WO2012011388A1 - 端子接続構造及びその製造方法 - Google Patents
端子接続構造及びその製造方法 Download PDFInfo
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- WO2012011388A1 WO2012011388A1 PCT/JP2011/065466 JP2011065466W WO2012011388A1 WO 2012011388 A1 WO2012011388 A1 WO 2012011388A1 JP 2011065466 W JP2011065466 W JP 2011065466W WO 2012011388 A1 WO2012011388 A1 WO 2012011388A1
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- WIPO (PCT)
- Prior art keywords
- conductor
- terminal
- wire crimping
- friction stir
- external connection
- Prior art date
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
-
- 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
-
- 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
- H01R4/187—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 combined with soldering or welding
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
- H01R43/0207—Ultrasonic-, H.F.-, cold- or impact welding
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49174—Assembling terminal to elongated conductor
- Y10T29/49179—Assembling terminal to elongated conductor by metal fusion bonding
Definitions
- the present invention relates to a terminal connection structure for connecting a terminal to an electric wire and a manufacturing method thereof.
- the electric wire W is comprised from the conductor 50 and the insulation coating 51 which covers the outer periphery of this. At the end of the electric wire W, the insulation coating 51 is peeled off and the conductor 50 is exposed. A terminal 60 is connected to the exposed conductor 50.
- the terminal 60 includes a wire crimping portion 61 and an external connection portion 62.
- the electric wire crimping portion 61 includes a base portion 61a and a pair of caulking portions 61b extending from both side edges of the base portion 61a.
- the conductor 50 is fixed to the electric wire crimping portion 61 by crimping force by crimping the pair of crimping portions 61b.
- the terminal 70 includes a wire crimping portion 71 and an external connection portion 72.
- the electric wire crimping part 71 is composed of a base part 71a and a pair of caulking parts 71b extending from both side edges of the base part 71a.
- the conductor 50 is fixed to the wire crimping portion 71 by crimping force by crimping the pair of crimping portions 71b.
- the conductor 50 and the pair of caulking portions 71b are provided with a friction stir welding portion 73 formed by plastic flow of these together.
- the friction stir welding portion 73 is formed by using a joining tool (not shown) having a pin at the front end of the shoulder and causing the joining tool to act from the pair of caulking portions 71b.
- the conductor 50 and the wire crimping portion 61 are fixed only by the crimping force.
- the electrical contact resistance between the conductor 50 and the wire crimping portion 61 is stabilized at a lower value as the crimping force is larger.
- the fixing force (tensile strength) between the conductor 50 and the wire crimping portion 61 is larger. The bigger it is, the lower it will be. This is because the conductor 50 extends in the axial direction and its cross-sectional area is reduced when the crimping force is large. Therefore, it is impossible to achieve both a decrease in electrical contact resistance and an increase in fixing force (tensile strength).
- the conductor 50 and the wire crimping portion 71 are fixed not only by the crimping force but also by the joining force of the friction stir welding portion 73. Therefore, it is possible to increase the fixing force (tensile strength) without increasing the crimping force of the wire crimping portion 61. Therefore, it is possible to increase the fixing force (tensile strength) while reducing the electric contact resistance as compared with the terminal connection structure of the former conventional example.
- a gap 80 is likely to be generated between the conductor 50 and the base portion 71a due to terminal deformation due to external force, or minute terminal deformation due to external environment or temperature change of energized heat generation.
- the conductor 50 is crimped with the spaces 81 on both sides in the wire crimping portion 71. Therefore, the strand 50a of the conductor 50 is easily frayed by an external force or the like, which also causes an increase in electrical contact resistance and a decrease in fixing force.
- the present invention has been made to solve the above-described problems, and a fixed terminal connection structure capable of sufficiently and reliably achieving a reduction in electrical contact resistance and an increase in fixing force, and its manufacture. It aims to provide a method.
- a first aspect of the present invention is a terminal connection structure for connecting a terminal to an electric wire, and includes the following: an electric wire crimping portion of the terminal, A base portion on which the conductor of the electric wire is disposed, and a crimp portion extending from the base portion and crimped so as to crimp the conductor; and the base portion and the crimp portion together with the conductor A friction stir weld formed by plastic flow of both.
- the terminal has an external connection portion that is separate from the wire crimping portion; Both external connection parts are also integrally formed by plastic flow.
- a third aspect of the present invention is a method for manufacturing a terminal connection structure, which includes the following steps: placing a conductor on the upper surface of a base portion of a wire crimping portion of a terminal, A wire crimping step of crimping the conductor by crimping a crimped portion extending from the base so as to cover the conductor; and, after the wire crimping step, friction stir to the wire crimping portion using a joining tool A friction stir welding process for forming a friction stir weld by joining and plastically flowing both the substrate portion and the crimped portion together with the conductor.
- the welding tool in the fourth aspect of the present invention, which is dependent on the third aspect, in the method for manufacturing the terminal connection structure, in the friction stir welding process, the welding tool is operated from the base side.
- the terminal includes an external connection part separate from the wire crimping part;
- the external connection portion is brought into close contact with the outer surface of the wire crimping portion, the bonding tool is operated from the external connection portion side, and the external connection portion is also plastically flowed integrally. A friction stir weld is formed.
- the conductor and the wire crimping portion are fixed by the crimping force and the joining force by the friction stir welding portion. And since a conductor is fixed to a base part by a friction stir welding part with a caulking part, a conductor is firmly fixed between both a caulking part and a base part. Therefore, no gap is generated between the conductor and the caulking portion and the base portion due to terminal deformation due to external force, or minute terminal deformation due to external environment or temperature change of energized heat generation. From the above, it is possible to sufficiently and reliably reduce the electrical contact resistance and increase the fixing force.
- FIG. 1 is a top view of a conventional terminal connection structure.
- FIG. 2 is an enlarged sectional view taken along line II-II in FIG.
- FIG. 3 is a perspective view of another conventional terminal connection structure.
- 4A is an enlarged cross-sectional view taken along the line IV-IV in FIG. 3
- FIG. 4B is an enlarged cross-sectional view taken along the line IV-IV in FIG. 3.
- a gap is generated between the conductor and the base portion. It is a figure which shows a state.
- FIG. 5 is an enlarged cross-sectional view taken along line IV-IV in FIG. 3 and shows a state in which the conductor wires are frayed.
- 6 (a), 6 (b) and 6 (c) show a first embodiment of the present invention, FIG.
- FIG. 6 (a) is a top view of a terminal connection structure
- FIG. FIG. 6C is a rear view of the terminal connection structure, and is an enlarged cross-sectional view taken along the line VIc-VIc in FIG.
- FIGS. 7A, 7B, and 7C are cross-sectional views showing a procedure for manufacturing the terminal connection structure according to the first embodiment of the present invention.
- FIG. 8 is a top view of the terminal connection structure according to the second embodiment of the present invention.
- FIG. 9 shows a second embodiment of the present invention and is a cross-sectional view showing a state in which the external terminal portion is brought into close contact with the back surface of the wire crimping portion.
- FIG. 10 is a cross-sectional view showing a second embodiment of the present invention and showing a state in which a friction stir weld is formed.
- FIGS. 6A to 6C show a terminal connection structure according to the first embodiment of the present invention.
- the electric wire W is composed of a conductor 1 and an insulating coating 2 covering the outer periphery thereof.
- the conductor 1 is configured by twisting a plurality of strands (not shown).
- the insulating coating 2 is formed of an insulating synthetic resin material. At the end of the electric wire W, the insulation coating 2 is peeled off and the conductor 1 is exposed. A terminal 10 is connected to the exposed conductor 1.
- the terminal 10 is formed by bending a sheet metal having a predetermined shape.
- the terminal 10 includes a wire crimping portion 11 and an external connection portion 12 formed integrally with the wire crimping portion 11.
- the electric wire crimping portion 11 includes a base portion 13 and a pair of caulking portions 14 extending from both side edges of the base portion 13.
- the conductor 1 is placed on the upper surface of the base portion 13, and a pair of crimping portions 14 are crimped so as to crimp the conductor 1 from above.
- the conductor 1, the pair of caulking portions 14, and the base portion 13 are provided with a friction stir welding portion 20 formed by plastic flow of these together.
- the external connection portion 12 is circular and has a mounting hole 12a at the center thereof. Other electric wires and the like are connected using the mounting holes 12a.
- the insulation coating 2 at the end of the electric wire W is peeled off to expose the conductor 1.
- the conductor 1 exposed from the electric wire W is placed on the upper surface of the base portion 13 of the electric wire crimping portion 11 of the terminal 10, and the pair of caulking portions 14 are connected to the conductor 1. It is crimped so as to cover the upper part of the wire (wire crimping process). Thus, the conductor 1 is crimped into the wire crimping portion 11.
- the joining tool 30 includes a shoulder portion 31 and a pin portion 32 protruding from the tip of the rotation center of the shoulder portion 31.
- the joining tool 30 can rotationally drive the shoulder portion 31 and the pin portion 32.
- the length dimension of the pin portion 32 is at least plastically flowable at the tip end portions 14a of the pair of caulking portions 14 (shown in FIGS. 7A and 7B) when the pin portions 32 are bitten from the bottom surface of the base portion 13. Set to dimensions.
- the bottom surface side of the base portion 13 of the wire crimping portion 11 is disposed opposite to the joining tool 30 having such a configuration.
- the shoulder portion 31 and the pin portion 32 are rotationally driven, and the rotating pin portion 32 is caused to bite into the electric wire crimping portion 11 from the base portion 13 and pulled out after a certain time.
- the rotating pin portion 32 bites into the wire crimping portion 11
- the wire crimping portion 11 and the conductor 1 in the portion are softened and plastically flowed by frictional heat generated by the frictional rotation stirring action of the pin portion 32, and the wire crimping is plastically fluidized.
- the part 11 and the conductor 1 are rapidly cooled and solidified by heat conduction after the pin part 32 is pulled out, and the friction stir welding part 20 shown in FIG. 7C is formed.
- the friction stir welding portion 20 is formed by plastic flow of the conductor 1, the base portion 13, and the pair of caulking portions 14 integrally. In this way, the terminal connection structure shown in FIGS. 6A to 6C is manufactured.
- the wire crimping portion 11 of the terminal 10 is a pair of base portions 13 on which the conductors 1 of the electric wires W are disposed and crimped so as to crimp the conductors 1 from above, extending from the base portion 13.
- a friction stir welding part 20 formed by plastic flow of both the base part 13 and the pair of caulking parts 14 together with the conductor 1. Accordingly, the conductor 1 and the wire crimping portion 11 are fixed by the crimping force and the joining force by the friction stir welding portion 20. Since the conductor 1 is fixed to the base portion 13 together with the pair of caulking portions 14 by the friction stir welding portion 20, the conductor 1 is firmly fixed between both the pair of caulking portions 14 and the base portion 13.
- a gap is formed not only between the conductor 1 and the pair of caulking portions 14 but also between the conductor 1 and the base portion 13 due to terminal deformation caused by external force or minute terminal deformation caused by external environment or temperature change of energized heat generation. It does not occur. As described above, it is possible to sufficiently and reliably reduce the electrical contact resistance and increase the fixing force (tensile strength).
- the conductor 1 is arranged in the electric wire crimping part 11 without a gap. Accordingly, since the strands of the conductor 1 are not frayed by an external force or the like, it is possible to prevent an increase in electrical contact resistance and a decrease in fixing force (tensile strength) due to the fraying of the strands.
- the welding tool 30 is operated from the base 13 side. Since the outer surface of the base portion 13 is a flat surface, workability is good.
- the external connection portion 12 has a round shape having a mounting hole 12a, but may be of other shapes.
- FIG. 8 shows a terminal connection structure according to the second embodiment of the present invention. 7A to 7C, when comparing the terminal connection structure of the second embodiment with that of the first embodiment, the terminal 10A includes a wire crimping portion 11A and a separate external part. A connecting portion 12A is configured.
- the external connection portion 12A has a flat connecting surface portion 12b.
- the friction stir welding portion 20A not only the base portion 13, the conductor 1, and the pair of caulking portions 14, but also the connecting surface portion 12b of the external connection portion 12A are integrally plastically flowed.
- the base part 13 and the external connection part 12A of the wire crimping part 11A are fixed by the joining force of the friction stir welding part 20A (see FIG. 10).
- the insulation coating 2 at the end of the electric wire W is peeled off to expose the conductor 1.
- the exposed conductor 1 of the electric wire W is placed on the upper surface of the base portion 13 of the electric wire crimping portion 11A, and the pair of crimping portions 14 are crimped so as to cover the conductor 1 (wire crimping step). ).
- the conductor 1 is crimped into the wire crimping portion 11.
- connection surface portion 12 b of the external connection portion 12 ⁇ / b> A is arranged in close contact with the lower surface of the base portion 13 of the wire crimping portion 11.
- the bottom side of the external connection portion 12A is disposed opposite to the welding tool. That is, it arrange
- the friction stir welding portion 20A is formed by integrally plastically flowing the conductor 1, the external connection portion 12A, the base portion 13, and the pair of caulking portions 14. Thus, the terminal connection structure shown in FIG. 9 is produced.
- the second embodiment can provide the same operations and effects as those of the first embodiment.
- the terminal 10A includes a wire crimping portion 11A and a separate external connection portion 12A, and the friction stir welding portion 20A is formed by plastic flow integrally with the external connection portion 12A. . Therefore, when the wire crimping portion 11 and the external connection portion 12 are integral parts (in the case of the first embodiment), the number of the wire crimping portions 11 is N and the number of the external connection portions 12 is M. In this case, it is necessary to produce (N ⁇ M) parts (terminals 10). In contrast, in the second embodiment, since it is sufficient to produce (N + M) parts, the number of parts of the terminal 10A can be reduced.
- the number of configurations of the wire crimping portions 11A (not shown) is two and the number of configurations of the external connection portions 12A to 12C is three (shown in FIG. 8), two wire crimping portions 11A are provided. If a total of five types of types and external connection portions 12A to 12C are produced, all combinations of terminals can be manufactured.
- a welding tool (not shown) is applied from the external connection portion 12A side. Since the outer surface of the external connection portion 12A is a flat surface, workability is good.
- the pin portion 32 of the joining tool 30 is bitten into a predetermined position of the electric wire crimping portion 11 and is pulled out after a predetermined time to form the point (spot) joint friction stir welding portion 20.
- the pin portion 32 biting into the wire crimping portion 11 is moved so that the friction stir welding portion 20 in a wide range is obtained. May be formed.
Abstract
Description
図6(a)~(c)は、本発明の第1実施形態に係る端子接続構造を示す。図6(a)~(c)において、電線Wは、導体1とこれの外周を覆う絶縁被覆2とから構成されている。導体1は、複数の素線(図示せず)が撚り合わされることによって構成されている。絶縁被覆2は、絶縁性の合成樹脂材にて形成されている。電線Wの端部は、絶縁被覆2が剥されて導体1が露出している。この露出した導体1に端子10が接続されている。
図8は、本発明の第2実施形態に係る端子接続構造を示す。図7(a)~(c)において、この第2実施形態の端子接続構造を前記第1実施形態のものと比較するに、端子10Aは、電線圧着部11Aと、これとは別体の外部接続部12Aとが構成されている。外部接続部12Aは、フラットな連結面部12bを有する。摩擦攪拌接合部20Aは、基底部13、導体1、一対の加締め部14のみならず外部接続部12Aの連結面部12bも共に一体に塑性流動して形成されている。電線圧着部11Aの基底部13と外部接続部12Aは、摩擦攪拌接合部20A(図10参照)の接合力によって固定されている。
前記第1及び第2実施形態では、接合ツール30のピン部32は、電線圧着部11の所定位置に食い込ませ、所定時間後にそのまま引き抜いて点(スポット)接合の摩擦攪拌接合部20が形成した。しかし、接合ツール30のピン部32に対し、端子10の電線圧着部11が大きい場合等には、電線圧着部11に食い込ませたピン部32を移動して、広い範囲の摩擦攪拌接合部20を形成しても良い。
Claims (6)
- 電線に端子を接続する端子接続構造が、以下を含む:
前記端子の電線圧着部であって、該電線圧着部は、前記電線の導体が配置される基底部と、前記基底部より延設され、前記導体を圧着するように加締めた加締め部とを有する;及び
前記導体と共に前記基底部と前記加締め部の双方を一体に塑性流動して形成された摩擦攪拌接合部。 - 請求項1に記載の端子接続構造において、
前記端子は、前記電線圧着部とは別体の外部接続部を有する;及び
前記摩擦攪拌接合部は、前記外部接続部も共に一体に塑性流動して形成されている。 - 端子接続構造の製造方法が、以下のステップを含む:
端子の電線圧着部の基底部の上面に導体を載置し、前記基底部より延設された加締め部を前記導体を被うように加締めて前記導体を圧着する電線圧着工程;及び
前記電線圧着工程後に、接合ツールを用いて前記電線圧着部に摩擦攪拌接合加工を行い、前記導体と共に前記基板部と前記加締め部の双方を一体に塑性流動して摩擦攪拌接合部を形成する摩擦攪拌接合加工工程。 - 請求項3に記載の端子接続構造の製造方法において、
前記摩擦攪拌接合加工工程では、前記接合ツールを前記基底部側から作用させている。 - 請求項3に記載の端子接続構造の製造方法において、
前記端子は、前記電線圧着部とは別体の外部接続部を備えている;及び
前記摩擦攪拌接合加工工程では、前記外部接続部を前記電線圧着部の外面に密着させ、前記接合ツールを前記外部接続部側より作用させ、前記外部接続部も一体に塑性流動して前記摩擦攪拌接合部を形成している。 - 請求項4に記載の端子接続構造の製造方法において、
前記端子は、前記電線圧着部とは別体の外部接続部を備えている;及び
前記摩擦攪拌接合加工工程では、前記外部接続部を前記電線圧着部の外面に密着させ、前記接合ツールを前記外部接続部側より作用させ、前記外部接続部も一体に塑性流動して前記摩擦攪拌接合部を形成している。
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DE112011102437.1T DE112011102437B8 (de) | 2010-07-22 | 2011-07-06 | Klemmenverbindungsstruktur und Verfahren zum Herstellen derselben |
US13/811,157 US9065233B2 (en) | 2010-07-22 | 2011-07-06 | Terminal connection structure and method of manufacturing the same |
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JP2010164761A JP5603692B2 (ja) | 2010-07-22 | 2010-07-22 | 端子接続構造及びその製造方法 |
JP2010-164761 | 2010-07-22 |
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DE102017218486A1 (de) | 2017-10-16 | 2019-04-18 | Te Connectivity Germany Gmbh | Verfahren und Anordnung zum Herstellen einer gecrimpten Verbindungsanordnung, Verbindungsanordnung |
DE102017124693B3 (de) * | 2017-10-23 | 2018-11-29 | Lisa Dräxlmaier GmbH | Verfahren zum stoffschlüssigen Fügen einer elektrischen Leitung an ein elektrisches Kontaktteil |
JP6974135B2 (ja) * | 2017-11-24 | 2021-12-01 | 矢崎総業株式会社 | 端子接続方法 |
JP6978294B2 (ja) * | 2017-11-30 | 2021-12-08 | 矢崎総業株式会社 | 端子接続方法及び端子 |
JP6939711B2 (ja) * | 2018-06-06 | 2021-09-22 | 住友電装株式会社 | 複合端子の締結構造 |
CN110091050A (zh) * | 2019-05-10 | 2019-08-06 | 无锡市晟锋金属材料有限公司 | 一种异型铜材软硬连接的焊接方法 |
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US20130112476A1 (en) | 2013-05-09 |
JP5603692B2 (ja) | 2014-10-08 |
DE112011102437B4 (de) | 2023-08-03 |
DE112011102437B8 (de) | 2023-11-09 |
US9065233B2 (en) | 2015-06-23 |
DE112011102437T5 (de) | 2013-05-02 |
JP2012028112A (ja) | 2012-02-09 |
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