JP2011014438A - Electric wire connection structure, and conductive line for vehicle having the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an electric wire connection structure of excellent reproducibility in manufacture, capable of reducing disconnection of an element wire in the vicinity of a tip part of a stranded wire conductor in an electric wire, and to provide a conductive line for a vehicle having the electric wire connection structure.SOLUTION: This electric wire connection structure connects linearly the first electric wire 3 having the first substantially cylindrical stranded wire conductor 2 stranded with a plurality of the first element wires, to the second electric wire 5 having the second substantially cylindrical stranded wire conductor 4 stranded with a plurality of the second element wires, by an ultrasonic connection means, wherein an end part of the second stranded wire conductor 4 of the second electric wire 5 is press-formed plate-likely, an end part of the first stranded wire conductor 2 of the first electric wire 3 is mounted on the end part of the plate-likely press-formed second stranded wire conductor 4, to be pressurized vibratedly from a first stranded wire conductor 2 side to a second stranded wire conductor 4 side by the ultrasonic connection means, the end parts of the both stranded wire conductors 2, 4 are thereby formed plate-likely, and the plate-like end parts of the both stranded wire conductors 2, 4 are layered to form a connected shape.

Description

  The present invention relates to an electric wire connecting structure for connecting electric wires in a straight line and a vehicle conductive path having the electric wire connecting structure.

  Light-weight aluminum wires with aluminum stranded conductors made by twisting a plurality of aluminum wires are widely used as electric wires used in vehicle conductive paths that connect devices such as motors, inverters, batteries, and air conditioners mounted on vehicles. It has been. Although this aluminum wire is lightweight, it has a characteristic of being susceptible to heat and vibration. Therefore, it is a copper wire having a copper twisted wire conductor in which copper strands are twisted together in a high temperature place such as the vicinity of a motor or a place where vibration is strong. Is used. For this reason, in the conductive path for vehicles, the electric wire connection structure which connects an aluminum electric wire and a copper electric wire is needed.

  As a conventional wire connection structure, for example, there is one that connects (connects) wires using a connector or the like, but in this case, the size of the connection portion between the wires becomes large, and the weight of the connector also increases. Since it becomes heavy, it is not suitable for a conductive path for a vehicle that requires space saving and weight reduction. Therefore, there is a demand for an electric wire coupling structure that directly connects electric wires in a straight line without using connection parts such as connectors.

  As a prior art of a wire connection structure for connecting wires in a straight line, for example, there is Patent Literature 1.

  FIG. 4 of Patent Document 1 relates to ultrasonic connection, but ultrasonic connection does not require a flux such as solder or brazing material when connecting wires, and a special surface treatment ( Since the cleaning process can be omitted, it is very simple and has great merit in terms of manufacturing cost.

JP 2009-9736 A JP-A-52-104786 JP 2004-220933 A

  However, the ultrasonic connection disclosed in Patent Document 1 has the following problems.

  As shown in FIG. 4 of Patent Document 1, when connecting electric wires in a straight line by ultrasonic connection, substantially cylindrical electric wires, that is, curved surfaces are brought into contact with each other. There is a problem that the phase positions of the connected wires are likely to be shifted, and the reproducibility in manufacturing may be deteriorated.

  In addition, in the ultrasonic connection disclosed in Patent Document 1, as shown in FIG. 4B of Patent Document 1, the joint surface between the stranded conductors of the electric wire is formed in an inclined shape. There is also a problem that the tip end portion of the stranded wire conductor of the electric wire is formed to be tapered, and the strand is often disconnected near the tip end portion of the stranded wire conductor.

  The present invention has been made in view of the above circumstances, and in an electric wire connection structure in which electric wires are linearly connected using ultrasonic connection, the reproducibility in production is good, and the vicinity of the tip of the stranded conductor of the electric wire is good. It aims at providing the electric wire connection structure which can reduce the disconnection of a strand, and the electrically conductive path for vehicles which has the electric wire connection structure.

  The present invention has been made to achieve the above object, and includes a first electric wire having a substantially cylindrical first stranded wire conductor formed by twisting a plurality of first strands, and a plurality of second strands. In a wire connection structure in which a second electric wire having a substantially cylindrical second stranded wire conductor formed by twisting together is linearly connected by ultrasonic connection means, the end of the second stranded wire conductor of the second electric wire Is formed into a plate shape, the end portion of the first stranded wire conductor of the first electric wire is placed on the end portion of the second stranded wire conductor formed into a plate shape, and the ultrasonic connection means By applying pressure while vibrating from the first stranded wire conductor side to the second stranded wire conductor side, both ends of both stranded wire conductors are made plate-like, and the plate-like ends of both stranded wire conductors It is the electric wire connection structure made into the shape which was laminated | stacked and connected.

  The present invention also provides a first cylindrical electric wire having a substantially cylindrical first stranded conductor formed by twisting a plurality of first strands, and a substantially cylindrical second formed by twisting a plurality of second strands. In the electric wire connection structure in which the second electric wire having the stranded wire conductor is linearly connected by the ultrasonic connection means, the end portion of the first stranded wire conductor of the first electric wire is formed into a plate shape, and the second An end portion of the second stranded wire conductor of the electric wire is formed into a plate shape, and an end portion of the first stranded wire conductor is formed into a plate shape on the end portion of the second stranded wire conductor formed into a plate shape. The plate-like end portions of both stranded wire conductors are laminated by placing and applying pressure while vibrating from the first stranded wire conductor side to the second stranded wire conductor side by the ultrasonic connection means. It is the electric wire connection structure made into the connected shape.

  The first electric wire is an aluminum electric wire having an aluminum stranded conductor formed by twisting a plurality of aluminum strands, and the second electric wire is a copper having a copper stranded conductor formed by twisting a plurality of copper strands. It may consist of electric wires.

  The outer diameter of the aluminum strand may be 0.3 to 2.0 mm, and the outer diameter of the copper strand may be 0.1 to 0.5 mm.

  The cross-sectional area of the first stranded wire conductor may be equal to or larger than the cross-sectional area of the second stranded wire conductor.

The cross-sectional area of the first stranded conductor is 8～50Mm ^2, the cross-sectional area of the second stranded conductor may be a 8～35Mm ^2.

  Moreover, this invention is a vehicle conductive path which has the said electric wire connection structure in the vehicle conductive path which connects between apparatuses, such as an inverter mounted in the vehicle, a motor, a battery, and an air-conditioner.

  Advantageous Effects of Invention According to the present invention, a wire connection structure that has good reproducibility in manufacturing and that can reduce the disconnection of the wire near the tip of the stranded conductor of the wire, and a vehicle conductive path having the wire connection structure Can provide.

It is a figure which shows the electric wire connection structure which concerns on one embodiment of this invention, (a) is a perspective view, (b) is sectional drawing of the connection part. (A)-(e) is a figure explaining the procedure at the time of forming the electric wire connection structure of FIG. (A)-(c) is a figure explaining the procedure at the time of forming the electric wire connection structure which concerns on one embodiment of this invention.

  Preferred embodiments of the present invention will be described below with reference to the accompanying drawings.

  Fig.1 (a) is a perspective view which shows the electric wire connection structure which concerns on this Embodiment, FIG.1 (b) is sectional drawing of the connection part.

  As shown to Fig.1 (a), (b), the electric wire connection structure 1 has the 1st electric wire 3 which has the substantially cylindrical 1st strand wire conductor 2 formed by twisting a some 1st strand, and plural This is a structure in which a second wire 5 having a substantially cylindrical second stranded wire conductor 4 formed by twisting the second strands is linearly connected by ultrasonic connection.

  The 1st electric wire 3 is the aluminum electric wire 3 which coat | covered the outer periphery of the aluminum strand wire conductor 2 which twisted together the aluminum strand as a 1st strand with the sheath (outer skin) 6. FIG.

  The 2nd electric wire 5 is the copper electric wire 5 which coat | covered the sheath (outer skin) 7 on the outer periphery of the copper twisted-wire conductor 4 which twisted together the copper strand as a 2nd strand.

  The outer diameter of the aluminum strand that is the first strand is formed larger than the outer diameter of the copper strand that is the second strand. More specifically, the outer diameter of the aluminum strand is 0.3 to 2.0 mm, and the outer diameter of the copper strand is 0.1 to 0.5 mm.

  The outer diameter of the aluminum wire is set to 0.3 to 2.0 mm. When the outer diameter of the aluminum wire is less than 0.3 mm, the aluminum wire is deformed by pressurization during ultrasonic connection. This is because there is a possibility of disconnection, and if it exceeds 2.0 mm, the rigidity of the aluminum stranded wire conductor 2 in which the aluminum strands are twisted together increases, and bending work during wiring (attachment) becomes difficult.

  The reason why the outer diameter of the copper wire is 0.1 to 0.5 mm is that when the outer diameter of the copper wire is less than 0.1 mm, the wire breaks during ultrasonic connection as in the case of the aluminum wire. If the thickness exceeds 0.5 mm, the rigidity of the copper stranded wire conductor 4 obtained by twisting the copper strands is increased, and bending during wiring becomes difficult.

The aluminum stranded wire conductor 2 in which the aluminum strands are twisted together preferably has a cross-sectional area equal to or larger than that of the copper stranded wire conductor 4. More specifically, the cross-sectional area of the aluminum stranded conductor 2 is a 8～50Mm ^2, the cross-sectional area of the copper twisted conductors 4 is a 8～35Mm ^2, towards the cross-sectional area of the aluminum stranded conductor 2 of copper The cross-sectional area of the stranded wire conductor 4 is preferably about 1.0 to 1.5 times.

  In the wire connection structure 1 according to the present embodiment, both ends of the two stranded wire conductors 2 and 4 are formed into a plate shape, and the plate-like end portions of the two stranded wire conductors 2 and 4 are laminated and connected. It is made into a shape. More specifically, the wire connection structure 1 is formed in a substantially cylindrical shape on the end of the copper stranded wire conductor 4 formed in advance in a plate shape by previously forming the end of the copper stranded wire conductor 4 into a plate shape. The aluminum stranded wire conductor 2 and the copper stranded wire conductor 4 are made to overlap each other by facing the ends of the aluminum stranded wire conductor 2 and pressurizing and vibrating the overlapped portion by ultrasonic connection. Both end portions of the two conductors are formed in a plate shape, and the plate-like end portions of the two stranded conductors 2 and 4 are laminated and connected.

  As shown in FIG.1 (b), in the connection part 8 which connected the edge parts of both the strand wire conductors 2 and 4, the edge part of both the strand wire conductors 2 and 4 is substantially rectangular plate shape by sectional view. The lower surface of the end portion of the aluminum stranded wire conductor 2 in the upper part of the figure is connected to the upper surface of the end part of the copper stranded wire conductor 4 in the lower part of the figure.

  In the electric wire connection structure 1, the width (width in the left-right direction in the figure) at the plate-like end portion of the aluminum stranded wire conductor 2 is smaller than the width of the plate-like end portion of the copper stranded wire conductor 4. The end portion of the wire conductor 2 is disposed at a substantially central portion in the width direction of the upper surface of the end portion of the copper stranded wire conductor 4. That is, in the connection portion 8, the end portion of the copper stranded wire conductor 4 is arranged outside (in the width direction outside) the end portion of the aluminum stranded wire conductor 2.

  The ratio between the thickness t and the width W at the plate-like end portions of the stranded conductors 2 and 4, that is, the aspect ratio W / t is 2 to 10. This is because when the aspect ratio W / t is less than 2, the thickness t becomes more than half of the original conductor diameter, and when the ends of the two stranded wire conductors 2 and 4 are laminated, the two stranded wire conductors 2 and 4 are laminated. If the aspect ratio W / t exceeds 10, the width W becomes more than three times the original conductor diameter and takes up space. This is because the wire that is arranged on the outer side in the width direction at the end of the shape is deformed into a substantially Z shape, and the wire is easily broken.

  The wire connection structure 1 is formed by using an ultrasonic connection device 21 as ultrasonic connection means shown in FIGS. The ultrasonic connecting device 21 is disposed on the anvil 23 fixed above the base 22, the horn 24 disposed above the anvil 23, and the anvil 23, and is opposed to the horizontal direction at a predetermined interval. And a pair of wall portions 25.

  A vibration device (not shown) is connected to the horn 24 so as to vibrate slightly in the axial direction (from the right front side to the left back side in the drawing). In addition, the horn 24 is provided with a pressing portion 24 a having a large number of fine grooves formed on the bottom surface so as to protrude below the horn 24.

  Moreover, the wall part 25 is each arrange | positioned on the anvil 23 so that advancing and retreating is possible, and although FIG. 2 (a)-(e) has shown the state which advanced both wall parts 25, the wall part 25 of the right side of illustration is shown. The wall 25 on the left side of the figure can be retracted to the right side.

  When forming the wire connection structure 1 using the ultrasonic connection device 21, first, as shown in FIG. 2A, the end of the copper stranded wire conductor 4 of the copper wire 5 on the anvil 23 between the wall portions 25. 2b, the horn 24 is lowered to the anvil 23 side while slightly vibrating, and the end portion of the copper stranded conductor 4 is moved to the anvil 23 side by the holding portion 24a of the horn 24. Pressurize. Then, the end of the copper stranded wire conductor 4 is crushed into a plate shape by pressurization of the horn 24, the copper stranded wire conductor 4 is heated by friction caused by slight vibration of the horn 24, and the copper strands are welded together. The ends of the copper stranded wire conductor 4 are formed into a plate shape.

  Then, as shown in FIG.2 (c), the edge part of the copper twisted wire conductor 4 shape | molded in plate shape is again mounted on the anvil 23, and as shown in FIG.2 (d), the copper twisted wire conductor 4 is shown. The end portion of the aluminum stranded wire conductor 2 of the aluminum electric wire 3 is placed above the plate-like end portion so as to overlap a predetermined length from the front end side of the copper stranded wire conductor 4.

  In this state, as shown in FIG. 2 (e), the horn 24 is slightly vibrated while being lowered toward the anvil 23, and the end portion of the aluminum stranded conductor 2 is connected to the copper stranded conductor 4 by the pressing portion 24 a of the horn 24. Pressurize to the side. Then, the end portion of the aluminum stranded wire conductor 2 is crushed into a plate shape by the pressurization of the horn 24, the aluminum stranded wire conductor 2 is heated by the friction caused by the slight vibration of the horn 24, and the aluminum strands are welded together. The ends of the aluminum stranded wire conductor 2 are formed into a plate shape. At the same time, the lower surface of the end portion of the aluminum stranded wire conductor 2 and the upper surface of the end portion of the copper stranded wire conductor 4 are welded, and the plate-like end portions of the stranded wire conductors 2 and 4 are laminated and connected. The connected portion 8 is formed.

  Although it is conceivable that the end of the aluminum stranded wire conductor 2 is formed into a plate shape in advance and the end of the substantially cylindrical copper stranded wire conductor 4 is placed thereon to perform ultrasonic connection. In this case, since the hardness of copper is higher than that of aluminum, there is a possibility that the end of the copper stranded wire conductor 4 may bite into the plate-like end of the aluminum stranded wire conductor 2 at the time of ultrasonic connection.

  After the connection portion 8 is formed, the horn 24 is moved upward, and the right wall portion 25 shown in the drawing is moved to the right side, and the left wall portion 25 shown in the drawing is moved back to the left side, whereby the wire connecting structure 1 shown in FIG.

  In addition, in the connection part 8, since aluminum and copper which are different metals contact, it is desirable to cover the connection part 8 with mold resin etc. in order to prevent a different metal contact corrosion.

  The operation of the present embodiment will be described.

  In the electric wire connection structure 1 according to the present embodiment, the end portion of the copper stranded wire conductor 4 of the copper electric wire 5 is formed into a plate shape, and the aluminum electric wire 3 is formed on the end portion of the copper stranded wire conductor 4 formed into a plate shape. The ends of the aluminum stranded wire conductor 2 are placed and pressed by the ultrasonic connection device 21 while vibrating from the aluminum stranded wire conductor 2 side to the copper stranded wire conductor 4 side, The four end portions are both plate-shaped, and the plate-shaped end portions of the two stranded wire conductors 2 and 4 are laminated and connected.

  Thereby, when connecting both the electric wires 3 and 5 by the ultrasonic connection apparatus 21, since the copper twisted-wire conductor 4 becomes plate shape, the shift | offset | difference of the relative position of the electric wires 3 and 5 to connect is reduced. As a result, reproducibility in manufacturing is improved.

  Moreover, in the electric wire connection structure 1, since both the aluminum stranded wire conductor 2 and the copper stranded wire conductor 4 are plate-shaped, it is reduced that the front-end | tip part of both the stranded wire conductors 2 and 4 becomes taper. It becomes possible to reduce the disconnection of the strands in the vicinity of the tips of the line conductors 2 and 4.

  Furthermore, in the wire connection structure 1, the copper stranded wire conductor 4 is arranged outside (in the width direction outside) the aluminum stranded wire conductor 2 in the connection portion 8. Since it does not protrude outward and the end portion in the width direction of the connection portion 8 can be formed of high-strength copper, the strength of the connection portion 8 can be improved.

  Moreover, in the electric wire connection structure 1, since the outer diameter of the aluminum strand is 0.3 to 2.0 mm and the outer diameter of the copper strand is 0.1 to 0.5 mm, the strand is disconnected at the time of ultrasonic connection. It will not be difficult to bend during wiring.

  In the said embodiment, only the edge part of the copper stranded wire conductor 4 is shape | molded previously in plate shape, the plate-like edge part of the copper stranded wire conductor 4, and the edge part of the substantially cylindrical aluminum stranded wire conductor 2; Are connected by ultrasonic connection, but both ends of both stranded wire conductors 2 and 4 are previously formed into a plate shape, and the ends of both stranded wire conductors 2 and 4 formed into a plate shape are ultrasonically connected to each other. You may make it connect by.

  In this case, as shown in FIG. 3 (a), the end of the copper stranded wire conductor 4 is formed into a plate shape using the ultrasonic connecting device 21, and as shown in FIG. 3 (b), an aluminum stranded wire is formed. The ends of the conductor 2 are formed into a plate shape using the ultrasonic connection device 21, and the ends of the two stranded wire conductors 2 and 4 formed into a plate shape are opposed to each other as shown in FIG. By connecting the overlapped portions with a predetermined length and applying pressure and vibration to the overlapped portion with the horn 24, the plate-like end portions of the two stranded wire conductors 2 and 4 are stacked and connected. May be formed.

  By forming the ends of the stranded conductors 2 and 4 in advance in a plate shape, the plate ends are connected by ultrasonic connection, so the relative positions of the wires 3 and 5 to be connected Can be further reduced. As a result, the reproducibility in manufacturing can be further improved.

  In addition, by forming the ends of the two stranded conductors 2 and 4 in advance into a plate shape by ultrasonic connection, the strands of the ends of the two stranded conductors 2 and 4 can be formed integrally, respectively. Bonding works as a whole and it is possible to suppress variations in the strands. In particular, as shown in FIG. 1 (b), when the width of the plate-like end portion of the aluminum stranded wire conductor 2 after ultrasonic connection is smaller than the width of the plate-like end portion of the copper stranded wire conductor 4, At the time of sonic connection, the outer strand in the width direction at the end of the aluminum stranded wire conductor 2 does not come into contact with the wall portion 25, and the aluminum strand may be scattered. If the end portions of 4 are formed into a plate shape in advance, such variations in the strands can be suppressed.

  The electric wire connection structure 1 of the present invention is used, for example, in a vehicle conductive path that connects devices such as an inverter, a motor, a battery, and an air conditioner mounted on a vehicle.

  Since the wire connection structure 1 can connect the aluminum wire 3 and the copper wire 5 in a straight line without using connection parts such as connectors, the connection portion can be reduced in space and weight, and the reproducibility in manufacturing is also possible. Since it is well suited for mass production, it is useful as a conductive path for vehicles.

1 Wire connection structure 2 Aluminum stranded conductor (first stranded conductor)
3 Aluminum wire (first wire)
4 Copper twisted conductor (second twisted conductor)
5 Copper wire (second wire)
8 connections

Claims (7)

A first electric wire having a substantially cylindrical first stranded wire conductor formed by twisting a plurality of first strands, and a first wire having a substantially cylindrical second stranded wire conductor formed by twisting a plurality of second strands. In the electric wire connection structure that connects two electric wires in a straight line by ultrasonic connection means,
The end portion of the second stranded wire conductor of the second electric wire is formed into a plate shape, and the end portion of the first stranded wire conductor of the first electric wire is formed on the end portion of the second stranded wire conductor formed into a plate shape. Both ends of both stranded wire conductors are plate-shaped by placing end portions and applying pressure while vibrating from the first stranded wire conductor side to the second stranded wire conductor side by the ultrasonic connection means. In addition, a wire connecting structure characterized in that the plate-like end portions of both stranded wire conductors are laminated and connected. A first electric wire having a substantially cylindrical first stranded wire conductor formed by twisting a plurality of first strands, and a first wire having a substantially cylindrical second stranded wire conductor formed by twisting a plurality of second strands. In the electric wire connection structure that connects two electric wires in a straight line by ultrasonic connection means,
The end portion of the first stranded wire conductor of the first electric wire is formed into a plate shape, the end portion of the second stranded wire conductor of the second electric wire is formed into a plate shape, and the first shape is formed into a plate shape. An end portion of the first stranded wire conductor formed in a plate shape is placed on an end portion of the two stranded wire conductors, and the second stranded wire conductor is disposed from the first stranded wire conductor side by the ultrasonic connection means. A wire connecting structure characterized in that the plate-like end portions of both stranded wire conductors are laminated and connected by applying pressure while vibrating to the side. The first electric wire comprises an aluminum electric wire having an aluminum stranded wire conductor formed by twisting a plurality of aluminum strands,
The electric wire connection structure according to claim 1 or 2, wherein the second electric wire is a copper electric wire having a copper stranded conductor formed by twisting a plurality of copper strands.   The electric wire connection structure according to claim 3, wherein an outer diameter of the aluminum strand is 0.3 to 2.0 mm, and an outer diameter of the copper strand is 0.1 to 0.5 mm.   The electric wire connection structure according to any one of claims 1 to 4, wherein a cross-sectional area of the first stranded wire conductor is equal to or larger than a cross-sectional area of the second stranded wire conductor. The electric wire connection structure according to claim 5, wherein a cross-sectional area of the first stranded wire conductor is 8 to 50 mm ² , and a cross-sectional area of the second stranded wire conductor is 8 to 35 mm ² . In conductive paths for vehicles that connect devices such as inverters, motors, batteries, and air conditioners mounted on vehicles,
A conductive path for a vehicle comprising the electric wire connection structure according to claim 1.

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