JP6688657B2 - Joint terminal, connecting electric wire, electric wire connection structure, and manufacturing method of connecting electric wire - Google Patents

Description

  The present invention relates to a joint terminal for connecting covered electric wires to each other, a connecting electric wire connecting covered electric wires to each other through the joint terminal, an electric wire connecting structure in which both ends of the connecting electric wire are crimp-connected with crimp terminals, and a manufacturing method of a connecting electric wire. Regarding the method.

  The electric wire connection structure that constitutes the wire harness to be installed in the vehicle may be formed of a connecting electric wire that connects the covered electric wires to each other in the axial direction, and as a joint terminal that connects the covered electric wires to each other in the axial direction, for example, Patent Document 1 discloses a joint terminal that crimps covered electric wires to connect them in the axial direction.

  The joint terminal described in Patent Document 1 includes a flat plate-shaped connecting portion that axially connects the connecting portions that connect to the coated electric wires, and the coated electric wires are connected to each other by connecting the coated electric wires to each other. It is said that they can be connected.

  However, since the connecting portion that connects the connecting portions is formed in a flat plate shape, it is vulnerable to an external force that acts when the connecting portion and the covered electric wire are crimped or an external force that acts in the coupled state. There was a problem.

JP, 2013-122869, A

  Therefore, an object of the present invention is to provide a joint terminal, a connecting electric wire, an electric wire connecting structure, and a method for manufacturing a connecting electric wire, which can improve the strength of a connecting portion.

The present invention is directed to a first connecting portion electrically connected to a first covered electric wire, a second connecting portion electrically connected to a second covered electric wire, the first connecting portion and the second connecting portion in an axial direction. is composed of a connecting portion for connecting the second connection portion prior SL is configured cross section perpendicular to the front SL-axis direction by the annular connection part of the annular Rutotomoni, the first connecting portion, perpendicular to the axial direction cross-section is formed in a substantially U-shaped, wherein at least a portion of the connecting portion is constituted by the high-strength, high-strength connecting portion than the first connection portion and the metal plate constituting the second connecting portion, the connecting A portion is formed in a substantially U-shape in a cross section orthogonal to the axial direction, the high-strength connecting portion includes a connecting portion main body forming the connecting portion, a width direction extending from the connecting portion main body, and the width. And a connecting portion main body having a cross section of approximately U. The bent-back portion is integrally formed so that the connecting portion side of the first connecting portion and the outer edge are continuous, and the connecting portion side of the second connecting portion and the outer edge are continuous. As described above, the high-strength connecting portion is formed with a connection overlapping portion that is overlapped with the connecting portion main body on the second connection portion side of the bending return portion, and the bending return portion is The first connecting portion side gradually rises toward the first connecting portion to form a connecting non-overlapping portion that does not overlap the connecting portion main body, and the connecting overlapping portion includes the connecting portion main body and the bent back portion. And the connecting non-overlapping portion is formed in a substantially U-shaped cross section such that the connecting portion main body and the bent back portion do not overlap each other. , The bending-back portion is in the width direction of the connecting portion main body. Characterized in that so that a substantially U-shaped cross section from both sides, the joint terminal is gradually risen.

  The first covered electric wire and the second covered electric wire are made of, for example, a covered electric wire in which a copper-based conductor made of a copper-based material such as copper or a copper alloy is covered with an insulating coating, or an aluminum-based material such as aluminum or an aluminum alloy. It is a concept that includes a coated electric wire in which the above-described aluminum-based conductor is covered with an insulating coating, and the like. The coated electric wire in which each of the first coated electric wire and the second coated electric wire is formed of the same kind of material in the same diameter, or the coating formed in a different diameter An electric wire, or a covered electric wire in which the first covered electric wire and the second covered electric wire are formed of different materials to have the same diameter, and a covered electric wire formed to have a different diameter are included.

  The first connecting portion and the second connecting portion are concepts including a connecting portion for crimping and connecting and a connecting portion for welding and connecting, and in the case of the connecting portion for crimping and connecting, they are orthogonal to the axial direction. The cross-section includes a substantially U-shaped open barrel type crimping portion, an annular closed barrel type crimping portion, and the like.

  The high-strength connecting portion having a higher strength than the above-described metal plate material is, for example, a connecting portion formed by overlapping a part of joint terminals to form a thick plate, or a connection formed by using a terminal base material having a plate thickness thicker than the connecting part. Part, the connecting portion made of a metal material having higher strength than the metal plate material forming the first connecting portion and the second connecting portion, or a connecting portion formed by thickening the plate thickness by stacking other members. Yes, it includes a connecting portion having a high-strength connecting portion in the entire range and a connecting portion having a high-strength connecting portion in a part.

The above-mentioned bent back portion bent back in the width direction means a bent back portion bent back so as to overlap the connecting portion main body, a bent back portion bent so as not to overlap the connecting portion main body, or the above bent back portion. It is a concept that includes a bent back portion configured by combining parts.

The above-mentioned bent back portion being bent back and overlapped with the connecting portion main body means that not only the bending back portion is bent back so that the connecting portion body overlaps but also the entire bending back portion and the connecting portion. It also includes folding back so that it overlaps with the main body.

The above-mentioned connecting portion formed in a substantially U-shape in a cross section orthogonal to the axial direction includes, for example, a connecting portion formed in a substantially U-shaped cross section, a connecting portion formed in a substantially U-shaped cross section, and a substantially V-shaped cross section. It is a concept including a connecting portion formed in a letter shape.

According to this invention, the strength of the connecting portion can be improved.
More specifically, by configuring the connecting portion with a high-strength connecting portion having a higher strength than the metal plate material forming the first connecting portion and the second connecting portion, the same connection as the first connecting portion and the second connecting portion can be achieved. It is possible to improve the strength as compared with a general connecting portion formed in a flat plate shape with a plate thickness.

Thereby, even when the first connecting portion and the first covered electric wire are crimped or the second connecting portion and the second covered electric wire are crimped, the strength is improved by the high-strength connecting portion. The connection part can be prevented from being damaged by being bent, cracked, or twisted by an external force applied by crimping. Further, even after mounting on the vehicle, it is possible to prevent the connecting portion from being damaged by an external force such as engine vibration or vehicle traveling vibration.
Therefore, the first covered electric wire and the second covered electric wire that are connected via the joint terminal can be surely conducted.

Further, the high strength connecting portion, the connecting portion body constituting the connecting portion, extends in the width direction from the coupling portion main unit, by configuring bending-back portion and which is bent back in the width direction, component It is possible to surely improve the strength of the connecting portion while reducing the number of points.

  In detail, by connecting the main body of the connecting portion constituting the connecting portion, and extending in the width direction from the connecting portion main body, by configuring the high-strength connecting portion with the bent back portion bent back in the width direction, Since the connecting portion main body and the bent-back portion can be integrally formed, the number of parts constituting the high-strength connecting portion can be reduced.

Further, even when the connecting portion is made of the same kind of metal plate material as the first connecting portion and the second connecting portion, the high-strength connecting portion provided with the bent-back portion is connected to the conventional flat plate-like connecting portion. In comparison, the strength due to the cross-sectional shape is improved. That is, since the cross-sectional strength is improved, the strength of the connecting portion can be reliably improved without using, for example, a separate member or forming a metal material having high strength.
Therefore, it is possible to surely improve the strength of the connecting portion while reducing the number of parts.

Also, the previous SL the connecting portion side of the first connecting portion, by a child integrally formed and at least one said bent-back portion of the connecting portion side of the second connecting portion, the strength of the connecting portion Can be improved more reliably.

  In detail, at least one of the connecting portion side of the first connecting portion and the connecting portion side of the second connecting portion and the bending return portion are integrally formed, so that the bending return portion is interrupted. Instead, it is connected to the first connecting portion and the second connecting portion.

That is, the boundary between the bent portion and the first connecting portion or the second connecting portion is eliminated, and the strength of the boundary that can be a weak portion can be improved.
Therefore, the strength of the connecting portion can be more surely improved.

Also, the high strength connecting portion, by forming the connecting overlapping portion in which the bent-back portion is superimposed with bending returned the connecting part body, a metal plate of the first connecting portion and a second connecting portion allogeneic Even when the connecting portion is configured with, the high-strength connecting portion provided with the connecting overlapping portion is thinner than the first connecting portion and the second connecting portion as compared with the conventional flat connecting portion. Since the thickness is increased and the cross-sectional strength is improved, the strength of the connecting portion can be surely improved.

Also, by forming into a substantially U-shape in a cross section perpendicular to the axial direction of the front Symbol connecting portion, cross-sectional intensity of the connection portion of the substantially U-shaped, common connection portion formed in a plate shape Therefore, the strength of the connecting portion can be further improved.
Therefore, it is possible to reliably prevent the connecting portion from being damaged by the external force due to the pressure bonding of the first connecting portion and the second connecting portion.

Further, the present invention is characterized in that it is a connection electric wire in which the first covered electric wire and the second covered electric wire are connected in the axial direction via the joint terminal. Further, the present invention provides a first coated electric wire and the second coating through a joint terminal in which a first connecting portion formed in a substantially U-shaped cross section and a second connecting portion formed in an annular cross section are connected by a connecting portion. A first connecting step of crimping the first covered electric wire having a conductor made of a copper-based material and the first connecting portion, the method comprising: A high-strength connecting portion forming step of forming a high-strength connecting portion having a strength higher than that of the metal plate material forming the connecting portion and the second connecting portion on at least a part of the connecting portion; and a conductor formed of an aluminum-based material. A second connecting step of crimping the second covered electric wire and the second connecting portion is performed in this order, and the high-strength connecting portion includes a connecting portion main body that constitutes the connecting portion, and a width direction from the connecting portion main body. Bending back to the width direction In the high-strength connecting portion forming step, the bending-back portion extending in the width direction from the connecting portion main body forming the connecting portion is bent back in the width direction to form the high-strength portion. A method of manufacturing a connected electric wire is characterized in that a connecting portion is formed and a part of the bent-back portion is bent back to form a connected overlapping portion that is superposed on the connecting portion main body .

  According to these aspects of the invention, the first covered electric wire and the second covered electric wire can be connected via the joint terminal in which the strength of the connecting portion is improved, so that the connecting portion is not damaged and has stable conduction performance. A connecting electric wire can be configured.

Further, the joint terminal is made of a copper-based material, the first connection portion is formed in a cross section orthogonal to the axial direction in a substantially U shape, and the first terminal has a conductor made of a copper-based material. It is possible to connect to the covered electric wire and to connect the second connecting portion to the second covered electric wire having the conductor made of an aluminum-based material while being constituted by the annular connecting portion. Further, in the method of manufacturing a connected electric wire, the first connecting step of crimping the first covered electric wire having a conductor made of a copper-based material and the first connecting portion, and the connecting portion main body forming the connecting portion. The bending-back portion extending in the width direction is bent back in the width direction to form the high-strength connection portion, and a part of the bending-back portion is bent back to form a connection overlapping portion superposed on the connection portion body. With the copper-based material, the high-strength connecting portion forming step and the second connecting step of crimping the second covered electric wire having a conductor made of an aluminum-based material and the second connecting portion are performed in this order. The first covered electric wire that constitutes a conductor and the second covered electric wire that constitutes a conductor made of an aluminum-based material can be surely conducted through a joint terminal made of a copper-based material, and a connection electric power can be obtained. It is possible to reduce the weight of the.

  More specifically, the second coated electric wire having a conductor made of an aluminum-based material and the joint terminal made of a copper-based material are different metals having different ionization tendencies, but the second connection portion is formed of an annular connection portion. By doing so, it is possible to prevent water from entering the contact portion between the second covered electric wire and the second connecting portion, and prevent electrolytic corrosion at the contact portion.

  Further, since the connecting electric wire is formed by using the second covered electric wire in which the conductor is formed of the aluminum-based material, it is possible to reduce the weight of the connected electric wire in which the covered electric wires in which the conductors are formed of the copper-based material are connected to each other. . By making the wire length of the second covered electric wire longer than that of the first covered electric wire, the weight of the connected electric wire can be further reduced.

  Therefore, the first covered electric wire having a conductor made of a copper-based material and the second covered electric wire having a conductor made of an aluminum-based material can be surely electrically connected to each other via a joint terminal made of a copper-based material. In addition, it is possible to reduce the weight of the connecting electric wire.

  In addition, the connecting wire configured as described above is manufactured by performing the first connecting step, the high-strength connecting portion forming step, and the second connecting step in this order, so that the first connecting step and the high-strength connecting portion are manufactured. It is possible to prevent the crimping state between the second connecting portion crimped in the second connecting step and the second coated electric wire from being relaxed by the external force accompanying the crimping in the forming step. Accordingly, it is possible to manufacture a connected electric wire in which the second connecting portion and the second covered electric wire are in close contact with each other, and it is possible to reliably connect the first covered electric wire and the second covered electric wire.

  In addition, as described above, when the second covered electric wire in which the conductor is made of an aluminum-based material has a longer wire length than the first covered electric wire in which the conductor is made of a copper-based material as a lighter weight connected electric wire The short-length first covered electric wire crimped to the joint terminal in the first connecting step can be easily transported to a position where the work of the second connecting step of crimping the second covered electric wire and the joint terminal is performed. Thereby, the manufacturability of the connecting electric wire can be improved.

Further, the present invention is characterized in that it is an electric wire connection structure in which a crimping terminal is crimped to an end portion of the first covered electric wire made of a copper-based material in the above-mentioned connected electric wire.
According to the present invention, since the crimp terminal can be crimped to the connecting electric wire in which the first covered electric wire and the second covered electric wire are connected through the joint terminal in which the strength of the connecting portion is improved, the connecting portion is stable without being damaged. It is possible to configure an electric wire connection structure having conduction performance.

  The second coated electric wire having a conductor made of an aluminum-based material has lower conduction performance than the first coated electric wire having a conductor made of a copper-based material and exhibits the same conductive performance as the first coated electric wire. The outer diameter of the conductor must be larger than that of the first covered electric wire. Therefore, if a crimp terminal suitable for the outer diameter of the conductor of the second covered electric wire is crimped, the crimp terminal may not be attached to the conventionally used connector housing.

  However, since the crimp terminal crimped to the first coated electric wire, which is a conductor made of a copper-based material, can be a crimp terminal having a terminal size that has been conventionally used, it can be mounted on a conventionally used connector housing. can do. As a result, it is possible to improve the versatility of the wire connection structure without lowering the conductive performance of the wire connection structure, and it is possible to reduce the cost of newly installing the connector housing.

  INDUSTRIAL APPLICABILITY The present invention can provide a joint terminal, a connecting electric wire, an electric wire connecting structure, and a method of manufacturing a connecting electric wire, which can improve the strength of a connecting portion.

The perspective view of an electric wire connection structure. The perspective view of a connection electric wire. The perspective view of a joint terminal. Explanatory drawing of a sealing part and a connection part. Explanatory drawing of a copper electric wire crimping process and a folding process. Explanatory drawing of an aluminum wire crimping process. Explanatory drawing of a terminal crimping process. The perspective view of the joint terminal in other embodiments.

An embodiment of the present invention will be described below with reference to the drawings.
1 shows a perspective view of the electric wire connection structure 1, FIG. 2 shows a perspective view of the connecting electric wire 2, FIG. 3 shows a perspective view of the joint terminal 5, and FIG. 4 (a) shows an aluminum electric wire. 4B shows a cross-sectional view of the sealing portion 52c viewed from the crimping portion 52 side, FIG. 4B shows a cross-sectional view of the connection overlapping portion 53c viewed from the aluminum electric wire crimping portion 52 side, and FIG. 4C shows an aluminum electric wire. The cross-sectional view of the connection non-overlapping portion 53d viewed from the crimp portion 52 side is shown.

  FIG. 5A shows a perspective view of the joint terminal 5 before the copper electric wire crimping step, FIG. 5B shows a perspective view of the joint terminal 5 after the copper electric wire crimping step, and FIG. 6A shows a cross-sectional view of the connecting portion 53 after the folding step, FIG. 6A shows a perspective view of the joint terminal 5 before the aluminum wire crimping step, and FIG. 6B shows a connection after the aluminum wire crimping step. The perspective view of the electric wire 2 is shown.

  7A shows a perspective view of the connecting electric wire 2 before the terminal crimping step, FIG. 7B shows a perspective view of the electric wire connection structure 1 after the terminal crimping step, and FIG. The perspective view of the joint terminal 50 in embodiment is shown.

The longitudinal direction of the joint terminal 5 when viewed from the plane is defined as the axial direction X, and the lateral direction is defined as the width direction Y.
Further, FIG. 1 shows only one side along the axial direction X from the aluminum electric wire 4 of the electric wire connection structure 1, and FIGS. 7A and 7B show the electric wire connection structure 1 or the connecting electric wire 2. Only the vicinity of one end along the axial direction of is shown.

  As shown in FIGS. 1 and 2, the electric wire connection structure 1 of the present embodiment has an end of a connecting electric wire 2 in which a copper electric wire 3 and an aluminum electric wire 4 are connected to each other along an axial direction X via a joint terminal 5. The crimp terminal 100 is crimped to the portion.

  The crimp terminal 100 is a general terminal of a so-called open barrel type, and includes a crimp portion 110, a connecting portion 120, and a terminal connecting portion 130 that connects the crimp portion 110 and the connecting portion 120 ( 7 (a) and 7 (b)).

The crimp portion 110 that constitutes the crimp terminal 100 includes a conductor crimp portion 111 that is crimped to a copper conductor exposed portion 31a of the copper electric wire 3 to be described later, and a coated crimp portion 112 that is crimped to the copper electric wire coating tip portion 32a. .
The connection part 120 is a box part formed in a box shape having an inner hollow shape, and has a configuration capable of being mated with a connection tab of a male crimp terminal.

  Therefore, the crimp terminal 100 can be attached to a conventionally used connector housing (not shown).

  The crimp terminal 100 is not limited to the female crimp terminal in which the connection portion 110 is the box portion, but may be a male crimp terminal in which the connection portion 110 is the connection tab.

The copper electric wire 3 is a general covered electric wire that has been used conventionally, and the outer circumference of a copper conductor 31 made of copper is covered with a copper electric wire coating 32 made of an insulating resin (Fig. 5 (a)).
This copper electric wire 3 has a copper conductor exposed portion 31a in which the copper electric conductor coating 32 on both ends is peeled off by a predetermined length to expose the copper conductor 31, and a copper electric wire coating tip portion of the copper conductor exposed portion 31a of the copper electric wire coating 32. A copper wire tip portion 3a constituted by 32a is provided.
The copper electric wire 3 is formed to have a length about three times that of the crimp terminal 100.

The aluminum electric wire 4 is formed by covering the outer circumference of an aluminum conductor 41 made of aluminum with an aluminum electric wire coating 42 made of an insulating resin (see FIG. 6A).
Similar to the copper electric wire 3, the aluminum electric wire 4 is composed of an aluminum conductor exposed portion 41a exposing the aluminum conductor 41 and an aluminum electric wire coating tip portion 42a on the aluminum conductor exposed portion 41a side of the aluminum electric wire coating 42. An aluminum wire tip portion 4a is provided.

  The aluminum electric wire 4 is formed longer than the copper electric wire 3. The aluminum conductor 41 has an outer diameter slightly larger than that of the copper conductor 31, and accordingly, the aluminum electric wire coating 42 has a wire diameter slightly larger than that of the copper electric wire coating 32.

  As shown in FIG. 3, the joint terminal 5 includes a copper electric wire crimping portion 51 that is crimped and connected to the copper electric wire 3, an aluminum electric wire crimping portion 52 that is crimped and connected to the aluminum electric wire 4, and a copper electric wire crimping portion 51. A connecting portion 53 that connects the aluminum wire crimping portion 52 along the axial direction X is integrally formed.

As shown in FIG. 3, the copper wire crimping portion 51 is a so-called open barrel type crimping portion in which a cross section orthogonal to the axial direction X is formed in a substantially U shape.
This copper electric wire crimping portion 51 separates a copper conductor crimping portion 51a that crimps with the copper conductor exposed portion 31a and a copper electric wire coating crimping portion 51b that crimps with the copper electric wire coating tip portion 32a from the connecting portion 53 side in this order. Are arranged.

The aluminum wire crimping portion 52 is a so-called closed barrel type crimping portion in which a cross section orthogonal to the axial direction X is formed in a substantially annular shape.
In this aluminum wire crimping portion 52, an aluminum conductor crimping portion 52a that crimps with the exposed aluminum conductor portion 41a and an aluminum wire coating crimping portion 52b that crimps with the aluminum wire coating tip portion 42a are arranged in this order from the connecting portion 53 side. A sealing portion 52c that is integrally formed and that seals the connecting portion 53 side of the aluminum conductor crimping portion 52a is provided.

  Further, the aluminum wire crimping portion 52 is formed in an annular shape by abutting both ends in the width direction Y, and a first welded portion 52d obtained by laser welding the abutted both ends along the axial direction X, and a sealing. A second welded portion 52e is formed by laser welding the portion 52c along the width direction Y.

  The aluminum conductor crimping portion 52a is formed in a ring shape having a larger diameter than the aluminum conductor 41, and the aluminum wire coating crimping portion 52b is formed in a ring shape having a larger diameter than the aluminum wire coating 42. The aluminum conductor crimping portion 52a and the aluminum wire covering crimping portion 52b are formed in a stepped shape so as to be continuous along the axial direction X.

  As shown in FIG. 4A, the sealing portion 52c is formed by crushing the aluminum conductor crimping portion 52a so that the connecting portion 53 side of the aluminum conductor crimping portion 52a is overlapped in a flat plate shape, and has a substantially U-shaped cross section. Has been done.

  As shown in FIGS. 3, 4 (b) and 4 (c), the connecting portion 53 includes a connecting portion main body 53a for connecting the copper electric wire crimping portion 51 and the aluminum electric wire crimping portion 52, and a connecting portion main body 53a. It is composed of bent back portions 53b extending on both sides in the width direction Y.

As shown in FIGS. 4B and 4C, the connecting portion main body 53a is formed in a substantially U-shaped cross section that is recessed downward.
The bent back portion 53b is integrally formed so as to smoothly connect the copper conductor crimping portion 51a of the copper electric wire crimping portion 51 and the sealing portion 52c of the aluminum electric wire crimping portion 52. That is, the bent-back portion 53b is integrally formed with the copper wire crimp portion 51 so that the outer edge is continuous, and is integrally formed with the aluminum wire crimp portion 52 so that the outer edge is continuous.

  As shown in FIG. 4 (b), the aluminum wire crimping portion 52 side of the bent back portion 53b constitutes a connection overlapping portion 53c in which the connection portion main body 53a and the bent back portion 53b overlap each other. As shown in FIG. 4C, the copper electric wire crimping portion 51 side gradually rises toward the copper electric wire crimping portion 51 and constitutes a connecting non-overlapping portion 53d that does not overlap the connecting portion main body 53a. .

As shown in FIG. 4B, the connection overlapping portion 53c is formed in a substantially U-shaped cross-section in which the connection portion main body 53a and the bent back portion 53b overlap each other.
As shown in FIG. 4 (c), the connecting non-overlapping portion 53d is formed in a substantially U-shaped cross-section such that the connecting portion main body 53a and the bent back portion 53b do not overlap each other.

  In the coupling portion 53 configured as described above, the coupling portion main body 53a and the bent back portion 53b overlap each other in the U-shaped cross section in the coupling overlapping portion 53c on the aluminum electric wire crimping portion 52 side, and In the connecting non-overlapping portion 53d, the bent back portions 53b gradually rise from both sides in the width direction Y of the connecting portion main body 53a so as to have a substantially U-shaped cross section. This is to prevent the copper wire tip portion 3a from being difficult to arrange in the copper wire crimping portion 51. That is, since the connecting non-overlapping portion 53d is formed on the copper wire crimping portion 51 side, the copper wire crimping portion 51 can be easily arranged with the copper wire tip portion 3a.

A method for manufacturing the wire connection structure 1 configured as described above will be described.
The method of manufacturing the electric wire connection structure 1 includes a copper electric wire crimping step of crimping the joint terminal 5 to the copper electric wire 3, a folding back step of completely folding back the bent portion 53b, and an aluminum electric wire crimping the joint terminal 5 to the aluminum electric wire 4. The crimping step and the terminal crimping step of crimping the crimp terminal 100 to the copper electric wire 3 are performed in this order.

  In the copper electric wire crimping step, as shown in FIG. 5A, one of the copper electric wire tip portions 3 a provided at both ends of the copper electric wire 3 is arranged on the copper electric wire crimping portion 51 of the joint terminal 5. Then, using an open barrel crimping machine (not shown) for crimping the open barrel type crimping portion, the copper electric wire crimping portion 51 is crimped to the copper electric wire tip portion 3a as shown in FIG. 5B.

At this time, the bent back portion 53b of the connecting portion 53 is deformed so as to approach the connecting portion main body 53a, that is, to fall toward the connecting portion main body 53a side, as the copper wire crimping portion 51 is pressed.
In this step, two copper electric wires 3 to which the joint terminals 5 are connected may be manufactured in advance.

  In the bending-back step, a bending-back crimping machine (not shown) that folds back the bending-back portion 53b of the connecting portion 53 is used to completely bend the bending-back portion 53b in the entire range of the connecting portion 53, as shown in FIG. 5C. Then, the connecting portion main body 53a and the bent back portion 53b are overlapped with each other in a substantially U-shaped cross section, and the connecting overlapping portion 53c is formed on the entire connecting portion 53.

  In the aluminum electric wire crimping step, as shown in FIG. 6A, the aluminum electric wire tip portion 4a of the aluminum electric wire 4 is inserted into the aluminum electric wire crimping portion 52 of the joint terminal 5. Then, using a closed barrel crimping machine (not shown) for crimping the closed barrel type crimping section, the aluminum wire crimping section 52 is crimped to the aluminum wire tip section 4a as shown in FIG. 6B.

  In this aluminum electric wire crimping step, the joint terminals 5 crimped to the two copper electric wires 3 produced in advance in the copper electric wire crimping step are crimped to the aluminum electric wire tip portions 4a on both ends of the aluminum electric wire 4 to form the shaft of the aluminum electric wire 4. A connecting electric wire 2 in which copper electric wires 3 are connected via joint terminals 5 on both sides in the direction X is manufactured.

In the terminal crimping step, as shown in FIG. 7A, the other end of the copper electric wire tip portion 3 a of the copper electric wire 3 is placed on the crimping portion 110 of the crimp terminal 100. Then, the open barrel crimping machine is used to crimp the crimp portion 110 to the copper wire tip portion 3a as shown in FIG. 7 (b).
In this terminal crimping step, the wire connection structure 1 in which the crimp terminals 100 are crimped to the copper electric wire tip portions 3a of the copper electric wires 3 on both sides of the connecting electric wire 2 in the axial direction X is manufactured.

  The joint terminal 1 as described above includes a copper wire crimping portion 51 electrically connected to the copper electric wire 3, an aluminum electric wire crimping portion 52 electrically connecting to the aluminum electric wire 4, a copper electric wire crimping portion 51, and an aluminum electric wire crimping portion. And a connecting portion 53 that connects the portion 52 in the axial direction X, the aluminum wire crimping portion 52 is formed in a ring shape in a cross section orthogonal to the axial direction X, and has a connecting portion main body 53a and a width from the connecting portion main body 53a. By forming the connecting portion 53 with the bent-back portion 53b bent back in the width direction Y while extending in the direction Y, it is possible to improve the strength of the connecting portion 53 while reducing the number of parts.

  More specifically, since the connecting portion 53 extends from the connecting portion main body 53a in the width direction Y and is bent back in the width direction Y to form the connecting portion 53, the connecting portion main body 53a and the bending return portion 53b are integrally formed. Since it can be formed, the number of parts can be reduced.

  Further, by forming the connecting portion 53 with the bent-back portion 53b, the cross-sectional shape is more than that of a general connecting portion formed in a flat plate shape with the same plate thickness as the copper electric wire crimping portion 51 or the aluminum electric wire crimping portion 52. Strength is improved. That is, since the cross-sectional strength is improved, the strength of the connecting portion 53 can be improved without using, for example, a separate member or forming a metal material having high strength.

As a result, it is possible to prevent the connecting portion 53 having improved strength from being bent, cracked, or twisted and damaged due to an external force acting by pressure bonding, while reducing the number of parts. Further, it is possible to prevent the connecting portion 53 from being damaged by an external force such as engine vibration or vehicle traveling vibration even after being mounted on the vehicle.
Therefore, the copper electric wire 3 and the aluminum electric wire 4 connected via the joint terminal 5 can be surely conducted to each other without damaging the connecting portion 53.

  Further, the copper conductor crimping portion 51a of the copper electric wire crimping portion 51 and the sealing portion 52c of the aluminum electric wire crimping portion 52 are integrally formed so as to be connected by the bent-back portion 53b, so that the strength of the connecting portion 53 can be further ensured. Can be improved.

More specifically, by integrally forming the copper conductor crimping portion 51a and the sealing portion 52c so as to be connected by the bent back portion 53b, it is possible to eliminate the boundary between the portions that can be weakened from the connecting portion 53.
Therefore, the strength of the connecting portion 53 can be more reliably improved.

  In addition, the bending portion 53b is folded back to the connecting portion 53 to form the connecting overlapping portion 53c which is overlapped with the connecting portion main body 53a. As compared with the solid connecting portion, the copper wire crimping portion 51 and the aluminum wire crimping portion 52 are thicker and the cross-sectional strength is improved, so that the strength of the connecting portion 53 can be surely improved.

Further, since the connecting portion 53 is formed in a substantially U-shape in a cross section orthogonal to the axial direction X, the cross-sectional strength is increased as compared with a general connecting portion formed in a flat plate shape, so that the strength of the connecting portion 53 is increased. It can be further improved.
Therefore, it is possible to reliably prevent the connecting portion 53 from being damaged by the external force due to the crimping of the copper wire crimping portion 51 and the aluminum wire crimping portion 52.

  Further, the above-described connecting electric wire 2 is configured by connecting the copper electric wire 3 and the aluminum electric wire 4 in the axial direction X via the joint terminal 5, and further, a copper electric wire crimping step and an aluminum electric wire crimping step, By performing the folding-back step, the copper electric wire 3 and the aluminum electric wire 4 can be connected through the joint terminal 5 in which the strength of the connecting portion 53 is improved, so that the connecting portion 53 is not damaged and the copper electric wire is not damaged. 3 and the aluminum electric wire 4 can be surely conducted.

  Further, the joint terminal 5 is made of a copper-based material, the copper electric wire crimping portion 51 is formed in a substantially U-shaped cross section, and is connected to the copper electric wire 3, and the aluminum electric wire crimping portion 52 is formed in an annular cross section. At the same time, by connecting the aluminum electric wire 4 and performing the copper electric wire crimping step, the folding step, and the aluminum electric wire crimping step in this order, the copper electric wire 3 and the aluminum electric wire 4 can be surely conducted and connected. The electric wire 2 can be reduced in weight.

  More specifically, although the aluminum conductor 41 and the aluminum wire crimping portion 52 of the joint terminal 5 are different metals having different ionization tendencies, the aluminum wire crimping portion 52 is formed in an annular cross section, so that It is possible to prevent water from entering the contact portion with the aluminum wire crimping portion 52 and prevent the contact portion from being electrolytically corroded.

Further, since the connecting electric wire 2 is configured by using the aluminum electric wire 4, the weight can be reduced as compared with the connecting electric wire 2 in which the copper electric wires 3 are connected to each other. By making the wire length of the aluminum electric wire 4 longer than that of the copper electric wire 3, the weight of the connecting electric wire 2 can be further reduced.
Therefore, the copper electric wire 3 and the aluminum electric wire 4 can be surely conducted, and the weight of the connecting electric wire 2 can be reduced.

  Furthermore, the copper electric wire crimping step, the folding step, and the aluminum electric wire crimping step are performed in this order to manufacture the connected electric wire 2, so that the aluminum electric wire crimping step can be performed by the external force accompanying the crimping of the copper electric wire crimping step and the folding back step. It is possible to prevent the crimped state between the crimped aluminum wire crimping portion 52 and the aluminum electric wire 4 from being relaxed. This makes it possible to manufacture the connecting electric wire 2 in a state where the aluminum electric wire crimping portion 52 and the aluminum electric wire 4 are in close contact with each other, and the copper electric wire 3 and the aluminum electric wire 4 can be surely brought into conduction.

  Further, as described above, as the lighter weight connecting electric wire 2, by setting the wire length of the aluminum electric wire 4 longer than the copper electric wire 3, and performing the aluminum electric wire crimping step after the copper electric wire crimping step, The short copper electric wire 3 crimped to the joint terminal 5 in the crimping step can be easily transported to the aluminum electric wire crimping step of crimping the aluminum electric wire 4 and the joint terminal 5. Thereby, the manufacturability of the connecting electric wire 2 can be improved.

  Further, in the electric wire connection structure 1 as described above, the crimping terminal is crimped to the end of the copper electric wire 3 of the connecting electric wire 2, so that the copper electric wire 3 is connected via the joint terminal 5 in which the strength of the connecting portion 53 is improved. Since the crimp terminal 100 can be crimped to the connection electric wire 2 in which the aluminum electric wire 4 is connected, the electric wire connection structure 1 having stable conduction performance can be configured without damaging the connection portion 53.

More specifically, since the electric wire connection structure 1 is configured by using the connecting electric wire 2 in which the copper electric wire 3 and the aluminum electric wire 4 are connected through the joint terminal 5 in which the strength of the connecting portion 53 is improved, the vehicle is connected. It is possible to prevent the connection portion 53 from being damaged by bending or the like caused by an external force such as traveling vibration.
Therefore, the electric wire connection structure 1 having stable conduction performance can be configured without damaging the connecting portion 53.

  Since the aluminum electric wire 4 has lower conduction performance than the copper electric wire 3 and exhibits the same electric conduction performance as the copper electric wire 3, the outer diameter of the aluminum conductor 41 is larger than the outer diameter of the copper conductor 31, that is, aluminum. The wire diameter of the electric wire 4 must be made larger than that of the copper electric wire 3. Therefore, if the crimp terminal 100 suitable for the outer diameter of the aluminum conductor 41 of the aluminum electric wire 4 is crimped, the crimp terminal 100 may not be attached to the conventionally used connector housing.

  However, since the crimp terminal 100 crimped to the copper electric wire 3 can use the crimp terminal 100 having the terminal size conventionally used, it can be mounted in the connector housing conventionally used. As a result, it is possible to improve the versatility of the wire connection structure 1 without deteriorating the conductive performance of the wire connection structure 1, and it is possible to reduce the cost of newly installing the connector housing.

  In addition, the wire connection structure 1 is manufactured by performing a copper wire crimping step, a folding step, an aluminum wire crimping step, and a terminal crimping step in this order to manufacture the wire connecting structure 1 having a desired wire length. Can be configured.

  More specifically, even if there is an error in the wire length of the connecting electric wire 2 in the previous step of connecting the copper electric wire 3 and the aluminum electric wire 4, the terminal crimping step to be performed last is the open barrel type copper electric wire crimping portion 51 and the copper electric wire crimping portion. Since this is a step of crimping the electric wire 3, it is possible to finely adjust the arrangement position of the covered electric wire to be arranged with respect to the open barrel type crimping portion having no sealing portion. Thereby, the wire connection structure 1 having a desired wire length can be configured.

In the correspondence between the configuration of the present invention and the above-described embodiment,
The first covered electric wire of the present invention corresponds to the copper electric wire 3 of the embodiment,
And so on
A conductor made of a copper-based material corresponds to the copper conductor 31,
The second coated electric wire corresponds to the aluminum electric wire 4,
A conductor made of an aluminum-based material corresponds to the aluminum conductor 41,
The connecting portion and the high-strength connecting portion correspond to the connecting portion 53,
The bent back portion corresponds to the bent back portion 53b,
The first connection step corresponds to the copper wire crimping step,
The second connection process corresponds to the aluminum wire crimping process,
The high-strength joint forming process corresponds to the folding process,
The present invention is not limited to the configurations of the above-described embodiments, and many embodiments can be obtained.

  For example, in the above description, the copper wire crimping portion 51 of the joint terminal 5 is configured by the copper conductor crimping portion 51a and the copper wire coating crimping portion 51b, and the aluminum wire crimping portion 52 is formed by the aluminum conductor crimping portion 52a and the aluminum wire coating. Although it is configured with the crimp portion 52b, as shown in FIG. 8, it may be a joint terminal 50 in which the copper wire crimp portion 51 is configured only with the copper conductor crimp portion 51a.

  Further, in the above description, the copper wire crimping step and the folding step were performed in this order, but for example, using a crimping machine integrally configured with the open barrel crimping machine and the folding crimping machine, a copper wire crimping step The folding step may be performed in the same step. As a result, the number of steps can be reduced.

  Further, in the above description, the copper wire crimping step, the folding step, the aluminum wire crimping step, and the terminal crimping step were performed in this order, but for example, the terminal crimping step, the copper wire crimping step, and the folding step The aluminum wire crimping step may be performed in this order. Thereby, workability in each manufacturing process can be further improved.

  More specifically, before the aluminum electric wire crimping step, a terminal crimping step, a copper electric wire crimping step, and a folding step are performed to connect the crimp terminal 100 and the joint terminal 5 to the copper electric wire 3, which is a final step. Since the short copper electric wire 3 is conveyed to the electric wire crimping step, the productivity of the electric wire connection structure 1 can be further improved.

  Further, the copper conductor 31 of the copper electric wire 3 is not limited to be made of copper, and may be made of a copper alloy. Similarly, the aluminum conductor 41 of the aluminum electric wire 4 is made of aluminum. Alternatively, it may be made of an aluminum alloy.

  Further, the copper wire tip portion 3a and the copper wire crimp portion 51 are not limited to being crimped and connected, but may be welded and connected, for example. The aluminum wire tip portion 4a and the aluminum wire crimping portion 52 are not limited to being connected by crimping, but may be connected by crimping while welding, for example.

  The copper wire crimping portion 51 may be not only an open barrel type crimping portion formed in a substantially U-shaped cross section but also a closed barrel type crimping portion formed in an annular cross section.

Further, the connecting portion 53 may be configured by using a pressed or rolled terminal base material so that a portion corresponding to the connected portion of the terminal base material forming the joint terminal 5 has a wall thickness, for example. Alternatively, the connecting portion 53 may be formed by thickening the plate thickness by stacking other members.
Further, the connecting portion 53 is not limited to be formed in a substantially U-shaped cross section, and may be formed in a substantially concave cross-section or may be formed in a substantially V-shaped cross section, for example.

DESCRIPTION OF SYMBOLS 1 ... Electric wire connection structure 2 ... Connection electric wire 3 ... Copper electric wire 4 ... Aluminum electric wire 5 ... Joint terminal 51 ... Copper electric wire crimping part 52 ... Aluminum electric wire crimping part 53 ... Connecting part 53a ... Connecting part main body 53b ... Bending return part 53c ... Connection overlapping part 100 ... Crimping terminal X ... Axial direction Y ... Width direction

Claims (5)

A first connecting portion electrically connected to the first covered electric wire;
A second connecting portion electrically connected to the second covered electric wire;
A connecting portion that connects the first connecting portion and the second connecting portion in the axial direction,
The second connecting portion before SL is configured cross section perpendicular to the front SL-axis direction by the annular connection part of the annular Rutotomoni, the first connecting portion, the cross section perpendicular to the axial direction is formed in a substantially U shape ,
At least a part of the connecting portion is formed of a high-strength connecting portion having higher strength than the metal plate material forming the first connecting portion and the second connecting portion ,
The connecting portion is formed in a substantially U shape in a cross section orthogonal to the axial direction,
The high-strength connecting portion,
A connecting portion body that constitutes the connecting portion,
While extending in the width direction from the connecting portion main body, it is configured by a bent back portion bent back in the width direction,
The connecting portion body is formed into a substantially U-shaped cross section,
The bending-back portion is integrally formed so that the connecting portion side of the first connecting portion is continuous with the outer edge thereof, and is integrally formed so that the connecting portion side of the second connecting portion is continuous with the outer edge thereof. Is
The high-strength connecting portion,
On the side of the second connecting portion of the bent back portion, a connection overlapping portion is formed which is overlapped with the connecting portion main body,
The first connection portion side of the bent back portion gradually rises toward the first connection portion, and constitutes a connection non-overlapping portion that does not overlap with the connection portion main body,
The connection overlapping portion is formed in a substantially U-shaped cross section in a manner in which the connection portion main body and the bent back portion overlap each other.
The connection non-overlapping portion is formed in a substantially U-shaped cross section in which the connection portion main body and the bent back portion do not overlap each other,
In the connection non-overlapping portion, the bent terminal gradually rises from both sides in the width direction of the connection portion main body so as to have a substantially U-shaped cross section . A connection electric wire in which the first covered electric wire and the second covered electric wire are connected in the axial direction via the joint terminal according to claim 1 . The joint terminal is made of a copper-based material,
The first connecting portion has a substantially U-shaped cross section orthogonal to the axial direction, and is connected to the first covered electric wire having a conductor made of a copper-based material,
The connection electric wire according to claim 2 , wherein the second connection portion is formed of the annular connection portion and is connected to the second covered electric wire having a conductor formed of an aluminum-based material. An electric wire connection structure in which a crimp terminal is crimped to an end portion of the first covered electric wire made of a copper-based material in the connected electric wire according to claim 3. The first covered electric wire and the second covered electric wire are axially connected to each other via a joint terminal in which a first connecting portion formed in a substantially U-shaped cross section and a second connecting portion formed in an annular cross section are connected by a connecting portion. A method of manufacturing a connected electric wire for connecting,
A first connecting step of crimping the first covered electric wire having a conductor made of a copper-based material and the first connecting portion;
A high-strength connecting portion forming step of forming a high-strength connecting portion having higher strength than a metal plate material forming the first connecting portion and the second connecting portion on at least a part of the connecting portion;
A second connecting step of crimping the second coated electric wire having a conductor made of an aluminum-based material and the second connecting portion is performed in this order ,
The high-strength connecting portion is formed into a substantially U-shaped cross section by a connecting portion main body that constitutes the connecting portion, and a bent back portion that extends from the connecting portion main body in the width direction and is bent back in the width direction. ,
The high-strength connecting portion forming step forms the high-strength connecting portion by bending back the bending-back portion extending in the width direction from the connecting-portion main body forming the connecting portion to form one of the bending-back portions. A method for manufacturing a connection electric wire, wherein the connection portion is bent back to form a connection overlapping portion that is superposed on the connection portion main body .

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