JP5445805B2 - Electric wire connection structure and vehicle conductive path having the electric wire connection structure - Google Patents

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 that it is weak against heat and vibration. Therefore, it is a copper wire having a copper twisted wire conductor in which copper strands are twisted together in a hot place such as the vicinity of a motor or a place with strong vibration. 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, the outer diameter of the first strand is that of the second strand. An outer diameter of the first electric wire is formed so that an end portion of the first stranded wire conductor of the first electric wire is bitten into an end portion of the second stranded wire conductor of the second electric wire. The wire connecting structure is characterized in that the diameter is 0.3 to 2.0 mm, and the outer diameter of the second strand is 0.1 to 0.5 mm.

  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 connecting portion connecting the first stranded wire conductor and the second stranded wire conductor may be substantially rectangular in cross-sectional view as a whole.

  The first strand and the second strand may be made of different metals, and a connecting portion between the first strand and the second strand may be covered with a mold resin.

  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 conductive path for vehicles which has the said electric wire connection structure in the conductive path for vehicles which connects between the apparatuses mounted in the vehicle.
The device may be an inverter, 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), (b) is a figure explaining the procedure at the time of forming the electric wire connection structure of FIG.

  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 conductor 4 obtained by twisting the copper strands increases, making bending difficult during wiring, and the aluminum stranded conductor 2 during ultrasonic connection. This is because it becomes difficult to bite the copper stranded conductor 4.

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 desirably about 1.0 to 1.5 times.

  The wire connection structure 1 according to the present embodiment has a shape in which the end of the aluminum stranded wire conductor 2 is bitten into the end of the copper stranded wire conductor 4 of the copper wire 5. More specifically, in the electric wire connection structure 1, the end portion of the aluminum stranded wire conductor 2 and the end portion of the copper stranded wire conductor 4 are opposed to each other by a predetermined length, and the overlapped portion is obtained by ultrasonic connection. Is pressed and excited so that the end portion of the aluminum stranded wire conductor 2 bites into the end portion of the copper stranded wire conductor 4 from the side surface side of the end portion of the copper stranded wire conductor 4.

  As shown in FIG.1 (b), the connection part 8 which connected the edge parts of both the strand wire conductors 2 and 4 becomes substantially rectangular shape by sectional view as a whole, The upper surface (illustration upper side surface) The aluminum twisted wire conductor 2 is cut into the central portion of the wire.

  The wire connection structure 1 is formed using the ultrasonic connection device 21 shown in FIGS. 2 (a) and 2 (b). The ultrasonic connection device 21 is disposed on the anvil 23, the anvil 23 fixed on the base 22, the horn 24 disposed opposite to the upper portion of 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), (b) 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. The end of the aluminum stranded wire conductor 2 of the aluminum electric wire 3 is placed above the end of the copper stranded wire conductor 4 so as to overlap a predetermined length from the front end side of the copper stranded wire conductor 4. Put.

  In this state, as shown in FIG. 2 (b), the horn 24 is lowered to the anvil 23 side while being slightly vibrated, and the end of the aluminum stranded wire conductor 2 is connected to the copper stranded wire conductor 4 by the pressing portion 24 a of the horn 24. Pressurize to the side. At this time, since the aluminum strands constituting the aluminum stranded wire conductor 2 are thicker than the copper strands constituting the copper stranded wire conductor 4, the copper strands are thinner and less rigid than the aluminum strands pressed from above. The wire escapes and the aluminum stranded wire conductor 2 bites into the copper stranded wire conductor 4. At the same time, the stranded conductors 2 and 4 are heated by friction caused by the slight vibration of the horn 24, and the strands of the stranded conductors 2 and 4 as well as the aluminum strands and the copper strands are welded. The connection portion 8 is formed by integration.

  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 outer diameter of the aluminum strand is formed to be larger than the outer diameter of the copper strand, and the end of the aluminum stranded wire conductor 2 of the aluminum electric wire 3 is connected to the copper stranded copper wire 5. A shape that bites into the end of the wire conductor 4 is formed.

  When the aluminum wire 3 and the copper wire 5 are connected by the ultrasonic connecting device 21 by forming the outer diameter of the aluminum wire larger than the outer diameter of the copper wire, the aluminum stranded conductor 2 and the copper stranded wire are connected. Even if the contact with the wire conductor 4 is a contact between curved surfaces, the end portion of the aluminum stranded wire conductor 2 bites into the end portion of the copper stranded wire conductor 4. The relative position shift is reduced. As a result, reproducibility in manufacturing is improved.

  Further, the shape in which the end portion of the aluminum stranded wire conductor 2 bites into the end portion of the copper stranded wire conductor 4 reduces the fact that the end portions of both the stranded wire conductors 2 and 4 are tapered. It becomes possible to reduce the disconnection of the strands in the vicinity of the tips of the line conductors 2 and 4.

  Furthermore, since the end portion of the aluminum stranded wire conductor 2 is bitten into the end portion of the copper stranded wire conductor 4, compared to the case where it is not bitten (for example, when joining only on the surfaces of both stranded wire conductors), The joint area of both the stranded wire conductors 2 and 4 increases, and the strength against bending when the two electric wires 3 and 5 are bent in a direction to be peeled off (for example, when they are bent by 90 °) increases.

  In addition, since the end portion of the aluminum stranded wire conductor 2 is bitten into the end portion of the copper stranded wire conductor 4, the connection portion 8 has a shape in which relatively low strength aluminum is encased in high strength copper. It is possible to improve the strength of the connection portion 8.

  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. Moreover, since the outer diameter of the copper strand is 0.5 mm or less, the aluminum strand wire conductor 2 is less likely to bite into the copper strand wire conductor 4 due to the high rigidity of the copper strand during ultrasonic connection. There is nothing.

  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 wire conductor (first stranded wire conductor)
3 Aluminum wire (first wire)
4 Copper twisted conductor (second twisted conductor)
5 Copper wire (second wire)
8 connections

Claims (8)

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 wire connection structure that connects two wires in a straight line by ultrasonic connection,
The outer diameter of the first strand is formed thicker than the outer diameter of the second strand,
The end of the first stranded wire conductor of the first electric wire is shaped to bite into the end of the second stranded wire conductor of the second electric wire,
The wire connecting structure, wherein an outer diameter of the first strand is 0.3 to 2.0 mm, and an outer diameter of the second strand is 0.1 to 0.5 mm. 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, wherein the second electric wire is a copper electric wire having a copper stranded wire conductor formed by twisting a plurality of copper strands.   The electric wire connection structure according to claim 1 or 2, wherein the connection portion connecting the first stranded wire conductor and the second stranded wire conductor has a substantially rectangular shape in a sectional view as a whole. The first strand and the second strand are made of different metals,
The wire connection structure according to any one of claims 1 to 3, wherein a connecting portion between the first strand and the second strand is covered with a mold resin.   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 a vehicle conductive path that connects devices mounted on a vehicle,
A conductive path for a vehicle comprising the electric wire connection structure according to claim 1.   The vehicle electrical path according to claim 7, wherein the device is an inverter, a motor, a battery, and an air conditioner.

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