KR20120137089A

KR20120137089A - Method for connecting wire to terminal

Info

Publication number: KR20120137089A
Application number: KR1020110056411A
Authority: KR
Inventors: 방순일; 김상기; 이관범; 김인섭
Original assignee: 현대자동차주식회사; 기아자동차주식회사; 주식회사 경신
Priority date: 2011-06-10
Filing date: 2011-06-10
Publication date: 2012-12-20

Abstract

PURPOSE: A connection method of a wire and a terminal is provided to increase a contact state between a conductor core line and a terminal by inserting a wire inside an accepting groove unit of the terminal. CONSTITUTION: A terminal is formed(S10). Conductive materials are charged inside an accommodating groove unit(S20). A part of the entire conductive core is inserted inside the accommodating groove unit(S30). Mobility is give to the conductive material by heat of the terminal(S50). The conductive material is filled by removing gap between an internal surface of the accommodating groove unit and an internal surface. The conductive material is infiltrated between threads of the conductor core. [Reference numerals] (510) Terminal formation step; (520) Conductive material charging step; (530) Wire insertion step; (540) Terminal pressure step; (550) Terminal heating step; (560) Rapid cooling step; (AA) Pressurizing; (BB) Heating; (CC) Cooling

Description

How to connect wires and terminals {METHOD FOR CONNECTING WIRE TO TERMINAL}

The present invention relates to a method of connecting a wire and a terminal, and more particularly, a wire and a terminal can be improved in contact state and a stable electric conductivity can be secured, and the problem that the wire is easily separated from the terminal can be solved. It relates to a method of connecting terminals.

Today, internal combustion engine (engine) vehicles using fossil fuels have many problems such as environmental pollution caused by exhaust gas, global warming caused by carbon dioxide, and respiratory diseases caused by ozone generation. And because fossil fuels on Earth are so limited, they are in danger of becoming exhausted someday.

Therefore, pure electric vehicles (EVs) that use electric motors as driving sources, hybrid electric vehicles (HEVs) using engines and electric motors as driving sources, fuel cells are used as power sources, and electric motors are used as driving sources. The development of eco-friendly electric vehicles such as fuel cell electric vehicles (FCEVs), which are used as fuel cell vehicles, is being actively conducted.

Such eco-friendly electric vehicles require high voltage / high current power compared to conventional internal combustion engine vehicles. That is, a high voltage battery supplies high voltage / high current power to various high voltage components in the vehicle including an electric motor (driving motor) .In the case of a pure electric vehicle or a plug-in hybrid vehicle, a high voltage power is supplied from an external charging device. The battery will be charged.

Therefore, in eco-friendly electric vehicles, the high voltage battery and the wires, terminals, and connectors that connect the components must be designed to stably provide high voltage / high current, and in particular, between the conductor core and the terminal of the wire to ensure stable electrical conductivity. The connection state needs to be optimized.

However, in the conventional connection process between the electric wire and the terminal, the conductor core of the electric wire exposed from the insulating coating is placed between the barrels extending from the terminal to face each other, and then compressed by the barrel. The conductor core and the terminal are connected to enable energization.

Therefore, in the related art, the conductor portion of the high-voltage wire is connected to the piece-shaped barrel, so that there is a small contact area for conducting electricity, and thus, there is a problem that it is difficult to supply a stable power, and the wire is easily separated from the barrel.

In addition, aluminum wires having advantages of price stability and light weight are widely used for high voltage, and problems of oxidative corrosion and weak electric conductivity, which are inherent properties of aluminum, also need to be improved.

Therefore, the present invention has been created to solve the above problems, the contact state between the wire and the terminal is improved to ensure a stable electrical conductivity, and the wire and the like can solve the problem that the wire is easily separated from the terminal and Its purpose is to provide a method of connecting terminals.

In particular, an object of the present invention is to provide a method for connecting wires and terminals that can improve oxidative corrosion and weak electrical conductivity, which are inherent characteristics of aluminum, in connecting aluminum wires and terminals.

In order to achieve the above object, the present invention, the terminal forming step of forming a terminal having a receiving groove open to one side; A conductive material filling step of filling a conductive material in the receiving groove of the terminal; A wire insertion step of inserting the entire conductor core wire and a part of the covering of the exposed wire together with a plurality of strands in the receiving groove of the terminal; Heating the terminal to impart fluidity to the conductive material so that the conductive material is filled while eliminating voids between the inner surface of the accommodating groove of the terminal and the conductor core and infiltrate between the strands of the conductor core; Provides a method of connecting wires and terminals.

Here, the conductive material is preferably filled in a gel state in the conductive material filling step.

In addition, between the wire insertion step and the terminal heating step, it is preferable to perform a terminal crimping step of pressing the circumferential surface of the receiving groove into which the electric wire is inserted together with the coating of the electric wire to fix the electric wire to the terminal.

In addition, the receiving groove is preferably formed in the shape of a tube open on one side, and in the terminal crimping step, it is preferable to completely seal the inside of the receiving groove filled with the conductive material by pressing the entire circumferential surface of the receiving groove.

In addition, after the terminal heating step, it is preferable to further perform a terminal rapid step of supplying cold air to the terminal in order to prevent thermal degradation of the coating.

Accordingly, in the connection method between the electric wire and the terminal according to the present invention, the electric wire is inserted into and connected to the tubular accommodating groove formed in the terminal, whereby the contact state between the conductor core of the electric wire and the terminal can be improved (increased conduction area, etc.) As a result, it is possible to secure a stable electrical conductivity between the wire and the terminal. In addition, it is also possible to solve the problem that the wire is easily separated from the terminal because the wire is inserted into the receiving groove of the tubular shape.

In particular, by charging the conductive material in the receiving groove of the terminal and then connecting the wire by inserting and heating the conductive material, the conductive material can penetrate between the conductor cores of the wire in a flow state, thereby eliminating the voids between the conductor cores. The conduction area between the conductor core and the terminal can be greatly increased.

In addition, the present invention can minimize the loss of the conductive material during heating by charging the conductive material and crimping the terminal in the state where the wire is inserted, and then prevent the thermal degradation of the wire coating by rapid cooling the terminal. do.

The present invention as described above can be usefully applied to the connection method of the conductive material filling method, in particular, the aluminum wire and the terminal, and has the advantage of improving the problems of oxidative corrosion and weak electrical conductivity inherent characteristics of aluminum Have

1 is a perspective view showing a connection state of a wire and a terminal according to an embodiment of the present invention.
2 is a cross-sectional perspective view showing a connection state of a wire and a terminal according to an embodiment of the present invention.
3 is a flowchart illustrating a method of connecting a wire and a terminal according to an embodiment of the present invention.

DETAILED DESCRIPTION Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those skilled in the art may easily implement the present invention. In this process, the thickness of the lines or the size of the components shown in the drawings may be exaggerated for clarity and convenience of description. In addition, terms to be described later are terms defined in consideration of functions in the present invention, which may vary according to the intention or convention of a user or an operator. Therefore, definitions of these terms should be made based on the contents throughout this specification.

The present invention relates to a method of connecting a wire and a terminal that can improve the contact state of the wire and the terminal to secure a stable electrical conductivity, and can solve the problem that the wire is easily separated from the terminal.

In particular, the present invention is a method of connecting a conductive material to the connection portion of the terminal, which can be usefully applied to connect the aluminum wire and the terminal, and improves the problems of oxidative corrosion and weak electrical conductivity inherent characteristics of aluminum It offers the benefits of doing so.

Referring to the configuration of the present invention with reference to the drawings, Figure 1 is a perspective view showing a connection state of a wire and a terminal according to an embodiment of the present invention, Figure 2 is a connection state of a wire and a terminal according to an embodiment of the present invention It is a cross-sectional perspective view shown.

3 is a flowchart illustrating a method of connecting a wire and a terminal according to an embodiment of the present invention.

First, as shown in FIG. 1 and FIG. 2, the electric wire 20 is comprised from the conductor core 21 which consists of several strands, and the insulation coating 22 surrounding these conductor cores 21. As shown in FIG.

In addition, the terminal 10 to which the electric wire 20 is connected has a coupling part 11 connected to a power supply such as a battery of a vehicle or electrical equipment on the front side, and a wire 20 on the rear side of the coupling part 11. The receiving groove part 12 which can be inserted and connected is formed.

Receiving groove 12 is a portion corresponding to the barrel of the existing terminal, a portion in which the conductive material 30 is filled and the conductor core 21 and the sheath 22 of the electric wire 20 is inserted and fixed It is a part which is actually connected to the conductor core wires 21 of the electric wire 20 so as to enable electrical connection.

In the present invention, the receiving groove 12 is considered to be filled with the conductive material 30 and at the same time to prevent the conductive material, which has fluidity upon heating, does not leak to the outside, except for the inlet side into which the wire 20 is inserted. Is formed in the shape of a pipe in which the remaining part is sealed.

As described above, in the present invention, the electric wire 20 is inserted in the state in which the conductive material 30 is charged in the receiving groove 12 so that the terminal 10 and the electric wire 20 are connected to each other. In FIG. 2, the conductor cores 21 as well as the sheath of the wire 20 may be directly contacted with the inner surface of the receiving groove 12 as shown in FIG. 2, or may be connected with a conductive material interposed therebetween.

In addition, the remaining inner side surface of the receiving groove 12 is also electrically connected to the conductor core line 21 in a state in which the conductive material 30 is filled between the conductor core line 21.

As a result, the entirety of the end portions of the conductor cores 21 is connected to the inner surface of the receiving groove 12 surrounding the periphery thereof, so that the conduction area can be increased, thereby enabling stable current supply.

In addition, a portion of the conductive material 30 is present in the state penetrated between the strands of the entire conductor core 21, the individual conductor cores 21 and the receiving groove portion 12 is penetrated into the conductive material 30 This enables a more stable current supply while forming a unitary structure that can be energized (increasing the conduction area).

Hereinafter, a connection method according to an embodiment of the present invention will be described with reference to FIG. 3. As shown, the connection method of the wire and the terminal of the present invention includes a terminal forming step (S10) and a conductive material filling step (S20). ), The wire insertion step (S30), the terminal crimping step (S40), the terminal heating step (S50) and the rapid cooling step (S60) is configured.

Here, the terminal forming step (S10) is a step of forming and providing a terminal 10 to which the wire 20 is to be connected, the coupling portion 11 which is a part connected to the terminal of the battery or electrical equipment, and the tube opened to one side It is formed to have a receiving groove portion 12 of the shape.

At this time, the receiving groove 12 is formed to a diameter and depth enough to insert the end of the wire 20, that is, the entire exposed conductor core 21 of the wire and a portion of the sheath 22.

Next, the conductive material filling step S20 is a process of filling the conductive material in a gel state in the receiving groove 12 of the terminal 10.

In other words, inside the receiving groove 12 of the terminal 10 is filled with a conductive material in a gel state, wherein the conductive material is a metal having high electrical conductivity, such as lead (Pb), tin (Sn), zinc (Zn), It may be a metal material such as nickel (Ni).

Of course, the component of the conductive material is not limited, and any conductive material may be employed as long as it is a high conductive material that can be gelled and flowable while solidifying upon cooling.

The reason for filling the accommodating groove 12 in a gel state when filling the conductive material 30 is that the conductive material does not have fluidity in the gel state, so that it can be prevented from flowing down during filling in the accommodating groove. This is because the filling operation can be facilitated while the surrounding cleanliness can be maintained.

In addition, since the conductive material 30 should be filled in an amount that can partially penetrate between the strands of the conductor core wire while surrounding the conductor core 21 when the terminal is pressed after heating, the conductive material 30 in the receiving groove 12 The initial filling height should be higher than the end position of the conductor core wire 21 fully inserted into the receiving groove.

That is, when the wire 20 is inserted into the receiving groove 12, at least a part of the end of the conductor core 21 should be inserted into the conductive material 30 (must be inserted into the conductive material), for this purpose, It is preferred that the conductive material is in a gel state.

In other words, the terminal 10 is crimped in the charged state as described below to fix the insertion state of the electric wire 20 (difficult to insert the electric wire), thereby providing heating for the fluidity of the conductive material 30. In the beginning, the initial filling amount of the conductive material 30 should be set to an amount that can penetrate between the strands while surrounding a part of the ends of the conductor cores 21 in a flow state when heated.

Next, the wire insertion step (S30) is a process of inserting together the entire conductor core wire 21 and part of the sheath 22 of the wire 20 exposed in a plurality of strands in the receiving groove portion 12 of the terminal 10, The conductor core 21 comes into contact with the conductive material 30 filled in the receiving groove 12, and a part of the end of the conductor core is inserted into the conductive material 30.

Next, the terminal crimping step (S40) is a process of pressing the circumferential surface of the receiving groove 12 of the terminal 10, in which the receiving groove 12 of the terminal is covered by the external force 22 by an external force. Crimped together) to secure the wires to the terminals.

At this time, the entire circumferential surface of the accommodating groove 12 is compressed to the electric wire 20 so that the inside of the accommodating groove 12 is completely sealed, and a part of the inner surface of the accommodating groove 12 is also directly connected to the conductor core wire 21. It can be compressed to make contact.

Accordingly, the wire 20 is not separated from the terminal 10, and the space around the conductor core 21 is minimized in the receiving groove 12, and in this state, the inside of the receiving groove 12 is completely sealed. In this state, leakage of the conductive material 30 filled in the receiving groove may be prevented.

Subsequently, the terminal heating step S50 is a process of applying heat to the terminal 10 to which the electric wire 20 is crimped and fixed. The heating of the terminal 10 provides fluidity to the conductive material 30 filled in the receiving groove 12. Will be given.

When the terminal 10 is heated, the conductive material 30 becomes fluid in a dissolved state, so that the conductive material 30 having fluidity penetrates between the strands of the conductor cores 21, thereby forming voids between the conductor cores. It will disappear.

In addition, since the conductive material 30 flows to surround the conductor core 21 and also flows into the empty space in the receiving groove 12, the contact area between the conductive material 30 and the conductor core wire 21 / the receiving groove 12. This increases, and thus the electrical conductivity between the conductor core line 21 and the receiving groove 12 can be improved.

As described above, in the present invention, after filling the conductive material and inserting the wire, the terminal is compressed to seal the inside of the accommodating groove, and then a heating process for imparting fluidity of the conductive material is performed. Is the same as

Before the terminal heating step for imparting fluidity of the conductive material, if the conductive material is filled and compressed to seal the inside of the accommodating groove, the conductive material may be evaporated while being heated to the outside.

For example, after applying heat to a part of the terminal before crimping, the conductive material is charged when the terminal is heated, and the conductive material is inserted in the state where the conductive material is dissolved to join the conductive core with the conductor core of the wire and the receiving groove of the terminal. A method of fixing a wire by crimping a terminal may be applied. However, in this case, when the conductive material is charged to the receiving groove of the heated terminal, the receiving groove is not sealed because the terminal is before crimping.

As such, when the accommodating groove is not sealed, the conductive material may be oxidized or evaporated by heat.

In this case, since a considerable time is required to complete the product, such as during the crimping process after the wire is inserted after the terminal heating, the insulation coating of the wire may deteriorate.

On the other hand, in the present invention, by filling the conductive material and sealing the inside of the accommodating groove through the terminal compression, the terminal is heated, so that oxidation and evaporation of the conductive material can be minimized, and the conductive material is not lost or minimized to the outside of the terminal.

In addition, since the conductor core of the wire is inserted into the receiving groove and mechanically completely combined with the terminal through compression, the fluid is provided to the conductive material through heating, thereby minimizing the gap between the sealed receiving groove and the conductor core. The conduction area of the core and the terminal can be increased, and the electrical performance of the product can be improved.

In addition, since the rapid cooling step is immediately performed without any intermediate step after heating, thermal degradation of the insulating coating can be suppressed.

That is, since the terminal 10 is heated after the electric wire 20 is inserted, the sheath 22 of the electric wire inserted into or in contact with the terminal may be thermally damaged. In order to suppress the heat deterioration phenomenon of the sheath 22, In the present invention, the rapid cooling step (S60) is performed without an intermediate step after the heating step.

Rapid cooling step (S60) is a process of rapidly cooling the terminal 10 in order to prevent thermal degradation of the sheath 22 after the terminal heating step (S50), the rapid cooling of the terminal by supplying cold air by a facility such as a cooler do.

At this time, since the terminal 10 is forcedly cooled by cold air instead of the natural cooling method, the covering 22 of the wire 20 inserted into the terminal may be protected, and the conductive material 30 in the receiving groove 12 may be It becomes a solid and becomes a fixture which connects between the conductor core wire 21 and the accommodating groove part 12 so that an electricity can be integrated integrally without a gap.

In this way, in the present invention, by inserting and connecting the electric wire to the tubular receiving groove formed in the rear side of the terminal, it is possible to improve the contact state between the conductor core wire of the electric wire and the terminal (increased conduction area, etc.), thereby through the electric wire and the terminal It is possible to secure a stable electrical conductivity of the liver. In addition, it is also possible to solve the problem that the wire is easily separated from the terminal because the wire is inserted into the receiving groove of the tubular shape.

As described above in detail with reference to the embodiments shown in the drawings for the present invention, the scope of the present invention is not limited to this, and those skilled in the art using the basic concept of the present invention defined in the following claims Many variations and modifications of the are also included in the scope of the present invention.

10 terminal 11 coupling portion
12: receiving groove 20: electric wire
21: conductor core 22: sheath
30: conductive material

Claims

A terminal forming step of forming a terminal having a receiving groove opened to one side;
A conductive material filling step of filling a conductive material in the receiving groove of the terminal;
A wire insertion step of inserting the entire conductor core wire and a part of the covering of the exposed wire together with a plurality of strands in the receiving groove of the terminal;
Heating the terminal to impart fluidity to the conductive material such that the conductive material is filled while eliminating voids between the inner surface of the receiving groove portion of the terminal and the conductor core and infiltrate between the strands of the conductor core;
Connection method of the wire and the terminal comprising a.

The method according to claim 1,
The method of connecting a wire and a terminal, wherein the conductive material is charged in a gel state in the conductive material filling step.

The method according to claim 1,
And a terminal crimping step for crimping the circumferential surface of the receiving groove into which the electric wire is inserted, together with the covering of the electric wire, between the electric wire insertion step and the terminal heating step to fix the electric wire to the terminal.

The method according to claim 3,
The receiving groove portion is formed in the shape of a tube open on one side, the wire and the terminal, characterized in that to completely seal the inside of the receiving groove filled with the conductive material by pressing the entire peripheral surface of the receiving groove in the terminal crimping step How to connect

The method according to claim 1 or 3,
And a terminal rapid step of supplying cold air to the terminal to prevent thermal degradation of the coating after the terminal heating step.