WO2020057399A1 - 接线端子与漆包线的连接结构及方法、线圈组件和电机 - Google Patents

接线端子与漆包线的连接结构及方法、线圈组件和电机 Download PDF

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Publication number
WO2020057399A1
WO2020057399A1 PCT/CN2019/105172 CN2019105172W WO2020057399A1 WO 2020057399 A1 WO2020057399 A1 WO 2020057399A1 CN 2019105172 W CN2019105172 W CN 2019105172W WO 2020057399 A1 WO2020057399 A1 WO 2020057399A1
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WO
WIPO (PCT)
Prior art keywords
terminal
enameled wire
fixed
groove
connection structure
Prior art date
Application number
PCT/CN2019/105172
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English (en)
French (fr)
Inventor
王红标
敖林
李昌建
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汉宇集团股份有限公司
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Application filed by 汉宇集团股份有限公司 filed Critical 汉宇集团股份有限公司
Publication of WO2020057399A1 publication Critical patent/WO2020057399A1/zh

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/40—Securing contact members in or to a base or case; Insulating of contact members
    • H01R13/405—Securing in non-demountable manner, e.g. moulding, riveting
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0263—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections for positioning or holding parts during soldering or welding process

Definitions

  • the invention belongs to the field of wiring and connection, and particularly relates to a terminal, a connection structure and a connection method therewith, a coil assembly, and a motor.
  • the enameled wire used in the motor can be copper wire or aluminum wire. Aluminium wire has been applied to the motor in the 1970s. No matter it is copper enameled wire or aluminum enameled wire, the connection between the existing enameled wire and the terminal is mainly soldered. The method of soldering requires first removing the enameled wire varnish with liquid tin. The specific method is to immerse the end of the enameled wire in an over-temperature tin furnace and melt off the surface of the enameled wire. It is fixed on the terminal.
  • this type of terminal makes the fixing (winding) of the enameled wire more labor-intensive, and the fixed enameled wire is still easy to come off and fall off; on the other hand, the enameled wire protruding outside the terminal is under the action of external force It is easy to be pulled off or injured, causing product failure and causing motor failure.
  • the object of the present invention is to provide a terminal block, which overcomes the shortcomings of the existing terminal blocks, can make the placement and fixing of the enameled wire more convenient and firm, reduce manual investment, and because the enameled wire is stored in the first In the groove, the enameled wire is favorably protected, and it is not easy to cause damage to the enameled wire due to external forces (such as injection pressure, etc.).
  • a terminal block includes: a terminal block body; and a terminal block for connecting with a terminal of an enameled wire, the terminal post is fixed to the terminal block body, includes a first surface, and is connected by the first surface.
  • a first groove is formed on a surface downward, and the first groove includes two side surfaces and a bottom surface. Due to the setting of the first groove, the terminals of the enameled wire can be filled therein, which is better protected from being damaged by the external force.
  • the structure is suitable for the butt welding of the enameled wire and the terminal post. It is not easy to loosen the fixation.
  • an included angle between a bottom surface of the first groove and the first surface is 0-20 °. This angle enables the bottom surface of the first groove to be a flat surface or an inclined surface with a smaller inclination than the first surface. If it is necessary to crimp or bump the enameled wire in the future, the contact between the enameled wire and the bottom surface of the first groove can be made closer, and the enameled wire can be prevented from being excessively deformed on the terminal, resulting in excessive reduction in strength. Better protection.
  • the bottom surface of the first groove is inclined with respect to the first surface. That is to further define the first groove with an angle between the bottom surface of the first groove and the first surface that is not zero and has a certain inclination. If the enameled wire may be pressed in the subsequent press or bump welding, the pre-stress of the enameled wire can be guaranteed. The height of the segment changes linearly and gradually. This angle can ensure the preload of the enameled wire while it is not being broken, and ensure its strength.
  • the terminal post further includes a wire-wound winding post at the top.
  • the terminal of the enameled wire passes through the first groove of the terminal post, and then can be wound around the wire winding post to be fixed.
  • the enameled wire is an aluminum enameled wire. Because aluminum enameled wire is more susceptible to air corrosion after the varnish is removed, more aluminum enameled wire is used in actual applications.
  • connection terminal further includes a fixed terminal which can be crimped and fixed to the terminal.
  • the fixed terminal may be a single stamped part, which may be wrapped and fixed to the terminal post after stamping; in other embodiments, the fixed terminal may also be a component that is itself fixed to the terminal post, Part of it is fixed to the terminal, and part can be fixed to the terminal after stamping.
  • the fixed terminal includes a crimping portion and a fixing portion connected to each other, the fixing portion is fixed to the terminal, and the crimping portion is crimped to cover a first surface of the terminal.
  • the fixed terminal is a component that is itself fixed to the terminal, and the crimping portion of the fixed terminal is crimped to the first surface of the terminal after pressing.
  • the cross section of the fixed terminal is U-shaped or semi-circular.
  • the fixed terminal is an independent stamped part. After stamping, the package is fixed to the terminal post. It may wrap the three surfaces of the terminal post, which is the first surface and the sides on both sides of the first surface. The four surfaces of the column also include the bottom surface.
  • a plurality of tooth-like structures are provided on an inner side surface of the fixed terminal. This will better prevent the enameled wire from coming loose.
  • the present invention also provides a connection structure between a terminal and an enameled wire, which is characterized by comprising the enameled wire and the above-mentioned terminal.
  • the enameled wire includes a terminal.
  • the terminal is fixed by bump welding.
  • the enameled wires of the prior art motors are removed by soldering, the enameled wires of the enameled wires need to be removed by liquid tin first.
  • the enameled wire ends are first overheated in a high-temperature tin furnace to melt off the enameled wires on the surface. This process is difficult to accurately control the length of the paint removal section and the time of the paint removal process, so that the length of the paint removal section may be too long or too short. If the length of the enameled section is too long, it may cause the enameled section of the enameled wire to be exposed to the air and easily oxidized.
  • the humid air contains acid and alkali substances, which will easily corrode the enameled wire and its welding points, leading to early failure of the motor; If the length of the paint removal section is too short, it may cause a break between the enameled wire and the terminal, or the insufficient contact area between the terminal and the aluminum wire will cause poor contact or large contact resistance, which will also cause the motor to fail.
  • the disadvantages of the soldering method are: First, tin Flux cleaning process needs to be added at the end of soldering. Second, if there is flux residue, it will affect the service life of the motor. Third, because the aluminum wire is soft, it is difficult to automate the soldering process, and a lot of manual investment is required in the manufacturing process.
  • connection structure of the terminal and the enameled wire of the present invention realizes the butt welding connection between the enameled wire and the terminal post, overcomes the disadvantages caused by the conventional soldering process described above, and enables the length of the enameled wire to be controlled to be removed , Minimize the possibility of air corrosion on the stripped paint section, and indirectly extend the life of the coil assembly or motor including the connection structure of the terminal and the enameled wire.
  • the present invention also provides a connection structure between a terminal and an enameled wire, characterized in that it includes the enameled wire and the above-mentioned terminal including the fixed terminal, the enameled wire includes a terminal, and the terminal of the enameled wire is placed in the first recess.
  • the fixed terminal is crimped and fixed to the terminal of the enameled wire and the terminal post, and the terminal of the enameled wire is connected to the fixed terminal and the terminal post by welding.
  • connection structure of the terminal and the enameled wire of the present invention also realizes the welding and fixing of the enameled wire and the terminal post. Because the terminal post has a specific structure, the enameled wire is initially placed in the first groove, and the terminal of the enameled wire is subjected to downward pressure. Due to its elasticity, the terminal of the enameled wire is pressed by the fixed terminal, and it is in close contact with the fixed terminal and the bottom surface of the first groove. At the same time, the width of the enameled wire in the first groove will increase so that both sides may contact On the side of the first groove, the terminal of the final enameled wire is filled in the through hole formed by the fixed terminal and the first groove of the terminal.
  • the preferred oblique setting of the first groove can prevent the fixed terminal from overly deforming the enameled wire and causing excessive reduction in strength, ensuring that the height of the pre-pressed section of the enameled wire changes linearly and gradually transitions to ensure that the wire is not crushed or shaped.
  • the mutation at the same time eliminates the hidden danger of subsequent breaking.
  • the fixed terminal and the terminal of the enameled wire and the terminal post are fixed by stamping, and the preload of the terminal of the enameled wire is not more than 80%.
  • the fixed terminal is fixed by stamping.
  • the enameled wire is fixed to the terminal by welding, since the enameled wire does not remove the varnish of the enameled wire outside the fixed terminal, the peeled enameled wire in the fixed terminal contacts the fixed terminal and the fixed terminal during the welding process.
  • the first groove of the terminal is in close contact, forming a closed space. It is difficult for the welding part to contact the air, and to protect it from air oxidation or corrosion.
  • the pre-stress of the enameled wire is not more than 80% to ensure that the wire has sufficient strength.
  • connection structure between the terminal and the enameled wire further includes an insulation part, which covers and seals at least the welding part of the enameled wire.
  • the insulating portion may be filled on the outside of the enameled wire in the through hole formed by the fixed terminal and the first groove.
  • the insulating portion may be formed by dropping the insulating varnish, or by connecting the terminal to the enameled wire. The whole structure is immersed in the insulating varnish to ensure that the welded parts are not oxidized or corroded.
  • connection structure between the terminal and the enameled wire further comprises a heat shrinkable tube, which is sleeved on the outer wall of the terminal, or is sleeved on the terminal and the terminal.
  • the outer wall of the fixed terminal The application of heat shrinkable tube is further protection.
  • the present invention also provides a connection method for a connection structure between a terminal and an enameled wire, which is characterized by including the following steps:
  • the present invention also provides another connection method for a connection structure between a terminal and an enameled wire, which is characterized by including the following steps:
  • S3 includes the following specific steps:
  • S32 Set the welding current and welding time, start the welding machine, and move the positive and negative electrodes to press the structure to be welded. One electrode is in contact with the top of the structure to be welded, and the other electrode is in contact with the structure to be welded. Then, the discharge process is started, and the positive and negative electrodes are turned on to melt off the varnish of the terminals of the enameled wire.
  • the terminals of the enameled wire are fixed to the terminal, or connected to the terminal and the fixed terminal.
  • the bump welding current in the S32 is 1000-5000A, and the bump welding time is not more than 100 ms. Controlling the soldering time within 100ms can not damage the wires; the soldering process generates instant high temperature due to the large current, so that the part of the enameled wire in contact with the fixed terminal and the terminal is melted and removed to achieve the purpose of conduction. For the structure to be bumped with fixed terminals, this process will not remove the varnish of the enameled wire outside the fixed terminal.
  • the peeled enameled wire in the fixed terminal is closely connected to the fixed terminal and the bottom surface of the first groove, which can effectively reduce air and Contact of wires. In order to strengthen the protection of the welded parts, the insulation paint can be dripped and heated to shrink the tube to protect it.
  • the preload of the terminals of the enameled wire is not more than 80%.
  • an automatic terminal machine can be used. After stamping, the fixed terminals are tightly wrapped with the terminals. The fixed terminals are pressed against the first surface of the terminals. The enameled wire is in contact with the fixed terminals and terminals with a certain amount of preload. , The pre-stressing amount is not more than 80% to ensure that the wire has sufficient strength.
  • connection method of the connection structure between the terminal and the enameled wire further includes S4: applying an insulating varnish to the enameled wire to seal the welding portion. This step is used to protect the welded part from the air.
  • a heat shrinkable tube is sleeved on the outer wall of the terminal, or the outer wall of the terminal and the fixed terminal.
  • the bottom of the heat shrinkable tube is 0-4 mm lower than the bottom of the fixed terminal, which can prevent the thread end from loosening or breaking during use or transportation.
  • the present invention also provides a coil component, comprising: a coil bobbin and a connection structure between the terminal and the enameled wire, the terminal is fixed to the coil bobbin, and the enameled wire is wound around the coil bobbin to form a coil, The terminal of the enameled wire is fixed by welding in the first groove of the terminal.
  • the coil bobbin includes a lead portion, and a lead slot is formed on the lead portion, the lead slot is in the same direction as the opening of the first groove, and the lead slot is located in the first groove. Directly below and the centerlines of the slots are aligned with each other.
  • This setting is beneficial for the terminal of the enameled wire to accurately enter the first groove.
  • the connection terminal of the drain pump motor is small, and the width of the first groove is only millimeters. Manually passing the terminal of the enameled wire needs to be very careful and labor-intensive, and the end of the enameled wire is set by the lead groove. The terminal first enters the lead groove into which the enameled wire is easily caught, and then directly enters the first groove without the need for careful manual alignment, which can improve production efficiency.
  • the lead groove is V-shaped.
  • the lead groove is V-shaped, with a large opening at the outer end, which makes the enameled wire easy to enter, a small opening at the inner end, and a width equal to the opening of the first groove, and the first groove is provided on the lead groove.
  • the terminals of the enameled wire are directly placed in the first groove.
  • the coil component further includes a plastic sealing layer, and the plastic sealing layer is wrapped around the outer layer of the coil skeleton, the coil, and the terminal.
  • the plastic sealing layer protects the coil component. On the one hand, it can protect the welded part to further isolate it from the air, and on the other hand, it can also play a waterproof role. For example, a motor with waterproof requirements can plastically seal the coil component. In a sealed environment.
  • the invention also provides a motor, which is characterized by comprising the coil assembly.
  • the specific structure of the terminal of the present invention can make the placing and fixing of the enameled wire more convenient and firm in the terminal, reduce manual investment, and because the enameled wire is stored in the first groove, the enameled wire is favorably protected. , It is not easy to cause damage to the enameled wire due to external forces;
  • connection terminal of the present invention and the connection structure with the enameled wire adopt a bump welding method to connect with the enameled wire.
  • it overcomes the disadvantages brought by the soldering method, makes the length of the enameled wire of the enameled wire controllable, and improves the product. Consistency and production efficiency, and the unpainted section of the same length is not exposed to the air, which can prolong the service life of the product.
  • the design of the first groove allows the terminals of the enameled wire to finally fill the fixed terminals and terminals.
  • the terminal of the enameled wire will not The strength is reduced due to being pressed to excessive deformation (especially for the softer aluminum wire), which has better protection for the wire;
  • connection method of the connection structure of the terminal and the enameled wire of the present invention has high production efficiency.
  • the process uses high temperature arc to melt the enameled wire in contact with the fixed terminal.
  • the degree of melting of the varnish can be controlled by the current and time parameters, because the process is instantaneous.
  • High temperature the area affected by heat is within the scope of the fixed terminal (if the fixed terminal is not included, the area affected by the heat is within the coverage of the welding electrode), the paint is wrapped in the fixed terminal and the through hole formed by the first groove
  • the wire has been isolated from the air, and further protection can be achieved through enhanced protection measures such as dripping insulation paint and sleeve heat shrinkable tubes.
  • the range of the paint removal of the connection method of the present invention is controlled within the range of fixed terminals or the coverage of the welding electrode, which can realize the protection of the wire, easier to control automatically, reduce manual operations, and does not require assistance. Flux to reduce subsequent processing procedures and further protect product safety;
  • connection terminal of the present invention and the connection structure with the enameled wire can be applied to various coil components and various electrical appliances including motors.
  • FIG. 1 is a schematic side view of a connection terminal of Embodiment 1;
  • FIG. 2 is a cross-sectional view of a connection terminal of Embodiment 1;
  • FIG. 3 is a schematic perspective view of a connection terminal of Embodiment 1;
  • FIG. 4 is a schematic perspective view of a connection structure between a terminal and an enameled wire in Embodiment 4;
  • FIG. 5 is a schematic perspective view of a fixed terminal in Embodiment 4.
  • FIG. 6 is a schematic perspective view of a fixed terminal in an embodiment
  • FIG. 7 is a schematic perspective view of a fixed terminal in another embodiment
  • FIG. 8 is a schematic perspective view of the connection structure between the terminal and the enameled wire in the initial state of Embodiment 9;
  • connection structure of the connection terminal and the enameled wire in the ninth embodiment after punching is a schematic perspective view of the connection structure of the connection terminal and the enameled wire in the ninth embodiment after punching;
  • FIG. 10 is a schematic diagram of the relative positions of the two electrodes of the welding machine before the welding in the connection structure between the terminal and the enameled wire in Embodiment 8 or 9.
  • FIG. 11 is a schematic diagram of the relative positions of the two electrodes of the butt welder during the butt welding process of the connection structure between the terminal and the enameled wire in Embodiment 8 or 9;
  • FIG. 12 is a schematic perspective view of the coil assembly before the fixed terminal is punched in Embodiment 11;
  • Example 13 is a schematic perspective view of the coil assembly in Example 11 after the fixed terminal is punched and subjected to bump welding;
  • FIG. 14 is a schematic diagram of a coil bobbin in Embodiment 11;
  • FIG. 15 is a schematic perspective view of a coil component according to Embodiment 12.
  • FIG. 16 is a schematic diagram of a drain pump motor of Embodiment 13;
  • connection terminals in the drainage pump motor all take the connection terminals in the drainage pump motor, the connection structure between the connection terminal and the enameled wire, and the connection method as examples, but are not limited to being applied to the drainage pump motor.
  • FIGS. 1 to 3 are schematic structural diagrams of a connection terminal of the present invention.
  • the connection terminal 1 of this embodiment includes a connection terminal body 11 and a connection post 12.
  • the terminal post 12 is used for connection with a terminal of an enameled wire.
  • the terminal post 12 is fixed to the terminal body 11 and includes a first surface 121, a first groove 122, and a wire winding post 123.
  • the first groove 122 is formed downward from the first surface 121 and includes two side surfaces 1222 and a bottom surface 1221.
  • the included angle ⁇ between the bottom surface 1221 of the first groove and the first surface 121 is 15 °.
  • the included angle ⁇ is preferably in the range of 0-20 °, that is, the first groove.
  • the bottom surface 1221 may be parallel to the first surface 121 or may be inclined.
  • the enameled wire is an aluminum enameled wire. In other embodiments, a conventional copper enameled wire may be used.
  • the terminal post 12 may not include the wire winding post 123.
  • the terminal 1 of this embodiment includes a terminal body 11, a terminal 12 and a fixed terminal 13.
  • the terminal 12 does not include a wire winding post 123, and other components, shapes and terminals of the terminal 12.
  • the structural relationship between the main body 11 and the terminal 12 is the same as that in the first embodiment.
  • the included angle ⁇ is 20 °.
  • the cross section of the fixed terminal 13 is U-shaped, and a plurality of tooth-shaped structures 131 are provided on the inner side surface thereof to further prevent the enameled wire from coming loose.
  • the tooth-shaped structure may not be provided. Structure 131.
  • the fixed terminal 13 and the terminal post 12 are separated and independent from each other.
  • the fixed terminal 13 can be stamped to be fixed to the terminal post 12 by a stamping process, and is wrapped on three outer surfaces of the terminal post, including the first surface. And sides of the first surface.
  • the cross section of the fixed terminal 13 may also be semi-circular, as shown in FIG. 6, or the cross section is generally U-shaped.
  • the U-shaped fixed terminal 13 includes two free ends, and the lengths of the two free ends are different, as shown in FIG. 6. 7 is shown.
  • connection terminal 1 of this embodiment includes a connection terminal body 11, a connection post 12, and a fixed terminal 13.
  • the shape and structure of the terminal 12 and the structural relationship between the terminal body 11 and the terminal 12 are the same as those in the first embodiment.
  • the included angle ⁇ is 10 °.
  • the fixed terminal 13 is fixed on the terminal 12 and includes a crimping portion 132 and a fixing portion 133 connected to each other.
  • the fixed terminal 13 is fixed on the side wall of the terminal 12 through the fixing portion 133.
  • the crimping portion 132 can pass through The crimping cover is fitted on the first surface 121 of the terminal 12.
  • the fixed portion 133 is fixed to the terminal 12, and the crimping portion 132 is located above the terminal 12 and does not contact the terminal 12.
  • the crimping portion 132 is stamped, as shown in FIG. 8.
  • the crimping portion 132 is crimped and covered on the first surface 121 of the terminal 12.
  • the connection structure between the terminal and the enameled wire in this embodiment includes the terminal 1 and the enameled wire 2.
  • the structure of the terminal 1 is the same as that of the embodiment 2.
  • the enameled wire 2 includes a terminal 21, the terminal 21 of the enameled wire is placed on the first groove 122, and the fixed terminal is crimped and fixed to the terminal 21 and the wiring of the enameled wire.
  • the terminal 21 of the enameled wire is fixedly connected to the fixed terminal 13 and the terminal post by welding.
  • the preload of the terminal of the enameled wire is not more than 80%.
  • connection structure of the connection terminal and the enameled wire in this embodiment further includes an insulation part and a heat-shrinkable tube on the basis of Embodiment 4.
  • the insulating portion is filled in the through hole formed by the fixed terminal 13 and the first groove 122, between the enameled wire and the fixed terminal, and between the enameled wire and the terminal post, and at least the welding portion of the enameled wire 2 is covered and sealed.
  • the heat shrinkable tube is sleeved on the outer wall of the fixed terminal 13 and the terminal post.
  • the connection structure between the terminal and the enameled wire in this embodiment includes the terminal 1 and the enameled wire 2.
  • the structure of the terminal 1 is the same as that of the embodiment 3.
  • the enameled wire 2 includes a terminal 21, the terminal 21 of the enameled wire is placed on the first groove 122, and the fixed terminal is crimped and fixed to the terminal 21 and the wiring of the enameled wire.
  • Column 12 the terminal 21 of the enameled wire is connected to the fixed terminal 13 and the terminal by welding, and the preload of the terminal of the enameled wire is not more than 80%.
  • Embodiment 5 may also be similar, and further includes an insulation portion, or both an insulation portion and a heat shrinkable tube.
  • connection structure (not shown) of the terminal and the enameled wire in this embodiment includes an enameled wire and a terminal.
  • the structure of the terminal is the same as that in Embodiment 1.
  • the enameled wire includes a terminal, and the terminal of the enameled wire is placed on the first groove It is fixed in contact with the terminal by welding.
  • connection structure between the terminal and the enameled wire in this embodiment includes the terminal, the enameled wire, and the fixed terminal of the present invention.
  • the fixed terminal can be crimped and fixed to the terminal and wrapped on at least two outer surfaces of the terminal. Both outer surfaces include the first surface.
  • the wiring post includes a wire-wound winding post.
  • connection method of the connection structure between the terminal and the enameled wire includes the following steps:
  • S1 Pass the terminal of the enameled wire and place it in the first groove of the terminal, and wrap the end on the wire winding post to fix it;
  • S2 Use an automatic terminal machine to punch the fixed terminals so as to wrap the terminals and terminals of the enameled wire, make the terminals of the enameled wire contact the bottom of the fixed terminal and the first groove, and pre-press the terminals of the enameled wire The amount is not more than 80%;
  • This embodiment is a preferred embodiment. In other embodiments, S4 may not be included.
  • connection method of the connection structure between the terminal and the enameled wire is not limited to the connection structure of the terminal and the enameled wire of the same structure in this embodiment.
  • the terminal 12 does not include the wire winding post 123
  • S1 may not include the enameled wire
  • the end of the terminal 21 is wound, and S3 does not include cutting off the wire winding post 123 and the enameled wire wound thereon. The other steps are the same.
  • connection structure between the terminal and the enameled wire in this embodiment is the same as that in Embodiment 6.
  • the connection method of the connection structure between the terminal and the enameled wire includes the following steps:
  • the fixed terminal 13 is punched, and the crimping portion 132 is crimped and covered on the first surface 121 of the terminal 12, so that the entire fixed terminal 13 functions as the terminal 21 and the terminal 12 of the fixed enameled wire.
  • the enameled wire The terminals 21 of the terminals are in contact with the fixed terminals 13 and the bottom surface 1221 of the first groove, respectively, and the preload of the terminals 21 of the enameled wire is not more than 80%;
  • connection structure between the terminal and the enameled wire in this embodiment is the same as that in Embodiment 7.
  • the connection method of the connection structure between the terminal and the enameled wire includes the following steps:
  • S32 Set the welding current and welding time, start the welding machine, move the positive and negative electrodes to press the terminals and terminals of the enameled wire, one of the electrodes and the upper surface of the terminal of the enameled wire and the first surface of the terminal Contact, the other electrode is in contact with the bottom of the terminal; then the discharge process is started, and the positive and negative electrodes are conducted to melt the varnish of the terminal of the enameled wire, and the terminal of the enameled wire is fixed to the terminal.
  • the coil assembly of this embodiment includes a coil bobbin 4 and a connection structure between the terminal and the enameled wire of the present invention.
  • connection terminal 1 can be fixed in the insertion slot on the coil bobbin 4 by plugging.
  • the enameled wire 2 is wound around the coil bobbin 4 to form a coil.
  • the terminal 21 of the enameled wire is fixed to the first groove 122 of the terminal 12 by welding.
  • 12 and 13 are three-dimensional schematic diagrams of the coil component of the fixed terminal 13 before punching, after punching, and bump welding, respectively. The paint is protected by dripping the bump, and can be dripped from the position A in the figure.
  • the coil bobbin 4 includes a lead portion 41, and a lead slot 411 is defined in the lead portion 41.
  • the lead slot 411 has the same opening direction as the first groove 122, and the lead slot 411 is located at the first
  • the grooves 411 are directly below the grooves 122 and the center lines of the grooves are aligned with each other.
  • the lead grooves 411 are V-shaped, and the outer opening width is larger than the inner opening width.
  • the coil assembly of this embodiment has a structure based on Embodiment 11 and further includes a plastic encapsulation layer 5 which is wrapped around the outer layer of the coil bobbin 4, the coil, and the terminal 12.
  • the drain pump motor of this embodiment (as shown in FIG. 16) includes a coil assembly 7, a stator core 8, a pump body 91 and a pump cover 92 of the present invention. In other embodiments, it may also be a motor including the coil assembly of the present invention and applied to other occasions.
  • connection terminal of the present invention, the connection structure with the enameled wire, and the coil assembly are not limited to being applied to a motor, but can be applied to all electrical appliances that may include the connection terminal, the connection structure with the enameled wire, or the coil assembly, such as electromagnetic Valves, transformers, etc.

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Abstract

一种接线端子（1）、其与漆包线（2）的连接结构及方法、线圈组件（7）和电机。所述接线端子（1），包括接线端子本体（11）；和用于与漆包线（2）的接线端（21）连接的接线柱（12），所述接线柱（12）固定于所述接线端子本体（11），包括第一表面（121），及由所述第一表面（121）向下开设的第一凹槽（122）。接线端子（1）与漆包线（2）的连接结构包括漆包线（2）和接线端子（1），所述漆包线（2）的接线端（21）置于所述第一凹槽（122）上，固定端子（13）压接并固定所述漆包线（2）的接线端（21）和所述接线柱（12），所述漆包线（2）的接线端（21）与所述固定端子（13）、所述接线柱（12）碰焊连接。从而使漆包线（2）在接线柱（12）的放置及固定更便捷牢固且对漆包线（2）进行了有利的保护，不易因外力而导致漆包线（2）损伤；实现了漆包线（2）与接线柱（12）的碰焊连接，使漆包线（2）的漆皮去除长度可控，延长线圈组件（7）或电机的寿命。

Description

接线端子与漆包线的连接结构及方法、线圈组件和电机 技术领域
本发明属于接线及其连接领域，尤其涉及一种接线端子、及其与漆包线的连接结构和连接方法、线圈组件和电机。
背景技术
电机中使用的漆包线可以是铜线或是铝线，上世纪70年代已有研究将铝线应用于电机。无论是铜漆包线或铝漆包线，现有的漆包线与接线端子之间的连接主要采用锡焊方式。锡焊方式需要先用液态锡去除漆包线漆皮，具体方法是其先将漆包线线头浸入过高温锡炉，熔掉表面的漆包线，为了使漆包线固定，接线端子的接线柱呈柱形，漆包线一般采用缠绕的方式固定于接线柱上。然而，一方面，这种接线端子使得漆包线的固定(缠绕)需要耗费较多的人工投入，且固定的漆包线仍然易松脱脱落；另一方面，凸起于接线柱外的漆包线在外力作用下容易被拉断或碰伤，造成产品不良进而引起电机失效。
发明内容
基于此，本发明的目的在于，提供一种接线端子，克服了现有接线端子的缺点，可使漆包线在接线柱的放置及固定更便捷牢固，减少人工投入，且由于漆包线被收纳于第一凹槽中，对漆包线进行了有利的保护，不易因外力(例如注塑压力等)而导致漆包线的损伤。
本发明采取的技术方案如下：
一种接线端子，其特征在于，包括：接线端子本体；和用于与漆包线的接线端连接的接线柱，所述接线柱固定于所述接线端子本体，包括第一表面，及由所述第一表面向下开设的第一凹槽，所述第一凹槽包括两个侧面和一底面。由于第一凹槽的设置，漆包线的接线端可填充于其中，得到较好的保护，不易因外力作用而受损伤；另外，该结构适用于对漆包线与接线柱的碰焊固定，一经碰焊固定也不易松脱。
进一步地，所述第一凹槽的底面与所述第一表面之间的夹角为0-20°。该角度使得第一凹槽的底面与第一表面相比，为一平面或为一斜面且斜度较小。如果后续需要对漆包线进行压接或碰焊，可使漆包线与第一凹槽底面的接触更紧密，且可防止漆包线在接线端子上被压至过度变形而导致强度降低过多，对导线起到更好的保护作用。
进一步地，所述第一凹槽的底面相对于所述第一表面呈倾斜状。即进一步限定第一凹槽底面与第一表面之间夹角不为零，具有一定倾斜度的第一凹槽，如果漆包线在后续可能被冲 压或碰焊时受压，可保证漆包线的预压段高度呈线性变化，逐渐过渡，该角度可保证漆包线的预压量的同时使其不被压断，并确保其强度。
进一步地，所述接线柱还包括位于顶部的线头缠绕柱。使用时，漆包线的接线端通过接线柱的第一凹槽，然后可缠绕于线头缠绕柱上固定。
作为一种实施方式，所述漆包线为铝漆包线。由于铝漆包线褪除漆皮后更易受到空气腐蚀，实际应用时铝漆包线更多。
进一步地，所述的接线端子，其特征在于，还包括一可压接固定于所述接线柱的固定端子。在某些实施方式中，固定端子可以是单个冲压件，其通过冲压后可包裹并固定于接线柱；在另一些实施方式中，固定端子还可以是本身固定于所述接线柱的一个部件，其部分与接线柱固定，部分可通过冲压后固定于接线柱。
作为一种实施方式，所述固定端子包括相互连接的压接部和固定部，所述固定部固定于所述接线柱，所述压接部压接盖合于所述接线柱的第一表面之上。该实施方式中，固定端子是本身固定于所述接线柱的一个部件，其压接部经冲压后压接盖合于接线柱的第一表面。
作为另一种实施方式，固定端子的截面呈U形或半环形。该实施方式中，固定端子是独立的冲压件，经冲压后实现包裹固定于接线柱，可能包裹接线柱的三个表面，是第一表面和位于第一表面两侧的侧面，也可能包裹接线柱的四个表面，还包括底面。
优选地，所述固定端子的内侧面设有多个齿状结构。这样可更好地防止漆包线松脱。
本发明还提供一种接线端子与漆包线的连接结构，其特征在于，包括漆包线和上述的接线端子，漆包线包括一接线端，所述漆包线的接线端置于所述第一凹槽上并与所述接线柱碰焊连接固定。
由于现有技术的电机漆包线通过锡焊方式去除漆皮时，需要先用液态锡去除漆包线漆皮，其先将漆包线线头过高温锡炉，熔掉表面的漆包线，锡焊退漆的长度完全靠经验，这一过程很难准确控制去漆段的长度以及去漆过程的时间，使得去漆段长度可能过长或过短。如果去漆段长度过长，可能导致漆包线去漆段裸露在空气中，容易被氧化，再加上潮湿的空气中含有酸碱性物质，容易腐蚀漆包线及其焊接点，进而导致电机早期失效；如果去漆段长度过短，则可能导致漆包线与接线端子之间断路，或者接线端子与铝线接触面积不足会导致接触不良或者接触电阻大，同样造成电机失效。而且，尤其对于铝漆包线来说，由于铝不易上锡，在锡焊过程中通常还会要加入助焊剂来辅助，助焊剂本身具有腐蚀性，因此锡焊方式带来的缺点有：一是锡焊结束需要增加助焊剂清洗工序，二是如果助焊剂有残留会影响电机的使用寿命，三是因铝线较软，锡焊工艺难以实现自动化，制造过程中需要大量的人工投入。
本发明的接线端子与漆包线的连接结构，基于特定结构的接线端子，实现了漆包线与接 线柱的碰焊连接，克服了上述常规锡焊工艺带来的缺点；且使得漆包线的漆皮去除长度可控，将空气对去漆皮段的腐蚀可能性降到最低，间接延长包括接线端子与漆包线的连接结构的线圈组件或电机的寿命。
本发明还提供一种接线端子与漆包线的连接结构，其特征在于，包括漆包线和上述包括固定端子的接线端子，所述漆包线包括一接线端，所述漆包线的接线端置于所述第一凹槽上，所述固定端子压接并固定所述漆包线的接线端和所述接线柱，所述漆包线的接线端与所述固定端子、所述接线柱碰焊连接。
本发明的接线端子与漆包线的连接结构同样实现了漆包线与接线柱的碰焊固定，由于接线柱具有特定结构，漆包线刚开始时置于第一凹槽中，漆包线的接线端受到向下的压力，由于其本身弹性，漆包线的接线端被固定端子压紧，其与固定端子和第一凹槽的底面之间接触紧密，同时漆包线在第一凹槽内的宽度会增加使其两侧可能接触第一凹槽的侧面，最终漆包线的接线端填充于固定端子与接线柱的第一凹槽所形成的通孔中。对于第一凹槽优选的倾斜设置，可防止固定端子将漆包线压得过度变形而导致强度降低过多，保证漆包线的预压段高度呈线性变化，逐渐过渡，确保导线不被压断或是形状的突变，同时消除了后续的拉断隐患。
进一步地，所述固定端子与所述漆包线的接线端和所述接线柱通过冲压固定，漆包线的接线端的预压量不大于80％。通过冲压固定的固定端子，在漆包线与接线柱碰焊固定后，由于碰焊工艺不会去除漆包线在固定端子以外部分的漆皮，固定端子内的已去皮的漆包线在碰焊过程与固定端子和接线柱的第一凹槽紧密接触，形成了一密闭空间，碰焊部位很难与空气接触，保护其不受空气氧化或腐蚀。漆包线的预压量不大于80％可保证导线具有足够的强度。
进一步地，所述的接线端子与漆包线的连接结构，其特征在于：还包括绝缘部，所述绝缘部覆盖密封至少所述漆包线的碰焊部位。对于包括固定端子的接线端子，绝缘部可填充于固定端子与第一凹槽形成的通孔内的漆包线外侧，该绝缘部可通过滴加绝缘漆形成，也可通过将接线端子与漆包线的连接结构整体浸入绝缘漆中形成，起到确保碰焊部位不被氧化或腐蚀的作用。
进一步地，所述的接线端子与漆包线的连接结构，其特征在于：还包括热缩管，所述热缩管套设于所述接线柱的外壁，或套设于所述接线柱及所述固定端子的外壁。热缩管的应用为更进一步的保护。
本发明还提供一种接线端子与漆包线的连接结构的连接方法，其特征在于包括如下步骤：
S1：将漆包线的接线端穿过并放置于所述接线柱的第一凹槽；
S3：对所述漆包线的接线端和所述接线柱进行碰焊，使漆包线的接线端的漆皮褪除，漆包线的接线端与接线柱连接固定，得到接线端子与漆包线的连接结构。
本发明还提供另一种接线端子与漆包线的连接结构的连接方法，其特征在于包括如下步骤：
S1：将漆包线的接线端穿过并放置于所述接线柱的第一凹槽；
S2：对固定端子进行冲压，使之包裹固定所述漆包线的接线端和所述接线柱，且使漆包线的接线端分别与固定端子和第一凹槽的底面接触；
S3：对所述固定端子、漆包线的接线端和所述接线柱进行碰焊，使漆包线的接线端的漆皮褪除，漆包线的接线端与接线柱、固定端子连接固定，得到接线端子与漆包线的连接结构。
进一步地，S3包括以下具体步骤：
S31：将待碰焊结构放入碰焊机的正负电极之间；
S32：设定碰焊电流以及碰焊时间，启动碰焊机，正负电极运动使之压紧待碰焊结构，其中一电极与待碰焊结构的顶部接触，另一电极与待碰焊结构的底部接触；然后启动放电过程，正负电极导通使漆包线的接线端的漆皮熔去褪除，漆包线的接线端与接线柱连接固定，或与接线柱及固定端子连接固定。
进一步地，所述S32中碰焊电流是1000-5000A，碰焊时间是不大于100ms。控制碰焊时间在100ms以内，可不损伤导线；碰焊过程因大电流产生瞬间的高温，使与固定端子和接线柱接触的那部分漆包线的漆皮熔掉去除，达到导通目的。对于具有固定端子的待碰焊结构，该过程不会去除漆包线在固定端子以外部分的漆皮，固定端子内的已去皮的漆包线与固定端子、第一凹槽底面紧密连接，可有效减少空气与导线的接触。为了加强对碰焊部位的保护，可后续滴加绝缘漆并加热缩管加以保护。
进一步地，所述S2中使漆包线的接线端的预压量不大于80％。S2对固定端子冲压时，可采用自动端子机，冲压后固定端子与接线柱包紧，固定端子紧压接线柱的第一表面，漆包线与固定端子、接线柱接触，并有一定的预压量，预压量不大于80％可保证导线具有足够的强度。
优选地，所述的接线端子与漆包线的连接结构的连接方法，其特征在于：还包括S4：向漆包线的碰焊部位涂覆绝缘漆使之密封。该步骤用于对碰焊部位的保护，使之与空气隔绝。
进一步地，所述的接线端子与漆包线的连接结构的连接方法，其特征在于：还包括S5：在接线柱的外壁、或接线柱及固定端子的外壁套设热缩管。优选地，热缩管底部低于固定端子底部0-4mm，可防止使用或运输过程中线头松动或拉断。
本发明还提供一种线圈组件，其特征在于，包括：线圈骨架和所述的接线端子与漆包线的连接结构，所述接线端子固定于所述线圈骨架，漆包线缠绕于所述线圈骨架形成线圈，漆包线的接线端碰焊固定于所述接线柱的第一凹槽内。
优选地，所述线圈骨架包括一引线部，所述引线部上开设有一引线槽，所述引线槽与所述第一凹槽的开口方向相同，所述引线槽位于所述第一凹槽的正下方且槽中心线相互对齐。该设置有益于漆包线的接线端准确地进入到第一凹槽中。尤其是排水泵电机的接线端子较小，而第一凹槽的宽度只有毫米级，人工将漆包线的接线端穿入时需要非常仔细，人力消耗大，而通过引线槽的设置，使漆包线的尾端先进入易将漆包线卡入的引线槽，再顺势直接进入第一凹槽，不需要人工仔细对准，可提高生产效率。
作为一种实施方式，所述引线槽呈V形。引线槽呈V形，其外端开口大，使漆包线易进入，内端开口小，与第一凹槽的开口宽度相当，而第一凹槽设于引线槽上，只需向上拉动即可使漆包线的接线端直接放入第一凹槽中。
进一步地，所述的线圈组件，其特征在于：还包括塑封层，所述塑封层包裹于所述线圈骨架、线圈及接线柱之外层。该塑封层起对线圈组件保护作用，一方面可对碰焊部位进行保护，使之进一步与空气隔绝，另一方面可起到防水作用，例如有防水要求的电机，可将该线圈组件塑封在密封环境中。
本发明还提供一种电机，其特征在于：包括所述的线圈组件。
本发明的有益效果是：
(1)本发明的接线端子，其特定的结构可使漆包线在接线柱的放置及固定更便捷牢固，减少人工投入，且由于漆包线被收纳于第一凹槽中，对漆包线进行了有利的保护，不易因外力而导致漆包线的损伤；
(2)本发明的接线端子及其与漆包线的连接结构，采用了碰焊方式与漆包线连接，一方面克服了锡焊方式带来的缺点，使漆包线的去漆段长度可控，提高了产品的一致性及生产效率，且长度一致的去漆段没有暴露于空气中，可延长产品使用寿命，另一方面，第一凹槽的设计，使漆包线的接线端最终填充于固定端子与接线柱的第一凹槽所形成的通孔中，或填充于第一凹槽中，作为底面优选的倾斜设计，使固定端子将接线端子的接线柱与漆包线压接固定后，漆包线的接线端不会因被压至过度变形而导致强度降低(尤其对于材质较软的铝线)，对导线起到了较好的保护作用；
(3)本发明接线端子与漆包线的连接结构的连接方法，生产效率高，该工艺通过高温电弧熔化与固定端子接触的漆包线，漆皮熔化程度可通过电流及时间参数进行控制，因该过程是瞬间高温，受热影响的区域在固定端子包裹范围内(如果不含固定端子，则受热影响区域在碰焊电极所覆盖范围内)，包裹在固定端子及第一凹槽形成的通孔内的去漆皮导线已隔绝了空气，进一步地还可以通过滴绝缘漆及套热缩管等增强保护措施达到进一步保护。与传统的锡焊工艺相比，本发明连接方法退漆的范围控制在固定端子范围内或碰焊电极覆盖范围内， 可实现对导线的保护，更易自动化控制，减少人工操作，不需使用助焊剂，减少后续处理程序，且进一步保护了产品的安全；
(4)本发明的接线端子、及其与漆包线的连接结构，可应用于各种线圈组件及包括电机在内的多种电器中。
附图说明
图1为实施例1的接线端子的侧面示意图；
图2为实施例1的接线端子的剖视图；
图3为实施例1的接线端子的立体示意图；
图4为实施例4的接线端子与漆包线的连接结构立体示意图；
图5为实施例4中固定端子的立体示意图；
图6为一实施例中固定端子的立体示意图；
图7为另一实施例中固定端子的立体示意图；
图8为实施例9的接线端子与漆包线的连接结构初始状态时的立体示意图；
图9为实施例9的接线端子与漆包线的连接结构冲压成型后的立体示意图；
图10为实施例8或9中接线端子与漆包线的连接结构碰焊前碰焊机两电极的相对位置状态示意图；
图11为实施例8或9中接线端子与漆包线的连接结构碰焊过程中碰焊机两电极的相对位置状态示意图；
图12为实施例11中线圈组件在固定端子冲压前的立体示意图；
图13为实施例11中线圈组件在固定端子冲压后并经过碰焊的立体示意图；
图14为实施例11中线圈骨架示意图；
图15为实施例12的线圈组件立体示意图；
图16为实施例13的排水泵电机示意图；
其中：1-接线端子，11-接线端子本体，12-接线柱，121-第一表面，122-第一凹槽，1221-底面，1222-侧面，123-线头缠绕柱，13-固定端子，131-齿状结构，132-压接部，133-固定部，2-漆包线，21-接线端，A-绝缘漆滴加位置，4-线圈骨架，41-引线部，411-引线槽，5-塑封层，61-上电极，62-下电极，7-线圈组件，8-定子铁芯，91-泵体，92-泵盖。
具体实施方式
以下实施例皆以排水泵电机中的接线端子、接线端子与漆包线的连接结构及其连接方法 为例，但并不限应用于排水泵电机中。
实施例1
请参阅图1～3，其为本发明的接线端子的结构示意图。
本实施例的接线端子1，包括接线端子本体11和接线柱12。接线柱12用于与漆包线的接线端连接，接线柱12固定于接线端子本体11，包括第一表面121、第一凹槽122和线头缠绕柱123。第一凹槽122由第一表面121向下开设形成，包括两个侧面1222和一底面1221。本实施例中，第一凹槽的底面1221与第一表面121之间的夹角θ为15°，其他实施例中，该夹角θ优选为0-20°范围内，即第一凹槽的底面1221既可以与第一表面121呈平行状态，也可以是呈倾斜状态。本实施例中漆包线为铝漆包线，其他实施例中也可用传统的铜漆包线。其他实施例中，接线柱12也可以不包括线头缠绕柱123。
实施例2
请参阅图4～5，本实施例的接线端子1，包括接线端子本体11、接线柱12和固定端子13，接线柱12不包括线头缠绕柱123，接线柱12的其他组成部分及形状、端子本体11与接线柱12的结构关系同实施例1，本实施例中夹角θ为20°。
本实施例中，固定端子13的截面呈U形，且其内侧面设有多个齿状结构131，以起到进一步防止漆包线松脱的作用，在其他实施例中，也可不设该齿状结构131。初始状态时，固定端子13与接线柱12为互相分离且独立，可通过冲压工艺将固定端子13冲压至与接线柱12固定，并包裹于接线柱的三个外表面，包括所述第一表面及第一表面两侧的侧面。
在其他实施例中，固定端子13的截面还可以呈半环形，如图6所示，或截面总体呈U形，该U形固定端子13包括两自由端，两自由端的长度不等，如图7所示。
实施例3
请参阅图8～9，本实施例的接线端子1包括接线端子本体11、接线柱12和固定端子13。本实施例中接线柱12的形状结构、端子本体11与接线柱12的结构关系同实施例1，本实施例中夹角θ为10°。
本实施例中，固定端子13固定于接线柱12上，包括相互连接的压接部132和固定部133，固定端子13通过固定部133固定于接线柱12的侧壁，压接部132可通过压接盖合于接线柱12的第一表面121。该固定端子13的初始状态时，如图8所示，固定部133与接线柱12固定，压接部132位于接线柱12上方不与接线柱12接触；压接部132经冲压后，如图9所示，压接部132压接盖合于接线柱12的第一表面121。
实施例4
如图4～5所示，本实施例的接线端子与漆包线的连接结构，包括接线端子1和漆包线2。 接线端子1的结构同实施例2，漆包线2包括一接线端21，漆包线的接线端21漆包线的接线端21置于第一凹槽122上，固定端子压接并固定漆包线的接线端21和接线柱，漆包线的接线端21与固定端子13、接线柱碰焊连接，漆包线的接线端的预压量不大于80％。
实施例5
本实施例的接线端子与漆包线的连接结构，在实施例4的基础上，还包括绝缘部和热缩管。绝缘部填充于固定端子13与第一凹槽122形成的通孔中、漆包线与固定端子及漆包线与接线柱之间，至少覆盖漆包线2的碰焊部位并使之密封。热缩管套设于固定端子13及接线柱的外壁。
实施例6
如图8～9所示，本实施例的接线端子与漆包线的连接结构，包括接线端子1和漆包线2。接线端子1的结构同实施例3，漆包线2包括一接线端21，漆包线的接线端21漆包线的接线端21置于第一凹槽122上，固定端子压接并固定漆包线的接线端21和接线柱12，漆包线的接线端21与固定端子13、接线柱碰焊连接，漆包线的接线端的预压量不大于80％。在其他实施例中，也可类似实施例5，还包括绝缘部，或既包括绝缘部又包括热缩管。
实施例7
本实施例的接线端子与漆包线的连接结构(未图示)，包括漆包线和接线端子，接线端子的结构同实施例1，漆包线包括一接线端，漆包线的接线端置于第一凹槽上并与接线柱碰焊连接固定。
实施例8
本实施例的接线端子与漆包线的连接结构，包括本发明的接线端子、漆包线和固定端子，固定端子可压接固定于所述接线柱并包裹于接线柱的至少两个外表面上，所述两个外表面包括所述第一表面。本实施例中，接线柱包括线头缠绕柱。
该接线端子与漆包线的连接结构的连接方法，包括以下步骤：
S1：将漆包线的接线端穿过并放置于接线柱的第一凹槽，将端部缠绕在线头缠绕柱上起固定作用；
S2：用自动端子机对固定端子进行冲压，使之包裹固定漆包线的接线端和接线柱，使漆包线的接线端分别与固定端子和第一凹槽的底面接触，并使漆包线的接线端的预压量不大于80％；
S3：对固定端子、漆包线的接线端和接线柱进行碰焊(参见图10～11)，使漆包线的接线端的漆皮褪除，漆包线的接线端与接线柱、固定端子连接固定，切除线头缠绕柱及缠绕于其上的漆包线；
S4：向漆包线的碰焊部位滴加绝缘漆覆盖使之密封，并在接线柱及固定端子的外壁套设热缩管，得到本实施例的接线端子与漆包线的连接结构。
本实施例为优选实施方式，在其他实施例中，也可不包括S4。
上述接线端子与漆包线的连接结构连接方法并不限于本实施例相同结构的接线端子与漆包线的连接结构，例如在其他实施例中如果接线柱12不包括线头缠绕柱123，则S1可不包括对漆包线的接线端21的端部缠绕，S3可不包括对线头缠绕柱123及缠绕于其上的漆包线的切除，其他步骤相同。
实施例9
参照图8～9，本实施例的接线端子与漆包线的连接结构，同实施例6。该接线端子与漆包线的连接结构的连接方法，包括以下步骤：
S1：将漆包线的接线端21穿过并放置于接线柱12的第一凹槽122，将端部缠绕在线头缠绕柱123上起固定作用；
S2：对固定端子13进行冲压，使压接部132压接盖合于接线柱12的第一表面121，使整个固定端子13起到包裹固定漆包线的接线端21和接线柱12的作用，漆包线的接线端21分别与固定端子13和第一凹槽的底面1221接触，并使漆包线的接线端21的预压量不大于80％；
S3：对固定端子13、漆包线的接线端和接线柱12进行碰焊，使漆包线的接线端的漆皮褪除，漆包线的接线端与接线柱、固定端子连接固定，得到本实施例的接线端子与漆包线的连接结构，具体步骤如下(参见图10～11)：
S31：将已压接固定的固定端子13、漆包线的接线端和接线柱12放入碰焊机的正负电极之间，本实施例中正负电极分别作为上电极和下电极设置于固定端子的上方和接线柱底部，初始状态时，使下电极62与接线柱底部接触，上电极61远离固定端子；
S32：设定好碰焊电流1000-5000A、以及碰焊时间不大于100ms(该碰焊时间可保证不损伤导线)，启动碰焊机，上电极61向下运动使之接触固定端子，然后启动放电过程，上下电极实现导通，瞬间的高温使漆包线的接线端的漆皮熔掉褪除，达到漆包线的接线端与接线柱和固定端子的导通和固定，切除线头缠绕柱123及缠绕于其上的漆包线。
实施例10
本实施例的接线端子与漆包线的连接结构，同实施例7。该接线端子与漆包线的连接结构的连接方法，包括以下步骤：
S1：将漆包线的接线端穿过并放置于所述接线柱的第一凹槽；
S3：对所述漆包线的接线端和所述接线柱进行碰焊，使漆包线的接线端的漆皮褪除，漆 包线的接线端与接线柱连接固定，得到接线端子与漆包线的连接结构，具体步骤如下：
S31：将所述漆包线的接线端和所述接线柱放入碰焊机的正负电极之间；
S32：设定碰焊电流以及碰焊时间，启动碰焊机，正负电极运动使之压紧漆包线的接线端和接线柱，其中一电极与漆包线的接线端上表面及接线柱的第一表面接触，另一电极与接线柱的底部接触；然后启动放电过程，正负电极导通使漆包线的接线端的漆皮熔去褪除，漆包线的接线端与接线柱连接固定。
实施例11
如图12～13所示，本实施例的线圈组件，包括：线圈骨架4和本发明的接线端子与漆包线的连接结构。
接线端子1可通过插接方式固定于线圈骨架4上的插接槽内，漆包线2缠绕于线圈骨架4形成线圈，漆包线的接线端21碰焊固定于接线柱12的第一凹槽122内。图12和图13分别为固定端子13冲压前、冲压后且碰焊完成的线圈组件立体示意图，对碰焊位置滴加绝缘漆保护，可从图中A位置处滴加。
优先地，如图14所示，线圈骨架4包括一引线部41，所述引线41部上开设有一引线槽411，引线槽411与第一凹槽122的开口方向相同，引线槽411位于第一凹槽122的正下方且槽中心线相互对齐，本实施例中，引线槽411呈V形，其外开口宽度大于内开口宽度。
实施例12
如图15所示，本实施例的线圈组件，其结构在实施例11的基础上，还包括塑封层5，塑封层5包裹于线圈骨架4、线圈及接线柱12之外层。
实施例13
本实施的排水泵电机(如图16所示)，包括本发明的线圈组件7、定子铁芯8、泵体91与泵盖92。在其他实施例中，也可以是包括本发明线圈组件的应用于其他场合的电机。
本发明的接线端子、及其与漆包线的连接结构、线圈组件不局限于应用于电机中，其可应用于一切可能包含接线端子、及其与漆包线的连接结构或线圈组件的电器中，例如电磁阀、变压器等。
在本发明的描述中，需要理解的是，术语“中心”、“纵向”、“横向”、“上”、“下”、“前”、“后”、“左”、“右”、“竖直”、“水平”、“顶”、“底”、“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本发明和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本发明的限制。在本发明的描述中，除非另有说明，“多个”的含义 是两个或两个以上。
以上所述实施例仅表达了本发明的几种实施方式，其描述较为具体和详细，但并不能因此而理解为对发明专利范围的限制。应当指出的是，对于本领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干变形和改进，这些都属于本发明的保护范围。

Claims (26)

  1. 一种接线端子，其特征在于，包括：
    接线端子本体；
    和用于与漆包线的接线端连接的接线柱，所述接线柱固定于所述接线端子本体，包括第一表面，及由所述第一表面向下开设的第一凹槽，所述第一凹槽包括两个侧面和一底面。
  2. 根据权利要求1所述的接线端子，其特征在于：所述第一凹槽的底面与所述第一表面之间的夹角为0-20°。
  3. 根据权利要求2所述的接线端子，其特征在于：所述第一凹槽的底面相对于所述第一表面呈倾斜状。
  4. 根据权利要求1所述的接线端子，其特征在于：所述接线柱还包括位于顶部的线头缠绕柱。
  5. 根据权利要求1所述的接线端子，其特征在于，所述漆包线为铝漆包线。
  6. 根据权利要求1～5任一所述的接线端子，其特征在于，还包括一可压接固定于所述接线柱的固定端子。
  7. 根据权利要求6所述的接线端子，其特征在于，所述固定端子包括相互连接的压接部和固定部，所述固定部连接于所述接线柱，所述压接部可压接盖合于所述接线柱的第一表面之上。
  8. 根据权利要求6所述的接线端子，其特征在于：固定端子的截面呈U形或半环形。
  9. 根据权利要求6所述的接线端子，其特征在于：所述固定端子的内侧面设有多个齿状结构。
  10. 一种接线端子与漆包线的连接结构，其特征在于，包括漆包线和权利要求1～5任一所述的接线端子，漆包线包括一接线端，所述漆包线的接线端置于所述第一凹槽上并与所述接线柱碰焊连接固定。
  11. 一种接线端子与漆包线的连接结构，其特征在于，包括漆包线和权利要求6～9任一所述的接线端子，所述漆包线包括一接线端，所述漆包线的接线端置于所述第一凹槽上，所述固定端子压接并固定所述漆包线的接线端和所述接线柱，所述漆包线的接线端与所述固定端子、所述接线柱碰焊连接。
  12. 根据权利要求11所述的接线端子与漆包线的连接结构，其特征在于：所述固定端子与所述漆包线的接线端和所述接线柱通过冲压固定，漆包线的接线端的预压量不大于80％。
  13. 根据权利要求10或11所述的接线端子与漆包线的连接结构，其特征在于：还包括 绝缘部，所述绝缘部覆盖密封至少所述漆包线的碰焊部位。
  14. 根据权利要求13所述的接线端子与漆包线的连接结构，其特征在于：还包括热缩管，所述热缩管套设于所述接线柱的外壁，或套设于所述接线柱及所述固定端子的外壁。
  15. 权利要求10所述的接线端子与漆包线的连接结构的连接方法，其特征在于包括如下步骤：
    S1：将漆包线的接线端穿过并放置于所述接线柱的第一凹槽；
    S3：对所述漆包线的接线端和所述接线柱进行碰焊，使漆包线的接线端的漆皮褪除，漆包线的接线端与接线柱连接固定，得到接线端子与漆包线的连接结构。
  16. 权利要求11～14任一所述的接线端子与漆包线的连接结构的连接方法，其特征在于包括如下步骤：
    S1：将漆包线的接线端穿过并放置于所述接线柱的第一凹槽；
    S2：对固定端子进行冲压，使之包裹固定所述漆包线的接线端和所述接线柱，且使漆包线的接线端分别与固定端子和第一凹槽的底面接触；
    S3：对所述固定端子、漆包线的接线端和所述接线柱进行碰焊，使漆包线的接线端的漆皮褪除，漆包线的接线端与接线柱、固定端子连接固定，得到接线端子与漆包线的连接结构。
  17. 根据权利要求15或16所述的接线端子与漆包线的连接结构的连接方法，其特征在于，S3包括以下具体步骤：
    S31：将待碰焊结构放入碰焊机的正负电极之间；
    S32：设定碰焊电流以及碰焊时间，启动碰焊机，正负电极运动使之压紧待碰焊结构，其中一电极与待碰焊结构的顶部接触，另一电极与待碰焊结构的底部接触；然后启动放电过程，正负电极导通使漆包线的接线端的漆皮熔去褪除，漆包线的接线端与接线柱连接固定，或与接线柱及固定端子连接固定。
  18. 根据权利要求17所述的接线端子与漆包线的连接结构的连接方法，其特征在于：所述S32中碰焊电流是1000-5000A，碰焊时间是不大于100ms。
  19. 根据权利要求17所述的接线端子与漆包线的连接结构的连接方法，其特征在于：所述S2中使漆包线的接线端的预压量不大于80％。
  20. 根据权利要求17所述的接线端子与漆包线的连接结构的连接方法，其特征在于：还包括S4：向漆包线的碰焊部位涂覆绝缘漆使之密封。
  21. 根据权利要求20所述的接线端子与漆包线的连接结构的连接方法，其特征在于：还包括S5：在接线柱的外壁、或接线柱及固定端子的外壁套设热缩管。
  22. 一种线圈组件，其特征在于，包括：线圈骨架和权利要求10～14任一所述的接线端 子与漆包线的连接结构，所述接线端子固定于所述线圈骨架，漆包线缠绕于所述线圈骨架形成线圈，漆包线的接线端碰焊固定于所述接线柱的第一凹槽内。
  23. 根据权利要求22所述的线圈组件，其特征在于：所述线圈骨架包括一引线部，所述引线部上开设有一引线槽，所述引线槽与所述第一凹槽的开口方向相同，所述引线槽位于所述第一凹槽的正下方且槽中心线相互对齐。
  24. 根据权利要求23所述的线圈组件，其特征在于：所述引线槽呈V形。
  25. 根据权利要求22所述的线圈组件，其特征在于：还包括塑封层，所述塑封层包裹于所述线圈骨架、线圈及接线柱之外层。
  26. 一种电机，其特征在于：包括权利要求22～25任一所述的线圈组件。
PCT/CN2019/105172 2018-09-20 2019-09-10 接线端子与漆包线的连接结构及方法、线圈组件和电机 WO2020057399A1 (zh)

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