CN102025090A - 用保形涂层制作密封电缆芯和端子的改进电连接的方法 - Google Patents

用保形涂层制作密封电缆芯和端子的改进电连接的方法 Download PDF

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CN102025090A
CN102025090A CN2010102875565A CN201010287556A CN102025090A CN 102025090 A CN102025090 A CN 102025090A CN 2010102875565 A CN2010102875565 A CN 2010102875565A CN 201010287556 A CN201010287556 A CN 201010287556A CN 102025090 A CN102025090 A CN 102025090A
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F·D·马尔陶茨
M·A·希尔
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    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
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    • Y10T29/00—Metal working
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49174—Assembling terminal to elongated conductor
    • Y10T29/49176—Assembling terminal to elongated conductor with molding of electrically insulating material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
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Abstract

一种在具有绝缘外套的电缆的导电芯和端子周围形成密封的方法，该方法包括如下步骤：提供延伸超出绝缘外套的轴向边缘的所述芯的引线；将保形涂层施加到引线上；在所述保形涂层仍然湿的时候将所述端子挤压到所述电缆上，从而将保形涂层从所述引线和所述端子的抵靠接触表面之间移位以便利用保形涂层覆盖和密封引线的没有与所述端子直接接触的剩余部分；以及使保形涂层在引线的剩余部分上固化。

Description

用保形涂层制作密封电缆芯和端子的改进电连接的方法
优先权要求的交叉引用
本申请是2009年10月8日提交的12/575,675号共同待决的美国申请的部分继续申请，并且要求2009年9月18日提交的61/243,650号共同待决的美国临时申请的优先权。
技术领域
本发明的领域涉及铝基电缆和铜基电端子之间的连接。
背景技术
绝缘铜基电缆通常用于汽车布线。铜具有高的导电性、良好的耐腐蚀性和足够的机械强度。然而，铜和铜基金属是相对较贵的金属并且也很重。
在汽车电力布线应用中节约重量和节省成本的考虑已使得铝基电缆成为替代铜基电线的有吸引力的选择。然而，一些布线和电接头仍需要是铜基的。因此，在电路的铝基部分和电路的铜基部分之间的电路的某些地方会存在过渡点。通常，此类过渡点可出现在端子处，因为端子由于尺寸和形状复杂性的原因会保持为铜基的，这种尺寸和复杂的形状利用铜基材料比利用铝基材料更容易获得。如果存在例如盐水的电解质，则铝基电缆至铜基端子的连接可产生铝的电解腐蚀。电解反应腐蚀铝是因为铝或者铝合金具有与端子的铜或铜合金不同的电解电势。本文中使用的“铜基”是指纯铜或铜合金，在铜合金中，铜是主要金属。类似地，本文中使用的“铝基”是指纯铝或铝合金，在铝合金中，铝是主要金属。
现在参考图1，已知当存在例如盐水的电解质时，明显的腐蚀会发生在不同材料之间。如图1所示的传统铜基端子35具有一对绝缘翼36和一对芯翼38，在其间有一个凹口40。成束的铝基线缆12在连接到由例如纯铜、黄铜或其他铜合金等更贵的金属制成的端子35时，其引线16的进行连接的暴露的线束端15基本上被腐蚀。四天的盐雾测试已经证明基本上会腐蚀掉几乎整个铝引线16。凹口40允许更多的盐及其他电解质更容易接触暴露的线束15。引线16在被完全腐蚀掉时导致电缆12和端子35之间的电连接断开。
需要在电缆及其连接端子之间提供改善的耐腐蚀的连接。在铝基电缆和铜基端子之间还需要通过改善的密封来将铝电缆与电解质密封开并同时维持与端子的电接触从而提供改善的耐腐蚀的连接。
发明内容
根据本发明的一个方面，一种在具有绝缘外套的电缆的铝基芯和铜基端子周围形成密封的方法，该方法包括如下步骤：提供延伸超出绝缘外套的轴向边缘的芯的引线；将保形涂层施加到引线上；在保形涂层仍然湿的时候将铜基端子挤压到引线上，从而将保形涂层从引线和铜基端子的抵靠接触表面之间移位，以便通过引线和端子之间的界面提供电接触，并且覆盖和密封引线的没有与端子直接接触的剩余部分；以及使保形涂层在引线的剩余部分上固化。
优选地，施加保形涂层是通过将引线浸入一个喷嘴中进行的。当引线处于喷嘴中时保形涂层被分配到喷嘴内。在一个实施方式中，电缆的铝基芯由多条线束制成，在线束之间具有空隙。保形涂层以足够的压力被分配到喷嘴中以便在被固化之前以湿的保形涂层填充上述空隙。在一个实施方式中，喷嘴以水平方式设置，而引线水平地移动到所述喷嘴中用于浸渍并且在其上携带着保形涂层的情况下从喷嘴中水平移出。
端子优选具有组合绝缘部和芯翼，当保形涂层仍然湿的时候，芯翼被挤压到绝缘外套上，且跨接在绝缘外套的边缘上并且被挤压到芯的引线上。
根据本发明的另一方面，一种在具有绝缘外套的电缆的导电芯和端子周围形成密封的方法，该方法包括如下步骤：提供延伸超出绝缘外套的轴向边缘的芯的引线，将保形涂层施加到引线上；在保形涂层仍然湿的时候将端子挤压到电缆上，从而将保形涂层从引线和端子的抵靠接触表面之间移位，以便通过引线和端子之间的界面提供电接触，并且用保形涂层覆盖和密封引线的没有直接接触端子的剩余部分；以及使保形涂层在引线的剩余部分上固化。
优选地，施加保形涂层是通过将引线浸入一个喷嘴中进行的。当引线在喷嘴中时配给保形涂层。优选地，芯由当暴露于电解质时比端子更具电阴性的材料制成。
根据本发明的另一方面，一种在具有绝缘外套的电缆的铝基芯和铜基端子周围形成密封的方法，该方法包括如下步骤：提供延伸超出绝缘外套的轴向边缘的芯的引线；将保形涂层喷洒到引线上；在保形涂层仍然是湿的时候将铜基端子挤压到引线上，从而将保形涂层从引线和铜基端子的抵靠接触表面之间移位，以便通过引线和端子之间的界面提供电接触，并且覆盖和密封引线的没有直接接触端子的剩余部分；以及使保形涂层在引线的剩余部分上固化。
优选地，喷洒保形涂层是从电缆沿着轴向朝向引线的远端喷洒以使得保形涂层从引线的远端流下来。
在一个实施方式中，电缆的铝基芯由多股线束制成，从而当被挤压时在其间具有间隙，这些间隙在保形涂层固化之前充满了湿的保形涂层。端子是绝缘部和芯翼的组合，芯翼在保形涂层仍然湿的时候被挤压在绝缘外套上，并且跨接在绝缘外套的边缘上，并且被挤压到芯的引线上。
根据本发明的另一方面，一种在具有绝缘外套的电缆的导电芯和端子周围形成密封的方法，该方法包括如下步骤：提供延伸超出绝缘外套的轴向边缘的芯的引线；将保形涂层喷洒到引线上；在保形涂层仍然湿的时候将端子挤压到引线上，从而将保形涂层从引线和端子的抵靠接触表面之间移位，以便通过引线和端子之间的界面提供电接触，并且利用保形涂层覆盖和密封引线的没有直接接触端子的剩余部分；以及使保形涂层在引线的剩余部分上固化。
优选地，喷洒保形涂层是从电缆沿着轴向朝向引线的远端喷洒以使保形涂层覆盖引线并从引线的远端流下来。
在一个实施方式中，电缆由多股线束制成；并且这些线束在被挤压时在其间具有间隙，这些间隙在保形涂层固化之前充满了湿的保形涂层。端子具有绝缘部和芯翼的组合，芯翼被挤压在绝缘外套上，并且跨接在绝缘外套的边缘上，并且芯翼被挤压到芯的引线上。优选地，芯由当暴露于电解质时比端子更具电阴性的材料制成。
附图说明
现在参考附图，其中：
图1是现有技术的常规铝基电缆和铜基端子的平面图，图中以虚线示出了已经基本被腐蚀掉的铝基电线的暴露的线束端部；
图2是根据本发明的一个实施方式的组装前的铜基端子和处理过的电缆的立体分解图，图2的电缆是铝基电缆，其引线被去除了绝缘外套，并且沿着轴向朝向导电电缆芯的暴露引线进行保形涂层的喷洒；
图3是端子和组装到端子上的铝基电缆的立体图；
图4是沿着图3中示出的线4-4截取的截面图；
图5是沿着图4中示出的线5-5截取的截面图；
图6是图5的放大局部视图；
图7是在引线***浸渍喷嘴之前的浸渍喷嘴和引线的立体图；
图8是立体图，示出了水平移动并***浸渍喷嘴的引线；以及
图9是示出了浸渍喷嘴中的引线的放大局部视图。
具体实施方式
参考图2，电缆10具有绝缘外套12和铝基芯14。芯14由捆扎和扭绞在一起的多个独立线束15制成。绝缘外套12的端部被去掉以暴露出芯14的引线16。喷洒机18将保形涂层20喷洒到芯的引线16上。喷洒头23的位置被定位成远离外套12并且朝向引线16的轴向远端21。喷洒的方向沿轴向远离绝缘外套12并且朝向轴向远端21。喷洒头23可在电缆被移入保形涂层20的喷雾中之前就开始喷洒保形涂层20。电缆随后被沿轴向移入喷雾中，使得轴向端21碰到喷雾并且被涂覆以保形涂层20。电缆可转动或者喷洒头18可环绕电缆12转动以保证引线16在360度上被涂覆。当电缆被朝向端子22向前移动时，喷洒头23可与绝缘外套12轴向对齐并且在绝缘外套12的边缘43上提供保形涂层20。整个引线16都被涂覆。
当保形涂层仍然湿的时候，电缆10相对于端子22进行定位，这在图3中显示得最清楚。端子22具有配合端31。端子22然后在其相对端被挤压到电缆10上，使得其与芯14的引线16电接触，这在图4、5和6中显示得最清楚。
当端子被挤压到电缆10上时，引线16上的保形涂层20被移位从而允许端子22和引线16之间的直接接触。保形涂层被移位而填充图6中突出显示的线束15和没有与端子22直接接触的引线16的其他暴露表面之间的空隙24，例如在翼26之间的区域42中以及端部21处的空隙，这在图4中显示得最清楚。在端子22挤压到电缆10上之后，保形涂层被允许固化以完成电连接30的组装。
端子22具有翼26，其消除了图1中所示的传统的凹口40。翼26被挤压在绝缘外套12上并且跨接在绝缘外套12的边缘43上，并且被挤压到引线16上。翼26可称为绝缘体和芯翼的组合。
每个翼26都在保形涂层20仍然湿的时候挤压到引线16上。保形涂层20从端子22和引线16的抵接表面移位以提供端子22和引线16之间的电界面和连接。保形涂层20被移位到引线16的不与端子直接接触的区域中，例如处于形成在挤压翼26之间的空隙42内和间隙24内以及在引线16的轴向外端部21处。
保形涂层20随后在合适的位置被固化以完成电组件30。
另一种改进方法在图7、8和9中示出。芯14的引线16面对浸渍喷嘴50，如图7所示。浸渍喷嘴具有接收引线16的沉孔52，如图8所示。图9示出了保形涂层20，保形涂层20从供给口55被分配进沉孔52以将引线浸入保形涂层20中。保形涂层的高粘度允许喷嘴50的位置被水平设置。保形涂层可在引线***沉孔52的同时或之前或者之后进行分配。电缆10和引线16随后被水平收回，而保形涂层20则粘到引线16上并且随引线一起缩回。引线16和电缆10可通过往复自动进给器56供给。保形涂层的分配或者引线16的***以如下方式执行：该方式使得能够提供足够的压力从而将保形涂层驱动到引线16内的线束之间的空隙58内。一旦电缆引线16缩回，就开始进行上述挤压和固化步骤。
通过将电连接与例如盐水的电解质密封开，铝基电缆和铜基电端子之间发生的电解腐蚀会显著下降。保形涂层20在仍然湿的时候发生的移位极大地改善了整个引线和铝基芯的结构密封，同时在端子和引线之间提供了密封的电界面和电接触。绝缘体和芯翼的组合还减少了将引线暴露于会增加电解腐蚀的风险的元件中的机会。
虽然本发明的主要应用是用于两种不同金属间的界面，但是可以设想，这种密封应用在用于由类似或相同金属制成的端子和引线之间的界面时也具有优势。
在不背离由所附权利要求限定的本发明的范围和精神的情况下，还能够作出其他变行或改行。
要求专有财产或者权益的实施方式在权利要求中进行了限定。

Claims (16)

1.一种在电缆和铜基端子周围形成密封的方法，该电缆具有绝缘外套和铝基的芯，所述方法包括如下步骤：
提供延伸超出所述绝缘外套的轴向边缘的所述芯的引线；
将湿的保形涂层施加到所述引线上；
在所述保形涂层仍然湿的时候将所述铜基端子挤压到所述引线上，从而将保形涂层从所述引线和所述铜基端子的所述抵靠接触表面之间移位，以便在所述引线和所述端子之间提供电接触并且覆盖和密封所述引线的没有与所述端子直接接触的剩余部分；以及
使所述保形涂层在所述引线的所述剩余部分上固化。
2.如权利要求1所述的方法，还包括：
通过将所述引线浸入喷嘴中而施加所述保形涂层；以及
当所述引线在所述喷嘴中时将所述保形涂层分配到所述喷嘴中。
3.如权利要求2所述的方法，其中所述喷嘴大致水平设置并且所述引线水平地移动到所述喷嘴中以便进行浸渍。
4.如权利要求2所述的方法，其中所述电缆的所述铝基芯由多个线束制成；
所述线束在其间具有空隙；以及
所述保形涂层以足够的压力被分配以便填充所述空隙。
5.如权利要求3所述的方法，其中所述电缆的所述铝基芯由多个线束制成；并且
所述线束在被挤压时在其间具有间隙，这些间隙在所述保形涂层固化之前被填充以所述湿的保形涂层。
6.如权利要求5所述的方法，其中所述端子具有绝缘部和芯翼的组合，所述芯翼被挤压到所述绝缘外套上并且跨接在所述绝缘外套的边缘上并且被挤压到所述芯的所述引线上。
7.如权利要求4所述的方法，其中所述端子具有绝缘部和芯翼的组合，所述芯翼被挤压到所述绝缘外套上并且跨接在所述绝缘外套的边缘上并且被挤压到所述芯的所述引线上。
8.一种在电缆和端子之间形成密封的方法，该电缆具有绝缘外套和导电的芯，所述方法包括如下步骤：
提供延伸超出所述绝缘外套的轴向边缘的所述芯的引线；
将湿的保形涂层施加到所述引线上；
在所述保形涂层仍然湿的时候将所述端子挤压到所述电缆上，从而将保形涂层从所述引线和所述端子的所述抵靠接触表面之间移位，并且用所述保形涂层覆盖和密封所述引线的没有与所述端子直接接触的剩余部分；以及
使所述保形涂层在所述引线的所述剩余部分上固化。
9.如权利要求8所述的方法，还包括：
通过将所述引线浸入喷嘴中而施加所述保形涂层；以及
当所述引线在所述喷嘴中时将所述保形涂层分配到所述喷嘴中。
10.如权利要求9所述的方法，其中所述喷嘴大致水平设置并且所述引线水平地移动到所述喷嘴中以便进行浸渍。
11.如权利要求8所述的方法，其中所述电缆由多个线束制成；
所述线束在其间具有空隙；以及
所述保形涂层以足够的压力被分配以便填充所述空隙。
12.如权利要求11所述的方法，其中所述电缆的所述铝基芯由多个线束制成；并且
所述线束在被挤压时在其间具有间隙，这些间隙在所述保形涂层固化之前被填充以所述湿的保形涂层。
13.如权利要求12所述的方法，其中所述端子具有绝缘部和芯翼的组合，所述芯翼被挤压到所述绝缘外套上并且跨接在所述绝缘外套的所述边缘上并且被挤压到所述芯的所述引线上。
14.如权利要求11所述的方法，其中所述端子具有绝缘部和芯翼的组合，所述芯翼被挤压到所述绝缘外套上并且跨接在所述绝缘外套的所述边缘上并且被挤压到所述芯的所述引线上。
15.如权利要求14所述的方法，其中所述芯由当暴露于电解质时比所述端子更具电阴性的材料制成。
16.如权利要求8所述的方法，其中所述芯由当暴露于电解质时比所述端子更具电阴性的材料制成。
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