JP2016096017A - Electric wire with terminal and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of an electric wire with a terminal in which, when a molding die is released after an anti-corrosion material is molded, peeling does not occur at an interface between a terminal and a resin so that anti-corrosion properties can be reliably secured.SOLUTION: In an electric wire with a terminal, a pressure bonded connection portion 12A between a crimp terminal 10 and an electric wire W is covered with an anti-corrosion material 20. In a step of setting a terminal in a molding die when the electric wire with a terminal is manufactured, a release accelerating member 50 for accelerating the release of the molding die from a resin is disposed at a position inside a cavity 110 corresponding to a front end upper surface of the anti-corrosion material 20, and the anti-corrosion material 20 is molded in this condition.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a terminal-attached electric wire in which a crimp connection portion between a terminal and an electric wire is covered with a resin-made anticorrosive material, and a method for manufacturing the electric wire.

  It is known that the connection part of different metals is likely to be corroded by the intrusion of water or chloride ions. Therefore, for example, when the material of the conductor of the covered wire and the material of the crimp terminal are different, the periphery of the crimp connection portion of the wire and the crimp terminal is covered with a resin anticorrosive material.

  In recent years, from the viewpoint of weight reduction of a vehicle, an aluminum electric wire (a covered electric wire using aluminum or an aluminum alloy as an internal conductor) is used instead of a copper wire (a covered electric wire using copper or a copper alloy as an internal conductor). Examples are increasing. For this reason, a terminal-attached electric wire in which an anticorrosive material is applied to a connection portion between an aluminum electric wire and a conventionally used copper crimp terminal has been proposed (see, for example, Patent Document 1).

  A conventional electric wire with a terminal and a manufacturing method thereof will be described with reference to FIGS.

  As shown in FIG. 7 and FIG. 9, the terminal-attached electric wire includes a conductor (core wire) Wa and an electric wire W having an insulation coating Wb covering the conductor Wa, a crimp terminal 10 connected to the end of the electric wire W, and an electric wire. And a resin-made anticorrosive material 20 provided so as to cover the connection portion between W and the crimp terminal 10.

  The crimp terminal 10 has an electrical connection portion (terminal connection portion) 11 that is electrically connected to the counterpart terminal by fitting with the counterpart terminal at the front portion, and a connecting portion 15 at the rear portion thereof. It has a conductor crimping part 12 that is crimped and connected to the conductor Wa of the electric wire W, and further has a covering crimping part 13 that is crimped to a portion of the electric wire W with the covered electric wire Wb.

  In this crimp terminal 10, a common terminal bottom plate 10 a extends in the front-rear direction from the electrical connection portion 11 to the cover crimping portion 13, and the connecting portion 15 includes a bottom plate 15 a common to the terminal bottom plate 10 a and the width of the bottom plate 15 a. It has a U-shaped cross section composed of left and right side plates 15b, 15b erected from both side edges in the direction.

  The conductor crimping portion 12 is crimped and connected to the conductor Wa with the exposed portion of the conductor Wa protruding forward from the insulating coating Wb at the end of the electric wire W placed on the terminal bottom plate 10a. A conductor crimping piece 13 is crimped behind the crimping connection portion 12A so as to enclose the covered wire Wb of the wire W.

  The anticorrosion material 20 uses a mold integrally with the electric wire W and the crimp terminal 10 so as to cover the periphery of the conductor Wa and the crimp connection portion 12A of the crimp terminal 10 and the periphery of the insulation coating Wb adjacent to the crimp connection portion 12A. Injection molding.

  Specifically, from the position covering the outer periphery of the insulation coating Wb of the electric wire W extending behind the conductor crimping piece 13 to the front side of the crimping connection part 12A by the conductor crimping part 12, the connection before the electrical connection part 11 The anticorrosion material 20 is formed so as to cover all the positions up to the middle of the part 15.

  When manufacturing this electric wire with a terminal, first, as shown in FIG. 7, the crimp terminal 10 and the electric wire W are crimp-connected (crimping process).

  Next, as shown in FIG. 8, the upper and lower molds 101 for molding the anticorrosion material 20 are applied to the entire area where the anticorrosion treatment such as the crimping connection portion 12 </ b> A of the crimping terminal 10 and the electric wire W and the covering crimping portion 13 is performed. , 102, the crimp terminal 10 and the electric wire W are set in the injection mold 100 (terminal setting step).

  Then, after the terminal setting step, the melted resin 22 is filled into the cavity 110 of the mold 100 to mold the anticorrosion material 20 (molding step).

  After molding, the mold 100 is released (the upper mold 101 and the lower mold 102 are separated), and the molded product is taken out (mold release process).

  By passing through the above process, a terminal-attached electric wire as shown in FIGS. 9 and 10 can be obtained. The front end part of the anticorrosion material 20 is located in the connection part 15 of the crimp terminal 10, and the cross section is as shown in FIG.

JP 2014-26796 A

  By the way, in molding the anticorrosion material 20, in order to make the crimp terminal 10 and the resin 22 for the anticorrosion material 20 tightly adhere, it is generally performed to apply a plummer (adhesion improving material) to the crimp terminal 10. Yes.

  However, since the process of applying the plummer is troublesome, it is considered that a resin that easily adheres to a metal is selected and used in advance as the material of the anticorrosion material 20.

  In that case, when the mold is released from the mold, if the adhesion between the mold and the resin is greater than the adhesion between the terminal and the resin, peeling occurs at the interface between the terminal and the resin, resulting in a gap between the anticorrosive material and the terminal. It has been found that there is a possibility that water may enter the inside of the crimping connection portion from the gap.

  More specifically, for example, as shown in FIG. 12A, the upper mold 101 and the lower mold 102 are closed, the cavity 110 is filled with the resin 22, and the anticorrosion material 20 is molded. As shown in FIG. 12B, when the mold 100 is released, if the adhesion force at the interface N2 between the mold 100 and the resin 22 is larger than the adhesion force at the interface N1 between the crimp terminal 10 and the resin 22, Peeling occurs at the interface N <b> 1 between the crimp terminal 10 and the resin 22, and a gap S <b> 1 is generated between the anticorrosive material 20 and the crimp terminal 10. As a result, as shown in FIG. 13, through the gap S1, as shown by the arrow Ys, water enters the contact surface (interface between the crimp terminal 10 and the conductor Wa) between the dissimilar metals of the crimp connection portion 12A. There is a possibility of causing corrosion in the crimp connecting portion 12A. In particular, it has been found that if the gap S1 is formed at the position of the connecting portion 15 of the crimp terminal 10 which is the entrance side of the water intrusion path at the front end portion of the anticorrosive material 20, corrosion easily occurs.

  In consideration of the above circumstances, the present invention can ensure corrosion resistance by preventing separation at the interface between the terminal and the resin when the mold is released after molding the anticorrosive material. An object is to provide an attached electric wire and a manufacturing method thereof.

  In order to solve the above-mentioned problem, an electric wire with a terminal according to claim 1 is an electric wire having a conductor and an insulating coating covering the conductor, and exposing the conductor protruding forward from the insulating coating at an end of the electric wire. A crimping terminal having a conductor crimping part crimped and connected to the conductor in a state where the part is placed on a terminal bottom plate extending in the front-rear direction, and the crimping connection part around the crimping connection part between the conductor and the crimping terminal. In the electric wire with a terminal provided with the anticorrosive material made of resin integrally formed with the electric wire and the crimp terminal so as to cover the periphery of the adjacent insulation coating, in front of the crimp connection portion and the front end of the conductor A resin that forms a close contact with the upper surface of the inner wall of the cavity of the mold for molding the anticorrosion material at the position of the upper surface of the front end portion of the anticorrosion material and forms the anticorrosion material when the mold is released. Promote mold release from Wherein the release promoting member is arranged that.

  According to a second aspect of the present invention, there is provided a method for producing a terminal-attached electric wire, comprising: a conductor and an electric wire having an insulating coating covering the conductor; and an exposed portion of the conductor protruding forward from the insulating coating at an end of the electric wire. A crimp terminal having a conductor crimping portion crimped and connected to the conductor in a state of being placed on a terminal bottom plate extending to the conductor, and the insulation coating adjacent to the crimp connection portion around the conductor and the crimp terminal In the method of manufacturing a terminal-attached electric wire comprising a resin anticorrosive material formed integrally with the electric wire and the crimp terminal so as to cover the periphery of the crimping step, the crimping step of crimping and connecting the crimp terminal and the electric wire, A terminal for setting the crimp terminal and the electric wire to the mold in a state where the crimp connection portion of the crimp terminal and the electric wire is disposed inside the mold cavity for molding the anticorrosion material after the crimping step. Set work And after the terminal setting step, a molding step of filling the molten resin into the mold cavity to mold the anticorrosive material, and after the molding step, releasing the mold and taking out the molded product. In the terminal setting step, the mold is closed at a position inside the cavity corresponding to the top surface of the front end portion of the anticorrosive material on the front side of the crimp connection portion and the front end of the conductor. In a state in which the upper surface of the member is in close contact with the upper surface of the inner wall of the cavity forming the upper surface of the anticorrosive material and the space filled with the resin is ensured between the crimp connection portion and the conductor and between the terminal bottom plate. A mold release accelerating member for accelerating mold release from the resin constituting the anticorrosion material at the time of mold release is arranged.

  Invention of Claim 3 is a manufacturing method of the electric wire with a terminal of Claim 2, Comprising: The said crimping terminal is provided with the electrical connection part of the said conductor crimping part and the other party terminal located ahead from it. In addition to connecting, there is provided a U-shaped connecting portion having a common bottom plate and a left and right side plates rising from both side edges of the bottom plate in the width direction of the bottom plate, in the terminal setting step, The crimp terminal and the electric wire are set in the mold in a state where the release promoting member is placed so as to bridge between upper ends of the left and right side plates of the connecting portion.

  According to the first and second aspects of the present invention, when the mold formed with the anticorrosion material is released, the release promoting member serves as a starting point of peeling, so that the resin and the mold on the rear side of the release promoting member are provided. Can be exfoliated. Therefore, even if a resin having strong adhesion to metal is used as a material for the anticorrosion material without applying the plummer, the resin for the anticorrosion material adheres to the mold at the time of mold release. In other words, the interface between the terminal and the resin is peeled off, and as a result, the problem that chloride ions and moisture enter the inside of the crimp connection through the gap between the terminal and the resin, causing the wire to corrode. Can improve the anticorrosion performance. In particular, by disposing the mold release promoting member only at the front end of the anticorrosive material, the mold release promoting member can be completed with a minimum size, and there is no fear of impeding the resin filling property. Moreover, since the stability of the location of the connection part which becomes the problem by most peeling can be improved, a highly reliable electric wire with a terminal can be manufactured.

  According to the invention of claim 3, it is possible to arrange the release promoting member at an appropriate position simply by placing the release promoting member on the connecting portion.

It is some explanatory drawing of the manufacturing process of the electric wire with a terminal of the embodiment of the present invention. It is explanatory drawing of the shaping | molding process in the manufacturing process of the electric wire with a terminal. It is explanatory drawing of the mold release process in the manufacturing process of the electric wire with a terminal, (a) is before a mold release, (b) is a figure which shows the state at the time of mold release. It is a perspective view of the finished product of the electric wire with a terminal of an embodiment of the present invention. It is sectional drawing of the finished product of the electric wire with the terminal. It is explanatory drawing of a part of manufacturing process of the electric wire with a terminal of other embodiments of the present invention. It is explanatory drawing of a part of manufacturing process of the conventional electric wire with a terminal. It is explanatory drawing of the shaping | molding process in the manufacturing process of the conventional electric wire with a terminal. It is a perspective view of the finished product of the conventional electric wire with a terminal. It is a side view of the finished product of the conventional electric wire with a terminal. It is sectional drawing which follows the AA line of FIG. It is explanatory drawing of the mold release process in the manufacturing process of the conventional electric wire with a terminal, (a) is before a mold release, (b) is a figure which shows the state at the time of mold release. It is side sectional drawing for description of the problem which may arise in the conventional electric wire with a terminal.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  FIG. 1 is an explanatory view of a part of a manufacturing process of an electric wire with a terminal according to the embodiment, FIG. 2 is an explanatory view of a molding process in the manufacturing process of the electric wire with the terminal, and FIG. FIG. 3A is an explanatory view of a mold release process in the process, FIG. 3A is a view before mold release, FIG. 3B is a diagram showing a state at the time of mold release, and FIG. FIG. 5 is a sectional view of a finished product of the electric wire with the terminal.

  As shown in FIGS. 1, 4, and 5, the terminal-attached electric wire 1 manufactured here (see FIG. 4 for a completed product) includes a conductor (core wire) Wa and an electric wire W having an insulation coating Wb covering the conductor Wa. The crimp terminal 10 connected to the end of the electric wire W, the resin anticorrosive 20 provided so as to cover the connection portion of the electric wire W and the crimp terminal 10, and the release promoting member 50 are provided. is there.

  When describing each material, the conductor Wa of the electric wire W is made of aluminum or an aluminum alloy. The insulation coating Wb of the electric wire W is made of polyethylene, polypropylene, ethylene copolymer, propylene copolymer, polyvinyl chloride, or the like. The crimp terminal 10 is made of copper, copper alloy, stainless steel, tin-plated copper, tin-plated copper alloy, tin-plated stainless steel, or the like. Moreover, the anticorrosion material 20 consists of a resin material which has a thermoplastic polyamide resin as a main component. The release promoting member 50 is made of the same type of metal plate as the crimp terminal 10.

  The crimp terminal 10 has an electrical connection part (terminal connection part) 11 that is electrically connected to the mating terminal by fitting with the mating terminal at the front part in the same manner as described above. There is a conductor crimping portion 12 that is crimped and connected to the conductor Wa of the electric wire W via the connecting portion 15, and a covering crimping portion 13 that is crimped to a portion of the electric wire W to which the covered electric wire Wb is attached. Have.

  A common terminal bottom plate 10a extends in the front-rear direction from the electrical connecting portion 11 to the cover crimping portion 13. As shown in FIG. 3, the connecting portion 15 includes a bottom plate 15a common to the terminal bottom plate 10a, and the bottom plate 15a. And a left and right side plate 15b erected from both side edges in the width direction.

  The conductor crimping portion 12 is crimped and connected to the conductor Wa with the exposed portion of the conductor Wa protruding forward from the insulating coating Wb at the end of the electric wire W placed on the terminal bottom plate 10a. A covered crimping portion 13 is crimped behind the crimp connecting portion 12A so as to wrap the covered wire Wb of the wire W.

  The anticorrosion material 20 uses a mold integrally with the electric wire W and the crimp terminal 10 so as to cover the periphery of the conductor Wa and the crimp connection portion 12A of the crimp terminal 10 and the periphery of the insulation coating Wb adjacent to the crimp connection portion 12A. Injection molding.

  Specifically, from the position covering the outer periphery of the insulation coating Wb of the electric wire W extending behind the coating crimping portion 13 to the front side of the crimping connection portion 12A by the conductor crimping portion 12, the connection before the electrical connection portion 11 The anticorrosion material 20 is formed so as to cover all the positions up to the middle of the part 15.

  A solid release promoting member 50 described in detail below is disposed on the upper surface of the front end portion of the anticorrosion material 20. This release promoting member 50 may be left to the end of the electric wire with terminal as a product, but may be removed if it can be removed.

  Next, the manufacturing method of this electric wire 1 with a terminal is demonstrated.

  When manufacturing this electric wire 1 with a terminal, first, as shown in FIG. 1, the crimp terminal 10 and the electric wire W are crimp-connected (crimping process).

  Next, as shown in FIG. 2, the upper and lower molds 101 for molding the anticorrosion material 20 are applied to the entire area to be subjected to the anticorrosion treatment such as the crimp terminal 10 and the crimp connection portion 12 </ b> A of the electric wire W. , 102, the crimp terminal 10 and the electric wire W are set in the injection mold 100 (terminal setting step).

  At that time, as shown in FIG. 1, a release promoting member 50 is placed in advance so as to bridge between the upper ends of the left and right side plates 15 b of the connecting portion 15 of the crimp terminal 10. The connecting portion of the electric wire W is accommodated in the cavity 110, and the crimp terminal 10 and the electric wire W are set in the mold 100.

  In this case, the release promoting member 50 is disposed at a position inside the cavity 110 corresponding to the upper surface of the front end portion of the anticorrosive material 20 on the front side of the crimp connection portion 12A and the front end of the conductor Wa.

  The mold release promoting member 50 is for accelerating the separation of the resin 22 constituting the anticorrosion material 20 and the mold 100 when the mold 100 is released, and is made of a metal plate of the same material as the crimp terminal 10. The shape is trapezoidal when viewed from above, with the wide bottom 51 located on the front side and the narrow upper side 52 located on the rear.

  The mold release promoting member 50 is formed such that the upper surface 50a thereof is in close contact with the upper surface of the inner wall of the cavity 110 for forming the upper surface 20a of the anticorrosive material 20 when the mold 100 is closed. That is, the upper surface 50a of the mold release promoting member 50 and the upper surface 20a of the anticorrosion material 20 are formed to be flush with each other.

  The release promoting member 50 is disposed in a state in which a space S filled with the resin 22 is secured between the crimping connection portion 12A and the conductor Wa and between the terminal bottom plate 10a of the crimping terminal 10.

  And after setting the crimp terminal 10 to the metal mold | die 100, inserting the mold release promotion member 50 together in this way, the inside of the cavity 110 of the metal mold | die 100 is filled with the molten resin 22, and the anticorrosion material 20 is filled. Is molded (molding process).

  After molding, the mold 100 is released (the upper mold 101 and the lower mold 102 are separated), and the molded product is taken out (mold release process).

  By passing through the above process, the electric wire 1 with a terminal as shown in FIG.4 and FIG.5 can be obtained.

  In this electric wire with terminal 1 and the manufacturing method thereof, when the mold release promoting member 50 is disposed as described above, the mold release promoting member 50 is formed when the mold 100 is released after the anticorrosion material 20 is formed. By becoming the starting point of peeling, peeling between the resin 22 on the rear side of the release promoting member 50 and the mold 100 can be actively promoted.

  That is, as shown in FIG. 3A, the upper surface 50 a of the mold release promoting member 50 is in close contact with the upper surface of the inner wall of the cavity 110 of the mold 100 on the upper surface of the front end portion of the anticorrosive material 20. At the interface N3 between 100 and the release promoting member 50, since the metal is in close contact with the metal, almost no adhesive force is generated. On the other hand, since the lower surface of the release promoting member 50 is in close contact with the resin 22, a large adhesive force acts on the interface N <b> 1 between the release promoting member 50 and the resin 22. Further, since the resin 22 and the mold 100 are in close contact with each other on the rear side of the release promoting member 50, a large adhesive force is generated at the interface N2.

  However, as shown in FIG. 3B, when the upper mold 101 and the lower mold 102 are released as indicated by the arrow Y1, the interface N3 between the mold release promoting member 50 and the mold 100 becomes a starting point. Thus, peeling of the interface N2 between the resin 22 on the rear side of the release promoting member 50 and the mold 100 is positively promoted. Therefore, even when a resin having strong adhesion to metal is used as a material for the anticorrosion material 20 without applying a plummer, the resin 22 for the anticorrosion material 20 is used as a mold during mold release. It is possible to prevent the contact with 100.

  As a result, in particular, it is possible to avoid a gap due to peeling at the interface between the resin 22 constituting the anticorrosive material 20 and the crimp terminal 10 in the connecting portion 15 on the inlet side of the water intrusion path of the crimp terminal 10. . That is, since it is possible to prevent a gap at the position indicated by S2 in FIG. 5, it is possible to solve the problem that water enters the inside of the crimping connection portion 12A through the gap and the wire is corroded. The anticorrosion performance can be enhanced.

  In particular, by disposing the release promoting member 50 only at the front end of the anticorrosive material 20 (on the entrance side of the water intrusion path), the release promoting member 50 can be completed with a minimum size, and the resin for the anticorrosive material 20 can be used. There is no worry of hindering the filling property of 22.

  Moreover, since the stability of the location of the connection part 15 which is the entrance side of the water penetration path | route which becomes the problem by the most peeling can be improved, the highly reliable electric wire 1 with a terminal can be manufactured.

  Moreover, according to this embodiment, since the mold release promotion member 50 can be arrange | positioned in an appropriate position only by mounting the mold release promotion member 50 on the connection part 15, work is completed easily.

  In addition, by configuring the crimp terminal 10 and the release promoting member 50 with the same kind of metal material, it is possible to eliminate the possibility of a problem occurring between different metals.

  It is possible to form the release promoting member 50 integrally with the crimp terminal 10.

  FIG. 6 shows a part of the process of the embodiment. The crimp terminal 210 is provided with a bridge-shaped frame portion 250 corresponding to a release promoting member integrally with the connecting portion 15 between the electrical connection portion 11 and the conductor crimp portion 12. It plays the same role as the mold release promoting member 50 of the embodiment.

  The type of the crimp terminal 10 may be a male terminal or a female terminal.

  Furthermore, in the said embodiment, although the case where the mold release promotion member 50 was made from the metal plate of the same material as the crimp terminal 10, the material is not ask | required if it is effective in mold release promotion. .

DESCRIPTION OF SYMBOLS 1 Electric wire with a terminal W Electric wire Wa Conductor Wb Insulation coating 10 Crimp terminal 10a Terminal bottom plate 11 Electrical connection part 12 Conductor crimp part 12A Crimp connection part 15 Connecting part 15a Bottom plate 15b Side plate 20 Corrosion-proof material 20a Upper surface 22 Resin 50 Mold release promotion member 50a Upper surface 100 Mold 110 Cavity 210 Crimping terminal 250 Frame (mold release promoting member)

Claims (3)

An electric wire having a conductor and an insulating coating covering the conductor;
A crimp terminal having a conductor crimping portion crimped to the conductor in a state where the exposed portion of the conductor protruding forward from the insulating coating at the end of the electric wire is placed on a terminal bottom plate extending in the front-rear direction; ,
A resin anticorrosion material formed integrally with the electric wire and the crimp terminal so as to cover the periphery of the crimp connection portion of the conductor and the crimp terminal and the periphery of the insulation coating adjacent to the crimp connection portion. For electric wires with terminals,
At the front side of the crimp connection and the front end of the conductor, at the position of the top surface of the front end portion of the anticorrosion material, when the anticorrosion material is molded, it closely adheres to the upper surface of the inner wall of the mold cavity for molding the anticorrosion material An electric wire with a terminal, wherein a release promoting member that promotes release of a mold from a resin constituting the anticorrosion material is disposed at the time of release. An electric wire having a conductor and an insulating coating covering the conductor;
A crimp terminal having a conductor crimping portion crimped to the conductor in a state where the exposed portion of the conductor protruding forward from the insulating coating at the end of the electric wire is placed on a terminal bottom plate extending in the front-rear direction; ,
A resin anticorrosion material formed integrally with the electric wire and the crimp terminal so as to cover the periphery of the crimp connection portion of the conductor and the crimp terminal and the periphery of the insulation coating adjacent to the crimp connection portion. In the manufacturing method of the electric wire with terminal,
A crimping step of crimping and connecting the crimp terminal and the electric wire;
A terminal for setting the crimp terminal and the electric wire to the mold in a state where the crimp connection portion of the crimp terminal and the electric wire is disposed inside the mold cavity for molding the anticorrosion material after the crimping step. A set process;
After the terminal setting step, a molding step of filling the molten resin inside the mold cavity and molding the anticorrosive material,
After the molding step, releasing the mold and taking out the molded product,
In the terminal setting step, the upper surface of the member is the upper surface of the anticorrosive material in a state where the mold is closed at a position inside the cavity corresponding to the upper surface of the front end portion of the anticorrosive material in front of the crimp connection portion and the front end of the conductor. The anticorrosive material is in close contact with the upper surface of the inner wall of the cavity for molding the mold, and a space filled with the resin is secured between the crimp connection portion and the conductor and between the terminal bottom plate and the mold. A method for producing a terminal-attached electric wire, comprising disposing a release-promoting member that promotes release of a mold from a resin that constitutes the structure. It is a manufacturing method of the electric wire with a terminal according to claim 2,
The crimping terminal connects the conductor crimping part and the electrical connection part of the mating terminal located in front of the conductor crimping part, and from the bottom plate common to the terminal bottom plate of the conductor crimping part and the widthwise side edges of the bottom plate A connecting portion having a U-shaped cross section having left and right side plates that stand is provided,
In the terminal setting step, the crimp terminal and the electric wire are set in the mold in a state where the release promoting member is placed so as to bridge between upper ends of the left and right side plates of the connecting portion. A method for manufacturing an electric wire with a terminal.

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