CN109103725B - 电缆与端子的连接工艺及连接结构 - Google Patents

电缆与端子的连接工艺及连接结构 Download PDF

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CN109103725B
CN109103725B CN201811006716.7A CN201811006716A CN109103725B CN 109103725 B CN109103725 B CN 109103725B CN 201811006716 A CN201811006716 A CN 201811006716A CN 109103725 B CN109103725 B CN 109103725B
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cable
terminal
conductor
tin wire
connection
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CN109103725A (zh
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冯海涛
张强
杨冬
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Shenzhen Woer New Energy Electric Technology Co Ltd
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Shenzhen Woer Heat Shrinkable Material Co Ltd
Changzhou Woer Heat Shrinkable Material Co Ltd
Huizhou LTK Electronic Cable Co Ltd
LTK Electric Wire Huizhou Co Ltd
Shenzhen Woer Special Cable Co Ltd
Shenzhen Woer New Energy Electric Technology Co Ltd
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    • H01R43/00Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048Crimping apparatus or processes
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    • H01R11/00Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
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    • H01R4/00Electrically-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
    • H01R4/10Electrically-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
    • H01R4/18Electrically-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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    • H01R4/00Electrically-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
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    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00Electrically-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
    • H01R4/10Electrically-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
    • H01R4/18Electrically-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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    • H01R43/00Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0207Ultrasonic-, H.F.-, cold- or impact welding
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Abstract

本发明公开一种电缆与端子的连接工艺及连接结构,所述端子包括具有连接孔的连接部,该电缆与端子的连接工艺包括以下步骤:S1:对所述电缆进行剥皮处理,使得电缆的导体外露;S2:将导体***所述连接部的连接孔内;S3:对所述导体和连接部进行压接处理;S4:在导体邻近所述连接部的自由端端部的位置缠绕锡丝;S5:对所述锡丝进行焊接处理。本发明技术方案可改善端子和电缆的压接工艺,提高电缆的使用性能。

Description

电缆与端子的连接工艺及连接结构
技术领域
本发明涉及电连接技术领域,特别涉及一种电缆与端子的连接工艺及应用该工艺加工的电缆与端子的连接结构。
背景技术
目前纯动电汽车、混动电动汽车等电动交通工具的市场需求不断扩大,对电动汽车的技术要求越来越高。在充电连接或汽车中大电流电路连接的过程中,线路及电缆的发热问题突出,导致电缆及相关附件快速老化,影响产品的寿命和安全性能。
目前,端子与电缆的连接普遍采用液压接机直接压接的方式,电缆与端子之间的间隙易导致空气污染导体,从而使得电缆的使用性能迅速降低。
发明内容
本发明的主要目的是提供一种电缆与端子的连接工艺,旨在对端子和电缆的压接工艺进行改善,提高电缆的使用性能。
为实现上述目的,本发明提出的电缆与端子的连接工艺,所述端子包括具有连接孔的连接部,包括以下步骤:
S1:对所述电缆进行剥皮处理,使得电缆的导体外露;
S2:将导体***所述连接部的连接孔内;
S3:对所述导体和连接部进行压接处理;
S4:在导体邻近所述连接部的自由端端部的位置缠绕锡丝;
S5:对所述锡丝进行焊接处理。
优选地,在所述“步骤S2:将导体***所述连接部的连接孔内”中,包括:
S21:将锡丝缠绕成盘状放入所述连接部的连接孔内;
S22:将导体***所述连接孔内并抵接所述锡丝;
S23:对应导体的自由端位置对连接部进行焊接处理。
优选地,所述焊接处理为非接触式高频加热。
优选地,所述锡丝的直径范围为0.6~1.0mm。
优选地,步骤S4中缠绕的所述锡丝的圈数范围为6~10,且/或,步骤S21中的锡丝厚度范围为2~3mm。
优选地,在所述“步骤S5:所述对所述锡丝进行焊接处理”之后,还包括:
S6:在所述连接部的端部与所述电缆的外皮之间套设防护管。
优选地,所述压接处理为正六边形压接。
优选地,所述锡丝为含银锡丝。
本发明还提出一种电缆与端子的连接结构,包括电缆和端子,所述电缆与端子使用如上所述的电缆与端子的连接工艺连接。
优选地,还包括防护管,所述防护管套设于所述连接部的端部与所述电缆的外皮之间。
本发明技术方案的电缆与端子的连接工艺通过在导体邻近所述连接部的自由端端部的位置缠绕锡丝,然后对该处进行焊接处理,从而使得锡丝熔化后可以填充连接部的端部与导体之间的间隙,防止外部空气进入,因锡具有较铜较高的抗氧化性能,故而可以防止铜导体被氧气氧化,在使用一段时间后铜导体还可以保持良好的电气性能和导电性能,延长电缆的使用寿命,从而提高连接器的连接性能。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案,下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍,显而易见地,下面描述中的附图仅仅是本发明的一些实施例,对于本领域普通技术人员来讲,在不付出创造性劳动的前提下,还可以根据这些附图示出的结构获得其他的附图。
图1为本发明电缆与端子的连接工艺一实施例的流程示意图;
图2为本发明电缆与端子的连接工艺另一实施例的流程示意图;
图3为本发明电缆与端子的连接结构的示意图;
图4为图3中沿A-A线的剖视图。
附图标号说明:
标号 名称 标号 名称
100 电缆与端子的连接结构 111 连接孔
1 端子 2 电缆
11 连接部 21 导体
本发明目的的实现、功能特点及优点将结合实施例,参照附图做进一步说明。
具体实施方式
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明的一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
需要说明,本发明实施例中所有方向性指示(诸如上、下、左、右、前、后……)仅用于解释在某一特定姿态(如附图所示)下各部件之间的相对位置关系、运动情况等,如果该特定姿态发生改变时,则该方向性指示也相应地随之改变。
在本发明中,除非另有明确的规定和限定,术语“连接”、“固定”等应做广义理解,例如,“固定”可以是固定连接,也可以是可拆卸连接,或成一体;可以是机械连接,也可以是电连接;可以是直接相连,也可以通过中间媒介间接相连,可以是两个元件内部的连通或两个元件的相互作用关系,除非另有明确的限定。对于本领域的普通技术人员而言,可以根据具体情况理解上述术语在本发明中的具体含义。
另外,在本发明中如涉及“第一”、“第二”等的描述仅用于描述目的,而不能理解为指示或暗示其相对重要性或者隐含指明所指示的技术特征的数量。由此,限定有“第一”、“第二”的特征可以明示或者隐含地包括至少一个该特征。另外,各个实施例之间的技术方案可以相互结合,但是必须是以本领域普通技术人员能够实现为基础,当技术方案的结合出现相互矛盾或无法实现时应当认为这种技术方案的结合不存在,也不在本发明要求的保护范围之内。
本发明提出一种电缆与端子的连接工艺,用于连接电缆2与端子1。
请参照图1至图4,在本发明一实施例中,该电缆与端子的连接工艺包括以下步骤:
S1:对所述电缆2进行剥皮处理,使得电缆2的导体21外露;
S2:将导体21***所述连接部11的连接孔111内;
S3:对所述导体21和连接部11进行压接处理;
S4:在导体21邻近所述连接部11的自由端端部的位置缠绕所述锡丝;
S5:对所述锡丝进行焊接处理。
本实施例中,端子1的材质为导体21材料,一般选择铜铝等导电性好的金属材料,且价格便宜,便于加工。端子1的一端设有连接部11,该连接部11开设有连接孔111,方便将电缆2的导体21***其中进行连接;端子1的另一端可以与其他导电部件焊接或螺纹连接,以实现电连接。具体地,端子1背离连接部11的一端开设有螺纹孔,与导电部件螺纹连接,可以实现稳定地连接,不易发生意外被扯开的情况,从而保证电缆2连接的稳定性。当然,端子1背离连接部11的一端还可以为扁平状,其上开设有连接孔111,通过固定件穿设连接孔111内与其他导电部件进行连接。
需要进行连接的电缆2一般由导体21、主绝缘层、屏蔽层及外皮组成,在进行安装连接时,先将电缆2进行剥皮处理,即将电缆2的外皮剥离一定长度,再剥离一段屏蔽层,然后再剥离部分主绝缘层,从而露出导体21以便与端子1进行连接。该电缆2处理完后呈接阶梯轴状,且导体21与连接部11的连接孔111的直径相匹配,以实现可靠连接。此处的导体21主要为铜丝,具有良好的导电性,且在进行连接前还可以对导体21进行清理异物或氧化物的过程,以便实现更好的电连接。
具体地,在常规尺寸的导体21上缠绕的锡丝的直径范围为0.6~1.0mm,缠绕的所述锡丝的圈数范围为6~10,以使焊接后的锡液可以有效填充导体21与连接部11的端部之间的空隙。当然,当电缆2的直径增大时,对应缠绕的锡丝的直径和缠绕圈数也应相应增大,从而保证导体21与端子1之间良好的接触性能。
锡丝的材质优选含银的锡丝,该材质的锡丝附着性能好,能够快速充盈于导体21的外表面和内部,提高加工的效率;且含银锡丝的导电性能好,可以进一步提高导体21与端子1之间的接触性能,减小接触电阻,在有大电流经过时,可以有效降低导体21的发热温度,从而延缓电缆的老化。
本发明技术方案的电缆与端子的连接工艺通过在导体21邻近所述连接部11的自由端端部的位置缠绕锡丝,然后对该处进行焊接处理,从而使得锡丝熔化后可以填充连接部11的端部与导体21之间的间隙,防止外部空气进入,因锡具有较铜较高的抗氧化性能,故而可以防止铜导体21被氧气氧化,在使用一段时间后铜导体21还可以保持良好的电气性能和导电性能,延长电缆的使用寿命,从而提高连接器的连接性能。
进一步地,在“步骤S2:将导体21***所述连接部11的连接孔111内”中,包括:
S21:将锡丝缠绕成盘状放入所述连接部11的连接孔111内;
S22:将导体21***所述连接孔111内并抵接所述锡丝;
S23:对应导体21的自由端位置对连接部11进行焊接处理。
本实施例中,将锡丝缠绕成盘状,该盘状可以是圆盘状或是方形等,也可以将锡丝切除粉末状放入连接孔111内。此处的锡丝可与导体21自由端的锡丝相同,且缠绕成盘状的锡丝厚度优选为2~3mm,可以满足导体21端部的间隙填补,实现有效连接,且不会过渡浪费。
在进行压接前,于导体21的自由端缠绕锡丝,并首先对连接孔111内的导体21进行焊接处理,使得位于导体21的自由端部的锡丝熔化,填充于导体21端部与连接孔111之间的空隙,操作简单,增加了导体21与端子1之间的接触面积,提高了接触性能,同时,电流经过该导体21与端子1时,可以直接由导体21流向端子1背离连接部11的一端,从而有效提高电连接的效率,并可以减少对端子1的连接部11的厚度要求;再进行压接处理,可以使锡液也充盈于导体21内部,增加导体21的横截面积,进而降低了接触电阻,在连通大电流电路时,可以有效缓解发热的问题。此外,缠绕锡丝的过程简单易操作,熔融的锡可自动填充空隙,可以有效提高加工效率。
当然,也可以调节导体21自由端的锡丝缠绕厚度,从而使得熔化后的锡液也填充连接部11的端部。
优选地,所述焊接处理为非接触式高频加热。
上述步骤中,对导体21进行焊接处理的装置为高频加热机,该装置高效快速,一般几秒就可以完成加工,有效节约能耗;且加工方式为非接触式,可以有效防止烫伤,提高作业安全性;内部的感应线圈的直径略大于端子1的直径即可,不依赖于导体21的外部形状,适用性强。在进行焊接时,高频加热机的加热电流在500~800A之间,加热时间优选为3~6秒,该工艺加工的电缆2与端子1的连接性能和电接触性能好,且能够有效降低大电流通过时的升温。
优选地,所述压接处理为正六边形压接。
上述步骤中的压接处理选择正六边形压接,该压接方式可以对导体21实施均匀的压力,从而使得铜丝受力均匀,不会发生局部断裂的情况,进而可以进一步减小压接电阻,本实施例中,铜丝的压缩比为75%~80%。该处的压接处理可以将液体的锡充分填充导体21与连接孔111孔壁的间隙,从而完成有效电接触。
此外,在步骤S5:对所述锡丝进行焊接处理之后,还包括:
S6:在所述连接部11的端部与所述电缆2的外皮之间套设防护管。
本实施例中,因锡的熔化温度相较于导体21的外皮温度较高,故为了保护导体21的外皮,并防止导体21氧化,在所述连接部11的端部与所述电缆2的外皮之间套设防护管,该防护管为热缩管,可以对电缆2起到保护作用,并可以提高结构强度。
本发明还提出一种电缆与端子的连接结构100,包括电缆2和端子1,所述电缆2与端子1使用如上所述的电缆与端子的连接工艺连接。由于电缆与端子的连接结构100采用了上述所有实施例的全部技术方案,因此至少具有上述实施例的技术方案所带来的所有有益效果,在此不再一一赘述。
此外,该电缆与端子的连接结构100还包括防护管(未图示),所述防护管套设于所述连接部11的端部与所述电缆2的外皮之间,可以对电缆2起到保护作用。
以上所述仅为本发明的优选实施例,并非因此限制本发明的专利范围,凡是在本发明的发明构思下,利用本发明说明书及附图内容所作的等效结构变换,或直接/间接运用在其他相关的技术领域均包括在本发明的专利保护范围内。

Claims (8)

1.一种电缆与端子的连接工艺,所述端子包括具有连接孔的连接部,其特征在于,包括以下步骤:
S1:对所述电缆进行剥皮处理,使得电缆的导体外露;
S2:将导体***所述连接部的连接孔内;
S3:对所述导体和连接部进行压接处理;
S4:在导体邻近所述连接部的自由端端部的位置缠绕锡丝;
S5:对所述锡丝进行焊接处理;
在所述“步骤S5:对所述锡丝进行焊接处理”之后,还包括:
S6:在所述连接部的端部与所述电缆的外皮之间套设防护管。
2.如权利要求1所述的电缆与端子的连接工艺,其特征在于,在所述“步骤S2:将导体***所述连接部的连接孔内”中,包括:
S21:将锡丝缠绕成盘状放入所述连接部的连接孔内;
S22:将导体***所述连接孔内并抵接所述锡丝;
S23:对应导体的自由端位置对连接部进行焊接处理。
3.如权利要求1所述的电缆与端子的连接工艺,其特征在于,所述焊接处理为非接触式高频加热。
4.如权利要求1所述的电缆与端子的连接工艺,其特征在于,所述锡丝的直径范围为0.6~1.0mm。
5.如权利要求2所述的电缆与端子的连接工艺,其特征在于,步骤S4中缠绕的所述锡丝的圈数范围为6~10,且/或,步骤S21中的锡丝厚度范围为2~3mm。
6.如权利要求1所述的电缆与端子的连接工艺,其特征在于,所述压接处理为正六边形压接。
7.如权利要求1所述的电缆与端子的连接工艺,其特征在于,所述锡丝为含银锡丝。
8.一种电缆与端子的连接结构,其特征在于,包括电缆和端子,所述电缆与端子使用如权利要求1~7中任一所述的电缆与端子的连接工艺连接。
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