TWI431647B - Coil coil and copper wire washing machine with electrical connection mechanism - Google Patents

Coil coil and copper wire washing machine with electrical connection mechanism Download PDF

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TWI431647B
TWI431647B TW098127592A TW98127592A TWI431647B TW I431647 B TWI431647 B TW I431647B TW 098127592 A TW098127592 A TW 098127592A TW 98127592 A TW98127592 A TW 98127592A TW I431647 B TWI431647 B TW I431647B
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Taiwan
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wire
crimping
coil
copper
crimping portion
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TW098127592A
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TW201013714A (en
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Shinsuke Yanagi
Shigeru Matsuo
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Panasonic Corp
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/2823Wires
    • H01F27/2828Construction of conductive connections, of leads
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00Fixed inductances not covered by group H01F17/00
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H01R11/16End pieces terminating in a soldering tip or socket
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02Soldered or welded connections
    • H01R4/023Soldered or welded connections between cables or wires and terminals
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02Soldered or welded connections
    • H01R4/029Welded connections
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/183Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H01R4/184Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/70Insulation of connections
    • H01R4/72Insulation of connections using a heat shrinking insulating sleeve
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/29Terminals; Tapping arrangements for signal inductances
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/187Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping combined with soldering or welding

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Coils Of Transformers For General Uses (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)

Description

捲線線圈與銅線之洗衣機用電連接機構 發明領域
本發明係有關於一種使用在電機、電子儀器中的反應器等具有使用鋁線之捲線線圈與銅線之洗衣機用電連接機構。
發明背景
第5圖係具有習知的捲線線圈與銅線之電連接機構的反應器之正視圖。
如第5圖所示,於鐵製之台座1上裝設有鐵製之鐵心芯部2,且於鐵心芯部2裝設有捲線線圈4,該捲線線圈4係捲裝有業已於表面繞結搪瓷薄膜之鋁線3。又,反應器全體係進行清漆浸透。捲線線圈4之材質係藉由鋁線3所構成,由於鋁線3可構成比銅線更廉價,因此近年來大多使用在反應器等的捲線中。
又,除去鋁線3於捲線線圈4之捲繞起點與捲繞終點之搪瓷部,且鋁芯線5係藉由焊料7焊接於另外設置之銅製電端子6。
於前述構造中,自外部朝反應器8之電源輸入係藉由將業已與導線等連接之焊片端子等插入電端子6來進行。
然而,於習知鋁材質之捲線線圈與銅線之電連接機構之構造中,一般的焊料並無法將鋁線固定在銅製電端子,因此必須使用鋁線專用之焊料。依此,會構成比一般的焊 料更高成本,且會有必須進行困難之作業等問題。
又,因來自捲線線圈之發熱傳送至端子而於電端子施加熱應力時,由於鋁與銅之熱膨脹係數之不同,於焊料部會含有裂紋且容易構成接觸不良,因此會有在可靠性方面上有所不安之問題。
先行技術文獻
〔專利文獻〕
〔專利文獻1〕日本專利公開公報特開平7-22258號公報
發明概要
本發明係解決習知問題,目的在提供一種捲線線圈與銅線之洗衣機用電連接機構,其係具有使用鋁線之捲線線圈與銅線之電連接部者,又,對於連接部之環境溫度之急遽變化不會構成接觸不良,且廉價而可靠性高。
為了解決前述問題,本發明之捲線線圈與銅線之洗衣機用電連接機構係構成為包含有:捲線線圈,係將鋁線盤繞在鐵製鐵心者;及銅製電端子,係與捲線線圈之端部連接者,又,電端子係於一端具有壓接連接捲線線圈之鋁線的壓接部,於另一端具有略呈平面形狀之熔接部。
藉此,可實現一種捲線線圈與銅線之洗衣機用電連接機構,其係具有廉價且擁有即使對於環境溫度之急遽變化亦不會構成接觸不良之可靠性的捲線線圈與銅線之洗衣機用電連接機構。
用以實施發明之形態 (實施形態1)
針對本實施形態,利用第1至4圖說明反應器單元,且該反應器單元係以反相器控制之洗衣機等的高次諧波電流之抑制或功率因子改善為目的,並具有使用鋁線之捲線線圈與電源輸入用之銅線之電連接部。另,本發明並不限於該實施形態。
第1圖係顯示於本發明之實施形態1中具有捲線線圈與銅線之洗衣機用電連接機構的反應器單元之截面圖。如第1圖所示,將捲裝有業已於表面燒結搪瓷薄膜之鋁線的捲線線圈10自上部嵌入E型芯部9,且該E型芯部9係積層、熔接有業已藉由壓製加工模具穿孔成字母符號之E型形狀的薄板電磁鋼板。積層、熔接有業已藉由壓製加工模具穿孔成字母符號之I型形狀的薄板電磁鋼板之I型芯部11係載置於E型芯部9上,且藉由熔接構件12,將外周之接觸側面進行熔接固定。
又,為了可螺絲固定於洗衣機等之應用機器,E型芯部9係藉由熔接構件12熔接固定於鐵製之台座13。
又,捲線線圈10之外周部係捲裝有絕緣用之絕緣帶15。
反應器全體係於完成所有熔接固定之程序後進行清漆浸透。清漆浸透之目的係E型芯部9及I型芯部11之鐵心之防鏽、磁致伸縮音之抑制、線圈絕緣膠帶之防濕等。
第2圖係顯示同反應器單元之正視圖。如第2圖所示,捲裝有鋁線18之捲線線圈10係裝設於藉由E型芯部9及I型 芯部11所形成之鐵製鐵心16。又,除去鋁線18於捲線線圈10之捲繞起點與捲繞終點之搪瓷部,並露出鋁線18之鋁芯線19約10mm,且壓接固定於銅製電端子17之壓接部25,並構成反應器單元14。
又,於電端子17之另一側之相對面側,用以將電源供給至反應器之附連接器22的銅製導線21之芯線係藉由點熔接,熔接固定於電端子17之略呈平面形狀之熔接部17c。
鋁芯線19與銅製電端子17之接合部20係由於構成鋁與銅之異種金屬之連接,因此會產生電位差,故,在附著有水或濕氣時會引起電蝕現象,且可能會增加接觸阻力。依此,藉由利用刷子等來塗布矽樹脂23,且至少完全地遮蓋異種金屬之接觸部,而可適當地保持電連接。
另,於接合部20之外周包覆可藉由照射高溫而收縮之熱收縮管24作為絕緣用帶,藉此,可進一步地提高防水效果。
第3圖係顯示電端子之詳情圖。第3A圖係顯示電端子之側視圖,第3B圖係顯示電端子之正視圖,第3C圖係顯示第3A圖之3C-3C截面圖,第3D圖係顯示第3A圖之3D-3D截面圖。
如第3A及3B圖所示,在將鋁線18之鋁芯線19壓接於電端子17時,進行壓接高度低之第一壓接部17a與壓接高度高之第二壓接部17b之二段壓接。
如第3C及3D圖所示,3C-3C截面係顯示壓接高度低之第一壓接部17a,且壓接高度為△A,相對於此,3D-3D截 面係顯示壓接高度高之第二壓接部17b,且壓接高度為△B。即,端子端部30係改變壓接高度而進行加工,使壓接高度構成△A<△B。
於3C-3C截面之第一壓接部17a中,在內部之鋁芯線19壓縮變形之程度下,對端子端部30施行彎曲加工,相對於此,於3D-3D截面之第二壓接部17b中,在內部之鋁芯線19不會產生塑性變形之程度下,對端子端部30施行彎曲加工。
一般而言,鋁線係與銅線不同且表面硬度軟,因此,於壓接時,鋁本身會藉由應力而伸展,因而會塑性變形,故,要滿足於壓接固定中所必須之接觸阻力之安定與拉伸強度之確保兩者是困難的。對於此種問題,實施形態1係劃分壓接高度,且於3C-3C截面之第一壓接部17a中使接觸阻力安定,於3D-3D截面之第二壓接部17b中確保拉伸強度,藉此,劃分對連接之作用而進行壓接。
電端子17之鋁線18之相對側係用以藉由點熔接將銅製導線21接合於電端子17之熔接部17c。
由於該熔接部17c係相同之銅材質之熔接,因此無熱膨脹係數之不同,故,接合部20對溫度變化之耐久性高。
第4圖係顯示於實施形態1中所示之反應器單元之電端子之壓接部之電特性圖形。電特性圖形係橫軸表示壓接部之壓接高度,縱軸表示壓接部之電接觸阻力值。如第4圖所示,在壓接例如Φ 2.0mm之鋁線時,接觸阻力值在壓接高度值從約1.8mm到約2.3mm時為約0.2mΩ以下而安定,然 而,若壓接高度值構成約2.3mm以上,則接觸阻力會逐漸地增加。
即,在鋁芯線強烈地壓縮而塑性變形時,接觸阻力低而安定,然而,對於脫出之拉伸強度會降低。
又,同樣地,拉伸強度在壓接高度值從約1.8mm到約2.3mm時,拉伸強度會逐漸地增強,在壓接高度值從約2.3mm到約2.6mm時,拉伸強度係約300N/m2 以上而安定。
依此,若為了使接觸阻力安定而以壓接高度值為1.9mm至2.1mm來壓接第一壓接部17a,且為了確保拉伸強度而以壓接高度值為2.4mm至2.6mm來壓接固定第二壓接部17b,則可滿足接觸阻力、拉伸強度兩者。
如前所述,於實施形態1中,將捲線線圈10之鋁線18壓接於銅材質之電端子17而固定異種材質,藉此,構成反應器單元14,且將銅線21與銅材質之電端子17進行同材質之點熔接,藉此,可實現一種反應器單元,其係具有廉價且需要即使對於環境溫度之急遽變化亦不會構成接觸不良之充分可靠性的鋁捲線線圈與銅線之電連接部。
又,藉由改變第一壓接部17a與第二壓接部17b之壓接時之壓接高度,可同時地使壓接部25之拉伸強度與接觸阻力安定,因此,即使對於長期變化,亦可確保充分之性能,並進一步地提升可靠性。
又,藉由矽樹脂於鋁材質與銅材質之接觸面施行防水處理,或者包覆可藉由接觸高溫而收縮之熱收縮管並進行防水處理,藉此,可防止於異種金屬間所發生之電蝕,並 進一步地提升可靠性。
1,13‧‧‧台座
2‧‧‧鐵心芯部
3,18‧‧‧鋁線
4,10‧‧‧捲線線圈
5,19‧‧‧鋁芯線
6,17‧‧‧電端子
7‧‧‧焊料
8‧‧‧反應器
9‧‧‧E型芯部
11‧‧‧I型芯部
12‧‧‧熔接構件
14‧‧‧反應器單元
15‧‧‧絕緣帶
16‧‧‧鐵製鐵心
17a‧‧‧第一壓接部
17b‧‧‧第二壓接部
17c‧‧‧熔接部
20‧‧‧接合部
21‧‧‧銅製導線
22‧‧‧連接器
23‧‧‧矽樹脂
24‧‧‧熱收縮管
25‧‧‧壓接部
30‧‧‧端子端部
△A,△B‧‧‧壓接高度
第1圖係於本發明之實施形態1中具有捲線線圈與銅線之洗衣機用電連接機構的反應器單元之截面圖。
第2圖係同反應器單元之正視圖。
第3A圖係同反應器單元之電端子之側視圖。
第3B圖係同反應器單元之電端子之正視圖。
第3C圖係同反應器單元之電端子之3C-3C截面圖。
第3D圖係同反應器單元之電端子之3D-3D截面圖。
第4圖係同反應器單元之電端子之壓接部之電特性圖形。
第5圖係具有習知的捲線線圈與銅線之電連接部的反應器之正視圖。
10‧‧‧捲線線圈
12‧‧‧熔接構件
14‧‧‧反應器單元
16‧‧‧鐵製鐵心
17‧‧‧電端子
17c‧‧‧熔接部
18‧‧‧鋁線
19‧‧‧鋁芯線
20‧‧‧接合部
21‧‧‧銅製導線
22‧‧‧連接器
23‧‧‧矽樹脂
24‧‧‧熱收縮管
25‧‧‧壓接部

Claims (2)

  1. 一種捲線線圈與銅線之洗衣機用電連接機構,包含有:捲線線圈,將鋁線盤繞在鐵製鐵心;銅製電端子,具有略呈平面形狀之熔接部與在前述熔接部之對面側之銅製壓接部;及銅線,用以輸入電源用,又,在前述壓接部壓接前述鋁線之鋁芯線,且在前述電端子之熔接部點熔接銅線,其中:前述壓接部分為第一壓接部與第二壓接部,且構造成可改變將鋁芯線壓接於前述第一壓接部與前述第二壓接部時之壓接高度,並且構造成至少前述第一及第二壓接部與鋁芯線之接觸部以矽樹脂覆蓋。
  2. 如申請專利範圍第1項之捲線線圈與銅線之洗衣機用電連接機構,其中壓接部藉由照射高溫而收縮之熱收縮管包覆所構成而進行防水處理。
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