WO2014129079A1 - 圧着端子、圧着接続構造体及び圧着接続構造体の製造方法 - Google Patents
圧着端子、圧着接続構造体及び圧着接続構造体の製造方法 Download PDFInfo
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- WO2014129079A1 WO2014129079A1 PCT/JP2013/084410 JP2013084410W WO2014129079A1 WO 2014129079 A1 WO2014129079 A1 WO 2014129079A1 JP 2013084410 W JP2013084410 W JP 2013084410W WO 2014129079 A1 WO2014129079 A1 WO 2014129079A1
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- crimping
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- crimp terminal
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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
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/02—Contact members
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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
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/02—Contact members
- H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
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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
- H01R4/10—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
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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
- H01R4/10—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
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/188—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping having an uneven wire-receiving surface to improve the contact
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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
- H01R4/10—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
- H01R4/20—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 using a crimping sleeve
- H01R4/203—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 using a crimping sleeve having an uneven wire-receiving surface to improve the contact
- H01R4/206—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 using a crimping sleeve having an uneven wire-receiving surface to improve the contact with transversal grooves or threads
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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
- H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
- H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
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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
- H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
- H01R43/048—Crimping apparatus or processes
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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
- H01R43/0221—Laser 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
- Y10T29/49176—Assembling terminal to elongated conductor with molding of electrically insulating material
Definitions
- the present invention relates to a crimp terminal that crimps and connects a covered electric wire, a crimp connection structure that crimp-connects the covered electric wire and the crimp terminal, and a method of manufacturing the crimp connection structure.
- Patent Document 1 describes a technique for preventing moisture from coming into contact with an exposed conductor by covering the exposed conductor with a resin insulator having a high viscosity.
- Patent Document 1 requires a new step of covering the exposed portion of the conductor with an insulator after the covered wire is crimped and connected. For this reason, according to the technique described in Patent Document 1, a lot of labor and time are required for crimping and connecting the covered electric wire, and the efficiency of the crimping step of the covered electric wire is reduced. From the above, without further reducing the efficiency of the crimping process of the covered electric wire, the water stoppage is further improved, and the conductor is corroded by the ingress of moisture, so that the mechanical strength is lowered or the conductivity of the conductor is lowered. Development of a technology capable of suppressing the deterioration of the so-called conductor is expected.
- the present invention has been made in view of the above problems, and its purpose is to further improve the water-stopping property without reducing the efficiency of the crimping process of the covered electric wire and to suppress the deterioration of the conductor due to the ingress of moisture.
- An object of the present invention is to provide a possible crimp terminal, a crimp connection structure, and a method for manufacturing the crimp connection structure.
- a crimp terminal includes a crimp portion that crimps and connects the exposed conductor portion of a covered electric wire having a conductor portion and a coating that covers the conductor portion.
- a crimp terminal wherein the crimp portion is formed and sealed in a hollow cylindrical shape with a sealed end on the opposite side to one end in the longitudinal direction in which the conductor portion is inserted. The opposite end is sealed by welding, and the crimping portion has an inner diameter smaller than the outer diameter of the sheath of the covered electric wire inside the exposed conductor portion, and the conductor.
- a guide portion having an inner diameter larger than the outer diameter of the portion, and the length from the end portion of the crimp portion into which the conductor portion is inserted to the guide portion is longer than the length of the exposed conductor portion of the covered electric wire It is short.
- an outer diameter of the exposed conductor portion is smaller than an outer diameter of the sheath of the covered electric wire, and the crimp portion is the crimp portion into which the exposed conductor portion is inserted.
- An inner diameter of the end portion of the coated wire is larger than an outer diameter of the coated wire.
- the crimp part further includes a latch part for latching the exposed conductor part inside the crimped part of the exposed conductor part.
- the length from the one end where the portion is inserted to the portion closest to the one end of the locking portion is longer than the length of the exposed conductor portion of the covered wire. To do.
- the crimp terminal according to the present invention is the above-described invention, wherein the crimp portion is reduced in diameter by a region for crimping the exposed conductor portion of the covered electric wire and a cross-sectional hollow cylindrical shape on the sealed side.
- the length from the boundary to the position where the diameter reduction starts when viewed from the end side of the crimping part where the conductor part is inserted in the guide part is longer than the length of the exposed conductor part of the covered electric wire. Characterized by its long length.
- the crimp terminal according to the present invention is characterized in that, in the above invention, the sealed end is sealed by fiber laser welding.
- the crimp terminal according to the present invention is characterized in that, in the above invention, the conductor portion is formed of an aluminum-based material, and the crimp portion is formed of a copper-based material.
- a crimped connection structure according to the present invention includes the crimp terminal according to the invention described above and the covered electric wire in which the conductor portion is crimped and connected to the crimp terminal.
- the crimp connection structure according to the present invention is characterized in that, in the above invention, a wire harness including at least one set of the crimp terminal and the covered electric wire is configured.
- the method for manufacturing a crimped connection structure according to the present invention is characterized in that the covered electric wire is inserted into the crimp terminal of the invention, and the exposed conductor portion of the covered electric wire is crimped and connected to the crimp terminal.
- the present invention without stopping the efficiency of the crimping process of the covered electric wire, it is possible to further improve the water-stopping property and suppress the decrease in the conductivity of the conductor due to the ingress of moisture.
- FIG. 1 is a longitudinal perspective view in which a crimp terminal according to a first embodiment of the present invention is divided at a central portion in the width direction.
- FIG. 2A is a schematic perspective view of the bottom surface side of the crimp terminal in which the box portion of the crimp terminal shown in FIG. 1 is in a transparent state.
- FIG. 2B is an enlarged view of the region shown in FIG. 2A.
- FIG. 2C is a cross-sectional view taken along line XX of the peripheral portion of the opposite end portion of FIG. 2B.
- FIG. 3 is an explanatory diagram for explaining a method of welding the crimping portion.
- FIG. 4A is a configuration diagram of a covered electric wire.
- FIG. 4B is an XZ cross-sectional view of the crimp portion of the crimp terminal shown in FIG. 1.
- 4C is an XY cross-sectional view of the crimp portion of the crimp terminal illustrated in FIG. 1.
- FIG. 5A is a perspective view showing a state before the covered electric wire is crimped and connected to the crimp terminal shown in FIG. 1.
- FIG. 5B is a perspective view showing a state after the covered electric wire is crimped and connected to the crimp terminal shown in FIG. 1.
- FIG. 6 is a diagram for explaining a state when a covered electric wire is inserted into the crimp portion of the crimp terminal shown in FIG. 1.
- FIG. 7 is a perspective view of the connector portion in the wire harness using the crimp terminal according to the first embodiment of the present invention.
- FIG. 8A is a cross-sectional view of a crimp portion of a crimp terminal according to the second embodiment of the present invention.
- FIG. 8B is a cross-sectional view of a crimp portion of a crimp terminal according to the second embodiment of the present invention.
- FIG. 9 is a sectional view showing another example of the crimp terminal according to the second embodiment of the present invention.
- FIG. 10A is a cross-sectional view of a crimp part of a crimp terminal according to a third embodiment of the present invention.
- FIG. 10A is a cross-sectional view of a crimp part of a crimp terminal according to a third embodiment of the present invention.
- FIG. 10B is a cross-sectional view of a crimp portion of a crimp terminal according to the third embodiment of the present invention.
- FIG. 11A is an explanatory diagram for explaining a method of welding a crimping part according to the fourth embodiment of the present invention.
- FIG. 11B is an explanatory diagram for explaining a method of welding a crimping portion according to the fourth embodiment of the present invention.
- FIG. 11C is an explanatory diagram for explaining a method of welding a crimping part according to the fourth embodiment of the present invention.
- FIG. 1 is a vertical perspective view in which a crimp terminal according to a first embodiment of the present invention is divided at a central portion in the width direction.
- the crimp terminal 10 according to the first embodiment of the present invention is formed as a female crimp terminal, and the male crimp terminal is arranged from the front side toward the rear side in the longitudinal direction X.
- the longitudinal direction X means a direction that coincides with the longitudinal direction of the covered electric wire to be crimped and connected by the crimping portion 30, and the width direction Y means the longitudinal direction X in a substantially horizontal plane. Means a direction perpendicular to.
- the height direction Z means a direction substantially perpendicular to the XY plane defined from the longitudinal direction X and the width direction Y.
- compression-bonding part 30 is described with the front, and conversely, the direction by the side of the crimping part 30 with respect to the box part 20 is described with the back.
- the crimp terminal 10 is formed as a female crimp terminal. However, if the crimp terminal has the crimp part 30, the crimp terminal 10 is inserted and connected to the box part 20 and the crimp part. 30 may be a male crimp terminal. Further, there may be a crimp terminal that has no box part or insertion tab and includes only a plurality of crimping parts 30, inserts the conductors of the plurality of covered electric wires, and crimps them to connect them together.
- the crimp terminal 10 is formed by punching a copper alloy strip such as brass whose surface as a plate material is subjected to tin plating (Sn plating) into the shape of the crimp terminal 10 which is flattened, and then forming the copper alloy strip into a hollow rectangular column.
- This is a closed barrel type terminal that is bent into a three-dimensional terminal shape composed of a body box portion 20 and a crimp portion 30 that is substantially O-shaped in a rear view and welded to the crimp portion 30.
- the box part 20 is provided with an elastic contact piece 21 that is bent rearward in the longitudinal direction X and comes into contact with the insertion tab of the male crimp terminal.
- the box portion 20 is formed in a substantially rectangular shape when viewed from the front side in the longitudinal direction X by bending the side surface portions 23 provided on both sides of the bottom surface portion 22 in the width direction Y so as to overlap each other.
- the crimping part 30 before crimping the covered electric wire is obtained by rolling the barrel constituent pieces 32 extending on both sides in the width direction Y of the crimping face 31 so that the crimping faces 31 are on the inner side. By butt welding each other, it is formed into a substantially O-shape when viewed from the rear.
- the length in the longitudinal direction X of the barrel constituting piece 32 is formed longer than the length in the longitudinal direction X of the conductor portion exposed from the covered electric wire.
- the crimping portion 30 includes a coated crimping range 30a for crimping an insulation coating as a coating for the coated wire, a wire crimping range 30b for crimping an electric wire exposed from the coated wire, and a wire crimping range 30b on the opposite side of the coated crimping range 30a. And a sealing portion 30c deformed so as to crush the front end portion into a substantially flat plate shape.
- a protrusion-shaped guide portion 33 is formed on the inner surface of the crimping portion 30 along the entire inner circumference of the crimping portion 30, and a wire locking groove 34 that is a groove extending in the YZ plane is predetermined along the longitudinal direction X.
- a plurality of lines are formed at intervals.
- the guide portion 33 is formed so as to form an annular protrusion in the crimping portion 30 at the boundary between the covering crimping range 30a and the wire crimping range 30b.
- the guide portion 33 is formed in an annular shape over the entire inner circumference of the crimping portion 30, but the guide portion does not necessarily have to be formed over the entire circumference.
- the guide part may be discretely formed in two or more spaced regions along the inner periphery.
- the point which becomes the center of the circle formed by the inner diameter of the guide portion 33 or the central angle of the circular arc substantially intersects with the central axis parallel to the X direction of the cylinder formed by the crimping portion 30. Composed.
- Three wire locking grooves 34 (also referred to as serrations) into which the wires exposed from the covered wires in the crimped state bite in the crimped state are formed on the inner surface of the wire crimping range 30b at predetermined intervals in the longitudinal direction X.
- the wire locking groove 34 is formed in a rectangular concave shape in cross section. Further, the wire locking groove 34 is formed from the crimping surface 31 to the middle of the barrel component piece 32, and improves the conductivity between the crimping portion 30 and the wire by biting the wire exposed from the covered wire. Yes.
- the wire locking groove may be formed continuously in the range from the crimping surface 31 to the barrel component piece 32, and an annular groove may be formed in the crimping portion 30.
- FIG. 2A is a schematic perspective view of the bottom surface side of the crimp terminal 10 with the box portion 20 of the crimp terminal 10 in a transparent state.
- FIG. 2B is an enlarged view of the region R shown in FIG. 2A.
- FIG. 2C is a sectional view taken along line XX of the peripheral portion of the opposed end portion 32a of FIG. 2B.
- FIG. 3 is an explanatory diagram for explaining a welding method of the crimping portion 30.
- the crimp terminal 10 is formed into a three-dimensional terminal shape composed of a box portion 20 of a hollow quadrangular prism and a crimp portion 30 having a substantially O-shape in rear view. Is manufactured by bending and welding the crimping portion 30.
- the crimping portion 30 is completely positioned in front of the crimping portion 30 at the longitudinal welding position W1 in the longitudinal direction X where the opposing end portions 32a of the barrel constituent pieces 32 are abutted with each other and the sealing portion 30c. It is formed by welding the width direction welding location W2 of the width direction Y sealed.
- the crimping part 30 when the crimping part 30 is manufactured, first, the crimping surface 31 and the barrel constituting piece 32 are rounded to form a cylindrical shape so that the opposed end parts 32a abut each other on the bottom surface side. Thereafter, as shown in FIG. 2B, the cylindrical front portion is pressed from the upper surface side to the bottom surface side to be deformed into a substantially flat plate shape. And as shown to FIG. 2C, after welding the longitudinal direction welding location W1 which faced
- the welding in the longitudinal direction welding location W1 and the width direction welding location W2 is performed by fiber laser welding using a fiber laser welding apparatus Fw.
- Fiber laser welding means welding using fiber laser light having a wavelength of about 1.08 ⁇ m.
- the fiber laser beam is an ideal Gaussian beam and can be condensed up to the diffraction limit, so that a condensing spot diameter of 30 ⁇ m or less, which could not be realized with a YAG laser or a CO 2 laser, can be configured. Therefore, welding with high energy density can be easily realized.
- the longitudinal direction welded portion W1 and the width direction welded portion W2 are welded by fiber laser welding, it is possible to configure the pressure-bonding portion 30 having waterstop.
- the conductor part of the covered electric wire crimp-connected by the crimping part 30 is not exposed to the outside air, and deterioration of the conductor part and secular change can be suppressed. Therefore, corrosion does not occur in the conductor portion, and an increase in electrical resistance caused by the corrosion can be prevented, so that stable conductivity can be obtained.
- fiber laser welding by performing the above welding by fiber laser welding, it is possible to configure the crimped portion 30 without a gap, and to reliably prevent moisture from entering the inside of the crimped portion 30 in the crimped state, thereby improving the water stoppage. it can.
- fiber laser welding can focus on an extremely small spot and realize high-power laser welding as compared with other laser welding, and continuous irradiation is possible. Therefore, by adopting fiber laser welding, it becomes possible to perform fine processing on the fine crimp terminal 10 while suppressing generation of laser marks and continuous processing. Therefore, it is possible to perform welding having a certain water stoppage.
- FIG. 4A is a configuration diagram of a covered electric wire to be crimped and connected to the crimp terminal 10.
- the covered electric wire 200 includes an aluminum core wire 201 that is a conductor portion and an insulating coating 202 that covers the aluminum core wire 201.
- the insulating coating 202 in the distal end region is removed, and an exposed wire portion 201a that is an exposed conductor portion is formed.
- the length of the electric wire exposed portion 201a is a
- the outer diameter of the aluminum core wire 201 (electric wire exposed portion 201a) is b
- the outer diameter of the covered electric wire 200 is c (that is, b ⁇ c).
- FIG. 4B is an XZ sectional view of the crimping portion 30 of the crimp terminal 10.
- FIG. 4C is an XY cross-sectional view of the crimping portion 30 of the crimp terminal.
- the inner diameter (smallest inner diameter) formed by the guide portion 33 is D1, where E1 is the inner diameter of the crimping portion 30 at the end in the X direction of the coated crimping range 30a, which is the end into which the covered electric wire 200 is inserted.
- the inner diameter D1 is, for example, 2.5 mm
- the inner diameter E1 is, for example, 3.1 mm.
- the inner diameter E1 of the end portion on the rear side in the X direction of the covered crimping range 30a is larger than the outer diameter c of the covered electric wire 200. That is, b ⁇ c ⁇ E1. Thereby, workability
- the guide The end of the coated crimping range 30a on the wire crimping range 30b side, which is the position at which the diameter reduction starts when viewed from the end side of the crimping portion 30 where the wire exposed portion 201a is inserted in the portion 33
- the length to the part is A1.
- the boundary between the region for crimping the exposed wire portion 201a and the region where the diameter of the sealed hollow cylinder on the sealed side is reduced is that the wire is inserted and arranged, and the tip of the wire exposed portion 201a comes. Become position.
- the length to the top of the cross section is B1.
- the length from the end in the X direction rear side of the coated crimping range 30a to the boundary between the wire crimping range 30b and the sealing portion 30c is C1.
- the electric wire engaging groove 34a that is the portion closest to the end.
- F1 be the length to the end of the coated crimping range 30a.
- the length A1 is, for example, 3.4 mm
- the length B1 is, for example, 3.9 mm
- the length C1 for example, is 6.8 mm
- F1 is, for example, 4.2 mm.
- 5A and 5B are perspective views showing states before and after a crimped connection of a covered electric wire to the crimp terminal shown in FIG.
- the electric wire exposed portion 201 a of the aluminum core wire 201 exposed on the tip side from the insulating coating 202 of the covered electric wire 200 is exposed to the electric wire.
- the covered electric wire 200 is inserted into the crimping part 30 and arranged so that the position in the longitudinal direction X of the tip 201aa of the part 201a is behind the sealing part 30c in the crimping part 30. And from the front-end
- compression-bonding part 30 is crimped
- FIG. Thereby, the crimp connection structure 1 is manufactured.
- the longitudinal direction welding location W1 and the width direction welding location W2 are welded. For this reason, in the state which crimped the covered electric wire 200, the water stop property which water does not permeate into the inside of the crimp part 30 from the front and the exterior of the crimp part 30 is implement
- the aluminum core wire 201 is made of an aluminum material, and the crimping part 30 is made of a copper material. For this reason, it can reduce in weight compared with the covered electric wire which has a core wire which consists of copper wires. As a result, the aluminum core wire 201 is not corroded, and the electrical resistance is not increased due to the corrosion, so that the conductivity of the aluminum core wire 201 is stabilized. As a result, for example, an aluminum core wire 201 such as a stranded wire, a single wire, or a flat wire can be reliably and firmly connected to the crimping portion 30 of the crimping terminal 10.
- FIG. 6 is a diagram for explaining a state when the covered electric wire 200 is inserted into the crimp part 30 of the crimp terminal 10.
- the length (length B1 in FIG. 4B) from the X direction rear side edge part of the covering crimping range 30a to the guide part 33 is the length of the wire exposed part 201a (length in FIG. 4A). Is shorter than a) (ie, B1 ⁇ a).
- the tip 201aa of the wire exposed portion 201a is inserted from the X direction rear side end of the covered crimping range 30a, and the tip 201aa passes through the guide portion 33.
- the coating tip 202a of the insulating coating 202 is inserted from the X direction rear side end of the coating crimping range 30a.
- the central axis parallel to the X direction passing through the center of the circular cross section perpendicular to the X direction in the covered electric wire 200 and the central axis parallel to the X direction of the crimping part 30 are substantially matched. Is preferred.
- the tip 201aa of the electric wire exposed portion 201a passes through the guide portion 33.
- the inner diameter D1 formed by the guide portion 33 is smaller than the inner diameter E1 of the end portion on the rear side in the X direction of the covering crimping range 30a. Therefore, the electric wire exposed portion 201 a is guided by the guide portion 33, and the posture of the covered electric wire 200 is regulated by the guide portion 33. As a result, the covered wire 200 is placed in a posture suitable for insertion rather than having a small inclination, and the insertion operation is performed.
- the central axis of the covered electric wire 200 is inserted in parallel with the longitudinal direction (X direction) of the crimp portion 30 of the crimp terminal 10. Thereby, the insertion operation of the covered electric wire 200 can be performed stably, and a decrease in the efficiency of the crimping process of the covered electric wire 200 is suppressed.
- the guide portion 33 has a taper portion on the side of the cover crimping range 30a, the wire exposed portion 201a is more smoothly inserted into the wire crimping range 30b.
- the wire exposed portion 201a is temporarily caught on the opening end of the coated crimping range 30a when the covered wire 200 is inserted, and the wire exposed portion 201a is bent 180 degrees toward the insulating coating 202 side. Even in this case, the bent wire exposed portion 201a is exposed from the open end of the covering crimping range 30a. Therefore, it is easy to find an insertion failure.
- compression-bonding part 30 it is a part nearest to this edge part among the latching grooves 34 for electric wires from the X direction back side edge part of the covering crimping
- the length (length F1 in FIG. 4B) to the end of the wire locking groove 34a on the side of the covering crimping range 30a is longer than the length of the wire exposed portion 201a (length a in FIG. 4A). (Ie, a ⁇ F1).
- the tip 201aa of the wire exposed portion 201a is inserted from the X direction rear side end portion of the covering crimping range 30a, and the tip 201aa is inserted into the wire locking groove 34a.
- the coating tip 202a of the insulating coating 202 is inserted into the X-direction rear side end of the coating crimping range 30a. Thereafter, the tip 201aa reaches the wire locking groove 34a.
- the covered electric wire 200 is guided by the covered crimping range 30a having an inner diameter of E1, and the posture of the covered electric wire 200 is regulated.
- the covered wire 200 is placed in a posture suitable for insertion rather than having a small inclination, and the insertion operation is performed.
- the central axis of the covered electric wire 200 is inserted in parallel with the longitudinal direction (X direction) of the crimp portion 30 of the crimp terminal 10.
- the inner diameter D1 which the guide part 33 forms is larger than the outer diameter b of the electric wire exposure part 201a, and the outer diameter c of the covered electric wire 200 is larger than the inner diameter D1 (that is, b ⁇ D1). ⁇ C).
- the coating tip 202a of the insulating coating 202 does not go deeper than the guide portion 33, so that the electrical connection quality between the aluminum core wire 201 and the crimp terminal 10 is stabilized.
- the length A1 from the boundary between the wire crimping range 30b and the sealing portion 30c to the end of the covering crimping range 30a on the side of the wire crimping range 30b is the length a of the wire exposed portion 201a. (Ie, a ⁇ A1).
- the covered wire 200 is in a posture suitable for insertion with a small inclination, so the tip 201aa of the wire exposed portion 201a is the wire. The situation of being caught in the locking groove 34 and being deformed is prevented.
- the positional relationship between the crimping portion 30 and the covered electric wire 200 at the time of insertion can be managed, it is possible to stably secure the water stoppage of the crimp terminal 10 even after crimping.
- the crimp connection structure 1 configured as described above can include at least one set of the crimp terminal 10 and the covered electric wire 200 to form a wire harness. .
- FIG. 7 is a perspective view showing a connector in which the wire harness having such a configuration is mounted on a pair of connector housings.
- a crimp connection structure 1 a using a female crimp terminal 11 as the crimp terminal 10 and a crimp connection structure 1 b using a male crimp terminal (not shown) as the crimp terminal 10, respectively. are attached to the pair of connector housings Hc. Then, by attaching the crimp connection structures 1a and 1b to the pair of connector housings Hc, the female connector Ca and the male connector Cb having reliable conductivity can be configured.
- the wire harness 100a including the female connector Ca is configured by mounting the crimp connection structure 1a configured to have the female crimp terminal 11 on the female connector housing Hc.
- the wire harness 100b provided with the male connector Cb is comprised by mounting
- the wire harnesses 100a and 100b can be electrically and physically connected to each other by fitting the female connector Ca and the male connector Cb along the X direction.
- FIG. 8A is a cross-sectional view of a crimp portion of a crimp terminal according to the second embodiment of the present invention.
- FIG. 8B is a cross-sectional view of a crimp portion of a crimp terminal according to the second embodiment of the present invention.
- 8A and 8B are cross-sectional views corresponding to FIGS. 4B and 4C, which are cross-sectional views of the crimp terminal 10.
- the box part of the crimp terminal 10A shown in FIGS. 8A and 8B has the same configuration as the box part 20 of the crimp terminal 10 shown in FIG.
- the wire crimping range 30Ab has an inner diameter smaller than that of the coating crimping range 30Aa, and the step portion at the boundary between the coating crimping range 30Aa and the wire crimping range 30Ab functions as a guide portion (hereinafter referred to as the coating crimping range 30Aa).
- the central axis parallel to the X direction in the cylinder constituted by the guide portion 33A and the central axis parallel to the X direction of the cylinder constituted by the crimping portion 30A are configured to substantially coincide with each other.
- compression-bonding part 30A is not provided with the locking groove for electric wires, it is good also as a structure provided with the locking groove for electric wires.
- the inner diameter of the crimping portion 30A, the end of the coated crimping range 30Aa, which is the end into which the covered electric wire 200 is inserted, in the X direction is E2, and the inner diameter of the guide portion 33A is D2.
- the inner diameter D2 is, for example, 2.5 mm
- the inner diameter E2 is, for example, 3.1 mm.
- the inner diameter E2 of the end portion on the rear side in the X direction of the covered crimping range 30Aa is larger than the outer diameter c of the covered electric wire 200. That is, b ⁇ c ⁇ E2.
- the guide Let A2 be the length to the end of the wire crimping range 30Ab side of the coating crimping range 30Aa, which is the diameter reduction start part in the portion 33A. Further, the length from the X direction rear side end portion of the covered crimping range 30Aa, which is the end portion into which the covered electric wire 200 is inserted, to the guide portion 33A is B2.
- the length from the X direction rear side end portion of the covering crimping range 30Aa to the boundary between the wire crimping range 30Ab and the sealing portion 30Ac is defined as C2.
- the length A2 is, for example, 3.4 mm
- the length B2 is, for example, 3.9 mm
- the length C2 is, for example, 6.8 mm.
- the length B2 from the X direction rear side end part of the covering crimping range 30Aa to the guide part 33A is shorter than the length a of the wire exposed part 201a. (Ie, B2 ⁇ a).
- the tip 201aa of the wire exposed portion 201a is inserted from the X direction rear side end of the covered crimping range 30Aa, and the tip 201aa passes through the entrance of the guide portion 33A.
- the coating tip 202a of the insulating coating 202 is inserted from the X direction rear side end of the coating pressure-bonding range 30Aa.
- the central axis of the covered electric wire 200 and the central axis parallel to the X direction of the crimping portion 30 ⁇ / b> A are substantially matched.
- the inner diameter D2 of the guide portion 33A is smaller than the inner diameter E2 of the end portion on the rear side in the X direction of the covering crimping range 30Aa. Therefore, the electric wire exposed portion 201a is guided by the guide portion 33A, and the posture of the covered electric wire 200 is regulated by the guide portion 33A. As a result, the covered electric wire 200 is placed in a posture more suitable for insertion, and the insertion operation is performed. Thereby, the insertion operation of the covered electric wire 200 can be performed stably, and a decrease in the efficiency of the crimping process of the covered electric wire 200 is suppressed.
- the tapered portion is provided on the side of the covering crimping range 30Aa of the guide portion 33A, the wire exposed portion 201a is more smoothly inserted into the wire crimping range 30Ab.
- the angle ⁇ formed with respect to the X direction of the tapered portion of the guide portion 33A is preferably 45 degrees or less. .
- the wire exposed portion 201a is temporarily caught by the X direction rear end of the coated crimping range 30Aa when the covered wire 200 is inserted, and the wire exposed portion 201a is bent 180 degrees toward the insulating coating 202 side. Even in the case where the wire is exposed, the bent wire exposed portion 201a is exposed from the X direction rear side end portion of the covering crimping range 30Aa. Therefore, it is easy to find an insertion failure.
- the inner diameter D2 of the guide portion 33A is larger than the outer diameter b of the wire exposed portion 201a, and the outer diameter c of the covered electric wire 200 is larger than the inner diameter D2 ( That is, b ⁇ D2 ⁇ c).
- the coating tip 202a of the insulating coating 202 does not go deeper than the guide portion 33A, so that the electrical connection quality between the aluminum core wire 201 and the crimp terminal 10A is stabilized.
- the length A2 from the boundary between the wire crimping range 30Ab and the sealing portion 30Ac to the end of the covering crimping range 30Aa on the side of the wire crimping range 30Ab is It is longer than the length a of the exposed portion 201a (that is, a ⁇ A2).
- the covered electric wire 200 is excessively inserted with a strong force, it is possible to prevent the electric wire exposed portion 201a from projecting into the sealing portion 30Ac and being deformed.
- good product quality of the crimped connection structure 1 can be ensured.
- the positional relationship between the crimping portion 30A and the covered electric wire 200 at the time of insertion can be managed, it is possible to stably secure the water stop of the crimp terminal 10A even after crimping.
- FIG. 9 is a cross-sectional view showing another example of the crimp terminal 10A according to the second embodiment.
- the crimp terminal 10A is inserted into the male crimp terminal from the front, which is the front end side in the longitudinal direction X, to the rear as in the first and second embodiments.
- the box portion 20A includes an elastic contact piece 21A that is bent toward the rear in the longitudinal direction X and comes into contact with the insertion tab of the male crimp terminal.
- the box portion 20A is formed in a substantially rectangular shape when viewed from the front side in the longitudinal direction X by bending the side surface portion 23A so as to overlap.
- the crimp terminal 10A is such that the joint portion between the sealing portion 30Ac and the transition portion 40A is on the central axis O side of the crimp portion 30A with respect to the bottom surface of the wire crimp range 30Ab.
- the shift neck 41 is shifted to By providing this shift neck portion 41, the inclined region of the bent portion is shortened as compared with the crimp terminal 10 in the first embodiment, so that the total length along the longitudinal direction X can be shortened, and the crimp terminal 10A. Can be miniaturized. Further, since the connecting portion of the shift neck portion 41 is bent, a supporting action is generated in the connecting portion, and an external force is applied in the vertical direction (Z direction) and the horizontal direction (Y direction). Since it is supported, the strength can be improved.
- a plurality of wire locking grooves 34A similar to those of the first embodiment are formed in the wire crimping range 30Ab of the crimping portion 30A at predetermined intervals along the longitudinal direction X.
- compression-bonding range 30Aa which is an edge part by which the covered electric wire 200 is inserted, among the locking grooves 34A for electric wires, the locking groove for electric wires which is a part nearest to this edge part
- the length F2 to the end of the coated crimping range 30a is longer than the length of the wire exposed portion 201a (length a in FIG. 4A) (that is, a ⁇ F2).
- Other configurations are the same as those of the crimp terminal 10A according to the second embodiment, and thus the description thereof is omitted.
- FIG. 10A is a cross-sectional view of a crimp part of a crimp terminal according to a third embodiment of the present invention.
- FIG. 10B is a cross-sectional view of a crimp portion of a crimp terminal according to the third embodiment of the present invention.
- 10A and 10B are cross-sectional views corresponding to FIGS. 8A and 8B, respectively.
- the box part of the crimp terminal 10B shown to FIG. 10A and FIG. 10B has the structure similar to the box part 20 of the crimp terminal 10 shown in FIG. 1, description is abbreviate
- the crimping part 30B includes a covering crimping range 30Ba, an electric wire crimping range 30Bb, and a sealing part 30Bc, like the crimping parts 30 and 30A.
- the outer diameters are substantially the same, but the thickness of the wire crimping range 30Bb is larger than the thickness of the coated crimping range 30Ba.
- the wire crimping range 30Bb has a smaller inner diameter than the coated crimping range 30Ba, and thus functions as a guide portion (hereinafter, the coated crimping range 30Ba is referred to as a guide portion 33B as appropriate).
- compression-bonding part 30B is not provided with the locking groove for electric wires, it is good also as a structure provided with the locking groove for electric wires.
- the inner diameter of the crimping portion 30B at the rear end in the X direction of the coated crimping range 30Ba, which is the end into which the covered electric wire 200 is inserted, is E3, and the inner diameter of the guide portion 33B is D3.
- the inner diameter D3 is, for example, 2.5 mm
- the inner diameter E3 is, for example, 3.1 mm.
- the inner diameter E3 of the X direction rear side end portion of the covered crimping range 30Ba is larger than the outer diameter c of the covered electric wire 200. That is, b ⁇ c ⁇ E3.
- the guide portion 30Bc which is the boundary between the region for crimping the exposed wire portion 201a and the region that is reduced in diameter in the sealed hollow cylindrical shape on the sealed side.
- the length to the end of the covered crimping range 30Ba on the wire crimping range 30Bb side, which is the diameter reduction start portion in the portion 33B, is A3.
- the length from the X direction rear side end portion of the covered crimping range 30Ba, which is the end portion into which the covered electric wire 200 is inserted, to the guide portion 33B is defined as B3.
- the length from the end in the X direction rear side of the cover crimping range 30Ba to the boundary between the wire crimping range 30Bb and the sealing portion 30Bc is C3.
- the length A3 is, for example, 3.4 mm
- the length B3 is, for example, 3.9 mm
- the length C3 is, for example, 6.8 mm.
- the length B3 from the X direction rear side end portion of the covering crimping range 30Ba to the guide portion 33B is longer than the length a of the wire exposed portion 201a. Shorter (ie, B3 ⁇ a).
- the tip 201aa of the wire exposed portion 201a is inserted from the X direction rear side end of the covered crimping range 30Ba, and the tip 201aa passes through the entrance of the guide portion 33B.
- the coating tip 202a of the insulating coating 202 is inserted from the X direction rear side end of the coating pressure-bonding range 30Ba.
- the central axis of the covered electric wire 200 and the central axis parallel to the X direction of the crimping portion 30B are substantially matched.
- the inner diameter D3 of the guide portion 33B is smaller than the inner diameter E3 of the end portion on the rear side in the X direction of the covering crimping range 30Ba. Therefore, the electric wire exposed portion 201a is guided by the guide portion 33B, and the posture of the covered electric wire 200 is regulated by the guide portion 33B. As a result, the covered electric wire 200 is placed in a posture more suitable for insertion, and the insertion operation is performed. Thereby, the insertion operation of the covered electric wire 200 can be performed stably, and a decrease in the efficiency of the crimping process of the covered electric wire 200 is suppressed.
- the tapered portion is provided on the side of the covering crimping range 30Ba of the guide portion 33B, the wire exposed portion 201a is more smoothly inserted into the wire crimping range 30Bb.
- the angle ⁇ formed with respect to the X direction of the tapered portion of the guide portion 33B is preferably 45 degrees or less. .
- the wire exposed portion 201a is temporarily caught by the X-direction rear end of the coated crimping range 30Ba when the covered wire 200 is inserted, and the wire exposed portion 201a is bent 180 degrees toward the insulating coating 202. Even in the case where the wire is exposed, the bent wire exposed portion 201a is exposed from the X-direction rear side end portion of the coated crimping range 30Ba. Therefore, it is easy to find an insertion failure.
- the inner diameter D3 of the guide portion 33B is larger than the outer diameter b of the electric wire exposed portion 201a, and the outer diameter c of the covered electric wire 200 is larger than the inner diameter D3.
- the coating tip 202a of the insulating coating 202 does not go deeper than the guide portion 33B, so that the electrical connection quality between the aluminum core wire 201 and the crimp terminal 10B is stabilized.
- the length A3 from the boundary between the wire crimping range 30Bb and the sealing portion 30Bc to the end of the covering crimping range 30Ba on the side of the wire crimping range 30Bb is It is longer than the length a of the exposed portion 201a (that is, a ⁇ A3).
- FIG. 11A, FIG. 11B, and FIG. 11C are perspective views showing a method of welding a crimping part in the method of manufacturing a crimp terminal according to the fourth embodiment.
- the fourth embodiment unlike the method for manufacturing the crimp terminal 10 according to the first embodiment, welding is performed in which the longitudinal welding location W3 changes in the height direction.
- the crimping portion 30 having various shapes and having water-stopping capability, and for example, it is possible to manufacture the crimping terminal 10A having the shift neck portion 41 described in the modification of the second embodiment. Become.
- a copper alloy strip as a plate material punched into a terminal shape by pressing is rounded, and a front end portion in the longitudinal direction X is crushed to a shape of a crimping portion 30C including a sealing portion 30Cc in advance.
- the opposite end portions 32Ca that are rounded and faced to each other are subjected to fiber laser welding along the longitudinal welding portion W3 in the longitudinal direction X, and are welded along the widthwise welding portion W4 in the width direction Y at the sealing portion 30Cc. And seal.
- the crimping portion 30C is completed.
- the contact terminal 10 according to the first embodiment as shown in FIG. 2A, FIG. 2B and FIG. 2C, the fiber laser welding is performed by the above-described series of processes in a so-called back-open state. It is necessary to turn the crimping terminal 10 upside down.
- this 4th Embodiment as shown to FIG. 11A and FIG.
- the manufacturing process can be simplified, and for example, mass production of about several hundred pieces / min can be realized, so that the cost can be reduced accordingly.
- the opposing end portions 32Ca may be butted against each other on the bottom surface side of the crimping portion 30C, and may be welded on the top surface side of the crimping portion 30C as shown in FIGS. 11A and 11B.
- the opposed end portions 32Ca may be butted against each other and welded.
- the crimping range 30Ca of the crimping portion 30C is crimped to the insulating coating 202 of the coated electric wire 200 in a circular shape when viewed from the front, and the crimping range 30Cb is You may press-fit with respect to 201 in the substantially U shape in front view.
- the crimp terminal 10 is welded to the crimped portion 30C while being attached to the belt-like carrier K, and then the crimped wire 200 is crimped or connected. After crimping and connecting 200, it may be separated from the carrier K, but the crimp terminal 10 may be formed in a state separated from the carrier K, and the covered electric wire 200 may be crimped and connected.
- the crimp terminal 10 that can realize a crimped state with a small gap and a high water-stopping property in a crimped state in which the aluminum core wire 201 is inserted into the crimping portion 30C. Therefore, even if the aluminum core wire 201 has a small diameter, the crimp terminal 10 such as a female crimp terminal that can realize a crimped state with little gap and high water-stopping property can be manufactured.
- the crimping portion 30 of the crimp terminal 10 is crimped and connected to the aluminum core wire 201 made of aluminum or aluminum alloy
- other metals may be used for the core wire
- a metal conducting wire made of copper (Cu) or a Cu alloy or a copper clad aluminum wire (CA wire) formed by arranging copper on the outer periphery of an aluminum wire.
- welding using other lasers such as a YAG laser and a CO 2 laser can also be performed under a predetermined condition other than the fiber laser welding.
- the present invention can be suitably used for a crimp terminal that crimps and connects a covered electric wire, a crimp connection structure that crimps and connects a covered electric wire and a crimp terminal, and a manufacturing method of the crimp connection structure.
- the crimp terminal and the crimp connection structure, and the method for manufacturing the crimp connection structure can be suitably used.
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Abstract
Description
〔圧着端子の構成〕
まず、図1を参照して、本発明の第1の実施形態である圧着端子の構成について説明する。
次に、図2A~2C及び図3を参照して、図1に示す圧着端子10の製造方法について説明する。図2Aは、圧着端子10のボックス部20を透過状態とした圧着端子10の底面側の概略斜視図である。図2Bは、図2Aに示す領域Rの拡大図である。図2Cは、図2Bの対向端部32aの周辺部分のX-X線断面図である。図3は、圧着部30の溶接方法を説明するための説明図である。
次に、圧着接続構造体の製造方法について説明する。図5A及び図5Bはそれぞれ、図1に示す圧着端子に被覆電線を圧着接続する前および後の状態を示す斜視図である。図5A、5Bに示すように、上述した圧着端子10に被覆電線を圧着接続する際には、被覆電線200の絶縁被覆202より先端側で露出するアルミニウム芯線201の電線露出部201aを、電線露出部201aの先端201aaの長手方向Xの位置が圧着部30における封止部30cより後方となるように、被覆電線200を圧着部30に挿入して配置する。そして、電線露出部201aの先端201aaから絶縁被覆202の被覆先端202aより後方までを圧着部30で圧着して一体的に囲繞する。これにより、圧着部30は、被覆電線200の絶縁被覆202及びアルミニウム芯線201の電線露出部201aの周面に対して密着した状態に圧着する。これによって、圧着接続構造体1が製造される。
図8Aは、本発明の第2の実施形態である圧着端子の圧着部の断面図である。図8Bは、本発明の第2の実施形態である圧着端子の圧着部の断面図である。なお、図8A、図8Bは、圧着端子10の断面図である図4B、図4Cに相当する断面図である。また、図8A、図8Bに示す圧着端子10Aのボックス部は図1に示す圧着端子10のボックス部20と同様の構成を有するため、説明を省略する。
次に、上述した第2の実施形態である圧着端子の変形例について説明する。図9は、この第2の実施形態である圧着端子10Aの他の例を示す断面図である。
図10Aは、本発明の第3の実施形態である圧着端子の圧着部の断面図である。図10Bは、本発明の第3の実施形態である圧着端子の圧着部の断面図である。なお、図10A及び図10Bはそれぞれ、図8A及び図8Bに相当する断面図である。また、図10A、図10Bに示す圧着端子10Bのボックス部は図1に示す圧着端子10のボックス部20と同様の構成を有するため、説明を省略する。
〔圧着端子の製造方法〕
次に、本発明の第4の実施形態である圧着端子の製造方法について説明する。図11A、図11B、及び図11Cは、この第4の実施形態による圧着端子の製造方法での圧着部の溶接方法を示す斜視図である。
10、10A、10B 圧着端子
11 雌型圧着端子
20、20A ボックス部
21、21A 弾性接触片
22 底面部
23、23A 側面部
30、30A、30B、30C 圧着部
30a、30Aa、30Ba、30Ca 被覆圧着範囲
30b、30Ab、30Bb、30Cb 電線圧着範囲
30c、30Ac、30Bc、30Cc 封止部
31 圧着面
32 バレル構成片
32a、32Ca 対向端部
33、33A、33B ガイド部
34、34A、34a 電線用係止溝
40、40A トランジション部
41 シフト首部
100a、100b ワイヤーハーネス
200 被覆電線
201 アルミニウム芯線
201a 電線露出部
201aa 先端
202 絶縁被覆
202a 被覆先端
Ca 雌型コネクタ
Cb 雄型コネクタ
Fw ファイバーレーザー溶接装置
Hc コネクタハウジング
K キャリア
O 中心軸
P 仮想平面
R 領域
W1、W3 長手方向溶接箇所
W2、W4 幅方向溶接箇所
X 長手方向
Y 幅方向
Z 高さ方向
Claims (9)
- 導体部と前記導体部を被覆する被覆とを有する被覆電線の露出した前記導体部を圧着接続する圧着部を備える圧着端子であって、
前記圧着部が、前記導体部が挿入される長手方向の一方の端部とは反対側の端部が封止された断面中空筒形状に形成され、
封止された前記反対側の端部は、溶接することによって封止されており、
前記圧着部は、前記露出した導体部が挿入される内部に、前記被覆電線の前記被覆の外径よりも内径が小さく前記導体部の外径よりも内径が大きいガイド部を有し、
前記導体部が挿入される前記圧着部の端部から前記ガイド部までの長さが、前記被覆電線の露出した導体部の長さよりも短い
ことを特徴とする圧着端子。 - 前記露出した導体部の外径が前記被覆電線の前記被覆の外径より小さく、前記圧着部は、前記露出した導体部が挿入される前記圧着部の端部の内径が、前記被覆電線の前記被覆の外径よりも大きいことを特徴とする請求項1に記載の圧着端子。
- 前記圧着部は、前記露出した導体部が圧着される内部に、前記露出した導体部を係止するための係止部をさらに有し、前記導体部が挿入される前記一方の端部から前記係止部のうち前記一方の端部に最も近い部分までの長さが、前記被覆電線の露出した前記導体部の長さよりも長いことを特徴とする請求項1又は2に記載の圧着端子。
- 前記圧着部は、前記被覆電線の露出した導体部を圧着するための領域と前記封止された側の断面中空筒形状で縮径されている領域との境界から、前記ガイド部において前記導体部が挿入される前記圧着部の端部側から見て縮径が開始される位置までの長さが、前記被覆電線の露出した導体部の長さより長いことを特徴とする請求項1~3のいずれか一つに記載の圧着端子。
- 前記封止された端部は、ファイバーレーザー溶接によって封止されていることを特徴とする請求項1~4のいずれか一つに記載の圧着端子。
- 前記導体部はアルミ系材料によって形成され、前記圧着部は銅系材料によって形成されていることを特徴とする請求項1~5のいずれか一つに記載の圧着端子。
- 請求項1~6のいずれか一つに記載の圧着端子と、
前記圧着端子に前記導体部を圧着接続した前記被覆電線と、
を備えることを特徴とする圧着接続構造体。 - 前記圧着端子と前記被覆電線との組を少なくとも一組備えたワイヤーハーネスを構成していることを特徴とする請求項7に記載の圧着接続構造体。
- 請求項1~6のいずれか一つに記載の圧着端子に、前記被覆電線を挿入し、前記圧着端子に前記被覆電線の露出した導体部を圧着接続することを特徴とする圧着接続構造体の製造方法。
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JP5884986B2 (ja) * | 2012-07-31 | 2016-03-15 | 矢崎総業株式会社 | 圧着端子付きアルミ電線 |
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CN104170167B (zh) * | 2013-02-22 | 2016-01-27 | 古河电气工业株式会社 | 压接端子、压接连接结构体及压接连接结构体的制造方法 |
WO2014129606A1 (ja) * | 2013-02-23 | 2014-08-28 | 古河電気工業株式会社 | 圧着端子、圧着端子の製造方法、電線接続構造体、及び電線接続構造体の製造方法 |
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JP6426907B2 (ja) * | 2014-04-04 | 2018-11-21 | 矢崎総業株式会社 | 圧着端子と電線の接続構造 |
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JP6362475B2 (ja) * | 2014-08-25 | 2018-07-25 | 古河電気工業株式会社 | 圧着端子の製造方法、端子付き電線の製造方法及びワイヤハーネスの製造方法 |
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JPWO2014129079A1 (ja) | 2017-02-02 |
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