Method for manufacturing a connection structure

Abstract

To provide a connection structure that ensures sufficient continuity and reliability between a litz wire and a general-purpose connector, alternatively, provide a manufacturing method for a connection structure that ensures sufficient continuity and reliability between a litz wire and a general-purpose connector.SOLUTION: A connection structure according to an embodiment of the present invention includes: a litz wire having a plurality of wires with an insulating film arranged on an outer peripheral surface of a conductor; a first connector that includes a first end and a second end, and in which the first end is disposed at the end of the litz wire, and the first end is electrically connected with the litz wire; and a second connector that includes a third end and a fourth end, and in which the third end is disposed on the second end of the first connector, and the third end is electrically connected to the first connector. At least some of the conductors of the plurality of wires is exposed from the insulating film at the end of the litz wire, and the exposed conductor is electrically connected to the first end.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] An embodiment of the present invention relates to a connection structure between a litz wire and a connector. Or, an embodiment of the present invention relates to a manufacturing method of a connection structure between a litz wire and a connector. [Background technology]

[0002] For example, in coil units used for wireless power supply, etc., Litz wire is used as the conductor of the cable for supplying high frequency. Dedicated connectors have been proposed for the purpose of electrical continuity with the Litz wire (Patent Documents 1 and 2). However, there is a concern that the use of dedicated connectors may reduce versatility for the devices in which they are installed.

[0003] Therefore, it is conceivable to configure a connection structure in which a general-purpose connector is connected to a cable, but in order to place the connector at the end of the cable, it is necessary to remove the insulating film at the end of the litz wire. In order to remove the insulating film at the end of the litz wire, a method is used in which the end of the litz wire is crimped while the connector is heated (Patent Documents 3 and 4). However, when the end of the litz wire is crimped while the general-purpose connector is heated, there is a concern that the reliability of the connector may be impaired due to thermal deformation or the like. In addition, there is a concern that the reliability of the connector may be impaired due to the thermal effect on the plating layer arranged on the inner surface of the connector. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2019-23983 A [Patent Document 2] Special Publication No. 2013-524419 [Patent Document 3] JP 2019-118183 A [Patent Document 4] JP 2010-282914 A Summary of the Invention [Problem to be solved by the invention]

[0005] One of the objects of the present invention is to provide a connection structure that ensures sufficient electrical continuity and reliability between a litz wire and a general-purpose connector. Another object of the present invention is to provide a manufacturing method for a connection structure that ensures sufficient electrical continuity and reliability between a litz wire and a general-purpose connector. [Means for solving the problem]

[0006] A connection structure according to one embodiment of the present invention comprises a litz wire having a plurality of strands with an insulating coating disposed on the outer peripheral surface of the conductor, a first connector having a first end and a second end, the first end being disposed at an end of the litz wire and electrically connecting the first end to the litz wire, and a second connector having a third end and a fourth end, the third end being disposed at a second end of the first connector and electrically connecting to the first connector, wherein at the end of the litz wire, at least a portion of the conductors of the plurality of strands are exposed from the insulating coating and the exposed conductor is electrically connected to the first end.

[0007] The first end of the first connector may have a first hole into which an end of a Litz wire can be inserted, the second end of the first connector may have a shape that allows it to be connected to the second connector, and the third end of the second connector may have a second hole into which the second end of the first connector can be inserted.

[0008] The second connector may have a metal layer disposed on an inner surface of the fourth end.

[0009] The first end of the first connector may have a first direction intersecting a central axis of the second connector at a first distance, and a second direction intersecting the central axis at a second distance greater than the first distance and intersecting the first direction.

[0010] The third end of the second connector may have a third direction intersecting a central axis of the second connector at a third distance, and a fourth direction intersecting the central axis at a fourth distance greater than the third distance and intersecting the third direction.

[0011] A manufacturing method of a connection structure according to one embodiment of the present invention includes inserting an end of a litz wire having multiple strands with an insulating coating disposed on the outer peripheral surface of the conductor into a first hole disposed in a first end of a first connector, crimping the first end to the end of the litz wire while heating the first end of the first connector to a temperature equal to or higher than the melting point of the insulating coating, exposing at least a portion of the conductors of the multiple strands at the end of the litz wire from the insulating coating, electrically connecting the exposed conductor to the first end, inserting a second end of the first connector disposed on the opposite side to the first end into a second hole disposed in a third end of the second connector, and crimping the third end of the second connector to the second end of the first connector.

[0012] The second connector may have a metal layer disposed on an inner surface of the fourth end.

[0013] The first end of the first connector may be crimped while being pressed in a first direction relative to a central axis direction of the second connector, and the first end of the first connector may have a first direction intersecting the central axis of the second connector and having a first distance, and a second direction intersecting the central axis and having a second distance longer than the first distance, and intersecting the first direction.

[0014] The third end of the second connector may be crimped while being pressed in a third direction relative to the central axis direction of the second connector, and the third end of the second connector may have a third direction that intersects the central axis of the second connector and has a third distance, and a fourth direction that intersects the central axis and has a fourth distance longer than the third distance and intersects the third direction. Effect of the Invention

[0015] An embodiment of the present invention provides a connection structure that ensures sufficient electrical continuity and reliability between a litz wire and a general-purpose connector. Alternatively, an embodiment of the present invention provides a manufacturing method for a connection structure that ensures sufficient electrical continuity and reliability between a litz wire and a general-purpose connector. [Brief description of the drawings]

[0016] [Figure 1] 1A is a side view of a litz wire connection part 1000 according to an embodiment of the present invention, and FIG. 1B is a side view of the litz wire connection part 1000 with a waterproof cover 1010 removed. [Diagram 2] 1A is a side view of a connection structure 100 according to one embodiment of the present invention, and FIG. 1B is a top view of the connection structure 100. FIG. [Diagram 3] 1 is a cross-sectional end view of a connection structure 100 according to an embodiment of the present invention, taken from a side direction of the connection structure 100.

[0023] FIG. [Figure 4] (A) is a side view of the litz wire 101, and (B) is a cross-sectional end view of the litz wire 101 taken along line segment AA' in (A). [Diagram 5] 1(A) to 1(D) are schematic diagrams illustrating a method for manufacturing a connection structure 100 according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. The embodiment described below is an example of the present invention, and the present invention is not limited to these embodiments.

[0018] In the drawings referred to in this embodiment, identical parts or parts having similar functions are given the same or similar symbols (symbols consisting of a number followed by A, B, etc.). In addition, the dimensional ratios in the drawings may differ from the actual ratios for the convenience of explanation, and some components may be omitted from the drawings. Note that ordinal numbers such as "first," "second," and "third" in this specification are used only to simplify the explanation and should not be interpreted in a restrictive manner.

[0019] [Connection structure] FIG. 1(A) is a side view of a litz wire connection part 1000 according to an embodiment of the present invention, and FIG. 1(B) is a side view of the litz wire connection part 1000 with the waterproof cover 1010 of FIG. 1(A) removed. FIG. 2 is a schematic diagram showing a connection structure 100 according to an embodiment of the present invention, FIG. 2(A) is a side view of the connection structure 100, and FIG. 2(B) is a top view of the connection structure 100. FIG. 3 is a cross-sectional end view of the connection structure 100 as viewed from the side direction of the connection structure 100. The litz wire connection part 1000 has a structure in which the connection structure 100 and the connection structure 100A are connected via the second connector 120 and the second connector 120A. In FIGS. 1 to 3, the central axis of the second connector 120 and the second connector 120A is defined as a central axis C. 1 In one embodiment, the litz wire connection portion 1000 may have a waterproof cover 1010 that covers the connection structure 100 and the connection structure 100A. The waterproof cover 1010 is made of a material having waterproof properties, such as rubber or resin.

[0020] The connection structure 100 is composed of a litz wire 101 and a second connector 120. The first connector 110 has a first end 111 and a second end 112. The first end 111 of the first connector 110 is disposed at the end of the litz wire 101, and the first end 111 is electrically connected to the litz wire 101. The second connector 120 has a third end 123 and a fourth end 124. The third end 123 of the second connector 120 is disposed at the second end 112 of the first connector 110, and the third end 123 is electrically connected to the first connector 110.

[0021] Fig. 4 is a schematic diagram of a litz wire 101, Fig. 4(A) is a side view of the litz wire 101, and Fig. 4(B) is a cross-sectional end view of the litz wire 101 taken along line segment AA' in Fig. 4(A). The litz wire 101 has a plurality of strands 107 each having an insulating coating 107b disposed on the outer peripheral surface of a conductor 107a. The strands 107 may be so-called enameled wires, and the conductor 107a is a metal wire, which may be, but is not limited to, copper, aluminum, or an alloy containing these metals. The insulating coating 107b may be, but is not limited to, enamel.

[0022] The litz wire 101 is composed of a bundle 109 made up of a plurality of wires 107. In one embodiment, the litz wire 101 may have a twisted wire structure in which the bundle 109 is twisted. Furthermore, the litz wire 101 may be covered with an insulator 103 and used as a cable 105.

[0023] The first connector 110 is a member that electrically connects the litz wire 101 and the second connector 120. The first connector 110 has a first end 111 that engages with an end of the litz wire 101 and a second end 112 that engages with a third end 123 of the second connector 120. In FIG. 2, the first end 111 and the second end 112 are arranged on a central axis C. 1 Although the first connectors 110 are illustrated as being arranged to face each other along the same axis, the first connectors 110 are not limited to this. For example, the first connectors 110 may have a bent or curved structure.

[0024] A first hole 115 into which an end of the litz wire 101 can be inserted is disposed in the first end 111 of the first connector 110 (FIG. 5(A)). The first hole 115 has a first opening 115a into which the litz wire 101 is inserted and a central axis C of the first hole 115. 2and a second opening 115b disposed on the opposite side to the first opening 115a along the first hole 115. The first hole 115 is not particularly limited as long as the shape allows the litz wire 101 to be inserted therein, but is preferably cylindrical. At the end of the litz wire 101, at least some of the conductors 107a of the multiple strands 107 are exposed from the insulating coating 107b. The exposed conductors 107a are electrically connected to the first end 111 of the first connector 110 through the first hole 115.

[0025] As described below, the end of the litz wire 101 and the first hole 115 are connected by pressing while heating, so that the insulating coating 107b melted and / or softened by the heat flows and is expelled from the first opening 115a and / or the second opening 115b of the first hole 115, exposing the conductor 107a.

[0026] As described below, the first end 111 is crimped in order to engage the Litz wire 101 with the first end 111. In one embodiment, as shown in FIG. 2(A) and FIG. 2(B), the height (width) L of the first end 111 of the first connector 110 in the Z-axis direction (vertical direction) is 100 mm. 1 is the length (width) L of the first connector 110 in the Y-axis direction. 2 In other words, the first end 111 of the first connector 110 is smaller than the central axis C of the second connector 120. 1 Intersect at the first distance L 1 A first direction (Z-axis direction) having a central axis C 1 Intersect at the first distance L 1 A second distance L that is longer than 2 The Z-axis direction and the Y-axis direction intersect and are orthogonal in one embodiment.

[0027] In one embodiment, the outer surface of the first hole 115 of the first connector 110 may be formed into a hexagonal or octagonal prism shape by heating and pressing the outer surface of the first hole 115 from, for example, six or eight directions.

[0028] The second end 112 of the first connector 110 has a structure that allows it to be inserted into the second connector 120, and has a shape that allows it to be connected to the second connector 120. The second end 112 of the first connector 110 may be a rod-shaped structure. Considering the resistance at the second end 112, it is preferable that the diameter (or cross section) of the second end 112 is as large as possible.

[0029] The first connector 110 is made of a metal, for example, but not limited to, copper or a copper alloy, in order to electrically connect the Litz wire 101 and the second connector 120. The surface of the first connector 110 may be covered with an insulating material.

[0030] The second connector 120 is a member for electrically connecting to an external terminal. The second connector 120 has a third end 123 that engages with the second end 112 of the first connector 110, and a fourth end 124 for electrically connecting to an external terminal. In FIG. 2, the third end 123 and the fourth end 124 are arranged on a central axis C. 1 Although the second connector 120 arranged so as to face each other above has been illustrated, the second connector 120 is not limited to this. For example, the second connector 120 may have a bent or curved structure.

[0031] A second hole 125 into which the second end 112 of the first connector 110 can be inserted is disposed at the third end 123 of the second connector 120 (FIG. 5(C)). At the third end 123 of the second connector 120, the second end 112 of the first connector 110 and a fourth end 124 of the second connector 120 are electrically connected via the second hole 125.

[0032] As described later, in order to engage the second end 112 of the first connector 110 with the third end 123, the third end 123 is crimped. For this reason, as shown in FIG. 2A, the height (width) L of the third end 123 of the second connector 120 in the Z-axis direction (vertical direction) is 3 is the height L of the second connector 120 in the Z-axis direction. 4On the other hand, as shown in FIG. 2B, the width L 5 is the width L of the second connector 120 in the fourth direction (Y-axis direction). 6 In other words, the third end 123 of the second connector 120 is approximately equal to or slightly larger than the central axis C of the second connector 120. 1 Intersect at a third distance L 3 A third direction (Z-axis direction) having a central axis C 1 Intersect at a third distance L 3 A fourth distance L that is longer than 5 2A and 2B, the fourth end 124 of the second connector 120 has a fourth direction (Y-axis direction) having a height (width) L 4 and the width in the Y-axis direction L 6 The height (width) L of the fourth end 124 in the Z-axis direction is equal to 4 and the width in the Y-axis direction L 6 may be different from.

[0033] The second connector 120 is made of a metal, for example, but not limited to, copper or a copper alloy, to electrically connect with the first connector 110. In one embodiment, the second connector 120 may be further coated with a metal layer. For example, the second connector 120 may be made of copper and have a tin plating layer. The surface of the second connector 120 may also be coated with an insulating material.

[0034] In one embodiment, the fourth end 124 has a recess. In one embodiment, the recess may have a metal layer 121 disposed on the inner surface thereof. In one embodiment, the second connector 120A of the connection structure 100A has a protrusion that can be connected to the recess of the second connector 120 of the connection structure 100 (or has a shape corresponding to the recess of the second connector 120). A metal layer is disposed on the protrusion of the second connector 120A (not shown). The metal layer disposed on the second connector 120 and the second connector 120A may be a plating layer. In the present invention, as described below, the first end 111 of the first connector 110 and the end of the litz wire 101 are crimped while being heated, while the second end 112 of the first connector 110 and the third end 123 of the second connector 120 are crimped by pressing, so that there is no thermal effect on the metal layers arranged on the second connector 120 and the second connector 120A, and sufficient conductivity and reliability between the litz wire 101 and the second connector 120 can be ensured.

[0035] [Method of manufacturing the connection structure] 5(A) to 5(D) are schematic diagrams illustrating a manufacturing method of a connection structure 100 according to an embodiment of the present invention. A litz wire 101 is prepared. If the litz wire 101 is covered with an insulator 103, the insulator 103 is removed from the end of the litz wire 101. The end of the litz wire 101 is inserted into a first hole 115 through a first opening 115a disposed at a first end 111 of a first connector 110 (FIG. 5(A)).

[0036] The first end 111 of the first connector 110 is pressed to the end of the litz wire 101 while being heated to a temperature equal to or higher than the melting point of the insulating coating 107b (FIG. 5(B)). The heating temperature is lower than the melting point of the conductor 107a and can be set arbitrarily in consideration of the melting points of the insulating coating 107b and the conductor 107a. For example, in the case of the insulating coating 107b having heat resistance up to 150°C, the heating temperature may be 200 to 1000°C. The insulating coating 107b at the end of the litz wire 101 melts and / or softens by heating, and the insulating coating 107b flows and is discharged from the second opening 115b of the first hole 115 by pressing, so that at least some of the conductors 107a of the multiple strands 107 can be exposed from the insulating coating 107b at the end of the litz wire 101. The exposed conductors 107 a make electrical connection by contacting a first end 111 of a first connector 110 .

[0037] In one embodiment, the outer surface of the first hole 115 of the first connector 110 may be deformed into a hexagonal or octagonal prism shape by heating and pressing the outer surface of the first hole 115 from, for example, six or eight directions, thereby engaging the Litz wire 101 with the first end 111.

[0038] The second end 112 of the first connector 110, which is located on the opposite side to the first end 111 of the first connector 110, is inserted into the second hole 125 located at the third end 123 of the second connector 120 (Figure 5(C)).

[0039] The third end 123 of the second connector 120 is pressed and crimped onto the second end 112 of the first connector 110. At this time, heating is not performed, and the third end 123 is crimped onto the second end 112 at room temperature (FIG. 5(D)).

[0040] In the method of the present embodiment, when the end of the litz wire 101 is connected to the first connector 110, it is heated while crimping, so that the insulating coating 107b melts due to the heat, the conductor 107a is exposed, and an electrical connection with the first end 111 of the first connector 110 can be obtained. Therefore, there is no need for a step of removing the insulating coating 107b in advance as in the conventional method, and the electrical connection can be easily performed. In addition, since no heat is applied when the third end 123 of the second connector 120 is crimped to the second end 112 of the first connector 110, there is no thermal effect on the metal layers arranged in the second connector 120 and the second connector 120A, and sufficient conduction and reliability between the litz wire 101 and the second connector 120 can be ensured.

[0041] Although one embodiment of the present invention has been described above with reference to the drawings, the present invention is not limited to the above embodiment and can be modified as appropriate without departing from the spirit of the present invention. For example, a structure in which a person skilled in the art appropriately adds, deletes, or modifies components based on the connection structure of this embodiment is also included in the scope of the present invention as long as it includes the gist of the present invention. Furthermore, the above-mentioned embodiments can be appropriately combined as long as there is no mutual contradiction, and technical matters common to each embodiment are included in each embodiment even if not explicitly stated.

[0042] Even if there are other effects and advantages different from those brought about by the aspects of each of the above-mentioned embodiments, those that are clear from the description in this specification or that can be easily predicted by a person skilled in the art are naturally understood to be brought about by the present invention. [Explanation of symbols]

[0043] 100 Connection structure, 100A Connection structure, 101 Litz wire, 103 Insulator, 105 Cable, 107 Wire, 107a Conductor, 107b Insulation coating, 109 Bundle, 110 First connector, 111 First end, 112 Second end, 115 First hole, 115a First opening, 115b Second opening, 120 Second connector, 120A Second connector, 121 Metal layer, 123 Third end, 124 Fourth end, 125 Second hole, 1000 Litz wire connection portion, 1010 Waterproof cover

Claims

1. An end of a Litz wire having a plurality of strands with an insulating coating disposed on the outer peripheral surface of the conductor is inserted into a first hole disposed in a first end of a first connector made of copper or a copper alloy; While heating the first end of the first connector to a temperature equal to or higher than the melting point of the insulating coating, the first end is crimped to the end of the Litz wire; At an end of the litz wire, at least a part of the conductors of the plurality of strands is exposed from the insulating coating, and the exposed conductors are electrically connected to the first end, Inserting a second end of the first connector, which is disposed opposite the first end, into a second hole disposed in a third end of a second connector made of copper or a copper alloy; The third end of the second connector is crimped to the second end of the first connector.

2. The method for manufacturing a connection structure according to claim 1 , wherein the second connector has a metal layer disposed on an inner surface of a fourth end portion.

3. crimping the first end of the first connector while pressing the first end in a first direction relative to a central axis of the first connector; 3. The method for manufacturing a connection structure described in claim 1 or 2, wherein the first end of the first connector has a first direction that intersects a central axis of the second connector and has a first distance, and a second direction that intersects the central axis and has a second distance longer than the first distance, and intersects the first direction.

4. crimping the third end of the second connector while pressing the third end of the second connector in a third direction relative to a central axis of the second connector; 4. The method for manufacturing a connection structure described in claim 3, wherein the third end of the second connector has a third direction that intersects a central axis of the second connector and has a third distance, and a fourth direction that intersects the central axis and has a fourth distance longer than the third distance, and intersects the third direction.

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