JP7393924B2 - Power supply connector with cable, manufacturing method of power supply connector with cable - Google Patents

Description

The present invention relates to a power supply connector with a cable and a method of manufacturing the power supply connector with a cable.

Patent Document 1 listed below discloses a power supply connector with a cable in which a cable including a power line formed by collectively twisting a plurality of conductor wires around a cooling pipe is connected to a terminal.

JP2018-018748A

By the way, if the conductor wire is inserted into the hole of the terminal while being twisted and is compressed and connected, the conductor wire and the terminal will be connected with a gap remaining between the inner surface of the hole and the conductor wire. In this case, the connection resistance between the conductor wire and the terminal becomes high, and there is a risk that heat will be generated at the connection part and the temperature of the terminal will rise. In particular, in power supply connectors that supply power to electric vehicles and the like, large currents of several hundred amperes flow through them, so excessive temperature rise at the terminals is considered a problem.

The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide a power supply connector with a cable and a method for manufacturing the power supply connector with a cable, which can suppress the temperature rise at the connection portion between a terminal and a conductor wire. do.

A power supply connector with a cable according to one aspect of the present invention includes a terminal having a hole formed therein, and a cable including a power line in which a conductor wire inserted into the hole is covered with a sheath in a twisted state. , wherein the conductor wire has a non-twisted portion extending linearly in a portion exposed from the sheath, and the non-twisted portion is connected to the hole of the terminal. is inserted and connected by compression.
According to this configuration, the untwisted portion of the conductor wire is inserted into the hole of the terminal and connected by compression, so that the conductor wire and the terminal are connected in the hole of the terminal with few gaps, and the conductor wire The contact area between the terminal and the terminal can be increased. Therefore, the connection resistance between the terminal and the conductor wire is suppressed, and the temperature rise at the connection part is suppressed.

In the power supply connector with a cable, the power line includes a cooling tube, the conductor wire has a cooling section in contact with the cooling tube, and a non-cooling section separated from the cooling tube, and the non-twisted portion includes: It may be provided at least in the non-cooled section.
According to this configuration, in the uncooled section away from the cooling tube, the conductor wires are not twisted and extend in a straight line, so heat is more difficult to trap than when the conductor wires are twisted, and the effect of air cooling and heat dissipation is improved. Therefore, it is possible to suppress the temperature rise at the connection portion between the terminal and the conductor wire.

Further, in the method for manufacturing a power supply connector with a cable according to one aspect of the present invention, a terminal in which a hole is formed and a conductor wire inserted into the hole are covered with a coating in a twisted state. A method for manufacturing a power supply connector with a cable, comprising: a cable including a power line; a first step of peeling off the covering of the power line to expose a part of the conductor wire; and after the first step, exposing the conductor wire. a second step of untwisting the conductor wire and stretching it straight; a third step of inserting the conductor wire into the hole of the terminal after the second step; and after the third step, and a fourth step of compressively deforming the hole and connecting the terminal and the conductor wire.
According to this method, a part of the conductor wire is exposed in the first step, the conductor wire is untwisted in the second step, the conductor wire is inserted into the hole of the terminal in the third step, and the conductor wire is inserted into the hole in the fourth step. Since the conductor wire is connected to the terminal by compressively deforming the conductor wire, the conductor wire and the terminal are connected with few gaps in the hole of the terminal, and the contact area between the conductor wire and the terminal can be increased. Therefore, the connection resistance between the terminal and the conductor wire is suppressed, and the temperature rise at the connection part is suppressed.

In the method for manufacturing a power supply connector with a cable, the conductor wires may be bundled with a band member after the second step and before the third step.
According to this method, since the untwisted conductor wires are bundled with a band member, the conductor wires can be easily inserted into the holes of the terminals.

According to one aspect of the present invention described above, it is possible to suppress the temperature rise at the connection portion between the terminal and the conductor wire.

FIG. 1 is a schematic diagram of a power supply connector with a cable according to an embodiment. FIG. 3 is a process diagram of connecting a conductor wire of a cable to a terminal according to an embodiment. FIG. 3 is a process diagram of connecting a conductor wire of a cable to a terminal according to an embodiment. FIG. 3 is a process diagram of connecting a conductor wire of a cable to a terminal according to an embodiment. FIG. 3 is a process diagram of connecting a conductor wire of a cable to a terminal according to an embodiment. It is an arrow AA view of FIG. 5(d).

Hereinafter, one embodiment of the present invention will be described with reference to the drawings.

FIG. 1 is a schematic diagram of a cable-equipped power supply connector 100 according to one embodiment.
As shown in FIG. 1, the cable-equipped power supply connector 100 includes a terminal 1, a cable 106, and a case 200. The terminal 1 and the cable 106 are connected to each other and are introduced into a case 200 that can be inserted into a charging port (inlet portion) of an electric vehicle. The cable 106 includes a conductor wire 102 for supplying power to a power supply target and a cooling tube 101 for cooling the conductor wire 102. As the cable 106, for example, a cable having the same configuration as the power feeding cable described in Japanese Patent No. 6078198 can be adopted. Specifically, the cable 106 has a plurality (an even number) of power lines 104 built inside the sheath 105, and the power lines 104 also have a cooling tube 101 and a conductor wire 102 built in. Inside the power line 104, a plurality of conductor wires 102 are collectively twisted around the cooling tube 101. Thereby, heat generation of the conductor wire 102 due to energization by the refrigerant liquid flowing through the cooling tube 101 can be suppressed. A signal line used for communication between the power supply device and the electric vehicle may be built into the cable 106.

The cooling tube 101 and the conductor wire 102 are branched behind the terminal 1 and are each connected to the terminal 1. The branched cooling tube 101 is connected to a terminal extension portion 40 of the terminal 1, which will be described later. Further, the branched conductor wire 102 is inserted into a conductor wire connecting portion 30, which will be described later, and is compressed and connected. Although not shown, the case 200 of the cable-equipped power supply connector 100 is provided with two terminals 1 and two cables 106 for a + terminal and a - terminal.

Power line 104 includes cooling tube 101 and conductor wire 102 . The cooling tube 101 and the conductor wire 102 are covered with an insulating coating 103. The cooling tube 101 is formed, for example, from a tube made of resin such as nylon. The conductor wire 102 is constructed by bundling and twisting approximately several dozen wires such as tin-plated annealed copper wire (for example, φ0.44 mm). In the power line 104, a plurality of conductor wires 102 are covered with a sheath 103 in a twisted state, as shown in FIG. 2(b), which will be described later. Specifically, inside the coating 103, a plurality of conductor wires 102 are collectively twisted around the cooling tube 101.

The case 200 includes an insertion part 201 in which a part of the terminal 1 (terminal contact part 20) is exposed to the outside of the case, a grip part 202 located behind the insertion part 201, and a grip part 202 in the grip part 202. A cable introduction part 203 is arranged below (diagonally behind the insertion part 201). Cable 106 is introduced into case 200 from outside of case 200 through cable introduction section 203 and connected to terminal 1 . According to the case 200 having the above configuration, the battery of the electric vehicle can be charged by holding the grip portion 202 and inserting the insertion portion 201 into the charging port of the electric vehicle.

A refrigerant flow path 2 is formed in the terminal 1 . A large current (for example, 400 A or more) flows through the terminal 1 when rapidly charging the battery of an electric vehicle. The refrigerant flow path 2 cools the Joule heat generated in the terminal 1 using a refrigerant.

The terminal 1 is a metal terminal, and is made of, for example, copper or a copper alloy. The surface of the terminal 1 is covered with silver plating or the like to prevent corrosion. The terminal 1 includes a terminal main body portion 10, a terminal contact portion 20, and a conductor wire connection portion 30. The terminal body portion 10, the terminal contact portion 20, and the conductor wire connection portion 30 are integrally molded. Such a terminal 1 can be formed by casting or cutting from an ingot.

The refrigerant flowing through the refrigerant flow path 2 is preferably an insulating refrigerant. By using an insulating refrigerant, it is possible to prevent electrical leakage from the terminal 1 through the refrigerant flow path 2 to a cooler (not shown). Examples of the insulating refrigerant include insulating oils such as silicone oil and mineral oil, fluorine-based refrigerants, and alcohol-based refrigerants. However, if an insulating layer, an insulating film, etc. are formed on the inner wall surface of the refrigerant channel 2, a non-insulating refrigerant can also flow.

The terminal body portion 10, the terminal contact portion 20, and the conductor wire connection portion 30 are coaxially arranged with the central axis of the terminal 1 as a common axis. Hereinafter, the direction along this central axis will be referred to as the axial direction, the direction that intersects the central axis when viewed from the axial direction will be referred to as the radial direction, and the direction that goes around the central axis will be referred to as the circumferential direction. Further, in the axial direction, the terminal contact portion 20 side with respect to the terminal body portion 10 is referred to as the front side, and the conductor wire connection portion 30 side with respect to the terminal body portion 10 is referred to as the rear side.

The above-mentioned refrigerant flow path 2 is formed inside the terminal main body portion 10 . A plug 50 is attached to the terminal main body portion 10 to close the processed hole of the refrigerant flow path 2 . The terminal main body portion 10 includes a pair of terminal extension portions 40 that protrude on both sides in the radial direction. An inlet and an outlet of the refrigerant flow path 2 are formed in the pair of terminal expansion parts 40 so as to face diagonally rearward.

The inlet of the refrigerant flow path 2 is formed in one terminal extension portion 40A. Further, the outlet of the refrigerant flow path 2 is formed in the other terminal extension portion 40B. A cooling tube 101 is connected to an inlet and an outlet of the refrigerant flow path 2 via a tube connector 101a. The cooling tube 101 is made of a resin tube such as nylon, and has flexibility. Further, the cooling tube 101 has a certain degree of elasticity against bending, that is, so-called firmness.

The terminal contact portion 20 projects forward of the terminal body portion 10. The terminal contact portion 20 of this embodiment has a solid pin shape (male terminal contact portion) extending in the axial direction. Since the refrigerant flow path 2 is not formed in the terminal contact portion 20, a large cross-sectional area of the conductor can be ensured, making it suitable for passing a large current. A flange 21 is formed at the base of the terminal contact portion 20. The flange 21 engages with the case 200 and determines the protrusion limit of the terminal contact portion 20 from the case 200. Although the terminal contact portion 20 of this embodiment is pin-shaped, it may be socket-shaped (female terminal contact portion) like a mating terminal into which the terminal contact portion 20 is inserted.

The conductor wire connection portion 30 projects to the rear of the terminal body portion 10. The conductor wire connection portion 30 is a cylindrical portion extending in the axial direction. A hole 31 that extends in the axial direction and opens rearward is formed in the conductor wire connection portion 30 . A conductor wire 102 is inserted into the hole 31 . The conductor wire 102 has a non-twisted portion 102A extending linearly in a portion exposed from the coating 103. The non-twisted portion 102A is inserted into the hole 31 of the terminal 1 and is compressed and connected.

The conductor wire 102 has a cooling section S1 that is in contact with the cooling tube 101 and a non-cooling section S2 that is separated from the cooling tube 101. Note that the cooling section S1 can also be rephrased as a "conductor wire covered section" in which the conductor wire 102 is covered with the coating 103 together with the cooling tube 101. Furthermore, the non-cooled section S2 can also be referred to as a "conductor wire exposed section" in which the conductor wire 102 is exposed from the coating 103. In other words, the non-cooled section S2 is a concept that includes a transitional section from when the conductor wire 102 is exposed from the coating 103 until it completely diverges from the cooling tube 101. The non-twisted portion 102A is provided at least in this non-cooled section S2.

Next, a method for manufacturing the cable-equipped power supply connector 100 having the above configuration (hereinafter referred to as the present method) will be described with reference to FIGS. 2 to 6.
2 to 5 are process diagrams for connecting the conductor wire 102 of the power line 104 to the terminal 1 according to one embodiment. FIG. 6 is a view taken along arrow AA in FIG. 5(d).

In this method, first, the covering 103 of the power line 104 shown in FIG. 2(a) is peeled off to expose a part of the conductor wire 102 as shown in FIG. 2(b) (first step).
By peeling off the coating 103, the twisted portions 102B of the conductor wires 102, which are collectively twisted around the cooling tube 101, are exposed.

Next, in this method, the exposed conductor wire 102 is untwisted and stretched into a straight line (second step).
In the second step, first, as shown in FIG. 2(c), a bundle of conductor wires 102 concentratedly twisted in the cooling tube 101 is separated. Then, as shown in FIG. 2(d), the twisted conductor wires 102 are loosened with fingers or the like, and the loosened wires 102a are aligned.

The process shown in FIGS. 2(c) and 2(d) is repeated to loosen and align other bundles of conductor wires 102. When the conductor wire 102 is loosened to some extent, the wire 102a is combed with an awl 300 or the like to separate the cooling tube 101 and the wire 102a, as shown in FIG. 3(a). The above process is then repeated for the other power line 104 (see FIG. 3(b)).

Next, in this method, as shown in FIG. 4A, the conductor wires 102 (strands 102a) of the two power lines 104 are bundled with a band member 301. The band member 301 may be a wire, a binding band, a string, or the like. After the conductor wires 102 are bundled at a plurality of locations with the band member 301, the ends of the strands 102a are cut with a cutting tool 302 to make the lengths of the ends of the conductor wires 102 uniform, as shown in FIG. 4(b).

Next, in this method, the conductor wire 102 is inserted into the hole 31 of the terminal 1 (third step).
In the third step, first, as shown in FIG. 5(a), the tip of the conductor wire 102, which has been cut to the same length, is inserted into the hole 31 of the terminal 1. Next, as shown in FIG. 5(b), the conductor wire 102 is inserted deep into the hole 31 while removing the band member 301.

Next, in this method, the hole 31 is compressed and deformed to connect the terminal 1 and the conductor wire 102 (fourth step).
In the fourth step, a compression tool is attached to the outer periphery of the conductor wire connection part 30 of the terminal 1, and as shown in FIG. (plastic deformation). Thereby, the conductor wire 102 is compressed and connected to the terminal 1. Finally, as shown in FIG. 5(d), the remaining band member 301 that is no longer needed is removed.

Through the above steps, as shown in FIG. 6, the void in the hole 31 of the terminal 1 is reduced (the filling rate of the conductor wire 102 is increased), and the terminal 1 and the conductor wire 102 can be connected.
If the conductor wires 102 are inserted into the hole 31 without untwisting them, a space S3 will be formed between the bundles of the conductor wires 102, as shown by the two-dot chain line in FIG. The voids in the holes 31 increase (the filling rate of the conductor wires 102 decreases), and the connection resistance increases. In addition, the hole 31 must also be made large.

On the other hand, according to this method, a part of the conductor wire 102 is exposed in the first step, the twist of the conductor wire 102 is untwisted in the second step, and the conductor wire 102 is inserted into the hole 3 of the terminal 1 in the third step. Since the conductor wire 102 is connected to the terminal 1 by compressing and deforming the hole 31 in the fourth step, the filling rate of the conductor wire 102 in the hole 31 of the terminal 1 is increased, and the conductor wire 102 and the terminal 1 are This increases the contact area and reduces connection resistance. Therefore, it is also possible to suppress a temperature rise at the connection portion (conductor wire connection portion 30) between the terminal 1 and the conductor wire 102.

In this way, according to the present method described above, the terminal 1 in which the hole 31 is formed and the power line 104 covered with the sheath 103 in a twisted state, the conductor wire 102 inserted into the hole 31. A method for manufacturing a power supply connector 100 with a cable, comprising: a first step of peeling off the covering 103 of the power line 104 to expose a part of the conductor wire 102; and after the first step, exposing the conductor wire 102. a second step of untwisting the conductor wire 102 and stretching it straight; a third step of inserting the conductor wire 102 into the hole 31 of the terminal 1 after the second step; By employing the method of compressing and deforming the conductor wire 31 and connecting the terminal 1 and the conductor wire 102, the filling rate of the conductor wire 102 in the hole 31 of the terminal 1 is increased and the connection resistance is reduced. It is possible to suppress the temperature rise at the connection portion between the terminal 1 and the conductor wire 102.

Further, according to this method, after the second step described above and before the third step, the conductor wires 102 are bundled with a band member 301, as shown in FIG. According to this method, since the untwisted conductor wires 102 are bundled with the band member 301, the conductor wires 102 can be easily inserted into the holes 31 of the terminals 1.

In addition, in the power supply connector 100 with a cable manufactured by the present method described above, the terminal 1 in which the hole 31 is formed and the conductor wire 102 inserted into the hole 31 are covered with the coating 103 in a twisted state. A power feeding connector 100 with a cable includes a cable 106 including a power line 104 that is twisted, the conductor wire 102 having a non-twisted portion 102A extending linearly in a portion exposed from the sheathing 103, The non-twisted portion 102A is inserted into the hole 31 of the terminal 1 and is compressed and connected. According to this configuration, since the untwisted portion 102A of the conductor wire 102 is inserted into the hole 31 of the terminal 1 and is compressed and connected, the filling rate of the conductor wire 102 in the hole 31 of the terminal 1 increases, and the connection resistance can be suppressed. Therefore, the temperature rise at the connection portion between the terminal 1 and the conductor wire 102 is suppressed.

Further, as shown in FIG. 1, the power line 104 includes a cooling tube 101, and the conductor wire 102 has a cooling section S1 in contact with the cooling tube 101 and a non-cooling section S2 separated from the cooling tube 101. The twisted portion 102A is provided at least in the non-cooled section S2. According to this configuration, since the conductor wires 102 are not twisted and extend in a straight line in the uncooled section S2 away from the cooling tube 101, heat is more difficult to accumulate than in the state where the conductor wires 102 are twisted, and air cooling and It is possible to promote heat dissipation and suppress a temperature rise at the connection portion between the terminal 1 and the conductor wire 102.

While preferred embodiments of the invention have been described and illustrated, it is to be understood that these are illustrative of the invention and are not to be considered limiting. Additions, omissions, substitutions, and other changes may be made without departing from the scope of the invention. Accordingly, the invention should not be considered limited by the foregoing description, but rather by the claims.

For example, in the above embodiment, the cooling tube 101 is connected to the terminal 1 having the refrigerant flow path 2 inside. The cooling tube 101 may be connected to the cooling tube 101.

DESCRIPTION OF SYMBOLS 1...Terminal, 31...Hole, 100...Power supply connector with cable, 101...Cooling tube, 102...Conductor wire, 102A...Non-twisted part, 103...Coating, 104...Power line, 106...Cable, 301...Band member, S1 ...cooling section, S2...non-cooling section

Claims (2)

A power supply connector with a cable, comprising: a terminal in which a hole is formed; and a cable including a power line in which a conductor wire inserted into the hole is covered with a sheath in a twisted state, the conductor The wire has a non-twisted portion extending linearly in a portion exposed from the coating,
The non-twisted portion is inserted into the hole of the terminal and is compressed and connected,
the power line includes a cooling tube;
The conductor wire has a cooling section in contact with the cooling tube and a non-cooling section away from the cooling tube,
The non-twisted portion is a power supply connector with a cable provided at least in the non-cooled section. A method for manufacturing a power supply connector with a cable, comprising: a terminal in which a hole is formed; and a cable including a power line in which a conductor wire inserted into the hole is covered with a sheath in a twisted state. ,
the power line includes a cooling tube;
Stripping the sheath of the power line to expose a part of the conductor wire to form a cooling section where the conductor wire contacts the cooling tube and an uncooled section where the conductor wire leaves the cooling tube. 1 process and
After the first step , a second step of untwisting the conductor wires exposed at least in the non-cooled section and stretching them in a straight line to form a non-twisted portion;
After the second step, a third step of inserting the non-twisted portion into the hole of the terminal;
A method for manufacturing a power supply connector with a cable, the method comprising, after the third step, compressing and deforming the hole to connect the terminal and the non-twisted portion.

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