JP6187299B2 - Terminal connection structure for aluminum wires - Google Patents

Terminal connection structure for aluminum wires Download PDF

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JP6187299B2
JP6187299B2 JP2014026802A JP2014026802A JP6187299B2 JP 6187299 B2 JP6187299 B2 JP 6187299B2 JP 2014026802 A JP2014026802 A JP 2014026802A JP 2014026802 A JP2014026802 A JP 2014026802A JP 6187299 B2 JP6187299 B2 JP 6187299B2
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aluminum
terminal
core wire
wire
aluminum core
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JP2015153622A (en
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卓也 大庭
卓也 大庭
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Sumitomo Wiring Systems Ltd
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Sumitomo Wiring Systems Ltd
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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
    • H01R4/625—Soldered or welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/52—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
    • H01R13/5216—Dustproof, splashproof, drip-proof, waterproof, or flameproof cases characterised by the sealing material, e.g. gels or resins
    • 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
    • H01R4/02—Soldered or welded connections
    • H01R4/023—Soldered or welded connections between cables or wires and terminals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R11/00—Individual connecting elements providing two or more spaced connecting locations for conductive members which are, or may be, thereby interconnected, e.g. end pieces for wires or cables supported by the wire or cable and having means for facilitating electrical connection to some other wire, terminal, or conductive member, blocks of binding posts
    • H01R11/11—End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member
    • H01R11/12—End pieces terminating in an eye, hook, or fork
    • 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
    • H01R4/02—Soldered or welded connections
    • H01R4/026—Soldered or welded connections comprising means for eliminating an insulative layer prior to soldering or welding
    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/70—Insulation of connections
    • H01R4/72—Insulation of connections using a heat shrinking insulating sleeve
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0207—Ultrasonic-, H.F.-, cold- or impact welding

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  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Connector Housings Or Holding Contact Members (AREA)

Description

本発明はアルミニウム系電線の端子接続構造に関し、特に、車両に配索されるアルミニウム系電線と端子として溶接する接続構造に関するものである。   The present invention relates to a terminal connection structure for an aluminum-based electric wire, and more particularly to a connection structure for welding as an aluminum-based electric wire arranged in a vehicle and a terminal.

近時、車両に配線する電線として、軽量等の理由からアルミウム系金属製の素線を撚ったアルミ芯線を絶縁樹脂で被覆したアルミニウム系電線（以下、アルミ電線と略称する）が用いられている。該アルミ電線の芯線断面積が８ｍｍ２以上で電源線等として用いられる太物電線では、端子との電気接続信頼性を高める点からアルミ芯線は端子に溶接されている。 Recently, as an electric wire to be wired to a vehicle, an aluminum electric wire (hereinafter abbreviated as an aluminum electric wire) in which an aluminum core wire twisted with an aluminum metal wire is covered with an insulating resin is used for reasons such as light weight. Yes. In a thick electric wire used as a power line or the like when the core cross-sectional area of the aluminum electric wire is 8 mm 2 or more, the aluminum core wire is welded to the terminal from the viewpoint of improving the reliability of electrical connection with the terminal.

即ち、図９に示すように、アルミ電線１００の端末で絶縁被覆１０２から露出させたアルミ芯線１０１は銅系金属板からなる端子１２０の基板１２１に溶接されている。かつ、アルミ芯線１０１に連続する絶縁被覆１０２は端子１２０の基板１２１から突設された絶縁被覆バレル１２２で加締め圧着されている。   That is, as shown in FIG. 9, the aluminum core wire 101 exposed from the insulating coating 102 at the end of the aluminum electric wire 100 is welded to the substrate 121 of the terminal 120 made of a copper-based metal plate. The insulation coating 102 continuous with the aluminum core wire 101 is crimped and crimped by an insulation coating barrel 122 protruding from the substrate 121 of the terminal 120.

前記端子１２０は銅系金属板を加工して形成されているため、該端子１２０の基板１２１とアルミ芯線１０１との接触は銅とアルミニウムの異種金属接触となり、該接触部分に溶雪剤やバッテリ液に含まれる電解液、塩分や溶残酸素を含む水分が付着すると、ガルバニック腐食が発生する。該腐食は、図１０（Ａ）に示すＡ領域では、アルミ芯線１０１と端子１２０の基板１２１との溶接部には隙間が殆ど生じないため電解液や水分の浸水を防止できる。しかしながら、アルミ電線１００の絶縁被覆１０２の皮剥端１０２ｅの境界位置までアルミ芯線１０１を溶接することは出来ない。よって、図１０（Ａ）に示すように、アルミ芯線１０１の溶接領域Ａと皮剥端１０２ｅとの間のＢ領域には溶接出来ない芯線露出部１０５がある。図１０（Ｂ）に示すように、この芯線露出部１０５のアルミ芯線の素線１０１ａ間および素線１０１ａと端子１２０の基板１２１との間に隙間Ｃが発生する。素線１０１ａ間の隙間を伝って、素線１０１ａと基板１２１の間の隙間Ｃに浸水が生じると、基板１２１に腐食が発生し、該腐食が芯線溶接部の領域へと広がる問題がある。   Since the terminal 120 is formed by processing a copper-based metal plate, the contact between the substrate 121 of the terminal 120 and the aluminum core wire 101 becomes a dissimilar metal contact between copper and aluminum, and a snow melting agent or a battery is applied to the contact portion. Galvanic corrosion occurs when water containing electrolyte, salt, or dissolved oxygen contained in the solution adheres. In the region A shown in FIG. 10 (A), the corrosion hardly prevents the electrolytic solution and water from being immersed in the welded portion between the aluminum core wire 101 and the substrate 121 of the terminal 120 because there is almost no gap. However, the aluminum core wire 101 cannot be welded to the boundary position of the peeled end 102e of the insulating coating 102 of the aluminum electric wire 100. Therefore, as shown to FIG. 10 (A), the core wire exposure part 105 which cannot be welded exists in the B area | region between the welding area A of the aluminum core wire 101, and the peeling end 102e. As shown in FIG. 10B, gaps C are generated between the strands 101 a of the aluminum core wire of the core wire exposed portion 105 and between the strand 101 a and the substrate 121 of the terminal 120. If water is generated in the gap C between the strand 101a and the substrate 121 through the gap between the strands 101a, the substrate 121 is corroded, and there is a problem that the corrosion spreads to the area of the core wire weld.

前記問題に対して、特開２０１３−６２２０６号公報で、図１１に示すアミル電線の接続構造が提供されている。該端子２００では、電線接続部２０１の基板の前部から後端まで連続する長いバレル２０３と２０４を基板の幅方向両側から突設している。アルミ電線１００のアルミ芯線１０１を基板に溶接した後に、バレル２０３と２０４とをアルミ芯線１０１および絶縁被覆１０２に連続して加締め圧着し、かつ、重ねたバレル２０３と２０４を溶接すると共に前端を端子基板側に押圧して前端面も封鎖し、端子２００に接続するアルミ芯線１０１をバレル２０３と２０４で覆って封止している。   In order to solve the above problem, Japanese Patent Application Laid-Open No. 2013-62206 provides a connection structure for amyl electric wires shown in FIG. In the terminal 200, long barrels 203 and 204 that continue from the front part to the rear end of the board of the electric wire connection part 201 are projected from both sides in the board width direction. After the aluminum core wire 101 of the aluminum electric wire 100 is welded to the substrate, the barrels 203 and 204 are continuously crimped and crimped to the aluminum core wire 101 and the insulating coating 102, and the stacked barrels 203 and 204 are welded and the front end is The front end face is also sealed by pressing toward the terminal board, and the aluminum core wire 101 connected to the terminal 200 is covered and sealed with barrels 203 and 204.

特開２０１３−６２２０６号公報JP2013-62206A

特許文献１のように、端子の幅方向両側から長尺なバレルを突設し、芯線及び絶縁被覆の両方に連続したバレルで加締め圧着する場合、芯線と絶縁被覆の外径が相違するため、種々の問題が発生する。即ち、芯線に圧着させると絶縁被覆にバレルが深く食い込んで、絶縁被覆に損傷が発生する恐れがある。一方、絶縁被覆に密着させるように加締めると、芯線外周に隙間は生じる。さらに、バレルの前端を端子基板に当接するまで押圧する必要がある。よって、バレルに負荷する押圧力を長さ方向で変える必要があるが、その場合、圧着装置の構成が非常に複雑になる問題がある。   When a long barrel protrudes from both sides in the width direction of the terminal and is crimped and crimped with a barrel continuous to both the core wire and the insulation coating as in Patent Document 1, the outer diameters of the core wire and the insulation coating are different. Various problems occur. That is, if the core wire is crimped, the barrel may dig deeply into the insulating coating, and the insulating coating may be damaged. On the other hand, when caulking so as to be in close contact with the insulating coating, a gap is generated on the outer periphery of the core wire. Furthermore, it is necessary to press the front end of the barrel until it comes into contact with the terminal board. Therefore, it is necessary to change the pressing force applied to the barrel in the length direction, but in this case, there is a problem that the configuration of the crimping apparatus becomes very complicated.

本発明は前記問題に鑑みてなされたもので、アルミ電線のアルミ芯線を銅系金属製の端子に溶接して接続する端子において、電線と端子との電気接続信頼性を維持しながら水分の付着する腐食を抑制することを課題としている。   The present invention has been made in view of the above problems, and in a terminal for welding and connecting an aluminum core wire of an aluminum electric wire to a terminal made of a copper-based metal, adhesion of moisture while maintaining electrical connection reliability between the electric wire and the terminal. The problem is to suppress the corrosion that occurs.

前記課題を解決するため、本発明は、アルミニウム系金属製の素線を撚って形成したアルミ芯線を絶縁樹脂製の絶縁被覆で被覆した電線を、端末側で絶縁被覆を皮剥してアルミ芯線を露出させ、銅系金属板からなる端子にアルミ芯線を溶接すると共に、皮剥端に隣接する絶縁被覆を前記端子に設けた絶縁被覆バレルで加締め圧着しており、
前記アルミ芯線と前記端子の溶接部の後端と前記電線の皮剥端との間のみアルミ芯線露出部を被覆材で覆い、
かつ、前記被覆材として絶縁樹脂テープを用い、該絶縁樹脂テープを前記アルミ芯線露出部に巻き付けて覆い、
あるいは前記被覆材として前記端子の前記溶接部の後部に前記絶縁被覆バレルと分離したバレルを該端子の基板の幅方向両側から突設し、該バレルで前記端子との溶接部の後部から前記絶縁被覆バレルの間の前記アルミ芯線露出部を囲んで加締めて被覆しているアルミニウム系電線の端子接続構造を提供している。 In order to solve the above-mentioned problems, the present invention provides an aluminum core wire in which an aluminum core wire formed by twisting an aluminum-based metal strand is covered with an insulating resin insulation coating, and the insulation coating is peeled off at the terminal side. Is exposed, and the aluminum core wire is welded to a terminal made of a copper-based metal plate, and the insulation coating adjacent to the peeled end is crimped and crimped with an insulation coating barrel provided on the terminal,
Aluminum exposed core portions only between the cut position of the trailing edge and the wire welding portion of the terminal and the aluminum core wire has covered with the covering material,
And using an insulating resin tape as the covering material, the insulating resin tape is wrapped around the exposed portion of the aluminum core wire and covered,
Alternatively, as the covering material, a barrel separated from the insulating coating barrel is provided at the rear portion of the welded portion of the terminal so as to protrude from both sides in the width direction of the substrate of the terminal, and the insulation is performed from the rear portion of the welded portion with the terminal by the barrel. Provided is a terminal connection structure for an aluminum-based electric wire which is covered by caulking and covering the exposed portion of the aluminum core wire between the coating barrels .

本発明者は、前記従来例の図９に示すアルミ電線の端子接続構造とした場合において、塩水噴霧試験して端子の腐食状態を観察した。
その結果、図１０（Ａ）のＩ−Ｉ線断面のアルミ芯線と端子の溶接部では、該溶接部の界面で腐食は殆ど発生していなかった。一方、図１０（Ａ）のＩＩ−ＩＩ線断面のアルミ芯線が端子に溶接されていないアルミ芯線露出部では、腐食が発生しており、この腐食はアルミ芯線が撚線であるため外周だけでなくアルミ芯線の中央部まで腐食していた。
前記試験結果より、アルミ芯線が基板に溶接されている領域Ａでは、溶接により隙間が発生しないため隙間を伝う浸水が起っていなかった。よって、アルミ芯線の外面に水分が付着してもアルミ芯線と端子の溶接部界面に腐食が発生しないため、該芯線溶接部を防水ためにバレル等で被覆する必要はないことが確認できた。
一方、溶接部の後端と皮剥端との間の領域Ｂの溶接出来ないアルミ芯線露出部が存在する領域では、アルミ芯線の素線の間に隙間が存在するため浸水が生じていた。
前記のように、浸水で端子に腐食が発生する恐れが多いのは、端子に溶接されていないアルミ芯線露出部であるため、該アルミ芯線露出部の防水を図る構成としている。 In the case of the aluminum wire terminal connection structure shown in FIG. 9 of the conventional example, the present inventor observed the corrosion state of the terminal through a salt spray test.
As a result, almost no corrosion occurred at the interface between the welded portion of the aluminum core wire and the terminal in the section taken along the line II in FIG. 10A. On the other hand, corrosion has occurred in the exposed portion of the aluminum core wire in which the aluminum core wire in the section II-II in FIG. 10A is not welded to the terminal. This corrosion is only at the outer periphery because the aluminum core wire is a stranded wire. It was corroded to the center of the aluminum core wire.
From the test results, in the region A where the aluminum core wire was welded to the substrate, no gap was generated by welding, so that no water was transmitted through the gap. Therefore, even if moisture adheres to the outer surface of the aluminum core wire, corrosion does not occur at the welded portion interface between the aluminum core wire and the terminal. Therefore, it has been confirmed that the core wire welded portion need not be covered with a barrel or the like for waterproofing.
On the other hand, in the region where there is an unweldable aluminum core wire exposed portion in the region B between the rear end and the peeled end of the welded portion, there is a gap between the strands of the aluminum core wire, resulting in flooding.
As described above, since it is the aluminum core wire exposed portion that is not welded to the terminal that is likely to cause corrosion in the terminal due to water immersion, the aluminum core wire exposed portion is configured to be waterproof.

本発明では、前記のように、アルミ芯線の溶接部の後端と前記電線の皮剥端との間のアルミ芯線露出部を粘着テープまたはバレルからなる被覆材で被覆して防水している。前記粘着テープで被覆する場合は、アルミ芯線の溶接部の後端から絶縁被覆バレルによる加締め部分を越えた電線の絶縁被覆の外周面まで被覆することが好ましい。 In the present invention, as described above, it is waterproof coated with a coating material comprising an aluminum core wire exposed portion between the rear end of the welding of the aluminum core wire and the cut position of the wire from the adhesive tape or barrels . If you be covered by the adhesive tape, it is preferably coated from the rear end of the welded portion of the aluminum core wire to the outer circumferential surface of the insulating coating of the wire beyond the caulking portion by insulating coating barrel.

本発明で用いるアルミ電線は、車両に配索される電線で、芯線断面積が８ｍｍ２以上の太物電線で電源線またはアース線として用いられるアルミ電線に好適に用いられる。これは、電源線等として用いられる太物のアルミ電線は、芯線を端子に溶接することで電気接続信頼性を高めることができることに因る。かつ、前記のように、アルミ電線では異種金属の銅系金属からなる端子との異種金属接触による腐食が発生しやすいため、該腐食発生の防止のために、太物アルミ電線と端子とは溶接で接続することが義務付けられている場合が多いことによる。 The aluminum electric wire used in the present invention is an electric wire that is routed in a vehicle, and is suitably used as an aluminum electric wire that is a thick electric wire having a core wire cross-sectional area of 8 mm 2 or more and is used as a power line or an earth line. This is because a thick aluminum electric wire used as a power supply line or the like can improve electrical connection reliability by welding a core wire to a terminal. In addition, as described above, in an aluminum wire, corrosion due to contact with a dissimilar metal with a terminal made of a copper metal of a dissimilar metal is likely to occur. Therefore, in order to prevent the corrosion, the thick aluminum wire and the terminal are welded. Because it is often required to connect with.

前記端子の電気接触部の形状は、タブ形状のオス型、ボックス形状のメス型、ボルト穴を設けたボルト締めタイプ等の任意の形状でよい。   The shape of the electrical contact portion of the terminal may be any shape such as a tab-shaped male type, a box-shaped female type, or a bolt tightening type provided with a bolt hole.

本発明のアルミ電線の端子接続構造の形成方法は、アルミ電線の端末で絶縁被覆を皮剥してアルミ芯線を露出させ、露出させたアルミ芯線を前記端子の電線接続部の基板の芯線溶接部上に配置して超音波溶接し、その後、圧着装置で絶縁被覆バレルを絶縁被覆に加締め圧着し、最後に、基板に溶接されていない溶接部後端から皮剥端のアルミ芯線露出部を少なくとも覆うように、前記絶縁樹脂テープを巻き付けている。なお、被覆材としてアルミ芯線露出部を囲むバレルを端子に設けている場合は、絶縁被覆バレルを加締め圧着する時に同時に前記アルミ芯線露出部を囲むバレルを加締め圧着して、該アルミ芯線露出部を被覆している。 In the method for forming a terminal connection structure for an aluminum electric wire of the present invention, the insulation coating is peeled off at the end of the aluminum electric wire to expose the aluminum core wire, and the exposed aluminum core wire is placed on the core wire welded portion of the substrate of the electric wire connection portion of the terminal. And then ultrasonically welded, and then crimped and crimped the insulation coating barrel to the insulation coating with a crimping device, and finally covers at least the exposed part of the aluminum core wire from the rear end of the weld that is not welded to the substrate Thus, the insulating resin tape is wound . In the case where there is provided a barrel surrounding the aluminum exposed core portion as coatings to the terminal is to the aluminum core wire exposed portions barrel caulking crimp surrounding the same time when the insulating coating barrel crimping crimping, the aluminum core wire exposed The part is covered.

前記のように、端子への芯線の溶接は超音波溶接で行うことが好ましい。
溶接方法としては、抵抗溶接と超音波溶接を用いることが可能であるが、芯線がアルミニウム系金属のアルミ電線では、アルミニウム系金属の融点が高いため、抵抗溶接では加熱温度が高くなり、熱影響で絶縁被覆の熱劣化が発生する可能性がある。よって、アルミ電線では超音波溶接が好適に用いられる。 As described above, the welding of the core wire to the terminal is preferably performed by ultrasonic welding.
As the welding method, resistance welding and ultrasonic welding can be used. However, in the case of an aluminum electric wire whose core is an aluminum-based metal, the melting point of the aluminum-based metal is high. This may cause thermal degradation of the insulation coating. Therefore, ultrasonic welding is preferably used for aluminum wires.

本発明のアルミニウム系電線の端子接続構造では、アルミ芯線の溶接部の後端と電線の絶縁被覆の皮剥端との間のみ溶接できずに芯線が露出するアルミ芯線露出部をテープまたはバレルからなる被覆材で被覆して防水している。該構造としているため、アルミ芯線を端子に溶接接続する際に発生する非溶接箇所からの浸水防止を図れ、アルミ芯線と銅系端子との異種金属接触部での腐食を防止、抑制できる。 In the terminal connection structure of an aluminum-based wire of the present invention, the core wire tape Puma other aluminum exposed core portion exposed unable welding only between the cut position of the insulating coating of the rear end wire welding of the aluminum core wire It is covered with a barrel covering material to be waterproof. Since this structure is adopted, it is possible to prevent water from being welded from a non-welded portion that occurs when the aluminum core wire is welded to the terminal, and corrosion at the dissimilar metal contact portion between the aluminum core wire and the copper-based terminal can be prevented and suppressed.

本発明の実施形態の端子の斜視図である。It is a perspective view of the terminal of the embodiment of the present invention. 前記端子に接続する電線の正面図である。It is a front view of the electric wire connected to the said terminal. 前記端子と電線との超音波接続方法を示す図面である。It is drawing which shows the ultrasonic connection method of the said terminal and an electric wire. 前記端子と電線とを溶接接続した状態を示し、（Ａ）は正面図、（Ｂ）は平面図である。The state which weld-connected the said terminal and the electric wire is shown, (A) is a front view, (B) is a top view. 前記端子と電線との溶接後に粘着テープを巻き付けた状態を示し、（Ａ）は断面図、（Ｂ）は一部正面図、（Ｃ）は平面図である。The state which wound the adhesive tape after the said terminal and an electric wire were wound is shown, (A) is sectional drawing, (B) is a partial front view, (C) is a top view. 参考実施形態を示す概略図である。It is the schematic which shows reference embodiment. 第２実施形態を示し、（Ａ）は端子の概略正面図、（Ｂ）はアルミ芯線露出部にバレルを加締めた状態を示す断面図である。A 2nd embodiment is shown, (A) is a schematic front view of a terminal, and (B) is a sectional view showing the state where a barrel was caulked to an aluminum core wire exposure part. 試験結果を示すグラフである。It is a graph which shows a test result. 従来例を示す図面である。It is drawing which shows a prior art example. （Ａ）（Ｂ）は従来例の問題点の説明図である。(A) (B) is explanatory drawing of the problem of a prior art example. 他の従来例を示す斜視図である。It is a perspective view which shows another prior art example.

以下、本発明の実施形態を図面を参照して説明する。
図１乃至図５に第１実施形態を示す。
図１に示す端子１は、前記図９に示す従来の端子１２０と同形状としている。即ち、銅系金属板を打ち抜き加工した後に折り曲げ加工して形成している。端子１は平板形状の基板２の長さ方向の一側（後側）に電線接続部３を設けると共に、他側（前側）に電気接触部４を設けている。電気接触部４は相手型端子（図示せず）の電気接触部と接触させて電気接続を行うものである。本実施形態では、図１に示すように、ボルト締め端子としているため、電気接触部４の基板２ａの幅を拡げ、その中央にボルト穴５を設けている。
前記電線接続部３は長方形の平板形状の基板２ｂの前部上面を芯線溶接部６としている。該芯線溶接部６の後部の基板の幅方向の両側の側面より絶縁被覆バレル７（７ａ、７ｂ）を突設している。 Hereinafter, embodiments of the present invention will be described with reference to the drawings.
1 to 5 show a first embodiment.
The terminal 1 shown in FIG. 1 has the same shape as the conventional terminal 120 shown in FIG. That is, the copper-based metal plate is punched and then bent. The terminal 1 is provided with a wire connecting portion 3 on one side (rear side) in the length direction of the flat substrate 2 and an electric contact portion 4 on the other side (front side). The electrical contact portion 4 is for making electrical connection by contacting with an electrical contact portion of a mating terminal (not shown). In this embodiment, as shown in FIG. 1, since it is a bolt fastening terminal, the width | variety of the board | substrate 2a of the electrical contact part 4 is expanded, and the bolt hole 5 is provided in the center.
The wire connection portion 3 has a core wire welding portion 6 on the front upper surface of a rectangular flat substrate 2b. Insulation coating barrels 7 (7a, 7b) are projected from both side surfaces in the width direction of the substrate at the rear portion of the core wire welding portion 6.

前記端子１に接続するアルミニウムまたはアルミニウム合金を芯線とするアルミニウム系電線１０（以下、アルミ電線１０と略称する）は、車両に配線する電線で、芯線断面積が８ｍｍ２以上太物電線からなり、電源線またはアース線として用いている。図２に示すように、電線１０は、端末で絶縁被覆１２を皮剥し、アルミニウム系金属からなる素線１１ａを撚ったアルミ芯線１１を絶縁被覆１２の皮剥端１２ｅから突出させている。 An aluminum-based electric wire 10 (hereinafter abbreviated as “aluminum electric wire 10”) having aluminum or aluminum alloy as a core wire connected to the terminal 1 is an electric wire to be wired to a vehicle, and has a core wire cross-sectional area of 8 mm 2 or more and a thick electric wire. Used as a power line or ground line. As shown in FIG. 2, in the electric wire 10, the insulation coating 12 is peeled off at a terminal, and an aluminum core wire 11 twisted with a wire 11 a made of an aluminum-based metal is protruded from a peeled end 12 e of the insulation coating 12.

前記端子１はアルミ電線１０に図３に示す方法で接続して、図４に示すように、アルミ電線１０を端子１に超音波接続している。即ち、アルミ芯線１１を端子１の芯線溶接部６上に超音波溶接し、絶縁被覆１２を絶縁被覆バレル７で加締め圧着している。この状態で、アルミ芯線１１の溶接部Ｘの後端から絶縁被覆の皮剥端１２ｅまでは溶接されていないアルミ芯線露出部１５が存在する。該アルミ芯線露出部１５及び絶縁被覆バレル７による加締め圧着部を越えた位置の絶縁被覆１２を、図５に示すように、塩化ビニール等の絶縁樹脂からなり、粘着剤が塗布された粘着テープ８（以下、テープ８と略称する）をハーフラップ巻きで巻き付けて被覆している。即ち、アルミ芯線露出部１５をテープ８からなる被覆材で被覆している。   The terminal 1 is connected to the aluminum electric wire 10 by the method shown in FIG. 3, and the aluminum electric wire 10 is ultrasonically connected to the terminal 1 as shown in FIG. That is, the aluminum core wire 11 is ultrasonically welded onto the core wire welding portion 6 of the terminal 1, and the insulation coating 12 is crimped and crimped by the insulation coating barrel 7. In this state, there is an aluminum core wire exposed portion 15 which is not welded from the rear end of the welded portion X of the aluminum core wire 11 to the peeled end 12e of the insulating coating. As shown in FIG. 5, an adhesive tape made of an insulating resin such as vinyl chloride and coated with an adhesive is provided on the insulating coating 12 at a position beyond the crimping and crimping portion by the aluminum core wire exposed portion 15 and the insulating coating barrel 7. 8 (hereinafter abbreviated as “tape 8”) is wrapped with a half wrap and covered. That is, the aluminum core wire exposed portion 15 is covered with the covering material made of the tape 8.

端子１とアルミ電線１０との接続方法を図３に基づいて説明する。
端末でアルミ芯線１１を露出させたアルミ電線１０を端子１上にセットし、アルミ芯線１１を端子１の芯線溶接部６上に位置させ、絶縁被覆１２の皮剥端１２ｅを絶縁被覆バレル７より僅か前方に位置させる。この状態で、超音波溶接装置３０の固定台（アンビル）３１の所定位置に端子１を定置し、上方から超音波電極（ホーン）３２を下降して、露出したアルミ芯線１１の上面を加圧する。この状態で超音波を負荷し、アルミ芯線１１を基板１の芯線溶接部６に溶接する。 A method for connecting the terminal 1 and the aluminum electric wire 10 will be described with reference to FIG.
The aluminum electric wire 10 with the aluminum core wire 11 exposed at the terminal is set on the terminal 1, the aluminum core wire 11 is positioned on the core wire welding portion 6 of the terminal 1, and the peeled end 12 e of the insulating coating 12 is slightly smaller than the insulating coating barrel 7. Position it forward. In this state, the terminal 1 is placed at a predetermined position of the fixing base (anvil) 31 of the ultrasonic welding apparatus 30, the ultrasonic electrode (horn) 32 is lowered from above, and the upper surface of the exposed aluminum core wire 11 is pressurized. . In this state, an ultrasonic wave is applied, and the aluminum core wire 11 is welded to the core wire welding portion 6 of the substrate 1.

ホーン３２を絶縁被覆１２の皮剥端１２ｅに当接させて位置させると、絶縁被覆１２に熱損傷が発生するため、ホーン３２の端面３２ａは皮剥端１２ｅとの間に隙間Ｚをあけている。よって、ホーン３２で端子１に溶接されるアルミ芯線１１の溶接部Ｘと皮剥端１２ｅとの間に、溶接されていないアルミ芯線露出部１５が残る。この溶接されていないアルミ芯線露出部１５が存在するＹ領域は、溶接部Ｘの後端から皮剥端１２ｅへ上方傾斜した状態で存在する。   When the horn 32 is placed in contact with the peeled end 12e of the insulating coating 12, thermal damage occurs in the insulating coating 12, so that a gap Z is formed between the end surface 32a of the horn 32 and the peeled end 12e. Therefore, the unwelded aluminum core wire exposed portion 15 remains between the welded portion X of the aluminum core wire 11 welded to the terminal 1 by the horn 32 and the peeled end 12e. The Y region where the unwelded aluminum core wire exposed portion 15 exists exists in a state of being inclined upward from the rear end of the welded portion X to the peeled end 12e.

前記アルミ芯線露出部１５、絶縁被覆バレル７による加締め圧着部、さらに端子１の後端１ｅより延在するアルミ電線１０の絶縁被覆１２の部分まで、即ち、領域Ｙの範囲を含めた領域に被覆材の前記テープ８を巻き付けて被覆している。詳しくは、図５に示すように、端子１の基板２の下面から上面側のアルミ芯線露出部１５、前記絶縁被覆バレル７による加締め圧着部の上面側にテープ８を巻き付け、さらに、端子１の基板２の後端から延在する電線１０の外周面にテープ８を連続的にハーフラップ巻きで巻き付けている。   The aluminum core wire exposed portion 15, the crimped crimping portion by the insulating coating barrel 7, and further to the insulating coating 12 portion of the aluminum electric wire 10 extending from the rear end 1 e of the terminal 1, that is, in the region including the range of the region Y The said tape 8 of a covering material is wound and covered. Specifically, as shown in FIG. 5, a tape 8 is wound around the upper surface side of the aluminum core wire exposed portion 15 on the upper surface side from the lower surface of the substrate 2 of the terminal 1 and the crimping and crimping portion by the insulating coating barrel 7. The tape 8 is continuously wound around the outer peripheral surface of the electric wire 10 extending from the rear end of the substrate 2 by half-wrapping.

このように、端子１と接続するアルミ電線１０は、溶接部Ｘはテープ８およびバレル等の被覆材で被覆していないが、溶接部Ｘの後端側の溶接されていないアルミ芯線露出部１５が存在するＹ領域はテープ８からなる被覆材で被覆され、水がかからないようにして防水している。   As described above, in the aluminum electric wire 10 connected to the terminal 1, the welded portion X is not covered with the covering material such as the tape 8 and the barrel, but the aluminum core wire exposed portion 15 on the rear end side of the welded portion X is not welded. The Y region where the water is present is covered with a covering material made of the tape 8, and is waterproofed so as not to be exposed to water.

図６に参考実施形態を示す。
該参考実施形態では、前記アルミ芯線露出部１５、絶縁被覆バレル７による加締め圧着部、さらに端子１の後端１ｅより延在する電線１０の絶縁被覆１２の部分までのＹ領域を含む範囲に、被覆材としてテープに代えて、絶縁樹脂からなる熱収縮チューブ２０で被覆している。
即ち、加熱前の熱収縮していない内径が大きな熱収縮チューブ２０を前記範囲に被せ、その後、所要温度で加熱して熱収縮チューブ２０を収縮し、アルミ芯線露出部１５、基板２、絶縁被覆１２の外周面に熱収縮チューブ２０を密着させ、浸水経路となる隙間を無くしている。他の構成は第１実施形態と同様であるため説明を省略する。 FIG. 6 shows a reference embodiment.
In the reference embodiment, the aluminum core wire exposed portion 15, the crimping and crimping portion by the insulating coating barrel 7, and the range including the Y region from the rear end 1 e of the terminal 1 to the portion of the insulating coating 12 of the electric wire 10. Instead of the tape as a covering material, it is covered with a heat shrinkable tube 20 made of an insulating resin.
That is, the heat-shrinkable tube 20 having a large inner diameter which is not heat-shrinked before heating is covered in the above range, and then the heat-shrinkable tube 20 is shrunk by heating at a required temperature, and the aluminum core wire exposed portion 15, the substrate 2, and the insulation coating The heat shrinkable tube 20 is brought into close contact with the outer peripheral surface of 12 so as to eliminate a gap serving as a water immersion path. Since other configurations are the same as those of the first embodiment, description thereof is omitted.

図７に第２実施形態を示す。
該第２実施形態では、前記アルミ芯線露出部１５の被覆材として、該アルミ芯線露出部１５を加締め圧着するバレル１９Ａ、１９Ｂを、端子１の電線接続部３の芯線溶接部６の後部に設けている。該バレル１９Ａ、１９Ｂは後端に設ける絶縁被覆バレル７とスリット状の隙間をあけて分離して設けている。 FIG. 7 shows a second embodiment.
In the second embodiment, as a covering material for the aluminum core wire exposed portion 15, barrels 19 </ b> A and 19 </ b> B for crimping and crimping the aluminum core wire exposed portion 15 are attached to the rear portion of the core wire welded portion 6 of the wire connecting portion 3 of the terminal 1. Provided. The barrels 19A and 19B are provided separately from the insulating coating barrel 7 provided at the rear end with a slit-shaped gap.

該バレル１９Ａ、１９Ｂと絶縁被覆バレル７を加締め圧着する圧着装置の押圧片（図示せず）は分離し、同時に加締め圧着作動をするが、加締め圧着動作は個別としている。 前記バレル１９Ａ、１９Ｂは図７（Ｂ）に示すように、一方のバレル１９Ａをアルミ芯線露出部１５の外面に密着させて先端側を折り返し、他方のバレル１９Ｂをバレル１９Ａの外面に重ねるようにして被覆している。   The pressing pieces (not shown) of the crimping device for crimping and crimping the barrels 19A and 19B and the insulation coating barrel 7 are separated and simultaneously crimped and crimped, but the crimping and crimping operations are separate. As shown in FIG. 7B, the barrels 19A and 19B are arranged such that one barrel 19A is brought into close contact with the outer surface of the aluminum core wire exposed portion 15 and the tip side is folded, and the other barrel 19B is overlapped with the outer surface of the barrel 19A. Covered.

「実験例」
アルミ電線を用い、前記参考実施形態の熱収縮チューブ２０でアルミ芯線露出部を被覆したアルミ電線の端子接続構造（参考実施例）と、前記熱収縮チューブ２０で被覆していないアルミ電線の前記図９に示す接続構造（従来例）について、塩水噴霧をしながら、腐食による電圧降下の有無を測定した。
その結果は、図８に示すように、参考実施例では９６時間経過しても電圧降下はなかった。一方、従来例では２４時間経過後から電圧降下が発生した。 "Experimental example"
Using an aluminum electric wire, the reference embodiment of the heat shrinkable tube 20 at the terminal connection structure of the A Rumi wire coated with aluminum exposed core part (Reference Example), the aluminum electric wire which is not covered with the heat shrinkable tube 20 For the connection structure (conventional example) shown in FIG. 9, the presence or absence of a voltage drop due to corrosion was measured while spraying salt water.
As a result, as shown in FIG. 8, in the reference example, there was no voltage drop even after 96 hours. On the other hand, in the conventional example, a voltage drop occurred after 24 hours.

前記のように、アルミ芯線の溶接部Ｘは被覆していない状態であっても、溶接されていないアルミ芯線露出部１５を被覆するだけで、腐食発生を防止または抑制できる。よって、アルミ芯線露出部１５の素線１１ａ間に隙間があり、溶存酸素が存在して腐食が発生しても、アルミ芯線露出部を被覆材で被覆していることにより、空気に含まれる溶存酸素の供給を遅延させることができ、その結果、腐食の進行を大幅に遅らせることができることが確認できた。   As described above, even if the welded portion X of the aluminum core wire is not covered, the occurrence of corrosion can be prevented or suppressed only by covering the unwelded aluminum core wire exposed portion 15. Therefore, even if there is a gap between the strands 11a of the aluminum core wire exposed portion 15 and corrosion occurs due to the presence of dissolved oxygen, the aluminum core wire exposed portion is covered with the covering material, so that dissolved dissolved in the air It was confirmed that the supply of oxygen can be delayed, and as a result, the progress of corrosion can be significantly delayed.

本発明は前記実施形態に限定されず、本発明の要旨を越えない範囲で種々に変更することができる。例えば、端子はボルト締め端子に変えて、電気接触部をタブ状としてオス端子としても良いし、ボックス状としてメス端子にしてもよい。   The present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the scope of the present invention. For example, the terminal may be replaced with a bolted terminal, and the electrical contact portion may be a tab-shaped male terminal, or a box-shaped female terminal.

１ 端子
２ 基板
３ 電線接続部
４ 電気接触部
６ 芯線溶接部
７ 絶縁被覆バレル
８ テープ
１０ 電線
１１ アルミ芯線
１２ 絶縁被覆
１２ｅ 皮剥端
１５ アルミ芯線露出部
２０ 熱収縮チューブ DESCRIPTION OF SYMBOLS 1 Terminal 2 Board | substrate 3 Electric wire connection part 4 Electrical contact part 6 Core wire welding part 7 Insulation coating barrel 8 Tape 10 Electric wire 11 Aluminum core wire 12 Insulation coating 12e Skinned end 15 Aluminum core wire exposed part 20 Heat shrinkable tube

Claims (2)

アルミニウム系金属製の素線を撚って形成したアルミ芯線を絶縁樹脂製の絶縁被覆で被覆した電線を、端末側で絶縁被覆を皮剥してアルミ芯線を露出させ、銅系金属板からなる端子にアルミ芯線を溶接すると共に、皮剥端に隣接する絶縁被覆を前記端子に設けた絶縁被覆バレルで加締め圧着しており、
前記アルミ芯線と前記端子の溶接部の後端と前記電線の皮剥端との間のみアルミ芯線露出部を被覆材で覆い、
かつ、前記被覆材として絶縁樹脂テープを用い、該絶縁樹脂テープを前記アルミ芯線露出部に巻き付けて覆い、
あるいは前記被覆材として前記端子の前記溶接部の後部に前記絶縁被覆バレルと分離したバレルを該端子の基板の幅方向両側から突設し、該バレルで前記端子との溶接部の後部から前記絶縁被覆バレルの間の前記アルミ芯線露出部を囲んで加締めて被覆しているアルミニウム系電線の端子接続構造。 A terminal made of a copper-based metal plate, with an aluminum core wire formed by twisting an aluminum-based metal strand covered with an insulating resin insulation coating, stripping the insulation coating on the terminal side to expose the aluminum core wire The aluminum core wire is welded, and the insulation coating adjacent to the peeled end is crimped and crimped with an insulation coating barrel provided on the terminal,
Aluminum exposed core portions only between the cut position of the trailing edge and the wire welding portion of the terminal and the aluminum core wire has covered with the covering material,
And using an insulating resin tape as the covering material, the insulating resin tape is wrapped around the exposed portion of the aluminum core wire and covered,
Alternatively, as the covering material, a barrel separated from the insulating coating barrel is provided at the rear portion of the welded portion of the terminal so as to protrude from both sides in the width direction of the substrate of the terminal, and the insulation is performed from the rear portion of the welded portion with the terminal by the barrel. A terminal connection structure for an aluminum-based electric wire covering and covering the exposed portion of the aluminum core wire between the covering barrels . 前記アルミニウム系電線は車両に配索される電線で、芯線断面積が８ｍｍ ２ 以上の太物電線で電源線、アース線として用いられるものである請求項１に記載のアルミニウム系電線の端子接続構造。 The aluminum-based electric wire terminal connection structure according to claim 1, wherein the aluminum-based electric wire is an electric wire arranged in a vehicle, and is used as a power supply line and a ground wire with a thick wire having a core cross-sectional area of 8 mm 2 or more. .
JP2014026802A 2014-02-14 2014-02-14 Terminal connection structure for aluminum wires Expired - Fee Related JP6187299B2 (en)

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