WO2012132066A1 - Method for manufacturing electrical cable provided with terminal, electrical cable provided with terminal, and molding apparatus - Google Patents

Method for manufacturing electrical cable provided with terminal, electrical cable provided with terminal, and molding apparatus Download PDF

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Publication number
WO2012132066A1
WO2012132066A1 PCT/JP2011/072515 JP2011072515W WO2012132066A1 WO 2012132066 A1 WO2012132066 A1 WO 2012132066A1 JP 2011072515 W JP2011072515 W JP 2011072515W WO 2012132066 A1 WO2012132066 A1 WO 2012132066A1
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WIPO (PCT)
Prior art keywords
terminal
electric wire
groove
manufacturing
protective agent
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PCT/JP2011/072515
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French (fr)
Japanese (ja)
Inventor
礼 西脇
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住友電装株式会社
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Publication of WO2012132066A1 publication Critical patent/WO2012132066A1/en

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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
    • 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
    • H01R4/70—Insulation of 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
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/005—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for making dustproof, splashproof, drip-proof, waterproof, or flameproof connection, coupling, or casing
    • 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

Definitions

  • This invention relates to a technique for forming a protective film at a connection portion between an electric wire and a terminal.
  • Patent Document 1 discloses a technique for forming a protective film by applying a resin around a connection portion between a terminal and a conductor.
  • Patent Document 1 since the surface of the connection portion between the terminal and the conductor has a complicated uneven shape, the technique disclosed in Patent Document 1 may not secure a film thickness necessary for protection. This is because if the resin is simply applied to the surface having the concavo-convex shape, the film thickness may be reduced at the protruding portion or the like.
  • an object of the present invention is to ensure a necessary film thickness as much as possible when forming a protective film at a connection portion between an electric wire and a terminal.
  • the first aspect is a method of manufacturing a terminal-attached electric wire in which a protective film is formed on the surface of the connection portion between the electric wire and the terminal, and (a) the terminal is connected to the core wire.
  • a step of preparing an electric wire (b) a step of arranging the connecting portion between the electric wire and the terminal in a groove formed in a mold, and (c) a step of pouring a protective agent into the groove; (d) forming a protective film by solidifying the protective agent poured into the groove in a state of covering the surface of the connecting portion.
  • a second aspect is a method for manufacturing a terminal-attached electric wire according to the first aspect, wherein a thermosetting material is used as the protective agent, and the thermosetting is performed by the heated mold in the step (d). The material is cured.
  • a third aspect is a method of manufacturing a terminal-attached electric wire according to the second aspect, and in the step (c), a protective agent is poured into the groove while the mold is heated.
  • a fourth aspect is a method for manufacturing a terminal-attached electric wire according to any one of the first to third aspects, and an outflow suppression wall that suppresses outflow from the connection part to the counterpart terminal connection part side.
  • the steps (c) and (d) are carried out in a state where is disposed.
  • a fifth aspect is a method of manufacturing a terminal-attached electric wire according to any one of the first to fourth aspects, wherein the step (c) and the step (c) are performed in a state where a ceiling part is disposed above the connection part. (d) is implemented.
  • a 6th aspect is a manufacturing method of the electric wire with a terminal concerning the 4th aspect, Comprising: The ceiling part extended in the position which reaches the coating
  • the seventh aspect is a method for manufacturing a terminal-attached electric wire according to the sixth aspect, wherein the hole for injecting the protective agent is formed in the ceiling portion.
  • An eighth aspect is a method of manufacturing a terminal-attached electric wire according to any one of the first to seventh aspects, wherein the groove is narrowed at an end portion on the terminal side of the covering portion of the electric wire. Yes.
  • the electric wire with a terminal includes an electric wire having a core wire exposed at an end, a terminal connected to the core wire of the electric wire, and a connection portion between the electric wire and the terminal in the groove. And a protective film that is formed by solidifying the protective agent poured into the groove and covers the surface of the connection portion.
  • a molding apparatus is a molding apparatus for manufacturing a terminal-attached electric wire having a protective film formed on the surface of a connection portion between the electric wire and the terminal, and the connection portion between the electric wire and the terminal. And a protective agent supply unit for supplying a protective agent into the groove.
  • the protective film is formed by solidifying the protective agent poured into the groove, the required film thickness can be ensured as reliably as possible.
  • thermosetting material can be rapidly cured by heating the mold.
  • the protective agent when the protective agent is poured into the groove, the protective agent can be quickly solidified, and flow out to an excessive portion can be suppressed.
  • the thickness of the protective film on the connection portion can be regulated.
  • the thickness of the protective film can be regulated almost entirely on the connection part.
  • the protective agent can be injected around the connection part covered with the ceiling part, and the protective film can be more reliably formed around the connection part.
  • the outflow of the protective agent to the covering portion side can be suppressed.
  • a protective film is formed by solidifying the protective agent poured into the groove in a state where the connection portion between the electric wire and the terminal is disposed in the groove. Therefore, the required film thickness can be ensured as reliably as possible.
  • the molding apparatus in a state where the connection portion between the electric wire and the terminal is disposed in the groove, by supplying a protective agent into the groove and solidifying the protective material, A protective film can be formed. For this reason, it is possible to ensure the required film thickness as reliably as possible.
  • FIG. 6 is a schematic sectional view taken along line VI-VI in FIG. 5. It is a schematic sectional drawing which shows the shaping
  • FIG. 1 is a schematic side view showing an electric wire 10 with a terminal
  • FIG. 2 is a schematic plan view showing the electric wire 10 with a terminal.
  • the electric wire with terminal 10 includes an electric wire 12, a terminal 20, and a protective film 30.
  • the electric wire 12 is configured such that the outer periphery of the core wire portion 13 is covered with a covering portion 14 by extrusion coating or the like.
  • the core wire portion 13 is configured by a single wire or a stranded wire of metal wires such as copper, copper alloy, aluminum, and aluminum alloy.
  • the core wire portion 13 is configured by combining a plurality of metal wires of aluminum or aluminum alloy will be described.
  • the covering portion 14 at the end of the electric wire 12 is peeled off, and an exposed core portion 13 a is formed at the end of the electric wire 12.
  • the terminal 20 is formed by appropriately pressing a metal plate material such as copper or copper alloy.
  • a plating layer of tin, nickel, or the like may be formed on the surface of the terminal 20.
  • a tin plating layer is formed on the surface of the terminal 20.
  • the terminal 20 has a wire connecting part 22 and a counterpart terminal connecting part 28.
  • the counterpart terminal connection portion 28 is a portion connected to a counterpart terminal or the like, and is here formed in a substantially cylindrical shape, a so-called female terminal shape. Then, a mating terminal (so-called male terminal) having a pin-shaped or tab-shaped connecting section is inserted and connected to the mating terminal connecting section 28. Further, a stabilizer 29 extending downward is formed by forming a U-shaped slit in a part of the bottom of the counterpart terminal connection portion 28 and cutting it downward. The stabilizer is guided in a groove formed in the cavity when the terminal 20 is inserted into the cavity of the connector. Thereby, the terminal 20 is maintained in a fixed posture in the cavity.
  • the mating terminal connection portion 28 may be formed in a pin-shaped or tab-shaped shape, a so-called male terminal shape, or in an annular shape that can be connected to the mating member by a screw or the like. May be.
  • the electric wire connecting portion 22 is configured to be connectable to the end portion of the electric wire 12.
  • the electric wire connection portion 22 includes a bottom plate portion 23, a pair of coated crimping pieces 24, and a pair of core wire crimping pieces 25.
  • the bottom plate portion 23 is formed in a long plate shape extending to the proximal end portion side of the counterpart terminal connection portion 28.
  • the integral covering crimping piece 24 is formed in a long piece shape extending from both side portions of the end portion of the bottom plate portion 23.
  • a portion of the electric wire connecting portion 22 where the pair of coated crimping pieces 24 are formed is formed in a substantially U-shaped cross section.
  • the pair of core wire crimping pieces 25 are formed in a long piece shape extending from both sides of the end portion of the bottom plate portion 23 between the pair of coated crimping pieces 24 and the mating terminal connection portion 28.
  • a portion of the electric wire connecting portion 22 where the pair of core wire crimping pieces 25 is formed is formed in a substantially U-shaped cross section.
  • the pair of core wire crimping pieces 25 are crimped to the exposed core wire portion 13a so as to hold the exposed core wire portion 13a, and the pair of covering crimping pieces 24 hold the end portions of the covering portion 14.
  • the end portion of the electric wire 12 and the terminal 20 are connected.
  • a portion where the pair of core wire crimping pieces 25 is crimped to the exposed core wire portion 13 a is referred to as a connection portion 26 between the electric wire 12 and the terminal 20.
  • the connection between the exposed core portion 13a and the terminal 20 is not limited to the case of crimping, but may be one using welding such as ultrasonic welding or resistance welding, or joining by soldering.
  • a rectangular hole 23 h is formed at the bottom between the mating terminal connection 28 and the wire connection 22. Then, in a state where the terminal 20 is inserted into the cavity of the connector, a locking projection (a so-called lance) formed so as to protrude into the cavity is fitted into the hole 23h and locked to the terminal 20. By doing so, the terminal 20 can be positioned in the cavity.
  • a locking projection a so-called lance
  • the protective film 30 is formed so as to cover the surface of the connecting portion 26, more specifically, the surface portion centering on the boundary between the exposed core portion 13 a and the terminal 20.
  • the protective film 30 is formed by solidifying the protective agent poured into the groove 44 in a state where the connecting portion 26 is disposed in the groove 44 described later.
  • the protective agent one that can be solidified by volatilization, cooling, heating, light, etc. (including volatilization by cooling, cooling, etc.) after coating in a liquid state can be used.
  • thermosetting is assumed as the protective agent will be described.
  • the protective film 30 as described above covers the surface of the connecting portion 26, thereby suppressing the adhesion of the liquid to the portion and thereby suppressing the deterioration.
  • a protective film 30 can be formed by various methods, for example, by applying a coating material such as a resin by melting it with heat and then cooling and solidifying it.
  • FIG. 3 is a schematic perspective view showing the molding apparatus 40
  • FIG. 4 is a schematic sectional view showing the molding apparatus 40.
  • the molding apparatus 40 includes a lower mold 42, an upper mold 50, and a protective agent supply unit 60.
  • the lower mold 42 is a member formed of metal or the like, and has a groove 44 formed in the upper part.
  • the groove 44 is formed in a shape and size capable of disposing the connecting portion 26. More specifically, the length dimension of the groove 44 is set to be larger than the length dimension of the wire connecting portion 22. Further, the width dimension of the groove 44 is set to be larger than the width dimension of the electric wire connecting portion 22.
  • the width dimension of the groove 44 is equal to the width dimension of the electric wire connection section 22 (the portion where protection is required). It is preferable to make it larger than the maximum width dimension) plus twice the required film thickness h.
  • the required film thickness h can be secured at both side portions of the wire connection portion 22.
  • the depth dimension of the groove 44 should be larger than the height dimension of the electric wire connecting portion 22 (the maximum height dimension of the portion where protection is required) plus the required film thickness h. Is preferred. This is because the necessary film thickness can be secured above the wire connection portion 22.
  • the protective film 30 may or may not be thin.
  • connection part 26 of the electric wire 12 and the terminal 20 does not protrude in the groove
  • the lower mold 42 incorporates a heating unit 46 such as a heater, and the heating unit 46 heats the lower mold 42 to a temperature at which the protective agent, which is a thermosetting resin, can be thermally cured.
  • the protective agent which is a thermosetting resin
  • the lower mold 42 may be heated to 85 degrees.
  • the heating may be performed by irradiation heat such as an infrared heater as well as by the heating unit 46 provided in the lower mold 42.
  • the heating unit 46 is not essential, as long as the protective agent in the groove 44 can be solidified.
  • the upper mold 50 has an outflow suppression wall portion 52 and a ceiling portion 54.
  • the outflow suppression wall portion 52 is configured to be able to suppress outflow from the connection portion 26 to the counterpart terminal connection portion 28 side, and the ceiling portion 54 is configured to be disposed above the connection portion 26.
  • the upper mold 50 is made of metal or the like, and has a shape in which a part of a block-like member that can be disposed in the groove 44 protrudes downward. And the downward protrusion part is formed in the said outflow suppression wall part 52, and the part extended to a side from the base end part of the outflow suppression wall part 52 is formed in the ceiling part 54. As shown in FIG.
  • the outflow suppression wall portion 52 can be inserted into the groove 44 from above, and is exposed between the wire connection portion 22 and the mating terminal connection portion 28 of the terminals 20 disposed in the groove 44. It is configured to be disposed at a position away from the tip of the core wire portion 13a.
  • the outflow suppression wall portion 52 is formed so as to be disposed between the pair of side wall portions 28a on the proximal end side of the counterpart terminal connection portion 28, and the distal end portion thereof can be disposed in the hole portion 23h. Is formed.
  • the ceiling portion 54 protrudes from the outflow suppression wall portion 52 toward the connection portion 26 side.
  • the downward surface of the ceiling portion 54 is in the groove 44 and in the groove 44. It is arrange
  • the protective agent supply unit 60 is a device for pouring a liquid protective agent into the groove 44.
  • a dispenser that discharges a predetermined amount of liquid from the nozzle 62 can be used.
  • the electric wire 12 in which the terminal 20 is connected to the exposed core portion 13a is prepared (see FIGS. 1 and 2).
  • the connecting portion 26 is disposed in the groove 44 (see FIG. 4).
  • the connecting portion 26 can be disposed at a fixed position in the groove 44.
  • the connecting portion 26 can be positioned at a fixed position in the axial direction of the groove 44 by abutting against the opening side edge of the groove 44 of the stabilizer 29.
  • the width dimension of the mating terminal connection portion 28 of the terminal 20 is matched with the width dimension of the groove 44, and both outer surfaces of the mating terminal connection portion 28 are brought into contact with both side surfaces of the groove 44. Can be positioned in the groove 44 at a fixed position in the width direction.
  • the lower mold 42 is moved into the groove 44.
  • the outflow suppression wall portion 52 is located between the wire connecting portion 22 and the mating terminal connecting portion 28 in the terminal 20 disposed in the groove 44 and away from the distal end portion of the exposed core portion 13a. It is arranged. Further, the ceiling portion 54 is disposed above the connection portion 26 in the groove 44.
  • the protective agent is poured into the groove 44 by the nozzle 62. It is preferable to dispose the tip of the nozzle 62 at a position above the core crimping piece 25 so that the protective agent is supplied around the boundary between the exposed core 13 a and the terminal 20. Further, in order to quickly solidify the protective agent poured into the groove 44, it is preferable to preheat the lower mold 42 before pouring the protective agent. Further, the discharge amount of the protective agent is an amount that can cover the desired portion of the connecting portion 26 in the groove 44, and can be determined by speculative consideration and experimental experience.
  • the protective agent is filled in the groove 44.
  • the outflow suppression wall portion 52 exists on the counterpart terminal connection portion 28 side with respect to the connection portion 26
  • the outflow of the protective agent to the counterpart terminal connection portion 28 side is suppressed.
  • the crimping portion of the covering crimping piece 24 is larger in diameter than the crimping portion of the core wire crimping piece 25, and the wire 12 is present inside and solid. For example, outflow to the covering portion 14 side is suppressed.
  • the protective agent is solidified in the course of flowing through the groove 44, and the groove 44 is directed toward the counterpart terminal connection portion 28 or the covering portion 14. Outflow is suppressed.
  • the protective agent which is a thermosetting resin, is solidified in the course of flowing in the groove 44, and the outflow to the mating terminal connecting portion 28 or the covering portion 14 side is suppressed. Is done.
  • the protective agent in the groove 44 is solidified by heating, so that the protective film 30 that covers the connection portion 26 and has an outer shape corresponding to the inner peripheral surface of the groove 44 is formed.
  • the terminal-attached electric wire 10 on which the protective film 30 is formed can be obtained by removing the electric wire 10 with the terminal from the groove 44.
  • the protective agent is formed by solidifying the protective agent poured into the groove 44, so that the protective film
  • the outer shape of 30 is a shape corresponding to the shape of the inner peripheral surface of the groove 44. For this reason, regardless of the shape of the surface of the connection portion 26, the protective film 30 having a fixed shape can be formed, and the required film thickness can be ensured more reliably.
  • the protective agent can be cured quickly and easily by heating the lower mold 42 or the like.
  • thermosetting resin it is easy to impart heat resistance to the cured protective film 30.
  • the protective agent can be solidified more quickly by pouring the protective agent into the groove 44 while the lower mold 42 is heated. Moreover, at this time, since the protective agent is supplied around the core wire crimping piece 25, the protective agent solidifies while flowing around it, and covers the connection portion 26. For this reason, it can suppress that a protective agent flows into the circumference
  • FIG. 1
  • a protective agent may be poured into the groove 44 of the lower mold 42, and it is not necessary to apply pressure to the internal space. For this reason, it is not necessary to prepare a large-scale mold facility such as a mold facility for resin injection molding, and the protective film 30 can be formed with a simple facility.
  • the protective agent is poured and solidified in the state where the outflow suppression wall portion 52 is disposed, the formation of the protective film 30 at the mating terminal connection portion 28 is suppressed. Thereby, the connection function of the other party terminal connection part 28 and the other party terminal is maintainable.
  • the outflow suppression wall 52 is fitted in the hole 23h for locking the locking protrusion of the cavity, the hole 23h is suppressed from being blocked by the protective film 30. Thereby, the positioning function at the time of inserting the terminal 20 in a cavity is maintained.
  • the outflow suppression wall 52 is not essential.
  • the part fitted in the said hole 23h protrudes from the bottom part of the groove
  • the ceiling part 54 is also disposed above the connection part 26, it is possible to suppress the protective film 30 from becoming unnecessarily thick on the connection part 26.
  • the ceiling 54 is not essential. Moreover, the said outflow suppression wall part 52 may be abbreviate
  • the outflow suppression wall portion 52 extends above the connection portion 26 so as to reach the covering portion 14 of the electric wire 12.
  • a ceiling portion 154 may be provided. Then, the protective agent may be poured or solidified in a state where the ceiling portion 154 is disposed above the connection portion 26.
  • the thickness dimension of the protective film 30 above the connecting portion 26 can be regulated, and the protective film 30 can be more reliably formed in a certain shape.
  • the hole 154h is preferably a hole into which the nozzle 62 can be inserted, and is formed at a position above the core wire crimping piece 25.
  • the protective agent can be injected around the connecting portion covered by the ceiling portion 154, particularly the core wire crimping piece 25 portion, and the protective film 30 can be more reliably formed around the connecting portion 26.
  • the groove 244 corresponding to the groove 44 may be narrow at a portion 244 a corresponding to the end portion of the covering portion 14 of the electric wire 12.
  • the width of the narrow portion 244a is preferably formed in a size corresponding to the diameter of the covering portion 14.
  • the depth dimension of the narrow part 244a is formed in the magnitude
  • the covering portion 14 is relatively stable in size and shape, unlike the crimping portions of the pair of covering crimping pieces 24. For this reason, the clearance gap between the narrow part 244a and the coating
  • each structure demonstrated by said each embodiment and each modification can be suitably combined unless it mutually contradicts.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Insulated Conductors (AREA)
  • Manufacturing Of Electric Cables (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Manufacturing Of Electrical Connectors (AREA)

Abstract

The purpose of the present invention is to ensure a necessary film thickness as reliably as possible at the time of forming a protection film on a connecting portion of an electrical cable and a terminal. Disclosed is a method for manufacturing an electrical cable that is provided with a terminal, said electrical cable having a protection film formed on the surface of a connecting portion of the cable and the terminal. The method is provided with: (a) a step of preparing the electrical cable having the terminal connected to an exposed core cable portion; (b) a step of disposing, in a groove formed in a lower molding die, the connecting portion of the electrical cable and the terminal; (c) a step of having a protecting agent flow into the groove; and (d) a step of forming the protection film by solidifying the protecting agent that has been made to flow into the groove, in a state wherein surface of the connecting portion is covered with the protecting agent.

Description

端子付電線の製造方法、端子付電線及び成型装置Manufacturing method of electric wire with terminal, electric wire with terminal and molding device
　この発明は、電線と端子との接続部分に保護膜を形成する技術に関する。 This invention relates to a technique for forming a protective film at a connection portion between an electric wire and a terminal.
　特許文献１には、端子と導体との接続部のまわりに樹脂を塗布して保護膜を形成する技術が開示されている。 Patent Document 1 discloses a technique for forming a protective film by applying a resin around a connection portion between a terminal and a conductor.
特開２０１０－１０８７９８号公報JP 2010-108798 A
　しかしながら、端子と導体との接続部表面は複雑な凹凸形状を呈しているため、特許文献１に開示の技術では、保護に必要な膜厚を確保できない恐れがあった。凹凸形状を呈する表面に樹脂を塗布するだけでは、突起部分等で膜厚が薄くなってしまう恐れがあるからである。 However, since the surface of the connection portion between the terminal and the conductor has a complicated uneven shape, the technique disclosed in Patent Document 1 may not secure a film thickness necessary for protection. This is because if the resin is simply applied to the surface having the concavo-convex shape, the film thickness may be reduced at the protruding portion or the like.
　そこで、本発明は、電線と端子との接続部分に保護膜を形成する際に、必要膜厚をなるべく確実に確保できるようにすることを目的とする。 Therefore, an object of the present invention is to ensure a necessary film thickness as much as possible when forming a protective film at a connection portion between an electric wire and a terminal.
　上記課題を解決するため、第１の態様は、電線と端子との接続部の表面に保護膜が形成された端子付電線を製造する方法であって、(a)芯線に端子が接続された電線を準備する工程と、(b)前記電線と前記端子との前記接続部を、型に形成された溝内に配設する工程と、(c)前記溝内に保護剤を流し込む工程と、(d)前記溝内に流し込まれた保護剤を、前記接続部の表面を覆った状態で固化させて、保護膜を形成する工程とを備える。 In order to solve the above-mentioned problem, the first aspect is a method of manufacturing a terminal-attached electric wire in which a protective film is formed on the surface of the connection portion between the electric wire and the terminal, and (a) the terminal is connected to the core wire. A step of preparing an electric wire, (b) a step of arranging the connecting portion between the electric wire and the terminal in a groove formed in a mold, and (c) a step of pouring a protective agent into the groove; (d) forming a protective film by solidifying the protective agent poured into the groove in a state of covering the surface of the connecting portion.
　第２の態様は、第１の態様に係る端子付電線の製造方法であって、前記保護剤として、熱硬化性材料を用い、前記工程(d)では、加熱された前記型によって前記熱硬化性材料を硬化させる。 A second aspect is a method for manufacturing a terminal-attached electric wire according to the first aspect, wherein a thermosetting material is used as the protective agent, and the thermosetting is performed by the heated mold in the step (d). The material is cured.
　第３の態様は、第２の態様に係る端子付電線の製造方法であって、前記工程(c)において、前記型を加熱した状態で、前記溝内に保護剤を流し込む。 A third aspect is a method of manufacturing a terminal-attached electric wire according to the second aspect, and in the step (c), a protective agent is poured into the groove while the mold is heated.
　第４の態様は、第１～第３のいずれか１つの態様に係る端子付電線の製造方法であって、前記接続部から前記端子の相手方端子接続部側への流出を抑制する流出抑制壁を配設した状態で、前記工程(c)及び(d)が実施される。 A fourth aspect is a method for manufacturing a terminal-attached electric wire according to any one of the first to third aspects, and an outflow suppression wall that suppresses outflow from the connection part to the counterpart terminal connection part side. The steps (c) and (d) are carried out in a state where is disposed.
　第５の態様は、第１～第４のいずれか１つの態様に係る端子付電線の製造方法であって、前記接続部の上方に天井部を配設した状態で、前記工程(c)及び(d)が実施される。 A fifth aspect is a method of manufacturing a terminal-attached electric wire according to any one of the first to fourth aspects, wherein the step (c) and the step (c) are performed in a state where a ceiling part is disposed above the connection part. (d) is implemented.
　第６の態様は、第４の態様に係る端子付電線の製造方法であって、前記流出抑制壁部から前記接続部の上方を通って前記電線の被覆部に達する位置に延出する天井部を、前記接続部の上方に配設した状態で、前記工程(c)及び(d)が実施される。 A 6th aspect is a manufacturing method of the electric wire with a terminal concerning the 4th aspect, Comprising: The ceiling part extended in the position which reaches the coating | coated part of the said electric wire through the upper part of the said connection part from the said outflow suppression wall part Are disposed above the connecting portion, the steps (c) and (d) are performed.
　第７の態様は、第６の態様に係る端子付電線の製造方法であって、前記天井部に前記保護剤注入用の孔が形成されている。 The seventh aspect is a method for manufacturing a terminal-attached electric wire according to the sixth aspect, wherein the hole for injecting the protective agent is formed in the ceiling portion.
　第８の態様は、第１～第７のいずれか１つの態様に係る端子付電線の製造方法であって、前記溝は、前記電線の被覆部のうち前記端子側の端部で狭くなっている。 An eighth aspect is a method of manufacturing a terminal-attached electric wire according to any one of the first to seventh aspects, wherein the groove is narrowed at an end portion on the terminal side of the covering portion of the electric wire. Yes.
　第９の態様に係る端子付電線は、端部に露出した芯線を有する電線と、前記電線の芯線に接続された端子と、前記電線と前記端子との接続部を前記溝内に配設した状態で、前記溝内に流し込まれた保護剤が固化することにより形成され、前記接続部の表面を覆う保護膜とを備える。 The electric wire with a terminal according to the ninth aspect includes an electric wire having a core wire exposed at an end, a terminal connected to the core wire of the electric wire, and a connection portion between the electric wire and the terminal in the groove. And a protective film that is formed by solidifying the protective agent poured into the groove and covers the surface of the connection portion.
　第１０の態様に係る成型装置は、電線と端子との接続部の表面に保護膜が形成された端子付電線を製造するための成型装置であって、前記電線と前記端子との前記接続部を配設可能な溝を有する型と、前記溝内に保護剤を供給する保護剤供給部とを備える。 A molding apparatus according to a tenth aspect is a molding apparatus for manufacturing a terminal-attached electric wire having a protective film formed on the surface of a connection portion between the electric wire and the terminal, and the connection portion between the electric wire and the terminal. And a protective agent supply unit for supplying a protective agent into the groove.
　第１の態様に係る端子付電線の製造方法によると、溝内に流し込んだ保護剤を固化させることで保護膜を形成しているため、必要膜厚をなるべく確実に確保できる。 According to the method for manufacturing a terminal-attached electric wire according to the first aspect, since the protective film is formed by solidifying the protective agent poured into the groove, the required film thickness can be ensured as reliably as possible.
　第２の態様によると、金型を加熱することで、熱硬化性材料を迅速に硬化させることができる。 According to the second aspect, the thermosetting material can be rapidly cured by heating the mold.
　第３の態様によると、溝内に保護剤を流し込むと、保護剤を迅速に固化させることができ、余分な部分への流れ出しを抑制することができる。 According to the third aspect, when the protective agent is poured into the groove, the protective agent can be quickly solidified, and flow out to an excessive portion can be suppressed.
　第４の態様によると、相手側端子接続部側での保護膜の形成が抑制される。 According to the 4th aspect, formation of the protective film in the other party terminal connection part side is suppressed.
　第５の態様によると、接続部上での保護膜の厚みを規制できる。 According to the fifth aspect, the thickness of the protective film on the connection portion can be regulated.
　第６の態様によると、接続部上ほぼ全体で保護膜の厚みを規制できる。 According to the sixth aspect, the thickness of the protective film can be regulated almost entirely on the connection part.
　第７の態様によると、天井部で覆われている接続部を中心に保護剤を注入でき、接続部周りにより確実に保護膜を形成できる。 According to the seventh aspect, the protective agent can be injected around the connection part covered with the ceiling part, and the protective film can be more reliably formed around the connection part.
　第８の態様によると、被覆部側への保護剤の流れ出しを抑制できる。 According to the eighth aspect, the outflow of the protective agent to the covering portion side can be suppressed.
　第９の態様に係る端子付電線によると、前記電線と前記端子との前記接続部を溝内に配設した状態で、前記溝内に流し込まれた保護剤が固化することにより保護膜が形成されているため、必要膜厚をなるべく確実に確保できる。 According to the terminal-attached electric wire according to the ninth aspect, a protective film is formed by solidifying the protective agent poured into the groove in a state where the connection portion between the electric wire and the terminal is disposed in the groove. Therefore, the required film thickness can be ensured as reliably as possible.
　第１０の態様に係る成型装置によると、前記電線と前記端子との前記接続部を溝内に配設した状態で、前記溝内に保護剤を供給して当該保護材を固化させることで、保護膜を形成することができる。このため、必要膜厚をなるべく確実に確保できるようにすることができる。 According to the molding apparatus according to the tenth aspect, in a state where the connection portion between the electric wire and the terminal is disposed in the groove, by supplying a protective agent into the groove and solidifying the protective material, A protective film can be formed. For this reason, it is possible to ensure the required film thickness as reliably as possible.
実施形態に係る端子付電線を示す概略側面図である。It is a schematic side view which shows the electric wire with a terminal which concerns on embodiment. 同上の端子付電線を示す概略平面図である。It is a schematic plan view which shows an electric wire with a terminal same as the above. 成型装置を示す概略斜視図である。It is a schematic perspective view which shows a shaping | molding apparatus. 同上の成型装置を示す概略断面図である。It is a schematic sectional drawing which shows a shaping | molding apparatus same as the above. 溝内に保護剤を流し込んだ状態を示す概略部分断面図である。It is a schematic fragmentary sectional view which shows the state which poured the protective agent in the groove | channel. 図５のＶＩ－ＶＩ線における概略断面図である。FIG. 6 is a schematic sectional view taken along line VI-VI in FIG. 5. 第１変形例に係る成型装置を示す概略断面図である。It is a schematic sectional drawing which shows the shaping | molding apparatus which concerns on a 1st modification. 溝内に保護剤を流し込んだ状態を示す概略部分断面図である。It is a schematic fragmentary sectional view which shows the state which poured the protective agent in the groove | channel. 図８のＩＸ－ＩＸ線における概略断面図である。It is a schematic sectional drawing in the IX-IX line of FIG. 第２変形例に係る溝を示す概略斜視図である。It is a schematic perspective view which shows the groove | channel which concerns on a 2nd modification.
　以下、実施形態に係る端子付電線の製造方法、端子付電線及び成型装置について説明する。 Hereinafter, the manufacturing method of the electric wire with a terminal concerning an embodiment, the electric wire with a terminal, and a molding device are explained.
　図１は端子付電線１０を示す概略側面図であり、図２は端子付電線１０を示す概略平面図である。この端子付電線１０は、電線１２と端子２０と保護膜３０を備えている。 FIG. 1 is a schematic side view showing an electric wire 10 with a terminal, and FIG. 2 is a schematic plan view showing the electric wire 10 with a terminal. The electric wire with terminal 10 includes an electric wire 12, a terminal 20, and a protective film 30.
　電線１２は、芯線部１３の外周に被覆部１４が押出被覆等によって被覆された構成とされている。芯線部１３は、銅、銅合金、アルミニウム、アルミニウム合金等の金属線の単線又は撚り合わせ線によって構成されている。ここでは、芯線部１３が、アルミニウム又はアルミニウム合金の金属線を複数より合わせることによって構成されている例で説明する。また、電線１２の端部の被覆部１４が皮剥され、電線１２の端部に露出芯線部１３ａが形成されている。 The electric wire 12 is configured such that the outer periphery of the core wire portion 13 is covered with a covering portion 14 by extrusion coating or the like. The core wire portion 13 is configured by a single wire or a stranded wire of metal wires such as copper, copper alloy, aluminum, and aluminum alloy. Here, an example in which the core wire portion 13 is configured by combining a plurality of metal wires of aluminum or aluminum alloy will be described. Further, the covering portion 14 at the end of the electric wire 12 is peeled off, and an exposed core portion 13 a is formed at the end of the electric wire 12.
　端子２０は、銅、銅合金等の金属板材を適宜プレス加工等することにより形成されている。端子２０の表面には、スズ、ニッケル等のメッキ層が形成されていてもよい。ここでは、端子２０の表面にスズメッキ層が形成されている例で説明する。 The terminal 20 is formed by appropriately pressing a metal plate material such as copper or copper alloy. A plating layer of tin, nickel, or the like may be formed on the surface of the terminal 20. Here, an example in which a tin plating layer is formed on the surface of the terminal 20 will be described.
　端子２０は、電線接続部２２と相手側端子接続部２８とを有している。 The terminal 20 has a wire connecting part 22 and a counterpart terminal connecting part 28.
　相手側端子接続部２８は、相手側の端子等と接続される部分であり、ここでは、略筒状の形状、いわゆるメス端子としての形状に形成されている。そして、この相手側端子接続部２８に、ピン状或はタブ状の接続部を有する相手側端子（いわゆるオス端子）が挿入接続される。また、相手側端子接続部２８の底部の一部にＵ字状のスリットを形成して下方に切り起すことにより下方に延出するスタビライザ２９が形成されている。このスタビライザは、本端子２０をコネクタのキャビティ内に挿入する際、当該キャビティに形成された溝内に案内される。これにより、キャビティ内で端子２０が一定姿勢に維持されるようになっている。 The counterpart terminal connection portion 28 is a portion connected to a counterpart terminal or the like, and is here formed in a substantially cylindrical shape, a so-called female terminal shape. Then, a mating terminal (so-called male terminal) having a pin-shaped or tab-shaped connecting section is inserted and connected to the mating terminal connecting section 28. Further, a stabilizer 29 extending downward is formed by forming a U-shaped slit in a part of the bottom of the counterpart terminal connection portion 28 and cutting it downward. The stabilizer is guided in a groove formed in the cavity when the terminal 20 is inserted into the cavity of the connector. Thereby, the terminal 20 is maintained in a fixed posture in the cavity.
　もっとも、相手側端子接続部２８は、ピン状或はタブ状の形状、いわゆるオス端子としての形状に形成されていてもよく、また、ねじ等によって相手側の部材に接続可能な環状形状に形成されていてもよい。 However, the mating terminal connection portion 28 may be formed in a pin-shaped or tab-shaped shape, a so-called male terminal shape, or in an annular shape that can be connected to the mating member by a screw or the like. May be.
　電線接続部２２は、電線１２の端部に接続可能に構成されている。ここでは、電線接続部２２は、底板部２３と、一対の被覆圧着片２４と、一対の芯線圧着片２５とを有している。底板部２３は、相手側端子接続部２８の基端部側に延出する長尺板状に形成されている。一体の被覆圧着片２４は、底板部２３の端部の両側部より延出する長尺片状に形成されている。電線接続部２２のうち一対の被覆圧着片２４が形成された部分は、断面略Ｕ字状に形成されている。一対の芯線圧着片２５は、一対の被覆圧着片２４と相手側端子接続部２８との間で、底板部２３の端部の両側部より延出する長尺片状に形成されている。電線接続部２２のうち一対の芯線圧着片２５が形成された部分は、断面略Ｕ字状に形成されている。 The electric wire connecting portion 22 is configured to be connectable to the end portion of the electric wire 12. Here, the electric wire connection portion 22 includes a bottom plate portion 23, a pair of coated crimping pieces 24, and a pair of core wire crimping pieces 25. The bottom plate portion 23 is formed in a long plate shape extending to the proximal end portion side of the counterpart terminal connection portion 28. The integral covering crimping piece 24 is formed in a long piece shape extending from both side portions of the end portion of the bottom plate portion 23. A portion of the electric wire connecting portion 22 where the pair of coated crimping pieces 24 are formed is formed in a substantially U-shaped cross section. The pair of core wire crimping pieces 25 are formed in a long piece shape extending from both sides of the end portion of the bottom plate portion 23 between the pair of coated crimping pieces 24 and the mating terminal connection portion 28. A portion of the electric wire connecting portion 22 where the pair of core wire crimping pieces 25 is formed is formed in a substantially U-shaped cross section.
　そして、上記一対の芯線圧着片２５が露出芯線部１３ａを抱持するように当該露出芯線部１３ａに圧着されると共に、一対の被覆圧着片２４が被覆部１４の端部を抱持するように当該被覆部１４に圧着されることにより、電線１２の端部と端子２０とが接続されている。ここでは、一対の芯線圧着片２５が露出芯線部１３ａに圧着された部分を、電線１２と端子２０との接続部２６という。もっとも、露出芯線部１３ａと端子２０との接続は、圧着による場合に限られず、超音波溶接、抵抗溶接等の溶接、半田付による接合を利用したものであってもよい。 The pair of core wire crimping pieces 25 are crimped to the exposed core wire portion 13a so as to hold the exposed core wire portion 13a, and the pair of covering crimping pieces 24 hold the end portions of the covering portion 14. By being crimped to the covering portion 14, the end portion of the electric wire 12 and the terminal 20 are connected. Here, a portion where the pair of core wire crimping pieces 25 is crimped to the exposed core wire portion 13 a is referred to as a connection portion 26 between the electric wire 12 and the terminal 20. Of course, the connection between the exposed core portion 13a and the terminal 20 is not limited to the case of crimping, but may be one using welding such as ultrasonic welding or resistance welding, or joining by soldering.
　なお、相手側端子接続部２８と電線接続部２２との間の底部には、方形状の孔部２３ｈが形成されている。そして、端子２０がコネクタのキャビティ内に挿入された状態で、キャビティ内に突出するように形成された係止突起（いわゆるランスと呼ばれる部分）が本孔部２３ｈに嵌り込んで端子２０に係止することで、キャビティ内での端子２０の位置決めが図られるようになっている。 A rectangular hole 23 h is formed at the bottom between the mating terminal connection 28 and the wire connection 22. Then, in a state where the terminal 20 is inserted into the cavity of the connector, a locking projection (a so-called lance) formed so as to protrude into the cavity is fitted into the hole 23h and locked to the terminal 20. By doing so, the terminal 20 can be positioned in the cavity.
　保護膜３０は、上記接続部２６の表面、より具体的には、露出芯線部１３ａと端子２０との境界を中心とする表面部分を覆うように形成されている。この保護膜３０は、上記接続部２６を後述する溝４４内に配設した状態で、当該溝４４内に流し込まれた保護剤が固化することにより形成されている。保護剤としては、液状態で塗布した後、揮発、冷却、加熱、光等（放置による揮発、冷却等も含む）によって固化可能なものを用いることができる。ここでは、保護剤として熱硬化性を想定した例で説明する。 The protective film 30 is formed so as to cover the surface of the connecting portion 26, more specifically, the surface portion centering on the boundary between the exposed core portion 13 a and the terminal 20. The protective film 30 is formed by solidifying the protective agent poured into the groove 44 in a state where the connecting portion 26 is disposed in the groove 44 described later. As the protective agent, one that can be solidified by volatilization, cooling, heating, light, etc. (including volatilization by cooling, cooling, etc.) after coating in a liquid state can be used. Here, an example in which thermosetting is assumed as the protective agent will be described.
　上記のような保護膜３０は、接続部２６表面を覆うことで、当該部分への液体の付着等を抑制し、もって劣化を抑制する役割を果す。特に、芯線部１３としてアルミニウム又はアルミニウム合金を用い、端子２０として銅又は銅合金の表面にスズメッキ層が形成された構成のものを用いた場合、両者間で電位差が大きくなる。このため、電線接続部２２と露出芯線部１３ａとの接続部分に水分が付着すると、水分が電解液として作用し、電食が生じてしまう恐れがある。そこで、上記のように、接続部２６の表面に保護膜３０を形成することで、その表面部分での電食を有効に抑制することができる。このような保護膜３０は、例えば、樹脂等の塗布材料を熱で溶融させて塗布した後、冷却固化する等、各種方法によって形成することができる。 The protective film 30 as described above covers the surface of the connecting portion 26, thereby suppressing the adhesion of the liquid to the portion and thereby suppressing the deterioration. In particular, when aluminum or an aluminum alloy is used as the core wire portion 13 and a structure in which a tin plating layer is formed on the surface of copper or a copper alloy as the terminal 20 is used, the potential difference between the two becomes large. For this reason, if moisture adheres to the connecting portion between the wire connecting portion 22 and the exposed core portion 13a, the moisture may act as an electrolytic solution, which may cause electrolytic corrosion. Therefore, as described above, by forming the protective film 30 on the surface of the connection portion 26, electrolytic corrosion on the surface portion can be effectively suppressed. Such a protective film 30 can be formed by various methods, for example, by applying a coating material such as a resin by melting it with heat and then cooling and solidifying it.
　上記保護膜３０の成形するための成型装置４０について説明する。図３は成型装置４０を示す概略斜視図であり、図４は同成型装置４０を示す概略断面図である。 A molding apparatus 40 for molding the protective film 30 will be described. FIG. 3 is a schematic perspective view showing the molding apparatus 40, and FIG. 4 is a schematic sectional view showing the molding apparatus 40.
　成型装置４０は、下型４２と、上型５０と、保護剤供給部６０とを備えている。 The molding apparatus 40 includes a lower mold 42, an upper mold 50, and a protective agent supply unit 60.
　下型４２は、金属等で形成された部材であり、上部に溝４４が形成されている。溝４４は、上記接続部２６を配設可能な形状及び大きさに形成されている。より具体的には、溝４４の長さ寸法は、電線接続部２２の長さ寸法よりも大きく設定されている。また、溝４４の幅寸法は電線接続部２２の幅寸法よりも大きく設定されている。保護膜３０が接続部２６を保護するのに必要と想定される膜厚をｈ（ｍｍ）とすると、溝４４の幅寸法は、電線接続部２２の幅寸法（保護が必要とされる部分の最大幅寸法）に、前記必要膜厚ｈの２倍を加算した大きさよりも大きくしておくことが好ましい。これにより、電線接続部２２の両側部で必要膜厚ｈを確保できるからである。また、溝４４の深さ寸法は、電線接続部２２の高さ寸法（保護が必要とされる部分の最大高さ寸法）に、前記必要膜厚ｈを加算した大きさよりも大きくしておくことが好ましい。これにより、電線接続部２２の上方で必要膜厚を確保できるからである。なお、電線接続部２２の下方部分は、端子２０の底板部２３の外面が一様に露出しており、露出芯線部１３ａと端子２０との境界部分から離れているため、保護の必要性は少ない。このため、保護膜３０は薄くても或は無くてもよい。 The lower mold 42 is a member formed of metal or the like, and has a groove 44 formed in the upper part. The groove 44 is formed in a shape and size capable of disposing the connecting portion 26. More specifically, the length dimension of the groove 44 is set to be larger than the length dimension of the wire connecting portion 22. Further, the width dimension of the groove 44 is set to be larger than the width dimension of the electric wire connecting portion 22. When the film thickness assumed to be necessary for the protective film 30 to protect the connection portion 26 is h (mm), the width dimension of the groove 44 is equal to the width dimension of the electric wire connection section 22 (the portion where protection is required). It is preferable to make it larger than the maximum width dimension) plus twice the required film thickness h. This is because the required film thickness h can be secured at both side portions of the wire connection portion 22. Further, the depth dimension of the groove 44 should be larger than the height dimension of the electric wire connecting portion 22 (the maximum height dimension of the portion where protection is required) plus the required film thickness h. Is preferred. This is because the necessary film thickness can be secured above the wire connection portion 22. In addition, since the outer surface of the bottom plate part 23 of the terminal 20 is uniformly exposed in the lower part of the wire connection part 22 and is away from the boundary part between the exposed core part 13a and the terminal 20, the necessity for protection is Few. For this reason, the protective film 30 may or may not be thin.
　そして、端子２０の相手側端子接続部２８及び電線１２を溝４４の両端開口から外方に延出させた状態で、電線１２と端子２０との接続部２６を、溝４４内に、はみ出ないように完全に収容できるようになっている（図４参照）。 And the connection part 26 of the electric wire 12 and the terminal 20 does not protrude in the groove | channel 44 in the state which made the other party terminal connection part 28 and the electric wire 12 of the terminal 20 extend outward from the both-ends opening of the groove | channel 44. (See FIG. 4).
　また、下型４２には、ヒータ等の加熱部４６が組込まれており、この加熱部４６によって、下型４２が、熱硬化性樹脂である保護剤を熱硬化可能な温度に加熱される。例えば、熱硬化性樹脂として硬化開始温度が７５℃であるものを用いた場合、下型４２を８５度に加熱するとよい。また、下型４２の熱が上型５０にも伝達され加熱されるため、上型５０を別の加熱装置で加熱しておくことは必要ではない。加熱は、下型４２に設けられた加熱部４６による他、赤外線ヒータ等の照射熱によって行われてもよい。また、保護剤として、その他の保護剤を用いた場合には、加熱部４６は必須ではなく、溝４４内の保護剤を固化可能な条件下に配設できればよい。 In addition, the lower mold 42 incorporates a heating unit 46 such as a heater, and the heating unit 46 heats the lower mold 42 to a temperature at which the protective agent, which is a thermosetting resin, can be thermally cured. For example, when a thermosetting resin having a curing start temperature of 75 ° C. is used, the lower mold 42 may be heated to 85 degrees. In addition, since the heat of the lower mold 42 is transmitted to the upper mold 50 and heated, it is not necessary to heat the upper mold 50 with another heating device. The heating may be performed by irradiation heat such as an infrared heater as well as by the heating unit 46 provided in the lower mold 42. In addition, when other protective agent is used as the protective agent, the heating unit 46 is not essential, as long as the protective agent in the groove 44 can be solidified.
　上型５０は、流出抑制壁部５２と天井部５４とを有している。流出抑制壁部５２は接続部２６から相手側端子接続部２８側への流出を抑制可能に構成され、天井部５４は接続部２６の上方に配設可能に構成されている。 The upper mold 50 has an outflow suppression wall portion 52 and a ceiling portion 54. The outflow suppression wall portion 52 is configured to be able to suppress outflow from the connection portion 26 to the counterpart terminal connection portion 28 side, and the ceiling portion 54 is configured to be disposed above the connection portion 26.
　より具体的には、上型５０は、金属等によって形成されており、上記溝４４内に配設可能なブロック状部材の一部を下方に突出させた形状とされている。そして、その下方突出部分が上記流出抑制壁部５２に形成され、流出抑制壁部５２の基端部より側方に延びる部分が天井部５４に形成されている。 More specifically, the upper mold 50 is made of metal or the like, and has a shape in which a part of a block-like member that can be disposed in the groove 44 protrudes downward. And the downward protrusion part is formed in the said outflow suppression wall part 52, and the part extended to a side from the base end part of the outflow suppression wall part 52 is formed in the ceiling part 54. As shown in FIG.
　流出抑制壁部５２は、溝４４内にその上方より挿入可能で、かつ、溝４４内に配設された端子２０のうち電線接続部２２と相手側端子接続部２８との間であって露出芯線部１３ａの先端部より離れた位置に配設可能に構成されている。ここでは、流出抑制壁部５２は、相手側端子接続部２８の基端側の一対の側壁部分２８ａ間に配設可能に形成され、また、その先端部は孔部２３ｈ内に配設可能に形成されている。 The outflow suppression wall portion 52 can be inserted into the groove 44 from above, and is exposed between the wire connection portion 22 and the mating terminal connection portion 28 of the terminals 20 disposed in the groove 44. It is configured to be disposed at a position away from the tip of the core wire portion 13a. Here, the outflow suppression wall portion 52 is formed so as to be disposed between the pair of side wall portions 28a on the proximal end side of the counterpart terminal connection portion 28, and the distal end portion thereof can be disposed in the hole portion 23h. Is formed.
　また、天井部５４は、上記流出抑制壁部５２より接続部２６側へ突出している。そして、上記流出抑制壁部５２が端子２０のうち電線接続部２２と相手側端子接続部２８との間に配設された状態で、天井部５４の下向き面が溝４４内でかつ溝４４内の接続部２６より上方に離れた位置に配設されるようになっている。 Further, the ceiling portion 54 protrudes from the outflow suppression wall portion 52 toward the connection portion 26 side. In the state where the outflow suppression wall portion 52 is disposed between the wire connection portion 22 and the counterpart terminal connection portion 28 in the terminal 20, the downward surface of the ceiling portion 54 is in the groove 44 and in the groove 44. It is arrange | positioned in the position away from the connection part 26 of this.
　保護剤供給部６０は、上記溝４４内に液状である保護剤を流し込む装置である。保護剤供給部６０として、ノズル６２から液体を一定量ずる吐出するディスペンサ等を用いることができる。 The protective agent supply unit 60 is a device for pouring a liquid protective agent into the groove 44. As the protective agent supply unit 60, a dispenser that discharges a predetermined amount of liquid from the nozzle 62 can be used.
　上記成型装置４０を用いた端子付電線１０の製造方法について説明する。 The manufacturing method of the electric wire 10 with a terminal using the said shaping | molding apparatus 40 is demonstrated.
　まず、露出芯線部１３ａに端子２０が接続された電線１２を準備する（図１及び図２参照）。 First, the electric wire 12 in which the terminal 20 is connected to the exposed core portion 13a is prepared (see FIGS. 1 and 2).
　次に、上型５０を下型４２の上方に移動させた状態で、接続部２６を溝４４内に配設する（図４参照）。この際、接続部２６を溝４４内の一定位置に配設できるようにすることが好ましい。ここでは、スタビライザ２９の溝４４の一方側開口縁部に当接させることで、接続部２６を溝４４の軸方向一定位置に位置決めすることができる。また、端子２０の相手側端子接続部２８の幅寸法と溝４４の幅寸法とを一致させ、相手側端子接続部２８の両外面を、溝４４の両側面に当接させることで、端子２０を溝４４内で幅方向一定位置に位置決めすることができる。そして、下型４２を溝４４内に向けて移動させる。これにより、流出抑制壁部５２が、溝４４内に配設された端子２０のうち電線接続部２２と相手側端子接続部２８との間であって露出芯線部１３ａの先端部より離れた位置に配設される。また、天井部５４が、溝４４内で接続部２６より上方に配設される。 Next, in a state where the upper mold 50 is moved above the lower mold 42, the connecting portion 26 is disposed in the groove 44 (see FIG. 4). At this time, it is preferable that the connecting portion 26 can be disposed at a fixed position in the groove 44. Here, the connecting portion 26 can be positioned at a fixed position in the axial direction of the groove 44 by abutting against the opening side edge of the groove 44 of the stabilizer 29. Further, the width dimension of the mating terminal connection portion 28 of the terminal 20 is matched with the width dimension of the groove 44, and both outer surfaces of the mating terminal connection portion 28 are brought into contact with both side surfaces of the groove 44. Can be positioned in the groove 44 at a fixed position in the width direction. Then, the lower mold 42 is moved into the groove 44. As a result, the outflow suppression wall portion 52 is located between the wire connecting portion 22 and the mating terminal connecting portion 28 in the terminal 20 disposed in the groove 44 and away from the distal end portion of the exposed core portion 13a. It is arranged. Further, the ceiling portion 54 is disposed above the connection portion 26 in the groove 44.
　この状態で、図５に示すように、ノズル６２により溝４４内に保護剤を流し込む。露出芯線部１３ａと端子２０との境界を中心として保護剤が供給されるように、ノズル６２の先端部を、芯線圧着片２５の上方位置に配設しておくことが好ましい。また、溝４４内に流し込まれた保護剤が迅速に固化するために、保護剤を流し込む前に、下型４２を予め加熱しておくことが好ましい。また、保護剤の吐出量は、溝４４内で接続部２６の所望部分を覆える程度の量であり、推論的考察、実験的経験的に決定することができる。 In this state, as shown in FIG. 5, the protective agent is poured into the groove 44 by the nozzle 62. It is preferable to dispose the tip of the nozzle 62 at a position above the core crimping piece 25 so that the protective agent is supplied around the boundary between the exposed core 13 a and the terminal 20. Further, in order to quickly solidify the protective agent poured into the groove 44, it is preferable to preheat the lower mold 42 before pouring the protective agent. Further, the discharge amount of the protective agent is an amount that can cover the desired portion of the connecting portion 26 in the groove 44, and can be determined by speculative consideration and experimental experience.
　すると、保護剤が溝４４内に充填される。この際、接続部２６に対して相手側端子接続部２８側では、流出抑制壁部５２が存在するため、相手側端子接続部２８側への保護剤の流出が抑制される。また、接続部２６に対して電線１２の被覆部１４側では、被覆圧着片２４の圧着部分が芯線圧着片２５の圧着部分よりも太径で、かつ、その内部に電線１２が存在し中実であること等によって、当該被覆部１４側への流出が抑制される。 Then, the protective agent is filled in the groove 44. At this time, since the outflow suppression wall portion 52 exists on the counterpart terminal connection portion 28 side with respect to the connection portion 26, the outflow of the protective agent to the counterpart terminal connection portion 28 side is suppressed. Further, on the side of the covering portion 14 of the electric wire 12 with respect to the connecting portion 26, the crimping portion of the covering crimping piece 24 is larger in diameter than the crimping portion of the core wire crimping piece 25, and the wire 12 is present inside and solid. For example, outflow to the covering portion 14 side is suppressed.
　また、上記溝４４を、保護剤を固化可能な条件下に曝しておくことによって、保護剤が溝４４内を流れる途中で固化し、上記相手側端子接続部２８或は被覆部１４側への流出が抑制される。ここでは、下型４２が加熱されているため、熱硬化性樹脂である保護剤が溝４４内を流れる途中で固化し、上記相手側端子接続部２８或は被覆部１４側への流出が抑制される。 Further, by exposing the groove 44 to a condition in which the protective agent can be solidified, the protective agent is solidified in the course of flowing through the groove 44, and the groove 44 is directed toward the counterpart terminal connection portion 28 or the covering portion 14. Outflow is suppressed. Here, since the lower mold 42 is heated, the protective agent, which is a thermosetting resin, is solidified in the course of flowing in the groove 44, and the outflow to the mating terminal connecting portion 28 or the covering portion 14 side is suppressed. Is done.
　また、少なくとも天井部５４が設けられた部分では、接続部２６の上方で保護膜３０が必要以上の厚みになることを抑制できる。 Further, at least in the portion where the ceiling portion 54 is provided, it is possible to prevent the protective film 30 from becoming thicker than necessary above the connection portion 26.
　そして、溝４４内の保護剤が加熱によって固化することで、接続部２６を覆い、かつ、溝４４の内周面に応じた外形状を有する保護膜３０が形成される。 Then, the protective agent in the groove 44 is solidified by heating, so that the protective film 30 that covers the connection portion 26 and has an outer shape corresponding to the inner peripheral surface of the groove 44 is formed.
　保護膜３０が固化した後、溝４４から端子付電線１０を取出すことで、保護膜３０が形成された端子付電線１０を得ることができる。 After the protective film 30 is solidified, the terminal-attached electric wire 10 on which the protective film 30 is formed can be obtained by removing the electric wire 10 with the terminal from the groove 44.
　以上のように構成された端子付電線１０の製造方法、端子付電線１０及び成型装置４０によると、溝４４内に流し込んだ保護剤を固化させることで保護剤を形成しているため、保護膜３０の外形状は溝４４の内周面形状に応じた形状となる。このため、接続部２６の表面の形状に拘らず、一定形状の保護膜３０を形成することができ、必要膜厚をより確実に確保できる。 According to the manufacturing method of the electric wire with terminal 10 configured as described above, the electric wire with terminal 10 and the molding apparatus 40, the protective agent is formed by solidifying the protective agent poured into the groove 44, so that the protective film The outer shape of 30 is a shape corresponding to the shape of the inner peripheral surface of the groove 44. For this reason, regardless of the shape of the surface of the connection portion 26, the protective film 30 having a fixed shape can be formed, and the required film thickness can be ensured more reliably.
　また、保護剤として熱硬化性樹脂を用いているため、下型４２を加熱等しておくことで、保護剤を迅速かつ簡易に硬化させることができる。 Also, since a thermosetting resin is used as the protective agent, the protective agent can be cured quickly and easily by heating the lower mold 42 or the like.
　また、熱硬化性樹脂を用いることで、硬化後の保護膜３０に耐熱性を持たせやすい。 In addition, by using a thermosetting resin, it is easy to impart heat resistance to the cured protective film 30.
　さらに、下型４２を加熱した状態で、保護剤を溝４４内に流し込むことで、当該保護剤をより迅速に固化させることができる。しかも、この際、芯線圧着片２５を中心として保護剤を供給しているため、保護剤がその周りに流れ込みつつ固化して、接続部２６を覆う。このため、保護剤が接続部２６の周囲に流れ込むことを抑制できる。 Furthermore, the protective agent can be solidified more quickly by pouring the protective agent into the groove 44 while the lower mold 42 is heated. Moreover, at this time, since the protective agent is supplied around the core wire crimping piece 25, the protective agent solidifies while flowing around it, and covers the connection portion 26. For this reason, it can suppress that a protective agent flows into the circumference | surroundings of the connection part 26. FIG.
　また、上記下型４２の溝４４に対しては、保護剤を流し込めればよく、内部空間に圧を加えたりする必要はない。このため、樹脂射出成型用の金型設備等の大がかりな金型設備を準備する必要がなく、簡易な設備で保護膜３０を形成できる。 In addition, a protective agent may be poured into the groove 44 of the lower mold 42, and it is not necessary to apply pressure to the internal space. For this reason, it is not necessary to prepare a large-scale mold facility such as a mold facility for resin injection molding, and the protective film 30 can be formed with a simple facility.
　また、流出抑制壁部５２を配設した状態で保護剤の流し込み及び固化を行っているため、相手側端子接続部２８での保護膜３０の形成が抑制される。これにより、相手側端子接続部２８と相手方端子との接続機能を維持できる。 Further, since the protective agent is poured and solidified in the state where the outflow suppression wall portion 52 is disposed, the formation of the protective film 30 at the mating terminal connection portion 28 is suppressed. Thereby, the connection function of the other party terminal connection part 28 and the other party terminal is maintainable.
　また、流出抑制壁部５２が、キャビティの係止突起が係止するための孔部２３ｈに嵌り込んでいるため、当該孔部２３ｈが保護膜３０によって塞がれることが抑制される。これにより、端子２０をキャビティ内に挿入する際の位置決め機能が維持される。 In addition, since the outflow suppression wall 52 is fitted in the hole 23h for locking the locking protrusion of the cavity, the hole 23h is suppressed from being blocked by the protective film 30. Thereby, the positioning function at the time of inserting the terminal 20 in a cavity is maintained.
　なお、流出抑制壁部５２は必須ではない。また、溝４４の底部から上記孔部２３ｈに嵌め込まれる部分が突出しており、この突出部分が孔部２３ｈ内及び相手側端子接続部２８への保護剤流出抑制を図っていてもよい。 In addition, the outflow suppression wall 52 is not essential. Moreover, the part fitted in the said hole 23h protrudes from the bottom part of the groove | channel 44, and this protrusion part may aim at the protective agent outflow suppression to the inside of the hole 23h and the other party terminal connection part 28. FIG.
　また、接続部２６の上方にも天井部５４を配設しているため、接続部２６上で保護膜３０が必要以上の厚さになってしまうことを抑制できる。 Moreover, since the ceiling part 54 is also disposed above the connection part 26, it is possible to suppress the protective film 30 from becoming unnecessarily thick on the connection part 26.
　勿論、天井部５４は必須ではなない。また、上記流出抑制壁部５２を省略し、天井部５４だけを設けてもよい。 Of course, the ceiling 54 is not essential. Moreover, the said outflow suppression wall part 52 may be abbreviate | omitted and only the ceiling part 54 may be provided.
　なお、図７～図９に示す変形例のように、上記天井部５４に代えて、流出抑制壁部５２から接続部２６の上方を通って電線１２の被覆部１４に達するように延出する天井部１５４を設けてもよい。そして、この天井部１５４を接続部２６の上方に配設した状態で、保護剤の流し込み、固化等を行ってもよい。 7 to 9, instead of the ceiling portion 54, the outflow suppression wall portion 52 extends above the connection portion 26 so as to reach the covering portion 14 of the electric wire 12. A ceiling portion 154 may be provided. Then, the protective agent may be poured or solidified in a state where the ceiling portion 154 is disposed above the connection portion 26.
　これにより、接続部２６の上方での保護膜３０の厚み寸法を規制でき、保護膜３０をより確実に一定形状に形成できる。 Thereby, the thickness dimension of the protective film 30 above the connecting portion 26 can be regulated, and the protective film 30 can be more reliably formed in a certain shape.
　この際、天井部１５４には、保護剤注入用の孔部１５４ｈを形成しておくことが好ましい。孔部１５４ｈは上記ノズル６２を挿入可能な孔で、かつ、芯線圧着片２５の上方位置に形成されていることが好ましい。 At this time, it is preferable to form a hole 154h for injecting the protective agent in the ceiling 154. The hole 154h is preferably a hole into which the nozzle 62 can be inserted, and is formed at a position above the core wire crimping piece 25.
　これにより、天井部１５４で覆われている接続部、特に、芯線圧着片２５部分を中心に保護剤を注入でき、接続部２６を中心としてより確実に保護膜３０を形成できる。 Thus, the protective agent can be injected around the connecting portion covered by the ceiling portion 154, particularly the core wire crimping piece 25 portion, and the protective film 30 can be more reliably formed around the connecting portion 26.
　また、図１０に示す第２変形例のように、上記溝４４に対応する溝２４４が、電線１２の被覆部１４の端部に対応する部分２４４ａで、狭くなっていてもよい。この狭部分２４４ａの幅は、被覆部１４の直径に応じた大きさに形成されていることが好ましい。また、狭部分２４４ａの深さ寸法は、被覆部１４の直径に応じた大きさに形成されていることが好ましい。 Further, as in the second modification shown in FIG. 10, the groove 244 corresponding to the groove 44 may be narrow at a portion 244 a corresponding to the end portion of the covering portion 14 of the electric wire 12. The width of the narrow portion 244a is preferably formed in a size corresponding to the diameter of the covering portion 14. Moreover, it is preferable that the depth dimension of the narrow part 244a is formed in the magnitude | size according to the diameter of the coating | coated part 14. FIG.
　これにより、溝２４４内に流し込まれた保護剤が被覆部１４側に流れ出すことを抑制できる。特に、被覆部１４は、一対の被覆圧着片２４の圧着部分とは異なり、比較的大きさ及び形状が安定している。このため、狭部分２４４ａと被覆部１４との隙間を安定して小さくすることができ、上記流れ出し防止効果が高い。 Thereby, it is possible to suppress the protective agent poured into the groove 244 from flowing out toward the covering portion 14 side. In particular, the covering portion 14 is relatively stable in size and shape, unlike the crimping portions of the pair of covering crimping pieces 24. For this reason, the clearance gap between the narrow part 244a and the coating | coated part 14 can be made small stably, and the said flow-out prevention effect is high.
　なお、上記各実施形態及び各変形例で説明した各構成は、相互に矛盾しない限り適宜組合わせることができる。 In addition, each structure demonstrated by said each embodiment and each modification can be suitably combined unless it mutually contradicts.
　以上のようにこの発明は詳細に説明されたが、上記した説明は、すべての局面において、例示であって、この発明がそれに限定されるものではない。例示されていない無数の変形例が、この発明の範囲から外れることなく想定され得るものと解される。 Although the present invention has been described in detail as described above, the above description is illustrative in all aspects, and the present invention is not limited thereto. It is understood that countless variations that are not illustrated can be envisaged without departing from the scope of the present invention.

Claims (10)

  1. 　電線と端子との接続部の表面に保護膜が形成された端子付電線を製造する方法であって、
    　(a)芯線に端子が接続された電線を準備する工程と、
    　(b)前記電線と前記端子との前記接続部を、型に形成された溝内に配設する工程と、
    　(c)前記溝内に保護剤を流し込む工程と、
    　(d)前記溝内に流し込まれた保護剤を、前記接続部の表面を覆った状態で固化させて、保護膜を形成する工程と、
    　を備える端子付電線の製造方法。     A method of manufacturing a terminal-attached electric wire in which a protective film is formed on the surface of the connection portion between the electric wire and the terminal,
    (a) preparing a wire having a terminal connected to the core wire;
    (b) the step of disposing the connection portion between the electric wire and the terminal in a groove formed in a mold;
    (c) pouring a protective agent into the groove;
    (d) a step of forming a protective film by solidifying the protective agent poured into the groove while covering the surface of the connecting portion;
    The manufacturing method of the electric wire with a terminal provided with.
  2. 　請求項１記載の端子付電線の製造方法であって、
    　前記保護剤として、熱硬化性材料を用い、
    　前記工程(d)では、加熱された前記型によって前記熱硬化性材料を硬化させる、
    　端子付電線の製造方法。     It is a manufacturing method of the electric wire with a terminal according to claim 1,
    As the protective agent, a thermosetting material is used,
    In the step (d), the thermosetting material is cured by the heated mold.
    Manufacturing method of electric wire with terminal.
  3. 　請求項２記載の端子付電線の製造方法であって、
    　前記工程(c)において、前記型を加熱した状態で、前記溝内に保護剤を流し込む、
    　端子付電線の製造方法。     It is a manufacturing method of the electric wire with a terminal according to claim 2,
    In the step (c), with the mold heated, a protective agent is poured into the groove.
    Manufacturing method of electric wire with terminal.
  4. 　請求項１記載の端子付電線の製造方法であって、
    　前記接続部から前記端子の相手方端子接続部側への流出を抑制する流出抑制壁を配設した状態で、前記工程(c)及び(d)が実施される、端子付電線の製造方法。     It is a manufacturing method of the electric wire with a terminal according to claim 1,
    A method for manufacturing a terminal-attached electric wire, wherein the steps (c) and (d) are performed in a state in which an outflow suppression wall that suppresses outflow of the terminal from the connection portion to the counterpart terminal connection portion side is provided.
  5. 　請求項１記載の端子付電線の製造方法であって、
    　前記接続部の上方に天井部を配設した状態で、前記工程(c)及び(d)が実施される、端子付電線の製造方法。     It is a manufacturing method of the electric wire with a terminal according to claim 1,
    The method for manufacturing a terminal-attached electric wire, wherein the steps (c) and (d) are performed in a state where a ceiling portion is disposed above the connection portion.
  6. 　請求項４記載の端子付電線の製造方法であって、
    　前記流出抑制壁部から前記接続部の上方を通って前記電線の被覆部に達する位置に延出する天井部を、前記接続部の上方に配設した状態で、前記工程(c)及び(d)が実施される、端子付電線の製造方法。     It is a manufacturing method of the electric wire with a terminal according to claim 4,
    In the state where the ceiling portion extending from the outflow suppression wall portion to the position reaching the covering portion of the electric wire through the connection portion is disposed above the connection portion, the steps (c) and (d) ) Is carried out.
  7. 　請求項６記載の端子付電線の製造方法であって、
    　前記天井部に前記保護剤注入用の孔が形成されている、端子付電線の製造方法。     It is a manufacturing method of the electric wire with a terminal according to claim 6,
    The manufacturing method of the electric wire with a terminal by which the hole for the said protective agent injection | pouring is formed in the said ceiling part.
  8. 　請求項１記載の端子付電線の製造方法であって、
    　前記溝は、前記電線の被覆部のうち前記端子側の端部で狭くなっている、端子付電線の製造方法。     It is a manufacturing method of the electric wire with a terminal according to claim 1,
    The said groove | channel is a manufacturing method of the electric wire with a terminal currently narrowed by the edge part by the side of the said terminal among the coating | coated parts of the said electric wire.
  9. 　端部に露出した芯線を有する電線と、
    　前記電線の芯線に接続された端子と、
    　前記電線と前記端子との接続部を前記溝内に配設した状態で、前記溝内に流し込まれた保護剤が固化することにより形成され、前記接続部の表面を覆う保護膜と、
    　を備える端子付電線。     An electric wire having a core wire exposed at the end;
    A terminal connected to the core of the electric wire;
    With the connecting portion between the wire and the terminal disposed in the groove, the protective agent poured into the groove is formed by solidification, and a protective film covering the surface of the connecting portion,
    An electric wire with a terminal.
  10. 　電線と端子との接続部の表面に保護膜が形成された端子付電線を製造するための成型装置であって、
    　前記電線と前記端子との前記接続部を配設可能な溝を有する型と、
    　前記溝内に保護剤を供給する保護剤供給部と、
    　を備える成型装置。     A molding device for producing a terminal-attached electric wire in which a protective film is formed on the surface of the connection portion between the electric wire and the terminal,
    A mold having a groove capable of disposing the connecting portion between the electric wire and the terminal;
    A protective agent supply unit for supplying a protective agent into the groove;
    A molding apparatus comprising:
PCT/JP2011/072515 2011-03-28 2011-09-30 Method for manufacturing electrical cable provided with terminal, electrical cable provided with terminal, and molding apparatus WO2012132066A1 (en)

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JP2011069353A JP2012204239A (en) 2011-03-28 2011-03-28 Method for manufacturing electric wire with terminal, electric wire with terminal, and molding device

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JP6117264B2 (en) * 2015-03-18 2017-04-19 矢崎総業株式会社 Manufacturing method of connection terminal
JP2016219216A (en) * 2015-05-19 2016-12-22 株式会社オートネットワーク技術研究所 Corrosion-proof method of wire with terminal, and wire with terminal
JP6547571B2 (en) * 2015-10-12 2019-07-24 株式会社オートネットワーク技術研究所 Connector and wire with terminal
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