JP5777861B2 - Production method of wire harness and wire terminal anticorrosion structure - Google Patents

Description

  The present invention mainly relates to a wire terminal anticorrosion structure for preventing electric corrosion that may occur when a terminal made of a metal other than aluminum is connected to an aluminum electric wire.

  Conventionally, electric wires (copper electric wires) made of copper or a copper alloy have been used in the field of automobile wire harnesses and the like. However, in recent years, there is a demand for using an aluminum or aluminum alloy wire (aluminum wire) instead of a conventional copper wire from the viewpoint of improving recyclability and weight reduction.

  On the other hand, a terminal made of copper or a copper alloy (copper terminal) has been conventionally used for the connection connector disposed at the end of the wire harness. This copper terminal has been developed and put to practical use after a huge endurance test and performance evaluation. Therefore, if the terminal of the wire harness is changed to aluminum (or aluminum alloy), enormous time and cost are required for optimization of design and confirmation of connection reliability.

  Therefore, a configuration in which the terminal is made of copper or copper alloy as in the past and only the electric wire portion is replaced with aluminum or aluminum alloy has been studied. However, since electrolytic corrosion can occur at the connection portion between the copper terminal and the aluminum wire, there is a problem in putting the aluminum wire into practical use. That is, when a copper terminal is connected to an aluminum electric wire, different metals come into contact with each other. Therefore, if there is moisture or moisture around the metal wires, different metal contact corrosion (electric corrosion) proceeds.

  In this respect, Patent Document 1 discloses a wire terminal anticorrosion in which one end of a short copper wire is connected to an end of an aluminum wire, the connection portion is covered with an insulator, and a copper terminal is crimped and connected to the other end of the copper wire. The structure is disclosed. Patent Document 1 covers the connection portion of the aluminum electric wire and the copper electric wire with an insulator as described above, thereby preventing water and water vapor from entering the connection portion from the outside and suppressing the occurrence of electrolytic corrosion. I can do it.

JP 2009-009736 A

  However, the configuration of Patent Document 1 requires an operation of connecting an aluminum electric wire and an operation of connecting a terminal to a short copper electric wire. That is, the configuration of Patent Document 1 is troublesome twice in that a connection operation is required twice to connect one terminal to an electric wire, and there is a problem that production cost increases.

  The present invention has been made in view of the above circumstances, and a main object of the present invention is to provide an electric wire terminal anticorrosion structure capable of preventing contact corrosion of different metals with a simple configuration.

Means and effects for solving the problems

  The problems to be solved by the present invention are as described above. Next, means for solving the problems and the effects thereof will be described.

According to the first aspect of the present invention, it is possible to prevent contact corrosion of different metals when a terminal made of a metal other than aluminum or aluminum alloy is connected to an electric wire in which a conductor made of aluminum or an aluminum alloy is covered with an insulating coating. An electric wire terminal anticorrosion structure for providing an electric wire terminal anticorrosion structure having the following configuration. That is, this electric wire terminal anticorrosion structure has the said terminal and a mold part. The terminal has an electrical connection for have a conductor connecting portion, which connects itself in electrical other terminals for connecting itself to the end of the conductor. The mold part is formed so as to cover at least the conductor connecting part and the end of the insulating coating, and is sealed only by resin molding so that moisture does not enter the conductor connecting part from the outside . And the said terminal is fixed with respect to the said insulation coating by the said mold part.

  In this way, by covering the conductor connection portion where aluminum and a metal other than aluminum are in contact with the mold, it is possible to prevent moisture from entering the conductor connection portion. Can be prevented. The mold part also has a function of fixing the terminal to the insulating coating. Thus, the wire terminal anticorrosion structure as a whole can be configured compactly by having the mold part serve as the function of sealing the conductor connection part and fixing the terminal.

  In the wire terminal anticorrosion structure, it is preferable that the terminal does not have an insulation barrel for fixing itself to the insulating coating.

  That is, in the electric wire terminal anticorrosion structure of the present invention, since the terminal is fixed to the insulating coating by the mold portion, the insulation barrel having overlapping functions can be omitted. By omitting the insulation barrel in this way, the mold portion can occupy the space occupied by the insulation barrel. That is, the thickness of the mold part can be increased, and as a result, the mechanical strength of the mold part can be improved. Furthermore, since the size of the mold part can be made compact for the above reason, the cavity shape of the connector housing can be made common with the conventional one.

According to the 2nd viewpoint of this invention, a wire harness provided with said electric wire terminal anticorrosion structure and the connector housing which accommodated at least one part of the said electric wire terminal anticorrosion structure in the cavity is provided. Then, said electrical connection part, and the mold portion, but are contained in all the cavities.

  Since this wire harness uses aluminum for the electric wire part, it is lightweight and excellent in recyclability, and since the above-mentioned wire terminal anticorrosion structure is adopted, it is considered that electric corrosion occurs at the connection part between the conductor and the terminal. Can be prevented. Furthermore, since this wire terminal anticorrosion structure can form the mold part compactly by omitting the insulation barrel, it is not necessary to form a particularly large cavity for accommodating the terminal. That is, a common connector housing can be employed. Thereby, the wire harness which was excellent in component compatibility and achieved cost reduction can be provided.

According to the third aspect of the present invention, the contact corrosion of dissimilar metals when a terminal made of a metal other than aluminum or aluminum alloy is connected to an electric wire in which a conductor made of aluminum or an aluminum alloy is coated with an insulating coating is prevented. A method for producing an electric wire terminal anticorrosion structure for providing the following is provided. That is, the production method of the wire terminal anticorrosion structure includes a terminal connection step, a terminal placement step, and a mold part forming step. In the terminal connection step, the terminal is connected to an end portion of the conductor by a conductor connection portion provided in the terminal. In the terminal placing step, the terminal connected to the conductor and the end portion of the insulating coating are placed on a lower mold. In the mold part forming step, an upper mold is combined with the lower mold, a mold part covering at least the conductor connection part and the end of the insulating coating is resin-molded, and only the resin molding is performed. The conductor connection portion is sealed so that moisture does not enter from the outside . Further, the terminal has an electrical connection part for electrically connecting to another terminal, and does not have an insulation barrel for fixing itself to the insulating coating, It is fixed to the insulating coating. The lower mold includes an inflow prevention wall that prevents the resin from flowing from the conductor connection portion toward the electric connection portion during the resin molding. Then, said electrical connection part, and the mold part, but can fit into the cavity of all connector housings.

  By the above production method, the electric wire terminal anticorrosion structure in which the end portion of the insulating coating and the conductor connection portion are covered with the mold portion can be produced. And as mentioned above, by forming a mold part using a mold having an inflow prevention wall that prevents the resin from flowing into the electrical connection part, the conductor connection part is sealed by the mold part. It is possible to prevent the resin from adhering to the electrical connection portion while ensuring the reliability.

  In the above-described production method of the wire terminal anticorrosion structure, it is preferable that the lower mold is formed with a recess corresponding to the conductor connection portion and the electrical connection portion.

  This facilitates installation of the terminals on the lower mold.

  In the production method of the wire terminal anticorrosion structure, a substantially U-shaped cut portion is formed on a side surface of the lower mold, and in the terminal placing step, the terminal is provided on the lower mold. And when installing the edge part of the said insulation coating, it is preferable to pass the said insulation coating through the said notch part.

  In this way, since the insulating coating is positioned by passing the insulating coating through the notch, it is possible to prevent the position of the insulating coating from being displaced when the lower mold and the upper mold are combined.

The figure which shows the structure of the wire harness which concerns on one Embodiment of this invention. The external appearance perspective view of an electric wire terminal anticorrosion structure. The side view of an electric wire terminal anticorrosion structure. The perspective view which shows the mode inside a mold part. The side view which shows the mode inside a mold part. The perspective view which shows the example of the conventional terminal connection structure. The figure which shows the schematic structure of a metal mold | die. (A) AA sectional drawing of FIG. (B) BB sectional drawing of FIG. The figure which shows a mode that the female terminal was mounted in the lower side metal mold | die. (A) CC sectional drawing of FIG. (B) DD sectional drawing of FIG. The figure which shows a mode that the mold part was resin-molded. (A) EE sectional drawing of FIG. (B) FF sectional drawing of FIG.

  Next, embodiments of the present invention will be described with reference to the drawings. FIG. 1 shows a distal end portion of a wire harness 1 according to an embodiment of the present invention. The wire harness 1 is a bundle of a plurality of electric wires 2 and generally has a predetermined branching structure (not shown). A female connector 3 as shown in FIG. 1 is arranged at each end of the branched wire harness 1.

  In the wire harness 1 of the present embodiment, each electric wire 2 is an aluminum electric wire in which an aluminum (or aluminum alloy) conductor 30 (not shown in FIG. 1) is covered with an insulating coating 31. Thus, since aluminum is adopted as the conductor 30 of the electric wire 2, the overall weight of the wire harness 1 can be reduced as compared with the conventional copper electric wire which employs copper (or copper alloy) as the conductor. At the same time, recycling can be improved.

  The female connector 3 has a female connector housing 4 shown in FIG. A plurality of cavities 5 are formed in the female connector housing 4, and an electric wire terminal anticorrosion structure 20 as shown in FIGS. 2 and 3 is arranged inside each cavity 5.

  As shown in FIGS. 2 and 3, the wire terminal anticorrosion structure 20 includes a female terminal 6. The female terminal 6 is electrically connected to the conductor 30 of the electric wire 2. A rectangular tube-shaped male terminal insertion portion (electrical connection portion) 10 is formed at the tip of the female terminal 6. A male terminal 9 described later can be inserted into the rectangular cylindrical male terminal insertion portion 10. Further, as shown by a dotted line in FIG. 3, an elastically deformable contact piece 11 is formed inside the male terminal insertion portion 10.

  On the other hand, an electrical component (not shown) connected to the wire harness 1 has a male connector 7 as shown in FIG. The male connector housing 8 included in the male connector 7 is formed so as to be fitted to the female connector housing 4 on the wire harness 1 side. A plurality of male terminals 9 are provided in the male connector housing 8 so as to protrude. And it is comprised so that each male terminal 9 may be inserted in the inside of the cavity 5 in a corresponding position by making connector housings 4 and 8 fit. The male terminal 9 inserted into the cavity 5 is inserted into the male terminal insertion portion 10 of the female terminal 6 disposed in the cavity 5, and further contacts with and electrically connects to the contact piece 11. Thereby, the wire harness 1 and the said electrical component can be electrically connected.

  Here, in the wire harness 1 of this embodiment, the female terminal 6 and the male terminal 9 are made of copper (or copper alloy) terminals (copper terminals) as usual. Copper terminals have been used for a long time and their connection reliability has been confirmed. Thus, the wire harness 1 of this embodiment has realized the improvement of recyclability and weight reduction by employ | adopting an aluminum electric wire, ensuring the connection reliability as usual by adopting a copper terminal. .

  However, when a copper terminal is connected to an aluminum electric wire as described above, electrolytic corrosion can occur at the dissimilar metal contact portion. Then, the wire harness 1 of this embodiment has said electric wire terminal anticorrosion structure 20 in order to prevent an electric corrosion. The electric wire terminal anticorrosion structure 20 will be described in detail below.

  As shown in FIG.2 and FIG.3, the electric wire terminal anticorrosion structure 20 is equipped with the above-mentioned female terminal 6 and the resin-made mold part 21. As shown in FIG. The mold part 21 is formed so as to cover and seal the dissimilar metal contact part where the female terminal 6 made of copper (or copper alloy) and the conductor 30 made of aluminum (or aluminum alloy) contact. Thereby, since it can prevent that a water | moisture content penetrate | invades into the said different metal contact part, generation | occurrence | production of the said electrolytic corrosion can be prevented.

  Next, the structure of the part covered with the mold part 21 is demonstrated in detail. For the sake of explanation, FIG. 4 and FIG. 5 show a state in which the mold part 21 is transparently illustrated by a two-dot chain line.

  As described above, the electric wire 2 includes the conductor 30 made of aluminum (or aluminum alloy) and the insulating coating 31 covering the periphery of the conductor 30. In order to connect the female terminal 6 to the conductor 30 at the distal end portion of the electric wire 2, a part of the insulating coating 31 is removed to expose the conductor 30. The conductor 30 may be a stranded wire made of a plurality of aluminum wires, or may be a single wire.

  The female terminal 6 has the male terminal insertion portion 10 described above and a pair of wire barrels (conductor connection portions) 12. And the conductor 30 of the electric wire 2 is crimped and fixed by caulking the wire barrel 12. Thereby, the conductor 30 and the female terminal 6 are electrically connected. The female terminal 6 is obtained by pressing a plate material made of copper (or copper alloy) and then bending, and the male terminal insertion portion 10 and the wire barrel 12 are integrally formed. .

  The mold portion 21 is formed so as to mainly cover the wire barrel 12 portion. That is, in the portion where the conductor 30 is crimped by crimping the wire barrel 12, contact between different metals of copper and aluminum occurs, so that electric corrosion occurs if moisture exists in the surroundings. Therefore, as shown by a two-dot chain line in FIG. 3 and FIG. 4, the portion of the wire barrel 12 is sealed by the mold portion 21 to prevent moisture from entering the dissimilar metal contact portion from the outside. Yes.

  Further, in the wire harness 1 of the present embodiment, the mold portion 21 is formed so as to cover a part of the end portion of the insulating coating 31 in addition to the portion of the wire barrel 12. With this configuration, the female terminal 6 can be fixed to the insulating coating 31 by the mold portion 21. That is, the mechanical strength of the wire terminal anticorrosion structure 20 is ensured by the mold part 21.

  Here, in order to compare with the electric wire terminal anticorrosion structure 20 of this embodiment, the structure of the terminal connection structure 120 using the conventional general female terminal 106 is illustrated in FIG. In addition, in description of the conventional terminal connection structure 120, the same code | symbol is attached | subjected to drawing and the description is abbreviate | omitted to the structure which is the same as that of the electric wire terminal anticorrosion structure 20 of this embodiment.

  In the conventional female terminal 106, in addition to the male terminal insertion portion 10 and the wire barrel 12, a portion called an insulation barrel 13 was formed. The insulation barrel 13 is for fixing the female terminal 106 to the insulating coating 31 by crimping the insulating coating 31. That is, in the conventional terminal connection structure 120, the mechanical strength is guaranteed by the insulation barrel 13.

  By the way, in this conventional terminal connection structure 120, the portion where the insulation coating 31 is pressure-bonded by the insulation barrel 13 is thicker by the thickness of the insulation barrel 13 than the other portions. Accordingly, if this part is covered with the mold part as in the present embodiment, the thickness of the mold part is reduced by the thickness of the insulation barrel 13 to ensure the mechanical strength of the mold part. It becomes difficult. Therefore, it is conceivable to form the mold part thick in order to ensure the thickness of the mold part, but in this case, the thick mold part cannot be accommodated in the cavity 5 of the conventional female connector housing 4. Therefore, in this case, the female connector housing needs to be designed exclusively. Thus, in the electric wire terminal anticorrosion structure of the structure which covers the female terminal 106 provided with the insulation barrel 13 with the mold part, there is a possibility that the parts cannot be shared and the cost may be increased.

  On the other hand, the female terminal 6 can be fixed to the insulating coating 31 by covering the wire barrel 12 and the insulating coating 31 with the mold portion 21 as in the wire terminal anticorrosion structure 20 of the present embodiment. That is, it can be said that the mold part 21 has the same function as the insulation barrel 13 provided in the conventional terminal connection structure 120 (the function of “fixing the female terminal to the insulating coating”). .

  Focusing on this point, the insulation terminal 13 provided in the conventional female terminal 106 is omitted from the female terminal 6 of the wire terminal anticorrosion structure 20 of the present embodiment. That is, the wire terminal anticorrosion structure 20 of the present embodiment is configured to fix the female terminal 6 to the insulating coating 31 only by the mold portion 21. Thus, in the electric wire terminal anticorrosion structure 20 of this embodiment, since the mold part 21 has two functions of sealing the wire barrel 12 and fixing the female terminal 6 to the insulating coating 31, the electric wire terminal The entire terminal anticorrosion structure 20 can be configured compactly.

  That is, in the electric wire terminal anticorrosion structure 20 of this embodiment, since the insulation barrel 13 is omitted as described above, the mold portion 21 occupies the space occupied by the insulation barrel 13 in the conventional terminal connection structure 120. be able to. Thereby, compared with the case where a mold part is formed in the conventional terminal connection structure 120, since the thickness of the mold part 21 can be formed thick by the thickness of the insulation barrel 13, the mechanical strength of the mold part 21 is increased. Can be secured. In other words, sufficient mechanical strength can be obtained without setting the wall thickness of the mold portion 21 to be excessively large, and as a result, the mold portion 21 can be formed compactly.

  Furthermore, since the mold part 21 can be formed compactly as described above, the degree of freedom in design of the mold part 21 is improved, and the mold part 21 can be accommodated in the cavity 5 of the conventional female connector housing 4. It becomes possible to design. As a result, the versatility of the wire terminal anticorrosion structure 20 is improved, and it is possible to reduce the cost by using common parts. That is, the wire terminal anticorrosion structure 20 of the present embodiment integrates the function of “fixing the terminal against the insulating coating” of the insulation barrel 13 provided in the conventional terminal connection structure 120 into the mold portion 21, This also solves the problem of space in which the mold part 21 is compactly configured and accommodated in the cavity 5.

  Moreover, in the electric wire terminal anticorrosion structure 20 of this embodiment, since the insulation barrel is not required, the wire barrel 12 is located on the rear side (the direction opposite to the tip of the female terminal 6) compared to the conventional female terminal 106. It becomes possible to slip. Therefore, according to the configuration of the present embodiment, the thickness of the resin in front of the mold portion 21 (the tip side of the female terminal 6) can be increased. Thereby, the strength against cracks and scratches can be improved.

  Next, a method for producing the wire terminal anticorrosion structure 20 described above will be described. This production method includes an insulating coating removing process, a terminal connecting process, a terminal placing process, and a mold part forming process.

  In the insulating coating removing step, the insulating coating 31 at the end of the electric wire 2 is removed, and the internal conductor 30 is exposed. Subsequently, in the terminal connection step, the female terminal 6 is connected to the exposed conductor 30 by caulking the wire barrel 12 of the female terminal 6.

  Subsequently, in the terminal placement process, the female terminal 6 connected to the conductor 30 and the tip of the insulating coating 31 are placed on the lower mold 40. The lower mold 40 and the upper mold 41 are molds for resin molding the mold part 21.

  As shown in FIG. 7, a recess 42 corresponding to the male terminal insertion portion 10 and the wire barrel 12 is formed in the lower mold 40. When placing the female terminal 6 on the lower mold 40, the male terminal insertion portion 10 and the wire barrel 12 are placed in the recess 42 as shown in FIG. Thus, since the recessed part 42 is formed in the lower side metal mold | die 40, it becomes easy to position at the time of installing the female terminal 6 in a metal mold | die, and workability | operativity improves.

  Moreover, as shown in FIG.8 (b), the notch part 43 whose cross-sectional shape is substantially U shape is formed in the side surface of the lower metal mold | die 40. As shown in FIG. When the female terminal 6 is placed on the lower mold 40, the remaining part of the insulating coating 31 (the part where the mold is not formed) is passed through the U-shaped part of the cut-out portion 43 to form the lower mold. It is mounted so as to be exposed to the outside of 40 (see FIG. 9 and FIG. 10B). Thus, since the electric wire 2 is passed through the U-shaped notch formed in the lower die, when the lower die 40 and the upper die 41 are combined, the position of the electric wire 2 is displaced and both the die It can prevent being pinched between the molds 40 and 41.

  When the female terminal and the insulation coating are placed on the lower mold as described above, resin molding is performed by combining the lower mold with the upper mold (mold part forming step). Thereby, as shown in FIG. 11, the mold part 21 is formed and the electric wire terminal anticorrosion structure 20 of this embodiment is produced. In addition, if the resin flows into the male terminal insertion portion 10 and adheres to the contact piece 11 or the like at the time of the resin molding, it causes a contact failure of the female terminal 6. Accordingly, as shown in FIGS. 7 and 8A and the like, the lower mold 40 is formed with an inflow prevention wall 44 that prevents the resin from flowing from the wire barrel 12 toward the male terminal insertion portion 10. Has been. Thereby, while improving the connection reliability of the female terminal 6, the wire barrel 12 can be reliably sealed by the mold part 21.

  As described above, the wire terminal anticorrosion structure 20 of the present embodiment includes the female terminal 6 and the mold part 21. The female terminal 6 has a wire barrel 12 for connecting itself to the end of the conductor 30. The mold part 21 is formed so as to cover at least the wire barrel 12 and the end part of the insulating coating 31. The female terminal 6 is fixed to the insulating coating 31 by the mold part 21.

  In this way, by covering the portion of the wire barrel 12 where aluminum and copper are in contact with each other by the mold portion 21, it is possible to prevent moisture from entering the portion of the wire barrel 12, so that electrolytic corrosion can be prevented. it can. The mold part 21 also has a function of fixing the female terminal 6 to the insulating coating. Thus, the wire terminal anticorrosion structure 20 can be configured compactly as a whole by having the mold part 21 have the functions of sealing the wire barrel 12 and fixing the female terminal 6.

  Further, in the wire terminal anticorrosion structure 20 of the present embodiment, the female terminal 6 does not have an insulation barrel for fixing itself to the insulating coating 31.

  That is, in the electric wire terminal anticorrosion structure 20 of the present embodiment, the female terminal 6 is fixed to the insulating coating 31 by the mold part 21, so that the insulation barrel having overlapping functions can be omitted. Thus, by omitting the insulation barrel, the mold portion 21 can occupy the space occupied by the insulation barrel. That is, the thickness of the mold part 21 can be increased, and as a result, the mechanical strength of the mold part 21 can be improved. Furthermore, since the size of the mold part 21 can be made compact for the above reason, the shape of the cavity 5 of the connector housing 4 can be made common.

  Moreover, the wire harness 1 of this embodiment includes the above-described wire terminal anticorrosion structure 20 and the connector housing 4 in which the wire terminal anticorrosion structure 20 is housed in the cavity 5.

  Since this wire harness 1 uses aluminum for the electric wire portion, it is lightweight and excellent in recyclability, and also employs the above-described electric wire terminal anticorrosion structure 20, so that electric corrosion occurs at the connection portion between the conductor and the terminal. This can be prevented. Further, since the wire terminal anticorrosion structure 20 can omit the insulation barrel to form the mold portion 21 in a compact manner, it is not necessary to form the cavity 5 for accommodating the female terminal 6 in a particularly large size. That is, the connector housing 4 common to the conventional one can be employed. Thereby, the wire harness 1 which was excellent in component compatibility and achieved cost reduction can be provided.

  Moreover, the production method of the wire terminal anticorrosion structure of the present embodiment includes a terminal connection step, a terminal placement step, and a mold part forming step. In the terminal connection step, the female terminal 6 is connected to the end of the conductor 30 by the wire barrel 12 provided in the female terminal 6. In the terminal placement step, the female terminal connected to the conductor 30 and the end of the insulating coating 31 are placed on the lower mold 40. In the mold part formation step, the upper mold 41 is combined with the lower mold 40, and the mold part 21 covering at least the wire barrel 12 and the end of the insulating coating 31 is resin-molded. The female terminal 6 has a male terminal insertion portion 10 for electrical connection with the male terminal 9 and is fixed to the insulating coating 31 by a mold portion 21. The lower mold 40 includes an inflow prevention wall 44 that prevents the resin from flowing from the wire barrel 12 toward the male terminal insertion portion 10 during the resin molding.

  With the above production method, the wire terminal anticorrosion structure 20 in which the end portion of the insulating coating 31 and the wire barrel 12 are covered with the mold portion 21 can be produced. And as mentioned above, by forming the mold part 21 using the lower mold 40 provided with the inflow prevention wall 44 for preventing the resin from flowing into the male terminal insertion part 10, the mold part It is possible to prevent the resin from adhering to the male terminal insertion portion 10 while ensuring the sealing of the wire barrel 12 by 21.

  Moreover, in the production method of the wire terminal anticorrosion structure 20 of the present embodiment, the lower mold 40 is formed with a recess 42 corresponding to the wire barrel 12 and the male terminal insertion portion 10.

  Thereby, installation of the female terminal 6 to the lower mold 40 is facilitated.

  Moreover, in the production method of the wire terminal anticorrosion structure 20 of the present embodiment, a substantially U-shaped cut portion 43 is formed on the side surface of the lower mold 40, and the lower metal When the female terminal 6 and the end portion of the insulating coating 31 are installed in the mold 40, the insulating coating 31 is passed through the cut portion 43.

  Thus, since the said insulating coating 31 is positioned by letting the insulating coating 31 pass through the notch part 43, when combining the lower metal mold | die 40 and the upper metal mold | die 41, the position of the insulating coating 31 will shift | deviate. Can be prevented.

  The preferred embodiment of the present invention has been described above, but the above configuration can be modified as follows, for example.

  Although the case where a copper terminal was connected to the aluminum electric wire which comprises wire harness 1 was explained in the above-mentioned embodiment, not only a wire harness but the case where a copper terminal is connected to an aluminum electric wire applies the composition of the present invention widely. be able to.

  Although the terminal arrange | positioned at the front-end | tip of the electric wire 2 demonstrated as a female terminal, it is not restricted to this, For example, you may apply the electric wire terminal anticorrosion structure of this invention to the connection part of a male terminal and an electric wire.

  The wire terminal connection structure 20 is arranged in the cavity 5 of the female connector housing 4, but it is sufficient that at least the female terminal 6 and the tip of the mold part 21 are accommodated in the cavity 5, The entire wire terminal connection structure 20 may not be accommodated in the cavity 5.

  Although it demonstrated that the raw material of a terminal was copper or a copper alloy, even if it is a case where the terminal which consists of metals other than this is employ | adopted, electric corrosion can be prevented with the electric wire terminal anticorrosion structure of this invention.

1 Wire harness 2 Electric wire 6 Female terminal (terminal)
10 Male terminal insertion part (electrical connection part)
12 Wire barrel (conductor connection part)
20 Terminal connection structure 21 Mold part 30 Conductor 31 Insulation coating

Claims (4)

Wire provided with a wire terminal anticorrosion structure for preventing contact corrosion of dissimilar metals when a terminal made of metal other than aluminum or aluminum alloy is connected to an electric wire in which a conductor made of aluminum or aluminum alloy is covered with an insulating coating A harness,
To have a conductor connection for connecting itself to the end of the conductor, to have an electrical connection for electrically connecting itself to other terminals, and to fix itself to the insulation coating The terminal not having an insulation barrel of
A mold part that is formed so as to cover at least the end part of the insulating coating and the conductor connection part, and is sealed only by resin molding so that moisture does not enter the conductor connection part from the outside , and
A wire terminal anticorrosion structure having
A connector housing containing at least a part of the wire terminal anticorrosion structure in a cavity;
With
The terminal is fixed to the insulating coating by the mold part,
Wire harness, wherein said electrical connection part, and the mold part, but that are contained in all the cavities. A method of producing a wire terminal anticorrosion structure for preventing contact corrosion of dissimilar metals when a terminal made of metal other than aluminum or aluminum alloy is connected to an electric wire coated with a conductor made of aluminum or aluminum alloy with an insulating coating. There,
A terminal connecting step of connecting the terminal to the end of the conductor by a conductor connecting portion provided in the terminal;
A terminal placing step of placing the terminal in a state connected to the conductor and an end of the insulating coating on a lower mold;
Combining the lower mold with the upper mold, resin-molding a mold part that covers at least the conductor connection part and the end of the insulating coating, and only the resin molding allows moisture to the conductor connection part. Mold part forming step for sealing so as not to enter from the outside ,
Including
The terminal has an electrical connection part for electrically connecting to another terminal, and does not have an insulation barrel for fixing itself to the insulating coating, and the insulation is provided by the mold part. Fixed against the sheath,
The lower mold includes an inflow prevention wall that prevents the resin from flowing from the conductor connection portion toward the electric connection portion during the resin molding,
And said electric connecting portion, and the mold portion, characterized in that but can fit into the cavity of all the connector housing, the method of producing wire terminal anticorrosion structure. It is a production method of the electric wire terminal anticorrosion structure according to claim 2,
The lower mold is formed with a recess corresponding to the conductor connecting portion and the electrical connecting portion, and the method for producing a wire terminal anticorrosion structure. It is a production method of the electric wire terminal anticorrosion structure according to claim 2 or 3,
A substantially U-shaped cut portion is formed on the side surface of the lower mold,
In the terminal mounting step, when installing the terminal and the end of the insulation coating on the lower mold, the insulation coating is passed through the cut portion, and the production of the wire terminal anticorrosion structure Method.

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