WO2020080092A1 - Structure de connexion de fil électrique et procédé de connexion de fil électrique - Google Patents

Structure de connexion de fil électrique et procédé de connexion de fil électrique Download PDF

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Publication number
WO2020080092A1
WO2020080092A1 PCT/JP2019/038678 JP2019038678W WO2020080092A1 WO 2020080092 A1 WO2020080092 A1 WO 2020080092A1 JP 2019038678 W JP2019038678 W JP 2019038678W WO 2020080092 A1 WO2020080092 A1 WO 2020080092A1
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WO
WIPO (PCT)
Prior art keywords
core wire
wires
core
layer
bonding layer
Prior art date
Application number
PCT/JP2019/038678
Other languages
English (en)
Japanese (ja)
Inventor
川田　祐司
宮本　賢次
玉川　達男
大地 白井
Original Assignee
株式会社オートネットワーク技術研究所
住友電装株式会社
住友電気工業株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by 株式会社オートネットワーク技術研究所, 住友電装株式会社, 住友電気工業株式会社 filed Critical 株式会社オートネットワーク技術研究所
Publication of WO2020080092A1 publication Critical patent/WO2020080092A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/10—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating making use of vibrations, e.g. ultrasonic welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-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
    • H01R4/02—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
    • H01R4/00—Electrically-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
    • H01R4/58—Electrically-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
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • 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
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G1/00—Methods or apparatus specially adapted for installing, maintaining, repairing or dismantling electric cables or lines
    • H02G1/14—Methods or apparatus specially adapted for installing, maintaining, repairing or dismantling electric cables or lines for joining or terminating cables
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G15/00—Cable fittings
    • H02G15/08—Cable junctions

Definitions

  • the technology disclosed in the present specification relates to an electric wire connection structure and an electric wire connection method.
  • a connection structure of electric wires in which core wires of a plurality of electric wires are joined is known.
  • a method for joining the core wires for example, there is a method in which the core wires of a plurality of electric wires are bundled, twisted and joined by ultrasonic welding (see Patent Document 1).
  • the welding conditions differ depending on the conductor strength of the core wire.
  • the welding conditions are adjusted to the core wire having a high conductor strength, the electric wire having a low conductor strength may be crushed or adhered to the mold.
  • the welding conditions are adjusted to a core wire having a low conductor strength, an electric wire having a high conductor strength may not be sufficiently welded and the welding strength may decrease.
  • the electric wire connection structure disclosed by the present specification includes a plurality of electric wires each including a core wire, and a joint portion in which the plurality of core wires are joined by ultrasonic welding, and the joint portion is arranged on the outermost side.
  • the electric wire connecting method disclosed in the present specification is an electric wire connecting method in which the core wires of a plurality of electric wires each including a core wire are joined by ultrasonic welding, and the plurality of core wires are stacked to form a laminated portion. And a welding step of ultrasonically welding the laminated portion to form a joint by an ultrasonic welding device including a welding horn and a receiving jig, and the laminated portion is arranged on the outermost side.
  • the conductor strength of a part of the core wires forming the core wire is lower than the conductor strength of other core wires forming the first core wire layer and the second core wire layer, and in the welding step, the first core wire layer and the core wire
  • a second core wire layer includes the receiving jig and the welding ho. Perform to weld into contact with the.
  • a part of the core wire having a relatively low conductor strength is sandwiched between the other core wires having a high conductor strength. Therefore, during ultrasonic welding, welding of a core wire having a high conductor strength is performed. It becomes possible to weld under the conditions, and the welding strength can be secured.
  • the first bonding layer and the second bonding layer may be composed of the core wire provided in the same electric wire.
  • the perspective view of the harness of Embodiment 1. Side view showing a stacking step in Embodiment 1.
  • Embodiment 1 a side view showing the welding process.
  • Embodiment 2 a side view showing a laminating step.
  • Embodiment 2 a side view showing the welding process.
  • the electric wire connection structure of the present embodiment is a part of a harness 1 to which a plurality of copper electric wires 10A (corresponding to electric wires) and aluminum electric wires 10B (corresponding to electric wires) are connected.
  • a copper electric wire 10A covers a copper core wire 11A (corresponding to a core wire and other core wires) 11A (corresponding to a core wire and another core wire) configured by a twisted wire formed by twisting a plurality of copper wires.
  • the first insulating coating 12A made of synthetic resin is provided.
  • 11 A of copper core wires have the part exposed from 12 A of 1st insulation coatings in the terminal part of 10 A of copper electric wires.
  • an aluminum electric wire 10B includes an aluminum core wire 11B (a core wire, which corresponds to a part of the core wire) 11B configured by a twisted wire formed by twisting a plurality of aluminum wires, and the aluminum core wire 11B.
  • the second insulating coating 12B made of synthetic resin is provided.
  • the aluminum core wire 11B has a portion exposed from the second insulating coating 12B in the end portion of the aluminum electric wire 10B.
  • the aluminum core wire 11B has lower conductor strength than the copper core wire 11A.
  • the "conductor strength” refers to the tensile strength of the core wire. More specifically, it refers to a value obtained by subjecting a core wire to a tensile test according to “JIS Z 2241” and dividing the maximum load that has reached up to breaking by the core wire cross-sectional area before loading.
  • the exposed portions of the plurality of copper core wires 11A and the plurality of aluminum core wires 11B are joined to each other to form a joint portion 20.
  • the bonding portion 20 has three layers in which a first bonding layer 21, a second bonding layer 22, and a third bonding layer 23 are laminated, and the first bonding layer 21 and the second bonding layer 21
  • the bonding layer 22 is arranged on the outermost side in the stacking direction, and the third bonding layer 23 is arranged between them.
  • Each of the first bonding layer 21 and the second bonding layer 22 is a layer composed of a plurality of copper core wires 11A
  • the third bonding layer 23 is a layer composed of a plurality of aluminum core wires 11B.
  • the first insulation coating 12A is peeled off at each end of each of the plurality of copper electric wires 10A to expose the copper core wire 11A.
  • the second insulating coating 12B is peeled off at the terminal portion to expose the aluminum core wire 11B.
  • the ultrasonic welding device 40 has a well-known configuration including an anvil 41 (corresponding to a receiving jig) and a welding horn 42.
  • the laminated portion 30 is composed of the copper core wire 11A, is arranged on the outermost first core wire layer 31 and the second core wire layer 32, and is composed of the aluminum core wire 11B, and is composed of the first core wire layer 31 and the second core wire layer 32. And a third core wire layer 33 arranged between.
  • the conductor strength of the aluminum core wire 11B forming the third core wire layer 33 is lower than the conductor strength of the copper core wire 11A forming the first core wire layer 31 and the second core wire layer 32.
  • the welding horn 42 is lowered to apply ultrasonic vibration along the axial direction of the copper electric wire 10A and the aluminum electric wire 10B while pressing the copper core wire 11A and the aluminum core wire 11B.
  • the anvil 41 contacts the first core wire layer 31, and the welding horn 42 contacts the second core wire layer 32.
  • the copper core wire 11A and the aluminum core wire 11B are welded to each other to form the joint portion 20 (welding process).
  • the welding condition may be a condition suitable for welding the copper core wire 11A, that is, a condition suitable for welding the core wire having a relatively high conductor strength.
  • harness 1 is completed.
  • the harness 1 includes the plurality of copper electric wires 10A including the copper core wire 11A, the plurality of aluminum electric wires 10B including the aluminum core wire 11B, and the plurality of copper core wires 11A and the aluminum core wire 11B.
  • the joining portion 20 joined by ultrasonic welding is provided, and the joining portion 20 has the first joining layer 21 and the second joining layer 22, which are arranged on the outermost side, and the first joining layer 21 and the second joining layer 22.
  • the conductor strength of the aluminum core wire 11B constituting the third bonding layer 23 is the same as that of the first bonding layer 21 and the third bonding layer 23.
  • the conductor strength is lower than the conductor strength of the copper core wire 11A forming the two-bonding layer 22.
  • the electric wire connecting method of the present embodiment is a method of joining the copper core wires 11A of the plurality of copper electric wires 10A and the aluminum core wires 11B of the plurality of aluminum electric wires 10B by ultrasonic welding, and the plurality of copper core wires 11A.
  • the aluminum core wire 11B are overlapped to form a laminated portion 30, and the ultrasonic welding device 40 including the welding horn 42 and the anvil 41 ultrasonically welds the laminated portion 30 to form the joint 20.
  • a third core wire in which the laminated portion 30 is arranged between the first core wire layer 31 and the second core wire layer 32, and the first core wire layer 31 and the second core wire layer 32 are arranged on the outermost side.
  • the conductor strength of the aluminum core wire 11B constituting the third core wire layer 33 is the first core wire layer 31 and the second core wire.
  • the conductor strength is lower than the conductor strength of the copper core wire 11A forming the layer 32, and welding is performed in the welding process such that the first core wire layer 31 and the second core wire layer 32 are in contact with the anvil 41 and the welding horn 42. .
  • the copper core wire 11A having a high conductor strength can be formed during ultrasonic welding. It becomes possible to weld under the welding conditions, and the welding strength can be secured.
  • the harness 50 of the present embodiment includes a plurality of copper electric wires 60A (corresponding to electric wires) and a plurality of aluminum electric wires 60B (corresponding to electric wires).
  • the copper electric wire 60A includes a copper core wire 61A (corresponding to a core wire and another core wire) and a first insulating coating 62A, and the copper core wire 61A is separated from the first insulating coating 62A. It has an exposed part.
  • the aluminum electric wire 60B includes an aluminum core wire 61B (corresponding to a core wire, a part of the core wire) and a second insulating coating 62B.
  • the aluminum core wire 61B includes the second insulating coating 62B. It has a part exposed from.
  • the exposed portion of the copper core wire 61A is approximately twice as long as the exposed portion of the aluminum core wire 61B.
  • the exposed portions of the plurality of copper core wires 61A and aluminum core wires 61B are welded by ultrasonic welding to form a joint 70.
  • the joint portion 70 includes three layers, that is, a first joint layer 71, a second joint layer 72, and a third joint layer 73.
  • the exposed portions of the plurality of copper core wires 61A are folded back in the middle in a bundled state to form a U shape as a whole, and are closer to the center side (the copper core wires 61A than the folding position 63).
  • the portion close to the portion covered by the first insulating coating 62A) forms the first bonding layer 71, and the tip side of the folding position 63 forms the second bonding layer 72.
  • the third bonding layer 73 is a layer composed of a plurality of aluminum core wires 61B, and is arranged between the first bonding layer 71 and the second bonding layer 72.
  • the first insulation coating 62A is peeled off at each end of each of the plurality of copper electric wires 60A to expose the copper core wire 61A.
  • the second insulating coating 62B is peeled off at the terminal portion to expose the aluminum core wire 61B.
  • the stripping length of the copper electric wire 60A is about twice that of the aluminum electric wire 60B.
  • the exposed portions of the copper core wire 61A and the aluminum core wire 61B are joined by ultrasonic welding.
  • the copper core wire 61A is set on the anvil 41, and a plurality of aluminum core wires 61B are superposed on the part of the copper core wire 61A closer to the center than the folded position 63.
  • the copper core wire 61A is folded back at the folding position 63, and a portion of the tip end side of the folding position 63 is stacked on the aluminum core wire 61B to form the laminated portion 80 (lamination step).
  • the laminated portion 80 is composed of a copper core wire 61A and is composed of a first core wire layer 81 and a second core wire layer 82 arranged on the outermost side, and an aluminum core wire 11B, and the first core wire layer 81. And a third core wire layer 83 disposed between the second core wire layer 82 and the second core wire layer 82.
  • the conductor strength of the aluminum core wire 61B forming the third core wire layer 83 is lower than the conductor strength of the copper core wire 61A forming the first core wire layer 81 and the second core wire layer 82.
  • the welding condition may be a condition suitable for welding the copper core wire 61A (copper core wire), that is, a condition suitable for welding the core wire having the stronger conductor strength of the two types of core wires 61A and 61B.
  • Test method 1. Preliminary test (measurement of conductor strength of electric wire) Core wires of a copper electric wire and an aluminum electric wire having a cross-sectional area of 0.75 mm 2 were each subjected to a tensile test in accordance with "JIS Z 2241", and the maximum load reached until breakage was measured. Five test pieces were tested, and the value obtained by dividing the average value of the maximum loads by the cross-sectional area before breaking was taken as the tensile strength (conductor strength). The results are shown in Table 1.
  • Test example 1 1) Preparation of test body Two copper electric wires and two aluminum electric wires each having a cross-sectional area of 0.75 mm 2 were cut into a length of 100 mm, and the insulating coating at the tip 10 mm was removed to expose the core wire. Subsequently, the exposed portion of the core wire was welded using an ultrasonic welding machine. The aluminum core wire was sandwiched between two copper core wires, and ultrasonic welding was performed under the copper recommended conditions of the welding machine. The obtained test body was subjected to a tear strength test.
  • Test example 2 Using two copper electric wires having a cross-sectional area of 1.25 mm 2 and one aluminum electric wire having a cross-sectional area of 2 mm 2 , a test piece was prepared in the same manner as in Test Example 1, and a tear strength test was performed. The results are shown in Table 3.
  • Test example 3 Using two copper electric wires having a cross-sectional area of 1.25 mm 2 and one aluminum electric wire having a cross-sectional area of 2.5 mm 2 , a test piece was prepared in the same manner as in Test Example 1 and a tear strength test was performed. The results are shown in Table 4.
  • Comparative Example 1 Using the same electric wire as in Test Example 1, the core wires of the two copper electric wires were put together on the core wire of the aluminum electric wire, and ultrasonic welding was performed under the aluminum recommended conditions of the welding machine. Others were the same as in Test Example 1, and a test piece was prepared and a tear strength test was performed. The results are shown in Table 2.
  • Comparative example 2 Using the same electric wire as in Test Example 2, a test piece was prepared in the same manner as in Comparative Example 1 and a tear strength test was performed. The results are shown in Table 3.
  • Comparative Example 3 Using the same electric wire as in Test Example 3, a test piece was prepared in the same manner as in Comparative Example 1 and a tear strength test was performed. The results are shown in Table 4.
  • Test Example 1 From Table 2, comparing Test Example 1 with Comparative Example 1, tearing of the bonded portion is found in Test Example 1 in which a copper core wire having a relatively high conductor strength is sandwiched between aluminum core wires having a low conductor strength. The strength was high, and it was found that the two types of core wires were firmly bonded at the bonded portion. The same applies to other test examples and comparative examples.
  • both the first bonding layer 21 and the second bonding layer 22 are made of a copper core wire, but the first bonding layer and the second bonding layer are made of different materials (for example, , Copper and copper alloy).
  • the first bonding layer 21 and the second bonding layer 22 are composed of the plurality of copper core wires 11A
  • the third bonding layer 23 is also composed of the plurality of aluminum core wires 11B.
  • the bonding layer, the second bonding layer, and the third bonding layer may each be composed of one core wire.
  • the joint portion 20 includes the single third joint layer 23.
  • the joint portion includes a plurality of third joint layers formed of core wires made of different materials. It doesn't matter.
  • the bonding portion includes a plurality of third bonding layers
  • the fourth layer formed of a core wire having a high conductor strength may be present between the two third bonding layers.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Insulated Conductors (AREA)
  • Processing Of Terminals (AREA)
  • Cable Accessories (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

La présente invention concerne un faisceau (1), pourvu : d'une pluralité de fils électriques en cuivre (10A) dotés d'un fil de noyau en cuivre (11A) et une pluralité de fils électriques en aluminium (10B) dotés d'un fil de noyau en aluminium (11B) ; et une partie de liaison (20) dans laquelle la pluralité de fils de noyau en cuivre (11A) et de fils de noyau en aluminium (11B) sont liés par soudage par ultrasons. La partie de liaison (20) est pourvue d'une première couche de liaison (21) et d'une deuxième couche de liaison (22) disposée au niveau de la position la plus à l'extérieur et d'une troisième couche de liaison (23) disposée entre la première couche de liaison (21) et la seconde couche de liaison (22). Parmi la pluralité de fils de noyau en cuivre (11A) et de fils de noyau en aluminium (11B), les fils de noyau en aluminium (11B) constituant la troisième couche de liaison (23) présentent une résistance conductrice qui est inférieure à celle des fils de noyau en cuivre (11A) constituant la première couche de liaison (21) et la seconde couche de liaison (22).
PCT/JP2019/038678 2018-10-16 2019-10-01 Structure de connexion de fil électrique et procédé de connexion de fil électrique WO2020080092A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2018194974A JP2020064737A (ja) 2018-10-16 2018-10-16 電線の接続構造、および、電線の接続方法
JP2018-194974 2018-10-16

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2024048719A1 (fr) * 2022-08-31 2024-03-07 古河電気工業株式会社 Structure liée par conducteur et procédé de liaison par ultrasons de conducteurs

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2017076497A (ja) * 2015-10-14 2017-04-20 株式会社オートネットワーク技術研究所 複数の電線の集合体及びその製造方法
JP2019008900A (ja) * 2017-06-21 2019-01-17 古河電気工業株式会社 電線接続構造体およびその製造方法

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2017076497A (ja) * 2015-10-14 2017-04-20 株式会社オートネットワーク技術研究所 複数の電線の集合体及びその製造方法
JP2019008900A (ja) * 2017-06-21 2019-01-17 古河電気工業株式会社 電線接続構造体およびその製造方法

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2024048719A1 (fr) * 2022-08-31 2024-03-07 古河電気工業株式会社 Structure liée par conducteur et procédé de liaison par ultrasons de conducteurs

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