GB2387280A - Waterproof terminal seal formed by rotary swaging - Google Patents
Waterproof terminal seal formed by rotary swaging Download PDFInfo
- Publication number
- GB2387280A GB2387280A GB0313272A GB0313272A GB2387280A GB 2387280 A GB2387280 A GB 2387280A GB 0313272 A GB0313272 A GB 0313272A GB 0313272 A GB0313272 A GB 0313272A GB 2387280 A GB2387280 A GB 2387280A
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- GB
- United Kingdom
- Prior art keywords
- wire
- wire connection
- connection portion
- insulating sheath
- terminal
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- 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
- H01R4/20—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 using a crimping sleeve
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/46—Bases; Cases
- H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- 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
- H01R43/058—Crimping mandrels
- H01R43/0585—Crimping mandrels for crimping apparatus with more than two radially actuated mandrels
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- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
Abstract
A conductor portion (3) and an insulating sheath (4) of a wire (2) are inserted in a generally-cylindrical wire connection portion (32) of a terminal, and in this condition the wire connection portion (32) is compressively pressed radially uniformly over an entire periphery thereof with a plurality of dies of a rotary swaging machine, so that the conductor portion and the insulating sheath are held in intimate contact with an inner peripheral surface of the wire connection portion. The wire connection portion (32) has a smaller-diameter insertion hole for the conductor portion (3), and a larger-diameter insertion hole for the insulating sheath (4), the insertion holes being disposed in coaxial relation to each other.
Description
STRUCTURE FOR WATERPROOFING TERMINAL-WIRE CONNECTING PORTION
AND METHOD OF WAll;RPROOFING THE SAME 5 This invention relates to a structure and a method of waterproofing a terminal-wire connecting portion, in which an end portion of a wire is inserted into a generally cylindrical terminal, and the terminal is compressively pressed over an entireperipherythereoftobeconnectedtothewireendportion, 10 end et the same time the end portion of the wire is waterproofed.
Figs. llA and llB show one form of related terminal-wire connecting portion waterproofing structure and method (See JP-A-2-12680U).
AsshowninFig.llA,awireconnectionportion45,provided at a rear half portion of a terminal 44, is press-fastened to anendportionof en insulatingsheathedwire41, end a conductor portion 42 of the wire 41 is held and connected between an 20 insulating sheath 43 of the wire 41 and the terminal 44, and a waterproof seal material 46 is filled between the terminal 44 and the insulating sheath 43, and the conductor portion 42 of the wire 41 is embedded in the waterproof seal material 46, and is waterproofed as shown in Fig. llB.
The insulating sheath 43 of the wire 41 is made of a soft vinyl resin or the like, and the wire 41 can be flexed to a certain degree. In this example, the conductor portion 42 comprises one copper wire ox aluminum wire for high voltage 5 purposes, and this conductor portion is folded back into a generally U-shape at the distal end portion of the insulating sheathes, andis disposed between the outer peripheralsurface of the insulating sheath 43 and a bottom plate portion 47 of the terminal44, andis pressed against the bottom plate portion 10 44 by a resilient force of the insulating sheath 43, and is connected thereto.
The wire connection portion 45 includes two (front and rear) pairs of press-cramping piece portions 48, and each pair IS of press-clamping piece portions extend upwardly respectively from opposite side edges of the bottom plate portion 47, and each press-clamping piece portion 48 is pressed into a curved shape around the outer periphery of the insulating sheath 43 asshownin Fig.llB. The waterproof sealmaterial46is filled 20 at the inner surface of each press-clamping piece portion 48 andtheinnersurfaceofthebottomplateportion47. Forexample, a hot-melt resin material or a soft resin material, such as rubber, isusedasthewaterproofsealmaterial46. Thehot-melt resin material has such a nature that it is melt upon heating, 25 end thenis solidified by natural cooling. The waterproof seal
material 46 prevents water from intruding into the portion of contact between the conductor portion 42 and the terminal 44.
Thepressingofeachpairofpress-clampingpieceportions 5 48 can tee effected using, for example, a pair of upper end lower dies (not shown) having arcuate inner surfaces, respectively.
The insulating sheath 43 is removed from the end portion of the wire 41, thereby exposing the conductor portion 42, and thisconductorportion42isbentandfoldedbackintoagenerally 10 U-shape to extend along the insulating sheath 43, and the end portion of the wire41isinserted end setin the wire connection portion45Of the terminal44, end the waterproof sealmaterial 46 is filled in the inside of the wire connection portion 45, and the press-clamping piece portions 48 are simultaneously 15 pressedinto a curved shape by the pair of upper andlower dies of a clamping machine knot shown). As a result, the portion of connection between the conductor portion 42 end the terminal 44 is covered with the waterproof seal material 46, and is protected, and also the conductor portion 42 is resiliently 20 held between the insulating sheath 43 and the bottom plate portion 47 of the terminal 44, and is connected thereto.
A front half portion of the terminal 44 is formed into afemaletypeelectricalcontactportion49foramatingterminal 25 (not shown). In this example, the electrical contact portion
Àd 49 includes a tubular portion 50 for receiving a male terminal (electrode) of high-voltage part, such as a spark plug and a secondary coil, and a resilient contact portion (not shown) provided within the tubular portion 50 so es to hold the mating 5 male terminal (not shown). For example, a secondary current of high voltage is fed from the conductor portion 42 of the wire 41 to the electrical contact portion 49 of the terminal 44, and is further fed from the electrical contact portion 49, for example, to a spark plug.
In the above related terminal-wire connecting portion waterproofing structure and method, however, the conductor portion42is exposed et a front end43aoftheinsulating sheath 43, and therefore there has been encountered a problem that 15 this exposed portion is liable to be oxidized. Even if the exposed portion of the conductor portion 42 is covered with the waterproof sealmaterial46 at the front end oftheinsulating sheath43,thewaterproofsealmaterial46doesnotexistbetween each pair of right and left press-clamping piece portions 48, 20 and when a strong force, such as a bending force, a pulling force and a twisting force, acted on the wire 41, there was a fear that a gap was liable to develop between the outer peripheralBurfaceoftheinsulatingsheath43andthewaterproof seal material 46, so that the waterproof performance could be 25 lowered.
À0 Andbesides,whenthewaterproofsealmaterial46intruded between the conductor portion 42 and the bottom plate portion 47 of the terminal 44 before the pressing operation, there was 5 a fear that the conducting performance after the pressing operation was deteriorated. In addition, when the conductor portion 42 bit into the soft insulating sheath 43, there was a fear that the pressure of contact between the terminal 44 and the conductor portion 42 decreased with the lapse of time, 10 so that the contactperformance was deteriorated. Furthermore, the conductor portion42is press-fastened between the terminal end the insulating sheath43by the front pair of press-clamping piece portions 48, and the press-clamping piece portions 48 do not exist at a position (upper side in Fig. llB) disposed 15 in symmetrical relation to the conductor portion 42, and therefore there was a fear that the press-fastening force was less liable to become uniform, so that the pressure of contact between the conductoxportion42 and the terminal 44 was liable to be varied.
With the foregoing in view, it is an object of this invention to provide a structure and a method of waterproofing a terminal-wire connecting portion, in which the performance 25 of contact between a wire conductor portion and a terminal can s
À 6 be enhanced, and besides a waterproof performance of a portion of connection between the conductor portion and th terminal can be enhanced.
In order to solve the aforesaid object, the invention 5 provides a structure for waterproofing a terminal-wire connecting portion comprising: a wire including a conductor portion and an insulating sheath; and a terminal including a substantially cylindrical wire 10 connection portion, wherein the conductor portion and the insulating sheath are inserted in the wire connection portion, and the wire connection portion is pressed radially uniformly over an entire periphery thereof so that the conductor portion 15 and the insulating sheath are held in intimate contact with an inner peripheral surface of the wire connection portion, further comprising: one of a waterproof seal material and a waterproof seal member arranged in an annular shape within the wire 20 connection portion, and wherein an outer peripheral surface of the insulating sheath is held in intimate contact with the one of the waterproof seal material and the waterproof seal member.
The wire connection portion may include a smaller 25 diameter insertion hole for the conductor portion and a larger-diameter insertion hole for the insulating sheath, the smaller-diameter and larger-diameter insertion holes being disposed in coaxial relation to each other.
The waterproofing structure may include a wire 30 connection portion including a peripheral groove for receiving the elastic waterproof seal member, and the waterproof seal member is compressed in the peripheral groove. The present invention also provides a method of 35 waterproofing a terminal-wire connecting portion comprising the steps of:
À 7 simultaneously inserting a conductor portion and an insulating sheath of a wire into a substantially cylindrical wire connection portion of a terminal; and pressing radially uniformly with a plurality of dies 5 of a rotary swaging machine the wire connection portion over an entire periphery thereof to be compressively plastically deformed.
The conductor portion may be inserted into a smaller-
diameter insertion hole formed in the wire connection 10 portion, with the insulating sheath inserted into a larger-
diameter insertion hole formed in the wire connection portion in coaxial relation to the smaller-diameter insertion hole, and the smaller-diameter and larger-diameter insertion 15 holes are pressed radially.
The pressing step may be performed under a state in which one of a waterproof seal material and a waterproof seal member is arranged in an annular shape with respect to an outer peripheral surface of the insulating sheath within 20 the wire connection portion.
The pressing step may be performed under a state in which a peripheral groove for receiving the elastic waterproof seal member is formed in an inner surface of the wire connection portion, and the waterproof seal member is 5 mounted in the peripheral groove.
the conductor portion is inserted into a smaller-diameter insertion hole formed in the wire connection portion, the insulating sheath isinserted into a larger-diameter 5 insertion hole formedin the wire connection portionin coaxial relation to the smaller-diameter insertion hole, and the smeller-diameter andlarger-diameterinsertionholes are pressed radially.
10 (7) The method according to (5), wherein the pressing step is performed under a state in which one of a waterproof seal material and a waterproof seal member is arranged in an annular shape with respect to an outer peripheral surface of the insulating sheath within the wire 15 connection portion.
(8) The method according to (7), wherein the pressing step is performed under a state in which a peripheral groove for receiving the elastic waterproof seal member is formed in an 20 inner surface of the wire connection portion, end the waterproof seal member is mounted in the peripheral groove.
(9) The method according to (5), wherein the pressing is effected by a rotary swaging machine.
In the Drawings; Fig.lisanexploded,perspective view showing a structure andamethodotwaterproofingaterminal-wireconnectingportion, providedin accordance with a first embodiment oftheinvention.
5 Fig. 2 is a perspective view showing a condition in which a terminal and a wire are connected together in a waterproofed manner by an entireperiphery pressing operation.
Fig. 3 is a cross-sectional view taken along the line A-A of Fig 2.
10 Fig. 4 a cross-sectional view taken along the line B-B of Fig. 2.
Fig.5isafront-elevationalviewshowingarotaryswaging machine which is one form of entire-periphery pressing means.
Fig. is a perspective view showing, for information 15 purposes, a structure and a method of waterproofing a terminal-wire connecting portion, provided in accordance with a second embodiment of the invention.
Fig.7isanexploded,perspectiveviewshowingastructure andamethodofwaterproofingaterminal-wireconnectinDportion, 20 providedin accordance with a third embodiment oftheinvention Fig. 8 is a crosssectional view taken along the line F-F of Fig. 7.
Fig. 9 is a perspective view showing a condition in which a terminal and a wire are connected together in a waterproofed 25 manner by an entireperiphery pressing operation.
Fig. 10 is a cross-sectional view taken along the line G-G of Fig. 9.
Fig.1lshowsoneformofrelatedterminal-wireconnecting portion waterproofing structure and method, and Fig. llA is 5 aside-elevationalview, and Fig. llB is across-sectional view taken along the line H-H of Fig. llA.
A preferred embodiment of the present invention will now 10 be described in detail with reference to the drawings.
Figs.lto4 show a structure end a method of waterproofing aterminalwireconnectingportion,providedinaccordancewith a first embodiment of the invention.
15 In Fig. 1, reference numeral 1 denotes a female terminal made of electrically-conductive metal such as a copper alloy, aluminum or an aluminum alloy, and reference numeral 2 denotes a wire in which a conductor portion 3, composed ofcopperwires, aluminumwiresorthelike, is exposed et anendportion "hereof.
The terminal 1 has a cylindrical electrical contact portion 5 (for mating male terminal (not shown)) at one side portion (front half portion), and also has a cylindrical wire connection portion 6 at the other side portion (rear half 25 portion), and the electrical contact portion 5 and the wire
connection portion 6 are integrally interconnected by an intermediate portion (interconnecting portion) 7 of a smaller diameter. In this embodiment, although the outer diameter of the electrical contact portion 5 is larger than the outer 5 diameter of the wire connection portion 6, the two outer diameters, inner diameters, wall thicknesses and lengths of the electrical contact portion 5 and wire connection portion 6 can be suitably determined in accordance with the kind of mating male terminal (not shown) and the kind of wire 2.
The wire connection portion 6 has a cross-sectionally-circular front insertion hole 8 ofa smaller diameter for the conductor portion 3 of the wire 2, and a cross-sectionally-circular rear insertion hole 9 of a larger 15 diameter for an insulating sheath 4, the two insertion holes being disposedincoaxialrelation to each other. The diameter of the front insertion hole 8 is slightly larger than the outer diameter of the conductor portion 3, and the diameter of the rear insertion hole9isslightlylarger than the outer diameter 20 of the insulating sheath 4, and therefore the wire 2 can be smoothly inserted into the wire connection portion 6. A wall thickness of a peripheral wall 10 of the front insertion hole 8 is larger while a wall thickness of a peripheral wall 11 of the rear insertion hole 9 is smaller. The outer peripheral 25 surfaces of the peripheral walls 10 and 11 of the two insertion
holes 8 and 9 have the same outer diameter, and are continuous with each other, with no step formed therebetween. The front insertion hole 8 has a length equal to or slightly larger than the length of the exposed portion of the conductor portion 3.
5 A step portion 12 is formed between the two insertion holes 8and9, andthelengthofinsertionofthewire2canbedetermined, for example, by abutting a front end4aof the insulating sheath 4 against the step portion 12.
10 A tapering portion 13 of a conical shape is formed in the front end of the insertion hole 8 bydrilling. A partition wall, defining the intermediate interconnecting portion 7, is formed between the front insertion hole 8 and the electrical contact portion 5, and the front insertion hole 8 is sealed 15 by the partition wall 7. A front end portion 6a of the wire connection portions end a rear end portion 5a of the electrical contact portion S are slanting in a tapering manner, and are continuous with the interconnecting portion 7 of a smaller diameter. Eveninthecasewhereanairventhole,communicating 20 the insertion hole 8, 9 with the exterior, is formed through each of the peripheral walls 10 and 11 of the wire connection portion6soastodischargetheairduringthepressingoperation, these air vent holes are completely closed during the entire-periphery pressing operation, and therefore this will 25 not be any problem at all from a waterproof point of view.
In Fig. 1, the end portion of the wire 2, that is, the exposed conductor portion 3, and the insulating sheath 4, extending from this conductor portion 3, are inserted and set 5 in the cylindricalwire connection portions. In this condition, the wire connection portion 6 is pressed to be compressively plastically deformed uniformly over the entire length thereof and over the entire periphery thereof. The term " pressed uniformly'' means that the outer peripheral surface of the wire 10 connection portion 6 is all pressed racially toward the center of the wire 2 with a uniform force as indicated by arrows P in Fig. 3.
As a result of this entire-periphery pressing, the IS cylindrical wire connection portion 6 is compressed radially, and is extended in the longitudinal direction, and thus is plastically deformed, and the conductor portion 3 of the wire 2 is pressed hard radially by the thick front peripheral wall 10, end those clement wires of the conductor portion3,disposed 20 at the outer peripheral portion thereof, bite into the inner peripheral surface of the front insertion hole 8, and is held inintimate contact therewith,withno gap formed therebetween, andalsotheelementwiresoftheconductorportion3arepressed hard in the radial direction, and are deformed to assume a 25 honeycomb-like shape, and are intimately contacted with one
another, with no gap formed therebetween, and at the same time the insulating sheath 4 of the wire 2 is pressed hard radially by the thin rear peripheral wall 10, and is compressively deformed, and the outer peripheral surface of the insulating 5 sheath 4 is held in firm, intimate contact with the inner peripheral surface of the rear insertion hole 9 by a restoring reaction force as indicated by arrows f in Fig. 4, thereby achieving a waterproof effect.
10 The wire connection portion 6 is compressively pressed overtheentireperipherythereof(overtheentirecircumference thereof) with the uniform force, and therefore the insulating sheath 4 is compressed over the entire periphery thereof with the uniform force by the wire connection portion 6, and is held 15 in intimate contact with the inner peripheral surface of the rear portion of the wire connection portion 6 over the entire periphery thereof with the uniform restoring reaction force (resilient force) f, with no gap formed therebetween. As a result, the high waterproof performance is achieved As shown 20 in Fig. 3, the insulating sheath 4 extends outwardly from a rear end 6b of the wire connection portion 6 in a tapering or curved manner to have the free diameter.
Even in the case where an aluminum material is used for 25 the conductor portion 3 of the wire 2 and the terminal 1, an
oxidefilmispreventedfrombeingformedontheouterperipheral surface of the conductor portion 3 and the inner peripheral surface of the wire connection portion 6 with thelapse oftime, since the outer peripheral surface of the conductor portion 5 3 is held in intimate contact with the inner peripheral surface ofthewireconnectionportion6, withnogapformedtherebetween Even if an oxide film is initially formed, this oxide film is removedbythefrictionwhenthoseelementwiresoftheconductor portion 3, disposed at the outer peripheral portion thereof, 10 bite into the inner peripheral surface of the wire connection portions, andtherefore the high electricalcontactperformance is achieved because of a lower conducting resistance.
The conductor portion 3 and the insulating sheath 4 are 15 pressed hard against the inner peripheral surface of the wire connection portion 6 by the restoring reaction force, so that the force of fixing of the wire 2 to the wire connection portion increases, and therefore the wire 2 is prevented from being withdrawn from the terminal 1 even when a strong pulling force 20 or the like acts on the wire 2. The conductor portion 3 and the insulating sheath 4 can be simultaneously press-fastened and fixed to the terminal 1 by one pressing operation, and therefore the structure of the terminal 1 is simplified, and also the pressing operation can be effected easily and 25 efficiently.
As shown in Fig. 3, the length of compressive pressing of the insulating sheath 4 need only to be generally equal to or smaller than the length of compressive pressing of the 5 conductor portion 3. The outer peripheral surface of the insulating sheath 4, compressively pressed radially uniformly over the entire periphery thereof, is held in intimate contact with theinnerperipheralsurfaceof the wire connection portion 6 with no gap formed therebetween, and therefore the intrusion 10 of water, dust and the like into the wire connection portion 6, that is, toward the conductor portion 3, is positively prevented. In Fig. 3, reference numeral 15 denotes one form of 15 resilientcontactmemberinsertedintheinsideoftheelectrical contact portion 5. This resilient contact member 15 comprises asingleelectricallyconductivemetalsheetl6,andaplurality of contact spring piece portions 17 are stamped and raised inwardly, and this metal sheet 16 is curled into a cylindrical 20 shape, so that the contact spring piece portions17 are arranged at equal intervals in the circumferential direction. The mating male terminal (not shown) are inserted along the inner surfaces of the contact spring piece portions 17, and is connected thereto.
One preferred form of entire-periphery pressing means for compressively pressing the wire connection portion 6 of the terminal 1 over the entire periphery is rotary swaging.
In this working method, the conductor portion 3 and insulating 5 sheath 4 of the wire 2 are simultaneously compressively pressed uniformly over their entire periphery within the cylindrical wire connection portion 6 of the terminal 1, using a rotary swaging machine 16 of Fig. 5.
10 The rotary swaging machine 16 includes a working portion which comprises a plurality of (four in this embodiment) dies 17, which are arranged at equal intervals in the direction of the periphery of the wire 2, and strike against the wire connection portion 6 radially to compressively deform the same 15 while rotating in a direction of arrow C, hammers 18 integrally connected respectively to the dies 17, a spindle 19 for rotating the dies 17 and the hammers 18 in the peripheral direction in unison, a motor (not shown) for driving the spindle 19, guide rollers 20 for sliding contact with cam surfaces 18a formed 20 respectively at outer surfaces of the hammers 18, and an outer ring 21 held in sliding contact with outer surfaces of the guide rollers 20.
Each of the guide rollers 20 is supported, for example, 25 on a working portion body 22 so as to rotate about its axis.
Each die 17 has an inner surface 17a of an arcuate shape which corresponds to or is larger than the outer diameter of the compressively- pressed wire connection portion 6. The die 17 end the hammer18 are fixedly secured to each other, forexample, 5 by a bolt or the like, and only the dies 17 can be exchanged in accordance with the outer diameter of the terminal 1 to be As the spindle 19 rotates, the cam surfaces 18a of the 10 hammers 18 contact the guide rollers20, respectively, and the dies17 are slidin a diameter-reducing direction (asindicated by arrow D) to compress the wire connection portion 6 of the terminal 1. When the apex of each cam surface 18a is brought into contact with the guide roller 20 as shown in Fig. 5, the 15 amount of inward movement of the die 17 is the maximum. Then, a foot portion of each cam surface 18a is brought into sliding contactwiththeguideroller20,andthedie17 isslidoutwardly under the influence of a centrifugal force, so that a gap is formed between the die and the wire connection portion 6 of 20 the terminal 1. As the spindle 19 rotates, the dies 17 are repeatedly opened and closed, and the wire connection portion 6 of the terminal 1 is compressively plastically deformed in the diameter-reducing direction uniformly over the entire periphery thereof. As a result, the conductor portion 3 of 25 the wire2isheldinintimate contact with the inner peripheral
surface of the front half portion of the wire connection portion 6 while the insulating sheath 4 is held in intimate contact with the inner peripheral surface of the rear half portion of the wire connection portion 6.
In Fig. 5, instead of providing the four guide rollers 20, eight guide rollers can be arranged circumferentially at equal intervals. Instead of providing the four dies 17, two dies can be arranged circumferentially at an equal interval.
Fig. 6 shows, for information purposes, a structure and a method of waterproofing a terminal-wire connecting portion, providedinaccordancewithasecondembodimentoftheinvention. 15 Thiswaterproofingstructureandmethodarecharacterized in that only a conductor portion 3 of a wire 2 is connected to a cylindrical wire connection portion 26 of a terminal 25 by compressively pressing the wire connection portion 26 uniformly over the entire periphery thereof by rotary swaging 20 as in the first embodiment, end then atleast an exposed portion of the conductor portion 3 (lying between a rear end of the wire connection portion 26 and a front end of an insulating sheath 4 ofthe wire 2) and those portions (the wire connection portion 26 and the insulating sheath 4), disposed immediately 25 adjacent respectively to front and rear ends of this exposed
portion, is covered with a waterproof seal material 2 7 ( indicated in''a broken line), and is waterproofed by this seal material.
One example of waterproof seal material 27 is an existing 5 hot-melt resinmaterial. The hot-melt resinmaterial is melted at a high temperature, and is cooled to be solidified at an ordinary temperature, and by doing so, the hot-melt resin material is caused to adhere to the exposed surface of the conductor portion 3, the surface of the insulating sheath 4 10 and the surface of the wire connection portion 26. Instead of the hot-melt resin material, a soft resin material, always exhibiting elasticity, can be caused to adhere to the exposed surface of the conductor portion 3, the surface of the insulating sheath 4 and the surface of the wire connection portion 26.
In this second embodiment, the conductor portion 3 of the wire 2 can tee tightly connected to the wire connectionportion 26 of the terminal 25 with no gap formed therebetween as in the first embodiment, and also element wires of the conductor 20 portion 3 can be intimately contacted with one another with no gap formed therebetween, so that the performance of the connection of the wire 2 and the terminal 25 can be enhanced.
Andbesides, the exposure of the conductor portion 3 is prevented by the waterproof seal material 27, thereby positively 25 preventing water, dust and so on from intruding into the
conductor portion 3 and the wire connection portion 26.
Figs.7tolOshowastructureandamethodofwaterproofing aterminalwireconnectingportion,providedinaccordancewith 5 a third embodiment of the invention.
This waterproofing structure and method are the most excellent as compared with the above two embodiments. More specifically, in the first embodiment, although the insulating 10 sheath 4 of the wire 2 is compressed, its resilient reaction force fis small, and the pressure of contact between the outer peripheral surface of the insulating sheath 4 and the inner peripheral surface of the wire connection portion 6 of the terminallisnotsolarge,andthereisafearthatthewaterproof 15 ability is lowered, for example, by a water pressure as developinginahighpressurewashingoperation,andthereduced elasticity of the insulating sheath 4 with the lapse of time.
In the second embodiment (Fig. 6), a relatively-bulky 20 apparatusisneeded,forexample,formeltingthehot-meltresin material (serving as the waterproof seal material 27) and for fillingitaroundtheexposedconductorportion3,andtherefore the cost is high, and besides there is a fear that the time and labor for the production increase partly because time is 25 required for cooling the hot-melt resin material.
1, As shown in Fig. 7 and Fig. 8 (cross-sectional view taken along the line F-F of Fig. 7), the terminal 31 has a cylindrical electrical contact portion 5 of the female type at one side 10 portion (front half portion),and also has the cylindricalwire connection portion 32 at the other side portion (rear half portion), and the electrical contact portion 5 and the wire connection portion 32 are interconnected by an intermediate interconnecting portion 7 of a smaller diameter in coaxial 15 relation to each other. The electrical contact portion 5 is simularto that of the first embodiment of Fig.3, and therefore explanation thereof will be omitted Those constituent ,\ portions, identical to those of the first embodiment, will be designated by identical reference numerals, respectively, and 20 detailed explanation thereof will be omitted.
The wire connection portion 32 is characterized in that it has a front insertion hole 8 of a smaller diameter for a conductor portion 3 of a wire 2, and a rear insertion hole 9 25 of a larger diameter for an insulating sheath 4 of the wire
2 as in the first embodiment of Figs. 1 and 3, the two insertion holes being disposed in coaxial relation to each other, and that an annular peripheral groove 34 for fittingly receiving the waterproof seal member is formed in an inner peripheral 5 surface of the rear insertion hole 9.
The annular waterproof seal member, such as an Oaring 33, is fitted in the peripheral groove 34, andin this condition the exposed conductor portion 3 (which is an end portion of 10 the wire 2) and the insulating sheath 4, extending from this conductor portion 3, are inserted respectively in the front andrearinsertionholes8and9, andtheouterperipheralsurface oftheinsulatingsheath4is contacted with aninner peripheral portion (inner diameter portion) 33a of the O-ring 33 with a 15 suitable contact pressure, thereby achieving a waterproof/dustproof effect for the interior of the wire connection portion 32.
Theinnerdiameterofthefrontinsertionhole8isslightly 20 larger than the outer diameter of the conductor portion 3, and the inner diameter of the rear insertion hole 9 is slightly larger than the outer diameter of the insulating sheath 4. A groovebottomdiameterD1oftheperipheralgroove34isDenerally equalto orslightlylarger than the outer diameterof the O-ring 25 33, and the inner diameter of the O-ring 33 is smaller than
the inner diameter of the rear insertion hole 9, and the inner diameter of the O-ring 33 is smaller than the outer diameter of the insulating sheath 4. The inner diameter of the O-ring 33 relative to the outer diameter of the insulating sheath 4, 5 thatisrafasteningamount, issuitablydeterminedinaccordance with the wire diameter Preferably, the outer diameter of the conductor portion 3 is smaller then the inner diameter ofthe O-ring 33, and with 10 this arrangement the conductor portions can tee smoothly passed through the O-ring 33 without being curled, bent or folded.
In the case where the conductor portion 3 comprises a single copper wire or a single aluminum:wire, there is no problem with the insertion even if the outer diameter of the conductor 15 portion3is generally equaltoorlarger than theinner diameter of the O-ring 33.
The depth (length) of the front insertion hole 8 is generally equal to the length of the exposed portion of the 20 conductor portion 3. A front end 4a of the insulating sheath 4 is abutted against a step portion 12 formed between the two insertion holes 8 and 9, so that the length of insertion of the wire 2 is accurately determined. The front end 4a of the insulating sheath 4 is inserted into the O-ring 33 while 25 spreading the inner peripheral portion 33a of the O-ring 33,
and the insulating sheath 4 is inserted into the insertion hole 9 While the outer peripheral surface of the insulating sheath 4 slides in contact with the inner peripheral surface 33a of the O-ring 33. The friction between the wire 2 and the O-ring 5 33 prevents the withdrawal of the wire 2 to a certain degree, and the wire 2 is held in its set condition unless the wire 2 is intentionally pulled. Therefore, the pressing operation at the subsequent step can be effected easily.
10 Although it is preferred that the peripheral groove 34 be disposed generally at a lengthwise-central portion of the rear insertion hole 9, it may be disposed closer to an opening 9a of the insertion hole 9. When it is desired to reduce the overall length of the terminal 31, the rear insertion hole 15 is shortened, and the peripheral groove 34 is disposed close to the opening 9a of the insertion hole 9, thereby securing the amount of insertion of the insulating sheath 4 of the wire 2 into the rear insertion hole 9.
20 As described above, the O-ring 33 is mounted in the wire connection portion 32 of the terminal 31, and the end portion of the wire 2 is inserted end set in the wire connection portion 32, and in this condition the wire connection portion 32 of the terminal 31 is compressively pressed radially uniformly 25 over the entire periphery thereof as shown in Figs. 9 and 10,
using entire-periphery pressing means such as rotary swaging means, es described above for the first embodiment. The rotary swaying can tee effected by the use of the rosary swaging machine 16 of Fig. 5. The working machine 16 is the same as described 5 above, and therefore explanation thereof will be omitted.
As a result of the entire-periphery uniform pressing of the wire connection portion 32 shown in Figs. g and 10, the wire connection portion 32 is reduced in diameter uniformly, 10 and therefore an outer peripheral portion (outer diameter portion) 33b of the O-ring 33 is pressed in a diameter-reducing direction by a groove bottom 34a of the peripheral groove 34.
Namely, the peripheral groove 34 is also reduced in diameter togetherwithaperipheralwallllofthewireconnectionportion 15 32, and therefore the O-ring 33 is compressed hard toward the center of the wire, so that the inner peripheral portion 33a of the O-ring 33 is held in firm, intimate contact with the outerperipheralsurfaceoftheinsulatingsheath4. Asaresult, regardless of the reduced elasticity of the O-ring 33 with the 20 lapseoftime, the O-ring 33 is forcibly held in firm, intimate contact with the insulating sheath 4, so that the waterproof effect is markedly enhanced.
Asin the first embodiment, the inner peripheralsurface 25 of the rear portion of the wire connection portion 32 of the
terminal 31 is held in firm, intimate contact with the outer peripheral surface of the insulating sheath 4, and this also achieves the waterproof and dustproof effect, and therefore the waterproof effect is further enhanced by the synergistic 5 effect achieved in cooperation with the Oring 33.
The O-ring 33 is held in firm, intimate contact with the outer peripheral surface of the insulating sheath 4 and the groove bottom surface 34a of the peripheral groove 34, and 10 therefore the interior of the wire connection portion 32 is kept air-tight, and the ambient atmosphere will not intrude intotheconductorportion3,andthereforetheouterperipheral surface of the conductor portion 3 of an aluminum material, the surface of each clement wire end theinnerperipheralsurface 15 of the terminal 31 of an aluminum material are prevented from oxidation (formation of an oxide film) with the lapse of time, and the good conducting performance is secured, and the reliability of the electrical connection is enhanced.
20 Even if the groove bottom diameter Dl of the peripheral groove 34 is larger than the outer diameter of the O-ring 33 intheinitialconditionofFig.8beforethepressingoperation, the groove bottomdiameterof the peripheralgroove34is reduced by the en/ire-periphery pressing of Fig. lOto thereby compress 25 the O-ring 33 radially. In the case where the initial groove
bottom diameter DlOf the peripheral groove34is set to a value larger than the outer diameter of the Oaring 33, the O-ring 33 is freely increased in diameter when the insulating sheath 4 of the wire 2 is inserted into the O-ring 33, and therefore 5 theinsertionforceofthewire2isreduced, sothattheoperation is easy.
Asin the first embodiment (Fig.3),theconductorportion 3 of the wire 2 is held in intimate contact with the inner 10 peripheral surface of the front portion of the peripheral wall llof the wire connectionportion32Of the terminal31 in biting relation thereto, with no gap formed therebetween, and also the element wires of the conductor portions 3 are intimately contacted with one another with no gap formed therebetween, 15 and therefore the electrical contact performance is enhanced.
By the en/ire-periphery pressing, the wire connection portion 32 is reduced in diameter, and at the same time it is extended longitudinally. 20 Instead of the O-ring 33, a square ring or other form of waterproof packing can be used. Such waterproof members (33) are not limited to elastic synthetic rubber, but can be made of a synthetic resin material such as soft vinyl similar to that used for insulating sheath 4 of the wire 2. The 25 peripheral groove 34 may not be provided, and an annular
waterproof sealmember(notshown),havinga fiat cross-section, can be mounted on the inner peripheral surface of the rear insertion hole 9 ofalarger diameter over the entire periphery thereof or on the outer peripheral surface of the insulating 5 sheath 4, and in this condition the insulating sheath 4 can be inserted into the insertion hole 9.
In the first embodiment of Fig. 3, a waterproof seal material (not shown), having an adhesive nature, a soft nature 10 or a solidifying nature, can be coated at an annular region between the outer peripheral surface of the insulating sheath 4andtheinnerperipheralsurfaceofthewireconnectionportion 6, and in this condition the wire connection portion 6 can be compressively pressed radially uniformly over the entire 15 periphery thereof, so that the waterproof seal material can achieve the waterproof/dustproof effect for the conductor portion 3. In this case, it is preferred that the waterproof seal material have at least a certain degree of flowability in its initial condition.
In the initial condition of Fig. 8 before the pressing operation, the inner diameter of the front insertion hole 8 and the inner diameter of the rear insertion hole 9 can be set to the same value, and in this case the end portion of the wire 25 2, that is, the conductor portion 3 and the insulating sheath
4 are inserted into the insertion holes 8 and 9, respectively, and in this condition the front insertion hole 8 is compressed into a diameter smaller than the diameter of the compressed rear insertion hole 9. In this case, for example, the outer 5 diameter oftheperipheralwallll, defining the frontinsertion hole 8, maybe beforehand set to a larger value while the outer diameter of the peripheral wall 10, defining the rearinsertion hole 9, may be set to a smaller diameter. Alternatively, the front insertion hole 8 and the rear insertion hole 9 may be 10 compressed separately from each other, using the dies 17 (Fig. 6) having different inner diameters.
As described above, according to the invention, the conductor portion of the wire is held in intimate contact with 15 the inner peripheral surface of the wire connection portion of the terminal over the entire periphery thereof with the uniformstress,withno gap formed therebetween, and therefore the electrical contact performance is enhanced. And besides, the insulating sheath of the wire is compressed radially 20 uniformly over the entire periphery "hereof, andis resiliently intimately contacted with the inner peripheral surface of the wire connection portion, and therefore theinteriorof the wire connection portion is waterproofed, and the conductor portion end theinner peripheral surface of the wire connection portion 25 arepreventedfromoxidation. Evenin the case where an aluminum
material, on which an oxide film is liable to be formed, is used for the conductor portion and the terminal, the formation of an oxide film with the lapse of time is prevented fro the above reason, and therefore the conducting resistance is kept 5 to a lower level, and the good electrical connection is always achieved. The smaller-diameter conductor portion can be held in intimate contact with the inner 10 peripheral surface of the insertion hole, having the corresponding diameter, with no gap formed therebetween, and the larger-diameter insulating sheath is held in intimate contactwiththeinnerperipheraleurfaceoftheinsertionhole, having the corresponding diameter, with no gap formed 15 therebetween. Therefore, theentire-peripherypressingofthe generally-tubular wire connection portion can be carried out effectivelywithlesstimeandlabor, andbesidesthereliability of the electrical connection and the reliability of the waterproof seal performance can both be enhanced.
According to the invention, the outer peripheral surface oftheinsulating sheath of the wire is held in intimate contact with the waterproof seal materialor the waterproof sealmeher over the entire periphery thereof with the uniform force, with 25 no gap formed therebetween (the waterproof seal material or
the waterproof seal member is held in intimate contact with the outer peripheral surface of the insulating sheath of the wire over the entire periphery thereof with the uniform force, with no gap formed therebetween) , and also the waterproof seal 5 material or the waterproof seal member is held in intimate contact with the inner surface of the wire connection portion of the terminal over the entire periphery thereof with the uniform stress, with no gap formed therebetween. Therefore, the intrusion of water and others into the wire connection 10 portion is more positively prevented, and the oxidation of the conductor portion, aswellas the oxidation oftheinner surface of the terminal, is more positively prevented. The waterproof effect is achieved by the intimate contact of the outer peripheral surface of the insulating sheath with the inner 15 peripheral surface of the wire connection portion, and also thewaterproofeffectisachievedbythewaterproofsealmaterial orthewaterproofsealmember,andwith this synergisticeffect, the interior of the wire connection portion is kept air-tight, and the assured waterproof performance is achieved over a long 20 period of time.
When the wire connection portion is pressed the waterproof seal member can be compressed in the peripheral groove, and is intimately contacted with the 25 outer peripheral surface of the insulating sheath with a large
pressure. As a result, the waterproof seal effect is markedly enhanced, andbesidestheinteriorofthewireconnectionportion is kept air-tight, and for example, the conductor portion of an aluminum.material and the inner surface of the terminal of 5 an aluminum material are more positively prevented from oxidation. In the initial condition before the pressing operation, the waterproof seal member is mounted in the peripheral groove in the terminal, and by doing so, the end portion of the wire can be easily inserted and set in the wire 10 connection portion. Before the wire is pressed, the wire is held by a tightly-holding force of the waterproof seal mummer, and the withdrawal of the wire is prevented, and therefore the entire-periphery pressing operation can be effected easily.
15 The generally-tubular wire connection portion of the terminal is repeatedly pounded by the plurality of rotating dies of the rotary swaying machine, and is compressively plastically deformed in the diameter-reducing direction. Therefore, the conductor 20 portion of the wire is compressively pressed with the uniform stress over the entire periphery thereof, and is connected to the wire connection portion, with no gap formed therebetween' and also the insulating sheath of the wire is held in intimate contact with theinnerperipheralaurfaceof the wire connection 25 portionwiththeuniformstressovertheentireperipherythereof,
with no gap formed therebetween, and the annular waterproof sent member is heldin intimate contact with the inner surface of the wire connection portion with the uniform stress over the entire periphery "hereof, with no gap formed therebetween.
5 Therefore, the enhanced reliability of the electrical connection and the enhanced waterproof effect are achieved at the same time.
do,
Claims (4)
1. Method of waterproofing a terminal-wire connecting portion comprising the steps of: 5 simultaneously inserting a conductor portion and an insulating sheath of a wire into a substantially cylindrical wire connection portion of a terminal; and pressing radially uniformly with a plurality of dies of a rotary swaging machine the wire connection portion 10 over an entire periphery thereof to be compressively plastically deformed.
2. The method according to claim 1, wherein the conductor portion is inserted into a smaller 15 diameter insertion hole formed in the wire connection portion, the insulating sheath is inserted into a larger-
diameter insertion hole formed in the wire connection portion in coaxial relation to the smaller-diameter 20 insertion hole, and the smallerdiameter and larger-diameter insertion holes are pressed radially.
3. The method according to claim 1, wherein 25 the pressing step is performed under a state in which one of a waterproof seal material and a waterproof seal member is arranged in an annular shape with respect to an outer peripheral surface of the insulating sheath within the wire connection portion.
4. The method according to claim 3, wherein the pressing step is performed under a state in which a peripheral groove for receiving the elastic waterproof seal member is formed in an inner surface of the wire connection portion, 35 and the waterproof seal member is mounted in the peripheral groove.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2001012311A JP2002216862A (en) | 2001-01-19 | 2001-01-19 | Waterproof structure of connection part of electric wire and terminal, and waterproofing method |
| GB0201029A GB2371418B (en) | 2001-01-19 | 2002-01-17 | Structure for waterproofing terminal-wire connecting portion |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| GB0313272D0 GB0313272D0 (en) | 2003-07-16 |
| GB2387280A true GB2387280A (en) | 2003-10-08 |
| GB2387280B GB2387280B (en) | 2004-10-13 |
Family
ID=27806718
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB0313272A Expired - Fee Related GB2387280B (en) | 2001-01-19 | 2002-01-17 | Method of waterproofing terminal-wire connecting portion |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2387280B (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP2175529A1 (en) * | 2008-10-07 | 2010-04-14 | Andrew LLC | Inner conductor sealing insulator for coaxial connector |
| EP2184815A1 (en) * | 2008-10-07 | 2010-05-12 | Andrew LLC | Sealed inner conductor contact for coaxial cable connector |
| EP3039747A1 (en) * | 2013-08-26 | 2016-07-06 | Carlisle Interconnect Technologies, Inc. | Terminal/connector having integral oxide breaker element |
-
2002
- 2002-01-17 GB GB0313272A patent/GB2387280B/en not_active Expired - Fee Related
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7819698B2 (en) | 2007-08-22 | 2010-10-26 | Andrew Llc | Sealed inner conductor contact for coaxial cable connector |
| EP2175529A1 (en) * | 2008-10-07 | 2010-04-14 | Andrew LLC | Inner conductor sealing insulator for coaxial connector |
| EP2184815A1 (en) * | 2008-10-07 | 2010-05-12 | Andrew LLC | Sealed inner conductor contact for coaxial cable connector |
| US7798847B2 (en) | 2008-10-07 | 2010-09-21 | Andrew Llc | Inner conductor sealing insulator for coaxial connector |
| EP3039747A1 (en) * | 2013-08-26 | 2016-07-06 | Carlisle Interconnect Technologies, Inc. | Terminal/connector having integral oxide breaker element |
Also Published As
| Publication number | Publication date |
|---|---|
| GB2387280B (en) | 2004-10-13 |
| GB0313272D0 (en) | 2003-07-16 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PCNP | Patent ceased through non-payment of renewal fee |
Effective date: 20200117 |