JP3971138B2

JP3971138B2 - Connection method for all-around crimping connection terminals

Info

Publication number: JP3971138B2
Application number: JP2001223974A
Authority: JP
Inventors: 康路 ▲桑▼山; 俊弘 ▲槙▼
Original assignee: Yazaki Corp
Current assignee: Yazaki Corp
Priority date: 2001-07-25
Filing date: 2001-07-25
Publication date: 2007-09-05
Anticipated expiration: 2021-07-25
Also published as: JP2003036898A

Description

【０００１】
【発明の属する技術分野】
本発明は、ロータリスウェージ加工機を用いて電線接続部に電線の芯線部を全周に渡って均一に加締め接続させる全周加締め接続用端子の接続方法に関するものである。
【０００２】
【従来の技術】
従来、電源用や電気自動車用等の大径の電線に対して、その芯線部を円筒状の電線接続部内に挿入した状態で周方向等配に加締める形態の端子が採用されている。図８は、その端子の一形態として、特公昭５０−４３７４６号公報に記載された加締め接続用端子の電線接続部４１を上下一対の加締め型４２，４２で六角形状に加締めて電線の芯線部４３に接続させる状態を示すものである。
【０００３】
各加締め型４２の各辺には突部４４が設けられ、端子の電線接続部４１は加締め型４２の各辺で六角形状に加締められると共に、各突部４４で電線径方向に押圧されて、凹んだ状態に加締められる。これにより、端子と電線との電気的接続と固定とが行われる。端子の他方には、相手側の雄端子（図示せず）に対する雌型の電気接触部（図示せず）が設けられている。
【０００４】
【発明が解決しようとする課題】
しかしながら、上記従来の加締め接続用端子とその接続方法（接続構造）にあっては、上下方向すなわち一対の加締め型４２の押圧方向の加締め力Ｐ₁が大きいのに対し、左右両側の加締め力Ｐ₂が減少しやすく、それによって端子の接続部の両側部分で電線の芯線部４３との間に隙間を生じやすく、電気的接触性が悪化するという懸念があった。その場合には、電気抵抗が増大し、通電効率が落ちると共に、接続部が加熱するといった問題を生じてしまう。
【０００５】
これらの問題を解消すべく、本出願人は先に特願２０００−３１７９８２で
スウェージ加工で全周加締め接続用端子（図示せず）の電線接続部を全周に渡って均一に加締める方法を提案しているが、スウェージ加工等によって電線の芯線部と端子の電線接続部との電気的接触性をさらに向上させると共に、電線の固定強度を向上させるべく、全周加締め接続用端子とその接続方法の改良が切望されていた。
【０００６】
本発明は、上記した点に鑑み、スウェージ加工等による全周加締めで電線の芯線部との電気的接触性及び固定強度を高めることのできる形態の全周加締め接続用端子とその接続方法を提供することを目的とする。
【０００７】
【課題を解決するための手段】
上記目的を達成するために、本発明の請求項１に係る全周加締め接続用端子の接続方法は、電線挿入孔とその周壁及び底壁とを有する電線接続部を備え、該底壁から該電線挿入孔の中心に電線長手方向の接触用突部が設けられた全周加締め接続用端子を用いて、該電線挿入孔に電線の芯線部を挿入し、該接触用突部を該芯線部の内部に進入させた状態で、ロータリスウェージ加工機で該電線接続部を該接触用突部に向けて径方向に全周に渡って均一に加締めることで、該芯線部の各素線を該接触用突部の外周面に強く押圧密着させることを特徴とする。
上記構成により、電線挿入孔内に電線の芯線部（複数本の素線で構成されている）を挿入した際に、芯線部内に接触用突部が進入し、その状態で全周加締め手段で電線接続部を全周に渡って均一に径方向に加締めることで、芯線部の各素線が接触用突部の外周面に強く押圧されて密着し、芯線部と電線接続部との接触面積が増大する。芯線部は電線接続部と接触用突部との間の環状の空間内で強く挟持固定される。また、接触用突部が前記電線挿入孔の中心に位置することで、全周加締め手段で電線接続部を加締めた際に、接触用突部が芯線部を介して全周に渡って均一に押圧され、接触用突部と芯線部の各素線とが隙間を生じることなく均一な力で密着する。
【０００９】
本発明の請求項２に係る全周加締め接続用端子の接続方法は、請求項１に係る全周加締め接続用端子の接続方法において、前記接触用突部を円柱状に形成したことを特徴とする。
上記構成により、芯線部の各素線の中心と接触用突部の中心と、素線と接触用突部との接点とが同一直線上に位置し、各素線が接触用突部の全周に渡って径方向に均一な力で密着する。
【００１０】
本発明の請求項３に係る全周加締め接続用端子の接続方法は、請求項１又は２に係る全周加締め接続用端子の接続方法において、前記接触用突部を前記電線挿入孔の１／３程度の初期長さとしたことを特徴とする。
上記構成により、電線挿入孔に芯線部を挿入した際に、芯線部内に接触用突部が各素線を分けてスムーズに進入し、且つ電線接続部の全周加締め時に接触用突部が各素線で径方向に押圧されて電線接続部と共に軸方向に伸長し、初期の電線挿入孔の１／２程度の長さになり、芯線部との十分な接触長さが確保される。
【００１２】
【発明の実施の形態】
以下に本発明の実施の形態を図面に基づいて詳細に説明する。
図１（ａ）（ｂ）は、本発明に係る全周加締め接続用端子の一実施形態を示すものである。電線は接続前の挿入状態を鎖線で示している。
【００１３】
この全周加締め接続用端子１は、好ましくは銅やアルミ及びそれらの合金を材料として、長手方向の一方に円筒状の電線接続部２、他方に相手側の雄端子（図示せず）に対する円筒形の電気接触部３をそれぞれ形成し、それらの境部にくびれた小径部４を形成すると共に、電線接続部２の断面円形の電線挿入孔（内部空間）５の中央に円柱形の小径な接触用突部６を底面７ａから一体に突出形成したことを特徴とするものである。
【００１４】
電線接続部２は円筒形の周壁８と、周壁８に続く小径部４の内側の基壁（底壁）７とで構成され、基壁７の底面７ａの中央に接触用突部６が突設されている。接触用突部６の軸中心は電線接続部８の軸心すなわち電線挿入孔５の中心と一致している。
【００１５】
一例として、電線接続前における電線挿入孔５の長さ（深さ）Ｌは１５ｍｍ、接触用突部６の長さＨは電線挿入孔５の長さＬの１／３である５ｍｍ、周壁８の外径は１１ｍｍ、周壁８の内径は７ｍｍ、接触用突部６の外径は周壁８の肉厚と同じ２ｍｍに設定される。
【００１６】
これはあくまでも一例であり、電線径の大小に応じて各部の寸法は適宜設定される。但し、接触用突部６の長さは電線挿入孔５の長さ以下であることが必要であり、好ましくは電線挿入孔５の長さの半分以下、電線挿入孔５の長さの１／３程度であることが、電線接続部２内への電線１０の芯線部１１の挿入性及び芯線部１１と接触用突部６との接触性の観点から好ましい。
【００１７】
電線１０の芯線部１１は必要に応じて予め撚りをほぐしておき、あるいは撚りのない芯線部１１を使用し、好ましくは芯線部１１の先端を末広がりに広げておくことで、接触用突部６が芯線部１１内にスムーズに進入可能である。電線接続部２の開口内周縁にはテーパ状のガイド面取り１３を形成しておき、必要に応じて内面テーパ状のガイド治具（図示せず）を用いて、電線接続部２内にスムーズに末広がりの芯線部１１を挿入可能である。
【００１８】
接触用突部６の加工方法としては、一例として、先ず大径のドリル（図示せず）を用いて電線接続部２の電線挿入孔５を長手方向中間部まで切削加工し、次いで小径のドリル（図示せず）を用いて電線接続孔５を基壁７の底面７ａまで環状に切削加工し、環状の空間５ａの内側に円柱状の接触用突部６を形成させる。その他、鋳造や鍛造等の手法で電線接続部２内に接触用突部６を一体成型することも可能である。
【００１９】
以下に全周加締め接続用端子１の接続方法の一形態を説明する。
先ず、図１に鎖線で示す如く電線１０の芯線部１１を端子１の電線接続部２内に挿入する。電線１０は絶縁被覆電線であり、銅製の芯線部１１と、芯線部１１を覆う絶縁樹脂製の被覆部１２とで構成されている。芯線部１１は複数本の素線で構成されている。所望長さに切断された電線１０の端末の絶縁被覆部１２をカッタ等で皮剥きして芯線部１１の一部を露出させ、その露出部を電線接続部２内に挿入する。
【００２０】
その状態で回転鍛造機であるロータリスウェージ加工機を用いて電線接続部２を全周に渡って均一に電線径方向に加締める。図２にロータリスウェージ加工機の加工部１５の一形態を示す。このロータリスウェージ加工による接続方法は先に出願人が特願２０００−３１７９８２で提案したものであり、図２で符号２は端子１の円筒状の電線接続部、１１は電線１０の芯線部、１６は外周リング、１７はローラ、１８はスピンドル、１９はハンマ（バッカ）、２０はダイスをそれぞれ示している。
【００２１】
図２で図示しないモータの駆動でスピンドル１８が回転し、それに伴ってダイス２０とハンマ１９が矢印Ｃ方向に一体に回転し、ハンマ１９の山型のカム面１９ａの頂部がローラ１７に接した時に、ダイス２０が矢印Ｄの如く内向きに閉じて端子１の電線接続部２を径方向に叩き（圧縮し）、カム面１９ａの裾部がローラ１７に接しつつダイス２０が遠心力で矢印Ｅの如く外側に開く。
【００２２】
この動作が短いピッチで繰り返されることにより、電線接続部２の加締めが全周に渡って均一に行われ、電線１０の芯線部１１に対して電線接続部２の内向きの内部応力が均一に作用する。これにより、芯線部１１を構成する各素線がほぼハニカム状に変形して相互に隙間なく密着し、且つ芯線部１１と電線接続部２との間が隙間なく周方向に均一に密着する。
【００２３】
上記ロータリスウェージ加工機はあくまでも一形態であり、例えばハンマ１９やダイス２０の数を上下一対にしたり、ボール１７の数を増やしたりすることは適宜行われる。また、これらロータリスウェージ加工は接続方法の一例であり、それ以外の手法で端子１と電線１０を全周方向から塑性変形させて加圧接続するようにしてもよい。
【００２４】
図２のスウェージ加工で端子１と電線１０を接続した状態を図３に示す。
図３の如く端子１の電線接続部２は径方向に圧縮されて図１（ｂ）の初期状態よりも小径化されると共に、長手方向に伸長して電線接続部２の全長Ｌ₁が少し長くなる。電線１０の芯線部１１は電線接続部２の周壁８で径方向に圧縮され、それに伴って中心の接触用突部６が径方向に圧縮されてやや小径化されつつ長手方向に延ばされる。接触用突部６の長さＨ₁は例えば初期の電線挿入孔５の長さＨの１／２程度になる。接触用突部６の外周面に芯線部２の各素線が食い込むようにして密着し、芯線部１１に対する接触面積が増大すると共に、電線１０の機械的な抜き出し強度が高まる。
【００２５】
これにより、接触用突部６を用いない周壁８だけの電線接続部２の場合に較べて電気抵抗が低減され、通電効率が高まると共に、電線１０の引張力に対する電線固定力が高まり、電気的接続の信頼性が向上する。
【００２６】
図４（ａ）の如く接触用突部６を用いた場合と図４（ｂ）の如く接触用突部６を用いない場合とで、電線１０の芯線部１１に対する電線接続部２，２’の接触面積を同一とした場合には、接触用突部６の表面積の分だけ周壁８の長さをＬ₃からＬ₂の如く短くすることができ、端子１の全長の短縮による小型化が可能となる。図４（ｂ）の電線接続部２’の長さＬ₃よりも図４（ａ）の電線接続部２の長さＬ₂を短く設定できる訳である。
【００２７】
上記実施形態においては、接触用突部６を円柱形として、芯線部１１の各素線との密着性を高めているが、接触用突部６を四角柱や三角柱等の角柱形とすることも可能である。また、接触用突部６の先端をテーパ状に尖らせて、芯線部１１内への挿入性を高めることも可能である。また、電線接続部２内に電線１０の芯線部１１と絶縁被覆部１２とを同時に挿入した状態で全周加締めすることも可能である。この場合は、電線接続孔５を二段に形成することが好ましい。
【００２８】
図５（ａ）は本発明に係る全周加締め接続用端子の他の実施形態（参考例）を図５（ｂ）の既存例（特願２０００−３１７９８２で提示のもの）と比較して示すものである。（ａ）（ｂ）共に電線を加締め接続する前の端子の初期状態を示している。
【００２９】
図５（ａ）の全周加締め接続用端子２１は、図５（ｂ）の全周加締め接続用端子２２に較べて電線接続部２３内の電線挿入孔２４の底部のテーパ部２５が深いことを特徴とするものである。テーパ部２５は円錐形に形成され、周壁２６の内周面に交差して続いている。テーパ部２５と周壁２６の内周面との交差角θは例えば６０゜程度ないしそれ以上であることが好ましい。
【００３０】
通常、孔明け用のドリル（図示せず）の刃先角度（交差角に対応する角度）は３０゜程度であるから、特殊形状のドリルを用いてテーパ部２５を加工するか、あるいは鍛造や鋳造で電線挿入孔２４と一体的にテーパ部２５を形成することが好ましい。既存の端子２２のテーパ部２５’の交差角度θ₁は３０゜程度である。
【００３１】
テーパ部２５は後半の電線接続部２３と前半の電気接触部２７との境の小径な基壁２８に穿設されている。電気接触部２７は内部に相手側の雄端子（図示せず）に対する例えば別体の弾性接触部（図示せず）を有している。この構成は前記図１の実施形態と同様である。
【００３２】
図５（ａ）の端子２１の電線接続部２３を前述のロータリスウェージ加工機の加工部１５（図２）で全周に渡って均一に圧縮すると、図６（ａ）の如く電線２９の芯線部３０が電線接続部２３のテーパ部２５内に進入し、芯線部３０が矢印Ｆの如く軸方向の前後両側に伸長する。
【００３３】
図５（ｂ）の端子２２の電線接続部２３’を同じくロータリスウェージ加工機で全周に渡って均一に圧縮した場合には、図６（ｂ）の如く電線２９の芯線部３０の先端３０ａがすぐに電線挿入孔２４のテーパ部２５’の底面に当接し、芯線部３０の伸びが矢印Ｆの如く一方向（電線挿入孔２４’の開口方向）のみに規制される。
【００３４】
このように、図６（ａ）の形態によれば、芯線部３０が電線接続部２３と一体的に軸方向の前後両側に伸びるから、図６（ｂ）の形態に較べて芯線部３０と電線接続部２３との接触面積が増大し、前記実施形態と同様に電気抵抗が低減され、通電効率が高まり、電気的接続の信頼性が向上する。
【００３５】
そして、図７（ａ）（ｂ）の如く、深いテーパ部２５の電線挿入孔２４を有する電線接続部２３と、浅いテーパ部２５’ないしは全くテーパ部のない電線挿入孔２４’を有する電線接続部２３’とを電線２９の芯線部３０に同一の接触面積で接触させた場合に、図７（ａ）の如く深いテーパ部２５の電線接続部２３の長さＧを図７（ｂ）の電線接続部２３の長さＧ₁よりも短くすることができ、端子２１の長手方向の小型化を図ることができる。
【００３６】
なお、図１の接触用突部６を用いた電線接続部２に図５の深いテーパ部２５を形成するようにすることも可能である。この場合、テーパ部２５の最も深い底部から接触用突部６が電線長手方向に突出することになる。この形態によれば、二つの実施形態の相乗効果で電線１０の芯線部１１に対する電線接続部２の接触面積が一層増大し、上記実施形態の効果が一層確実に発揮される。
【００３７】
【発明の効果】
以上の如く、請求項１記載の発明によれば、電線挿入孔内に電線の芯線部を挿入した際に、芯線部内に接触用突部が進入し、その状態で全周加締め手段で電線接続部を全周に渡って均一に径方向に加締めることで、芯線部の各素線が接触用突部の外周面に強く押圧されて密着し、芯線部と電線接続部との接触面積が増大するから、端子と電線との接続部の電気抵抗が低減され、通電効率が高まり、より高い電圧の電流を流すことができるようになる。また、芯線部に対して既存の全周加締め接続用端子と同じ接触面積とすれば、接触用突部の接触面積の分だけ電線接続部の長さを短くでき、端子の長手方向の小型化が可能となる。また、芯線部が電線接続部と接触用突部との間の環状の空間内で挟持されるから、電線の固定力が増大し、たとえ電線に強い引張力が作用しても、芯線部が電線接続部から抜け出すことがない。これらにより、電気的接続の信頼性が向上する。
【００３８】
また、全周加締め手段で電線接続部を加締めた際に、接触用突部が芯線部を介して全周に渡って均一に押圧され、接触用突部と芯線部の各素線とが隙間を生じることなく均一な力で密着するから、接触用突部を無理に変形させたり、素線を破断させることなく、電気的接続の信頼性を高めることができる。
【００３９】
請求項２記載の発明によれば、芯線部の各素線の中心と接触用突部の中心と、素線と接触用突部との接点とが同一直線上に位置し、各素線が接触用突部の全周に渡って径方向に均一な力で隙間なく密着するから、電気的接続の信頼性が高まる。
【００４０】
請求項３記載の発明によれば、電線挿入孔に芯線部を挿入した際に、芯線部内に接触用突部が各素線を分けてスムーズに進入するから、接続作業が容易化する。また、電線接続部の全周加締め時に接触用突部が各素線で径方向に押圧されて電線接続部と共に軸方向に伸長し、初期の電線挿入孔の１／２程度の長さになり、芯線部との十分な接触長さが確保されるから、電気的接触性と電線保持強度が保証される。
【図面の簡単な説明】
【図１】（ａ）は本発明に係る全周加締め接続用端子の一実施形態を示す斜視図、（ｂ）は同じく要部を断面とした側面図である。
【図２】全周加締め接続用端子をロータリスウェージ加工機で電線と接続する状態の一形態を示す正面図である。
【図３】全周加締め接続用端子を電線に接続した状態を示す要部を断面とした側面図である。
【図４】（ａ）の本発明の全周加締め接続用端子と（ｂ）の既存の全周加締め接続用端子とを同じ接触面積で電線の芯線部に接続させた場合の長さの比較例を示す要部断面図である。
【図５】（ａ）は全周加締め接続用端子の他の実施形態（参考例）を示す要部を断面とした側面図、（ｂ）は既存の全周加締め接続用端子を示す要部を断面とした側面図である。
【図６】（ａ）は他の実施形態の全周加締め接続用端子を電線に接続した状態を示す要部を断面とした側面図、（ｂ）は既存の全周加締め接続用端子を電線に接続した状態を示す要部を断面とした側面図である。
【図７】（ａ）の他の実施形態の全周加締め接続用端子と（ｂ）の既存の全周加締め接続用端子とを同じ接触面積で電線の芯線部に接続させた場合の長さの比較例を示す要部断面図である。
【図８】従来の加締め接続用端子とその接続方法の一形態を示す縦断面図である。
【符号の説明】
１全周加締め接続用端子
２電線接続部
５電線挿入孔
６接触用突部
１０電線
１１芯線部
１５ロータリスウェージ加工機の加工部（全周加締め手段）[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for connecting a terminal for all-around swaged connection in which a core wire portion of a wire is uniformly crimped and connected to the wire connecting portion over the entire circumference using a rotary wage processing machine.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, a terminal having a configuration in which a core wire portion is inserted into a cylindrical wire connection portion and crimped in a circumferential direction is used for a large-diameter electric wire for a power supply or an electric vehicle. FIG. 8 shows, as one form of the terminal, a wire connecting portion 41 of a crimping connection terminal described in Japanese Patent Publication No. 50-43746 is crimped into a hexagonal shape by a pair of upper and lower crimping dies 42, 42. The state connected to the core wire part 43 is shown.
[0003]
A protrusion 44 is provided on each side of each crimping die 42, and the terminal wire connection portion 41 is crimped in a hexagonal shape at each side of the crimping die 42, and is pressed in the wire radial direction by each protrusion 44. And is caulked in a recessed state. Thereby, electrical connection and fixing of a terminal and an electric wire are performed. On the other side of the terminal, a female electrical contact portion (not shown) for a mating male terminal (not shown) is provided.
[0004]
[Problems to be solved by the invention]
However, in the above-described conventional crimping connection terminal and its connection method (connection structure), the caulking force P _{1 in} the vertical direction, that is, the pressing direction of the pair of caulking dies 42 is large. There is a concern that the caulking force P ₂ is likely to decrease, whereby a gap is easily formed between the both ends of the connecting portion of the terminal and the core wire portion 43 of the electric wire, and the electrical contact property is deteriorated. In that case, the electrical resistance increases, the energization efficiency is lowered, and the connection portion is heated.
[0005]
In order to solve these problems, the applicant previously applied Japanese Patent Application No. 2000-317982 to swage the wire connection portion of the all-around crimping connection terminal (not shown) uniformly over the entire circumference by swaging. In order to further improve the electrical contact between the core part of the electric wire and the electric wire connection part of the terminal by swaging, etc., and to improve the fixing strength of the electric wire, Improvement of the connection method was anxious.
[0006]
In view of the above points, the present invention provides an all-around crimping connection terminal and a connection method thereof capable of enhancing electrical contact and fixing strength with the core portion of an electric wire by all-around crimping by swaging or the like. The purpose is to provide.
[0007]
[Means for Solving the Problems]
In order to achieve the above object, a connection method for a terminal for all-around crimping connection according to claim 1 of the present invention is provided with an electric wire connecting portion having an electric wire insertion hole and its peripheral wall and bottom wall, Using an all-around caulking connection terminal provided with a contact projection in the longitudinal direction of the wire at the center of the wire insertion hole, the core portion of the wire is inserted into the wire insertion hole, and the contact projection is Each wire of the core wire portion is caulked uniformly over the entire circumference in the radial direction with the rotary swage machine in the state of entering the inside of the core wire portion toward the contact protrusion. The element wire is strongly pressed and brought into close contact with the outer peripheral surface of the contact projection .
With the above configuration, when the core portion of the electric wire (consisting of a plurality of strands) is inserted into the electric wire insertion hole, the contact protrusion enters the core portion, and in this state all-around caulking means By crimping the wire connection part uniformly over the entire circumference in the radial direction, each strand of the core wire part is strongly pressed and closely adhered to the outer peripheral surface of the contact projection, and the core wire part and the wire connection part The contact area increases. The core wire portion is strongly clamped and fixed in an annular space between the wire connecting portion and the contact projection . In addition, since the contact protrusion is positioned at the center of the wire insertion hole, the contact protrusion extends over the entire circumference via the core wire portion when the wire connection portion is crimped by the all-around crimping means. The contact protrusions and the strands of the core wire part are in close contact with each other with a uniform force without causing a gap.
[0009]
Method of connecting the entire periphery caulking connection terminal according to claim 2 of the present invention is the method for connecting the entire periphery caulking connection terminal according to claim 1, in that the contact projections are formed in a cylindrical shape Features.
With the above configuration, the center of each strand of the core wire portion, the center of the contact projection, and the contact point between the strand and the contact projection are located on the same straight line, and each strand is the entire contact projection. It adheres with a uniform force in the radial direction over the circumference.
[0010]
The connection method of the all-around crimping connection terminal according to claim 3 of the present invention is the connection method of the all-around crimping connection terminal according to claim 1 or 2 , wherein the contact protrusion is connected to the wire insertion hole. The initial length is about 1/3 .
With the above configuration, when the core wire portion is inserted into the electric wire insertion hole, the contact protrusion enters the core wire portion smoothly by dividing each element wire, and the contact protrusion is at the time of caulking all around the wire connection portion. Each element wire is pressed in the radial direction and extends in the axial direction together with the electric wire connection portion, and is about half the length of the initial electric wire insertion hole, so that a sufficient contact length with the core wire portion is ensured.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
1 (a) and 1 (b) show an embodiment of the all-around caulking connection terminal according to the present invention. The electric wire has shown the insertion state before a connection with the chain line.
[0013]
This all-around caulking connection terminal 1 is preferably made of copper, aluminum, or an alloy thereof, with a cylindrical wire connection portion 2 on one side in the longitudinal direction and a male terminal (not shown) on the other side on the other side. Each of the cylindrical electrical contact portions 3 is formed, and a narrow diameter portion 4 is formed at the boundary between them, and a cylindrical small diameter is formed at the center of the circular wire insertion hole (internal space) 5 of the wire connection portion 2. The contact protrusions 6 are formed so as to project integrally from the bottom surface 7a.
[0014]
The electric wire connecting portion 2 is composed of a cylindrical peripheral wall 8 and a base wall (bottom wall) 7 inside the small diameter portion 4 following the peripheral wall 8, and the contact protrusion 6 protrudes from the center of the bottom surface 7 a of the base wall 7. It is installed. The axial center of the contact protrusion 6 coincides with the axis of the electric wire connecting portion 8, that is, the center of the electric wire insertion hole 5.
[0015]
As an example, the length (depth) L of the wire insertion hole 5 before connection of the wire is 15 mm, the length H of the contact projection 6 is 5 mm, which is 1/3 of the length L of the wire insertion hole 5, and the peripheral wall 8 The outer diameter of the peripheral wall 8 is set to 11 mm, the inner diameter of the peripheral wall 8 is set to 7 mm, and the outer diameter of the contact projection 6 is set to 2 mm which is the same as the thickness of the peripheral wall 8.
[0016]
This is merely an example, and the dimensions of each part are appropriately set according to the size of the wire diameter. However, the length of the contact projection 6 needs to be equal to or shorter than the length of the wire insertion hole 5, and is preferably equal to or less than half the length of the wire insertion hole 5 and 1 / length of the length of the wire insertion hole 5. It is preferably about 3 from the viewpoint of the insertability of the core wire portion 11 of the electric wire 10 into the wire connection portion 2 and the contact property between the core wire portion 11 and the contact protrusion 6.
[0017]
The core wire portion 11 of the electric wire 10 is untwisted in advance if necessary, or a core wire portion 11 that is not twisted is used, and preferably the tip of the core wire portion 11 is widened so that the contact projection 6 Can smoothly enter the core part 11. A tapered guide chamfer 13 is formed on the inner peripheral edge of the opening of the wire connecting portion 2 and smoothly smoothed into the wire connecting portion 2 using an inner tapered guide jig (not shown) if necessary. The core line part 11 which spreads at the end can be inserted.
[0018]
As a method for processing the contact protrusion 6, as an example, first, the wire insertion hole 5 of the wire connection portion 2 is cut to the middle in the longitudinal direction using a large-diameter drill (not shown), and then a small-diameter drill. (Not shown) is used to cut the wire connection hole 5 into a ring shape up to the bottom surface 7a of the base wall 7 to form a cylindrical contact protrusion 6 inside the annular space 5a. In addition, the contact protrusion 6 can be integrally formed in the electric wire connecting portion 2 by a technique such as casting or forging.
[0019]
Below, one form of the connection method of the terminal 1 for all-around crimp connection is demonstrated.
First, the core wire portion 11 of the electric wire 10 is inserted into the electric wire connecting portion 2 of the terminal 1 as shown by a chain line in FIG. The electric wire 10 is an insulation-coated electric wire, and includes a copper core wire portion 11 and an insulating resin cover portion 12 that covers the core wire portion 11. The core wire portion 11 is composed of a plurality of strands. The insulation coating portion 12 of the end of the electric wire 10 cut to a desired length is peeled off with a cutter or the like to expose a part of the core wire portion 11 and the exposed portion is inserted into the electric wire connection portion 2.
[0020]
In this state, the electric wire connecting portion 2 is crimped uniformly in the electric wire radial direction over the entire circumference using a rotary wage processing machine which is a rotary forging machine. FIG. 2 shows an embodiment of the processing unit 15 of the rotary swage machine. This connection method using rotary swage processing was previously proposed by the applicant in Japanese Patent Application No. 2000-317982. In FIG. 2, reference numeral 2 denotes a cylindrical wire connection portion of the terminal 1, 11 denotes a core portion of the wire 10, Reference numeral 16 denotes an outer ring, 17 a roller, 18 a spindle, 19 a hammer (backer), and 20 a die.
[0021]
The spindle 18 is rotated by the driving of a motor (not shown in FIG. 2), and the die 20 and the hammer 19 are integrally rotated in the direction of the arrow C, and the top of the mountain-shaped cam surface 19a of the hammer 19 is in contact with the roller 17. Occasionally, the die 20 closes inward as indicated by the arrow D and strikes (compresses) the wire connecting portion 2 of the terminal 1 in the radial direction, and the die 20 is moved by the centrifugal force while the bottom of the cam surface 19a is in contact with the roller 17 Open outward as E.
[0022]
By repeating this operation at a short pitch, the caulking of the electric wire connecting portion 2 is performed uniformly over the entire circumference, and the inward internal stress of the electric wire connecting portion 2 is uniform with respect to the core wire portion 11 of the electric wire 10. Act on. Thereby, each strand which comprises the core wire part 11 deform | transforms into a substantially honey-comb shape, and it closely_contact | adheres without a gap | interval, and between the core wire part 11 and the electric wire connection part 2 adheres | attaches uniformly in the circumferential direction without a gap | interval.
[0023]
The above rotary wage processing machine is only one form, and for example, the number of hammers 19 and dies 20 is paired up and down or the number of balls 17 is increased as appropriate. Moreover, these rotary swage processes are an example of a connection method, and the terminal 1 and the electric wire 10 may be plastically deformed from the entire circumferential direction by other methods to be pressure-connected.
[0024]
FIG. 3 shows a state in which the terminal 1 and the electric wire 10 are connected by the swaging process of FIG.
Wire connection portion 2 of the terminal 1 as shown in FIG. 3 is compressed in the radial direction while being reduced in diameter from the initial state of FIG. 1 (b), the overall length L ₁ of the wire connecting portion 2 and extends in the longitudinal direction a little become longer. The core wire portion 11 of the electric wire 10 is compressed in the radial direction by the peripheral wall 8 of the electric wire connecting portion 2, and the central contact protrusion 6 is compressed in the radial direction along with this, and is extended in the longitudinal direction while being slightly reduced in diameter. The length H ₁ of the contact protrusion 6 is, for example, about ½ of the length H of the initial wire insertion hole 5. The strands of the core wire portion 2 are in close contact with the outer peripheral surface of the contact projection 6 so that the contact area with the core wire portion 11 is increased, and the mechanical extraction strength of the electric wire 10 is increased.
[0025]
Thereby, compared with the case of the electric wire connection part 2 with only the peripheral wall 8 that does not use the contact protrusion 6, the electric resistance is reduced, the energization efficiency is increased, and the electric wire fixing force against the tensile force of the electric wire 10 is increased. Connection reliability is improved.
[0026]
When the contact protrusion 6 is used as shown in FIG. 4 (a) and when the contact protrusion 6 is not used as shown in FIG. 4 (b), the wire connecting portions 2 and 2 ′ with respect to the core portion 11 of the wire 10 are used. If the contact areas are the same, the length of the peripheral wall 8 can be shortened from L ₃ to L ₂ by the surface area of the contact projection 6, and downsizing by shortening the overall length of the terminal 1 can be achieved. It becomes possible. Is always capable of setting shorter length L ₂ of the wire connection portion 2 shown in FIG. 4 (a) than 4 length L ₃ of the wire connecting portion 2 'of (b).
[0027]
In the above-described embodiment, the contact protrusion 6 is formed in a cylindrical shape, and the adhesion with each element wire of the core wire portion 11 is enhanced. However, the contact protrusion 6 is formed in a prismatic shape such as a quadrangular prism or a triangular prism. Is also possible. It is also possible to sharpen the tip of the contact projection 6 in a taper shape to enhance the insertion property into the core wire portion 11. Further, it is possible to caulk the entire circumference in a state where the core wire portion 11 and the insulation coating portion 12 of the electric wire 10 are simultaneously inserted into the electric wire connection portion 2. In this case, it is preferable to form the wire connection holes 5 in two stages.
[0028]
FIG. 5A is a comparison of another embodiment (reference example) of the all-around crimping connection terminal according to the present invention with the existing example of FIG. 5B (presented in Japanese Patent Application No. 2000-317982). It is shown. (A) (b) has shown the initial state of the terminal before crimping and connecting an electric wire.
[0029]
5 (a) has a taper portion 25 at the bottom of the wire insertion hole 24 in the wire connection portion 23 as compared to the all-around crimp connection terminal 22 in FIG. 5 (b). It is characterized by deepness. The tapered portion 25 is formed in a conical shape and continues across the inner peripheral surface of the peripheral wall 26. The crossing angle θ between the tapered portion 25 and the inner peripheral surface of the peripheral wall 26 is preferably about 60 ° or more, for example.
[0030]
Usually, the cutting edge angle (an angle corresponding to the crossing angle) of a drill for drilling (not shown) is about 30 °. Therefore, the tapered portion 25 is processed using a specially shaped drill, or forging or casting. Thus, it is preferable to form the tapered portion 25 integrally with the wire insertion hole 24. The intersection angle θ ₁ of the taper portion 25 ′ of the existing terminal 22 is about 30 °.
[0031]
The tapered portion 25 is formed in a small-diameter base wall 28 at the boundary between the latter-half electric wire connecting portion 23 and the former-half electrical contact portion 27. The electrical contact portion 27 has, for example, a separate elastic contact portion (not shown) with respect to the mating male terminal (not shown). This configuration is the same as that of the embodiment of FIG.
[0032]
When the wire connecting portion 23 of the terminal 21 in FIG. 5A is uniformly compressed over the entire circumference by the processing portion 15 (FIG. 2) of the rotary swaging machine described above, the wire 29 of FIG. The core wire portion 30 enters the taper portion 25 of the electric wire connection portion 23, and the core wire portion 30 extends on both the front and rear sides in the axial direction as indicated by the arrow F.
[0033]
When the wire connection portion 23 ′ of the terminal 22 in FIG. 5B is uniformly compressed over the entire circumference with the same rotary swaging machine, the tip of the core portion 30 of the wire 29 as shown in FIG. 6B. 30a immediately comes into contact with the bottom surface of the taper portion 25 ′ of the electric wire insertion hole 24, and the extension of the core wire portion 30 is restricted only in one direction (the opening direction of the electric wire insertion hole 24 ′) as indicated by an arrow F.
[0034]
As described above, according to the configuration of FIG. 6A, the core wire portion 30 extends integrally with the electric wire connection portion 23 on both the front and rear sides in the axial direction. The contact area with the electric wire connection portion 23 is increased, the electrical resistance is reduced as in the above-described embodiment, the energization efficiency is increased, and the reliability of the electrical connection is improved.
[0035]
Then, as shown in FIGS. 7A and 7B, a wire connection portion 23 having a wire insertion hole 24 having a deep taper portion 25 and a wire connection portion 24 'having a shallow taper portion 25 ′ or no taper portion. When the portion 23 'is brought into contact with the core wire portion 30 of the electric wire 29 with the same contact area, the length G of the electric wire connecting portion 23 of the deep tapered portion 25 as shown in FIG. The length can be shorter than the length G ₁ of the wire connecting portion 23, and the terminal 21 can be downsized in the longitudinal direction.
[0036]
In addition, it is also possible to form the deep taper part 25 of FIG. 5 in the electric wire connection part 2 using the contact protrusion 6 of FIG. In this case, the contact protrusion 6 protrudes in the longitudinal direction of the electric wire from the deepest bottom of the taper portion 25. According to this form, the contact area of the electric wire connection part 2 with respect to the core part 11 of the electric wire 10 increases further by the synergistic effect of two embodiments, and the effect of the said embodiment is more reliably exhibited.
[0037]
【The invention's effect】
As described above, according to the first aspect of the present invention, when the core wire portion of the electric wire is inserted into the electric wire insertion hole, the contact protrusion enters the core wire portion, and in that state, the entire circumference crimping means By crimping the connecting part uniformly over the entire circumference in the radial direction, each strand of the core wire part is strongly pressed and closely adhered to the outer peripheral surface of the contact projection, and the contact area between the core wire part and the wire connection part Therefore, the electrical resistance of the connection portion between the terminal and the electric wire is reduced, the energization efficiency is increased, and a higher voltage current can be passed. In addition, if the contact area is the same as that of the existing all-around crimping connection terminal for the core wire part, the length of the wire connection part can be shortened by the contact area of the contact protrusion, and the length of the terminal in the longitudinal direction can be reduced. Can be realized. In addition, since the core wire portion is sandwiched in the annular space between the electric wire connection portion and the contact projection, the fixing force of the electric wire increases, and even if a strong tensile force acts on the electric wire, the core wire portion is It does not come out of the wire connection part. As a result, the reliability of the electrical connection is improved.
[0038]
Further, when the electric wire connecting portion is crimped by the all-around crimping means, the contact projection is uniformly pressed over the entire circumference via the core wire portion, and the contact projection and each strand of the core wire portion Since the contact is made with a uniform force without generating a gap, the reliability of the electrical connection can be improved without forcibly deforming the contact protrusion or breaking the element wire.
[0039]
According to invention of Claim 2 , the center of each strand of a core wire part, the center of a contact protrusion, and the contact of a strand and a contact protrusion are located on the same straight line, and each strand is Since the contact protrusions are in close contact with each other with a uniform force in the radial direction over the entire circumference of the contact protrusion, the reliability of electrical connection is increased.
[0040]
According to the third aspect of the present invention, when the core wire portion is inserted into the electric wire insertion hole, the contact projection smoothly enters the core wire portion by dividing each element wire, thereby facilitating the connection work. In addition, when caulking the entire circumference of the wire connection portion, the contact protrusions are pressed in the radial direction by the strands and extend in the axial direction together with the wire connection portion, so that the length is about ½ of the initial wire insertion hole. Thus, since a sufficient contact length with the core wire portion is ensured, electrical contact and electric wire holding strength are guaranteed.
[Brief description of the drawings]
FIG. 1A is a perspective view showing an embodiment of an all-around crimping connection terminal according to the present invention, and FIG.
FIG. 2 is a front view showing one form of a state in which the entire circumference caulking connection terminal is connected to an electric wire by a rotary swaging machine.
FIG. 3 is a side view of a cross-section of the main part showing a state in which the entire circumference caulking connection terminal is connected to an electric wire.
FIG. 4A is a length when connecting the entire circumference caulking connection terminal of the present invention in FIG. 4A and the existing entire circumference caulking connection terminal in FIG. 4B to the core portion of the electric wire with the same contact area. It is principal part sectional drawing which shows these comparative examples.
FIG. 5A is a side view with a cross-sectional view showing the main part of another embodiment (reference example) of the all-around caulking connection terminal, and FIG. 5B shows an existing all-around caulking connection terminal. It is the side view which made the principal part the cross section.
FIG. 6A is a side view with a cross-section of the main part showing a state in which the entire circumference caulking connection terminal of another embodiment is connected to an electric wire, and FIG. 6B is an existing all circumference caulking connection terminal. It is the side view which made the principal part the state which connected the electric wire to the electric wire in the cross section.
FIG. 7A shows a case where the all-around crimping connection terminal of another embodiment of FIG. 7A and the existing all-around crimping connection terminal of FIG. 7B are connected to the core portion of the electric wire with the same contact area. It is principal part sectional drawing which shows the comparative example of length.
FIG. 8 is a longitudinal sectional view showing one embodiment of a conventional crimping connection terminal and its connection method.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Terminal for whole circumference caulking 2 Electric wire connection part 5 Electric wire insertion hole 6 Contact protrusion 10 Electric wire 11 Core part 15 Processing part of a rotary swage processing machine (full circumference caulking means)

Claims

A wire connection portion having a wire insertion hole and a peripheral wall and a bottom wall of the wire insertion hole is used. The wire connecting portion is inserted into the contact protrusion by a rotary swage machine with the core portion of the wire inserted into the wire insertion hole and the contact protrusion entering the inside of the core portion. A terminal for all-around crimping characterized in that each strand of the core wire portion is firmly pressed and brought into close contact with the outer peripheral surface of the contact projection by crimping uniformly over the entire circumference in the radial direction. Connection method .

2. The method of connecting terminals for caulking all-around crimping according to claim 1, wherein the contact protrusions are formed in a columnar shape .

The connection method of the terminal for whole circumference caulking connection according to claim 1 or 2, wherein the contact protrusion has an initial length of about 1/3 of the wire insertion hole .