Wire unit and method for assembling the wire unit

Abstract

The present invention provides a wire unit that allows the temperature sensor to be easily fixed in a stable position to the wire connection portion of the terminal while the temperature sensor is in contact with the wire connection portion of the terminal, and a method for assembling the wire unit. [Solution] One embodiment of the wire unit comprises a wire 15, a terminal 12, a temperature sensor 20, and a water-sealing member. The wire 15 has a conductor 17 and an insulating coating 19. The terminal 12 has a wire connection portion 13 that is connected to the conductor 17 of the wire 15. The temperature sensor 20 detects the temperature of the wire connection portion 13. The water-sealing member covers the wire connection portion 13 and the wire 15 in a liquid-tight manner. The water-sealing member is made of adhesive tape 23 with adhesive backing. The adhesive tape 23 with adhesive backing is wrapped around the outer surfaces of the wire connection portion 13 and the temperature sensor 20 and the outer surface of the wire 15, with the temperature sensor 20 in contact with the wire connection portion 13.

Description

Technical Field

[0001] Embodiments of the present invention relate to a wire unit and a method for assembling the wire unit.

Background Art

[0002] In charging connectors mounted on electric vehicles or hybrid vehicles, a plurality of wire units are intensively used. Each wire unit includes a wire having a conductor and an insulating coating, and a metal terminal connected to the conductor of the wire. The metal terminal has a terminal body portion formed on one end side in the axial direction and a wire connection portion formed on the other end side in the axial direction. The terminal body portion is, for example, a male terminal portion. In this case, the terminal body portion can be fitted and connected to a female mating terminal.

[0003] When a high-voltage current flows through the conductor and the terminal of this type of wire unit for a long time, the terminal and the wire become hot. Therefore, it is important to detect the temperature of the wire connection portion of the terminal and appropriately control the energized portion or the like according to the detected temperature. As a wire unit, a unit provided with a temperature sensor at the wire connection portion of the terminal has been devised (see, for example, Patent Document 1). <关于专利文献1的引用,这里保留原文

[0004] In the wire unit described in Patent Document 1, the conductor of the wire is connected in an inserted state to the wire connection portion of the terminal, and the periphery of the butting portion between the wire connection portion and the coating of the wire is covered with a shrink tube for water stop with an adhesive. The shrink tube for water stop is heated after being mounted around the butting portion between the wire connection portion and the coating of the wire. The shrink tube for water stop shrinks by heating, and the adhesive melts to hermetically seal the space between the wire connection portion and the wire in a liquid-tight manner. A temperature sensor is overlaid on the outer peripheral surface of the shrink tube for water stop. The temperature sensor is fixed to the outer peripheral surface of the shrink tube for water stop by a shrink tube for sensor fixing. The shrink tube for sensor fixing shrinks by heating and presses the temperature sensor against the outer peripheral surface of the shrink tube for water stop.

Prior Art Documents

[0005] [Patent Document 1] Japanese Patent Publication No. 2021-125339 [Overview of the project] [Problems that the invention aims to solve]

[0006] The wire unit described in Patent Document 1 requires, when attaching the temperature sensor, to press the temperature sensor against the outer surface of the heat-shrink tubing for water sealing, and then to cover the temperature sensor and the wire connection with heat-shrink tubing for sensor fixing. However, it is difficult to stably maintain the temperature sensor in the correct position on the wire connection until the heat-shrink tubing for sensor fixing shrinks due to heating. Furthermore, the wire unit described in Patent Document 1 requires, after fixing the heat-shrink tubing for water sealing to the terminal and the wire, to further fix the temperature sensor to the wire connection with heat-shrink tubing for sensor fixing. Because of these steps, the number of work steps required for assembling the parts is large, making the work complicated.

[0007] Furthermore, in the wire unit described in Patent Document 1, the temperature sensor is mounted on top of the heat-shrinkable tube for water sealing, meaning that a separate component is interposed between the temperature sensor and the terminal, which is the heat-generating part. Due to this configuration of the wire unit, from the viewpoint of more accurately detecting the temperature of the heat-generating part, it is desirable to more directly detect the temperature of the wire connection part of the terminal.

[0008] One embodiment of the present invention provides a wire unit that allows a temperature sensor to be easily fixed in a stable position to a wire connection portion of a terminal while the temperature sensor is in contact with the wire connection portion of the terminal, and a method for assembling the wire unit. [Means for solving the problem]

[0009] An electric wire unit according to one embodiment of the present invention comprises an electric wire having a conductor and an insulating coating, a terminal having an electric wire connection portion connected to the conductor of the electric wire, a temperature sensor for detecting the temperature of the electric wire connection portion, and a water-sealing member that liquid-tightly covers the electric wire connection portion and the area around the electric wire, wherein the water-sealing member is made of adhesive tape with adhesive backing that is wrapped around the outer surfaces of the electric wire connection portion and the temperature sensor and the outer surface of the electric wire while the temperature sensor is in contact with the electric wire connection portion.

[0010] A method for assembling a wire unit according to one embodiment of the present invention is a method for assembling a wire unit comprising a wire having a conductor and an insulating coating, a terminal having a wire connection portion connected to the conductor of the wire, a temperature sensor for detecting the temperature of the wire connection portion, and a water-sealing member that liquid-tightly covers the wire connection portion and the area around the wire, and includes the steps of: bringing the temperature sensor into contact with the wire connection portion; preparing an adhesive tape with adhesive as the water-sealing member, wrapping the adhesive tape around the outer surface of the wire connection portion and the temperature sensor and the outer surface of the wire to temporarily fix the temperature sensor and the wire connection portion; and permanently fixing the temperature sensor and the wire connection portion with the adhesive of the adhesive tape. [Effects of the Invention]

[0011] According to the wire unit and the method for assembling the wire unit of one embodiment of the present invention, the temperature sensor can be easily fixed in a stable position to the wire connection portion of the terminal when the temperature sensor is in contact with the wire connection portion of the terminal. [Brief explanation of the drawing]

[0012] [Figure 1] This is a perspective view of a charging connector employing the wire unit of the embodiment. [Figure 2] This is a perspective view of the wire unit of the embodiment. [Figure 3] This is a perspective view showing the assembly procedure of the wire unit according to the embodiment. [Figure 4] This is an exploded perspective view showing a modified version of the wire unit. [Figure 5] This is a perspective view showing some modified versions of the wire unit. [Modes for carrying out the invention]

[0013] The following description of a wire unit according to one embodiment will be explained with reference to the drawings. In the following description, components having the same or similar functions will be denoted by the same reference numeral. For components denoted by the same reference numeral, redundant explanations may be omitted.

[0014] In this disclosure, terms are defined as follows: “Connection” may include, but is not limited to, a mechanical connection; and “Connection” may include, but is not limited to, a case where two elements to be connected are directly connected; and may include a case where two elements to be connected are connected with another element in between.

[0015] (Charging connector) Figure 1 is a perspective view of a charging connector 1 employing the wire unit 10 of this embodiment. Note that Figure 1 shows a state in which some of the wire units 10 have been separated from the connector body 60. The charging connector 1 shown in Figure 1 is a connector installed in electric vehicles and hybrid vehicles. The charging connector 1 comprises a resin connector body 60 and a plurality of wire units 10 attached to the connector body 60. The connector body 60 comprises a columnar portion 65 that protrudes in one direction and a flange portion 61 that extends outward from the outer circumference of the base side of the columnar portion 65. The flange portion 61 can be fixed to the edge of an opening (not shown) in the connector installation area on the vehicle side. Multiple terminal housing holes 63 are formed in the inner region of the columnar portion 65, which accommodate a part of the wire unit 10 (terminal body portion 11, described later). Hereafter, for the sake of explanation, the charging connector 1 will be referred to as the "front" side from which the columnar portion 65 protrudes relative to the flange portion 61, and the side opposite to the side from which the columnar portion 65 protrudes, and as the "rear" side. Furthermore, for each wire unit 10, the direction that aligns with the front side of the charging connector 1 will be referred to as the "front," and the direction that aligns with the rear side of the charging connector 1 will be referred to as the "rear."

[0016] (Wire unit) Figure 2 is a perspective view of the wire unit 10 alone. The wire unit 10 includes a conductive metal terminal 12 having a cylindrical male terminal body portion 11, a wire 15 with one end connected to the terminal 12, a temperature sensor 20 for detecting the temperature of the terminal 12, and an adhesive tape 23 with an adhesive that constitutes a water stop member. As shown in FIG. 1, in the wire unit 10, the terminal body portion 11 of the terminal 12 is inserted into the corresponding terminal accommodation hole 63 of the connector body 60 from the rear side of the connector body 60. Each wire unit 10 is fixed to the connector body 60 in this state. The end of the wire 15 opposite to the terminal 12 is connected to a charging circuit or the like for charging a battery (not shown). In this embodiment, the wire unit 10 is used in the charging connector 1 mounted on the vehicle, but the application of the wire unit 10 is not limited to the charging connector 1. The wire unit 10 can be applied to various other devices.

[0017] The wire 15 has a conductor 17 and an insulating coating 19 that is an insulator covering the periphery of the conductor 17. The terminal portion of the conductor 17 to which the terminal 12 is connected is exposed from the insulating coating 19 by a certain length in advance. The conductor 17 is formed of a conductive metal wire. As the conductor 17, a stranded wire or a single wire having a plurality of strands can be used.

[0018] The terminal 12 has a cylindrical terminal body portion 11 formed on the front end side, and a wire connection portion 13 formed on the rear end side of the terminal body portion 11. The terminal body portion 11 is a male terminal that is inserted and connected to a mating terminal fitting (female terminal) not shown. The terminal body portion 11 is electrically connected to the mating terminal fitting by being inserted and connected to the mating terminal fitting. A tapered (tapered) insertion guide 11a for facilitating insertion into the mating terminal fitting is formed at the front end portion of the terminal body portion 11.

[0019] The wire connection part 13 of the terminal 12 is formed in a columnar shape. A conductor insertion hole 13a is formed in the wire connection part 13 from the rear end side. The exposed conductor 17 at one end of the wire 15 is inserted into the conductor insertion hole 13a. The wire connection part 13 is connected to the conductor 17 of the wire 15 by being appropriately caulked or the like in this state. The conductor 17 of the wire 15 and the terminal 12 are electrically connected in this state.

[0020] The temperature sensor 20 is constituted by, for example, a contact type temperature sensor such as a thermistor. A detection line 25 connected to the sensor body is drawn out from the rear end part of the temperature sensor 20. The detection line 25 is connected to a detection substrate not shown. The temperature sensor 20 is fixed to the wire connection part 13 in a state of being abutted against the outer peripheral surface of the wire connection part 13 of the terminal 12. The temperature sensor 20 is fixed to the wire connection part 13 by an adhesive tape 23 with an adhesive. Note that the temperature sensor 20 is not limited to a thermistor, and may be another sensor such as a bimetal as long as it is a contact type temperature sensor.

[0021] FIG. 3 is an exploded perspective view showing the assembling procedure of the wire unit 10. FIG. 3 shows a state when the temperature sensor 20 is temporarily fixed to the wire connection part 13 of the terminal 12 by the adhesive tape 23 with an adhesive. The adhesive tape 23 with an adhesive has an adhesive 31 having liquid tightness applied to one surface of the sheet-like tape body 30 (the surface that becomes the inner side when wound around the outside of the temperature sensor 20, the terminal 12, and the wire 15). The tape body 30 is formed of, for example, polyethylene. As the adhesive 31, a thermoplastic adhesive can be adopted. As the adhesive 31, for example, the following (a) or (b) can be adopted. (a) Polyamide, ethylene acrylic acid copolymer (10Wt%) (b) Nylon, ethylene acrylic acid copolymer (10Wt%) The adhesive 31 applied to the tape body 30 can be adhered to a plurality of members to be adhered by melting by heating, and the plurality of members can be fixed to each other by solidification by subsequent cooling.

[0022] Furthermore, the adhesive 31 applied to the back surface (one side as described above) of the tape body 30 is one that is tacky at room temperature (for example, 20°C ± 15°C). However, an adhesive 31 that is not tacky at room temperature may be used, and a different adhesive may be applied to the surface of the tape body 30 and the adhesive 31.

[0023] (Method for assembling the wire unit) Next, with reference to Figure 3, the assembly method of the wire unit 10 will be described.

[0024] The wire unit 10 can be assembled as follows. (1) Connect the end of the conductor 17 of the electric wire 15 to the electric wire connection part 13 of the terminal 12 in advance. (2) The temperature sensor 20 is brought into contact with the outer surface of the wire connection part 13 in this state. (3) Prepare adhesive tape 23 and wrap the adhesive tape 23 around the wire connection part 13, the outer surface of the temperature sensor 20, and the outer surface of the end of the wire 15. At this time, the overlapping parts of the wrapped adhesive tape 23 are fixed to each other by 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 surface of the wire connection part 13 by the adhesive tape 23. (4) Next, the thermoplastic adhesive 31 applied to the adhesive tape 23 is heated to a predetermined temperature to melt the adhesive 31. At this time, the adhesive 31 adheres tightly to the area around the butt joint of the wire connection part 13 and the wire 15, and to the temperature sensor 20, on the inside of the tape body 30. As a result, the area around the butt joint of the wire connection part 13 and the wire 15 is covered in a liquid-tight manner by the adhesive 31. Furthermore, when the melted adhesive 31 solidifies due to cooling, the temperature sensor 20 is permanently fixed to the outer surface of the wire connection part 13 by the adhesive 31.

[0025] (Mechanism of Action and Effects) In this embodiment, the wire unit 10 has a waterproofing member that covers the wire connection part 13 and the wire 15, which is made of adhesive tape 23 with adhesive backing. The adhesive tape 23 is wrapped around the outer surfaces of the wire connection part 13 and the temperature sensor 20, and the outer surface of the wire 15, with the temperature sensor 20 in contact with the wire connection part 13. At this time, the wire unit 10 can temporarily fix the temperature sensor 20 in a stable position to the wire connection part 13 of the terminal 12 by bringing the adhesive part of the adhesive tape 23 into contact with the overlapping part of the tape or other members. In this state, the molten adhesive 31 is brought into close contact with the wire connection part 13 and the wire 15. After this, when the adhesive 31 of the adhesive tape 23 solidifies, the space between the wire connection part 13 and the wire 15 is sealed liquid-tight, and the temperature sensor 20 is directly fixed to the outer surface of the wire connection part 13. As a result, the temperature state of the wire connection portion 13 of terminal 12 can be directly detected by the temperature sensor 20. Therefore, when the wire unit 10 of this embodiment is used, the temperature sensor 20 can be easily fixed to the wire connection part 13 of the terminal 12 in a stable position while the temperature sensor 20 is in contact with the wire connection part 13 of the terminal 12.

[0026] Furthermore, the wire unit 10 of this embodiment employs a thermoplastic adhesive as the adhesive 31 applied to the adhesive tape 23. Because of this adhesive, when the adhesive tape 23 is wrapped around the temperature sensor 20 or the wire connection part 13 of the terminal 12, there is no need to worry about the adhesive 31 dripping, making it easy to handle. In addition, after the adhesive tape 23 is wrapped around the temperature sensor 20 or the wire connection part 13 of the terminal 12, the adhesive 31 can be melted by external heating to adhere it tightly to the target area. Therefore, by adopting this configuration, it becomes possible to simplify the application of the adhesive tape 23.

[0027] Furthermore, the wire unit 10 of this embodiment employs an adhesive 31 that is tacky at room temperature as the adhesive 31 applied to the adhesive tape 23. Because of this adhesive, it is not necessary to apply two types of materials to the tape body 30 of the adhesive tape 23: a permanent fixing adhesive and a temporary fixing adhesive. Therefore, by adopting this configuration, the manufacturing of the adhesive-coated adhesive tape 23 can be simplified.

[0028] In this embodiment, the assembly method of the wire unit 10 involves fixing the temperature sensor 20 to the wire connection portion 13 of the terminal 12 by the steps (1) to (4) described above. Because of this assembly method, when this embodiment is adopted, the temperature sensor 20 can be easily fixed to the wire connection portion 13 of the terminal 12 in a stable position while in contact with the wire connection portion 13.

[0029] (modified version) Figure 4 is an exploded perspective view of a part of the wire unit 10A of this modified example, and Figure 5 is a perspective view of a part of the wire unit 10A of this modified example after some components have been assembled. In this modified example, the wire unit 10A differs from the terminal 12 in the embodiment described above in the configuration of terminal 12A. The configuration of the other parts is the same as in the embodiment described above. In Figures 4 and 5, the temperature sensor and adhesive tape with adhesive are omitted.

[0030] In this modified example, the terminal 12 consists of a wire connection portion 13A to which the electric wire 15 is connected, and a male terminal body portion 11A that is inserted into the mating terminal, as separate parts. The cylindrical wire connection portion 13A has a screw hole 40 formed on the end face opposite to the side to which the electric wire 15 is connected. The screw hole 40 has a female thread. The terminal body portion 11A has a male thread 42 formed on the outer circumference of the end opposite to the side where the tapered insertion guide 11a is placed. As shown in Figure 5, the male thread 42 portion of the terminal body portion 11A can be tightened and fixed into the screw hole 40 of the wire connection portion 13A. In other words, in this modified example, the terminal body portion 11A of the terminal 12A is detachable from the wire connection portion 13A.

[0031] In this modified example, terminal 12A can be used by appropriately connecting multiple wire connection parts 13A of different specifications, such as the outer diameter and the inner diameter of the conductor insertion hole 13a, to a terminal body part 11A of one specification. Normally, the terminal body 11A is repeatedly inserted into and removed from the mating terminal (female terminal), so it needs to have a thick plating on its outer surface. On the other hand, the wire connection part does not need to have a plating as thick as that of the terminal body. However, if the terminal body and the wire connection part are a single component, the wire connection part will inevitably be plated to the same thickness as the terminal body. In this modified example, terminal 12A has a terminal body 11A and a wire connection part 13A, which are each made up of separate parts. Therefore, the thickness of the plating applied to the wire connection part 13A can be made thinner than the thickness of the plating applied to the terminal body 11A.

[0032] Furthermore, the outer diameter of the conductors in electric wires typically varies depending on the magnitude of the current being used. Due to these differences in outer diameter, when different current values ​​are used, it is necessary to use electric wires with different specifications, and the terminals to which the electric wires are connected must also be of a specification that matches the specifications of the electric wires. Because of these requirements, it was necessary to produce terminals with different specifications for each current value being used, which was not desirable from the standpoint of production efficiency. In this modified example, the terminal 12A consists of a terminal body 11A and a wire connection part 13A, which are separate components. Therefore, even if the current values ​​used differ, the terminal body 11A can be of a common specification. In other words, the terminal body 11A can be of a common specification, and only the wire connection part 13A can be made according to the specifications of the wire 15. Due to this configuration of separate components, the terminal body 11A can be mass-produced efficiently using common equipment.

[0033] Therefore, in this modified example, the terminal 12A allows the plating applied to the wire connection portion 13A to be set to a sufficiently thick thickness, and moreover, the terminal body portion 11A with a thicker plating thickness can be shared among multiple types of terminals with different specifications. Thus, if this modified example of the terminal 12A is adopted, the production efficiency of the terminal 12A can be further increased.

[0034] While embodiments of the present disclosure have been described above, these embodiments are provided as examples and are not intended to limit the scope of the present disclosure. These embodiments can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the present disclosure. [Explanation of symbols]

[0035] 10, 10A... Wire unit 12, 12A… terminals 13…Wire connection section 15...Electric wire 17...Conductor 19...Insulating coating 20...Temperature sensor 23…Adhesive tape 31…Adhesive

Claims

1. A wire having a conductor and an insulating coating, A terminal having a wire connection portion connected to the conductor of the electric wire, A temperature sensor for detecting the temperature of the wire connection part, The aforementioned wire connection portion and a watertight sealing member that covers the area around the wire in a liquid-tight manner, Equipped with, The water-stopping member is made of adhesive tape with adhesive backing, which is wrapped around the outer surface of the wire connection and the temperature sensor and the outer surface of the wire while the temperature sensor is in contact with the wire connection. Wire unit.

2. The adhesive provided on the adhesive tape is a thermoplastic adhesive. The wire unit according to claim 1.

3. The adhesive provided on the aforementioned adhesive tape is an adhesive that is tacky to the surface at room temperature. The wire unit according to claim 1 or 2.

4. A wire having a conductor and an insulating coating, A terminal having a wire connection portion connected to the conductor of the electric wire, A temperature sensor for detecting the temperature of the wire connection part, The aforementioned wire connection portion and a watertight sealing member that covers the area around the wire in a liquid-tight manner, A method for assembling an electric wire unit equipped with, The steps include bringing the temperature sensor into contact with the wire connection portion, The process involves preparing an adhesive tape with adhesive backing as the water-stopping member, wrapping the adhesive tape around the outer surface of the wire connection and the temperature sensor and the outer surface of the wire, thereby temporarily fixing the temperature sensor and the wire connection. The process involves permanently fixing the temperature sensor and the wire connection part using the adhesive of the aforementioned adhesive tape, A method for assembling a wire unit including [a specific component].

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