JP2012190635A - Wire harness, and method for manufacturing wire harness - Google Patents
Wire harness, and method for manufacturing wire harness Download PDFInfo
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- JP2012190635A JP2012190635A JP2011052476A JP2011052476A JP2012190635A JP 2012190635 A JP2012190635 A JP 2012190635A JP 2011052476 A JP2011052476 A JP 2011052476A JP 2011052476 A JP2011052476 A JP 2011052476A JP 2012190635 A JP2012190635 A JP 2012190635A
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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
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Abstract
Description
本発明は自動車等に用いられるワイヤハーネスおよびワイヤハーネスの製造方法に関するものである。 The present invention relates to a wire harness used for an automobile or the like and a method for manufacturing the wire harness.
従来、自動車、ＯＡ機器、家電製品等分野では、電力線や信号線として、電気導電性に優れた銅系材料からなる導電線が使用されている。特に、自動車分野においては、車両の高性能化、高機能化が急速に進められており、車載される各種電気機器や制御機器が増加している。したがって、これに伴い、使用されるワイヤハーネスも増加する傾向にある。 Conventionally, in the fields of automobiles, OA equipment, home appliances, etc., conductive wires made of a copper-based material having excellent electrical conductivity have been used as power lines and signal lines. In particular, in the automobile field, the performance and functionality of vehicles are rapidly increasing, and various electric devices and control devices mounted on the vehicle are increasing. Therefore, along with this, the wire harness used tends to increase.
一方、環境問題が注目される中、自動車の軽量化が要求されている。したがって、ワイヤハーネスの使用量増加に伴う重量増加が問題となる。このため、従来使用されている銅線に代えて、軽量なアルミニウム電線が注目されている。 On the other hand, while environmental problems are attracting attention, the weight reduction of automobiles is required. Therefore, an increase in weight accompanying an increase in the amount of wire harness used becomes a problem. For this reason, it replaces with the copper wire currently used conventionally and the lightweight aluminum electric wire attracts attention.
ここで、このような電線同士を接続する際や機器類等の接続部においては、接続用端子が用いられる。しかし、アルミニウム心線を用いたワイヤハーネスであっても、接続部の信頼性等のため、端子部には、電気特性に優れる銅が使用される場合がある。このような場合には、アルミニウム電線と銅製の端子とが接合されて使用される。 Here, a connection terminal is used when connecting such electric wires or in a connection portion such as a device. However, even in the case of a wire harness using an aluminum core wire, copper having excellent electrical characteristics may be used for the terminal portion because of the reliability of the connecting portion. In such a case, an aluminum electric wire and a copper terminal are joined and used.
しかし、異種金属を接触させると、標準電極電位の違いから、いわゆる電食が発生する恐れがある。特に、アルミニウムと銅との標準電極電位差は大きいため、接触部への水の飛散や結露等の影響により、電気的に卑であるアルミニウム側の腐食が進行する。このため、接続部における電線と端子との接続状態が不安定となり、接触抵抗の増加や線径の減少による電気抵抗の増大、更には断線が生じて電装部品の誤動作、機能停止に至る恐れがある。 However, when different metals are brought into contact, so-called electrolytic corrosion may occur due to the difference in standard electrode potential. In particular, since the standard electrode potential difference between aluminum and copper is large, corrosion on the aluminum side, which is electrically base, progresses due to the influence of water scattering and condensation on the contact portion. For this reason, the connection state between the electric wire and the terminal at the connection portion becomes unstable, and there is a risk that the electrical resistance increases due to an increase in contact resistance or a decrease in wire diameter, and further, the disconnection may occur, resulting in malfunction of the electrical component or a malfunction. is there.
このような異種金属を接続したアルミ電線用端子としては、電線と端子との接続部を覆うように端子に樹脂材を充填した物がある（特許文献１）。 As a terminal for an aluminum electric wire to which such a dissimilar metal is connected, there is a product in which a terminal is filled with a resin material so as to cover a connection portion between the electric wire and the terminal (Patent Document 1).
しかし、特許文献１において電線と端子との接続部を樹脂で被覆する際には、絶縁被覆された電線を端子に圧着する部分（被覆線圧着部）も上から樹脂で被覆している。被覆線圧着部を樹脂で覆うと、電線が外力を受け屈曲した際などに被覆線圧着部から水が浸入するおそれがある。さらに、端子と電線との間に隙間があれば、電線と端子との接触部に水が入り込み、電食が促進されてしまう。 However, in Patent Document 1, when a connecting portion between an electric wire and a terminal is covered with a resin, a portion (covered wire crimping portion) for crimping the insulated wire to the terminal is also covered with the resin from above. If the coated wire crimping portion is covered with resin, there is a possibility that water may enter from the coated wire crimping portion when the electric wire is bent by receiving an external force. Furthermore, if there is a gap between the terminal and the electric wire, water enters the contact portion between the electric wire and the terminal, and electric corrosion is promoted.
図５は従来技術による、端子１０３および電線の接続部を樹脂１０１で覆ったワイヤハーネスの一部を示す断面図である。断面形状がコの字状の端子１０３に、導線被覆部１０５と導体１０９から形成される電線を配置し、導線被覆部１０５を端子１０３の開口部から樹脂１０１を充填することによって被覆する。端子１０３の底面と電線の間には隙間１０７が生じる。 FIG. 5 is a cross-sectional view showing a part of a wire harness in which a terminal 103 and a connecting portion of an electric wire are covered with a resin 101 according to the prior art. An electric wire formed of the conductive wire covering portion 105 and the conductor 109 is disposed on the terminal 103 having a U-shaped cross section, and the conductive wire covering portion 105 is covered by filling the resin 101 from the opening of the terminal 103. A gap 107 is formed between the bottom surface of the terminal 103 and the electric wire.
したがって、ワイヤハーネスが安定して電気特性を維持するためには、端子と電線の接続部への浸水を確実に防止する構造を具備し、かつ簡易な構造であるワイヤハーネスが望まれる。 Therefore, in order for the wire harness to stably maintain the electrical characteristics, a wire harness having a structure that reliably prevents water from entering the connection portion between the terminal and the electric wire and having a simple structure is desired.
本発明は、このような問題に鑑みてなされたもので、止水性に優れ、構造が簡易である異種金属によるワイヤハーネスおよびワイヤハーネスの製造方法を提供することを目的とする。 This invention is made | formed in view of such a problem, and it aims at providing the manufacturing method of the wire harness by the dissimilar metal which is excellent in water-stopping and has a simple structure, and a wire harness.
前述した目的を達成するために、第１の発明は、周囲を絶縁被覆する導線被覆部を有する電線導体と、前記電線導体とは異なる金属からなる端子とが接続されるワイヤハーネスであって、前記端子は、導線圧着部と、被覆線圧着部と、前記導線圧着部と前記被覆線圧着部との間に設けられる樹脂溜め部と、を具備し、前記導線被覆部から露出する前記電線導体の端部は前記導線圧着部によって前記端子に圧着され、前記導線被覆部は前記被覆線圧着部によって前記端子に圧着され、
前記導線被覆部から露出する前記電線導体の表面および前記導線圧着部が樹脂材で被覆されるとともに、前記樹脂溜め部において、前記導線被覆部の外周面の全周が樹脂材で被覆されることを特徴とするワイヤハーネスである。
In order to achieve the above-described object, the first invention is a wire harness in which an electric wire conductor having a conductive wire covering portion that insulates the periphery is connected to a terminal made of a metal different from the electric wire conductor, The terminal includes a conductive wire crimping portion, a covered wire crimping portion, and a resin reservoir provided between the conductive wire crimping portion and the coated wire crimping portion, and the wire conductor exposed from the conductive wire coating portion. The end portion of the wire is crimped to the terminal by the lead wire crimping portion, the lead wire coating portion is crimped to the terminal by the sheathed wire crimping portion,
The surface of the wire conductor exposed from the conductive wire covering portion and the conductive wire crimping portion are covered with a resin material, and the entire circumference of the outer peripheral surface of the conductive wire covering portion is covered with the resin material in the resin reservoir portion. It is a wire harness characterized by these.
前記樹脂溜め部には外部に貫通する孔が設けられることが望ましい。 Preferably, the resin reservoir is provided with a hole penetrating to the outside.
前記樹脂溜め部の前記電線導体の長手方向の長さは前記電線導体を前記端子に圧着させる際に生じる前記電線導体の伸びより長いことが望ましい。 The length of the resin conductor in the longitudinal direction of the wire conductor is preferably longer than the elongation of the wire conductor that occurs when the wire conductor is crimped to the terminal.
第１の発明によれば、端子が樹脂溜め部を具備することによって、樹脂溜め部における導線被覆部の外周面の全周を樹脂材で覆うことが可能となり、被覆導線と端子との間に隙間を設けることなく樹脂材を充填することができる。したがって、端子と電線導体の接続部への浸水を確実に防止することができ、構造が簡易であるワイヤハーネスを提供することができる。 According to the first invention, since the terminal includes the resin reservoir portion, the entire circumference of the outer peripheral surface of the conductive wire covering portion in the resin reservoir portion can be covered with the resin material, and between the coated conductive wire and the terminal. The resin material can be filled without providing a gap. Therefore, it is possible to reliably prevent water from entering the connection portion between the terminal and the wire conductor, and to provide a wire harness with a simple structure.
また、導線圧着部および、導線被覆部から露出する電線導体の表面が樹脂材で被覆され、樹脂溜め部においても、導線被覆部の外周面の全周が樹脂材で覆われているため、例えば電線導体が屈曲した際にも電線と端子の接続部に浸水することがなく、安定して電気特性を維持するワイヤハーネスを提供することができる。 Further, the surface of the conductor crimping portion and the wire conductor exposed from the conductor covering portion is covered with a resin material, and the entire circumference of the outer peripheral surface of the conductor covering portion is also covered with the resin material in the resin reservoir portion. Even when the wire conductor is bent, it is possible to provide a wire harness that stably maintains electrical characteristics without being immersed in the connection portion between the wire and the terminal.
また、樹脂溜め部には外部に貫通する孔が設けられることから、樹脂材を樹脂溜め部に充填させる際に、樹脂材を充填する箇所に混入する空気を孔の外側の空気と置換するため、空気溜まりを形成することなく樹脂を充填させることができる。 In addition, since a hole penetrating to the outside is provided in the resin reservoir portion, when the resin material is filled in the resin reservoir portion, the air mixed in the portion where the resin material is filled is replaced with the air outside the hole. The resin can be filled without forming an air pocket.
また、樹脂溜め部の電線導体の長手方向の長さが、電線導体を端子に圧着させる際に生じる電線導体の伸びより長いことによって、電線導体を端子に圧着させる際に電線導体に伸びが生じても、導線被覆部の端部を樹脂溜め部上の位置に配置することができ、確実に導線被覆部の外周面の全周を樹脂材で被覆することが可能となる。 In addition, since the length of the resin conductor in the longitudinal direction of the wire conductor is longer than the elongation of the wire conductor that occurs when the wire conductor is crimped to the terminal, the wire conductor is stretched when the wire conductor is crimped to the terminal. Even in this case, the end portion of the conductive wire covering portion can be disposed at a position on the resin reservoir portion, and the entire circumference of the outer peripheral surface of the conductive wire covering portion can be reliably covered with the resin material.
第２の発明は、ワイヤハーネスの製造方法であって、導線圧着部と、被覆線圧着部と、前記導線圧着部と前記被覆線圧着部との間に設けられる樹脂溜め部と、前記樹脂溜め部に形成される外部に貫通する孔と、を具備する端子を用い、前記導線被覆部から露出する前記電線導体の端部を、前記導線圧着部によって前記端子に圧着し、前記導線被覆部を、前記被覆線圧着部によって前記端子に圧着し、前記導線圧着部と、前記導線被覆部から露出する前記電線導体の表面と、前記樹脂溜め部と、に前記樹脂材を塗布することによって、前記樹脂溜め部には前記樹脂材が充填され、前記樹脂溜め部における前記導線被覆部の外周面の全周を前記樹脂材で被覆することを特徴とするワイヤハーネスの製造方法である。 2nd invention is a manufacturing method of a wire harness, Comprising: A conducting wire crimping part, a covered wire crimping part, a resin reservoir provided between the conducting wire crimping part and the coated wire crimping part, and the resin reservoir A terminal having a hole penetrating to the outside formed in the portion, the end of the wire conductor exposed from the conductor coating portion is crimped to the terminal by the conductor crimping portion, and the conductor coating portion is The resin wire is crimped to the terminal by the coated wire crimping portion, and the resin material is applied to the conductive wire crimping portion, the surface of the electric wire conductor exposed from the conductive wire coating portion, and the resin reservoir portion. In the wire harness manufacturing method, the resin reservoir is filled with the resin material, and the entire circumference of the outer peripheral surface of the conductive wire covering portion in the resin reservoir is covered with the resin material.
第２の発明によれば、樹脂溜め部における導線被覆部の外周面の全周を樹脂材で覆われたワイヤハーネスを製造することができる。したがって、被覆導線と端子との間に隙間を設けることなく樹脂材を充填することができる。 According to the second invention, it is possible to manufacture a wire harness in which the entire circumference of the outer peripheral surface of the conductive wire covering portion in the resin reservoir portion is covered with the resin material. Therefore, the resin material can be filled without providing a gap between the coated conductor and the terminal.
また、導線圧着部および、導線被覆部から露出する電線導体の表面が樹脂材で被覆されるとともに、樹脂溜め部において、導線被覆部の外周面の全周が樹脂材で被覆されることから、電線導体が屈曲した際にも電線と端子の接続部に浸水することがなく、安定して電気特性を維持するワイヤハーネスを製造することが可能となる。 In addition, since the surface of the wire conductor exposed from the lead wire crimping portion and the lead wire covering portion is covered with a resin material, and the entire circumference of the outer peripheral surface of the lead wire covering portion is covered with the resin material in the resin reservoir portion, Even when the electric wire conductor is bent, it is possible to manufacture a wire harness that stably maintains electric characteristics without being immersed in the connection portion between the electric wire and the terminal.
本発明によれば、止水性に優れ、構造が簡易である、異種金属によるワイヤハーネスおよびワイヤハーネスの製造方法を提供することができる。 ADVANTAGE OF THE INVENTION According to this invention, it can provide the manufacturing method of the wire harness and wire harness by a dissimilar metal which are excellent in water-stop and simple structure.
以下、図面を参照しながら、本発明の実施形態について説明する。図１はワイヤハーネス１を示す図であり、図１（ａ）は端子３の樹脂材７で被覆する面（以下端子表面）を示す斜視図で、図１（ｂ）は端子裏面を示す斜視図である。図２は樹脂材７によって被覆する前のワイヤハーネス１を示す図であり、図２（ａ）は端子表面を示す斜視図で、図２（ｂ）は端子裏面を示す斜視図である。 Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a view showing a wire harness 1, FIG. 1 (a) is a perspective view showing a surface (hereinafter referred to as a terminal surface) covered with a resin material 7 of a terminal 3, and FIG. 1 (b) is a perspective view showing a terminal back surface. FIG. 2 is a view showing the wire harness 1 before being covered with the resin material 7, FIG. 2 (a) is a perspective view showing the terminal surface, and FIG. 2 (b) is a perspective view showing the back surface of the terminal.
ワイヤハーネス１は、端子３および被覆電線５等から構成される。端子３は、銅もしくは黄銅などが使用される。端子３には、電線導体である被覆電線５が接続される。導線２５を導線被覆部２３によって絶縁被覆した被覆電線５には、アルミニウムもしくはアルミニウム合金製の導線が使用される。すなわち、被覆電線５の導線２５を構成する金属と端子３を構成する金属は異種金属である。なお、以下の説明においては、銅製の端子と、アルミニウム製の（導体を有する）被覆電線である例について説明する。 The wire harness 1 includes a terminal 3 and a covered electric wire 5. The terminal 3 is made of copper or brass. The terminal 3 is connected to a covered wire 5 that is a wire conductor. A conductive wire made of aluminum or an aluminum alloy is used for the covered electric wire 5 in which the conductive wire 25 is insulation-coated by the conductive wire covering portion 23. That is, the metal constituting the conductive wire 25 of the covered electric wire 5 and the metal constituting the terminal 3 are different metals. In addition, in the following description, the example which is a copper terminal and a covered electric wire made of aluminum (having a conductor) will be described.
被覆電線５の先端は、導線被覆部２３が剥離され、内部の導線２５が露出している。被覆電線５の絶縁被覆されている部分は、端子３の一部である被覆線圧着部１１によって端子３に圧着される。また、導線被覆部２３が剥離されて露出している導線２５は、端子３の一部である導線圧着部１３によって端子３に圧着される。導線圧着部１３において導線２５と端子３とが電気的に接続される。 At the tip of the covered electric wire 5, the conductive wire covering portion 23 is peeled off, and the internal conductive wire 25 is exposed. A portion of the covered electric wire 5 that is covered with insulation is crimped to the terminal 3 by a covered wire crimping portion 11 that is a part of the terminal 3. Further, the conductive wire 25 exposed by peeling the conductive wire covering portion 23 is crimped to the terminal 3 by the conductive wire crimping portion 13 which is a part of the terminal 3. In the lead wire crimping portion 13, the lead wire 25 and the terminal 3 are electrically connected.
また、端子３および導線２５の接続部の表面は樹脂材７によって被覆される。樹脂材７の詳細は後述する。 Further, the surface of the connection portion between the terminal 3 and the conductive wire 25 is covered with the resin material 7. Details of the resin material 7 will be described later.
端子３の先端部には、例えば筒状の端子本体１５が設けられる。図１は、雌型の端子を示す例であり、端子本体１５内部に雄端子が挿入されて電気的に接続される。前述の通り、端子３は、被覆線圧着部１１、導線圧着部１３、端子本体１５等から構成され、被覆線圧着部１１と導線圧着部１３との間には樹脂溜め部１７が設けられる。樹脂溜め部１７の詳細は後述する。端子３の樹脂材７が充填される面の裏側の樹脂溜め部１７の位置には、孔９が設けられる。孔９についても後述する。 For example, a cylindrical terminal body 15 is provided at the tip of the terminal 3. FIG. 1 is an example showing a female terminal, and a male terminal is inserted into the terminal body 15 and electrically connected thereto. As described above, the terminal 3 includes the covered wire crimping portion 11, the conductive wire crimping portion 13, the terminal main body 15, and the like, and the resin reservoir 17 is provided between the covered wire crimping portion 11 and the conductive wire crimping portion 13. Details of the resin reservoir 17 will be described later. A hole 9 is provided at the position of the resin reservoir 17 on the back side of the surface of the terminal 3 where the resin material 7 is filled. The hole 9 will also be described later.
端子本体１５の内部（下部）には例えば、雄端子と接触する端子接触部１９が設けられる。すなわち、端子３と接続される雄端子は、端子接触部１９の接触面（上面）、端子本体１５の両側面（内面）および端子本体１５の上面（内面）と接触する。なお、端子３の形状は前述した形状の記載および図面で示した形状にとらわれない。 For example, a terminal contact portion 19 that comes into contact with the male terminal is provided inside (lower) the terminal body 15. That is, the male terminal connected to the terminal 3 contacts the contact surface (upper surface) of the terminal contact portion 19, both side surfaces (inner surface) of the terminal body 15, and the upper surface (inner surface) of the terminal body 15. The shape of the terminal 3 is not limited to the shape described above and the shape shown in the drawings.
次に樹脂溜め部１７について説明する。図３はワイヤハーネス１を示す図で、図３（ａ）は正面図、図３（ｂ）は正面断面図、図３（ｃ）は平面図である。図３（ｃ）に示したように、被覆線圧着部１１と導線圧着部１３との間には被覆導線５の幅方向に端子３を拡幅して樹脂溜め部１７が設けられる。 Next, the resin reservoir 17 will be described. 3A and 3B are diagrams showing the wire harness 1, in which FIG. 3A is a front view, FIG. 3B is a front sectional view, and FIG. 3C is a plan view. As shown in FIG. 3C, a resin reservoir 17 is provided between the coated wire crimping portion 11 and the conductive wire crimping portion 13 by widening the terminal 3 in the width direction of the coated conductive wire 5.
また、図４はワイヤハーネス１の断面を示す図で、図４（ａ）は図３におけるＡ−Ａ線断面図、図４（ｂ）はＢ−Ｂ線断面図である。図４（ａ）に示すように、樹脂溜め部１７の端子３の幅方向の断面形状はコの字状である。樹脂溜め部１７の開口部からは樹脂材７が充填される。導線２５を絶縁被覆する導線被覆部２３の外周面は全周にわたって樹脂材７で覆われ、樹脂材７は樹脂溜め部１７を隙間なく満たすまで充填される。 4 is a view showing a cross section of the wire harness 1. FIG. 4 (a) is a cross-sectional view taken along line AA in FIG. 3, and FIG. 4 (b) is a cross-sectional view taken along line BB. As shown to Fig.4 (a), the cross-sectional shape of the width direction of the terminal 3 of the resin reservoir part 17 is U shape. The resin material 7 is filled from the opening of the resin reservoir 17. The outer peripheral surface of the conductor covering portion 23 that insulates the conductor 25 is covered with the resin material 7 over the entire circumference, and the resin material 7 is filled until the resin reservoir portion 17 is filled without any gaps.
図３（ａ）および図３（ｂ）に示したように、樹脂溜め部１７は端子３を、端子３の幅方向に拡幅し、端子３の深さ方向にも長さを拡張することで樹脂材７を充填するのに適した形状となる。 3A and 3B, the resin reservoir 17 expands the terminal 3 in the width direction of the terminal 3 and extends the length in the depth direction of the terminal 3 as well. The shape is suitable for filling the resin material 7.
図４（ａ）において示す樹脂溜め部１７の位置の端子３の幅方向の断面形状（Ａ−Ａ線断面形状）と、図４（ｂ）において示す導線圧着部１３の位置の端子３の幅方向の断面形状（Ｂ−Ｂ線断面形状）を比較すると、樹脂溜め部１７の位置の端子３の幅および深さは、導線圧着部１３の位置の端子３の幅および深さよりも大きい。したがって、導線圧着部１３の位置における導線２５は、導線圧着部１３によって端子３に圧着されることから、樹脂溜め部１７の位置における導線２５と比較して、潰れた形状となる。 The cross-sectional shape (AA line cross-sectional shape) in the width direction of the terminal 3 at the position of the resin reservoir 17 shown in FIG. 4A and the width of the terminal 3 at the position of the conductor crimping portion 13 shown in FIG. Comparing the sectional shape in the direction (BB sectional shape), the width and depth of the terminal 3 at the position of the resin reservoir 17 are larger than the width and depth of the terminal 3 at the position of the conductor crimping portion 13. Therefore, since the conducting wire 25 at the position of the conducting wire crimping portion 13 is crimped to the terminal 3 by the conducting wire crimping portion 13, it becomes a crushed shape as compared with the conducting wire 25 at the position of the resin reservoir portion 17.
また、図３（ｂ）および図４（ａ）に示すように、樹脂溜め部１７における端子３の底面には外部に貫通する孔９が設けられる。 Further, as shown in FIGS. 3B and 4A, a hole 9 penetrating to the outside is provided on the bottom surface of the terminal 3 in the resin reservoir 17.
次に、樹脂材７について説明する。樹脂材７には耐塩水性（絶縁性）の樹脂を用い、−４０℃〜１２５℃における端子３等に対する接着強度が３ＭＰａ以上、引張強度が３０ＭＰａ以上、かつ、弾性率が２００〜１０００ＭＰａであることが望ましい。樹脂材７の接着強度が小さいと、使用時等において樹脂材７が剥離脱落する恐れがあり、弾性率および引張強度が上記範囲から外れると、樹脂材７の破損や剥離が生じやすくなるため望ましくない。また、樹脂材７の吸水率（沸騰水で２時間における）は５％以下であることが望ましい。 Next, the resin material 7 will be described. The resin material 7 is a salt water resistant (insulating) resin, and has an adhesive strength of 3 MPa or more, a tensile strength of 30 MPa or more, and an elastic modulus of 200 to 1000 MPa at −40 ° C. to 125 ° C. Is desirable. If the adhesive strength of the resin material 7 is small, the resin material 7 may be peeled off during use or the like, and if the elastic modulus and tensile strength are out of the above ranges, the resin material 7 is likely to be damaged or peeled off. Absent. The water absorption rate of the resin material 7 (boiling water in 2 hours) is desirably 5% or less.
このような樹脂材７としては、例えば、シリコン系、アクリル系、ウレタン系、ポリアミド系、エポキシ系等、またはこれらの混合樹脂を使用することができる。 As such a resin material 7, for example, silicon-based, acrylic-based, urethane-based, polyamide-based, epoxy-based, or a mixed resin thereof can be used.
樹脂材７を設けるには、たとえば、前述の方法で製造された端子３および被覆電線５を接続し、接続された状態で、導線２５と、導体圧着部１３と、樹脂溜め部１７と、を被覆するように、硬化前の樹脂材７を塗布する。樹脂材７の塗布の方法としては、例えば、ノズル等から樹脂材７を滴下させることによって端子３に樹脂材７を塗布する。この場合、硬化前の樹脂材料として、ＪＩＳ Ｚ ８８０３における流体の粘度の測定方法に準じた粘度が５０００ｍＰａ・ｓ〜２００００ｍＰａ・ｓの範囲に調整した物が用いられる。粘度が低すぎると、樹脂材７の塗布後に樹脂材７が流れてしまい、粘度が大きすぎると、樹脂材７が完全に接続部を被覆することが困難となるためである。 In order to provide the resin material 7, for example, the terminal 3 and the covered electric wire 5 manufactured by the above-described method are connected, and in the connected state, the conductive wire 25, the conductor crimping portion 13, and the resin reservoir portion 17 are provided. The resin material 7 before curing is applied so as to cover it. As a method for applying the resin material 7, for example, the resin material 7 is applied to the terminals 3 by dropping the resin material 7 from a nozzle or the like. In this case, as the resin material before curing, a material whose viscosity is adjusted in the range of 5000 mPa · s to 20000 mPa · s according to the method for measuring the viscosity of the fluid in JIS Z 8803 is used. If the viscosity is too low, the resin material 7 flows after the resin material 7 is applied. If the viscosity is too large, it is difficult for the resin material 7 to completely cover the connection portion.
樹脂材７の塗布後、前述したような接着強度、引張強度、弾性率が得られるように、紫外線、熱等を加えることで樹脂材７を硬化させる。以上により、樹脂材７が設けられる。 After application of the resin material 7, the resin material 7 is cured by applying ultraviolet rays, heat, or the like so that the adhesive strength, tensile strength, and elastic modulus as described above can be obtained. Thus, the resin material 7 is provided.
次に、ワイヤハーネス１の製造方法について説明する。前述した、導線圧着部１３と、被覆線圧着部１１と、導線圧着部１３と被覆線圧着部１１との間に設けられる樹脂溜め部１７と、樹脂溜め部１７に形成される外部に貫通する孔９と、を具備する端子３を用いてワイヤハーネス１を製造する。 Next, a method for manufacturing the wire harness 1 will be described. The lead wire crimping portion 13, the covered wire crimp portion 11, the resin reservoir portion 17 provided between the lead wire crimp portion 13 and the sheath wire crimp portion 11, and the outside formed in the resin reservoir portion 17 are penetrated. The wire harness 1 is manufactured using the terminal 3 having the hole 9.
まず、導線被覆部２３から露出する導線２５の端部と端子３とを、導線圧着部１３によって圧着するとともに、導線被覆部２３と端子３とを、被覆線圧着部１１によって圧着する。次に、導線圧着部１３と、導線被覆部２３から露出する導線２５の表面と、樹脂溜め部１７と、に樹脂材７を塗布する。樹脂溜め部１７には樹脂材７が充填され、樹脂溜め部１７における導線被覆部２３の外周面の全周は樹脂材７によって被覆される。なお、端子３の開口部からのみだけではなく、孔９から樹脂材７を充填させることもできる。 First, the end of the conductor 25 exposed from the conductor covering portion 23 and the terminal 3 are crimped by the conductor crimping portion 13, and the conductor covering portion 23 and the terminal 3 are crimped by the covered wire crimping portion 11. Next, the resin material 7 is applied to the lead wire crimping portion 13, the surface of the lead wire 25 exposed from the lead wire covering portion 23, and the resin reservoir portion 17. The resin reservoir 17 is filled with the resin material 7, and the entire outer peripheral surface of the conductive wire covering portion 23 in the resin reservoir 17 is covered with the resin material 7. The resin material 7 can be filled not only from the opening of the terminal 3 but also from the hole 9.
また、導線圧着部１３によって導線２５を圧着する際に、導線２５に伸びが生じ、導線被覆部２３の端部が被覆線圧着部１１の下にずれてしまう可能性がある。しかし、導線被覆部２３の外周部の全周を樹脂材７で被覆する目的を達成するためには、導線被覆部２３の端部が樹脂溜め部１７上の位置に配置される必要がある。したがって、樹脂溜め部１７の被覆導線５の長手方向の長さは導線２５を端子３に圧着させる際に生じる導線２５の伸びより長いことが必要である。 Further, when the conducting wire 25 is crimped by the conducting wire crimping portion 13, the conducting wire 25 is stretched and the end portion of the conducting wire covering portion 23 may be shifted below the covered wire crimping portion 11. However, in order to achieve the purpose of covering the entire circumference of the outer periphery of the conductor covering portion 23 with the resin material 7, the end portion of the conductor covering portion 23 needs to be disposed at a position on the resin reservoir portion 17. Therefore, the length of the resin reservoir 17 in the longitudinal direction of the coated conductor 5 needs to be longer than the elongation of the conductor 25 that occurs when the conductor 25 is crimped to the terminal 3.
以上説明したように、本実施形態のワイヤハーネス１によれば、端子３が樹脂溜め部１７を具備することによって、樹脂溜め部１７における導線被覆部２３の外周面の全周を樹脂材７で覆うことが可能となる。このため、被覆導線５と端子３との間に隙間を設けることなく樹脂材７を充填することができる。したがって、隙間からの浸水を確実に防止することができ、構造が簡易であるワイヤハーネス１を提供することができる。 As described above, according to the wire harness 1 of the present embodiment, since the terminal 3 includes the resin reservoir portion 17, the entire circumference of the outer peripheral surface of the conductive wire covering portion 23 in the resin reservoir portion 17 is made of the resin material 7. It becomes possible to cover. For this reason, the resin material 7 can be filled without providing a gap between the coated conductor 5 and the terminal 3. Therefore, it is possible to reliably prevent water from entering the gap and provide the wire harness 1 having a simple structure.
また、導線圧着部１３および、導線被覆部２３から露出する電線導体の表面が樹脂材７で被覆され、樹脂溜め部１７においても、導線被覆部２３の外周面の全周が樹脂材７で覆われているため、例えば被覆導線５が屈曲した際にも電線と端子３の接触部に浸水することがなく、安定して電気特性を維持するワイヤハーネス１を提供することができる。 In addition, the surface of the wire conductor exposed from the lead wire crimping portion 13 and the lead wire covering portion 23 is covered with the resin material 7, and the entire circumference of the outer peripheral surface of the lead wire covering portion 23 is also covered with the resin material 7 in the resin reservoir portion 17. Therefore, for example, even when the coated conductor 5 is bent, the wire harness 1 that stably maintains the electrical characteristics without being immersed in the contact portion between the electric wire and the terminal 3 can be provided.
また、樹脂溜め部１７に外部に貫通する孔９が設けられることから、樹脂材７を樹脂溜め部１７に充填させる際に、樹脂材７を充填する箇所に混入する空気を孔９の外側の空気と置換するため、空気溜まりを形成することなく樹脂材７を充填させることができる。 In addition, since the resin reservoir portion 17 is provided with a hole 9 penetrating to the outside, when the resin material 7 is filled into the resin reservoir portion 17, air mixed in the portion where the resin material 7 is filled is placed outside the hole 9. Since it replaces with air, the resin material 7 can be filled without forming an air pocket.
また、樹脂溜め部１７の電線導体の長手方向の長さが、電線導体を端子３に圧着させる際に生じる電線導体の伸びより長いことによって、電線導体を端子３に圧着させる際に電線導体に伸びが生じても、導線被覆部２３の端部を樹脂溜め部１７上の位置に配置することができ、確実に導線被覆部１７の外周面の全周を樹脂材７で被覆することが可能となる。 Further, since the length of the resin conductor 17 in the longitudinal direction of the electric wire conductor is longer than the elongation of the electric wire conductor that occurs when the electric wire conductor is crimped to the terminal 3, Even if elongation occurs, the end portion of the conductor covering portion 23 can be disposed at a position on the resin reservoir portion 17, and the entire outer circumference of the conductor covering portion 17 can be reliably covered with the resin material 7. It becomes.
以上、添付図を参照しながら、本発明の実施の形態を説明したが、本発明の技術的範囲は、前述した実施の形態に左右されない。当業者であれば、特許請求の範囲に記載された技術的思想の範疇内において各種の変更例または修正例に想到し得ることは明らかであり、それらについても当然に本発明の技術的範囲に属するものと了解される。 As mentioned above, although embodiment of this invention was described referring an accompanying drawing, the technical scope of this invention is not influenced by embodiment mentioned above. It is obvious for those skilled in the art that various modifications or modifications can be conceived within the scope of the technical idea described in the claims, and these are naturally within the technical scope of the present invention. It is understood that it belongs.
１………ワイヤハーネス
３………端子
５………被覆導線
７………樹脂材
９………孔
１１………被覆線圧着部
１３………導線圧着部
１５………端子本体
１７………樹脂溜め部
１９………端子接触部
２３………導線被覆部
２５………導線
１０１………樹脂
１０３………端子
１０５………導線被覆部
１０７………隙間
１０９………導体
DESCRIPTION OF SYMBOLS 1 ......... Wire harness 3 ......... Terminal 5 ......... Coating conductor 7 ......... Resin material 9 ......... Hole 11 ......... Coated wire crimping part 13 ......... Wire crimping part 15 ......... Terminal body 17 ......... Resin reservoir 19 ......... Terminal contact part 23 ......... Conductor covering part 25 ......... Conductor 101 ......... Resin 103 ......... Terminal 105 ......... Conductor covering part 107 ......... Gap 109 ... …conductor
Claims (4)
前記端子は、導線圧着部と、被覆線圧着部と、前記導線圧着部と前記被覆線圧着部との間に設けられる樹脂溜め部と、を具備し、
前記導線被覆部から露出する前記電線導体の端部は前記導線圧着部によって前記端子に圧着され、
前記導線被覆部は前記被覆線圧着部によって前記端子に圧着され、
前記導線被覆部から露出する前記電線導体の表面および前記導線圧着部が樹脂材で被覆されるとともに、前記樹脂溜め部において、前記導線被覆部の外周面の全周が樹脂材で被覆されることを特徴とするワイヤハーネス。 A wire harness to which a wire conductor having a conductive wire covering portion that insulates the periphery and a terminal made of a metal different from the wire conductor are connected,
The terminal includes a conductive wire crimping portion, a covered wire crimping portion, and a resin reservoir provided between the conductive wire crimping portion and the coated wire crimping portion,
The end portion of the electric wire conductor exposed from the conductive wire covering portion is crimped to the terminal by the conductive wire crimping portion,
The conducting wire covering portion is crimped to the terminal by the covering wire crimping portion,
The surface of the wire conductor exposed from the conductive wire covering portion and the conductive wire crimping portion are covered with a resin material, and the entire circumference of the outer peripheral surface of the conductive wire covering portion is covered with the resin material in the resin reservoir portion. A wire harness characterized by.
導線圧着部と、被覆線圧着部と、前記導線圧着部と前記被覆線圧着部との間に設けられる樹脂溜め部と、前記樹脂溜め部に形成される外部に貫通する孔と、を具備する端子を用い、
前記導線被覆部から露出する前記電線導体の端部を、前記導線圧着部によって前記端子に圧着し、前記導線被覆部を、前記被覆線圧着部によって前記端子に圧着し、
前記導線圧着部と、前記導線被覆部から露出する前記電線導体の表面と、前記樹脂溜め部と、に前記樹脂材を塗布することによって、前記樹脂溜め部には前記樹脂材が充填され、前記樹脂溜め部における前記導線被覆部の外周面の全周を前記樹脂材で被覆することを特徴とするワイヤハーネスの製造方法。 A method of manufacturing a wire harness,
A conductive wire crimping portion; a covered wire crimping portion; a resin reservoir provided between the conductive wire crimping portion and the coated wire crimping portion; and a hole penetrating to the outside formed in the resin reservoir. Use the terminal
The end portion of the electric wire conductor exposed from the conductive wire coating portion is crimped to the terminal by the conductive wire crimping portion, and the conductive wire coating portion is crimped to the terminal by the coated wire crimping portion,
The resin reservoir is filled with the resin material by applying the resin material to the conductive wire crimping portion, the surface of the electric wire conductor exposed from the conductive wire covering portion, and the resin reservoir. A method of manufacturing a wire harness, wherein the entire circumference of the outer peripheral surface of the conductive wire covering portion in the resin reservoir portion is covered with the resin material.
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| WO2015174258A1 (en) * | 2014-05-13 | 2015-11-19 | 株式会社村田製作所 | Terminal connection method and terminal connection structure |
| JPWO2015174258A1 (en) * | 2014-05-13 | 2017-04-20 | 株式会社村田製作所 | Terminal joining method and terminal joining structure |
| WO2016186021A1 (en) * | 2015-05-15 | 2016-11-24 | 株式会社オートネットワーク技術研究所 | Terminal and terminal-equipped electric wire |
| JP2018006205A (en) * | 2016-07-05 | 2018-01-11 | 株式会社フジクラ | Electric wire with terminal |
| JP2020035525A (en) * | 2018-08-27 | 2020-03-05 | 古河電気工業株式会社 | Wire with terminal and manufacturing method thereof |
| JP7145696B2 (en) | 2018-08-27 | 2022-10-03 | 古河電気工業株式会社 | Electric wire with terminal and manufacturing method thereof |
| JP7311308B2 (en) | 2019-05-13 | 2023-07-19 | 矢崎総業株式会社 | Wires with terminals and terminal fittings |
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