Conductor Wire Connecting Method, and Connecting Terminal, Stator, and Rotary Electric Machine

• US 20090315419A1
• Filed: 05/26/2009
• Published: 12/24/2009
• Est. Priority Date: 06/18/2008
• Status: Active Grant

• Current Assignee: Hitachi Astemo Ltd. (Hitachi, Ltd.)
• Original Assignee: Hitachi, Ltd.
• Inventors: Saito, Yuji, Mita, Toru
• Granted Patent: US 8,153,899 B2
• Time in Patent Office: Days
• US Class Current: 310/71
• CPC Class Codes: H01R 4/20 using a crimping sleeve H01R4/01 takes precedence
• CPC Class Codes: H01R 43/05 with wire-insulation stripping
• CPC Class Codes: Y10T 29/49179 by metal fusion bonding
• CPC Class Codes: Y10T 29/49185 of terminal
• CPC Class Codes: Y10T 29/49201 with overlapping orienting
• CPC Class Codes: Y10T 29/53235 Means to fasten by deformation

Abstract

After melted enamel coating is discharged from the crimping connectors, electrical wire-to-wire connection, that is, the fusion process, is carried out inside the crimping connector. In this conductor connection method based on the fusion process, plural the above enamel-coated conductor wires are inserted in the above crimping connector prior to the start of the fusion process. Further, the temporary crimping process which provides the crimping connector a temporary crimping by mechanical pressurizing means is also a part of entire process. Addition of force at both the end parts or either one of them of the cross-section orthogonal to the axis of the above crimping connector may cause expansion, which needs to be suppressed with external fore. At the same time, the areas of cross-section corresponding to both the end parts or either of them mentioned above should preferably be held as small as possible. The above temporary crimping is applied to the above crimping connector for this purpose.

Claims

1. An electric conductor wire connecting method comprising the steps of:

inserting a plurality of enamel-coated conductor wires into a tube-shaped crimping connector, a connection component;

heating and crimping the enamel-coated conductor wires by pinching, and pressing, with electrodes and electrifying the crimping connector;

pressing and deforming the crimping connector and the enamel-coated wires simultaneously; and

discharging melted enamel coating from the crimping connector,

wherein the method includes;

a fusing process wherein the conductor wires are electrically connected altogether in the crimping connector; and

a temporary crimping process wherein prior to the fusing process, a plurality of the enamel-coated conductor wires are inserted in the crimping connector and by mechanical pressurizing means temporary crimping is applied to the crimping connector, and

wherein with respect to the cross-section of the crimping connector orthogonal to the axis of the crimping connector, temporary crimping applied to the crimping connector is utilized to suppress possible expansion in area due to external force given to both the end parts or either one of them in the cross-section while trying also to keep the area of both the end parts or either of them of the cross section as small as possible

2. The conductor wire connecting method according to claim 1, wherein a temporary crimping process of the crimping connector is performed such that both the end parts or either of them of the cross-section of the crimping connector is made to become slimmer toward outside or dented toward inside while the remaining portion is made flat.

3. The conductor wire connecting method according to claim 1, wherein the crimping connector which has a tubular shape originally is pressed and deformed into a hexagonal shape through the crimping process carried out by a pair of mold with its pressing face having a cross-section of trapezoidal concave, and subsequently in the fusing process, pressure is further applied to the hexagonal shape by means of the pair of electrodes having flat pressing faces.

4. The conductor wire connecting method according to claim 1, wherein the enamel-coated conductor wire is one of the two sets of conductor wire for connection to the neutral point as well as to be connected with the fellow lead wires for connection to the neutral point of the windings of respective phases in a polyphase rotary electric machine and, in the twisted state, is to be arranged in both the end parts of the cross-section of the crimping connector, as if guarding the other lead wires for the use for neutral point, and further to be servicing for the temporary crimping process and the fusing process accompanied by pressurization and electrification.

5. A connecting terminal comprising:

a plurality of enamel-coated conductor wires; and

crimping connectors as the connection components used for electrically connecting the enamel-coated conductor wires with the mating target of electrical conductor wires,

wherein the enamel-coated conductor wires along with the connection mate of electrical conductor wires are inserted together into the crimping connector and made to undergo the fusing process for electrical connection;

the crimping connector, pressurized and formed, having a mixture of flattened as well as tubular shape;

the cross-section of the crimping connector orthogonal to its axis having both the end parts or either of them jetting out slimly toward outside forming an acute angle or being dented inward.

6. The connecting terminal according to claim 5, wherein the crimping connector has a flattened cross-section in a hexagonal shape.

7. The connecting terminal according to claim 5, wherein a plurality of enamel-coated conductor wires are twisted and located in both the end parts or either of them of the cross-section of the crimping connector.

8. The connecting terminal according to claim 5,

wherein the enamel-coated conductor wire is one of the two sets of the conductor wires for connection to the neutral point as well as to be connected with the fellow lead wires of the windings of respective phases in a polyphase rotary electric machine;

and

wherein the enamel-coated wires being in twisted state are to be arranged in both the end parts of the cross-section of the crimping connector, holding in between, as if embracing, the other lead wires for the use for neutral point.

9. A stator, wherein the stator of the polyphase rotary electric machine has its windings provided with the connecting terminals according to claim 8.

10. A rotary electric machine, wherein the polyphase rotary electric machine has the stator claimed in claim 9.