WO2009102074A1 - Press-clamping terminal and crimped structure using the press-clamping terminal - Google Patents

Press-clamping terminal and crimped structure using the press-clamping terminal Download PDF

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Publication number
WO2009102074A1
WO2009102074A1 PCT/JP2009/052601 JP2009052601W WO2009102074A1 WO 2009102074 A1 WO2009102074 A1 WO 2009102074A1 JP 2009052601 W JP2009052601 W JP 2009052601W WO 2009102074 A1 WO2009102074 A1 WO 2009102074A1
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WO
WIPO (PCT)
Prior art keywords
press
clamping
conductor
bottom plate
terminal
Prior art date
Application number
PCT/JP2009/052601
Other languages
French (fr)
Inventor
Yasumichi Kuwayama
Tadahisa Sakaguchi
Original Assignee
Yazaki Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Yazaki Corporation filed Critical Yazaki Corporation
Publication of WO2009102074A1 publication Critical patent/WO2009102074A1/en

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-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
    • H01R4/10—Electrically-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
    • H01R4/18—Electrically-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
    • H01R4/183—Electrically-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 for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H01R4/184—Electrically-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 for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-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
    • H01R4/10—Electrically-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
    • H01R4/18—Electrically-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
    • H01R4/183—Electrically-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 for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H01R4/184—Electrically-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 for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
    • H01R4/185—Electrically-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 for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion combined with a U-shaped insulation-receiving portion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-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
    • H01R4/10—Electrically-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
    • H01R4/18—Electrically-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
    • H01R4/188—Electrically-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 having an uneven wire-receiving surface to improve the contact
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-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
    • H01R4/58—Electrically-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
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors

Definitions

  • the present invention relates to a press-clamping terminal suitable for press-clamping connection to an aluminum electric wire having a conductor made of aluminum or an aluminum alloy , as well as a crimped structure using this press-clamping terminal.
  • press-clamping is a method wherein a conductor of an electric wire (such as a conductor exposed from one end of an electric wire) is positioned on a conductor press-clamping portion provided in a terminal body, and the conductor press-clamping portion is crimped by a crimping jig or the like so as to be wrapped around this conductor to thereby effect connection between the electric wire and the terminal body.
  • a terminal is generally called a press-clamping terminal.
  • Fig. 6 is an explanatory diagram of a - method of crimping a press-clamping terminal onto an electric wire, which method is generally known from patent document 1 and the like.
  • Fig. 7 is a cross-sectional view of a portion of this press-clamping terminal which is crimped onto the electric wire.
  • reference numeral 110 denotes a press-clamping terminal
  • 100 denotes an electric wire
  • reference numerals 131 and 132 respectively denote a lower die and an upper die of a crimping jig.
  • the press-clamping terminal 110 has an electrical connection portion
  • a terminal body 110a of this press-clamping terminal 110 so as to be electrically connected to a mating terminal or the like; a covering press-fastening portion 114 disposed at the other end portion thereof in the front-back direction so as to crimp a portion of the electric wire having a covering portion 100b, and a conductor press-clamping portion 113 disposed in an intermediate portion thereof in the front-back direction so as to crimp a conductor 100a exposed at the one end portion of the electric wire 100.
  • the covering press-fastening portion 114 and the conductor press-clamping portion 113 are respectively provided so as to extend from both ends in the left-right direction of a bottom plate portion 111 of the terminal body 110a.
  • the conductor press-clamping portion 113 includes a pair of conductor crimping pieces 113a formed so as to be erected upward from both ends in the left-right direction of an intermediate portion of the bottom plate portion 111 , and a portion of the bottom plate portion 111 which is sandwiched by the pair of conductor crimping pieces 113a.
  • a plurality of grooves (i.e., shallow grooves linearly stamped by a press) 113b are provided on an inner surface of this conductor press-clamping portion 113 so as to extend in the left-right direction.
  • the covering press-fastening portion 114 has a pair of covering crimping pieces 114a which are formed so as to be erected upward from both end portions in the left-right direction of the other end portion of the bottom plate portion 111 , and a portion of the bottom plate portion 111 which is sandwiched by the pair of covering crimping pieces 114a.
  • the conductor press-clamping portion 113 and the covering press-fastening portion 114 are disposed at a predetermined interval therebetween in the front-back direction.
  • the press-clamping terminal 110 is placed on a placing surface 131a of the lower die 131 , and the conductor 100a is placed on the bottom plate portion 111 so as to be disposed between the conductor crimping pieces 113a of the conductor press-clamping portion 113.
  • the leading end portion sides of the conductor crimping pieces 113a are gradually bent toward the inner side by slanting guide surfaces 132a of the upper die 132, and leading ends of the conductor crimping pieces 113a are finally rounded so as to be turned back toward the conductor 100a side by curved surfaces continuing from the slanting guide surfaces 132a to a ridge-shaped portion 132b.
  • the conductor crimping pieces 113a are crimped so as to be wrapped around the conductor 100a.
  • the covering press-fastening portion 114 prior to the crimping of the conductor press-clamping portion 113, the covering press-fastening portion 114 is crimped in advance onto the portion of the aluminum electric wire 100 having the insulative covering 100b in the same way as described above.
  • the conductor press-clamping portion 113 is crimped onto the conductor 100a of the electric wire 100 by crimping the conductor crimping pieces 113a, the electrically conductive metal making up the terminal body 110a and the conductor 100a of the electric wire 100 are adhered to each other (are bonded at the molecular or atomic level), so that the press-clamping terminal 110 and the electric wire 100 can be firmly bonded electrically and mechanically.
  • Patent Document 2 a method is conventionally known in which a softer metallic powder (tin, zinc, etc.) than the material of the strands is applied in advance on the portion of the strands (conductor) to be crimped, and press-clamping is effected, whereby the metallic powder is deformed by the impact at the time of press-clamping so as to fill the gaps between the strands with the metallic powder while being made to adhere to the surfaces of the strands.
  • a softer metallic powder titanium, zinc, etc.
  • the invention has been devised in view of the above-described circumstances, and its object is to provide a press-clamping terminal which allows only a necessary portion of the terminal body to metallically elongate easily during the press-clamping connection, whereby the press-clamping terminal is not excessively crimped, and the adhesion with the conductor by press-clamping can be promoted and improvement of the electrical connection performance can be attained while avoiding unexpected deformation.
  • a press-clamping terminal comprising: a terminal body having a bottom plate portion, the terminal body comprised of an electrically conductive metal; and a conductor press-clamping portion having a pair of conductor crimping pieces which are provided at both end portions of the bottom plate portion in a direction intersecting a longitudinal direction of the terminal body for conducting press-clamping connection between a conductor of an electric wire and the terminal body, wherein an opening is provided in at least one of two portions of the bottom plate portion, the two portions being respectively located on both sides of a portion of the bottom plate portion positioned between the pair of conductor crimping pieces in the longitudinal direction; and wherein the opening absorbs a metallic elongation in the longitudinal direction due to a pressurizing force during the press-clamping connection.
  • At least one groove is provided on the portion of the bottom plate portion positioned between the pair of conductor crimping pieces so as to extend in a direction intersecting the longitudinal direction.
  • the at least one groove extends until parts of the pair of conductor crimping pieces.
  • the opening is smaller in a width in the direction intersecting the longitudinal direction than the groove.
  • the opening is formed as a rectangular slit.
  • a width of the slit in the direction intersecting the longitudinal direction is greater than a width of the slit in the longitudinal direction.
  • the opening is formed as a U-shaped slit.
  • An orientation of the slit is set so that an open side of the U-shaped slit faces the portion of the bottom plate portion positioned between the pair of conductor crimping pieces.
  • the conductor press-clamping portion is arranged at an intermediate portion of the terminal body in the longitudinal direction.
  • An electrical connection portion for being electrically connected to a mating terminal is provided at one end portion of the terminal body in the longitudinal direction.
  • a covering press-fastening portion for fixing the electric wire to the terminal body by crimping a covering portion of the electric wire is provided at another end portion of the terminal body in the longitudinal direction.
  • a first gap is provided between the electrical connection portion and the conductor press-clamping portion.
  • a second gap is provided between the covering press-fastening portion and the conductor press-clamping portion.
  • an opening is provided in at least one of both sides in the front-back direction (longitudinal direction ) of the bottom plate portion of the conductor press-clamping portion.
  • the bottom plate portion can be made to mechanically elongate easily in the front-back direction during the press-clamping connection. If the bottom plate portion of the conductor press-clamping portion is made to metallically elongate easily in the front-back direction, the destruction of the oxidized film on the surface of the bottom plate portion is promoted by this elongation.
  • the oxidized film is efficiently broken by using the groove as a starting point, so that the electrical connection performance can be enhanced further.
  • the bottom plate portion of the conductor press-clamping portion can be made to metallically elongate easily in a wide range in the left-right direction. Furthermore, in this case, if the width in the front-back direction of the slit is made as practically small as possible within a range which is capable of sufficiently absorbing the elongation of the bottom plate portion, it is possible to minimize the decline in the strength of the bottom plate portion caused by the provision of the slit.
  • the press-clamping terminal having the configuration of item (4) above, since a U-shaped slit is provided as the opening, and the orientation of the slit is set such that an open side of the letter U of the slit faces a side of the conductor press-clamping portion, the portion surrounded by the U-shaped slit remains as a tongue piece in such a form as to continue to the bottom plate portion of the conductor press-clamping portion. Therefore, the bottom plate portion of the conductor press-clamping portion is elongated in the front-back direction in a state in which the conductor is placed on that tongue piece during the press-clamping connection, so that it is possible to attain greater enlargement of the contact area.
  • the opening can be provided in a form which does not affect the electrical connection portion and the covering press-fastening portion, so that the performance of the press-clamping terminal is not impaired.
  • a crimped structure in which the conductor press-clamping portion of the press-clamping terminal according to any one of items (1) to (5) above is crimped so as to be electrically connected to the conductor of the electric wire, wherein the conductor press-clamping portion is crimped to the conductor of the electric wire in a condition that the bottom plate portion is metallically elongated toward the opening by a pressurizing force.
  • the electric wire is an aluminum electric wire having a conductor comprised of aluminum or an aluminum alloy.
  • the terminal body is formed of copper or a copper alloy. Tin is plated on a surface of the terminal body.
  • the press-clamping operation can be carried out without applying an excess burden to the conductor made of aluminum or an aluminum alloy which is inferior in strength and ductility as compared to the conductor made of copper.
  • the terminal body which is made of copper or a copper alloy whose surface is tin plated, it is possible to enhance the adhesiveness between the tin on the surface of the terminal body and the conductor of the aluminum electric wire, thereby making it possible to attain improvement of the electrical connection performance.
  • the tin on the surface of the terminal body fills the gaps between the strands while adhering to the surfaces of the strands making up the conductor owing to the press-clamping connection, it is possible to enlarge the areas of contact between the strands and between the stands and the terminal, thereby making it possible to attain a reduction of contact resistance.
  • tin is a softer metal than copper or a copper alloy.
  • the press-clamping terminal is not excessively crimped, and the adhesion with the conductor by press-clamping can be promoted and improvement of the electrical connection performance can be attained while avoiding unexpected deformation.
  • FIG. 1 is a perspective view illustrating the configuration of a press-clamping terminal according to an embodiment of the invention.
  • Figs. 2(a) and 2(b) are plan views of essential portions of the press-clamping terminal according to a first embodiment, in which Fig. 2(a) is a diagram illustrating a state before press-clamping, and Fig. 2(b) is a diagram illustrating a state after press-clamping.
  • Figs. 3(a) and 3(b) are plan views of essential portions of the press-clamping terminal according to a second embodiment, in which Fig. 2(a) is a diagram illustrating a state before press-clamping, and Fig. 2(b) is a diagram illustrating a state after press-clamping.
  • Figs. 4(a) to 4(c) are diagrams illustrating a change in the contact surface between a conductor and a terminal during press-clamping in the case of a comparative example in which openings are not provided in front and rear of a bottom plate portion of a conductor press-clamping portion, in which Fig. 4(a) is a schematic cross-sectional view illustrating a state before press-clamping, Fig. 4(b) is a schematic cross-sectional view illustrating a state during an initial stage of press-clamping, and Fig. 4(c) is a schematic cross-sectional view illustrating a state during a later stage of press-clamping.
  • Figs. 5(a) to 5(c) are diagrams illustrating a change in the contact surface between the conductor and the terminal during press-clamping in the case of the embodiment of the invention in which the openings are respectively provided in front and rear of the bottom plate portion of the conductor press-clamping portion, in which Fig. 5(a) is a schematic cross-sectional view illustrating a state before press-clamping, Fig. 5(b) is a schematic cross-sectional view illustrating a state during an initial stage of press-clamping, and Fig. 5(c) is a schematic cross-sectional view illustrating a state during a later stage of press-clamping.
  • Fig. 6 is a diagram explaining a commonly employed method of press-clamping a press-clamping terminal onto an electric wire.
  • Fig. 7 is a cross-sectional view of a crimped portion thereof.
  • Fig. 1 is a perspective view illustrating the configuration of a press-clamping terminal according to an embodiment of the invention.
  • Figs. 2(a) and 2(b) are plan views of essential portions of the press-clamping terminal according to a first embodiment, in which Fig. 2(a) is a diagram illustrating a state before press-clamping, and Fig. 2(b) is a diagram illustrating a state after press-clamping.
  • Figs. 3(a) and 3(b) are plan views of essential portions of the press-clamping terminal according to a second embodiment, in which Fig. 2(a) is a diagram illustrating a state before press-clamping, and Fig. 2(b) is a diagram illustrating a state after press-clamping.
  • Figs. 4(a) to 4(c) are diagrams illustrating a change in the contact surface between a conductor and a terminal during press-clamping in the case of a comparative example in which openings are not provided in front and rear of a bottom plate portion of a conductor press-clamping portion, in which Fig. 4(a) is a schematic cross-sectional view illustrating a state before press-clamping, Fig. 4(b) is a schematic cross-sectional view illustrating a state during an initial stage of press-clamping, and Fig. 4(c) is a schematic cross-sectional view illustrating a state during a later stage of press-clamping.
  • Figs. 4(a) is a schematic cross-sectional view illustrating a state before press-clamping
  • Fig. 4(b) is a schematic cross-sectional view illustrating a state during an initial stage of press-clamping
  • Fig. 4(c) is a schematic cross-sectional view illustrating a state during
  • FIGS. 5(a) to 5(c) are diagrams illustrating a change in the contact surface between the conductor and the terminal during press-clamping in the case of the embodiment of the invention in which the openings are respectively provided in front and rear of the bottom plate portion of the conductor press-clamping portion, in which Fig. 5(a) is a schematic cross-sectional view illustrating a state before press-clamping, Fig. 5(b) is a schematic cross-sectional view illustrating a state during an initial stage of press-clamping, and Fig. 5(c) is a schematic cross-sectional view illustrating a state during a later stage of press-clamping.
  • reference character W denotes an aluminum electric wire
  • reference numeral 10 denotes a press-clamping terminal which is connected to a terminal of the electric wire W.
  • the aluminum electric wire W is constructed such that an outer periphery of a conductor Wa in which a plurality of strands made of aluminum or an aluminum alloy are twined is covered with an insulative covering Wb which surrounds it in the circumferential direction of the aluminum electric wire W. At one end portion of the aluminum electric wire W, the covering Wb is removed over a predetermined length to expose the conductor Wa, and the press-clamping terminal 10 is crimped onto this one end portion.
  • the aluminum alloy it is possible to cite an alloy of aluminum and iron. In the case where this alloy is adopted, as compared with a conductor made of aluminum, this aluminum alloy can be easily elongated and is capable of increasing its strength (particularly its tensile strength).
  • the press-clamping terminal 10 is constructed such that tin (Sn) plating is provided on the surface of a copper- or aluminum alloy-made terminal body 10a having a bottom plate portion 13.
  • tin (Sn) plating is provided on the surface of a copper- or aluminum alloy-made terminal body 10a having a bottom plate portion 13.
  • the press-clamping terminal 10 is provided with an electrical connection portion 11 for being electrically connected to a mating terminal by being brought into fitting contact therewith as well as a mounting portion 12 for being mounted and fixed to a connector housing.
  • the press-clamping terminal 10 is provided with an electric wire holding portion 14 for holding the aluminum electric wire W.
  • the electric wire holding portion 14 has on its front side (i.e., an intermediate portion of the terminal body 10a) a conductor press-clamping portion 15 for crimping the conductor Wa of the aluminum electric wire W and has on its rear side (i.e., the other end portion of the terminal body 10a a covering press-fastening portion 16 for crimping the insulative covering Wb of the aluminum electric wire W to fix the aluminum electric wire W to the terminal body 10a.
  • the electrical connection portion 11 , the mounting portion 12, the conductor press-clamping portion 15, and the covering press-fastening portion 16 are configured as respectively including the bottom plate portion 13.
  • the conductor press-clamping portion 15 has a pair of conductor crimping pieces 15a and a portion of the bottom plate portion 13.
  • the pair of conductor crimping pieces 15a are formed integrally with the terminal body 10a so as to extend upwardly from both end portions in the left-right direction of the bottom plate portion 13 and are adapted to effect press-clamping connection of the terminal body 10a onto the aluminum electric wire W with the conductor Wa held in close contact with the upper surface of the bottom plate portion 13 as the pair of conductor crimping pieces 15a are bent toward the inner side of the terminal body 10a so as to be wrapped around the conductor Wa of the aluminum electric wire W.
  • the portion of the bottom plate portion 13 is sandwiched by the pair of conductor crimping pieces 15a.
  • the conductor press-clamping portion 15 is thus formed with a U-shaped cross section.
  • a plurality of (in the illustrated example, three) grooves (i.e., shallow grooves linearly stamped by a press) 17 are provided on an inner surface of this conductor press-clamping portion 15 so as to extend in the left-right direction of the press-clamping terminal 10 and at intervals in the front-back direction.
  • the covering press-fastening portion 16 has a pair of covering crimping pieces 16a and a portion of the bottom plate portion 13.
  • the pair of covering crimping pieces 16a are formed integrally with the terminal body 10a so as to extend upwardly from both end portions in the left-right direction of the bottom plate portion 13 and are adapted to fix the aluminum electric wire W by crimping as the pair of covering crimping pieces 16a are bent toward the inner side of the terminal body 10a so as to be wrapped around the covering Wb of the aluminum electric wire W.
  • the portion of the bottom plate portion 13 is sandwiched by the pair of covering crimping pieces 16a.
  • the covering press-fastening portion 16 is thus formed with a U-shaped cross section.
  • An appropriate gap is provided between the conductor press-clamping portion 15 and the covering press-fastening portion 16 on the rear side thereof for forming a connecting portion. Also, an appropriate gap (second predetermined gap) is provided between the conductor press-clamping portion 15 and the mounting portion 12 on the front side thereof for forming a connecting portion.
  • Two openings 20, for absorbing the metallic elongation in the front-back direction of the bottom plate portion 13 of the conductor press-clamping portion 15 by the pressurizing force (crimping force) during press-clamping connection, are respectively provided in the portions of the bottom plate portion 13 constituting these connecting portions, i.e., on the both front and rear sides of the conductor press-clamping portion 15.
  • Each of these openings 20 is provided as a rectangular slit having an appropriate width in the left-right direction, and each of these slits is disposed such that its width in the left-right direction is wider than its width in the front-back direction.
  • the press-clamping terminal 10 is placed on a lower die 131 , and the conductor Wa of the aluminum electric wire W is placed on the bottom plate portion 13 so as to be disposed between the conductor crimping pieces 15a of the conductor press-clamping portion 15.
  • the leading end portion sides of the conductor crimping pieces 15a are bent toward the inner side by slanting guide surfaces 132a of the upper die 132 so as to be crimped onto the conductor Wa, thereby making it possible to obtain a crimped structure in which the conductor press-clamping portion 15 is crimp-connected to the conductor Wa.
  • the covering press-fastening portion 16 prior to the crimping of the conductor press-clamping portion 15, the covering press-fastening portion 16 is crimped in advance onto the portion of the aluminum electric wire W having the insulative covering Wb in the same way as described above.
  • the bottom plate portion 13 of the conductor press-clamping portion 15 is made to metallically elongate easily in the front-back direction due to the pressurizing force during the press-clamping connection. If the bottom plate portion 13 of the conductor press-clamping portion 15 is made to metallically elongate easily in the front-back direction, the destruction of the oxidized film on the surface of the bottom plate portion is promoted by this elongation. Consequently, a newly generated surface which was concealed below the oxidized film can be easily exposed, and since the terminal and the conductor slide in this state, the area of adhesion between the terminal and the conductor expands.
  • Figs. 4(a) to 4(c) are schematic cross-sectional views illustrating a change in the press-clamping connection process in the case where the openings 20 are not present.
  • Figs. 5(a) to 5(c) are schematic cross-sectional views illustrating a change in the press-clamping connection process in the case where the openings 20 are present.
  • reference character A denotes the terminal body 10a
  • B denotes the conductor Wa of the aluminum electric wire W.
  • tin a2 is plated on the surface of copper a1 and an oxidized film a3 is formed thereon.
  • the conductor B side the oxidized film a3 is formed on the surface of aluminum b1.
  • press-clamping connection is carried out by applying a pressurizing force F, as shown in Figs. 4(b) and 5(b), since aluminum b1 is softer than copper a1 , the aluminum b1 is first elongated as indicated by arrow Yb, so that an oxidized film b2 on the surface of the aluminum b1 is destroyed, allowing a newly generated surface Pb of the aluminum b1 to be exposed.
  • the oxidized film a3 on the A side is destroyed by the elongation of the copper a1 on the A side, allowing a newly generated surface Pa of tin a2 to be exposed.
  • tin is a softer metal than copper or a copper alloy.
  • the press-clamping terminal 10 According to the press-clamping terminal 10 according to this embodiment, excessive press-clamping becomes unnecessary, and it becomes possible to enhance the contact conductivity (electrical connection performance) between the conductor Wa of the aluminum electric wire W and the terminal body 10a without entailing a decline in the fixing force (mechanical connection performance) based on excessive press-clamping.
  • the metallic elongation in the front-back direction of the bottom plate portion 13 of the conductor press-clamping portion 15 is absorbed by the openings 20, unexpected deformation due to press-clamping connection does not occur, and the mountability on the connector housing or the like is not impaired.
  • the grooves 17 are present on the inner surface of the conductor press-clamping portion 15, the oxidized film is efficiently broken by using the grooves 17 as a starting point, so that a state of electrically more favorable contact can be obtained.
  • the bottom plate portion 13 of the conductor press-clamping portion 15 can be made to metallically elongate easily in a wide range in the left-right direction. Furthermore, in this case, if the width in the front-back direction of the slits is made as practically small as possible within a range which is capable of sufficiently absorbing the elongation of the bottom plate portion 13, it is possible to minimize the decline in the strength of the bottom plate portion caused by the provision of the slits.
  • first predetermined gap an appropriate gap
  • second predetermined gap an appropriate gap also provided between the conductor press-clamping portion 15 and the mounting portion 12 on the front side thereof for forming a connecting portion
  • the effect of the openings 20 is not exerted on the electrical connection portion 11 and the mounting portion 12 or the covering press-fastening portion 16, and the intrinsic performance of the press-clamping terminal 10 is not impaired.
  • the press-clamping operation can be carried out without applying an excess burden to the conductor Wa made of aluminum or an aluminum alloy which is inferior in strength and ductility as compared to the conductor made of copper.
  • the terminal body 10a which is made of copper or a copper alloy whose surface is tin plated, it is possible to enhance the adhesiveness between the tin on the surface of the terminal body 10a and the aluminum conductor, thereby making it possible to attain improvement of the electrical connection performance.
  • the tin on the surface of the terminal body 10a fills the gaps between the strands while adhering to the surfaces of the strands making up the conductor Wb owing to the press-clamping connection, it is possible to enlarge the areas of contact between the strands and between the stands and the terminal, thereby making it possible to attain a reduction of contact resistance.
  • the construction is such that, as shown in Figs. 2(a) and 2(b), the rectangular openings 20 are respectively provided on both front and rear sides of the conductor press-clamping portion 15, i.e., on both front and rear sides of the three grooves 17, in the press-clamping terminal according to this second embodiment two openings 21 , which are U-shaped slits, are respectively formed on both front and rear sides of the three grooves 17.
  • the orientation of each slit 21 is set such that open sides of the letters U of these U-shaped openings (slits) 21 respectively face the conductor press-clamping portion 15 side.
  • the bottom plate portion 13 of the conductor press-clamping portion 15 is made to metallically elongate easily in the front-back direction due to the pressurizing force during the press-clamping connection.
  • openings 20 and 21 are respectively provided, openings having other shapes may be provided.
  • the openings 20 and 21 are respectively provided in front and rear of the bottom plate portion 13 of the conductor press-clamping portion 15
  • a similar effect can also be exhibited in a case where the opening is provided on either one side. It should be noted that, in this case, a higher effect can be expected if the opening is provided on the front side.
  • the invention can provide a press-clamping terminal in which a necessary portion of a terminal body is allowed to metallically elongate easily during a press-clamping connection, the press-clamping terminal is not excessively crimped, and the contact with the conductor by press-clamping can be promoted and improvement of the electrical connection performance can be attained while avoiding unexpected deformation.

Landscapes

  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)

Abstract

A press-clamping terminal (10) includes a terminal body (10a) having a bottom plate portion (13), the terminal body (10a) comprised of an electrically conductive metal, and a conductor press-clamping portion (15) having a pair of conductor crimping pieces (15a) which are provided at both end portions of the bottom plate portion (13) in a direction intersecting a longitudinal direction of the terminal body (10a) for conducting press-clamping connection between a conductor (Wa) of an electric wire (W) and the terminal body (10a). An opening (20) is provided in at least one of two portions of the bottom plate portion (13). The two portions are respectively located on both sides of a portion of the bottom plate portion (13) positioned between the pair of conductor crimping pieces (15a) in the longitudinal direction. The opening (20) absorbs a metallic elongation in the longitudinal direction due to a pressurizing force during the press-clamping connection.

Description

DESCRIPTION
PRESS-CLAMPING TERMINAL AND CRIMPED STRUCTURE USING THE
PRESS-CLAMPING TERMINAL
Technical Field
The present invention relates to a press-clamping terminal suitable for press-clamping connection to an aluminum electric wire having a conductor made of aluminum or an aluminum alloy , as well as a crimped structure using this press-clamping terminal.
Background Art
A method called press-clamping is widely used as a method of connecting a terminal and an electric wire. Press-clamping is a method wherein a conductor of an electric wire (such as a conductor exposed from one end of an electric wire) is positioned on a conductor press-clamping portion provided in a terminal body, and the conductor press-clamping portion is crimped by a crimping jig or the like so as to be wrapped around this conductor to thereby effect connection between the electric wire and the terminal body. Such a terminal is generally called a press-clamping terminal.
Fig. 6 is an explanatory diagram of a - method of crimping a press-clamping terminal onto an electric wire, which method is generally known from patent document 1 and the like. Fig. 7 is a cross-sectional view of a portion of this press-clamping terminal which is crimped onto the electric wire. In the drawings, reference numeral 110 denotes a press-clamping terminal, 100 denotes an electric wire, and reference numerals 131 and 132 respectively denote a lower die and an upper die of a crimping jig.
The press-clamping terminal 110 has an electrical connection portion
112 disposed at one end portion in the longitudinal direction (hereafter this direction will also be referred to as the "front-back direction" and a direction perpendicular thereto as a "left-right direction") of a terminal body 110a of this press-clamping terminal 110 so as to be electrically connected to a mating terminal or the like; a covering press-fastening portion 114 disposed at the other end portion thereof in the front-back direction so as to crimp a portion of the electric wire having a covering portion 100b, and a conductor press-clamping portion 113 disposed in an intermediate portion thereof in the front-back direction so as to crimp a conductor 100a exposed at the one end portion of the electric wire 100. In addition, the covering press-fastening portion 114 and the conductor press-clamping portion 113 are respectively provided so as to extend from both ends in the left-right direction of a bottom plate portion 111 of the terminal body 110a.
Namely, the conductor press-clamping portion 113 includes a pair of conductor crimping pieces 113a formed so as to be erected upward from both ends in the left-right direction of an intermediate portion of the bottom plate portion 111 , and a portion of the bottom plate portion 111 which is sandwiched by the pair of conductor crimping pieces 113a. A plurality of grooves (i.e., shallow grooves linearly stamped by a press) 113b are provided on an inner surface of this conductor press-clamping portion 113 so as to extend in the left-right direction. Meanwhile, the covering press-fastening portion 114 has a pair of covering crimping pieces 114a which are formed so as to be erected upward from both end portions in the left-right direction of the other end portion of the bottom plate portion 111 , and a portion of the bottom plate portion 111 which is sandwiched by the pair of covering crimping pieces 114a. The conductor press-clamping portion 113 and the covering press-fastening portion 114 are disposed at a predetermined interval therebetween in the front-back direction.
To effect press-clamping connection of this conductor press-clamping portion 113 of the press-clamping terminal 110 onto the conductor 100a of the electric wire 100, the press-clamping terminal 110 is placed on a placing surface 131a of the lower die 131 , and the conductor 100a is placed on the bottom plate portion 111 so as to be disposed between the conductor crimping pieces 113a of the conductor press-clamping portion 113. Then, as the upper die 132 is lowered, the leading end portion sides of the conductor crimping pieces 113a are gradually bent toward the inner side by slanting guide surfaces 132a of the upper die 132, and leading ends of the conductor crimping pieces 113a are finally rounded so as to be turned back toward the conductor 100a side by curved surfaces continuing from the slanting guide surfaces 132a to a ridge-shaped portion 132b. As a result, as shown in Fig. 7, as the leading ends are made to bite into the conductor 100a while rubbing against each other, the conductor crimping pieces 113a are crimped so as to be wrapped around the conductor 100a. As for the covering press-fastening portion 114, prior to the crimping of the conductor press-clamping portion 113, the covering press-fastening portion 114 is crimped in advance onto the portion of the aluminum electric wire 100 having the insulative covering 100b in the same way as described above.
In the case where the conductor press-clamping portion 113 is crimped onto the conductor 100a of the electric wire 100 by crimping the conductor crimping pieces 113a, the electrically conductive metal making up the terminal body 110a and the conductor 100a of the electric wire 100 are adhered to each other (are bonded at the molecular or atomic level), so that the press-clamping terminal 110 and the electric wire 100 can be firmly bonded electrically and mechanically.
Here, to improve the connection performance based on the press-clamping connection, for example, as shown in Patent Document 2, a method is conventionally known in which a softer metallic powder (tin, zinc, etc.) than the material of the strands is applied in advance on the portion of the strands (conductor) to be crimped, and press-clamping is effected, whereby the metallic powder is deformed by the impact at the time of press-clamping so as to fill the gaps between the strands with the metallic powder while being made to adhere to the surfaces of the strands.
In addition, instead of using such a troublesome technique of applying a metallic powder, a technique is exercised in which the terminal body is provided with plating in advance to thereby attain improvement of the performance of the press-clamping connection. In such a case where the plated terminal body is crimped onto the conductor of the electric wire, it is known that further improvement of the press-clamping connection can be attained as the plating metal acts as an intermediary between the conductor of the electric wire and the terminal body.
Incidentally, it is commonplace to use copper wires for the wire harness which is routed inside a vehicle such as an automobile, and aluminum electric wires, which are inferior in the properties (physical properties) such as electrical conductivity and strength, have not been particularly used. In recent years, however, there has been an increasing demand for the use of aluminum electric wires in view of the reduction of weight of vehicles and resultant low fuel consumption as well as the recycling feature.
In the case where aluminum electric wires are used, since the aluminum or aluminum alloy constituting the conductor is inferior to copper in mechanical strength and electrical conductivity, it becomes necessary to further enhance the performance of the press-clamping connection of the conductor press-clamping portion. In addition, since an oxidized film whose electrical resistance value is high is usually generated on the surface of the conductor made of aluminum or an aluminum alloy, at the time of the press-clamping connection it is necessary to establish sufficient contact continuity between the conductors (between the terminal body and the conductor made of aluminum or an aluminum alloy) while breaking the oxidized film. However, since aluminum electric wires have been infrequently used, the situation has hitherto been such that sufficient studies have not been made of this aspect. [Patent Document 1] JP-A-7-135031 (Fig. 8) [Patent Document 2] JP-A-8-321330
Disclosure of Invention Technical Problem
In the case of effecting the press-clamping connection of the press-clamping terminal onto the aluminum electric wire, the above-described application of a metallic powder and use of a plated terminal contribute to the improvement of the connection performance, but that alone cannot expect sufficient performance improvement of the press-clamping connection. The reason is that the oxidized film which is generated on the conductor surface of the aluminum electric wire is firmer and has a higher resistance value as compared with the oxidized film which is generated on the conductor surface of the normal copper wire.
Here, to effect the press-clamping connection of the press-clamping terminal onto the aluminum electric wire with a stable low resistance value, how to enlarge the area of adhesion between the terminal body and the conductor of the aluminum electric wire holds a key. To enlarge the adhesion area, it is effective to apply a large pressurizing force (i.e., crimping force) to thereby greatly deform the contact area between the terminal body and the conductor and destroy the oxidized film. Nevertheless, in the case where a conventional press-clamping terminal is used, there has been a problem in that unless the conductor press-clamping portion is excessively crimped, the oxidized film cannot be sufficiently destroyed and electrically sufficient performance cannot be obtained. However, if the conductor press-clamping portion is excessively crimped, it is known that another problem occurs in that in the case of the aluminum electric wire the mechanical strength conversely declines. Additionally, if the terminal body undergoes unexpected deformation on application of a strong press-clamping force, there is a propensity that the mountability to a connector housing or the like deteriorates.
The invention has been devised in view of the above-described circumstances, and its object is to provide a press-clamping terminal which allows only a necessary portion of the terminal body to metallically elongate easily during the press-clamping connection, whereby the press-clamping terminal is not excessively crimped, and the adhesion with the conductor by press-clamping can be promoted and improvement of the electrical connection performance can be attained while avoiding unexpected deformation.
Technical Solution
The above-described object of the invention is accomplished by the following press-clamping terminal.
(1 ) A press-clamping terminal, comprising: a terminal body having a bottom plate portion, the terminal body comprised of an electrically conductive metal; and a conductor press-clamping portion having a pair of conductor crimping pieces which are provided at both end portions of the bottom plate portion in a direction intersecting a longitudinal direction of the terminal body for conducting press-clamping connection between a conductor of an electric wire and the terminal body, wherein an opening is provided in at least one of two portions of the bottom plate portion, the two portions being respectively located on both sides of a portion of the bottom plate portion positioned between the pair of conductor crimping pieces in the longitudinal direction; and wherein the opening absorbs a metallic elongation in the longitudinal direction due to a pressurizing force during the press-clamping connection.
(2) Preferably, at least one groove is provided on the portion of the bottom plate portion positioned between the pair of conductor crimping pieces so as to extend in a direction intersecting the longitudinal direction.
Here, it is preferable that, the at least one groove extends until parts of the pair of conductor crimping pieces.
Here, it is preferable that, the opening is smaller in a width in the direction intersecting the longitudinal direction than the groove.
(3) Preferably, the opening is formed as a rectangular slit. A width of the slit in the direction intersecting the longitudinal direction is greater than a width of the slit in the longitudinal direction.
(4) Preferably, the opening is formed as a U-shaped slit. An orientation of the slit is set so that an open side of the U-shaped slit faces the portion of the bottom plate portion positioned between the pair of conductor crimping pieces.
(5) Preferably, the conductor press-clamping portion is arranged at an intermediate portion of the terminal body in the longitudinal direction. An electrical connection portion for being electrically connected to a mating terminal is provided at one end portion of the terminal body in the longitudinal direction. A covering press-fastening portion for fixing the electric wire to the terminal body by crimping a covering portion of the electric wire is provided at another end portion of the terminal body in the longitudinal direction. A first gap is provided between the electrical connection portion and the conductor press-clamping portion. A second gap is provided between the covering press-fastening portion and the conductor press-clamping portion.
According to the press-clamping terminal having the configuration of item (1) above, an opening is provided in at least one of both sides in the front-back direction (longitudinal direction ) of the bottom plate portion of the conductor press-clamping portion. For this reason, the bottom plate portion can be made to mechanically elongate easily in the front-back direction during the press-clamping connection. If the bottom plate portion of the conductor press-clamping portion is made to metallically elongate easily in the front-back direction, the destruction of the oxidized film on the surface of the bottom plate portion is promoted by this elongation. Consequently, a newly generated surface which was concealed below the oxidized film can be easily exposed, and since the terminal body and the conductor of the electric wire slide in this state, the enlargement of the area of adhesion between the terminal body and the conductor can be attained. Therefore, excessive press-clamping becomes unnecessary, and it becomes possible to enhance the contact conductivity (electrical connection performance) between the terminal body and the conductor without entailing a decline in the fixing force (mechanical connection performance) based on excessive press-clamping. In addition, since the metallic elongation in the front-back direction of the bottom plate portion of the conductor press-clamping portion is absorbed by the opening, unexpected deformation due to press-clamping connection does not occur, and the mountability on the connector housing or the like is not impaired. It should be noted that this effect is noticeable in the case where the electric wire is formed of an aluminum electric wire, and the terminal body is formed of copper or copper alloy whose surface is tin plated.
According to the press-clamping terminal having the configuration of item (2) above, since the groove is provided on the conductor press-clamping portion, the oxidized film is efficiently broken by using the groove as a starting point, so that the electrical connection performance can be enhanced further.
According to the press-clamping terminal having the configuration of item (3) above, since the rectangular slit which is wider in , for example, the left-right direction is provided as the opening, the bottom plate portion of the conductor press-clamping portion can be made to metallically elongate easily in a wide range in the left-right direction. Furthermore, in this case, if the width in the front-back direction of the slit is made as practically small as possible within a range which is capable of sufficiently absorbing the elongation of the bottom plate portion, it is possible to minimize the decline in the strength of the bottom plate portion caused by the provision of the slit.
According to the press-clamping terminal having the configuration of item (4) above, since a U-shaped slit is provided as the opening, and the orientation of the slit is set such that an open side of the letter U of the slit faces a side of the conductor press-clamping portion, the portion surrounded by the U-shaped slit remains as a tongue piece in such a form as to continue to the bottom plate portion of the conductor press-clamping portion. Therefore, the bottom plate portion of the conductor press-clamping portion is elongated in the front-back direction in a state in which the conductor is placed on that tongue piece during the press-clamping connection, so that it is possible to attain greater enlargement of the contact area.
According to the press-clamping terminal having the configuration of item (5) above, the opening can be provided in a form which does not affect the electrical connection portion and the covering press-fastening portion, so that the performance of the press-clamping terminal is not impaired.
The above object of the invention is also attained by the below-described configuration of the crimped structure.
(6) A crimped structure in which the conductor press-clamping portion of the press-clamping terminal according to any one of items (1) to (5) above is crimped so as to be electrically connected to the conductor of the electric wire, wherein the conductor press-clamping portion is crimped to the conductor of the electric wire in a condition that the bottom plate portion is metallically elongated toward the opening by a pressurizing force.
(7) Preferably, the electric wire is an aluminum electric wire having a conductor comprised of aluminum or an aluminum alloy.
(8) Preferably, the terminal body is formed of copper or a copper alloy. Tin is plated on a surface of the terminal body.
According to the crimped structure having the configuration of item (6) above, as the bottom plate portion of the conductor press-clamping portion is made to metallically elongate easily, the destruction of the oxidized film on the surface of the bottom plate portion is promoted by this elongation. Consequently, a newly generated surface which was concealed below the oxidized film can be easily exposed, and since the terminal body and the conductor slide in this state, the enlargement of the area of adhesion between the terminal body and the conductor can be attained. Therefore, excessive press-clamping becomes unnecessary, and it becomes possible to enhance the contact conductivity (electrical connection performance) between the terminal body and the conductor without entailing a decline in the fixing force (mechanical connection performance) based on excessive press-clamping. In addition, since the elongation in the front-back direction of the bottom plate portion of the conductor press-clamping portion is absorbed by the opening, unexpected deformation due to press-clamping connection does not occur, and the mountability on the connector housing or the like is not impaired. It should be noted that this effect is noticeable in the case where the electric wire is formed of an aluminum electric wire, and the terminal body is formed of copper or copper alloy whose surface is tin plated.
According to the crimped structure having the configuration of item (7) above, since the crimped structure is applied to the aluminum electric wire having the conductor made of aluminum or an aluminum alloy, the press-clamping operation can be carried out without applying an excess burden to the conductor made of aluminum or an aluminum alloy which is inferior in strength and ductility as compared to the conductor made of copper. In addition, it is possible to enhance the adhesiveness of the terminal body with respect to the conductor made of aluminum or an aluminum alloy which is inferior in electrical conductivity as compared to the conductor made of copper, thereby making it possible to attain improvement of the electrical connection performance.
According to the crimped structure having the configuration of item (8) above, since the terminal body is used which is made of copper or a copper alloy whose surface is tin plated, it is possible to enhance the adhesiveness between the tin on the surface of the terminal body and the conductor of the aluminum electric wire, thereby making it possible to attain improvement of the electrical connection performance. In particular, since the tin on the surface of the terminal body fills the gaps between the strands while adhering to the surfaces of the strands making up the conductor owing to the press-clamping connection, it is possible to enlarge the areas of contact between the strands and between the stands and the terminal, thereby making it possible to attain a reduction of contact resistance. Furthermore, since the oxidized film on the surface of the conductor press-clamping portion is destroyed, and the newly generated surface of the plated tin is adhered to the conductor of the electric wire, so that a gastight structure can be obtained, and contact reliability can be improved. It goes without saying that tin is a softer metal than copper or a copper alloy.
Advantageous Effects
According to the invention, as only a necessary portion of the terminal body is allowed to metallically elongate easily during the press-clamping connection, the press-clamping terminal is not excessively crimped, and the adhesion with the conductor by press-clamping can be promoted and improvement of the electrical connection performance can be attained while avoiding unexpected deformation.
A brief description has been given of the invention. The details of the invention will become more apparent upon perusal of the best mode for carrying out the invention which will be described below, with reference to the accompanying drawings.
Brief Description of Drawings Fig. 1 is a perspective view illustrating the configuration of a press-clamping terminal according to an embodiment of the invention.
Figs. 2(a) and 2(b) are plan views of essential portions of the press-clamping terminal according to a first embodiment, in which Fig. 2(a) is a diagram illustrating a state before press-clamping, and Fig. 2(b) is a diagram illustrating a state after press-clamping.
Figs. 3(a) and 3(b) are plan views of essential portions of the press-clamping terminal according to a second embodiment, in which Fig. 2(a) is a diagram illustrating a state before press-clamping, and Fig. 2(b) is a diagram illustrating a state after press-clamping. Figs. 4(a) to 4(c) are diagrams illustrating a change in the contact surface between a conductor and a terminal during press-clamping in the case of a comparative example in which openings are not provided in front and rear of a bottom plate portion of a conductor press-clamping portion, in which Fig. 4(a) is a schematic cross-sectional view illustrating a state before press-clamping, Fig. 4(b) is a schematic cross-sectional view illustrating a state during an initial stage of press-clamping, and Fig. 4(c) is a schematic cross-sectional view illustrating a state during a later stage of press-clamping.
Figs. 5(a) to 5(c) are diagrams illustrating a change in the contact surface between the conductor and the terminal during press-clamping in the case of the embodiment of the invention in which the openings are respectively provided in front and rear of the bottom plate portion of the conductor press-clamping portion, in which Fig. 5(a) is a schematic cross-sectional view illustrating a state before press-clamping, Fig. 5(b) is a schematic cross-sectional view illustrating a state during an initial stage of press-clamping, and Fig. 5(c) is a schematic cross-sectional view illustrating a state during a later stage of press-clamping.
Fig. 6 is a diagram explaining a commonly employed method of press-clamping a press-clamping terminal onto an electric wire.
Fig. 7 is a cross-sectional view of a crimped portion thereof.
Best Mode for Carrying Out the Invention
Referring now to the drawings, a description will be given of the preferred embodiments of the invention.
Fig. 1 is a perspective view illustrating the configuration of a press-clamping terminal according to an embodiment of the invention. Figs. 2(a) and 2(b) are plan views of essential portions of the press-clamping terminal according to a first embodiment, in which Fig. 2(a) is a diagram illustrating a state before press-clamping, and Fig. 2(b) is a diagram illustrating a state after press-clamping. Figs. 3(a) and 3(b) are plan views of essential portions of the press-clamping terminal according to a second embodiment, in which Fig. 2(a) is a diagram illustrating a state before press-clamping, and Fig. 2(b) is a diagram illustrating a state after press-clamping. Figs. 4(a) to 4(c) are diagrams illustrating a change in the contact surface between a conductor and a terminal during press-clamping in the case of a comparative example in which openings are not provided in front and rear of a bottom plate portion of a conductor press-clamping portion, in which Fig. 4(a) is a schematic cross-sectional view illustrating a state before press-clamping, Fig. 4(b) is a schematic cross-sectional view illustrating a state during an initial stage of press-clamping, and Fig. 4(c) is a schematic cross-sectional view illustrating a state during a later stage of press-clamping. Figs. 5(a) to 5(c) are diagrams illustrating a change in the contact surface between the conductor and the terminal during press-clamping in the case of the embodiment of the invention in which the openings are respectively provided in front and rear of the bottom plate portion of the conductor press-clamping portion, in which Fig. 5(a) is a schematic cross-sectional view illustrating a state before press-clamping, Fig. 5(b) is a schematic cross-sectional view illustrating a state during an initial stage of press-clamping, and Fig. 5(c) is a schematic cross-sectional view illustrating a state during a later stage of press-clamping.
(First Embodiment)
First, a description will be given of a first embodiment according to the invention.
In Fig. 1 , reference character W denotes an aluminum electric wire, and reference numeral 10 denotes a press-clamping terminal which is connected to a terminal of the electric wire W.
The aluminum electric wire W is constructed such that an outer periphery of a conductor Wa in which a plurality of strands made of aluminum or an aluminum alloy are twined is covered with an insulative covering Wb which surrounds it in the circumferential direction of the aluminum electric wire W. At one end portion of the aluminum electric wire W, the covering Wb is removed over a predetermined length to expose the conductor Wa, and the press-clamping terminal 10 is crimped onto this one end portion. It should be noted that, as a preferred specific example of the aluminum alloy, it is possible to cite an alloy of aluminum and iron. In the case where this alloy is adopted, as compared with a conductor made of aluminum, this aluminum alloy can be easily elongated and is capable of increasing its strength (particularly its tensile strength).
As shown in Fig. 1 , the press-clamping terminal 10 is constructed such that tin (Sn) plating is provided on the surface of a copper- or aluminum alloy-made terminal body 10a having a bottom plate portion 13. In a front-side portion (one end portion) in its longitudinal direction (hereafter, this direction will also be referred to as the "front-back direction," and a direction perpendicular thereto as the "left-right direction"), the press-clamping terminal 10 is provided with an electrical connection portion 11 for being electrically connected to a mating terminal by being brought into fitting contact therewith as well as a mounting portion 12 for being mounted and fixed to a connector housing. In its rear-end portion (other end portion), the press-clamping terminal 10 is provided with an electric wire holding portion 14 for holding the aluminum electric wire W.
Further, the electric wire holding portion 14 has on its front side (i.e., an intermediate portion of the terminal body 10a) a conductor press-clamping portion 15 for crimping the conductor Wa of the aluminum electric wire W and has on its rear side (i.e., the other end portion of the terminal body 10a a covering press-fastening portion 16 for crimping the insulative covering Wb of the aluminum electric wire W to fix the aluminum electric wire W to the terminal body 10a. The electrical connection portion 11 , the mounting portion 12, the conductor press-clamping portion 15, and the covering press-fastening portion 16 are configured as respectively including the bottom plate portion 13.
The conductor press-clamping portion 15 has a pair of conductor crimping pieces 15a and a portion of the bottom plate portion 13. The pair of conductor crimping pieces 15a are formed integrally with the terminal body 10a so as to extend upwardly from both end portions in the left-right direction of the bottom plate portion 13 and are adapted to effect press-clamping connection of the terminal body 10a onto the aluminum electric wire W with the conductor Wa held in close contact with the upper surface of the bottom plate portion 13 as the pair of conductor crimping pieces 15a are bent toward the inner side of the terminal body 10a so as to be wrapped around the conductor Wa of the aluminum electric wire W. The portion of the bottom plate portion 13 is sandwiched by the pair of conductor crimping pieces 15a. The conductor press-clamping portion 15 is thus formed with a U-shaped cross section. A plurality of (in the illustrated example, three) grooves (i.e., shallow grooves linearly stamped by a press) 17 are provided on an inner surface of this conductor press-clamping portion 15 so as to extend in the left-right direction of the press-clamping terminal 10 and at intervals in the front-back direction.
Meanwhile, the covering press-fastening portion 16 has a pair of covering crimping pieces 16a and a portion of the bottom plate portion 13. The pair of covering crimping pieces 16a are formed integrally with the terminal body 10a so as to extend upwardly from both end portions in the left-right direction of the bottom plate portion 13 and are adapted to fix the aluminum electric wire W by crimping as the pair of covering crimping pieces 16a are bent toward the inner side of the terminal body 10a so as to be wrapped around the covering Wb of the aluminum electric wire W. The portion of the bottom plate portion 13 is sandwiched by the pair of covering crimping pieces 16a. The covering press-fastening portion 16 is thus formed with a U-shaped cross section.
An appropriate gap (first predetermined gap) is provided between the conductor press-clamping portion 15 and the covering press-fastening portion 16 on the rear side thereof for forming a connecting portion. Also, an appropriate gap (second predetermined gap) is provided between the conductor press-clamping portion 15 and the mounting portion 12 on the front side thereof for forming a connecting portion.
Two openings 20, for absorbing the metallic elongation in the front-back direction of the bottom plate portion 13 of the conductor press-clamping portion 15 by the pressurizing force (crimping force) during press-clamping connection, are respectively provided in the portions of the bottom plate portion 13 constituting these connecting portions, i.e., on the both front and rear sides of the conductor press-clamping portion 15. Each of these openings 20 is provided as a rectangular slit having an appropriate width in the left-right direction, and each of these slits is disposed such that its width in the left-right direction is wider than its width in the front-back direction. To effect press-clamping connection of this conductor press-clamping portion 15 of the press-clamping terminal 10 onto the conductor Wa of the aluminum electric wire W, as shown in Fig. 6, the press-clamping terminal 10 is placed on a lower die 131 , and the conductor Wa of the aluminum electric wire W is placed on the bottom plate portion 13 so as to be disposed between the conductor crimping pieces 15a of the conductor press-clamping portion 15. Then, as an upper die 132 is lowered, the leading end portion sides of the conductor crimping pieces 15a are bent toward the inner side by slanting guide surfaces 132a of the upper die 132 so as to be crimped onto the conductor Wa, thereby making it possible to obtain a crimped structure in which the conductor press-clamping portion 15 is crimp-connected to the conductor Wa. As for the covering press-fastening portion 16, prior to the crimping of the conductor press-clamping portion 15, the covering press-fastening portion 16 is crimped in advance onto the portion of the aluminum electric wire W having the insulative covering Wb in the same way as described above.
The following operational effect is exhibited in this press-clamping connection process.
Namely, as the rectangular openings 20 are respectively formed in the front and rear of the bottom plate portion 13 of the conductor press-clamping portion 15, the bottom plate portion 13 of the conductor press-clamping portion 15 is made to metallically elongate easily in the front-back direction due to the pressurizing force during the press-clamping connection. If the bottom plate portion 13 of the conductor press-clamping portion 15 is made to metallically elongate easily in the front-back direction, the destruction of the oxidized film on the surface of the bottom plate portion is promoted by this elongation. Consequently, a newly generated surface which was concealed below the oxidized film can be easily exposed, and since the terminal and the conductor slide in this state, the area of adhesion between the terminal and the conductor expands.
Figs. 4(a) to 4(c) are schematic cross-sectional views illustrating a change in the press-clamping connection process in the case where the openings 20 are not present. Figs. 5(a) to 5(c) are schematic cross-sectional views illustrating a change in the press-clamping connection process in the case where the openings 20 are present.
In Figs. 4(a) to 4(c) and 5(a) to 5(c), reference character A denotes the terminal body 10a, and B denotes the conductor Wa of the aluminum electric wire W. Here, as shown in Figs. 4(a) and 5(a), on the terminal body A side, tin a2 is plated on the surface of copper a1 and an oxidized film a3 is formed thereon. Meanwhile, on the conductor B side, the oxidized film a3 is formed on the surface of aluminum b1.
If press-clamping connection is carried out by applying a pressurizing force F, as shown in Figs. 4(b) and 5(b), since aluminum b1 is softer than copper a1 , the aluminum b1 is first elongated as indicated by arrow Yb, so that an oxidized film b2 on the surface of the aluminum b1 is destroyed, allowing a newly generated surface Pb of the aluminum b1 to be exposed. Next, as shown in Figs. 4(c) and 5(c), the oxidized film a3 on the A side is destroyed by the elongation of the copper a1 on the A side, allowing a newly generated surface Pa of tin a2 to be exposed. Then, as the newly generated surface Pa of the tin a2 slides on the newly generated surface Pb of the aluminum b1 exposed in advance, friction occurs at the boundary surface, allowing adhesion P between the aluminum b1 and the tin a2 to take place. At this time, as for the elongation (arrow Ya) of the copper a1 , if a comparison is made between the case of Fig. 4(c) in which the openings 20 are not present and the case of Fig. 5(c) in which the openings 20 are present, its metallic elongation is greater in the case where the openings 20 are present, so that the sliding distance becomes long, and the area of adhesion is enlarged.
It goes without saying that tin is a softer metal than copper or a copper alloy.
Therefore, according to the press-clamping terminal 10 according to this embodiment, excessive press-clamping becomes unnecessary, and it becomes possible to enhance the contact conductivity (electrical connection performance) between the conductor Wa of the aluminum electric wire W and the terminal body 10a without entailing a decline in the fixing force (mechanical connection performance) based on excessive press-clamping. In addition, since the metallic elongation in the front-back direction of the bottom plate portion 13 of the conductor press-clamping portion 15 is absorbed by the openings 20, unexpected deformation due to press-clamping connection does not occur, and the mountability on the connector housing or the like is not impaired. Furthermore, in the case where the grooves 17 are present on the inner surface of the conductor press-clamping portion 15, the oxidized film is efficiently broken by using the grooves 17 as a starting point, so that a state of electrically more favorable contact can be obtained.
In addition, in the press-clamping terminal 10 according to this embodiment, since the rectangular slits which are wider in the left-right direction are provided as the openings 20, the bottom plate portion 13 of the conductor press-clamping portion 15 can be made to metallically elongate easily in a wide range in the left-right direction. Furthermore, in this case, if the width in the front-back direction of the slits is made as practically small as possible within a range which is capable of sufficiently absorbing the elongation of the bottom plate portion 13, it is possible to minimize the decline in the strength of the bottom plate portion caused by the provision of the slits.
In addition, according to this embodiment, since an appropriate gap (first predetermined gap) is provided between the conductor press-clamping portion 15 and the covering press-fastening portion 16 on the rear side thereof for forming a connecting portion, and an appropriate gap (second predetermined gap) is also provided between the conductor press-clamping portion 15 and the mounting portion 12 on the front side thereof for forming a connecting portion, the effect of the openings 20 is not exerted on the electrical connection portion 11 and the mounting portion 12 or the covering press-fastening portion 16, and the intrinsic performance of the press-clamping terminal 10 is not impaired.
In addition, according to the crimped structure according to this embodiment, since the crimped structure is applied to the aluminum electric wire W having the conductor Wa made of aluminum or an aluminum alloy, the press-clamping operation can be carried out without applying an excess burden to the conductor Wa made of aluminum or an aluminum alloy which is inferior in strength and ductility as compared to the conductor made of copper. In addition, it is possible to enhance the adhesiveness of the terminal body 10a with respect to the conductor Wa made of aluminum or an aluminum alloy which is inferior in electrical conductivity as compared to the conductor made of copper, thereby making it possible to attain improvement of the electrical connection performance.
In addition, according to the crimped structure according to this embodiment, since the terminal body 10a is used which is made of copper or a copper alloy whose surface is tin plated, it is possible to enhance the adhesiveness between the tin on the surface of the terminal body 10a and the aluminum conductor, thereby making it possible to attain improvement of the electrical connection performance. In particular, since the tin on the surface of the terminal body 10a fills the gaps between the strands while adhering to the surfaces of the strands making up the conductor Wb owing to the press-clamping connection, it is possible to enlarge the areas of contact between the strands and between the stands and the terminal, thereby making it possible to attain a reduction of contact resistance. Furthermore, since the oxidized film on the surface of the conductor press-clamping portion is destroyed, and the newly generated surface of the plated tin is adhered to the conductor of the electric wire, so that a gastight structure can be obtained, and contact reliability improves.
(Second Embodiment)
Next, a description will be given of a second embodiment according to the invention.
Although in the above-described first embodiment the construction is such that, as shown in Figs. 2(a) and 2(b), the rectangular openings 20 are respectively provided on both front and rear sides of the conductor press-clamping portion 15, i.e., on both front and rear sides of the three grooves 17, in the press-clamping terminal according to this second embodiment two openings 21 , which are U-shaped slits, are respectively formed on both front and rear sides of the three grooves 17. The orientation of each slit 21 is set such that open sides of the letters U of these U-shaped openings (slits) 21 respectively face the conductor press-clamping portion 15 side. In the case where the U-shaped slits 21 are thus provided, portions surrounded by the U-shaped slits 21 remain as tongue pieces 22 in such a form as to continue to the bottom plate portion 13 of the conductor press-clamping portion 15. Since the other forms are similar to those of the first embodiment, a description of common portions will be omitted.
In this embodiment as well, since the U-shaped slits 21 are present in front and rear of the bottom plate portion 13 of the conductor press-clamping portion 15, as shown in Fig. 3, the bottom plate portion 13 of the conductor press-clamping portion 15 is made to metallically elongate easily in the front-back direction due to the pressurizing force during the press-clamping connection.
Therefore, according to this embodiment, an operational effect similar to that of the above-described first embodiment is exhibited. In particular, since the portions surrounded by the U-shaped slits 21 remain as the tongue pieces 22 in such a form as to continue to the bottom plate portion 13 of the conductor press-clamping portion 15, the bottom plate portion 13 of the conductor press-clamping portion 15 is elongated in the front-back direction in a state in which the conductor Wa is placed on these tongue pieces 22 during the press-clamping connection, so that it is possible to attain greater enlargement of the adhesion area.
It should be noted that the invention is not limited to the foregoing embodiments, and modifications, improvements, and the like are possible, as required. In addition, the material, shape, size, number, the place of disposition, and the like of each of the respective component elements in the foregoing embodiments are arbitrary insofar as the invention is attainable.
For example, although in the foregoing embodiments examples have been shown in which the rectangular openings 20 and the U-shaped openings 21 are respectively provided, openings having other shapes may be provided. In addition, although in the foregoing embodiments examples have been shown in which the openings 20 and 21 are respectively provided in front and rear of the bottom plate portion 13 of the conductor press-clamping portion 15, a similar effect can also be exhibited in a case where the opening is provided on either one side. It should be noted that, in this case, a higher effect can be expected if the opening is provided on the front side.
The present application is based on Japanese Patent Application No. 2008-035012 filed on February 15, 2008, the contents of which are incorporated herein for reference.
Industrial Applicability
The invention can provide a press-clamping terminal in which a necessary portion of a terminal body is allowed to metallically elongate easily during a press-clamping connection, the press-clamping terminal is not excessively crimped, and the contact with the conductor by press-clamping can be promoted and improvement of the electrical connection performance can be attained while avoiding unexpected deformation.

Claims

1. A press-clamping terminal, comprising: a terminal body having a bottom plate portion, the terminal body comprised of an electrically conductive metal; and a conductor press-clamping portion having a pair of conductor crimping pieces which are provided at both end portions of the bottom plate portion in a direction intersecting a longitudinal direction of the terminal body for conducting press-clamping connection between a conductor of an electric wire and the terminal body, wherein an opening is provided in at least one of two portions of the bottom plate portion, the two portions being respectively located on both sides of a portion of the bottom plate portion positioned between the pair of conductor crimping pieces in the longitudinal direction; and wherein the opening absorbs a metallic elongation in the longitudinal direction due to a pressurizing force during the press-clamping connection.
2. The press-clamping terminal according to claim 1 , wherein at least one groove is provided on the portion of the bottom plate portion positioned between the pair of conductor crimping pieces so as to extend in a direction intersecting the longitudinal direction.
3. The press-clamping terminal according to claim 2, wherein the at least one groove extends until parts of the pair of conductor crimping pieces.
4. The press-clamping terminal according to claim 2 or 3, wherein the opening is smaller in a width in the direction intersecting the longitudinal direction than the groove.
5. The press-clamping terminal according to any one of claims 1 to 4, wherein the opening is formed as a rectangular slit; and wherein a width of the slit in the direction intersecting the longitudinal direction is greater than a width of the slit in the longitudinal direction.
6. The press-clamping terminal according to any one of claims 1 to 4, wherein the opening is formed as a U-shaped slit; and wherein an orientation of the slit is set so that an open side of the
U-shaped slit faces the portion of the bottom plate portion positioned between the pair of conductor crimping pieces.
7. The press-clamping terminal according to any one of claims 1 to 6, wherein the conductor press-clamping portion is arranged at an intermediate portion of the terminal body in the longitudinal direction; wherein an electrical connection portion for being electrically connected to a mating terminal is provided at one end portion of the terminal body in the longitudinal direction; wherein a covering press-fastening portion for fixing the electric wire to the terminal body by crimping a covering portion of the electric wire is provided at another end portion of the terminal body in the longitudinal direction; wherein a first gap is provided between the electrical connection portion and the conductor press-clamping portion; and wherein a second gap is provided between the covering press-fastening portion and the conductor press-clamping portion.
8. A crimped structure in which the conductor press-clamping portion of the press-clamping terminal according to any one of claims 1 to 7 is crimped so as to be electrically connected to the conductor of the electric wire, wherein the conductor press-clamping portion is crimped to the conductor of the electric wire in a condition that the bottom plate portion is metallically elongated toward the opening by a pressurizing force.
9. The crimped structure according to claim 8, wherein the electric wire is an aluminum electric wire having a conductor comprised of aluminum or an aluminum alloy.
10. The crimped structure according to claim 9, wherein the terminal body is formed of copper or a copper alloy; and wherein tin is plated on a surface of the terminal body.
PCT/JP2009/052601 2008-02-15 2009-02-10 Press-clamping terminal and crimped structure using the press-clamping terminal WO2009102074A1 (en)

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JP2008035012A JP5119533B2 (en) 2008-02-15 2008-02-15 Crimp terminal and crimp structure using this crimp terminal
JP2008-035012 2008-02-15

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