Conductor connection structure

Abstract

To provide a conductor connection structure that improves the corrosion resistance of the conductor connection part. [Solution] The conductor connection structure 1 includes a first conductor 2 which includes a first conductor portion 20 with a flat end and a first insulating portion 21 that covers the periphery of the first conductor portion 20; a second conductor 3 which includes a second conductor portion 30 with a flat end and a second insulating portion 31 that covers the periphery of the second conductor portion 30 and is connected to the first conductor 2; and a protective member 40 which covers at least a portion of the periphery of the first conductor portion 20 and the second conductor portion 30, and the periphery of the first insulating portion 21 and the second insulating portion 31. The cross-sectional area S of the portion surrounded by the inner wall of the protective member 40 is smaller than the sum of the cross-sectional areas of the first insulating portion 21 and the first conductor portion 20, and also smaller than the sum of the cross-sectional areas of the second insulating portion 31 and the second conductor portion 30, before the protective member 40 is attached.

Description

[Technical Field]

[0001] This invention relates to a conductor connection structure. [Background technology]

[0002] Automobiles are equipped with a wide variety of electronic devices, and wire harnesses are routed to transmit power, control signals, and other information to these devices. A wire harness consists of multiple wires and connectors, and these connectors are mated to the connectors of the electronic device or other wire harnesses, thereby connecting to the electronic device or other wire harnesses.

[0003] Copper wires have long been used as wiring materials for automotive wire harnesses, and more recently, aluminum wires have been used, but there is a movement to replace them with busbars. If busbars are to be used as wiring materials for automobiles, due to wiring constraints, it becomes necessary to connect them with dissimilar metals, such as a combination of copper and aluminum. Patent Document 1 discloses an electrical junction box having a busbar body made of aluminum or an aluminum alloy and a connection terminal made of copper or a copper alloy electrically coupled to the busbar body. [Prior art documents] [Patent Documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2018-007430 [Overview of the Initiative] [Problems that the invention aims to solve]

[0005] However, in conductor connection structures using dissimilar metals, such as those described in Patent Document 1, corrosion is a concern when the connection is exposed to corrosive factors such as salt or water in the vehicle environment. Therefore, improving the corrosion resistance of the conductor connection was a challenge.

[0006] This invention has been made in view of the problems of the prior art. The object of this invention is to provide a conductor connection structure that improves the corrosion resistance of the conductor connection portion. [Means for solving the problem]

[0007] A conductor connection structure according to an aspect of the present invention comprises a first conductor including a first conductor portion with a flat end and a first insulating portion covering the periphery of the first conductor portion; a second conductor including a second conductor portion with a flat end and a second insulating portion covering the periphery of the second conductor portion, and connected to the first conductor; and a protective member covering at least a portion of the periphery of the first and second conductor portions, and the periphery of the first and second insulating portions. The cross-sectional area of ​​the portion enclosed by the inner wall of the protective member is smaller than the sum of the cross-sectional areas of the first insulating portion and the first conductor portion, and also smaller than the sum of the cross-sectional areas of the second insulating portion and the second conductor portion, before the protective member is attached. [Effects of the Invention]

[0008] According to the present invention, it is possible to provide a conductor connection structure that improves the corrosion resistance of the conductor connection portion. [Brief explanation of the drawing]

[0009] [Figure 1] This is a perspective view showing the state of the conductor before the protective component is attached. [Figure 2] This is a perspective view showing an example of a conductor connection structure according to this embodiment. [Figure 3] This is a plan view showing an example of a conductor connection structure according to this embodiment. [Figure 4] This is a cross-sectional view showing the insulating portion covering the conductor. [Figure 5] This is a cross-sectional view of AA in Figure 2. [Figure 6] This is a cross-sectional view showing how the insulating portion is compressed by the protective member. [Modes for carrying out the invention]

[0010] Hereinafter, the conductor connection structure according to the present embodiment will be described in detail using the drawings. Note that the dimensional ratios in the drawings are exaggerated for convenience of explanation and may differ from the actual ratios.

[0011] [Conductor Connection Structure] As shown in FIGS. 2 and 3, the conductor connection structure 1 according to the present embodiment includes a first conductor 2, a second conductor 3, and a protective member 40. In this specification and the drawings, the direction (extension direction) in which the first conductor 2 and the second conductor 3 are arranged is indicated by an arrow Y, the direction (thickness direction) orthogonal to the arrow Y is indicated by an arrow Z, and the direction (width direction) orthogonal to both the arrow Y and the arrow Z is indicated by an arrow X.

[0012] The first conductor 2 is made of a metal having conductivity and has a first conductor portion 20 whose at least end portion is flat plate-shaped. As such a first conductor 2, for example, a bus bar can be used. Also, the second conductor 3 is made of a metal having conductivity and has a second conductor portion 30 whose at least end portion is flat plate-shaped. As such a second conductor 3, for example, a bus bar can be used.

[0013] The first conductor portion 20 and the second conductor portion 30 are formed by processing a plate material made of a conductive metal material. Note that the first conductor portion 20 and the second conductor portion 30 may be composed of a single-layer metal plate or may be composed of a laminated plate formed by laminating a plurality of thin metal plates.

[0014] The conductive metal material constituting the first conductor portion 20 and the second conductor portion 30 is not particularly limited, and for example, copper, a copper alloy, aluminum, or an aluminum alloy can be used. Note that the first conductor portion 20 and the second conductor portion 30 may be made of the same type of conductive metal material or may be combined with different types of conductive metal materials. For example, the first conductor portion 20 can be made of copper or a copper alloy, and the second conductor portion 30 can be made of aluminum or an aluminum alloy.

[0015] The first conductor 2 has a first insulating portion 21 that surrounds the first conductor portion 20. The second conductor 3 has a second insulating portion 31 that surrounds the second conductor portion 30. In other words, the first conductor portion 20 and the second conductor portion 30 are covered with an electrical insulating material except at the connection point of the conductor portion. In the conductor connection structure shown in Figure 1, the first conductor portion 20 of the first conductor 2 has a first insulating portion 21 so that its end is exposed, and the second conductor portion 30 of the second conductor 3 has a second insulating portion 31 so that its end is exposed. The electrical insulating material constituting the first insulating portion 21 and the second insulating portion 31 is not particularly limited, but for example, an electrically insulating resin such as polyvinyl chloride resin or rubber can be used.

[0016] The first conductor 2 and the second conductor 3 are electrically connected. Specifically, the end face of the first conductor portion 20 and the end face of the second conductor portion 30 are connected by a connecting portion 50. As shown in Figure 1, the first conductor portion 20 and the second conductor portion 30 may also be fastened together using a fastening member 51.

[0017] The fastening member 51 may have a head with a flat top surface and a shaft portion which is at least partly threaded. The material constituting the fastening member 51 is not particularly limited, but for example, copper, copper alloy, aluminum, aluminum alloy, steel, or stainless steel can be used.

[0018] The connection configuration of the first conductor section 20 and the second conductor section 30 is not particularly limited. That is, as shown in Figure 1, the first conductor section 20 and the second conductor section 30 may be connected at their mid-sections, the other may be connected to the mid-section of either the first conductor section 20 or the second conductor section 30, or the first conductor section 20 and the second conductor section 30 may be connected so that they abut each other. Alternatively, a connection portion 50 may be formed between the end face of the first conductor section 20 and the end face of the second conductor section 30 using a joining method such as FSW (friction stir welding), heat pressure welding, or laser welding.

[0019] The thickness dimension of the first conductor portion 20 of the first conductor 2 along the Z direction is approximately the same as the thickness dimension of the second conductor portion 30 of the second conductor 3 along the Z direction. Preferably, the thickness dimension of the first conductor portion 20 of the first conductor 2 is within ±30% of the thickness dimension of the second conductor portion 30 of the second conductor 3. The thickness dimensions of the first conductor portion 20 of the first conductor 2 and the second conductor portion 30 of the second conductor 3 are not particularly limited, but can be, for example, 3 mm to 6 mm.

[0020] The width dimension of the first conductor portion 20 of the first conductor 2 along the X direction is approximately the same as the width dimension of the second conductor portion 30 of the second conductor 3 along the X direction. Preferably, the width dimension of the first conductor portion 20 of the first conductor 2 is within ±30% of the width dimension of the second conductor portion 30 of the second conductor 3.

[0021] Furthermore, the first conductor 2 and the second conductor 3 may have leaf springs, protrusions, through holes, etc., formed on them to prevent them from coming loose when inserted into a connector or the like.

[0022] The protective member 40 covers at least a portion of the periphery of the first conductor portion 20 and the second conductor portion 30, as well as the periphery of the first insulating portion 21 and the second insulating portion 31. By providing the protective member 40, corrosion of the connection portion of the first conductor portion 20 and the second conductor portion 30 can be prevented.

[0023] The shape and manufacturing method of the protective member 40 are not particularly limited as long as the structure described above can cover the connection portion of the first conductor portion 20 and the second conductor portion 30. For example, as shown in Figures 1 and 2, the protective member 40 may be composed of a pair of protective members 40A and 40B made of a resin such as PBT (polybutylene terephthalate) resin, and may be manufactured by sandwiching the pair of protective members 40A and 40B from above and below. Furthermore, the protective member 40 may be manufactured by providing a dowel on one of the dividing surfaces of the pair of protective members 40A and 40B, and a dowel hole structure on the other dividing surface, and fitting the pair of protective members 40A and 40B together. On the other hand, the protective member 40 may be manufactured by integrally molding it using resin so as to cover the connection portion of the first conductor portion 20 and the second conductor portion 30.

[0024] The protective member 40 covers at least a portion of the periphery of the first insulating portion 21 and the second insulating portion 31. As shown in Figures 2 and 3, the protective member 40 has a structural portion 60B that covers the periphery of the first insulating portion 21 and a structural portion 60A that covers the periphery of the second insulating portion 31. The inner wall of the protective member 40 in structural portion 60A presses against the second insulating portion 31, and the inner wall of the protective member 40 in structural portion 60B presses against the first insulating portion 21, thereby sealing them and preventing the intrusion of corrosive factors such as salt or water from the outside. Figure 4 shows the inside of the protective member 40 in structural portion 60A, where the second insulating portion 31 covers the periphery of the second conductor portion 30.

[0025] Figure 5 shows a cross-sectional view of the structural part 60A. The cross-sectional area S is defined as the portion enclosed by the inner wall of the protective member 40. Before the protective member 40 is installed, the cross-sectional area S is smaller than the sum of the cross-sectional areas of the first insulating part 21 and the first conductor part 20, and also smaller than the sum of the cross-sectional areas of the second insulating part 31 and the second conductor part 30. With this structure, when the protective member 40 is installed, as shown in Figure 6, the second insulating part 31 is compressed by the protective member 40, increasing the adhesion between the protective member 40 and the second insulating part 31, and preventing the intrusion of corrosive factors such as salt or water from the outside.

[0026] An example of a design method for the protection member 40 in the conductor connection structure 1 is shown below. Let S be the total cross-sectional area of the second insulating portion 31 and the second conductor portion 30 in the state before attaching the protection member 40. init Also, let S be the maximum value of the total cross-sectional area of the second insulating portion 31 and the second conductor portion 30 after the plasticizer in the second insulating portion 31 has escaped due to the endurance stress. MAX S MAX becomes the maximum size that can generate sufficient repulsive force on the contact surface between the protection member 40 and the second insulating portion 31. Furthermore, let S be the minimum value of the total cross-sectional area of the second insulating portion 31 and the second conductor portion 30 when the second insulating portion 31 is compressed and cut occurs. MIN S MIN becomes the minimum size such that the second insulating portion 31 does not break and no hole is formed.

[0027] When the second insulating portion 31 is made of polyvinyl chloride resin, when the cross-sectional area of the second conductor portion 30 is defined as X, the cross-sectional area S, S init , S MAX , S MIN and X preferably satisfy the following formulas (1), (2) and (3).

[0028] [Equation 1] (S MAX - X) / (S init - X)×100 = 84 (1) [Equation 2] (S MIN - X) / (S init - X)×100 = 45 (2) [Equation 3] S MIN ≦ S ≦ S MAX (3)

[0029] First, find the total cross-sectional area S init of the second insulating portion 31 and the second conductor portion 30 in the state before attaching the protection member 40. Then, using formulas (1) and (2), find the maximum value S MAX and the minimum value S MINThese are calculated respectively. Then, the cross-sectional area S of the portion enclosed by the inner wall of the protective member 40 is set to satisfy equation (3). MIN Above, S MAX By designing the value to be less than or equal to this value, when the protective member 40 is attached, the second insulating part 31 is compressed by the protective member 40, as shown in Figure 6. This improves the adhesion between the protective member 40 and the second insulating part 31 in the conductor connection structure 1, preventing the intrusion of corrosive factors such as salt or water from the outside.

[0030] In the above explanation, the case where the second insulating part 31 is made of polyvinyl chloride resin was described, but the same effect can be obtained when the first insulating part 21 is made of polyvinyl chloride resin. In equations (1), (2), and (3), the sum of the cross-sectional areas of the first insulating part 21 and the first conductor part 20 in the state before the protective member 40 is attached is S. init The maximum value of the sum of the cross-sectional areas of the first insulating portion 21 and the first conductor portion 20 is S. MAX The minimum value of the sum of the cross-sectional areas of the first insulating part 21 and the first conductor part 20 is S. MIN You may also interpret the cross-sectional area of ​​the first conductor portion 20 as X.

[0031] As described above, the conductor connection structure 1 according to this embodiment includes a first conductor 2 which includes a first conductor portion 20 with a flat end and a first insulating portion 21 that surrounds the first conductor portion 20. The conductor connection structure 1 also includes a second conductor 3 which includes a second conductor portion 30 with a flat end and a second insulating portion 31 that surrounds the second conductor portion 30, and is connected to the first conductor 2. Furthermore, the conductor connection structure 1 includes a protective member 40 that surrounds at least a portion of the first conductor portion 20 and the second conductor portion 30, and the first insulating portion 21 and the second insulating portion 31. The cross-sectional area S of the portion surrounded by the inner wall of the protective member 40 is smaller than the sum of the cross-sectional areas of the first insulating portion 21 and the first conductor portion 20, and also smaller than the sum of the cross-sectional areas of the second insulating portion 31 and the second conductor portion 30, before the protective member 40 is attached. Therefore, the conductor connection structure 1 of this embodiment can provide a conductor connection structure with improved corrosion resistance of the conductor connection portion.

[0032] Although this embodiment has been described above, this embodiment is not limited to these, and various modifications are possible within the scope of the gist of this embodiment. [Explanation of symbols]

[0033] 1. Conductor connection structure 2 First conductor 3. Second conductor 20 First conductor section 30 Second conductor section 21 First Insulation Section 31 Second insulating section 40 Protective component 40A, 40B Pair of protective members 50 Connection part Cross-sectional area of ​​the portion enclosed by the inner wall of the protective member S

Claims

1. A first conductor including a first conductor portion with a flat end and a first insulating portion covering the periphery of the first conductor portion, A second conductor includes a second conductor portion with a flat end and a second insulating portion that covers the periphery of the second conductor portion, and is connected to the first conductor, The system includes a protective member that covers at least a portion of the periphery of the first conductor portion and the second conductor portion, and the periphery of the first insulating portion and the second insulating portion, A conductor connection structure in which the cross-sectional area of ​​the portion enclosed by the inner wall of the protective member is smaller than the sum of the cross-sectional areas of the first insulating portion and the first conductor portion, and also smaller than the sum of the cross-sectional areas of the second insulating portion and the second conductor portion, in the state before the protective member is attached.

2. If the second insulating part is made of polyvinyl chloride resin, the cross-sectional area is S, and the sum of the cross-sectional areas of the second insulating part and the second conductor part in the state before the protective member is attached is S. ｉｎｉｔ , the maximum value of the sum of the cross-sectional areas of the second insulating part and the second conductor part is S ＭＡＸ S is the minimum value of the sum of the cross-sectional areas of the second insulating part and the second conductor part. ＭＩＮ When the cross-sectional area of ​​the second conductor portion is defined as X, S, S ｉｎｉｔ S ＭＡＸ S ＭＩＮ The conductor connection structure according to claim 1, wherein X satisfies the following formulas (1), (2), and (3). [Mathematics 1] (S ＭＡＸ -X) / (S ｉｎｉｔ -X)×100=84 (1) [Math 2] (S ＭＩＮ -X) / (S ｉｎｉｔ -X)×100=45 (2) [Mathematics 3] S ＭＩＮ ≦S≦S ＭＡＸ (3)

3. The conductor connection structure according to claim 1 or 2, wherein the protective member is composed of a pair of protective members.

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