JP2020174005A - Terminal and terminal manufacturing method - Google Patents

Abstract

To provide a terminal and the like that can sufficiently reduce the electrical resistance between wires.SOLUTION: A terminal 10 includes a mating connection portion 11, a tubular portion 20 which is fixed to the mating connection portion 11 and into which one end side of an electric wire W in which a core wire 1 composed of a large number of strands is exposed to the outside is inserted, a needle-shaped rod 30 that is fixed to the mating connection portion 11 and protrudes into the tubular portion 20, and a crimping portion 25 provided on the tubular portion 20 and crimped and deformed in the direction of pressing the core wire 1 against the outer peripheral surface of the needle-shaped rod 30.SELECTED DRAWING: Figure 2

Description

The present invention relates to a terminal to which an electric wire is connected and a method for manufacturing the terminal.

As shown in FIGS. 14 and 15, the terminal 100 of the conventional example is fixed to the mating connection portion 101 for connecting to the mating electrical component (not shown) and the mating connecting portion 101, and is composed of a large number of strands. A crimping portion 103 in which one end side of an electric wire W whose core wire 111 is exposed to the outside is inserted, and a crimping portion 103 provided in the tubular portion 102 and crimped and deformed so that the core wire 111 comes into close contact with the inner surface of the tubular portion 102. And have. The crimping portion 103 has a flat crimping portion 103a crimped so that the inner surfaces of the tubular portion 102 abut each other on both sides in the width direction, and the center of the tubular portion 102 in the width direction follows the circular cross section of the core wire 111. It is composed of a cylindrical crimping portion 103b that has been crimped to.

A conductive coating portion (for example, solder) 112 (shown in FIG. 15) is arranged so as to penetrate into the exposed core wire 111 portion of the electric wire W. The conductive coating portion 112 is interposed between the inner surface of the tubular portion 102 and the core wire 111, and between the strands 111a. By filling such a gap with the conductive coating portion 112, the electric resistance between the electric wire W and the terminal 100 is reduced.

JP-A-2007-73491

However, in the above-mentioned conventional example, since the conductive coating portion 112 does not penetrate to the central portion of the core wire 111, a gap remains between the strands 111a in the central portion of the core wire 111. Therefore, there is a problem that the conduction between the wire 111a at the center of the core wire 111 and the terminal 100 becomes insufficient, and the effect of sufficiently reducing the electric resistance cannot be obtained.

Therefore, the present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide a terminal capable of sufficiently reducing the electric resistance between the electric wire and the terminal, and a method for manufacturing the terminal.

The terminal of the present invention includes a mating connection portion for connecting to a mating electrical component and a tubular portion into which one end side of an electric wire fixed to the mating connecting portion and having a core wire composed of a large number of strands exposed to the outside is inserted. , A needle-shaped rod fixed to the mating connection portion and protruding into the tubular portion, and a crimping portion provided on the tubular portion and deformed in a direction of pressing the core wire against the outer peripheral surface of the needle-shaped rod. It is characterized by having and.

The terminal manufacturing method of the present invention is performed after the diameter-expanding processing step of expanding the diameter of one end side of the tubular member to form the enlarged diameter portion and the diameter-expanding processing step, and the needle-shaped rod is formed of the tubular member. A flat beating process of inserting from one end side, crushing the other end side of the tubular member into a flat plate shape in which two plates overlap, and sandwiching and fixing the needle-shaped rod between the two overlapping plates. After the flattening process, the mating connection part processing step of processing the flat plate-shaped portion formed by the flatning process into the mating connection portion, and after the mating connecting portion machining step, or after the mating connecting portion machining It is performed before the process and after the flat beating process to insert one end side of the electric wire into the tubular portion, and after the electric wire insertion step, the core wire is inserted into the outer circumference of the needle-shaped rod. It is characterized by including a crimping process for forming a crimping portion that crimps and deforms the tubular portion in a direction of pressing against a surface.

According to the present invention, since the core wire is arranged in a state of being filled between the inner circumference of the crimping portion and the outer circumference of the needle-shaped rod, the strands located on the inner circumference of the crimping portion and the periphery thereof. Since it is difficult to create a gap between the wires, between the wires, and between the outer circumference of the needle-shaped rod and the wires located around the rod, the electrical resistance between the wires and the wires can be sufficiently reduced.

The first embodiment of this invention is shown and is the perspective view of the terminal. It is sectional drawing of the terminal which shows 1st Embodiment of this invention. A first embodiment of the present invention is shown, and is a cross-sectional view taken along the line AA of FIG. The first embodiment of the present invention is shown, (a) is a cross-sectional view of a terminal before crimping and connecting an electric wire, and (b) is a view taken along the line B of (a). A first embodiment of the present invention is shown, and FIGS. (A) and (B) are perspective views for explaining a terminal diameter expansion processing step, respectively. A first embodiment of the present invention is shown, and FIGS. (A) and (b) are cross-sectional views for explaining a terminal flattening process. A first embodiment of the present invention is shown, and FIGS. (A) and (b) are cross-sectional views illustrating a process of processing a mating connection portion of a terminal. A first embodiment of the present invention is shown, and FIGS. (A) and (b) are cross-sectional views for explaining a terminal wire insertion step. It is sectional drawing which shows 1st Embodiment of this invention and explains the electric wire crimping process of a terminal. It is a figure which shows the 1st Embodiment of this invention and shows the relationship between the diameter of a needle-shaped rod, and the electric resistance. It is sectional drawing of the terminal which shows the 2nd Embodiment of this invention. It is sectional drawing of the terminal which shows the 3rd Embodiment of this invention. A fourth embodiment of the present invention is shown, where (a) is a cross-sectional view of a terminal when the hollow portion is not crushed, and (b) is a cross-sectional view of a terminal when the hollow portion is crushed. A conventional example is shown, and it is sectional drawing of a terminal. A conventional example is shown, and it is sectional drawing taken along the line DD of FIG.

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

(First Embodiment)
1 to 10 show a first embodiment of the present invention. As shown in FIGS. 1 to 3, in the electric wire W, a core wire 1 composed of a large number of strands 1a is covered with an insulating coating 2. The strand 1a is made of aluminum or an aluminum alloy. That is, the electric wire W is a so-called aluminum electric wire. At one end of the electric wire W, the insulating coating 2 is removed and the core wire 1 is exposed to the outside. A terminal 10 is connected to one end of the electric wire W. Hereinafter, the terminal 10 will be described.

The terminal 10 is made of aluminum or an aluminum alloy. The terminal 10 has a mating connection portion 11 for connecting to a mating electrical component (not shown), a tubular portion 20 integrally provided in the mating connecting portion 11, and a needle protruding in the electric wire insertion direction in the tubular portion 20. It includes a shape rod 30 and a crimping portion 25 provided on the tubular portion 20.

The mating connection portion 11 is bent in a direction perpendicular to the tubular portion 20. The mating connection portion 11 has a flat plate shape in which two plates overlap each other. A hole 12 is formed in the mating connection portion 11. The mating connection portion 11 is connected to a mating electrical component (for example, a terminal of an electric device) or the like by using the hole 12.

The tubular portion 20 has a cylindrical shape. An electric wire insertion hole 21 is formed in the tubular portion 20. One end of the electric wire insertion hole 21 is opened, and the other end is closed by the mating connection portion 11. The tubular portion 20 is formed with an enlarged diameter portion 22 on the opening side of the electric wire insertion hole 21. One end side of the electric wire W is inserted into the electric wire insertion hole 21 of the tubular portion 20. Specifically, the core wire 1 exposed to the outside is inserted into the inner diameter portion 22 inserted from the enlarged diameter portion 22 of the tubular portion 20, and the electric wire W covered with the insulating coating 2 is inserted into the enlarged diameter portion 22 of the tubular portion 20. The part of is inserted. The tip surface 2a of the insulating coating 2 is in contact with the stepped surface 22a of the enlarged diameter portion 22.

The needle-shaped bar 30 is a solid round bar. The root portion of the needle-shaped rod 30 is fixed by being sandwiched between two overlapping plates of the mating connecting portion 11. The tip side of the needle-shaped rod 30 protrudes from the root portion into the electric wire insertion hole 21 of the tubular portion 20. As shown in FIG. 4, the needle-shaped rod 30 is located at the center of the axis of the tubular portion 20 and protrudes along the insertion direction of the electric wire W. The tip of the needle-shaped rod 30 reaches the opening position of the tubular portion 20, specifically, the opening position of the enlarged diameter portion 22. The tip of the needle-shaped rod 30 is formed in a tapered shape whose diameter decreases toward the tip. The needle-shaped rod 30 is arranged so as to bite into the core wire 1 of the electric wire W. The tip of the needle-shaped rod 30 penetrates into the core wire 1 covered with the insulating coating 2.

The crimping portion 25 is crimped and deformed in a direction in which the core wire 1 is pressed against the outer peripheral surface of the needle-shaped rod 30. Specifically, as shown in FIG. 3, a flat crimping portion 25a that crimps both sides of the tubular portion 20 in the width direction so that their inner surfaces abut against each other, and a core wire 1 centered in the width direction of the tubular portion 20. It is composed of a cylindrical crimping portion 25b that crimps so as to follow a circular cross section. That is, the crimping portion 25 is crimped and deformed so that the entire circumference of the core wire 1 is in close contact with the inner surface of the tubular portion 20.

Next, a method of manufacturing the terminal 10 will be described. First, as shown in FIG. 5, one end side of a tubular member (cylindrical aluminum pipe) 40 having the same diameter is expanded in diameter to form an enlarged diameter portion 22 (diameter expansion processing step). Next, as shown in FIG. 6A, the needle-shaped rod 30 held by the jig 50 is inserted from one end side (diameter-expanded portion 22 side) of the tubular member 40. Then, as shown in FIG. 6B, the other end side of the tubular member 40 is crushed by a compressive force to form a flat plate shape in which the two plates overlap, and the needle-shaped rod 30 is formed by the two overlapping plates. Hold and fix (flat processing process). As a result, a tubular portion 20 having a diameter-expanded portion 22 on one end side, an opening on one end side, and an electric wire insertion hole 21 in which the other end side is closed is formed.

In the flat beating process, the needle-shaped rod 30 is sandwiched and fixed by two overlapping plates, and a flat plate-shaped basic form to be a mating connection portion 11 is formed in a subsequent process. Therefore, the process is simplified.

Next, as shown in FIG. 7 (a), a hole 12 is formed in the flat plate-shaped portion, and as shown in FIG. 7 (b), the flat plate-shaped portion is bent in the direction orthogonal to the tubular portion 20 (coupling connection). The latter part of the partial processing process). This completes the production of the mating connection portion 11. By the bending process, the root portion of the needle-shaped rod 30 is also bent in the orthogonal direction. As a result, the needle-shaped rod 30 is firmly fixed to the mating connection portion 11.

Next, as shown in FIGS. 8A and 8B, one end side of the electric wire W in which the core wire 1 composed of a large number of strands 1a is exposed to the outside is one end side of the tubular portion 20 (diameter expansion portion 22 side). ) (Wire insertion process). The electric wire W is forcibly inserted by acting on the resistance from the needle-shaped rod 30. The electric wire W is inserted until the tip surface 2a of the insulating coating 2 comes into contact with the stepped surface 22a of the enlarged diameter portion 22 (see FIG. 9).

Next, as shown in FIG. 9, the tubular portion 20 is crimped and deformed in the direction of pressing the core wire 1 against the outer peripheral surface of the needle-shaped rod 30 to form the crimping portion 25 (crimping process). Specifically, as shown in FIG. 3, the both sides of the tubular portion 20 in the width direction are crimped so that the inner surfaces of the tubular portions abut each other, and the center of the tubular portion in the width direction is crimped so as to follow the circular cross section of the core wire. Tighten.

The wire insertion step may be performed after the mating connection processing step as in this embodiment, but may be performed before the mating connection machining step and after the flattening machining step.

FIG. 10 shows the results of measuring the cross-sectional area (diameter) of the needle-shaped rod 30 and the electric resistance value at the terminal connection point. It was confirmed that the electric resistance value is the highest when there is no needle-shaped rod 30 (the cross-sectional area of the needle-shaped rod is zero), and the electric resistance value tends to decrease as the cross-sectional area (diameter) of the needle-shaped rod 30 increases. Was done. It is presumed that this is because the contact area between the outer peripheral surface of the needle-shaped rod 30 and the wire 1a increases as the cross-sectional area (diameter) of the needle-shaped rod 30 increases.

As described above, the terminal 10 is fixed to the mating connection portion 11 for connecting to the mating electrical component (not shown) and the mating connecting portion 11, and the core wire 1 composed of a large number of strands 1a is exposed to the outside. A tubular portion 20 into which one end side of the electric wire W is inserted, a needle-shaped rod 30 fixed to the mating connection portion 11 and protruding in the electric wire insertion direction in the tubular portion 20, and a core wire 1 provided in the tubular portion 20. A crimping portion 25 in which the tubular portion 20 is crimped and deformed in a direction of pressing against the outer peripheral surface of the needle-shaped rod 30 is provided.

Further, in the method of manufacturing the terminal 10, a diameter-expanding process of expanding the diameter of one end side of the tubular member 40 to form the enlarged diameter portion 22 and a diameter-expanding process are performed after the diameter-expanding process, and the needle-shaped rod 30 is formed into the tubular member. A flat beating process in which the needle-shaped rod 30 is inserted from one end side of the 40, the other end side of the tubular member 40 is crushed into a flat plate shape in which two plates overlap, and the needle-shaped rod 30 is sandwiched and fixed by the two overlapping plates. , After the mating joint machining process and the mating connection part machining step of machining the flat plate-shaped portion formed by the flat striking step into the mating connection portion 11, and after the mating connection machining step or after the mating connection machining Performed before the process and after the flattening process, the wire insertion step of inserting one end side of the wire W into the tubular portion 20, and after the wire insertion step, the core wire 1 is inserted into the outer peripheral surface of the needle-shaped rod 30. It includes a crimping process for forming a crimping portion 25 that crimps and deforms the tubular portion 20 in the direction of pressing.

Therefore, the terminal 10 is arranged between the inner circumference of the crimping portion 25 and the outer circumference of the needle-shaped rod 30 in a state where the wire 1a of the core wire 1 is filled, so that the terminal 10 is arranged with the inner circumference of the crimping portion 25. Since it is difficult to create a gap between the strands 1a located around the strands 1a, between the strands 1a, and between the outer circumference of the needle-shaped rod 30 and the strands 1a located around it, the electric wire W and the terminal 10 The electrical resistance between them can be sufficiently reduced. In particular, since the wire 1a at the center of the core wire 1 conducts to the terminal 10 via the needle-shaped rod 30, the electrical resistance can be sufficiently reduced.

Further, the strand 1a located on the inner circumference of the crimping portion 25 is in the crimping process of the tubular portion 20, and the strand 1a in the central portion of the core wire 1 is in the process of inserting the needle rod 30 and the tubular portion 20. In the crimping process, the destruction of the oxide film due to shearing is promoted, so that the electrical resistance can be reduced.

In the tubular portion 20, a diameter-expanded portion 22 is formed on the opening side into which the electric wire W is inserted, and the diameter-expanded portion 22 is inserted up to the portion of the electric wire W covered with the insulating coating 2. The electric wire W in which the core wire 1 is composed of a large number of strands 1a is excellent in flexibility as compared with the electric wire composed of one thick core wire. In the case of the electric wire W having excellent flexibility as described above, when only the core wire 1 exposed from the insulating coating 2 is housed in the tubular portion 20, the electric wire W is easily bent, so that the tubular portion is formed. The core wire 1 comes into contact with the end face of 20 and is easily cut. However, as in this embodiment, when the portion of the core wire 1 covered with the insulating coating 2 is housed in the tubular portion 20, the core wire 1 does not come into contact with the end surface of the tubular portion 20. From the above, it is possible to prevent the core wire 1 exposed from the insulating coating 2 from being cut while maintaining excellent flexibility.

The tip of the needle-shaped rod 30 reaches the position of the enlarged diameter portion 22 of the tubular portion 20. Therefore, since the needle-shaped rod 30 also enters the region of the core wire 1 covered with the insulating coating 2, the wire 1a of the core wire 1 is filled between the insulating coating 2 and the needle-shaped rod 30, and a gap is formed. It's hard to do. This contributes to the reduction of the electric resistance value. Further, since the core wire 1 presses the insulating coating 2 toward the outside in the radial direction, the adhesion between the insulating coating 2 and the enlarged diameter portion 22 is improved, and thus bending fatigue of the core wire 1 can be suppressed. Further, since the adhesion between the insulating coating 2 and the enlarged diameter portion 22 is improved, the waterproof property is improved.

The needle-shaped rod 30 is formed in a tapered shape in which the diameter decreases toward the tip of the tip. Therefore, when the core wire 1 of the electric wire W is inserted into the tubular portion 20, the insertion resistance can be reduced, so that the workability of inserting the electric wire W is good.

(Second Embodiment)
FIG. 11 shows a terminal according to the second embodiment. In this second embodiment, the needle-shaped rod 30A has an uneven surface 30a on the outer peripheral surface. The unevenness 30a has a shape in which concave portions and convex portions are repeated along the axial direction.

Since other configurations are the same as those in the first embodiment, duplicate description will be omitted. The same components in the drawings are designated by the same reference numerals for clarification.

Also in this second embodiment, the electrical resistance between the electric wire W and the terminal 10 can be sufficiently reduced for the same reason as in the first embodiment.

In the second embodiment, when the crimping portion 25 is formed on the tubular portion 20, the unevenness 30a on the outer peripheral surface of the needle-shaped rod 30A causes the wire to break the oxide film due to shearing, so that the electrical resistance is increased. It will be further reduced.

(Third Embodiment)
FIG. 12 shows a terminal according to the third embodiment. In this third embodiment, a spiral unevenness 30b is formed on the outer peripheral surface of the needle-shaped rod 30B.

Since other configurations are the same as those in the first embodiment, duplicate description will be omitted. The same components in the drawings are designated by the same reference numerals for clarification.

Also in this third embodiment, the electric resistance between the electric wire W and the terminal 10 can be sufficiently reduced for the same reason as in the first embodiment.

In the third embodiment, as in the second embodiment, when the crimping portion 25 is formed on the tubular portion 20, the oxide film breaks due to shearing on the wire due to the unevenness 30b on the outer peripheral surface of the needle-shaped rod 30. Is generated, so that the electrical resistance is further reduced.

In the third embodiment, by inserting the core wire 1 into the tubular portion 20 while rotating the electric wire W, the core wire 1 is guided in the rotational depth direction by the spiral shape, so that the insertion workability of the electric wire W is improved.

(Fourth Embodiment)
FIG. 13 shows a terminal according to the fourth embodiment. In the fourth embodiment, the needle-shaped rod 30C has an uneven surface 30a on the outer peripheral surface as in the second embodiment, and a hollow portion 30c is formed inside the needle-shaped rod 30C. When the cross-sectional area of the core wire 1 is smaller than the inner diameter of the tubular portion 20, as shown in FIG. 13A, the crimping portion 25 is formed without crushing the hollow portion 30c of the needle-shaped rod 30C. When the cross-sectional area of the core wire 1 is the same as or slightly smaller than the inner diameter of the tubular portion 20, the hollow portion 30c of the needle-shaped rod 30C is crushed to form the crimping portion 25 as shown in FIG. 13B.

Since other configurations are the same as those in the first embodiment, duplicate description will be omitted. The same components in the drawings are designated by the same reference numerals for clarification.

Also in this fourth embodiment, the electrical resistance between the electric wire W and the terminal 10 can be sufficiently reduced for the same reason as in the first embodiment.

In the fourth embodiment, as in the second embodiment, when the crimping portion 25 is formed on the tubular portion 20, the oxide film is broken on the wire due to the unevenness 30a on the outer peripheral surface of the needle-shaped rod 30. Is generated, so that the electrical resistance is further reduced.

In the fourth embodiment, the needle-shaped rod 30C has a hollow portion 30c. Therefore, various sizes of the electric wire W (core wire 1) can be accommodated by not crushing the hollow portion 30c of the needle-shaped rod 30C or crushing or adjusting the hollow portion 30c of the needle-shaped rod 30C.

(Other)
In each of the above embodiments, the conductive coating portion (for example, solder) may be arranged so as to permeate the portion of the core wire 1 exposed from the insulation coating 2.

In each of the above embodiments, the wire 1a of the electric wire W is formed of aluminum or an aluminum alloy. That is, the electric wire W is a so-called aluminum electric wire. The wire 1a of the electric wire W may be formed of copper or a copper alloy. That is, the electric wire W may be a so-called copper electric wire. The wire 1a of the electric wire W may be a conductive metal (for example, silver) other than the above.

In each of the above embodiments, the terminal 10 is formed of aluminum or an aluminum alloy, but may be formed of copper or a copper alloy. The electric wire W and the terminal 10 may be made of different metals. In this case, it is preferable to take measures to prevent galvanic corrosion.

W Electric wire 1 Core wire 1a Wire 2 Insulation coating 10 terminals 11 Mating connection part 20 Cylinder part 22 Diameter expansion part 25 Clamping part 30, 30A to 30C Needle rod 30a Concavo-convex 30b Spiral concavo-convex 30c Hollow part 40 Cylindrical member

Claims (8)

The other party's connection part that connects to the other party's electrical components,
A tubular portion into which one end of an electric wire fixed to the mating connection portion and having a core wire composed of a large number of strands exposed to the outside is inserted.
A needle-shaped rod fixed to the mating connection portion and protruding into the tubular portion,
A terminal provided on the tubular portion and provided with a crimping portion deformed by crimping in a direction of pressing the core wire against the outer peripheral surface of the needle-shaped rod. The terminal according to claim 1.
The tubular portion has an enlarged diameter portion formed on the opening side into which the electric wire is inserted.
A terminal characterized in that a portion of the electric wire covered with the insulating coating is inserted into the enlarged diameter portion. The terminal according to claim 2.
The tubular rod is a terminal characterized in that the tip reaches the position of the enlarged diameter portion of the tubular portion. The terminal according to any one of claims 1 to 3.
The needle-shaped rod is a terminal characterized in that the tip portion is formed in a tapered shape whose diameter decreases toward the tip end. The terminal according to any one of claims 1 to 4.
The tubular rod is a terminal characterized by having irregularities on the outer peripheral surface. The terminal according to claim 5.
The unevenness is a terminal characterized in that it is formed in a spiral shape. The terminal according to any one of claims 1 to 6.
The tubular rod is a terminal having a hollow portion inside. A diameter-expanding process that expands the diameter of one end of the tubular member to form a diameter-expanded portion,
Performed after the diameter expansion processing step, a needle-shaped rod is inserted from one end side of the tubular member, the other end side of the tubular member is crushed into a flat plate shape in which two plates overlap, and the two overlapping plates are overlapped. In the flat beating process of sandwiching and fixing the needle-shaped rod in
A mating connection portion machining step performed after the flat striking process and processing the flat plate-shaped portion formed by the flat striking step into a mating connecting portion.
An electric wire insertion step of inserting one end side of the electric wire into the tubular portion after the mating connection processing step, before the mating connecting portion processing process, and after the flat beating process.
It is characterized by including a crimping process which is performed after the electric wire insertion step to form a crimping portion which crimps and deforms the tubular portion in a direction of pressing the core wire against the outer peripheral surface of the needle-shaped rod. Terminal manufacturing method.

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