JP2011181189A - Connection terminal, and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a connection terminal capable of obtaining bonding strength equivalent to that of a clad material. <P>SOLUTION: A brazing material is bonded to a part of a copper plate constituting the connection terminal where a material to be bonded should like to be bonded, and is resistance welded for temporary fixing. For this, a single or a plurality of projections are molded on the copper plate, which are pinched with a pair of electrodes of a resistance welded machine to be compressed so as to face with each other and electrically conducted, whereby, the copper plate and the brazing material are bonded to make a connection terminal. <P>COPYRIGHT: (C)2011,JPO&amp;INPIT

Description

  The present invention relates to a structure of a connection terminal when a connection terminal and a material to be joined are joined, and a manufacturing method thereof.

  In order to connect the conductor and the conductor terminal, a method is known in which a brazing material is attached in advance to the conductor terminal, sandwiched between a pair of electrodes, and the brazing material is melted and joined by applying pressure and energizing ( For example, see Patent Document 1). In order to attach the brazing material, there are soldering, placing, etc., and a method of supplying the brazing material to a stable position becomes a problem. Therefore, in order to stabilize the brazing operation, a clad material in which a copper plate and a brazing material are bonded together by pressure welding may be used (for example, see Patent Document 2). However, although the clad material is expensive and the brazing workability is good, the brazing material may be cracked or peeled off by the molding process.

Japanese Patent Laid-Open No. 5-114450 Japanese Patent No. 3554305

  In order to stabilize the joining quality by brazing, it is preferable to automate the brazing operation, and it is desirable to temporarily fix and supply the brazing material to a position where the terminal material and the material to be joined are desired to be joined.

  As a method of temporarily fixing the brazing material to the terminal material, there are laser welding, arc welding, resistance welding and caulking. However, according to laser welding and arc welding, an auxiliary facility for shielding gas supply, arc light and laser light is required, and a jig for fixing the terminal material and the brazing material is also necessary for welding. .

  Since the caulking is due to the plastic deformation, there is a concern that the brazing material may be peeled off from the caulking portion when the bonding strength is insufficient. Therefore, in the present invention, it is possible to obtain a flexible terminal structure by bonding a brazing material only to a portion where the material to be bonded is to be bonded, and temporarily fixing it, and a connection terminal having workability and bonding quality equivalent to that of a clad material. Is to provide.

  Resistance welding is performed to join and temporarily fix a brazing material to a portion of the copper plate constituting the connection terminal where the material to be joined is to be joined. For this reason, one or a plurality of projections are formed on the copper plate, and the copper plate and the brazing material are joined to each other by joining with a pair of electrodes arranged so as to face each other of the resistance welder, and applying pressure to energize the copper plate. Become.

  According to the present invention, it is possible to provide a connection terminal that can obtain a bonding quality equivalent to that of a clad material.

Single view of projection-molded copper plate and brazing material. Sectional drawing of the projection shape shape | molded on a copper plate. The front view and side view of a connection terminal which have a flat plate and a clamping part. The front view when the connection terminal which has a clamping part, and several to-be-joined materials are welded, and sectional drawing of a junction part. The front view when the connection terminal which has a clamping part, and a single to-be-joined material are welded, and sectional drawing of a junction part. The front view when a flat plate connection terminal and a plurality of materials to be joined are welded, and a sectional view of a joined part. The front view when welding a flat plate connection terminal and a single to-be-joined material, and sectional drawing of a junction part. The front view of the notch part shape provided in the clamping part of the connection terminal. The front view of the connecting terminal which welded the to-be-joined material to both ends. Schematic diagram of seam welding. The perspective view of the lead wire and connection terminal of the stator of a rotary electric machine.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  In FIG. 1, a copper plate 1 having a thickness of 1.5 mm is punched into a terminal shape, and the shape of the projection 2 is formed by extruding four points from the back side of the copper plate with a punch so that the height is φ2 and 0.15 mm. Is. The brazing filler metal is a phosphor copper brazing foil 5 (15Ag-5P-Cu) which has the advantage that it can be brazed without using a flux because it has a self-flux effect, and uses a brazing material having a width of 3 mm and a thickness of 0.1 mm. It was. At this time, the projection shape formed on the copper plate 1 may be conical or rectangular in addition to the cylindrical shape.

  FIG. 2 is a cross-sectional view of a projection formed on a copper plate. FIG. 2A is a cross-sectional view when it is formed into a rectangular or cylindrical shape, and FIG. 2B is a cross-sectional view when it is formed into a conical shape.

  Since the copper plate 1 and the phosphor copper brazing foil 5 are sandwiched between a pair of electrodes arranged so as to face the resistance welder and are energized while being pressurized, current flows in the projection 2 in a concentrated manner. The contact portion of the brazing foil 5 is locally heated, and the phosphor copper brazing foil 5 is melted and joined to the copper plate 1 to be temporarily fixed to become the connection terminal 6. Further, the connection terminals 6 can be made by resistance welding the projection portions one by one.

  FIG. 3 is a front view and a side view of a connection terminal having a flat plate and a clamping portion. If the phosphor copper brazing foil 5 is joined and temporarily fixed to the copper plate 1 as shown in FIG. 3A, it can be used as the connection terminal 6 as it is. However, as shown in FIG. By forming the sandwiching portion 4 of the connection terminal 6 into a rectangular or cylindrical shape using, for example, at least two surfaces facing each other can be brazed, so that the connection terminal has high bonding strength reliability.

  4 to 7 are a front view and a cross-sectional view of the joint when the connection terminal 6 and the material 7 to be joined are brazed. At this time, the material 7 to be joined to the connection terminal 6 may be a flat coil wire, a round coil wire, a stranded wire, or the like.

  FIG. 4A is a front view when a plurality of materials 7 to which the enamel film at the end portions is removed are inserted into the sandwiching portions 4 of the connection terminals 6 and welded, and FIG. 4B is a material to be bonded. 7 is a cross-sectional view of the joint portion when a flat coil wire is used, and FIG. 4C is a cross-sectional view of the joint portion when a round coil wire is used for the material 7 to be joined.

  FIG. 5A is a front view when a single material to be joined 7 from which the enamel film at the end is removed is inserted into the sandwiching portion 4 of the connection terminal 6 and welded, and FIG. 5B is a diagram of the material 7 to be joined. FIG. 5C is a cross-sectional view of the joint when a round coil wire is used for the material 7 to be joined.

  FIG. 6A is a front view when welding a plurality of materials to be joined 7 from which the enamel film at the end is removed to the connection terminals 6, and FIG. 6B is a diagram showing a rectangular coil wire on the materials to be joined 7. FIG. 6C is a cross-sectional view of the joint when a round coil wire is used for the material 7 to be joined.

  FIG. 7A is a front view when a single material to be joined 7 is welded to the connection terminal 6, and FIG. 7B is a cross-section of the joint when a flat coil wire is used for the material 7 to be joined. FIG. 7 (c) is a cross-sectional view of the joint when a round coil wire is used for the material 7 to be joined.

  As shown in FIG. 4 to FIG. 7, a stable joining quality can be obtained by welding the connecting terminal 6 and the material 7 to be joined, which are obtained by joining and temporarily fixing the phosphor copper brazing foil 5 to the copper plate 1.

  Further, the shape of the notch 3 provided in the holding part 4 of the connection terminal 6 may be C chamfered or R processed, FIG. 8A is a C chamfered, and FIG. 8B is an R processed. It is. The presence or absence of the phosphor copper brazing foil 5 temporarily fixed to the inner peripheral surface of the clamping part 4 can be confirmed by the notch 3 provided in the clamping part 4 of the connection terminal 6. After brazing, the brazing material Since it can be seen whether or not the molten metal is melted, it is possible to prevent entry and outflow of defective products.

  FIG. 9A shows a case in which a phosphor copper brazing foil 5 is joined to both ends of the connection terminal 6 to connect a material 7 to be joined. FIG. 9B shows the connection terminal 6 and the material 7 to be joined, which are obtained by joining a phosphor copper brazing foil to a flat copper plate. Thus, it can also be used as a connection terminal for connecting materials to be joined.

  The electrode used for resistance welding is desirably a material having high electrical resistance such as tungsten or molybdenum. The brazing material can also be joined with a brazing foil other than phosphor copper brazing.

  As mentioned above, in this invention, in order to temporarily fix the copper plate and brazing material which comprise a connection terminal, it joins by resistance welding. The copper plate and the brazing material are resistance welded by being sandwiched between a pair of electrodes arranged so as to face each other of the resistance welding machine and energized while being pressurized.

  Since the copper plate is excellent in thermal conductivity, it is difficult for resistance to generate heat. For this reason, one or a plurality of projections are provided on the copper plate.

  By providing a projection on the copper plate, when a welding current is applied, the welding current flows in a concentrated manner in the projection, so the contact portion between the projection and the brazing material generates local heat, and the copper plate and the brazing material are joined to temporarily fix it. Connection terminal. Although it can be used as a flat connection terminal as it is, if the clamping part is formed in a rectangular or cylindrical shape so that the brazing material is located on the inner peripheral side of the clamping part with a mold or the like, the materials to be joined are joined. At this time, since at least two surfaces can be brazed, reliability of the bonding strength is increased.

  If a projection is molded near the bent part of the sandwiching part and the brazing material is joined, the copper plate and the brazing material have different material elongations. Therefore, when the sandwiching part is molded into a rectangular or cylindrical shape with a mold, etc. When stress is applied and the brazing material is broken or the welding strength is weak, the welded part is peeled off. In the present invention, the brazing material is joined and temporarily fixed at the projection portion, and the bending portion is bent without fixing the brazing material, so that it is less susceptible to the tensile stress at the time of bending molding. Can be prevented from cracking and peeling.

  FIG. 10 shows an example of seam welding a copper plate 1 having a thickness of 1.5 mm and a phosphor copper brazing foil 5 (15Ag-5P-Cu) having a width of 3 mm and a thickness of 0.1 mm.

  The welding machine uses a pair of upper and lower roller electrodes 8 to overlap the copper plate 1 and the phosphor copper brazing foil 5 and sandwich them between the roller electrodes 8. By pressing and energizing the roller electrode 8 while rotating, the copper plate 1 and the phosphor copper brazing foil 5 can be joined continuously or intermittently. At this time, the copper plate 1 can be joined without plating, but if the tin plating is applied, the weldability of the brazing material is improved.

  FIG. 11 shows an application example to a rotating electrical machine. This motor is a three-phase motor. A conductor 10 is housed in the stator core 9 and has a lead wire 11 for connection to the outside. The end of the lead wire 11 is pre-machined with an enamel film. Remove it.

  Next, the end portion of the lead wire 11 from which the enamel film has been removed is inserted into the clamping portion 4 provided in the connection terminal 6. Then, it positions with a jig | tool and it supplies with electricity, pressing with the electrode arrange | positioned so that it may oppose up and down with a resistance welding machine.

  At this time, the clamping portion 4 of the connection terminal 6 is provided with a gap in order to stabilize the insertability of the lead wire 11, and the connection terminal 6 and the lead wire 11 can be brought into close contact by the caulking process. By energizing, the same effect as the caulking step can be obtained.

  First, in primary energization, in order to bring the pinching portion 4 of the connection terminal 6 and the lead wire 11 into close contact with each other, a low current is energized while being pressurized and slowly heated. As a result, the clamping portion 4 of the connection terminal 6 is softened, and an effect equivalent to that of close contact is obtained by the applied pressure and thermal deformation of the electrode. Thereafter, a current higher than the primary current is applied in a short time so that the brazing material is melted in the secondary energization, whereby the lead wire 11 and the connection terminal 6 are completely brazed.

DESCRIPTION OF SYMBOLS 1 Copper plate 2 Projection 3 Notch part 4 Clamping part 5 Phosphor copper brazing foil 6 Connection terminal 7 Joined material 8 Roller electrode 9 Stator core 10 Conductor 11 Lead wire

Claims (6)

  A connection terminal characterized by joining a copper plate and a brazing material. The connection terminal according to claim 1,
One or more projections are provided on the copper plate to join the brazing material. The connection terminal according to claim 2,
A connection terminal having a holding part for holding and joining a material to be joined to one end or both ends of the connection terminal, wherein the projection is arranged in the holding part. The connection terminal according to claim 3,
The shape of the clamping part is a cylinder or a rectangle,
A connection terminal characterized in that a notch is provided at an end of the clamping part. The connection terminal according to claim 4, wherein the presence or absence of a brazing material resistance-welded to the inner peripheral surface of the holding portion provided in the connection terminal can be seen by the notch.   A rotating electrical machine comprising the connection terminal according to claim 1.

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