JPH1174005A - Electric wire connecting method and structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To simply form a splicing part for connection of electric wires. SOLUTION: A flexible protection material 11 made of resin or rubber is formed with a U-section some greater than an intermediate joint terminal 10 having U-section with the two-side barrels continued at the bottom surface and with a length greater than that of the intermediate joint terminal 10. One side of each barrel of the joint terminal 10 is protruded farther than one side of the protection material 11 while the other side of the protection material 11 is protruded farther than the forefront of the other side of the barrel, and in this condition, the joint terminal 10 is secured to the inner surface of the middle part of the protection material 11 about its longitudinal direction, and then the part of the cores overlapped is inserted to the joint terminal 10 laid on the inner surface of the protection material 11. The two barrels are caulked together with the protection material 11 into pressure attachment, and thus the intended intermediate splicing part is accomplished in such an arrangement that the periphery of the terminal 10 in pressure attachment to the cores is covered with the protection material 11 simultaneously.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electric wire connection method and an electric wire connection structure formed by the method. More particularly, in a wire harness to be routed to an automobile, a core wire of an intermediate stripped portion of the electric wire and another electric wire are used. An intermediate splice portion is formed by crimp-connecting the core wire exposed from the terminal with an intermediate joint terminal.

[0002]

2. Description of the Related Art Conventionally, when connecting an electric wire by forming an intermediate splice portion of this kind, first, as shown in FIG. 10 (A), the insulation coating of required portions X1, X2 of the electric wire of the main line 1 is stripped. Stripping and exposing the core wire 1a, while connecting the branch wire 2
The insulating coatings at the terminals of A, 2B, 3A and 3B are peeled off to expose the core wires 2a and 3a, respectively. Next, FIG.
As shown in (1), the core wires 1a and 2a are superimposed on X1, and the core wires 1a and 3a are superimposed on X2, and crimped with intermediate joint terminals (splice terminals) 4A and 4B, respectively.

Thereafter, as shown in FIG. 10 (C), tapes 5A and 5B are wound around each crimping portion, and the core wires and the intermediate joint terminals 4A and 4B are completely covered and subjected to insulation treatment.

[0004] In the intermediate splice portion having the above-described structure, the core wires 2a, 3a exposed from the terminals are connected to the tapes 5A, 5B.
And the core wire easily protrudes to the outside. In this case, there is a possibility that a short circuit may occur when the core wire comes into contact with an external member. Also, after crimping the intermediate joint terminals 4A and 4B, it is necessary to wind the tapes 5A and 5B,
There was also a problem that labor was required.

To solve the above problem, Japanese Utility Model Laid-Open No. 5-531
In No. 39, as shown in FIG. 11, a protective material 6 made of an elastic material made of a rubber material or the like is provided, and after covering the intermediate joint terminal 5, the protective material 6 is melted with hot melt to form an intermediate joint terminal. 5 further,
After that, a configuration in which a waterproof sheet 7 is attached to the outer periphery of the protective material 6 and molded by press bonding or ultrasonic welding or the like has been proposed.

[0006]

The connection structure shown in FIG. 11 is particularly required when a waterproof treatment is required. However, it is necessary to provide the protective material 6 and to perform a crimping process of the intermediate joint terminal. A step of attaching the protective material 6, a step of bringing the protective material 6 into close contact with hot melt, and a step of molding the waterproof sheet 7 are required.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems, and has as its object to provide a simple and reliable insulating process for an intermediate splice part with very few working steps.

[0008]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems, the present invention relates to a cross section U having both barrels continuous at a bottom surface.
A flexible resin or rubber protective material having a U-shaped cross section slightly larger than the U-shaped intermediate joint terminal and having a length longer than the length of the intermediate joint terminal is provided. In a state in which one side of the barrel of the intermediate joint terminal protrudes, while the other side of the protective material protrudes from the tip of the other side of the barrel of the intermediate joint terminal, the length direction of the protective material The above-mentioned intermediate joint terminal is fixed to the inner surface of the intermediate part, and in this state, the part where the core wire exposed by peeling off the intermediate skin of the main line and the core wire exposed from the end of the branch line is overlapped with the above-mentioned protection. Insert the intermediate joint terminal placed on the inner surface of the material, crimp and crimp the barrels on both sides of the intermediate joint terminal together with the protective material, and simultaneously cover the outer peripheral portion of the intermediate joint terminal crimped to the core wire with the protective material. Provides a wire connecting method according to claim to that forming the intermediate spliced portion to.

According to the above method, at the time of caulking and crimping, the tip of one side of the intermediate joint terminal protruding from the protective material is located inside the distal end of the other end of the intermediate joint terminal located inside the protective material. It is crimped so as to be involved. Therefore, the outer peripheral surface of the core wire connected by the intermediate joint terminal can be reliably surrounded. In addition, the protection material on the other side overlaps the outer circumference of the protection material on the side to be wound, so that the intermediate joint terminal can be completely covered with the protection material.

In the above-mentioned method, since the protective material is simultaneously coated on the intermediate joint terminal and the outer periphery of the electric wire at both ends in the longitudinal direction of the intermediate joint terminal in the caulking and crimping step of the intermediate joint terminal, only one operation step is required.

In the step of forming a wire harness, the intermediate splice portion is wound around an outer peripheral surface together with another group of electric wires by tape, and the outer peripheral surface of the protective material is also wound by the tape, so that the tips of the protective material overlap. (Claim 2).

Further, the present invention provides an electric wire connection structure formed by the method according to the first or second aspect.

[0013]

Embodiments of the present invention will be described below with reference to the drawings.

As shown in FIG. 1 and FIG. 2, both barrels 10a and 10b are made of conductive metal material and
Surrounding the intermediate joint terminal 10 having a U-shaped cross section and a long U-shaped cross section, the length of the intermediate joint terminal 10 being longer than the length L1 of the intermediate joint terminal 10. In. The protective material is made of an elastomer or rubber to have flexibility.

The intermediate joint terminal 10 laid on the inside of the protective material 11 is connected to the upper end 11 of one side 11 a of the protective material 11.
the barrel 10 on one side of the intermediate joint terminal 10
The exposed portion 10d is provided by protruding a. Further, the other side portion 11c of the protection member 11 is made to protrude from the tip of the barrel 10b on the other side of the intermediate joint terminal 10, and a protruding portion 11d is provided. Further, the intermediate joint terminal 10 is arranged at an intermediate portion in the length direction of the protection member 11, and the protection member 11 extends from both ends in the length direction of the intermediate joint terminal 10. In this state, the intermediate joint terminal 10 is fixed to the protective material 11 by using an adhesive 12 or by welding.

On the other hand, the electric wire side connected by the intermediate joint terminal 10 is, as shown in FIG.
A core wire 1a which is exposed by peeling the middle of the main line 1 and a branch wire 2A
And the core wire 2a exposed from the 2D terminal is overlapped,
As shown in FIG. 4, a portion where the core wires 1a and 2a are overlapped is inserted into an intermediate joint terminal 10 arranged on the inner surface of the protective member 11, and the main wire 1 following these core wires 1a and 2a is inserted.
And the branch line 2 is passed through the inside of the protective material 11.

In this state, as shown in FIGS. 5 and 6, the lower mold 21 and the upper mold 22 are crimped by a crimping mold 20. The fixed lower mold 21 has an insulation anvil 23 on both sides and a wire anvil 24 in the center, and the upper mold 22 which operates up and down also has an insulation crimper 2 on both sides.
5. A wire crimper 26 is provided at the center.

As shown in FIG. 6, the upper die 22 is disposed on the lower die 21 with the core wires 1a and 2a of the main line 1 and the branch line 2 passed through the intermediate joint terminal 10 surrounded by the protective material 11.
Is lowered. The upper mold 22 is fitted with the lower mold 21 to connect the barrels 10a and 10b of the intermediate joint terminal 10 to the core wires 1a,
2a, and at the same time as crimping the protective material 11
The two side portions 11a and 11c are rounded and brought into close contact with the outer peripheral surface of the intermediate joint terminal 10 having a circular shape, and at the same time, are brought into close contact with the outer peripheral surfaces of the insulating coating of the main line 1 and the branch line 2 on both sides thereof.

That is, as shown in FIGS. 7 and 8, the exposed portion 10d of the intermediate joint terminal 10 protruding from the protective member 11 on the barrel 10a side is connected to the barrel 10b on the other side from the tip.
The core wires 1a and 2a are completely compressed by the intermediate joint terminal 10 and crimped. Also, the upper end 11 of one side portion 11a of the protective material 11 on the outer periphery.
b is a position where it abuts on the tip of the barrel 10b, the protruding portion 11d of the other side portion 11c is wound around the outer peripheral surface of the one side portion 11a, and the intermediate joint terminal 10 is completely covered with the protective material 11. .

As described above, by connecting the branch lines 2A to 2D to the main line 1, the protective member 11 made of an elastomer or rubber is formed.
As shown in FIG. 9, the electric wire group formed with the intermediate splice portions 15 and 16 covered with the wire is wound around the outer peripheral surface thereof with the tape 18 together with the other electric wire group W, and is finally bound in a wire harness forming step. As a result, the outer peripheral surface of the protective material 11 is also wound, and the tip of the protective material 11 is held in an overlapping state.

When the above-described method is used, in the caulking and crimping step of the intermediate joint terminal 10, the protective member 11 is also provided at the same time as the intermediate joint terminal 10 and the main line 1 and the branch lines 2A to 2D extending from both longitudinal ends of the intermediate joint terminal 10. Since the insulating coating is also covered, only one working process is required.

Further, since the core end of the branch line 2 to be crimped by the intermediate joint terminal 10 is covered with the protective material 11 made of an elastomer or rubber, the core end generated in the conventional tape winding breaks through the tape. Can be prevented from protruding outward.

[0023]

As apparent from the above description, according to the present invention, a resin or rubber protective material made of an elastomer or the like is attached to the intermediate joint terminal in advance,
In this state, the intermediate joint terminal is crimped to the core wire to connect the electric wires, and at the same time, the intermediate joint terminal and the electric wires on both sides thereof are covered with a protective material for insulation protection. In the process, the intermediate splice portion that is insulated and protected can be formed easily and reliably.

Further, since a resin or rubber such as an elastomer is used as the protective material, it is possible to reliably prevent the core wire terminal to be spliced and pierced from protruding to the outside, thereby eliminating the possibility of occurrence of a short circuit. be able to.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view of an intermediate joint terminal and a protective material used in the present invention.

FIG. 2A is a perspective view in which an intermediate joint terminal and a protective material are combined, and FIG. 2B is a side view of FIG.

FIG. 3 is a schematic diagram showing electric wires to be connected.

FIG. 4 is a perspective view showing a state where an electric wire to be connected is passed through an intermediate joint terminal.

FIG. 5 is a schematic front view of the crimping device.

FIG. 6 is a schematic view showing the operation of the crimping device.

FIG. 7 is a schematic diagram of an electric wire in which an intermediate splice portion is formed by crimping.

8 is a sectional view taken along line II of FIG. 7;

FIG. 9 is a schematic diagram of the wire harness in a state of being fully bound.

FIGS. 10A, 10B, and 10C are schematic views showing steps of a conventional example.

FIG. 11 is a drawing showing another conventional example.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Main line 1a Core wire 2A-2D Branch line 2a Core wire 10 Intermediate joint terminal 10a, 10b Barrel 10d Exposed part 11 Protective material 12 Adhesive 15, 16 Intermediate splice part 18 Tape 20 Crimping device

Claims (3)

[Claims] 1. A cross section U in which both barrels are continuous at the bottom.
A flexible resin or rubber protective material having a U-shaped cross section slightly larger than the U-shaped intermediate joint terminal and longer than the length of the intermediate joint terminal is provided. In a state in which one side of the barrel of the intermediate joint terminal protrudes, while the other side of the protective material protrudes from the tip of the other side of the barrel of the intermediate joint terminal, the length direction of the protective material The intermediate joint terminal is fixed to the inner surface of the intermediate part of the above, and in this state, the core wire exposed by peeling the intermediate skin of the main line and the core wire exposed from the terminal of the branch line are overlapped,
It is inserted into the intermediate joint terminal arranged on the inner surface of the protective material, and both barrels of the intermediate joint terminal are caulked and crimped together with the protective material, so that the outer peripheral portion of the intermediate joint terminal crimped to the core wire is simultaneously covered with the protective material. And forming an intermediate splice. 2. The intermediate splice portion is wound around an outer peripheral surface of the intermediate splice portion together with another wire group by a tape, and the outer peripheral surface of the protective material is also wound by the tape to form a tip of the protective material. The electric wire connection method according to claim 1, wherein the wires are held in an overlapping state. 3. An electric wire connection structure formed by the method according to claim 1.