JP4616700B2

JP4616700B2 - Wire connection structure

Info

Publication number: JP4616700B2
Application number: JP2005155765A
Authority: JP
Inventors: 哲哉芦田
Original assignee: Mitsubishi Cable Industries Ltd
Current assignee: Mitsubishi Cable Industries Ltd
Priority date: 2005-05-27
Filing date: 2005-05-27
Publication date: 2011-01-19
Anticipated expiration: 2025-05-27
Also published as: JP2006331931A

Description

本発明は、電線の端子接続構造に関する。 The present invention relates to a terminal connection structure of the electric wire.

従来、自動車等に使用されるバッテリーケーブルの一つとして、アルミニウム製等の多数本の導線（導体）を絶縁体で被覆して形成された電線が使用されている。そして、この電線とバッテリーは接続端子を介して接続されており、従来の電線の接続構造は、電線の一端部を剥離して露出させた導線端部に、端子をかしめ加工して圧着保持させていた（例えば、特許文献１参照）。
特開２０００−２９９１４０号公報 Conventionally, as one of battery cables used for automobiles or the like, an electric wire formed by covering a large number of conductors (conductors) made of aluminum or the like with an insulator is used. And this electric wire and the battery are connected via a connection terminal, and the conventional electric wire connection structure is such that one end of the electric wire is peeled and exposed, and the terminal is caulked and crimped and held. (For example, refer to Patent Document 1).
JP 2000-299140 A

しかし、従来の電線の接続構造（接続方法）では、絶縁体が剥離された導線端部の表面は剥き出しになっており、特に、電線が自動車のバッテリーケーブル等に使用される場合は、電線が雨水や海水等に曝されることがあり、導線端部が腐食し易いという問題があった。
そこで、本発明は、導線の接続端部の腐食を防止する電線の接続構造を提供することを目的とする。 However, in the conventional wire connection structure (connection method), the surface of the conductor end from which the insulator has been peeled is exposed, especially when the wire is used for a battery cable of an automobile, etc. There was a problem that the end of the conductive wire was easily corroded in some cases exposed to rainwater or seawater.
Accordingly, an object of the present invention is to provide a connection structure of the electric wire to prevent corrosion of the connection end of the conductor.

上記目的を達成するために、本発明に係る電線の接続構造は、多数本の導線を絶縁体で被覆して成る電線の一端部の絶縁体を剥離して露出させた導線端部と、端子とを、接続する電線の接続構造に於て、上記端子に有底孔状の挿入孔が形成されたスリーブ部が設けられ、上記挿入孔内に上記導線端部と上記絶縁体の剥離側先端部が挿入され、上記挿入孔の開口部近傍より底部側の上記スリーブ部の中間部にて上記端子をその外面からかしめ加工して上記スリーブ部の外面にかしめ凹部を形成するとともに該かしめ凹部に対応する上記スリーブ部の内周面部にかしめ凸部を形成して上記端子が上記導線端部に接続され、さらに、上記開口部近傍にて上記端子が上記絶縁体の剥離側先端部に圧着され、上記端子のかしめ加工される部位と上記開口部近傍との間にスリットが貫設され、かつ、上記端子の上記スリットと上記導線端部との間、及び、上記端子の上記開口部近傍の内周面と上記絶縁体の剥離側先端部との間に、連続的に防水材が介在しているものである。 In order to achieve the above object, a wire connection structure according to the present invention includes a wire end portion in which an insulator at one end portion of a wire formed by coating a large number of wires with an insulator is peeled and exposed, and a terminal In the connection structure of the electric wire to be connected, a sleeve portion in which a bottomed hole-like insertion hole is formed in the terminal is provided, and the conductor wire end portion and the insulation-side end of the insulator are provided in the insertion hole. The terminal is caulked from the outer surface at the intermediate portion of the sleeve portion on the bottom side from the vicinity of the opening portion of the insertion hole to form a caulking recess on the outer surface of the sleeve portion, and the caulking recess A crimping protrusion is formed on the inner peripheral surface portion of the corresponding sleeve portion, the terminal is connected to the end portion of the conductor, and the terminal is crimped to the distal end portion on the peeling side of the insulator in the vicinity of the opening. The part of the terminal to be caulked and the opening A slit is provided between the terminal and the slit, and between the slit of the terminal and the conductor end, and an inner peripheral surface of the terminal in the vicinity of the opening and a peeling-side tip of the insulator. Between them, a waterproof material is continuously interposed.

また、上記導線がアルミニウム製又はアルミニウム合金製である。
また、上記電線が自動車のバッテリーケーブルに使用されているものである。 The conducting wire is made of aluminum or aluminum alloy.
Moreover, the said electric wire is used for the battery cable of a motor vehicle .

本発明は、次のような著大な効果を奏する。
本発明に係る電線の接続構造によれば、導線端部は端子の挿入孔内に挿入されており、外部に剥き出しになっていないので、導線端部に雨水や海水等が付着するのを防止できる。このことによって、雨水や海水等によって導線端部が腐食するのを防止して、導線の導通性を長期に維持することができる。 The present invention has the following remarkable effects.
According to the connection structure of the wire according to the present invention, lead end is inserted into the insertion hole of the terminal, since no bared to the outside, the rain water or sea water or the like from adhering to the lead end Can be prevented. This prevents the end of the conductor from being corroded by rainwater, seawater, etc., and can maintain the conductivity of the conductor for a long time.

以下、実施の形態を示す図面に基づき本発明を詳説する。
まず、本発明の電線の接続構造について説明する。
図１〜図３に示す本発明と関係が深い参考例に於て、１は、多数本の導線２を絶縁体３で被覆して成る電線であり、その電線１の一端部の絶縁体３は剥離され導線端部２ａが露出している。
４は、電線に接続される端子であり、図３に示すように、端子４は有底孔状の挿入孔９を有している。この挿入孔９内に導線端部２ａと絶縁体３の剥離先端部３ａが挿入され、挿入孔９の開口部14近傍より底部12側にて、端子４はその外面からかしめ加工されて導線端部２ａに圧着されている。さらに、挿入孔９の開口部14近傍にて、端子４が絶縁体３の先端部３ａに圧着されている。 Hereinafter, the present invention will be described in detail with reference to the drawings illustrating embodiments.
First, the electric wire connection structure of the present invention will be described.
In a reference example closely related to the present invention shown in FIGS. 1 to 3, reference numeral 1 denotes an electric wire formed by coating a large number of conducting wires 2 with an insulator 3, and the insulator 3 at one end of the electric wire 1. Is peeled off and the conductor end 2a is exposed.
Reference numeral 4 denotes a terminal connected to the electric wire. As shown in FIG. 3, the terminal 4 has an insertion hole 9 having a bottomed hole shape. The lead wire end 2a and the peeling tip 3a of the insulator 3 are inserted into the insertion hole 9, and the terminal 4 is caulked from the outer surface of the insertion hole 9 in the vicinity of the opening 14 and the lead wire end. It is crimped to the part 2a. Further, in the vicinity of the opening 14 of the insertion hole 9, the terminal 4 is crimped to the tip 3 a of the insulator 3.

図３に於て、具体的には、端子４は、先端部に図外の電気機器の端子等に接続される端子本体部７を有し、端子本体部７の基端にはスリーブ部８が一体状に連設されている。さらに、スリーブ部８には、有底孔状の挿入孔９が形成されている。挿入孔９は、スリーブ部８の内周面部13と、端子本体部７の基端側に配置された底部12と、底部12と反対側に配置された開口部14と、から形成されている。また、端子本体部７は、自動車のバッテリー等の端子を挿入して接続するための孔部10を有している。 In FIG. 3, specifically, the terminal 4 has a terminal body portion 7 connected to a terminal of an electric device (not shown) at the distal end portion, and a sleeve portion 8 at the base end of the terminal body portion 7. Are connected in one piece. Furthermore, a bottomed hole-shaped insertion hole 9 is formed in the sleeve portion 8. The insertion hole 9 is formed from an inner peripheral surface portion 13 of the sleeve portion 8, a bottom portion 12 disposed on the base end side of the terminal main body portion 7, and an opening portion 14 disposed on the opposite side of the bottom portion 12. . The terminal body 7 has a hole 10 for inserting and connecting a terminal such as a battery of an automobile.

また、挿入孔９の開口部14近傍より底部12側では、スリーブ部８の外面からプレス機等によりリング状に縮径塑性加工されている（かしめ加工されている）。その縮径塑性加工されたスリーブ部８の外面には、かしめ凹部15が形成され、かしめ凹部15に対応するスリーブ部８の内周面部13には、かしめ凸部16が形成されている。このかしめ凸部16が、挿入孔９内の導線端部２ａの表面に圧着され、電気的接続（導通接続）されている。
さらに、挿入孔９の開口部14近傍では、スリーブ部８の内周面部13が絶縁体３の先端部３ａの表面に圧着されている。 Further, from the vicinity of the opening 14 of the insertion hole 9 to the bottom 12 side, the outer diameter of the sleeve portion 8 is subjected to diameter-reducing plastic processing (caulking) by a press machine or the like. A caulking concave portion 15 is formed on the outer surface of the sleeve portion 8 that has been subjected to the reduced diameter plastic processing, and a caulking convex portion 16 is formed on the inner peripheral surface portion 13 of the sleeve portion 8 corresponding to the caulking concave portion 15. This caulking convex portion 16 is crimped to the surface of the conductor end portion 2a in the insertion hole 9 and is electrically connected (conducting connection).
Further, in the vicinity of the opening 14 of the insertion hole 9, the inner peripheral surface portion 13 of the sleeve portion 8 is pressure-bonded to the surface of the distal end portion 3 a of the insulator 3.

図９に示す本発明と関係が深い他の参考例に於て、端子４の挿入孔９内には導線端部２ａと絶縁体３の先端部３ａが挿入されており、導線端部２ａの先端Ｚは、ハンダ11を介して端子４と電気的接続されている。挿入孔９内の底部12近傍にはハンダ11が配設され、導線端部２ａの先端Ｚはこのハンダ11に埋設されている。
端子４は、挿入孔９の中間部20にてかしめ加工されて導線端部２ａに圧着されている。そして、スリーブ部８には、挿入孔９の中間部20にてかしめ凸部16（かしめ凹部15）が形成されている。
また、挿入孔９の開口部14近傍にて、絶縁体３の先端部３ａに圧着されている。
なお、図９に於て、図３と同一の符号は図３と同様の構成であるので、説明を省略する。 In another reference example deeply related to the present invention shown in FIG. 9, the conductor end 2a and the tip 3a of the insulator 3 are inserted into the insertion hole 9 of the terminal 4, and the conductor end 2a The tip Z is electrically connected to the terminal 4 via the solder 11. Solder 11 is disposed in the vicinity of the bottom 12 in the insertion hole 9, and the leading end Z of the conductor end 2 a is embedded in the solder 11.
The terminal 4 is crimped at the intermediate portion 20 of the insertion hole 9 and is crimped to the conductor end portion 2a. In the sleeve portion 8, a caulking convex portion 16 (caulking concave portion 15) is formed at an intermediate portion 20 of the insertion hole 9.
Further, it is crimped to the tip 3 a of the insulator 3 in the vicinity of the opening 14 of the insertion hole 9.
In FIG. 9, the same reference numerals as those in FIG. 3 have the same configurations as those in FIG.

図10に示す本発明と関係が深いさらに他の参考例に於て、絶縁体３の先端部３ａと端子４の開口部14近傍の内周面との間に防水材19を介在させている。この防水材19は、例えば、ブチルゴムを含む粘着剤をテープ状に形成し、絶縁体３の先端部３ａに巻着している。そして、先端部３ａに巻着された防水材19は、スリーブ部８の開口部14近傍の内周面部13に密着し、導線端部２ａが挿入された挿入孔９内は密封状態となっている。
また、導線端部２ａは、挿入孔９内に配設されたハンダ11を介して端子４と電気的接続されている。ハンダ11は挿入孔９内の底部12から中間部20に配設され、導線端部２ａはこのハンダ11に埋設されている。端子４は、挿入孔９の中間部20にてかしめ加工され、ハンダ11を介して導線端部２ａに圧着されている。 In still another reference example closely related to the present invention shown in FIG. 10, a waterproof material 19 is interposed between the tip 3a of the insulator 3 and the inner peripheral surface in the vicinity of the opening 14 of the terminal 4. . The waterproof material 19 is formed by, for example, forming a pressure-sensitive adhesive containing butyl rubber in a tape shape and winding it around the tip 3 a of the insulator 3. And the waterproof material 19 wound around the front-end | tip part 3a is closely_contact | adhered to the inner peripheral surface part 13 of the opening part 14 vicinity of the sleeve part 8, and the inside of the insertion hole 9 in which the conducting wire end part 2a was inserted becomes a sealing state. Yes.
The conducting wire end 2 a is electrically connected to the terminal 4 through solder 11 disposed in the insertion hole 9. The solder 11 is disposed from the bottom portion 12 in the insertion hole 9 to the intermediate portion 20, and the conductor end portion 2 a is embedded in the solder 11. The terminal 4 is caulked at the intermediate portion 20 of the insertion hole 9 and is crimped to the conductor end portion 2 a via the solder 11.

なお、この中間部20のかしめ加工による端子４と導線端部２ａとの接続は、主に機械（強度）的接続であり、端子４や導線端部２ａ（電線１）にかかる引張力や衝撃によって端子４と導線端部２ａとが分離するのを防止することを目的とするものであるが、端子４と導線端部２ａはハンダ11を介して電気的接続（導通接続）もされている。また、（かしめ加工しない）底部12近傍での端子４と導線端部２ａの先端Ｚとのハンダ11を介した接続は、主に電気的接続を目的とするものである。
なお、図10に於て、図３と同一の符号は図３と同様の構成であるので、説明を省略する。 The connection between the terminal 4 and the conductor end 2a by caulking of the intermediate portion 20 is mainly a mechanical (strength) connection, and a tensile force or an impact applied to the terminal 4 or the conductor end 2a (electric wire 1). Is intended to prevent the terminal 4 and the conductive wire end 2a from being separated, but the terminal 4 and the conductive wire end 2a are also electrically connected (conductive connection) via the solder 11. . Further, the connection between the terminal 4 and the tip end Z of the conductor end 2a in the vicinity of the bottom 12 (not caulking) is mainly for the purpose of electrical connection.
In FIG. 10, the same reference numerals as those in FIG. 3 have the same configurations as those in FIG.

図11と図12に於ける本発明の実施の形態に於て、端子４の挿入孔９内に導線端部２ａと絶縁体３の剥離先端部３ａが挿入されている。そして、挿入孔９の開口部14近傍より底部12側にて、端子４はその外面からかしめ加工されて導線端部２ａに圧着され、挿入孔９の開口部14近傍にて、端子４が絶縁体３の先端部３ａに圧着されている。
さらに、端子４の上記かしめ加工される部位（かしめ凸部16）と開口部14との間には一対のスリット18，18が形成されている。スリット18は、スリーブ部８の外面から内周面部13へ貫通して設けられ、スリーブ部８の周方向に伸びて形成されている。 In the embodiment of the present invention shown in FIGS. 11 and 12, the conductor wire end portion 2 a and the peeling tip portion 3 a of the insulator 3 are inserted into the insertion hole 9 of the terminal 4. The terminal 4 is caulked from the outer surface near the opening 14 near the opening 14 of the insertion hole 9 and crimped to the conductor end 2a. The terminal 4 is insulated near the opening 14 of the insertion hole 9. Crimped to the tip 3 a of the body 3.
Further, a pair of slits 18 and 18 are formed between the above-described portion (caulking convex portion 16) of the terminal 4 and the opening 14. The slit 18 is provided so as to penetrate from the outer surface of the sleeve portion 8 to the inner peripheral surface portion 13, and is formed to extend in the circumferential direction of the sleeve portion 8.

端子４のスリット18と導線端部２ａとの間、及び、端子４の開口部14近傍の内周面部13と絶縁体３の先端部３ａとの間に、防水材19が介在されている。この防水材19は、例えば、ホットメルト接着剤であり、熱可塑性樹脂を加熱溶融して、絶縁体３の先端部３ａとスリーブ部８の内周面部13との間、及び、スリット18の開口部とを、塞ぐように充填し、その後冷却固化されている。これにより、導線端部２ａが挿入された挿入孔９内は密封状態となっている。
なお、図11及び図12に於て、図２及び図３と同一の符号は図２及び図３と同様の構成であるので、説明を省略する。 A waterproof material 19 is interposed between the slit 18 of the terminal 4 and the conducting wire end portion 2 a and between the inner peripheral surface portion 13 near the opening 14 of the terminal 4 and the distal end portion 3 a of the insulator 3. The waterproof material 19 is, for example, a hot-melt adhesive, and heats and melts a thermoplastic resin so that the gap between the tip 3a of the insulator 3 and the inner peripheral surface 13 of the sleeve 8 and the opening of the slit 18 is obtained. The portion is filled so as to close, and then cooled and solidified. Thereby, the inside of the insertion hole 9 in which the conducting wire end 2a is inserted is in a sealed state.
11 and 12, the same reference numerals as those in FIGS. 2 and 3 have the same configurations as those in FIGS.

また、電線１が自動車のバッテリーケーブルに使用される場合は、軽量化のため導線２はアルミニウム製又はアルミニウム合金製であることが好ましい。
そして、導体２がアルミニウム合金製の場合は、耐熱性を有する点でＡｌ− 0.01 ｗｔ％〜 0.2ｗｔ％Ｚｒ合金が好ましい。さらに、電線１は、酸化皮膜を形成防止及びハンダ11との密着性を高めるため（図９、図10参照）、導線端部２ａの表面をハンダで覆ったりジンケート浴等による亜鉛めっき処理をすることが望ましい。
また、端子４はアルミニウム合金製（ＪＩＳ規格Ａ６０６３−Ｏ）であり、さらに、耐食性を向上させるためにＳｎメッキを施したものが好ましい。 Moreover, when the electric wire 1 is used for the battery cable of a motor vehicle, it is preferable that the conducting wire 2 is a product made from aluminum or aluminum alloy for weight reduction.
And when the conductor 2 is an aluminum alloy, an Al-0.01 wt%-0.2 wt% Zr alloy is preferable at the point which has heat resistance. Further, in order to prevent the formation of an oxide film and to improve the adhesion to the solder 11 (see FIGS. 9 and 10), the electric wire 1 covers the surface of the conductive wire end 2a with solder or is subjected to galvanizing treatment using a zincate bath or the like. It is desirable.
Further, the terminal 4 is made of an aluminum alloy (JIS standard A6063-O), and is preferably plated with Sn in order to improve the corrosion resistance.

本発明と関係が深い電線の接続方法について説明する。
予め電線１の一端部の絶縁体３を剥離して導線端部２ａを露出させ、図４に示すように、端子４の挿入孔９内に導線端部２ａと絶縁体３の先端部３ａを挿入する。次に、図５に示すように、押さえ具21，21でスリーブ部８（端子４）の開口部14近傍の外面を押さえる。なお、開口部14近傍を押さえる力（押圧力）Ｐは、スリーブ部８を押圧変形させない程度の力である。そして、図６に示すように、スリーブ部８の開口部14近傍の外面を押さえ具21，21で押さえつつ（押圧力Ｐを付与したまま）、かしめ具22，22によりスリーブ部８の中間部20をその外面から押圧する。このかしめ具22，22による押圧力Ｑにて、中間部20が縮径塑性加工（かしめ加工）し、中間部20に形成されるかしめ凸部16が導線端部２ａに圧着される。
また、押圧力Ｑによってスリーブ部８の中間部20が縮径塑性変形すると同時に（中間部20での縮径塑性変形に伴って）、開口部14近傍でも縮径塑性変形し、スリーブ部８の開口部14近傍の内周面部13が、絶縁体３の先端部３ａに圧着される。つまり、中間部20に押圧力Ｑを付与することによって、中間部20と開口部14近傍とが同時に電線１（導線端部２ａと絶縁体３の先端部３ａ）に圧着される。このようにして、電線１が端子４に接続される。 A method for connecting electric wires that is closely related to the present invention will be described.
The insulator 3 at one end of the electric wire 1 is peeled in advance to expose the conductor end 2a, and the conductor end 2a and the tip 3a of the insulator 3 are inserted into the insertion hole 9 of the terminal 4 as shown in FIG. insert. Next, as shown in FIG. 5, the outer surface of the sleeve portion 8 (terminal 4) in the vicinity of the opening portion 14 is pressed by the pressing tools 21 and 21. The force (pressing force) P that presses the vicinity of the opening 14 is a force that does not cause the sleeve portion 8 to be pressed and deformed. Then, as shown in FIG. 6, while pressing the outer surface of the sleeve portion 8 in the vicinity of the opening portion 14 with the pressing members 21 and 21 (while the pressing force P is applied), the intermediate portion of the sleeve portion 8 by the caulking tools 22 and 22. Press 20 from its outer surface. With the pressing force Q by the caulking tools 22, 22, the intermediate portion 20 is subjected to reduced-diameter plastic working (caulking), and the caulking convex portion 16 formed on the intermediate portion 20 is crimped to the conductor end portion 2 a.
In addition, the intermediate portion 20 of the sleeve portion 8 is subjected to the reduced diameter plastic deformation by the pressing force Q (with the reduced diameter plastic deformation in the intermediate portion 20), and at the same time, the reduced diameter plastic deformation is performed in the vicinity of the opening portion 14. An inner peripheral surface portion 13 in the vicinity of the opening portion 14 is pressure-bonded to the distal end portion 3 a of the insulator 3. That is, by applying a pressing force Q to the intermediate portion 20, the intermediate portion 20 and the vicinity of the opening 14 are simultaneously crimped to the electric wire 1 (the conductive wire end portion 2 a and the distal end portion 3 a of the insulator 3). In this way, the electric wire 1 is connected to the terminal 4.

また、電線１の絶縁体３の径寸法が小さい場合は、中間部20にてスリーブ部８の外面から押圧力Ｑを付与しても、開口部14近傍で端子４が絶縁体３の先端部３ａに圧着しないことがある。つまり、図７に示すように、絶縁体３の先端部３ａの表面と、二点鎖線で示すスリーブ部８の開口部14近傍の内周面部13との間に隙間Ｓが生じる場合がある。この場合は、開口部14近傍にてスリーブ部８を外面から押圧力Ｒにて押圧し、絶縁体３の先端部３ａに圧着させるとよい。 Further, when the diameter dimension of the insulator 3 of the electric wire 1 is small, even if the pressing force Q is applied from the outer surface of the sleeve portion 8 at the intermediate portion 20, the terminal 4 is near the opening portion 14 in the vicinity of the opening portion 14. It may not be crimped to 3a. That is, as shown in FIG. 7, there may be a gap S between the surface of the tip 3a of the insulator 3 and the inner peripheral surface 13 near the opening 14 of the sleeve 8 indicated by a two-dot chain line. In this case, the sleeve portion 8 may be pressed from the outer surface with a pressing force R in the vicinity of the opening portion 14 to be crimped to the distal end portion 3 a of the insulator 3.

また、図８は、本発明の電線の接続方法の比較例を示す図であり、かしめ具22，22によりスリーブ部８の中間部20をその外面から押圧して縮径塑性加工する際に、開口部14近傍でスリーブ部８を外面から押さえていない。この場合、スリーブ部８の中間部20に於ける縮径塑性変形に伴って、スリーブ部８の開口部14は外側へ膨張し、開口部14近傍にてスリーブ部８の内周面部13は、絶縁体３の先端部３ａを押圧することができない。 FIG. 8 is a view showing a comparative example of the electric wire connection method of the present invention. When the intermediate portion 20 of the sleeve portion 8 is pressed from its outer surface by the caulking tools 22 and 22, the diameter reduction plastic processing is performed. The sleeve portion 8 is not pressed from the outer surface in the vicinity of the opening portion 14. In this case, the opening portion 14 of the sleeve portion 8 expands outward in accordance with the reduced diameter plastic deformation in the intermediate portion 20 of the sleeve portion 8, and the inner peripheral surface portion 13 of the sleeve portion 8 near the opening portion 14 The tip 3a of the insulator 3 cannot be pressed.

次に、38ＳＱのアルミニウム製の導線２を有する電線１を用いて、図13の（イ)(ロ)(ハ）に示すように、３種類の接続構造（接続方法）にて導線２と端子４とを接続し、それぞれの接続構造に於て、初期及び振動を与えた後の電圧降下値と端子固着力（接続強度）を測定する試験を行った。 Next, using the electric wire 1 having the 38SQ aluminum conductor 2, the conductor 2 and the terminal are connected in three types of connection structures (connection methods) as shown in FIGS. 4 were connected to each other, and a test was conducted to measure the voltage drop value and the terminal fixing force (connection strength) after the initial and vibration were applied to each connection structure.

図13の（イ)(ロ)(ハ）に示される接続構造について説明する。
（イ）比較例：挿入孔９の中間部20にて導線端部２ａと端子４とをかしめ加工して圧
着し、絶縁体３の先端部３ａと端子４とは接続（圧着）されていない。
（ロ）本発明と関係が深い参考例：挿入孔９の中間部20にて導線端部２ａと端子４とをかしめ加工して圧着し、開口部14近傍にて絶縁体３の先端部３ａと端子４とを圧着した。
（ハ）本発明と関係が深い他の参考例：端子４は挿入孔９の中間部20と開口部14近傍との間にスリット18，18を有しており、中間部20にて導線端部２ａと端子４とをかしめ加工して圧着し、開口部14近傍にて絶縁体３の先端部３ａと端子４とを圧着した。 A connection structure shown in (a), (b), and (c) of FIG. 13 will be described.
(A) Comparative example: The lead wire end 2a and the terminal 4 are crimped at the intermediate portion 20 of the insertion hole 9 and pressed, and the tip 3a of the insulator 3 and the terminal 4 are connected (crimped). Absent.
(B) Reference example closely related to the present invention: the end portion 2a of the insulator 3 is crimped by crimping the conductor end 2a and the terminal 4 at the intermediate portion 20 of the insertion hole 9, and the tip 3a of the insulator 3 in the vicinity of the opening 14. And terminal 4 were crimped.
(C) Another reference example closely related to the present invention: The terminal 4 has slits 18 and 18 between the intermediate portion 20 of the insertion hole 9 and the vicinity of the opening portion 14, and the end of the conductor wire is formed at the intermediate portion 20. The portion 2 a and the terminal 4 were crimped and crimped, and the tip 3 a of the insulator 3 and the terminal 4 were pressed in the vicinity of the opening 14.

そして、具体的には、（イ)(ロ)(ハ）のそれぞれの場合の接続構造で接続した時（初期）の電圧降下値と、その後一定時間振動を与えた後の各接続構造に於ける電圧降下値を測定した。
また、端子固着力（接続強度）を測定するために、（イ)(ロ)(ハ）のそれぞれ接続した状態（初期状態）で、導線２に引張力を徐々に強く与えていき、導線２が破断して端子４と分離するまでの引張力を測定した。さらに、（イ)(ロ)(ハ）の接続を行って一定時間振動を与えた後、導線２に引張力を徐々に強く与えていき、導線２が破断して端子４と分離するまでの引張力を測定した。
なお、図13の（イ)(ロ)(ハ）の全ての接続構造に於て、導線端部２ａの先端Ｚは挿入孔９内のハンダ11を介して端子４に電気的に接続され、端子４の材質はアルミニウム合金（Ａ６０６３−Ｏ）製で表面にＳｎメッキを施している。
それぞれの試験結果を下記の表１及び表２に示す。 Specifically, in each of the connection structures (i), (b), and (c), the voltage drop value at the time of connection (initial) and the connection structure after vibration for a certain period of time. The voltage drop value was measured.
In addition, in order to measure the terminal fixing force (connection strength), a tensile force is gradually applied to the conductor 2 in the connected state (initial state) of (A), (B), and (C). The tensile force until the wire breaks and separates from the terminal 4 was measured. Furthermore, after (i) (b) (c) is connected and vibration is applied for a certain period of time, a tensile force is gradually applied to the conductor 2 until the conductor 2 breaks and separates from the terminal 4. Tensile force was measured.
In all connection structures (a), (b), and (c) in FIG. 13, the tip end Z of the conductor end 2a is electrically connected to the terminal 4 via the solder 11 in the insertion hole 9. The material of the terminal 4 is made of an aluminum alloy (A6063-O), and the surface is Sn plated.
The respective test results are shown in Tables 1 and 2 below.

表１について説明すると、（イ)(ロ)(ハ）の接続構造の初期の電圧降下値は、全て0.05ｍΩであった。また、一定時間振動を与えた後、（イ）の場合は、導線２が、露出した導線２の部分（導線端部２ａ）と絶縁体３で被覆される導線２の部分との境界近傍で破断（断線）したので、電圧降下値は測定できなかった。これに対し、振動付与後の（ロ）の電圧降下値は0.06ｍΩであり、（ハ）の電圧降下値は0.05ｍΩであった。つまり、（ロ)(ハ）の場合は一定時間振動を与えても、導線２は破断せず、また、電圧降下値も初期の値からほとんど変化することはなく導通性を維持されていることが確認できた。 Referring to Table 1, the initial voltage drop values of the connection structures (A), (B) and (C) were all 0.05 mΩ. In addition, in the case of (a) after applying vibration for a certain time, the conductor 2 is near the boundary between the exposed portion of the conductor 2 (the conductor end 2a) and the portion of the conductor 2 covered with the insulator 3. Since it broke (disconnected), the voltage drop value could not be measured. On the other hand, the voltage drop value of (b) after applying the vibration was 0.06 mΩ, and the voltage drop value of (c) was 0.05 mΩ. In other words, in the case of (b) and (c), even if vibration is applied for a certain period of time, the conducting wire 2 does not break, and the voltage drop value hardly changes from the initial value, and the electrical conductivity is maintained. Was confirmed.

表２について説明すると、（イ)(ロ)(ハ）の初期の端子固着力は、（イ）の場合は3200Ｎであり、（ロ）の場合は3150Ｎであった。また、（ハ）の場合は3200Ｎとなった。
そして、振動を与えた後、（イ）の場合は振動によって、導線２が、露出した導線２の部分（導線端部２ａ）と絶縁体３で被覆される導線２の部分との境界近傍で破断（断線）したので、端子固着力は測定できなかった。（ロ)(ハ）の振動付与後の端子固着力は、（ロ）の場合は3200Ｎであり、（ハ）の場合は3150Ｎとなった。このことにより、（ロ)(ハ）の場合は一定時間振動を与えても、導線２は破断せず、また、端子固着力は初期の値からほとんど変化することはなく維持されていることが確認できた。 Referring to Table 2, the initial terminal fixing force of (A), (B) and (C) was 3200 N in the case of (A) and 3150 N in the case of (B). In the case of (c), it was 3200N.
After the vibration is applied, in the case of (A), the conductor 2 is vibrated near the boundary between the exposed portion of the conductor 2 (the conductor end 2a) and the portion of the conductor 2 covered with the insulator 3. Since it was broken (disconnected), the terminal fixing force could not be measured. (B) The terminal fixing force after applying vibration in (c) was 3200 N in (b) and 3150 N in (c). As a result, in the case of (b) and (c), even if vibration is applied for a certain period of time, the conductor 2 is not broken and the terminal fixing force is maintained with almost no change from the initial value. It could be confirmed.

以上のように、本発明である電線の接続構造は、多数本の導線２を絶縁体３で被覆して成る電線１の一端部の絶縁体３を剥離して露出させた導線端部２ａと、端子４とを、接続する電線の接続構造に於て、端子４は有底孔状の挿入孔９を有し、挿入孔９内に導線端部２ａと絶縁体３の剥離側先端部３ａが挿入され、挿入孔９の開口部14近傍より底部12側にて端子４をその外面からかしめ加工して導線端部２ａに接続され、さらに、開口部14近傍にて端子４が絶縁体３の剥離側先端部３ａに圧着されているので、導線端部２ａに雨水や海水等が付着するのを防止できる。つまり、導線端部２ａは端子４の挿入孔９内に挿入されており、外部に剥き出しになっていないので、導線端部２ａに雨水・海水等が付着して腐食するのを防ぐことができる。このことにより、導線２の導通性を長期に維持することが可能となる。
さらに、互いに接続された端子４及び電線１に振動が付与された場合、露出した導線２の部分（導線端部２ａ）と絶縁体３で被覆される導線２の部分との境界近傍で応力が集中して、導線２が破断する虞れがあったが、開口部14近傍にて端子４が絶縁体３の剥離側先端部３ａに圧着されているので、導線２の応力集中を低減させることができ、導線２の破断を確実に防止することができる。 As described above, the electric wire connection structure according to the present invention includes the conductor end portion 2a in which the insulator 3 at one end portion of the electric wire 1 formed by coating a large number of conductor wires 2 with the insulator 3 is peeled and exposed. In the connection structure of the electric wire for connecting the terminal 4, the terminal 4 has a bottomed hole-like insertion hole 9, and the conductor wire end 2 a and the peeling-side tip 3 a of the insulator 3 are inserted in the insertion hole 9. Is inserted, and the terminal 4 is caulked from the outer surface thereof near the opening 12 of the insertion hole 9 and connected to the conductor end 2a, and the terminal 4 is connected to the insulator 3 near the opening 14. Therefore, it is possible to prevent rainwater, seawater, and the like from adhering to the conductive wire end 2a. That is, since the conducting wire end 2a is inserted into the insertion hole 9 of the terminal 4 and is not exposed to the outside, it is possible to prevent corrosion and rainwater / seawater from adhering to the conducting wire end 2a. . This makes it possible to maintain the conductivity of the conducting wire 2 for a long time.
Furthermore, when vibration is applied to the terminal 4 and the electric wire 1 connected to each other, stress is generated in the vicinity of the boundary between the exposed portion of the conducting wire 2 (the conducting wire end portion 2a) and the portion of the conducting wire 2 covered with the insulator 3. There is a possibility that the conductive wire 2 may break due to concentration, but since the terminal 4 is pressure-bonded to the peeling-side tip portion 3a of the insulator 3 in the vicinity of the opening 14, the stress concentration of the conductive wire 2 is reduced. Thus, breakage of the conductor 2 can be reliably prevented.

また、絶縁体３の剥離側先端部３ａと端子４の開口部14近傍の内周面との間に防水材19を介在させたので、挿入孔９内に雨水や海水等が浸入するのを確実に防ぐことができ、導線端部２ａに雨水・海水等が付着して腐食するのを防止することができる。このことにより、導線２の導通性を長期に維持することができる。
また、防水材19が粘着性を有するものであれば、開口部14近傍にて端子４と絶縁体３の剥離側先端部３ａとを強固に固着することができる。 Further, since the waterproof material 19 is interposed between the peeling-side distal end portion 3a of the insulator 3 and the inner peripheral surface in the vicinity of the opening 14 of the terminal 4, rainwater, seawater, etc. enter the insertion hole 9. It can prevent reliably, and it can prevent that rainwater, seawater, etc. adhere and corrode to the conducting wire end part 2a. Thereby, the conductivity of the conducting wire 2 can be maintained for a long time.
Moreover, if the waterproof material 19 has adhesiveness, the terminal 4 and the peeling-side tip portion 3a of the insulator 3 can be firmly fixed in the vicinity of the opening 14.

また、有底孔状の挿入孔９を有する端子４のかしめ加工される部位と開口部14近傍との間にスリット18を設けたので、（開口部14近傍より底部12側での）かしめ加工による端子４の縮径塑性変形に伴って、開口部14近傍にて端子４が絶縁体３の先端部３ａに過度に圧着するのを抑制できる。従って、その過度の圧着力にて絶縁体３の先端部３ａが破損するのを防止することができ、端子４は絶縁体３の先端部３ａを適度に圧着保持することができる。言い換えれば、スリット18を設けることにより、端子４と絶縁体３の先端部３ａとの圧着強度を調整することができる。 In addition, since the slit 18 is provided between the portion of the terminal 4 having the bottomed hole-shaped insertion hole 9 to be crimped and the vicinity of the opening 14, the crimping is performed (on the bottom 12 side from the vicinity of the opening 14). It is possible to suppress the terminal 4 from being excessively pressure-bonded to the distal end portion 3 a of the insulator 3 in the vicinity of the opening 14 due to the reduced diameter plastic deformation of the terminal 4. Therefore, it is possible to prevent the distal end portion 3a of the insulator 3 from being damaged by the excessive crimping force, and the terminal 4 can appropriately crimp and hold the distal end portion 3a of the insulator 3. In other words, by providing the slit 18, the crimping strength between the terminal 4 and the tip 3 a of the insulator 3 can be adjusted.

また、端子４のスリット18と導線端部２ａとの間、及び、端子４の開口部14近傍の内周面と絶縁体３の剥離側先端部３ａとの間に、防水材19を介在させたので、挿入孔９内に雨水や海水等が浸入するのを確実に防止でき、導線端部２ａに雨水・海水等が付着し腐食するのを防止できる。このことにより、導線２の導通性を長期に維持することができる。
また、防水材19が粘着性を有するものであれば、開口部14近傍にて端子４と絶縁体３の剥離側先端部３ａとを強固に固着することができる。 Further, a waterproof material 19 is interposed between the slit 18 of the terminal 4 and the conducting wire end 2a, and between the inner peripheral surface near the opening 14 of the terminal 4 and the peeling-side tip 3a of the insulator 3. Therefore, it is possible to reliably prevent rainwater, seawater, etc. from entering the insertion hole 9, and to prevent rainwater, seawater, etc. from adhering to the conductor end 2a and corroding. Thereby, the conductivity of the conducting wire 2 can be maintained for a long time.
Moreover, if the waterproof material 19 has adhesiveness, the terminal 4 and the peeling-side tip portion 3a of the insulator 3 can be firmly fixed in the vicinity of the opening 14.

また、導線２がアルミニウム製又はアルミニウム合金製であるので、電線１を軽量化できると共に、強度の低いアルミニウム製又はアルミニウム合金製の導線２であっても、開口部14近傍にて端子４が絶縁体３の剥離側先端部３ａに圧着されているので、導線２の応力集中を低減させることができ、導線２の破断を確実に防止することができる。 Moreover, since the conducting wire 2 is made of aluminum or aluminum alloy, the electric wire 1 can be reduced in weight, and the terminal 4 is insulated in the vicinity of the opening 14 even if the conducting wire 2 is made of aluminum or aluminum alloy having low strength. Since it is crimped | bonded to the peeling side front-end | tip part 3a of the body 3, the stress concentration of the conducting wire 2 can be reduced and the fracture | rupture of the conducting wire 2 can be prevented reliably.

また、電線１が自動車のバッテリーケーブルに使用されているので、自動車の走行時に発生する振動によって、導線２（導線端部２ａ）が破断（断線）することはない。また、自動車が雨水や海水に曝されることがあっても、導線端部２ａに雨水や海水が付着することがなく、導線２の導通性を長期に維持できる。 Moreover, since the electric wire 1 is used for the battery cable of a motor vehicle, the conducting wire 2 (conducting wire end part 2a) is not broken (disconnected) by the vibration generated when the vehicle travels. Moreover, even if the automobile is exposed to rainwater or seawater, rainwater or seawater does not adhere to the conductor end 2a, and the conductivity of the conductor 2 can be maintained for a long time.

また、本発明である電線の接続方法は、多数本の導線２を絶縁体３で被覆して成る電線１の一端部の絶縁体３を剥離して露出させた導線端部２ａに端子４をかしめ加工にて接続する電線の接続方法に於て、端子４の有底孔状の挿入孔９内に導線端部２ａと絶縁体３の剥離側先端部３ａを挿入して、端子４の開口部14近傍の外面を押さえつつ挿入孔９の開口部14近傍よりも底部12側にて端子４をかしめ加工して導線端部２ａに圧着させると同時に、又は、その圧着後に、端子４を開口部14近傍にて絶縁体３の剥離側先端部３ａに圧着させるので、導線端部２ａに雨水や海水等が付着するのを防止できる。つまり、導線端部２ａは端子４の挿入孔９内に挿入されており、外部に剥き出しになっていないので、導線端部２ａに雨水・海水等が付着して腐食するのを防ぐことができる。このことにより、導線２の導通性を長期に維持することが可能となる。
さらに、互いに接続された端子４及び電線１に振動が付与された場合、露出した導線２の部分（導線端部２ａ）と絶縁体３で被覆される導線２の部分との境界近傍で応力が集中して、導線２が破断する虞れがあったが、開口部14近傍にて端子４が絶縁体３の剥離側先端部３ａに圧着されているので、導線２の応力集中を低減させることができ、導線２の破断を確実に防止することができる。
また、端子４の開口部14近傍の外面を押さえつつ（開口部14近傍よりも底部12側にて）かしめ加工するので、端子４のかしめ加工による縮径塑性変形に伴って、端子４の開口部14が外側へ膨張することを防止し、端子４は開口部14近傍にて絶縁体３の先端部３ａに圧着させることができる。 In addition, in the method for connecting electric wires according to the present invention, the terminal 4 is connected to the end portion 2a of the electric wire 1 which is formed by peeling and exposing the insulator 3 at one end portion of the electric wire 1 formed by covering a large number of the electric wires 2 with the insulator 3. In the connection method of the electric wire to be connected by caulking, the lead wire end portion 2a and the peeling-side tip portion 3a of the insulator 3 are inserted into the bottomed hole-like insertion hole 9 of the terminal 4 to open the terminal 4 The terminal 4 is opened at the same time as the terminal 4 is crimped to the lead wire end 2a by pressing the outer surface in the vicinity of the opening 14 while pressing the outer surface in the vicinity of the opening 14 of the insertion hole 9 to the bottom 12 side. Since it is crimped | bonded to the peeling side front-end | tip part 3a of the insulator 3 in the vicinity of the part 14, it can prevent that rainwater, seawater, etc. adhere to the conducting wire end part 2a. That is, since the conducting wire end portion 2a is inserted into the insertion hole 9 of the terminal 4 and is not exposed to the outside, it is possible to prevent the rainwater, seawater, etc. from adhering to the conducting wire end portion 2a to be corroded. . This makes it possible to maintain the conductivity of the conducting wire 2 for a long time.
Furthermore, when vibration is applied to the terminal 4 and the electric wire 1 connected to each other, stress is generated in the vicinity of the boundary between the exposed portion of the conducting wire 2 (the conducting wire end portion 2a) and the portion of the conducting wire 2 covered with the insulator 3. There is a possibility that the conductive wire 2 may break due to concentration, but since the terminal 4 is pressure-bonded to the peeling-side tip portion 3a of the insulator 3 in the vicinity of the opening 14, the stress concentration of the conductive wire 2 is reduced. Thus, breakage of the conductor 2 can be reliably prevented.
Further, since the caulking process is performed while pressing the outer surface in the vicinity of the opening 14 of the terminal 4 (on the bottom 12 side from the vicinity of the opening 14), the opening of the terminal 4 is accompanied by the reduced diameter plastic deformation due to the caulking process of the terminal 4. The portion 14 can be prevented from expanding outward, and the terminal 4 can be crimped to the tip 3 a of the insulator 3 in the vicinity of the opening 14.

本発明と関係が深い参考例を示す側面図である。It is a side view which shows the reference example deeply related to this invention. 平面図である。It is a top view. 断面側面図である。It is a cross-sectional side view. 説明用断面側面図である。It is a sectional side view for explanation. 説明用断面側面図である。It is a sectional side view for explanation. 説明用断面側面図である。It is a sectional side view for explanation. 説明用断面側面図である。It is a sectional side view for explanation. 比較例を示す説明用断面側面図である。It is a cross-sectional side view for explanation showing a comparative example. 本発明と関係が深い他の参考例を示す断面側面図である。It is a cross-sectional side view which shows the other reference example deeply related to this invention . 本発明と関係が深いさらに他の参考例を示す断面側面図である。FIG. 10 is a cross-sectional side view showing still another reference example deeply related to the present invention . 本発明の実施の形態を示す平面図である。It is a top view which shows embodiment of this invention . 断面側面図である。It is a cross-sectional side view. 説明用断面側面図であって、（イ）は比較例の断面側面図、（ロ）は本発明と関係が深い参考例の断面側面図、（ハ）は本発明と関係が深い他の参考例の断面側面図である。It is sectional side view for description, (a) is a sectional side view of a comparative example, (b) is a sectional side view of a reference example closely related to the present invention, and (c) is another reference closely related to the present invention. It is a cross-sectional side view of an example.

１電線
２導線
２ａ導線端部
３絶縁体
３ａ剥離先端部
４端子
８スリーブ部
９挿入孔
12 底部
14 開口部
15 かしめ凹部
16 かしめ凸部
18 スリット
19 防水材
20 中間部 1 Electric Wire 2 Conductor 2a Conductor End 3 Insulator 3a Stripping Tip 4 Terminal
8 Sleeve part 9 Insertion hole
12 Bottom
14 opening
15 Caulking recess
16 Caulking projection
18 slits
19 Waterproof material
20 Middle part

Claims

A conductor end (2a) which is exposed by peeling off the insulator (3) at one end of the electric wire (1) formed by coating a large number of conductors (2) with an insulator (3), and a terminal (4) In the connection structure of the connecting wires,
The terminal (4) is provided with a sleeve portion (8) in which a bottomed hole-like insertion hole (9) is formed, and the conductor end (2a) and the insulator (3) are formed in the insertion hole (9). ) On the peel side (3a) is inserted, and the terminal (20) at the intermediate portion (20) of the sleeve portion (8) on the bottom (12) side from the vicinity of the opening (14) of the insertion hole (9). 4) is caulked from the outer surface to form a caulking concave portion (15) on the outer surface of the sleeve portion (8), and the inner peripheral surface portion (13) of the sleeve portion (8) corresponding to the caulking concave portion (15). A caulking projection (16) is formed to connect the terminal (4) to the conductor end (2a), and in the vicinity of the opening (14), the terminal (4) is connected to the insulator (3). ) On the peeling side tip (3a),
A slit (18) is provided between the portion to be crimped of the terminal (4) and the vicinity of the opening (14),
And between the said slit (18) of the said terminal (4) and the said conducting wire end part (2a), and the inner peripheral surface of the said terminal (4) vicinity of the said opening part (14), and the said insulator (3 ), The waterproof material (19) is continuously interposed between the peeling-side tip (3a).

The electric wire connection structure according to claim 1, wherein the conductive wire (2) is made of aluminum or aluminum alloy.

The electric wire connection structure according to claim 1 or 2, wherein the electric wire (1) is used in a battery cable of an automobile.