SPECIAL- SHAPED JOINT

Abstract

A special-shaped joint includes at least one connection terminal (1) for connecting an electrical device, and at least one wire (4). The connection terminal is connected to a core (2) of the wire. The special-shaped joint has a simple structure and is easy to assemble. An included angle between the connection terminal and the core is greater than 0 degree and smaller than 180 degrees, so that the special-shaped joint can be applied to an electrical device with a specific connection requirement for the included angle between the connection terminal and the wire, thus having a wide application range.

Claims

1. A special-shaped joint comprising at least one connection terminal for connecting an electrical device and at least one wire, with the connection terminal being connected to a core of the wire, and an included angle between the connection terminal and the core being greater than 0 degree and smaller than 180 degrees.

2. The special-shaped joint according to claim 1, wherein the material of the core is aluminum, aluminum alloy, copper or copper alloy.

3. The special-shaped joint according to claim 1, wherein the core is a single solid conductor or a multi-core conductor.

4. The special-shaped joint according to claim 1, wherein the angle between the connection terminal and the core is 90 degrees.

5. The special-shaped joint according to claim 1, wherein the core is a single solid conductor, and the solid conductor and the connection terminal are connected by one selected from the group consisting of friction welding, resistance welding, ultrasonic welding, electromagnetic welding, pressure diffusion welding, arc welding, and laser welding.

6. The special-shaped joint according to claim 1, wherein the core is a multi-core conductor, and the multi-core conductor having a hard structure is connected to the connection terminal by one selected from the group consisting of friction welding, resistance welding, ultrasonic welding, electromagnetic welding, pressure diffusion welding, arc welding, and laser welding.

7. The special-shaped joint according to claim 6, wherein the hard structure is formed from the multi-core conductor by one or more selected from the group consisting of ultrasonic welding, resistance welding, pressure diffusion welding, explosive welding, fusion welding, electromagnetic welding, arc welding, and laser welding.

8. The special-shaped joint according to claim 7, wherein the hard structure also includes a transfer terminal for connecting the multi-core conductor, and the hard structure is formed from the multi-core conductor and the transfer terminal by one or more selected from the group consisting of crimping, ultrasonic welding, resistance welding, pressure diffusion welding, explosive welding, fusion welding, electromagnetic welding, arc welding, and laser welding.

9. The special-shaped joint according to claim 8, wherein the transfer terminal is of a cylindrical structure, a U-shaped structure, a ring structure, or a flat plate structure.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 is a structural schematic of a first exemplary embodiment of a special-shaped joint according to the present disclosure;

[0013] FIG. 2 is a structural schematic of a second exemplary embodiment of a special-shaped joint according to the present disclosure;

[0014] FIG. 3 is a structural schematic of a third exemplary embodiment of a special-shaped joint according to the present disclosure;

[0015] FIG. 4 is a structural schematic of a fourth exemplary embodiment of a special-shaped joint according to the present disclosure;

[0016] FIG. 5 is a structural schematic of a fifth exemplary embodiment of a special-shaped joint according to the present disclosure;

[0017] FIG. 6 is a structural schematic of a transfer terminal of FIG. 5.

REFERENCE NUMERALS

[0018] 1. connection terminal; 2. core; 3. insulation layer; 4. wire; 5. transfer terminal.

DETAILED DESCRIPTION

[0019] In order to further illustrate the technical features and effect of the present disclosure for achieving the intended objective of the present disclosure, specific embodiments, structures, features and functions thereof according to the present disclosure will now be described in detail with reference to the drawings and exemplary embodiments.

The First Embodiment

[0020] FIG. 1 shows a first exemplary embodiment of the special-shaped joint according to the present disclosure, including at least one connection terminal 1 for connecting an electrical device and at least one wire 4. The connection terminal 1 is connected to a core 2 of the wire 4, and an included angle between the connection terminal 1 and the core 2 is greater than 0 degree and smaller than 180 degrees. The special-shaped joint of the present disclosure has a simple structure and is easy to assemble, and can be applied to an electrical device with a specific connection requirement for the included angle between the connection terminal 1 and the wire 4, thus having a wide application range.

[0021] It should be noted that, in the present disclosure, the included angle between the connection terminal 1 and the core 2 is any angle value between 0° and 180° (not including end point values). As an example, (a) to (e) of FIG. 1 respectively show structural schematics of the special-shaped joint with the angle between the connection terminal 1 and the core 2 being 90°, 30°, 60°, 120° and 135°. In actual use, the angle between the connection terminal 1 and the core 2 of the special-shaped joint can be set according to actual installation requirements of the electrical device and the special-shaped joint.

[0022] In this embodiment, the number of the connection terminal 1 and the number of the wire 4 are both one.

[0023] As a further exemplary technical solution, the material of the core 2 is aluminum, aluminum alloy, copper or copper alloy. This is because copper and aluminum are both excellent electrical conductor materials, wherein (1) the resistivity of copper is 1.75×10-8Ωm, which is second only to silver among the commonly used conductive metals in nature, therefore, the cores of most wires are made of copper; however, since the material of pure copper is soft and has poor mechanical properties, as a more exemplary solution, the material of the core 2 is a copper alloy; (2) the resistivity of aluminum is 2.83×10-8Ωm, and aluminum is lighter and cheaper than copper; however, since the material of pure aluminum is soft and has poor mechanical properties, as a more exemplary technical solution, the material of the core 2 is an aluminum alloy.

[0024] In this embodiment, the core 2 is a single solid conductor. Moreover, the solid conductor and the connection terminal 1 are connected by one selected from the group consisting of friction welding, resistance welding, ultrasonic welding, electromagnetic welding, pressure diffusion welding, arc welding, and laser welding, which will be described below.

[0025] (1) The friction welding is to perform welding using friction welding equipment, which rotates a first workpiece and causes a second workpiece to apply pressure to the rotating first workpiece, so heat is generated by friction and the first and second workpieces are welded together by the pressure, thereby having advantages of fast welding speed without pollution such as noise, smoke, and strong light.

[0026] (2) The resistance welding uses resistance heat generated by the current passing through weldments and the contact place thereof as a heat source to heat the weldments locally, and at the same time, pressure is applied for welding. The advantages are that no filler metal is required, the productivity is high, the deformation of the weldment is small, and the automation is easy to realize.

[0027] (3) The ultrasonic welding is to transmit high frequency vibration waves to surfaces of two objects that need to be welded. Under pressure, fusion between the molecular layers is formed by rubbing the surfaces of the two objects against each other, which has the advantages of short welding time, no need of any flux, gas, solder, no spark for welding, environmental protection and safety.

[0028] (4) The electromagnetic welding is to generate a strong magnetic field by utilizing instantaneous electric current, such that weldments are welded together under the action of magnetic field force, which has the advantages of non-contact welding, high welding speed, low welding internal stress and high machining precision.

[0029] (5) The pressure diffusion welding is to press two weldments together, and metallurgically connect the weldments by interatomic diffusion through heat preservation, which has advantages that the weldments are not overheat or melted, the quality of the welding joint is high, a large-area weldment can be welded, the welding precision of the weldments is high, and the deformation is small.

[0030] (6) The arc welding is a physical phenomenon using an electric arc as a heat source and discharging electricity utilizing air, to convert the electric energy into the heat and mechanical energy required for welding, so as to achieve the purpose of connecting metal. The arc welding has advantages that the welding environment is not limited, and it is suitable for welding weldments with various metal materials, various thicknesses and various structural shapes. Plasma welding, as a kind of arc welding, can be used to realize precise welding. The plasma arc has concentrated energy, high productivity, fast welding speed, small stress deformation and more stable arc.

[0031] (7) The laser welding is to perform welding by using heat generated by bombarding the weldment with a focused laser beam as an energy source. Due to the optical properties of laser, such as refraction and focusing, laser welding is very suitable for the welding of micro parts and parts with poor accessibility.

[0032] As an exemplary technical solution, as shown in FIG. 1 (a), the angle between the connection terminal 1 and the core 2 is 90 degrees. In the special-shaped joint disclosed by the present disclosure, the connection terminal 1 and the core 2 may be vertically connected by one selected from the group consisting of friction welding, resistance welding, ultrasonic welding, electromagnetic welding, pressure diffusion welding, arc welding, and laser welding. Therefore, the angle between the connection terminal 1 and the core 2 of the special-shaped joint can achieve higher accuracy. Moreover, the special-shaped joint does not need to be subjected to bending treatment, so it has a longer service life compared with the connection terminal with 90 degrees in the prior art.

[0033] In order to demonstrate the influence of the connection terminal with 90 degrees formed by bending in the prior art and the special-shaped joint with 90 degrees in the present disclosure on mechanical properties and electrical properties of the wire harness joint, the inventor has conducted a series of experiments on the mechanical properties, electrical properties and service life of the wire harness joints including the above two different connection terminals respectively and the same kind of wires. The experimental results are shown in Table 1.

TABLE-US-00001 TABLE 1 the influence of the connection terminal with 90 degrees formed by bending and the special-shaped joint with 90 degrees on the pulling force and voltage drop of the wire harness joints Terminal type Connection Novel special- Connection Novel special- terminal with shaped joint with terminal with shaped joint with 90 degrees 90 degrees 90 degrees 90 degrees State After wire harness joint is made After aging test for 6000 hours Pulling Voltage Pulling Voltage Pulling Voltage Pulling Voltage force drop force drop force drop force drop Test (N) (mV) (N) (mV) (N) (mV) (N) (mV) 1 2645 0.36 3125 0.31 2156 0.43 2686 0.37 2 2561 0.34 3086 0.32 2138 0.46 2743 0.38 3 2772 0.36 3145 0.31 2182 0.45 2756 0.35 4 2744 0.38 3258 0.31 2162 0.46 2835 0.36 5 2642 0.36 3182 0.32 2084 0.43 2846 0.38 6 2665 0.38 3143 0.31 2126 0.46 2913 0.37 7 2785 0.37 3244 0.33 2067 0.45 2694 0.36 8 2556 0.36 3081 0.29 2085 0.44 2789 0.36 9 2683 0.37 3168 0.30 2164 0.45 2775 0.38 10 2659 0.37 3192 0.31 2187 0.46 2864 0.35 Average 2671.2 0.37 3163.1 0.311 2135.1 0.449 2790.1 0.366 value

[0034] From the results of the above Table 1, the pulling force of the wire harness joint including the connection terminal with 90 degrees that is formed by bending in the prior art is significantly lower than that of the wire harness joint including the special-shaped joint with 90 degrees of the present disclosure. Moreover, after aging test for 6000 hours, the pulling force value of the wire harness joint including the connection terminal with 90 degrees that is formed by bending in the prior art is reduced, and the voltage drop value is increased, and unqualified products are prone to appear, which may result in function failure of the wire harness joint.

[0035] However, the pulling force value and the voltage drop value of the wire harness joint including the special-shaped joint with 90 degrees of the present disclosure still meet the requirements of mechanical and electrical properties of the wire harness joint, and can ensure the function of the wire harness joint to be stable and reliable.

[0036] In this embodiment, as shown in FIG. 1, the connection terminal 1 is a hollow cylinder, and the cross section of the internal cavity of the connection terminal 1 is circular or oval or polygonal or special-shaped, such that the special-shaped joint can be connected with electrical devices having different plug ends. Moreover, if the cross section of the internal cavity of the connection terminal 1 is circular, the inner wall of the internal cavity of the connection terminal 1 is smooth or provided with an internal thread.

[0037] In specific connection, if the plug end of the electrical device is a cylinder with a smooth outer wall, the cross section of the internal cavity of the connection terminal 1 is circular, and the inner wall of the internal cavity is smooth. If the plug end of the electrical device is a cylinder with external thread on the outer wall, the cross section of the internal cavity of the connection terminal 1 is circular, and the inner wall of the internal cavity is provided with internal threads matching the external threads. If the plug end of the electrical device is a regular prism, the cross section of the internal cavity of the connection terminal is a regular polygon matching the regular prism.

The Second Embodiment

[0038] As shown in FIG. 2, the difference between the present embodiment and the first embodiment is only that the connection terminal 1 is a solid cylinder with a circular, elliptical, polygonal, or special-shaped cross section.

[0039] In specific connection, if the plug end of the electrical device is a circular plug groove with a smooth inner wall, the connection terminal is a cylinder with a circular cross section and a smooth outer wall. If the plug end of the electrical device is a circular plug groove whose inner wall is provided with internal threads, the connection terminal is a cylinder, and the external surface of the connection terminal is provided with external threads matching the internal threads. If the connection terminal is a regular prism, the plug end of the electrical device is a plug groove matching the regular prism.

The Third Embodiment

[0040] The difference between this embodiment and the second embodiment only lies in that, as shown in FIG. 3, the number of the connection terminals 1 and the wires 4 is in plural, such as 2, 3, etc., and the specific number can be set according to the actual demand of the electrical device.

[0041] In addition, FIG. 3 only shows the structural schematic diagram of the special-shaped joint with the angle between the connection terminal 1 and the core 2 being 90 degrees. The included angle between the connection terminal 1 and the core 2 is any angle value between 0° and 180° (not including end point values), and can be set according to the actual installation requirements of the electrical device and the special-shaped joint.

[0042] As an example, as shown in (a) of FIG. 3, the number of the connection terminals 1 is two. Alternatively, as shown in (b) of FIG. 3, the number of the connection terminal 1 is one, and the connection terminal 1 is located in the middle of the wire 4.

The Fourth Embodiment

[0043] The difference between this embodiment and the second embodiment only lies in that, as shown in FIG. 4, the core 2 is a multi-core conductor, and the multi-core conductor having a hard structure is connected to the connection terminal 1 by one selected from the group consisting of friction welding, resistance welding, ultrasonic welding, electromagnetic welding, pressure diffusion welding, arc welding, and laser welding.

[0044] And, the hard structure is formed from the multi-core conductor by one or more selected from the group consisting of ultrasonic welding, resistance welding, pressure diffusion welding, explosive welding, fusion welding, electromagnetic welding, arc welding, and laser welding.

The Fifth Embodiment

[0045] The difference between this embodiment and the fourth embodiment only lies in that, as shown in FIG. 5, the hard structure also includes a transfer terminal 5 for connecting the multi-core conductor, and the hard structure is formed from the multi-core conductor and the transfer terminal 5 by one or more selected from the group consisting of crimping, ultrasonic welding, resistance welding, pressure diffusion welding, explosive welding, fusion welding, electromagnetic welding, arc welding, and laser welding.

[0046] When connecting the multi-core conductor and the transfer terminal 5, firstly the transfer terminal 5 and a plurality of thin wires of the multi-core conductor are formed into the hard structure by one or more selected from the group consisting of crimping, ultrasonic welding, resistance welding, pressure diffusion welding, explosive welding, fusion welding, electromagnetic welding, arc welding, and laser welding. In the hard structure, the distance between two adjacent thin wires is not greater than the diameter of the thin wire.

[0047] As shown in FIG. 6, the transfer terminal 5 is of a cylindrical structure, U-shaped structure, ring-shaped structure, or flat plate structure.

[0048] (1) As shown in (a) of FIG. 6, if the transfer terminal 5 is of a cylindrical structure, the core 2 of the wire 4 may be inserted into the internal hollow body of the transfer terminal 5; and then, by means of crimping or welding, the transfer terminal 5 is connected with the core 2. If the transfer terminal 5 is of a cylindrical structure, the transfer terminal 5 can be completely closed and connected to the core 2, so as to obtain a large contact area, strong connection, and good conductive effect.

[0049] (2) As shown in (b) and (c) of FIG. 6, if the transfer terminal 5 is of a U-shaped or ring-shaped structure, the core 2 of the wire 4 may be inserted into the transfer terminal 5, or the core 2 of the wire 4 may also be placed into the transfer terminal 5 through the opening of the transfer terminal 5, and then the core 2 and the U-shaped or ring-shaped connection terminal are connected together by crimping or welding, which has high production efficiency and stable connection, thereby reducing production cost and improving production quality.

[0050] (3) As shown in (d) of FIG. 6, if the transfer terminal 5 is of a flat plate structure, the transfer terminal 5 and the core 2 are connected together by welding, which has simple structure, processing convenience, fast and convenient welding, high connection quality, and is suitable for metal connection of different materials.

[0051] The above embodiments are only exemplary embodiments of the present disclosure, and the scope of protection of the present disclosure is not limited thereto. Any non-essential changes and substitutions made by those skilled in the art on the basis of the present disclosure are within the scope of the claimed invention.