CN110707443B - 带端子的电线 - Google Patents

带端子的电线 Download PDF

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CN110707443B
CN110707443B CN201910597654.XA CN201910597654A CN110707443B CN 110707443 B CN110707443 B CN 110707443B CN 201910597654 A CN201910597654 A CN 201910597654A CN 110707443 B CN110707443 B CN 110707443B
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electric wire
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佐藤庆
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Yazaki Corp
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    • H—ELECTRICITY
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    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
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    • H01R4/10—Electrically-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
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    • H01R4/58—Electrically-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 characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
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    • H01R4/70—Insulation of connections
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    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus 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
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    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
    • H—ELECTRICITY
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    • H01R4/00—Electrically-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
    • H01R4/10—Electrically-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
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    • H01R4/00—Electrically-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
    • H01R4/10—Electrically-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
    • H01R4/18—Electrically-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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    • H01R4/24—Connections using contact members penetrating or cutting insulation or cable strands
    • H01R4/2495—Insulation penetration combined with permanent deformation of the contact member, e.g. crimping
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    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus 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
    • H01R43/048—Crimping apparatus or processes

Abstract

带端子的电线(1)包括：电线(10)和端子金属配件(20)。端子金属配件(20)具有：筒部(41)和接触部(31)。筒部(41)具有：基端部(46、47)，压紧在电线(10)的覆盖体(12)上；末端部(45)，与基端部(46、47)隔开并被压紧以电连接到导体芯线(11)。覆盖体(12)在末端部(45)的基端侧开口部(45a)内延伸。覆盖体(12)和导体芯线(11)在基端侧开口部(45a)处紧固在一起。覆盖体(12)将位于基端部(46、47)和末端部(45)之间的导体芯线(11)与外部隔离。

Description

带端子的电线
相关申请的交叉引用(S)
本申请基于2018年7月9日提交的日本专利申请No.2018-130102并要求其优先权，并且其全部内容通过引用结合于此。
技术领域
本发明涉及一种带端子的电线，其中端子金属配件连接到电线。
背景技术
近年来，从减轻重量等观点来看，在由具有铝或铝合金制成的导体芯线的电线上安装有由铜或铜合金制成的端子金属配件的带端子的电线(以下称为“铝电线”)已经开始用于例如在车辆中布线的线束。
顺便提及，在上述类型的带端子的电线中，可能发生以存在于电线的芯线和由不同金属制成的端子金属配件之间的水变成电解质的方式的电偶腐蚀 (异种金属接触腐蚀)。众所周知，由于不同金属的标准电极电位之间的差异会发生电偶腐蚀。
鉴于上述情况，在一种使用铝电线的传统的带端子的电线中，端子金属配件的筒部设置有止水密封构件，由此导体芯线的被压接有筒部的整个露出部分与外部隔离。通过这种措施，可以抑制导体芯线的露出部分的电偶腐蚀，并且可以长时间保持端子金属配件和导体芯线之间的电连接的可靠性(例如参见专利文献1)。
至于上述带端子的电线的细节，可参见JP5940198B。
发明内容
然而，在上述传统的带端子的电线中，在带端子的电线的实际批量生产中，需要在将密封件定位的同时将密封件安装到每个端子金属配件的筒部上，以免引起位置偏差等，这使得难以提高带端子的电线的生产率。这样，上述传统的带端子的电线虽然可以保持电连接的高可靠性，但在实际制造方面仍有改进的余地。
因此，本发明的目的是提供一种带端子的电线，其能够实现高生产率并保持电连接的高可靠性。
本发明的实施例提供以下项目(1)至(3)：
(1)一种带端子的电线，包括：
电线；和
安装到所述电线的端子金属配件，
所述端子金属配件具有：
筒部，压接在从所述电线露出的导体芯线上；和
接触部，连接到配对端子，
所述筒部具有：基端部，压紧在所述电线的覆盖体上；和末端部，与所述基端部隔开并被压紧以电连接到所述导体芯线，
所述覆盖体被延伸到所述末端部的基端侧开口部内，所述覆盖体和所述导体芯线在所述基端侧开口部处紧固在一起，并且所述覆盖体将位于所述基端部和所述末端部之间的所述导体芯线与外部隔离。
(2)根据第(1)项所述的带端子的电线，其中，
在所述末端部的基端侧开口部处，所述筒部具有贯穿所述末端部的贯穿部，以允许所述覆盖体经由所述贯穿部可见。
(3)根据第(1)项或第(2)项所述的带端子的电线，其中，
所述导体芯线的端部从所述筒部的末端侧开口部露出并远离所述筒部延伸。
根据本发明的第一方面，关于项目(1)，构成筒部的基端部和末端部彼此间隔开。基端部压接到电线的覆盖体上，而末端部压接到电线的导体芯线上以电连接到电线。在末端部的基端侧开口部周围，电线的覆盖体和导体芯线与设置在基端侧开口部内的覆盖体的一部分紧固在一起。结果，在筒部的末端部和基端部之间，导体芯线被覆盖体覆盖，即，导体芯线的任何部分都不露出。此外，由于覆盖体的一部分被筒部的末端部45的基端侧开口部紧固，所以由树脂制成的覆盖体的一部分变形从而密封筒部和导体芯线之间的间隙。因此，可以抑制水通过末端部的基端侧开口部进入。结果，尽管不能对导体芯线的整个露出部分完全止水，但是在末端部和基端部之间以及末端部的基端侧开口部周围可以适当地实现止水，由此，可以保持带端子的电线的功能。
这样，具有上述结构的带端子的电线虽然没有如传统的带端子的电线中所使用的止水密封件，但却具有实用的止水性能。此外，端子金属配件压接到电线上不需要任何特殊技术并且可以采用传统的技术。结果，具有上述结构的带端子的电线可以获得高生产率和保持电连接的高可靠性。
根据本发明的第二方面，关于项目(2)，由于贯穿部形成为在其厚度方向上穿过筒部的末端部，所以覆盖体的端部的位置可以容易地在例如当筒部压接时，在视觉上识别。这使得可以进一步提高带端子的电线的生产率。在其厚度方向上穿过筒部的末端部的贯穿部的形状没有特别限制；它可以是切口、通孔、狭缝等。
根据本发明的第三方面，关于项目(3)，由于导体芯线的端部从筒部露出，所以当导体芯线被电偶腐蚀(如上所述)腐蚀时，从筒部露出的端部优先于被筒部覆盖的部分腐蚀。也就是说，由于腐蚀从导体芯线的端部逐渐进行，所以被筒部覆盖的部分的腐蚀可以延迟导体芯线的从筒部露出的端部腐蚀所花费的时间。换言之，通过使导体芯线的从筒部露出的部分牺牲性地腐蚀，可以延迟导体芯线的与筒部接触(即，位于其内部)的部分的腐蚀。
本发明使得可以提供一种能够实现高生产率和保持电连接的高可靠性的带端子的电线。
以上简要描述了本发明的几个方面。通过参考附图阅读以下描述，将使本发明的进一步细节更清楚。
附图说明
图1的A和图1的B分别是根据一个实施例的带端子的电线的透视图和平面图。
图2是表示电线如何安装在端子金属配件上的透视图。
图3是图1的B的AA剖视图。
具体实施方式
下面参照附图描述根据本发明实施例的电线10上安装端子金属配件20 的带端子的电线1。在下文中，为了便于描述，在端子金属配件20的轴向方向(嵌合方向)上，与配对端子(未示出)嵌合的一侧，即图1的A和图1 的B、图2和3中的左侧将被称为末端侧(前侧)并且与其相对的一侧，即图1的A和图1的B、图2和3中的右侧将被称为基端侧(后侧)。此外，顶侧和底侧定义为如图1的A和图1的B、图2和3所示。
如图1的A和图1的B、图2和3所示，端子金属配件20压接在电线 10的端部上，从而电连接到电线10的导体芯线11。电线10和端子金属配件 20构成了带端子的电线1。例如，带端子的电线1用作在诸如汽车的车辆中布线的线束的一部分。
电线10是具有导体芯线11和覆盖导体芯线11的树脂覆盖物12的绝缘电线。导体芯线11通过将由铝或铝合金制成的多个线材捻合在一起而形成。由于电线10的导体芯线11由铝或铝合金制成，所以带端子的电线1更轻，因此包括带端子的电线1的线束也变得更轻。轻的带端子的电线1特别适用于采用多种线束的车辆，例如电动车辆和混合动力车辆。
端子金属配件20在末端侧具有连接到配对端子(未示出)的接触部31，并且在基端侧具有连接到电线10的电导体芯线11的筒部41。接触部31和筒部41由一个连杆部35彼此连接。
端子金属配件20通过在金属板(板状体)上进行压力加工(冲压和弯曲) 而形成。端子金属配件20由与由铝或铝合金制成的导体芯线11不同的金属材料制成。更具体地，端子金属配件20使用例如由铜或铜合金制成的金属板(板状体)作为基材形成。
例如，为了抑制电线10的导体芯线11的腐蚀(即，增加其耐腐蚀性)，优选在压制基底金属板之后和压接到电线10之前在端子金属配件20上进行电镀。在本实施例中，在被压接到电线10之前，端子金属配件20经过锡(Sn) 电镀。更具体地，在前表面、后表面和通过压力加工形成的侧表面上形成包含锡的镀层。
在进行表面处理之后，接触部31形成为具有开口末端部的矩形管的形状 (见图1的A和图1的B)。配对端子(未示出)插入到接触部31的开口部中，由此接触部31和配对端子彼此电连接。
如图1的A和图1的B所示，筒部41被压接到电线10的端部上，从而电连接到导体芯线11。为了能够进行这种压接和连接，筒部41具有一对压接片45以压接并连接到导体芯线11以及压接片46和47以压接在覆盖物12 上。在下文中，因为它们位于筒部41中的末端侧位置，这对压接片45也将被称为“末端侧压接部45”。由于压接片46和47位于筒部41中的基端侧位置，因此它们也将被称为“基端侧压接部46和47”。末端侧压接部45在电线10的轴向上与基端侧压接部46和47隔开。
更具体地说，如图1的A和图1的B所示，末端侧压接部45通过将它们的延伸端部彼此面对地压紧的方式而压接到电线10的端部上。在该实施例中，电线10的导体芯线11的端部11a位于具有管状形状的末端侧压接部45 的末端侧开口的末端侧并且从筒部41露出。
如图2所示，压接之前的筒部41的顶表面(内表面)是电线10的端部将安装于其上的安装表面41a。一对压接片45和压接片46和47使用例如已知的压接机在电线10安装在安装表面41a上的状态下进行压紧，以这样的方式即导体芯线11的端子部分和覆盖物12介于一对压接片45之间并且覆盖物 12的远离端子部分的部分介于压接片46和47之间。
结果，如图1的A和图1的B以及图3所示，末端侧压接部45压接到导体芯线11和覆盖物12的端子部分上，并且基端侧压接部46和47压接到覆盖物12上。特别是在末端侧压接部45的基端侧开口部45a的周围，电线 10的覆盖物12和导体芯线11被设置在基端侧开口部45a内侧的覆盖物12 的一部分紧固在一起。结果，在末端侧压接部45与基端侧压接部46和47之间，导体芯线11被覆盖物12覆盖，即，导体芯线11的任何部分都不露出。此外，由于覆盖物12通过设置在基端侧开口部45a内部的覆盖物12的一部分紧固，在基端侧开口部45a周围，覆盖物12变形以密封末端侧压接部45 和导体芯线11之间的间隙。
此外，如图1的B所示，筒部41的末端侧压接部45的基端侧开口部45a 形成有贯穿部45b，其沿厚度方向贯穿末端侧压接部45以使覆盖物12的一部分可见。在该实施例中，贯穿部45b是通过将基端侧开口部45a的原始片朝向末端侧切割而形成的V形切口。如图2所示，切口形贯穿部45b通过在压接之前对一对压接片45的延伸端部的角部45c进行倒角而形成。
如上所述，在根据本发明的实施例的带端子的电线1中，基端侧压接部 46和47与末端侧压接部45(末端侧压接部45和基端侧压接部46和47构成筒部41)间隔开。基端侧压接部46和47压接到电线10的覆盖物12上，并且末端侧压接部45压接到电线10的导体芯线11上以电连接到电线10。
在末端侧压接部45的基端侧开口部45a的周围，电线10的覆盖物12和导体芯线11通过设置在基端侧开口部45a内部的覆盖物12的一部分紧固在一起。结果，在末端侧压接部45和筒部41的基端侧部分之间，导体芯线11 被覆盖物12覆盖，即导体芯线11没有露出任何一部分。
此外，由于覆盖物12的一部分被筒部41的末端侧压接部45的基端侧开口部45a紧固，因此覆盖物12的一部分变形从而密封筒部41和导体芯线11 之间的间隙。因此，可以抑制水通过末端侧压接部45的基端侧开口部45a进入。
利用上述结构，虽然不能对导体芯线11的整个露出部分实现完全止水，但是可以在末端侧压接部45和基端侧压接部46和47之间以及筒部41的基端侧开口部45a的周围适当地实现止水，因此带端子的电线1的功能可以保持有效。
此外，由于贯穿部45b形成为在其厚度方向上穿过筒部41的末端侧压接部45，因此可以在例如筒部41被压接时，容易地在视觉上识别覆盖物12的端部的位置。这使得可以进一步提高带端子的电线1的生产率。另外，由于在本实施例中，贯穿部45b的形状类似于切口，因此，由于后面描述的原因，可以进一步提高基端侧开口部45a的止水性能。
更具体地说，如果一对压接片45的延伸端部在将它们压接到导体芯线 11和盖子12上以便彼此面对时咬入覆盖物12太深，可能发生它们在厚度方向上穿透覆盖物12的损坏。相反，由于切口形的贯穿部45b的存在，在基端侧开口部45a附近不易发生这种深度咬合，并且可以抑制或防止在覆盖物12 中发生这种损坏。结果，可以抑制或防止水通过基端侧开口部45a周围的覆盖物12的损坏部分进入，并且可以在基端侧开口部45a周围提高止水性能。这样，除了增加覆盖物12的端部的位置的可视性之外，切口形的贯穿部45b 还具有增强基端侧开口部45a周围的止水性能的效果。
此外，由于导体芯线11的端部11a从筒部41露出，所以当导体芯线11 被电偶腐蚀(如上所述)腐蚀时，从筒部41露出的端部11a腐蚀优先于被筒部41覆盖的部分腐蚀。也就是说，由于腐蚀从导体芯线11的端部逐渐进行，所以被筒部41覆盖的部分的腐蚀可以延迟用于从筒部41露出的端部11a腐蚀的时间。换句话说，通过使导体芯线11的从筒部41露出的部分牺牲性地腐蚀，可以延迟导体芯线11的与筒部41接触(即，位于其内部)的部分的腐蚀。
如上所述，虽然没有在传统的带端子的电线中使用的止水密封构件，但是带端子的电线1表现出实用的止水性能。此外，端子金属配件20压接到电线10上不需要任何特殊技术并且可以采用传统技术。结果，带端子的电线1 可以实现高生产率和保持电连接的高可靠性。
其他实施例
本发明不限于上述实施例，并且可以在本发明的范围内适当地进行各种修改、改进等。上述实施例的各个组成元件的材料、形状、尺寸、数量、位置等不限于所公开的那些，而是可以以期望的方式确定，只要可以实现本发明即可。
例如，在该实施例中，筒部41的末端侧压接部45的基端侧开口部45a 形成有切口形贯穿部45b(参见图1的B)。但是，从提高覆盖物12的可视性的观点出发，只要贯穿部45b在厚度方向上贯穿末端侧压接部45即可；贯穿部45b不限于切口。例如，贯穿部45b可以是通孔或狭缝。为了提高基端侧开口部45a周围的止水性能，只要贯穿部45b被形成为抑制末端侧压接部45 过度咬入基端侧开口部45a周围的覆盖物12中的形状即可；贯穿部45b的形状不限于V形。例如，贯穿部45b可以是U形切口或其中末端侧压接部45 的角部(45c)(见图2)在远离覆盖物12的方向上折叠的部分。
下面将以项[1]至[3]的形式简要地概述根据本发明的实施例的上述带端子的电线1的特征：
[1]一种带端子的电线(1)，包括：
电线(10)；和
安装到电线(10)的端子金属配件(20)，
端子金属配件(20)具有：
筒部(41)，压接在从电线(10)露出的导体芯线(11)上；和
接触部(31)，连接到配对端子，
筒部(41)具有：基端部(46、47)，压紧在电线(10)的覆盖体(12) 上；和末端部(45)，与基端部(46、47)隔开并被压紧以电连接到导体芯线 (11)，
覆盖体被延伸到末端部(45)的基端侧开口部(45a)内，覆盖体(12) 和导体芯线(11)在基端侧开口部(45a)处紧固在一起，并且覆盖体(12) 将位于基端部(46、47)和末端部(45)之间的导体芯线(11)与外部隔离。
[2]根据[1]所述的带端子的电线(1)，其中，
在末端部(45)的基端侧开口部(45a)处，筒部(41)具有贯穿末端部 (45)的贯穿部(45b)，以允许覆盖体(12)经由贯穿部(45b)可见。
[3]根据[1]或[2]所述的带端子的电线(1)，其中，
导体芯线(11)的端部(11a)从筒部(41)的末端侧开口部露出并远离筒部(41)延伸。
参考符号列表
1：带端子的电线
10：电线
11：导体芯线
12：覆盖物(覆盖体)
20：端子金属配件
31：接触部
41：筒部
45：末端侧压接部(末端部)
45a：基端侧开口部
46、47：基端侧压接部(基端部)

Claims (2)

1.一种带端子的电线，包括：
电线；和
安装到所述电线的端子金属配件，
所述端子金属配件具有：
筒部，压接在从所述电线露出的导体芯线上；和
接触部，连接到配对端子，
所述筒部具有：基端部，压紧在所述电线的覆盖体上，所述基端部由两个交错的压接片构成；和末端部，与所述基端部隔开并被压紧以电连接到所述导体芯线，
所述覆盖体被延伸到所述末端部的基端侧开口部内，所述覆盖体和所述导体芯线在所述基端侧开口部处紧固在一起，并且所述覆盖体将位于所述基端部和所述末端部之间的所述导体芯线与外部隔离，
在所述末端部的基端侧开口部处，所述筒部具有贯穿所述末端部的贯穿部并且所述贯穿部为通过将上述基端侧开口部朝向末端侧切割而形成的V形切口，以允许所述覆盖体经由所述贯穿部可见，并且所述贯穿部的切入深度小于所述覆盖体在所述端子金属配件的轴方向上向所述筒部的所述末端部的插入长度。
2.根据权利要求1所述的带端子的电线，其中，
所述导体芯线的端部从所述筒部的末端侧开口部露出并远离所述筒部延伸。
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