Conductor connection structure and method for manufacturing the same

Abstract

The present invention provides a conductor connection structure and a method for manufacturing the same, which improve the corrosion resistance of the conductor connection to a level that can stop water leakage. [Solution] The conductor connection structure 1 comprises a first conductor 2 including a first conductor portion 20 with a flat end and a first insulating portion 21 covering the periphery of the first conductor portion; a second conductor 3 including a second conductor portion 30 with a flat end and a second insulating portion 31 covering the periphery of the second conductor portion, and connected to the first conductor; a protective member 40 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; and a filler layer 60 formed between the protective member and the first conductor, and between the protective member and the second conductor. The protective member 40 is provided with a filling hole 41 for injecting a filler to form the filler layer. Furthermore, the method for manufacturing the conductor connection structure comprises the steps of connecting the first conductor portion and the second conductor portion, covering with the protective member, and forming the filler layer.

Description

Technical Field

[0001] The present invention relates to a conductor connection structure and a method for manufacturing the same.

Background Art

[0002] Automobiles are equipped with a variety of electronic devices, and wire harnesses are routed to transmit power, control signals, etc. to the electronic devices. A wire harness includes a plurality of electric wires and connectors, and is connected to an electronic device or another wire harness by fitting the connectors to the connectors of the electronic device or another wire harness.

[0003] Copper electric wires have been used for a long time as the wiring material for automotive wire harnesses, and recently, aluminum electric wires have been used. However, there is a movement to replace them with busbars. Assuming the use of a busbar as the wiring material for automobiles, due to wiring restrictions, it is necessary to connect different metals such as a combination of copper and aluminum. Patent Document 1 discloses an electrical connection 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

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, in a conductor connection structure for different metals such as that of Patent Document 1, corrosion is a concern when the connection part is exposed to corrosion factors such as salt or water in a vehicle-mounted environment. Therefore, it has been a problem to improve the corrosion resistance of the connection part of the conductor. In addition, there are cases where the corrosion protection technology is required to have a protection performance at the water-stopping level.

[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 and a method for manufacturing the same that improve the corrosion resistance of the conductor connection to a watertight level. [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; 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; and a filler layer formed between the protective member and the first conductor, and between the protective member and the second conductor. The protective member is provided with a filling hole for injecting a filler to form the filler layer.

[0008] A method for manufacturing a conductor connection structure according to an aspect of the present invention includes the steps of: connecting the end face at the end of the first conductor portion with the end face at the end of the second conductor portion; covering 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, with a protective member; and injecting a filler through a filling hole in the protective member to form a filler layer between the protective member and the first conductor, and between the protective member and the second conductor. [Effects of the Invention]

[0009] According to the present invention, it is possible to provide a conductor connection structure and a method for manufacturing the same that improve the corrosion resistance of the conductor connection portion to a watertight level. [Brief explanation of the drawing]

[0010] [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 the state of the conductor after the protective component has been attached. [Figure 3]This is an example of a conductor connection structure according to this embodiment, and is a perspective view showing the state during the formation of the filler layer. [Figure 4] This is an example of a conductor connection structure according to this embodiment, and is a perspective view showing the state after the formation of the filler layer. [Figure 5] This is a plan view showing an example of a conductor connection structure according to this embodiment, illustrating the state after the formation of the filler layer. [Modes for carrying out the invention]

[0011] The conductor connection structure according to this embodiment will be described in detail below with reference to the drawings. Note that the dimensional ratios in the drawings are exaggerated for illustrative purposes and may differ from the actual ratios.

[0012] [Conductor connection structure] As shown in Figures 3 to 5, the conductor connection structure 1 according to this embodiment comprises a first conductor 2, a second conductor 3, a protective member 40, and a filler layer 60. In this specification and drawings, the direction in which the first conductor 2 and the second conductor 3 are aligned (extension direction) is indicated by arrow Y, the direction perpendicular to arrow Y (thickness direction) is indicated by arrow Z, and the direction perpendicular to both arrow Y and arrow Z (width direction) is indicated by arrow X. Arrow Y also indicates the longitudinal direction of the first conductor 2 and the second conductor 3.

[0013] The first conductor 2 is made of a conductive metal and has a first conductor portion 20 that is flat at least at its end. For example, a busbar can be used as such the first conductor 2. The second conductor 3 is also made of a conductive metal and has a second conductor portion 30 that is flat at least at its end. For example, a busbar can be used as such the second conductor 3.

[0014] The first conductor portion 20 and the second conductor portion 30 are formed by processing a plate material made of a conductive metal material. The first conductor portion 20 and the second conductor portion 30 may be made of a single layer of metal plate, or they may be made of a laminated plate made by stacking multiple thin metal plates.

[0015] The conductive metal material constituting the first conductor portion 20 and the second conductor portion 30 is not particularly limited, but for example, copper, copper alloy, aluminum, or aluminum alloy can be used. The first conductor portion 20 and the second conductor portion 30 can be made of the same conductive metal material, or a combination of different conductive metal materials can be used. 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.

[0016] 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 or rubber can be used.

[0017] 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.

[0018] 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.

[0019] The connection form of the first conductor part 20 and the second conductor part 30 is not particularly limited. That is, as shown in FIG. 1, they may be connected at the middle parts of the first conductor part 20 and the second conductor part 30, one of the first conductor part 20 and the second conductor part 30 may be connected to the middle part of the other, or they may be connected so that the first conductor part 20 and the second conductor part 30 abut. Also, a connection part 50 may be formed and joined between the end face at the end of the first conductor part 20 and the end face at the end of the second conductor part 30 using a joining method such as FSW (friction stir welding), thermocompression bonding, laser welding, etc.

[0020] The thickness dimension along the Z direction in the first conductor part 20 of the first conductor 2 is substantially the same as the thickness dimension along the Z direction in the second conductor part 30 of the second conductor 3. It is preferable that the thickness dimension of the first conductor part 20 of the first conductor 2 is within ±30% of the thickness dimension of the second conductor part 30 of the second conductor 3. Note that the thickness dimension of the first conductor part 20 of the first conductor 2 and the thickness dimension of the second conductor part 30 of the second conductor 3 are not particularly limited, but for example, they can be set to 3 mm to 6 mm.

[0021] The width dimension along the X direction in the first conductor part 20 of the first conductor 2 is substantially the same as the width dimension along the X direction in the second conductor part 30 of the second conductor 3. It is preferable that the width dimension of the first conductor part 20 of the first conductor 2 is within ±30% of the width dimension of the second conductor part 30 of the second conductor 3.

[0022] Note that the first conductor 2 and the second conductor 3 may be formed with leaf springs, protrusions, through holes, etc. for suppressing disengagement when inserted into a connector or the like.

[0023] The protective member 40 covers at least a part of the periphery of the first conductor part 20 and the second conductor part 30, as well as the periphery of the first insulating part 21 and the second insulating part 31. By providing the protective member 40, corrosion of the connection part of the first conductor part 20 and the second conductor part 30 can be prevented. Furthermore, by providing the protective member 40, a gap for forming the filler layer can be secured inside the protective member 40.

[0024] 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.

[0025] The protective member 40 is provided with filling holes 41 for injecting filler to form a filler layer 60. The filling holes 41 may be provided in one location, or multiple locations may be provided to improve filling efficiency.

[0026] As a filler, a substance that is fluid when injected but hardens to stay in a predetermined position can be used, such as UV-curable resin, moisture-curable resin, or silicone rubber. The filler layer formed with such a filler fills the gaps between the protective member 40 and the first conductor 2, and between the protective member 40 and the second conductor 3, thereby preventing the intrusion of corrosive factors such as salt, water, or oxygen into the connection portion of the first conductor section 20 and the second conductor section 30.

[0027] Then, by injecting the filler through the filling hole 41, a filler layer 60 can be formed. The method of injecting the filler is not particularly limited. When injecting the filler, it may be injected directly through the filling hole 41, or, as shown in Figure 3, the filling port 42 may be connected to the filling hole 41 and the filler may be injected from the top of the filling port 42. The injected filler flows through the gaps inside the protective member 40 and hardens at a predetermined position, thereby forming a filler layer 60 between the protective member 40 and the first conductor 2, and between the protective member 40 and the second conductor 3. By providing such a filler layer 60, the corrosion resistance of the connection portion between the first conductor portion 20 and the second conductor portion 30 can be improved to a watertight level.

[0028] Preferably, the filling holes 41 in the protective member 40 are located equidistant from both ends of the protective member 40 in the longitudinal direction of the first conductor 2 and the second conductor 3. If there is only one filling hole 41, it is located at the midpoint of the protective member 40. By positioning the filling holes 41 equidistant from both ends of the protective member 40 in this way, the filling efficiency of the filler can be increased.

[0029] Preferably, the filler layer 60 is formed on the outside of the protective member 40 along the longitudinal direction of the first conductor 2 and the second conductor 3, i.e., the Y direction, and covers at least a portion of the periphery of the first insulating portion 21 and the second insulating portion 31. Specifically, as shown in Figure 5, it is preferable that the filler layer 60 is formed so as to protrude from both ends of the protective member 40 in the Y direction, and that the length L2 of the filler layer 60 is longer than the length L1 of the protective member 40. By forming the filler layer 60 in this way, the filler layer 60 is formed without gaps between the protective member 40 and the first conductor 2, and between the protective member 40 and the second conductor 3, and the completion of filling can be visually confirmed. Furthermore, from the viewpoint of improving corrosion resistance, it is preferable that the filling holes 41 are blocked by the filler layer 60 and sealed with the filler, as shown in Figures 4 and 5. In other words, by sealing both the inlet and outlet sides of the filler with the filler, corrosion resistance can be improved to a watertight level.

[0030] 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 covers the periphery of 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 covers the periphery of the second conductor portion 30 and is connected to the first conductor 2. The conductor connection structure 1 includes a protective member 40 that 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 conductor connection structure 1 includes a filler layer 60 formed between the protective member 40 and the first conductor 2, and between the protective member 40 and the second conductor 3. The protective member 40 is provided with a filling hole 41 for injecting a filler to form the filler layer 60. Therefore, the conductor connection structure 1 of this embodiment can provide a conductor connection structure that improves the corrosion resistance of the conductor connection portion to a watertight level.

[0031] [Manufacturing method for conductor connection structure] Next, a method for manufacturing the conductor connection structure 1 according to this embodiment will be described.

[0032] The manufacturing method for the conductor connection structure 1 includes a step of connecting the end face of the first conductor portion 20 and the end face of the second conductor portion 30. This step is for electrically connecting the first conductor 2 and the second conductor 3, and as described above, the first conductor portion 20 and the second conductor portion 30 may be fastened using a fastening member 51, or the first conductor portion 20 and the second conductor portion 30 may be joined using various joining methods.

[0033] The manufacturing method for the conductor connection structure 1 includes a step of covering 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, with a protective member 40. This step is a preparatory step before forming the filler layer 60 by injecting the filler.

[0034] The manufacturing method for the conductor connection structure 1 includes the step of injecting a filler through the filling hole 41 of the protective member 40 to form a filler layer 60 between the protective member 40 and the first conductor 2, and between the protective member 40 and the second conductor 3. This step, by forming the filler layer 60 through the injection of the filler, can improve the corrosion resistance of the connection portion of the first conductor section 20 and the second conductor section 30 to a watertight level.

[0035] Thus, the manufacturing method of the conductor connection structure 1 according to this embodiment includes a step of connecting the end face of the end of the first conductor portion 20 and the end face of the end of the second conductor portion 30. Furthermore, the manufacturing method includes a step of covering 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, with a protective member 40. In addition, the manufacturing method includes a step of injecting a filler through a filling hole 41 of the protective member 40 to form a filler layer 60 between the protective member 40 and the first conductor 2, and between the protective member 40 and the second conductor 3. Therefore, the manufacturing method of the conductor connection structure 1 according to this embodiment can provide a manufacturing method for a conductor connection structure that improves the corrosion resistance of the conductor connection portion to a watertight level.

[0036] 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]

[0037] 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 41 Filling hole 50 Connection part 60 Filler layer

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, 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, The device comprises a filler layer formed between the protective member and the first conductor, and between the protective member and the second conductor, A conductor connection structure wherein the protective member is provided with a filling hole for injecting a filler to form the filler layer.

2. The conductor connection structure according to claim 1, wherein the filler layer is also formed on the outside of the protective member along the longitudinal direction of the first conductor and the second conductor, and covers at least a portion of the periphery of the first insulating portion and the second insulating portion.

3. The conductor connection structure according to claim 1 or 2, wherein the filling holes are located equidistant from both ends of the protective member in the longitudinal direction of the first conductor and the second conductor.

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

5. A method for manufacturing a conductor connection structure according to claim 1 or 2, A step in which the end face at the end of the first conductor portion and the end face at the end of the second conductor portion are connected, The steps include covering 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, with the protective member, A method for manufacturing a conductor connection structure, comprising the steps of: injecting a filler through the filling hole of the protective member to form the filler layer between the protective member and the first conductor, and between the protective member and the second conductor.

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