JP5718303B2 - Crimp terminal, connection structure, connector, and manufacturing method of connection structure - Google Patents

Description

  The present invention includes, for example, a crimp terminal attached to a connector or the like for connecting an automobile wire harness, a connection structure using the crimp terminal, a connector equipped with such a connection structure, and a connection structure The present invention relates to a method for manufacturing a body.

  Recent automobiles are equipped with various electrical devices, and the electrical circuits of each device tend to be complicated. Therefore, it is indispensable to ensure a stable electrical connection state. Such electric circuits of various electrical equipment are configured by wiring a wire harness formed by bundling a plurality of covered electric wires to an automobile and connecting the wire harnesses with a connector. Moreover, the crimp terminal which crimp-connected the covered electric wire of the wire harness to the crimp part is mounted | worn in the inside of a connector.

  However, when connecting a coated wire to a crimp terminal, a gap is likely to form between the exposed portion of the conductor portion exposed from the tip of the insulation coating portion of the coated wire and the crimp portion of the crimp terminal, and the conductor portion is exposed to the outside air. When the moisture enters the crimping part of the crimping terminal mounted inside the connector, the surface of the conductor part crimped to the crimping part is corroded and the conductivity is lowered. was there.

  As a method for preventing a decrease in conductivity in the crimped part due to the ingress of moisture, the applicant, for example, in a crimped state in which the conductor part is crimped by the crimped part, the exposed part of the conductor part is made of a resin insulating coating having a high viscosity Has proposed a connection structure (see Patent Document 1) closed by the.

  However, the connection structure of Patent Document 1 is a so-called open barrel type crimp terminal, and since the insulation coating is exposed, the water stopping performance is reduced due to aging of the resin material itself, and the conductivity may be lowered. was there.

  Therefore, in recent years, a crimp section with a hollow cross section that crimps the conductor portion and the insulating coating portion so as to straddle the wire crimping range for crimping the conductor portion of the coated electric wire and the coating crimp range for crimping the insulating coating portion. A so-called closed-barrel type crimp terminal provided with is proposed (see Patent Document 2 below).

  However, even if a closed barrel type crimp terminal is used, a gap may be generated between the insulation coating part and the crimping part (coating crimping range) due to, for example, the thinning of the insulation coating part due to deterioration over time. Due to the processing accuracy of the parts (accuracy of welding processing, accuracy of bending processing, etc.), the conductor part is exposed to the outside air by forming a hole that connects the inside (conductor part) of the crimping part and the outside. There was a risk of exposure.

  Here, a method of applying a sealing material made of resin, solder, or the like between the insulating coating part and the crimping part or in the hole of the crimping part is conceivable. In this case, the coated electric wire and the crimping terminal are connected. When the connection structure is assembled to the connector housing, there has been a problem that the assembly cannot be performed because the sealing material swelled in a bump shape outside the crimping portion interferes with the connector housing.

  In particular, when sealing between the insulation coating portion and the crimping portion, it is conceivable to use a resin as the sealing material. A metal layer composed of many kinds of metals such as plating and tin plating is exposed, and the adhesive force of the resin on the surface of the many kinds of metal layers differs for each metal. Also, PVC and non-halogen material are generally used as the material used for the insulating coating. At present, the actual situation is that there is no adhesive (resin) that stably maintains the adhesive force between different kinds of materials, and the resin is crimped for the purpose of sealing between the insulation coating and the crimping part. Even if it was applied to the terminal end face, it could not be sufficiently adhered.

In addition, since the resin is not sufficiently bonded to the end face of the crimp terminal, a large external force is applied in the vicinity of the end face of the crimp terminal, or because the thermal expansion difference is individually different even in a temperature environment, There was also a problem that peeling occurred. In addition, when an inexpensive resin is employed, there is a problem that the resin is hydrolyzed and the gap cannot be sufficiently sealed.
For these reasons, the method of applying a sealing material to seal between the insulating coating portion and the crimping portion has not been able to reliably obtain stable conductivity.

JP 2011-233328 A JP-A-7-37670

  It is an object of the present invention to provide a crimp terminal, a connection structure, a connector, and a method for manufacturing the connection structure that can obtain stable conductivity while ensuring assemblability.

The present invention provides a crimp terminal including at least a crimp section having a hollow cross section that allows crimp connection to a conductor portion exposed from the tip of an insulating coating section of a covered electric wire, and the crimp section has a hollow cross section. In addition to bending the plate material in the width direction, welding the end portions in the width direction of the plate material in the longitudinal direction, the wire crimping range for crimping the conductor portion, and the coating crimping range for crimping the insulating coating portion, the addition to the conductor portion and configured to crimp across said insulating coating portion, the crimping portion, a filler injection port for injecting a filling material between the covered wire and the piezoelectric attachment part, said end It is characterized in that a plurality of parts are arranged side by side along the welded part where the parts are welded together .

The crimp terminal is a closed barrel type terminal having a crimp section with a hollow cross section, and only a connection terminal having a connection section that allows connection with the connection section of the other terminal of a pair of terminal sets, or only the crimp section Including a terminal constituted by
The filler can be made of resin or solder.

To weld the end portions in the width direction of the plate material in the longitudinal direction means to butt-weld the end portions in the width direction of the plate material, or to overlap the end portions in the width direction of the plate material by a predetermined width. This is a concept including welding the overlapped portion. Here, the end-to-end end in the width direction of the plate material described above is not only the end-to-end contact in the width direction in the hollow cross-section formed by bending the plate material in the width direction, but also the end-to-end contact with a slight gap in the width direction. It is a concept that also includes Further, not only the side surface in the plate thickness direction of the plate material but also the inclined side surface in which the side surface of the end portion is inclined or the side surfaces constituting the surface having a height equal to or greater than the thickness of the plate material.

According to the present invention, it is possible to configure a crimp terminal capable of obtaining stable conductivity while ensuring assemblability.
Specifically, if the filler is injected between the crimping portion and the covered electric wire from the filler inlet while the crimping portion is crimped across the conductor portion and the insulation coating portion, the gap between the crimping portion and the covered electric wire Can be filled with a filler. Thus, by filling the space between the crimping part and the covered electric wire with the filler, for example, the thinning of the insulating coating part due to deterioration over time, the gap between the insulating coating part and the crimping part (covering crimping range) For example, a gap may be generated or a hole that connects the inside (conductor part) and the outside of the crimping part may be formed due to the precision of the crimping part (welding precision, crimping precision, etc.) Even if a situation occurs, the filler can reliably prevent the conductor portion from being exposed to the outside air. For this reason, the stable electroconductivity can be obtained.

  In addition, since a plurality of filler inlets are provided, if the filler is injected from any one filler inlet, the air between the crimping part and the covered electric wire is supplied from the other filler inlets. The filler can be injected while escaping. For this reason, the filler can be filled substantially uniformly without being pushed out (overflow) on the way by the action of the air, and as a result, the conductor is more exposed to the outside air. It can be surely prevented.

  In addition, when the filler is injected from any one filler inlet, the filling state of the filler can be confirmed based on the arrival state of the filler to the other filler inlet, It is possible to reliably prevent the filler from being injected more than necessary. For this reason, it can prevent reliably that the situation where a filler overflows to the exterior of a crimping | compression-bonding part and swells in the shape of a knob is generated. In this case, it is possible to reliably prevent the inconvenience that the filling material raised in the shape of a bump outside the crimping portion interferes with the connector housing and cannot be assembled. Therefore, the connection structure in which the covered electric wire and the crimping terminal are connected. Assembling property when assembling the connector to the connector housing can be ensured.

In addition, the plate member is bent in the width direction so that the crimped portion has a hollow cross-section, the ends in the width direction of the plate material are welded in the longitudinal direction, and the filler inlet is connected to the end portions. By bending a plurality of crimped portions along the welded locations, the plate material is bent in the width direction so that the cross-section is hollow, and the end portions in the width direction of the plate material are welded in the longitudinal direction. Therefore, a crimp terminal having a crimp section having a hollow cross-section can be easily manufactured from a metal plate, and the conductor can be reliably prevented from being exposed to the outside air.

Specifically, for example, a metal plate material is punched into a desired shape to obtain a material portion to be a crimp terminal connected to a belt-like carrier, and then sequentially bent and welded between end portions. By applying, it can be formed into a desired crimp terminal shape. Therefore, a crimp terminal provided with a crimp section having a hollow cross section can be easily manufactured from a metal plate.

However, since the plate-like ends are welded in the longitudinal direction, the longer the distance between the welded portions extending in the longitudinal direction, the higher the accuracy of the welding process (welding reliability) is required. The probability that a hole that communicates the inside (conductor portion) and the outside is formed. According to the above-described configuration, the filler can be injected between the crimping portion and the covered electric wire from the plurality of filler inlets along the welding location, and the gap between the crimping portion and the covered electric wire can be filled with the filler. By comprising in this way, a filler can be inject | poured into the wide range of a longitudinal direction between the said welding location and a covered electric wire. For this reason, as described above, due to accuracy reasons when welding the welded portion extending in the longitudinal direction, a situation has occurred in which a hole that connects the inside (conductor portion) and the outside of the crimping portion is formed. Even so, the conductor portion can be reliably prevented from being exposed to the outside air.

In particular, when the sealing portion is configured on one end side in the longitudinal direction, the welded portion of the sealing portion intersecting the longitudinal direction and the end portions in the width direction of the plate material are welded in the longitudinal direction. An intersecting portion intersecting with the welded portion is formed, and the intersecting portion is softened more than other portions because the crimping portion is melted at least twice. For this reason, the accuracy (welding reliability) of the welding process is lowered at the intersecting portion, and there is a possibility that a hole that connects the inside (conductor portion) of the crimping portion and the outside is formed.

According to the configuration described above, the filler can be injected between the sealing portion and the covered electric wire from the filler inlet provided in the sealing portion, and the space between the sealing portion and the covered electric wire can be filled with the filler. In particular, as described above, there is a situation in which a hole that connects the inside (conductor part) and the outside of the crimping part is formed due to accuracy reasons when welding the intersecting part. Even if it does, it can prevent more reliably by a filler that a conductor part is exposed to external air.

As an aspect of the present invention, the filler inlet can be provided at least in the covering pressure-bonding range.
According to the present invention, when a filler is injected between the coated crimping range and the coated electric wire from the filler injection port, the gap between the coated crimped range and the coated electric wire can be filled with the filler. In this way, since the space between the covered crimping area and the covered electric wire can be filled with the filler, the insulating coated part and the crimped part (coated crimped part) are particularly reduced due to the thinning of the insulating coated part due to deterioration over time. Even if a gap occurs with the filler, the conductor can be more reliably prevented from being exposed to the outside air.

Moreover, as an aspect of the present invention, a plurality of the filler inlets can be arranged side by side in the longitudinal direction in the hollow cross-sectional shape.
The longitudinal direction can be a direction substantially coinciding with the longitudinal direction of the covered electric wire to be crimped to the crimping portion.
By this invention, a filler can be inject | poured into the wide range of the longitudinal direction of a crimping | compression-bonding part.

  Further, as an aspect of the present invention, the longitudinal side conductor portion side formed in a sealing shape for sealing one end side on the side of the conductor portion in the longitudinal direction in the hollow cross-sectional shape and formed in the sealing shape to be sealed On one end side, a sealing portion can be formed by welding in a direction intersecting the longitudinal direction, and the filler inlet can be provided in the sealing portion.

The one end side of the conductor portion side in the longitudinal direction in the hollow cross-sectional shape described above means the end portion side opposite to the insertion side where the conductor portion is inserted into the crimping portion.
The welding in the direction intersecting the longitudinal direction described above is, for example, welding in the width direction substantially orthogonal to the longitudinal direction, and welding that is continuous with welding in the longitudinal direction, or even if welding in the longitudinal direction is not continuous, It can be an intersecting weld. In addition, the formation of the sealing shape and the welding in the direction intersecting the longitudinal direction may be performed in the state of the crimp terminal alone, or the sealing shape is formed together with the crimp deformation of the crimp portion with respect to the conductor portion, Thereafter, welding that intersects the longitudinal direction may be performed.

  According to the present invention, only by crimping the crimping part into which the conductor part is inserted, the conductor part of the covered electric wire is not exposed to the outside of the crimping part, and can be crimped in a water-tight enveloping state, The conductor can be more reliably prevented from being exposed to the outside air by the filler.

  Specifically, at one end in the longitudinal direction of the hollow cross-section, an insertion location for inserting a conductor portion into the crimping section having a hollow cross-section to form a sealing portion by welding in a direction intersecting the longitudinal direction Other than the above, the conductor part in the crimping part is not exposed to the outside air, so that moisture can be prevented from entering the inside, and deterioration and secular change can be suppressed. Therefore, corrosion does not occur in the conductor portion, and an increase in electrical resistance caused by the corrosion can be prevented, so that stable conductivity can be obtained.

  In addition, in particular, in the case of forming a sealing part by sealing in a direction intersecting the longitudinal direction, in addition to forming in advance a sealing shape that seals one end side of the longitudinal direction of the hollow cross section, Other than the insertion point where the conductor part is inserted into the crimping part having a hollow cross-section, the conductor part of the covered electric wire can be exposed outside the crimping part simply by crimping the crimping part into which the conductor part is inserted. And can be pressure-bonded in a sealed state. Therefore, in order to ensure the water-stopping property, the conductor portion crimped to the crimping portion is not exposed to the outside air without using a cap or the like that is configured as a separate part for the conductor portion.

  However, as described above, both ends in the width direction intersecting the longitudinal direction become folded portions when bent so as to have a sealing shape that seals one end in the longitudinal direction of the hollow cross section. , Both ends of the width direction are formed with wrinkles and portions that cannot be sealed for reasons of bending accuracy. As a result, the sealing portion includes an inner portion (conductor portion) and an outer portion of the crimp portion. There is a risk of forming a hole communicating with.

  According to the configuration described above, by providing the filler inlet in the sealing portion, if the filler is injected between the sealing portion and the covered electric wire from the filler inlet, the sealing portion and the covered electric wire The space can be filled with a filler. In this way, since the space between the sealing portion and the covered electric wire can be filled with the filler, particularly, as described above, the crimping portion due to accuracy reasons when bending the sealing portion. Even if the situation where the hole which connects the inside (conductor part) and the exterior of this occurs, the conductor part can be more reliably prevented from being exposed to the outside air.

Moreover, as an aspect of the present invention, the filler inlet can be disposed so as to sandwich the welded portion where the ends are welded.
According to this invention, if the filler is injected from one filler inlet that sandwiches the weld location, the weld location and the covered electric wire are based on the state of arrival of the filler to the other filler inlet. It is possible to reliably check the filling state of the filler during the interval. In this case, it is assumed that the welded portion is recessed inward by caulking of the crimping portion and comes into contact with the covered electric wire, and the filling space filled with the filler is partially interrupted in the circumferential direction of the covered electric wire and the crimping portion. Even so, the space between the welded portion and the covered electric wire can be reliably filled with the filler.

Further, the present invention is a connection structure in which the covered electric wire and the crimp terminal are connected by a crimp portion in the crimp terminal and the space between the crimp portion and the covered electric wire is filled with the filler. It is characterized by.
According to the present invention, it is possible to obtain stable conductivity while ensuring assembling property by simply surrounding and crimping with the crimping portion of the crimping terminal and filling the space between the crimping portion and the covered electric wire with the filler. Can do.

  As an aspect of the present invention, a filling space for filling the filler is provided between the insulating coating portion and the coating pressure-bonding range, and the filler inlet is provided so as to communicate with the filling space, The filling space can be filled with the filler.

  The filling space is provided in the circumferential direction of the insulating coating portion and the coating crimping range. For example, when the crimping portion is caulked in the coating crimping range, a portion spaced outward from the insulating coating portion is formed. Prior to caulking the crimping part, it is assumed that the groove is formed in advance on the inner peripheral surface of the coated crimping range, or the groove is formed on the surface of the insulating coating part. be able to.

  Even if a situation occurs such that a gap is generated between the insulation coating portion and the crimping portion (coating crimping range) due to the thinning of the insulation coating portion due to deterioration over time, the conductor portion is exposed to the outside air. Exposure can be more reliably prevented by the filler filled in the filling space.

As an aspect of the present invention, the filling space can be provided between the insulating coating portion and an intermediate portion in the longitudinal direction of the coating pressure-bonding range.
By this invention, it becomes the structure which crimped | bonded the one end part by the side of the front-end | tip of an insulation coating part. For this reason, the filler injected from the filler inlet can be prevented from flowing between the conductor portion and the insulating coating. In this case, since the covered electric wire can be prevented from being hardened by the filler, the flexibility of the covered electric wire can be ensured. For example, even if a large external force is applied to the covered electric wire by swinging the covered electric wire, Damage and deterioration can be suppressed.

  On the other hand, since the other end portion of the covering crimping range is also crimped, the filler injected from the filler inlet can be prevented from flowing out from the insertion side where the conductor portion is inserted into the crimping portion. In this case, for example, it is possible to reliably prevent the inconvenience that the filling material that has flowed out of the crimping portion and swelled in the shape of a bump interferes with the connector housing and cannot be assembled. Assembling property when assembling the connected connection structure to the connector housing can be ensured.

Furthermore, the present invention is a connector in which a crimp terminal in the connection structure is disposed in a connector housing.
According to this invention, it is possible to connect the connection structure while ensuring stable conductivity.

  More specifically, for example, when the female connector and the male connector are fitted to each other and the crimp terminals of each connector are connected to each other, the crimp terminals of each connector can be connected to each other while ensuring water-tightness. As a result, it is possible to ensure a connection state having reliable conductivity.

Furthermore, the present invention provides a method for manufacturing a connection structure in which the covered electric wire and the crimp terminal are connected by a crimp portion having a hollow cross section that allows crimp connection to a conductor portion exposed from the tip of the insulating coating portion of the covered electric wire. In this case, the plate material is bent in the width direction so that the cross-section is hollow , the ends in the width direction of the plate material are welded in the longitudinal direction, and the conductor crimping range is crimped. And a configuration in which crimping is performed across the conductor portion and the insulating coating portion, and a plurality of filler inlets are arranged in parallel along the welded portion where the end portions are welded together. An electric wire insertion step of inserting a terminal portion of the covered electric wire including the conductor portion against the crimp portion, and crimping the crimp portion on the conductor portion by crimping the crimp portion within the wire crimp range, A crimping step of crimping the crimping part to the insulating coating part so as to form a filling space filled with a filler between the insulating coating part and an intermediate part in the longitudinal direction of the coating crimping range in the crimping range. And a filling step of filling the filling space with the filler by injecting the filler from the filler inlet.

  According to this invention, for example, even if a large external force is applied to the covered electric wire, damage and deterioration of the covered electric wire can be suppressed, and the connection structure in which the covered electric wire and the crimp terminal are connected to the connector housing. It is possible to configure a connection structure that can ensure assemblability when assembling.

  Specifically, the filling space is provided between the insulating coating and the intermediate portion in the longitudinal direction of the coating pressure-bonding range, and the filler injected from the filler inlet is a conductor to crimp one end of the insulating coating on the tip side. Inflow between the portion and the insulating coating portion can be prevented. In this case, since the covered electric wire can be prevented from being hardened by the filler, the flexibility of the covered electric wire can be ensured. For example, even if a large external force is applied to the covered electric wire by swinging the covered electric wire, Damage and deterioration can be suppressed.

  On the other hand, since the other end portion of the covering crimping range is also crimped, the filler injected from the filler inlet can be prevented from flowing out from the insertion side where the conductor portion is inserted into the crimping portion. In this case, for example, it is possible to reliably prevent the inconvenience that the filling material that has flowed out of the crimping portion and swelled in the shape of a bump interferes with the connector housing and cannot be assembled. Assembling property when assembling the connected connection structure to the connector housing can be ensured.

  According to the present invention, it is possible to provide a crimp terminal, a connection structure, a connector, and a method for manufacturing a connection structure that can obtain stable conductivity while securing assembly.

The perspective view of a crimp terminal. The perspective view of a crimping connection structure. The perspective view of a wire harness. Sectional drawing of a crimp terminal, a top view, and sectional drawing of a crimping connection structure. The perspective view which shows the manufacturing process of a crimp terminal. Sectional drawing of a primary press molding process. The principal part expanded sectional view of a crimping connection structure. FIG. 8 is a cross-sectional view taken along line AA in FIG. 7. The perspective view of a primary welding process. Sectional drawing of a primary welding process. Sectional drawing of a secondary press molding process. The perspective view which shows a part of manufacturing process of a crimp terminal. The perspective view of a secondary welding process. Sectional drawing of a secondary welding process. The perspective view which shows the manufacturing process of the crimp terminal which concerns on another example. Sectional drawing which shows the crimping | compression-bonding process in a covering crimping range. Sectional drawing which shows the crimping | compression-bonding process in a covering crimping range. Sectional drawing which shows the crimping | compression-bonding process in an electric wire crimping range. Sectional drawing which shows a filling process. The perspective view which shows the manufacturing process of the crimping connection structure which concerns on another example. Sectional drawing which shows the covering crimping | compression-bonding range which concerns on another example.

An embodiment of the present invention will be described in detail with reference to the drawings.
1 is a perspective view of the crimp terminal 11, FIG. 2 is a perspective view of a crimp connection structure 61, and FIG. 3 is a perspective view of a wire harness 74. As shown in FIG. 4A is a cross-sectional view of the crimp terminal 11, FIG. 4B is a plan view of the same, and FIG. 4C is a cross-sectional view of the crimp connection structure 61. FIG. 5 is a perspective view showing the manufacturing process of the crimp terminal 11, and FIG. 6 is a cross-sectional view of the primary press molding process. FIG. 7 is an enlarged cross-sectional view of a main part of the crimp connection structure 61, and FIG. 8 is a cross-sectional view taken along line AA in FIG.

  The crimp terminal 11 shown in FIG. 1 integrally has a terminal connection part 12 to be described later and a crimp part 13 having a hollow cross section that allows crimp connection to the wire exposed part 52a of the covered electric wire 51 shown in FIG. In the crimping part 13, it is the closed barrel type crimping terminal 11 which integrally comprised the covering crimping range 13a, the electric wire crimping range 13b, and the sealing part 13c (refer FIG. 2).

  The crimp terminal 11 is used to obtain a crimp connection structure 61 by connecting to the terminal portion of the covered electric wire 51 as shown in FIG. For this reason, the crimp terminal 11 integrally includes a terminal connection portion 12 to which the other pair of terminals are connected, and a crimp portion 13 to be crimped so as to be electrically connected to the covered electric wire 51. The terminal connection part 12 of the example of illustration is formed in the square cylinder shape, and this is the terminal connection part 12 of the female terminal 11a as an example of the crimp terminal 11. FIG.

  Inside the terminal connection portion 12 is a terminal insertion portion 21 into which the other pair of terminals (male terminal 11b (see FIG. 3)) is inserted, and the terminal insertion portion 21 is integrally provided with an urging spring 22. It has been.

The female terminal 11a (crimp terminal 11) is connected to the covered electric wire 51 and is held in the cavity 73 of the connector housing 72 of the female connector 71 as shown in FIG. 3, and a plurality of the covered electric wires 51 are bundled. The wire harness 74 is configured. The wire harness 74 is meant to include a wire harness 74 in a state where a plurality of covered electric wires 51 are further bundled.
The female connector 71 is detachably connected to a pair of male connectors 75.

  The terminal connection portion 12 is drawn in a square tube shape because the crimp terminal 11 is the female terminal 11a, but the crimp terminal 11 may be a male terminal 11b (see FIG. 3). In the case of the male terminal 11b, the terminal connection portion 12 is formed in a narrow plate shape inserted into the terminal connection portion 12 having a rectangular tube shape.

  As shown in FIG. 2, the covered electric wire 51 includes a conductor 52 and an insulating coating 53 that covers the conductor 52. The conductor 52 is illustrated as an example in which a plurality of aluminum or aluminum alloy aluminum wires are arranged, but the conductor 52 is a single wire, even if it is a stranded wire obtained by twisting a plurality of aluminum wires. Also good.

  As shown in FIGS. 1 and 4, the crimping portion 13 is formed in a hollow cross-sectional shape in which one end portion on the terminal connection portion 12 side is closed. The thickness of the crimping portion 13 is a size that allows the terminal portion of the covered electric wire 51 to be inserted, and the length that covers from the exposed wire portion 52a where the conductor 52 is exposed from the insulating coating 53 to the distal end portion of the insulating coating 53. is there.

  An insertion port 31 for inserting the covered electric wire 51 is opened in a substantially circular longitudinal section at the other end of the crimping portion 13 opposite to the terminal connection portion 12. On the other hand, the closed portion of the end portion (the one end portion) on the terminal connection portion 12 side has a flat shape that is crushed in the vertical direction. This portion is a sealing portion 13c having a water-stopping property.

  One seam portion 33 extending in the longitudinal direction is provided between the insertion port 31 and the sealing portion 13c. The formation position of the joint portion 33 is the upper end portion (top portion) having a substantially circular longitudinal section in the illustrated example, but may be the lower end portion. 5A and 6, the joint portion 33 is shaped-retaining welded for shape retention that integrally connects the end portion 33 a of the plate-like base material 41 that is rounded into a hollow cross section. It consists of the part 33b (refer FIG.5 (b) and FIG. 1).

  The plate-like base material 41 is a portion to be the crimping portion 13 among materials obtained by punching when the crimping terminal 11 is manufactured. Briefly, the crimp terminal 11 is formed by punching a copper alloy strip (not shown) such as brass whose surface is tin-plated (Sn-plated) into a desired shape, and is connected to a belt-like carrier (not shown). A raw material portion (not shown) to be the crimp terminal 11 in a state of being obtained is obtained, and this is subjected to bending processing or the like in order to form the desired crimp terminal 11 in shape.

  Further, as shown in FIGS. 1 and 4, a water-stop welded portion 32 for improving water-stop is formed in the sealing portion 13 c in the crimping portion 13. The water-stop welded part 32 is formed to extend in a straight line in the width direction orthogonal to the shape-retaining welded part 33b.

These welds, that is, the shape retaining weld 33b and the water stop weld 32 are preferably formed by welding using a high energy density beam.
This high-density energy beam includes a laser beam and an electron beam. Among them, a single focus using a fiber laser or an SM fiber laser is preferable.

  As shown in FIGS. 1, 2, 4, and 5, the crimping portion 13 formed in this manner has a coating crimping range 13 a for crimping the insulating coating 53 and the conductor 52 exposed from the insulating coating 53. An electric wire crimping range 13b for crimping the electric wire exposed portion 52a is integrally formed, and the covering crimping range 13a and the electric wire crimping range 13b are crimped across the conductor 52 and the insulating coating 53.

  Further, a plurality of resin injection ports 101, 102, 103 are formed in the crimping part 13. The resin injection ports 101 to 103 extend along the shape-retained welded portion 33b so that the shape-retained welded portion 33b is sandwiched between the covering pressure-bonded range 13a, the wire crimped range 13b, and the sealing portion 13c, respectively. A pair of six resin inlets 101, 101, 102, 102, 103, 103 are arranged in parallel in the longitudinal direction in the hollow cross section of the crimping part 13.

  Further, in the cover crimping range 13a, as shown in FIG. 7, one end 13a1 on the distal end side of the insulating coating 53 and the other end 13a3 on the opposite side to the one end 13a1 are crimped to the insulating coating 53. Then, by separating the intermediate portion 13a2 in the longitudinal direction of the coating pressure-bonding range 13a, specifically, the intermediate portion 13a2 between the one end portion 13a1 and the other end portion 13a3 from the insulating coating 53, the insulating coating 53 and A filling space 104 described later is provided between the intermediate portion 13a2. In the present embodiment, among the resin injection ports 101 to 103 described above, the resin injection port 101 in the coated crimping range 13 a is provided so as to communicate with the filling space 104.

  And in the crimp connection structure 61 comprised by connecting the crimp terminal 11 to the terminal part of the covered electric wire 51, as shown in FIG. 7, FIG. 8, the above-mentioned filling space 104 is made of resin 105 as a filler. Filled.

  In the present embodiment, as shown in FIG. 8, the filling space 104 is provided in the circumferential direction of the cover crimping range 13 a and the insulating coating 53. Specifically, the gap between the coating crimping range 13 a and the insulating coating 53 is provided. The filling space 104 is provided in the circumferential direction so as to be substantially uniform over the entire circumference. Thereby, the resin 105 is filled so as to surround the insulating coating 53. However, the present invention is not necessarily limited to this, and the resin 105 (filling space 104) may be interrupted in a part in the circumferential direction when the coating pressure-bonding range 13a and the insulating coating 53 are partially in contact. .

  In the wire crimping range 13b, the space between the wire exposed portion 52a and the wire crimping range 13b is filled with the resin 105. Moreover, in the sealing part 13c, the space between the front-end | tip part of the electric wire exposure part 52a and the sealing part 13c (water stop welding part 32) is filled with the resin 105. FIG.

  Here, as the resin 105, for example, an epoxy, urethane, silicon, or acrylic resin is used. Preferably, the viscosity at 25 ° C. measured in accordance with JIS Z8803 is 1000 mPa · s or more and 20000 mPa · s. An anticorrosion resin in the range of less than s is used. More preferably, an anticorrosion resin having an elongation measured in accordance with ASTM D-1708 of 100% or more and a water absorption measured in accordance with JIS K7209 of 1.0% or less is used.

A method for manufacturing the crimp terminal having the above-described configuration will be described below.
First, as described above, a copper alloy strip (not shown) such as a strip-shaped brass whose surface was tin-plated (Sn plated) was punched into a desired shape and connected to a strip-shaped carrier (not illustrated). After that, a material portion (not shown) to be a crimp terminal is obtained. Subsequently, the material portion is sequentially subjected to necessary bending processing while being conveyed using a carrier to obtain the crimp terminal 11 having the above-described configuration.

  The portions other than the portion that becomes the crimping portion 13 in the material portion are the same as those in the conventional art, and thus the description thereof will be omitted.

  The plate-like base material 41 is formed in a substantially square plate shape capable of forming the crimping part 13. The plate thickness t (see FIG. 6) is set as appropriate, but is desirably as thin as possible. Specifically, it is 0.4 mm or less, specifically 0.1 mm to 0.4 mm, more preferably 0.2 mm to 0.3 mm, and more specifically 0.25 mm. This is because the weight can be reduced and the terminal portion can be reduced in size without reducing the thickness of the covered electric wire 51.

  Further, as shown in FIGS. 5A and 6, the resin injection ports 101 to 103 are formed in advance in the longitudinal direction in the longitudinal direction corresponding to the both end portions 33 a and 33 a in the plate-like base material 41. Keep it.

  Such a plate-like base material 41 is bent so as to have a substantially circular longitudinal section as shown in FIGS. 5A and 6 (primary press molding step). Here, “substantially circular” means to include a perfect circle. The end portions 33a of the plate-like base material 41 are preferably brought into contact with each other by rolling, but there may be a gap as long as welding is possible.

  Next, welding is performed in which the opposing portions of the end portions 33a of the cylindrical portion 42 having a hollow cross-section with both ends opened, which are obtained from the plate-like base material 41 through a primary press molding step, are integrally coupled (primary welding). Process). As shown in FIG. 9, this welding is performed from the end to the end of the tubular portion 42 by using a fiber laser welding apparatus 81. With the formation of the shape retaining weld 33b by this welding, the end portions 33a of the plate-like base material 41 are integrated to form a single seam 33 extending in the longitudinal direction.

  In addition, as shown in FIG. 10A, fiber laser welding is performed such that the facing portion between the end portions 33a to be welded and the laser irradiation portion 82 move in parallel at a predetermined distance. Is called. In other words, since the cylindrical part 42 opened at both ends just rounded in the primary press molding process has the same diameter from end to end, the portion to be welded and the bottom surface of the cylindrical part 42, the cylindrical part 42 The stage 83 to be mounted is parallel to the moving path 84 of the laser irradiation unit.

This fiber laser welding is welding using fiber laser light having a wavelength of about 1.08 μm. The fiber laser beam is an ideal Gaussian beam and can be condensed up to the diffraction limit, so that a condensing spot diameter of 30 μm or less that cannot be realized by a YAG laser or a CO ₂ laser can be formed. That is, the welding is narrow and energy density is high. Moreover, deep penetration can be obtained at high speed. Nevertheless, since the heat input is low, high-precision welding is possible with little deformation of the material.

  In addition, in welding using a high energy density beam, unlike the case of joining and integrating by brazing, a recess for brazing is not necessary, so that a material having a thin plate thickness can be used as described above. In other words, the material of the crimp terminal can be thinned.

  In addition, since the copper alloy has a high reflectance and transmittance with respect to the fiber laser wavelength, as described above, tin plating (Sn plating) is applied to the surface of the portion to be welded as the light absorbing material.

  As shown in FIG. 10 (b), the shape-retaining weld 33b is formed by so-called through welding formed in the entire thickness direction from the surface on which the laser beam hits to the back surface on the opposite side.

  By the primary welding process described above, a pair of resin injection ports 101, 102, and 103 are arranged along the shape retaining weld 33b so as to sandwich the shape retaining weld 33b. The resin injection ports 101, 102, and 103 are arranged in parallel in the longitudinal direction in the hollow cross section of the cylindrical portion 42 as a whole.

After such a primary welding process, the process proceeds to a secondary pressing process.
In the secondary press molding step, as shown in FIG. 11, at one end of the cylindrical connecting portion 42 having a hollow cross section at both ends obtained through the primary press molding step on the terminal connection portion 12 side. Then, the metal mold 91 (lower mold 91a, upper mold 91b) is pressed in the vertical direction to perform a bending process of crushing so that the substantially vertical shape is slightly U-shaped. By this crushing, the sealing portion 13c having a substantially flat shape and water-stopping property is obtained.

Subsequently, as shown in FIG. 12, the process proceeds to the secondary welding process.
In the secondary welding process, the water stop weld 32 is formed. That is, the water-stop welded portion 32 is formed in the sealing portion 13c obtained by crushing. The welding is performed by fiber laser welding as one of the welding using a high energy density beam, which is the same as the formation of the shape retaining weld 33b. However, as shown in FIG. 13, the welding direction is a width direction orthogonal to the longitudinal direction of the crimping part 13, unlike the shape-retaining welded part 33 b. By this secondary welding, as shown in FIG. 14, a water-stop welded portion 32 extending in the entire thickness direction is formed, and the water-stop performance obtained in the secondary press forming step can be further enhanced.

  Here, the resin injection port 103 is disposed in the vicinity of the boundary portion between the portion crushed in the secondary press molding step and the portion not crushed, and a position substantially corresponding to the distal end portion of the wire exposed portion 52a in the longitudinal direction. Placed in.

In this way, in addition to the primary press forming step, the primary welding step, the secondary press forming step, and the secondary welding step, for example, as shown in FIG. 15, the primary press forming step (see FIG. 15A) is performed. The secondary press molding step (see FIG. 15B) can be performed, followed by the primary welding step (see FIG. 15C). In this case, the cylindrical part 42 is not a cylindrical part having both ends opened, but a cylindrical part having one end closed by the sealing part 13c.
Further, the secondary welding process may be omitted.

The covered electric wire 51 is connected to the crimp terminal 11 manufactured in this way.
That is, as shown by a virtual line in FIG. 4A, the terminal portion of the covered electric wire 51 including the electric wire exposed portion 52a is inserted into the crimp portion 13 (electric wire insertion step).

  Subsequently, the process proceeds to a crimping process, and the crimping portion 13 is crimped and crimped to the exposed wire portion 52a in the wire crimping range 13b, while the crimping portion 13 is crimped and crimped to the insulating coating 53 in the coating crimping range 13a.

  The crimping to the insulating coating 53 in the coating crimping range 13a is performed by bending with the lower die 92 and the upper die 93 as shown in FIGS. 16 (a) and 17 (a). The lower die 92 and the upper die 93 have cavities 94 and 95 that are curved in an arc shape, and the cavities 94 and 95 are partially formed with recesses 94a and 95a. These concave portions 94a and 95a are opposed to each other, and are in a positional relationship such that the concave portions 94a and 95a are continuous in the circumferential direction at the time of pressure bonding.

  Moreover, the size of the both sides of the recesses 94a and 95a in the cavities 94 and 95 can be compressed so that the one end 13a1 and the other end 13a3 of the covering crimping range 13a corresponding to the mold clamping are in close contact with the insulating coating 53. One end portion 13a1 and the other end portion 13a3 of the coating pressure-bonding range 13a facing the insulating coating 53 by compression are compressed, and the space between the coating pressure-bonding range 13a and the insulating coating 53 is sealed in a water-stopped state. . The one end 13a1 and the other end 13a3 of the covering crimping range 13a are substantially circular in longitudinal section as shown in FIGS. 16 (b) and 17 (b).

  Here, since the recesses 94a and 95a described above are formed in the cavities 94 and 95, as shown in FIG. 17B, one end portion 13a1 of the coating crimping range 13a facing the insulating coating 53 by crimping. While the other end portion 13a3 is compressed, the intermediate portion 13a2 between the one end portion 13a1 and the other end portion 13a3 is not compressed, or the amount of compression is suppressed to be smaller than that of the one end portion 13a1 and the other end portion 13a3. It is like that. Thus, a sealed space that is sealed by the one end portion 13a1 and the other end portion 13a3, that is, a filling space 104 is formed between the insulating coating 53 and the intermediate portion 13a2. In this crimping step, the lower mold 92 and the upper mold 93 (the concave portions 94a and 95a of the cavities 94 and 95) in the longitudinal direction with respect to the crimping portion 13 are arranged so that the resin injection port 101 is disposed at a position corresponding to the filling space 104. After positioning the position, crimping is performed.

The crimping of the conductor 52 in the wire crimping range 13b is performed by bending with the lower die 96 and the upper die 97 as shown in FIG. The lower die 96 has a cavity 98 that is curved in an arc shape, and the upper die 97 has a cavity 99 having a shape having a pressing portion 99a that protrudes downward on a recessed ceiling surface. As a result, the wire crimping range 13b corresponding to the wire exposed portion 52a of the crimping portion 13 is compressed to become a substantially concave or U-shaped longitudinal section as shown in FIG. Are electrically connected to the conductor 52 by crimping.
By this crimping step, the resin inlet 102 in the wire crimping range 13b is arranged at a position corresponding to the wire exposed portion 52a.

These wire insertion process and crimping process can be performed separately from the carrier (not shown), but it is desirable to perform the process with the carrier attached.
When connecting the covered electric wire 51 while being connected to the carrier, the crimp terminal 11 is removed from the carrier during the crimping step or after the crimping step (separation step).

Subsequently, as shown in FIG. 19, the process proceeds to a filling step.
In the filling step, the resin 105 is injected from the resin injection ports 101 to 103 and the space between the crimping portion 13 and the covered electric wire 51 is filled with the resin 105. Here, the resin 105 is injected from any one of the pair of resin injection ports 101 to 103 using an appropriate injection device 110. In this case, since the resin 105 is injected while letting the air between the crimping portion 13 and the covered electric wire 51 escape from the other resin injection ports 101 to 103, the resin 105 is externally intermediated by the action of the air. It is filled almost uniformly without being pushed out (overflowing).

  The injection of the resin 105 is terminated when the resin 105 reaches the other resin injection ports 101 to 103, thereby preventing the resin 105 from being injected more than necessary.

  By this filling step, the above-described filling space 104 is filled with the resin 105 in the coated crimping range 13a, and the space between the wire exposed portion 52a and the wire crimping range 13b is filled with the resin 105 in the wire crimping range 13b. Furthermore, in the sealing part 13c, the space between the tip of the electric wire exposed part 52a and the sealing part 13c (water stop weld part 32) is filled with the resin 105.

  In this way, when the resin 105 is injected from each of the resin injection ports 101 to 103 and the space between the crimping portion 13 and the covered electric wire 51 is filled with the resin 105, the crimp connection structure 61 is obtained.

  The connection of the covered wire 51 to the crimp terminal 11 can also be performed in the manufacturing process of the crimp terminal 11. That is, for example, as shown in FIG. 20A, the covered electric wire 51 is inserted into the crimp terminal 11 in which the cylindrical portion 42 is formed through the primary press molding step and the primary welding step, and this state When the process proceeds to the secondary press molding process and the filling process in sequence, a crimp connection structure 61 is obtained. In this secondary press molding process, the same insulation between the insulating coating 53 and the crimping part 13 is stopped using the same lower molds 91 and 95 and upper molds 92 and 96 (see FIGS. 16 to 18) used in the crimping process. While being in a water state, the conductor 52 and the crimping part 13 are electrically connected.

If necessary, the secondary welding process may be performed thereafter, and then the separation process may be performed.
Although illustration is omitted, the primary welding process may be performed after the secondary press molding process is performed after the primary press molding process.

  As described above, the crimping portion 13 in the crimping terminal 11 including at least the crimping portion 13 having a hollow cross section that allows crimping connection to the wire exposure portion 52a exposed from the tip of the insulating coating 53 of the covered wire 51 is replaced with the wire exposure portion 52a. The wire crimping range 13b for crimping and the coating crimping range 13a for crimping the insulating coating 53 are configured to be crimped across the wire exposed portion 52a and the insulating coating 53. Since a plurality of resin injection ports 101 to 103 for injecting a resin 105 as a filler are provided between the coated wire 51 and the covered electric wire 51, it is possible to obtain a stable conductivity while ensuring assemblability. The terminal 11 can be configured.

  Specifically, if the resin 105 is injected between the crimping portion 13 and the covered electric wire 51 from the resin inlets 101 to 103 in a state where the crimping portion 13 is crimped across the electric wire exposed portion 52a and the insulating coating 53, the crimping is performed. The space between the portion 13 and the covered electric wire 51 can be filled with the resin 105. In this way, by filling the space between the crimping portion 13 and the covered electric wire 51 with the resin 105, for example, the insulation coating 53 and the crimping portion 13 (covering crimping range 13 a) due to thinning of the insulating coating 53 due to deterioration over time. Or the processing accuracy of the crimping portion 13 (accuracy of welding processing in the water-stop welded portion 32 and the shape retaining welded portion 33b, the crimping range 13a, the crimping range 13b of the electric wire, and the crimping portion 13c. Even if a situation in which a hole communicating the inside (wire exposed portion 52a) and the outside of the crimping portion 13 is formed due to reasons for processing accuracy, etc., the wire exposed portion 52a is exposed to the outside air. This can be reliably prevented by the resin 105. For this reason, the stable electroconductivity can be obtained. In addition, since the resin 105 is exposed to the outside from the communicating hole, the effect of facilitating detection of the communicating hole is also obtained.

  In addition, since a plurality of resin injection ports 101 to 103 are provided (one pair in this embodiment), if the resin 105 is injected from either one, the space between the crimping portion 13 and the covered electric wire 51 is increased. The resin 105 can be injected while letting air escape from the other resin injection ports 101 to 103. For this reason, the resin 105 can be filled almost uniformly without being pushed out (overflow) on the way by the action of the air, and as a result, the resin 105 indicates that the exposed wire portion 52a is exposed to the outside air. Can be more reliably prevented.

  Further, when the resin 105 is injected from either one, the filling state of the resin 105 can be confirmed based on the arrival state of the resin 105 to the other resin inlets 101 to 103. Injecting more than necessary can be surely prevented. For this reason, it can prevent reliably that the situation where the resin 105 overflows to the exterior of the crimping | compression-bonding part 13, and it swells in the shape of a knob is generated. In this case, it is possible to surely prevent the inconvenience that the resin 105 swelled in the shape of a knob outside the crimping portion 13 interferes with the connector housing 72 (see FIG. 3) and cannot be assembled. The assembling property when assembling the crimp connection structure 61 connected to the terminal 11 to the connector housing 72 can be ensured.

  In addition, since the resin injection port 101 is provided at least in the coated crimping range 13a, if the resin 105 is injected between the coated crimping range 13a and the coated wire 51 from the resin inlet 101, the coated crimped range 13a and the coated range are covered. The space between the electric wires 51 can be filled with the resin 105. As described above, since the space between the coated crimping range 13a and the coated electric wire 51 can be filled with the resin 105, the insulating coating 53 and the crimping portion 13 ( Even if a situation occurs such that a gap is generated between the coated crimping range 13a), the resin 105 can more reliably prevent the exposed wire portion 52a from being exposed to the outside air.

  Moreover, the resin 105 can be inject | poured into the wide range of the longitudinal direction of the crimping | compression-bonding part 13 by arranging the resin injection ports 101-103 in the longitudinal direction in the said cross-sectional hollow shape.

  Moreover, while making it the sealing shape which seals the one end side by the side of the electric wire exposure part 52a of the longitudinal direction in the said cross-sectional hollow shape, the one end side by the side of the said electric wire exposure part 52a of the said longitudinal direction formed in the sealing shape to seal In this case, the sealing portion 13c is formed by welding in a direction intersecting the longitudinal direction, and the resin injection port 103 is provided in the sealing portion 13c, so that the crimping portion 13 into which the electric wire exposed portion 52a is inserted. The wire exposed portion 52a of the covered electric wire 51 is not exposed to the outside of the crimp portion 13 and can be crimped in a sealed state while the wire exposed portion 52a is exposed to the outside air. This can be more reliably prevented by the resin 105.

  Specifically, in order to configure the sealing portion 13c by welding in a direction intersecting the longitudinal direction at one end side in the longitudinal direction of the hollow cross-sectional shape, the wire exposed portion 52a is connected to the crimping portion 13 having the hollow cross-sectional shape. The portion other than the insertion portion to be inserted is sealed, and the wire exposed portion 52a in the crimping portion 13 is not exposed to the outside air, so that moisture can be prevented from entering the inside, and deterioration and secular change can be suppressed. . Therefore, corrosion does not occur in the exposed wire portion 52a and an increase in electrical resistance caused by the corrosion can be prevented, so that stable conductivity can be obtained.

  In particular, when the sealing portion 13c is formed by previously forming a sealing shape that seals one end side in the longitudinal direction of the hollow cross section and welding in a direction intersecting the longitudinal direction. In addition, the portion other than the insertion portion where the wire exposed portion 52a is inserted into the crimp portion 13 having a hollow cross-section is sealed, and the wire exposed portion 52a of the covered wire 51 is simply crimped to the crimp portion 13 into which the wire exposed portion 52a is inserted. Without being exposed to the outside of the crimping portion 13 and can be crimped in a sealed state with water-stopping properties. Therefore, the wire exposed portion 52a crimped to the crimping portion 13 is not exposed to the outside air without using a cap or the like formed of a separate part for the wire exposed portion 52a in order to ensure water-stopping.

  However, as described above, when bending is performed so as to seal one end side in the longitudinal direction of the hollow cross section, both end portions 32a in the width direction intersecting the longitudinal direction (see FIG. 11) Therefore, at both ends in the width direction, wrinkles and portions that cannot be sealed are formed for reasons of bending accuracy. As a result, the sealing portion 13c has There is a risk of forming a hole that communicates the inside (wire exposed portion 52a) and the outside.

  In this embodiment, since the resin injection port 103 is provided in the sealing portion 13c, if the resin 105 is injected between the sealing portion 13c and the covered electric wire 51 from the resin injection port 103, the sealing portion 13c and the covering portion 13c are covered. The space between the electric wires 51 can be filled with the resin 105. Thus, by having comprised so that between the sealing part 13c and the covered electric wire 51 can be filled with the resin 105, as mentioned above, especially for the reason on the precision at the time of bending the sealing part 13c The resin 105 can more reliably prevent the exposed wire portion 52a from being exposed to the outside air even when a hole is formed that connects the inside (wire exposed portion 52a) of the crimping portion 13 to the outside. it can.

  Further, the plate-like base material 41 is bent in the width direction so that the crimping portion 13 has a hollow cross-section, and the end portions 33a in the width direction of the plate-like base material 41 are welded in the longitudinal direction to fill the filler. Since a plurality of the inlets 101 to 103 are arranged side by side along the shape-keeping welded portion 33b where the end portions 33a are welded together, the crimping terminal 11 provided with the crimping portion 13 having a hollow cross section can be easily formed from a metal plate material. While being able to manufacture, it can prevent reliably by the resin 105 that the electric wire exposure part 52a is exposed to external air.

  Specifically, for example, a metal plate material (in this embodiment, a copper alloy strip such as brass) is punched into a desired shape to obtain a material portion that becomes the crimp terminal 11 in a state connected to a belt-like carrier. The desired crimp terminal 11 can be formed in a desired shape by sequentially bending and welding the end portions 33a. Therefore, the crimp terminal 11 including the crimp section 13 having a hollow cross section can be easily manufactured from a metal plate.

  However, since the end portions 33a of the plate-like base material 41 are welded in the longitudinal direction, the higher the distance of the shape-retaining welded portion 33b extending in the longitudinal direction, the higher the accuracy of the welding process (welding reliability) is required. In other words, the probability of forming a hole that connects the inside (wire exposed portion 52a) of the crimping portion 13 to the outside increases. In the present embodiment, the resin 105 is injected between the crimping portion 13 and the covered electric wire 51 from the plurality of resin injection ports 101 to 103 along the shape retaining weld portion 33 b, and between the crimping portion 13 and the covered electric wire 51. Since the resin 105 can be filled with the resin 105, the resin 105 can be injected in a wide range in the longitudinal direction between the shape-keeping weld 33 b and the covered electric wire 51. For this reason, as described above, there is a situation in which a hole that connects the inside (wire exposed portion 52a) and the outside of the crimping portion 13 is formed due to accuracy reasons when welding the shape-retaining weld 33b. Even if it does, it can prevent reliably that the electric wire exposure part 52a is exposed to external air by the resin 105. FIG.

  In particular, when the sealing portion 13c is configured on one end side in the longitudinal direction, the water-stop welded portion 32 of the sealing portion 13c and the end portions 33a in the width direction of the plate-like base material 41 are welded in the longitudinal direction. The cross-shaped portion X (see FIG. 1 and the like) intersecting with the shape-preserving welded portion 33b will be formed. It becomes softer than the part. For this reason, in the crossing part X, the precision (welding reliability) of welding processing falls, and there exists a possibility that the hole which connects the inside (electric wire exposure part 52a) of the crimping | compression-bonding part 13 and the exterior may be formed.

  In the present embodiment, the resin 105 is injected between the sealing portion 13c and the covered electric wire 51 from the resin injection port 103 provided in the sealing portion 13c, and the resin 105 is interposed between the sealing portion 13c and the covered electric wire 51. In particular, as described above, the hole that communicates the inside (wire exposed portion 52a) and the outside of the crimping portion 13 for accuracy reasons when welding the intersecting portion X is provided. Even when a situation occurs, the resin 105 can more reliably prevent the exposed wire portion 52a from being exposed to the outside air.

  In addition, since the resin injection ports 101 to 103 are disposed so as to sandwich the shape retaining welded portion 33b in which the end portions 33a and 33a are welded to each other, one resin injection port 101 to 103 that sandwiches the shape retaining welded portion 33b. If the resin 105 is injected from the other end, the filling state of the resin 105 between the shape-retaining weld 33b and the covered electric wire 51 is ensured based on the arrival state of the resin 105 to the other resin injection ports 101 to 103. Can be confirmed. In this case, suppose that the shape retaining weld 33b is indented inward by crimping of the crimping portion 13 and comes into contact with the covered electric wire 51, and the filling space 104 is partially interrupted in the circumferential direction of the covered electric wire 51 and the crimping portion 13. Even if it becomes, it can be reliably filled with the resin 105 between the shape-retaining welded part 33b and the covered electric wire 51.

  In addition, the crimped connection structure 61 in which the covered wire 51 and the crimped terminal 11 are connected by the crimped portion 13 in the crimped terminal 11 and the space between the crimped portion 13 and the covered wire 51 is filled with the resin 105 is a crimped terminal. 11, it is possible to obtain stable conductivity while ensuring assemblability only by filling the space between the crimping portion 13 and the covered electric wire 51 with the resin 105.

  In addition, a filling space 104 for filling the resin 105 is provided between the insulating coating 53 and the coating pressure-bonding range 13 a, and a resin injection port 101 is provided so as to communicate with the filling space 104. In particular, even when a gap occurs between the insulation coating 53 and the crimping portion 13 (coating crimping range 13a) due to the thinning of the insulation coating 53 due to aging, the exposed wire portion The resin 105 filling the filling space 104 can more reliably prevent the 52a from being exposed to the outside air.

  Further, by providing the filling space 104 between the insulating coating 53 and the intermediate portion 13a2 in the longitudinal direction of the coating crimping range 13a, in this case, the one end portion 13a1 on the distal end side of the insulating coating 53 is crimped. Therefore, the resin 105 injected from the resin injection port 101 can be prevented from flowing between the conductor 52 and the insulating coating 53. In this case, since the covered electric wire 51 can be prevented from being hardened by the resin 105, the flexibility of the covered electric wire 51 can be ensured. For example, even if a large external force is applied to the covered electric wire 51, Damage and deterioration of the covered electric wire 51 can be suppressed.

  On the other hand, since the other end portion 13a3 of the covering crimping range 13a is also crimped, the resin 105 injected from the resin injection port 101 flows out from the insertion port 31 side into which the wire exposed portion 52a is inserted into the crimping portion 13 to the outside. Can be prevented. In this case, for example, it is possible to surely prevent the inconvenience that the resin 105 that has flowed out of the crimping portion 13 and swelled in the shape of a bump interferes with the connector housing 72 and cannot be assembled. The assembling property when assembling the crimp connection structure 61 connected to the terminal 11 to the connector housing 72 can be ensured.

  Furthermore, the female connector 71 in which the crimp terminal 11 in the crimp connection structure 61 is disposed in the connector housing 72 can connect the crimp connection structure 61 while ensuring stable conductivity.

  More specifically, for example, when the female connector 71 and the male connector 75 are fitted to each other and the crimp terminals 11 of the connectors 71 and 75 are connected to each other, the crimp terminals 11 of the connectors 71 and 75 are secured while maintaining water-tightness. Can be connected to each other. As a result, it is possible to ensure a connection state having reliable conductivity.

  Further, the crimp connection structure 61 in which the covered wire 53 and the crimp terminal 11 are connected by the crimp section 13 having a hollow cross-section that allows crimp connection to the exposed wire portion 52a exposed from the tip of the insulating coating 53 of the covered wire 51. As a manufacturing method, the wire crimping range 13b for crimping the wire exposed portion 52a and the coating crimping range 13a for crimping the insulating coating 53 are configured to be crimped across the wire exposed portion 52a and the insulating coating 53, and resin. A wire insertion step of inserting the terminal portion of the covered wire 51 including the wire exposed portion 52a into the crimped portion 13 provided with a plurality of inlets 101, and crimping the crimped portion 13 in the wire crimping range 13b to the wire exposed portion 52a On the other hand, a filling space 104 is formed between the insulating coating 53 and the intermediate portion 13a2 in the longitudinal direction of the coating crimping range 13a in the coating crimping range 13a. In this way, for example, by covering the crimping portion 13 and crimping to the insulating coating 53, and by filling the filling space 104 with the resin 105 by injecting the resin 105 from the resin injection port 101, for example, coating Even if a large external force is applied to the electric wire 51, damage and deterioration of the covered electric wire 51 can be suppressed, and the crimp connection structure 61 connecting the covered electric wire 51 and the crimp terminal 11 is assembled to the connector housing 72. The crimp connection structure 61 that can ensure the ease of assembling can be configured.

  Specifically, the filling space 104 is provided between the insulating coating 53 and the intermediate portion 13a2 in the longitudinal direction of the coating pressure-bonding range 13a, and is injected from the resin injection port 101 in order to crimp the one end portion 13a1 on the distal end side of the insulating coating 53. It is possible to prevent the resin 105 from flowing between the conductor 52 and the insulating coating 53. In this case, since the covered electric wire 51 can be prevented from being hardened by the resin 105, the flexibility of the covered electric wire 51 can be ensured. For example, even if a large external force is applied to the covered electric wire 51, Damage and deterioration of the covered electric wire 51 can be suppressed.

  On the other hand, since the other end portion 13a3 of the coated crimping range 13a is also crimped, the resin 105 injected from the resin injection port 101 is prevented from flowing out from the insertion port 31 side where the wire exposed portion 52a is inserted into the crimping portion 13. it can. In this case, for example, it is possible to surely prevent the inconvenience that the resin 105 that has flowed out of the crimping portion 13 and swelled in the shape of a bump interferes with the connector housing 72 and cannot be assembled. The assembling property when assembling the crimp connection structure 61 connected to the terminal 11 to the connector housing 72 can be ensured.

  By the way, in embodiment mentioned above, although the cross-sectional shape of the crimping | compression-bonding part 13 (covering crimping | compression-bonding range 13a) is formed in substantially circle shape, this invention is not necessarily limited to this, For example, FIG. ), And (b), the cross-sectional shape may be formed in a polygon such as an octagon or a square, as in the crimping portions 213 (covered crimping range 213a) and 313 (covered crimping range 313a). In FIG. 21, the same components as those of the previous embodiment shown in FIGS.

  In the above-described embodiment, when the crimping portion 13 is caulked in the covering crimping range 13a, the filling space 104 is formed by forming the intermediate portion 13a2 that is spaced outward from the insulating coating 53. The invention is not necessarily limited to this. For example, before the crimping portion 13 is crimped, a filling space is formed in advance by forming a concave groove on the inner peripheral surface of the coated crimping range 13 a or by forming a concave groove on the surface of the insulating coating 53. It may be.

In the correspondence between the configuration of the present invention and the embodiment,
The conductor portion of the present invention corresponds to the wire exposed portion 52a,
Similarly,
The filler corresponds to the resin 105,
The filler inlets correspond to the resin inlets 101 to 103,
The plate material corresponds to the plate-like base material 41,
The welding location corresponds to the shape retaining weld 33b,
The connection structure corresponds to the crimp connection structure 61,
The present invention is not limited to the configuration of the above-described embodiment, but can be applied based on the technical idea shown in the claims, and many embodiments can be obtained.

In the above description, the crimp terminal 11 in which the terminal connection portion 12 and the crimp portion 13 are arranged in this order has been described. However, a crimp terminal constituted only by the crimp portion 13 may be used.
The abutting of the end portions 33a in the width direction of the plate-like base material 41 described above is not only the side surfaces of the end portion 33a of the plate-like base material 41 but also the inclined side surfaces in which the side surfaces of the end portion 33a are inclined or It can be set as the butt | matching of the side surfaces which comprised the surface which has the height more than 41 thickness.

  Moreover, it is not necessarily limited to comprising the shape-retaining weld part 33b by butting the end parts 33a in the width direction of the plate-like base material 41 to each other, and for example, the end part in the width direction of the plate-like base material 41 The shape-retaining welded portion 33b may be configured by welding an overlapped portion in which 33a is overlapped with each other by a predetermined width.

Moreover, although fiber laser welding was performed by irradiating fiber laser light from the fiber laser welding apparatus 81, welding may be performed by irradiating an electron beam.
Moreover, although resin 105 was used as a filler, it is not necessarily limited to this, Especially, you may use solder as a filler in the part corresponding to the electric wire crimping range 13b and the sealing part 13c.

DESCRIPTION OF SYMBOLS 11 ... Crimp terminal 13 ... Crimp part 13a ... Cover crimping range 13b ... Electric wire crimp range 13c ... Sealing part 32 ... Water stop weld 33a ... End part 33b ... Shape retention weld 41 ... Plate-shaped base material 51 ... Cover electric wire 52a ... Wire exposed part 53 ... Insulation coating 61 ... Crimp connection structure 72 ... Connector housing 101 to 103 ... Resin inlet 104 ... Filling space 105 ... Resin

Claims (10)

A crimp terminal having at least a crimp section having a hollow cross section that allows crimp connection to a conductor portion exposed from the tip of an insulation coating section of a covered wire,
The crimping portion is bent in the width direction so that the cross-section is hollow, the ends in the width direction of the plate material are welded in the longitudinal direction, and the conductor crimping range is crimped, and the insulation With a configuration in which the conductor portion and the insulation coating portion are straddled across the conductor portion and the insulating coating portion with a covering pressure bonding range for crimping the covering portion,
A plurality of filler inlets for injecting a filler between the crimping part and the covered electric wire are provided in parallel in the crimping part along a welded portion where the end parts are welded to each other. Terminal. The crimp terminal according to claim 1, wherein at least the filler inlet is provided in the coated crimp range. The crimp terminal according to claim 1 or 2, wherein a plurality of the filler inlets are arranged side by side in the longitudinal direction of the hollow cross section. With a sealing shape that seals one end side of the conductor portion side in the longitudinal direction in the cross-sectional hollow shape,
In one end side of the conductor portion side in the longitudinal direction formed in a sealing shape to be sealed, a sealing portion is constructed by welding in a direction intersecting the longitudinal direction,
The crimp terminal according to claim 1, wherein the filler inlet is provided in the sealing portion. The crimp terminal according to any one of claims 1 to 4, wherein the filler inlet is disposed so as to sandwich the welded portion where the ends are welded to each other. While connecting the said covered electric wire and the said crimp terminal by the crimp part in the crimp terminal in any one of Claims 1 thru | or 5 ,
A connection structure in which the space between the crimping portion and the covered electric wire is filled with the filler. While providing a filling space for filling the filler between the insulating coating portion and the coating crimping range,
Providing the filler inlet so as to communicate with the filling space;
The connection structure according to claim 5 , wherein the filling space is filled with the filler. The connection structure according to claim 7 , wherein the filling space is provided between the insulating coating portion and an intermediate portion in the longitudinal direction of the coating pressure-bonding range. The connector which has arrange | positioned the crimp terminal in the connection structure in any one of Claim 6 thru | or 8 in the connector housing. A method of manufacturing a connection structure in which the coated wire and the crimp terminal are connected by a crimped portion having a hollow cross-section that allows crimped connection to the conductor portion exposed from the tip of the insulating coating portion of the coated wire,
The plate material is bent in the width direction so as to have a hollow cross-section, the ends in the width direction of the plate material are welded in the longitudinal direction, and the wire crimping range for crimping the conductor portion is crimped. In the crimping range, the crimping unit is configured to crimp the conductor part and the insulating coating part across the insulating coating part, and a plurality of filler inlets are juxtaposed along the welded portion where the end parts are welded to each other. On the other hand, an electric wire insertion step of inserting a terminal portion of the covered electric wire including the conductor portion,
Clamping the crimping part in the wire crimping range and crimping to the conductor part, and filling the filler between the insulating coating part and the intermediate part in the longitudinal direction of the coating crimping range in the coating crimping range A crimping step of crimping the crimping part on the insulating coating part so as to form a space; and
And a filling step of filling the filling space with the filler by injecting the filler from the filler inlet.

Images