JP5077697B2 - Electric wires with terminal fittings and terminal fittings - Google Patents

Description

  The present invention relates to an electric wire with a terminal fitting and a terminal fitting.

  When the terminal fitting is attached to the covered electric wire, the exposed core wire of the covered electric wire is crimped and connected to the terminal fitting (see Patent Document 1).

Here, when crimping the core wire to the terminal fitting, for example, an open barrel type terminal fitting having a pair of barrels raised from the side edge of the bottom plate portion is placed on the anvil, and the core wire is attached to the bottom plate portion. Address. When the crimper disposed above the terminal fitting is lowered, the barrel portion is gradually deformed so as to wrap the core wire, and the tip of the barrel portion is pressed into the core wire so as to crush the core wire. .
JP 2007-12341 A

By the way, since the core wire of an electric wire is a conductive metal, an oxide film is easily formed around the core wire. In particular, when aluminum or an aluminum alloy is used for the core wire, an oxide film is easily formed. Therefore, when the wire barrel and the core wire are crimped (crimped), the core wire is rubbed against the wire barrel to break the oxide film.
From this point of view, it is desirable to crimp the wire barrel and the core wire with a strong force from the viewpoint of breaking the oxide film.

However, when the wire barrel and the core wire are crimped with a strong force, the core wire is crushed and a strong force is applied to the bottom plate portion below the core wire. At this time, the bottom plate portion is crushed and stretched in the axial direction of the core wire, whereby the entire terminal fitting is stretched.
When such extension of the terminal fitting occurs, the overall length becomes longer than the design dimension by an unexpected amount, causing interference with other parts, and causing problems such as difficulty in dimensional management during manufacturing. Let

  The present invention has been completed based on the above circumstances, and provides an electric wire with terminal fittings and a terminal fitting that can ensure a good electrical connection state without being crimped with a strong force. With the goal.

  The electric wire with a terminal fitting according to the present invention has a single core wire, and includes an electric wire formed by penetrating a terminal insertion hole in a terminal portion of the single core wire, and a terminal fitting caulked to the single core wire of the electric wire, The terminal fitting includes a connection part electrically connected to a mating terminal, a bottom plate part extending from the connection part on which a terminal part of the single core wire is placed, and a tip part protruding from the bottom plate part. A feature is that the terminal insertion hole includes a caulking portion that penetrates the terminal insertion hole and is caulked to a hole edge of the terminal insertion hole (means 1).

In the means 1, the caulking portion protrudes in opposite directions by punching a metal plate material having a predetermined thickness, and a pair of male terminals that are long in the axial direction of the single core wire are both bent toward the single core wire side. (Means 2).
If it does in this way, a male terminal can be easily formed by stamping. Further, since the male terminal is long in the axial direction of the single core wire, the length of the male terminal can be freely set as compared with the case where the male terminal is long in the width direction.

In means 1 or 2, in addition to the caulking part, an insulation barrel part having a pair of caulking pieces for holding the electric wire from above the insulating coating of the electric wire may be provided (means 3).
If it does in this way, an electric wire can be held reliably rather than holding an electric wire only by connection with a caulking part and a single core wire.

The terminal fitting according to the present invention includes a connection part that is electrically connected to the counterpart terminal,
A bottom plate portion on which a terminal portion of an electric wire extending from the connection portion and having a single core wire is placed;
A tip portion protruding from the bottom plate portion is capable of penetrating a terminal insertion hole formed through the single core wire of the terminal portion, and a caulking portion that is crimped to a hole edge of the terminal insertion hole; (Means 4).

In the means 4, the caulking portion protrudes in opposite directions by punching a metal plate material having a predetermined thickness, and a pair of male terminals that are long in the axial direction of the single core wire are arranged together with the single core wire. It may be formed by being bent to the side (means 5).
If it does in this way, a male terminal can be easily formed by stamping. Further, since the male terminal is long in the axial direction of the single core wire, the length of the male terminal can be freely set as compared with the case where the male terminal is long in the width direction.

In the means 4 or means 5, in addition to the caulking part, an insulation barrel part having a pair of caulking pieces for holding the electric wire from above the insulating coating of the electric wire may be provided (means 6).
If it does in this way, an electric wire can be held reliably rather than holding an electric wire only by connection with a caulking part and a single core wire.

According to this configuration, the tip end portion of the caulking portion is inserted until it penetrates the terminal insertion hole, and the tip end portion is caulked to the hole edge of the terminal insertion hole. Here, when the tip of the caulking portion is caulked to the hole edge of the terminal insertion hole, even if the caulking portion is not caulked by a strong force, the portion of the tip of the caulking portion that contacts the hole edge is the hole edge of the terminal insertion hole. The insulating film such as the oxide film or hydroxide film of the single core wire is broken by rubbing against the edge portion of the wire. Thereby, even if it does not crimp by strong force, a favorable electrical connection state is obtained between a single core wire and a terminal metal fitting.
Moreover, since it is not necessary to press-fit with a strong force, the extension by the part of a terminal metal fitting being strongly crushed does not arise, and the extension as a whole terminal metal fitting can be suppressed.

<Embodiment 1>
Hereinafter, the electric wire 10 with a terminal metal fitting of Embodiment 1 which actualized this invention is demonstrated with reference to FIGS.
As shown in FIG. 1, the electric wire 10 with terminal metal fittings of the present embodiment is formed by connecting a terminal metal fitting 30 to a terminal portion of a covered electric wire 20, for example, a battery and an inverter that constitute a power source for traveling in an electric vehicle. The device is routed between devices (not shown) such as a motor. Note that the right side of FIG. 1 is assumed to be the front and the left side is assumed to be the rear.

  The covered electric wire 20 (electric wire) is obtained by coating a single core wire 21 made of aluminum with a resin insulating coating 22 (insulating layer), and the insulating coating 22 is peeled off at the end portion of the single core wire 21. Exposed. In addition, the single core wire 21 is reduced in weight and cost by using an aluminum single core wire instead of the conventional single core wire made of copper alloy. Moreover, the single core wire 21 refers to a core wire composed of only one wire, not a plurality of wires bundled or twisted.

  The exposed end portion of the single core wire 21 is a flat portion 23 processed into a flat shape (see FIG. 8), and the central portion of the flat portion 23 has an axis of the single core wire 21 as shown in FIG. A rectangular terminal insertion hole 25 that is long in the direction is formed so as to penetrate in the plate thickness direction.

The method for forming the single core wire 21 having the flat portion 23 will be described. First, the covered electric wire 20 is cut by a cutting machine so that the cut end surface is perpendicular to the axial direction, and an insulating coating is applied to the terminal portion (tip portion) of the covered electric wire 20. The single core wire 21 is exposed.
Next, an exposed portion of the single core wire 21 is formed using a mold including an upper die 61 and a lower die 62 having a flat pressing surface having a length corresponding to the length of the flat portion 23 in the axial direction (FIG. 4). It is formed into a flat shape by forging with a mold (FIG. 5). Thereafter, the center portion of the flat portion 23 is punched by a rectangular (square tube) mold (not shown) by punching, whereby the terminal insertion hole 25 is formed in the flat portion 23, and the terminal portion of the covered electric wire 20 is processed. finish.

The terminal metal fitting 30 is made of a copper alloy that can obtain higher strength than aluminum, and as shown in FIG. 1, a connection part 31 connected to a counterpart terminal (not shown), and extends from the connection part 31. A bottom plate portion 35 on which a terminal portion of the single core wire 21 is placed and an insulation barrel portion 41 that holds the covered electric wire 20 are provided, and these are integrally formed.
The connection portion 31 is a box-shaped female terminal, and electrical connection is achieved by inserting a male terminal (not shown) into the insertion hole 31A.

The insulation barrel portion 41 is formed integrally with the bottom plate portion 35 and is continuous with the bottom plate portion 35 in the axial direction of the covered electric wire 20 (the axial direction refers to the axial direction of the covered electric wire 20; that is, the left-right direction in FIG. 1). Arranged in position.
Specifically, the insulation barrel portion 41 includes a pair of caulking pieces 41A and 41A raised from the left and right side edges of the bottom plate continuous from the bottom plate portion 35, and the pair of caulking pieces 41A and 41A are covered with the covered electric wire. By being bent toward the 20 side, the covered electric wire 20 is held so as not to be detached or displaced.

The bottom plate portion 35 is substantially flat and has a rectangular shape that is long in the front-rear direction (the axial direction of the single core wire 21), and a lower portion of the rear end portion of the connection portion 31 (substantially the lower half of the side surface portion 31A and the bottom surface portion 31B) and the shaft. It is lined up in the direction.
The length in the front-rear direction (axial direction) of the bottom plate portion 35 is slightly longer than the exposed portion of the single core wire 21, and the width dimension of the bottom plate portion 35 is slightly larger than the width of the flat portion 23 of the single core wire 21. It is a dimension.

The bottom plate portion 35 is provided with a caulking portion 50 for caulking the single core wire 21.
The caulking portion 50 includes two male terminals 51 and 52 each having a rectangular shape (strip shape) projecting upward, and a pair of front and rear axial directions with a predetermined interval corresponding to the terminal insertion hole 25 in the bottom plate portion 35. Are formed side by side.

  The pair of male terminals 51 and 52 pass through the terminal insertion hole 25, and tip portions 51 </ b> A and 52 </ b> A of the male terminals 51 and 52 passing through the terminal insertion hole 25 are caulked to the hole edge 25 </ b> A of the terminal insertion hole 25. . That is, the male terminals 51 and 52 are locked to the hole edge 25A by bending forward, and the male terminals 51 and 52 are locked to the hole edge 25A by bending backward.

First, as shown in FIG. 7, a method of forming the caulking portion 50 of the terminal fitting 30 is a pair of metal plates having a predetermined thickness that project in opposite directions by being punched and that are long in the axial direction of the single core wire 21. Male terminals 51 and 52 are formed. In FIG. 7, the crimping pieces 41A and 41A of the insulation barrel portion 41 and both side edges of the bottom plate portion 35 are bent by bending the punched terminal original plate.
Then, as shown in FIG. 8, the pair of male terminals 51 and 52 are bent upward at a right angle using a jig (not shown), thereby completing the formation of the caulking portion 50. Note that the rectangular opening 39 is left in the bottom plate portion 35 after the bending of the male terminals 51 and 52.

Next, the manufacturing method of the electric wire with a terminal metal fitting is demonstrated.
As shown in FIG. 8, the caulking portion 50 is inserted into the terminal insertion hole 25 from a position where the covered wire 20 is above the terminal fitting 30 and the surface of the flat portion 23 is parallel to the surface of the bottom plate portion 35. Thus, the flat part 23 of the covered electric wire 20 is mounted on the upper surface of the bottom plate part 35 (FIG. 9).

  Then, as shown in FIG. 10, for example, in a state where the terminal fitting 30 is placed on the base 70, the angle-shaped caulking jig 80 having the inclined surfaces 81 and 82 at symmetrical positions in the axial direction is formed. The top is inserted between the pair of male terminals 51 and 52. Then, press down with a strong force. At this time, the male terminals 51 and 52 are pushed and deformed by the inclined surfaces 81 and 82, and the portions of the male terminals 51 and 52 (tip portions 51 </ b> A) that are in contact with the hole edge 25 </ b> A of the terminal insertion hole 25. 52A) is gradually caulked while being rubbed against the edge portion of the hole edge 25A. And as shown in FIG. 1, the front-end | tip parts 51A and 52A of the male terminals 51 and 52 are crimped to the hole edge 25A of the terminal insertion hole 25, and manufacture of an electric wire with a terminal metal fitting is complete | finished.

According to this embodiment, the following effects can be obtained.
The front end portions 51A and 52A of the caulking portion 50 are inserted until they penetrate the terminal insertion hole 25, and the front end portions 51A and 52A are caulked to the hole edge 25A of the terminal insertion hole 25. Here, when the front end portions 51A and 52A of the caulking portion 50 are caulked to the hole edge 25A of the terminal insertion hole 25, the hole edge 25A of the front end portions 51A and 52A of the caulking portion 50 is not caulked by a strong force. The portion in contact with the terminal is rubbed against the edge portion of the hole edge 25A of the terminal insertion hole 25, and the insulating film such as an oxide film or a hydroxide film of the single core wire 21 is broken. Thereby, even if it does not crimp by strong force, the favorable electrical connection state is obtained between the single core wire 21 and the terminal metal fitting 30.

  Moreover, since it is not necessary to press-fit with strong force, the extension by the one part of the terminal metal fitting 30 being strongly crushed does not arise, and the extension as the terminal metal fitting 30 whole can be suppressed.

Further, the caulking portion 50 protrudes in opposite directions by punching a metal plate material of a predetermined thickness, and a pair of male terminals 51 and 52 that are long in the axial direction of the single core wire 21 are both bent toward the single core wire 21 side. Is formed.
In this way, the male terminals 51 and 52 can be easily formed by punching. Moreover, since the male terminals 51 and 52 are long in the axial direction of the single core wire 21, the length of the male terminals 51 and 52 can be freely set compared with the case where it is long in the width direction.

  Furthermore, in addition to the caulking part 50, since the insulation barrel part 41 having a pair of caulking pieces 41 </ b> A and 41 </ b> A for holding the covered electric wire 20 from the insulating coating 22 of the covered electric wire 20 (electric wire) is provided, the caulking part 50 Rather than holding the covered electric wire 20 only by connection with the single core wire 21, the covered electric wire 20 can be reliably held.

<Embodiment 2>
Next, the electric wire 110 with a terminal metal fitting of Embodiment 2 of this invention is demonstrated with reference to FIGS. In addition, about the structure same as Embodiment 1, the same code | symbol is attached | subjected and description is abbreviate | omitted.
In the first embodiment, the caulking portion 50 includes a pair of male terminals 51 and 52. However, the caulking portion 150 of the second embodiment has a cylindrical shape as shown in FIGS. is there. Therefore, the terminal insertion hole 125 of the covered electric wire 20 has a circular shape (FIG. 13).

More specifically, as shown in FIG. 11, a caulking portion 150 protruding upward is integrally provided on the bottom plate portion 35 of the second embodiment.
In the caulking portion 150, a cylindrical tubular terminal portion 151 rising from the bottom plate portion 35 is inserted into the terminal insertion hole 125, and a distal end portion 151A penetrating the terminal insertion hole 125 is caulked to a hole edge 125A of the terminal insertion hole 125. As a result, the distal end portion 151A is locked to the hole edge 125A in a state of being warped over the entire circumference.
Prior to caulking of the caulking portion 150, as shown in FIG. 14, the distal end portion 151A of the cylindrical terminal portion 151 of the terminal fitting 130 is not warped, and is entirely cylindrical.

Next, the manufacturing method of the electric wire with a terminal metal fitting is demonstrated.
As shown in FIG. 15, the crimped portion 150 is disposed in the terminal insertion hole 125 from the position where the covered wire 20 is above the terminal fitting 30 and the flat portion 23 is parallel to the bottom plate portion 35. The flat portion 23 of the covered electric wire 20 is placed on the upper surface of the bottom plate portion 35 (see FIG. 16).

  Then, as shown in FIG. 17, for example, in the state where the vicinity of the caulking portion 150 of the bottom plate portion 35 of the terminal fitting 30 is placed on the base 70, the tapered inclined surface 181 is provided over the entire circumference. Are inserted into the cylindrical shape of the cylindrical terminal portion 151 from the top of the mountain of the crimping jig 180 having Then, press down with a strong force. At this time, as the distal end portion 151A of the cylindrical terminal portion 151 is pushed and deformed by the inclined surface 181, a portion of the cylindrical terminal portion 151 that contacts the hole edge 125A of the terminal insertion hole 125 is in contact with the hole edge 125A. The (tip portion 151A) is gradually caulked while being rubbed against the edge portion of the hole edge 125A. And as shown in FIG. 11, the front-end | tip part 151A of the cylindrical terminal part 151 is crimped to the hole edge 125A of the terminal insertion hole 125 over the perimeter, and manufacture of an electric wire with a terminal metal fitting is complete | finished.

According to this embodiment, the following effects can be obtained.
The leading end portion 151A of the caulking portion 150 is inserted until it penetrates the terminal insertion hole 125, and the leading end portion 151A is caulked to the hole edge 125A of the terminal insertion hole 125. Here, when the front end portion 151 of the caulking portion 150 is caulked to the hole edge 25A of the terminal insertion hole 25, the portion of the front end portion 151A of the caulking portion 150 that contacts the hole edge 125A is not caulked by a strong force. By rubbing against the edge portion of the hole edge 125A of the terminal insertion hole 125, an insulating film such as an oxide film or a hydroxide film of the single core wire 21 is broken. Thereby, even if it does not crimp by strong force, the favorable electrical connection state is obtained between the single core wire 21 and the terminal metal fitting 130.

  Moreover, since it is not necessary to press-fit with strong force, the extension by the one part of the terminal metal fitting 30 being strongly crushed does not arise, and the extension as the terminal metal fitting 30 whole can be suppressed.

  Furthermore, in addition to the caulking portion 150, the insulation barrel portion 41 having a pair of caulking pieces 41A and 41A for holding the electric wire from above the insulating coating of the electric wire is provided, so that only the caulking portion 150 and the single core wire 21 are connected. The electric wire can be securely held rather than holding the electric wire.

<Other embodiments>
The present invention is not limited to the embodiments described with reference to the above description and drawings. For example, the following embodiments are also included in the technical scope of the present invention.
(1) In the above embodiment, the covered electric wire 20 is held by the insulation barrel portion 41 in addition to the caulking portions 50 and 150, but the covered electric wire 20 may be held only by the caulking portion 50.

  (2) Although the single core wire 21 is made of aluminum, a single core wire 21 made of an aluminum alloy or other types may be used. However, in the case of using a single core wire of aluminum or aluminum alloy, in general, it must be caulked with a strong force to break the oxide film or the like. However, according to the configuration of the present invention, the oxide film is not caulked with a strong force. Etc. are suitable because they can be broken.

The figure which represented a part of electric wire with a terminal metal fitting concerning Embodiment 1 in the side section Top view of wires with terminal fittings Top view of the end of the covered wire The figure explaining the molding method of a flat part The figure which shows the state by which the flat part was shape | molded by the metal mold | die Top view of terminal fitting Diagram showing the shape of the male terminal before bending The figure explaining the manufacturing method of the electric wire with a terminal metal fitting The figure which shows the state in which the male terminal was inserted in the terminal insertion hole Diagram explaining the caulking method The figure which represented a part of electric wire with a terminal metal fitting concerning Embodiment 2 by the side section Top view of wires with terminal fittings Top view of the end of the covered wire Top view of terminal fitting The figure explaining the manufacturing method of the electric wire with a terminal metal fitting The figure which shows the state by which the cylindrical terminal part was inserted in the terminal insertion hole Diagram explaining the caulking method

Explanation of symbols

DESCRIPTION OF SYMBOLS 10,110 ... Electric wire with a terminal metal fitting 20 ... Coated electric wire 21 ... Single core wire 22 ... Insulation coating 23 ... Flat part 25, 125 ... Terminal insertion hole 25A, 125A ... Hole edge 30,130 ... Terminal metal fitting 31 ... Connection part 35 ... Bottom plate Part 41 ... Insulation barrel part 41A ... Caulking piece 50, 150 ... Caulking part 51, 52 ... Male terminal 51A, 52A, 151A ... Tip part 151 ... Cylindrical terminal part

Claims (6)

An electric wire having a single core wire and having a terminal insertion hole formed through the terminal portion of the single core wire;
It consists of a terminal fitting crimped to the single core wire of this wire,
The terminal fitting is
A connection part electrically connected to the counterpart terminal;
A bottom plate portion extending from the connecting portion and on which the terminal portion of the single core wire is placed;
An electric wire with a terminal fitting, comprising: a tip portion protruding from the bottom plate portion penetrating the terminal insertion hole, and a tip portion that is caulked to a hole edge of the terminal insertion hole. The caulking portion is formed by punching a metal plate having a predetermined thickness and projecting in opposite directions, and a pair of male terminals that are long in the axial direction of the single core wire are bent toward the single core wire. The electric wire with a terminal metal fitting according to claim 1. The terminal fitting according to claim 1 or 2, further comprising an insulation barrel portion having a pair of caulking pieces for holding the electric wire from above the insulating coating of the electric wire in addition to the caulking portion. Electrical wire. A connection part electrically connected to the counterpart terminal;
A bottom plate portion on which a terminal portion of an electric wire extending from the connection portion and having a single core wire is placed;
A tip portion protruding from the bottom plate portion is capable of penetrating a terminal insertion hole formed through the single core wire of the terminal portion, and a caulking portion that is crimped to a hole edge of the terminal insertion hole; A terminal fitting comprising: The caulking portions protrude in opposite directions by punching a metal plate material having a predetermined thickness, and a pair of male terminals that are long in the axial direction of the single core wire are both bent toward the side where the single core wire is disposed. The terminal fitting according to claim 4, wherein the terminal fitting is formed. The terminal fitting according to claim 4 or 5, further comprising an insulation barrel portion having a pair of caulking pieces for holding the electric wire from above the insulating coating of the electric wire in addition to the caulking portion.

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