JP2005050736A - Method of manufacturing terminal crimping structure to aluminum wire and aluminum wire with terminal - Google Patents

Method of manufacturing terminal crimping structure to aluminum wire and aluminum wire with terminal Download PDF

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JP2005050736A
JP2005050736A JP2003283237A JP2003283237A JP2005050736A JP 2005050736 A JP2005050736 A JP 2005050736A JP 2003283237 A JP2003283237 A JP 2003283237A JP 2003283237 A JP2003283237 A JP 2003283237A JP 2005050736 A JP2005050736 A JP 2005050736A
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barrel
aluminum
crimping
wire
terminal
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Toshiyuki Hashimoto
利行 橋本
Shuhei Kaneko
周平 金子
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Furukawa Electric Co Ltd
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Furukawa Electric Co Ltd
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Priority to JP2003283237A priority Critical patent/JP2005050736A/en
Priority claimed from EP12160295.7A external-priority patent/EP2472674B1/en
Publication of JP2005050736A publication Critical patent/JP2005050736A/en
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Abstract

<P>PROBLEM TO BE SOLVED: To provide crimping terminal with a sufficient terminal retaining force while securing electrical continuity of a terminal connecting part with an aluminum wire when the terminal is press bonded to the aluminum wire. <P>SOLUTION: In a terminal crimping structure for the aluminum wire, for connecting the terminal 10 to the aluminum wire 1, an insulation barrel 15 for crimping of covered part of the aluminum wire, a crimping barrel for continuity of the aluminum wire 12 and a crimping barrel for retaining the aluminum wire 13 are provided. The crimping barrel for retaining the aluminum wire is formed in a position adjacent to the insulation barrel. The crimping barrel for aluminum wire continuity is also formed on the opposite side of the insulation barrel, in regard to the crimping barrel for retaining the aluminum wire. In the state where both crimping barrels are press bonded to the aluminum wire, the crimping barrel for aluminum wire conduction is press bonded to the aluminum wire at a height that is lower than the crimping barrel for retaining the aluminum wire, viewed in the direction of the terminal crimping. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

本発明は、アルミ電線に圧着されて使用される端子であってコネクタハウジング内に装着される端子のアルミ電線への圧着構造及び当該端子付アルミ電線の製造方法に関する。   TECHNICAL FIELD The present invention relates to a crimping structure for a terminal to be used by being crimped to an aluminum electric wire and mounted in a connector housing, and a method for manufacturing the terminal-equipped aluminum electric wire.

従来、自動車の車内に配索されるワイヤーハーネスは銅電線が一般的であり導通性・強度などの特性(物性)が劣るアルミ電線は使用が困難であり、あまり使われたことがない。しかしながら、近年、車両の軽量化とリサイクル性に鑑みてアルミ電線の使用に関する要望が高まっている。このようなワイヤーハーネス同士や車載用機器とワイヤーハーネスを接続するに当って電気コネクタが一般的に使用されている。かかる電気コネクタは互いに嵌合し合うコネクタハウジングとこれらのコネクタハウジング内に挿入嵌合され、ワイヤーハーネスの電線を圧着接続した複数の圧着端子とから構成されている。   Conventionally, a copper wire is generally used as a wire harness routed in an automobile, and an aluminum wire having poor properties (physical properties) such as conductivity and strength is difficult to use and has not been used so much. However, in recent years, there has been an increasing demand for the use of aluminum wires in view of weight reduction and recyclability of vehicles. An electrical connector is generally used for connecting such wire harnesses to each other or a vehicle harness and a wire harness. Such an electrical connector is composed of connector housings that are fitted to each other and a plurality of crimp terminals that are inserted and fitted into these connector housings and crimped and connected to wires of a wire harness.

ここで、従来の銅電線への端子圧着構造に基づいて当該端子をアルミ電線に仮に圧着した場合の圧着工程を説明する。図12は、銅電線に圧着される従来の端子を示している。図12に示すように、端子80は端子間接続部80aと電線接続部80bとから構成され、電線接続部80bは、端子長手方向に或る程度の長さを有するワイヤーバレル81と、これと隣接して銅電線の被覆部に圧着されるインシュレーションバレル85とから構成されている。図13は、このような端子80を銅電線の代わりにアルミ電線1に圧着する工程について説明した図である。同図から明らかなように、この端子圧着に際して端子80のワイヤーバレル81とインシュレーションバレル85にそれぞれ対応する端子圧着部181,185を備えた段付きの圧着治具180を使用する。なお、圧着治具180には圧着する端子長手方向で見て逆V字型で先端がバレル先端を加締める方向に屈曲(カール)させるためにM字状をなした圧着溝が形成されている。そして、かかる圧着治具180を端子80の上方から下方に向かって移動させ(図中、端子圧着方向を示す矢印X参照)、治具180の逆V字型の溝面に沿って端子80の各バレル81,85を変形させる(図13(b)及び図13(c)参照)。治具180の逆V字型の溝面は逆V字の先端がM字になっているので、治具180を端子80に向かってさらに押し付けることによって、各バレル81,85の端部がそれぞれバレル先端を加締める方向にアルミ電線1に向かってカール(屈曲)される。これによって、各バレル81,85をアルミ電線1の導体部1aと被覆部1bに圧着する(図13(c)及び図14(a)参照)。端子80がアルミ電線1にしっかりと圧着されると、圧着治具180を図中Y方向に上昇させて端子圧着工程を完了する。   Here, the crimping | compression-bonding process at the time of temporarily crimping | bonding the said terminal to an aluminum electric wire based on the conventional terminal crimping structure to a copper electric wire is demonstrated. FIG. 12 shows a conventional terminal that is crimped to a copper wire. As shown in FIG. 12, the terminal 80 includes an inter-terminal connection portion 80a and an electric wire connection portion 80b. The electric wire connection portion 80b includes a wire barrel 81 having a certain length in the terminal longitudinal direction, It is comprised from the insulation barrel 85 adjoined to the coating | coated part of a copper electric wire adjacently. FIG. 13 is a diagram illustrating a process of crimping such a terminal 80 to the aluminum electric wire 1 instead of the copper electric wire. As is apparent from the figure, a stepped crimping jig 180 provided with terminal crimping portions 181 and 185 respectively corresponding to the wire barrel 81 and the insulation barrel 85 of the terminal 80 is used for the terminal crimping. The crimping jig 180 has an inverted V-shape when viewed in the longitudinal direction of the terminal to be crimped, and an M-shaped crimp groove is formed so that the tip bends (curls) in the direction of caulking the barrel tip. . Then, the crimping jig 180 is moved from the upper side to the lower side of the terminal 80 (see the arrow X indicating the terminal crimping direction in the drawing), and the terminal 80 is moved along the inverted V-shaped groove surface of the jig 180. The barrels 81 and 85 are deformed (see FIGS. 13B and 13C). Since the inverted V-shaped groove surface of the jig 180 has an M-shaped inverted V-shaped tip, the ends of the barrels 81 and 85 are respectively pressed by further pressing the jig 180 toward the terminal 80. It is curled (bent) toward the aluminum electric wire 1 in the direction of caulking the barrel tip. As a result, the barrels 81 and 85 are pressure-bonded to the conductor portion 1a and the covering portion 1b of the aluminum electric wire 1 (see FIGS. 13C and 14A). When the terminal 80 is firmly crimped to the aluminum electric wire 1, the crimping jig 180 is raised in the Y direction in the drawing to complete the terminal crimping process.

なお、ワイヤーバレルが上述の端子80のように単一のバレルから構成されるのではなく、複数のバレルから構成された構造を有する端子もいくつか知られている(特許文献1乃至特許文献3参照。)。   In addition, a wire barrel is not comprised from a single barrel like the above-mentioned terminal 80, but some terminals which have the structure comprised from the some barrel are also known (patent document 1 thru | or patent document 3). reference.).

実開平6−36215号公報(第4−5頁、図2)Japanese Utility Model Publication No. 6-36215 (page 4-5, FIG. 2) 実開平6−36216号公報(第4−5頁、図2)Japanese Utility Model Publication No. 6-36216 (page 4-5, FIG. 2) 特開平11−297375号公報(第3−4頁、図1)JP-A-11-297375 (page 3-4, FIG. 1)

従来の銅電線と端子の接続方法においては、端子80と銅電線を構成する各撚り線とが全て接触することはないが、銅電線の機械的特性及び電気的特性上、端子を特に問題なく銅電線に接続できた。   In the conventional method for connecting a copper wire and a terminal, the terminal 80 and each stranded wire constituting the copper wire are not in contact with each other, but the terminal has no particular problem in terms of mechanical and electrical characteristics of the copper wire. Connected to copper wire.

しかしながら、アルミ電線は銅電線に比べて機械的強度や溶断温度が低く、また、電線を構成する撚り線1本1本が酸化被膜を形成し易いという特性を有している。そのため、特定の撚り線にのみ電流が流れて集中抵抗が発生しやすく、かかる集中抵抗による溶断の発生や導通不良が懸念される。   However, an aluminum electric wire has characteristics such that mechanical strength and fusing temperature are lower than that of a copper electric wire, and each stranded wire constituting the electric wire easily forms an oxide film. For this reason, current flows only through a specific stranded wire, and concentrated resistance is likely to occur, and there is a concern about occurrence of fusing or poor conduction due to such concentrated resistance.

具体的には、各撚り線の酸化被膜を破壊して各撚り線間とワイヤーバレルが極度に密着するほど端子をアルミ電線に強く圧着すると、電気的導通特性については冷熱サイクルなどの環境試験にも耐えられるようになるが、端子圧着部に作用する過度の応力に起因して電線保持力が極端に低下し、端子と電線の接続構造として使用不適当となってしまうことがある。   Specifically, when the oxide film of each stranded wire is destroyed and the terminal is strongly crimped to the aluminum wire so that the wire barrel and the wire barrel are in close contact with each other, the electrical continuity characteristics can be applied to environmental tests such as a thermal cycle. However, due to excessive stress acting on the terminal crimping portion, the wire holding force is extremely reduced, and the connection structure between the terminal and the wire may be inappropriate.

図14はこのようなアルミ電線1に端子80が圧着された状態を平面図(図14(a))と側面図(図14(a),(b))で示している。なお、図14(b)では、アルミ電線1の導体部1aに対してワイヤーバレル81の圧着部が端子圧着方向で見て従来銅電線の圧着と同様な高さを有している(図中高さHe参照)。また、図14(c)は、図14(b)に比べて端子80をアルミ電線1に大きな圧縮率(減面率)で圧着させた状態を示しており、図14(b)に比べて端子圧着方向で見て圧着された端子80の高さが低くなっている(図中高さHf参照)。   FIG. 14 is a plan view (FIG. 14 (a)) and side views (FIGS. 14 (a) and (b)) showing a state in which the terminal 80 is crimped to such an aluminum electric wire 1. FIG. In FIG. 14B, the crimping portion of the wire barrel 81 has the same height as the crimping of the conventional copper wire when viewed in the terminal crimping direction with respect to the conductor portion 1a of the aluminum wire 1 (high in the drawing). See He). Moreover, FIG.14 (c) has shown the state which crimped | bonded the terminal 80 to the aluminum electric wire 1 with the big compression rate (area reduction rate) compared with FIG.14 (b), compared with FIG.14 (b). The height of the crimped terminal 80 is low as seen in the terminal crimping direction (see height Hf in the figure).

図14(b)に示す従来銅電線と同様の圧着状態では端子圧着強度(電線保持力)には問題ないが、導体部1aの各撚り線表面の酸化被膜を十分破壊することができず、また、冷熱サイクルなどの環境試験にて接触抵抗の上昇が発生し、電気的導通特性の点では不十分となる。一方、図14(c)に示すように大きな圧縮率(減面率)で端子80をアルミ電線1に圧着すると、電気的導通は十分図れるが、電線の端子圧着部に作用する大きな応力により電線保持力が低下し、各電線サイズに必要な端子圧着強度を得ることができない。   In the same crimping state as the conventional copper wire shown in FIG. 14 (b), there is no problem with the terminal crimping strength (wire holding force), but the oxide film on the surface of each stranded wire of the conductor portion 1a cannot be sufficiently destroyed, In addition, an increase in contact resistance occurs in environmental tests such as a cooling / heating cycle, which is insufficient in terms of electrical conduction characteristics. On the other hand, as shown in FIG. 14 (c), when the terminal 80 is crimped to the aluminum electric wire 1 with a large compression ratio (area reduction), sufficient electrical continuity can be achieved, but the electric wire is affected by a large stress acting on the terminal crimping portion of the electric wire. Holding power is reduced, and terminal crimping strength required for each wire size cannot be obtained.

なお、特許文献1乃至特許文献3に記載された端子はインシュレーションバレルに加えて複数のワイヤーバレルが形成された構成を有している。しかしながら、これらのワイヤーバレルは圧着される電線の電線径に対応するように個別に形成されたものであり、同一径のアルミ電線に適用したときにこのアルミ電線の導体部を異なる圧縮率(減面率)で圧着させるような構成のものは開示されていない。   The terminals described in Patent Documents 1 to 3 have a configuration in which a plurality of wire barrels are formed in addition to the insulation barrel. However, these wire barrels are individually formed to correspond to the wire diameter of the wire to be crimped, and when applied to aluminum wires of the same diameter, the conductor portion of the aluminum wire has a different compression ratio (reduction). There is no disclosure of a configuration in which pressure bonding is performed at a surface area).

本発明の目的は、端子をアルミ電線に圧着する際にアルミ電線と端子との十分な電気的導通特性を確保しつつ必要な端子圧着強度(端子の電線保持力)をもつ端子構造を提供することにある。   An object of the present invention is to provide a terminal structure having a necessary terminal crimping strength (wire holding force of a terminal) while ensuring sufficient electrical conduction characteristics between the aluminum wire and the terminal when the terminal is crimped to the aluminum wire. There is.

上述の課題を解決するために、本発明にかかるアルミ電線への端子圧着構造は、アルミ電線被覆部圧着用インシュレーションバレルに加えてアルミ電線導通用圧着バレルとアルミ電線保持用圧着バレルとを備えた端子をアルミ電線に圧着するアルミ電線への端子圧着構造であって、インシュレーションバレルに隣接する位置にアルミ電線保持用圧着バレルが形成されると共に、当該アルミ電線保持用圧着バレルに関してインシュレーションバレルと反対側にアルミ電線導通用圧着バレルが形成され、両圧着バレルがアルミ電線に圧着された状態において、端子圧着方向で見てアルミ電線導通用圧着バレルがアルミ電線保持用圧着バレルよりも低い高さで当該アルミ電線に圧着されていることを特徴としている。   In order to solve the above-described problems, a terminal crimping structure to an aluminum electric wire according to the present invention includes an aluminum electric wire conduction crimping barrel and an aluminum electric wire holding crimping barrel in addition to the insulation barrel for aluminum electric wire covering portion crimping. A crimping structure for crimping an aluminum wire to an aluminum wire, a crimp barrel for holding an aluminum wire is formed at a position adjacent to the insulation barrel, and an insulation barrel for the crimp barrel for holding the aluminum wire When the crimp barrel for aluminum wire conduction is formed on the opposite side and both the crimp barrels are crimped to the aluminum wire, the crimp barrel for conducting the aluminum wire is lower than the crimp barrel for holding the aluminum wire when viewed in the terminal crimp direction. Now, it is characterized by being crimped to the aluminum electric wire.

アルミ電線導通用バレルがアルミ電線保持用バレルよりも電線先端(端子内側)で圧着されているので、導通用バレル部の端子圧着強度が弱くても、後方の保持用バレルの働きで端子と電線の保持力に問題が生じない。また、後方の保持用バレルでしっかりと電線を保持しているので、前方で導通用バレルを大きな圧縮率(減面率)で圧着することでアルミ電線の絶縁酸化膜を破壊し、かつ密着することで端子とアルミ電線間で十分な電気的特性を得ることができる。   Since the aluminum wire conduction barrel is crimped at the tip of the wire (inside the terminal) than the aluminum wire holding barrel, even if the terminal crimping strength of the conduction barrel is weak, the terminal and wire are operated by the rear holding barrel. There is no problem with the holding power. In addition, since the electric wire is firmly held by the rear holding barrel, the insulating oxide film of the aluminum electric wire is destroyed and brought into close contact with the front by pressing the conducting barrel with a large compression ratio (area reduction rate). Thus, sufficient electrical characteristics can be obtained between the terminal and the aluminum electric wire.

また、本発明の請求項2に記載のアルミ電線への端子圧着構造は、請求項1に記載のアルミ電線への端子圧着構造において、アルミ電線導通用圧着バレルとアルミ電線保持用圧着バレルとの間にスリットが形成されていることを特徴としている。   Moreover, the terminal crimping structure to the aluminum electric wire according to claim 2 of the present invention is the terminal crimping structure to the aluminum electric wire according to claim 1, wherein the crimping barrel for connecting the aluminum electric wire and the crimping barrel for holding the aluminum electric wire are provided. It is characterized in that a slit is formed between them.

かかるスリットを形成することで、アルミ電線導通用圧着バレルとアルミ電線保持用圧着バレルとを別個に圧着することが可能となる。これによって、アルミ電線保持用圧着バレルは従来の銅電線と同様な圧縮率(減面率)でアルミ電線を保持し、アルミ電線導通用圧着バレルでアルミ電線を大きな圧縮率(減面率)で圧着し、絶縁酸化膜を破壊し、かつ密着することで電気的導通特性を確保しながら圧着することができる。   By forming such a slit, it is possible to crimp the aluminum wire conduction crimp barrel and the aluminum wire holding crimp barrel separately. As a result, the crimp barrel for holding aluminum wires retains the aluminum wires at the same compression rate (area reduction) as conventional copper wires, and the aluminum wires are compressed at a large compression rate (area reduction) by the crimp barrel for connecting aluminum wires. By crimping, the insulating oxide film can be destroyed and brought into close contact with each other while securing electrical continuity characteristics.

また、本発明の請求項3に記載のアルミ電線への端子圧着構造は、請求項1に記載のアルミ電線への端子圧着構造において、アルミ電線導通用圧着バレルとアルミ電線保持用圧着バレルとがワイヤーバレルとして一体に形成され、端子が圧着された状態において端子圧着方向で見て高さの低い領域がアルミ電線導通用圧着バレルに対応しかつ高さの高い領域がアルミ電線保持用圧着バレルに対応することを特徴としている。   Moreover, the terminal crimping structure to the aluminum electric wire according to claim 3 of the present invention is the terminal crimping structure to the aluminum electric wire according to claim 1, wherein the aluminum electric wire conduction crimping barrel and the aluminum electric wire holding crimping barrel are provided. Formed integrally as a wire barrel, when the terminal is crimped, the lower region corresponds to the crimping barrel for aluminum wire conduction when viewed in the terminal crimping direction, and the higher region is the crimp barrel for holding the aluminum wire. It is characterized by corresponding.

アルミ電線保持用圧着バレルに対応する高さの高い端子圧着領域において従来銅電線と同様な圧縮率(減面率)でアルミ電線を保持し、アルミ電線導通用圧着バレルに対応する高さの低い領域においてアルミ電線を大きな圧縮率(減面率)で圧着し、撚り線の絶縁酸化膜を破壊し、かつ密着することで電気的導通特性を確保しながら圧着することができる。   Holds aluminum wires with the same compression ratio (area reduction) as conventional copper wires in the high terminal crimping region corresponding to crimping barrels for holding aluminum wires, and has a low height corresponding to crimping barrels for conducting aluminum wires. In the region, the aluminum electric wire can be crimped with a large compression ratio (area reduction ratio), and the insulating oxide film of the stranded wire can be destroyed and adhered to each other while ensuring electrical continuity characteristics.

また、本発明の請求項4に記載のアルミ電線への端子圧着構造は、アルミ電線被覆部圧着用インシュレーションバレルに加えて前後の高さ(長さ)の異なる導体圧着用バレルを備えた端子をアルミ電線に圧着するアルミ電線への端子圧着構造であって、インシュレーションバレルに隣接する位置にアルミ電線導体圧着用バレルが形成され、当該導体圧着用バレルはインシュレーションバレルと離れる方向(端子前方)に向かって、バレル高さが高くなる斜めの構造(前方が高く、後方が低い構造)をなし、導体圧着用バレルがアルミ電線に圧着された状態において、導体圧着用バレルの前後の高さが違うことにより、高さの低い部分(後方部分)はアルミ電線への食い込みが少なく、高い部分(前方部分)はアルミ電線への食い込みが大きく、アルミ電線を構成する各素線との接触の度合いがアルミ電線との端子長手方向で異なる(前方部分が多く後方部分が少ない)ことを特徴としている。   According to a fourth aspect of the present invention, there is provided a terminal crimping structure for an aluminum electric wire, which is provided with a conductor crimping barrel having different front and rear heights (lengths) in addition to an insulation barrel for crimping an aluminum wire covering portion. Is a terminal crimping structure to an aluminum wire, and a barrel for crimping an aluminum wire conductor is formed at a position adjacent to the insulation barrel. The conductor crimping barrel is away from the insulation barrel (front of the terminal). ), The height of the front and rear of the conductor crimping barrel in a state where the barrel for crimping the conductor is crimped to the aluminum wire. Due to the difference, the lower part (rear part) has less bite into the aluminum wire, and the higher part (front part) has more bite into the aluminum wire. It is characterized in that the degree of contact between the wires constituting the aluminum electric wire is different terminals longitudinal direction between the aluminum electric wire (less often rearward portion front portion).

アルミ電線との圧着において、導体圧着用バレルの後方(バレル長さの低い部分)はアルミ電線への食い込みが少なく電線をしっかりと保持し、導体圧着用バレルの前方(バレル長さの高い部分)はアルミ電線の中心まで大きく食い込んでアルミ電線を構成する各素線(撚り線)の多くと接触して、安定した導通を確保することができる。   When crimping with an aluminum wire, the back of the conductor crimping barrel (the part with the short barrel length) has little biting into the aluminum cable and holds the wire firmly, and the front of the conductor crimping barrel (the part with the long barrel length) Can penetrate into the center of the aluminum electric wire and come into contact with many of the strands (stranded wires) constituting the aluminum electric wire to ensure stable conduction.

また、本発明の請求項5に記載の端子付アルミ電線の製造方法は、アルミ電線被覆部圧着用インシュレーションバレルに加えてアルミ電線導通用圧着バレルとアルミ電線保持用圧着バレルとを備えた端子をアルミ電線に圧着するに当って、アルミ電線導通用圧着バレルとアルミ電線保持用圧着バレルがアルミ電線に圧着された状態において前記アルミ電線導通用圧着バレルをアルミ電線保持用圧着バレルよりも端子圧着方向で見て低い高さで当該アルミ電線に圧着することで、当該端子を圧着したアルミ電線を製造することを特徴としている。   Moreover, the manufacturing method of the aluminum electric wire with a terminal of Claim 5 of this invention is a terminal provided with the crimping barrel for aluminum electric wire conduction | electrical_connection and the crimping barrel for aluminum electric wire holding | maintenance in addition to the insulation barrel for aluminum electric wire coating | coated part crimping | compression-bonding. When crimping the aluminum wire to the aluminum wire, the aluminum wire conducting crimp barrel and the aluminum wire retaining crimp barrel are crimped to the aluminum wire with the terminal crimping the aluminum wire conducting crimp barrel more than the aluminum wire retaining crimp barrel. A feature of the present invention is that an aluminum electric wire with the terminal crimped is manufactured by crimping the aluminum electric wire at a low height when viewed in the direction.

また、本発明の請求項6に記載の端子付アルミ電線の製造方法は、アルミ電線被覆部圧着用インシュレーションバレルに加えて前後でバレルの長さが異なるアルミ電線導体圧着用バレルを備えた端子をアルミ電線に圧着するに当って、アルミ電線導体圧着用バレルがアルミ電線に圧着された状態において、アルミ電線導体用圧着バレルの前後の高さが違うことによって、低い部分(後方部分)はアルミ電線への食い込みが少なく、高い部分(前方部分)はアルミ電線への食い込みが大きく、アルミ電線を構成する各素線との接触の度合いが端子長手方向(導体圧着用バレルの前後方向)で異なる圧着をしたアルミ電線を製造することを特徴としている。   Moreover, the manufacturing method of the aluminum electric wire with a terminal of Claim 6 of this invention is a terminal provided with the barrel for aluminum electric wire conductor crimping in which the length of a barrel differs in front and back in addition to the insulation barrel for aluminum electric wire coating | coated part crimping When crimping aluminum wire to the aluminum wire, the aluminum wire conductor crimping barrel is crimped to the aluminum wire. There is little biting into the electric wire, and the high part (front part) is biting into the aluminum electric wire, and the degree of contact with each wire constituting the aluminum electric wire differs in the terminal longitudinal direction (front and rear direction of the conductor crimping barrel) It is characterized by producing crimped aluminum wires.

本発明の請求項5及び請求項6に記載のアルミ電線の圧着方法を実施すれば、アルミ電線の各電線サイズに必要な端子圧着強度(端子と電線の保持力)を確保すると共に、アルミ電線の絶縁酸化膜を破壊し、かつ密着することで電気導通性を確保した端子を圧着したアルミ電線を得ることが可能となる。   When the aluminum wire crimping method according to claims 5 and 6 of the present invention is carried out, the terminal crimping strength (terminal and wire holding force) required for each wire size of the aluminum wire is secured, and the aluminum wire is secured. It is possible to obtain an aluminum electric wire in which a terminal that secures electrical conductivity is crimped by destroying and closely adhering the insulating oxide film.

アルミ電線導通用圧着バレルとアルミ電線保持用圧着バレルをアルミ電線導体部に圧着することによって、端子とアルミ電線との安定した導通接続を図ると共に長期にわたって端子がアルミ電線をしっかりと保持する。   By crimping the aluminum wire conduction crimp barrel and the aluminum wire holding crimp barrel to the aluminum wire conductor, the terminal and the aluminum wire can be stably connected to each other and the terminal holds the aluminum wire firmly for a long time.

また、ワイヤーバレルにスリットを形成してバレル二股形状にすることによって段差をつけた圧着構造を容易にし、更に安定した導通接続及び長期にわたる端子保持を可能とする。   Further, by forming a slit in the wire barrel to form a bifurcated barrel, a stepped crimp structure is facilitated, and a stable conductive connection and long-term terminal retention are possible.

さらには、ワイヤーバレルのアルミ電線導体部における圧着部に2段の段差をつけた状態で圧着することで、端子とアルミ電線との安定した導通接続及び端子のアルミ電線に対する長期間の保持を可能する。   Furthermore, by crimping the crimping part of the aluminum wire conductor part of the wire barrel with a two-step difference, stable connection between the terminal and the aluminum cable and long-term holding of the terminal to the aluminum cable are possible. To do.

更に、端子自体にもアルミ合金端子を使用すれば異種金属間による電食の発生も防止することができる。   Furthermore, if an aluminum alloy terminal is used for the terminal itself, the occurrence of electrolytic corrosion between different kinds of metals can be prevented.

図1は、本発明の一実施形態にかかるアルミ電線圧着端子10の平面図(図1(a))及び側面図(図1(b))である。同図から明らかなように、アルミ電線圧着端子10は、端子の長手方向一側に形成された端子間接続部10aと長手方向他側に形成された電線接続部10bとから構成され、電線接続部10bは、アルミ電線の電線被覆部に圧着するインシュレーションバレル15と、端子間接続部10aとインシュレーションバレル15間に形成された導通バレル12及び保持バレル13とを備えている。なお、導通バレル12は端子間接続部側、即ち圧着されるアルミ電線1(図3参照)の先端部側に形成され、保持バレル13はインシュレーションバレル側、即ちアルミ電線1の電線被覆部側近傍に形成されている。なお、本実施形態の場合、導通バレル12と保持バレル13とは互いに隣接し合い、両者の間には幅狭のスリット19が形成されている。   Drawing 1 is a top view (Drawing 1 (a)) and side view (Drawing 1 (b)) of aluminum electric wire crimp terminal 10 concerning one embodiment of the present invention. As is apparent from the figure, the aluminum wire crimping terminal 10 is composed of an inter-terminal connection portion 10a formed on one side in the longitudinal direction of the terminal and an electric wire connection portion 10b formed on the other side in the longitudinal direction. The portion 10 b includes an insulation barrel 15 that is crimped to a wire covering portion of an aluminum electric wire, and a conduction barrel 12 and a holding barrel 13 that are formed between the interterminal connection portion 10 a and the insulation barrel 15. The conduction barrel 12 is formed on the terminal connecting portion side, that is, on the tip end side of the aluminum wire 1 to be crimped (see FIG. 3), and the holding barrel 13 is on the insulation barrel side, that is, on the wire covering portion side of the aluminum wire 1. It is formed in the vicinity. In the case of this embodiment, the conduction barrel 12 and the holding barrel 13 are adjacent to each other, and a narrow slit 19 is formed between them.

続いて、本実施形態にかかるアルミ電線圧着端子10をアルミ電線1に圧着する工程について説明する。図2(a)に示すように、最初にアルミ電線圧着端子10を基台210に固定し、アルミ電線1をアルミ電線圧着端子10の適所に位置決めする。即ち、アルミ電線1の被覆部1b(図3(a)参照)をインシュレーションバレル15で挟まれた領域に位置決めすると共にアルミ電線1の導体部1a(図3(a)参照)を導通バレル12と保持バレル13とでそれぞれ挟まれた領域に位置決めする。この状態で、端子長手方向で見て逆V字型で先端がM字形状の圧着溝を有する圧着治具110を端子の上方から接近させる(図2(a)の端子圧着方向を示す矢印X2参照)。図2から明らかなように、圧着治具110には圧着する3つの導通バレル12、保持13、及びインシュレーションバレル15に対応する圧着部112,113,115が形成されている。即ち、導通バレル12に対応する圧着部112が端子圧着方向に最も突出して形成され、次いで保持バレル13に対応する圧着部113が形成され、インシュレーションバレル15に対応する圧着部115が最も引っ込んで形成されている。そして、この圧着治具110を図示しないアクチュエータによって端子側に向かって下降させる(図2(a)の矢印X2参照)。この下降動作によって、各バレル12,13,15の端部が圧着治具110の逆V字型の圧着溝に沿ってしだいに屈曲され、やがては、圧着治具110のM字状先端部において図2(c)に示すように各バレル端部がアルミ電線1の中心軸線方向に変形(カール)する。そして、圧着治具110をさらに下降することによってアルミ電線導体部1aに導通バレル12と保持バレル13が圧着されると共にアルミ電線1の被覆部1bにもインシュレーションバレル15が圧着される。この端子圧着作業が終わると、図2(d)に示すように、圧着治具を上昇(図中、矢印Y2参照)させて端子圧着工程を完了する。   Then, the process of crimping | bonding the aluminum electric wire crimp terminal 10 concerning this embodiment to the aluminum electric wire 1 is demonstrated. As shown in FIG. 2A, first, the aluminum wire crimp terminal 10 is fixed to the base 210, and the aluminum wire 1 is positioned at an appropriate position of the aluminum wire crimp terminal 10. That is, the covering portion 1b (see FIG. 3A) of the aluminum electric wire 1 is positioned in a region sandwiched between the insulation barrels 15, and the conductor portion 1a (see FIG. 3A) of the aluminum electric wire 1 is connected to the conduction barrel 12. And the holding barrel 13 are positioned in the respective regions. In this state, a crimping jig 110 having a crimp groove having an inverted V shape and an M-shaped tip as viewed in the longitudinal direction of the terminal is approached from above the terminal (an arrow X2 indicating a terminal crimping direction in FIG. 2A). reference). As is apparent from FIG. 2, the crimping jig 110 is formed with three conducting barrels 12 to be crimped, a holding 13, and crimping portions 112, 113, and 115 corresponding to the insulation barrel 15. That is, the crimping portion 112 corresponding to the conduction barrel 12 is formed so as to protrude most in the terminal crimping direction, then the crimping portion 113 corresponding to the holding barrel 13 is formed, and the crimping portion 115 corresponding to the insulation barrel 15 is most retracted. Is formed. Then, the crimping jig 110 is lowered toward the terminal side by an actuator (not shown) (see arrow X2 in FIG. 2A). By this descending operation, the end portions of the barrels 12, 13, 15 are gradually bent along the inverted V-shaped crimp groove of the crimping jig 110, and eventually, at the M-shaped tip portion of the crimping jig 110. As shown in FIG. 2C, each barrel end is deformed (curled) in the direction of the central axis of the aluminum electric wire 1. Then, by further lowering the crimping jig 110, the conduction barrel 12 and the holding barrel 13 are crimped to the aluminum wire conductor portion 1a, and the insulation barrel 15 is also crimped to the covering portion 1b of the aluminum wire 1. When this terminal crimping operation is completed, as shown in FIG. 2D, the crimping jig is raised (see arrow Y2 in the figure) to complete the terminal crimping process.

このようにして圧着されたアルミ電線1の端子圧着構造を図3に示す。図2に示した特別な圧着治具110を用いることによって、導通バレル12の圧着部分は保持バレル13の圧着部分に比べて大きい圧縮率(減面率)でアルミ電線1に圧着され、結果的に端子圧着方向で見て導通バレル12の圧着高さが保持バレル13の圧着高さよりも低くなるように圧着されている。   A terminal crimping structure of the aluminum wire 1 crimped in this way is shown in FIG. By using the special crimping jig 110 shown in FIG. 2, the crimping portion of the conduction barrel 12 is crimped to the aluminum electric wire 1 at a compression rate (area reduction rate) larger than that of the crimping portion of the holding barrel 13. The crimping height of the conducting barrel 12 is crimped to be lower than the crimping height of the holding barrel 13 when viewed in the terminal crimping direction.

すなわち、保持バレル13は、導通バレル12ほど大きな圧縮率(減面率)で圧着されていない。これによって、アルミ電線1の被覆部1bから導出した導体部1aは、導通バレル12において大きい圧縮率(減面率)によって圧着されると共に保持バレル13によって保持される。従って、保持バレル13の圧着部においては端子10がアルミ電線1を機械強度的に無理のない程度で保持し、かつこれと隣接する導通バレル12の圧着部においてはアルミ電線1の表面酸化膜を破壊し、かつ密着する十分大きい圧縮率(減面率)で端子が圧着されている。このような段階的な圧着によってアルミ電線への過大な端子圧縮率(減面率)に起因する端子保持力の低下や不十分な端子圧縮率(減面率)に起因する導通不良なども一挙に解決することができる。   That is, the holding barrel 13 is not pressure-bonded at a compression rate (area reduction rate) as large as that of the conduction barrel 12. As a result, the conductor portion 1 a led out from the covering portion 1 b of the aluminum electric wire 1 is pressed by the conductive barrel 12 with a large compression rate (area reduction rate) and is held by the holding barrel 13. Accordingly, the terminal 10 holds the aluminum electric wire 1 at a pressure level of the holding barrel 13 to an extent that the mechanical strength is not excessive, and the surface oxide film of the aluminum electric wire 1 is applied to the pressure-bonding portion of the conductive barrel 12 adjacent thereto. The terminals are crimped at a sufficiently high compression rate (area reduction rate) to break and adhere. Such step-by-step crimping causes a decrease in terminal holding force due to excessive terminal compression rate (area reduction) to aluminum wires and poor conduction due to insufficient terminal compression rate (area reduction rate). Can be solved.

続いて、図3に示したアルミ電線圧着端子に関する様々な変形例を図4乃至図11の図面に基づいて説明する。なお、図3に示したアルミ電線圧着端子10と同一の構成については対応する符号を付して詳細な説明を省略する。   Next, various modifications relating to the aluminum wire crimp terminal shown in FIG. 3 will be described with reference to FIGS. 4 to 11. In addition, about the structure same as the aluminum electric wire crimp terminal 10 shown in FIG. 3, corresponding code | symbol is attached | subjected and detailed description is abbreviate | omitted.

図4に示すアルミ電線圧着端子20は、図3に示すアルミ電線圧着端子10と基本的構成を同一とするが、導通バレル22と保持バレル23間のスリット29が、図3に示すアルミ電線圧着端子10のスリット19に比べて幅広に形成されている(図4(b)参照)。これによって、図5に示すように、特殊な段付きの圧着治具120を用いて導通バレル22、保持バレル23及びインシュレーションバレル25を圧着するに当って、アルミ電線圧着端子20の圧着される導通バレル22、保持バレル23と圧着治具120との間に多少の位置ずれが生じても、導通バレル22を大きな圧縮率(減面率)で圧着できると共に保持バレル23を導通バレル22に比べて小さな圧縮率(減面率)で圧着できる。   The aluminum wire crimping terminal 20 shown in FIG. 4 has the same basic configuration as the aluminum wire crimping terminal 10 shown in FIG. 3, but the slit 29 between the conduction barrel 22 and the holding barrel 23 has the aluminum wire crimping contact shown in FIG. 3. It is formed wider than the slit 19 of the terminal 10 (see FIG. 4B). As a result, as shown in FIG. 5, the aluminum wire crimp terminal 20 is crimped when the conduction barrel 22, the holding barrel 23, and the insulation barrel 25 are crimped by using a special stepped crimping jig 120. Even if there is a slight misalignment between the conduction barrel 22 and the holding barrel 23 and the crimping jig 120, the conduction barrel 22 can be crimped with a large compression ratio (area reduction) and the holding barrel 23 is compared with the conduction barrel 22. Can be crimped with a small compression ratio (area reduction).

図6は、このような圧着治具120を用いたアルミ電線1への端子圧着状態を示している。図6(b)から明らかなように、導通バレル22の圧着部と保持バレル23の圧着部とを比較すると、端子圧着方向で見て導通バレル22の圧着部が保持バレル23の圧着部よりも低く圧着されている(図6(b)中、高さHmと高さHnとを比較参照)。即ち、アルミ電線1の被覆部1bから導出したアルミ電線導体部1aは保持バレル23の圧着部において機械強度的に無理のない十分な保持力で保持される。これと共に、保持バレル23よりアルミ電線端部側に隣接して形成された導通バレル22の圧着部においてはアルミ電線1の導体部1aの表面酸化膜を破壊し、かつ密着するのに十分な大きさの圧縮率(減面率)によって圧着され、結果的に十分な電気的導通特性をこの部分で達成している。   FIG. 6 shows a terminal crimping state to the aluminum electric wire 1 using such a crimping jig 120. As apparent from FIG. 6B, when the crimping portion of the conduction barrel 22 and the crimping portion of the holding barrel 23 are compared, the crimping portion of the conduction barrel 22 is more than the crimping portion of the holding barrel 23 when viewed in the terminal crimping direction. It is crimped low (see FIG. 6B for comparison between height Hm and height Hn). That is, the aluminum wire conductor portion 1 a led out from the covering portion 1 b of the aluminum wire 1 is held with a sufficient holding force that is not unreasonable in mechanical strength at the crimping portion of the holding barrel 23. At the same time, in the crimping portion of the conductive barrel 22 formed adjacent to the end portion of the aluminum wire from the holding barrel 23, the surface oxide film of the conductor portion 1a of the aluminum wire 1 is sufficiently large to break and adhere closely. The pressure is reduced by the compression ratio (area reduction ratio), and as a result, sufficient electrical conduction characteristics are achieved in this portion.

続いて、図7に示すアルミ電線圧着端子30について説明する。図7に示すアルミ電線圧着端子30は、前述した2種類のアルミ電線圧着端子10,20とは異なり、導通バレル32と保持バレル33とが一体化した導電バレル31として形成されている。即ち、導通バレル32と保持バレル33との間にはスリットが形成されていない。このような圧着端子を用いても、前述した特別な段付きの圧着治具120(図5参照)を用いてアルミ電線圧着端子30をアルミ電線1に圧着することで導通バレル32と保持バレル33とを圧着治具120の段差に応じた段付き状態で圧着させることが可能となる。その結果、図8に示すように、端子圧着方向で見て導通バレル32に対応する端子圧着領域の方が保持バレル33に対応する端子圧着領域よりも高さが低く圧着される(図中の高さHcと高さHdを比較参照)。これによって、前述した場合と同様な効果、すなわち、保持バレル33に対応する端子圧着領域においては被覆部1bから導出したアルミ電線導体部1aに機械強度的に無理なく当該導体部1aを長期間にわたってしっかりと保持する。これと共に保持バレル33に隣接してアルミ電線端部側に形成された導通バレル32に対応する端子圧着領域においてはアルミ電線導体部1aの酸化膜を破壊し、かつ密着するのに十分な大きさの圧縮率(減面率)で圧着され、この部分で十分な電気的導通特性を得ることができる。   Next, the aluminum wire crimp terminal 30 shown in FIG. 7 will be described. The aluminum wire crimp terminal 30 shown in FIG. 7 is formed as a conductive barrel 31 in which a conduction barrel 32 and a holding barrel 33 are integrated, unlike the two types of aluminum wire crimp terminals 10 and 20 described above. That is, no slit is formed between the conduction barrel 32 and the holding barrel 33. Even when such a crimp terminal is used, the conduction barrel 32 and the holding barrel 33 are obtained by crimping the aluminum wire crimp terminal 30 to the aluminum wire 1 using the above-described special stepped crimp jig 120 (see FIG. 5). Can be crimped in a stepped state corresponding to the level difference of the crimping jig 120. As a result, as shown in FIG. 8, when viewed in the terminal crimping direction, the terminal crimping region corresponding to the conduction barrel 32 is crimped lower than the terminal crimping region corresponding to the holding barrel 33 (in FIG. 8). Compare height Hc and height Hd). As a result, the same effect as described above, that is, in the terminal crimping region corresponding to the holding barrel 33, the conductor portion 1a is extended over a long period of time without excessive mechanical strength to the aluminum wire conductor portion 1a derived from the covering portion 1b. Hold firmly. At the same time, in the terminal crimping region corresponding to the conductive barrel 32 formed on the end side of the aluminum wire adjacent to the holding barrel 33, the oxide film of the aluminum wire conductor portion 1a is sufficiently large to be broken and adhered. With this compression ratio (area reduction ratio), sufficient electrical conduction characteristics can be obtained at this portion.

なお、前述した図7に示したアルミ電線圧着端子30に対して段付きの圧着治具120を用いる代わりに、圧着する端子の長手方向で見て逆V字型溝で先端M字型(溝底M字型)の溝深さが連続的に変化する圧着治具(図示せず)を用いても良い。すなわち、図9に示すようなアルミ電線の端子圧着状態を実現するに当って、例えば、圧着治具の逆V字型圧着溝の溝深さが圧着されるアルミ電線の絶縁被覆側に向かうに従って連続的に深くなるように(アルミ電線の電線先端側に向かうに従って圧着治具の逆V字型圧着溝の溝深さが連続的に浅くなるように)形成した治具(ここでは図示せず)を用いても良い。このような圧着治具を用いて端子を圧着することで、導通バレル42と保持バレル43とがワイヤーバレルとして一体に形成された端子であっても、圧着後には図9(a)に示すようにアルミ電線の先端に向かうに従って導通バレル42の方が保持バレル43よりも端子圧着方向で見て連続的に高さが低くなるように圧着することができる。   Instead of using the stepped crimping jig 120 for the aluminum wire crimping terminal 30 shown in FIG. 7 described above, the tip is M-shaped (grooved) with an inverted V-shaped groove as viewed in the longitudinal direction of the terminal to be crimped. A crimping jig (not shown) in which the bottom M-shaped groove depth continuously changes may be used. That is, in realizing the terminal crimping state of the aluminum wire as shown in FIG. 9, for example, as the groove depth of the reverse V-shaped crimping groove of the crimping jig moves toward the insulation coating side of the aluminum wire to be crimped. A jig (not shown here) formed so as to be continuously deep (so that the depth of the reverse V-shaped crimp groove of the crimping jig is continuously reduced toward the tip of the aluminum wire) ) May be used. By crimping the terminal using such a crimping jig, even if the conduction barrel 42 and the holding barrel 43 are integrally formed as a wire barrel, after crimping, as shown in FIG. In addition, the conductive barrel 42 can be crimped so as to be continuously lower in the terminal crimping direction than the holding barrel 43 as it goes toward the tip of the aluminum wire.

このように圧着されたアルミ電線圧着端子40の圧着状態の断面を図9(b)に示す。同図から明らかなように、導通バレル42に対応する圧着領域ではかなり強い力で圧着され(図9(b)のAA-AA断面図参照)、これによってアルミ電線(ここでは図示せず)と十分な電気的導通を図ることが可能となる。一方、保持バレル43に対応する圧着領域では導通バレル42ほど大きな圧縮率(減面率)で圧着されていない(図9(b)のBB-BB断面図参照)。これによって、アルミ電線被覆部からの導体導出部であって保持バレル43においてはアルミ電線の導体部に機械強度的に無理なく、アルミ電線を長期にわたってしっかりと保持することが可能となる。また、アルミ電線の端部側に向かうに従って導通バレル42に対応する領域がより大きい圧縮率(減面率)で圧着され、アルミ電線の酸化膜を破壊して十分な電気的導通を可能としている。   FIG. 9B shows a cross-section of the crimped state of the aluminum wire crimp terminal 40 thus crimped. As is apparent from the figure, the crimping region corresponding to the conduction barrel 42 is crimped with a considerably strong force (refer to the AA-AA cross-sectional view of FIG. 9B), and thereby an aluminum wire (not shown here) Sufficient electrical conduction can be achieved. On the other hand, the crimping region corresponding to the holding barrel 43 is not crimped with a compression rate (area reduction) as large as that of the conductive barrel 42 (see the BB-BB cross-sectional view of FIG. 9B). As a result, it is possible to hold the aluminum wire firmly for a long period of time in the holding barrel 43, which is a conductor lead-out portion from the aluminum wire covering portion, without excessive mechanical strength on the conductor portion of the aluminum wire. Moreover, the area | region corresponding to the conduction | electrical_connection barrel 42 is crimped | bonded by a bigger compression rate (area reduction ratio) as it goes to the edge part side of an aluminum electric wire, and the oxide film of an aluminum electric wire is destroyed and sufficient electric conduction is enabled. .

なお、このような圧着治具側の圧着溝形状を工夫する代わりに、すなわち圧着治具に特別な段付き部や端子長手方向に向かって深さの変化する溝部を備える代わりに、図10に示すようにアルミ電線圧着端子50のワイヤーバレル形状を工夫することによっても同様の作用効果を発揮することが可能である。   Instead of devising such a crimping groove shape on the crimping jig side, that is, instead of providing a crimping jig with a special stepped portion or a groove portion whose depth changes in the terminal longitudinal direction, FIG. As shown, it is possible to exert the same effect by devising the wire barrel shape of the aluminum electric wire crimp terminal 50.

図10に示すアルミ電線圧着端子50は導通バレル52と保持バレル53とが導電バレル51として一体化しているが、導通バレル52に対応する部分が保持バレル53に対応する部分よりも高さが高く起立した状態で形成されている(図10(b),(c)の角度α参照)。即ち、圧着されるアルミ電線の先端部に向かうに従ってワイヤーバレル51の高さが徐々に高くなるように形成されている。   In the aluminum wire crimping terminal 50 shown in FIG. 10, the conducting barrel 52 and the holding barrel 53 are integrated as the conducting barrel 51, but the portion corresponding to the conducting barrel 52 is higher than the portion corresponding to the holding barrel 53. It is formed in an upright state (see angle α in FIGS. 10B and 10C). That is, the height of the wire barrel 51 is gradually increased toward the tip of the aluminum wire to be crimped.

そして、図13に示した従来型の圧着治具180を用いて圧着した場合、図11(a)に示すように端子圧着方向で見て導通バレル52に対応する圧着部と保持バレル53に対応する圧着部との高さは同一となる(図11(a)の高さHe及び高さHf比較参照)。しかしながら、元々、導通バレル52の領域が保持バレル53の領域よりも端子圧着方向の長さが長く形成されているので、図11(b)に示す端子圧着状態の断面比較図からも分かるように、導通バレル52の領域の端子先端部が保持バレル53の領域の端子先端部よりアルミ電線の撚り線(図示せず)内に深くくい込む。これによって、保持バレル53に対応する領域において過度の応力をアルミ電線(図示せず)に作用させることなくアルミ電線を長期にわたってしっかりと保持できる。これと共に、導通バレル52に対応する領域においてはアルミ電線の各撚り線(素線)と多く接触すると同時に、表面酸化物を破壊し、密着する端子圧縮率で圧着され、十分な電気的導通特性を確保できる。   When the conventional crimping jig 180 shown in FIG. 13 is used for crimping, the crimping portion corresponding to the conduction barrel 52 and the holding barrel 53 are viewed in the terminal crimping direction as shown in FIG. The height of the crimping part is the same (see the comparison of height He and height Hf in FIG. 11A). However, since the region of the conduction barrel 52 is originally formed to have a longer length in the terminal crimping direction than the region of the holding barrel 53, as can be seen from the sectional comparison view of the terminal crimped state shown in FIG. The terminal tip in the region of the conduction barrel 52 is deeper than the terminal tip in the region of the holding barrel 53 into the stranded wire (not shown) of the aluminum electric wire. Thus, the aluminum electric wire can be firmly held for a long time without applying excessive stress to the aluminum electric wire (not shown) in the region corresponding to the holding barrel 53. At the same time, in the region corresponding to the conduction barrel 52, a large amount of contact is made with each stranded wire (elementary wire) of the aluminum electric wire, and at the same time, the surface oxide is destroyed and crimped with an intimate terminal compression ratio, and sufficient electrical conduction characteristics are obtained. Can be secured.

以上示したように、圧着治具の形状を工夫するかアルミ電線圧着端子のワイヤーバレル形状を工夫することで、アルミ電線の圧縮率(減面率)を保持バレルの圧着部から導通バレルの圧着部まで段階的に又は連続的に強めて端子の長期にわたるしっかりした保持を維持しつつ十分な電気的導通特性を確保する。また、アルミ電線を備えたワイヤーハーネスに、このような端子を上述した工程で圧着することで、十分な機械的強度と電気的導通特性を有するワイヤーハーネスを製造することが可能となる。かかるワイヤーハーネスを車両に配索した場合、配索作業に十分耐えうる強度を当該ワイヤーハーネスが有するので、ワイヤーハーネス配索作業の効率化を図ることができる。これとともに、長期にわたって導通特性に優れかつ信頼性を有したワイヤーハーネスの配索作業を実現することが可能となる。   As described above, by devising the shape of the crimping jig or by devising the wire barrel shape of the aluminum wire crimping terminal, the compression rate (area reduction) of the aluminum wire is crimped from the crimping part of the holding barrel to the conduction barrel. Intensify stepwise or continuously to the part to ensure sufficient electrical continuity while maintaining a long hold of the terminal. Moreover, it becomes possible to manufacture a wire harness having sufficient mechanical strength and electrical conduction characteristics by crimping such a terminal to a wire harness provided with an aluminum electric wire in the above-described process. When such a wire harness is routed in a vehicle, the wire harness has sufficient strength to withstand the routing operation, so that the efficiency of the wire harness routing operation can be improved. At the same time, it is possible to realize the wiring work of the wire harness having excellent conduction characteristics and reliability over a long period of time.

尚、本実施形態に示す圧着端子の端子接続部は従来型の圧着端子のメス形状(すなわち、舌片バネ構造)を有しているが、必ずしもこれに限定されずこの部分をオス形状としても適用可能であり、端子接続部の構造は新旧様々な端子構造が使用可能である。   In addition, although the terminal connection part of the crimp terminal shown in this embodiment has a female shape of a conventional crimp terminal (that is, a tongue spring structure), the present invention is not necessarily limited thereto, and this part may be a male shape. Applicable, and various terminal structures can be used for the terminal connection part.

また、適用される端子材料としては電食防止の観点から異種金属を避け、アルミ合金系端子を使用するのが好ましいが、必ずしもこの材料に限定されるものではない。   In addition, as a terminal material to be applied, it is preferable to avoid a dissimilar metal and use an aluminum alloy-based terminal from the viewpoint of preventing electrolytic corrosion, but it is not necessarily limited to this material.

また、端子接続部における空気による酸化や湿気による腐食を防止するため、端子接続部や端子圧着部に防錆用のグリース等を塗布しておくと、更に高い信頼性を得ることが可能となる。   In addition, in order to prevent oxidation due to air and corrosion due to moisture at the terminal connection portion, it is possible to obtain higher reliability by applying a rust preventive grease to the terminal connection portion and the terminal crimping portion. .

導体としてアルミを使用するアルミ電線を接続するための挿抜可能なコネクタ用圧着端子に本発明は適用可能であるが、主な用途としての自動車内ワイヤーハーネス配索にこの用途が限定されることはなく、このようなアルミ電線端部に端子を圧着する様々な分野で利用可能である。   Although the present invention can be applied to a crimping terminal for a connector that can be inserted / removed for connecting an aluminum electric wire that uses aluminum as a conductor, this application is limited to the wiring harness wiring in an automobile as a main application. In addition, the present invention can be used in various fields in which a terminal is crimped to the end of such an aluminum electric wire.

本発明の一実施形態にかかるアルミ電線圧着端子の平面図((図1(a))及び側面図(図1(b))である。It is a top view ((Drawing 1 (a)) and a side view (Drawing 1 (b)) of an aluminum electric wire crimp terminal concerning one embodiment of the present invention. 図1に示したアルミ電線圧着端子を圧着治具を介して当該アルミ電線に圧着する状態を図2(a)乃至図2(d)の工程順に示した第1の側面図(左側)及び第2の側面図(右側)である。A first side view (left side) and a second side view showing a state in which the aluminum wire crimping terminal shown in FIG. 1 is crimped to the aluminum wire via a crimping jig in the order of steps of FIGS. 2 (a) to 2 (d). It is a side view (right side) of 2. 図1に示したアルミ電線圧着端子をアルミ電線に圧着した状態を示した平面図(図3(a))及び側面図(図3(b))である。It is the top view (Drawing 3 (a)) and the side view (Drawing 3 (b)) which showed the state where the aluminum electric wire crimping terminal shown in Drawing 1 was crimped to the aluminum electric wire. 図1に示したアルミ電線圧着端子の変形例を示した平面図(図4(a))及び側面図(図4(b))である。It is the top view (FIG.4 (a)) and side view (FIG.4 (b)) which showed the modification of the aluminum electric wire crimp terminal shown in FIG. 図4に示したアルミ電線圧着端子の圧着工程を図2に対応して示した工程説明図である。It is process explanatory drawing which showed the crimping process of the aluminum electric wire crimp terminal shown in FIG. 4 corresponding to FIG. 図4に示したアルミ電線圧着端子をアルミ電線に圧着した状態を示した平面図(図6(a))及び側面図(図6(b)である。They are the top view (Drawing 6 (a)) and the side view (Drawing 6 (b)) which showed the state where the aluminum electric wire crimping terminal shown in Drawing 4 was crimped to the aluminum electric wire. 図4に示したアルミ電線圧着端子の更なる変形例を示した平面図(図7(a))及び側面図(図7(b))である。It is the top view (FIG.7 (a)) and side view (FIG.7 (b)) which showed the further modification of the aluminum electric wire crimp terminal shown in FIG. 図7に示したアルミ電線圧着端子をアルミ電線に圧着した状態を示す平面図(図8(a))及び側面図(図8(b))である。It is the top view (Drawing 8 (a)) and the side view (Drawing 8 (b)) which show the state where the aluminum electric wire crimping terminal shown in Drawing 7 was crimped to the aluminum electric wire. 図7に示したアルミ電線圧着端子とは異なるアルミ電線圧着端子をアルミ電線に圧着した状態を、アルミ電線を除いて示す側面図(図9(a))、及び図9(a)におけるAA-AA断面図とBB-BB断面図(図9(b))である。The side view (FIG. 9 (a)) which shows the state which crimped the aluminum electric wire crimping terminal different from the aluminum electric wire crimping terminal shown in FIG. 7 to the aluminum electric wire except for the aluminum electric wire, and AA- in FIG. 9 (a) It is AA sectional drawing and BB-BB sectional drawing (FIG.9 (b)). 図9のアルミ電線圧着端子の変形例を示した平面図(図10(a)及び側面(図10(b))並びに当該圧着端子の展開状態図(図10(c))である。It is the top view (FIG. 10 (a) and side surface (FIG.10 (b))) which showed the modification of the aluminum electric wire crimp terminal of FIG. 9, and the expanded state figure (FIG.10 (c)) of the said crimp terminal. 図10に示したアルミ電線圧着端子を用いてアルミ電線を圧着した状態を示す側面図(図11(a))及びその所定断面を示したCC-CC断面図とDD-DD断面図(図11(b))である。The side view (FIG. 11 (a)) which shows the state which crimped the aluminum electric wire using the aluminum electric wire crimp terminal shown in FIG. 10, CC-CC sectional drawing which showed the predetermined cross section, and DD-DD sectional drawing (FIG. 11) (B)). 従来の銅電線圧着端子を示した断面図(図12(a))及び側面図(図12(b)である。It is sectional drawing (FIG. 12 (a)) and the side view (FIG.12 (b)) which showed the conventional copper electric wire crimp terminal. 図12に示した銅電線圧着端子をアルミ電線に圧着する工程を示した図2に対応する工程説明図である。It is process explanatory drawing corresponding to FIG. 2 which showed the process of crimping | bonding the copper electric wire crimp terminal shown in FIG. 12 to the aluminum electric wire. 図12に示したアルミ電線圧着端子をアルミ電線に圧着した状態を示した平面図(図14(a))及び小さな圧縮率(減面率)で圧着した場合の圧着状態を示した側面図(図14(b))並びに大きな圧縮率(減面率)で圧着した場合の圧着状態を示した側面図(図14(c))である。The top view (FIG. 14 (a)) which showed the state which crimped | bonded the aluminum electric wire crimp terminal shown in FIG. 12 to the aluminum electric wire, and the side view which showed the crimping state at the time of crimping | bonding with a small compression rate (area reduction rate) ( FIG. 14 (b)) and a side view (FIG. 14 (c)) showing a crimped state when crimped with a large compression rate (area reduction rate).

符号の説明Explanation of symbols

1a 導体部
1b 被覆部
10,20,30,40,50 アルミ電線圧着端子
10a,80a 端子間接続部
10b,80b 電線接続部
12,22,32,42,52 導通バレル
13,23,33,43,53 保持バレル
15,85 インシュレーションバレル
19,29 スリット
25 インシュレーションバレル
51,81 ワイヤーバレル
80 端子
110,120,180 圧着治具
181,185 圧着部
210 基台
DESCRIPTION OF SYMBOLS 1a Conductor part 1b Covering part 10, 20, 30, 40, 50 Aluminum electric wire crimp terminal 10a, 80a Terminal connection part 10b, 80b Electric wire connection part 12, 22, 32, 42, 52 Conduction barrel 13, 23, 33, 43 , 53 Holding barrel 15, 85 Insulation barrel 19, 29 Slit 25 Insulation barrel 51, 81 Wire barrel 80 Terminal 110, 120, 180 Crimping jig 181, 185 Crimping part 210 Base

Claims (6)

アルミ電線被覆部圧着用インシュレーションバレルに加えてアルミ電線導通用圧着バレルとアルミ電線保持用圧着バレルとを備えた端子をアルミ電線に圧着するアルミ電線への端子圧着構造であって、
前記インシュレーションバレルに隣接する位置に前記アルミ電線保持用圧着バレルが形成されると共に、当該アルミ電線保持用圧着バレルに関して前記インシュレーションバレルと反対側にアルミ電線導通用圧着バレルが形成され、前記両圧着バレルがアルミ電線に圧着された状態において、端子圧着方向で見て前記アルミ電線導通用圧着バレルがアルミ電線保持用圧着バレルよりも低い高さで当該アルミ電線に圧着されていることを特徴とするアルミ電線への端子圧着構造。
In addition to the insulation barrel for crimping the aluminum wire covering portion, in addition to the crimping barrel for conducting the aluminum wire and the crimping barrel for holding the aluminum wire, the terminal crimping structure to the aluminum wire for crimping the aluminum wire to the aluminum wire,
The aluminum wire holding crimp barrel is formed at a position adjacent to the insulation barrel, and the aluminum wire conducting crimp barrel is formed on the opposite side of the insulation barrel with respect to the aluminum wire holding crimp barrel. When the crimp barrel is crimped to the aluminum wire, the aluminum wire conduction crimp barrel is crimped to the aluminum wire at a lower height than the aluminum wire holding crimp barrel when viewed in the terminal crimp direction. Terminal crimping structure to aluminum wires.
前記アルミ電線導通用圧着バレルと前記アルミ電線保持用圧着バレルとの間にはスリットが形成されていることを特徴とする、請求項1に記載のアルミ電線への端子圧着構造。   The terminal crimping structure to an aluminum electric wire according to claim 1, wherein a slit is formed between the aluminum electric wire conduction crimping barrel and the aluminum electric wire holding crimping barrel. 前記アルミ電線導通用圧着バレルと前記アルミ電線保持用圧着バレルとがワイヤーバレルとして一体に形成され、端子が圧着された状態において端子圧着方向で見て当該ワイヤーバレルの高さの低い領域が前記アルミ電線導通用圧着バレルに対応し、かつ高さの高い領域が前記アルミ電線保持用圧着バレルに対応することを特徴とする、請求項1に記載のアルミ電線への端子圧着構造。   The aluminum wire conducting crimping barrel and the aluminum wire holding crimping barrel are integrally formed as a wire barrel, and when the terminal is crimped, the lower region of the wire barrel as viewed in the terminal crimping direction is the aluminum The terminal crimping structure to an aluminum electric wire according to claim 1, wherein a region having a high height corresponding to the crimping barrel for electric wire conduction corresponds to the crimping barrel for holding an aluminum electric wire. アルミ電線被覆部圧着用インシュレーションバレルに加えて前後の高さの異なる導体圧着用バレルを備えた端子をアルミ電線に圧着するアルミ電線への端子圧着構造であって、
前記インシュレーションバレルに隣接する位置に前記アルミ電線導体圧着用バレルが形成され、当該導体圧着用バレルはインシュレーションバレルと離れる方向に向かって、バレル高さが高くなる斜めの構造をなし、前記導体圧着用バレルが前記アルミ電線に圧着された状態において、前記導体圧着用バレルの前後の高さが違うことにより、高さの低い部分は前記アルミ電線への食い込みが少なく、高い部分は前記アルミ電線への食い込みが大きく、前記アルミ電線を構成する各素線との接触の度合いが前記アルミ電線との端子長手方向で異なることを特徴とするアルミ電線への端子圧着構造。
In addition to the insulation barrel for crimping the aluminum wire covering portion, in addition to the insulation crimp barrel having different front and rear heights, it is a terminal crimping structure to the aluminum wire that crimps the terminal to the aluminum wire,
The aluminum wire conductor crimping barrel is formed at a position adjacent to the insulation barrel, and the conductor crimping barrel has an oblique structure in which the barrel height increases toward the direction away from the insulation barrel, and the conductor In the state where the crimping barrel is crimped to the aluminum electric wire, the front and rear heights of the conductor crimping barrel are different, so that the lower portion has less biting into the aluminum electric wire and the higher portion is the aluminum electric wire. A terminal crimping structure to an aluminum electric wire, characterized in that the bite into the aluminum electric wire is large and the degree of contact with each wire constituting the aluminum electric wire differs in the terminal longitudinal direction with respect to the aluminum electric wire.
アルミ電線被覆部圧着用インシュレーションバレルに加えてアルミ電線導通用圧着バレルとアルミ電線保持用圧着バレルとを備えた端子をアルミ電線に圧着するに当って、
アルミ電線導通用圧着バレルとアルミ電線保持用圧着バレルがアルミ電線に圧着された状態において前記アルミ電線導通用圧着バレルをアルミ電線保持用圧着バレルよりも端子圧着方向で見て低い高さで当該アルミ電線に圧着することで、当該端子を圧着したアルミ電線を製造することを特徴とする端子付アルミ電線の製造方法。
In crimping a terminal equipped with an aluminum wire conduction crimp barrel and an aluminum wire holding crimp barrel to an aluminum wire in addition to an insulation barrel for crimping an aluminum wire cover,
The aluminum wire conducting crimp barrel and the aluminum wire retaining crimp barrel are crimped to the aluminum wire, and the aluminum wire conducting crimp barrel is lower than the aluminum wire retaining crimp barrel in the terminal crimping direction. A method for producing an aluminum electric wire with a terminal, characterized in that an aluminum electric wire obtained by crimping the terminal is produced by crimping the electric wire.
アルミ電線被覆部圧着用インシュレーションバレルに加えて前後の高さの異なる導体圧着用バレルを備えた端子をアルミ電線に圧着するに当って、
前記インシュレーションバレルに隣接する位置に前記アルミ電線導体圧着用バレルが形成され、当該導体圧着用バレルはインシュレーションバレルと離れる端子方向に向かって、バレル高さが高くなる斜めの構造をなした前記端子を用いて当該端子を前記アルミ電線に圧着した際に、前記導体圧着用バレルが当該アルミ電線に圧着された状態において、導体圧着用バレルの前後の高さが違うことにより、高さの低い部分はアルミ電線への食い込みが少なく、高い部分はアルミ電線への食い込みが大きく、アルミ電線を構成する各素線との接触度合いがアルミ電線との端子長手方向で異なるように当該端子を前記アルミ電線に圧着することで、当該端子を圧着したアルミ電線を製造することを特徴とする端子付アルミ電線の製造方法。
In crimping a terminal equipped with a barrel for conductor crimping with different front and rear heights in addition to an insulation barrel for crimping an aluminum wire coating,
The aluminum wire conductor crimping barrel is formed at a position adjacent to the insulation barrel, and the conductor crimping barrel has an oblique structure in which the barrel height increases toward the terminal direction away from the insulation barrel. When the terminal is crimped to the aluminum electric wire using a terminal, the height of the conductor crimping barrel is low because the conductor crimping barrel is crimped to the aluminum electric wire. The part has little bite into the aluminum wire, the high part has big bite into the aluminum wire, and the terminal is made of the aluminum wire so that the contact degree with each wire constituting the aluminum wire differs in the terminal longitudinal direction with the aluminum wire. A method for producing an aluminum electric wire with a terminal, characterized in that an aluminum electric wire obtained by crimping the terminal is produced by crimping the electric wire.
JP2003283237A 2003-07-30 2003-07-30 Method of manufacturing terminal crimping structure to aluminum wire and aluminum wire with terminal Pending JP2005050736A (en)

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EP12160295.7A EP2472674B1 (en) 2003-07-30 2004-06-29 Terminal crimping method onto aluminum electric-wire
EP12160296.5A EP2472675B1 (en) 2003-07-30 2004-06-29 Terminal crimping structure and terminal crimping method onto aluminum electric-wire
EP04015167.2A EP1503454B1 (en) 2003-07-30 2004-06-29 Terminal crimping structure for aluminium wire and producing method
US10/880,666 US7306495B2 (en) 2003-07-30 2004-07-01 Terminal crimping structure and terminal crimping method onto aluminum electric-wire and producing method of aluminum electric-wire with terminal
CNB2004100590753A CN100481617C (en) 2003-07-30 2004-07-27 Terminal crimping structure and terminal crimping method onto aluminum electric-wire and producing method of aluminum electric-wire with terminal
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