JP6935310B2 - Manufacturing method of electric wire with terminal - Google Patents
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- JP6935310B2 JP6935310B2 JP2017226026A JP2017226026A JP6935310B2 JP 6935310 B2 JP6935310 B2 JP 6935310B2 JP 2017226026 A JP2017226026 A JP 2017226026A JP 2017226026 A JP2017226026 A JP 2017226026A JP 6935310 B2 JP6935310 B2 JP 6935310B2
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本発明は、被覆導線と端子とを接続する端子付き電線の製造方法に関するものである。 The present invention relates to a method for manufacturing an electric wire with a terminal for connecting a coated conductor and a terminal.
従来、自動車、ＯＡ機器、家電製品等の分野では、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、使用される端子付き電線も増加する傾向にある。 Conventionally, in the fields of automobiles, OA equipment, home appliances, etc., electric wires made of copper-based materials having excellent electrical conductivity have been used as power lines and signal lines. In particular, in the field of automobiles, the performance and functionality of vehicles are rapidly increasing, and the number of various electric devices and control devices mounted on vehicles is increasing. Therefore, along with this, the number of electric wires with terminals 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, as environmental problems are attracting attention, weight reduction of automobiles is required. Therefore, an increase in weight due to an increase in the amount of wire harness used becomes a problem. For this reason, lightweight aluminum electric wires are attracting attention in place of the conventionally used copper wires.
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、アルミニウム電線を用いた端子付き電線であっても、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 at a connection portion of equipment or the like. However, even in the case of an electric wire with a terminal using an aluminum electric wire, copper having excellent electrical characteristics may be used for the terminal portion for the sake of reliability of the connecting portion and the like. In such a case, the aluminum electric wire and the 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 dissimilar metals are brought into contact with each other, so-called galvanic 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 electrically base aluminum side progresses due to the influence of water scattering and dew condensation on the contact portion. For this reason, the connection state between the electric wire and the terminal at the connection part becomes unstable, and there is a risk that the electrical resistance increases due to the increase in contact resistance and the decrease in wire diameter, and further, the disconnection occurs, resulting in malfunction or malfunction of the electrical component. be.
このため、電線と端子との接続部への水分の浸入を防ぐ方法が提案されている。例えば、被覆導線の導線と被覆部をそれぞれ圧着する圧着部が一体で構成され、管状の圧着部の一端が封止されることで、被覆導線が挿入される部位を除き、他の部位が封止された圧着端子がある（例えば、特許文献１参照）。 Therefore, a method for preventing the ingress of moisture into the connection portion between the electric wire and the terminal has been proposed. For example, a crimping portion that crimps the coated conductor and the coated portion is integrally formed, and one end of the tubular crimping portion is sealed to seal other parts except the part where the coated conductor is inserted. There is a crimp terminal that has been stopped (see, for example, Patent Document 1).
図８（ａ）は、従来の圧着端子の圧着工程を示す図である。被覆導線１０５は、先端の被覆部１０９が剥離されて、導線１０７が所定の長さ露出する。端子１００は、導線１０７と被覆部１０９を一括して圧着する圧着部１０３を有する。圧着部１０３は、略筒状であり、先端部が封止部１０１で封止される。このため、後端部１１３を除き、圧着部１０３は他の部位が封止される。 FIG. 8A is a diagram showing a crimping process of a conventional crimping terminal. In the coated conductor 105, the coated portion 109 at the tip is peeled off, and the conductor 107 is exposed to a predetermined length. The terminal 100 has a crimping portion 103 that collectively crimps the conducting wire 107 and the covering portion 109. The crimping portion 103 has a substantially cylindrical shape, and the tip portion is sealed by the sealing portion 101. Therefore, except for the rear end portion 113, other portions of the crimping portion 103 are sealed.
被覆導線１０５と端子１００は、端子１００の後端部１１３から、被覆導線１０５の先端を挿入し、上下から金型１１１ａ、１１１ｂで挟み込むことで圧着することができる。 The coated conductor 105 and the terminal 100 can be crimped by inserting the tip of the coated conductor 105 from the rear end portion 113 of the terminal 100 and sandwiching it between the dies 111a and 111b from above and below.
図８（ｂ）は、被覆導線１０５と端子１００とを圧着した状態を示す図である。導線１０７の圧着は、被覆部１０９の圧着と比較して強圧着となる。この際、導線１０７が軸方向に大きく伸びるため、被覆部１０９は、後端部１１３から後方へ押し出されながら、被覆部１０９自体も圧着される。 FIG. 8B is a diagram showing a state in which the coated conductor 105 and the terminal 100 are crimped. The crimping of the conductor 107 is stronger than the crimping of the covering portion 109. At this time, since the conducting wire 107 extends significantly in the axial direction, the covering portion 109 is also crimped while being pushed backward from the rear end portion 113.
ここで、圧着部１０３は、例えば、板状部材を丸めて縁部同士を溶接することで筒状に成形される。このため、圧着部１０３は、長手方向に沿って溶接部が形成される。このような溶接部は、圧着部１０３の内面側に膨らむ凸形状となるため、被覆部１０９が圧着部１０３に圧着されながら後方に押し出されると、凸形状に沿って傷１１５が形成される恐れがある。また、溶接部のような凸形状が形成されない場合でも、例えば、圧着部１０３の後端部１１３のエッジや、圧着部１０３の内面に残る金属くずなどを起点として、被覆部１０９に傷１１５が形成される場合もある。 Here, the crimping portion 103 is formed into a cylindrical shape by, for example, rolling a plate-shaped member and welding the edge portions to each other. Therefore, in the crimping portion 103, a welded portion is formed along the longitudinal direction. Since such a welded portion has a convex shape that bulges toward the inner surface side of the crimping portion 103, if the covering portion 109 is pushed backward while being crimped to the crimping portion 103, a scratch 115 may be formed along the convex shape. There is. Further, even when a convex shape such as a welded portion is not formed, for example, a scratch 115 is formed on the covering portion 109 starting from the edge of the rear end portion 113 of the crimping portion 103 or the metal scrap remaining on the inner surface of the crimping portion 103. It may be formed.
このように、被覆部１０９の一部に傷１１５が形成されると、傷１１５を伝って、圧着部１０３の内部に水が浸入するおそれがある。すなわち、圧着部１０３の止水性を低下させる要因となる。 When the scratch 115 is formed on a part of the covering portion 109 in this way, water may infiltrate into the crimping portion 103 along the scratch 115. That is, it becomes a factor that lowers the water stopping property of the crimping portion 103.
本発明は、前述した問題点に鑑みてなされたもので、止水性に優れた端子付き電線の製造方法を提供することを目的とする。 The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide a method for manufacturing an electric wire with a terminal having excellent water stopping property.
前述した目的を達成するために本発明は、被覆導線と端子とが接続される端子付き電線の製造方法であって、前記端子は、前記被覆導線が圧着される圧着部と、端子本体とを有し、前記圧着部は、前記被覆導線の被覆部を圧着する被覆圧着部と、前記被覆部から露出する導線を圧着する導線圧着部とを有し、前記被覆導線が挿入される部位を除き、他の部位が封止されており、前記圧着部に前記被覆導線を挿入し、前記導線圧着部と前記導線を圧着するとともに、前記被覆圧着部を仮圧縮する第１圧着工程と、前記第１圧着工程の後、前記被覆圧着部と、前記被覆部を強圧着する第２圧着工程と、を具備し、前記第１圧着工程において、前記被覆部に対する前記被覆圧着部の圧縮率が、１００％以上１１０％以下であり、
前記第１圧着工程後における前記被覆圧着部の内部の断面積は、前記第１圧着工程前における前記被覆圧着部の内部の断面積よりも小さく、前記端子は、前記圧着部の長手方向に沿って溶接部が形成されており、前記第１圧着工程において、前記溶接部における前記被覆圧着部の内径が前記被覆部の外径より大きくなるように前記被覆圧着部を仮圧縮することを特徴とする端子付き電線の製造方法である。
In order to achieve the above-mentioned object, the present invention is a method for manufacturing an electric wire with a terminal in which a coated conductor and a terminal are connected. The crimping portion has a coated crimping portion for crimping the coated portion of the coated conducting wire and a conducting wire crimping portion for crimping a conducting wire exposed from the covering portion, except for a portion where the coated conducting wire is inserted. , The first crimping step of inserting the coated conductor into the crimping portion, crimping the conducting wire crimping portion and the conducting wire, and temporarily compressing the coated crimping portion, and the first crimping step. After one crimping step, the coated crimping portion and a second crimping step of strongly crimping the covering portion are provided, and in the first crimping step, the compression ratio of the coated crimping portion with respect to the covering portion is 100. Ri der 110% and not more than%,
The cross-sectional area inside the coated crimping portion after the first crimping step is smaller than the cross-sectional area inside the coated crimping portion before the first crimping step, and the terminals are along the longitudinal direction of the crimping portion. weld is formed Te, wherein the first bonding step, characterized that you temporary compression of the insulation crimp portion to be larger than the outer diameter of an inner diameter the cover portion of the insulation crimp portion in the welded portion This is a method for manufacturing an electric wire with a terminal.
前記第１圧着工程における、前記被覆圧着部の仮圧縮形状が略円形であることが望ましい。 It is desirable that the temporary compression shape of the coated crimping portion in the first crimping step is substantially circular.
前記被覆導線の径が３ｓｑ以上であることが望ましい。 It is desirable that the diameter of the coated conductor is 3 sq or more.
圧縮前の前記被覆圧着部の内径は、前記被覆導線の前記被覆部の外径に対して、１倍超であり１．４倍以下であることが望ましい。 It is desirable that the inner diameter of the coated crimping portion before compression is more than 1 times and 1.4 times or less the outer diameter of the coated portion of the coated conducting wire.
本発明によれば、圧着部を２回に分けて圧縮し、導線を圧着した後に、被覆部を圧着するようにしたため、導線圧着時における導体の変形や電線の伸びなどの影響により、被覆部に傷が生じることを抑制することができる。したがって、圧着端子と被覆部の隙間から水分が端子内に浸入し、電線と端子との接触部に水分が付着するのを防止することができる。 According to the present invention, since the crimping portion is compressed in two steps, the conducting wire is crimped, and then the covering portion is crimped, the covering portion is affected by deformation of the conductor and elongation of the electric wire during crimping of the conducting wire. It is possible to suppress the occurrence of scratches on the wire. Therefore, it is possible to prevent moisture from entering the terminal through the gap between the crimp terminal and the covering portion and adhering to the contact portion between the electric wire and the terminal.
特に、第１圧着工程における被覆圧着部の仮圧縮形状を略円形とすることで、第２圧着工程において被覆部を圧着する際に、被覆圧着部の部位による変形量の差を抑制し、周方向で略均一に圧縮することができる。このため、被覆圧着部の部分的な大きな変形が要因となって、被覆部に傷が生じることを抑制することができる。 In particular, by making the temporary compression shape of the covering crimping portion substantially circular in the first crimping step, when crimping the covering portion in the second crimping step, the difference in the amount of deformation depending on the portion of the covering crimping portion is suppressed, and the circumference is suppressed. It can be compressed almost uniformly in the direction. Therefore, it is possible to prevent the covering portion from being scratched due to a large partial deformation of the covering crimping portion.
また、圧着部が、長手方向に沿って溶接されている場合には、第１圧着工程において、溶接部における管内径が被覆部の外径より大きくなるように被覆圧着部を仮圧縮することで、溶接部によって被覆部に傷が生じることを抑制することができる。 Further, when the crimping portion is welded along the longitudinal direction, in the first crimping step, the covering crimping portion is temporarily compressed so that the inner diameter of the pipe in the welded portion is larger than the outer diameter of the covering portion. , It is possible to prevent the coated portion from being scratched by the welded portion.
また、上述したような各効果は、特に、被覆導線の径が３ｓｑ以上の太径である場合により効率よく得ることができる。 In addition, each of the above-mentioned effects can be obtained more efficiently, especially when the diameter of the coated conducting wire is a large diameter of 3 sq or more.
また、圧縮前の被覆圧着部の内径を、被覆部の外径に対して、１倍超〜１．４倍以下とすることで、第２圧着工程における被覆圧着部の圧縮量が過剰に大きくなることを防ぐことができる。 Further, by setting the inner diameter of the coated crimping portion before compression to be more than 1 time to 1.4 times or less the outer diameter of the covering portion, the amount of compression of the coated crimping portion in the second crimping step is excessively large. It can be prevented from becoming.
本発明によれば、止水性に優れた端子付き電線の製造方法を提供することができる。 According to the present invention, it is possible to provide a method for manufacturing an electric wire with a terminal having excellent water stopping property.
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、端子付き電線１０を示す斜視図であり、図２は断面図である。端子付き電線１０は、端子１と被覆導線２３とが接続されて構成される。 Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a perspective view showing an electric wire 10 with a terminal, and FIG. 2 is a cross-sectional view. The electric wire 10 with a terminal is configured by connecting the terminal 1 and the coated conductor wire 23.
被覆導線２３は、導線２５が絶縁性の被覆部２７によって被覆されて構成される。導線２５は、例えばアルミニウム系材料製である。すなわち、被覆導線２３は、被覆部２７と、その先端から露出する導線２５とを具備する。導線２５は、例えば、複数の素線が撚り合わせられた撚り線である。なお、被覆部２７としては、ポリ塩化ビニル（ＰＶＣ）、ポリエチレン等、この技術の分野において通常用いられるものを選択することができる。 The coated conductor 23 is configured such that the conductor 25 is covered with an insulating covering portion 27. The conductor 25 is made of, for example, an aluminum-based material. That is, the coated conductor 23 includes a coated portion 27 and a conductor 25 exposed from the tip thereof. The conductor 25 is, for example, a stranded wire in which a plurality of strands are twisted together. As the covering portion 27, those usually used in the field of this technology such as polyvinyl chloride (PVC) and polyethylene can be selected.
端子１は、例えば銅系材料製であり、端子本体３と、被覆導線２３が圧着される圧着部５とからなる。端子本体３は、所定の形状の板材を、断面が矩形の筒体に形成したものである。端子本体３は、前端部１７に、板材を矩形の筒体内に折り込んで形成される弾性接触片１５を有する。端子本体３は、前端部１７から雄端子などが挿入されて接続される。 The terminal 1 is made of, for example, a copper-based material, and includes a terminal body 3 and a crimping portion 5 to which the coated conducting wire 23 is crimped. The terminal body 3 is formed by forming a plate material having a predetermined shape into a tubular body having a rectangular cross section. The terminal body 3 has an elastic contact piece 15 formed by folding a plate material into a rectangular cylinder at the front end portion 17. The terminal body 3 is connected by inserting a male terminal or the like from the front end portion 17.
なお、以下の説明では、端子本体３が、雄型端子等の挿入タブ（図示省略）の挿入を許容する雌型端子である例を示すが、本発明において、この端子本体３の細部の形状は特に限定されない。例えば、雌型の端子本体３に代えて雄型端子の挿入タブを設けてもよいし、丸型端子のようなボルト締結部を設けても良い。 In the following description, an example is shown in which the terminal body 3 is a female terminal that allows insertion of an insertion tab (not shown) such as a male terminal. In the present invention, the detailed shape of the terminal body 3 is shown. Is not particularly limited. For example, instead of the female terminal body 3, a male terminal insertion tab may be provided, or a bolt fastening portion such as a round terminal may be provided.
圧着部５は、断面が円形の筒体となるように丸められ、側縁部同士を突き合わせて接合部２１で接合して一体化することにより形成される。筒状に形成された圧着部５の後端部１９から、被覆導線２３が挿入される。また、圧着部５の前端部（端子本体３側）には封止部１１が設けられる。すなわち、圧着部５は、一方が閉じた略筒状で、被覆導線が挿入される後端部１９以外の他の部位は、封止される。なお、接合部２１および封止部１１は、例えばレーザ溶接やろう付け等によって接合および封止される。 The crimping portion 5 is rolled so as to form a tubular body having a circular cross section, and is formed by abutting the side edge portions and joining them at the joining portion 21 to integrate them. The coated conducting wire 23 is inserted from the rear end portion 19 of the crimping portion 5 formed in a cylindrical shape. Further, a sealing portion 11 is provided at the front end portion (terminal body 3 side) of the crimping portion 5. That is, the crimping portion 5 has a substantially cylindrical shape with one closed, and other portions other than the rear end portion 19 into which the coated conducting wire is inserted are sealed. The joint portion 21 and the sealing portion 11 are joined and sealed by, for example, laser welding or brazing.
圧着部５は、被覆導線２３の被覆部２７を圧着する被覆圧着部９と、被覆導線２３の先端部分において、被覆部が除去されて導線２５が露出した部位を圧着する導線圧着部７とからなる。すなわち、被覆部２７が剥離されて露出する導線２５は、導線圧着部７により圧着され、導線２５と端子１とが電気的に接続される。 The crimping portion 5 is composed of a coated crimping portion 9 that crimps the covering portion 27 of the coated conducting wire 23, and a conducting wire crimping portion 7 that crimps a portion of the tip portion of the coated conducting wire 23 where the covering portion is removed and the conducting wire 25 is exposed. Become. That is, the conductor 25 whose covering portion 27 is peeled off and exposed is crimped by the conductor crimping portion 7, and the conductor 25 and the terminal 1 are electrically connected.
なお、導線圧着部７の内面の一部には、周方向に、図示を省略したセレーションが設けられる。このようにセレーションを形成することで、導線２５を圧着した際に、導線２５の表面の酸化膜を破壊しやすく、また、導線２５との接触面積を増加させることができる。 A part of the inner surface of the conductor crimping portion 7 is provided with serrations (not shown) in the circumferential direction. By forming the serrations in this way, when the conductor 25 is crimped, the oxide film on the surface of the conductor 25 is easily broken, and the contact area with the conductor 25 can be increased.
次に、端子付き電線１０の製造方法について説明する。図３は、端子１へ被覆導線２３を挿入する前の状態を示す分解斜視図である。なお、圧着前の端子１の導線圧着部７は、被覆圧着部９に対して外径および内径が小さい。このように、導線圧着部７と被覆圧着部９の径をあらかじめ変えておき、より径の大きな被覆部２７を圧着する被覆圧着部９の内径を、より径の小さな導線２５を圧着する導線圧着部７の内径よりも大きくしておくことで、端子１の圧縮量を少なくすることができる。 Next, a method of manufacturing the electric wire 10 with a terminal will be described. FIG. 3 is an exploded perspective view showing a state before the covered conductor 23 is inserted into the terminal 1. The conductor crimping portion 7 of the terminal 1 before crimping has a smaller outer diameter and inner diameter than the coated crimping portion 9. In this way, the diameters of the conductor crimping portion 7 and the covering crimping portion 9 are changed in advance, and the inner diameter of the covering crimping portion 9 that crimps the covering portion 27 having a larger diameter is crimped to the conductor crimping portion 25 having a smaller diameter. By making it larger than the inner diameter of the portion 7, the amount of compression of the terminal 1 can be reduced.
まず、被覆導線２３の先端の所定長さの被覆部２７を剥離して、内部の導線２５を露出させる。次に、筒状の圧着部５に被覆導線２３を挿入する。この際、導線圧着部７の内部には導線２５の露出部が位置し、被覆圧着部９の内部には被覆部２７が位置する。すなわち、被覆部２７の端面は、被覆圧着部９と導線圧着部７の間に位置する。 First, the coated portion 27 having a predetermined length at the tip of the coated conductor 23 is peeled off to expose the internal conductor 25. Next, the coated conductor 23 is inserted into the tubular crimping portion 5. At this time, the exposed portion of the conductor 25 is located inside the conductor crimping portion 7, and the covering portion 27 is located inside the covering crimping portion 9. That is, the end face of the covering portion 27 is located between the covering crimping portion 9 and the conductor crimping portion 7.
図４（ａ）は、圧着前における金型３１ａ、３１ｂ等を示す断面図、図４（ｂ）は、圧着中の圧着部５を示す断面図である。金型３１ａは、長手方向に延びる半円柱状の空洞を有し、被覆圧着部９に対応するとともに被覆圧着部９の半径よりも僅かに小さい半径を有する大径部３４と、導線圧着部７に対応するとともに大径部３４よりも小さい半径を有する小径部３２とを備える。金型３１ｂは、長手方向に延びる半円柱状の空洞を有し、導線圧着部７および被覆圧着部９に対応する部位の半径が、金型３１ａと同様に異なる。大径部３４は、被覆圧着部９を圧着する部位であり、小径部３２は、導線圧着部７を圧着する部位である。 FIG. 4A is a cross-sectional view showing the dies 31a, 31b and the like before crimping, and FIG. 4B is a cross-sectional view showing the crimping portion 5 during crimping. The mold 31a has a semi-cylindrical cavity extending in the longitudinal direction, and has a large diameter portion 34 corresponding to the covering crimping portion 9 and having a radius slightly smaller than the radius of the covering crimping portion 9, and a lead wire crimping portion 7. A small diameter portion 32 having a radius smaller than that of the large diameter portion 34 is provided. The mold 31b has a semi-cylindrical cavity extending in the longitudinal direction, and the radii of the portions corresponding to the conductor crimping portion 7 and the covering crimping portion 9 are different from those of the mold 31a. The large diameter portion 34 is a portion for crimping the covering crimping portion 9, and the small diameter portion 32 is a portion for crimping the conductor crimping portion 7.
図４（ｂ）に示すように、金型３１ａ、３１ｂを噛み合わせて、圧着部５を圧縮すると、導線圧着部７が導線２５に圧着され（図中Ｂ）、被覆圧着部９は、仮圧縮される（図中Ｃ）（第１圧着工程）。すなわち、金型３１ａ、３１ｂを用いた第１圧着工程は、導線圧着部７と導線２５を完全に圧着するとともに、被覆圧着部９を仮圧縮するものである。 As shown in FIG. 4 (b), when the dies 31a and 31b are engaged and the crimping portion 5 is compressed, the conductor crimping portion 7 is crimped to the conductor 25 (B in the figure), and the covering crimping portion 9 is provisionally It is compressed (C in the figure) (first crimping step). That is, in the first crimping step using the dies 31a and 31b, the conductor crimping portion 7 and the conducting wire 25 are completely crimped, and the covering crimping portion 9 is temporarily compressed.
ここで、仮圧縮とは、被覆圧着部９によって、被覆部２７を圧着することなく、被覆圧着部９をわずかに圧縮するものである。すなわち、第１圧着工程において、被覆部２７に対する被覆圧着部９の圧縮率は、１００％以上である。被覆圧着部９の圧縮率とは、第１圧着工程前の被覆部２７における断面積（被覆部２７の外周面に対する内側の全断面積。以下同様。）をＡとし、金型３１ａ、３１ｂによって圧縮された後の被覆圧着部９の内部の断面積をＡ１とすると、圧縮率＝Ａ１／Ａである。したがって、被覆圧着部９の圧縮率が１００％以上であるとは、被覆部２７は、被覆圧着部９によって全周にわたって圧縮されることがないことを意味する。例えば、被覆圧着部９の圧縮率が１００％以上であっても、被覆部２７の周方向の一部が被覆圧着部９によって圧縮される場合もあるが、この場合でも、被覆部２７の周方向の少なくとも一部に圧縮されない部分を有し、被覆圧着部９によって全周から完全に拘束されなければよい。 Here, the temporary compression means that the covering crimping portion 9 is slightly compressed without crimping the covering portion 27 by the covering crimping portion 9. That is, in the first crimping step, the compressibility of the coated crimping portion 9 with respect to the covering portion 27 is 100% or more. The compressibility of the covering crimping portion 9 is defined by the cross-sectional area of the covering portion 27 before the first crimping step (the total cross-sectional area inside the covering portion 27 with respect to the outer peripheral surface; the same applies hereinafter) as A, and the molds 31a and 31b. Assuming that the cross-sectional area inside the covering crimping portion 9 after being compressed is A1, the compressibility is A1 / A. Therefore, when the compressibility of the covering crimping portion 9 is 100% or more, it means that the covering portion 27 is not compressed over the entire circumference by the covering crimping portion 9. For example, even if the compression ratio of the covering crimping portion 9 is 100% or more, a part of the covering portion 27 in the circumferential direction may be compressed by the covering crimping portion 9, but even in this case, the circumference of the covering portion 27 It does not have to have an uncompressed portion in at least a part of the direction and is not completely restrained from the entire circumference by the covering crimping portion 9.
なお、圧縮前の被覆圧着部９の内部の断面積をＡ０（図４（ａ））とすると、Ａ０＞Ａ１である。すなわち、仮圧縮では、被覆圧着部９は、わずかに圧縮されて縮径する。なお、第１圧着工程における被覆圧着部９の圧縮率は、１００％以上１１０％以下であることが望ましい。圧縮率が大きすぎると、後述する第２圧着工程において圧縮量が大きくなりすぎて、変形や傷の発生の要因となるため望ましくない。 Assuming that the cross-sectional area inside the coated crimping portion 9 before compression is A0 (FIG. 4A), A0> A1. That is, in the temporary compression, the coating crimping portion 9 is slightly compressed and the diameter is reduced. The compressibility of the coated crimping portion 9 in the first crimping step is preferably 100% or more and 110% or less. If the compression ratio is too large, the amount of compression becomes too large in the second crimping step described later, which causes deformation and scratches, which is not desirable.
図５（ａ）は、第１圧着工程前における、被覆圧着部９の断面図であり、図５（ｂ）は、第１圧着工程後における、被覆圧着部９の断面図である。ここで、図５（ａ）に示すように、第１圧着工程前において、圧縮前の被覆圧着部９の内径（図中Ｄ０）は、圧着前の被覆部２７の外径（図中Ｄ）の１倍超であり１．４倍以下であることが望ましい。被覆圧着部９の内径が大きすぎると、仮圧縮における圧縮量が大きくなりすぎ、被覆圧着部９の変形等の要因となる。 FIG. 5A is a cross-sectional view of the covering crimping portion 9 before the first crimping step, and FIG. 5B is a cross-sectional view of the covering crimping portion 9 after the first crimping step. Here, as shown in FIG. 5A, before the first crimping step, the inner diameter of the coated crimping portion 9 before compression (D0 in the figure) is the outer diameter of the covering portion 27 before crimping (D in the figure). It is desirable that it is more than 1 times and 1.4 times or less of. If the inner diameter of the covering crimping portion 9 is too large, the amount of compression in the temporary compression becomes too large, which causes deformation of the covering crimping portion 9.
また、被覆圧着部９の仮圧縮形状は略円形であることが望ましい。ここで、仮圧縮形状が略円形とは、図５（ｂ）に示すように、圧縮方向の外径（図中ａ）と、これと垂直な方向の外径（図中ｂ）の比率が、０．９〜１．１であるとする。仮圧縮形状がこれ以上偏平形状であると、後述する第２圧着工程において、縦横で圧縮量が大きく異なり、これに伴い、被覆圧着部９の変形や、これに伴う傷の要因となり得る。 Further, it is desirable that the temporary compression shape of the covering crimping portion 9 is substantially circular. Here, when the temporary compression shape is substantially circular, as shown in FIG. 5 (b), the ratio of the outer diameter in the compression direction (a in the figure) to the outer diameter in the direction perpendicular to this (b in the figure) is , 0.9 to 1.1. If the temporary compression shape is flatter than this, the amount of compression differs greatly in the vertical and horizontal directions in the second crimping step described later, which may cause deformation of the covering crimping portion 9 and scratches associated therewith.
次に、図６（ａ）に示すように、第１圧着工程後の端子付き電線を、金型３３ａ、３３ｂの間に配置する。金型３３ａ、３３ｂは、金型３１ａ、３１ｂとほぼ同様の構造であるが、大径部３４の径が異なる。金型３３ａ、３３ｂの大径部３４の内径は、金型３１ａ、３１ｂの大径部３４の内径よりも小さい。なお、金型３３ａ、３３ｂの小径部３２の内径と、金型３３ａ、３３ｂの小径部３２の内径と略同一である。 Next, as shown in FIG. 6A, the electric wire with a terminal after the first crimping step is arranged between the dies 33a and 33b. The molds 33a and 33b have almost the same structure as the molds 31a and 31b, but the diameter of the large diameter portion 34 is different. The inner diameter of the large diameter portion 34 of the molds 33a and 33b is smaller than the inner diameter of the large diameter portion 34 of the molds 31a and 31b. The inner diameter of the small diameter portion 32 of the molds 33a and 33b is substantially the same as the inner diameter of the small diameter portion 32 of the molds 33a and 33b.
次に、図６（ｂ）に示すように、金型３３ａ、３３ｂを噛み合わせて、圧着部５を圧縮すると、被覆圧着部９が強く圧着される（図中Ｄ）（第２圧着工程）。すなわち、被覆圧着部９が本圧着される。圧着後の被覆圧着部９の内部（被覆部２７）の断面積をＡ２とすると、Ａ２／Ａが、最終的な被覆部２７の圧縮率となる。最終的な圧縮率は、被覆が破れるのを抑制するため、５０％以上であるのが好ましく、圧着部の密着性を確保するため、９０％未満であるのが好ましい。 Next, as shown in FIG. 6B, when the dies 33a and 33b are engaged and the crimping portion 5 is compressed, the covering crimping portion 9 is strongly crimped (D in the figure) (second crimping step). .. That is, the covering crimping portion 9 is main crimped. Assuming that the cross-sectional area of the inside (covered portion 27) of the coated crimped portion 9 after crimping is A2, A2 / A is the final compression ratio of the coated portion 27. The final compressibility is preferably 50% or more in order to suppress tearing of the coating, and preferably less than 90% in order to ensure the adhesion of the pressure-bonded portion.
なお、金型３３ａ、３３ｂによって圧着部５を圧着する際には、導線圧着部７は、それ以上圧着されない。したがって、金型３３ａ、３３ｂの小径部３２は、導線圧着部７の変形を抑える目的で機能する。また、金型３３ａ、３３ｂに小径部３２を形成せずに、大径部３４のみの金型で圧着を行ってもよい。 When the crimping portion 5 is crimped by the dies 33a and 33b, the conductor crimping portion 7 is not crimped any more. Therefore, the small diameter portions 32 of the dies 33a and 33b function for the purpose of suppressing deformation of the conductor crimping portion 7. Further, the crimping may be performed only with the large diameter portion 34 without forming the small diameter portion 32 on the dies 33a and 33b.
このように、金型３３ａ、３３ｂによる圧着後には、被覆圧着部９の内面と被覆部２７の外面との密着によって圧着部５を封止することができる。この際、圧着部５の後端部１９以外の他の部位は、接合部２１および封止部１１によって水密に封止されるため、圧着部５への水分の浸入を防止することができる。 In this way, after crimping with the dies 33a and 33b, the crimping portion 5 can be sealed by the close contact between the inner surface of the covering crimping portion 9 and the outer surface of the covering portion 27. At this time, since the parts other than the rear end portion 19 of the crimping portion 5 are watertightly sealed by the joining portion 21 and the sealing portion 11, it is possible to prevent the infiltration of water into the crimping portion 5.
以上、本実施の形態のように、被覆導線２３を端子１に対して２段階で圧着することにより、止水性に優れた端子付き電線１０を製造することができる。 As described above, as described in the present embodiment, by crimping the coated conducting wire 23 to the terminal 1 in two steps, the electric wire 10 with a terminal having excellent water stopping property can be manufactured.
また、前述した従来の方法の様に、導線圧着部７を圧着する際に被覆部２７を同時に圧着すると、導線２５が被覆圧着部９側に伸びるため、被覆部２７が被覆圧着部９の伸びに追従しながら圧着される。この結果、被覆部２７が、被覆圧着部９の内面やエッジに対して擦れながら圧着される。このため、被覆部２７に傷が生じ、傷を起点として、水密性が悪くなる恐れがある。 Further, as in the conventional method described above, when the covering portion 27 is crimped at the same time when the conducting wire crimping portion 7 is crimped, the conducting wire 25 extends toward the covering crimping portion 9, so that the covering portion 27 extends the covering crimping portion 9. It is crimped while following. As a result, the covering portion 27 is crimped while rubbing against the inner surface and the edge of the covering crimping portion 9. For this reason, the covering portion 27 may be scratched, and the watertightness may be deteriorated starting from the scratch.
これに対し、本発明では、導線圧着部７を圧着する際には、被覆圧着部９は仮圧縮されるのみであり、被覆部２７は圧着されない。すなわち、被覆圧着部９によって被覆部２７は押圧されないため、被覆部２７は自由に軸方向へ移動することができる。このため、導線圧着部７を圧着する際に、導線２５の伸びによって被覆部２７が後方に押し出されても、被覆圧着部９の内面やエッジで擦れて傷が生じることを抑制することができる。 On the other hand, in the present invention, when the conductor crimping portion 7 is crimped, the covering crimping portion 9 is only temporarily compressed, and the covering portion 27 is not crimped. That is, since the covering portion 27 is not pressed by the covering crimping portion 9, the covering portion 27 can freely move in the axial direction. Therefore, when the conductor crimping portion 7 is crimped, even if the covering portion 27 is pushed out rearward due to the elongation of the conducting wire 25, it is possible to prevent scratches from being rubbed on the inner surface or the edge of the covering crimping portion 9. ..
特に、接合部２１が溶接部である場合には、圧着部５の長手方向に沿って、被覆圧着部９の内面へ溶接部の凸形状が生じる場合がある。この場合には、第１圧着工程において、溶接部における被覆圧着部９の内径（溶接部を通る内径）が被覆部２７の外径より大きくなるように被覆圧着部９を仮圧縮することで、溶接部で被覆部２７が擦れて傷が生じることを抑制することができる。 In particular, when the joint portion 21 is a welded portion, a convex shape of the welded portion may be formed on the inner surface of the coated crimping portion 9 along the longitudinal direction of the crimping portion 5. In this case, in the first crimping step, the covering crimping portion 9 is temporarily compressed so that the inner diameter of the covering crimping portion 9 (inner diameter passing through the welded portion) in the welded portion is larger than the outer diameter of the covering portion 27. It is possible to prevent the covering portion 27 from being rubbed and scratched at the welded portion.
なお、第１圧着工程において、導線圧着部７のみを圧着して、被覆圧着部９に対しては、仮圧縮も行わない方法も考えられる。しかし、このようにすると、導線圧着部７の強圧着によって、導線圧着部７と被覆圧着部９との間に大きな変形（例えば、被覆圧着部９が上方に跳ね上がるように変形するベントアップなど）が生じるおそれがある。例えば、圧着部５にベントアップが生じると、被覆圧着部９のエッジに被覆部２７が強く押し付けられて傷が生じるおそれがあり、また、第２圧着工程において、被覆圧着部９を安定して圧着することが困難となる。したがって、第１圧着工程においては、被覆部２７を圧着せずに、被覆圧着部９をわずかに仮圧縮することで、このような変形を抑えることができる。 In the first crimping step, a method in which only the conductor crimping portion 7 is crimped and the covering crimping portion 9 is not temporarily compressed is also conceivable. However, in this way, the strong crimping of the conductor crimping portion 7 causes a large deformation between the conductor crimping portion 7 and the covering crimping portion 9 (for example, a vent-up in which the covering crimping portion 9 is deformed so as to jump upward). May occur. For example, if the crimping portion 5 is vented up, the covering portion 27 may be strongly pressed against the edge of the covering crimping portion 9 to cause scratches, and the covering crimping portion 9 may be stably pressed in the second crimping step. It becomes difficult to crimp. Therefore, in the first crimping step, such deformation can be suppressed by slightly temporarily compressing the covering crimping portion 9 without crimping the covering portion 27.
また、第１圧着工程において、被覆圧着部９の仮圧縮形状を略円形とすることで、第２圧着工程において、被覆圧着部９の部分的な圧縮量の差が生じにくい。このため、被覆圧着部９の部分的な大きな圧縮に伴う変形などを抑制して、部位によらず均等に圧縮することができ、被覆部２７の圧着の際に傷が生じることを抑制することができる。 Further, in the first crimping step, by making the temporary compression shape of the covering crimping portion 9 substantially circular, it is difficult for a difference in the partial compression amount of the covering crimping portion 9 to occur in the second crimping step. Therefore, it is possible to suppress deformation due to partial large compression of the covering crimping portion 9 so that the covering crimping portion 9 can be compressed evenly regardless of the portion, and it is possible to suppress the occurrence of scratches during crimping of the covering portion 27. Can be done.
また、第１圧着工程前の被覆圧着部９の内径が、被覆部２７の外径に対して、１倍超であり１．４倍以下とすることで、第１圧着工程において、仮圧縮量が大きくなり過ぎず、仮圧縮に伴う被覆圧着部９の変形等を抑制することができる。 Further, by setting the inner diameter of the coated crimping portion 9 before the first crimping step to be more than 1 times and 1.4 times or less the outer diameter of the covering portion 27, the amount of temporary compression in the first crimping step is increased. Does not become too large, and deformation of the coating crimping portion 9 due to temporary compression can be suppressed.
なお、上述した効果は、圧着による電線の伸び量が大きくなる３ｓｑ以上の太径の被覆導線２３を圧着する場合に、特に効果的に得ることができる。また、本発明にかかる端子付き電線１０を複数本束ねてワイヤハーネスとして使用することもできる。 The above-mentioned effect can be obtained particularly effectively when crimping a coated conductor wire 23 having a large diameter of 3 sq or more, which increases the amount of elongation of the electric wire by crimping. Further, a plurality of electric wires 10 with terminals according to the present invention can be bundled and used as a wire harness.
まず、１４０℃×３０分と−４０℃×３０分のサイクルを２４０サイクル繰り返す熱サイクル試験後の端子付き電線の被覆導線側を負圧にして、水漏れの有無を評価した。なお、被覆導線の径は、５ｓｑとした。 First, the presence or absence of water leakage was evaluated by setting the coated conductor side of the wire with a terminal after a thermal cycle test in which a cycle of 140 ° C. × 30 minutes and −40 ° C. × 30 minutes was repeated 240 cycles to a negative pressure. The diameter of the coated conductor was 5 sq.
図８には、評価方法の概要を示す。評価は、水を入れた水槽４１中に被覆導線２３を圧着した端子１を入れ、長さ１５０ｍｍの被覆導線２３の端部を、容器４５内に挿入し、容器４５内をポンプ４７によって−３０ｋＰａの負圧にして１０分間保持した。それぞれの条件において、ｎ＝１０のサンプルについて評価した。結果を表１に示す。 FIG. 8 shows an outline of the evaluation method. For the evaluation, the terminal 1 in which the coated conductor 23 was crimped was put in the water tank 41 filled with water, the end of the coated conductor 23 having a length of 150 mm was inserted into the container 45, and the inside of the container 45 was -30 kPa by the pump 47. The pressure was reduced to 10 minutes. Under each condition, n = 10 samples were evaluated. The results are shown in Table 1.
表中、「被覆部の傷」は、傷の有無および大きさを示し、圧着後に、被覆圧着部９の後端から見える被覆部２７の傷の長さが０．１ｍｍ未満の物を「なし」とし、０．１ｍｍ以上０．３ｍｍ未満のものを「小」とし、０．３ｍｍ以上１．０ｍｍ未満のものを「中」とし、１．０ｍｍ以上の物を「大」とした。 In the table, "scratch on the covering portion" indicates the presence or absence and size of the scratch, and "none" means that the length of the scratch on the covering portion 27 visible from the rear end of the coating crimping portion 9 after crimping is less than 0.1 mm. , 0.1 mm or more and less than 0.3 mm was defined as "small", 0.3 mm or more and less than 1.0 mm was defined as "medium", and 1.0 mm or more was defined as "large".
実施例１〜４は、前述したように、圧着を２工程とした。すなわち、第１圧着工程では、導線圧着部７と導線２５との圧着と、被覆圧着部９の仮圧縮を行い、第２圧着工程において、被覆圧着部９と被覆部２７とを圧着した。なお、第１圧着工程における被覆圧着部９の仮圧縮は、圧縮率１０５％とした。 In Examples 1 to 4, as described above, crimping was performed in two steps. That is, in the first crimping step, the conductor crimping portion 7 and the conducting wire 25 were crimped and the covering crimping portion 9 was temporarily compressed, and in the second crimping step, the covering crimping portion 9 and the covering portion 27 were crimped. The temporary compression of the coated crimping portion 9 in the first crimping step was set to a compression rate of 105%.
実施例１では、第１圧着工程後の被覆圧着部９の仮圧縮形状が略円形とした。また、実施例２〜４では、仮圧縮形状が縦長の偏平形状（それぞれ、図５（ｂ）におけるａ／ｂ＝０．９、１．１、１．２）とした。 In the first embodiment, the temporary compression shape of the covering crimping portion 9 after the first crimping step is substantially circular. Further, in Examples 2 to 4, the temporary compression shape was a vertically long flat shape (a / b = 0.9, 1.1, 1.2 in FIG. 5B, respectively).
これに対し、比較例１では、１回の圧着工程で、導線圧着部７と被覆圧着部９の両方を圧着した。 On the other hand, in Comparative Example 1, both the conductor crimping portion 7 and the covering crimping portion 9 were crimped in one crimping step.
比較例２では、圧着工程を２工程としたが、第１圧着工程においても、被覆圧着部９と被覆部２７とを圧縮率９０％で弱く圧着した。 In Comparative Example 2, the crimping step was two steps, but also in the first crimping step, the coated crimping portion 9 and the covering portion 27 were weakly crimped at a compression rate of 90%.
比較例３では、圧着工程を２工程としたが、第１圧着工程において、被覆圧着部９の仮圧縮を行わず、導線圧着部７のみを圧縮した。 In Comparative Example 3, the crimping step was two steps, but in the first crimping step, the coated crimping portion 9 was not temporarily compressed, and only the conductor crimping portion 7 was compressed.
なお、実施例１〜４および比較例１〜３は、いずれも、最終的な被覆部２７の圧縮率は６０％で同一とした。 In both Examples 1 to 4 and Comparative Examples 1 to 3, the final compression ratio of the covering portion 27 was 60%, which was the same.
結果より、実施例１〜４は、負圧試験において、合格率が５０％以上であり、傷も「小」のみであった。特に、実施例１〜３は、合格率が１００％であり、傷の発生も見られなかった。 From the results, in Examples 1 to 4, the passing rate was 50% or more and the scratches were only "small" in the negative pressure test. In particular, in Examples 1 to 3, the pass rate was 100%, and no scratches were observed.
これに対し、１回圧着の比較例１では、大きな傷が発生し、負圧試験でも全て不合格であった。また、第１圧着工程で被覆部２７を圧着した比較例２では、「中」の傷が見られ、負圧試験の合格率も３０％となった。また、第１圧着工程で被覆圧着部の仮圧縮を行わない比較例３では、圧着部の変形が大きく、第２圧着工程後の品質がばらつき、傷は小さいながらも、負圧試験の合格率が３０％となった。 On the other hand, in Comparative Example 1 of one-time crimping, large scratches were generated, and all of them failed the negative pressure test. Further, in Comparative Example 2 in which the covering portion 27 was crimped in the first crimping step, “medium” scratches were observed, and the pass rate of the negative pressure test was 30%. Further, in Comparative Example 3 in which the coated crimping portion is not temporarily compressed in the first crimping step, the crimping portion is greatly deformed, the quality after the second crimping step varies, and the scratches are small, but the pass rate of the negative pressure test is small. Was 30%.
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。 Although the embodiments of the present invention have been described above with reference to the accompanying drawings, the technical scope of the present invention does not depend on the above-described embodiments. It is clear that a person skilled in the art can come up with various modifications or modifications within the scope of the technical idea described in the claims, and these are naturally included in the technical scope of the present invention. It is understood that it belongs.
１………端子
３………端子本体
５………圧着部
７………導線圧着部
９………被覆圧着部
１０………端子付き電線
１１………封止部
１５………弾性接触片
１７………前端部
１９………後端部
２１………接合部
２３………被覆導線
２５………導線
２７………被覆部
３１ａ、３１ｂ、３３ａ、３３ｂ………金型
３２………小径部
３４………大径部
４１………水槽
４５………容器
４７………ポンプ
１００………端子
１０１………封止部
１０３………圧着部
１０５………被覆導線
１０７………導線
１０９………被覆部
１１１ａ、１１１ｂ………金型
１１３………後端部
１１５………傷
1 ………… Terminal 3 ………… Terminal body 5 ………… Crimping part 7 ………… Conductor crimping part 9 ………… Covered crimping part 10 ………… Wire with terminal 11 ………… Sealing part 15 ………… Elastic Contact piece 17 ………… Front end 19 ………… Rear end 21 ………… Joint 23 ………… Covered conductor 25 ………… Conductor 27 ………… Covered parts 31a, 31b, 33a, 33b ………… Mold 32 ………… Small diameter part 34 ………… Large diameter part 41 ………… Water tank 45 ………… Container 47 ………… Pump 100 ………… Terminal 101 ………… Sealing part 103 ………… Crimping part 105 ………… Covered conductor 107 ………… Conductor 109 ………… Covered parts 111a, 111b ………… Mold 113 ………… Rear end 115 ………… Scratch
Claims (4)
前記端子は、前記被覆導線が圧着される圧着部と、端子本体とを有し、
前記圧着部は、前記被覆導線の被覆部を圧着する被覆圧着部と、前記被覆部から露出する導線を圧着する導線圧着部とを有し、前記被覆導線が挿入される部位を除き、他の部位が封止されており、
前記圧着部に前記被覆導線を挿入し、
前記導線圧着部と前記導線を圧着するとともに、前記被覆圧着部を仮圧縮する第１圧着工程と、
前記第１圧着工程の後、前記被覆圧着部と、前記被覆部を強圧着する第２圧着工程と、
を具備し、
前記第１圧着工程において、前記被覆部に対する前記被覆圧着部の圧縮率が、１００％以上１１０％以下であり、
前記第１圧着工程後における前記被覆圧着部の内部の断面積は、前記第１圧着工程前における前記被覆圧着部の内部の断面積よりも小さく、
前記端子は、前記圧着部の長手方向に沿って溶接部が形成されており、
前記第１圧着工程において、前記溶接部における前記被覆圧着部の内径が前記被覆部の外径より大きくなるように前記被覆圧着部を仮圧縮することを特徴とする端子付き電線の製造方法。 It is a method of manufacturing an electric wire with a terminal that connects a coated conductor and a terminal.
The terminal has a crimping portion to which the coated conductor is crimped and a terminal body.
The crimping portion has a coated crimping portion for crimping the covering portion of the coated conducting wire and a conducting wire crimping portion for crimping a conducting wire exposed from the covering portion, except for a portion where the coated conducting wire is inserted. The part is sealed and
The coated conductor is inserted into the crimping portion,
A first crimping step of crimping the conductor crimping portion and the conducting wire and temporarily compressing the coated crimping portion.
After the first crimping step, the covering crimping portion and the second crimping step of strongly crimping the covering portion,
Equipped with
In the first bonding step, the insulation crimp portion of the compression ratio relative to the coating unit state, and are 100% to 110% or less,
The cross-sectional area inside the coated crimping portion after the first crimping step is smaller than the cross-sectional area inside the coated crimping portion before the first crimping step.
The terminal has a welded portion formed along the longitudinal direction of the crimping portion.
Wherein the first bonding step, the manufacturing method of the electric wire with terminal inside diameter of the insulation crimp portion of the weld characterized that you temporary compression of the insulation crimp portion to be larger than the outer diameter of the coating portion.
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