を交差させることで接続部分が明確になり、軟導線を接続する際に導電射出材の無駄を無くし、コストの削減ができる。
【００５３】
請求項６の発明によれば、請求項５記載の発明の効果に加えて、複数の導電体の接続部分を接続部分の周辺部を含めて導電射出材で固定できるため、接続部分の機械的強度を向上させることができる。
【００５４】
請求項７の発明によれば、ブスバーと軟銅線を非接触状態に配索したままで導電射出材によって電気的に接続するので予備成形の工程を削減できると共に、要求された寸法精度を提供することができる。また、ブスバーと軟銅線を交差させることで接続部分が明確になり、ブスバーと軟導線を接続する際に導電射出材の無駄を無くし、コストの削減ができる。
【００５５】
請求項８の発明によれば、ブスバーと軟銅線を非接触状態に配索したままで導電射出材によって電気的に接続するので予備成形の工程を削減できると共に、要求された寸法精度を提供することができる。また、ブスバーと軟銅線を交差させることで接続部分が明確になり、ブスバーと軟導線を接続する際に導電射出材の無駄を無くし、コストの削減ができる。
【図面の簡単な説明】
【図１】本発明の第１実施形態に係る導電体の接続構造を示し、（ａ）はブスバーと軟銅線とを配索した状態を示す斜視図、（ｂ）は（ａ）のブスバーと軟銅線との間の隙間に導電射出材を注入した状態を示す斜視図である。
【図２】本発明の第２実施形態に係る導電体の接続構造について、複数のブスバーに複数の軟銅線を配索する状態を示す斜視図である。
【図３】本発明の第２実施形態に係る導電体の接続構造について、（ａ）は図３のブスバーと軟銅線を導電射出材で結合した状態を示す斜視図で、（ｂ）は（ａ）のＡ−Ａ線に沿って切断した断面図である。
【図４】本発明の第２実施形態に係る導電体の接続構造について、図４（ａ）のブスバーと軟銅線を絶縁体でインサート成形した状態を示す斜視図である。
【図５】本発明の第２実施形態に係る導電体の接続構造について、インサート成形品として完成した状態を示す斜視図である。
【図６】本発明の第３実施形態に係る導電体の接続構造を示し、（ａ）は２本の軟銅線を配索し、芯線を導電射出材によって結合した状態を示す斜視図、（ｂ）は（ａ）のＣ−Ｃ線に沿って切断した断面図である。
【図７】従来技術の抵抗溶接を用いた接続構造を示す斜視図である。
【図８】従来技術の抵抗溶接を用いた接続構造を示し、（ａ）は図７ののＤ−Ｄ線に沿って切断した軟銅線を所定の位置に配索した状態を示す断面図で、（ｂ）はＤ−Ｄ線に沿って切断した抵抗溶接前の予備成形を行った状態を示す断面図である。
【符号の説明】
１０　導電体の接合構造
１１　ブスバー
１２　軟銅線
１２ａ　芯線
１３　絶縁体
１４　空間
１５　導電射出材[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a conductor connection structure for electrically connecting a plurality of conductors, and a conductor connection method.
[0002]
[Prior art]
Conventionally, a connection structure using resistance welding as shown in FIG. 7 has been used for connecting this kind of conductor. In the connection structure using this resistance welding, when the bus bar 2 and the soft copper wire 3 are electrically connected, the core wire 3a of the soft copper wire 3 is routed to the connection portion of the bus bar 2 (FIG. 8A), and the connection is performed. The preforming is performed so that there is no gap between the bus bar 2 and the core wire 3 (FIG. 8B), and a current is applied while applying a mechanical pressure to the connection portion, and heat generated when the current flows is applied. The bus bar 2 and the soft copper wire 3a are electrically connected by welding the bus bar 2 and the core wire 3a.
[0003]
[Problems to be solved by the invention]
However, in the conventional connection structure of the conductor by resistance welding, since the preforming operation step is required as described above, there are problems that the number of operation steps is increased and the required dimensional accuracy is not sufficient. Further, if resistance welding is performed in a state where there is a gap between the bus bar 2 and the core wire 3a, the welded portion explodes and the bus bar 2 is broken, so that careful product inspection after welding is required. . In addition, products that have been lost due to the explosion must be discarded, deteriorating product yields and increasing product costs.
[0004]
Accordingly, an object of the present invention is to provide an inexpensive connection structure of a conductor and a connection method while providing a sufficient joining strength of a connection portion while reducing a step of preforming for bringing a conductor portion into contact. .
[0005]
[Means for Solving the Problems]
In order to achieve the above object, an invention according to claim 1 is a connection structure of a conductor in which a plurality of conductors are electrically connected by using a conductive injection material, wherein the plurality of conductors are a bus bar and a soft copper wire. The conductive injection material is injected into a portion where the bus bar and the core wire of the soft copper wire cross in a non-contact state, and the crossed portion is electrically connected.
[0006]
In this conductor connection structure, the bus bar and the soft copper wire are electrically connected by the conductive injection material while being routed in a non-contact state, so that the preforming step can be reduced and the required dimensional accuracy is provided. Can be. Also, by connecting the bus bar and the soft copper wire, the connection portion becomes clear, and when connecting the bus bar and the soft conductive wire, waste of the conductive injection material can be eliminated, and the cost can be reduced.
[0007]
According to a second aspect of the present invention, in the conductor connecting structure according to the first aspect, the bus bar and the core wire of the annealed copper wire are routed inside the mold in a state where they cross each other in a non-contact state. Wherein the conductive injection material is injected into the substrate and the crossed portions are electrically connected.
[0008]
In this connection structure of conductors, in addition to the effect of the invention described in claim 1, the connection portions of the plurality of conductors can be fixed with the conductive injection material including the peripheral portion of the connection portions, so that the mechanical strength of the connection portions Can be improved.
[0009]
The invention according to claim 3 is a conductor connection method for electrically connecting a plurality of conductors using a conductive injection material, wherein a bus bar as the plurality of conductors and a core wire of a soft copper wire are in a non-contact state. Intersect, then a predetermined portion of the bus bar and the annealed copper wire excluding the intersected part is integrally molded with an insulator, and then a conductive injection material is injected into the intersected part and the periphery thereof, and The crossed portions are electrically connected.
[0010]
According to this method of connecting a conductor, the bus bar and the soft copper wire are electrically connected by a conductive injection material while being routed in a non-contact state, so that the preforming step can be reduced and the required dimensional accuracy is provided. Can be. Also, by connecting the bus bar and the soft copper wire, the connection portion becomes clear, and when connecting the bus bar and the soft conductive wire, waste of the conductive injection material can be eliminated, and the cost can be reduced.
[0011]
The invention according to claim 4 is a conductor connection method for electrically connecting a plurality of conductors using a conductive injection material, wherein a bus bar as the plurality of conductors and a core wire of a soft copper wire are in a non-contact state. Intersect, then inject a conductive injection material into the intersecting portion, and then integrally mold the bus bar and a predetermined portion of the soft conductive wire with an insulator to electrically connect the intersecting portion. It is characterized.
[0012]
In this method of connecting a conductor, the bus bar and the soft copper wire are electrically connected by a conductive injection material while being routed in a non-contact state, so that the preforming step can be reduced and the required dimensional accuracy is provided. Can be. Also, by connecting the bus bar and the soft copper wire, the connection portion becomes clear, and when connecting the bus bar and the soft conductive wire, waste of the conductive injection material can be eliminated, and the cost can be reduced.
[0013]
The invention according to claim 5 is a conductor connection structure for electrically connecting a plurality of conductors by using a conductive injection material, wherein the plurality of conductors are formed of a plurality of soft copper wires, and the core wires of these soft copper wires are provided. Are crossed in a non-contact state, and are electrically connected by the conductive injection material injected into the crossed portion of the soft copper wire.
[0014]
In this connection structure of the conductor, since the soft copper wire is electrically connected by the conductive injection material while being routed in a non-contact state, the preforming step can be reduced and the required dimensional accuracy can be provided. . In addition, by connecting the soft copper wires, the connection portion becomes clear, and when connecting the soft conductive wires, waste of the conductive injection material can be eliminated, and the cost can be reduced.
[0015]
According to a sixth aspect of the present invention, in the conductor connection structure according to the fifth aspect, the cores of the plurality of soft copper wires are routed inside the mold in a state where they are crossed in a non-contact state, and the inside of the mold is formed. Wherein the conductive injection material is injected into the substrate and the crossed portions are electrically connected.
[0016]
In this connection structure of conductors, in addition to the effect of the invention described in claim 5, since the connection portions of the plurality of conductors can be fixed by the conductive injection material including the peripheral portion of the connection portions, the mechanical strength of the connection portions Can be improved.
[0017]
The invention according to claim 7 is a conductor connection method for electrically connecting a plurality of conductors using a conductive injection material, wherein the plurality of soft copper wires as the plurality of conductors are brought into a non-contact state. Intersecting, then, a predetermined portion of the plurality of annealed copper wires except for the intersecting portion is integrally molded with an insulator, and then, a conductive injection material is injected into the intersecting portion and the periphery thereof, and The crossed portions are electrically connected.
[0018]
According to this method of connecting a conductor, the bus bar and the soft copper wire are electrically connected by a conductive injection material while being routed in a non-contact state, so that the preforming step can be reduced and the required dimensional accuracy is provided. Can be. Also, by connecting the bus bar and the soft copper wire, the connection portion becomes clear, and when connecting the bus bar and the soft conductive wire, waste of the conductive injection material can be eliminated, and the cost can be reduced.
[0019]
The invention of claim 8 is a conductor connection method for electrically connecting a plurality of conductors using a conductive injection material, wherein the plurality of annealed copper wires as the plurality of conductors are in a non-contact state. Then, a conductive injection material is injected into the crossed portion, and then predetermined portions of the plurality of soft conductive wires are integrally formed with an insulator to electrically connect the crossed portions. It is characterized by the following.
[0020]
According to this method of connecting a conductor, the bus bar and the soft copper wire are electrically connected by a conductive injection material while being routed in a non-contact state, so that the preforming step can be reduced and the required dimensional accuracy is provided. Can be. Also, by connecting the bus bar and the soft copper wire, the connection portion becomes clear, and when connecting the bus bar and the soft conductive wire, waste of the conductive injection material can be eliminated, and the cost can be reduced.
[0021]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, an embodiment of a conductor connection structure according to the present invention will be described.
[0022]
A first embodiment according to the present invention shown in FIGS. 1A and 1B is a connection structure of a conductor for connecting a bus bar routed inside an insulator and a soft copper wire.
[0023]
First, as shown in FIG. 1A, a bus bar 11 and an annealed copper wire 12 are routed in a non-contact state in a mold (not shown), and an insulator 13 is injected into the mold. Perform primary molding. At this time, the insulator 13 is injected so that the connecting portion where the bus bar 11 and the soft copper wire 12 intersect is not filled with the insulator 13. Further, since the bus bar 11 and the soft copper wire 12 are disposed in a non-contact state, the bus bar 11 and the soft copper wire 12 are not conductive.
[0024]
Next, as shown in FIG. 1B, a conductive injection material 15 is injected into a connection portion between the bus bar 11 and the soft copper wire 12 to perform secondary molding. As a result, the bus bar 11 and the soft copper wire 12 are electrically connected.
[0025]
In the conductor connection structure of the present embodiment, the bus bar 11 and the soft copper wire 12 are electrically connected by the conductive injection material 15 while being routed in a non-contact state, so that the step of preforming can be reduced and the required. Dimensional accuracy can be provided.
[0026]
In addition, since the conductive injection material 15 hardly generates heat during energization, a problematic thermal stress is not generated in the connection portion, and the bonding material has sufficient bonding strength for a long period of time and simplifies the inspection process. Can reduce product costs.
[0027]
Further, by connecting the bus bar 11 and the soft copper wire 12, the connection portion is clarified, and when connecting the bus bar 11 and the soft conductive wire 12, waste of the conductive injection material 15 can be eliminated and cost can be reduced.
[0028]
Furthermore, since the connecting portion between the bus bar 11 and the soft copper wire 12 is fixed by the conductive injection material 15 including the space 14, the mechanical strength of the connecting portion can be improved.
[0029]
The second embodiment according to the present invention shown in FIGS. 2 to 5 is a connection structure of a conductor when connecting a plurality of bus bars and a soft copper wire to manufacture an insert molded product as a more complicated circuit body. .
[0030]
First, as shown in FIG. 2, the bus bars 21, 21, 21 are disposed in a lower mold (not shown), and the soft copper wires 22, 22, 22 cross each of the bus bars 21, 21, 21 in a non-contact state. To be arranged.
[0031]
In this embodiment, the bus bars 21, 21, 21 are arranged on the same plane, and the bus bars 21, 21, 21 are arranged while the soft copper wires 22, 22, 22 are arranged on the same plane. It is routed on a plane parallel to the plane.
[0032]
When the soft copper wire 22 is routed, the distal end portion 22b of the one end side 22a of the soft copper wire 22 is fixed at a predetermined position using a chuck (not shown).
[0033]
Next, as shown in FIG. 3A, a conductive injection material 23 is injected into a desired gap between the bus bar 21 and the soft copper wire 22, and the bus bar 21 and the soft copper wire 22 are electrically connected. FIG. 3B is a cross-sectional view taken along line AA of FIG. 3A, and shows a state in which the bus bar 21 and the soft copper wire 22 are electrically connected by the conductive injection material 23. .
[0034]
Next, an upper mold (not shown) is aligned with a lower mold, and an insulator is injected into an internal space formed by the upper mold and the lower mold to form an insert molded body 20a of a circuit body, as shown in FIG. In the present embodiment, the insert-molded body 20b of the circuit body is formed at the other end of the soft copper wires 22, 22, 22 in the same process as in FIGS.
[0035]
Next, the insert molded product 20b is rotated in the direction of B in FIG. 4 and the insert molded product 20a and the insert molded product 20b are overlapped to form the insert molded product 20 shown in FIG.
[0036]
In the conductor connection structure of the present embodiment, the bus bar 21 and the soft copper wire 22 are electrically connected by the conductive injection material 23 while being routed in a non-contact state. Dimensional accuracy can be provided.
[0037]
In addition, since the conductive injection material 23 hardly generates heat during energization, a problematic thermal stress is not generated at the connection portion, and a sufficient bonding strength is provided for a long period of time, and the inspection process is simplified. Can reduce product costs.
[0038]
Furthermore, by crossing the bus bar 21 and the soft copper wire 22, the connection portion becomes clear, and when connecting the bus bar 21 and the soft conductive wire 22, waste of the conductive injection material 23 is eliminated, and the cost can be reduced.
[0039]
Furthermore, since the connecting portion between the bus bar 21 and the soft copper wire 22 is fixed by the conductive injection material 23 including the peripheral portion of the connecting portion, the mechanical strength of the connecting portion can be improved.
[0040]
In addition, since the circuit body is insert-molded, the mechanical strength of the circuit body is improved, and there is no electric shock even if the circuit body is touched during power supply.
[0041]
A third embodiment according to the present invention shown in FIGS. 6 (a) and 6 (b) is a connection structure of a conductor for connecting core wires of two soft copper wires provided with an insulating coating wired in a non-contact state. It is.
[0042]
First, as shown in FIG. 6 (a), the insulating coating is removed from the portions of the soft copper wires 31 and 31 'to be connected to expose the core wires 31a and 31a', and the wires are crossed in a non-contact state. . At this time, since the soft copper wires 31, 31 'are routed in a non-contact state, the core wires 31a, 31a' are not conducting.
[0043]
Next, the conductive injection material 32 is injected into the gap between the core wires 31a and 31a '. Thereby, the core wires 31a and 31a 'are electrically connected.
[0044]
In the conductor connection structure of the present embodiment, since the soft copper wires 31 and 31 ′ are electrically connected by the conductive injection material 32 while being routed in a non-contact state, the number of preforming steps can be reduced and required. Dimensional accuracy can be provided.
[0045]
In addition, since the conductive injection material 32 hardly generates heat during energization, a problematic thermal stress is not generated at the connection portion, and a sufficient bonding strength is provided over a long period of time, and the inspection process is simplified. Can reduce product costs.
[0046]
Further, by connecting the soft copper wires 31 and 31 ′, the connection portion becomes clear, and when connecting the soft conductive wires 31 and 31 ′, waste of the conductive injection material can be eliminated and the cost can be reduced.
[0047]
Furthermore, since the connecting portions of the soft copper wires 31 and 31 'can be fixed by the conductive injection material 32 including the peripheral portion of the connecting portions, the mechanical strength of the connecting portions can be improved.
[0048]
【The invention's effect】
As described above, according to the first aspect of the present invention, since the bus bar and the soft copper wire are electrically connected by the conductive injection material while being routed in a non-contact state, the number of preforming steps can be reduced and the required Dimensional accuracy can be provided. Also, by connecting the bus bar and the soft copper wire, the connection portion becomes clear, and when connecting the bus bar and the soft conductive wire, waste of the conductive injection material can be eliminated, and the cost can be reduced.
[0049]
According to the second aspect of the present invention, in addition to the effect of the first aspect, the connecting portions of the plurality of conductors can be fixed by the conductive injection material including the peripheral portion of the connecting portions, so that the mechanical properties of the connecting portions can be improved. Strength can be improved.
[0050]
According to the third aspect of the invention, the bus bar and the soft copper wire are electrically connected by the conductive injection material while being routed in a non-contact state, so that the preforming step can be reduced and the required dimensional accuracy is provided. be able to. Also, by connecting the bus bar and the soft copper wire, the connection portion becomes clear, and when connecting the bus bar and the soft conductive wire, waste of the conductive injection material can be eliminated, and the cost can be reduced.
[0051]
According to the invention of claim 4, since the bus bar and the soft copper wire are electrically connected by the conductive injection material while being routed in a non-contact state, it is possible to reduce the number of preforming steps and to provide the required dimensional accuracy. be able to. Also, by connecting the bus bar and the soft copper wire, the connection portion becomes clear, and when connecting the bus bar and the soft conductive wire, waste of the conductive injection material can be eliminated, and the cost can be reduced.
[0052]
According to the invention of claim 5, since the soft copper wire is electrically connected by the conductive injection material while being wired in a non-contact state, it is possible to reduce the number of preforming steps and to provide the required dimensional accuracy. it can. In addition, by connecting the soft copper wires, the connection portion becomes clear, and when connecting the soft conductive wires, waste of the conductive injection material can be eliminated, and the cost can be reduced.
[0053]
According to the invention of claim 6, in addition to the effect of the invention of claim 5, the connecting portions of the plurality of conductors can be fixed with the conductive injection material including the peripheral portion of the connecting portions, so that the mechanical properties of the connecting portions can be improved. Strength can be improved.
[0054]
According to the invention of claim 7, since the bus bar and the soft copper wire are electrically connected by the conductive injection material while being routed in a non-contact state, the preforming step can be reduced and the required dimensional accuracy is provided. be able to. Also, by connecting the bus bar and the soft copper wire, the connection portion becomes clear, and when connecting the bus bar and the soft conductive wire, waste of the conductive injection material can be eliminated, and the cost can be reduced.
[0055]
According to the invention of claim 8, since the bus bar and the soft copper wire are electrically connected by the conductive injection material while being routed in a non-contact state, the preforming step can be reduced, and the required dimensional accuracy is provided. be able to. Also, by connecting the bus bar and the soft copper wire, the connection portion becomes clear, and when connecting the bus bar and the soft conductive wire, waste of the conductive injection material can be eliminated, and the cost can be reduced.
[Brief description of the drawings]
1A and 1B show a connection structure of a conductor according to a first embodiment of the present invention, in which FIG. 1A is a perspective view showing a state in which a bus bar and a soft copper wire are routed, and FIG. It is a perspective view which shows the state which injected the electroconductive injection material into the clearance gap between soft copper wires.
FIG. 2 is a perspective view showing a state in which a plurality of soft copper wires are routed on a plurality of bus bars in a conductor connection structure according to a second embodiment of the present invention.
3 (a) is a perspective view showing a state in which the bus bar and the soft copper wire of FIG. 3 are connected by a conductive injection material, and FIG. 3 (b) is a perspective view of a connection structure of a conductor according to a second embodiment of the present invention. It is sectional drawing cut | disconnected along the AA of a).
FIG. 4 is a perspective view showing a state in which a bus bar and a soft copper wire of FIG. 4A are insert-molded with an insulator in a connection structure of a conductor according to a second embodiment of the present invention.
FIG. 5 is a perspective view showing a state in which a conductor connection structure according to a second embodiment of the present invention is completed as an insert molded product.
FIG. 6 is a perspective view showing a connection structure of a conductor according to a third embodiment of the present invention, in which (a) shows a state in which two soft copper wires are routed and a core wire is connected by a conductive injection material; (b) is a cross-sectional view taken along line CC of (a).
FIG. 7 is a perspective view showing a connection structure using resistance welding according to the related art.
8A and 8B are cross-sectional views showing a connection structure using resistance welding according to the prior art, in which a soft copper wire cut along a line DD of FIG. 7 is arranged at a predetermined position. (B) is a cross-sectional view showing a state in which preforming before resistance welding is performed along a line D-D.
[Explanation of symbols]
Reference Signs List 10 Conductor joining structure 11 Bus bar 12 Soft copper wire 12a Core wire 13 Insulator 14 Space 15 Conductive injection material

Claims

A conductor connection structure in which a plurality of conductors are electrically connected using a conductive injection material,
The plurality of conductors are made of a bus bar and a soft copper wire, and the conductive injection material is injected into a portion where the bus bar and the core wire of the soft copper wire cross in a non-contact state, and the crossed portion is electrically connected. A connection structure for a conductor, characterized in that:

The connection structure for a conductor according to claim 1,
The bus bar and the core wire of the annealed copper wire are routed inside the mold in a state of crossing in a non-contact state, and the conductive injection material is injected into the mold and the crossed portion is electrically connected. A connection structure for a conductor, characterized in that:

A conductor connection method for electrically connecting a plurality of conductors using a conductive injection material,
The bus bars as the plurality of conductors and the core wire of the soft copper wire intersect in a non-contact state, and then a predetermined portion of the bus bar and the soft copper wire excluding the crossed portion are integrally formed with an insulator, and A conductive injection material is injected into the crossed portion and the periphery thereof to electrically connect the crossed portion.

A conductor connection method for electrically connecting a plurality of conductors using a conductive injection material,
The bus bars as the plurality of conductors and the core wire of the soft copper wire are crossed in a non-contact state, and then a conductive injection material is injected into the crossed portion, and then the bus bar and a predetermined portion of the soft conductive wire are insulated. A method of connecting conductors, wherein the crossed portions are electrically connected by being integrally formed with a body.

A conductor connection structure for electrically connecting a plurality of conductors using a conductive injection material,
The plurality of conductors are composed of a plurality of soft copper wires, and the core wires of these soft copper wires are crossed in a non-contact state, and are electrically connected by the conductive injection material injected into the crossed portions of the soft copper wires. Characteristic conductor connection structure.

The connection structure for a conductor according to claim 5,
The plurality of annealed copper wires are routed inside a mold in a state where they cross in a non-contact state, and the conductive injection material is injected into the mold and the crossed portions are electrically connected. A connection structure for a conductor, characterized in that:

A conductor connection method for electrically connecting a plurality of conductors using a conductive injection material,
The core wires of the plurality of soft copper wires as the plurality of conductors intersect in a non-contact state, and then a predetermined portion of the plurality of soft copper wires excluding the crossed portion is integrally formed with an insulator, and A conductive injection material is injected into the crossed portion and the periphery thereof to electrically connect the crossed portion.

A conductor connection method for electrically connecting a plurality of conductors using a conductive injection material,
The cores of the plurality of soft copper wires as the plurality of conductors intersect in a non-contact state, and then a conductive injection material is injected into the crossed portion, and then a predetermined portion of the plurality of soft conductive wires is A method of connecting a conductor, wherein the crossed portion is electrically connected by integrally molding with an insulator.