Conductor connection structure and method for manufacturing the same

Abstract

To provide a conductor connection structure that improves the corrosion resistance of the conductor connection part. [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 20; 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 30, and connected to the first conductor 2; and a protective member 40 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. The outer circumferential surfaces of the first insulating portion 21 and the second insulating portion 31 each have at least one groove portion 23, 33, and at least a portion of the protective member 40 is formed inside the groove portion 23, 33. Furthermore, the manufacturing method of the conductor connection structure 1 comprises a conductor connection step in which the first conductor portion 20 and the second conductor portion 30 are connected, and a protective member formation step in which the protective member 40 is formed inside the groove portion 23, 33.

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 laid 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 this connector to the connector of the electronic device or the connector of 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, but there is a movement to replace them with busbars. Assuming the use of a busbar as the wiring material for automobiles, due to restrictions on wiring, it becomes necessary to connect with dissimilar 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 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. While protecting the conductor connection with a protective member could be considered to improve corrosion resistance, simply ensuring close contact between the protective member and the insulating coating of the conductor may not satisfy the corrosion resistance requirements of automobile manufacturers.

[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, as well as the periphery of the first and second insulating portions. The outer circumferential surfaces of the first and second insulating portions each have at least one groove, and at least a portion of the protective member is formed inside the groove.

[0008] A method for manufacturing a conductor connection structure according to an aspect of the present invention comprises a conductor connection step in which the end face at the end of a first conductor portion is connected to the end face at the end of a second conductor portion, and a protective member formation step in which a protective member is formed to cover 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, and at least a portion of the protective member is formed inside the groove. [Effects of the Invention]

[0009] 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]

[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 an example of a conductor connection structure according to this embodiment. [Figure 3] This is a cross-sectional view along line AA in Figure 2, showing an example of a conductor connection structure according to this embodiment. [Figure 4] This is a cross-sectional view showing how the protective member is formed inside the groove. [Modes for carrying out the invention]

[0011] The conductor connection structure and its manufacturing method 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 Figure 2, the conductor connection structure 1 according to this embodiment comprises a first conductor 2, a second conductor 3, and a protective member 40. 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.

[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 for the connection points of the conductor portions. As 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 polyamide 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 midsections 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 midsection 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 faces at the ends of the first conductor part 20 and the end faces at the ends 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 dimensions of the first conductor part 20 of the first conductor 2 and the second conductor part 30 of the second conductor 3 are not particularly limited, but for example, they can be 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 plate springs, protrusions, through holes, etc. for suppressing detachment when inserted into a connector or the like may be formed on the first conductor 2 and the second conductor 3.

[0023] The protective member 40 covers at least a part of the peripheries of the first conductor part 20 and the second conductor part 30, as well as the peripheries 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.

[0024] The shape and manufacturing method of the protective member 40 are not particularly limited as long as it can cover the connection portion of the first conductor portion 20 and the second conductor portion 30, as shown in Figure 2, for example. For example, the protective member 40 may be manufactured by integrally molding a thermoplastic resin such as PBT (polybutylene terephthalate) resin or an ultraviolet-curing resin such as a urethane acrylate resin to cover the connection portion of the first conductor portion 20 and the second conductor portion 30. Alternatively, the protective member 40 may be composed of a pair of protective members and manufactured by sandwiching the pair of protective members 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 and a dowel hole structure on the other dividing surface, thereby fitting the pair of protective members together.

[0025] The protective member 40 covers at least a portion of the periphery of the first insulating portion 21 and the second insulating portion 31. Furthermore, as shown in Figures 2 and 3, the protective member 40 may have 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.

[0026] As shown in Figures 2 and 3, the outer surfaces of the first insulating portion 21 and the second insulating portion 31 each have at least one groove 23, 33. Then, as shown in Figure 4, at least a portion of the protective member 40 is formed inside the grooves 23, 33.

[0027] In structural part 60B, the groove 23 is provided on the outer circumferential surface of the first insulating part 21, that is, the surface in contact with the protective member 40. The groove 23 may be provided at intervals in the Y direction from the end 25 of the first insulating part 21. Furthermore, the groove 23 may extend over the entire circumference of the first insulating part 21. Also, in structural part 60A, the groove 33 is provided on the outer circumferential surface of the second insulating part 31, that is, the surface in contact with the protective member 40. The groove 33 may be provided at intervals in the Y direction from the end 35 of the second insulating part 31. Furthermore, the groove 33 may extend over the entire circumference of the second insulating part 31.

[0028] When the protective member 40 is formed on the outer circumferential surface of the first insulating portion 21 in which the groove portion 23 is formed, that is, in the protective member formation process described later, the resin constituting the protective member 40 flows into the interior of the groove portion 23. Therefore, as shown in Figure 3, in the structural portion 60B, the protective member 40 is provided so as to cover at least a part of the periphery of the first insulating portion 21, and as shown in Figure 4, the protective member 40 is formed inside the groove portion 23.

[0029] Compared to conventional structures where the conductor connection structure 1 does not have grooves 23 on the outer surface of the first insulating portion 21, the contact area between the protective member 40 and the first insulating portion 21 is increased. As a result, compared to conventional structures, the conductor connection structure 1 increases the fixing force between the protective member 40 and the first insulating portion 21 due to the anchoring effect, improving adhesion to the protective member 40 and enhancing the corrosion resistance of the conductor connection.

[0030] When the protective member 40 is formed on the outer circumferential surface of the second insulating portion 31 in which the groove portion 33 is formed, that is, in the protective member formation process described later, the resin constituting the protective member 40 flows into the interior of the groove portion 33. Therefore, as shown in Figure 3, in the structural portion 60A, the protective member 40 is provided so as to cover at least a part of the periphery of the second insulating portion 31, and as shown in Figure 4, the protective member 40 is formed inside the groove portion 33.

[0031] Compared to conventional structures where the conductor connection structure 1 does not have grooves 33 on the outer surface of the second insulating portion 31, the contact area between the protective member 40 and the second insulating portion 31 is increased. As a result, compared to conventional structures, the conductor connection structure 1 increases the fixing force between the protective member 40 and the second insulating portion 31 due to the anchoring effect, improving adhesion to the protective member 40 and enhancing the corrosion resistance of the conductor connection.

[0032] In Figure 4, the cross-sectional shape intersecting the extending direction of the grooves 23 and 33 is not particularly limited and may be formed in a substantially trapezoidal, substantially rectangular, or substantially semicircular shape, for example. Also, a pair of corner edges 27 may be formed at the opening of the groove 23, and a pair of corner edges 37 may be formed at the opening of the groove 33. The shape of the corner edges 27 and 37 is not particularly limited and may be acute, obtuse, or arc-shaped, for example.

[0033] When corner edges 27 and 37 are formed in the opening portions of grooves 23 and 33, the corner edges 27 and 37 can make strong contact with the protective member 40 when the protective member 40 is formed on the outer circumferential surfaces of the first insulating portion 21 and the second insulating portion 31. As a result, stress concentration at the corner edges 27 and 37 increases the sealing performance of the protective member 40, further enhancing the corrosion resistance of the conductor connection.

[0034] Compared to conventional structures that do not have grooves 23 and 33 on the outer surfaces of the first insulating part 21 and the second insulating part 31, the conductor connection structure 1 has a longer creepage distance, which is the path for corrosion factors to penetrate between the first insulating part 21 and the second insulating part 31 and the protective member 40. As a result, the time it takes for corrosion factors to reach the inside of the conductor connection structure 1 from the outside is extended, delaying the progression of corrosion, and the conductor connection structure 1 can exhibit good corrosion resistance.

[0035] The depth of the grooves 23 and 33 is not particularly limited as long as the anchoring effect can be fully realized. For example, it may be deeper than the surface roughness of the first insulating part 21 or the second insulating part 31, or shallower than the thickness of the first insulating part 21 or the second insulating part 31.

[0036] 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 outer circumferential surfaces of the first insulating portion 21 and the second insulating portion 31 each have at least one groove portion 23, 33, and at least a portion of the protective member 40 is formed inside the groove portion 23, 33. Therefore, the conductor connection structure 1 of this embodiment can provide a conductor connection structure with improved corrosion resistance of the conductor connection portion.

[0037] [Manufacturing method for conductor connection structure] Next, a method for manufacturing the conductor connection structure 1 according to this embodiment will be described.

[0038] The manufacturing method for the conductor connection structure 1 includes a conductor connection step in which 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 are connected. The conductor connection step is a step 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.

[0039] The manufacturing method for the conductor connection structure 1 includes a protective member forming step, in which a protective member 40 is formed to cover 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, and at least a portion of the protective member 40 is formed inside the grooves 23 and 33. The method for forming the protective member 40 is not particularly limited; for example, when using an ultraviolet-curable resin, it can be formed by applying it using a dispenser coating machine and curing it with ultraviolet light. When the protective member 40 is formed on the outer circumferential surfaces of the first insulating portion 21 and the second insulating portion 31 on which the grooves 23 and 33 are formed, the resin constituting the protective member 40 flows into the grooves 23 and 33. Therefore, the protective member 40 is formed inside the grooves 23 and 33. The conductor connection structure 1 manufactured in this way has an increased contact area between the protective member 40 and the first insulating portion 21 and the second insulating portion 31 compared to a conventional structure that does not have grooves 23 and 33 on the outer circumferential surfaces of the first insulating portion 21 and the second insulating portion 31. Therefore, compared to conventional designs, the conductor connection structure 1 increases the bonding force between the protective member 40 and the first insulating part 21 and the second insulating part 31 due to the anchoring effect, improving adhesion to the protective member 40 and enhancing the corrosion resistance of the conductor connection.

[0040] Thus, the manufacturing method of the conductor connection structure 1 according to this embodiment includes a conductor connection step in which 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 are connected. Furthermore, the manufacturing method includes a protective member forming step in which a protective member 40 is formed to cover 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, and at least a portion of the protective member 40 is formed inside the grooves 23 and 33. Therefore, the manufacturing method of the conductor connection structure 1 according to this embodiment can provide a manufacturing method for a conductor connection structure with improved corrosion resistance of the conductor connection portion.

[0041] 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]

[0042] 1. Conductor connection structure 2 First conductor 3. Second conductor 20 First conductor section 21 First Insulation Section 23 Groove 27 Corner edge 30 Second conductor section 31 Second insulating section 33 Groove 37 Corner edge 40 Protective component

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, The outer circumferential surfaces of the first insulating portion and the second insulating portion each have at least one groove, At least a portion of the protective member is a conductor connection structure formed inside the groove.

2. The conductor connection structure according to claim 1, wherein the groove extends over the entire circumference in the circumferential direction of the first insulating portion and the second insulating portion.

3. The conductor connection structure according to claim 1 or 2, wherein a pair of corner edges are formed in the opening of the groove.

4. A method for manufacturing a conductor connection structure according to claim 1 or 2, A conductor connection 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, A method for manufacturing a conductor connection structure, comprising: a protective member forming step of forming the protective member so as to cover 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, and forming at least a portion of the protective member inside the groove portion.

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