JP2006059655A - Connector for electric wire - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a connector for electric wire capable of suppressing tracking. <P>SOLUTION: The connector for the electric wire comprises a first connector section 100 and a second connector section 200 mutually engaged. This first connector section has an electric wire terminal in which the end part of the electric wire having an inner conductor 111, an insulating layer 112, an outer conductor 113, and a sheath 114 in order from the inside is scraped in step and the inner conductor, the insulating layer, and the outer conductor are exposed step by step in order, a connector part 120 fixed to the exposed inner conductor, and a discharge suppressing member 130 which is provided outside of the exposed insulating layer and cuts off the conductive passage from the exposed inner conductor to the outer conductor. Then, the second connector section has a discharge suppressing layer 220 which is jointed to the discharge suppressing member and covers the surroundings of the surface of the insulation layer to become the conductive passage and further, has a coming-off stop engaging part 240 which is engaged with the connector part 120 of the first connector section. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a connector suitable for connecting a high-voltage wire harness for a hybrid vehicle.

  High voltage is applied between the battery, converter, inverter, and motor of the hybrid vehicle to supply power. In particular, there is an example in which a high voltage is applied to the power system of the inverter, motor from the converter, and for example, a commercial vehicle is supplied with a voltage of up to 500 V, and the voltage is increased as the motor output increases.

  The electric wire for wiring harnesses shown in FIG. 6 is used for power supply in such an electric power system. This includes an inner conductor 111, an insulating layer 112, an outer conductor 113, and a sheath 114 in this order from the center side (for example, Patent Document 1).

  Moreover, the connector of FIGS. 6-8 is utilized for the terminal connection of such an electric wire. This connector is composed of a first connector portion and a second connector portion that fit together.

  For forming the first connector portion, as shown in FIG. 6, first, the wire terminal 110 having the inner conductor 111, the insulating layer 112, the outer conductor 113, and the sheath 114 in order from the center is stepped off, and the inner conductor 111, the insulation is formed. The layer 112 and the outer conductor 113 are exposed in stages. On the other hand, the outer conductor fixing member 140 and the connection terminal portion 120 are prepared. The outer conductor fixing member 140 is a ring-shaped member and is fitted on the outer periphery of the exposed outer conductor 113, and the connection terminal portion 120 is fixed to the exposed inner conductor 111. The connection terminal portion 120 has a crimping portion 121 whose one end is crimped to the internal conductor, and a contact portion 122 whose other end is fitted into a second connector portion described later. A fitting hole 122a is formed on the bottom surface of the contact portion 122, and a lock claw of the second connector portion described below is fitted into the fitting hole 122a to function as a retaining member.

  On the other hand, the second connector portion 200 is a member that is fitted to the first connector portion and constitutes the distal end side of the connector, and has a substantially block-shaped connector housing 210 as shown in FIG. An insertion hole 211 for the first connector portion is formed on one end surface of the first connector portion. In the insertion hole, a plate-like outer conductor connection layer 230 that contacts the outer conductor fixing member 140 of the first connector portion and a retaining engagement portion 240 that engages the contact portion 122 of the first connector portion are provided. ing. The retaining engagement portion 240 is formed with a lock claw 240b that is fitted into the fitting hole of the first connector portion.

  The first connector portion and the second connector portion are combined as shown in FIG. That is, the first connector portion is inserted into the insertion hole of the second connector portion, the outer conductor connection layer 230 is brought into contact with the outer periphery of the outer conductor fixing member 140, and the lock claw 240b is fitted into the fitting hole 122a of the first connector portion. And connect them so that they do not come out of each other.

JP-A-6-124608 (Fig. 17)

  However, the above-described connector has a problem that a so-called tracking phenomenon occurs and power supply cannot be normally performed.

  In the above connector, there is a possibility that a discharge occurs on the surface of the insulating layer between the inner conductor and the outer conductor exposed in stages. During this time, insulation is ensured by an insulating layer made of polyethylene or the like, but the surface of the insulating layer is in contact with air. In the initial state, no foreign matter adheres to the surface of the insulating layer, so that insulation is ensured. For example, a surface of a clean insulating layer that is not contaminated by foreign substances has a dielectric strength exceeding 10 kV per cm. However, this portion is in contact with air, and moisture may adhere due to condensation or the like, and air dust may adhere. Dust also contains components such as salt, and when such an ionic substance adheres, a conductive path is formed. As a result, the temperature rises on the surface of the insulating layer, and a tracking phenomenon that eventually leads to discharge may occur. For example, when the surface of the insulating layer is soiled with an ionic substance, flashover may occur at about several hundred volts. When such a discharge phenomenon occurs, a short-circuited state occurs, and power cannot be supplied by the electric wire.

  Accordingly, a main object of the present invention is to provide an electric wire connector capable of suppressing tracking.

  The present invention achieves the above object by blocking the conductive path on the surface of the insulating layer, in particular, sealing the periphery of the conductive path.

  The connector for electric wire of the present invention is provided on the outer end of the exposed insulating layer, the terminal of the electric wire in which the inner conductor, the insulating layer, and the outer conductor are exposed in stages, the connection terminal portion fixed to the exposed inner conductor. And a discharge suppressing member that blocks the conductive path from the exposed inner conductor to the outer conductor.

  In the connector according to the present invention, the conductive path is interrupted by providing a discharge suppressing member in the insulating layer located between the inner conductor exposed by stepping and the outer conductor. Thereby, generation | occurrence | production of tracking can be suppressed.

  Here, it is preferable to further have a discharge suppressing layer that is joined to the discharge suppressing member and covers the periphery of the surface of the insulating layer that becomes a conductive path. With this configuration, the surface of the insulating layer that becomes a conductive path is sealed. As a result, the surface of the insulating layer can be accommodated in the sealed space, and adhesion of foreign matter to the surface of the insulating layer can be avoided, and formation of a conductive path can be suppressed.

  The outer diameter of the discharge suppressing member is preferably formed in a tapered shape that is smaller on the front end side and larger on the rear end side. By forming the outer diameter of the discharge suppression member in a tapered shape, the insertion of the discharge suppression member into the discharge suppression layer can be facilitated.

  Furthermore, in the electric wire connector of the present invention, it is desirable that the electric wire connector has a retaining engagement portion that is integrated with the discharge suppression layer and that engages with the connection terminal portion. By providing the retaining engagement portion, it is possible to prevent the contact portion between the discharge suppressing member and the discharge suppressing layer from being removed.

  Hereinafter, the configuration of the present invention will be described in more detail.

  The connector of the present invention is preferably composed of a first connector portion and a second connector portion, and the two connector portions are preferably fitted to each other to form a single connector. By forming a single connector by fitting both connector portions, a structure that effectively blocks the conductive path on the surface of the insulating layer between the inner conductor and the outer conductor can be easily constructed. In particular, by providing the first connector portion with a discharge suppression member and the second connector portion with a discharge suppression layer, a configuration covering the conductive path can be easily formed. Each connector part is demonstrated separately.

[First connector section]
The first connector part typically includes an electric wire terminal, a connection terminal part, and a discharge suppressing member. In addition, it usually has an outer conductor fixing member.

(Wire terminal)
The electric wire on which the connector of the present invention is formed has, for example, an inner conductor, an insulating layer, an outer conductor, and a sheath. If necessary, an internal semiconductive layer and an external semiconductive layer may be provided. At the time of forming the connector, the covering layer at the end of the electric wire is stepped off to expose the inner conductor, the insulating layer, and the outer conductor step by step.

<Inner conductor>
The inner conductor is not particularly limited as long as the necessary power transmission capacity can be secured, and the material and configuration are not particularly limited. Examples of the material include copper wire, tin-plated copper wire, aluminum wire, aluminum alloy wire, steel core aluminum wire, copper fly wire, nickel-plated copper wire, silver-plated copper wire, and copper-covered aluminum wire. As a configuration of the internal conductor, a single wire and a stranded wire are conceivable, but generally a stranded wire structure in which a plurality of strands are combined is preferable.

<Insulating layer>
The insulating layer is configured to have voltage resistance according to the voltage of the electric wire. Examples of the material for the insulating layer include ethylene propylene rubber, vinyl resin (for example, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, polystyrene, etc.), polyethylene, chlorosulfonated polyethylene rubber, silicon rubber, polytetrafluoroethylene, and the like. . In particular, a cross-linked polyolefin, particularly a cross-linked polyethylene is preferred.

<Internal / external semiconductive layer>
By providing an internal semiconductive layer inside the insulating layer, a small gap at the interface between the internal conductor and the insulating layer is filled, and by providing an external semiconductive layer outside the insulating layer, at the interface between the insulating layer and the external conductor. A minute gap can be filled and generation of partial discharge can be suppressed. Further, by eliminating these minute gaps, the starting point of water tree generation can be eliminated, and insulation deterioration due to water tree generation can be suppressed.

  The inner and outer semiconductive layers are preferably composed of a mixture of resin and conductive filler. Predetermined conductivity can be imparted to the semiconductive layer by mixing conductive fillers. The resin is preferably at least one selected from the group consisting of polyethylene, polyvinyl chloride, and polyvinyl acetate. Carbon black can be suitably used as the filler.

<External conductor>
For the outer conductor, a braided material of a metal wire such as a copper wire can be used. By providing the outer conductor, shielding for preventing induction and shielding for preventing danger can be performed.

<Sheath>
In addition, a sheath may be provided on the outer conductor. By providing the sheath, the shield layer can be mechanically protected. The sheath is generally made of chloroprene rubber, vinyl resin, polyethylene or the like.

<Connection terminal section>
A connection terminal portion is fixed to the exposed inner conductor. This connection terminal part is connected to the terminal part of the apparatus side connector with which this invention connector is fitted. As an example of the configuration of the connection terminal portion, one having a crimp portion where one end is crimped to the internal conductor and a contact portion where the other end is fitted into the second connector portion can be mentioned. And it is desirable to provide the contact part with a stopper against the second connector part. For example, a fitting hole may be formed in the bottom surface of the contact portion, and the lock claw of the second connector portion may be fitted into the fitting hole.

<Discharge suppression member>
A discharge inhibiting member is provided on the outer periphery of the exposed insulating layer of the first connector portion. The discharge suppression member is formed of an insulating material and blocks a conductive path that is to be generated in the exposed insulating layer. Any material may be used for the discharge suppressing member as long as it has an insulating property capable of suppressing the occurrence of tracking. Typical examples include polyethylene and rubber. Moreover, the shape of the discharge suppressing member is preferably an annular shape. By making it annular, it is possible to easily install the discharge suppressing member in a collar shape outside the insulating layer. The outer diameter of the annular discharge suppressing member is preferably slightly smaller than the outer diameter of the outer conductor fixing member described later. By setting it as such an outer diameter, while joining a discharge suppression member and a discharge suppression layer, a connection with an external conductor fixing member and an external conductor connection layer can be performed reliably.

<External conductor fixing member>
The external conductor fixing member is, for example, a ring-shaped member, is fitted on the outer periphery of the exposed external conductor, and is connected to the external conductor connection layer of the second connector portion. A conductive material is used as the material of the fixing member. For example, copper, copper alloy, tin-plated copper, conductive resin, and the like can be suitably used.

[Second connector section]
The second connector portion typically includes a housing having an insertion hole into which the first connector portion is inserted, a discharge suppression layer provided in the housing, and a connection terminal portion of the first connector portion. And a retaining engagement portion.

<Housing>
The housing functions as a case for forming the outer shape of the second connector portion and ensuring insulation. For example, the second connector part is fitted on the distal end side of the first connector part, and the housing forms an insertion port of the first connector part. Typically, it has a substantially block shape, and various materials used as an electrical insulating material are used. More specifically, polybutylene terephthalate can be suitably used.

  The housing is provided with an insertion hole for the first connector portion. When connecting a single wire, a housing with one insertion hole may be used. However, if the terminal member has multiple insertion holes, multiple wires can be connected together by inserting the wires into each insertion hole. can do. For example, in the housing of the second connector portion to which the three-phase electric wires are connected, the housing itself may be a flat block shape, and three insertion holes may be arranged in parallel at one end surface thereof. In the case of having a plurality of insertion holes, of course, a later-described discharge suppression layer and engagement terminal portion are formed for each insertion hole.

<Discharge suppression layer>
The discharge suppression layer is disposed in the housing and covers the periphery of the conductive path generation location of the first connector portion inserted into the second connector portion, avoiding the adhesion of foreign matter to this generation location, forming a conductive path It has a function to suppress. It is preferable that the discharge suppression layer provided in the second connector portion is also made of the same material as the discharge suppression member. Moreover, the shape of this suppression layer is desirable to be cylindrical. By using a cylindrical suppression layer, when the first connector portion is inserted into the second connector portion, the surface of the insulating layer serving as a conductive path is sealed in a space surrounded by the discharge suppression member and the discharge suppression layer. Can be easily done.

<Retaining engagement part>
The retaining engagement portion is provided in the insertion hole of the housing and is engaged with the connection terminal portion of the first connector portion to prevent the first and second connector portions from coming off. The retaining engagement portion only needs to have a structure that can be fitted to the connection terminal portion, and may be composed of an insulating material or a conductive material. For example, forming the locking claw that fits into the fitting hole of the first connector portion is included in the retaining engagement portion.

  According to the connector of the present invention, the following effects can be obtained.

  (1) Electric power can be safely supplied by blocking the conductive path on the surface of the insulating layer exposed by stripping at the end of the electric wire with the discharge suppressing member.

  (2) By covering the periphery of the place where the conductive path is generated by the discharge suppression layer, it is possible to suppress foreign matter from adhering to the conductive path generation place and effectively suppress the generation of the conductive path.

  (3) With a simple configuration, it is possible to provide an electric wire connector that can stably supply a high voltage.

  (4) By forming the outer diameter of the discharge suppression member in a tapered shape, insertion into the discharge suppression layer can be facilitated. In connection with it, the quality of the junction location of a discharge suppression member and a discharge suppression layer can be stabilized.

  (5) By forming the retaining engagement portion, it is possible to prevent the joined discharge suppression member and the discharge suppression layer from being inadvertently detached. The retaining engagement portion also has a positioning function when joining the discharge suppressing member and the discharge suppressing layer.

  Embodiments of the present invention will be described below.

  The connector of the present invention will be described with reference to FIGS. The connector according to the present invention includes a first connector portion 100 formed at an end portion of an electric wire for a wire harness in an electric vehicle, and a second connector portion 200 that is fitted at the tip of the first connector portion. Both connectors 100 and 200 are joined together to form a single wire-side connector at the end of the wire.

[First connector section]
As shown in FIGS. 1 and 2A, the first connector portion 100 includes a wire terminal 110, a connection terminal portion 120, a discharge suppressing member 130, and an external conductor fixing member 140.

  The electric wire on which the connector of the present invention is formed has an internal conductor 111, an internal semiconductive layer, an insulating layer 112, an external semiconductive layer, an external conductor 113, and a sheath 114. At the time of forming the connector, the covering layer at the end of the electric wire is stepped off to expose the inner conductor 111, the insulating layer 112, and the outer conductor 113 in order.

The specific structure / material of each component is as follows.
Inner conductor: Copper strand Inner / outer semiconductive layer: Mixture of polyethylene and carbon black Insulating layer: Polyethylene Outer conductor: Braided material made of annealed copper wire Sheath: Polyvinyl chloride

  A connection terminal portion 120 for connecting to the second connector portion side is fixed to the exposed internal conductor 111 in the above electric wire. The connection terminal portion 120 has a crimping portion 121 that is crimped to the internal conductor 111 at one end, and a contact portion 122 that is fitted into the second connector portion 200 at the other end. The crimping part 121 is a cylindrical metal piece with a notch formed in part. The crimping part 121 is fitted on the outer periphery of the inner conductor 111 and is fixed to the inner conductor 111 by being compressed by a crimping machine. The contact portion 122 is a prismatic metal piece having a substantially rectangular cross section. A notch is formed on the upper surface side, and a fitting hole 122a for engaging with the second connector portion 200 is formed on the lower surface side. The crimping part 121 and the contact part 122 are integrated by a flat connecting piece 123.

  Further, a discharge suppressing member 130 is provided on the outer periphery of the exposed insulating layer 112 of the first connector portion. The discharge suppressing member 130 is a thin annular member made of polyethylene, and has an inner diameter that is slightly smaller than the outer diameter of the exposed insulating layer 112, slightly smaller than the outer diameter of the outer conductor fixing member described later, and 2 The outer diameter of the connector portion is slightly larger than the inner diameter of the discharge suppressing layer. This suppression member 130 is fitted into the inner periphery of the discharge suppression layer of the second connector portion.

  Further, an outer conductor fixing member 140 is provided on the outer periphery of the exposed outer conductor 113 of the first connector portion. The fixing member 140 is a thin annular member made of tin-plated copper, and has an inner diameter that is slightly smaller than the outer diameter of the exposed outer conductor 113 and slightly smaller than the inner diameter of the outer conductor connection layer of the second connector portion. Have a large outer diameter. The fixing member 140 is fitted into the inner periphery of the outer conductor connection layer of the second connector portion.

  In the procedure of forming the first connector portion 100, the outer conductor fixing member 140 is first fitted on the outer circumference of the outer conductor 113 of the electric wire, and then the discharge suppressing member is fitted on the outer circumference of the insulating layer 112. Thereafter, the connection terminal portion 120 is attached to the inner conductor 111.

[Second connector section]
As shown in FIG. 2B, the second connector portion 200 includes a housing 210 having an insertion hole into which the first connector portion 100 is inserted, a discharge suppression layer 220 provided in the housing 210, and a discharge suppression. The outer conductor connection layer 230 is formed on the outer side of the layer 220, and the retaining engagement portion 240 is fitted to the connection terminal portion of the first connector portion.

<Housing>
The housing 210 is a flat block member made of polybutylene terephthalate, and an insertion hole 211 for the first connector portion is formed on one end surface. Here, a housing in which a total of three insertion holes 211 are arranged in parallel is used in order to connect three-phase electric wire terminals.

  A discharge suppression layer 220 is provided inside the housing 210. The discharge suppression layer 220 covers the periphery of the conductive path generation site of the first connector unit 100 inserted into the second connector unit 200, avoids foreign matter from adhering to the generation site, and suppresses the formation of the conductive path. It has a function. Here, the discharge suppression layer 220 is also made of the same polyethylene as the discharge suppression member 130.

  The suppression layer 220 is configured in a cylindrical shape. That is, when the first connector portion 100 is inserted into the second connector portion 200, the discharge suppression layer 220 is fitted around the outer periphery of the discharge suppression member 130, so that the surface of the insulating layer serving as a conductive path is discharged with the discharge suppression member 130. Sealing is performed in a space surrounded by the suppression layer 220. Thereby, it can suppress that a foreign material adheres to a conductive path generation location, and suppresses generation | occurrence | production of a conductive path effectively.

  In addition, an outer conductor connection layer 230 is coaxially formed on the outer periphery of the discharge suppression layer 220 in the housing. This connection layer 230 is also a cylindrical member, and is composed of a braided material made of annealed copper wire, like the outer conductor 113. When the first connector part 100 is inserted into the second connector part 200, the outer conductor fixing member 140 is fitted inside the connection layer 230, so that the outer conductor 113 of the first connector part is connected to the second connector part. Connect to layer 230.

  Further, a retaining engagement portion 240 is provided on the inner periphery of the discharge suppression layer 220 in the housing. The retaining engagement part 240 is engaged with the connection terminal part 120 of the first connector part to prevent the connector parts 100 and 200 from coming off. Here, a resin retaining engagement portion 240 in which a lock claw 240b protrudes from a flat base 240a is used. The locking claw 240b is engaged with the fitting hole 122a of the first connector portion described above, thereby preventing the first connector portion 100 from being inadvertently removed from the second connector portion 200.

  The first connector unit 100 and the second connector unit 200 are connected by inserting the former into the latter insertion hole 211. That is, as shown in FIG. 3, the locking claw 240b of the retaining engagement portion is engaged with the fitting hole 122a of the connection terminal portion 120. At the same time, the discharge suppressing member 130 is fitted into the inner circumference of the discharge inhibiting layer, and the outer conductor fixing member 140 is fitted into the inner circumference of the outer conductor connecting layer 230, whereby the connection between the connectors 100 and 200 is completed.

  Next, a modification of the first embodiment will be described. This example is characterized in that the outer peripheral surface of the discharge suppression member in the first connector portion is formed in a taper shape, and the end portion side of the discharge suppression layer in the second connector portion is shaped to fit the taper. Since the configuration is the same as that of the first embodiment, the description thereof is omitted.

  As shown in FIG. 4, the outer peripheral surface of the discharge suppression member 130 is formed in a tapered shape having a smaller outer diameter toward the front end and a larger outer diameter toward the rear end. On the other hand, the discharge suppressing layer 220 of the second connector portion also has a shape that is easily adapted to the discharge suppressing member 130 by increasing the inner diameter toward the opening side.

  With such a configuration, when the first connector portion 100 is inserted into the second connector portion 200, the discharge suppression member 130 can be smoothly fitted into the discharge suppression layer 220.

  Next, a modification of the second embodiment will be described. This example is characterized in that an engaging portion is provided at a joint portion between the discharge suppression layer and the discharge suppression member in the second embodiment, and the other configurations are the same as those in the second embodiment, so that the description thereof is omitted.

  As shown in FIG. 5, a recess 130 a is formed on the outer periphery of the discharge suppression member 130, and a protrusion 220 a that engages the recess is formed on the inner periphery of the discharge suppression layer 220. Thereby, when the first connector part 100 is fitted into the second connector part 200, the convex part 220a of the discharge restraining layer is fitted into the concave part 130a of the discharge restraining member 130, so that it is possible to prevent the both from coming off.

  Although this invention connector can be utilized for the connection of various electric wires, it can be used suitably for the connection of the electric wire for motor vehicles. In particular, it is expected to be applied to connections among batteries, converters, inverters, motors, and generators of electric vehicles and hybrid vehicles whose voltage is increasing.

The exploded state of this invention 1st connector part of Example 1 is shown, (A) is a front view of an electric wire terminal, (B) is a front view of an external conductor fixing member, (C) is a front view of a discharge suppressing member, (D) is a three-side view of the connection terminal portion, (E) is a side view of the outer conductor fixing member, and (F) is a side view of the discharge suppressing member. (A) is a schematic block diagram of the 1st connector part which shows the state before insertion of Example 1, (B) is a schematic block diagram of the 2nd connector part. It is a schematic block diagram which shows the state after insertion of the 1st connector part of Example 1, and a 2nd connector part. It is a schematic block diagram which shows the state after insertion of the 1st connector part of Example 2, and the 2nd connector part. It is a schematic block diagram which shows the state after insertion of the 1st connector part of Example 3, and a 2nd connector part. FIG. 5 is a schematic configuration diagram of a first connector portion of a conventional example, where (A) is a front view, (B) is a side view of the connection terminal portion, and (C) is a bottom view of the connection terminal portion. It is a schematic block diagram of the 2nd connector part of a prior art example, (A) is a side view, (B) is a front view. FIG. 6 is a configuration diagram showing a coupling state of first and second connector portions of a conventional example.

Explanation of symbols

100 1st connector
110 Electric wire terminal 120 Connection terminal part 130 Discharge suppression member
140 Outer conductor fixing member
111 Inner conductor 112 Insulation layer 113 Outer conductor 114 Sheath
121 Crimp part 122 Contact part 123 Connecting piece 122a Fitting hole
200 Second connector
210 Housing 220 Discharge suppression layer 230 Outer conductor connection layer
240 Retaining engagement part
211 Insertion hole 240a Base 240b Lock claw
130a Concave part 220a Convex part

Claims (4)

An electric wire terminal in which the inner conductor, the insulating layer, and the outer conductor are sequentially exposed, and
A connection terminal portion fixed to the exposed inner conductor;
A connector for electric wires, comprising: a discharge suppressing member provided outside the exposed insulating layer and blocking a conductive path from the exposed inner conductor to the outer conductor.   2. The electric wire connector according to claim 1, further comprising a discharge suppressing layer that is joined to the discharge suppressing member and covers the periphery of the surface of the insulating layer serving as a conductive path.   3. The electric wire connector according to claim 2, wherein an outer diameter of the discharge inhibiting member is formed in a tapered shape that is smaller toward the front end side and larger toward the rear end side.   3. The electric wire connector according to claim 2, further comprising a retaining engagement portion that is integrally formed with the discharge suppression layer and that engages with a connection terminal portion.

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