JP5657179B1 - Connection structure, connector, method for manufacturing connection structure, electric wire connection structure, and tubular terminal - Google Patents

Abstract

An object of the present invention is to provide a connection structure, a connector, and a method of manufacturing the connection structure that can reliably prevent moisture from entering from the insulating coating side. A sheathing part 131 for crimping the outer periphery of an aluminum core wire 201 in the vicinity of the distal end of the insulating coating 202 in a coated electric wire 200 coated with an insulating insulating coating 202, and covering from the distal end of the insulating coating 202 Barrel portion in crimp terminal 100 having a barrel section 130 having a hollow cross section integrally formed with a conductor crimping portion 132 that crimps and crimps an aluminum core wire 201 exposed for a predetermined length in the longitudinal direction X of the electric wire 200. 130 is a connection structure 1 in which the covered electric wire 200 and the crimp terminal 100 are connected to each other, and an adhesive 134 is interposed between the covered surrounding portion 131 and the insulating coating 202 in the covered electric wire 200. To do.

Description

The present invention is, for example, a connection structure, a connector, and a method for manufacturing the connection structure as used for a connector of an automobile wire harness,
In addition, the present invention relates to a wire connection structure and a wire.

An electrical equipment equipped in an automobile or the like constitutes an electrical circuit by being connected to another electrical equipment or a power supply device via a wire harness in which covered electric wires are bundled. At this time, the wire harness and the electrical equipment and the power supply device are connected to each other by connectors attached thereto.
These connectors have a configuration in which a crimp terminal connected by crimping to a covered electric wire is mounted inside, and a female connector and a male connector that are connected corresponding to the unevenness are fitted.

  By the way, since such a connector is used in various environments, unintended moisture may adhere to the surface of the covered electric wire due to dew condensation due to a change in ambient temperature. And when moisture penetrates into the connector through the surface of the covered electric wire, there is a problem that the surface of the electric wire conductor exposed from the tip of the covered electric wire is corroded.

Accordingly, various techniques for preventing moisture from entering the wire conductor crimped by the crimp terminal have been proposed.
For example, the crimp terminal described in Patent Document 1 is a crimp terminal including a conductor crimping portion that crimps a conductor of an electric wire, and a wire connection portion that is configured by a covering enclosure portion that surrounds an insulating coating of the electric wire. Serrations are provided in a direction intersecting the longitudinal direction of the electric wire, and the boundary between the covering surrounding portion and the insulating coating is made uneven. As a result, the crimp terminal disclosed in Patent Document 1 complicates the moisture intrusion path and prevents moisture from entering from the insulating coating side.

  However, the crimp terminal as in Patent Document 1 has a configuration in which a serration having a concave shape is simply provided on the covering surrounding portion. Therefore, if the covering surrounding portion is not securely crimped, the water stoppage due to the serration is more reliably ensured. There is a problem that you can not.

JP2011-216253A

  In view of the above problems, the present invention provides a connection structure, a connector, and a method for manufacturing a connection structure that can reliably prevent moisture from entering from the insulating coating side and can improve durability against thermal cycling. The purpose is to provide.

According to the present invention, there is provided a covering surrounding portion surrounding a vicinity of a tip of the insulating coating in a coated electric wire in which an outer periphery of a wire conductor formed by bundling a plurality of strands is covered with an insulating insulating coating, and a tip of the insulating coating The wire connection portion in the crimp terminal including a wire connection portion having a hollow cross-section formed integrally with a conductor crimp portion that crimps and crimps the wire conductor exposed for a predetermined length in the longitudinal direction of the covered wire A liquid adhesive having a viscosity that does not permeate between the plurality of strands in the vicinity of the tip of the insulating coating in the covered electric wire, wherein the covered electric wire is connected to the crimp terminal. Is applied in advance, and at least the wire conductor is crimped and connected to the conductor crimping portion, and the vicinity of the tip of the insulating coating is adhesively connected to the sheathing surrounding portion, so Wherein between the insulating coating, characterized in that by interposing the liquid adhesive in.

The crimp terminal is a closed barrel type terminal having an electric wire connection part having a hollow cross section, and a connection terminal having a connection part that allows connection with the connection part of the other terminal of the pair of terminals, or electric wire connection Including a terminal composed of only a portion.
The liquid adhesive is not limited to an organic resin material such as a synthetic resin or rubber, and can be an adhesive composed of an inorganic resin material.

According to this invention, it is possible to reliably prevent moisture from entering from the insulating coating side.
Specifically, the liquid adhesive adheres between the coated enclosure portion and the insulation coating of the coated electric wire, so that moisture enters the inside of the coated enclosure portion from the end portion on the insulation coating side of the crimp terminal. It can be prevented. In particular, by using a liquid adhesive, it is possible to reliably close the gap between the covered enclosure portion and the insulating coating in the covered electric wire over a long period of time, thus preventing water from entering from the insulating coating side more reliably. In addition, the durability against thermal cycling can be improved.

  Furthermore, after applying the liquid adhesive to the insulation coating in the covered electric wire, the liquid adhesive can be interposed between the covered enclosure portion and the insulation coating in the covered electric wire simply by inserting the covered electric wire into the electric wire connecting portion. . For this reason, compared with the structure which apply | coats a liquid adhesive to a covering surrounding part, or the structure which inject | pours a liquid adhesive between a covering surrounding part and the insulation coating in a covering electric wire, the insulation covering in a covering surrounding part and a covering electric wire A liquid adhesive can be easily interposed between the two.

Further, the electric wire conductor, thereby constituting bundled strands of a plurality of, more of the liquid adhesive, to the construction and child having a viscosity that will not penetrate between the plurality of wires, liquid adhesive When the agent permeates between a plurality of strands, it is possible to prevent an adverse effect such as a decrease in conductivity of the wire conductor formed by bundling the strands.

  As an aspect of the present invention, the liquid adhesive can be formed of a curable synthetic resin material and cured in a state of being interposed between the covering surrounding portion and the insulating coating.

  According to this invention, since the liquid adhesive is formed of a curable synthetic resin material, it can be easily and reliably cured by various external factors such as heat, ultraviolet rays, and moisture. .

  In addition, for example, when the liquid adhesive is cured by heat curing, ultraviolet curing, or moisture curing, the liquid adhesive does not unexpectedly soften due to external factors such as heat, ultraviolet radiation, or moisture. It can prevent that the water-stopping property of a body falls.

  Therefore, the connection structure can ensure a stable water-stopping property over a long period even under a severe use environment such as an automobile.

  Furthermore, by forming the liquid adhesive with a curable synthetic resin material, the connection structure can be applied to the end portion on the insulating coating side of the wire connection portion when an external force due to vibration or the like is applied to the covered wire. It is possible to prevent the covered electric wire from being excessively bent.

  For this reason, the connection structure prevents the insulating coating from coming into contact with the end of the electric wire connecting portion and is damaged, and a liquid adhesive interposed between the covering surrounding portion and the insulating coating is provided. It can prevent peeling easily.

  Accordingly, the connection structure is provided with a liquid adhesive formed of a curable synthetic resin material, thereby preventing a decrease in water stoppage due to external factors such as moisture, temperature fluctuation, vibration, and aging of the insulation coating. It is possible to ensure stable water-stopping and electrical conductivity over a longer period of time.

  Here, the synthetic resin material is, for example, a resin that is cured by a chemical reaction induced by an external factor such as heat, ultraviolet light, or external force, or by a chemical reaction with an external factor such as a curing agent or moisture ( (Chemically reactive curable resin).

  Examples of the chemically reactive curable resin include a thermosetting resin, a thermoplastic resin, an ultraviolet (UV) curable resin, a curing agent mixed resin, a moisture curable resin, an anaerobic curable resin, or an additive that is cured by pressure. A pressure curable resin can be mentioned.

  Specifically, examples of the thermosetting resin include phenol resin, epoxy resin, melamine resin, urea resin (urea resin), unsaturated polyester resin, alkyd resin, polyurethane, and thermosetting polyimide.

  Examples of the thermoplastic resin include polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyvinyl acetate, ABS resin (acrylonitrile butadiene styrene resin), AS resin, and acrylic resin (PMMA).

  Examples of the ultraviolet (UV) curable resin include a radical type mainly composed of acrylate and unsaturated polyester, and a cation type mainly composed of epoxy, oxetane and vinyl ether.

For example, in the case of a UV curable silicone resin as a radical type, a polyfunctional silicone oligomer which is a main component contains a photopolymerization initiator. Is in an excited state to generate radicals for polymerizing the silicone oligomer.
Examples of the curing agent mixed resin include a resin that cures by mixing two liquids of the present agent such as an epoxy resin and a curing agent.

  The moisture curable resin is a resin that is cured by reacting with moisture in the air in the presence of a catalyst, and examples thereof include a moisture curable silicone resin and a moisture curable urethane-based adhesive resin.

  The anaerobic curable resin is a resin that cures when air is blocked at the metal portion, and examples thereof include an acrylate type (acrylic resin type).

Further, as an aspect of the present invention, the liquid adhesive may be provided in a step between the end face of the covering surrounding portion and the outer peripheral surface of the insulating coating in the covered electric wire.
The step between the end face of the covered surrounding portion and the outer peripheral surface of the insulating coating in the covered electric wire constitutes an inlet of the covered electric wire with respect to the electric wire connecting portion, and the covered electric wire is inserted into the inlet, By crimping the crimp terminal, it means a step formed over the entire circumference of the end surface of the covered enclosure portion between the end surface of the covered enclosure portion and the outer peripheral surface of the insulating coating in the covered electric wire. The configuration provided for the above-described step means that the coating is applied so as to straddle the end surface of the covering surrounding portion that forms the step and the outer peripheral surface of the insulating coating.

  However, the liquid adhesive is not limited to the step between the end face of the covering surrounding portion and the outer peripheral surface of the insulating coating in the covered electric wire, the entire outer periphery of the electric wire connecting portion, the distal end side in the longitudinal direction of the electric wire connecting portion, etc. In the connection portion between the electric wire connecting portion and the insulating coating, at least a step between the end surface of the covering surrounding portion and the outer peripheral surface of the insulating coating can be provided.

  According to the present invention, at the entrance of the covered electric wire to the wire connecting portion, the intrusion of moisture can be prevented by the liquid adhesive applied over the entire circumference of the end face of the covered enclosure portion. Can be prevented more reliably.

Moreover, as an aspect of the present invention, the liquid adhesive provided in the step can be applied so as to straddle the outer peripheral surface on the end portion side of the covering surrounding portion.
According to the above-described configuration, it is possible to reliably ensure water-stopping between the covering surrounding portion and the insulating coating.

  Specifically, with the above-described configuration, the outer periphery of the insulating coating from the outer peripheral surface on the end side of the coated surrounding portion in the vicinity of a step between the end surface of the coated surrounding portion and the outer peripheral surface of the insulating coating in the coated electric wire. Since the liquid adhesive can be formed continuously over the surface, the liquid adhesive can be brought into close contact with at least the outer peripheral surface on the end side of the covering surrounding portion and the outer peripheral surface of the insulating coating.

  For this reason, for example, when the wire connection portion and the insulating coating are connected by pressure bonding, moisture may be temporarily formed between the covering surrounding portion and the insulating coating due to a change in the inner and outer diameters of the covering surrounding portion, a change in the outer diameter of the insulating coating, or the like. Even if the intrusion path is formed, it is possible to prevent the intrusion of moisture from the end side of the covering surrounding portion by the liquid adhesive.

  Furthermore, for example, when the covered electric wire is bent due to the wiring state of the covered electric wire or due to vibration, the adhesion between the covered surrounding portion and the insulating coating is lowered, and a gap is generated between the electric wire connecting portion and the insulating coating. Even in such a case, the liquid adhesive provided in the step can prevent moisture from entering the inside of the covering surrounding portion from the end side of the covering surrounding portion.

  Thereby, since the connection structure can ensure the stable water stop for a long period of time, it can ensure the stable electroconductivity.

  Furthermore, for example, when the connection structure is exposed to the outside air for a long period of time, corrosion of the wire connection portion or deterioration of the insulation coating may occur at the connection portion between the wire connection portion and the insulation coating. For this reason, there exists a possibility that a clearance gap may arise between an electric wire connection part and insulation coating, and water stop may fall.

  On the other hand, by interposing the liquid adhesive over the entire circumference of the covered electric wire, the connection structure has the covering surrounding portion and the insulating covering at the boundary portion between the insulating covering and the end portion of the covering surrounding portion. Can be prevented from coming into direct contact with outside air.

  For this reason, the connection structure is formed in the boundary between the insulating coating and the end of the covering enclosure, and the covering enclosure and the insulating coating are exposed to the outside air over a long period of time. Can be prevented by a liquid adhesive. Thereby, the connection structure can ensure the stable water stop and electroconductivity over a long period of time.

  As an aspect of the present invention, the liquid adhesive can be interposed over the entire circumference of the covered electric wire.

As described above, the water-stopping property can be improved by interposing a liquid adhesive between the covering surrounding portion and the insulating coating over the entire circumference of the covered electric wire.
In particular, by interposing the liquid adhesive over the entire circumference of the coated electric wire, the connection structure can be connected to the end of the coated enclosure portion without crimping the coated enclosure portion against the insulation coating. It is possible to reliably prevent moisture from entering from the part side.

  Therefore, the connection structure can easily improve the water-stopping property between the covering surrounding portion and the insulating coating, and can secure more stable conductivity.

In addition, as an aspect of the present invention, the liquid adhesive is configured in a capsule shape encapsulated in a capsule, and the capsule in the coated surrounding portion and the coated electric wire are subjected to crushing when the coated surrounding portion is crimped. It can be comprised with the capsule-like adhesive agent which adhere | attaches an insulation coating.
The capsule adhesive can be composed of microcapsules in which an adhesive component is encapsulated.

According to this invention, when the coated surrounding portion is crimped, the capsule adhesive capsule is simultaneously disposed in the coated surrounding portion, and the capsule is crushed to bond the coated surrounding portion and the insulating coating on the covered electric wire. be able to. For this reason, the adhesive component of the capsule adhesive does not leak out of the capsule before the covering surrounding portion is crimped, and the adhesive component is prevented from adhering to an unexpected part such as a wire conductor. be able to.
Furthermore, since the capsule of the capsule adhesive can be crushed at the same time when the covering surrounding portion is pressure-bonded, the working efficiency can be improved.

  Moreover, as an aspect of the present invention, the conductor crimping portion can be provided with a sealing portion that extends toward the distal end in the longitudinal direction and seals the distal end in the longitudinal direction.

  According to the configuration described above, the crimp terminal can prevent moisture from entering the inside of the conductor crimping portion from the opening in the longitudinal direction of the conductor crimping portion (conductor exposed portion side). Furthermore, the connection structure can make the inside of the conductor crimping part in a crimped state hermetically sealed by the above-mentioned liquid adhesive provided between the sealing part and the covering surrounding part and the insulating coating.

  Therefore, the connection structure can secure a reliable water stop and secure more stable conductivity by sealing the inside of the conductor crimping portion in the crimped state.

As an aspect of the present invention, the electric wire conductor can be made of an aluminum material, and at least the electric wire connection portion can be made of a copper material.
According to the present invention, it is possible to reduce the weight as compared with a covered electric wire having a wire conductor made of copper wire, and it is possible to prevent so-called dissimilar metal corrosion (hereinafter referred to as electric corrosion) due to the above-described reliable water stoppage.

  Specifically, when the copper-based material conventionally used for the wire conductor of the covered wire is replaced with an aluminum-based material such as aluminum or aluminum alloy, and the wire conductor made of the aluminum-based material is crimped to the crimp terminal, The phenomenon that the base metal is corroded by contact with a noble metal such as tin plating, gold plating, or copper alloy of the terminal material, that is, electrolytic corrosion becomes a problem.

Electrocorrosion is a phenomenon in which when a moisture adheres to a site where a noble metal and a base metal are in contact, a corrosion current is generated, and the base metal is corroded, dissolved, or lost. Due to this phenomenon, the conductor portion made of an aluminum-based material that is crimped to the wire connection portion of the crimp terminal is corroded, dissolved, or lost, and eventually the electrical resistance increases. As a result, there is a problem that a sufficient conductive function cannot be achieved.
However, so-called galvanic corrosion can be prevented by reducing the weight as compared with the covered electric wire having a conductor portion made of a copper-based material due to the above-described reliable water-stopping property.

In addition, the present invention is a connector in which the crimp terminal in the connection structure described above is disposed in a connector housing.
According to this invention, the crimp terminal can be connected while ensuring stable conductivity.

Specifically, for example, when the female connector and the male connector are fitted to each other and the crimp terminals arranged in the connector housing of each connector are connected to each other, the crimping of each connector is ensured while ensuring water-tightness. The terminals can be connected to each other.
Therefore, the connector can ensure a connection state with reliable conductivity.

Further, the present invention provides a covering surrounding portion that surrounds the vicinity of the end of the insulating coating in a covered electric wire in which the outer periphery of the wire conductor is covered with an insulating insulating coating, and a predetermined length in the longitudinal direction of the covered electric wire from the tip of the insulating coating. The covered electric wire and the crimp terminal are formed by the wire connection portion in the crimp terminal having a hollow cross-section electric wire connection portion configured by crimping by crimping the wire conductor exposed to the length of the wire. A connection structure for crimping and connecting a liquid adhesive to the vicinity of the tip of the insulating coating, exposing the wire conductor from the tip of the insulating coating, and connecting the coated wire to the crimp terminal. After inserting the liquid adhesive between the covering surrounding portion and the insulating coating in the coated electric wire, at least the conductor crimping portion with respect to the electric wire conductor With crimped, said insulating coating adhered connected to the covering surrounding portion, and wherein the crimping connecting the crimp terminal and the covered electric wire by the liquid adhesive.

  The liquid adhesive can be applied in a predetermined range in the longitudinal direction of the covered electric wire from the tip of the insulating coating in the covered electric wire before exposing the electric wire conductor.
  The predetermined range may be greater than or equal to the range where the wire conductor is exposed and less than or equal to the range where the crimp terminal is crimped.

According to this invention, it is possible to reliably prevent moisture from entering from the insulating coating side.
Specifically, when the coated electric wire and the crimp terminal are connected by crimping, the covering enclosure portion and the insulating coating in the coated electric wire can be securely bonded. By adhering the liquid adhesive between the coated surrounding portion and the insulating coating of the coated electric wire, it is possible to prevent moisture from entering the inside of the coated surrounding portion from the end portion on the insulating coating side of the crimp terminal. In particular, by using a liquid adhesive, it is possible to reliably close the gap between the covered enclosure portion and the insulating coating in the covered electric wire over a long period of time, thus preventing water from entering from the insulating coating side more reliably. be able to.

  Furthermore, before inserting the tip of the covered wire into the inside of the wire connecting portion, by applying a liquid adhesive to the outer peripheral surface of the insulating coating, the inner peripheral surface of the covered surrounding portion and the insulating coating Compared with the case where the tip of the covered electric wire is inserted between the outer peripheral surface and the outer peripheral surface, the liquid adhesive is smoothly applied between the inner peripheral surface of the covering surrounding portion and the outer peripheral surface of the insulating coating. In addition, it is possible to intervene without any spots.

  In addition, after applying the liquid adhesive to the insulating coating in the covered electric wire, the wire conductor is exposed from the tip of the insulating coating, and the covered electric wire and the crimp terminal are connected by crimping. According to the present invention, after the liquid adhesive is applied to the insulating coating in the coated electric wire, the portion of the insulating coating from which the electric wire conductor is exposed can be removed together with the liquid adhesive by exposing the electric wire conductor from the tip of the insulating coating. it can. For this reason, a liquid adhesive agent can be interposed between the coating | coated surrounding part to the front-end | tip of the insulation coating which remained in the covered electric wire, ie, the boundary of the exposed wire conductor and insulation coating.

  Therefore, in the insulating coating, the liquid adhesive can be applied over a wide range within a necessary range, so that the adhesive force is improved and the invasion of moisture from the insulating coating side can be more reliably prevented.
  Furthermore, the liquid adhesive can be easily removed at the portion where the electric wire conductor is exposed, and the liquid adhesive can be prevented from adhering to the electric wire conductor, so that stable conductivity can be ensured.

  In addition, as an aspect of the present invention, the liquid adhesive is spaced from the inner peripheral surface of the covered surrounding portion and the outer peripheral surface of the covered electric wire in a state where the tip of the covered electric wire is inserted into the covered surrounding portion. The tip of the covered electric wire can be applied to the outer peripheral surface of the covered electric wire before being inserted into the covered surrounding portion so as to be thicker.

  According to the above-described configuration, the liquid adhesive is applied to the outer peripheral surface of the covered electric wire so as to be thicker than the distance between the inner peripheral surface of the covered surrounding portion and the outer peripheral surface of the covered electric wire. The liquid adhesive applied to the outer peripheral surface of the covered electric wire is surely spread between the inner peripheral surface of the covered electric wire and the outer peripheral surface of the covered electric wire when the tip is inserted into the inner portion of the covered electric wire. Can be made. Furthermore, when inserting the end of the covered electric wire into the inside of the covered surrounding portion, a part of the liquid adhesive comes into contact with the end surface of the covered surrounding portion, so that a sufficient amount of liquid adhesive is removed from the end of the covered surrounding portion. Therefore, the gap between the inner peripheral surface of the covered enclosure portion and the outer peripheral surface of the covered electric wire can be reliably closed.

  Here, the liquid adhesive is thicker than the interval between the inner peripheral surface of the covered surrounding portion and the outer peripheral surface of the covered electric wire in a state where the tip of the covered electric wire is inserted into the inner portion of the covered surrounding portion. After applying to the outer peripheral surface of the covered electric wire, the tip of the covered electric wire is inserted into the inside of the electric wire connecting portion, and in this state, the crimped connection between the covered electric wire and the crimp terminal is performed on the electric wire conductor. On the other hand, only the conductor crimping portion may be crimped and crimped, and in addition to crimping the conductor crimping portion against the wire conductor, the sheathing surrounding portion may also be crimped against the insulating coating. May be crimped.

  In particular, the liquid adhesive is preferably provided over the entire circumference of the covered wire between the covered surrounding portion and the covered electric wire when the covered surrounding portion is not crimped to the covered electric wire.

  Further, as an aspect of the present invention, the liquid adhesive may be disposed between the inner peripheral surface of the covered surrounding portion and the outer peripheral surface of the covered electric wire in a state where the tip of the covered electric wire is inserted into the covered surrounding portion. When applied to the outer peripheral surface of the covered electric wire so as to be thinner, and when the covered electric wire and the crimp terminal are connected by crimping, the insulation coating in the covered electric wire inserted into the inside of the electric wire connecting portion Thus, the covering surrounding portion can be crimped and crimped.

  According to this invention, since the liquid adhesive can be suppressed to a small application amount, the connection structure can be reduced in weight and the material cost of the liquid adhesive can be reduced.

  Further, as described above, the liquid adhesive is applied to the outer peripheral surface of the covered electric wire so as to be thinner than between the inner peripheral surface of the covered surrounding portion and the outer peripheral surface of the covered electric wire. Also, when crimping and connecting the coated electric wire and the crimp terminal, the outer peripheral surface of the insulating coating and the inner peripheral surface of the coated peripheral portion are crimped by crimping the coated surrounding portion against the insulating coating. The covered electric wire and the crimp terminal can be crimped and connected without any gap in the state where the liquid adhesive is interposed therebetween.

Moreover, as an aspect of this invention, it can be set as the structure apply | coated to the said insulation coating in the said covered electric wire by immersing the front-end | tip part of the said covered electric wire in the said liquid adhesive consisting of a liquid.
The front end portion of the covered electric wire can be in a predetermined range in the longitudinal direction of the covered electric wire from the front end of the insulating coating in the covered electric wire before exposing the electric wire conductor.
The predetermined range may be greater than or equal to the range where the wire conductor is exposed and less than or equal to the range where the crimp terminal is crimped.

According to the present invention, the liquid adhesive can be easily applied to the necessary range of the insulation coating simply by immersing the tip end portion of the covered electric wire in the liquid adhesive made of liquid, thereby improving the work efficiency. Can do.
Furthermore, by dipping the tip of the covered electric wire in a liquid adhesive made of liquid, the liquid adhesive can be applied evenly to the required area of the insulation coating, improving the adhesive force and improving the insulation coating side. It is possible to more reliably prevent moisture from entering.

Further, as an aspect of the present invention, when the wire conductor is exposed from the tip of the insulating coating, the liquid adhesive is applied to the insulating coating in the coated wire, and then the coated wire and the crimp terminal are crimped. It can be set as the structure connected.
According to the present invention, it is possible to prevent an adverse effect such as a decrease in conductivity of an electric wire conductor formed by bundling the strands by allowing the liquid adhesive to permeate between the plurality of strands.

  Further, the present invention is an electric wire connection structure in which an electric wire having a core wire and a conductor insulating layer formed on the outer periphery of the core wire, and a tubular terminal formed by bending the conductor into a tubular shape are pressure-bonded, A portion of the tubular terminal facing the conductor insulating layer is preliminarily coated with a liquid adhesive in a deployed state before bending, and the core wire of the electric wire inserted into the tubular terminal and the conductor insulating layer are provided. On the other hand, the tubular terminal is crimped, and the liquid adhesive is interposed between the conductor insulating layer and the tubular terminal.

In this configuration, the tubular terminal may be made of copper or a copper alloy, and the core wire of the electric wire may be made of aluminum or an aluminum alloy.
Further, the liquid adhesive may be hardened in a joined state, and may be composed of an adhesive having fluidity before hardening.
Further, the tubular terminal has a joint portion where conductors are joined, and the thickness of the conductor in the joint portion is thicker than a portion other than the joint portion, and the liquid adhesive is disposed inside the joint portion. It is good also as a structure.

  Moreover, the said conductor insulating layer is good also as a structure containing the layer comprised by the halogen-free resin composition. Alternatively, the conductor insulating layer may include a layer made of polyvinyl chloride resin.

  Further, the tubular terminal of the present invention is formed by bending a conductor and has a tubular crimping portion to be joined by being crimped together with an electric wire, and the liquid bonding is applied to the crimping portion in a developed state before bending. An agent is applied in advance.

  In this configuration, the liquid adhesive may be arranged in an annular shape along the inner peripheral surface of the press-bonding portion at least in the axial direction of the press-bonding portion. Further, the liquid adhesive may be configured to have flexibility after curing. Further, the liquid adhesive may be made of a thermoplastic material.

  According to the present invention, it is possible to provide a connection structure, a connector, and a method of manufacturing the connection structure that can reliably prevent moisture from entering from the insulating coating side and can improve durability against thermal cycling.

The external appearance perspective view which shows the external appearance from the upper direction in a covered electric wire and a crimp terminal. Explanatory drawing explaining the welding in a barrel part. Explanatory drawing explaining the crimping | compression-bonding process in the AA arrow cross section in FIG. Sectional drawing which shows the cross-sectional shape of a connection structure. The perspective view which shows the connection corresponding state of a female connector and a male connector. Explanatory drawing explaining another cross-sectional shape in a connection structure. Explanatory drawing explaining another cross-sectional shape in a connection structure. Explanatory drawing explaining the structure of a capsule-like adhesive agent. Explanatory drawing of the manufacturing method of the connection structure of 2nd Embodiment A. FIG. Explanatory drawing explaining the crimping | compression-bonding process of 2nd Embodiment A, and a connection structure. Explanatory drawing of the other crimping | compression-bonding process of 2nd Embodiment A, and another connection structure. Explanatory drawing of the manufacturing method of the connection structure of 2nd Embodiment B. FIG. Explanatory drawing explaining the crimping | compression-bonding process of 2nd Embodiment B, and a connection structure. Explanatory drawing of the manufacturing method of the connection structure of 2nd Embodiment C. FIG. Explanatory drawing of the manufacturing method of the connection structure of 2nd Embodiment C. FIG. Explanatory drawing explaining the crimping | compression-bonding process of 2nd Embodiment C, and a connection structure. Explanatory drawing of the other crimping | compression-bonding process of 2nd Embodiment C, and another connection structure. Explanatory drawing explaining the method of apply | coating an adhesive agent to the outer peripheral surface of the insulation coating in a covered electric wire. Explanatory drawing explaining another method of apply | coating an adhesive agent to the outer peripheral surface of the insulation coating in a covered electric wire. Explanatory drawing explaining another cross-sectional shape in a connection structure. It is a perspective view which shows the tubular terminal concerning 3rd Embodiment to which this invention is applied. It is sectional drawing of a tubular terminal, (A) is principal part sectional drawing in a longitudinal direction, (B) is a cross-sectional view in a cylinder part. It is explanatory drawing of the crimping process with respect to a tubular terminal. It is a figure which shows the structure of an electric wire connection structure, (A) is a perspective view, (B) is sectional drawing which shows the longitudinal direction cross section of a tubular crimping part. It is a cross-sectional view which shows the radial direction cross section of a tubular crimping part. It is explanatory drawing which shows the manufacturing method of a tubular terminal. It is explanatory drawing which shows the manufacturing method of a tubular terminal. It is a figure which shows the tubular terminal which concerns on 4th Embodiment. It is a figure which shows the tubular terminal which concerns on 5th Embodiment. It is a perspective view which shows the electric wire connection structure concerning 6th Embodiment. It is principal part sectional drawing of the longitudinal direction of an electric wire connection structure. It is a perspective view which shows the tubular terminal and electric wire before crimping joining.

An embodiment of the present invention will be described below with reference to the drawings.
[First Embodiment]

First, the covered electric wire 200 and the crimp terminal 100 in the present embodiment will be described in detail with reference to FIGS. 1 and 2.
1 shows an external perspective view of the covered electric wire 200 and the crimp terminal 100 from above, and FIG. 2 shows an explanatory view for explaining the welding in the barrel portion 130.

In FIG. 1, an arrow X indicates the longitudinal direction (hereinafter referred to as “longitudinal direction X”), and an arrow Y indicates the width direction (hereinafter referred to as “width direction Y”). Furthermore, in the longitudinal direction X, a box part 110 side (left side in the figure) described later is defined as the front, and a covered electric wire 200 side (right side in the figure) described later with respect to the box part 110 is defined as the rear.
2A shows a schematic perspective view of the bottom surface side of the crimp terminal 100 in which the box portion 110 is in a transmissive state indicated by a two-dot chain line, and FIG. 2B is an enlarged Z portion in FIG. 2A. The figure is shown.

The covered electric wire 200 is configured by covering an aluminum core wire 201 in which aluminum strands 201a are bundled with an insulating coating 202 made of an insulating resin. Specifically, the aluminum core wire 201 is formed by twisting an aluminum alloy wire so that the cross section becomes, for example, 0.75 mm ² . Furthermore, the covered electric wire 200 exposes the aluminum core wire 201 having a predetermined length from the tip of the insulating coating 202.
The covered electric wire 200 may be not only the aluminum core wire 201 that constitutes aluminum or an aluminum alloy, but may also be a copper-based core wire that is constituted by copper or a copper alloy, and the aluminum core wire 201 has a cross section of only 0.75 mm ^2. Not limited to.

  The crimp terminal 100 is a female terminal and has a box portion 110 that allows insertion of a male tab of a male terminal (not shown) from the front to the rear in the longitudinal direction X, and a predetermined length at the rear of the box portion 110. The barrel portion 130 disposed via the transition portion 120 is integrally formed.

  This crimp terminal 100 is formed by punching a copper alloy strip (not shown) such as brass whose surface is tin-plated (Sn-plated) into a planarly expanded terminal shape, and then rearwardly viewing the box portion 110 of the hollow rectangular column body. This is a closed barrel type terminal which is formed by bending a three-dimensional terminal shape including a substantially O-shaped barrel portion 130 and welding the barrel portion 130.

  The box portion 110 is formed by bending one of the side surface portions 112 continuously provided on both side portions in the width direction Y orthogonal to the longitudinal direction X of the bottom surface portion 111 so as to overlap the other end portion. It is composed of a hollow quadrangular prism body that is in a substantially rectangular inverted shape as viewed from above.

  Further, an insertion tab of a male terminal (illustrated) is formed inside the box portion 110 by extending the front side in the longitudinal direction X of the bottom surface portion 111 and bending it toward the rear in the longitudinal direction X. The elastic contact piece 113 (refer FIG. 3) which contacts (omission) is provided.

  The barrel portion 130 is configured integrally with a covering surrounding portion 131 (covering pressure-bonding portion 131) for pressure-bonding the insulating coating 202 and a conductor pressure-bonding portion 132 for pressure-bonding the exposed aluminum core wire 201. The sealing portion 133 is deformed so that the portion is crushed into a substantially flat plate shape.

  As shown in FIG. 2, the barrel portion 130 is formed by rounding the barrel portion 130 in a copper alloy strip punched into a terminal shape to a size that surrounds the outer periphery of the covered electric wire 200, and butting the rounded end portions 130 a to each other. It welds along the welding part W1 of the direction X, and is formed in the back view substantially O type. In other words, the barrel part 130 forms the cross-sectional shape in the width direction Y and the height direction into a closed cross-sectional shape.

Further, as shown in FIG. 2, the sealing portion 133 of the barrel portion 130 forms a planar shape by superposing the front end in the longitudinal direction X of the barrel portion 130 in a planar shape, and is closed in the longitudinal direction. It is welded and sealed along the welding point W2 in the width direction Y at an intermediate position of X.
That is, the barrel part 130 is formed in a substantially cylindrical shape having a front end in the longitudinal direction X and an end part 130 a which are welded and closed, and an opening is provided in the rear in the longitudinal direction X.

  Next, the step of inserting the covered electric wire 200 into the barrel portion 130 of the crimp terminal 100 having such a configuration, crimping the crimp portion by crimping the barrel portion 130, and the connection structure 1 after the crimping are illustrated in FIGS. 3 and 4. Will be described in detail.

3 shows an explanatory view for explaining the crimping process in the cross section taken along the line AA in FIG. 1, and FIG. 4 shows a cross-sectional view of the cross-sectional shape of the connection structure 1.
Further, FIG. 3A shows a cross-sectional view taken along the line AA in FIG. 1, and FIG. 3B shows a process of crimping the crimp terminal 100 into which the covered electric wire 200 is inserted by crimping with the crimp tool 10. FIG.

As shown in FIG. 3A, an adhesive 134 is applied in advance to the covering surrounding part 131 in the barrel part 130 of the crimp terminal 100. The adhesive 134 is made of, for example, an epoxy resin as a thermosetting resin. The adhesive 134 may be applied to the covering surrounding portion 131 when the crimp terminal 100 is manufactured, or may be applied to the covering surrounding portion 131 immediately before the crimping.
The adhesive 134 is preferably applied with a uniform thickness along the inner peripheral surface of the covering surrounding portion 131.

If the adhesive 134 is applied to the inner peripheral surface of the covered surrounding portion 131 so as to correspond to the entire area of the covered electric wire 200 to be crimped, the entire area can be bonded.
However, the present invention is not limited to this, and the adhesive 134 may be applied to the inner peripheral surface of the covering surrounding portion 131 so as to correspond to a region narrower in the longitudinal direction X than the region to be crimped in the covered electric wire 200.

As shown in FIG. 3A, the covered electric wire 200 with the aluminum core wire 201 exposed is inserted into the barrel portion 130 of the crimp terminal 100 described above from the rear. At this time, the exposed aluminum core wire 201 is inserted so as to be disposed in the conductor crimping portion 132 as shown in FIG.
Thereafter, as shown in FIG. 3 (b), the crimping terminal 100 into which the covered electric wire 200 is inserted is crimped so as to be sandwiched by a pair of crimping tools 10 constituted by an anvil and a crimper.

  As shown in FIG. 3B, the one set of crimping tools 10 includes a first crimping die 11 that becomes an anvil and a second crimping die 12 that becomes a crimper. Furthermore, the inner surface shape of the crimping tool 10 is formed in a shape corresponding to the outer surface shape of the covering surrounding portion 131 and the conductor crimping portion 132 after the crimping.

  The connecting structure 1 is formed by crimping the conductor crimping portion 132 and the covering surrounding portion 131 into which the covered electric wire 200 is inserted so as to be sandwiched between the pair of crimping tools 10 and crimping the aluminum core wire 201 and the insulating coating 202. Configure.

  Specifically, as shown in FIG. 4, in the connection structure 1, the conductor crimping part 132 and the aluminum core wire 201 are crimped and connected to be conductive by crimping the conductor crimping part 132 with the crimping tool 10. ing. Furthermore, the covering surrounding part 131 and the insulating coating 202 are crimped and connected by crimping the covering surrounding part 131 with the crimping tool 10.

  Furthermore, after interposing the adhesive 134 between the covering surrounding part 131 and the insulating coating 202 in the covering electric wire 200, the covering surrounding part 131 and the insulating covering 202 are bonded by crimping the covering surrounding part 131. Glue.

  In this way, the connection structure 1 is configured in which the barrel portion 130 of the crimp terminal 100 is crimped and the covered electric wire 200 is crimped and connected, and the electrical conductivity between the aluminum core wire 201 and the crimp terminal 100 is ensured.

Next, a connector in which the connection structure 1 described above is mounted inside the connector housing will be described with reference to FIG.
FIG. 5 is a perspective view of the connection state of the female connector 21 and the male connector 31. In FIG. 5, the male connector 31 is indicated by a two-dot chain line.

  The female connector housing 22 has a plurality of cavities in which the crimp terminal 100 can be mounted along the longitudinal direction X, and is formed in a box shape having a substantially rectangular cross section in the width direction Y and the height direction. ing. A plurality of connection structures 1 composed of the above-described crimp terminals 100 are mounted along the longitudinal direction X with respect to the inside of the female connector housing 22 to constitute a wire harness 20 including the female connector 21. To do.

  Similarly to the female connector housing 22, the male connector housing 32 corresponding to the female connector housing 22 has a plurality of cavities to which crimp terminals can be attached, and is in the width direction Y and the height direction. The cross-sectional shape is a substantially rectangular shape, and the female connector housing 22 is formed so as to be connectable to the female connector housing 22 corresponding to the unevenness.

A wire harness 30 provided with a male connector 31 by mounting the connection structure 1 composed of male crimp terminals (not shown) along the longitudinal direction X to the inside of such a male connector housing 32. Configure.
Then, the wire harness 20 and the wire harness 30 are connected by fitting the female connector 21 and the male connector 31 together.

The manufacturing method of the connection structure 1, the female connector 21, and the connection structure 1 that realizes the above-described configuration can reliably prevent moisture from entering from the insulating coating 202 side, and can also prevent thermal cycle. Durability can be improved.
Specifically, the adhesive 134 adheres between the coated surrounding portion 131 and the insulating coating 202 of the coated electric wire 200, so that the end portion on the insulating coating 202 side of the crimp terminal 100 enters the inside of the coated surrounding portion 131. It is possible to prevent moisture from entering. In particular, by using the adhesive 134, the gap between the covered enclosure 131 and the insulating coating 202 in the covered electric wire 200 can be reliably closed over a long period of time, so that moisture can be prevented from entering from the insulating coating 202 side. While being able to prevent reliably, durability with respect to a heat cycle can be improved.

Further, the female connector 21 is configured by disposing the crimp terminal 100 in the connection structure 1 inside the female connector housing 22, so that the male connector 31 is connected to the crimp terminal 100 disposed in the female connector housing 22. When the crimp terminal is connected, the crimp terminal 100 of the female-side connector 21 can be connected to the male connector 31 while ensuring water-stopping.
Therefore, the female connector 21 can ensure a connection state with reliable conductivity.

  In addition, the core wire of the covered electric wire 200 is made of an aluminum alloy, and the barrel portion 130 is made of a copper alloy, so that the weight can be reduced compared to the covered electric wire 200 having a core wire made of copper wire. Furthermore, the above-described reliable water-stopping property can prevent the occurrence of electrolytic corrosion due to the crimp terminal 100 and the covered electric wire 200 made of different metals.

  In addition, since the adhesive 134 is interposed between the covered surrounding portion 131 and the insulating coating 202 in the covered electric wire 200, the manufacturing method of the connection structure 1 in which the covered electric wire 200 and the crimp terminal 100 are connected by crimping is used. When the covered electric wire 200 and the crimp terminal 100 are crimped and connected, the insulation between the covered enclosure portion 131 and the insulating coating 202 in the covered electric wire 200 can be reliably bonded. For this reason, the penetration | invasion of the water | moisture content from the insulating coating 202 side can be prevented more reliably. Therefore, durability against thermal cycling can be improved.

In the above-described first embodiment, after the adhesive 134 is applied to the covered surrounding portion 131, the covered electric wire 200 is inserted into the barrel portion 130, and the covered electric wire 200 and the crimp terminal 100 are connected by crimping. However, the present invention is not limited to this, and it is also possible to adopt a configuration in which the adhesive 134 is injected between the covered surrounding portion 131 and the insulating coating 202 after the covered electric wire 200 is inserted into the barrel portion 130.
In addition, the crimp terminal 100 and the covered electric wire 200 may be bonded not only between the covered surrounding portion 131 and the insulating coating 202 in the covered electric wire 200 but also in other portions.

  For example, as shown in FIG. 6 showing an explanatory diagram for explaining another cross-sectional shape in the connection structure 1, not only between the sheath portion 131 and the insulating coating 202 in the covered wire 200, but also the conductor crimping portion 132 and the covered wire. The adhesive 134 can also be interposed between the aluminum core wire 201 in 200.

  The adhesive 134 interposed between the conductor crimping portion 132 and the aluminum core wire 201 has a viscosity that does not penetrate between the plurality of aluminum strands 201a in the aluminum core wire 201.

  The adhesive 134 interposed between the covered surrounding portion 131 and the insulating coating 202 in the covered electric wire 200 and the adhesive 134 interposed between the conductor crimping portion 132 and the aluminum core wire 201 in the covered electric wire 200 are the same. Although there may be, it is not limited to this, The adhesive 134 of a different kind may be sufficient.

  Adhesive force is improved by the adhesive 134 being interposed not only between the covering surrounding portion 131 and the insulating coating 202 in the covered electric wire 200 but also between the conductor crimping portion 132 and the aluminum core wire 201 in the covered electric wire 200. Intrusion of moisture from the insulating coating 202 side can be prevented more reliably.

  Furthermore, it is possible to prevent an adverse electrical effect on the aluminum core wire 201 due to the adhesive 134 penetrating between the plurality of aluminum strands 201a, so that stable conductivity can be ensured. .

  Furthermore, after inserting the covered electric wire 200 into the barrel portion 130 and injecting the adhesive 134 between the covering surrounding portion 131 and the insulating coating 202, the adhesive 134 is injected after the conductor crimping portion 132 is crimped. Thus, a decrease in conductivity due to the interposition of the adhesive 134 can be suppressed.

  Further, as shown in FIG. 7 showing an explanatory diagram for explaining another cross-sectional shape in the connection structure 1, not only between the covered surrounding portion 131 and the insulating coating 202 in the covered electric wire 200 but also the end surface of the covered surrounding portion 131. The adhesive 134 can also be applied to the step 135 of the insulated wire 200 with respect to the outer peripheral surface of the insulating coating 202.

An end surface of the barrel portion 130 on the rear side of the covered surrounding portion 131, that is, an end surface opposite to the conductor crimping portion 132 side constitutes an inlet of the covered electric wire 200 to the barrel portion 130.
The covered electric wire 200 and the crimp terminal 100 are brought into close contact with each other by inserting the covered electric wire 200 into the inlet and crimping the covered electric wire 200 and the crimp terminal 100. As a result, a step 135 is formed over the entire circumference of the end surface of the covered surrounding portion 131 between the end surface of the covered surrounding portion 131 and the outer peripheral surface of the insulating coating 202 in the covered electric wire 200.

  As shown in FIG. 7, the adhesive 134 can be applied in a range that does not reach the outer peripheral surface of the covering surrounding part 131 beyond the step 135, but is not limited thereto, and the adhesive 134 exceeds the step 135. Then, it may be configured to apply up to the outer peripheral surface of the covering surrounding portion 131.

  The adhesive 134 interposed between the covering surrounding portion 131 and the insulating coating 202 in the covered electric wire 200 and the adhesive 134 applied to the step 135 may be the same, but are not limited thereto, and are different. A type of adhesive 134 may be used.

By applying an adhesive 134 to the step 135 between the end surface of the covered enclosure portion 131 and the outer peripheral surface of the insulating coating 202 in the covered electric wire 200, the entire end surface of the covered surrounding portion 200 at the inlet of the covered electric wire 200 to the barrel portion 130. The adhesive 134 applied over the periphery can prevent moisture from entering.
Accordingly, it is possible to more reliably prevent moisture from entering from the insulating coating 202 side.

The adhesive 134 is composed of a liquid adhesive component and can be configured to be cured by applying heat after application, but is not limited thereto, and can be composed of an appropriate material.
For example, in FIG. 8 showing an explanatory diagram for explaining the configuration of the capsule adhesive 134K, as shown in FIG. 8A, the adhesive 134 and the capsule adhesive 134K in which the adhesive component 134a is sealed with the capsule 134b are used. You may comprise. In this case, the adhesive 134 can be configured by a microcapsule in which an adhesive component 134a is enclosed.
8A is a perspective view of the capsule adhesive 134K, and FIG. 8B is a perspective view of the capsule 134b of the capsule adhesive 134K in a crushed state.

  The capsule 134b can be formed of a sealed hollow sphere. By encapsulating a liquid adhesive component 134a in the capsule 134b, a capsule-like adhesive 134K is formed, and a plurality of capsule-like adhesives 134K are interposed between the covered surrounding portion 131 and the insulating coating 202 in the covered electric wire 200. Let

When the coated surrounding portion 131 is crimped, the capsule adhesive 134K is compressed between the coated surrounding portion 131 and the insulating coating 202 of the coated electric wire 200, and the capsule 134b is crushed as shown in FIG. As a result, the adhesive component 134a in the capsule 134b leaks out of the capsule 134b.
Thereby, the covering surrounding part 131 and the insulation coating 202 in the covered electric wire 200 can be bonded.

By using the capsule-shaped adhesive 134K, when the coated surrounding portion 131 is pressure-bonded, the capsule 134b of the capsule-shaped adhesive 134K is simultaneously crushed to bond the coated surrounding portion 131 and the insulating coating 202 in the coated electric wire 200. be able to. For this reason, the adhesive component 134a of the capsule-like adhesive 134K does not leak out of the capsule 134b before the covering surrounding portion 131 is pressure-bonded, and the adhesive component 134a is applied to an unexpected part such as the aluminum core wire 201. Adhesion can be prevented.
Furthermore, since the capsule 134b of the capsule adhesive 134K can be crushed simultaneously when the covering surrounding part 131 is crimped, the working efficiency can be improved.
[Second Embodiment A]

Next, a method for manufacturing the connection structure 1 different from the first embodiment will be described with reference to FIGS. 9 and 10.
9 shows an explanatory view for explaining the crimp terminal 100 and the connection structure 1 in the second embodiment A. Specifically, FIG. 9A shows the crimp terminal 100 and the covered electric wire 200 in the longitudinal direction X. A sectional view of the sectional shape is shown, and FIG. 9B is a sectional view taken along line BB in FIG. 9A.

  FIG. 10A is a cross-sectional view showing a state of a crimping process in which crimping is performed by sandwiching the barrel portion 130 of the crimp terminal 100 into which the distal end portion of the covered electric wire 200 is inserted with a pair of crimp tools 10. FIG. 10B is a cross-sectional view of the connection structure 1 configured by crimping the barrel portion 130 of the crimp terminal 100 to the tip portion of the covered electric wire 200.

In the manufacturing method of the connection structure 1 in the second embodiment A, as shown in FIG. 9A, the adhesive 210 is applied to the outer peripheral surface of the insulating coating 202 in the covered electric wire 200 and then crimped to the covered electric wire 200. The point which crimp-connected with the terminal 100 differs from the above-mentioned 1st Embodiment.
In the second embodiment A, the same components as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

  As shown in FIGS. 9A and 9B, the connection structure 1 of the second embodiment A is formed on the entire peripheral surface of the outer peripheral surface of the covering tip portion 202t provided on the tip side of the insulating coating 202 in the covered electric wire 200. The adhesive 210 is applied with a substantially uniform thickness.

  Here, the covered tip portion 202t indicates a portion surrounded by the covered surrounding portion 131 in a state where the tip end of the covered electric wire 200 is inserted into the barrel portion 130.

  In 2nd Embodiment A, when inserting the front-end | tip part of the covered electric wire 200 in the barrel part 130, it coat | covers the adhesive agent 210 so that it may contact with respect to the perimeter of the inner peripheral surface of the barrel part 130 of the crimp terminal 100. It is applied to the outer peripheral surface of the coating tip portion 202t with a thickness equivalent to or slightly thicker than the clearance between the inner peripheral surface of the surrounding portion 131 and the outer peripheral surface of the coating tip portion 202t.

  Specifically, as shown in FIG. 10A, the adhesive 210 is equivalent to a thickness (t) that is half of the difference between the inner diameter (D) of the covering surrounding part 131 and the outer diameter (d) of the covering tip part 202t. Alternatively, it is applied to the outer peripheral surface of the coating tip portion 202t so as to have a slightly thicker thickness.

  In this way, the tip portion of the covered electric wire 200 in a state where the adhesive 210 is applied to the outer peripheral surface of the covered tip portion 202t is inserted into the barrel portion 130, and as shown in FIG. The connection crimping part 132 into which the covered electric wire 200 is inserted and the covering surrounding part 131 are crimped and the aluminum core wire 201 and the insulating coating 202 are crimped to constitute the connection structure 1.

According to the manufacturing method of the connection structure 1 as described above, the adhesive 210 can be easily interposed between the covered surrounding portion 131 and the insulating coating 202 in the covered electric wire 200.
Specifically, after the adhesive 210 is applied to the insulating coating 202 in the coated electric wire 200, the covered electric wire 200 is inserted into the barrel portion 130, and the gap between the coated surrounding portion 131 and the insulating coating 202 in the coated electric wire 200 is reduced. An adhesive 210 can be interposed. For this reason, compared with the structure which apply | coats the adhesive agent 134 to the covering surrounding part 131, or the structure which inject | pours the adhesive agent 134 between the covering surrounding part 131 and the insulation coating 202 in the covered electric wire 200, it covers the covering surrounding part 131 and the covering part 131. An adhesive 210 can be easily interposed between the electric wire 200 and the insulating coating 202.

  In particular, paying attention to the crimping of the insulating coating 202 by the coating surrounding portion 131, the adhesive 210 is applied between the inner peripheral surface of the coating surrounding portion 131 and the outer peripheral surface of the insulating coating 202 by the crimping by the crimping tool 10. It can interpose in the state which improved adhesiveness without the clearance gap over the perimeter of.

  Specifically, the connection structure is often used as an automotive part. In such a case, the temperature fluctuation is severe, and it is likely to be affected by moisture or at least one of drying, vibration, and ultraviolet rays. Often exposed to harsh environments.

  Then, for example, the insulation coating 202 of the covered electric wire 200 in the conventional connection structure is faded due to aging, and in that case, even if it is a hollow closed barrel type with a sealing portion 133 formed at the tip portion. Even in the case of the crimp terminal 100, there is a possibility that a gap is generated between the covering surrounding portion 131 and the covering tip portion 202t.

  On the other hand, as described above, the connection structure 1 of the first embodiment has the adhesive 210 over the entire circumference of the covered electric wire 200 between the covered surrounding portion 131 and the insulating coating 202 in the covered electric wire 200. By interposing, even if the coating tip portion 202t deteriorates over time, the gap between the coating surrounding portion 131 and the coating tip portion 202t can be closed by the adhesive 210, and excellent water stoppage can be ensured. it can.

  Furthermore, the connection structure 1 is an adhesive formed of a curable synthetic resin material even when an external force due to vibration or the like is applied to the covered electric wire or when the covered electric wire is routed so as to be excessively curved. Since the covering tip 202t can be protected by 210, it is possible to prevent a gap from being generated between the covering surrounding portion 131 and the covering tip 202t.

  Therefore, the connection structure 1 includes the adhesive 210 formed of a curable synthetic resin material, thereby preventing a decrease in water stoppage due to external factors such as moisture, temperature fluctuation, vibration, and aging of the insulating coating. It is possible to ensure stable water-stopping and electrical conductivity over a longer period of time, so that the high-quality connection structure 1 can be efficiently manufactured.

  Further, as shown in FIG. 9A, when the distal end portion of the covered electric wire 200 is inserted into the barrel portion 130, it is applied to the base end surface 130X1 in the longitudinal direction X of the barrel portion 130 on the outer peripheral surface of the covered distal end portion 202t. Since the adhesive 210 does not come into contact, the tip end portion of the covered electric wire 200 can be smoothly inserted into the barrel portion 130 with almost no contact resistance with respect to the barrel portion 130.

  As described above, the adhesive 210 is preferably applied with a uniform thickness along the outer peripheral surface of the insulating coating 202. However, when the tip of the coated electric wire 200 is inserted into the barrel portion 130, the coating is performed. In anticipation of the adhesive 210 applied to the outer peripheral surface of the tip end portion 202t coming into contact with the inner peripheral surface of the covering surrounding portion 131, the tip of the coating is applied such that the tip end side is thicker than the base side of the covering tip end portion 202t. You may apply | coat so that the thickness of the adhesive agent 210 may fluctuate in the circumferential direction or the longitudinal direction X of the part 202t. Alternatively, the adhesive 210 may be applied to the outer peripheral surface of the insulating coating 202 at the time of manufacturing the coated electric wire 200, or may be applied to the outer peripheral surface of the insulating coating 202 immediately before crimping.

  If the adhesive 210 is applied to the entire area of the covered electric wire 200 to be crimped, the entire area can be bonded. However, the present invention is not limited to this, and the adhesive 210 may be applied to a region narrower in the longitudinal direction X than the region to be crimped on the covered electric wire 200.

Further, as shown in FIG. 10A, when the tip end portion of the covered electric wire 200 is crimped by the barrel portion 130, the aluminum core wire 201 is crimped by the conductor crimp portion 132, and the sheath tip portion 202t is covered by the sheath portion 131. As another example attached to the second embodiment A, as shown in FIG. 11 (a), the aluminum core wire 201 is not crimped without crimping the covering tip portion 202t and the covering surrounding portion 131. The connection structure 1Pa may be configured as shown in FIG. 11B by performing only the crimping between the conductor crimping part 132 and the conductor crimping part 132.
FIG. 11A is a cross-sectional view showing a state of the crimping process in another example attached to the second embodiment A. FIG.11 (b) is sectional drawing of the connection structure 1Pa in the other Example accompanying 2nd Embodiment A. FIG. FIG.10 (c) is CC sectional view taken on the line of FIG.11 (b).

  As shown in FIG. 11A, the crimping tool 10 is configured with only a portion for crimping the conductor crimping portion 132 without including a portion for crimping the covering surrounding portion 131 in the longitudinal direction X of the connection structure 1. Without using the first crimping die 11A as the anvil and the second crimping die 12A as the crimper as a pair of crimping tools 10A, By crimping only the conductor crimping portion 132, only the crimping of the aluminum core wire 201 and the conductor crimping portion 132 can be performed.

  As described above, the adhesive 210 is interposed between the inner peripheral surface of the covering surrounding portion 131 and the outer peripheral surface of the covering leading end portion 202t without any gap, even without crimping the covering leading end portion 202t and the covering surrounding portion 131. Therefore, it is possible to ensure the water stoppage inside the conductor crimping part 132.

Here, the adhesive 210 that is interposed between the covering surrounding portion 131 and the covering tip portion 202t is not limited to being cured by applying heat from a liquid state, but the type of resin that forms the adhesive 210 Depending on the characteristics, for example, it can be naturally dried from a liquid state, or can be cured by means such as exposure to air to apply moisture, or other means such as irradiation with ultraviolet rays.
[Second Embodiment B]

Next, the manufacturing method of the connection structure 2B in 2nd Embodiment B different from the Example mentioned above is demonstrated using FIG. 12 and FIG.
12A is an explanatory view of the method for manufacturing the connection structure 2B in the second embodiment B showing the insertion step of inserting the tip end portion of the covered electric wire 200 into the barrel portion 130 of the crimp terminal 100. FIG. (B) has shown the BB line expanded sectional view in Fig.12 (a).

  FIG. 13A is a cross-sectional view showing a state of a crimping process in which crimping is performed by sandwiching the barrel portion 130 of the crimping terminal 100 into which the distal end portion of the covered electric wire 200 is inserted with a pair of crimping tools 10. FIG. 13B is a cross-sectional view of the connection structure 2 </ b> B configured by crimping the barrel portion 130 of the crimp terminal 100 to the tip portion of the covered electric wire 200. FIG.13 (c) has shown CC sectional view taken on the line of FIG.13 (b).

  In the connection structure 2B of the second embodiment B, the adhesive 210 is applied to the inner peripheral surface of the covering surrounding portion 131 and the outer peripheral surface of the covering front end portion 202t in a state where the front end portion of the covered electric wire 200 is inserted into the barrel portion 130. It is applied to the outer peripheral surface of the coating tip portion 202t with a thickness that is thinner than the gap.

  Specifically, as shown in FIGS. 12A and 12B, the adhesive 210 has a thickness that is half the difference between the inner diameter (D) of the covering surrounding portion 131 and the outer diameter (d) of the covering tip portion 202t ( It is applied to the outer peripheral surface of the coating tip 202t so as to have a thickness (ts) that is thinner than t).

  As described above, the adhesive 210 is applied to the outer peripheral surface of the coating tip portion 202t so as to have a thickness thinner than the gap between the coating surrounding portion 131 and the coating tip portion 202t, thereby FIG. As shown in FIG. 4, when the tip end portion of the covered electric wire 200 is inserted into the barrel portion 130, the adhesive 210 applied to the outer peripheral surface of the covered tip portion 202t is applied to the inner peripheral surface of the covered surrounding portion 131 or the base end surface of the barrel portion 130. It is possible to smoothly insert the tip end portion of the covered electric wire 200 into the barrel portion 130 without receiving resistance due to contact with 131 × 1.

  However, as shown in FIG. 13A, in the state where the tip end portion of the covered electric wire 200 is inserted into the barrel portion 130, the bonding is performed between the outer peripheral surface of the covered tip portion 202t and the inner peripheral surface of the covering surrounding portion 131. Although the agent 210 can be interposed, a gap where the adhesive 210 does not exist remains.

  However, in the subsequent crimping step, as shown in FIG. 13A, the conductor crimping part 132 and the covering surrounding part 131 are crimped so as to be sandwiched by one set of crimping tools 10, and the aluminum core wire 201 and the insulation By crimping the coating 202, there is no gap between the inner circumferential surface of the coating surrounding portion 131 and the outer circumferential surface of the insulating coating 202 with the adhesive 210 interposed, and there is no gap between the inner circumferential surface of the coating surrounding portion 131 and the insulating coating 202. It is possible to perform pressure bonding in a state where the adhesion with the outer peripheral surface of the material is improved.

  Furthermore, since the adhesive 210 interposed between the inner peripheral surface of the covering surrounding part 131 and the outer peripheral surface of the insulating coating 202 is in a thin state, it can be applied by applying external factors such as heat, moisture, and external force. Can be cured quickly. Thus, by hardening the adhesive 210, the connection structure 2B of the second embodiment B as shown in FIG. 13B can be configured.

According to the connection structure 2B in the second embodiment B, by applying the adhesive 210 to the outer peripheral surface of the insulating coating 202 so as to be thin, the adhesive 210 can be suppressed to a small application amount, and the connection structure The weight of the body 2B can be reduced and the material cost of the adhesive 210 can be reduced.
[Second Embodiment C]

Next, a manufacturing method of the connection structure 2C according to the second embodiment C different from the above-described example will be described with reference to FIGS.
FIG. 14A illustrates a method for manufacturing the connection structure 2C in the second embodiment C, showing a state immediately after the start of insertion in the insertion step of inserting the tip end portion of the covered electric wire 200 into the barrel portion 130 of the crimp terminal 100. FIG. 14B is an enlarged sectional view taken along line BB in FIG. 14A.

  FIG. 15A is an explanatory diagram of a method for manufacturing the connection structure 2C in the second embodiment C, showing a state in the middle of insertion in the insertion step of inserting the tip end portion of the covered electric wire 200 into the barrel portion 130 of the crimp terminal 100. FIG. 15 (b) shows an explanatory view of the manufacturing method of the connection structure 2 </ b> C in the second embodiment C showing the state when the insertion is completed.

  FIG. 16A is a cross-sectional view showing a state of a crimping process in which crimping is performed by sandwiching the barrel portion 130 of the crimp terminal 100 into which the distal end portion of the covered electric wire 200 is inserted with one set of the crimping tool 10. FIG. 16B is a cross-sectional view of the connection structure 2 </ b> C configured by crimping the barrel portion 130 of the crimp terminal 100 against the tip portion of the covered electric wire 200. FIG.16 (c) has shown CC sectional view taken on the line of FIG.16 (b).

  In the connection structure 2C of the second embodiment C, the adhesive 210 is applied between the inner peripheral surface of the covering surrounding portion 131 and the outer peripheral surface of the covering front end portion 202t in a state where the tip portion of the covered electric wire 200 is inserted into the barrel portion 130. It is applied to the outer peripheral surface of the coating tip portion 202t with a thickness that is thicker than the gap.

  Specifically, as shown in FIGS. 14A and 14B, the adhesive 210 has a gap that is half the difference between the inner diameter (D) of the covering surrounding portion 131 and the outer diameter (d) of the covering tip portion 202t ( It is applied to the outer peripheral surface of the coating tip portion 202t so as to be thicker (th) than t). Note that the adhesive 210 is applied to the outer peripheral surface of the coating tip portion 202t with a thickness (th) that is not bulkier than the outer diameter of the coating surrounding portion 131.

  Further, in the connection structure 2C, the adhesive 210 is applied to the outer peripheral surface of the covering tip portion 202t. In addition to the portion surrounded by the insulating covering 202 by the covering surrounding portion 131, the surrounding portion In addition, it is applied to the base portion 130X side in the longitudinal direction X, that is, including the portion corresponding to the peripheral edge of the opening portion of the barrel portion 130, and is bonded to the outer peripheral surface of the covering tip portion 202t in the second embodiments A and 2B. It is applied over a wider range in the longitudinal direction X than the application range of the agent 210.

  As described above, in the connection structure 2C of the second embodiment C, the adhesive 210 is applied to the outer peripheral surface of the coated tip portion 202t in a state where the tip portion of the covered wire 200 is inserted along the central axis of the barrel portion 130. Since the coating is applied so as to be thicker than the inner peripheral surface of the covering surrounding portion 131, the adhesive 210 overlaps the end surface 130 x 1 of the base portion 130 x of the barrel portion 130 along the longitudinal direction X. .

  For this reason, in the insertion step, as shown in FIG. 15A, the adhesive 210 applied to the outer peripheral surface of the coating tip portion 202 t comes into contact with the end surface 130 x 1 of the base portion 130 x of the barrel portion 130.

  For this reason, if the distal end portion of the covered electric wire 200 is further inserted into the barrel portion 130, as shown in FIG. 15A, particularly a partially enlarged view in FIG. 15A, the base portion 130x of the barrel portion 130 is obtained. The thickness of the adhesive 210 is further increased so that the adhesive 210 is scraped off by the end surface 130x1, and the step S between the end surface 130x1 of the base portion 130x of the barrel portion 130 and the outer peripheral surface of the insulating coating 202 in the covered electric wire 200, that is, The adhesive 210 rises at the open end of the barrel portion 130.

  In this state, when the distal end portion of the covered electric wire 200 is continuously inserted into the barrel portion 130, the liquid adhesive 210 is applied to the outer peripheral surface of the insulating coating 202 as the distal end portion of the covered electric wire 200 is inserted. Depending on the thickness of 210, it flows over the end surface 130 x 1 of the base portion 130 x of the barrel portion 130 until it reaches the outer peripheral surface.

  Thereby, in the state where the insertion of the distal end portion of the covered electric wire 200 into the barrel portion 130 is completed, as shown in a partially enlarged view in FIG. The provided adhesive 210 is applied to a portion reaching the outer peripheral surface of the insulating coating 202 so as to straddle the outer peripheral surface of the covering surrounding portion 131 on the base 130x side. In other words, the coating is continuously applied across the outer peripheral surface on the end side of the covering surrounding portion 131 and the outer peripheral surface of the insulating coating 202.

  Subsequently, in the crimping step, as shown in FIG. 16A, the conductor crimping portion 132 and the covering surrounding portion 131 are crimped so as to be sandwiched by one set of crimping tools 10, and the aluminum core wire 201 and the insulating coating 202 are placed. Crimp the.

  Finally, as described above, by applying external factors such as heat, moisture, and external force to the adhesive 210, the resin material 21 is made to adhere to the inner peripheral surface of the coating surrounding portion 131 and the outer periphery of the insulating coating 202. The connection structure 2C of the second embodiment C as shown in FIG. 16B can be configured by curing the portion including the portion interposed between the surfaces.

  Of the adhesive 210 applied to the outer peripheral surface of the insulating coating 202, the portion provided on the step S between the end surface 130 x 1 of the covering surrounding portion 131 and the outer peripheral surface of the insulating coating 202 is the outer periphery of the covering surrounding portion 131 on the base 130 x side. By applying so as to straddle the surface, the water stoppage between the covering surrounding portion 131 and the insulating coating 202 can be reliably ensured.

  With the above-described configuration, for example, when the barrel portion 130 and the insulating coating 202 are crimped and connected, the coating surrounding portion 131 and the insulating coating 202 are temporarily changed due to a change in the inner diameter of the covering surrounding portion 131 or a change in the outer diameter of the insulating coating 202. Even if a moisture intrusion path is formed between them, the adhesive 210 can prevent moisture from entering from the base portion 130x side of the covering surrounding portion 131.

  Furthermore, for example, when the covered electric wire 200 is bent due to the wiring state of the covered electric wire 200 or due to vibration, the adhesion between the covered surrounding portion 131 and the insulating coating 202 is lowered, and the covering surrounding portion 131 and the insulating coating 202 are Even when there is a gap between them, the adhesive 210 provided in the step S can prevent moisture from entering the inside of the covering surrounding portion 131 from the base portion 130x side of the covering surrounding portion 131. .

  Thereby, since the connection structure 3C can ensure stable water-stopping for a long period of time, it can ensure stable conductivity.

  Furthermore, for example, in the conventional connection structure, the barrel portion 130 is corroded or the insulating coating 202 is deteriorated at the connection portion between the barrel portion 130 and the insulating coating 202 by being in contact with the outside air for a long period of time. was there. For this reason, there is a possibility that a gap is generated between the barrel portion 130 and the insulating coating 202 and the water stoppage is lowered.

  In contrast, the connecting structure 3C allows the adhesive 210 to be interposed over the entire circumference of the covered electric wire 200 between the covered surrounding portion 131 and the covered tip portion 202t, and the outer peripheral surface of the covered surrounding portion 131. Since the coating is applied to the step S with respect to the outer peripheral surface of the insulating coating 202 so as to straddle the outer peripheral surface on the base 130x side of the covering surrounding portion 131, the outer peripheral surface of the covering surrounding portion 131 and the outer peripheral surface of the insulating tip portion 202t are outside air. Can be prevented from contacting directly.

  For this reason, the connection structure 3C has a covering surrounding portion 131 formed by the outside of the covering surrounding portion 131 and the insulating covering 202 coming into contact with the outside air for a long time at the boundary portion between the insulating covering 202 and the base portion 130x side of the covering surrounding portion 131. Corrosion and deterioration of the insulating coating 202 can be prevented by the adhesive 210. Thereby, 3 C of connection structures can ensure the stable water stop and electroconductivity over a long period of time.

  Further, as described above, the adhesive 210 applied to the outer peripheral surface of the covered tip portion 202t is inserted into the inner periphery of the covered surrounding portion 131 in a state where the tip portion of the covered electric wire 200 is inserted along the central axis of the barrel portion 130. Since it is applied so as to be thicker than the surface, as is apparent from FIG. 15 (b) showing the insertion completion state, the adhesive has no gap between the covering surrounding portion 131 and the covering front end portion 202t after insertion. 210 may be interposed.

Therefore, as shown in FIG. 17A, as another example attached to the second embodiment C, as in the other example attached to the second embodiment A described above (see FIG. 11A). ), Only the aluminum core wire 201 and the conductor crimping part 132 are crimped without crimping the sheathing tip 202t and the sheathing part 131 to form the connection structure 1Pb as shown in FIG. May be.
FIG. 17A is a cross-sectional view showing a state of the crimping process in another example associated with the second embodiment C, and FIG. 17B is another diagram associated with the second embodiment C. It is sectional drawing of the connection structure 1Pb in an Example. FIG.17 (c) is CC sectional drawing in FIG.17 (b).

  As described above, the connection structure 1Pb allows the adhesive 210 to pass between the covering surrounding part 131 and the covering front end part 202t without any gap between the covering front end part 202t and the covering surrounding part 131. In addition to being able to intervene, it is applied so as to straddle the step S between the outer peripheral surface of the covering surrounding portion 131 and the outer peripheral surface of the insulating coating 202 and the outer peripheral surface of the covering surrounding portion 131 on the base 130x side. The water stop inside the crimping part 132 can be remarkably improved.

The connection structure of the present invention or the manufacturing method thereof is not limited to the above-described embodiments, and can be configured in various embodiments.
For example, in the first embodiment, the second embodiment (2A, 2B, 2C) described above, or the above-described examples accompanying them, a method of applying the adhesive 210 to the outer peripheral surface of the insulating coating 202 in the covered electric wire 200 As shown in FIG. 18, after applying the adhesive 210 to the outer peripheral surface of the insulating coating 202 in the covered electric wire 200, the aluminum core wire 201 is exposed from the tip of the insulating coating 202, as shown in FIG. The crimp terminal 100 may be crimped and connected.

  For example, as shown in FIG. 18, after applying the adhesive 210 to the outer peripheral surface of the insulating coating 202 in the coated electric wire 200, the aluminum core wire 201 is exposed from the tip of the insulating coating 202, and the coated electric wire 200 and the crimp terminal 100 are connected. Crimp connection may be used.

  18A shows a cross-sectional view of the covered electric wire 200 when the adhesive 210 is applied to the outer peripheral surface of the insulating coating 202, and FIG. 18B shows the aluminum core wire 201 exposed from the tip of the insulating coating 202. FIG. 18C shows a cross-sectional view of the covered electric wire 200 with the aluminum core wire 201 exposed from the tip of the insulating coating 202.

When applying the adhesive 210 to the outer peripheral surface of the insulating coating 202, as shown in FIG. 18A, so-called dipping is performed by immersing the tip of the covered electric wire 200 in the adhesive 210 made of liquid. At this time, the adhesive 210 is applied in a predetermined range in the longitudinal direction X of the covered electric wire 200 from the tip of the insulating coating 202 in the covered electric wire 200 before exposing the aluminum core wire 201.
Specifically, the predetermined range is a range 210a or more where the aluminum core wire 201 is exposed and a range 210b or less where the crimp terminal 100 is crimped and connected.

As shown in FIG. 18B, the insulation coating 202 of the coated electric wire 200 to which the adhesive 210 is applied is cut by the cutting device 220 at a position corresponding to the above-described range 210a from the tip, and is closer to the tip than the cutting position. Pull out the part.
As a result, the aluminum core wire 201 can be exposed from the tip of the insulating coating 202 as shown in FIG.

  As described above, after the adhesive 210 is applied to the insulating coating 202 in the covered electric wire 200, the aluminum core wire 201 is exposed from the tip of the insulating coating 202, thereby bonding the portion of the insulating coating 202 where the aluminum core wire 201 is exposed. It can be removed together with the agent 210. For this reason, the adhesive 210 can be interposed between the sheath portion 131 up to the tip of the insulating coating 202 remaining on the coated electric wire 200, that is, to the boundary 210c between the exposed aluminum core wire 201 and the insulating coating 202.

Therefore, since the adhesive 210 can be applied over a wide range within the required range in the insulating coating 202, the adhesive force is improved, and the intrusion of moisture from the insulating coating 202 side can be more reliably prevented.
Furthermore, the adhesive 210 can be easily removed at the portion where the aluminum core wire 201 is exposed, and the adhesive 210 can be prevented from adhering to the aluminum core wire 201, thereby ensuring stable conductivity. it can.

In particular, it is possible to easily apply the adhesive 210 to the necessary range of the insulating coating 202 simply by immersing the tip end portion of the covered electric wire 200 in the adhesive 210 made of a liquid, so that the work efficiency can be improved. .
Furthermore, since the tip of the covered electric wire 200 is immersed in an adhesive 210 made of a liquid, the adhesive 210 can be evenly applied to the required range of the insulating coating 202, so that the adhesive force is improved and the insulation is improved. Intrusion of moisture from the coating 202 side can be more reliably prevented.

  In the second embodiment (2A, 2B, 2C) described above, the adhesive 210 is applied to the insulating coating 202 of the covered electric wire 200, and then the aluminum core wire 201 is exposed from the tip of the insulating coating 202. The present invention is not limited to this, and the adhesive 210 may be applied to the insulating coating 202 when the aluminum core wire 201 is exposed from the tip of the insulating coating 202.

  For example, in FIG. 19 for explaining another method for applying the adhesive 210 to the outer peripheral surface of the insulating coating 202 in the covered electric wire 200, as shown in FIGS. 19 (a) to 19 (c), a cutting application device 230 is used. Thus, the step of cutting the insulating coating 202 and the step of applying the adhesive 210 can be performed simultaneously.

  19A shows a cross-sectional view of the covered electric wire 200 before the adhesive 210 is applied to the outer peripheral surface of the insulating coating 202, and FIG. 19B shows the insulating coating 202 cut simultaneously with the application of the adhesive 210. FIG. 19C is a cross-sectional view of the covered electric wire 200 in a state where the aluminum core wire 201 is exposed from the tip of the insulating coating 202.

First, as shown in FIG. 19A, an adhesive 210 is prepared at a portion of the cutting and coating apparatus 230 that comes into contact with the insulating coating 202.
Next, as shown in FIG. 19 (b), cutting is performed by the cutting application device 230 at a position corresponding to the range in which the aluminum core wire 201 is exposed.

  At the same time, the adhesive coating 210 is applied to the insulating coating 202 by the cutting and coating device 230, and then the tip side of the cutting position is pulled out, thereby removing the tip of the insulating coating 202 as shown in FIG. The aluminum core wire 201 can be exposed.

As a result, the adhesive 210 can be applied to the insulating coating 202 in the covered electric wire 200 during the operation of exposing the aluminum core wire 201 from the tip of the insulating coating 202. Specifically, the adhesive 210 can be applied to the insulating coating 202 when the insulating coating 202 is cut to expose the aluminum core wire 201.
The adhesive 210 can be applied to the outer peripheral surface of the insulating coating 202 by printing, but is not limited thereto, and the adhesive 210 can be applied by an appropriate method.

  Thus, since the adhesive 210 can be applied to the insulating coating 202 when the aluminum core wire 201 is exposed from the tip of the insulating coating 202, the operation of exposing the aluminum core wire 201 from the tip of the insulating coating 202 and bonding The work efficiency can be improved as compared with the configuration in which the work of applying the agent 210 to the insulating coating 202 is performed separately.

  In FIG. 19, when the insulating coating 202 is cut to expose the aluminum core wire 201, the adhesive 210 is applied to the insulating coating 202. However, the present invention is not limited to this, and the insulating coating 202 after cutting is applied. When removing the adhesive, the adhesive 210 may be applied to the insulating coating 202.

  The adhesive 210 is provided at a step S between the end face of the covered enclosure portion 131 and the outer peripheral surface of the insulating coating 202 in the covered electric wire 200 or between the insulating cover portion 131 and the insulating coating 202 in the covered electric wire 200. Not only, but also the entire outer peripheral surface of the barrel part 130 or, for example, the sealing part 133 configured at the front end part from the conductor crimping part 132 may be provided.

  Furthermore, the adhesive 134 interposed between the covering surrounding part 131 and the insulating coating 202 is not limited to be interposed over the entire circumference of the insulating coating 202, but the first anvil on the outer peripheral surface of the covered electric wire 200. Only the portion corresponding to the boundary portion in the state where the crimping die 11 and the second crimping die 12 serving as the crimper are close to each other is applied, so that the waterproof property is improved in a reinforcing manner only at a predetermined portion in the circumferential direction of the covered electric wire 200. You may apply to do.

In the first embodiment and the second embodiment described above, the crimp terminal 100 is the female crimp terminal 100, but the present invention is not limited to this, and the male that fits in the longitudinal direction X with respect to the female crimp terminal 100. It may be a crimp terminal of a type.
Moreover, although the core wire in the covered electric wire 200 is made of an aluminum alloy and the crimp terminal 100 is made of a copper alloy such as brass, the core wire in the covered electric wire 200 and the crimp terminal 100 are made of a copper alloy such as brass or an aluminum alloy. You may comprise with the same metal.

In correspondence between the configuration of the present invention and the above-described embodiment,
The electric wire conductor of this invention corresponds to the aluminum core wire 201 of the embodiment,
Similarly,
The wire connection portion corresponds to the barrel portion 130,
The connection structure corresponds to the connection structure 1, 1Pa, 1Pb, 2A, 2B, 2C,
The end side of the covering surrounding portion corresponds to the base portion 130x in the longitudinal direction X of the barrel portion 130 (covering surrounding portion 131),
The strand corresponds to the aluminum strand 201a,
Aluminum material corresponds to aluminum alloy,
Copper material corresponds to copper alloy strips such as brass,
The connector housing corresponds to the female connector housing 22 and the male connector housing 32,
The connector corresponds to the female connector 21 and the male connector 31,
The present invention is not limited only to the configuration of the above-described embodiment, and many embodiments can be obtained.
For example, instead of the adhesive 134, grease having water-stopping properties may be interposed.
Furthermore, as shown in FIG. 20, a bell mouth 136 whose diameter is increased outward may be formed at the rear end of the covering surrounding part 131 constituting the barrel part 130.
By forming the bell mouth 136 at the rear end of the covering surrounding portion 131, it becomes easy to inject the adhesive 134 between the covering surrounding portion 131 and the insulating coating 202. Specifically, even when the covered electric wire 200 is inserted into the barrel portion 130 in which the adhesive 134 has been injected into the covered surrounding portion 131 in advance, or the covered electric wire 200 coated with the adhesive 134 is removed from the barrel portion 130. Even in the case of being inserted into 130, the diameter of the bell mouth 136 is increased with respect to the covered surrounding portion 131, so that the covered electric wire 200 can be easily inserted. Conversely, even when the adhesive 134 is injected after the covered wire 200 is inserted into the barrel portion 130, the diameter of the bell mouth 136 is increased with respect to the covered surrounding portion 131. Can be inserted easily.
In addition, since the bell mouth 136 is formed at the rear end of the covered surrounding portion 131, even if the covered electric wire 200 is curved with respect to the barrel portion 130, the rear end of the covered surrounding portion 131 has the adhesive 134. The durable adhesive 134 can be formed without being damaged. Accordingly, the durability against thermal cycling can be improved.

The third embodiment of the present invention will be described below with reference to the drawings.
FIG. 21 is a perspective view of the tubular terminal 311 and the electric wire 313 joined to the tubular terminal 311 according to the embodiment.
The tubular terminal 311 has a box part 320 and a tubular part 325 of a female terminal, and has a transition part 340 as a bridge between them. The tubular portion 325 includes an enlarged diameter portion 326 that gradually increases in diameter from the transition portion 340 and a cylindrical portion 327 that extends in a cylindrical shape from the edge of the enlarged diameter portion 326. The tubular portion 325 is a hollow tube, and an electric wire insertion port 331 into which the electric wire 313 can be inserted is opened at one end of the tubular portion 325. The other end of the tubular portion 325 is connected to the transition portion 340. The transition part 340 side is closed by means such as welding, and is formed so that moisture or the like does not enter from the transition part 340 side. That is, the space inside the tubular portion 325 is closed on the transition portion 340 side. The electric wire 313 is inserted into the tubular portion 325 from the electric wire insertion port 331, and the tubular portion 327 is compressed by a crimping tool, whereby the tubular terminal 311 and the electric wire 313 are bonded by pressure bonding, and an electric wire connection structure 310 (FIG. 24) described later is formed. Composed.

  The box part 320 of the tubular terminal 311 is a box part of a female terminal that allows insertion of an insertion tab such as a male terminal. In the present invention, the shape of the details of the box portion 320 is not particularly limited. That is, the tubular terminal 311 only needs to include the tubular portion 325 via at least the transition portion 340, for example, the box portion may not be provided, or the box portion may be an insertion tab of a male terminal, for example. good. Moreover, the shape by which the terminal part which concerns on another form to the tubular part 325 was connected may be sufficient. In this specification, in order to explain the tubular terminal of the present invention, an example in which a female box is provided for convenience is shown.

The tubular terminal 311 is basically made of a base material made of a metal material (copper or copper alloy in this embodiment) in order to ensure conductivity and strength. In addition, the base material of the tubular terminal 311 is not limited to copper or a copper alloy, and aluminum, steel, an alloy containing these as a main component, or the like can also be used.
Moreover, in order to ensure various characteristics as a terminal, the tubular terminal 311 may be subjected to a plating process such as tin, nickel, silver plating, or gold on part or all of the tubular terminal 311. Further, not only plating but also reflow treatment of tin or the like may be performed. The tubular terminal 311 exemplified in this embodiment is partially or entirely subjected to a treatment such as tin plating.

As will be described in detail later, the tubular terminal 311 is formed by bending a plate-like material obtained by punching the strip made of the metal material. The box part 320 and the tubular part 325 can be made of a single plate material, or the box part 320 and the tubular part 325 can be formed of different plate materials and then joined at the transition part 340. is there.
The tubular portion 325 is formed by bending the plate material so as to have a C-shaped cross section, butting both open ends and joining them by welding or the like. Laser welding is preferable for joining the tubular portion 325, but welding methods such as electron beam welding, ultrasonic welding, and resistance welding may be used. By joining the openings by laser welding, the opening is formed into a closed tube. Also, joining using a connection medium such as solder or solder may be used. In this embodiment, an example in which the tubular portion 325 is formed by laser welding is shown. In this example, as shown in FIG. 21, a weld bead 343 extending in the axial direction is formed in the tubular portion 325. The transition part 340 is formed by pressing and closing one end of the tubular part 325. Specifically, the transition portion 340 is configured to be pressed so as to crush one end of the tubular portion 325 so as to overlap in a planar shape, and its intermediate position in the longitudinal direction is closed by means such as welding in the width direction. Further, it is formed so that moisture or the like does not enter from the transition part 340 side. Further, the internal space of the tubular portion 325 is closed at the transition portion 340. The tubular portion 325 is not limited to the method of joining both end portions of the C-shaped cross section described above, and may be formed by a deep drawing method. Further, the tubular portion 325 and the transition portion 340 may be formed by cutting the continuous tube and closing one end side.
Note that the tubular portion 325 may be tubular, and is not necessarily cylindrical with respect to the longitudinal direction. The cross section may be an ellipse or a rectangular tube. Further, the diameter does not need to be constant, and may be a shape whose radius changes in the longitudinal direction.

The electric wire 313 is configured, for example, by covering a core wire 314 in which strands 314a made of a metal or alloy material are bundled with a conductor insulating layer 315 made of an insulating resin (for example, polyvinyl chloride). The core wire 314 is formed by twisting the wire 314a so as to have a predetermined cross-sectional area. However, the core wire 314 is not limited to this form and may be formed by a single wire.
In addition, the metal material which comprises a core wire should just be a metal which has high electroconductivity, and you may use copper or a copper alloy other than aluminum or an aluminum alloy.

  The resin material constituting the conductor insulating layer 315 of the electric wire 313 is polyvinyl chloride. Besides this polyvinyl chloride, for example, a halogen-based resin mainly composed of crosslinked polyvinyl chloride, chloroprene rubber or the like, polyethylene Further, halogen-free resins mainly composed of crosslinked polyethylene, ethylene propylene rubber, silicon rubber, polyester, etc. are used, and these may contain additives such as plasticizers and flame retardants.

FIG. 22 is a cross-sectional view of the tubular terminal 311, (A) a main-part cross-sectional view showing a longitudinal cross-section of the tubular terminal 311, and (B) a transverse cross-sectional view of the tubular terminal 311 in the tubular part 327.
As shown in FIG. 22A, serrations 333 are formed on the inner peripheral surface of the tubular portion 325. The serration 333 is a groove extending in the circumferential direction on the inner peripheral surface of the tubular portion 325. The serration 333 may be formed so as to go around the inner peripheral surface of the tubular portion 325 or may be provided only on a part of the inner peripheral surface of the tubular portion 325 in the circumferential direction. A plurality of serrations 333 are formed side by side in the longitudinal direction of the tubular portion 325. These serrations 333 are provided in the tubular portion 325 at a portion where the conductor crimping reduced diameter portion 335 (FIG. 24), which will be described later, is crimped to the core wire 314. In the conductor crimping reduced diameter portion 335, the core wire 314 from which the conductor insulating layer 315 is peeled and the tubular portion 325 are joined. The core wire 314 is locked by the serration 333, and the contact pressure between the core wire 314 and the tubular portion 325 is increased. When aluminum or an aluminum alloy is used for the core wire 314, it is pointed out that the contact resistance of the core wire 314 is lower than when copper or a copper alloy is used. Can be secured. The serration 333 can be formed by, for example, pressing the chain terminal before bending when the tubular portion 325 is formed by bending the plate-shaped chain terminal from which the strip material is punched.

And the adhesive agent 355 is arrange | positioned at the inner peripheral surface of the tubular part 325 at the electric wire insertion port 331 side. The adhesive 355 is attached in a strip shape having a predetermined width in the longitudinal direction of the tubular portion 325. The position of the adhesive 355 is a portion of the tubular portion 325 that is a pressure-bonded and reduced-diameter portion 336 (FIG. 24), which will be described later, and is pressure-bonded to the conductor insulating layer 315 (FIG. 21).
As shown in FIG. 22B, the adhesive 355 goes around the inner peripheral surface of the tubular portion 325, and the adhesive 355 is also arranged inside the weld bead 343. When the electric wire 313 is inserted into the tubular portion 325, the periphery of the electric wire 313 is surrounded by the adhesive 355 and the outer side thereof is surrounded by the cylindrical portion 327.

FIG. 23 is an explanatory diagram of a process of crimping and joining the electric wire 313 to the tubular terminal 311, and is a cross-sectional view corresponding to a transverse cross section of the cylindrical portion 327. In FIG. 23, the width of the anvil 403 is indicated by symbol A, and the lateral width (diameter) of the tubular terminal 311 when installed on the anvil 403 is indicated by symbol B.
24 and 25 are diagrams showing a configuration of a wire connection structure 310 formed by joining an electric wire 313 to a tubular terminal 311. FIG. 24A is a perspective view, and FIG. 25 is a cross-sectional view showing a longitudinal cross section of the tubular caulking portion 330, and FIG.

As shown in FIG. 23, the tubular terminal 311 and the electric wire 313 are pressure-bonded (crimped) using a crimper 401 and an anvil 403 which are a pair of crimping tools. The crimper 401 has a crimping wall 402 formed by a curved surface of the tubular terminal 311, and the anvil 403 has a receiving portion 404 on which the tubular terminal 311 is placed. The receiving portion 404 of the anvil 403 is a curved surface corresponding to the outer shape of the tubular portion 325.
As shown in FIG. 23, with the electric wire 313 inserted into the tubular terminal 311, the tubular terminal 311 is placed on the receiving portion 404, and the crimper 401 is lowered as indicated by an arrow in the drawing, thereby The tubular portion 325 is compressed by the receiving portion 404 and is pressure-bonded.

  23 shows a cross section of the cylindrical portion 327, the conductor insulating layer 315 outside the core wire 314, the adhesive 355, and the cylindrical portion 327 are shown, but the crimper 401 and the anvil 403 are In addition to the cylindrical portion 327, other portions can be compressed. That is, since the crimper 401 and the anvil 403 have a depth that allows compression of almost the entire diameter of the tubular portion 325 except for the enlarged diameter portion 326, the portion where the core wire 314 and the tubular portion 325 are pressure-bonded and the conductor insulating layer 315 are provided. Both the included electric wire 313 and the portion where the tubular portion 325 is bonded by crimping can be compressed by the pair of crimpers 401 and the anvil 403 at a time. Moreover, you may compress these parts separately.

FIG. 23 shows an example in which the inner diameter of the cylindrical portion 327 (the diameter of the space inside the adhesive 355) and the outer diameter of the electric wire 313 are substantially equal, and there is almost no space around the electric wire 313. The scope of application is not limited to this. The outer diameter of the electric wire 313 is smaller than the inner diameter of the cylindrical portion 327 (the diameter of the space inside the adhesive 355) and there is a gap around the electric wire 313, so that crimping can be performed as shown in FIG. . Also in this case, the diameter of the cylindrical portion 327 is reduced by compression, and the cylindrical portion 327, the adhesive 355, and the conductor insulating layer 315 are in close contact with each other, so that the electric wire 313 can be reliably bonded to the tubular terminal 311.
When the outer diameter of the electric wire 313 is larger than the diameter of the space inside the adhesive 355, the adhesive 355 adheres to the electric wire 313 when the electric wire 313 is inserted into the tubular portion 325, and the adhesive 355 becomes the enlarged portion. It may move to 326 side or insertion of the electric wire 313 may be hindered. For this reason, when the outer diameter of the electric wire 313 is thinner than the space inside the adhesive 355, it can be said that the tubular terminal 311 and the electric wire 313 can be more easily joined, which is preferable.

The tubular terminal 311 after the crimping constitutes an electric wire connection structure 310 together with the electric wire 313. As shown in FIGS. 24A and 24B, the tubular portion 325 is compressed to form a tubular caulking portion 330 including a conductor crimping reduced diameter portion 335 and a coated crimping reduced diameter portion 336. Moreover, the enlarged diameter part 326 is not compressed among the tubular parts 325.
The conductor crimping reduced-diameter portion 335 is bonded to the tubular terminal 311 by the core wire tip 314b of the core wire 314 being reduced in diameter by causing the plastic deformation of the tubular portion 325 by the crimping process shown in FIG. As shown in FIG. 24 (B), the core wire tip 314b is locked by a serration 333 and is more firmly joined. The conductor crimping reduced diameter portion 335 is a portion having the highest diameter reduction ratio in the tubular caulking portion 330.
In the coated crimping reduced diameter portion 336, the tubular portion 325 is plastically deformed and reduced in diameter by the crimping process shown in FIG. 23, and the electric wire 313 is compressed together with the adhesive 355 and joined to the tubular terminal 311.
As shown in FIGS. 24A and 24B, in the tubular crimped portion 330, the conductor crimping reduced diameter portion 335 and the coated crimping reduced diameter portion 336 have different diameter reduction ratios, but the crimping wall 402 (FIG. 23). And by adjusting the shape and depth in the depth direction of the receiving portion 404 (FIG. 23) according to the conductor crimping reduced diameter portion 335 and the cover crimping reduced diameter portion 336, it is tubular with a necessary diameter reduction ratio by a single crimping process. The caulking portion 330 can be configured.

  The tubular caulking portion 330 is required to have a function of maintaining the electrical conductivity by strongly compressing the core wire 314 and a function of maintaining the sealing performance by compressing the conductor insulating layer 315. In the coated crimping reduced diameter portion 336, the cross section thereof is caulked into a substantially circular shape, and by applying substantially the same pressure over the entire circumference of the conductor insulating layer 315, a uniform elastic repulsive force is generated over the entire circumference. It is preferable to obtain a sealing property. However, in the actual crimping process, as shown in FIG. 23, since the anvil 403 and the crimper 401 are crimped from above and below, the metal material of the tubular terminal 311 protrudes into the gap between the two tools. Occur. More specifically, the behavior in which the tubular terminal 311 protrudes from the contact portion between the edge 405 of the anvil 403 and the crimping wall 402 occurs. This behavior occurs because the compression space formed between the anvil 403 and the crimper 401 does not become a perfect circle, and can occur regardless of the size of the anvil 403. That is, FIG. 23 shows a case where the width A of the anvil 403 is larger than the lateral width B of the tubular terminal 311, but even if the width A of the anvil 403 is smaller than the lateral width B of the tubular terminal 311, The above behavior can occur.

For this reason, as shown in FIG. 25, the shape of the inner surface of the coated crimped reduced diameter portion 336 in the cross section is not a substantially circular shape, and the portions 337 and 337 corresponding to the gaps between the tools are projected to the outside. turn into. Since the protrusions of the portions 337 and 337 occur at the contact positions of the crimper 401 and the anvil 403, they occur along the depth direction of the crimper 401 and the anvil 403. Therefore, in the tubular caulking portion 330, a similar bulge occurs in the conductor crimping reduced diameter portion 335, and this bulge extends in the axial direction of the tubular caulking portion 330.
At positions corresponding to the portions 337 and 337, the pressure from the coated crimping reduced diameter portion 336 to the conductor insulating layer 315 is insufficient, and a gap is generated between the inner surface of the coated crimped reduced diameter portion 336 and the surface of the conductor insulating layer 315. There is a concern that moisture may enter the tubular caulking portion 330 from the side of the electric wire insertion port 331 as the gap becomes a leak path.
When moisture adheres to the joint between the metal substrate (copper or copper alloy) of the tubular terminal 311 and the core wire 314 (aluminum or aluminum alloy), the core wire 314 is corroded due to the difference in electromotive force (ionization tendency) between the two metals. Further, even if the tubular terminal 311 and the core wire 314 are made of aluminum, their joints are easily corroded due to a subtle difference in alloy composition. For this reason, in the configuration in which moisture enters the inside of the tubular caulking portion 330 in the wire connection structure 310, the progress of corrosion is a concern.

In the present embodiment, the tubular caulking portion 330 has a weld bead 343 that is welded when the tubular portion 325 is formed. Depending on the welding conditions, sink marks may occur in the weld bead 343, the thickness of the weld bead 343 is reduced, and the bead of the weld bead 343 forms an irregular concavo-convex structure instead of a smooth inner surface. There is also concern that the inner surface near 343 may be a leak path.
Further, since the strength of a portion adjacent to the weld bead 343 and affected by heat due to welding is reduced, the weld bead 343 and the vicinity thereof are subjected to inhomogeneous deformation during the crimping process, so that the inner surface near the weld bead 343 has a leak path. There is a possibility of becoming.
Further, in the crimping process of the anvil 403 and the crimper 401 from the vertical direction, the pressure on the lower side (anvil 403 side) of the tubular caulking portion 330 tends to be higher than the upper side (the crimper 401 side). The elastic repulsion force of the conductor insulating layer 315 sometimes became stronger on the lower side (anvil 403 side) than on the upper side (crimper 401 side). For this reason, the elastic repulsive force on the upper side (crimper 401 side) of the tubular caulking portion 330 is insufficient, and the entire interface between the conductor insulating layer 315 and the tubular caulking portion 330 on the upper side may become a leak path.

  Therefore, in this embodiment, the adhesive 355 is disposed on the inner peripheral surface of the tubular portion 325 in the tubular terminal 311, and the electric wire 313 is inserted into the adhesive 355 to be crimped.

The adhesive 355 has a liquid, sol, or gel-like fluidity state, and reversibly or irreversibly increases its hardness through the passage of time, temperature change, moisture absorption, drying, and the like. is there. The adhesive 355 is disposed on the inner peripheral surface of the tubular portion 325 by a method such as coating or spraying in a state of having fluidity before being cured.
In order to increase the water-stopping property after the electric wire 313 is pressure-bonded to the tubular portion 325 more reliably, the adhesive 355 is more preferably flexible (elastic) in an increased hardness state.
As a suitable material used for the adhesive 355, an adhesive material using a synthetic resin or a natural resin can be given. Adhesive materials include reactive adhesives that cure by causing a chemical reaction over time, solvent-based adhesives that increase hardness by volatilization of the solvent, fluidity is developed by heating, and then cooled. Hot-melt adhesives that increase hardness, and solvent-type adhesives include emulsion-based adhesives.
More specific examples include an adhesive material containing a polyurethane resin, a modified silicon resin, a vinyl resin, a polyamide resin, a polyimide resin, a melamine resin, a urea resin, or the like as a main component. In addition, a rubber-based adhesive in which a solvent or the like is added to silicone rubber, fluorine rubber, butyl rubber, butadiene rubber, styrene-butadiene rubber, ethylene propylene rubber, epichlorohydrin rubber, chloroprene rubber, nitrile rubber or the like known as a synthetic rubber. It can also be used.

A particularly preferred example is a hot melt adhesive. For example, a hot-melt adhesive mainly composed of ethylene vinyl acetate resin, polyamide resin, polyurethane resin, polyolefin resin, modified silicon resin, etc. is suitable, and a mixture of these or those containing other additive components, etc. But it ’s okay. When a hot melt adhesive is used as the adhesive 355, the tubular terminal 311 can be heated or placed in a high temperature environment to give fluidity to the adhesive 355 attached to the tubular portion 325 any number of times. is there. For this reason, before and after the step of attaching the adhesive 355 to the tubular portion 325 and the step of crimping and joining the electric wire 313 to the tubular terminal 311, fluidity can be imparted to the adhesive 355 as necessary.
As a more preferred example, among hot melt adhesives, those having flexibility (elasticity) even when the hardness is increased at room temperature are preferable. More specifically, those containing ethylene vinyl acetate resin, polyurethane resin, polyolefin resin, modified silicon resin and the like as the main agent can be mentioned.
Moreover, when using thermoplastic materials, such as a hot-melt-adhesive, as the adhesive agent 355, it is preferable to set the melting process temperature of the adhesive agent 355 to the maximum temperature or more in the environment where the wire connection structure 310 is arrange | positioned. For example, when the electric wire connection structure 310 is used as an automobile harness, a resin material having a melting temperature of 120 to 160 degrees is preferable if it is used in a vehicle interior or the vicinity thereof, and is used in an engine room. In this case, a higher melting temperature of about 180 degrees is preferable. On the other hand, the tubular terminal 311 is partially or entirely subjected to a treatment such as tin plating. For this reason, it is preferable that the upper limit of the melting temperature of the adhesive 355 does not exceed 231.9 degrees which is the melting point of tin. Moreover, if it has a flame retardance, it is still more preferable.

For the conductor insulating layer 315 of the electric wire 313, a polyvinyl chloride resin or a crosslinked polyvinyl chloride resin can be used. Further, as the conductor insulating layer 315, a halogen-free resin (non-halogen resin) whose main component is polyolefin resin, ethylene-propylene rubber, silicon rubber, polyester, silicon resin, or the like can be used. These halogen-free resins may be a mixture of a flame retardant such as a metal hydrate.
In selecting the material of the adhesive 355, the material of the conductor insulating layer 315 is selected so that the combination of the conductive insulating layer 315 and the adhesive 355 does not cause a change in physical properties due to the transfer of additives, oils or solvents. Corresponding selection is preferred. Specifically, when a halogen-free resin other than a silicon resin is used for the conductor insulating layer 315, an adhesive material containing a halogen-containing resin, an oil or fat, or an organic solvent is preferably avoided as the adhesive 355.

In this configuration, the tubular caulking portion 330 is formed in a bottomed tubular shape, so that intrusion of moisture and the like is suppressed from the outside, and corrosion of the joint portion between the tubular terminal 311 and the electric wire 313 can be suppressed.
In the present embodiment, the conductor insulating layer 315 of the electric wire 313 and the metal material constituting the coated crimping reduced diameter part 336 are crimped and bonded via the adhesive 355 in the coated crimping reduced diameter part 336. The adhesive 355 has plasticity or flexibility. For this reason, even if a gap is generated between the inner surface of the tubular caulking portion 330 and the conductor insulating layer 315 in the crimping process, for example, a portion 337 shown in FIG. 25, the gap is filled with the adhesive 355. Thereby, the sealing performance in the covering crimping reduced diameter portion 336 can be enhanced, and the intrusion of moisture into the internal space of the tubular caulking portion 330 can be suppressed. Therefore, since the corrosion of the core wire 314 can be suppressed, the wire connection structure 310 with higher corrosion resistance can be realized.

26 and 27 are explanatory views showing a method for manufacturing the tubular terminal 311. 26A is a cross-sectional view in the longitudinal direction of the tubular terminal 311, and FIG. 26B shows the chain terminal 451 before the tubular terminal 311 is formed by bending, and each part of the tubular terminal 311 and the chain terminal 451. Is shown by a broken line. For convenience of understanding, the surface of the adhesive 355 is indicated by hatching.
The manufacturing method of the tubular terminal 311 includes a punching process, a bending process (including a process of applying the adhesive 355 and a welding process), and a cutting process.
In the punching process, the strip 450, which is a long metal plate, is punched out by press working to form a chain terminal 451. The strip 450 is a tape-like material having a thickness of, for example, 0.25 mm, in which a metal material (copper or copper alloy in the present embodiment) is previously subjected to a treatment such as plating or surface coating. As shown in FIG. 26B, the chain terminal 451 punched from the strip 450 has a plurality of terminal molded pieces 460 each forming one tubular terminal 311, and each terminal molded piece 460 is connected by a connecting tape 464. It has a shape. The chain terminal 451 is a flat plate since the strip 450 is punched out. Further, when the chain terminal 451 is punched from the strip 450, at the same time, the positioning hole 465 indicating the position of each terminal molding piece 460 is punched in the connecting tape 464.

The terminal molding piece 460 includes a box molding part 461 that is molded into the box part 320 by bending, and a spring molding part 462 that is connected to the box molding part 461 and molded into a spring inside the box part 320 by bending. . In addition, the box forming portion 461 is connected to a tubular forming portion 463 that is formed into a tubular portion 325 by bending.
In the bending step, the process of forming the box part 320 by bending the box molding part 461 a plurality of times substantially at right angles and the process of bending the spring molding part 462 to fit inside the box part 320 are performed in parallel. A bending process for rounding the tubular forming portion 463 is performed. The tubular forming portion 463 is first bent into a U-shaped cross section by pressing from the top and bottom directions with respect to the surface of the connecting tape 464, and then formed into a C-shaped cross section by rounding the front end side of the U shape. The bending process for the box forming part 461 and the spring forming part 462 and the process for the tubular forming part 463 may be executed individually or in parallel. Further, the plurality of terminal molded pieces 460 connected by the connecting tape 464 may be bent at the same time to form the plurality of tubular terminals 311.

The tubular terminal 311 formed by bending is cut off from the connecting tape 464 in the cutting process.
The electric wire connection structure 310 is manufactured by inserting the electric wire 313 from the electric wire insertion port 331 and crimping and bonding the tubular terminal 311 thus manufactured as shown in FIG.

  The serration 333 provided in the tubular portion 325 is formed by pressing the strip 450 before punching or the chain terminal 451 after punching. That is, the serration 333 may be formed by press working at a position where the strip 450 is to become the tubular forming portion 463. In this case, the serration 333 may be formed at the same time in the press work for punching the chain terminal 451 from the strip 450. Further, in the bending process, the serration 333 may be formed at the same time when the chain terminal 451 is pressed to perform the bending process.

Prior to the bending step, a step of attaching the adhesive 355 to the chain terminal 451 is performed, and the adhesive 355 is disposed in a portion corresponding to the tube portion 327 when the tubular formed portion 463 is formed into the tubular portion 325.
When the adhesive 355 is in a liquid, sol, or gel form, the adhesive 355 is disposed by a method of application or dropping.
In the case where the adhesive 355 is a solid material such as a hot melt adhesive, the adhesive 355 may be heated and melted and adhered to the chain terminal 451 in a molten state, or a sheet-like hot melt. The adhesive 355 made of an adhesive may be placed on the chain terminal 451 and then heated and melted to adhere the adhesive 355 to the chain terminal 451.

FIG. 26 shows an example in which the adhesive 355 is attached to each tubular molded portion 463 after the punching process. However, the adhesive 355 can be attached before the punching process.
For example, as shown in FIGS. 27A and 27B, an adhesive 355 may be attached to the strip 450 before the punching process. In the example of FIG. 27A, an adhesive 355 is attached to a position where the strip 450 is to be molded into the tubular molded portion 463 in the bending process. If this method is used, the adhesive 355 can be used without waste. In addition, there is an advantage that the adhesive 355 hardly adheres to the mold in the punching process. The method illustrated in FIG. 27A is preferable in the case where a liquid, sol, or gel adhesive 355 is attached by a method such as coating, dropping, or spraying. On the other hand, in the example of FIG. 27B, the adhesive 355 is attached to a region extending in the longitudinal direction of the strip 450 regardless of the position of the terminal molding piece 460. In this case, the position where the adhesive 355 is attached may be adjusted by adjusting the position of the strip 450 in the width direction, and positioning of the strip 450 in the longitudinal direction is unnecessary. For this reason, there exists an advantage that the process which adheres the adhesive agent 355 can be processed rapidly. The method illustrated in FIG. 27B is suitable when, for example, the adhesive 355 processed into a long sheet is attached to the strip 450.

  Examples of the method for forming the tubular portion 325 by bending the tubular formed portion 463 include a method in which both ends of the tubular formed portion 463 are butted and joined by laser welding as described above, but the present invention is limited thereto. Not. Hereinafter, another example of the joining method of the tubular molded portion 463 will be described.

<Fourth embodiment>
28A and 28B are diagrams showing the configuration of a tubular terminal 311A according to the fourth embodiment, in which FIG. 28A is a perspective view and FIG.
The tubular terminal 311A has a box portion 320 similar to the tubular terminal 311 described in the third embodiment. For convenience of understanding, the box part 320 is indicated by a virtual line.
The tubular terminal 311 has a box part 320 and a tubular part 325a, and has a transition part 340A as a bridge between them. The tubular portion 325a includes a diameter-enlarged portion 326A that gradually increases in diameter from the transition portion 340A, and a tube portion 327A that extends in a cylindrical shape from the edge of the diameter-enlarged portion 326A. The tubular portion 325a is a hollow tube, and an electric wire insertion port 331 into which the electric wire 313 can be inserted is opened at one end of the tubular portion 325a. The other end of the tubular portion 325a is connected to the transition portion 340A.
The transition part 340A is configured to press the one end of the tubular part 325 so as to be crushed and overlap in a planar shape, and the intermediate position in the longitudinal direction is closed by means such as welding in the width direction. It is formed so that moisture or the like does not enter from the 340 side.
Then, the electric wire 313 is inserted into the tubular portion 325a from the electric wire insertion port 331, and the tubular portion 327A is compressed by a crimping tool so that the tubular terminal 311 and the electric wire 313 are pressure bonded to each other, thereby configuring the electric wire connection structure.

The tubular portion 325a is configured by bending the tubular molded portion 463 shown in FIG. 26 into a C-shaped cross section. Here, the end of the tubular molded portion 463 is further bent at a substantially right angle to form rising portions 345 and 345 at the joint. Therefore, when the tubular portion 325a is a closed tube, the side surfaces of the rising portion 345 are abutted and joined.
When joining the rising portions 345 and 345 by laser welding, the welding bead 343A has a tubular portion 325a as shown in FIG. It does not reach the inner surface of the tubular portion 325a.

As described with reference to FIGS. 26 to 27, when the method of attaching the adhesive 355 before forming the tubular portion 325a into a tubular shape is adopted, when the inner peripheral surface of the tubular portion 325a is exposed to a high temperature by laser welding. There is a possibility of unintentional dissolution of the adhesive 355 and the like. As shown in FIG. 28, the rising part 345 is provided in the tubular molding part 463, and welding is performed by irradiating a laser from the rising part (outer surface of the tubular part 325a) side of the rising part 345, so that the melting part becomes the tubular part. The inner surface of 325a is not reached. For this reason, there exists an advantage that the tubular part 325a can be shape | molded, without affecting the adhesive agent 355 which has already adhered.
When the rising portion 345 is provided, the overlapping portion 44 may be formed by applying laser welding to the transition portion 340A in order to ensure that the end of the tubular portion 325a is closed in the transition portion 340A. .

<Fifth Embodiment>
FIG. 29 is a diagram illustrating a configuration of a tubular terminal 311B according to the fifth embodiment, in which (A) is a perspective view and (B) is a cross-sectional view of relevant parts.
The tubular terminal 311B has a box portion 320 similar to the tubular terminal 311 described in the third embodiment. For convenience of understanding, the box part 320 is indicated by a virtual line.
The tubular terminal 311 has a box part 320 and a tubular part 325b, and has a transition part 340B as a bridge between them. The tubular portion 325b includes an enlarged diameter portion 326B that gradually increases in diameter from the transition portion 340B, and a tubular portion 327B that extends in a cylindrical shape from the edge of the enlarged diameter portion 326B. The tubular portion 325b is a hollow tube, and an electric wire insertion port 331 into which the electric wire 313 can be inserted is opened at one end of the tubular portion 325b. The other end of the tubular portion 325b is connected to the transition portion 340B.
Then, the electric wire 313 is inserted into the tubular portion 325b from the electric wire insertion port 331, and the tubular portion 327B is compressed by a crimping tool, whereby the tubular terminal 311 and the electric wire 313 are crimped and joined to form an electric wire connection structure.

The tubular portion 325b is configured by bending the tubular molded portion 463 shown in FIG. 26 into a C-shaped cross section. Here, the end portions of the tubular molded portion 463 are overlapped with each other. By irradiating the overlapping portion 346 with laser from the outer surface side of the tubular portion 325b in the overlapping direction, the tubular portion 325b is closed. When the overlapping portion 346 is joined by laser welding, since two plate materials overlap in the laser irradiation direction, the weld bead 343B remains outside the tubular portion 325b as shown in FIG. It does not reach the inner surface of the portion 325b.
The transition portion 340B is configured to press the one end of the tubular portion 325 so as to be crushed and overlap each other in a planar shape, and the intermediate position in the longitudinal direction is closed by means such as welding in the width direction. It is formed so that moisture or the like does not enter from the 340 side.

As described in FIGS. 26 to 27, the tubular terminal 311B of the fifth embodiment can be applied with the method of attaching the adhesive 355 before the tubular portion 325b is formed into a tubular shape. In other words, since the laser welding does not expose the inner peripheral surface of the tubular portion 325b to a high temperature, welding can be performed without causing the adhesive 355 to melt. For this reason, there exists an advantage that the tubular part 325b can be shape | molded, without affecting the adhesive agent 355 already adhered. In addition, since the overlapping portion 346 can be realized without increasing the number of bending processes, the influence on the productivity of the tubular terminal 311B is slight.
In the case where the overlapping portion 346 is provided, the end portion of the tubular portion 325b is reliably closed in the transition portion 340B. Therefore, even if the overlapping portion 44 is formed by performing laser welding on the transition portion 340B. Good.

Next, Example 1 will be described.
Example 1
In the wire connection structure 310 of Example 1, Furukawa Electric Co., Ltd. copper alloy FAS-680 (thickness 0.25 mm, H material) was used as the base material of the tubular terminal 311. The alloy composition of FAS-680 is nickel (Ni) 2.0-2.8 mass%, silicon (Si) 0.45-0.6 mass%, zinc (Zn) 0.4-0.55. It contains 0.1% to 0.25% by mass of tin (Sn) and 0.05 to 0.2% by mass of magnesium (Mg), with the balance being copper (Cu) and inevitable impurities.
The tubular portion 325 was subjected to laser welding so that both end portions of the bent C-shaped cross section were butted to have an inner diameter of 3.2 mm.

  The core wire 314 of the electric wire 313 has an alloy composition of about 0.2% by mass of iron (Fe), about 0.2% by mass of copper (Cu), about 0.1% by mass of magnesium (Mg), and silicon (Si). As an element wire 314a, an aluminum alloy wire (wire diameter: 0.3 mm) having approximately 0.04% by mass of aluminum and the balance being aluminum (Al) and unavoidable impurities was used. Eleven strands 314a were used to form a core wire 314 of 0.75 sq, 11 circular compression strands.

  For the conductor insulating layer 315 of the electric wire 313, an ethylene vinyl acetate copolymer was used as a halogen-free resin. The conductor insulating layer 315 was formed by an extrusion method around the core wire 314 so that the outer diameter was 1.4 mm.

  As the adhesive 355, an elastic adhesive mainly containing a modified silicone resin was used. This elastic adhesive exhibits elasticity even after curing. This adhesive 355 was coated on the inner peripheral surface of the tubular portion 325 so as to have a thickness of about 0.25 mm.

  For the electric wire 313, the conductor insulating layer 315 at the end of the electric wire was peeled off using a wire stripper to expose the core wire 314. In this state, the electric wire 313 was inserted into the tubular portion 325 of the tubular terminal 311, and the tubular portion 327 of the tubular portion 325 was pressure-bonded by partial strong compression using the crimper 401 and the anvil 403.

(Comparative Example 1)
The wire connection structure of Comparative Example 1 was the same as Example 1 except that the adhesive 355 was not used.

As an environmental test, an air leak test was performed before and after being left at high temperature.
The high temperature storage was left in an environment of 120 degrees Celsius for 120 hours.
The air leak test was performed by immersing the electric wire 313 crimp-connected to the tubular terminal 311 in water stored in the container. With the tubular terminal 311 submerged, an air tube extending from the pressurized air supply device was connected to the end of the electric wire 313 opposite to the tubular terminal 311. Pressurized air is injected at a predetermined air pressure from this pressurized air supply device, and the occurrence of bubbles from the tubular caulking portion 330 is visually determined. If bubbles are generated, Air pressure was detected. When bubbles were not generated, the pressure of pressurized air to be injected was increased to 50 kPa, and the test was completed.

In the wire connection structure 310 of Example 1, bubbles were not generated in both the air leak test before being left at high temperature and the air leak test after being left at high temperature. Since the air pressure reached 50 kPa without generation of bubbles, the test was terminated.
On the other hand, the wire connection structure of Comparative Example 1 did not generate bubbles even when the air pressure reached 50 kPa in the air leak test before leaving at high temperature, but after the high temperature was left at 10 kPa when the air pressure was 10 kPa. The generation of bubbles was visually recognized from between the insulating layers.
As a result, it has been clarified that the adhesive 355 tightly joins the tubular portion 325 and the conductor insulating layer 315 and greatly improves the water stoppage on the wire insertion port 331 side.
As described above, according to the tubular terminal 311 of the present invention, by providing the adhesive in the tubular crimping portion to be crimped and joined to the electric wire, the electric wire and the terminal are firmly bonded via the adhesive.

  More specifically, in a conventional wire harness used in an automobile or the like, an electric wire formed by coating a core wire (conductive wire) with an insulator is used, and this type of electric wire is a core wire that is exposed by peeling off the coating. A metal terminal is crimped to the end. In the conventional wire-terminal connection structure, the surface of the end of the core wire from which the insulator has been peeled is exposed. Therefore, when applied to applications such as vehicles, the wire is exposed to rainwater, etc. Corrosion of the core wire has been a concern when running for a long time in a humid environment.

In particular, in recent years, in order to reduce the weight of a wire harness for the purpose of improving the fuel efficiency of an automobile, the core wire material has been replaced with an aluminum-based material such as aluminum or aluminum alloy from a conventional copper-based material.
When the core wire of aluminum material is used for the electric wire and the copper material is used for the metal terminal of the crimping part, there is a potential difference between the metal constituting the electric wire (aluminum material) and the metal constituting the metal terminal (copper material). Arise. At this time, when moisture or the like adheres to the connecting portion between the electric wire and the terminal, the conductor (core wire) of the electric wire is exposed, so that corrosion between different metals occurs and corrosion of any metal proceeds. In the corrosion between dissimilar metals of an aluminum-based material and a copper-based material, the aluminum-based material is thinned by the corrosion. For this reason, there is a risk that poor contact may occur in the wire connection portion.
In order to solve these problems, conventionally, a technique has been proposed in which the entire outer periphery of the end exposed region of the crimping portion and the vicinity thereof is molded with resin (see, for example, Japanese Patent Application Laid-Open No. 2011-222243).
Further, a technique has been proposed in which a metal intermediate cap is attached to the exposed portion of the core of the electric wire and then the terminal is crimped to protect the crimped portion between the electric wire and the terminal (see, for example, Japanese Patent Application Laid-Open No. 2004-207172). .
However, according to the present invention, the electric wire and the terminal are firmly bonded to each other through the adhesive by providing the adhesive in the tubular pressure-bonded portion to be pressure-bonded to the electric wire. Thereby, the water stop performance can be improved and the corrosion of the wire conductor due to moisture can be suppressed. Further, since no processing is performed on the electric wire side, the crimping process can be efficiently performed. Therefore, corrosion of the core wire can be suppressed by a configuration that can be easily manufactured without going through a complicated process. Therefore, durability against thermal cycling can be improved.
Note that grease may be used instead of the adhesive 355. Furthermore, a bell mouth 136 (see FIG. 20) whose diameter is increased outward may be formed at the rear end of the tubular portion 325 of the tubular terminal 311, and the bell mouth 136 can achieve the same effect.

Hereinafter, a sixth embodiment of the present invention will be described with reference to the drawings.
FIG. 30 is a perspective view showing an electric wire connection structure 510 of the sixth embodiment.
The electric wire connection structure 510 includes a tubular terminal 511 and an electric wire 513 that is pressure-bonded to the tubular terminal 511. The tubular terminal 511 has a female terminal box portion 520 and a tubular caulking portion 530, and has a transition portion 540 as a bridge between them.
The tubular terminal 511 is basically made of a base material made of a metal material (copper or copper alloy in the sixth embodiment) in order to ensure conductivity and strength. Note that the base material of the tubular terminal 511 is not limited to copper or a copper alloy, and aluminum, steel, an alloy containing these as a main component, or the like can also be used.
Moreover, in order to ensure various characteristics as the terminal, for example, a part or all of the tubular terminal 511 may be plated with tin, nickel, silver plating, gold, or the like. Further, not only plating but also reflow treatment of tin or the like may be performed.

The box portion 520 of the tubular terminal 511 is a box portion of a female terminal that allows insertion of an insertion tab such as a male terminal. In the present invention, the detailed shape of the box portion 520 is not particularly limited. In other words, the tubular terminal 511 only needs to include the tubular caulking portion 530 via at least the transition portion 540. For example, the tubular portion 511 may not have the box portion. For example, the box portion is an insertion tab of the male terminal. Also good. Moreover, the shape by which the terminal edge part which concerns on another form to the tubular crimp part 530 may be connected. In this specification, in order to explain the tubular terminal of the present invention, an example in which a female box is provided for convenience is shown.
The transition part 540 of the tubular terminal 511 is configured by pressing so that one end of the tubular part 525 is crushed and overlapping in a planar shape, and its intermediate position in the longitudinal direction is closed by means such as welding in the width direction. In addition, it is formed so that moisture or the like does not enter from the transition portion 540 side.

FIG. 31 is a cross-sectional view of the main part of the wire connection structure 510 in the longitudinal direction.
The electric wire 513 is configured, for example, by covering a core wire 514 in which strands 514a made of a metal or alloy material are bundled with a conductor insulating layer 515 made of an insulating resin (for example, polyvinyl chloride). The core wire 514 is formed by twisting the wire 514a so as to have a predetermined cross-sectional area. However, the core wire 514 is not limited to this form and may be formed by a single wire.
In addition, the metal material which comprises a core wire should just be a metal which has high electroconductivity, and may use copper or a copper alloy other than aluminum or an aluminum alloy.

The tubular caulking part 530 is a part for crimping and joining the tubular terminal 511 and the electric wire 513 and includes a conductor crimping reduced diameter part 535 and a coated crimping reduced diameter part 536.
Usually, when crimped, the conductor crimped reduced diameter portion 535 and the coated crimped reduced diameter portion 536 are plastically deformed to be reduced in diameter compared to the original diameter, so that the core wire tip 514b and the sheath tip of the electric wire 513 (Crimped part) 515a is crimped and joined.
One end of the tubular caulking portion 530 has an electric wire insertion port 531 into which the electric wire 513 can be inserted, and the other end is connected to the transition portion 540. The transition portion 540 side of the tubular caulking portion 530 is closed by means such as welding, and is formed so that moisture or the like does not enter from the transition portion 540 side.
When moisture adheres to the joint between the metal substrate (copper or copper alloy) of the tubular terminal 511 and the core wire 514 (aluminum or aluminum alloy), the core wire 514 corrodes due to the difference in electromotive force (ionization tendency) between the two metals. Further, even if the tubular terminal 511 and the core wire 514 are made of aluminum, their joints are easily corroded due to a subtle difference in alloy composition.

  In this configuration, the tubular caulking portion 530 is formed in a bottomed tubular shape, so that intrusion of moisture and the like is suppressed from the outside, and corrosion of the joint portion between the tubular terminal 511 and the electric wire 513 can be suppressed. The tubular caulking portion 530 is not necessarily cylindrical with respect to the longitudinal direction, and may be an elliptical or rectangular tube depending on the case because a certain effect against corrosion can be obtained if it is tubular. . Further, the diameter does not need to be constant, and the radius may change in the longitudinal direction.

The tubular caulking portion 530 is formed, for example, by punching a strip made of copper or a copper alloy into a planarly developed shape and bending it. In this case, the box portion may be provided integrally.
Since the portion corresponding to the caulking portion has a C-shaped cross section when bent from a flat state, the tubular caulking portion 530 is formed by joining both open ends and joining them by welding or the like. The Laser welding is preferable for joining the tubular caulking portion 530, but welding methods such as electron beam welding, ultrasonic welding, and resistance welding may be used. Also, joining using a connection medium such as solder or solder may be used. Further, the tubular caulking portion 530 is not limited to the method of joining both end portions of the C-shaped cross section, and may be formed by a deep drawing method. Further, the tubular crimping portion 530 may be formed by cutting the continuous tube and closing one end side.

In the tubular caulking portion 530, the metal base material constituting the tubular caulking portion 530 and the electric wire 513 are mechanically bonded by pressure, thereby ensuring electrical connection at the same time. The caulking is performed by plastic deformation of a base material or an electric wire (core wire). Accordingly, the tubular caulking portion 530 needs to be designed to have a thickness so that it can be caulked and joined, but since it can be joined freely by manual machining or machining, it is particularly limited. is not.
The tubular caulking portion 530 is required to have a function of maintaining the electrical conductivity by strongly compressing the core wire 514 and a function of maintaining the sealing performance by compressing the conductor insulating layer 515. In the coated crimping reduced diameter portion 536, the cross section thereof is caulked into a substantially circular shape, and an almost equal pressure is applied over the entire circumference of the conductor insulating layer 515, thereby generating a uniform elastic repulsive force over the entire circumference. It is preferable to obtain a sealing property.

  Since aluminum or an aluminum alloy has a higher contact resistance than copper and a copper alloy, when aluminum or an aluminum alloy is used for the core wire, there is concern about the connection between the electric wire and the terminal. For this reason, the inner wall surface of the tubular caulking portion 530 is provided with an electric wire locking groove (not shown) extending in the circumferential direction of the electric wire 513 at a position in contact with the core wire 514 of the electric wire 513 inserted from the electric wire insertion port 531. It is good also as a structure which maintains the contact pressure with the electric wire 513. FIG.

  The conductor insulating layer 515 of the electric wire 513 includes a resin layer 541 made of, for example, polyvinyl chloride, and a coating tip portion (crimped portion) 515a is provided with a layer of an adhesive 555 outside the resin layer 541. It is formed as a two-layer coating layer. In the sixth embodiment, the conductor insulating layer (covering layer) 515 has a two-layer structure with the coating tip (crimped portion) 515a. However, if the adhesive 555 is provided in the outermost layer, two or more layers are provided. Of course, you may comprise. In addition, if two or more conductor insulating layers (covering layers) 515 are partially provided at least on the covering tip portion (crimping portion) 515a in the length direction (axial direction) of the electric wire 513, the length of the electric wire 513 is not necessarily obtained. It does not have to be provided over the entire length in the direction.

FIG. 32 is a perspective view showing the tubular terminal 511A and the electric wire 513 before being crimp-bonded.
The tubular terminal 511 </ b> A before being crimp-bonded has a box portion 520 and a tubular portion 525 of a female terminal, and has a transition portion 540 as a bridge between them. The tubular portion 525 includes an enlarged diameter portion 526 that gradually increases in diameter from the transition portion 540 and a cylindrical portion 527 that extends in a cylindrical shape from the edge of the enlarged diameter portion 526.
The enlarged diameter portion 526 is formed with a conductor crimping reduced diameter portion 535 (see FIG. 30), and the cylindrical portion 527 is formed with a coated crimping reduced diameter portion 536 (see FIG. 30). The tubular terminal 511A is partially or entirely subjected to a treatment such as tin plating.

  As a resin material constituting the resin layer 541 of the conductor insulating layer 515, a polyvinyl chloride resin or a crosslinked polyvinyl chloride resin can be used. Alternatively, the resin layer 541 can be formed using a halogen-free resin (non-halogen resin) mainly composed of polyolefin resin, ethylene propylene rubber, silicon rubber, polyester, silicon resin, or the like. These halogen-free resins may be a mixture of a flame retardant such as a metal hydrate.

The adhesive 555 has a liquid, sol- or gel-like fluidity state, and increases the hardness through the passage of time, temperature change, moisture absorption, drying, and the like. The adhesive 555 is disposed by a method such as application or spraying on the surface of the coating tip portion (crimping portion) 515a in a state having fluidity before being cured.
Specifically, after applying the adhesive 555 to a predetermined region of the tip of the resin layer 541 of the electric wire 513, using a tool such as a wire stripper, the tip of the resin layer 541 to which the adhesive 555 is applied is applied. Part of the region (tip side) is peeled off from the core wire 514. As a result, the adhesive 555 is reliably applied in the axial direction from the tip of the resin layer 541, and the adhesive 555 can be prevented from adhering to the core wire 514 in the application process. An increase in resistance at the portion can be prevented.

The adhesive 555 is more flexible (in a state where the hardness is increased) in order to increase the water-stopping property after the electric wire 513 is crimped and joined to the tubular caulking portion 530 (the coated crimping reduced diameter portion 536). What has elasticity is more preferable.
As a suitable material for the adhesive 555, an adhesive using a synthetic resin or a natural resin can be given. Adhesives include reactive adhesives that cure by causing a chemical reaction over time, solvent-based adhesives that increase hardness by volatilization of the solvent, fluidity is developed by heating, and then cooled. Hot-melt adhesives that increase hardness are included, and solvent-based adhesives include emulsion-based adhesives.
More specific examples include those containing polyurethane resin, modified silicon resin, vinyl resin, polyamide resin, polyimide resin, melamine resin, urea resin and the like as main components. In addition, a rubber-based adhesive in which a solvent or the like is added to silicone rubber, fluorine rubber, butyl rubber, butadiene rubber, styrene-butadiene rubber, ethylene propylene rubber, epichlorohydrin rubber, chloroprene rubber, nitrile rubber or the like known as a synthetic rubber. It can also be used.

A particularly preferred example is a hot melt adhesive. For example, a hot-melt adhesive mainly composed of ethylene vinyl acetate resin, polyamide resin, polyurethane resin, polyolefin resin, modified silicon resin, etc. is suitable, and a mixture of these or those containing other additive components, etc. But it ’s okay. When a hot-melt adhesive is used as the adhesive 555, fluidity can be imparted to the adhesive 555 attached to the tip of the resin layer 541 any number of times by placing the electric wire 513 in a high temperature environment. For this reason, before and after the process of attaching the adhesive 555 to the tip of the resin layer 541 and the process of crimping and bonding the electric wire 513 to the tubular terminal 511, the adhesive 555 can be given fluidity as necessary.
As a more preferred example, among hot melt adhesives, those having flexibility (elasticity) even when the hardness is increased at room temperature are preferable. More specifically, those containing ethylene vinyl acetate resin, polyurethane resin, polyolefin resin, modified silicon resin and the like as the main agent can be mentioned.
In addition, when a thermoplastic material such as a hot melt adhesive is used as the adhesive 555, the melting processing temperature of the adhesive 555 is preferably set to be equal to or higher than the maximum temperature in the environment where the wire connection structure 510 is disposed. For example, when the electric wire connection structure 510 is used as an automobile harness, a resin material having a melting temperature of 120 to 160 degrees is preferable if it is used in a vehicle interior or the vicinity thereof, and is used in an engine room. In this case, a higher melting temperature of about 180 degrees is preferable. On the other hand, the tubular terminal 511 is partially or entirely subjected to a treatment such as tin plating. For this reason, it is preferable that the upper limit of the melting temperature of the adhesive 555 does not exceed 231.9 degrees which is the melting point of tin. Moreover, if it has a flame retardance, it is still more preferable.

  In selecting the material of the adhesive 555, the material of the resin layer 541 is selected so that the combination of the resin layer 541 and the adhesive 555 does not cause a change in physical properties due to transfer of additives, oils and fats, or solvents. Are preferably selected. Specifically, in the case where a halogen-free resin other than a silicon resin is used as the resin layer 541, an adhesive containing a halogen-containing resin, an oil or fat, or an organic solvent may be avoided as the adhesive 555.

  In the sixth embodiment, the conductor insulating layer 515 of the electric wire 513 has a two-layer structure in which a layer of an adhesive 555 is provided outside the resin layer 541 at the coating tip portion (crimped portion) 515a. For this reason, when the electric wire 513 is crimped and joined to the tubular caulking portion 530, the inner surface of the tubular caulking portion 530 (covered crimping reduced diameter portion 536) and the surface of the resin layer 541 are brought into close contact via the adhesive 555. For this reason, when crimped and joined, water is prevented from entering the tubular caulking portion 530 through the gap between the inner surface of the coated crimped reduced diameter portion 536 and the surface of the conductor insulating layer 515, and corrosion of the core wire 514 can be suppressed. .

Next, Example 2 will be described.
(Example 2)
In the wire connection structure 510 of Example 2, Furukawa Electric Co., Ltd. copper alloy FAS-680 (thickness 0.25 mm, H material) was used as the base material of the tubular terminal 511 (511A). The alloy composition of FAS-680 is nickel (Ni) 2.0-2.8 mass%, silicon (Si) 0.45-0.6 mass%, zinc (Zn) 0.4-0.55. It contains 0.1% to 0.25% by mass of tin (Sn) and 0.05 to 0.2% by mass of magnesium (Mg), with the balance being copper (Cu) and inevitable impurities.
The tubular portion 525 was subjected to laser welding so that both end portions of the bent C-shaped cross section were abutted and the inner diameter was 3.2 mm.

  The core wire 514 of the electric wire 513 has an alloy composition of about 0.2% by mass of iron (Fe), about 0.2% by mass of copper (Cu), about 0.1% by mass of magnesium (Mg), and silicon (Si). As an element wire 514a, an aluminum alloy wire (wire diameter: 0.42 mm) having approximately 0.04% by mass of aluminum and the balance being aluminum (Al) and inevitable impurities was used. 19 strands 514a were used to form a core wire 514 of 2.5 sq, 19 strands.

  For the resin layer 541 (conductor insulating layer 515) of the electric wire 513, an ethylene vinyl acetate copolymer was used as a halogen-free resin. The resin layer 541 was formed by an extrusion method around the core wire 514 so that the outer diameter was 2.8 mm.

  As the adhesive 555, an elastic adhesive mainly composed of a modified silicone resin was used. This elastic adhesive exhibits elasticity even after curing. This adhesive 555 was coated on the surface of the resin layer 541 so as to have a thickness of about 0.25 mm.

  For the electric wire 513, the conductor insulating layer 515 (the resin layer 541 and the adhesive 555) at the end of the electric wire was peeled off using a wire stripper to expose the core wire 514. In this state, the electric wire 513 was inserted into the tubular portion 525 of the tubular terminal 511, and the tubular portion 527 of the tubular portion 525 was pressure-bonded by partial strong compression using a crimper and an anvil.

(Comparative Example 2)
The wire connection structure of Comparative Example 2 was the same as Example 2 except that the adhesive 555 was not used.

As an environmental test, an air leak test was performed before and after being left at high temperature.
The high temperature storage was left in an environment of 120 degrees Celsius for 120 hours.
The air leak test was performed by immersing the electric wire 513 crimped to the tubular terminal 511 in water stored in the container. With the tubular terminal 511 submerged, an air tube extending from the pressurized air supply device was connected to the end of the electric wire 513 opposite to the tubular terminal 511. Pressurized air is injected at a predetermined air pressure from the pressurized air supply device, and the occurrence of bubbles from the tubular caulking portion 530 is visually determined. If bubbles are generated, the pressurized air supply device Air pressure was detected. When bubbles were not generated, the pressure of pressurized air to be injected was increased to 50 kPa, and the test was completed.

The wire connection structure 510 of Example 2 did not generate bubbles in both the air leak test before being left at high temperature and the air leak test after being left at high temperature. Since the air pressure reached 50 KPa in the absence of bubbles, the test was terminated.
On the other hand, the wire connection structure of Comparative Example 2 did not generate bubbles even when the air pressure reached 50 KPa in the air leak test before leaving at high temperature, but the tube part and the conductor when the air pressure was 10 KPa after leaving at high temperature. The generation of bubbles was visually recognized from between the insulating layers.
Thereby, it became clear that the adhesive 555 tightly joins the tubular portion 525 and the resin layer 541 and greatly improves the water stoppage on the wire insertion port 531 side.
As described above, according to the annular terminal 511 of the present invention, an electric wire connection structure in which an electric wire having a core wire and a conductor insulating layer formed on the outer periphery of the core wire and a tubular terminal are pressure-bonded, Since the insulating layer has two or more coating layers whose outermost layer is made of an adhesive, the tubular terminal and the conductor insulating layer of the electric wire are in close contact with each other by the adhesive layer.

  More specifically, in a conventional wire harness used in an automobile or the like, an electric wire formed by coating a core wire (conductive wire) with an insulator is used, and this type of electric wire is a core wire that is exposed by peeling off the coating. A metal terminal is crimped to the end. In the conventional wire-terminal connection structure, the surface of the end of the core wire from which the insulator has been peeled is exposed. Therefore, when applied to applications such as vehicles, the wire is exposed to rainwater, etc. When running for a long time in a humid environment, there is a problem that the core wire is easily corroded.

In particular, in recent years, in order to reduce the weight of a wire harness for the purpose of improving the fuel efficiency of an automobile, the core wire material has been replaced with an aluminum-based material such as aluminum or aluminum alloy from a conventional copper-based material.
When the core wire of aluminum material is used for the electric wire and the copper material is used for the metal terminal of the crimping part, there is a potential difference between the metal constituting the electric wire (aluminum material) and the metal constituting the metal terminal (copper material). Arise. At this time, when moisture or the like adheres to the connecting portion between the electric wire and the terminal, the conductor (core wire) of the electric wire is exposed, so that corrosion between different metals occurs and corrosion of any metal proceeds. In the corrosion between dissimilar metals of an aluminum-based material and a copper-based material, the aluminum-based material is thinned by the corrosion. For this reason, there is a risk that poor contact may occur in the wire connection portion.
In order to solve these problems, conventionally, a technique has been proposed in which the entire outer periphery of the end exposed region of the crimping portion and the vicinity thereof is molded with resin (see, for example, Japanese Patent Application Laid-Open No. 2011-222243).
In addition, a technique has been proposed in which a terminal is crimped after a metal intermediate cap is attached to the exposed portion of the core of the electric wire to protect the crimped portion between the electric wire and the terminal (for example, see Japanese Patent Application Laid-Open No. 2004-207172).
However, according to the present invention, there is provided a wire connection structure in which an electric wire having a core wire and a conductor insulating layer formed on the outer periphery of the core wire and a tubular terminal are pressure-bonded, and the conductor insulating layer has an outermost layer. Since it has two or more coating layers which are layers made of an adhesive, the tubular terminal and the conductor insulating layer of the electric wire are brought into close contact with each other by the adhesive layer. Therefore, durability against thermal cycling can be improved.
Note that grease may be used instead of the adhesive 555. Furthermore, a bell mouth 136 (see FIG. 20) whose diameter is increased outward may be formed at the rear end of the tubular portion 525 of the tubular terminal 511, and the bell mouth 136 can achieve the same effect.

1, 1 Pa, 1 Pb, 2 A, 2 B, 2 C... Connection structure 21... Female connector 22... Female connector housing 31... Male connector 32 ... Male connector housing 100. 132 ... Conductor crimping portions 134, 210 ... Adhesive 134a ... Adhesive component 134b ... Capsule 134K ... Capsule-like adhesive 135 ... Step 200 ... Covered wire 201 ... Aluminum core wire 201a ... Aluminum strand 202 ... Insulation coating X ... Longitudinal direction 310 ... Wire connection structure 311, 311A, 311B ... Tubular terminal (terminal)
313 ... Electric wire 314 ... Core wire 315 ... Conductor insulation layer 320 ... Box part 325, 325A, 325B ... Tubular part (part to be crimped)
327, 327A, 327B ... tubular portion 330 ... tubular crimping portion 333 ... serration 335 ... conductor crimping reduced diameter portion 336 ... coated crimping reduced diameter portion 340, 340A, 340B ... transition portion 355 ... adhesive 510 ... electric wire connection structure 511, 511A ... Tubular terminal 513 ... Electric wire 515 ... Conductor insulation layer 515a ... Covering tip (crimp)
525 ... Tubular part 526 ... Diameter enlarged part 527 ... Tube part 530 ... Tubular caulking part 531 ... Electric wire insertion port 535 ... Conductor crimping reduced diameter part 536 ... Covering crimping reduced diameter part 541 ... Resin layer 555 ... Adhesive

Claims (24)

A coated surrounding portion that surrounds the vicinity of the tip of the insulating coating in the coated wire in which the outer periphery of the electric wire conductor configured by bundling a plurality of strands is coated with an insulating insulating coating; and from the tip of the insulating coating, The covering by the wire connecting portion in the crimping terminal provided with the wire connecting portion having a hollow cross-section formed integrally with the wire crimping portion that is crimped and crimped to the wire conductor exposed for a predetermined length in the longitudinal direction. A connection structure in which an electric wire and the crimp terminal are connected,
In the vicinity of the tip of the insulating coating in the coated electric wire , a liquid adhesive having a viscosity that does not penetrate between the plurality of strands is previously applied,
At least the wire conductor is crimped and connected to the conductor crimping portion, and the vicinity of the tip of the insulating coating is adhesively connected to the coated surrounding portion, between the coated surrounding portion and the insulating coating in the coated electric wire, Connection structure with liquid adhesive interposed. The liquid adhesive,
The connection structure according to claim 1, wherein the connection structure is formed of a curable synthetic resin material and cured in a state of being interposed between the covering surrounding portion and the insulating coating. 3. The connection structure according to claim 1, wherein the liquid adhesive is provided at a step between an end surface of the coated surrounding portion and an outer peripheral surface of the insulating coating in the coated electric wire. The connection structure according to claim 3 , wherein the liquid adhesive provided in the step is applied so as to straddle an outer peripheral surface on an end portion side of the covering surrounding portion. The connection structure according to any one of claims 1 to 4 , wherein the liquid adhesive is interposed over the entire circumference of the covered electric wire. The liquid adhesive,
Constructed in a capsule shape encapsulated with a capsule,
Wherein the crushing of the capsule at the time of crimping the covering surrounding portion, the covering surrounding portion and according to any one of claims 1 to 5 which is constituted by a capsule-like adhesive for bonding the said insulating coating on said coated electric wire Connection structure. In the conductor crimping part,
The connection structure according to any one of claims 1 to 6 , further comprising a sealing portion that extends toward a distal end in the longitudinal direction and seals the distal end in the longitudinal direction. The wire conductor is made of an aluminum-based material,
The connection structure according to any one of claims 1 to 7 , wherein at least the electric wire connection portion is made of a copper-based material. The connector which has arrange | positioned the crimp terminal in the connection structure as described in any one of Claim 1 to 8 in the connector housing. A coated surrounding portion that surrounds the vicinity of the distal end of the insulating coating in the coated electric wire in which the outer periphery of the electric wire conductor is coated with an insulating insulating coating; and the predetermined length exposed in the longitudinal direction of the coated electric wire from the distal end of the insulating coating A connection structure in which the covered wire and the crimp terminal are crimped and connected by the wire connection portion in the crimp terminal having a hollow cross-section electric wire connection portion configured by crimping and crimping the wire conductor. A method for manufacturing a body,
After applying a liquid adhesive in the vicinity of the tip of the insulation coating, the wire conductor is exposed from the tip of the insulation coating, the covered wire is inserted into the wire connection portion of the crimp terminal,
After interposing the liquid adhesive between the coated surrounding portion and the insulating coating in the coated electric wire,
At least the conductor crimping portion is crimped to the electric wire conductor, and the insulating coating is adhesively connected to the covering surrounding portion with the liquid adhesive, and the connecting electric wire and the crimping terminal are crimped and connected. Manufacturing method. The liquid adhesive,
In the state where the tip of the covered electric wire is inserted into the inside of the covered surrounding portion, the tip of the covered electric wire is made thicker than the distance between the inner peripheral surface of the covered surrounding portion and the outer peripheral surface of the covered electric wire. The manufacturing method of the connection structure of Claim 10 apply | coated to the outer peripheral surface of the said covered electric wire, before inserting in the inside of a covering surrounding part. The liquid adhesive,
On the outer peripheral surface of the covered electric wire so as to be thinner than the space between the inner peripheral surface of the covered surrounding portion and the outer peripheral surface of the covered electric wire in a state where the tip of the covered electric wire is inserted into the inner portion of the covered electric wire. Apply,
When crimping connecting the crimp terminal and the covered electric wire, according to claim 10 for crimping crimped the covering surrounding portion with respect to the insulating coating of the covered electric wire inserted into the interior of the wire connecting portion A manufacturing method of a connection structure. The manufacturing method of the connection structure as described in any one of Claim 10 to 12 apply | coated to the said insulation coating in the said covered electric wire by immersing the front-end | tip part of the said covered electric wire in the said liquid adhesive consisting of a liquid. . 13. When the electric wire conductor is exposed from the tip of the insulating coating, the liquid adhesive is applied to the insulating coating in the coated electric wire, and then the coated electric wire and the crimp terminal are connected by crimping . The manufacturing method of the connection structure as described in any one of them . An electric wire connection structure in which an electric wire having a core wire and a conductor insulating layer formed on the outer periphery of the core wire, and a tubular terminal formed by bending the conductor into a tubular shape are bonded by pressure bonding,
In a portion facing the conductor insulating layer in the tubular terminal, a liquid adhesive is applied in advance in a developed state before bending,
The tubular terminal is crimped to the core wire and the conductor insulating layer of the electric wire inserted into the tubular terminal, and the liquid adhesive is interposed between the conductor insulating layer and the tubular terminal. Wire connection structure. The wire connection structure according to claim 15, wherein the tubular terminal is made of copper or a copper alloy, and the core wire of the wire is made of aluminum or an aluminum alloy. The wire connection structure according to claim 15 or 16 , wherein the liquid adhesive is cured in a joined state and is made of a fluid adhesive before curing. The tubular terminal has a joint where conductors are joined;
18. The electric wire according to claim 15 , wherein a thickness of the conductor in the joint is thicker than a portion other than the joint, and the liquid adhesive is disposed inside the joint. Connection structure. The conductor insulating layer is
The electric wire connection structure according to any one of claims 15 to 18 , further comprising a layer made of a halogen-free resin composition. The conductor insulating layer is
The wire connection structure according to any one of claims 15 to 19 , further comprising a layer made of polyvinyl chloride resin. A tubular terminal formed by bending a conductor and having a tubular crimping portion to be joined by being crimped together with an electric wire,
A tubular terminal, wherein a liquid adhesive is applied in advance to the portion to be crimped in a developed state before bending. The liquid adhesive is
The tubular terminal according to claim 21 , wherein the tubular terminal is arranged in an annular shape along an inner peripheral surface of the to-be-crimped portion at least in a part of the to-be-crimped portion in the axial direction. The liquid adhesive is
The tubular terminal according to claim 21 or 22 , wherein the tubular terminal has flexibility after curing. The liquid adhesive is
The tubular terminal according to any one of claims 21 to 23 , wherein the tubular terminal is made of a thermoplastic material.

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