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WO2013111465A1 - 端子金具 - Google Patents

端子金具 Download PDF

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Publication number
WO2013111465A1
WO2013111465A1 PCT/JP2012/082146 JP2012082146W WO2013111465A1 WO 2013111465 A1 WO2013111465 A1 WO 2013111465A1 JP 2012082146 W JP2012082146 W JP 2012082146W WO 2013111465 A1 WO2013111465 A1 WO 2013111465A1
Authority
WO
WIPO (PCT)
Prior art keywords
core wire
wire
barrel
crimping
terminal fitting
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2012/082146
Other languages
English (en)
French (fr)
Inventor
武史 相澤
悟史 森川
義裕 内山
和亜希 武田
貴志 外崎
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sumitomo Wiring Systems Ltd
AutoNetworks Technologies Ltd
Sumitomo Electric Industries Ltd
Original Assignee
Sumitomo Wiring Systems Ltd
AutoNetworks Technologies Ltd
Sumitomo Electric Industries Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sumitomo Wiring Systems Ltd, AutoNetworks Technologies Ltd, Sumitomo Electric Industries Ltd filed Critical Sumitomo Wiring Systems Ltd
Priority to CN201280067633.3A priority Critical patent/CN104067446B/zh
Priority to US14/373,189 priority patent/US9147944B2/en
Priority to KR1020147020615A priority patent/KR101629125B1/ko
Priority to IN5806DEN2014 priority patent/IN2014DN05806A/en
Publication of WO2013111465A1 publication Critical patent/WO2013111465A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H01R4/184—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H01R4/184—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
    • H01R4/185—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion combined with a U-shaped insulation-receiving portion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/188—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping having an uneven wire-receiving surface to improve the contact
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors

Definitions

  • the present invention relates to a terminal fitting that is crimped to an electric wire having a core wire in which a plurality of strands are combined.
  • An aluminum electric wire has, for example, a structure in which a core wire made of a twisted wire obtained by twisting a plurality of aluminum strands is covered with an insulating coating, and when a harness is formed, a terminal fitting is generally connected to the end of the electric wire. Specifically, the terminal end of the aluminum wire is peeled off to expose the end of the core wire, and the wire barrel (electric wire connecting portion) provided in the terminal fitting is crimped to the exposed end of the core wire. An insulation barrel provided behind the wire barrel is crimped and connected to the remaining end of the insulation coating (see, for example, Patent Document 1). Such terminal fittings are formed by pressing a metal plate having good conductivity.
  • the ends of the wire barrels are crimped so as to be pushed in between the stranded wires while being in contact with each other while being bent inwardly. Is easily formed. And if water stop processing is performed by covering each wire barrel with a resin material, the resin material becomes thick because the resin material enters the gap, and the thickness of the entire resin material cannot be made uniform. In addition, even if water-stopping treatment is performed by covering each wire barrel with a heat-shrinkable tube or the like instead of a resin material, the abutting part of each wire-barrel cannot be covered with a heat-shrinkable tube without any gaps. Performance will be degraded.
  • the present invention has been completed based on the above circumstances, and an object thereof is to reduce the gap formed in the abutting portion of each wire barrel.
  • the present invention is a terminal fitting to be crimped to an electric wire having a core wire in which a plurality of strands are combined, and a bottom plate portion on which the core wire is placed and a bottom plate portion so as to wrap the core wire placed on the bottom plate portion.
  • a pair of crimping pieces that are connected and crimped to the same core wire, and a thin portion is formed at the abutting portion of each crimping piece, and the thin portion deforms when each crimping piece is crimped to the core wire This is characterized in that the bent portion is formed.
  • the bent portion is formed by preferentially deforming the thin portion by pressure bonding, the bending angle of the butt portion of each crimping piece can be made smaller than when there is no thin portion. it can. Therefore, the clearance gap formed in the butting part of each crimping piece can be made small.
  • Each crimping piece includes an inner crimping piece arranged inside the core wire and an outer crimping piece arranged outside the core wire, and the thin portion is formed between the inner crimping piece and the outer crimping piece. It is good also as composition which has. According to such a configuration, the bent portion can be easily formed by bending the inner pressure-bonded piece inward along with the pressure bonding.
  • a thin part is good also as a structure made into the groove part extended in the axial direction of an electric wire. According to such a configuration, the thin portion can be more easily bent.
  • a thin part is good also as a structure currently formed in each crimping
  • the bent portions are formed by the deformation of the thin portions, and the gaps can be further reduced by abutting the bent portions.
  • a portion of the crimping piece that extends from the thin portion to the base end side may be a flat portion. Moreover, it is good also as a structure which has comprised the flat part of one crimping piece, and the flat part of the other crimping piece. According to such a structure, when each crimping piece is covered with a resin material as a water stop treatment, the thickness of the entire resin material can be made uniform, and the amount of resin material used can be reduced. Moreover, when each crimping piece is covered with a heat-shrinkable tube as a water-stopping treatment, a gap formed between the heat-shrinkable tube and the abutting portion of each wire barrel can be reduced.
  • a thin part is good also as a structure currently formed in the side which contacts the core wire in the butt
  • the bent part may be a corner part. According to such a structure, the clearance gap formed in the butt
  • Sectional view showing wire barrel in unfolded state Sectional drawing which shows the wire barrel after bending from the state of FIG.
  • Embodiment 1 of the present invention will be described with reference to the drawings of FIGS.
  • the aluminum electric wire has a structure in which a core wire 12 is formed by a stranded wire obtained by twisting a plurality of strands 11 made of aluminum or aluminum alloy, and the core wire 12 is covered with an insulating coating (not shown) made of a synthetic resin. ing.
  • the female terminal fitting 20 is formed by pressing a metal plate made of copper alloy or the like having excellent conductivity, and has a substantially rectangular tube shape that is electrically connected to a mating male terminal fitting (not shown).
  • a wire barrel 25 and an insulation barrel 26 are provided behind the terminal connection portion 21.
  • An elastic contact piece 23 is provided inside the terminal connection portion 21 so as to be folded back from the front edge of the bottom plate portion 22, and the tab of the mating male terminal fitting described above is forward of the terminal connection portion 21.
  • the male terminal fitting and the female terminal fitting 20 are electrically connected to each other by being elastically contacted with the elastic contact piece 23.
  • the wire barrel 25 is an open barrel type, and a pair of left and right wide barrel pieces 25L and 25R are connected to the bottom plate portion 22 so as to rise from the left and right side edges of the bottom plate portion 22 so as to face each other. ing.
  • the wire barrel 25 is crimped and crimped to the end of the core wire 12 of the aluminum electric wire by crimping the barrel pieces 25L and 25R from above and below. For example, as shown in FIG. 25L and 25R are crimped to the core wire 12 in a flat shape so as to wrap around the entire circumference of the end of the core wire 12 while abutting corner portions 30 and 30 described later.
  • the insulation barrel 26 is also of an open barrel type, and a pair of left and right barrel pieces 26L and 26R that are narrower and taller than the barrel pieces 25L and 25R on the wire barrel 25 side are also provided on the left and right sides of the bottom plate portion 22.
  • the bottom plate portion 22 is continuously provided so as to stand up from the edge so as to face each other.
  • the insulation barrel 26 is crimped by crimping the barrel pieces 26L and 26R from above and below to the ends of the above-described insulation coating of the aluminum electric wires.
  • both the barrel pieces 26L and 26R are respectively connected to the insulation barrel 26. While overlapping the protruding ends, the outer periphery of the terminal of the insulating coating is embraced from both the left and right sides, so that it can be caulked into a so-called overlap type.
  • a plurality of recesses 24 are formed on the crimp surface (the inner surface in FIG. 3) of the wire barrel 25. As shown in FIG. 1, the recess 24 is a bottomed recess whose opening shape forms a substantially parallelogram.
  • the core wire 12 bites into each recess 24 by crimping. At the time of this biting, the edge of each recess 24 breaks the insulating film formed on the surface of the core wire 12, The edge of each recessed part 24 is connected so that conduction
  • a pair of thin portions 27 are formed on the side of the wire barrel 25 that comes into contact with the core wire 12 at the tip of each barrel piece 25L, 25R.
  • the thin portion 27 is formed by hitting by pressing, and has a form extending in the front-rear direction (the axial direction of the electric wire) over the entire length from the front edge to the rear edge of the barrel pieces 25L, 25R. Further, the thin portion 27 has a semicircular cross section as shown in FIG.
  • each barrel piece 25 ⁇ / b> L, 25 ⁇ / b> R has an internal crimp piece 28 disposed inside the core wire 12 and an external portion disposed outside the core wire 12. It comprises a crimping piece 29.
  • a corner portion 30 is formed in the outer portion between the inner crimping piece 28 and the outer crimping piece 29 and not in contact with the core wire 12.
  • the corner 30 is formed by bending the thin portion 27 inward (core wire 12 side), and the bending angle of each corner 30 is substantially a right angle, and there is no thin portion 27. It is much smaller than.
  • portions of the barrel pieces 25L and 25R that are continuous from the thin portions 27 and 27 to the base end side are flat portions 31 and 31, respectively.
  • the flat portion 31 is formed between the corner portion 30 and the concave portion 24 located closest to the corner portion 30.
  • the flat portion 31 of the one barrel piece 25L and the flat portion 31 of the other barrel piece 25R are aligned in a horizontal direction (a direction perpendicular to the crimping direction of the barrel pieces 25L and 25R).
  • the butted portions of the barrel pieces 25L and 25R are configured by butting the corner portions 30 and 30 bent at substantially right angles. In other words, the wire barrel 25 is held in a closed state by closely contacting each corner 30, 30.
  • the outer periphery of the wire barrel 25 is water-stopped by applying and sealing the resin material 40.
  • the resin material 40 is formed with a substantially uniform thickness, and the resin material 40 is not extremely thick even at the abutting portion between the corner portions 30 and 30. That is, the corners 30 and 30 having a small bending angle are arranged closer to each other, so that the gap formed between the corners 30 and 30 is reduced, and the resin material 40 is filled in the gap.
  • the thickness of the resin material 40 can be kept small.
  • FIG. 2 is a cross-sectional view showing the wire barrel 25 in the unfolded state, in which a metal plate serving as a base material of the female terminal fitting 20 is punched into a predetermined shape.
  • a plurality of recesses 24 are provided in the crimping surface of the wire barrel 25, and at the same time, a pair of thin portions 27, 27 are provided on the left and right sides of the plurality of recesses 24.
  • the barrel pieces 25 ⁇ / b> L and 25 ⁇ / b> R are raised in an opposed state by bending the bottom plate portion 22 into a substantially U shape.
  • the wire barrel 25 shown in FIG. 1 is formed, and the female terminal fitting 20 is completed.
  • the core wire 12 is placed on the bottom plate portion 22 of the wire barrel 25, and the barrel pieces 25L and 25R are crimped and crimped so as to wrap the core wire 12.
  • the tip of each barrel piece 25L, 25R comes into contact with a crimping die (not shown), and the inner crimping piece 28 is bent inward with the thin portion 27 as the center.
  • the inner crimping piece 28 enters between the strands 11 and at the same time, the barrel pieces 25L and 25R are crimped to the core wire 12.
  • angular part 30 is formed when the thin part 27 deform
  • a resin material 40 is applied to the outer periphery of the wire barrel 25.
  • the resin material 40 is formed with a substantially uniform thickness and is held in a state where the interior of the wire barrel 25 is stopped. Thereby, the anticorrosion effect which prevents the electric corrosion which generate
  • the pair of thin portions 27 and 27 are formed at the abutting portions of the barrel pieces 25L and 25R, and the corner portions 30 are formed by deforming the thin portions 27 and 27.
  • the gap formed between the corner portions 30 can be reduced, and the thickness of the resin material 40 filled in the gap can be kept small.
  • Embodiment 2 of the present invention will be described with reference to the drawing of FIG.
  • water stop treatment is performed using a heat shrinkable tube 50 instead of the resin material 40 of the first embodiment.
  • the heat contraction tube 50 contracts and the inside of the wire barrel 25 is stopped.
  • the gap S is very small and does not allow water to enter. Has been. Therefore, the water stop effect and the anticorrosion effect are not lost.
  • the thin portions 27 and 27 are formed on the barrel pieces 25L and 25R in the above embodiment, according to the present invention, the thin portions may be formed only on one of the barrel pieces.
  • the flat portions 31, 31 are formed in the portion of the barrel pieces 25L, 25R that are continuous from the thin portions 27, 27 to the base end side, but according to the present invention, curved surfaces are used instead of the flat portions. A portion may be provided so that these curved portions are aligned and aligned.
  • the thin portion 27 is formed on the side of the barrel pieces 25L and 25R that contacts the core wire 12 in the above embodiment, the thin portion may be formed on the opposite side of the core wire 12 according to the present invention. .
  • corner portion 30 having a bending angle of about 90 ° is illustrated as the bent portion in the above embodiment, according to the present invention, a bent portion having a bending angle of about 120 ° is formed instead of the corner portion 30. May be.
  • the present invention may be applied to a copper electric wire having a core wire made of a copper alloy or the like.
  • the female terminal metal fitting is illustrated in the said embodiment, according to this invention, you may apply to the male terminal metal fitting which has a tab.
  • the strand wire is illustrated in the said embodiment, according to this invention, you may apply to the straight-shaped core wire which has not twisted each strand.

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

Description

端子金具
　本発明は、複数の素線が合わされた芯線を有する電線に圧着される端子金具に関する。
　近年、自動車のワイヤハーネス等の分野においても、軽量化等を目的としてアルミ電線を使用するようになった。アルミ電線は例えば、複数本のアルミ素線を撚り合わせた撚り線からなる芯線を絶縁被覆で覆った構造であって、ハーネス化される場合は一般に、電線の端末に端子金具が接続される。具体的には、アルミ電線の被覆の端末が皮剥ぎされて芯線の端末が露出され、この露出された芯線の端末に対して、端子金具に設けられたワイヤバレル（電線接続部）が圧着され、残った絶縁被覆の端末に、ワイヤバレルの後方に設けられたインシュレーションバレルが圧着されて接続されるようになっている（例えば、特許文献１参照）。このような端子金具は、導電性のよい金属板をプレス加工することによって形成されている。
特開２００５－５０７３６号公報
　しかしながら、上記の端子金具では、各ワイヤバレルの先端を内側に曲げつつ互いに突き合わせながら撚り線間に押し込むように圧着されるため、各ワイヤバレルの突当部分が丸みを帯びてこれらの間に隙間が形成されやすくなっている。そして、各ワイヤバレルを樹脂材で覆うことによって止水処理を行うと、前記隙間に樹脂材が入り込むことで樹脂材が厚くなり、樹脂材全体として厚さを均一にすることができなくなる。また、樹脂材に代わって熱収縮チューブなどで各ワイヤバレルを覆うことによって止水処理を施すにしても、各ワイヤバレルの突当部分を熱収縮チューブによって隙間なく覆うことができないため、止水性能が低下してしまう。
　本発明は上記のような事情に基づいて完成されたものであって、各ワイヤバレルの突当部分に形成される隙間を小さくすることを目的とする。
　本発明は、複数の素線が合わされた芯線を有する電線に圧着される端子金具であって、芯線が載置される底板部と、底板部に載置される芯線を包むように同底板部に連設されて同芯線に圧着される一対の圧着片と、を備え、各圧着片の突き合わせ部分に薄肉部が形成されており、各圧着片が芯線に圧着されたときに薄肉部が変形することで折り曲げ部が形成されている構成としたところに特徴を有する。
　このような構成によると、圧着によって薄肉部が優先的に変形することで折り曲げ部が形成されるため、薄肉部がないとした場合よりも各圧着片の突き合わせ部分の曲げ角度を小さくすることができる。したがって、各圧着片の突き合わせ部分に形成される隙間を小さくすることができる。
　本発明の実施の態様として、以下の構成が好ましい。
　各圧着片は、芯線の内部に配された内部圧着片と、芯線の外部に配された外部圧着片とを備えて構成され、薄肉部は、内部圧着片と外部圧着片の間に形成されている構成としてもよい。
　このような構成によると、圧着に伴って内部圧着片が内側に折り曲げられることで折り曲げ部を形成しやすくできる。
　薄肉部は、電線の軸線方向に延びる溝部とされている構成としてもよい。
　このような構成によると、薄肉部をさらに折り曲げやすくできる。
　薄肉部は、各圧着片にそれぞれ形成されている構成としてもよい。
　このような構成によると、各薄肉部が変形することによって折り曲げ部がそれぞれ形成され、各折り曲げ部を突き合わせることで隙間をより小さくすることができる。
　圧着片のうち薄肉部から基端側に連なる部分は、平坦部とされている構成としてもよい。また、一方の圧着片の平坦部と他方の圧着片の平坦部とは、面一をなしている構成としてもよい。
　このような構成によると、止水処理として各圧着片を樹脂材で覆う際に、樹脂材全体の厚さを均一にすることができ、樹脂材の使用量を減らすことができる。また、止水処理として各圧着片を熱収縮チューブで覆う際に、熱収縮チューブと各ワイヤバレルの突当部分との間に形成される隙間を小さくすることができる。
　薄肉部は、各圧着片の突き合わせ部分における芯線と接触する側に形成されている構成としてもよい。
　このような構成によると、薄肉部を変形させた際に肉が集中しやすい内側部分に薄肉部を形成しているから、折り曲げ部の曲げ角度をより小さくできる。
　折り曲げ部は角部である構成としてもよい。このような構成によると、各圧着片の突き合わせ部分に形成される隙間をより小さくすることができる。
　本発明によれば、各ワイヤバレルの突当部分に隙間が形成されないようにすることができる。
実施形態１における端子金具を示す斜視図 展開状態のワイヤバレルを示す断面図 図２の状態から曲げ加工を行った後のワイヤバレルを示す断面図 図３の状態から芯線に圧着された後のワイヤバレルを示す断面図 図４の状態から樹脂材を塗布してワイヤバレルに止水処理を施した状態を示す断面図 実施形態１の樹脂材の代わりに熱収縮チューブを被着してワイヤバレルに止水処理を施した状態を示す断面図
　＜実施形態１＞
　本発明の実施形態１を図１ないし図５の図面を参照しながら説明する。本実施形態では、図１に示すように、アルミ電線（図示せず）の端末に接続される雌端子金具２０を例示している。アルミ電線は、アルミニウムまたはアルミニウム合金製の素線１１を複数本撚り合わされた撚り線によって芯線１２を形成し、この芯線１２が合成樹脂製の絶縁被覆（図示せず）によって覆われた構造となっている。
　雌端子金具２０は、銅合金等からなる導電性に優れた金属板をプレス加工することで形成され、相手の雄端子金具（図示せず）と電気的に接続される略角筒形をなす端子接続部２１の後方に、ワイヤバレル２５とインシュレーションバレル２６とが設けられた構造である。
　端子接続部２１の内部には、底板部２２の前縁から折り返されるようにして弾性接触片２３が設けられており、同端子接続部２１に対して上記した相手の雄端子金具のタブが前方から挿入され、弾性接触片２３と弾性的に接触することにより、雄端子金具と雌端子金具２０とが電気的に接続されるようになっている。
　ワイヤバレル２５は、オープンバレル形式であって、左右一対の幅広のバレル片２５Ｌ，２５Ｒが、底板部２２の左右の側縁から互いに対向するようにして立ち上がる形態で同底板部２２に連設されている。ワイヤバレル２５は、各バレル片２５Ｌ，２５Ｒを上下方向から圧着することで上記したアルミ電線の芯線１２の端末にかしめ圧着されるものであって、例えば、図５に示すように、両バレル片２５Ｌ，２５Ｒが後述する角部３０，３０同士を突き当てつつ、芯線１２の端末の全周を包むように扁平形状をなして芯線１２に圧着されるようになっている。
　インシュレーションバレル２６は、同じくオープンバレル形式であって、ワイヤバレル２５側のバレル片２５Ｌ，２５Ｒよりも幅狭で背が高い左右一対のバレル片２６Ｌ，２６Ｒが、同じく底板部２２の左右の側縁から互いに対向するようにして立ち上がる形態で同底板部２２に連設されている。インシュレーションバレル２６は、各バレル片２６Ｌ，２６Ｒを上下方向から圧着することで上記したアルミ電線の絶縁被覆の端末にかしめ圧着されるものであって、例えば、両バレル片２６Ｌ，２６Ｒがそれぞれの突出端を重ね合わせつつ、絶縁被覆の端末の外周を左右両側から抱き込むようにして、いわゆるオーバラップ型にかしめられるようになっている。
　ワイヤバレル２５の圧着面（図３における内側の面）には、複数の凹部２４が形成されている。この凹部２４は、図１に示すように、開口形状が略平行四辺形をなす有底の凹部とされている。各凹部２４の内部には、圧着によって芯線１２が食い込むようになっており、この食い込みの際に、各凹部２４のエッジが芯線１２の表面に形成された絶縁被膜を破ることで、芯線１２と各凹部２４のエッジが導通可能に接続されるようになっている。
　さて、ワイヤバレル２５の各バレル片２５Ｌ，２５Ｒの先端部における芯線１２と接触する側には、一対の薄肉部２７が形成されている。この薄肉部２７は、プレス加工によって叩くことで形成され、バレル片２５Ｌ，２５Ｒの前縁から後縁にかけて全長に亘って前後方向（電線の軸線方向）に延びる形態とされている。また、薄肉部２７は、図３に示すように、断面半円状とされている。
　ワイヤバレル２５を芯線１２に圧着した状態では、図５に示すように、各バレル片２５Ｌ，２５Ｒは、芯線１２の内部に配された内部圧着片２８と、芯線１２の外部に配された外部圧着片２９とを備えて構成されている。そして、内部圧着片２８と外部圧着片２９の間であって芯線１２と接触しない外側部分には、角部３０が形成されている。この角部３０は、薄肉部２７を内側（芯線１２側）に折り曲げることで形成されたものであって、各角部３０の曲げ角度は略直角であって、薄肉部２７がないとした場合よりも格段に小さくなっている。
　また、各バレル片２５Ｌ，２５Ｒのうち薄肉部２７，２７から基端側に連なる部分は、平坦部３１，３１とされている。この平坦部３１は、角部３０とこの角部３０に最も近い位置にある凹部２４との間に形成されている。一方のバレル片２５Ｌの平坦部３１と他方のバレル片２５Ｒの平坦部３１とは、水平方向（各バレル片２５Ｌ，２５Ｒの圧着方向と直交する方向）に面一をなして揃う形態とされている。すなわち、本実施形態では、略直角に折り曲げられた各角部３０，３０を突き合わせることで、各バレル片２５Ｌ，２５Ｒの突き合わせ部分が構成されている。言い換えると、各角部３０，３０を密着して突き合わせることでワイヤバレル２５が閉じられた状態に保持されている。
　ワイヤバレル２５の外周には、樹脂材４０が塗布されて封止されることで止水処理が施されている。樹脂材４０は、ほぼ均一な厚さで形成されており、各角部３０，３０の突き合わせ部分においても、樹脂材４０が極端に厚くならないようになっている。つまり、曲げ角度の小さい角部同士３０、３０がより近くに配置されることで各角部３０，３０間に形成される隙間が小さくなっており、この隙間に樹脂材４０が充填されたとしても、樹脂材４０の厚さを小さめに抑えることができるようになっている。
　本実施形態は以上のような構成であって、続いて雌端子金具２０のワイヤバレル２５の製造工程および圧着工程を図２ないし図５の図面を参照しながら簡単に説明する。図２は、展開状態におけるワイヤバレル２５を示した断面図であって、雌端子金具２０の母材となる金属板を所定の形状に打ち抜いたものである。このとき、ワイヤバレル２５の圧着面に複数の凹部２４を凹設すると同時に、複数の凹部２４の左右両側に一対の薄肉部２７，２７を凹設する。
　次に、図３に示すように、底板部２２を略Ｕ字状に折り曲げることにより各バレル片２５Ｌ，２５Ｒを対向状態で立ち上げる。この結果、図１に示すワイヤバレル２５が形成され、雌端子金具２０が完成する。
　この後、ワイヤバレル２５の底板部２２に芯線１２を載置し、その芯線１２を包むように各バレル片２５Ｌ，２５Ｒをかしめて圧着する。このとき、図４に示すように、各バレル片２５Ｌ，２５Ｒの先端が圧着型（図示せず）に当接して薄肉部２７を中心として内部圧着片２８が内側に折り曲げられる。すると、内部圧着片２８が各素線１１間に入り込むと同時に、各バレル片２５Ｌ，２５Ｒが芯線１２に圧着される。さらに、薄肉部２７が変形することで角部３０が形成され、これらの角部３０，３０が密着して突き当てられることによりワイヤバレル２５が閉じられた状態に保持される。
　次に、図５に示すように、ワイヤバレル２５の外周に樹脂材４０を塗布する。樹脂材４０は、ほぼ均一の厚さで形成され、ワイヤバレル２５の内部が止水された状態に保持される。これにより、異種金属間で発生する電食を未然に防ぐ防食効果が発揮される。
　以上のように本実施形態では各バレル片２５Ｌ，２５Ｒの突き合わせ部分に一対の薄肉部２７，２７を形成し、薄肉部２７，２７を変形させることで角部３０が形成されるようにしたから、各角部３０，３０の間に形成される隙間を小さくすることができ、この隙間に充填される樹脂材４０の厚さを小さめに抑えることができる。
　＜実施形態２＞
　次に、本発明の実施形態２を図６の図面を参照しながら説明する。本実施形態は、実施形態１の樹脂材４０の代わりに熱収縮チューブ５０を用いて止水処理を施したものである。収縮前の熱収縮チューブ５０をワイヤバレル２５に被せて加熱処理を行うと、熱収縮チューブ５０が収縮してワイヤバレル２５の内部が止水される。このとき、各角部３０，３０の突き合わせ部分と熱収縮チューブ５０との間には、わずかな隙間Ｓが形成されるものの、この隙間Ｓは極めて小さく、水の浸入を許容しない程度の大きさとされている。よって、止水効果および防食効果が失われることはない。
　＜他の実施形態＞
　本発明は上記記述及び図面によって説明した実施形態に限定されるものではなく、例えば次のような実施形態も本発明の技術的範囲に含まれる。
　（１）上記実施形態では前後方向に延びる溝状に形成された薄肉部２７を例示しているものの、本発明によると、貫通孔を形成するとともに、この貫通孔の孔縁部にすり鉢状の薄肉部を形成してもよい。
　（２）上記実施形態では各バレル片２５Ｌ，２５Ｒに一対の薄肉部２７，２７を形成しているものの、本発明によると、いずれか一方のバレル片のみに薄肉部を形成してもよい。
　（３）上記実施形態ではバレル片２５Ｌ，２５Ｒのうち薄肉部２７，２７から基端側に連なる部分に平坦部３１，３１が形成されているものの、本発明によると、平坦部の代わりに曲面部を設けてこれらの曲面部が面一をなして揃うように配置してもよい。
　（４）上記実施形態ではバレル片２５Ｌ，２５Ｒにおける芯線１２と接触する側に薄肉部２７を形成しているものの、本発明によると、芯線１２とは反対側に薄肉部を形成してもよい。
　（５）上記実施形態では折り曲げ部として曲げ角度が９０°くらいの角部３０を例示しているものの、本発明によると、角部３０の代わりに曲げ角度が１２０°ぐらいの折り曲げ部を形成してもよい。
　（６）上記実施形態ではアルミ電線を例示しているものの、本発明によると、銅合金等からなる芯線を有する銅電線に適用してもよい。また、上記実施形態では雌端子金具を例示しているものの、本発明によると、タブを有する雄端子金具に適用してもよい。また、上記実施形態では撚り線を例示しているものの、本発明によると、各素線を撚り合わせていないストレート形状の芯線に適用してもよい。
　１１…素線
　１２…芯線
　２０…雌端子金具
　２２…底板部
　２５Ｌ，２５Ｒ…バレル片（圧着片）
　２７…薄肉部
　２８…内部圧着片
　２９…外部圧着片
　３０…角部（折り曲げ部）
　３１…平坦部

Claims (8)

  1. 　複数の素線が合わされた芯線を有する電線に圧着される端子金具であって、
    　前記芯線が載置される底板部と、
    　前記底板部に載置される前記芯線を包むように同底板部に連設されて同芯線に圧着される一対の圧着片と、を備え、
    　各圧着片の突き合わせ部分に薄肉部が形成されており、前記各圧着片が前記芯線に圧着されたときに前記薄肉部が変形することで折り曲げ部が形成されている端子金具。
  2. 　前記各圧着片は、前記芯線の内部に配された内部圧着片と、前記芯線の外部に配された外部圧着片とを備えて構成され、前記薄肉部は、前記内部圧着片と前記外部圧着片の間に形成されている請求項１に記載の端子金具。
  3. 　前記薄肉部は、前記電線の軸線方向に延びる溝部とされている請求項１または請求項２に記載の端子金具。
  4. 　前記薄肉部は、前記各圧着片にそれぞれ形成されている請求項１ないし請求項３のいずれか一項に記載の端子金具。
  5. 　前記圧着片のうち前記薄肉部から基端側に連なる部分は、平坦部とされている請求項１ないし請求項４のいずれか一項に記載の端子金具。
  6. 　一方の前記圧着片の前記平坦部と他方の前記圧着片の前記平坦部とは、面一をなしている請求項５に記載の端子金具。
  7. 　前記薄肉部は、前記各圧着片の突き合わせ部分における前記芯線と接触する側に形成されている請求項１ないし請求項６のいずれか一項に記載の端子金具。
  8. 　前記折り曲げ部は角部である請求項１ないし請求項７のいずれか一項に記載の端子金具。
PCT/JP2012/082146 2012-01-23 2012-12-12 端子金具 Ceased WO2013111465A1 (ja)

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JP2009152162A (ja) * 2007-11-27 2009-07-09 Yazaki Corp 電線に対する圧着端子の圧着構造、および圧着端子

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KR20140111680A (ko) 2014-09-19
US20150244084A1 (en) 2015-08-27
KR101629125B1 (ko) 2016-06-09
CN104067446B (zh) 2017-07-18
JP2013149564A (ja) 2013-08-01
US9147944B2 (en) 2015-09-29
CN104067446A (zh) 2014-09-24

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