JP2004111058A - Terminal for aluminum wire and connector - Google Patents

Terminal for aluminum wire and connector Download PDF

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JP2004111058A
JP2004111058A JP2002267844A JP2002267844A JP2004111058A JP 2004111058 A JP2004111058 A JP 2004111058A JP 2002267844 A JP2002267844 A JP 2002267844A JP 2002267844 A JP2002267844 A JP 2002267844A JP 2004111058 A JP2004111058 A JP 2004111058A
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terminal
aluminum
connector
rear end
wire
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Japanese (ja)
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Yutaka Matsuda
松田　裕
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Furukawa Electric Co Ltd
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Furukawa Electric Co Ltd
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  • Connector Housings Or Holding Contact Members (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To provide a connector for connecting an aluminum wire to a connector equipped with a terminal made of copper group metal, preventing electric corrosion generated at a contact part of different kind of metals. <P>SOLUTION: A back end part of a terminal 12, to which an aluminum conductor 18 of the aluminum wire 16 is to be connected, is made of aluminum alloy, and a top end part of a terminal 14, to be connected to the mate side terminal mate of copper group terminal, is made of copper alloy. A jointing terminal 46 is formed by jointing the back end part of the terminal 12 and the top end part of the terminal 14, and the jointing terminal is mounted to a connector housing 48. The jointing part, where the back end part of the terminal 12 is jointed to the top end part of the terminal 14, is sealed by a resin 50 filled in the connector housing 48, and a resin flow blocking wall 54 is formed. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】本発明は、アルミ電線（導体にアルミ又はアルミ合金を用いた電線）の接続に用いられる端子及びコネクタに関するものである。
【０００２】
【従来の技術】従来、自動車のワイヤハーネス等の分野では、銅電線が使用され、アルミ電線はほとんど使用されていなかった。近年、リサイクル性向上、軽量化の目的から従来の銅電線に代えて、アルミ電線を使用する動きがある。ワイヤハーネスにアルミ電線を使用する場合、ワイヤハーネスのコネクタの端子をアルミ化しても、電装品側のコネクタの端子をアルミ化できない場合があり、アルミ電線ワイヤハーネスを実用化する上でのネックとなっている。
【０００３】
【発明が解決しようとする課題】すなわち、ワイヤハーネス側がアルミ電線、アルミ系端子となっても、電装品側が銅系端子のままであると、アルミ系端子と銅系端子の接触部が、水や湿気の存在により、電食を起こすという問題がある。
【０００４】このため、アルミ系端子と銅系端子の結合部にグリースを充填する技術が提案されているが、グリースの充填は、作業現場が汚れやすく、また物流時、完成品のハンドリング時に、グリースが流れ出て車両部品を汚し、商品価値を損なう等の問題がある。
【０００５】また防水コネクタを用いるという提案もあるが、従来防水コネクタが不要とされていた部位に防水コネクタを使用することは、大幅なコストアップを招くと共に、何らかの原因で防水コネクタ内にいったん水が浸入すると、逆に電食を促進する結果となる。
【０００６】本発明の目的は、以上のような問題点に鑑み、アルミ又はアルミ合金と銅又は銅合金との接触部での電食を防止したアルミ電線用端子及びコネクタを提供することにある。
【０００７】
【課題を解決するための手段】異種金属接触部の電食を防ぐため本発明では、アルミ電線が接続される端子後端部をアルミ又はアルミ合金で形成し、相手方端子と接続される端子先端部を銅又は銅合金で形成し、前記端子後端部と端子先端部を溶接等の手段により接合して、その接合部を樹脂等の絶縁体により封止することにより、異種金属接触部に水、湿気等を付着させないようにした。
【０００８】また、アルミ又はアルミ合金で形成した端子後端部は、表面に酸化被膜が生成、成長することから、表面に、ニッケル下地メッキを施した後、スズ等の酸化被膜を形成しにくい金属のメッキをすることが必要となるが、そのメッキ部分と非メッキ部分の境界が異種金属接触部を形成するため、本発明では、メッキ境界を前記接合部近傍に設定し、メッキ境界を含んで前記絶縁体により封止するようにした。
【０００９】また端子後端部が連鎖端子として形成され、メッキが施されている場合には、隣り合う端子後端部との切断部にも異種金属接触部が生じるので、本発明ではこの切断部も併せて前記絶縁体により封止するようにした。
【００１０】またアルミ電線のアルミ導体が、水又は湿気等の浸入によって腐食するのを防止するため、本発明ではアルミ電線の絶縁被覆の端部も併せて前記絶縁体により封止するようにした。
【００１１】さらに本発明では、端子後端部のアルミ電線を接続する部分を圧接刃とすることにより、端子をコネクタハウジングにセットした後に、アルミ電線を圧接接続し、端子の接合部と圧接接続部を一括して絶縁体で封止することにより、封止を安価に実現できるようにした。
【００１２】また異種金属接触部を絶縁体で封止する際に、封止材が端子先端部へ流入して相手方端子との接触不良が発生するの防止するため、本発明では、端子、コネクタハウジング又はその両方に、封止用絶縁体の流入阻止壁を設けた。
【００１３】また本発明では、全体が銅又は銅合金で形成された端子を使用し、その端子にアルミ電線を直接接続する場合にも、同様に、コネクタハウジング内で接続部を絶縁体で封止することにより、電食防止を図った。
【００１４】より具体的には、本発明は、端子の形態とコネクタの形態に分けることができる。本発明に係るアルミ電線用端子は、アルミ電線が接続される端子後端部をアルミ又はアルミ合金で形成し、相手方端子と接続される端子先端部を銅又は銅合金で形成し、前記端子後端部と端子先端部を接合して、その接合部を絶縁体で封止したことを特徴とするものである。
【００１５】端子後端部と端子先端部との接合は、抵抗溶接、レーザー溶接、超音波溶接、ＴＯＸ接合（一方の金属板に形成した凹部の外側を、他方の金属板に形成した凹部の内側に圧入することにより２枚の金属板を接合する方法）及びリベット接合のいずれかで行なうことができる。この端子は、端子後端部にアルミ電線を接続し、コネクタハウジングに組み込んで使用されるものである。
【００１６】本発明に係るアルミ電線用端子は、端子後端部に、端子先端部との接合部分を除いて、表面に酸化被膜を生じにくい金属によるメッキが施され、封止用の絶縁体がメッキ部分と非メッキ部分の境界部をも覆うように形成されていることが好ましい。
【００１７】また本発明に係るアルミ電線用端子は、端子後端部にアルミ電線が接続され、封止用の絶縁体がアルミ電線の絶縁被覆の端部をも覆うように形成されていることが好ましい。
【００１８】また本発明に係るアルミ電線用端子は、端子後端部が、連鎖端子の連結部を切断した連結切断部を有している場合には、封止用の絶縁体がこの連結切断部をも覆うように形成されていることが好ましい。
【００１９】次に、本発明に係るアルミ電線用コネクタは、アルミ電線が接続される端子後端部をアルミ又はアルミ合金で形成し、相手方端子と接続される端子先端部を銅又は銅合金で形成し、前記端子後端部と端子先端部を接合して接合端子を構成し、この接合端子をコネクタハウジングに組み込み、前記端子後端部と端子先端部との接合部をコネクタハウジング内に充填した絶縁体で封止したことを特徴とするものである。
【００２０】本発明に係るアルミ電線用コネクタは、端子先端部又はコネクタハウジングに、コネクタハウジング内に充填した絶縁体が端子先端部の相手方端子との接触部に流入しないようにする流入阻止壁を設けておくことが好ましい。
【００２１】また本発明に係るアルミ電線用コネクタは、端子後端部に、端子先端部との接合部分を除いて、表面に酸化被膜を生じにくい金属によるメッキが施され、封止用の絶縁体がメッキ部分と非メッキ部分の境界部をも覆うように充填されていることが好ましい。
【００２２】また本発明に係るアルミ電線用コネクタは、端子後端部にアルミ電線が接続され、封止用の絶縁体がアルミ電線の絶縁被覆の端部をも覆うように充填されていることが好ましい。
【００２３】また本発明に係るアルミ電線用コネクタにおいて、端子後端部が連鎖端子の連結部を切断した連結切断部を有している場合には、封止用の絶縁体がこの連結切断部をも覆うように充填されていることが好ましい。
【００２４】また本発明に係るアルミ電線用コネクタは、端子後端部がアルミ電線を圧接接続する圧接刃を有しており、封止用の絶縁体がアルミ電線を圧接接続した圧接刃をも覆うように充填されていることが好ましい。
【００２５】次に、本発明に係るアルミ電線用コネクタは、銅又は銅合金製の端子にアルミ電線を直接接続し、端子とアルミ電線の接続部を、コネクタハウジング内に充填した絶縁体で封止したものであってもよい。
【００２６】このコネクタの場合も、封止用の絶縁体がアルミ電線の絶縁被覆の端部をも覆うように充填されていることが好ましい。
【００２７】また本発明に係るアルミ電線用コネクタは、銅又は銅合金製の端子を溶接ヘッド挿入用の開口部を有するコネクタハウジング内にセットし、アルミ電線の端部を前記コネクタハウジング内にセットして、コネクタハウジング内で端子とアルミ電線を溶接接続し、前記開口部から絶縁体を充填して前記端子とアルミ電線の溶接接続部を封止した構成とすることもできる。
【００２８】また銅又は銅合金製の端子を用いる場合にも、端子又はコネクタハウジングに、コネクタハウジング内に充填した絶縁体が端子の相手方端子との接触部に流入しないようにする流入阻止壁を設けておくことが好ましい。
【００２９】次に、本発明に係るアルミ電線用コネクタは、アルミ又はアルミ合金製の端子を有するアルミ電線側のコネクタが接続される機器側のコネクタであってもよく、その場合は、前記アルミ電線側コネクタの端子に接続される端子先端部をアルミ又はアルミ合金で形成し、機器側に接続される端子後端部を銅又は銅合金で形成し、前記端子先端部と端子後端部を接合して、その接合部をコネクタハウジングの樹脂壁により又はコネクタハウジング内に充填された絶縁体により封止した構成とすればよい。
【００３０】このアルミ電線用機器側コネクタの場合も、アルミ又はアルミ合金よりなる端子先端部は、端子後端部との接合部分を除いて、表面に酸化被膜を生じにくい金属によるメッキが施され、メッキ部分と非メッキ部分の境界部が、コネクタハウジングの樹脂壁により又はコネクタハウジング内に充填された絶縁体により封止されていることが好ましい。
【００３１】
【発明の実施の形態】以下、本発明の実施の形態を、図面を参照して詳細に説明する。
【００３２】
〔実施形態１〕　図１は本発明に係るアルミ電線用端子の一実施形態を示す。この端子１０は、アルミ合金板のプレス加工により成形された端子後端部１２と、銅合金板のプレス加工により成形された端子先端部１４とを備えている。
【００３３】端子後端部１２は、アルミ電線１６のアルミ導体１８を圧着するワイヤバレル部２０と、アルミ電線１６の絶縁被覆２２を把持するインシュレーションバレル部２４と、端子先端部１４側へ伸びる接合片２６とを有している。アルミ合金は、放置しておくと、表面に絶縁性の酸化被膜を生成するため、板材の状態でニッケル下地メッキとスズメッキを施して、表面の酸化被膜が成長し難くなるように処理した後、端子後端部１２を形成するためのプレス加工を行なう。この場合、プレスで打ち抜き加工された断面及びプレスで曲げ加工されてメッキが破壊された部分に、メッキ材とアルミ合金母材との異種金属接触部が出現してしまうことが考えられるが、アルミとスズの電食は、アルミと銅の電食に比較すると軽微であり、例えば車室内環境等の良好な条件においては十分な品質を確保できる。
【００３４】端子先端部１４は雌型接触子の形態で、角筒部２８と、その中に折り返された弾性接触片３０と、角筒部２８から端子後端部１２側へ伸びる接合片３２とを有している。端子先端部１４は、表面にスズメッキを施した銅合金板をプレス加工することにより形成される。
【００３５】端子後端部１２の接合片２６と端子先端部１４の接合片３２は重ね合わせて溶接等の手段により接合される。接合手段としては、抵抗溶接、レーザー溶接等の溶接接合のほか、ＴＯＸ接合、リベット接合等の機械的接合、あるいは半田接合なども利用できる。接合片２６と３２の接合部は樹脂３４により封止する。この樹脂封止によってアルミ合金と銅合金の接合部に水又は湿気が付着することがなくなり、電食を防止できる。
【００３６】接合部の樹脂封止は図２のようにして行なうことができる。すなわち、接合片２６と３２の接合部を中心にして、その両側を含むようにモールド容器３６をセットする。このモールド容器３６は接合片２６、３２を境に上下に分割可能である。分割された容器はバックル等で結合することにより、接合片２６、３２を挟み付けるようになっている。容器３６を図２のようにセットした後、容器３６内に樹脂３４を注入し、硬化させる。樹脂硬化後にモールド容器３６を取り外せば、図１のような端子１０が得られる。
【００３７】以上のように構成された端子１０は、端子後端部１２に通常の圧着法又は圧接法でアルミ電線１６を接続し、コネクタハウジング３８に組み込んで使用される。この端子１０は端子先端部１４が銅合金製であるため、電装品や電気接続箱側の銅系端子と通常どおり接続することができる。
【００３８】
〔実施形態２〕　図３は本発明に係るアルミ電線用端子の他の実施形態を示す。この実施形態は、端子後端部１２の接合片２６と端子先端部１４の接合片３２とを超音波溶接により接合する場合に好適である。超音波溶接の場合は、接合部分にメッキが存在すると、メッキ面が滑り、良好な溶接ができないので、メッキを存在させないことが好ましい。このため、アルミ合金製の端子後端部１２は、接合片２６の先端部分（端子先端部１４の接合片３４との接合部分）を除いて、メッキ４０が施されている。このような端子後端部１２は、プレス加工後に、接合片２６の先端部分を除いて、酸洗等の処理後、ニッケル下地メッキ及びスズメッキ４０を施すことにより製造できる。このようにすると、プレスで打ち抜いた断面も含めてスズメッキできるため、電食対策箇所を少なくできる。
【００３９】銅合金製の端子先端部１４は実施形態１と同様である。端子先端部１４は、弾性接触片３０にメッキを施すことが不可欠であるが、切断面に銅とスズの接触が生じても電食の問題は軽微であるため、例えば必要範囲だけスズメッキを施した銅合金板をプレス加工して、接合片３２の部分にメッキのない端子先端部１４を形成することもできる。
【００４０】上記のようにメッキのない接合片２６と３２を超音波溶接により接合すれば、良好な溶接部を得ることができる。なお、接合片２６、３２にメッキを施さない場合も、超音波溶接ではなく、抵抗溶接、レーザー溶接、ＴＯＸ接合等で接合することも可能である。
【００４１】接合片２６、３２を接合した後、接合部を樹脂３４で封止するが、この樹脂封止は、特に端子後端部１２のメッキ部分と非メッキ部分の境界部Ｐを含むように行なう。このようにすればより確実に電食を防止できる。
【００４２】上記以外の構成は実施形態１と同じであるので、同一部分には同一符号を付して説明を省略する。
【００４３】
〔実施形態３〕　図４は本発明に係るアルミ電線用端子のさらに他の実施形態を示す。この端子１０が、実施形態２と異なる点は、樹脂３４による封止を、接合片２６と３２の接合部及び端子後端部１２のメッキ部と非メッキ部の境界部Ｐだけでなく、アルミ電線１６の絶縁被覆２２の端部を含めて行なったことである。このようにするとアルミ電線１６のアルミ導体１８に水や湿気が浸入することを防止できる。
【００４４】何らかの原因でアルミ電線の導体（通常は撚線）に水が付着すると、毛細管現象で絶縁被覆の中にまで水が浸入してしまい、なかなか水が電線から抜けないという現象が生じるが、樹脂３４で上記のように封止すると、水の浸入を防止できる。またアルミ導体の場合は、いったん素線間に水が入り込むと、隙間腐食を起し、導体が膨張し、当該電線の通電自体に問題が出るばかりでなく、腐食が進行すると、膨張により絶縁被覆が突き破られ、さらに他の電線に対しても損傷を及ぼすおそれがあるが、樹脂３４で上記のように封止することにより、アルミ導体１８の腐食も防止できる。
【００４５】上記以外の構成は実施形態２と同じであるので、同一部分には同一符号を付して説明を省略する。この実施形態は実施形態１の端子にも適用可能である。
【００４６】
〔実施形態４〕　図５は本発明に係るアルミ電線用端子のさらに他の実施形態を示す。この実施形態は、端子後端部１２が、連鎖端子の連結部を切断した連結切断部４２を有している場合である。連結切断部４２では、アルミ合金母材とメッキ材が接触し、電食が発生するおそれがある。そこでこの実施形態では、連結切断部４２を接合片２６の近くに設定し（連鎖端子の連結部を接合片２６の近くに形成しておく）、封止用の樹脂３４を、連結切断部４２をも覆うように形成したものである。このようにすれば、連結切断部４２での電食をも防止できる。それ以外の構成は実施形態２と同じであるので、同一部分には同一符号を付して説明を省略する。この実施形態は実施形態１の端子にも適用可能である。
【００４７】
〔実施形態５〕　図６は本発明に係るアルミ電線用コネクタの一実施形態を示す。このコネクタ４４は、アルミ合金製の端子後端部１２と銅合金製の端子先端部１４とを、各々の接合片２６と３２を接合することにより一体化した接合端子４６を備えている。端子後端部１２及び端子先端部１４の構成は実施形態１と同じであり、接合片２６、３２の接合の仕方も実施形態１と同じである。
【００４８】このコネクタ４４は、上記のような接合端子４６（接合部が樹脂封止されていないもの）をコネクタハウジング４８に組み込み、接合片２６と３２の接合部をコネクタハウジング４８内に充填した樹脂５０により封止したものである。なおアルミ電線１６は、接合端子４６をコネクタハウジング４８に組み込む前に、端子後端部１２に接続される。
【００４９】コネクタハウジング４８には充填した樹脂５０が端子後端部１２及び端子先端部１４に流れ込まないように流入阻止壁５２、５４が形成されている。特に端子先端部１４に樹脂が流入すると、弾性接触片３０に樹脂が付着して接触不良を起こすおそれがあるので、端子先端部１４側の流入阻止壁５４は重要である。このような流入阻止壁５２、５４を有するコネクタハウジング４８は、接合端子４６の組み込みを可能にするため、上下に分割できるようにしておくとよい。
【００５０】また流入阻止壁はコネクタハウジングではなく端子側に設けることも可能である。その一例を図７（Ａ）、（Ｂ）に示す。すなわち、端子先端部１４を製作するときに、（Ａ）に示すように接合片３２の両側（又は片側）に壁板片５６を形成しておき、この壁板片５６を、点線部分を内折りにして折り立てれば、（Ｂ）のように流入阻止壁５４を形成することができる。図示してないが、端子後端部にも同様にして流入阻止壁を形成することができる。このように端子側に流入阻止壁を設けておけば、コネクタハウジングの構造が簡単になる。
【００５１】
〔実施形態６〕　図８は本発明に係るアルミ電線用コネクタの他の実施形態を示す。この実施形態はアルミ電線用端子の場合の実施形態２（図３）に相当するものである。すなわち、このコネクタ４４は、端子後端部１２に、接合片２６の先端部（端子先端部との接合部分）を除いて、表面に酸化被膜を生じにくい金属によるメッキ４０が施され、そのメッキ部分と非メッキ部分の境界部Ｐが、接合片２６、３２の接合部と共に、コネクタハウジング４８内に充填された樹脂５０により封止されているものである。上記以外の構成は実施形態５と同じであるので、同一部分には同一符号を付して説明を省略する。
【００５２】
〔実施形態７〕　図９は本発明に係るアルミ電線用コネクタのさらに他の実施形態を示す。この実施形態はアルミ電線用端子の場合の実施形態３（図４）に相当するものである。すなわち、このコネクタ４４は、端子後端部１２にアルミ電線１６が接続され、接合片２６、３２の接合部を封止する樹脂５０が、アルミ電線１６の絶縁被覆２２の端部をも覆うようにコネクタハウジング４８に充填されているものである。このようにすれば、アルミ導体１８内に水や湿気が浸入しなくなり、実施形態３と同様な効果が得られる。上記以外の構成は実施形態６と同じであるので、同一部分には同一符号を付して説明を省略する。
【００５３】
〔実施形態８〕　図１０は本発明に係るアルミ電線用コネクタのさらに他の実施形態を示す。この実施形態はアルミ電線用端子の場合の実施形態４（図５）に相当するものである。すなわち、このコネクタ４４は、端子後端部１２が、連鎖端子の連結部を切断した連結切断部４２を有しており、接合片２６、３２の接合部を封止する樹脂５０が、この連結切断部４２をも覆うようにコネクタハウジング４８に充填されているものである。上記以外の構成は実施形態６と同じであるので、同一部分には同一符号を付して説明を省略する。
【００５４】
〔実施形態９〕　図１１は本発明に係るアルミ電線用コネクタのさらに他の実施形態を示す。この実施形態は、アルミ合金製の端子後端部１２が、アルミ電線２２のアルミ導体１８を圧接接続する圧接刃５８を備えている場合である。すなわち、このコネクタ４４は、端子後端部１２の圧接刃５８にアルミ電線１６のアルミ導体１８が圧接接続され、接合片２６、３２の接合部を封止する樹脂５０が、その圧接接続部をも覆うようにコネクタハウジング４８に充填されているものである。圧接接続部では、端子後端部１２のメッキが損傷して腐食が発生するおそれがあるが、樹脂５０で圧接接続部を含めて封止しておけば、圧接接続部の腐食を防止できる。端子後端部１２へのアルミ電線１６の圧接接続は、接合端子４６をコネクタハウジング４８に組み込む前に行なってもよいし、組み込んだ後で行なってもよい。上記以外の構成は実施形態６と同じであるので、同一部分には同一符号を付して説明を省略する。
【００５５】
〔実施形態１０〕　図１２は本発明に係るアルミ電線用コネクタのさらに他の実施形態を示す。この実施形態は、全体が銅合金製の端子にアルミ電線２２を直接接続する場合である。すなわち、このコネクタ４４は、銅合金製の端子６０のワイヤバレル部２０にアルミ電線１６のアルミ導体１８を溶接接続すると共に、インシュレーションバレル部２４でアルミ電線１６の絶縁被覆２２を把持し、ワイヤバレル部２０とアルミ導体１８との溶接接続部を、コネクタハウジング４８内に充填した樹脂５０により封止したものである。このようにすると、異種金属接触部に水や湿気が付着するおそれがないので、電食を防止できると共に、通常の銅合金製の端子を使用できるのでコスト安である。
【００５６】銅合金製の端子６０にはスズメッキが施されているが、ワイヤバレル部２０とアルミ導体１８との接続を超音波溶接で行なう場合には、ワイヤバレル部２０にメッキを存在させないことが好ましい。したがって超音波溶接を採用する場合は、メッキを部分的に施した銅合金板をプレス加工して、ワイヤバレル部２０にメッキのない端子６０を製作し、使用することが好ましい。
【００５７】図１２のコネクタ４４は、銅合金製の端子６０にアルミ電線１６を接続した後、端子６０をコネクタハウジング４８内にセットし、コネクタハウジング４８内に、端子６０とアルミ導体１８の溶接接続部を埋め込むように樹脂５０を充填することにより製作される。この場合も、コネクタハウジング４８内に充填した樹脂５０が端子６０の角筒部２８内に流れ込まないように、コネクタハウジング４８には流入阻止壁５４が設けられている。
【００５８】
〔実施形態１１〕　図１３は本発明に係るアルミ電線用コネクタのさらに他の実施形態を示す。この実施形態も銅合金製の端子にアルミ電線を直接接続する場合であるが、この実施形態が実施形態１０と異なる点は、封止用の樹脂５０が、端子６０とアルミ導体１８の溶接接続部だけでなく、アルミ電線１６の絶縁被覆２２の端部をも覆うようにコネクタハウジング４８内に充填されていることである。このようにすれば、アルミ導体１８内に水や湿気が浸入しなくなり、実施形態３と同様な効果が得られる。上記以外の構成は実施形態１０と同じであるので、同一部分には同一符号を付して説明を省略する。
【００５９】
〔実施形態１２〕　図１４は本発明に係るアルミ電線用コネクタのさらに他の実施形態を示す。この実施形態も銅合金製の端子にアルミ電線を直接接続する場合であるが、この実施形態が実施形態１０と異なる点は、端子６０のワイヤバレル部２０とアルミ電線１６のアルミ導体１８との溶接接続をコネクタハウジング４８内で行なうようにしたことである。
【００６０】この場合には、端子６０をコネクタハウジング４８内にセットし、コネクタハウジング４８には予め端子６０のワイヤバレル部２０に相当する位置の上下に開口部６２Ａ、６２Ｂを形成しておき、この開口部６２Ａ、６２Ｂに溶接ヘッド６４Ａ、６４Ｂを挿入してアルミ導体１８とワイヤバレル部２０を挟み付け、その状態で抵抗溶接を行なう。その後、下側の開口部６２Ｂを適当な治具で塞ぎ、上側の開口部６２Ａから樹脂を注入して、溶接接続部を封止する。上記以外の構成は実施形態１０と同じであるので、同一部分には同一符号を付して説明を省略する。
【００６１】
〔実施形態１３〕　図１５は本発明に係るアルミ電線用コネクタのさらに他の実施形態を示す。この実施形態は、アルミ電線側のコネクタの端子がアルミ合金製である場合に、そのアルミ電線側のコネクタが接続される機器側のコネクタに本発明を適用したものである。このコネクタ６６は、アルミ電線側コネクタの端子に接続される端子先端部６８をアルミ合金で形成し、機器側の導体に接続される端子後端部７０を銅合金で形成して、端子先端部６８と端子後端部７０を溶接等で接合し、その接合部をコネクタハウジング７２の樹脂壁で封止したものである。
【００６２】端子先端部６８は、雄タブ状で、アルミ合金の板材をプレス加工して製作する。アルミ合金は放置しておくと、表面に酸化被膜を生成するため、プレス加工後に、ニッケル下地メッキとスズメッキを施し、表面の酸化被膜が成長し難くなるように処理する。メッキは、プレス加工前に板の状態で行なうことも考えられるが、そうすると、プレスで打ち抜いた断面に、メッキ材とアルミ合金母材との異種金属接触部が出現してしまい、電食防止処理が必要となるので、プレス加工後にメッキ処理を行なうことが好ましい。プレス加工後のメッキ処理で、端子後端部との接合部分にメッキを施さない場合は、メッキ部分と非メッキ部分の境界を接合部付近に設定する。
【００６３】端子後端部７０は、電装品内の回路基板等に半田付けされる部分であり、黄銅等の銅合金にスズメッキを施したものである。
【００６４】端子先端部６８と端子後端部７０は端部を重ね合わせて、スポット溶接（抵抗溶接）等により接合する。接合方法としては、スポット溶接の他、超音波溶接、レーザー溶接、ＴＯＸ接合、リベット接合、半田接合などを利用できる。超音波溶接の場合は接合面にメッキが存在しないことが好ましい。
【００６５】以上のようにして製作された接合端子７４は、ハウジング７２の樹脂壁に圧入して、接合部をハウジング７２の樹脂壁の中に埋め込むようにする。またメッキ部分と非メッキ部分の境界部がある場合には、それもハウジング７２の樹脂壁の中に埋め込むようにする。さらに接合時にメッキが破損した部分がある場合には、それもハウジング７２の樹脂壁の中に埋め込むようにする。このようにすれば接合端子７４の異種金属接触部に水や湿気が付着しなくなり、電食を防止できる。圧入部の気密性を高めるためには、圧入部に溶融樹脂を供給して密閉してもよい。また圧入の際の圧入抵抗を少なくするためには、図示のように端子先端部６８と端子後端部７０の接合部で両者の板厚をほぼ１／２ずつにして、全長にわたって板厚を一様にすることが好ましい。
【００６６】
〔実施形態１４〕　図１６は本発明に係るアルミ電線用コネクタのさらに他の実施形態を示す。この実施形態も実施形態１３と同様、アルミ電線側のコネクタの端子がアルミ合金製である場合に、そのアルミ電線側コネクタが接続される機器側のコネクタに本発明を適用したものである。このコネクタ６６が実施形態１３のコネクタと異なる点は、アルミ合金製の端子先端部６８と銅合金製の端子後端部７０との接合部をコネクタハウジング７２に設けた空洞内に位置させ、その空洞内に樹脂７６を充填することにより接合部を封止したものである。樹脂７６としては、ホットメルト樹脂又はコネクタハウジングと同じ樹脂例えばＰＢＴなどを使用することができる。上記以外の構成は実施形態１３と同じであるので、同一部分には同一符号を付して説明を省略する。
【００６７】図１７及び図１８はそれぞれ、実施形態１４のコネクタ６６の使用状態を示す。いずれもコネクタ６６の端子後端部７０は、電装品のケース７８内に収納された回路基板８０に半田付け接続されている。８２は回路基板８０に実装された電子部品である。図１７はコネクタハウジング７２を回路基板８０に固定した場合であり、図１８はコネクタハウジング７２をケース７８に固定した場合である。コネクタ６６の端子先端部６８には、アルミ電線１６側のコネクタ８４のアルミ合金製の端子（雌端子）が接続される。この接続はアルミ合金製の端子同士の接触となるので電食の問題は生じない。実施形態１３のコネクタもこれと同様に使用される。
【００６８】
【発明の効果】以上説明したように本発明によれば、ワイヤハーネス等にアルミ電線を使用する場合の異種金属接触部をコネクタハウジング内のきわめて限られた範囲に限定し、その部分を絶縁体で封止したので、異種金属接触部の電食を効果的にかつ経済的に防止することができる。
またメッキ部分と非メッキ部分の境界部や連鎖端子の連結切断部を含めて絶縁体で封止することにより、メッキ金属と端子母材との接触部における電食も効果的に防止することができる。
【図面の簡単な説明】
【図１】本発明に係るアルミ電線用端子の一実施形態を示す一部切開側面図。
【図２】図１の端子の製作過程を示す一部切開側面図。
【図３】本発明に係るアルミ電線用端子の他の実施形態を示す一部切開側面図。
【図４】本発明に係るアルミ電線用端子のさらに他の実施形態を示す一部切開側面図。
【図５】本発明に係るアルミ電線用端子のさらに他の実施形態を示す一部切開平面図。
【図６】本発明に係るアルミ電線用コネクタの一実施形態を示す垂直断面図。
【図７】（Ａ）、（Ｂ）は本発明に用いる流入阻止壁付き端子先端部の製作過程を示す斜視図。
【図８】本発明に係るアルミ電線用コネクタの他の実施形態を示す垂直断面図。
【図９】本発明に係るアルミ電線用コネクタのさらに他の実施形態を示す垂直断面図。
【図１０】本発明に係るアルミ電線用コネクタのさらに他の実施形態を示す水平断面図。
【図１１】本発明に係るアルミ電線用コネクタのさらに他の実施形態を示す水平断面図。
【図１２】本発明に係るアルミ電線用コネクタのさらに他の実施形態を示す垂直断面図。
【図１３】本発明に係るアルミ電線用コネクタのさらに他の実施形態を示す垂直断面図。
【図１４】本発明に係るアルミ電線用コネクタのさらに他の実施形態を製作過程で示す垂直断面図。
【図１５】本発明に係るアルミ電線用機器側コネクタの一実施形態を示す断面図。
【図１６】本発明に係るアルミ電線用機器側コネクタの他の実施形態を示す断面図。
【図１７】図１６と同じコネクタの使用状態の一例を示す断面図。
【図１８】図１６と同じコネクタの使用状態の他の例を示す断面図。
【符号の説明】
１０：アルミ電線用端子
１２：アルミ合金製の端子後端部
１４：銅合金製の端子先端部
１６：アルミ電線
１８：アルミ導体
２６：端子後端部１４の接合片
３２：端子先端部１４の接合片
３４：封止樹脂
４０：メッキ
Ｐ：メッキ部分と非メッキ部分の境界部
４２：連鎖端子の連結切断部
４４：アルミ電線用コネクタ
４６：接合端子
４８：コネクタハウジング
５０：封止樹脂
５２、５４：流入阻止壁
５８：圧接刃
６０：銅合金製端子
６２Ａ、６２Ｂ：開口部
６４Ａ、６４Ｂ：溶接ヘッド
６６：アルミ電線用機器側コネクタ
６８：アルミ合金製の端子先端部
７０：銅合金製の端子後端部
７２：コネクタハウジング
７４：接合端子[0001]
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a terminal and a connector used for connecting an aluminum electric wire (an electric wire using aluminum or an aluminum alloy for a conductor).
[0002]
2. Description of the Related Art Conventionally, copper wires have been used and aluminum wires have hardly been used in the field of wire harnesses for automobiles. In recent years, there has been a trend to use aluminum electric wires instead of conventional copper electric wires for the purpose of improving recyclability and reducing weight. When aluminum wire is used for the wire harness, even if the terminal of the connector of the wire harness is made of aluminum, the terminal of the connector on the electrical component side may not be made of aluminum. Has become.
[0003]
That is, even if the wiring harness side is an aluminum wire or an aluminum terminal, if the electrical component side is a copper terminal, the contact portion between the aluminum terminal and the copper terminal becomes water. There is a problem that electrolytic corrosion is caused by the presence of moisture and moisture.
For this reason, a technique of filling grease into a joint between an aluminum-based terminal and a copper-based terminal has been proposed. However, the filling of grease tends to contaminate a work site, and also causes a problem during distribution and handling of a finished product. There is a problem in that grease flows out and contaminates vehicle parts, thereby deteriorating the commercial value.
[0005] There is also a proposal to use a waterproof connector. However, using a waterproof connector in a portion where a waterproof connector is not necessary conventionally causes a significant increase in cost and also causes water to temporarily enter the waterproof connector for some reason. Infiltration results in the promotion of electrolytic corrosion.
SUMMARY OF THE INVENTION An object of the present invention is to provide an aluminum electric wire terminal and a connector in which electric corrosion is prevented at a contact portion between aluminum or an aluminum alloy and copper or a copper alloy in view of the above problems. .
[0007]
According to the present invention, in order to prevent electrolytic corrosion of a dissimilar metal contact portion, a rear end portion of a terminal to which an aluminum electric wire is connected is formed of aluminum or an aluminum alloy, and a terminal end portion connected to a mating terminal is provided. The part is formed of copper or a copper alloy, and the terminal rear end and the terminal front end are joined by means such as welding, and the joined part is sealed with an insulator such as a resin, so that the dissimilar metal contact part is formed. Water, moisture, etc. were prevented from adhering.
[0008] In addition, since the oxide film is formed and grows on the surface of the rear end portion of the terminal formed of aluminum or aluminum alloy, it is difficult to form an oxide film of tin or the like after plating the surface with nickel. Although it is necessary to perform metal plating, since the boundary between the plated portion and the non-plated portion forms a dissimilar metal contact portion, in the present invention, the plating boundary is set near the junction, and the plating boundary is included. To seal with the insulator.
In the case where the rear end of the terminal is formed as a chain terminal and is plated, a dissimilar metal contact portion also occurs at a cut portion between adjacent terminal rear ends. The part was also sealed with the insulator.
Further, in order to prevent the aluminum conductor of the aluminum electric wire from corroding due to intrusion of water or moisture, in the present invention, the end of the insulating coating of the aluminum electric wire is also sealed with the insulator. .
Further, according to the present invention, by setting the terminal at the rear end of the terminal to be connected to the aluminum wire as a pressure contact blade, the terminal is set in the connector housing, and then the aluminum wire is pressed and connected to the terminal joint. By sealing the parts together with an insulator, the sealing can be realized at low cost.
In order to prevent the sealing material from flowing into the tip of the terminal when the foreign metal contact portion is sealed with an insulator, and to prevent a poor contact with the counterpart terminal, the present invention provides a terminal and a connector. The housing or both were provided with an inflow-preventing wall for the sealing insulator.
In the present invention, when a terminal made entirely of copper or a copper alloy is used and an aluminum wire is directly connected to the terminal, the connection portion is similarly sealed with an insulator in the connector housing. By stopping, we tried to prevent electrolytic corrosion.
More specifically, the present invention can be divided into a terminal form and a connector form. The terminal for an aluminum electric wire according to the present invention, the rear end of the terminal to which the aluminum electric wire is connected is formed of aluminum or an aluminum alloy, and the terminal end of the terminal connected to the counterpart terminal is formed of copper or a copper alloy. The end and the terminal tip are joined, and the joint is sealed with an insulator.
The rear end of the terminal and the front end of the terminal are connected by resistance welding, laser welding, ultrasonic welding, or TOX bonding (the outside of the recess formed on one metal plate is replaced by the recess formed on the other metal plate). (A method of joining two metal plates by press-fitting inside) or rivet joining. This terminal is used by connecting an aluminum electric wire to the rear end of the terminal and assembling it into a connector housing.
The terminal for an aluminum electric wire according to the present invention has a rear end portion which is plated with a metal which is unlikely to form an oxide film on its surface, except for a joint portion with the terminal end portion, and has a sealing insulator. Is preferably formed so as to cover the boundary between the plated portion and the non-plated portion.
Further, in the aluminum wire terminal according to the present invention, the aluminum wire is connected to the rear end of the terminal, and the sealing insulator is formed so as to cover the end of the insulating coating of the aluminum wire. Is preferred.
Further, in the aluminum electric wire terminal according to the present invention, when the terminal rear end portion has a connection cut portion obtained by cutting the connection portion of the chain terminal, the sealing insulator cuts the connection cut portion. Preferably, it is formed so as to cover the portion.
Next, in the connector for an aluminum electric wire according to the present invention, the rear end of the terminal to which the aluminum electric wire is connected is formed of aluminum or aluminum alloy, and the terminal end of the terminal connected to the counterpart terminal is made of copper or copper alloy. Forming and joining the terminal rear end and the terminal tip to form a joint terminal, assembling the joint terminal into the connector housing, and filling the joint between the terminal rear end and the terminal tip into the connector housing. It is characterized by being sealed with an insulator.
In the connector for an aluminum electric wire according to the present invention, an inflow-preventing wall for preventing the insulator filled in the connector housing from flowing into the contact portion of the terminal tip portion with the counterpart terminal is provided at the terminal tip portion or the connector housing. It is preferable to provide them.
Further, the aluminum wire connector according to the present invention has a rear end portion plated with a metal that is unlikely to form an oxide film on its surface except for a joint portion with the terminal front end portion. Preferably, the body is filled so as to cover the boundary between the plated portion and the non-plated portion.
In the connector for an aluminum wire according to the present invention, the aluminum wire is connected to the rear end of the terminal, and the sealing insulator is filled so as to cover the end of the insulating coating of the aluminum wire. Is preferred.
In the aluminum electric wire connector according to the present invention, when the rear end of the terminal has a connection cut portion obtained by cutting the connection portion of the chain terminal, a sealing insulator is provided at the connection cut portion. Is preferably filled so as to cover the surface.
Further, the aluminum electric wire connector according to the present invention has a pressure contact blade at the rear end of the terminal for press-connecting the aluminum electric wire, and a sealing insulator for press-connecting the aluminum electric wire. Preferably, it is filled to cover.
Next, in the connector for an aluminum electric wire according to the present invention, an aluminum electric wire is directly connected to a terminal made of copper or a copper alloy, and a connection portion between the terminal and the aluminum electric wire is sealed with an insulator filled in a connector housing. It may be stopped.
Also in this connector, it is preferable that the sealing insulator is filled so as to cover the end of the insulating coating of the aluminum electric wire.
In the connector for an aluminum electric wire according to the present invention, a terminal made of copper or a copper alloy is set in a connector housing having an opening for inserting a welding head, and an end of the aluminum electric wire is set in the connector housing. Then, the terminal and the aluminum wire may be welded and connected in the connector housing, and an insulator may be filled from the opening to seal the welded connection between the terminal and the aluminum wire.
In the case where a terminal made of copper or a copper alloy is used, an inflow-preventing wall for preventing the insulator filled in the connector housing from flowing into the contact portion of the terminal with the counterpart terminal is provided in the terminal or the connector housing. It is preferable to provide them.
Next, the connector for an aluminum electric wire according to the present invention may be a connector on the equipment side to which a connector on the aluminum electric wire side having an aluminum or aluminum alloy terminal is connected. The front end of the terminal connected to the terminal of the wire side connector is formed of aluminum or aluminum alloy, the rear end of the terminal connected to the device side is formed of copper or copper alloy, and the front end of the terminal and the rear end of the terminal are formed. The connector may be joined and the joint may be sealed by a resin wall of the connector housing or by an insulator filled in the connector housing.
Also in the case of the aluminum wire device-side connector, the terminal end portion made of aluminum or aluminum alloy is plated with a metal which is unlikely to form an oxide film on the surface except for a joint portion with the terminal rear end portion. Preferably, the boundary between the plated portion and the non-plated portion is sealed by a resin wall of the connector housing or by an insulator filled in the connector housing.
[0031]
Embodiments of the present invention will be described below in detail with reference to the drawings.
[0032]
Embodiment 1 FIG. 1 shows an embodiment of a terminal for an aluminum electric wire according to the present invention. The terminal 10 includes a terminal rear end portion 12 formed by pressing an aluminum alloy plate and a terminal front end portion 14 formed by pressing a copper alloy plate.
The terminal rear end 12 extends to the terminal barrel 14 for crimping the aluminum conductor 18 of the aluminum wire 16, the insulation barrel 24 for gripping the insulating coating 22 of the aluminum wire 16, and the terminal tip 14. And a joining piece 26. The aluminum alloy, if left untreated, generates an insulating oxide film on the surface, so it is treated with a nickel base plating and tin plating in the state of a sheet material so that the oxide film on the surface is difficult to grow, Press processing for forming the terminal rear end 12 is performed. In this case, it is conceivable that a dissimilar metal contact portion between the plating material and the aluminum alloy base material appears at the cross section punched by the press and at the portion where the plating is broken by the press bending. The electrolytic corrosion of tin and tin is lighter than that of aluminum and copper, and sufficient quality can be ensured under favorable conditions such as, for example, a vehicle interior environment.
The terminal end portion 14 is in the form of a female contact, and has a rectangular tube portion 28, an elastic contact piece 30 folded therein, and a joining piece 32 extending from the rectangular tube portion 28 to the terminal rear end portion 12 side. And The terminal tip 14 is formed by pressing a copper alloy plate having a surface plated with tin.
The joining piece 26 of the terminal rear end 12 and the joining piece 32 of the terminal tip 14 are overlapped and joined by means such as welding. As joining means, mechanical joining such as TOX joining, rivet joining, solder joining, etc. can be used in addition to welding joining such as resistance welding and laser welding. The joint between the joining pieces 26 and 32 is sealed with a resin 34. By this resin sealing, water or moisture does not adhere to the joint between the aluminum alloy and the copper alloy, and electrolytic corrosion can be prevented.
The resin sealing of the joint can be performed as shown in FIG. That is, the mold container 36 is set so as to include both sides of the joint between the joint pieces 26 and 32. The mold container 36 can be vertically divided by the joining pieces 26 and 32. The divided containers are joined with a buckle or the like so as to sandwich the joining pieces 26 and 32. After setting the container 36 as shown in FIG. 2, the resin 34 is injected into the container 36 and cured. If the mold container 36 is removed after the resin is cured, the terminal 10 as shown in FIG. 1 is obtained.
The terminal 10 constructed as described above is used by connecting the aluminum electric wire 16 to the terminal rear end 12 by a normal crimping method or pressure welding method and incorporating the aluminum electric wire 16 into a connector housing 38. Since the terminal end portion 14 is made of a copper alloy, the terminal 10 can be connected to the electrical components and the copper-based terminal on the electric connection box side as usual.
[0038]
Embodiment 2 FIG. 3 shows another embodiment of the terminal for an aluminum electric wire according to the present invention. This embodiment is suitable when the joining piece 26 of the terminal rear end 12 and the joining piece 32 of the terminal tip 14 are joined by ultrasonic welding. In the case of ultrasonic welding, if plating is present at the joint, the plating surface slips and good welding cannot be performed. Therefore, it is preferable that plating does not exist. For this reason, the aluminum alloy terminal rear end portion 12 is plated 40 except for the distal end portion of the joint piece 26 (the joint portion of the terminal distal end portion 14 with the joint piece 34). Such a terminal rear end portion 12 can be manufactured by applying a nickel base plating and a tin plating 40 after performing a process such as pickling, except for the front end portion of the joining piece 26 after press working. With this configuration, tin plating can be performed including the cross section punched out by the press, so that the number of locations for preventing electrolytic corrosion can be reduced.
The terminal portion 14 made of copper alloy is the same as that of the first embodiment. It is essential that the terminal tip 14 be plated on the resilient contact piece 30. However, even if the cut surface makes contact with copper and tin, the problem of electrolytic corrosion is slight. The plated copper alloy plate can be pressed to form the terminal tip portion 14 without plating at the joint piece 32.
As described above, if the joint pieces 26 and 32 without plating are joined by ultrasonic welding, a good weld can be obtained. In addition, even when the joining pieces 26 and 32 are not plated, they can be joined by resistance welding, laser welding, TOX joining or the like instead of ultrasonic welding.
After joining the joining pieces 26 and 32, the joint is sealed with a resin 34. This resin sealing is performed so as to particularly include a boundary portion P between the plated portion and the non-plated portion of the terminal rear end portion 12. Perform In this way, electrolytic corrosion can be prevented more reliably.
Since the configuration other than the above is the same as that of the first embodiment, the same portions are denoted by the same reference numerals and description thereof will be omitted.
[0043]
Embodiment 3 FIG. 4 shows still another embodiment of the terminal for an aluminum electric wire according to the present invention. The difference of this terminal 10 from the second embodiment is that the sealing by the resin 34 is performed not only at the junction between the joining pieces 26 and 32 and at the boundary P between the plated portion and the non-plated portion at the terminal rear end 12 but also at the aluminum. This is done including the end of the insulating coating 22 of the electric wire 16. This can prevent water and moisture from entering the aluminum conductor 18 of the aluminum electric wire 16.
If water adheres to the conductor (usually a stranded wire) of an aluminum electric wire for some reason, the water penetrates into the insulating coating due to a capillary phenomenon, and a phenomenon that water does not easily escape from the electric wire occurs. The sealing with the resin 34 as described above can prevent intrusion of water. In the case of aluminum conductors, once water enters between the strands, corrosion of the crevice occurs, and the conductor expands, causing not only a problem in energizing the wire itself, but also, as corrosion progresses, insulation coating due to expansion. May be pierced and may damage other electric wires, but by sealing with the resin 34 as described above, the corrosion of the aluminum conductor 18 can be prevented.
Since the configuration other than the above is the same as that of the second embodiment, the same portions are denoted by the same reference numerals and description thereof will be omitted. This embodiment is also applicable to the terminal of the first embodiment.
[0046]
Embodiment 4 FIG. 5 shows still another embodiment of the aluminum wire terminal according to the present invention. This embodiment is a case where the terminal rear end portion 12 has a connection cutting portion 42 obtained by cutting the connection portion of the chain terminal. In the connection cutting portion 42, the aluminum alloy base material and the plating material come into contact with each other, and there is a possibility that electrolytic corrosion occurs. Therefore, in this embodiment, the connection cutting portion 42 is set near the joining piece 26 (the connecting portion of the chain terminal is formed near the joining piece 26), and the sealing resin 34 is removed from the connection cutting portion 42. Is formed so as to cover the surface. By doing so, it is also possible to prevent electrolytic corrosion at the connection cutting section 42. The other configuration is the same as that of the second embodiment, and thus the same portions are denoted by the same reference numerals and description thereof will be omitted. This embodiment is also applicable to the terminal of the first embodiment.
[0047]
Embodiment 5 FIG. 6 shows an embodiment of an aluminum electric wire connector according to the present invention. The connector 44 includes a joint terminal 46 in which the rear end portion 12 made of an aluminum alloy and the terminal end portion 14 made of a copper alloy are integrated by joining respective joint pieces 26 and 32. The configurations of the terminal rear end portion 12 and the terminal front end portion 14 are the same as those in the first embodiment, and the manner of joining the joining pieces 26 and 32 is also the same as in the first embodiment.
In the connector 44, the above-described connection terminal 46 (the connection portion is not resin-sealed) is incorporated in the connector housing 48, and the connection portion between the connection pieces 26 and 32 is filled in the connector housing 48. It is sealed with a resin 50. The aluminum electric wire 16 is connected to the terminal rear end portion 12 before the joining terminal 46 is assembled in the connector housing 48.
The connector housing 48 is formed with inflow prevention walls 52 and 54 so that the filled resin 50 does not flow into the terminal rear end portion 12 and the terminal front end portion 14. In particular, if the resin flows into the terminal tip 14, the resin may adhere to the elastic contact piece 30 and cause a contact failure. Therefore, the inflow prevention wall 54 on the terminal tip 14 side is important. The connector housing 48 having such inflow blocking walls 52 and 54 may be divided into upper and lower portions so that the joining terminal 46 can be incorporated.
The inflow preventing wall can be provided not on the connector housing but on the terminal side. One example is shown in FIGS. 7A and 7B. That is, when manufacturing the terminal end portion 14, the wall plate pieces 56 are formed on both sides (or one side) of the joining piece 32 as shown in FIG. By folding and folding up, the inflow prevention wall 54 can be formed as shown in FIG. Although not shown, an inflow-preventing wall can be similarly formed at the rear end of the terminal. Providing the inflow prevention wall on the terminal side in this way simplifies the structure of the connector housing.
[0051]
Embodiment 6 FIG. 8 shows another embodiment of the connector for an aluminum electric wire according to the present invention. This embodiment corresponds to the second embodiment (FIG. 3) in the case of an aluminum electric wire terminal. That is, the connector 44 is provided with a plating 40 made of a metal that is unlikely to form an oxide film on the surface thereof, except for the distal end portion of the joining piece 26 (the joint portion with the terminal distal end portion), on the terminal rear end portion 12. The boundary portion P between the portion and the non-plated portion is sealed with the resin 50 filled in the connector housing 48 together with the joining portions of the joining pieces 26 and 32. Since the configuration other than the above is the same as that of the fifth embodiment, the same portions are denoted by the same reference numerals and description thereof will be omitted.
[0052]
Embodiment 7 FIG. 9 shows still another embodiment of the connector for an aluminum electric wire according to the present invention. This embodiment corresponds to Embodiment 3 (FIG. 4) in the case of an aluminum electric wire terminal. That is, in this connector 44, the aluminum electric wire 16 is connected to the terminal rear end 12, and the resin 50 for sealing the joint between the joint pieces 26 and 32 also covers the end of the insulating coating 22 of the aluminum electric wire 16. Is filled in the connector housing 48. In this way, water and moisture do not enter the aluminum conductor 18, and the same effect as in the third embodiment can be obtained. Since the configuration other than the above is the same as that of the sixth embodiment, the same portions are denoted by the same reference numerals and description thereof will be omitted.
[0053]
Embodiment 8 FIG. 10 shows a further embodiment of the aluminum electric wire connector according to the present invention. This embodiment corresponds to Embodiment 4 (FIG. 5) in the case of an aluminum electric wire terminal. That is, in the connector 44, the terminal rear end portion 12 has a connection cut portion 42 obtained by cutting the connection portion of the chain terminal, and the resin 50 for sealing the connection portion of the connection pieces 26 and 32 is connected to the connection cut portion 42. The connector housing 48 is filled so as to cover the cutting portion 42 as well. Since the configuration other than the above is the same as that of the sixth embodiment, the same portions are denoted by the same reference numerals and description thereof will be omitted.
[0054]
Embodiment 9 FIG. 11 shows still another embodiment of the connector for an aluminum electric wire according to the present invention. In this embodiment, the rear end portion 12 made of an aluminum alloy is provided with a press-contact blade 58 for press-connecting the aluminum conductor 18 of the aluminum electric wire 22. That is, in this connector 44, the aluminum conductor 18 of the aluminum electric wire 16 is press-connected to the press-contact blade 58 of the terminal rear end portion 12, and the resin 50 that seals the connection portion of the connection pieces 26 and 32 forms the press-connection portion. Is filled in the connector housing 48 so as to cover the same. In the press-connecting portion, the plating of the terminal rear end portion 12 may be damaged and cause corrosion. However, if the press-connecting portion is sealed with the resin 50, the corrosion of the press-connecting portion can be prevented. The crimp connection of the aluminum electric wire 16 to the terminal rear end portion 12 may be performed before or after the joining terminal 46 is incorporated in the connector housing 48. Since the configuration other than the above is the same as that of the sixth embodiment, the same portions are denoted by the same reference numerals and description thereof will be omitted.
[0055]
Embodiment 10 FIG. 12 shows still another embodiment of the aluminum electric wire connector according to the present invention. This embodiment is a case where the aluminum electric wire 22 is directly connected to a terminal made entirely of a copper alloy. That is, the connector 44 connects the aluminum conductor 18 of the aluminum wire 16 to the wire barrel portion 20 of the copper alloy terminal 60 by welding, and holds the insulating coating 22 of the aluminum wire 16 with the insulation barrel portion 24. The welded connection between the barrel portion 20 and the aluminum conductor 18 is sealed with a resin 50 filled in the connector housing 48. In this case, since there is no possibility that water or moisture adheres to the dissimilar metal contact portion, electric corrosion can be prevented, and a terminal made of a normal copper alloy can be used, so that the cost is reduced.
The terminal 60 made of copper alloy is tin-plated. However, when the connection between the wire barrel portion 20 and the aluminum conductor 18 is performed by ultrasonic welding, no plating should be present on the wire barrel portion 20. Is preferred. Therefore, when employing ultrasonic welding, it is preferable to press-process a partially plated copper alloy plate to manufacture and use a terminal 60 having no plating on the wire barrel portion 20.
In the connector 44 of FIG. 12, after the aluminum wire 16 is connected to the copper alloy terminal 60, the terminal 60 is set in the connector housing 48, and the terminal 60 and the aluminum conductor 18 are welded in the connector housing 48. It is manufactured by filling the resin 50 so as to bury the connection portion. Also in this case, the connector housing 48 is provided with an inflow prevention wall 54 so that the resin 50 filled in the connector housing 48 does not flow into the rectangular tube portion 28 of the terminal 60.
[0058]
Embodiment 11 FIG. 13 shows still another embodiment of the aluminum electric wire connector according to the present invention. This embodiment also relates to a case where an aluminum electric wire is directly connected to a terminal made of a copper alloy. However, this embodiment is different from the tenth embodiment in that a sealing resin 50 is used for welding connection between a terminal 60 and an aluminum conductor 18. That is, the connector housing 48 is filled so as to cover not only the end but also the end of the insulating coating 22 of the aluminum electric wire 16. In this way, water and moisture do not enter the aluminum conductor 18, and the same effect as in the third embodiment can be obtained. Since the configuration other than the above is the same as that of the tenth embodiment, the same portions are denoted by the same reference numerals and description thereof will be omitted.
[0059]
Embodiment 12 FIG. 14 shows still another embodiment of the aluminum electric wire connector according to the present invention. This embodiment also relates to a case where an aluminum electric wire is directly connected to a terminal made of a copper alloy. However, this embodiment is different from the tenth embodiment in that the wire barrel portion 20 of the terminal 60 and the aluminum conductor 18 of the aluminum electric wire 16 are connected to each other. The welding connection is made in the connector housing 48.
In this case, the terminal 60 is set in the connector housing 48, and the connector housing 48 is formed with openings 62A and 62B above and below a position corresponding to the wire barrel portion 20 of the terminal 60 in advance. The welding heads 64A, 64B are inserted into the openings 62A, 62B to sandwich the aluminum conductor 18 and the wire barrel 20, and resistance welding is performed in that state. Thereafter, the lower opening 62B is closed with an appropriate jig, and resin is injected from the upper opening 62A to seal the welded connection. Since the configuration other than the above is the same as that of the tenth embodiment, the same portions are denoted by the same reference numerals and description thereof will be omitted.
[0061]
Embodiment 13 FIG. 15 shows still another embodiment of the aluminum electric wire connector according to the present invention. In this embodiment, when the terminal of the connector on the aluminum electric wire side is made of an aluminum alloy, the present invention is applied to the connector on the device side to which the connector on the aluminum electric wire side is connected. In this connector 66, a terminal tip 68 connected to a terminal of an aluminum electric wire side connector is formed of an aluminum alloy, and a terminal rear end 70 connected to a conductor on the device side is formed of a copper alloy. 68 and the terminal rear end portion 70 are joined by welding or the like, and the joined portion is sealed with a resin wall of the connector housing 72.
The terminal tip portion 68 has a male tab shape and is manufactured by pressing an aluminum alloy plate material. If the aluminum alloy is left as it is, an oxide film is formed on the surface. Therefore, after pressing, a nickel base plating and a tin plating are applied so that the oxide film on the surface hardly grows. It is conceivable to perform plating in the form of a plate before press working, but in that case, a dissimilar metal contact portion between the plating material and the aluminum alloy base material will appear on the cross section punched by the press, and the electrolytic corrosion prevention treatment Therefore, it is preferable to perform plating after press working. When plating is not performed on the joint portion with the terminal rear end portion in the plating process after the press working, the boundary between the plated portion and the non-plated portion is set near the joint portion.
The terminal rear end portion 70 is a portion to be soldered to a circuit board or the like in the electrical component, and is made by plating a copper alloy such as brass with tin.
The terminal front end portion 68 and the terminal rear end portion 70 are overlapped at their ends and are joined by spot welding (resistance welding) or the like. As the joining method, in addition to spot welding, ultrasonic welding, laser welding, TOX joining, rivet joining, solder joining and the like can be used. In the case of ultrasonic welding, it is preferable that plating does not exist on the joint surface.
The joint terminal 74 manufactured as described above is pressed into the resin wall of the housing 72 so that the joint is embedded in the resin wall of the housing 72. If there is a boundary between the plated portion and the non-plated portion, it is also embedded in the resin wall of the housing 72. Further, if there is a portion where the plating is broken at the time of joining, it is also embedded in the resin wall of the housing 72. In this way, water and moisture do not adhere to the dissimilar metal contact portion of the joining terminal 74, so that electrolytic corrosion can be prevented. In order to increase the airtightness of the press-fitting portion, a molten resin may be supplied to the press-fitting portion to seal the press-fitting portion. Further, in order to reduce the press-in resistance at the time of press-fitting, as shown in FIG. Preferably, it is uniform.
[0066]
Embodiment 14 FIG. 16 shows still another embodiment of the connector for an aluminum electric wire according to the present invention. In this embodiment, similarly to the thirteenth embodiment, the present invention is applied to a device-side connector to which the aluminum-wire-side connector is connected when the terminal of the aluminum-wire-side connector is made of an aluminum alloy. This connector 66 is different from the connector of the thirteenth embodiment in that a joint between a terminal portion 68 made of an aluminum alloy and a terminal end portion 70 made of a copper alloy is located in a cavity provided in a connector housing 72. The joint is sealed by filling the cavity with a resin 76. As the resin 76, a hot melt resin or the same resin as the connector housing, for example, PBT can be used. Since the configuration other than the above is the same as that of the thirteenth embodiment, the same portions are denoted by the same reference numerals and description thereof will be omitted.
FIGS. 17 and 18 show the usage state of the connector 66 of the fourteenth embodiment. In each case, the terminal rear end portion 70 of the connector 66 is connected by soldering to a circuit board 80 housed in a case 78 of electrical components. Reference numeral 82 denotes an electronic component mounted on the circuit board 80. FIG. 17 shows a case where the connector housing 72 is fixed to the circuit board 80, and FIG. 18 shows a case where the connector housing 72 is fixed to the case 78. The aluminum alloy terminal (female terminal) of the connector 84 on the aluminum electric wire 16 side is connected to the terminal end portion 68 of the connector 66. Since this connection is made between the aluminum alloy terminals, the problem of electrolytic corrosion does not occur. The connector of the thirteenth embodiment is used similarly.
[0068]
As described above, according to the present invention, when an aluminum electric wire is used for a wire harness or the like, the dissimilar metal contact portion is limited to a very limited range in the connector housing, and the portion is made of an insulator. , It is possible to effectively and economically prevent the electrolytic corrosion of the dissimilar metal contact portion.
In addition, it is possible to effectively prevent electrolytic corrosion at the contact area between the plated metal and the terminal base material by sealing it with an insulator including the boundary between the plated part and the non-plated part and the connection cut part of the chain terminal. it can.
[Brief description of the drawings]
FIG. 1 is a partially cutaway side view showing an embodiment of an aluminum electric wire terminal according to the present invention.
FIG. 2 is a partially cut-away side view showing a manufacturing process of the terminal of FIG. 1;
FIG. 3 is a partially cut-away side view showing another embodiment of the aluminum electric wire terminal according to the present invention.
FIG. 4 is a partially cut-away side view showing still another embodiment of the aluminum electric wire terminal according to the present invention.
FIG. 5 is a partially cutaway plan view showing still another embodiment of the aluminum electric wire terminal according to the present invention.
FIG. 6 is a vertical sectional view showing an embodiment of the connector for an aluminum electric wire according to the present invention.
FIGS. 7A and 7B are perspective views showing a process of manufacturing a terminal end portion with an inflow prevention wall used in the present invention.
FIG. 8 is a vertical sectional view showing another embodiment of the aluminum electric wire connector according to the present invention.
FIG. 9 is a vertical sectional view showing still another embodiment of the aluminum electric wire connector according to the present invention.
FIG. 10 is a horizontal sectional view showing still another embodiment of the aluminum electric wire connector according to the present invention.
FIG. 11 is a horizontal sectional view showing still another embodiment of the connector for an aluminum electric wire according to the present invention.
FIG. 12 is a vertical sectional view showing still another embodiment of the connector for an aluminum electric wire according to the present invention.
FIG. 13 is a vertical sectional view showing still another embodiment of the aluminum electric wire connector according to the present invention.
FIG. 14 is a vertical sectional view showing still another embodiment of the aluminum electric wire connector according to the present invention in a manufacturing process.
FIG. 15 is a cross-sectional view showing an embodiment of an aluminum electric wire device-side connector according to the present invention.
FIG. 16 is a cross-sectional view showing another embodiment of the aluminum electric wire device-side connector according to the present invention.
17 is a sectional view showing an example of a use state of the same connector as in FIG. 16;
FIG. 18 is a sectional view showing another example of the state of use of the same connector as in FIG. 16;
[Explanation of symbols]
10: Terminal for aluminum wire
12: Rear end of aluminum alloy terminal
14: Copper alloy terminal tip
16: Aluminum wire
18: Aluminum conductor
26: joining piece of terminal rear end 14
32: Joint piece of terminal tip 14
34: sealing resin
40: Plating
P: Boundary part between plated part and non-plated part
42: Connection cutting part of chain terminal
44: Aluminum wire connector
46: Joint terminal
48: Connector housing
50: sealing resin
52, 54: Inflow prevention wall
58: Pressing blade
60: Copper alloy terminal
62A, 62B: opening
64A, 64B: welding head
66: Equipment side connector for aluminum electric wire
68: Aluminum alloy terminal tip
70: Copper alloy terminal rear end
72: Connector housing
74: joining terminal

Claims (16)

アルミ電線が接続される端子後端部をアルミ又はアルミ合金で形成し、相手方端子と接続される端子先端部を銅又は銅合金で形成し、前記端子後端部と端子先端部を接合して、その接合部を絶縁体で封止したことを特徴とするアルミ電線用端子。The rear end of the terminal to which the aluminum wire is connected is formed of aluminum or aluminum alloy, the front end of the terminal connected to the counterpart terminal is formed of copper or copper alloy, and the rear end of the terminal and the front end of the terminal are joined. A terminal for an aluminum electric wire, the joint of which is sealed with an insulator. 請求項１記載の端子であって、端子後端部には、端子先端部との接合部分を除いて、表面に酸化被膜を生じにくい金属によるメッキが施され、封止用の絶縁体がメッキ部分と非メッキ部分の境界部をも覆うように形成されていることを特徴とするアルミ電線用端子。2. The terminal according to claim 1, wherein the rear end portion of the terminal is plated with a metal that does not easily form an oxide film on the surface except for a joint portion with the terminal front end portion, and the sealing insulator is plated. A terminal for an aluminum electric wire, which is formed so as to cover also a boundary portion between a portion and a non-plated portion. 請求項１又は２記載の端子であって、端子後端部にアルミ電線が接続され、封止用の絶縁体がアルミ電線の絶縁被覆の端部をも覆うように形成されていることを特徴とするアルミ電線用端子。3. The terminal according to claim 1, wherein an aluminum wire is connected to a rear end of the terminal, and a sealing insulator is formed so as to cover an end of the insulating coating of the aluminum wire. Terminal for aluminum wire. 請求項１ないし３のいずれかに記載の端子であって、端子後端部は、連鎖端子の連結部を切断した連結切断部を有しており、封止用の絶縁体がこの連結切断部をも覆うように形成されていることを特徴とするアルミ電線用端子。The terminal according to any one of claims 1 to 3, wherein the rear end portion of the terminal has a connection cut portion obtained by cutting a connection portion of the chain terminal, and the sealing insulator is provided with the connection cut portion. A terminal for an aluminum electric wire, characterized in that it is formed so as to cover the same. アルミ電線が接続される端子後端部をアルミ又はアルミ合金で形成し、相手方端子と接続される端子先端部を銅又は銅合金で形成し、前記端子後端部と端子先端部を接合して接合端子を構成し、この接合端子をコネクタハウジングに組み込み、前記端子後端部と端子先端部との接合部をコネクタハウジング内に充填した絶縁体で封止したことを特徴とするアルミ電線用コネクタ。The rear end of the terminal to which the aluminum wire is connected is formed of aluminum or aluminum alloy, the front end of the terminal connected to the counterpart terminal is formed of copper or copper alloy, and the rear end of the terminal and the front end of the terminal are joined. A connector for an aluminum electric wire, comprising a joining terminal, incorporating the joining terminal into a connector housing, and sealing a joint between the terminal rear end and the terminal tip with an insulator filled in the connector housing. . 請求項５記載のコネクタであって、端子先端部又はコネクタハウジングに、コネクタハウジング内に充填した絶縁体が端子先端部の相手方端子との接触部に流入しないようにする流入阻止壁を設けたことを特徴とするアルミ電線用コネクタ。6. The connector according to claim 5, wherein an inflow prevention wall is provided at the terminal end portion or the connector housing to prevent the insulator filled in the connector housing from flowing into a contact portion of the terminal end portion with the counterpart terminal. A connector for aluminum wires. 請求項５又は６記載のコネクタであって、端子後端部には、端子先端部との接合部分を除いて、表面に酸化被膜を生じにくい金属によるメッキが施され、封止用の絶縁体がメッキ部分と非メッキ部分の境界部をも覆うように充填されていることを特徴とするアルミ電線用コネクタ。7. The sealing insulator according to claim 5, wherein a rear end portion of the terminal is plated with a metal that does not easily form an oxide film on a surface except for a joint portion with the terminal front end portion, and a sealing insulator. Is filled so as to cover the boundary between the plated portion and the non-plated portion. 請求項５ないし７のいずれかに記載のコネクタであって、端子後端部にアルミ電線が接続され、封止用の絶縁体がアルミ電線の絶縁被覆の端部をも覆うように充填されていることを特徴とするアルミ電線用コネクタ。The connector according to any one of claims 5 to 7, wherein an aluminum wire is connected to a rear end of the terminal, and a sealing insulator is filled so as to cover the end of the insulating coating of the aluminum wire. A connector for aluminum electric wires. 請求項５ないし８のいずれかに記載のコネクタであって、端子後端部が連鎖端子の連結部を切断した連結切断部を有しており、封止用の絶縁体がこの連結切断部をも覆うように充填されていることを特徴とするアルミ電線用コネクタ。The connector according to any one of claims 5 to 8, wherein a rear end of the terminal has a connection cut portion obtained by cutting a connection portion of the chain terminal, and a sealing insulator forms the connection cut portion. A connector for aluminum electric wires, characterized in that the connector is filled so as to cover the entire surface. 請求項５ないし９のいずれかに記載のコネクタであって、端子後端部がアルミ電線を圧接接続する圧接刃を有しており、封止用の絶縁体がアルミ電線を圧接接続した圧接刃をも覆うように充填されていることを特徴とするアルミ電線用コネクタ。The connector according to any one of claims 5 to 9, wherein a rear end portion of the terminal has a press-contact blade for press-connecting the aluminum wire, and the sealing insulator press-connects the aluminum wire. A connector for aluminum electric wires, characterized in that the connector is filled so as to cover the surface. 銅又は銅合金製の端子にアルミ電線を接続し、端子とアルミ電線の接続部を、コネクタハウジング内に充填した絶縁体で封止したことを特徴とするアルミ電線用コネクタ。An aluminum electric wire connector characterized by connecting an aluminum electric wire to a copper or copper alloy terminal, and sealing a connection portion between the terminal and the aluminum electric wire with an insulator filled in a connector housing. 請求項１１記載のコネクタであって、封止用の絶縁体がアルミ電線の絶縁被覆の端部をも覆うように充填されていることを特徴とするアルミ電線用コネクタ。12. The connector according to claim 11, wherein the sealing insulator is filled so as to cover the end of the insulating coating of the aluminum wire. 銅又は銅合金製の端子を溶接ヘッド挿入用の開口部を有するコネクタハウジング内にセットし、アルミ電線の端部を前記コネクタハウジング内にセットして、コネクタハウジング内で端子とアルミ電線を溶接接続し、前記開口部から絶縁体を充填して前記端子とアルミ電線の溶接接続部を封止したことを特徴とするアルミ電線用コネクタ。A terminal made of copper or a copper alloy is set in a connector housing having an opening for inserting a welding head, an end of an aluminum wire is set in the connector housing, and the terminal and the aluminum wire are welded and connected in the connector housing. A connector for an aluminum electric wire, wherein an insulator is filled from the opening to seal a welded connection between the terminal and the aluminum electric wire. 請求項１１ないし１３のいずれかに記載のコネクタであって、端子又はコネクタハウジングに、コネクタハウジング内に充填した絶縁体が端子の相手方端子との接触部に流入しないようにする流入阻止壁を設けたことを特徴とするアルミ電線用コネクタ。The connector according to any one of claims 11 to 13, wherein the terminal or the connector housing is provided with an inflow prevention wall for preventing an insulator filled in the connector housing from flowing into a contact portion of the terminal with a counterpart terminal. A connector for aluminum electric wires. アルミ又はアルミ合金製の端子を有するアルミ電線側のコネクタが接続される機器側のコネクタであって、前記アルミ電線側コネクタの端子に接続される端子先端部をアルミ又はアルミ合金で形成し、機器側に接続される端子後端部を銅又は銅合金で形成し、前記端子先端部と端子後端部を接合して、その接合部をコネクタハウジングの樹脂壁により又はコネクタハウジング内に充填された絶縁体により封止したことを特徴とするアルミ電線用コネクタ。A device-side connector to which an aluminum wire-side connector having an aluminum or aluminum alloy terminal is connected, wherein a terminal end connected to the aluminum wire-side connector terminal is formed of aluminum or aluminum alloy, The terminal rear end connected to the side is formed of copper or copper alloy, the terminal front end and the terminal rear end are joined, and the joint is filled with the resin wall of the connector housing or in the connector housing. An aluminum electric wire connector sealed with an insulator. 請求項１５記載のコネクタであって、端子先端部は、端子後端部との接合部分を除いて、表面に酸化被膜を生じにくい金属によるメッキが施され、メッキ部分と非メッキ部分の境界部が、コネクタハウジングの樹脂壁により又はコネクタハウジング内に充填された絶縁体により封止されていることを特徴とするアルミ電線用コネクタ。16. The connector according to claim 15, wherein the terminal tip portion is plated with a metal that is unlikely to form an oxide film on a surface except for a joint portion with the terminal rear end portion, and a boundary portion between a plated portion and a non-plated portion. Is sealed by a resin wall of the connector housing or by an insulator filled in the connector housing.
JP2002267844A 2002-09-13 2002-09-13 Terminal for aluminum wire and connector Pending JP2004111058A (en)

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