JP2006179369A - Connection method of aluminum wire and connection structure of aluminum wire - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a connection method of an aluminum wire capable of adequately securing electrical connection and mechanical (strength) connection of a conductive wire made of aluminum or an aluminum alloy to a terminal. <P>SOLUTION: This connection method of the aluminum wire is used for connecting, by means of crimping, a terminal 4 to a conductive wire end 2a exposed by peeling an insulating material 3 at one end of the aluminum wire 1 composed by covering multiple conductive wires 2 made of aluminum or aluminum alloy with the insulating material 3. In the connection method, molten solder 11 is injected into a bottomed insertion hole 9 of the terminal 4 or the solder 11 is melted in the insertion hole 9. Next, the conductive wire end 2a is inserted into the insertion hole 9 so as to contact the molten solder 11 in the vicinity of at least a bottom part 12 of the insertion hole 9. Then, the conductive wire end 2a is crimped and held by crimping the terminal 4. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to an aluminum electric wire terminal connection method and an aluminum electric wire terminal connection structure.

Conventionally, copper and copper alloys have been used for battery cable conductors (conductors) mainly used in automobiles, etc., for low voltage applications. However, to reduce the weight of the car body, the conductors are made from copper or aluminum. Or the ratio which uses the aluminum electric wire changed into the product made from aluminum alloy has increased.
However, conventional conductors made of copper or the like could be sufficiently conducted (conductive) only by caulking the terminals (caulking), but an oxide film is formed on the surface of the conductor made of aluminum or aluminum alloy. There is a drawback that it is difficult to conduct (it is difficult to ensure electrical connection) due to an increase in contact resistance between the conductor and the terminal. In particular, when an aluminum wire is used in an environment where the temperature rises like a battery cable, there has been a problem that the formation of an oxide film is promoted and the oxide film becomes thicker, making conduction more difficult.

And in order to solve the above-mentioned problem, the conventional connection method (connection structure) of an aluminum electric wire uses a metal with excellent extensibility between the conductor and the terminal in order to ensure electrical conductivity (electrical connection). The contact resistance is lowered by increasing the contact area between the lead wire and the terminal by interposing and caulking (see Patent Documents 1 and 2).
JP 2000-299140 A JP-A-8-321330

  However, in the conventional connection method (connection structure), due to the thickness of the intervening metal, the terminal cannot be caulked to stably hold the lead wire (to ensure mechanical strength), and There is a possibility that the intervening metal may be cracked if it is caulked strongly in order to stably hold the pressure bonding.

  Then, this invention aims at providing the connection method of an aluminum electric wire and the connection structure of an aluminum electric wire which can fully ensure the electrical connection and the mechanical (strength) connection with the conducting wire and terminals which are made of aluminum or an aluminum alloy. And

  In order to achieve the above object, the method for connecting an aluminum electric wire according to the present invention includes peeling off the insulator at one end of an aluminum electric wire formed by covering a large number of conductors made of aluminum or aluminum alloy with an insulator. In the connecting method of the aluminum electric wire for connecting the terminal to the exposed end portion of the conductive wire by caulking, molten solder is injected into the bottomed hole-shaped insertion hole of the terminal, or the insertion hole Then, the solder wire is melted in the insertion hole, and then the lead wire end is inserted into the insertion hole so as to come into contact with the molten solder at least near the bottom of the insertion hole, and the terminal is caulked to form the lead wire end. Hold by crimping.

The position where the terminal is caulked is set near the opening of the insertion hole of the terminal. The terminal is made of an aluminum alloy.
Moreover, the said aluminum electric wire is used for the battery cable of a motor vehicle.

  In addition, the connection structure of the aluminum electric wire according to the present invention includes an end portion of an aluminum electric wire formed by peeling and exposing one end portion of an aluminum electric wire formed by covering a large number of aluminum or aluminum alloy conductive wires with an insulator, and a terminal. In the connection structure of the aluminum wire to be connected, the terminal and the conductive wire end are soldered at least near the tip of the conductive wire and are conductively connected, and in the vicinity of the tip of the conductive wire end. The terminal is caulked and connected to the base end side.

  Also, the connection structure of the aluminum wire to which the terminal is connected to the end portion of the aluminum wire formed by peeling and exposing one end portion of the aluminum wire formed by covering a large number of aluminum or aluminum alloy wires with an insulator. The terminal has an insertion hole having a bottomed hole shape, and the conductor end is inserted into the insertion hole, and the terminal and the conductor end are soldered at least near the bottom of the insertion hole. In addition, the terminal is caulked from the outer surface thereof and connected on the opening side from the vicinity of the bottom of the insertion hole.

The present invention has the following remarkable effects.
According to the aluminum electric wire connection method and the aluminum electric wire connection structure according to the present invention, electrical connection and mechanical (strength) connection between the terminal and the conductor end can be sufficiently ensured.
In other words, since the terminal and the conductive wire end are connected by using both caulking and soldering, the connection strength can be improved and the electrical conductivity can be maintained for a long time.
In particular, the terminal and the conductor end can be mechanically firmly connected at the position where the terminal is caulked, and the formation of an oxide film on the end of the conductor is prevented at the soldering position (reducing contact resistance). And) can be connected with sufficient conductivity.

Hereinafter, the present invention will be described in detail with reference to the drawings illustrating embodiments.
First, an aluminum electric wire connection structure will be described. In the first embodiment shown in FIGS. 1 to 6, an aluminum electric wire 1 used for an automobile battery cable is made of a large number of aluminum or aluminum alloys. The conductive wire 2 (twisted wire) is covered with an insulator 3. At one end of the aluminum electric wire 1, the insulator 3 is peeled off, and the conductor end 2a is exposed. Reference numeral 4 denotes a terminal.

As shown in FIG. 3, the terminal 4 and the exposed conductor end 2a are soldered and connected at least near the tip end Z of the conductor end 2a, and closer to the base end side than the tip Z vicinity of the lead end 2a. The terminals 4 are connected by caulking.
Specifically, the terminal 4 includes a terminal main body portion 7 connected to a terminal or the like of an electric device (not shown), and a sleeve portion 8 integrally connected to the base end portion of the terminal main body portion 7. ing. Furthermore, a bottomed hole-shaped insertion hole 9 is formed in the sleeve portion 8. The insertion hole 9 is formed from an inner peripheral surface portion 13 of the sleeve portion 8, a bottom portion 12 disposed on the proximal end side of the terminal main body portion 7, and an opening portion 14 disposed on the opposite side of the bottom portion 12. Yes. The terminal body 7 has a hole 10 for inserting and connecting a terminal of a car battery.

In addition, the conducting wire end 2a is inserted into the insertion hole 9, and solder 11 is interposed between the inner peripheral surface portion 13 and the bottom 12 and the conducting wire end 2a. That is, a part of the conductive wire end 2 a (portion from the tip Z to the middle) is embedded in the solder 11 and is not in contact with the inner peripheral surface portion 13 and the bottom portion 12.
In the direction of the arrow P in FIG. 6, in the vicinity of the opening 14 of the sleeve portion 8, the outer diameter of the sleeve portion 8 is subjected to reduction-diameter plastic processing (caulking processing) into a ring shape by a press machine or the like. A caulking concave portion 15 is formed on the outer surface of the sleeve portion 8 subjected to the reduced diameter plastic processing, and a caulking convex portion 16 is formed on the inner peripheral surface portion 13 of the sleeve portion 8 corresponding to the caulking concave portion 15.

  Further, the substantially entire surface of the bottom 12 and the inner peripheral surface portion 13 of the insertion hole 9 and the substantially entire surface of the outer surface portion inserted into the insertion hole 9 of the conductor wire end portion 2 a are fixed through the solder 11. Further, in the vicinity of the opening 14 of the insertion hole 9 (in the middle of the conductor end 2a), the crimping projection 16 is crimped to the conductor end 2a via the solder 11, so that the terminal 4 and the conductor end 2a are connected. ing. In other words, the terminal 4 and the conductor end portion 2a are connected to each other by a crimping portion 5 obtained by caulking the terminal 4 and a conductive connecting portion 6 that is soldered and fixed without being caulked. Moreover, the crimping | compression-bonding part 5 is arrange | positioned near the base end of the conducting wire end part 2a, and the conduction | electrical_connection connection part 6 is arrange | positioned near the front-end | tip Z of the conducting wire end part 2a. In the specific example of FIG. 6, the connection structure at the crimping portion 5 is that the terminal 4 and the conductor end 2 a are separated mainly from the tensile force and impact applied to the terminal 4 and the conductor end 2 a (aluminum wire 1). The terminal 4 and the conductive wire end 2a are also electrically connected (conductive connection) through the solder 11, although the purpose is to make mechanical (strength) connection to prevent this. Further, the connection at the conductive connection portion 6 is mainly intended for electrical connection.

Moreover, when the conducting wire 2 is made of an aluminum alloy, an Al-0.01 wt% to 0.2 wt% Zr alloy is preferable in terms of heat resistance. Furthermore, in order to prevent the formation of an oxide film and to improve the adhesion to the solder 11, the aluminum electric wire 1 is preferably covered with solder or subjected to a galvanizing process using a zincate bath or the like.
As the terminal 4, a conventionally used metal may be applied, and examples thereof include brass (Cu—Zn alloy). Moreover, the thing made from an aluminum alloy is suitable for weight reduction. Furthermore, in order to improve corrosion resistance, what gave Sn plating to the terminal surface which consists of an above-described brass (Cu-Zn alloy) and aluminum alloy is preferable.

  In the second embodiment shown in FIG. 7, the terminal 4 and the exposed conductor end 2a are soldered and electrically connected in the vicinity of the tip Z of the conductor end 2a, and the tip Z of the conductor end 2a is connected. The terminal 4 is caulked and connected to the base end side (in the middle) from the vicinity. In other words, the crimping portion 5 is disposed in the vicinity of the opening portion 14 of the insertion hole 9, and the conductive connection portion 6 is disposed in the vicinity of the bottom portion 12 of the insertion hole 9.

Specifically, the terminal 4 and the conducting wire end 2a are fixed to each other through the solder 11 near the bottom 12 in the insertion hole 9 (near the tip Z of the conducting wire end 2a). In the vicinity of 14 (in the middle of the conductor end portion 2a), the caulking convex portion 16 is connected by directly crimping to the conductor end portion 2a. That is, no solder 11 is provided between the caulking convex portion 16 and the conductor end portion 2a. Further, the bottom 12 of the insertion hole 9 and the inner peripheral surface 13 near the bottom 12 and the outer surface near the tip Z of the conductive wire end 2 a are fixed via solder 11.
Moreover, although this crimping | compression-bonding part 5 is mainly for mechanical (strength) connection, it also serves as electrical connection in part. The portion of the conductive wire end portion 2a that contacts the caulking convex portion 16 may be formed with an oxide film, and the first connection shown in FIG. This embodiment is preferred.
In FIG. 7, the same reference numerals as those in FIG. 3 have the same configurations as those in FIG.

In addition, the design of the connection structure of the aluminum electric wire of the present invention can be freely changed, and the caulking process is a spiral or partial caulking concave part 15 (caulking convex part 16) in addition to the ring-shaped reduced diameter plastic working. Is also free to form. Further, the caulking process is not limited to one place, and may be performed at a plurality of places. Although not shown in the drawings, when the terminal 4 is formed by punching a metal plate into a predetermined shape and pressing it, the conductor end portion 2a is disposed between the pair of caulking pieces, and the caulking pieces are bent inward. Caulking may be performed.
Further, the shape of the terminal 4 can be variously changed, and it may be made to correspond to the shape of the terminal of the electric device to be connected, and the multiple conducting wires 2 may be linear instead of stranded wire. .

  Next, the method of connecting the aluminum wires will be described. In FIGS. 4 to 6, first, the terminals 4 are arranged vertically in the vertical direction so that the opening 14 of the insertion hole 9 faces upward. A predetermined amount of molten solder 11a is injected into the inside. Alternatively, the solder 11 may be melted in the insertion hole 9 (see FIG. 4). Then, the conductor end portion 2a, which is exposed by peeling off the insulator 3 at one end portion of the aluminum electric wire 1 in advance, is inserted into the insertion hole 9 so as to contact the molten solder 11a (see FIG. 5). At this time, as the tip end Z of the conductive wire end 2a is inserted to the vicinity of the bottom 12 of the insertion hole 9, the molten solder 11a that has been injected is filled from the bottom 12 of the insertion hole 9 to the vicinity of the opening. Then, the conductive wire end portion 2a and the terminal 4 are held (fixed) until the molten solder 11a is cooled and solidified so that the conductive wire end portion 2a does not contact the inner peripheral surface portion 13 and the bottom portion 12 of the insertion hole 9. When the molten solder 11a is solidified, it is subjected to diameter reduction plastic processing (caulking) from the outer surface of the sleeve portion 8 in the direction of arrow P in FIG. At this time, the caulking convex portion 16 formed by the reduced diameter plastic working is pressure-bonded to the solidified solder 11b, and the solder 11b is pressure-bonded to the conductor end portion 2a.

  Further, the connection method of the aluminum electric wire of the present invention can be freely changed in design, and the insertion end 9 is inserted into the insertion hole 9 before the molten solder 11a in the insertion hole 9 is cooled and solidified. The terminal 4 may be subjected to reduced-diameter plastic working in the vicinity of 14, and then the solder 11a may be cooled and solidified. At this time, the caulking convex portion 16 is in contact with the conductor end portion 2a. However, the molten solder 11a enters the slight gap between the caulking convex portion 16 and the bundled conductive wires 2, and then solidifies. . That is, the caulking convex portion 16 and the conductive wire end portion 2a are partially abutted (directly crimped), and are connected (fixed) via the solder 11 at portions other than the abutting portion.

Next, using the 38SQ aluminum wire 1 and the terminal 4, the conductor 2 and the terminal 4 are connected by the following three types of connection methods (connection structure) (b) (b) (c). The test which measured the voltage drop value and the terminal adhering force (connection strength) at the initial stage after the method and after overheating was conducted.
(A) Conventional example 1: The lead wire 2 and the terminal 4 are connected by crimping at the crimping part 5 (only crimping).
(B) Conventional example 2: The conductive wire 2 and the terminal 4 are connected by soldering at the conductive connection portion 6 (solder filling only).
(C) Embodiment of the present invention: The conductive wire 2 and the terminal 4 are connected by soldering at the conductive connecting portion 6, and further crimped at the crimping portion 5 to be connected (solder filling + crimping, FIG. 3). See).
Specifically, (i) (b) (c) Measure the voltage drop value when connected by the connection method in each case (initial) and then the voltage drop value after overheating at 120 ° C for 500 hours did.
In addition, in order to measure the terminal fixing force (connection strength), in each of the cases (A), (B), and (C), a tensile force is gradually applied to the conducting wire 2 so that the conducting wire 2 and the terminal 4 are connected. The tensile force and breaking condition (breaking method) until breaking and separation were measured.
The conductive wires 2 are covered with solder, and the terminals 4 are made of an aluminum alloy (A6063-O) and are plated with Sn.
The respective test results are shown in Tables 1 and 2 below.

  Explaining Table 1, the initial voltage drop value of (b) and (c) is 0.04 and 0.05, respectively, while the initial voltage drop value of (b) is 0.19. Was about a quarter of the value of (A). In addition, the voltage drop value after overheating in (I) was 0.27, an increase of 40% or more, while the voltage drop values after overheating in (B) and (C) were 0.05 and 0.06, (B) And (c) remained almost unchanged from their initial values after overheating. Therefore, the voltage drop value in the initial state is higher in the case of (b) and (c) having the connection part filled with solder (soldering) than in the case of only the connection part by crimping (b). It was confirmed that the voltage drop value (conductivity) was maintained in the cases of (b) and (c) even after overheating.

Explaining Table 2, in the case of (a) and (b), when the tensile force (terminal fixing force) reaches 2900N and 3000N, the conductor 2 is pulled out from the terminal 4; When the force (terminal fixing force) reached 3200 N, the lead wire 2 was broken on the near side (the side where the tensile force was applied) from the crimping portion 5. Therefore, in the case of (C), the lead wire 2 is not pulled out from the terminal 4 until it breaks, and in the case of (C), the terminal fixing force is remarkably larger than in the cases of (A) and (B). I was able to confirm.
In the case of (c), the terminal fixing force is 3200 N in Table 2, but since the conducting wire 2 is broken, the measurement limit value is 3200 N, which is actually a value of 3200 N or more.

  Furthermore, from Table 1 and Table 2, solder filling and crimping (c) showed excellent values in both points of conductivity (voltage drop value) and connection strength (terminal fixing force). By using the connection at the part 5 and the connection at the conduction connection part 6 together, the mechanical (strength) connection and the electrical connection between the lead wire 2 and the terminal 4 are sufficiently secured, and further, the electrical connection is possible even in a high temperature environment. It was confirmed that the general connection could be maintained.

As described above, the connection method of the aluminum electric wire according to the present invention is such that the insulator 3 is peeled off at one end of the aluminum electric wire 1 formed by covering a large number of conductors 2 made of aluminum or aluminum alloy with the insulator 3. In the connecting method of the aluminum wire in which the terminal 4 is connected to the exposed conductor end 2a by caulking, molten solder 11 is injected into the bottomed hole-like insertion hole 9 of the terminal 4, or Then, the solder 11 is melted in the insertion hole 9, and then the conductor end 2 a is inserted into the insertion hole 9 so as to contact the molten solder 11 at least near the bottom 12 of the insertion hole 9, and the terminal 4 is Since the lead end portion 2a is crimped and held by crimping, electrical connection and mechanical (strength) connection between the terminal 4 and the lead end portion 2a can be sufficiently secured.
In other words, since the terminal 4 and the conductive wire end 2a are connected by using both caulking and soldering, the connection strength can be improved and the electrical conductivity can be maintained for a long time.
In particular, the terminal 4 and the conductor end 2a can be mechanically firmly connected at the position where the terminal 4 is crimped, and the formation of an oxide film on the conductor end 2a is prevented at the soldering position ( It can be connected with sufficient electrical conductivity (reducing contact resistance).
Furthermore, even when used in a high temperature environment, the conductivity can be maintained for a long time.

  Further, since the position where the terminal 4 is caulked is set in the vicinity of the opening 14 of the insertion hole 9 of the terminal 4, the terminal 4 and the conductor end 2a can be stably connected and the connection strength (mechanical strength) thereof. Can be further improved.

  Further, since the terminal 4 is made of an aluminum alloy, it is possible to reduce the weight of the terminal 4 while ensuring sufficient conductivity between the terminal 4 and the conductor end portion 2a.

  Moreover, since the aluminum electric wire 1 is used for the battery cable of a motor vehicle, the weight of the vehicle body can be reduced and the continuity between the battery and other electric devices can be sufficiently maintained for a long time.

In addition, the connection structure of the aluminum electric wire according to the present invention is such that the end portion of the aluminum electric wire 1 formed by covering a large number of the electric wires 2 made of aluminum or aluminum alloy with the insulator 3 is peeled and exposed. In the connection structure of the aluminum electric wire connecting the terminal 2a and the terminal 4, the terminal 4 and the conductor end 2a are soldered at least in the vicinity of the tip end Z of the conductor end 2a and are electrically connected. Since the terminal 4 is caulked and connected from the vicinity of the distal end Z of the end portion 2a to the proximal end side, electrical connection and mechanical (strength) connection between the terminal 4 and the conductor end portion 2a can be sufficiently ensured.
In other words, since the terminal 4 and the conductive wire end 2a are connected by using both caulking and soldering, the connection strength can be improved and the electrical conductivity can be maintained for a long time.
In particular, the terminal 4 and the conductor end 2a can be mechanically firmly connected at the position where the terminal 4 is crimped, and the formation of an oxide film on the conductor end 2a is prevented at the soldering position ( It can be connected with sufficient electrical conductivity (reducing contact resistance).
Furthermore, even when used in a high temperature environment, the conductivity can be maintained for a long time.

Further, an aluminum for connecting a terminal 4 and a conductor end 2a, which is exposed by peeling off one end of an aluminum electric wire 1 formed by coating a large number of conductors 2 made of aluminum or aluminum alloy with an insulator 3. In the electric wire connection structure, the terminal 4 has a bottomed hole-like insertion hole 9, and the conductor end 2 a is inserted into the insertion hole 9, and the terminal 4 and the conductor end 2 a are arranged at least in the insertion hole 9. In the vicinity of the bottom portion 12, it is electrically connected via the solder 11, and the terminal 4 is caulked from the outer surface thereof near the bottom portion 12 of the insertion hole 9 so as to be connected. The electrical connection and the mechanical (strength) connection of the conductive wire end 2a can be sufficiently secured.
In other words, since the terminal 4 and the conductive wire end 2a are connected by using both caulking and soldering, the connection strength can be improved and the electrical conductivity can be maintained for a long time.
In particular, the terminal 4 and the conductor end 2a can be mechanically firmly connected at the position where the terminal 4 is crimped, and the formation of an oxide film on the conductor end 2a is prevented at the soldering position ( It can be connected with sufficient electrical conductivity (reducing contact resistance).
Furthermore, even when used in a high temperature environment, the conductivity can be maintained for a long time.
Further, since the solder is soldered in the insertion hole 9, the solder 11 is hardly broken by an external impact or the like, and the impact resistance (especially at the conductive connection portion 6) is improved.

It is a side view which shows the 1st Embodiment of this invention. It is a top view. It is a cross-sectional side view. It is a sectional side view for explanation. It is a sectional side view for explanation. It is a sectional side view for explanation. It is a cross-sectional side view which shows 2nd Embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Aluminum electric wire 2 Conductor 2a Conductor end 3 Insulator 4 Terminal 9 Insertion hole
11 Solder
12 Bottom
14 Opening Z Tip

Claims (6)

Conductor end where the insulator (3) is peeled off and exposed at one end of an aluminum wire (1) formed by coating a large number of conductors (2) made of aluminum or aluminum alloy with the insulator (3) In the connection method of the aluminum wire for connecting the terminal (4) to the part (2a) by caulking,
The molten solder (11) is injected into the bottomed hole-shaped insertion hole (9) of the terminal (4), or the solder (11) is melted in the insertion hole (9) and then inserted. The conductor end (2a) is inserted into the insertion hole (9) so as to contact the molten solder (11) at least near the bottom (12) of the hole (9), and the terminal (4) is caulked. A method for connecting aluminum wires, characterized in that the end portion (2a) of the conductive wire is processed and crimped and held.   The connection method of the aluminum electric wire of Claim 1 which made the position which crimps the said terminal (4) be the opening part (14) vicinity of the said insertion hole (9) of the said terminal (4).   The method of connecting aluminum wires according to claim 1 or 2, wherein the terminal (4) is made of an aluminum alloy.   The method for connecting aluminum wires according to claim 1, 2 or 3, wherein the aluminum wires (1) are used for battery cables of automobiles. One end of an aluminum electric wire (1) formed by coating a large number of conductors (2) made of aluminum or aluminum alloy with an insulator (3), and exposed one end (2a) and a terminal ( 4) In the connection structure of aluminum wires to be connected,
The terminal (4) and the conductive wire end (2a) are soldered and electrically connected at least in the vicinity of the distal end (Z) of the conductive wire end (2a), and the distal end of the conductive wire end (2a) (Z) An aluminum electric wire connection structure characterized in that the terminal (4) is caulked and connected from the vicinity to the base end side. One end of an aluminum electric wire (1) formed by coating a large number of conductors (2) made of aluminum or aluminum alloy with an insulator (3), and exposed one end (2a) and a terminal ( 4) In the connection structure of aluminum wires to be connected,
The terminal (4) has a bottomed hole-shaped insertion hole (9). The conductor end (2a) is inserted into the insertion hole (9), and the terminal (4) and the conductor end ( 2a) is conductively connected via solder (11) at least near the bottom (12) of the insertion hole (9), and has an opening (14) near the bottom (12) of the insertion hole (9). The aluminum wire connection structure is characterized in that the terminal (4) is caulked from the outer surface of the terminal (4) and connected on the side.

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