Electrical wiring unit and method for assembling an electrical wiring unit

Abstract

An electrical wiring unit comprises an electrical wire, a connector, a temperature sensor, and a waterproof element. The electrical wire contains a conductor and an insulating sheath. The connector includes an electrical wire connection section that is connected to the conductor of the electrical wire. The temperature sensor detects the temperature of the electrical wire connection section. The waterproof element provides a liquid-tight seal to the periphery of the electrical wire connection section and the electrical wire. The waterproof element consists of adhesive tape. When the temperature sensor is in contact with the electrical wire connection section, the adhesive tape is wrapped around the outer periphery of the electrical wire connection section, the temperature sensor, and an outer periphery of the electrical wire.

Description

BACKGROUND OF THE INVENTION Area of ​​the invention

[0001] Embodiments of the present invention relate to an electrical wiring unit and a method for assembling the electrical wiring unit. Description of the state of the art

[0002] Multiple electrical wiring units are used together in a charging connector attached to an electric or hybrid vehicle. Each electrical wiring unit contains an electrical cable with a conductor and an insulating sheath, and a metal connector that is connected to the conductor of the electrical cable. The metal connector has a terminal body at one end, extending axially, and an electrical cable connection section at the other end, also extending axially. The terminal body might, for example, be a male connector. In this case, the terminal body can be inserted into and connected to a female counterpart.

[0003] If a high-voltage current flows through the conductor and terminal of this type of electrical wiring unit for an extended period, the temperature of the terminal and the electrical conductor will rise. Therefore, it is important to monitor the temperature of the electrical conductor's connection point and to appropriately control the current-carrying sections and similar components based on the detected temperature.

[0004] An electrical conductor unit was developed which includes a temperature sensor on an electrical conductor connection section of a terminal (see e.g. patent document 1).

[0005] In the electrical wiring unit described in patent document 1, a conductor of an electrical cable is connected to the electrical cable connection section of the connector in the plugged-in state, and the periphery of a butt joint between the electrical cable connection section and the sheathing of the electrical cable is covered with a waterproof heat-shrink tube containing an adhesive. The waterproof heat-shrink tube is placed around the end joint between the electrical cable connection section and the sheathing of the electrical cable and then heated. The heat causes the waterproof heat-shrink tube to shrink and melts the adhesive, thus forming a liquid-tight seal between the electrical cable connection section and the electrical cable.

[0006] A temperature sensor is attached to an outer peripheral surface of the waterproof heat shrink tubing. The temperature sensor is secured to the outer peripheral surface of the waterproof heat shrink tubing with a sensor-mounting heat shrink tube. Heat causes the sensor-mounting heat shrink tube to shrink, which in turn presses the temperature sensor against the outer peripheral surface of the waterproof heat shrink tubing. [State of the art document][Patent document]

[0007] [Patent document 1]: Japanese unexamined patent application, first publication no. 2021-125339 SUMMARY OF THE INVENTION

[0008] In the electrical wiring unit described in patent document 1, attaching the temperature sensor requires covering the periphery of the temperature sensor and the electrical wiring connection section with the sensor-mounting heat-shrink tubing while holding the temperature sensor pressed against the outer peripheral surface of the waterproof heat-shrink tubing. However, it is difficult to hold the temperature sensor stably in a suitable position on the electrical wiring connection section until the sensor-mounting heat-shrink tubing has shrunk due to heating. Furthermore, in the electrical wiring unit described in patent document 1, it is necessary to attach the waterproof heat-shrink tubing to the connector and the electrical wire, and then to attach the temperature sensor to the electrical wiring connection section using the sensor-mounting heat-shrink tubing.Such steps increase the workload for assembling components and make the work more complicated.

[0009] Furthermore, in the electrical wiring unit described in patent document 1, the temperature sensor is attached to the waterproof heat shrink tubing, meaning that a separate element is positioned between the temperature sensor and the connector, which is a heat source. Given this configuration of the electrical wiring unit, from the perspective of more accurate temperature measurement of the heat source, it is desirable to detect the temperature of the electrical wiring connection section of the connector more directly.

[0010] One embodiment of the present invention provides an electrical conductor assembly and a method for mounting the electrical conductor assembly, wherein a temperature sensor can be easily attached to an electrical conductor connection section of a terminal in a stable position in a state in which the temperature sensor is in contact with the electrical conductor connection section.

[0011] An electrical conductor assembly according to an embodiment of the present invention comprises: an electrical conductor comprising a conductor and an insulating sheath; a connector comprising an electrical conductor connection section connected to the conductor of the electrical conductor; a temperature sensor detecting the temperature of the electrical conductor connection section; and a waterproof element that liquid-tightly covers the peripheries of the electrical conductor connection section and the electrical conductor, wherein the waterproof element is formed from an adhesive tape, the adhesive tape being wrapped around outer peripheral surfaces of the electrical conductor connection section and the temperature sensor and an outer peripheral surface of the electrical conductor when the temperature sensor is in contact with the electrical conductor connection section.

[0012] According to an electrical conductor unit and a method for mounting the electrical conductor unit of an embodiment of the present invention, a temperature sensor can be easily attached to an electrical conductor connection section of a terminal in a stable position in a state in which the temperature sensor is in contact with the electrical conductor connection section. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a perspective view of a charging connector using an electrical wiring unit according to one embodiment; Fig. Figure 2 is a perspective view of the electrical wiring unit according to the embodiment; Fig. Figure 3 is a perspective view showing a method for assembling the electrical wiring unit according to the embodiment; Fig. Figure 4 is a perspective exploded view showing part of a modification example of the electrical conductor unit; and Fig. Figure 5 is a perspective view that represents part of the modification example of the electrical conductor unit. DETAILED DESCRIPTION OF THE INVENTION

[0013] An electrical wiring unit according to one embodiment is described below with reference to the drawings. In the following description, components with the same or similar functions are designated by the same reference numerals. Redundant descriptions of components marked with the same reference numerals may be omitted.

[0014] In the present disclosure, terms are defined as follows. “Connection” is not limited to a mechanical connection and may include an electrical connection. Furthermore, “connection” is not limited to a case where two elements to be connected are directly connected to each other and may include a case where two elements to be connected are connected to each other via an intervening element. (Charging connector)

[0015] Fig. Figure 1 is a perspective view of a charging connector 1 using an electrical wiring unit 10 according to the present embodiment. It should be noted that Fig. 1 represents a state in which one of the electrical conductor units 10 is separated from a connector body 60.

[0016] The in Fig. The charging connector 1 shown is a connector attached to an electric or hybrid vehicle. The charging connector 1 comprises the connector body 60, which is made of resin, and a plurality of electrical conductor units 10 attached to the connector body 60. The connector body 60 includes a columnar section 65 projecting in one direction and a flange 61 extending outward from the outer periphery of a base of the columnar section 65. The flange 61 can be attached to an edge of an opening (not shown) of a connector installation section on a side of the vehicle. In an inner region of the columnar section 65, a plurality of terminal receiving holes 63 are formed, each receiving a section (a terminal main body 11, to be described later) of an electrical conductor unit 10.

[0017] For the sake of simplicity, in connector 1, the side towards which the columnar section 65 projects from the flange 61 is referred to as the "front," and the side opposite the side towards which the columnar section 65 projects is referred to as the "rear." Furthermore, in each electrical conductor unit 10, the direction oriented towards the front in connector 1 is referred to as the "front," and the direction oriented towards the rear in connector 1 is referred to as the "rear." (Electrical conductor unit) FIG. 2 is a perspective view of a single electrical conductor

[0018] The electrical conductor unit 10 includes a terminal 12 made of a conductive metal with a terminal body 11 that is columnar and male, an electrical conductor 15, one end of which is connected to the terminal 12, a temperature sensor 20 that detects the temperature of the terminal 12, and an adhesive tape 23 that forms a waterproof element. As shown in Fig. As shown in Figure 1, in the electrical conductor unit 10, the main body 11 of the terminal 12 is inserted from the rear side of the connector body 60 into a corresponding terminal receiving hole 63 of the connector body 60. In this state, each electrical conductor unit 10 is attached to the connector body 60. One end of the electrical conductor 15 opposite the terminal 12 is connected to a charging circuit or the like for charging a battery (not shown).

[0019] In the present embodiment, the electrical wiring unit 10 is used for the charging connector 1 mounted on a vehicle, but the application of the electrical wiring unit 10 is not limited to the charging connector 1. The electrical wiring unit 10 can also be used for various other devices.

[0020] The electrical cable 15 contains a conductor 17 and an insulating sheath 19, which is an insulator covering the periphery of the conductor 17. A terminal section of the conductor 17, to which the terminal 12 is connected, is exposed over a certain length of the insulating sheath 19. The conductor 17 is made of a conductive metal conductor material. A standard multi-stranded wire or a solid wire can be used as the conductor 17.

[0021] In the terminal 12, the column-shaped terminal body 11 is formed at the front end, and an electrical conductor connection section 13 is formed at the rear end of the terminal body 11. The terminal body 11 represents a male terminal that is inserted into and connected to a mating terminal (a female terminal) (not shown). The terminal body 11 is electrically connected to the mating terminal by being inserted into and connected to it. At the front end of the terminal body 11, an insertion guide IIa is formed, which tapers (its diameter decreases towards the tip) to facilitate insertion into the mating terminal.

[0022] The electrical conductor connection section 13 of terminal 12 has a column-like shape. The electrical conductor connection section 13 has a conductor entry hole 13a formed at its rear end. The conductor 17, exposed at one end of the electrical conductor 15, is inserted into the conductor entry hole 13a. In this state, the electrical conductor connection section 13 is suitably crimped to connect with the conductor 17 of the electrical conductor 15. The conductor 17 of the electrical conductor 15 and the terminal 12 are electrically connected in this state.

[0023] The temperature sensor 20 is, for example, configured as a contact-type temperature sensor such as a thermistor. A detection line 25, leading to a sensor body, extends from the rear end of the temperature sensor 20. The detection line 25 is connected to a detection board (not shown). The temperature sensor 20 is attached to the electrical conductor connection section 13 in such a way that it is in contact with an outer peripheral surface of the electrical conductor connection section 13 of the terminal 12. The temperature sensor 20 is attached to the electrical conductor connection section 13 with the adhesive tape 23.

[0024] It should be noted that the temperature sensor 20 is not limited to a thermistor and can be a different contact-type temperature sensor, such as a bimetallic sensor.

[0025] Fig. Figure 3 is a perspective exploded view showing a method for assembling the electrical wiring unit 10. Fig. Figure 3 shows how the temperature sensor 20 is temporarily attached to the electrical conductor connection section 13 of the terminal 12 using the adhesive tape 23.

[0026] In the adhesive tape 23, a liquid-tight adhesive 31 is applied to a surface of a sheet-like tape body 30 (a surface located on the inside when wrapped around the temperature sensor 20, the outside of the connector 12, and the outside of the electrical conductor 15). The tape body 30 is, for example, made of polyethylene. A thermoplastic adhesive can be used as the adhesive 31. For example, (a) and (b) below can be used as the adhesive 31. (a) Polyamide, ethylene-acrylic acid copolymer (10 wt%) (b) Nylon, ethylene-acrylic acid copolymer (10 wt%)

[0027] The adhesive 31 applied to the tape body 30 can be melted by heating to adhere tightly to a plurality of elements as adhesive targets, and then solidified by cooling to fasten the plurality of elements together.

[0028] The adhesive 31 applied to the back (the surface described above) of the tape body 30 is an adhesive that is tacky at normal temperature (for example, 20 °C ± 15 °C). It should be noted that an adhesive 31 that is not tacky at normal temperature can also be used, and a different tacky agent can be applied to the surface of the tape body 30 or to the adhesive 31. (Method for assembling the electrical wiring unit)

[0029] Next, a procedure for assembling the electrical wiring unit 10 is described with reference to Fig. 3 described.

[0030] The electrical wiring unit 10 can be mounted as follows.

[0031] (1) The end of conductor 17 of electrical line 15 is pre-connected to the electrical line connection section 13 of terminal 12. (2) In this state, the temperature sensor 20 is brought into contact with an outer peripheral surface of the electrical line connection section 13.

[0032] (3) The adhesive tape 23 is prepared, and the adhesive tape 23 is wrapped around the outer peripheral surfaces of the electrical conductor connection section 13 and the temperature sensor 20, and an outer peripheral surface of the electrical conductor 15 at the end. At this point, overlapping sections of the wrapped adhesive tape 23 are stuck together due to the adhesive on the back of the adhesive tape 23. As a result, the temperature sensor 20 is temporarily fixed in a stable position on the outer peripheral surface of the electrical conductor connection section 13 by the adhesive tape 23.

[0033] (4) The thermoplastic adhesive 31 applied to the adhesive tape 23 is then heated to a predetermined temperature to melt. At this point, the adhesive 31 adheres tightly to the periphery of an end section between the electrical conductor connection section 13 and the electrical conductor 15, and to the temperature sensor 20 inside the tape body 30. As a result, the periphery of the end section between the electrical conductor connection section 13 and the electrical conductor 15 is liquid-tightly covered with the adhesive 31. Furthermore, when the molten adhesive 31 has solidified upon cooling, the temperature sensor 20 is completely attached to the outer periphery of the electrical conductor connection section 13 by the adhesive 31. (Operation and effect)

[0034] In the electrical wiring unit 10 of the present embodiment, the waterproof element covering the periphery of the electrical wiring connection section 13 and the electrical wire 15 is formed by the adhesive tape 23. The adhesive tape 23 is wrapped around the outer peripheral surfaces of the electrical wiring connection section 13 and the temperature sensor 20, as well as the outer peripheral surface of the electrical wire 15, when the temperature sensor 20 is in contact with it. At this point, an adhesive section of the adhesive tape 23 is brought into contact with an overlapping section of the tape and the other elements within the electrical wiring unit 10, thus temporarily securing the temperature sensor 20 to the electrical wiring connection section 13 of the terminal 12 in a stable position.In this state, the molten adhesive 31 adheres tightly to the periphery of the electrical connection section 13 and the electrical conductor 15. The adhesive 31 of the tape 23 then hardens, forming a liquid-tight seal between the electrical connection section 13 and the electrical conductor 15, and the temperature sensor 20 is directly attached to the outer peripheral surface of the electrical connection section 13. This allows the temperature sensor 20 to directly detect the temperature of the electrical connection section 13 of the terminal 12.

[0035] When the electrical conductor unit 10 of the present embodiment is used, the temperature sensor 20 can therefore be easily attached to the electrical conductor connection section 13 of the terminal 12 in a stable position in a state in which the temperature sensor 20 is in contact with the electrical conductor connection section 13.

[0036] Furthermore, in the electrical wiring unit 10 of the present embodiment, a thermoplastic adhesive, namely adhesive 31, is applied to the adhesive tape 23. Such an adhesive eliminates concerns about the adhesive 31 dripping or similar issues when the adhesive tape 23 is wrapped around the temperature sensor 20, the electrical wiring connection section 13 of the terminal 12, and the like, thus facilitating easy handling. After the adhesive tape 23 has been wrapped around the temperature sensor 20, the electrical wiring connection section 13 of the terminal 12, and the like, the adhesive 31 can be melted by external heating to ensure a tight bond to the adhesive targets. Therefore, when this configuration is used, the bonding process of the adhesive tape 23 is simplified.

[0037] Furthermore, in the electrical conductor unit 10 of the present embodiment, an adhesive, which is tacky at normal temperature, is applied to the adhesive tape 23, namely adhesive 31. This adhesive eliminates the need to apply two types of materials to the tape body 30 of the adhesive tape 23: an adhesive for permanent bonding and a tacky agent for temporary bonding. Therefore, the adhesive tape 23 can be manufactured more easily when this arrangement is chosen.

[0038] In the method for mounting the electrical wiring unit 10 of the present embodiment, the temperature sensor 20 is attached to the electrical wiring connection section 13 of the terminal 12 by the steps (1) to (4) described above. Therefore, when the mounting method of the present embodiment is applied, the temperature sensor 20 can be easily attached to the electrical wiring connection section 13 of the terminal 12 in a stable position in a state in which the temperature sensor 20 is in contact with the electrical wiring connection section 13. (Modification example)

[0039] Fig. Figure 4 is a perspective exploded view of part of an electrical conductor unit 10A of the present modification example, and Fig. Figure 5 is a perspective view of part of the electrical wiring unit 10A of the present modification example, after the components have been assembled.

[0040] The electrical wiring unit 10A of the present modification example has a terminal 12A whose configuration differs from that of terminal 12 of the embodiment described above. The other component configurations are similar to those of the embodiment described above. Fig. 4 and Fig. 5. A temperature sensor and an adhesive tape are omitted.

[0041] The terminal 12A of the present embodiment comprises, as separate components, an electrical conductor connection section 13A, to which the electrical conductor 15 is connected, and a male terminal body 11A, which is inserted into a mating terminal. In the column-shaped electrical conductor connection section 13A, a screw hole 40 is formed in an end face opposite the side to which the electrical conductor 15 is connected. The screw hole 40 is provided with an internal thread. In the terminal body 11A, a screw with an external thread 42 is formed on the outer periphery of an end opposite a side on which a tapered insertion guide IIa is located. As in Fig.As shown in Figure 5, the outer screw section 42 of the main connection body 11A can be attached and fixed to the screw hole 40 of the electrical conductor connection section 13A. That is, in connection 12A of the present modification example, the main connection body 11A can be attached to and detached from the electrical conductor connection section 13A.

[0042] In the 12A terminal of the present modification example, electrical conductor connection sections 13A of a plurality of specifications with different outer diameters and different conductor entry holes 13a inner diameters can be connected and used to fit the terminal main body 11A of a single specification.

[0043] Normally, the terminal body 11A is repeatedly inserted into and removed from a mating terminal (female terminal), and therefore it is necessary to apply a thick coating to the outer surface of the terminal body 11A. On the other hand, it is not necessary to apply a coating as thick to an electrical conductor connection section as to a terminal body. However, in a case where a terminal body and an electrical conductor connection section are arranged as a single component, the coating applied to the electrical connection section would naturally have the same thickness as that on the terminal body.

[0044] In the case of terminal 12A of the present modification example, the coating applied to the electrical connection section 13A may be thinner than the coating applied to the terminal main body 11A, since the terminal main body 11A and the electrical connection section 13A are designed as separate components.

[0045] Furthermore, the outer diameter of electrical conductors typically varies depending on the current being used. Because of this difference in outer diameter, when using currents with different values, it is necessary to use electrical conductors with different specifications and connectors that match the specifications of the conductors. Such requirements necessitate manufacturing a connector with a different specification for each current value, which is undesirable from a production efficiency standpoint.

[0046] Since, in the terminal 12A of the present modification example, the terminal body 11A and the electrical conductor connection section 13A are configured as separate components, the terminal body 11A can be of a common specification, even if a current with a different current value is used. That is, the terminal body 11A with a common specification can be used, and only for an electrical conductor connection section 13A can one be used that conforms to the specification of the electrical conductor 15. With such a configuration of separate components, the terminal body 11A can be efficiently manufactured in large quantities by a single plant.

[0047] Therefore, in the 12A terminal of the present modification example, the thickness of the coating applied to the electrical conductor connection section 13A can be adjusted to a necessary and sufficient level, and the terminal body 11A, onto which a thick coating is applied, can be shared by a variety of terminal types with different specifications. This means that the production efficiency of the 12A terminal can be further improved when the 12A terminal of the present modification example is used.

[0048] Although one embodiment of the present disclosure has been described above, this embodiment is presented as an example and is not intended to limit the scope of the present disclosure. This embodiment can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the essence of the present disclosure. INDUSTRIAL APPLICABILITY

[0049] According to the present disclosure, a temperature sensor can easily be attached to an electrical conductor connection section of a terminal in a stable position when the temperature sensor is in contact with the electrical conductor connection section. REFERENCE MARK LIST 10.10A Electrical wiring unit 12, 12A connection 13 Electrical line connection section 15 electrical lines 17 leaders 19 Insulating jacket 20 Temperature sensor 23 Adhesive tape 31 Adhesive

Claims

[1] Electrical line unit (10, 10A), comprising: an electrical line (15) containing a conductor (17) and an insulating sheath (19); a terminal (12, 12A) which contains an electrical conductor connection section (13) which is connected to the conductor (17) of the electrical line (15); a temperature sensor (20) that detects the temperature of the electrical conductor connection section (13); and a waterproof element that liquid-tightly covers the peripheries of the electrical conductor connection section (13) and the electrical conductor (15), wherein the waterproof element consists of an adhesive tape (23) with an adhesive, wherein the adhesive tape (23) is wrapped around outer peripheral surfaces of the electrical conductor connection section (13) and the temperature sensor (20) and an outer peripheral surface of the electrical conductor (15) in a state in which the temperature sensor (20) is in contact with the electrical conductor connection section (13). [2] Electrical conduction unit (10, 10A) according to claim 1, wherein the adhesive (31) with which the adhesive tape (23) is provided is a thermoplastic adhesive. [3] Electrical conduction unit (10, 10A) according to claim 1 or 2, wherein the adhesive (31) applied to the adhesive tape (23) is an adhesive which is tacky to a surface at normal temperature. [4] Method for assembling an electrical conductor assembly (10, 10A) wherein the electrical conductor assembly (10, 10A) contains: an electrical line (15) containing a conductor (17) and an insulating sheath (19); a terminal (12, 12A) which contains an electrical conductor connection section (13) which is connected to the conductor (17) of the electrical line (15); a temperature sensor (20) that detects the temperature of the electrical conductor connection section (13); and a waterproof element that liquid-tightly covers the peripheries of the electrical conductor connection section (13) and the electrical conductor (15), the procedure includes the following steps: Bringing the temperature sensor (20) into contact with the electrical conductor connection section (13); temporary fastening of the temperature sensor (20) and the electrical conductor connection section (13) by preparing, as the waterproof element, an adhesive tape (23) with an adhesive and by wrapping the adhesive tape (23) around outer peripheral surfaces of the electrical conductor connection section (13) and the temperature sensor (20) and an outer peripheral surface of the electrical conductor (15); and Completely secure the temperature sensor (20) and the electrical conductor connection section (13) with the adhesive (31) of the adhesive tape (23).

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