KR20150120846A - Electric wire connecting structure, a method of manufacturing the electric wire connecting structure, a connector comprising the electric wire connecting structure and a crimp die - Google Patents

Electric wire connecting structure, a method of manufacturing the electric wire connecting structure, a connector comprising the electric wire connecting structure and a crimp die Download PDF

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Publication number
KR20150120846A
KR20150120846A KR1020147021886A KR20147021886A KR20150120846A KR 20150120846 A KR20150120846 A KR 20150120846A KR 1020147021886 A KR1020147021886 A KR 1020147021886A KR 20147021886 A KR20147021886 A KR 20147021886A KR 20150120846 A KR20150120846 A KR 20150120846A
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South Korea
Prior art keywords
wire
crimping
terminal
longitudinal
mold
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Application number
KR1020147021886A
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Korean (ko)
Inventor
아키라 다치바나
겐고 미토세
이사오 스즈키
야스시 기하라
히로시 오리토
유키히로 가와무라
다카시 도노이케
Original Assignee
후루카와 덴키 고교 가부시키가이샤
후루카와 에이에스 가부시키가이샤
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Priority to JP2013030350 priority Critical
Priority to JPJP-P-2013-030350 priority
Priority to JP2013033857 priority
Priority to JPJP-P-2013-033857 priority
Priority to JPJP-P-2013-034019 priority
Priority to JP2013034019 priority
Application filed by 후루카와 덴키 고교 가부시키가이샤, 후루카와 에이에스 가부시키가이샤 filed Critical 후루카와 덴키 고교 가부시키가이샤
Priority to PCT/JP2014/050167 priority patent/WO2014129220A1/en
Publication of KR20150120846A publication Critical patent/KR20150120846A/en

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    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/20Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • HELECTRICITY
    • H01BASIC ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048Crimping apparatus or processes

Abstract

Thereby improving the exponential property between the crimp portion and the insulating cover of the coated wire in the wire connecting structure.
The wire connecting structure 10 includes a covered wire 100 covered with an insulating covering member 102 and a crimping portion 230 connected to the core wire 101 and the insulating covering member 102, As shown in Fig. The crimping portion 230 has a closed end surface shape surrounding the covered electric wire 100. The crimping portion 230 has protruding portions 234 at the portions of the crimping portion 230 corresponding to the boundary portions of the pair of male and female molds 300 in the crimped state. At least one pressing portion 235 is provided on the protruding portion 234.

Description

TECHNICAL FIELD [0001] The present invention relates to a wire connecting structure, a method of manufacturing a wire connecting structure, a connector having a wire connecting structure, and a metal mold for press bonding. BACKGROUND OF THE INVENTION 1. Field of the Invention DIE}
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wire connecting structure, a method of manufacturing a wire connecting structure, a connector provided with a wire connecting structure, and a mold for press fitting, which are attached to, for example, a connector of a wire harness for automobiles.
Electronic equipment equipments such as automobiles are connected to other electronic equipments or power supply devices through a wire harness bundled with covered wires to constitute an electric circuit. As described in Patent Document 1, a plurality of coated wires are bundled in a housing and a connector is provided at the tip of the wire harness. In this way, the wire harness, the electronic equipment apparatus, and the power supply apparatus are connected by matingly fitting the connectors mounted on each. Inside the connector, a crimp terminal for holding the core wire portion (wire conductor) of the covered wire and the insulating cover member by pressing is mounted. As the crimp terminal, there is conventionally known a structure (open barrel structure) in which a core wire of a covered wire is exposed in a crimp portion.
Since such a connector is used under various environments, unintentional moisture may adhere to the surface of the coated wire due to condensation due to a change in ambient temperature. Further, when moisture penetrates into the inside of the connector, and thus the crimp terminal, on the surface of the coated wire, there is a problem that the surface of the core wire exposed from the tip of the coated wire is corroded. Particularly, in order to reduce the weight of the wire harness, when the core wire of the coated wire is changed from copper to a light material such as aluminum or aluminum alloy, the core wire made of the aluminum-based material is connected to the crimp terminal made of the copper-based material. At this time, if water or the like adheres to the connection portion between the core wire portion and the crimp terminal, electrolytic corrosion such as contact corrosion of different metals tends to occur.
In order to enhance the cut-off performance in the crimping portion, Patent Document 2 discloses a technique of completely covering the exposed portion of the coated wire and the entire outer periphery in the vicinity thereof with a mold resin Has been proposed. However, in this structure, the crimped terminal is large enough to be covered by the molded resin, and the connector housing needs to be formed largely in accordance with this, so that the wire harness can not be formed with high density and small size. Further, since the molding process is performed on the respective crimping portions after the crimping, there is a problem that the process of manufacturing the wire harness is greatly increased, and the work is troublesome.
Further, as a type of crimp terminal for realizing a connection with a high index compared to an open barrel structure having a structure in which a core wire of a covered wire is exposed in a crimp portion, a crimp portion for crimping a covered wire is a closed barrel barrel structure (Patent Document 3). As a general crimping method for the crimped terminal of this closed barrel structure, there is a method of crimping crimping the crimped portion of the crimped terminal into which the covered wire is inserted so as to reduce the diameter thereof.
The conductor connecting method described in Patent Document 4 is a method of inserting a core wire of a covered wire into a connecting tube portion of a crimp terminal having a compression collar mounted on the outer circumferential surface thereof, By caulking, it is possible to crimp the core wire portion uniformly by shrinking the connecting tube portion while maintaining the inner circumferential surface shape of the circular cross section.
As another method of pressing, there is a method of pressing the crimped terminal 200 in which the covered wire 100 is inserted to a pair of male and female molds 300 (see FIGS. 8 and 9). A pair of male molds 320 each having a female mold 320 having a female concave portion 321 having a substantially inverted U-shaped cross section and a male concave portion 312 having a semicircular cross- Male and female molds 300 sandwich the coated wire 100 and the crimping terminal 200 and crimp to crimp the crimped portion 230 to connect the coated wire 100 to the crimped terminal 200. At this time, due to the repulsive force of the insulating cover body 102 compressed by the compression bonding portion 230 of the compression bonding terminal 200, the compression bonding terminal 200 and the insulating cover body 102 closely contact with each other without gaps to secure the exponential property have.
9, when the compression bonding terminal 200 is compressed by the pair of male and female molds 300, the compression bonding portion 230 of the compression bonding terminal 200 along the shape of the pair of male and female molds 300, The protruding portion 234 (see Fig. 10) is formed on the outer peripheral surface of the squeezed terminal 200 after the squeezing so as to follow the boundary portion of the pair of male and female molds 300.
The compression ratio of the insulation covering body 102 opposed to the protruding portion 234 in the radial direction is partially reduced since the diameter ratio of the projection 234 is smaller than that of other portions of the compression bonding terminal 200 . The repulsive force of the insulating cover body 102 corresponding to the protruding portion 234 is reduced so that a gap is formed between the inner surface of the protruded portion and the insulating cover body, There is a fear that moisture may penetrate through the coated wire 100 inside. Since the insulating cover member of the coated wire has elasticity, the surface layer portion follows the inner surface shape of the compressed portion to obtain a constant sealing performance at the initial stage of the pressing, but when the thermal load is applied, the inner surface of the protruded portion And the insulating cover body are separated from each other, so that the index portion in the crimping portion is deteriorated.
Japanese Patent Application Laid-Open No. 2002-367714 Japanese Laid-Open Patent Publication No. 2011-222243 Japanese Laid-Open Patent Publication No. 2006-331931 Japanese Laid-Open Patent Publication No. 2011-243467
SUMMARY OF THE INVENTION In view of the above problems, it is an object of the present invention to provide a wire connecting structure, a method of manufacturing a wire connecting structure, a connector having a wire connecting structure, and a pressing mold capable of reducing moisture penetration into the press- .
In order to solve the above-described problems, the present invention provides a method of manufacturing a semiconductor device, comprising the steps of: covering a conductive wire with a conductive core wire portion with an insulating insulating cover material; forming a core wire portion having a predetermined length in a longitudinal direction of the coated wire, And a crimp portion of the terminal is crimped and connected to the crimp portion of the terminal by a pair of crimp dies, wherein the crimp portion has a cross-sectional shape perpendicular to the longitudinal direction of the crimp portion, Each of the protruding portions having a closed end surface shape surrounding the crimping portion and the covering wire and having a protruding portion corresponding to a boundary portion of the set of the pressing molds of the crimping portion, And a pressed portion to be connected to the wire.
In the present invention, the term " longitudinal direction " refers to the longitudinal direction of the terminal, and is also the same as the extending direction of the covered wire disposed in the crimped portion of the terminal. The term " closed end face shape " indicates a shape in which the wall portion constituting the pressed portion extends in a ring shape without breaking. The "pressure-applied portion" means that the protrusion formed on the portion corresponding to the boundary portion of one set of the press mold in the press-contact portion is recessed toward the covered wire inside the press-contact portion by a predetermined mold or tool, It refers to the deformed part.
The crimping portion may be a closed barrel type having an inner hollow shape. The one set of the pressing molds can be a compression mold having a two-divided, three-divided or four-divided inner mold having a crimping portion capable of crimping. For example, a pair of compression molds having the same inner shape, a pair of female and male molds made of male and female molds, or a compression mold in which the crimping portion is caulked in three directions or in four directions can be used.
The shape of the closed end face can be a closed end face shape formed by welding both end portions in the circumferential direction to each other and fused to each other or a closed end face shape integrally formed by overlapping both end portions in the circumferential direction and welding overlapping ends.
The portion corresponding to the boundary portion of one set of the pressing die in the pressing portion is a portion corresponding to the fitting surface of one set of the pressing die or the range of the pressing portion in which the splice in the male and female mold is in pressing contact, And a portion corresponding to the vicinity of the boundary line of the range of the crimping portion.
The pressurized-pressurizing portion may be formed on the entirety of a portion corresponding to the boundary portion of one set of the press-forming molds in the press-bonding portion, or may be formed on the entirety of the portion corresponding to the boundary portion of one set of press- It is possible to form them in plural. The pressure-applying portion may be formed by a mold different from a set of the pressing molds or a mold appearing at a boundary portion after the pressing in a set of pressing molds.
According to the present invention, it is possible to provide a wire connecting structure capable of reducing the penetration of moisture from the gap between the crimping portion and the insulating cover. Specifically, when the crimping portion is caulked by a pair of crimping dies, a part of the crimping portion is plastically deformed in a direction substantially orthogonal to the crimping direction. Therefore, in the crimping portion, In the corresponding portion, a projecting portion protruding outward is formed.
Therefore, in the pressed state, the portion corresponding to the boundary portion of one set of the pressing die in the pressed portion becomes a portion having a smaller compressibility of the insulating covering body as compared with the other portions. In other words, the portion corresponding to the boundary portion of one set of the press mold in the crimping portion is insufficient in the repulsive force of the insulating covering body, and the adhesion with the insulating covering body may be deteriorated in some cases.
Here, in the crimped state, the pressed portion for pressing the insulating covering body is preferably formed on the portion corresponding to the boundary portion of one set of the pressing metal molds in the crimped portion, So that the repulsive force of the insulating covering body can be ensured.
Therefore, according to the wire connection structure of the present invention, the crimp terminal and the insulating cover body can be brought into close contact with each other with less clearance, and the exponential property between the crimped portion and the insulating cover body can be further improved.
However, for example, when the compression bonding between the coated wire and the crimping portion and the formation of the pressured portion are performed at the same time, the compression ratio locally increases, so that a portion with a high load due to compression is formed in the crimping portion, Or a crack at the welded portion of the pressed portion may occur.
Here, in an advantageous form of the present invention, the press-contact pressure portion is formed in the press-contact portion after the press-bonding with one set of the press mold. As a result, it is possible to prevent a portion having a high load due to compression from being generated in the crimping portion and to prevent a crack from occurring in the compressed portion and the welded portion, so that the penetration of moisture from the portion between the crimping portion and the insulating covering body Can be further reduced.
As an advantageous form of the present invention, the pressure-receiving portion can be locally formed in the projecting portion. This makes it possible to easily prevent moisture from entering between the crimping portion and the insulating covering body.
In a more advantageous form of the present invention, a plurality of pressure-receiving portions can be formed at predetermined intervals along a portion corresponding to the boundary portion of one set of the press-forming molds in the press-bonding portion. This makes it possible to complicate the intrusion path of moisture between the crimping portion and the insulating covering body and to more easily allow the penetration of moisture into the inside of the crimping portion from between the crimping portion and the insulating covering body, It can surely be reduced. In this case, it is preferable that the predetermined distance, that is, the spacing distance between adjacent pressure receiving portions in the longitudinal direction is 0.3 mm or more if the length in the longitudinal direction of the crimping portion is about 10 mm. This is because, if the spacing distance is less than 0.3 mm, there is a fear that uniform compression bonding can not be maintained in the crimping portion due to the concentration of the load at the time of pressing. When a plurality of pressure-applying portions are provided, it is preferable that the pressure-applying portions are uniformly provided on the projecting portions as viewed in the longitudinal direction. Thus, more uniform compression bonding can be realized between the pressing portions and the covering wires.
In an advantageous form of the present invention, the depth of the pressure-receiving portion can be 3% or more and 20% or less of the outside diameter of the portion where the pressure-receiving portion is not formed. When the depth of the pressure-receiving portion is set to be less than 3% of the outer diameter of the portion where the pressure-receiving portion is not formed, the effect of increasing the exponential property by closing the gap between the press- If it exceeds 20%, the crimped portion may be excessively deformed or twisted, and the index may be deteriorated.
Further, as an advantageous form of the present invention, the cross-sectional shape perpendicular to the longitudinal direction of the pressure-receiving portion can preferably be formed in the shape of a cross-sectional protruding portion in which the inner surface of the pressure-receiving portion protrudes toward the center of the insulating cover . That is, the inner surface of the press-contact portion protrudes inward from the region adjacent to the pressure-applied portion in the region where the pressure-applied portion is formed. In this case, the insulating covering body can be reliably compressed by the pressure-receiving portion. That is, the repulsive force of the insulating covering body can be made larger. As a result, the crimped portion of the crimp terminal and the insulating covering body can be brought into close contact with each other with smaller clearance, so that invasion of moisture from between the pressed portion and the insulating covering body can be more reliably reduced.
Further, in an advantageous form of the present invention, the pressure-receiving portion can be provided at both portions corresponding to the boundary portions of two portions of one set of the press mold in the press-bonding portion. By doing so, the intrusion of moisture into the crimping portion can be further reduced.
In order to solve the above-described problems, the present invention provides a printed wiring board, comprising: a covered wire covered with an insulating insulating covering body with a conductive core wire portion; a core wire portion having a predetermined length exposed in the longitudinal direction of the covered wire from the front end of the insulating cover body; And a crimping portion of the terminal and a covering wire are crimped and connected by a pair of crimping dies, wherein the crimping portion of the terminal and the covering wire are connected to each other by a pair of crimping dies, Wherein an angle formed by intersection of a tangent line of the outer surface of the protruding portion at an intersection of a line of the outer periphery of the portion and a line of the outer surface of the protruded portion is an obtuse angle and a protruding portion is formed from the tangent to the compressed portion side .
According to the present invention, by making the angle of the tip end of the projecting portion formed on the outer periphery of the pressed portion obtuse, the followability of the coated wire to the pressed portion can be improved. It is possible to reduce the gap between the crimping portion and the covering wire and to reduce the penetration of moisture into the crimping portion. As a result, the crimping portion and the core wire are not subjected to electric conduction, and the connection can be maintained in a good state.
As an advantageous form of the present invention, there is provided an encapsulating portion (sealing portion) for sealing the tip end (the end of the crimping portion) in the longitudinal direction at the tip of the core wire side of the crimping portion, can do. According to this, the sealing portion can prevent the moisture from entering from the end of the crimp portion on the side of the core wire portion. In addition, the sealing portion and the pressure-applying portion can form a seal at both end portions of the press-bonding portion, so that the inside of the press-bonding portion in the press-bonding state can be sealed. As a result, penetration of moisture into the inside of the crimping portion can be more reliably reduced. Therefore, by keeping the inside of the pressed portion in the pressed state in a sealed state, it is possible to secure a reliable exponential property and to secure more stable conductivity.
As an advantageous form of the present invention, the core wire portion may be made of an aluminum-based material, and at least the crimp portion may be made of a copper-based material. According to this, the core wires can be made lighter than the coated wires made of the copper-based material, and the so-called dissimilar metal corrosion (hereinafter referred to as "electric corrosion") can be prevented by the above-
Specifically, when the copper-based material conventionally used at the core wire of the coated wire is replaced with an aluminum-based material such as aluminum or aluminum alloy and the core wire made of the aluminum-based material is pressed to the terminal, There is a problem that the aluminum-based material, which is a base metal, is corroded by contact with noble metals such as tin plating, gold plating, and copper alloy, that is, electric current is a problem.
In addition, when the moisture is attached to a portion where a noble metal and a base metal are in contact with each other, a corrosion current is generated, and the nonmetal is corroded, melted, and lost. By this phenomenon, the conductor portion made of the aluminum-based material pressed on the crimping portion of the terminal is corroded, melted and lost, and the electric resistance is increased eventually. As a result, there has been a problem that sufficient conducting functions can not be achieved. However, by virtue of the above-described good exponential property, so-called electromagnetism can be prevented while reducing the weight of the core wire portion compared with the coated wire composed of a copper-based material.
Further, in an advantageous form of the invention, the press-bonding portion may have a structure in which the plate material is formed into a cylindrical shape and the joint is sealed by welding. According to this, a crimped portion having a closed end face shape in which the cross section perpendicular to the longitudinal direction surrounds the covered wire can be easily formed.
Further, in an advantageous form of the invention, the crimping portion of the terminal may have two or more portions having different diameters from each other, and a portion having a larger diameter may be disposed on the wire insertion port side. In this way, when the covering of the front end of the coated wire is removed and the end portion is inserted into the pressed portion, the insulating coating of the wire is caught between the small diameter portion and the large portion, It is possible to easily position it directly below the small diameter portion), and to achieve a good connection between the crimping portion and the core wire portion.
Further, in order to solve the above problems, the present invention is characterized in that the above-mentioned wire connecting structure is a connector in which a connector housing is arranged. According to the present invention, it is possible to connect the crimp terminal without securing the stable conductivity, regardless of the kind of metal constituting the crimp terminal and the core wire portion.
Specifically, for example, when connecting the connector of the armpit and the connector of the male connector to each other and connecting the crimping terminals arranged in the connector housing of the respective connectors to each other, the crimping terminals of the connectors can be connected to each other while securing a good index. Therefore, the connector can secure a connection state with reliable conductivity.
In order to solve the above-described problems, the present invention provides a printed wiring board, comprising: a covered wire covered with an insulating insulating covering body with a conductive core wire portion; a core wire portion having a predetermined length exposed in the longitudinal direction of the covered wire from the front end of the insulating cover body; A method of manufacturing a wire connecting structure comprising a terminal having a crimping portion connected to a vicinity of a tip end of a crimping portion and crimping and connecting a crimping portion of a terminal with a crimping portion of a terminal with a pair of crimping dies, A protruding portion is formed at a portion corresponding to a boundary portion of a set of the pressing molds of the crimping portion by using a terminal having a shape of a closed end surrounding the covering wire so as to compress the crimping portion and the covering wire, And a pressure-applying portion is formed on the projecting portion.
In order to solve the above-described problems, the present invention provides a printed wiring board, comprising: a covered wire covered with an insulating insulating covering body with a conductive core wire portion; a core wire portion having a predetermined length exposed in the longitudinal direction of the covered wire from the front end of the insulating cover body; A method of manufacturing a wire connecting structure comprising a terminal having a crimping portion connected to a vicinity of a tip end of a sieve and crimping a crimped portion of the terminal and a covering wire with a pair of crimping dies to connect the crimping portion and the covering wire, Characterized in that an angle formed by intersection of tangential lines of the lines of the outer surface of the projecting portion at the intersection of the line of the outer periphery of the pressed portion and the line of the outer surface of the projecting portion is obtuse and the projecting portion is formed from the tangent to the press- And a method for manufacturing a connection structure.
In order to solve the above problems, the present invention provides a compression mold for placing a covered wire inside a crimp portion of a crimp terminal, and pressing the crimp portion and the core of the covered wire and the insulating cover, And a relief portion provided at least on one of the first mold and the second mold and having at least a portion of the crimp portion when the crimp portion is pressed on the first mold and the second mold, The angle formed by the intersection of straight lines formed from the intersection of the formation surface of the concave portion and the formation surface of the relief portion is an obtuse angle in a cross section perpendicular to the longitudinal direction of the coated wire and the relief portion is formed on the concave portion side from the straight line Is a mold for pressing.
According to the present invention, the above-described projecting portion can be formed by the relief portion of the press-molding die, and the space between the press-bonding portion and the coated wire can be sealed. The connection structure made of the pressing die of the present invention can prevent the above-described electromotive force.
According to the present invention, it is possible to provide a wire connecting structure, a method of manufacturing a wire connecting structure, a connector provided with a wire connecting structure, and a mold for crimping, which can reduce the intrusion of moisture from between the crimping portion and the insulating cover have.
BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is an external perspective view showing an appearance from above in a wire connecting structure according to an embodiment of the present invention; FIG.
2 is an enlarged view of a portion B in Fig.
Fig. 3 is an external perspective view showing the appearance of the coated wire and the crimp terminal from above. Fig.
Fig. 4 is an explanatory view for explaining welding in the crimping portion. Fig.
5 is an enlarged view of the Z portion in Fig.
6 is a cross-sectional view taken along the direction of arrow AA in Fig.
7 is a cross-sectional view taken along the AA arrow direction showing a state before compression bonding in which a covering wire is inserted into the crimping portion.
8 is an explanatory view for explaining the first step in the pressing process of the crimping portion.
Fig. 9 is an explanatory diagram for explaining the second step in the pressing process of the crimping portion. Fig.
Fig. 10 is a cross-sectional view taken along the AA arrow direction showing a state in which the coated wire is squeezed in the crimping portion. Fig.
11 is an explanatory view for explaining the first step in the drawing process of the projecting portion.
12 is an explanatory view for explaining the second step in the drawing process of the protruding portion.
Fig. 13 is an external perspective view showing a connection state between the armature connector and the male connector; Fig.
Fig. 14 is a cross-sectional view of another wire connection structure in a direction indicated by arrow AA, in which the pressure-receiving portion is provided only on one of the projections.
15 is a perspective view showing another crimp terminal having a step in the crimping portion;
16 is a perspective view showing another crimp terminal in which the connector portion is a male terminal;
17 is a perspective view of a wire connecting structure according to another embodiment of the present invention.
18 is a cross-sectional view along the longitudinal direction of the wire connecting structure of Fig.
19 is a bottom view showing a main part of the wire connecting structure of Fig.
20 is a cross-sectional view taken along line CC in Fig.
21 is a cross-sectional view taken along line DD in Fig.
Fig. 22 is a perspective view showing a front side of a compression bonding apparatus suitably used for manufacturing the wire connection structure of Fig. 17; Fig.
23 is a side view of the compression bonding apparatus of Fig.
Fig. 24 is a perspective view showing a crimp terminal and electric wires before assembly of the wire connection structure of Fig. 17; Fig.
25 is a perspective view showing a wire connecting structure according to still another embodiment of the present invention.
26 is a sectional view taken along the line EE of Fig.
27 is an enlarged view of a portion surrounded by a dashed circle in Fig.
Fig. 28 is an enlarged view of the same portion as Fig. 27, showing an example in which the tip of the protrusion is rounded.
Fig. 29 is an enlarged view at the same position as in Fig. 27, showing an example in which the tips of the projections are made flat.
Fig. 30 is an enlarged view at the same portion as Fig. 27, showing a protrusion made up of a curve.
31 is a cross-sectional view of a press-bonded portion showing a gap formed between the crimped portion and the coated wire.
Fig. 32 is an enlarged view of a portion surrounded by a dashed line in Fig. 31;
Fig. 33 is a cross-sectional view showing a mold usable for manufacturing the wire connecting structure of Fig. 25;
Fig. 34 is an enlarged view of a portion surrounded by a dashed line in Fig. 33, showing a contact portion between the first mold and the second mold;
Fig. 35 is an enlarged cross-sectional view of the same portion as Fig. 34, showing a mold having a curved line in the relief portion.
Fig. 36 is a perspective view for explaining a method of manufacturing the wire connecting structure, showing a state before inserting a covered wire into the crimping portion. Fig.
37 is a perspective view showing a state in which a covering wire is inserted into a crimping portion, illustrating a method for manufacturing a wire connecting structure;
38 is a cross-sectional view showing an aspect of driving the first mold with respect to the second mold and compressing the pressed portion with the first mold and the second mold.
39 is a cross-sectional view showing an aspect in which the first mold is separated from the second mold after compression.
40 is a cross-sectional view showing a state in which a compression bonding portion or the like is inserted into a concave portion of the first metal mold and the second metal mold is inserted into the concave portion of the first metal mold.
41 is a cross-sectional view showing a state in which the second mold is separated from the first mold after the press-bonding.
One embodiment of the present invention will be described below with reference to the drawings. First, the wire connecting structure in this embodiment will be described in detail with reference to Figs. 1 to 6. Fig. 1 is an enlarged view of part B in Fig. 1, Fig. 3 is an enlarged view of part B in Fig. 1, and Fig. 3 is a cross-sectional view of a covered wire 100 and a compression terminal 200. Fig. Fig. 4 and Fig. 5 show explanatory diagrams for explaining the welding in the crimping portion 230, and Fig. 6 shows a sectional view taken in the AA arrow direction in Fig. 1 .
1, the arrow X indicates the longitudinal direction (hereinafter referred to as the "longitudinal direction X"), and the arrow Y indicates the width direction (the shorter direction) (Y) "). 1) on the side of the covered electric wire 100 (the right side in Fig. 1), which will be described later, with respect to the connector portion 210, with the connector portion 210 side (left side in Fig. Rear direction. The upper side in Fig. 1 is set upward and the lower side in Fig. 1 is set downward.
As shown in Fig. 1, the wire connection structure 1 is composed of a covered wire 100 and a crimped terminal 200 obtained by crimping and covering the covered wire 100. As shown in Fig. As shown in Fig. 3, the coated wire 100 is formed by inserting a core wire (core wire portion) 101, which is a bundle of a plurality of wire rods 101a made of a conductive material, And is covered with a covering member 102. The core wire 101 may be composed of a single thick wire. The core wire portion 101 may be made of various known metals such as copper or copper alloy, but it may be made of aluminum or aluminum alloy in order to reduce the weight. For example, the thickness of the core wire portion 101 can be appropriately set in accordance with the flow current or the like. For example, the total area of the core wire portions in a cross section perpendicular to the longitudinal direction is 0.75 mm 2 or 1.00 2 mm, 1.25mm may be a 2, 2.00mm 2, 2.50mm 2, 3.00mm 2 and the like. The core wire 101 can be constructed by twisting the wire 101a. However, in the drawings, a twisted shape is not shown for the sake of simplicity. The coated wire 100 exposes a predetermined length core 101 from a tip end of the insulating cover 102 in the longitudinal direction X. [
As the core wire made of aluminum, for example, iron (Fe), copper (Cu), magnesium (Mg), silicon (Si), titanium (Ti), zirconium (Zr), tin (Sn) And the like can be used. 7 to 19 aluminum core wires can be twisted and used as core wires. As the material of the insulating coating, for example, polyolefin such as polyethylene (PE) or polypropylene (PP) as a main component or polyvinyl chloride (PVC) as a main component can be used.
In this example, as shown in Figs. 1 and 3, the compression terminal 200 is a female terminal, and the insertion of the male tabs of the male terminal (see Fig. 16) is performed from the front in the longitudinal direction X backward (Barrel portion) 230 disposed via a transition portion 220 having a predetermined length from the back (wire side) of the connector portion 210 to the side of the connector portion 210 Respectively. The crimping portion 230 is a portion where the end portion of the covered electric wire 100 is crimped and joined to the crimp terminal 200. [ The crimping portion 230 has an opening (insertion opening) for permitting the insertion of the end portion of the covered electric wire 100 at one end (rear end) of the longitudinal direction X before the compression, and the other end Is connected to the transition unit 220 and is closed.
The compression terminal 200 is basically made of a base material of a metal material (copper, aluminum, steel, or an alloy mainly composed of these materials) in order to secure conductivity and strength. However, in order to secure various characteristics required for the crimp terminal, for example, even if a metal member having tin plating (Sn plating), silver plating, gold plating or the like is applied to part or all of the crimping terminal 200 good. The crimping terminal 200 is formed by flattening a plate material (not shown) of a predetermined metal member (for example, a copper alloy such as brass or the like whose surface is plated with tin (Sn) A box portion 210 of a hollow square cylinder body and a substantially O-shaped crimping portion 230 as viewed from the rear side, and the end portions of the bending crimping portion 230 are bent Is a closed-barrel type terminal formed by welding. A preferred welding method is laser welding, in particular laser welding with a fiber laser. Of course, different known welding methods may be used. Alternatively, a cylindrical compression bonding portion 230 may be formed by punching a solid metal cylinder with a drill or the like, or by drawing from a flat plate. In this manner, the crimping portion 230 is configured to enclose the insulating cover body 102 of the covered electric wire 100 over the entire circumference so as to prevent moisture and the like from entering from the outside. Even if the crimping terminal 200 and the core wire portion 101 of the coated wire 100 are made of aluminum, there is a case where corrosion of these joint portions occurs due to the difference in the composition of the alloy. If the insulating clad 102 of the covered electric wire 100 can be wrapped around the entire circumference in a close contact state, a certain effect can be obtained with respect to corrosion, so that the crimping portion 230 does not necessarily have to be cylindrical, It may be an ellipse or a square tube. Further, the crimping portion 230 need not have a constant diameter, and the diameter may be changed in the longitudinal direction. However, as will be described later, it is preferable that the crimping portion 230 has a shape that allows the inner surface of the crimping portion 230 to be sufficiently close to the surface of the insulating cover member 102 of the covered electric wire 100 when compressed.
3 and 4, one side of the side portion 212 extending to both side portions in the width direction Y perpendicular to the longitudinal direction X of the bottom surface portion 211 is connected to the connector portion 210, And is formed into a hollow rectangular column which is folded so as to be superimposed on the other end portion and is substantially in a collapsed state when viewed from the front side in the longitudinal direction (X). The connector portion 210 may be a substantially U-shaped or ring-shaped flat plate instead of a box.
The inside of the connector portion 210 is formed by extending the front side in the longitudinal direction X of the bottom surface portion 211 and bending the rear side in the longitudinal direction X, And an elastic contact piece 213 contacting the insertion tab (see Fig. 16). Further, in the present embodiment, detailed illustration of the elastic contact piece 213 is omitted.
1 and 3, the crimping portion 230 includes a cover crimping portion 231 for crimping the insulating covering member 102, a conductor crimping portion 232 for pressing the exposed core portion 101, And a sealing portion 233 formed by pressing and pressing the front end portion of the conductor crimping portion 232 in a substantially flat plate shape. In the conductor crimping portion 232, electrical connection is ensured at the same time by mechanically pressing and bonding the metal base (or metal member) constituting the crimping portion 230 and the exposed core wire 101 of the coated wire 100 . The metal clad part (metal member) constituting the crimping part 230 and the insulating clad 102 of the clad wire 100 are mechanically crimped and bonded in the clad part 232, And a seal is formed between the crimping portion 230 and the insulating cover 102 of the coated wire 100. In addition, The crimping process of the crimping portion 230 is performed by plastic deformation of the substrate or electric wire (core wire). Therefore, the crimping portion 230 needs to be designed as a thick wall so that crimping can be performed. However, the crimping portion 230 is not particularly limited as it can be bonded by gravitation or machining.
As shown in Figs. 4 and 5, the crimping portion 230 is formed by pressing a plate material made of copper alloy or the like, which is formed in a deployed shape of a terminal, into an inner diameter slightly larger than the outer diameter of the covered electric wire 100 And the rounded end portions 230a and 230b are formed to be substantially O-shaped (see FIG. 7) when viewed from the rear side by welding along the welding spot W1 in the longitudinal direction X so that the rounded ends 230a and 230b are rounded to surround the outer periphery . In other words, the crimping portion 230 has a closed end surface shape in the width direction Y (a cross section perpendicular to the longitudinal direction X).
4, the sealing portion 233 of the crimping portion 230 is provided with a welding spot W2 in the width direction Y so as to close the front end in the longitudinal direction X of the crimping portion 230 Therefore, it is welded and sealed. That is, the crimping portion 230 is formed into a substantially cylindrical shape having an opening at the back of the longitudinal direction X by melting and welding the front end and the end portions (end portions 230a and 230b) in the longitudinal direction X .
As shown in Figs. 1 and 6, in the crimped portion 231 of the crimping portion 230, the crimped portion 230 and the coated cable 100 are crimped, (A drawing portion) (a drawing portion) in which a predetermined portion of the projection 234 is pressed and plastically deformed inward in the width direction Y (a drawing portion 234) protruding toward the outside in the width direction Y 235 are formed. The protruding portion 234 and the pressure-receiving portion 235 will be described later in detail.
Next, a step of inserting the covered electric wire 100 into the pressed part 230 of the compressed terminal 200 having such a structure and crimping the pressed part 230 to manufacture the electric wire connecting structure 1 , And Fig. 7 to Fig. 12.
7 is a sectional view taken along the arrow AA direction in the state before the crimp portion 230 is inserted into the crimp portion 230 and FIG. 8 is a sectional view taken along the first step in the crimping process of the crimp portion 230 And FIG. 9 shows an explanatory diagram for explaining the second step in the pressing process of the crimping portion 230. As shown in FIG. 10 is a sectional view taken along the arrow AA direction in a state in which the cover wire 100 is pressed to the crimping portion 230 and FIG. 11 is a cross-sectional view taken along line AA in the first step in the pressing (or drawing) Fig. 12 shows an explanatory diagram for explaining the second step in the pressing step of the projecting portion 234. As shown in Fig. In FIG. 10, the inner and outer circumferential shapes of the coated crimp portion 231 before compression and the outer circumferential shape of the insulating cover 102 are indicated by two-dot chain lines.
First, as shown in Fig. 3, a covered electric wire 100 in which the core wire 101 is exposed at the tip end is inserted into the crimping portion 230 of the crimp terminal 200 from the rear side in the longitudinal direction X. As shown in Fig. 7, since the inner diameter of the crimping portion 230 is slightly larger than the outer diameter of the covered wire 100, the covered wire 100 is loosely inserted into the crimping portion 230 .
As shown in Fig. 8, the cover crimping portion 231 of the crimping portion 230 into which the covered wire 100 is inserted is vertically caulked with a pair of male and female molds 300 as a pair of crimping dies , And the insulation covering body (102) and the compression bonding terminal (200) are pressed together. Although not described in detail, the conductor crimping portion 232 of the crimping portion 230 is caulked with an appropriate crimping die to press the core wire portion 101 and the crimping terminal 200 together. In order to serve as an electrical connection, a severe plastic deformation is usually performed on a part. At this time, each element wire 101a of the core wire portion 101 does not have to retain its original shape unless it is disconnected. That is, each of the elemental wires 101a may be pressed and pressed to be plastically deformed. In addition, in the figure, for the sake of simplification, the aspect of the pressed portion of the core wire portion 101 after compression is not specifically shown.
As shown in Figs. 8 and 9, the pair of male and female molds 300 has a male mold 310 having a length in the longitudinal direction X in which the cover crimping portion 231 can be pressed, And a mold 320.
The cross section of the male mold 310 in the width direction Y has a cross section having a length in the width direction Y slightly smaller than the outer diameter of the crimping section 230 in the compression bonding terminal 200, Respectively. The upper surface of the male die 310 is sandwiched between flat portions 311 provided at both ends in the width direction Y so as to have a slightly smaller diameter with respect to the outer diameter of the crimping portion 230, Side concave portion 312 having a substantially semicircular cross section is formed.
The female mold 320 is formed by a female concave portion 321 having a size that allows the male die 310 to be fitted and is recessed in a substantially inverted U shape with a slightly smaller diameter with respect to the outer diameter of the crimping portion 230, (A cross section perpendicular to the longitudinal direction X) in the width direction Y is formed into a substantially gate-like shape. The male concave portion 312 and the female concave portion 321 are formed to have a substantially circular inner surface shape when the male die 310 and the female die 320 are combined in the vertical direction .
When the pair of male and female molds 300 described above are pressed and caulked in the vertical direction with respect to the cover crimping portion 231 of the crimping portion 230 into which the covered wire 100 is inserted, As shown in Fig. 9, plastic deformation is performed so as to conform to the inner surface shape of the pair of male and female molds 300. As shown in Fig.
9 and 10, the inner circumferential surface of the cover crimp portion 231 is made to compress the insulating cover member 102 of the covered electric wire 100 toward the center of the coated electric wire 100 It shrinks. The outer peripheral surface of the cover pressing portion 231 is reduced in diameter along the male concave portion 312 and the female side concave portion 321 as well as the diameter of the flat portion 311 of the male die 310 and the cross- Side concave portions 321 protrude in the width direction Y and extend in the longitudinal direction X to portions corresponding to the two boundary portions of the water recess 312 and the female recess 321, A protrusion 234 is formed.
Thereafter, as shown in Figs. 11 and 12, a pair of drawing dies (pressing molds) 330 are used to press the pressing portion 234 of the cover pressing portion 231 in the press- (Press-fitting) is performed. At this time, the crimp terminal 200 is held in the crimped mold with the conductor crimping portion 232 caulked.
11, the pair of drawing dies 330 are arranged on an extension line extending from the center of the coated electric wire 100 through the protruding portion 234 in the cross section in the width direction Y, The surface facing the protruding portion 234 is formed into a sectional shape protruding in a substantially semicircular shape in cross section toward the protruding portion 234. [
Although not shown in detail, the pair of drawing dies 330 are formed to have a length in the longitudinal direction X corresponding to the pressure-receiving portion 235 in Fig. 1, and in the longitudinal direction X And two are arranged at predetermined intervals.
As shown in FIG. 12, the pair of drawing dies 330 move toward the center of the covered electric wire 100, and move the protruding portions 234 of the cover-pressed portions 231 in the pressed state Direction (M) and subjected to plastic deformation. The pair of drawing dies 330 are pressed against the cover pressing portion 231 until the inner surface of the cover pressing portion 231 opposed to the protruding portion 234 protrudes toward the center of the covering wire 100 do.
2 and 6, the protruding portion 234 of the cover press-fitting portion 231 is provided with a protruding portion 234 extending in the longitudinal direction ( X) is formed at a position spaced apart by a predetermined distance. As shown in Fig. 6, this pressure-receiving portion 235 is formed in a cross-sectional protruding shape in which the inner surface of the cover-pressing portion 231 protrudes toward the center of the covered electric wire 100. [ That is, the inner surface of the crimping portion 230 protrudes inward in the radial direction from the region adjacent to the pressure-receiving portion 235 in the region where the pressure-receiving portion 235 is formed.
The crimped portion 230 of the crimped terminal 200 is caulked to press-fit the covered wire 100 and the wire connecting structure 100 having the core 101 and the crimped terminal 200 secured 1).
Next, a connector in which the above-described wire connecting structure 1 is mounted inside the connector housing will be described with reference to Fig. Fig. 13 shows an external perspective view of the connection between the female connector 11 and the male connector 21, and Fig. 13 shows the male connector 21 in two-dotted chain lines.
The armature connector housing 12 has a plurality of openings that can be mounted along the longitudinal direction X of the compression terminal 200 and is formed into a box shape having a substantially rectangular cross section in the width direction Y . The wire harness 10 having the armature connector 11 is constructed by mounting the plurality of wire connection structure 1 described above along the longitudinal direction X with respect to the inside of the armature connector housing 12.
Similarly to the armature connector housing 12, the male connector housing 22 corresponding to the female connector housing 12 has a plurality of openings into which the female terminal 200 can be mounted, And is formed so as to be connectable to the female connector housing 12 so as to correspond to the concavo-convex shape.
A crimp connecting structure 1 composed of a shoelace fitting terminal (see Fig. 16) is attached to the inside of the male connector housing 22 along the longitudinal direction X to form a wire harness (Fig. 20). The wire harness 10 is connected to the wire harness 20 by fitting the female connector 11 and the male connector 21 together.
The wire connecting structure 1 and the armature connector 11 for realizing the above-described structure are arranged in such a manner that the distance from the slight gap between the insulation covering body 102 of the electric wire 100 and the compression bonding part 230 to the inside of the compression bonding part 230 It is possible to reduce invasion of moisture and the like. That is, it is possible to secure the exponential property on the side of the insulating covering member 102 (rear end side) of the wire connecting structure 1. Specifically, when the crimping portion 230 is caulked by the pair of male and female molds 300, a part of the crimping portion 230 is plastically deformed in the width direction Y substantially orthogonal to the vertical direction, Protruding portions 234 protruding outward are respectively formed at portions corresponding to the boundary portions of two portions of the pair of male and female molds 300 in the crimping portion 230 . A necking portion or a concave portion is formed on the inner surface portion of the crimping portion 230 corresponding to the protruding portion 234 and a gap (not shown) is formed between the crimping portion 230 and the insulating covering member 102 (See the gap (V) in FIG. 31) may occur.
Therefore, in the pressed state, the protruding portion 234 of the crimping portion 230 becomes a portion having a smaller compressibility of the insulating cover body 102 as compared with other portions. In other words, the protruding portion 234 of the crimping portion 230 is a portion in which the repulsive force of the insulating covering body 102 is insufficient and the adhesion with the insulating covering body 102 is reduced. This portion (the gap V) where the adhesion is degraded is formed continuously from the open end (rear end) of the crimping portion 230 to at least the front end edge of the insulating cover 102, Moisture may enter the exposed core wire 101 inside the crimping portion 230, and water may adhere to the exposed core wire 101 inside the crimped portion 230.
Here, by forming the pressure-applying portion 235 for pressing the insulating covering member 102 against the protruding portion 234 of the crimping portion 230 in the compressed state, the portion of the insulating covering member 102 having a small compression ratio The repulsive force of the insulating cover member 102 can be secured.
As a result, the crimped portion 203 of the crimping terminal 200 and the insulating cover member 102 can be brought into close contact with each other with less gap. In addition, even when the above-mentioned continuous gap is generated between the crimping portion 230 and the insulating cover 102, the gap can be closed by the pressure-receiving portion 235 to be discontinuous. Even if a gap is formed by the protruding portion 234 between the cover crimp portion 231 and the insulating cover 102 of the electric wire 100 in the cover crimp portion 231, The moisture from the outside is hardly reaching the core wire 101 in the crimping portion 230. As a result, Such prevention of water intrusion also becomes effective when the wire connecting structure 1 receives thermal load. This is because the gap is blocked by the pressure-receiving portion 235 even when a space is formed between the cover-contact compressed portion 231 and the insulating cover 102 in the region of the protrusion 234 by thermal load. Therefore, according to the wire connection structure 1 of the present embodiment and the method of manufacturing the wire connection structure, the index from the side of the insulating cover 102 in the crimping portion 230 can be further improved.
However, when the compression bonding of the coated wire 100 and the cover-contact bonding portion 231 and the formation of the press-contact pressure portion 235 are performed at the same time, the compression ratio locally increases, There is a possibility that a crack in the compression portion and a crack in the fusion portion of the compression bonding portion 230 may occur.
On the other hand, by forming the pressure-applying portion on the cover-pressing portion 231 after pressing the pair of male and female molds 300, it is possible to prevent a portion having a high load due to compression from being generated in the cover- It is possible to prevent cracks from occurring at the compressed portions or welded portions and to prevent moisture from entering between the crimped portions 230 and the insulating cover body 102 with certainty.
It is preferable that the depth h of the pressure-receiving portion 235 is not less than 3% and not more than 20% of the width (outer diameter) d of the press-bonded portion 231 after compression. The depth h indicates the length when the distance from the apex of the protrusion 235 to the bottom of the pressure-receiving portion 235 is measured along the radial direction. The width d indicates the length of the pressure-receiving portion 235, And the outer end of the protruding portion 234 at a portion where the protruding portion 234 is not formed (see Fig. 6). This depth h is preferable because if the depth h of the pressure-receiving portion 235 is less than 3% of the width d of the cover-contact portion 19, If the ratio exceeds 20%, uniform compression of the cover pressing portion 231 is not maintained due to the concentration of the load, and a gap is formed between the cover pressing portion 231 and the insulating covering member 102, There is.
A plurality of pressure-receiving portions 235 are provided at predetermined intervals along the longitudinal direction X of the protruding portions 234 of the press-bonding portions 230, so that the press-contact portions 230 (corresponding to the protruding portions 234) And the insulating cover body 102 can be blocked in a superimposed manner, so that the penetration of water into the crimped portion 230 from the insulating cover body 102 can be prevented more easily and more reliably Can be reduced. Specifically, since the crimping portion 230 is pressed in the up-and-down direction, the protruding portion 234 is in the longitudinal direction X of the covered electric wire 100. Therefore, by forming a plurality of pressure-receiving portions 235 locally on the protruding portions 234 of the crimping portion 230, it is possible to easily remove the moisture from between the crimping portion 230 and the insulating covering body 102 Can be reduced.
A plurality of pressure-receiving portions 235 are formed at predetermined intervals along the protruding portions 234 of the crimping portion 230 so that the pressure of the moisture from between the crimping portion 230 and the insulating covering body 102 The intrusion path can be complicated and the penetration of moisture into the inside of the crimping portion 230 from between the crimping portion 230 and the insulating covering member 102 can be more easily and more reliably reduced.
When a plurality of pressure-application pressure portions 235 are provided, the distance between the pressure-application pressure portions 235 adjacent to each other in the longitudinal direction X is 0.3 mm or more when the length in the longitudinal direction X of the compression portion 230 is about 10 mm . This is because, if the spacing distance is less than 0.3, there is a fear that uniform compression bonding is not maintained in the cover press-fitting portion 231 due to the concentration of the load at the time of pressing.
In the case where a plurality of pressure-application pressure portions 235 are provided, it is preferable that the pressure-application pressure portions 235 are equally disposed in the cover-contact portions 231 in the longitudinal direction X. According to this, ) And the insulating cover member 102 can be realized more uniformly.
When the pressure-receiving portion 235 is provided for each of the projections 234 on the left and right sides, the pressure-receiving portions 235 opposed to each other in the width direction Y are aligned with each other in the longitudinal direction X .
The cross section of the pressure-receiving portion 235 in the short-side direction (the cross-section perpendicular to the longitudinal direction X) is a cross-section in which the inner surface of the pressure-receiving portion 235 projects toward the center of the insulating cover 102 The insulating cover body 102 can be reliably compressed by the pressure-receiving portion 235, that is, the repulsive force of the insulating cover body 102 can be made larger. Thereby, the crimp terminal 200 and the insulating cover member 102 can be pressed without further gap, and the adhesion can be further improved. Therefore, intrusion of moisture from the insulating cover 102 can be more reliably suppressed by reliably compressing the insulating cover 102 in the compression bonding portion 230. [
The sealing portion 233 is provided at one end of the crimping portion 230 of the terminal 200 constituting the wire connecting structure 1 of the present embodiment. By providing the sealing portion 233, it is possible to prevent moisture from intruding from the transition portion 220 side (front side) of the crimping portion 230. The sealing portion 233 and the pressure-receiving portion 235 of the cover-pressing portion 231 can seal the inside of the crimping portion 230 in the crimped state. This makes it possible to more reliably prevent moisture from entering the inside of the crimping portion 230. Therefore, by keeping the inside of the crimping portion 230 in a compressed state in an enclosed state, it is possible to secure a reliable exponential and to secure a more stable conductivity.
Further, since the pressure-receiving portion 235 brings additional compression between the covered wire 100 and the crimped terminal 200, it is possible to constitute the wire connecting structure 1 that can secure a reliable index . Therefore, the wire connecting structure 1 can secure stable conductivity.
In the case where the core wire portion 101 (each wire element 101a) of the coated wire 100 is made of aluminum or an aluminum alloy and the base of the crimping portion 230 is made of copper or a copper alloy, (101) can be made lighter than a covered wire formed of copper or a copper alloy. The sealing member 233 and the pressure sensitive portion 235 of the cover pressing portion 231 prevent the occurrence of electromagnetism by the crimping terminal 200 and the covered electric wire 100 made of dissimilar metals can do.
The crimp terminal 200 disposed in the armature connector housing 12 can be formed by configuring the armature connector 11 in which the crimp terminal 200 of the wire connection structure 1 is disposed in the armature connector housing 12. [ The compression terminal 200 of the female connector 21 can be connected to the male connector 21 while ensuring the exponent when connecting the compression terminal of the male connector 21 to the male connector 21. Therefore, the female connector 11 can secure a connected state with reliable conductivity.
Although the present invention can be carried out as described above, the present invention is not limited to the wire connecting structure according to the above-described embodiment and the manufacturing method thereof, but various variations and modifications based on the technical idea of the present invention It is possible.
For example, as shown in Fig. 15, even if the crimping terminal 400 has a stepped shape (a shape having two or more portions having different tube diameters) in the state before crimping with the covering wire good. Specifically, the crimping portion 430 is a cylindrical member closed on the side of the transition portion 420. The crimping portion 430 includes a cover crimping portion 431 that is pressed against the insulating cover body of a covered wire (not shown) A reduced diameter portion 432 whose diameter is reduced toward the transition portion 420 side and a conductor crimping portion 433 which is pressed against the conductor of the electric wire and a larger diameter toward the transition portion 420 side from the insertion opening 434 side And a reduced diameter portion 435 whose end is closed by welding.
When the covering portion of the covering wire end portion is removed and the end portion is inserted into the compression bonding portion 430, the insulation covering of the wire is caught by the constriction portion 432 by having the pressing portion 430 having a step shape, The insulation covering body is located immediately below the cover crimping portion 431 and the core wire is located directly below the conductor crimping portion 433. [ Therefore, it is possible to easily position the end of the electric wire, to reliably perform the compression bonding of the cover crimping portion 431 and the insulating cover, and the crimping of the conductor pressing portion 433 and the conductor, Connection can be made compatible, and excellent adhesion can be realized.
1, the connector portion is a box-shaped terminal in the form of a box, but the present invention is not limited to this, and the connector portion may be a jacket terminal. Concretely, as the crimp terminal 500 shown in Fig. 16, a cylindrical crimping portion 530 to be crimped with a wire (not shown), and a crimp portion 530 integrally with the crimp portion 530 and the transition portion 520 And a connector portion 510 which is provided to be electrically connected to an external terminal (not shown). The connector 510 has an elongated connection portion 510a. The connection portion 510a is inserted into the unshown underwire terminal, which is an external terminal, along the longitudinal direction, Respectively.
Even when the crimping terminals 400 and 500 as shown in Figs. 15 and 16 are used, the crimping portions 430 and 530 have a cross-sectional shape perpendicular to the longitudinal direction X, Shape. In the state where the crimping portions 430 and 530 and the covering wire are pressed, the crimping portions 430 and 530 have protrusions (not shown), and at least one pressing portion (not shown) . By adopting this form, it is possible to provide a wire connection structure having improved index.
In the above-described embodiments, the core wire of the coated wire 100 is made of an aluminum alloy and the pressed terminal 200 is made of a copper alloy of brass or the like. However, the present invention is not limited to this, The core wire portion 101 and the compression bonding terminal 200 may be made of the same metal such as copper alloy or aluminum alloy such as brass.
In addition, a part of the copper alloy alloy plate (plate material) that has been formed in the deployed shape of the terminal is rounded, the opposing end portions 230a and 230b of the rounded portions are abutted against each other, However, the present invention is not limited to this, and it is also possible to use a crimped portion having a closed end shape in which opposite end portions of the rounded portions are overlapped and welded together.
Although the crimping portion 230 is formed of a copper alloy plate (plate) formed so that the cover crimping portion 231 and the conductor crimping portion 232 have substantially the same diameter, the present invention is not limited thereto, The pressed portion 230 may be formed of a copper alloy alloy plate (plate material) so that inner diameters of the conductor portion 231 and the conductor crimp portion 232 are different from each other. The sealing portion 233 is formed at the front end of the pressing portion 230 on the side of the transition portion 220. The sealing portion 230 is not limited to the sealing portion 233, May be omitted.
However, the present invention is not limited to this, and it is also possible to use a pair of male and female male molds 300 having a two-divided male and female molds 300, Or the like. For example, a pair of press molds having the same inner shape or a press mold having a configuration in which the cover press portion 231 is caulked in three or four directions may be used. In this case as well, the pressure-receiving portion 235 may be provided on the protruding portion 234 formed in the crimping portion 230 by each pair of dies. It is preferable to provide the pressing portion 235 with respect to the projecting portion 234 close to the insertion port of the coated wire.
In this case, for example, in the case of a pair of the pressing molds having the same inner shape, when the crimping terminal 200 into which the covering wire 100 is inserted is caulked, the crimping portion 230 is formed so as to flow to the fitting surface of one set of the pressing mold. The portion corresponding to the boundary portion of one set of the press mold in the crimping portion 230 can not sufficiently compress the insulating cover body 102. As a result, Here, by forming the pressure-receiving portion 235 as described above, the compression bonding structure of the compression bonding terminal 200 can prevent moisture from entering the insulating cover body 102.
The pressure applying portion 235 is formed at a predetermined interval in the longitudinal direction X of the protruding portion 234 but the present invention is not limited thereto and the pressure applying portion 234 may be formed so as to press the entire protruding portion 234 toward the center of the coated electric wire 100 The pressing portion 235 may be formed.
Although the cover crimping portion 231 is caulked by the pair of male and female molds 300, the cover crimping portion 231 and the conductor crimping portion 232 are not limited to this, It may be caulked.
Further, the pressure-receiving portion 235 is formed of a pair of drawing dies 330 after releasing the pair of male and female molds 300 pressing the cover-pressing portion 231. However, the present invention is not limited to this, A pair of drawing dies may appear toward the protruding portion 234 to form the pressure-receiving portion 235 with the cover-pressing portion 231 sandwiched between male and female molds.
In addition, although two pressure-receiving portions 235 are formed in the cover crimping portion 231 pressed by the pair of male and female molds 300, the present invention is not limited to this, and the cross-sectional view of the other wire- The pressure-receiving portion 235 may be formed on one of the two projecting portions 234 of the press-fitted portion 231 to be compressed. In the above embodiment, two pressure-sensitive portions 235 are provided for one projection 234. However, three or more pressure-sensitive portions 235 may be provided.
Next, a wire connecting structure according to another embodiment of the present invention and a manufacturing method thereof will be described with reference to Figs. 17 to 23. Fig. This embodiment differs from the above-described embodiment in the constitution of the metal mold for forming the press-contact pressure portion in the crimping portion. However, the main structure and constituent material of the crimp terminal and the coated wire described in the above- A detailed description thereof will be omitted.
17 and 18 show a wire connecting structure 60 according to another embodiment of the present invention. This wire connection structure 60 is formed by press-connecting the exposed core wire 101 of the coated wire 100 to the crimping portion 630 of the crimp terminal 600. [ In addition, in the sectional view of Fig. 18, aspects of each element wire 101a pressed by the conductor crimping portion 632 are not shown in detail for the sake of simplification. Actually, after the crimping, the wire 101a may not have the original shape, that is, it may be plastically deformed by being pressed at the time of crimping.
The crimping terminal 600 includes a box-shaped connector portion 610, a closed-end cylindrical crimping portion 630 located at the rear (on the wire side) of the connector portion 610, And a substantially flat transition portion 620 connecting the connector portion 610 and the crimping portion 630 of the connector portion 610 to each other. The crimping portion 630 includes a cover crimping portion 631 that is pressed onto the insulating cover 102 of the coated wire 100 and a conductor 631 that is pressed onto the core wire 101 exposed from the insulating cover 102 at the tip end A pressing portion 632 and a sealing portion 633 provided adjacent to the transition portion 620. [
In this example, the connector portion 610 is an armpit terminal that allows insertion of an insertion tab (see Fig. 16) such as a male terminal, but the detailed shape of the connector portion 610 is not particularly limited. In another embodiment of the present invention, instead of the connector portion 610 of the armpit, for example, an insertion tab of a male terminal as shown in Fig. 16 may be provided.
8 and 9, when the cylindrical crimping portion 630 is caulked by a set of pressing molds (for example, the male and female molds 300 described above), the female mold 320 Compressive stress accompanying diameter reduction is concentrated on the wall portion of the tubular press-contact portion 630 at the boundary portion (the portion where the tubular press-contact portion 630 and the male mold 310 are engaged) A pair of necking portions or depressions extending in the terminal length direction is formed on the inner surface of the insulating cover body 102 of the cover wire 100 and a gap is formed between the compression bonding portion 630 and the insulating cover body 102 of the cover wire 100 V) may occur in some cases. The gaps thus formed are continuously formed from the open end of the crimping portion 630 to the front end edge of at least the insulating cover 102 so that the gap between the exposed cores of the crimped portion 630 There is a problem that moisture adheres. In addition, although it is not impossible that the protruding portion 634 itself is not formed, there is a fear of complication of design or manufacturing or deterioration of the pressure bonding property.
19 to 21, at least one protruding portion 634 (at both sides in this embodiment) of at least one (in this embodiment, each of the protruding portions 634 in this embodiment) (Two for the protruding portion 634) are provided. The pressure-receiving portion 635 may be provided by applying an external pressure, for example. 16) of the inner surface of the protruding portion 634 continuously formed in the longitudinal direction X of the cover pressing portion 631 is consequently reduced by the pressure-receiving portion 635 (see Fig. 16) The degree of sealing of the cover crimping portion 631 is improved and the gap between the insulating covering member 102 of the covering wire 100 in the cover crimping portion 631 and the crimping terminal 600 It is possible to reduce moisture intrusion from the inside. Even if a gap is formed between the cover crimping portion 631 and the insulating cover member 102 of the electric wire 100 due to a molding defect of the protrusion 634 in the cover crimping portion 631, It is difficult for moisture from the outside to reach the conductor crimping portion 632 of the crimping portion 630 because it is blocked by the pressing portion 635. [ Such reduction in moisture intrusion is also effective when the wire connecting structure 60 receives thermal load. This is because there is no gap between the crimping portion 630 and the insulating covering body 102 at the initial stage of use and a thermal load is applied to the portion of the cover crimping portion 631 and the wire 100 Even if a gap is formed between the insulating cover body 102, the gap is still blocked at the position of the pressure-receiving portion 635. [
The depth h of the pressure-applied portion 635 is preferably 3% or more and 20% or less of the width (outer diameter) d of the portion where the pressure-applied portion 635 is not formed . This is because when the depth h of the pressure-applying portion 635 is less than 3% of the width d of the cover-contact portion 631, the continuous gap on the inner surface of the projection 634 may not be sufficiently blocked, If the ratio exceeds 20%, uniform compression of the cover crimping portion 631 is not maintained due to the concentration of the load, and a gap is formed between the cover crimping portion 631 and the insulating covering member 102 of the wire 100, This is because there is a possibility of badness.
It is preferable that the pressure-receiving portion 635 is provided at a plurality of positions with respect to one protrusion 635 as shown in the example shown in the drawing. By this, the gaps in the inner surface of the protrusion 635 can be blocked in an overlapping manner, It is possible to compensate the hermeticity as another pressure-receiving portion 635 even if a molding failure occurs in one pressure-receiving portion 635. [
When a plurality of pressure-receiving portions 635 are provided, it is preferable that the distance L between the pressure-receiving portions 634 adjacent to each other in the longitudinal direction X is 0.3 mm or more. This is because, if the spacing distance L is less than 0.3, there is a possibility that the uniform pressure squeezing at the cover press contact portion 631 may not be maintained due to the concentration of the load.
When a plurality of pressure-application pressure portions 635 are provided, it is preferable that the pressure-application pressure portions 635 are evenly arranged in the cover-contact-bonding portion 631 as viewed in the longitudinal direction X. According to this, ) And the insulating cover body 102 of the electric wire 100 can be realized.
When the pressure-receiving portion 635 is provided for the left and right projections 634, the pressure-receiving portions 635 opposed to each other in the width direction Y are provided so that their positions in the longitudinal direction X coincide with each other good.
Next, an example of a manufacturing method of the wire connecting structure 60 having such a structure will be described. First, a predetermined planar shape corresponding to the deployed shape of the compression terminal 630 is punched out from a plate material (a material) of a metal (copper alloy, aluminum alloy, steel or the like) And a box-shaped connector portion 610 and a cylindrical crimping portion 630 are formed by bending. The crimping portion 630 before crimping has an opening diameter capable of inserting the electric wire 100 without difficulty. At this time, since the crimping portion 630 has a C-shape in section in the bending process from a planar shape, the joint is joined by welding so as to have a sealing structure. A preferred welding method is laser welding, in particular laser welding with a fiber laser. Of course, different known welding methods may be used. Alternatively, a cylindrical compression bonding portion 630 may be formed by drilling a solid metal column with a drill or the like, or by drawing a flat metal plate.
Next, the crimping portion is compressed by using a crimping device. Before explanation thereof, a crimping device that can be used in the method of manufacturing the wire connecting structure of the present invention is exemplified.
22 and 23, the compression bonding apparatus 700 used here has a compression mold 752 as a pair of compression molds for pressing the compression bonding portion 630 of the compression bonding terminal 600, The pressing frame 752 includes an anvil 754 receiving the lower surface of the pressing portion 630 and a pressing mechanism for crimping the crimping portion 630 in the diameter reducing direction. ) ≪ / RTI > In addition, in this embodiment, since the shape of the mold is complicated, it is not to be referred to as a two-dimensional metal mold or an armpit metal mold.
The receiving box 754 is provided with a front receiving portion 758 having a substantially U-shaped receiving groove 758a receiving the conductor crimping portion 632 of the crimping portion 630, (Rear) receiving portion 760 having a substantially U-shaped cross section for receiving the first and second receiving portions 631 and 631. The front side receiving portion 758 and the rear side receiving portion 760 may be separate.
The pressing tool 756 includes a front pressing portion 762 for pressing the conductor crimping portion 632 by pressing and a front pressing portion 762 for pressing the cover pressing portion 631 to the rear side And has a pressing portion 764 integrally formed around the longitudinal direction (X). The front pressing portion 762 protrudes toward the receiving receptacle 754 with a convex portion 762a for pressing the conductor crimping portion 632 of the crimping portion 630. The front side pressing portion 762 and the rear side pressing portion 764 may be separate.
The pressing apparatus 700 further includes pressing molds 766 and 768 as pressing molds arranged adjacent to the rear side of the longitudinal direction X of the pressing mold 752. [ In this case, the pressing molds 766 and 768 are provided so as to oppose each other on the left and right sides. However, when the pressure-receiving pressure portion 635 is provided only for one of the protrusions 634, good. In this case, the side of the cover pressing portion 631 on which the pressure-receiving portion 635 is not formed may be supported by a support frame (not shown). Each of the pressing molds 766 and 768 is formed by pressing a protruding portion 634 formed in correspondence with the boundary portion between the rear pressing portion 764 and the rear receiving portion 760 to the plastic press- And two pushing edges 770 each having a substantially V-shaped (or U-shaped) tip. The pressing knobs 770 opposed to each other in the left and right directions (directions orthogonal to the longitudinal direction) are located on the same line.
24, when the crimping portion 630 of the crimping terminal 600 is crimped using the crimping device 700 thus formed, the insulating covering member 102 is peeled off at the wire front end portion, The crimped portion 630 in which the end of the exposed wire 100 is inserted at a predetermined position through the wire insertion opening 630a (FIG. 17) is inserted into the front side receiving portion 758 of the receiving side 754 and the rear side After being received by the receiving portion 760, the receiving portion 754 and the pressing portion 756 are pressed in the vertical direction as shown by the arrows in FIGS. The conductor crimping portion 631 of the crimping portion 630 presses the exposed core wire 101 of the wire 100 and the crimped portion 631 of the crimping portion 630 contacts the wire 100 The insulating cover member 102 is squeezed.
A press contact portion 631 sandwiched between the receiving groove 754 and the pressing groove 756 is formed on the left and right sides of the cover press portion 631 of the press portion 630 by the pressing process of the press portion 630, A protruding portion 634 extending continuously in the longitudinal direction X is formed. The projections 634 located on the left and right sides are formed at angular intervals of about 180 degrees.
After the cover crimping portion 631 is compressed by the crimping frame 752 as described above, the wire connecting structure 60 is automatically closed by a gripping jig or the like not shown in the longitudinal direction (X) (766, 768). The movement and positioning of the wire connecting structure 60 may be performed manually. Thereafter, the pressing molds 766 and 768 opposed to each other in the width direction Y are moved in the direction of the arrow (width direction Y) in Fig. 22 toward the protruding portion 634 of the cover-pressing portion 631, The pressurizing pressure portion 635 can be formed by dugging the protruding portion 770 into the protruding portion 634 of the cover pressing portion 631.
Next, a wire connecting structure according to still another embodiment of the present invention, a method of manufacturing the same, and a pressing mold usable for manufacturing the wire connecting structure will be described with reference to Figs. 25 to 41. Fig. In this embodiment, it is not necessary to form the above-described pressure-applying portion on the projecting portion of the crimping portion, but the wire connecting structure capable of improving the index in the crimping portion, the manufacturing method thereof, and the pressing mold are described. Since the main structures and constituent materials of the crimp terminals and the coated wires described in the above embodiments can be applied to the present embodiment, detailed description is omitted.
25 and 26, the crimp portion 830 of the crimp terminal 800 is pressed against the outer periphery of the front end of the covered wire 100, and the crimp portion 830 of the crimp portion 830 A protrusion 834 is formed on the outer periphery. The coated wire (100) is obtained by covering the core wire (101) with an insulating cover (102). In Fig. 25, the core wire 101 is composed of a plurality of wire strands, but it may be composed of one thick wire (not shown). The thickness of the insulating cover member 102 is, for example, about 0.3 mm.
The crimping terminal 800 integrally includes a connector portion 810 of a box-shaped armrest and a crimping portion 830. The crimping terminal 800 is formed by cutting a plate made of a metal such as copper or a copper alloy into a deployed shape of a terminal and folding the connector portion 810 and the tubular crimping portion 830 of the box- . (See Fig. 16) of another electrical appliance is inserted into the connector portion 810 of the armrest and electrically connected thereto. The pressing portion 830 has one end 830a opened and the other end 830b sealed so that the membrane has a tubular shape. When the crimping portion 830 and the coated electric wire 100 are pressed, the other end 830b may also be pressed. The thickness of the pressing portion 830 is, for example, about 0.25 mm.
The inner surface of the crimping portion 830 is press-bonded to the covered wire 100 by a compression mold as a pair of crimping dies as described later. The tip end portion of the coated wire 100 is inserted from the opening of one end 830a of the crimping portion 830 and the crimping portion 830 and the insulating covering member 102 are compressed in the vicinity of the one end 830a. The crimping portion 830 and the core wire 101 are pressed together in the vicinity of the other end 830b of the crimping portion 830. For example, when the crimping terminal 800 is a metal member or a metal member (plating member) And the core wire portion 101 is formed of an aluminum-based material, the crimping portion 830 and the core wire portion 101 are bonded to each other by dissimilar metals. The moisture can not reach the vicinity of the other end 830b of the inner side of the pressed portion 830 when the gap between the crimped portion 830 and the insulating clad body 102 does not exist, (101) does not occur.
Two projections 834 are provided on the outer periphery of the crimping portion 830. The protruding portion 834 is a portion formed by a relief portion of a mold described later, and the protruding portion 834 extends in the longitudinal direction X of the covered electric wire 100. When the protruding portion 834 is formed in at least a cover crimping portion (near one end 830a of the crimping portion 830) of the crimping portion 830 to be pressed to the insulating covering member 102 of the covering wire 100 good. If there is no clearance between the crimping portion 830 and the insulating covering member 102, water does not enter the inside of the crimping portion 830 and no electric current is generated.
Further, when a plurality of dies are arranged in the longitudinal direction X of the coated wire 100, the positions of the protrusions 834 may be changed by the mold. The projecting portion 834 may be somewhat changed in shape or size in the cover crimping portion 831 of the coated wire 100 and the conductor crimping portion 832 pressed on the core wire 101 of the crimping portion 830 , And may have a step as in the above-described embodiment (see Fig. 15).
As shown in Figs. 26 and 27, when the shape of the projecting portion 834 is seen in the cross section perpendicular to the longitudinal direction X of the covered electric wire 100, the projecting portion 834 has a shape in which the angled portion protrudes. The angle? 1 of the tip (apex) of the protrusion 834 formed by the two straight lines L1 and L2 constituting the outer surface of the protrusion 834 is an obtuse angle. By making the obtuse angle, the followability of the insulating covering member 102 with respect to the crimping portion 830 is improved. The angle? 1 of the protruding portion 834 in the present invention is preferably set appropriately in accordance with the size of the crimping portion 830 and the protruding portion 834 or the like. In addition, in the present description, the obtuse angle includes 90 degrees, and the acute angle does not include 90 degrees.
As shown in Fig. 28, the tip of the protrusion 834 may be rounded, or may have a trapezoidal tip with a flat tip as shown in Fig. 29, and may not have a protruding angled portion. Therefore, the two straight lines L1 and L2 are formed from the intersections P1 and P2 between the outer periphery of the pressed portion 16 and the outer surface of the protruding portion 834. 28, when two straight lines L1 and L2 extending along the outer surface of the projecting portion 834 are extended through the intersections P1 and P2, they intersect in the same way as in Fig. 27, and the angle? Obtuse angle. The change from the pressing portion 830 to the protruding portion 834 becomes gentle and the followability of the insulating covering member 102 to the pressing portion 830 is good.
29, the shape of the protruding portion 834 in the case of the cross section perpendicular to the longitudinal direction X is a shape free of protruding angular portions. However, even in the shape of the protruding portion 834, When the two straight lines L1 and L2 formed from the intersections P1 and P2 with the outer periphery of the pressing portion 830 on the outer surface of the protruding portion 834 are intersected with each other, 1) is set to an obtuse angle.
Basically, the outer shape of the protrusion 834 is formed by the straight lines L1 and L2, but the outer shape of the protrusion 834 may be formed only as a curved surface as shown in FIG. In this case, the contour of the protruding portion 834 is received from the straight lines L1 and L2 extending from the intersecting points P1 and P2 toward the pressing portion 830 side. That is, when two imaginary straight lines L1 and L2 intersecting each other at an obtuse angle are drawn on the outside of the pressed portion 830 through the intersecting points P1 and P2, the protruding portion 834 is divided into two straight lines L1 and L2 In the virtual area surrounded by the virtual area. The angle? 1 of the intersection of the straight line L1 and the straight line L2 is an obtuse angle and is the same as in FIGS.
When the shape of the projecting portion 834 is viewed from a cross section perpendicular to the longitudinal direction X of the coated wire 100, it can be seen that (A) one projecting portion 834 In the case where the straight lines L1 and L2 are formed from the intersections P1 and P2 of the outer periphery of the pressing portion 830 and the outer surface of the projecting portion 834, The outer shape of the protrusion 834 enters the side of the bonded portion 830 from the straight lines L1 and L2. The outer shape of the projecting portion 934 may coincide with the straight lines L1 and L2 or may not coincide with the straight lines L1 and L2.
On the other hand, when the angle? 1 formed by the straight lines L1 and L2 is an acute angle as shown in FIG. 31, the change from the pressed portion 830 to the protruded portion 834 becomes urgent, The followability of the body 102 deteriorates. A gap V is formed between the crimping portion 830 and the insulating cover member 102. [ The gap V extends continuously in the longitudinal direction X. Moisture tends to penetrate from the one end 830a of the pressed portion 830 to the inside of the pressed portion 830 after passing through the gap V. [ When moisture penetrates and comes into contact with the contact point between the core wire portion 101 and the crimping terminal 800, the dissimilar metals are transferred to each other. Therefore, in the present invention, by setting the angle [theta] 1 to an obtuse angle, intrusion of moisture is reduced.
When the angle? 1 is an acute angle, the gap between the first mold 852 and the second mold 854 enters the middle of the formation of the protrusion 834, and an irregular burr is generated . When this bur is formed, there is a fear that a gap V may be formed between the crimp portion 830 and the insulating cover member 102 due to breakage of the protrusion 834 or the like. The burr formed is irregular, and when the connector (Fig. 13) is formed, a predetermined connector can not be formed. If the angle? 1 is acute, the leading end of the projecting portion 834 is likely to be broken and the shape of the projecting portion 834 is not fixed even if there is no burr, so that a predetermined connector can not be formed. In order to make the angle? 1 obtuse, the intersection of the straight lines L3 and L4 of the pressing mold 850 as a pair of the pressing molds in FIGS. 33 and 34, which will be described later, ) On the straight line L4 side than a horizontal line not shown. In other words, the intersection point of the straight lines L3 and L4 in Fig. 34 is arranged above the straight line L3. In this case, the force (drag force) that the crimp terminal 800 receives from the straight line L3 portion of the second mold 854 at the time of pressing is directed to the direction of the inner space. That is, the terminal is prevented from dug into the gap between the first mold 852 and the second mold 854, and when the protrusion 834 is formed, irregular burrs do not occur to the outside.
The wire connecting structure 80 formed by connecting the crimping terminal 800 and the covering wire 100 is arranged so that the ends of the plate material when the crimping portion 830 has a tubular shape and the other end 830b may be welded. By welding, the crimping portion 830 is formed into a completely tubular shape (a shape which is a closed end surface surrounding the covered electric wire 100 in a cross section perpendicular to the longitudinal direction X). As the welding, laser welding using a fiber laser can be mentioned, but it is not limited to use of a fiber laser or laser welding.
As shown in Figs. 33 and 34, a pair of compression molds 850 as compression molds for pressing the crimping terminal 800 and the coated electric wire 100 are provided with a first mold 852 and a second mold 854, Respectively. The first mold 852 and the second mold 854 are provided with recesses 856 and 858, respectively. The shape of the surface on which the concave portions 856 and 858 are formed is a shape in which the crimped terminal 800 and the covered electric wire 100 are sandwiched between the first metal mold 852 and the second metal mold 854, . 33 and 34, the external shape of the compression bonding terminal 800 (except for the protrusion 834) is formed to be substantially circular by the recesses 856 and 858.
The concave portion 856 of the first mold 852 is deeper than the concave portion 858 of the second mold 852 and the space formed by the concave portion 856 of the first mold 852, (Not shown). The coated wire 100 is inserted into the crimping portion 830 and the crimping portion 830 or the like is inserted into the concave portion 856 of the first mold 852 and further the second mold 854 is inserted into the concave portion 856 of the first mold 852. [ Is inserted into the concave portion 854 of the side plate 852 and pressed. In the concave portion 856 of the first mold 852, the portion that is in contact with the compression bonding portion 830 is located inside the relief portion 860.
A relief portion 860 is provided at the connection portion (boundary portion) between the first mold 852 and the second mold 854. The relief portion 860 is a portion where the force applied to the pressing portion 830 is reduced when pressed and is formed by a small recessed portion with respect to each of the recessed portions 856 and 858. [ The crimped portion 830 and the covered wire 100 are compressed and the crimped portion 830 is pushed into the relief portion 860 to form the protruded portion 834. [ At this time, a part of the insulating covering member 102 may also enter the relief portion 860. [
When the relief portion 860 is viewed in a cross section perpendicular to the longitudinal direction X of the coated wire 100, the shape of the relief portion 860 is triangular. The angle 2 formed by the two straight lines L3 and L4 coinciding with the surface forming the relief portion 860 is an obtuse angle. The angle [theta] 2 is the same as the angle [theta] 1, and the protrusion 834 as described above can be formed. The size of the relief portion 860 is appropriately changed due to the size of the crimping portion 830 or the covered wire 100 and the size of the protrusion 834 is changed accordingly.
28 and 29, when the relief portion 860 is viewed from a vertical plane with respect to the longitudinal direction X of the coated wire 100, the tip of the relief portion 860 may be rounded, or the relief portion 860 may be rounded. May be a polygonal shape such as a trapezoidal shape. Further, as shown in Fig. 35, a curved line may be formed in addition to the tip of the relief portion 860. [ Although the straight line L3 in Fig. 34 is a curved line in Fig. 35, the straight line L4 may also be a curved line.
(A) In one relief portion 860, when the mold 850 is viewed from the vertical plane of the coated wire 100 with respect to the longitudinal direction X of the covered wire 100, In the case where straight lines L3 and L4 are formed from the intersections P3 and P4 between the surfaces forming the portions 856 and 858 and the surface forming the relief portion 860, (B) the surface on which the relief portion 860 is formed extends from the straight lines L3 and L4 toward the concave portions 854 and 856 (the concave portions 854 and 856) (The space 862 side formed by the first and second electrodes 856 and 856). The surface forming the relief portion 860 may be coincident with or not coincident with the straight lines L3 and L4.
The concave portion 856 of the first mold 852 gradually widens from the relief portion 860 toward the opening 864. This is because the protruding portion 834 protrudes from the crimping portion 830 and the wire connecting structure 80 after the crimping is taken out from the first mold 852.
The wire connecting structure 80 is manufactured in the following order (1) to (3). (1) As shown in Figs. 36 and 37, the insulating cover body 102 of the front end portion of the covered electric wire 100 is removed, the tip of the covered electric wire 100 is inserted into the pressed portion 830, As well as above the concave portion 858 of the second mold 854. 36 and 37, the other end 830b of the crimping portion 830 is closed, but may be closed at the time of pressing using the mold 850. [
(2) The first mold 852 is driven to put the above-mentioned crimping portion 830 or the like and the second mold 854 into a space formed by the recess 856 of the first mold 852, The crimped portion 830 and the coated electric wire 100 are compressed by the mold 852 and the second mold 854. A part of the pressing portion 830 is pushed into the relief portion 860 at the time of pressing so as to become the protruding portion 834. [
(3) As shown in Fig. 39, the first mold 852 is removed from the second mold 854. On the concave portion 858 of the second mold 854, a wire connecting structure 80 is formed and picked up by a robot arm or the like. Further, if necessary, the end and the other end 830b of the copper strip constituting the pressing portion 830 are welded. A wire harness can be formed by forming a connector (see Fig. 13) by arranging the wire connecting structures 80 in the required number.
In the above (1) to (3), the first mold 852 may be driven, but the second mold 854 may be driven. As shown in Fig. 40, a compression bonding portion 830 in which the covered electric wire 100 is inserted is disposed in a space formed by the recess 856 of the first mold 852. [ As shown in Fig. 41, the second mold 854 is inserted into the space, and is compressed. The second mold 854 is removed from the first mold 852 and the wire connecting structure 80 remaining in the recess 856 of the first mold 852 is taken out. When the molds are pressed and separated from each other, the wire connecting structure 80 is left in the stopped metal mold. Thus, the wire connecting structure 80 is manufactured.
As described above, according to the present invention, by making the angle [theta] 1 of the vertex of the protruding portion 834 formed on the outer periphery of the crimping portion 830 obtuse, the insulating cover of the covered wire 100 The followability of the outer periphery of the sieve is good. A gap is not formed between the crimping portion 830 and the insulating covering member 102, and invasion of water or dust from the outside can be prevented. The moisture or the like can not reach the connection portion between the crimping portion 830 and the core wire 101, and the electromotive force can be prevented.
Although the embodiments of the present invention have been described above, the present invention is not limited to the above embodiments. For example, the relief portion 860 is provided at the connection portion between the first mold 852 and the second mold 854 as shown in Figs. 33 and 34, but the relief portion 860 may be provided at another portion, The number of the relief portions 860 is not limited to two. The relief portion 860 may be provided on either the first mold 852 or the second mold 854. [ When the position or number of the relief portion 860 is changed, the position or number of the protrusion 834 is changed accordingly.
In the above embodiment, the one end 830a of the crimping portion 830 is opened and the other end 830b is closed. However, both ends 830a and 830b may be opened. It can be used in places where it is not necessary to pay attention to the adhesion of moisture and the like. In this case, the other end 830b may be sealed with a resin. The outer shape (excluding the protruding portion 834) of the pressing portion 830 is not limited to a circular shape, but may be flat or polygonal.
Although the dissimilar metal connection of the aluminum-based material and the copper-based material has been described as an example, other metal materials may be used. The connection structure of the present invention is not limited to the one used for the dissimilar metal connection, and may be a connection of the same kind of metal material. It may be used for connecting the core wire 101 and the compression bonding terminal 800 between the copper-based materials as in the prior art.
In addition, the matters described in all of the above embodiments can be freely combined with each other appropriately. For example, the pressure-receiving portions 235 and 635 shown in Figs. 2 and 17 may be formed on the projecting portion 834 of the crimping portion 830 of the wire connecting structure 80 shown in Fig. , The index can be further increased. Similarly, at the protruding portions 234 and 634 of the crimping portions 230 and 630 shown in Figs. 2 and 17, the tips of the protruding portions 234 and 634 may be formed at an obtuse angle, have.
Example
Next, the wire connecting structures (Examples 1 to 5) and the wire connecting structures (Comparative Examples Samples 1 to 5) as comparative examples according to the present invention were made by a test and performance tests were conducted on each sample. do.
(Example)
Example 2 A copper alloy material FAS-680 (manufactured by Furukawa Denki Kogyo Co., Ltd., Ni: 2.3% by mass, Si: 0.6% by mass, 17, and 18 were used, using Sn: 0.15%, Zn: 0.5%, Mg: 0.1%, and the balance: Cu and unavoidable impurities). An Al-Mg-Si-based aluminum alloy wire (wire diameter 0.43 mm) was used for the electric wire. The diameter of the core wire is 2.1mm, the outer diameter of the wire is 2.8mm, and the length of the wire is 30cm. The end of the wire exposed with the core wire was inserted into the crimping portion of the crimp terminal, and the crimp portion of the crimp terminal was pressed by the crimping frame shown in Figs. The compression ratio at this time (the ratio of the cross-sectional area after compression to the cross-sectional area before compression) was 70%. As a result, protrusions extending in the longitudinal direction were formed on the right and left sides of the cover-pressed portion. Thereafter, two points of each projecting portion were locally pressed using a nipper blade tip to form a pressure-receiving portion. The depth of the pressure-receiving portion was 0.2 mm, and the distance between the pressure-receiving portions formed on the same projection was 1.5 mm.
(Comparative Example)
COMPARATIVE EXAMPLES The wire connecting structures of Samples 1 to 5 were formed by crimping a crimping portion using a crimping device in the same manner as in the Example Samples and forming projections extending to the entire length of the crimping portion on the left and right sides of the crimping portion It is. Comparative Example The wire connecting structure of samples 1 to 5 was not provided with the pressure-applying portion, and the other configurations were the same as those of the wire connecting structure of Examples 1 to 5.
(Confirmation test for airtightness)
Air tightness test (30 minutes at -40 占 폚, 30 占 폚 at 120 占 폚 for 30 minutes at room temperature) Min for 240 cycles) and a high-temperature test (120 hours at 120 占 폚), and then the holding pressure of the air was measured.
As a result of the test, both of the samples of the examples and the comparative example were kept at 50 kPa as the initial average value. However, in the average value after the thermal shock and the high temperature storage, the wire connecting structure of the sample of Example was maintained at 50 kPa, , And the holding pressure dropped to 1 kPa. Thus, it has been confirmed that the application of the present invention improves the hermeticity of the wire connecting structure.
1, 60, 80: wire connection structure
11: Female connector
12: Housing for female connector
21: Suttle connector
22: Socket connector housing
100: Coated wire
101: core wire
102: Insulation covering body
200, 400, 500, 600, 800:
230, 430, 530, 630, 830: a crimping portion (barrel portion)
233:
234, 634, 834:
235, 635: pressure-receiving portion (drawing portion, pressing portion)
300: A pair of male and female molds (one set of compression molds)
700: Crimping device
752: Crimping frame (1 set of pressing mold)
850: Press mold
860: relief part
X: Longitudinal direction
Y: width direction

Claims (16)

  1. A coated wire covered with an insulating insulating covering body of a conductive core wire portion,
    And a terminal having a crimp portion connected to the core wire portion exposed at a predetermined length in the longitudinal direction of the coated wire from the tip end of the insulating cover and the vicinity of the tip end of the insulating cover,
    A wire connecting structure for crimping and connecting a crimped portion of a terminal and a covered wire with a pair of crimping dies,
    Wherein the crimping portion has a sectional shape perpendicular to the longitudinal direction is a closed end surface shape surrounding the covering wire and in a state in which the crimping portion and the covering wire are compressed, Each having a protrusion at a portion corresponding to the protrusion,
    Wherein at least one of the projecting portions is provided with at least one pressing portion.
  2. The wire connecting structure according to claim 1, wherein a plurality of the pressure-applying portions are provided at predetermined intervals along the projecting portion.
  3. The wire connecting structure according to claim 2, wherein the predetermined interval is 0.3 mm or more.
  4. The wire connection structure according to claim 2 or 3, wherein a plurality of the press-contact pressure portions are evenly arranged on the projecting portion.
  5. The wire connecting structure according to any one of claims 1 to 4, wherein the depth of the pressure-receiving portion is not less than 3% and not more than 20% of an outer diameter of the portion where the pressure-applying portion is not formed.
  6. The pressure-sensitive adhesive sheet according to any one of claims 1 to 5, wherein a cross-sectional shape perpendicular to the longitudinal direction of the pressure-sensitive portion is formed in a cross-sectional protruding shape in which an inner surface of the pressure-sensitive portion protrudes toward the center of the insulating cover One wire connection structure.
  7. 7. The wire connection structure according to any one of claims 1 to 6, wherein the press-contact pressure portion is provided at both portions corresponding to the two boundary portions of the pair of press molds in the crimping portion.
  8. A coated wire covered with an insulating insulating covering body of a conductive core wire portion,
    And a terminal having a crimp portion connected to a vicinity of the tip of the insulation covering body and the core wire portion exposed in a predetermined length in the longitudinal direction of the covering conductor from the tip end of the insulating cover body,
    A wire connecting structure for crimping and connecting a crimped portion of a terminal and a covered wire with a pair of crimping dies,
    The angle formed by intersection of the line of the outer periphery of the crimped portion and the line of the outer surface of the protruding portion at the intersection of the line of the outer surface of the protruded portion and the tangential line of the outer surface of the protruded portion is obtuse, Wherein the wire connecting structure is formed with a plurality of through holes.
  9. The sealing member according to any one of claims 1 to 8, further comprising a sealing portion (sealing portion) which extends in the longitudinal direction and which seals the front end in the longitudinal direction, And a wire connecting structure.
  10. 10. The wire connecting structure according to any one of claims 1 to 9, wherein the core wire portion is made of an aluminum-based material, and at least the crimping portion is made of a copper-based material.
  11. 11. The wire connecting structure according to any one of claims 1 to 10, wherein the crimping portion has a structure in which a plate material is formed into a tubular shape and the joint is sealed by welding.
  12. 12. The wire connecting structure according to any one of claims 1 to 11, wherein the crimping portion of the terminal has at least two portions different in diameter from each other, and a portion with a larger diameter is disposed at the wire insertion port side.
  13. A connector in which the wire connecting structure according to any one of claims 1 to 12 is arranged in a connector housing.
  14. A core wire which is exposed at a predetermined length in a longitudinal direction of the coated wire from a tip end of the insulating cover and which is connected to a vicinity of a tip end of the insulating cover body, Wherein the crimping portion of the terminal and the covering wire are pressed and connected by a pair of crimping dies, the method comprising the steps of:
    Wherein the crimping portion and the covering wire are crimped by using a terminal having a sectional shape perpendicular to the longitudinal direction of the crimping portion and enclosing the covering wire so as to form a boundary between the pair of crimping dies A protruding portion is formed at a portion corresponding to the portion,
    And the pressure-applying portion is formed on at least one of the projections.
  15. A core wire which is exposed at a predetermined length in a longitudinal direction of the coated wire at a tip end of the insulating cover body and which is connected to the vicinity of the tip end of the insulating cover body, Wherein the crimping portion of the terminal and the covering wire are pressed and connected by a pair of crimping dies, the method comprising the steps of:
    An angle formed by intersection of a tangent line of the outer surface of the projecting portion at the intersection of the line of the outer periphery of the projected portion and the line of the outer surface of the projected portion is obtuse at the vertical surface with respect to the longitudinal direction of the coated wire, Wherein said wire connection structure is formed by a method comprising the steps of:
  16. A compression mold for placing a covered wire inside a crimped portion of a terminal and pressing the crimped portion and the core wire of the covered wire and the insulating cover,
    A first mold and a second mold having recesses for fitting and pressing the crimping portion and the covering wire,
    And a relief portion which is provided on at least one of the first mold and the second mold and at least a part of the crimped portion enters during the pressing,
    The angle formed by the intersection of the straight line formed at the intersection of the formation surface of the concave portion and the formation surface of the relief portion is an obtuse angle and a relief portion is formed from the straight line to the concave portion side in a cross section perpendicular to the longitudinal direction of the coated wire Wherein the metal mold is a metal mold.
KR1020147021886A 2013-02-19 2014-01-08 Electric wire connecting structure, a method of manufacturing the electric wire connecting structure, a connector comprising the electric wire connecting structure and a crimp die KR20150120846A (en)

Priority Applications (7)

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JP2013030350 2013-02-19
JPJP-P-2013-030350 2013-02-19
JP2013033857 2013-02-22
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JP2013034019 2013-02-23
JPJP-P-2013-034019 2013-02-23
PCT/JP2014/050167 WO2014129220A1 (en) 2013-02-19 2014-01-08 Electric wire connection structure, method for manufacturing said electric wire connection structure, connector provided with said electric wire connection structure, and crimping die

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CN104126252A (en) 2014-10-29
JPWO2014129220A1 (en) 2017-02-02
JP5625136B1 (en) 2014-11-12
JP5654161B2 (en) 2015-01-14
CN104126252B (en) 2018-05-08
JP2014187045A (en) 2014-10-02

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