JP2017143645A - Wire/cable connection structure and wire/cable connection method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To connect a wire/cable of an aluminum conductor to a device for which a connection of a copper conductor is estimated, at a low cost.SOLUTION: The present invention relates to a connection structure 100 for connecting a first wire/cable 10 including an aluminum conductor 11 and a conductor coating layer 12 and a second wire/cable 20 including a copper conductor 21 and a conductor coating layer 22. The connection structure comprises: a connector 30 for connecting the aluminum conductor that is exposed from the conductor coating layer of the first wire/cable, with the copper conductor that is exposed from the conductor coating layer of the second wire/cable; conductive compounds 40 that are interposed among the aluminum conductor, the copper conductor and the connector; a cover layer 50 which covers the connector, and a connection part of the aluminum conductor and the copper conductor connected to the connector and encapsulates the conductive compounds inside; and an insulation layer 60 in which the cover layer, the connector and the connection part of the aluminum conductor and the copper conductor connected to the connector are encapsulated and which is formed from an electrically insulative resin.SELECTED DRAWING: Figure 3

Description

  The present invention relates to an electric wire / cable connection structure and an electric wire / cable connection method.

Conventionally, copper or copper alloys have been widely used for electric wires and cable conductors for power distribution applications, but in recent years, the use of aluminum or aluminum alloys for electric wires and cable conductors has been studied for the purpose of weight reduction. .
However, when the aluminum conductor is exposed to the air, an oxide film tends to be formed on the surface thereof. Since this oxide film has very high insulation, it causes heat generation during energization. For this reason, when connecting the aluminum conductor, the surface of the aluminum conductor is polished in advance to remove the oxide film, and a compound composed of metal fine particles and an oil component is applied to the aluminum conductor to prevent the formation of a new oxide film. (For example, refer to Patent Document 1).

On the other hand, distribution boards and distribution boards (hereinafter referred to as “distribution boards, etc.”) that are widely used at present are designed on the assumption that they are connected to copper conductors. Corrosion is a problem. In other words, if moisture is present due to dew condensation at the connection location, the aluminum conductor is damaged due to corrosion, so it is necessary to take measures against dew condensation / humidity such as a switchboard.
As a measure for preventing such corrosion of aluminum, there are a terminal having a copper plate plated on the face of the terminal and a terminal having a copper plate attached thereto (for example, see Non-Patent Document 1). Since this terminal has strong adhesion between aluminum and copper thick plating or copper plate, there is no ingress of moisture or the like at the aluminum / copper interface, and it has excellent corrosion resistance.

Utility registration No. 2558578

Furukawa Electric Copper Thick Plating Aluminum Terminal Catalog, [October 30, 2014 Search], Internet <URL: http://www.furukawa.co.jp/tukuru/pdf/aluminum-tanshi_d321.pdf>

However, although the copper thick plating terminal is effective in preventing corrosion of different metals, it is problematic in that it is very expensive as compared with a normal terminal.
Therefore, as a method of connecting to conventional equipment such as switchboards that are assumed to be connected to copper conductor wires and cables while using wires and cables having aluminum conductors, copper conductor wires are used for wires and cables having aluminum conductors. -A method of connecting a cable and connecting to conventional equipment via the copper conductor wire / cable can be considered.
With this method, it is possible to realize electrical continuity between an electric wire / cable having an aluminum conductor and a conventional facility without using an expensive copper thick plating terminal.

In the case of the above configuration, it is important to have a good connection between an aluminum conductor wire / cable and a copper conductor wire / cable. Connection between electric wires and cables requires connection between conductors and formation of an insulating layer around them.
The conductors are connected by inserting the conductors into the insertion holes or gaps of the aluminum connector, compressing the connectors from the outside, and caulking them. When an aluminum conductor wire / cable is used, the connection is performed by caulking with the compound of Patent Document 1 filled inside the connector.
For the formation of the insulating layer, a method of winding an insulating tape is also frequently used, but this method has skill in winding work and may cause variations in insulation performance. Formation is desired. By performing mold processing in a factory where quality is controlled, the quality of the insulating layer is stabilized and connection work on site can be omitted.

However, the conductive compound used for the connection between conductors plays a role of preventing moisture and moisture from entering the conductor in addition to removing the oxide film on the surface of the aluminum conductor. It is necessary to fill the connector and positively protrude the compound during caulking to adhere to the entire surface of the conductor.
When resin molding is performed around the connection portion of such a conductor, the compound is likely to be mixed into the resin before curing, and the insulating performance of the insulating layer may be significantly lowered due to the conductivity of the compound.
In addition, if a compound enters between the resin and the outer periphery of the electric wire / cable, there is a risk that the water-tight treatment between the resin and the electric wire / cable will be hindered and moisture will easily enter the inside.

  An object of the present invention is to satisfactorily connect an aluminum conductor wire / cable and a copper conductor wire / cable.

The invention according to claim 1 is an electric wire / cable connection structure.
A connection structure for connecting a first electric wire / cable having an aluminum conductor and a conductor covering layer and a second electric wire / cable having a copper conductor and a conductor covering layer,
A connector for connecting an aluminum conductor exposed from the conductor coating layer of the first electric wire / cable and a copper conductor exposed from the conductor coating layer of the second electric wire / cable;
A conductive compound interposed between the aluminum conductor and the copper conductor and the connector;
A coating layer that covers the connector and the connection portion of the aluminum conductor and the copper conductor connected to the connector and seals the conductive compound inside;
An insulating layer made of an electrically insulating resin that seals the connection portion of the covering layer, the connector, and the aluminum conductor and the copper conductor connected to the connector.

The invention according to claim 2 is the electric wire / cable connection structure according to claim 1,
The covering layer is a tape or a sheet having water tightness and insulating properties.

The invention according to claim 3 is the electric wire / cable connection structure according to claim 2,
The tape or sheet has a self-bonding property.

The invention according to claim 4 is the electric wire / cable connection structure according to claim 1,
The covering layer is a putty having water tightness and insulating properties.

The invention according to claim 5 is the electric wire / cable connection structure according to claim 1,
The coating layer is a case for accommodating the connector and a connection portion of the aluminum conductor and the copper conductor connected to the connector.

The invention according to claim 6 is the electric wire / cable connection structure according to claim 1,
The coating layer is a resin layer that is separate from the insulating layer and seals the connection portion of the connector and the aluminum conductor and the copper conductor connected to the connector.

The invention according to claim 7 is the electric wire / cable connection structure according to any one of claims 1 to 6,
In the first electric wire / cable, the aluminum conductor is exposed from the conductor coating layer at an intermediate position in the longitudinal direction,
The aluminum conductor exposed from the conductor coating layer and the copper conductor of the second electric wire / cable are connected by the connector.

The invention according to claim 8 is the electric wire / cable connection structure according to any one of claims 1 to 7,
The surface of the outer portion of the connector in the aluminum conductor and the copper conductor is also covered with the conductive compound.

The invention according to claim 9 is the electric wire / cable connection structure according to any one of claims 1 to 8,
The aluminum conductor of the first electric wire / cable and the copper conductor of the second electric wire / cable are connected by the compressed connector.

The invention according to claim 10 is an electric wire / cable connection method,
A connection method for connecting a first electric wire / cable having an aluminum conductor and a conductor coating layer and a second electric wire / cable having a copper conductor and a conductor coating layer,
Connecting the aluminum conductor exposed from the conductor coating layer of the first electric wire / cable and the copper conductor exposed from the conductor coating layer of the second electric wire / cable by a connector;
Forming a coating layer covering the connector and the connecting portion of the aluminum conductor and the copper conductor connected to the connector, and forming a conductive compound interposed between the aluminum conductor and the copper conductor and the connector; Sealing inside the coating layer;
Forming an insulating layer for sealing the connecting layer, the connector, and the connection portion of the aluminum conductor and the copper conductor connected to the connector with an electrically insulating resin.

The invention described in claim 11 is the electric wire / cable connection method according to claim 10,
The coating layer is formed by winding or sticking a tape or sheet having watertightness and insulating properties.

The invention described in claim 12 is the electric wire / cable connection method according to claim 11,
The tape or sheet has a self-bonding property.

The invention according to claim 13 is the electric wire / cable connection method according to claim 10,
The coating layer is formed by applying a putty having watertightness and insulating properties.

The invention described in claim 14 is the electric wire / cable connection method according to claim 10,
The covering layer is formed by attaching a case that accommodates the connector and the connection portion of the aluminum conductor and the copper conductor connected to the connector.

The invention of claim 15 is the electric wire / cable connection method of claim 10,
The coating layer is formed by sealing the connector and the connection portion of the aluminum conductor and the copper conductor connected to the connector by resin molding.

The invention according to claim 16 is the electric wire / cable connection method according to any one of claims 10 to 15,
The connector connects the aluminum conductor of the first electric wire / cable and the copper conductor of the second electric wire / cable by compression connection.

The invention described in claim 17 is the electric wire / cable connection method according to claim 16,
The compound is leaked to the outside of the connector by compression connection of the connector.

The invention described in claim 18 is the electric wire / cable connection method according to claim 17,
The method further comprises a step of wiping off the excess compound leaked to the outside of the connector.

The invention according to claim 19 is the electric wire / cable connection method according to any one of claims 10 to 18,
The insulating layer is formed by sealing the covering layer, the connector, and the connecting portion of the aluminum conductor and the copper conductor connected to the connector by molding an electrically insulating resin.

Since the present invention seals the covering layer, the connection end of the first electric wire / cable, the connection end of the second electric wire / cable, and the connector with an insulating layer made of an electrically insulating resin, it has skill. Since it is not necessary to wrap an insulating tape or the like that tends to cause variations in the insulating performance, and the insulating layer can be formed through an industrial manufacturing process, an insulating layer with stable insulating performance can be formed.
Furthermore, according to the present invention, it is possible to achieve good conduction between the aluminum conductor and the copper conductor, which are different metals, and to reduce the corrosion of the aluminum conductor due to the intrusion of moisture by the conductive compound.
In addition, aluminum conductors, copper conductors and connectors are covered with a coating layer, and the conductive compound is sealed on the inside, so mixing of the conductive compound into the electrically insulating resin forming the insulating layer is suppressed. Thus, the insulating layer can maintain high insulating performance. In addition, since the compound is sealed in the coating layer, when watertight treatment is performed between the insulating layer and the conductor coating layer of the first and second electric wires / cables, the compound is not hindered and high watertight performance is achieved. Can be obtained.
Therefore, high conductivity and insulation performance can be achieved while achieving a good connection between the aluminum conductor wire / cable and the copper conductor wire / cable with good conductivity and reduced corrosion by the conductive compound. An insulating layer can be formed by stable resin molding.
In addition, the first electric wire / cable and the second electric wire / cable can be connected while maintaining high electrical conductivity and high insulation against the outside. In addition, it is possible to connect to conventional equipment such as a distribution board assuming connection with copper conductor wires / cables at good cost.

It is sectional drawing of a 1st electric wire and cable. It is sectional drawing of a 2nd electric wire and cable. It is sectional drawing of the connection structure of the electric wire and cable which is 1st embodiment. It is sectional drawing which shows the conductor connection process of the connection structure of an electric wire and a cable. It is sectional drawing which shows the wiping off process of the connection structure of an electric wire and a cable. It is sectional drawing which shows the coating layer formation process of the connection structure of an electric wire and a cable. It is sectional drawing of the connection structure of the electric wire and cable which is 2nd embodiment. It is sectional drawing which shows the coating layer formation process of the connection structure of an electric wire and a cable. It is a perspective view of a coating layer. It is sectional drawing of the connection structure of the electric wire and cable which is 3rd embodiment. It is sectional drawing which shows the conductor connection process of the connection structure of an electric wire and a cable. It is sectional drawing which shows the wiping off process of the connection structure of an electric wire and a cable. It is sectional drawing which shows the coating layer formation process of the connection structure of an electric wire and a cable. It is sectional drawing of the connection structure of the electric wire and cable which is 4th embodiment. It is sectional drawing which shows the conductor connection process of the connection structure of an electric wire and a cable. It is sectional drawing which shows the wiping off process of the connection structure of an electric wire and a cable. It is sectional drawing which shows the coating layer formation process of the connection structure of an electric wire and a cable.

Hereinafter, with reference to drawings, the embodiment of the connection structure of the electric wire and cable concerning the present invention is described in detail. However, the embodiments described below are given various technically preferable limitations for carrying out the present invention, but the scope of the present invention is not limited to the following embodiments and illustrated examples.
In addition, the technique regarding the electric wire and cable described below is a technique applicable to both an electric wire and a cable.

[First embodiment]
FIG. 1 is a cross-sectional view of a first electric wire / cable 10 connected in the electric wire / cable connection structure 100, and FIG. 2 is a cross-sectional view of a second electric wire / cable 20 connected in the electric wire / cable connection structure 100. FIG.

[First wire / cable]
Aluminum or aluminum alloy is used for the material of the aluminum conductor 11 of the first electric wire / cable 10.
The aluminum conductor 11 is formed by twisting a plurality of strands 11a. As shown in FIG. 1, the aluminum conductor 11 is a conductor having a cross-sectional area of 60 mm ^{2 obtained} by twisting 19 strands 11a having a diameter of 2.0 mm. The aluminum conductor 11 is covered with an insulating layer 12 as a conductor covering layer made of an insulating material (for example, crosslinked polyethylene, ethylene propylene rubber, polyvinyl chloride).
The outer periphery of the insulating layer 12 may be covered with a sheath (not shown).
Further, the above numerical values of the respective parts are examples, and the dimensions can be arbitrarily changed.

[Second electric wire / cable]
Copper or copper alloy is used for the material of the copper conductor 21 of the second electric wire / cable 20.
The copper conductor 21 is formed by twisting a plurality of strands 21a. As shown in FIG. 2, the copper conductor 21 is a conductor having a cross-sectional area of 38 mm ^{2 obtained} by twisting seven strands 21 a having a diameter of 2.6 mm. The copper conductor 21 is covered with an insulating layer 22 as a conductor covering layer made of an insulating material (for example, crosslinked polyethylene, ethylene propylene rubber, polyvinyl chloride). The outer periphery of the insulating layer 22 may be covered with a sheath (not shown).
Here, assuming that the conductivity of copper is 100, the conductivity of aluminum is about 60. Therefore, in order to obtain substantially the same current carrying capacity between the copper conductor and the aluminum conductor, The cross-sectional area of the copper conductor may be about 60% of the cross-sectional area of the aluminum conductor.
The outer periphery of the insulating layer 22 may be covered with a sheath (not shown).
Further, the above numerical values of the respective parts are examples, and the dimensions can be arbitrarily changed in consideration of the correspondence with the first electric wire / cable 10.

[Schematic configuration of wire / cable connection structure]
FIG. 3 is a cross-sectional view of the wire / cable connection structure 100.
The electric wire / cable connection structure 100 includes a connector 30 that connects the aluminum conductor 11 exposed from the insulating layer 12 of the first electric wire / cable 10 and the copper conductor 21 exposed from the insulating layer 22 of the second electric wire / cable 10. The conductive compound 40 interposed between the aluminum conductor 11 and the copper conductor 21 and the connector 30, and the aluminum conductor 11, the copper conductor 21 and the connector 30 are covered and the conductive compound 40 is sealed inside. A covering layer 50 and an insulating layer 60 made of an electrically insulating resin that seals the covering layer 50, the aluminum conductor 11, the copper conductor 21, and the connector 30 are provided.

[connector]
The connector 30 is a metal member made of aluminum or aluminum alloy in which an insertion groove 31 for the aluminum conductor 11 is formed at one end and an insertion groove 32 for the copper conductor 21 is formed at the other end.
The connector 30 is inserted with the aluminum conductor 11 in an exposed state by removing the insulating layer 12 at the tip of the first electric wire / cable 10 with respect to one end thereof, and with respect to the other end. The copper conductor 21 in a state where the insulating layer 22 at the tip of the electric wire / cable 20 is removed and exposed is inserted. Then, in a state where these are inserted, pressure is applied from the outside so that the groove is closed using a die, and the aluminum conductor 11 and the copper conductor 21 are connected by compression connection.

The connector 30 is not limited to the above structure, and may have another structure. For example, it is possible to use a connector having a structure in which two grooves are provided in parallel, the aluminum conductor 11 and the copper conductor 21 are individually inserted into these grooves, and the compression connection is individually performed. Alternatively, a connector having a structure in which a cylindrical metal tube is formed and the aluminum conductor 11 and the copper conductor 21 are inserted from the respective end portions to perform compression connection may be used.
The connector 30 is not limited to aluminum or the like, and may be a copper or copper alloy connector.

[Conductive compound]
The connector 30 and the insertion grooves 31 and 32 are filled with a conductive compound 40 before the aluminum conductor 11 and the copper conductor 21 are inserted, and the aluminum conductor 11 and the copper conductor 21 are connected by compression connection. The conductive compound 40 is distributed between the connector 30 and the aluminum conductor 11 and the copper conductor 21.

The conductive compound 40 is made of a mixture containing conductive fine metal particles (for example, zinc fine particles) and viscous grease (mineral oil-based grease, silicone grease, other general grease, or castor oil). The metal fine particles of the conductive compound 40 break the oxide film on the surface of each element wire 11 a of the aluminum conductor 11 and the connector 30, so that the conductivity between the aluminum conductor 11 and the copper conductor 21 and the connector 30 is improved.
In addition, the grease of the conductive compound 40 inhibits the regeneration of each element wire 11a of the aluminum conductor 11 and the oxide film of the connector 30, and prevents moisture from entering the gaps between the aluminum conductor 11, the copper conductor 21, and the connector 30. And prevent these corrosions.

  The insertion grooves 31 and 32 of the connector 30 are preliminarily filled with an electrically conductive compound 40. When the aluminum conductor 11 and the copper conductor 21 are inserted and compression connection is performed, the connector 30 Although overflowing from the insertion grooves 31, 32, the excess compound 40 is wiped off. Further, the compound 40 remaining after wiping contributes to waterproofing and improvement of conductivity at the interface between the connector 30 and the aluminum conductor 11 and the copper conductor 21.

[Coating layer]
As shown in FIG. 3, the covering layer 50 extends from the outer periphery of the distal end portion of the insulating layer 12 of the first electric wire / cable 10 connected on both sides of the connector 30 to the distal end of the insulating layer 22 of the second electric wire / cable 20. The outer periphery of the aluminum conductor 11 exposed to the outside of the connector 30, the entire surface of the connector 30, and the outer periphery of the copper conductor 21 exposed to the outside of the connector 30 are all covered over the outer periphery of the portion.

The covering layer 50 is formed of a ribbon-like tape made of a material that has water tightness and insulating properties and does not react with the conductive compound 40. This tape is obtained by forming a self-adhesive blend mainly composed of butyl rubber into a tape shape, and more specifically, “Efco Tape No. 1” (manufactured by Furukawa Electric Power Systems Co., Ltd.) is used.
The covering layer 50 is formed by wrapping the tape by 1/2 wrapping from the outer periphery of the distal end portion of the insulating layer 22 of the first electric wire / cable 10 to the outer periphery of the distal end portion of the insulating layer 12 of the second electric wire / cable 20. It is formed by winding so that no gap is generated. Note that 1/2 wrap winding refers to, for example, a winding method in which half of the tape width overlaps.
Since the tape has a self-bonding property, the overlapped portion by wrapping is fused and integrated, so that the entire coating layer 50 can be formed into a cylindrical shape without a gap.
Thus, the conductive material attached to the connector 30, the aluminum conductor 11, the copper conductor 21, the end face of the first electric wire / cable insulating layer 12, the end face of the second electric wire / cable insulating layer 22, and the like. The sealing compound 40 is sealed inside the coating layer 50 to prevent leakage to the outside.

The tape is not limited to 1/2 wrap, but the wrap width may be changed, or the covering layer 50 may be formed vertically.
The covering layer 50 may be formed by winding a sheet having the same properties as the tape, or may be formed by a tube having the same properties as the tape. Alternatively, it may be formed by applying a putty having the same properties as the tape.

[Insulation layer]
As shown in FIG. 3, the insulating layer 60 is a cylindrical body in which the entire portion from one end to the other end of the coating layer 50 is accommodated inside.
That is, the outer periphery of the insulating layer 12 of the first electric wire / cable 10 and the outer periphery of the insulating layer 22 of the second electric wire / cable 20 from the position farther from the tip than the covering layer 50. It is formed over a position farther from the tip than 50.
As a result, the insulating layer 60 includes the entire covering layer 50, the connection portion (tip portion) of the first electric wire / cable 10 covered with the covering layer 50, the connector 30, and the second electric wire / cable 20. The connecting portion (tip portion) is sealed inside.

The outer periphery of the insulating layer 60 has a cylindrical shape with the same outer diameter except for both ends, and a small-diameter portion is formed at each end through a conical portion that is gradually reduced in diameter. Further, the tip of the small diameter portion is formed in a chamfered shape so as not to cause a corner. The insulating layer 60 may have a simple cylindrical shape having a constant outer diameter over the entire length.
The insulating layer 60 is formed by a mold process for supplying polyvinyl chloride, ethylene propylene rubber, silicone rubber, or other resin having high insulating performance to a mold for forming the above shape.
Therefore, the inside of the insulating layer 60 can be blocked from the outside and sealed in a sealed state.
The inner peripheries of both ends of the insulating layer 60 are in close contact with the outer periphery of the insulating layer 12 of the first electric wire / cable 10 and the outer periphery of the insulating layer 22 of the second electric wire / cable 20, respectively. It is desirable that a watertight adhesive is interposed between the layers to prevent moisture from entering inside more strictly.
Moreover, it replaces with said adhesive material, the outer periphery of the insulating layer 12 of the 1st electric wire and cable 10 from the one end part of the insulating layer 60, and the insulating layer 22 of the 2nd electric wire and cable 20 from the other end part of the insulating layer 60 A waterproof / protective layer may be formed by wrapping a waterproof tape around the outer periphery of the substrate to prevent moisture from entering more strictly.

[Wire / cable connection method]
An electric wire / cable connection method for forming the electric wire / cable connection structure 100 will be described with reference to FIGS.
As shown in FIG. 4, the aluminum conductor 11 of the first electric wire / cable 10 and the second electric wire / cable 20 are inserted into the two insertion grooves 31, 32 of the connector 30 previously filled with the conductive compound 40. Copper conductors 21 are inserted respectively. Then, the connector 30 is pressed from the outside and caulked to firmly hold and connect the aluminum conductor 11 and the copper conductor 21 in the insertion grooves 31 and 32 (conductor connection step).

At this time, the metal fine particles of the conductive compound 40 break the respective oxide wires 11a of the aluminum conductor 11 and the oxide film on the surface of the connector 30, and connect the aluminum conductor 11, the copper conductor 21 and the connector 30 in a good conductive state. To do.
In addition, the conductive compound 40 overflows to the outside from the insertion grooves 31 and 32 and adheres to the outer periphery of the aluminum conductor 11 and the copper conductor 21 in a state exposed to the outside of the insertion grooves 31 and 32. The entire surface of the aluminum conductor 11 and the copper conductor 21 exposed from the insulating layers 12 and 22 is spread, and a watertight state by the conductive compound 40 is ensured.

  Next, as shown in FIG. 5, the excess conductive compound 40 leaked to the outside of the insertion grooves 31 and 32 of the connector 30 is wiped off (wiping process). If the amount of the conductive compound 40 leaked to the outside of the connector 30 is too large, the conductive compound 40 may leak to the outside of the coating layer 50 when the coating layer 50 is formed. Minutes are wiped off.

Next, as shown in FIG. 6, a covering layer 50 that covers the aluminum conductor 11, the copper conductor 21, and the connector 30 is formed (covering layer forming step).
That is, the tape having the self-bonding property described above is stretched from the outer periphery of the insulating layer 12 of the first electric wire / cable 10 to the outer periphery of the insulating layer 22 of the second electric wire / cable 20. The covering layer 50 is formed by manually winding it with a 1/2 wrap.
As a result, the outer periphery of the connector 30 and the aluminum conductor 11 and the copper conductor 21 exposed from both sides thereof becomes the inside of the coating layer 50, and the conductive compound 40 used for these is sealed in the coating layer 50. The

Then, as shown in FIG. 3, the covering layer 50 and the connecting end of the first electric wire / cable 10 covered by the covering layer 50, the connecting end of the second electric wire / cable 20, and the connector 30 are electrically insulating resin. The insulating layer 60 to be sealed is formed (insulating layer forming step).
That is, the connector 30 covered with the covering layer 50, the connection portion of the first electric wire / cable 10 and the connection portion of the second electric wire / cable 20 are formed on the mold for forming the shape of the insulating layer 60 described above. Store.
Further, molding is performed by injecting a resin into the interior of the mold at a predetermined pressure.
At this time, since the resin is supplied to a range outside the both end portions of the coating layer 50, the coating layer 50 and the aluminum conductor 11, the copper conductor 21 and the connector 30 coated thereon are completely inside the insulating layer 60. Sealed.
In addition, since the conductive compound 40 is sealed by the covering layer 50, even if the resin is supplied to the surroundings at a constant pressure, mixing of the conductive compound 40 into the resin is suppressed.
And after resin hardens | cures, the insulating layer 60 is taken out from a metal mold | die. If necessary, watertight processing is performed on both ends of the insulating layer 60. The electric wire / cable connection structure 100 is completed through the above steps.

[Technical effects of the first embodiment]
In the electric wire / cable connection structure 100, the covering layer 50, the connecting portion of the first electric wire / cable 10, the second electric wire / cable 20 and the connector 30 are sealed with an insulating layer 60 made of an electrically insulating resin. Therefore, it is possible to form the insulating layer 60 with high productivity through an industrial manufacturing process without requiring winding of an insulating tape or the like that has a skill and is likely to cause variations in the insulating performance, so that the insulating performance is stable. Layer 60 can be formed.
Further, the electric wire / cable connection structure 100 uses the conductive compound 40 to achieve good electrical continuity between the aluminum conductor 11 and the copper conductor 21, which are dissimilar metals, and to corrode the aluminum conductor 11 and the connector 30 due to moisture intrusion. It is possible to reduce.

  In addition, since the aluminum conductor 11, the copper conductor 21, and the connector 30 are covered with the covering layer 50 and the conductive compound 40 is sealed inside thereof, the conductivity to the electrically insulating resin forming the insulating layer 60 is increased. The mixing of the compound 40 is suppressed, and the insulating layer 60 can maintain high insulating performance. In addition, since the compound 40 is sealed by the covering layer 50, the compound 40 is used when a watertight treatment is performed between the insulating layer 60 and the insulating layers 12 and 22 of the first and second electric wires / cables 10 and 20. Therefore, high watertightness performance can be obtained.

Therefore, the conductive compound 40 achieves good connection between the first electric wire / cable 10 and the second electric wire / cable 20 which has good conductivity and suppresses the occurrence of corrosion, and has high productivity, The insulating layer 60 can be formed by resin molding with stable insulation performance.
Further, since the first electric wire / cable 10 and the second electric wire / cable 20 can be connected while maintaining high electrical conductivity and high insulation against the outside, the first electric wire having the aluminum conductor 11 can be connected. It is possible to connect the cable to a conventional facility such as a switchboard that is assumed to be connected to a copper conductor wire / cable at good cost.

Moreover, the coating layer 50 can be easily formed by forming the coating layer 50 with a tape or a sheet having watertightness and insulation.
In particular, by using a self-bonding tape or sheet, the overlapping portion of the tape or sheet can be fused, effectively reducing moisture ingress from the outside and leaking the compound to the outside. Can be effectively reduced.

  Further, when the covering layer is formed with a putty having watertightness and insulating properties, it is easy even if the connector 30 connecting the aluminum conductor 11 and the copper conductor 21 has a complicated shape or gap. Thus, it is possible to effectively reduce moisture intrusion from the outside and effectively reduce leakage of the compound 40 to the outside.

  The insertion grooves 31 and 32 of the connector 30 are filled with a conductive compound, and the aluminum conductor 11 of the first electric wire / cable 10 and the copper conductor 21 of the second electric wire / cable 20 are connected by compression connection. Since the configuration is adopted, the conductive compound 40 is pushed out to the outside of the connector 30, and the conductive compound 40 is effectively supplied to the exposed portions of the aluminum conductor 11 and the copper conductor 21 outside the connector 30. Therefore, it is possible to improve the conductivity between the two while performing the connection work easily and quickly.

This also allows the conductive compound 40 to cover the surfaces of the aluminum conductor 11 and the copper conductor 21 that are exposed outside the connector 30, and the aluminum conductor 11 and the copper conductor 21 formed by the conductive compound 40. Thus, it is possible to more strictly prevent water-tightness and to more effectively prevent corrosion.
In addition, even when the conductive compound 40 is leaked to the outside of the connector 30 and the aluminum conductor 11 and the copper conductor 21 are covered, the insulating layer 60 is effectively formed by the covering layer 50. Mixing into the resin is suppressed, and it is possible to maintain the high insulation and water tightness of the insulating layer 60.

  In addition, since the electric wire / cable connection method includes a wiping process of the conductive compound 40 leaked to the outside of the connector 30, the leakage of the compound from the coating layer 50 is effectively suppressed, and the insulation is effectively performed. Mixing into the electrically insulating resin forming the layer 60 is suppressed, and high watertight performance can be obtained.

[Second Embodiment]
A wire / cable connection structure 100A according to the second embodiment will be described with reference to FIGS.
Regarding the electric wire / cable connection structure 100A, the same components as those in the electric wire / cable connection structure 100 are denoted by the same reference numerals, and redundant description is omitted, and differences from the electric wire / cable connection structure 100 are mainly described. To do.

The wire / cable connection structure 100A is different from the wire / cable connection structure 100 in the structure of the covering layer 50A.
The covering layer 50 </ b> A includes a connector 30 and a case that accommodates a connection portion of the first electric wire / cable 10 and the second electric wire / cable 20 connected to the connector 30.
The covering layer 50A has a cylindrical shape as shown in the figure, and, like the covering layer 50 described above, has a water tightness and an insulating property and does not react with the conductive compound 40. Further, it is made of a flexible material, for example, the same resin as the insulating layer 60.

As shown in FIG. 8, the covering layer 50 </ b> A has a hollow portion 51 </ b> A that accommodates the connector 30 and the connection portion of the aluminum conductor 11 and the copper conductor 21 connected to the connector 30 in the middle portion in the longitudinal direction. In the longitudinal direction one end and the other end of the coating layer 50A, communication holes 52A and 53A communicating with the hollow portion 51A are formed.
One communication hole 52A has an inner diameter equal to or less than the outer diameter of the insulating layer 12 of the first electric wire / cable 10, and the other communication hole 53A has an inner diameter of the insulating layer 22 of the second electric wire / cable 10. It is equal to or less than the outer diameter.
Thus, when the covering layer 50A accommodates the connector 30 and the connecting portion of the first electric wire / cable 10 and the second electric wire / cable 20 connected to the connector 30, the inner peripheral surface of the communication hole 52A is Since the outer peripheral surface of the insulating layer 12 of the first electric wire / cable 10 is in close contact, and the inner peripheral surface of the communication hole 53A is in close contact with the outer peripheral surface of the insulating layer 22 of the second electric wire / cable 20, the internal conductive compound 40 leaks can be reduced and prevented. In addition, you may add a watertight sealing process between each communication hole 52A, 53A, the insulating layer 12 of the 1st electric wire and cable 10, and the insulating layer 22 of the 2nd electric wire and cable 20. FIG.

As shown in FIG. 9, a cutout portion 54 </ b> A reaching the hollow portion 51 </ b> A and the communication holes 52 </ b> A and 53 </ b> A is formed along the entire length in the longitudinal direction on the outer peripheral surface of the coating layer 50 </ b> A.
Furthermore, a convex strip 55A having a narrowed base that protrudes toward the other end surface is formed on one end surface of the cut portion 54A over the entire length of the coating layer 50A, and the convex strip 55A is formed on the other end surface. A concave groove 56A having a narrow opening end corresponding to is formed over the entire length of the coating layer 50A.

  With these structures, the covering layer 50A is opened from the cut portion 54A, the connecting portion of the first electric wire / cable 10, the connecting portion of the second electric wire / cable 20, and the connector 30 are accommodated. The cut portion 54A can be closed by pushing into 56A. By these operations, the coating layer 50A can be easily and quickly formed around the connector 30.

An electric wire / cable connection method for forming the electric wire / cable connection structure 100A will be briefly described.
First, a conductor connection step is performed, and the aluminum conductor 11 of the first electric wire / cable 10 and the copper conductor 21 of the second electric wire / cable 20 are connected to the connector 30 in the same manner as the electric wire / cable connection structure 100 described above. (See FIG. 4).
Then, a wiping process is performed, and the surplus conductive compound 40 around the aluminum conductor 11 of the first electric wire / cable 10, the copper conductor 21 of the second electric wire / cable 20, and the connector 30 is converted into the electric wire / Wiping is performed in the same manner as the cable connection structure 100 (see FIG. 5).
In the covering layer forming step, the covering layer 50A manufactured industrially in advance is mounted around the connector. That is, the covering layer 50A is opened from the notch 54A, the connecting portion of the first electric wire / cable 10, the connecting portion of the second electric wire / cable 20, and the connector 30 are accommodated, and the protrusion 55A is pushed into the groove 56A. Then, the formation of the coating layer 50A is completed.
Then, the insulating layer forming step is performed by the same operation as that of the electric wire / cable connection structure 100, and when necessary, both ends of the insulating layer 60 are subjected to water-tight processing to complete the electric wire / cable connection structure 100A.

In this way, the covering layer 50A is formed in a case that accommodates the connecting portion of the first electric wire / cable 10, the connecting portion of the second electric wire / cable 20, and the connector 30, thereby forming the covering layer 50A. It is possible to reduce the work load and perform the formation work quickly and easily.
Further, by providing the cut layer 54A, the ridges 55A, and the concave grooves 56A in the covering layer 50A, the forming operation can be performed more quickly and easily.
In addition, since the coating layer 50A having the above-described configuration can be industrially manufactured in advance, the coating layer 50A can be formed more easily, and the coating layer has stable water-tightness performance and compound sealing performance. 50A can be used.

[Third embodiment]
A wire / cable connection structure 100B according to a third embodiment will be described with reference to FIGS.
Regarding the electric wire / cable connection structure 100B, the same components as those in the electric wire / cable connection structure 100 are denoted by the same reference numerals and redundant description is omitted, and the differences from the electric wire / cable connection structure 100 are mainly described. To do.

The electric wire / cable connection structure 100B is different from the electric wire / cable connection structure 100 in the structure of the covering layer 50B.
This covering layer 50B is composed of a resin layer separate from the insulating layer 60 that seals the connector 30 and the connecting portion of the first electric wire / cable 10 and the second electric wire / cable 20 connected to the connector 30. Has been.
The covering layer 50B has a cylindrical shape as shown in the figure, and has a water-tight property and does not react with the conductive compound 40, for example, the insulating layer 60, like the covering layer 50 described above. Are formed from the same resin or the like.

As shown in FIG. 10, the covering layer 50 </ b> B is formed by filling the connector 30, the exposed aluminum conductor 11 of the first electric wire / cable 10, the connection portion of the insulating layer 12, and the second electric wire / cable 20. The exposed connection portion of the copper conductor 21 and the insulating layer 22 and the conductive compound 40 attached to these surfaces are wrapped and sealed without any gap.
In addition, you may add a watertight sealing process between the coating layer 50B, the insulating layer 12 of the 1st electric wire and cable 10, and the insulating layer 22 of the 2nd electric wire and cable 20. FIG.

An electric wire / cable connection method for forming the electric wire / cable connection structure 100B will be described.
First, as shown in FIG. 11, a conductor connecting step is performed, and the aluminum conductor 11 of the first electric wire / cable 10 and the copper conductor 21 of the second electric wire / cable 20 are connected to each other as described above. The connector 30 is connected in the same manner as 100.
Then, as shown in FIG. 12, a wiping process is performed, and the surplus conductive compound around the aluminum conductor 11 of the first electric wire / cable 10, the copper conductor 21 of the second electric wire / cable 20, and the connector 30. 40 is wiped off in the same manner as the wire / cable connection structure 100 described above.

Then, as shown in FIG. 13, a coating layer 50 </ b> B that seals the connection portion of the first electric wire / cable 10, the connection portion of the second electric wire / cable 20, and the connector 30 with a resin is formed (coating layer formation). Process).
That is, the connector 30, the connection portion of the first electric wire / cable 10 and the connection portion of the second electric wire / cable 20 are stored in the mold for forming the shape of the covering layer 50 </ b> B described above, and the resin is contained therein. Is injected at a predetermined pressure to perform mold processing. And after hardening of resin, coating layer 50B is taken out from a metal mold | die.

Then, the insulating layer 60 is formed by sealing the covering layer 50B, the connecting portion of the first electric wire / cable 10 covered by the covering layer 50B, the connecting portion of the second electric wire / cable 20 and the connector 30 with an electrically insulating resin. (Insulating layer forming step).
That is, the connector 30 covered with the coating layer 50B, the connection portion of the first electric wire / cable 10 and the connection portion of the second electric wire / cable 20 are formed on the mold for forming the shape of the insulating layer 60 described above. The resin is stored, and resin is injected into the interior at a predetermined pressure to perform molding.
At this time, since the resin is supplied to a range outside the both end portions of the coating layer 50B, the coating layer 50B and the aluminum conductor 11, the copper conductor 21 and the connector 30 coated thereon are completely inside the insulating layer 60. Sealed.
In addition, since the conductive compound 40 is sealed by the covering layer 50B, the conductive compound 40 may be mixed into the resin forming the insulating layer 60 even if the resin is supplied to the surroundings at a constant pressure. Reduced and prevented.
And after cooling of resin, the insulating layer 60 is taken out from a metal mold | die. If necessary, watertight processing is performed on both ends of the insulating layer 60. The electric wire / cable connection structure 100B is completed through these processes.

  Thus, by forming the coating layer 50B with a resin layer that seals the connection portion of the first electric wire / cable 10, the connection portion of the second electric wire / cable 20, and the connector 30, the coating layer 50B is industrially manufactured. Therefore, it is possible to use the coating layer 50B that reduces the work burden of forming the coating layer 50B and stabilizes the watertight performance and the compound sealing performance.

[Fourth embodiment]
A wire / cable connection structure 100C according to a fourth embodiment will be described with reference to FIGS.
Regarding the wire / cable connection structure 100C, the same components as those of the wire / cable connection structure 100 are denoted by the same reference numerals, and redundant description is omitted, and differences from the wire / cable connection structure 100 are mainly described. To do.

  The electric wire / cable connection structure 100 described above has been described with reference to the connection structure in which the tip of the first electric wire / cable 10 is connected to the tip of the second electric wire / cable 20. The connection structure 100 </ b> C is different in that the connection structure is connected to the tip of the second electric wire / cable 20 using the midway position in the longitudinal direction of the first electric wire / cable 10 as a connection part.

  That is, as shown in FIG. 14, in the first electric wire / cable 10, the insulating layer 12 is removed at an intermediate position in the longitudinal direction, and the aluminum conductor 11 is exposed. The copper conductor 21 exposed from the tip of the second electric wire / cable 20 is connected using the exposed portion as a connecting portion.

The connector 30C of the first electric wire / cable connection structure 100C is formed with an insertion groove 31C for the aluminum conductor 11 and an insertion groove 32C for the copper conductor 21 in parallel.
In the first electric wire / cable 10, the aluminum conductor 11 exposed while penetrating the connector 30 </ b> C is held in the insertion groove 31 </ b> C, and the copper conductor 21 of the second electric wire / cable 20 is inserted into the insertion groove from one end of the connector 30 </ b> C. It is inserted and held in 32C.
The connector 30C may have a half structure in order to easily hold the aluminum conductor of the first electric wire / cable 10.
The insertion grooves 31C and 32C of the connector 30C are filled with a conductive compound 40 in advance, the aluminum conductor 11 and the copper conductor 21 are inserted, and compression connection is performed, so that leakage occurs from both ends of the connector 30C. Thus, the surfaces of the aluminum conductor 11 and the copper conductor 21 exposed from both sides of the connector 30C are covered.

The covering layer 50 </ b> C is formed by winding a tape having the same self-bonding property as the tape forming the covering layer 50 with a 1/2 wrap winding.
That is, from the outer periphery of the end portion of the insulating layer 12 on one side of the exposed aluminum conductor 11 in the first electric wire / cable 10 through the entire connector 30C, the opposite side of the exposed aluminum conductor 11 in the first electric wire / cable 10 A covering layer 50 </ b> C is formed between the outer periphery of the end of the insulating layer 12 and the outer periphery of the tip of the insulating layer 22 of the second electric wire / cable 20.
The aluminum conductor 11 of the first electric wire / cable 10, the copper conductor 21 of the second electric wire / cable 20, the insulating layer 12 of the first electric wire / cable 10, and the insulating layer 22 of the second electric wire / cable 20. Gaps are likely to occur between them, and it may be difficult to fill them with tape.
For this reason, these gaps are filled with fillers 51C and 52C made of the same material as the tape forming the covering layer 50C.
Thereby, the conductive compound 40 can be effectively sealed inside the coating layer 50C.

  The insulating layer 60C includes the connector 30C, the connecting portion of the first electric wire / cable 10 that penetrates both sides of the connector 30C, the distal end portion of the second electric wire / cable 20 aligned in parallel with the first electric wire / cable 10, and the covering layer 50C. Are the same as those of the insulating layer 60 described above except that the shape can be covered.

An electric wire / cable connection method for forming the electric wire / cable connection structure 100C will be described.
First, as shown in FIG. 15, a conductor connecting step is performed, and the aluminum conductor 11 of the first electric wire / cable 10 and the copper conductor 21 of the second electric wire / cable 20 are connected by the connector 30C.
That is, the aluminum conductor 11 of the first electric wire / cable 10 is inserted into the insertion groove 31C, the copper conductor 21 of the second electric wire / cable 20 is inserted into the insertion groove 32C, the connector 30C is pressurized, and the compression connection is established. Done.
Then, as shown in FIG. 16, a wiping process is performed, and the surplus conductive compound around the aluminum conductor 11 of the first electric wire / cable 10, the copper conductor 21 of the second electric wire / cable 20, and the connector 30C. 40 is wiped off.

  Then, as shown in FIG. 17, the fillers 51C and 52C are filled in gaps with respect to the connecting portion of the first electric wire / cable 10, the connecting portion of the second electric wire / cable 20, and the connector 30C, and then self-bonding. The covering layer 50C is formed by winding a conductive tape (covering layer forming step).

Then, the covering layer 50C and the connecting portion of the first electric wire / cable 10 covered with the covering layer 50C, the connecting portion of the second electric wire / cable 20 and the connector 30C are sealed with an electrically insulating resin, and the insulating layer 60C is sealed. (Insulating layer forming step).
That is, the connector 30C covered with the coating layer 50C, the connection portion of the first electric wire / cable 10 and the connection portion of the second electric wire / cable 20 are formed on the mold for forming the shape of the insulating layer 60C. The resin is stored, and resin is injected into the interior at a predetermined pressure to perform molding.
At this time, since the resin is supplied to the outside of both ends of the coating layer 50C, the coating layer 50C and the aluminum conductor 11, the copper conductor 21 and the connector 30 coated thereon are completely inside the insulating layer 60C. Sealed.
Further, since the conductive compound 40 is sealed by the covering layer 50C, the conductive compound 40 may be mixed into the resin forming the insulating layer 60C even if the resin is supplied to the surroundings at a constant pressure. Reduced and prevented.
Then, after the resin is cured, the insulating layer 60C is taken out from the mold. If necessary, watertight processing is performed on both ends of the insulating layer 60C. The electric wire / cable connection structure 100C is completed through the above steps.

  In this way, when the connector 30C is configured to connect the aluminum conductor 11 exposed at a midway position in the longitudinal direction of the first electric wire / cable 10 and the copper conductor 21 of the second electric wire / cable 20, The second electric wire / cable 20 can be connected so as to be branched from the first electric wire / cable 10, and a plurality of second electric wires / cables 20 can be connected to the first electric wire / cable 10. It becomes easy and the first electric wire / cable 10 having the aluminum conductor 11 is good and low-cost with respect to a plurality of conventional facilities such as a distribution board assuming connection with a copper conductor electric wire / cable or a plurality of locations of the conventional facilities. It becomes possible to connect.

  In the above-described embodiments, it is needless to say that specific detailed structures and the like can be changed as appropriate.

10 First electric wire / cable 11 Aluminum conductor 12 Insulating layer (conductor covering layer)
20 Second electric wire / cable 21 Copper conductor 22 Insulating layer (conductor covering layer)
30, 30C Connector 31, 32, 31C, 32C Insertion groove 40 Conductive compound 50, 50A, 50B, 50C Covering layer 51C, 52C Filling 60, 60C Insulating layer 100, 100A, 100B, 100C Connection structure

Claims (19)

A connection structure for connecting a first electric wire / cable having an aluminum conductor and a conductor covering layer, a copper conductor, and a second electric wire / cable having a conductor covering layer,
A connector for connecting an aluminum conductor exposed from the conductor coating layer of the first electric wire / cable and a copper conductor exposed from the conductor coating layer of the second electric wire / cable;
A conductive compound interposed between the aluminum conductor and the copper conductor and the connector;
A coating layer that covers the connector and the connection portion of the aluminum conductor and the copper conductor connected to the connector and seals the conductive compound inside;
An electric wire / cable connection structure comprising: the covering layer; the connector; and an insulating layer made of an electrically insulating resin that seals a connection portion of the aluminum conductor and the copper conductor connected to the connector. .   The wire / cable connection structure according to claim 1, wherein the coating layer is a tape or a sheet having watertightness and insulating properties.   3. The electric wire / cable connection structure according to claim 2, wherein the tape or the sheet has a self-bonding property.   The wire / cable connection structure according to claim 1, wherein the coating layer is a putty having water tightness and insulating properties.   The wire / cable connection structure according to claim 1, wherein the coating layer is a case that accommodates the connector and a connection portion of the aluminum conductor and the copper conductor connected to the connector.   The said coating layer is a resin layer separate from the said insulating layer which seals the connection part of the said aluminum conductor and the said copper conductor connected to the said connector and the said connector. Electric wire / cable connection structure. In the first electric wire / cable, the aluminum conductor is exposed from the conductor coating layer at an intermediate position in the longitudinal direction,
7. The electric wire according to claim 1, wherein the aluminum conductor exposed from the conductor covering layer and the copper conductor of the second electric wire / cable are connected by the connector. Cable connection structure.   The electric wire / cable connection structure according to any one of claims 1 to 7, wherein a surface of an outer portion of the connector in the aluminum conductor and the copper conductor is also covered with the conductive compound. .   The aluminum conductor of the first electric wire / cable and the copper conductor of the second electric wire / cable are connected by the compressed connector, according to any one of claims 1 to 8. Wire / cable connection structure as described. A connection method for connecting a first electric wire / cable having an aluminum conductor and a conductor coating layer and a second electric wire / cable having a copper conductor and a conductor coating layer,
Connecting the aluminum conductor exposed from the conductor coating layer of the first electric wire / cable and the copper conductor exposed from the conductor coating layer of the second electric wire / cable by a connector;
Forming a coating layer covering the connector and the connecting portion of the aluminum conductor and the copper conductor connected to the connector, and forming a conductive compound interposed between the aluminum conductor and the copper conductor and the connector; Sealing inside the coating layer;
A step of forming an insulating layer that seals the connecting portion of the covering layer, the connector, and the aluminum conductor and the copper conductor connected to the connector with an electrically insulating resin. How to connect the cable.   The wire / cable connection method according to claim 10, wherein the covering layer is formed by winding or sticking a tape or sheet having water tightness and insulation.   12. The electric wire / cable connection method according to claim 11, wherein the tape or the sheet has a self-bonding property.   The wire / cable connection method according to claim 10, wherein the coating layer is formed by applying a putty having watertightness and insulating properties.   The wire / cable connection method according to claim 10, wherein the covering layer is formed by attaching a case that accommodates the connector and the connection portion of the aluminum conductor and the copper conductor connected to the connector.   11. The electric wire / cable connection according to claim 10, wherein the covering layer is formed by sealing the connector and a connecting portion of the aluminum conductor and the copper conductor connected to the connector by resin molding. Method.   16. The connector according to claim 10, wherein the connector connects the aluminum conductor of the first electric wire / cable and the copper conductor of the second electric wire / cable by compression connection. How to connect wires and cables.   17. The electric wire / cable connection method according to claim 16, wherein the compound is leaked to the outside of the connector by compression connection of the connector.   The electric wire / cable connection method according to claim 17, further comprising a step of wiping off the surplus compound leaked to the outside of the connector.   The insulating layer is formed by sealing the covering layer, the connector, and a connection portion of the aluminum conductor and the copper conductor connected to the connector by molding an electrically insulating resin. Item 19. The electric wire / cable connection method according to any one of Items 10 to 18.

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