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JP5039619B2 - Crimping method of terminal to electric wire - Google Patents
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JP5039619B2 - Crimping method of terminal to electric wire - Google Patents

Crimping method of terminal to electric wire Download PDF

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Publication number
JP5039619B2
JP5039619B2 JP2008075711A JP2008075711A JP5039619B2 JP 5039619 B2 JP5039619 B2 JP 5039619B2 JP 2008075711 A JP2008075711 A JP 2008075711A JP 2008075711 A JP2008075711 A JP 2008075711A JP 5039619 B2 JP5039619 B2 JP 5039619B2
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terminal
crimping
electric wire
strand
aluminum
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JP2009231078A (en
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貴哉 近藤
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Yazaki Corp
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Yazaki Corp
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Priority to PCT/JP2009/054946 priority patent/WO2009119352A1/en
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/187—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping combined with soldering or welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/20—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve
    • H01R4/203—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve having an uneven wire-receiving surface to improve the contact
    • H01R4/206—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve having an uneven wire-receiving surface to improve the contact with transversal grooves or threads
    • 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
    • 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
    • H01R43/0214—Resistance 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
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048—Crimping apparatus or processes

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  • Manufacturing Of Electrical Connectors (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)

Description

本発明は、特にアルミニウム電線に対して端子を圧着する場合に有効な圧着方法に関するものである。   The present invention relates to a crimping method effective particularly when crimping a terminal to an aluminum electric wire.

自動車用のワイヤーハーネスに使用されている電線は、従来では一般的に銅電線であったが、最近では、軽量性やリサイクル性の良さからアルミニウム電線に置き換える動きがある。   Conventionally, the electric wire used for the wire harness for automobiles is generally a copper electric wire, but recently, there is a movement to replace it with an aluminum electric wire because of its light weight and good recyclability.

アルミニウムは、銅に比べて、導電率が６０％程度であるが、重さが１／３ですむので、大幅な軽量化が期待できるからである。また、銅の融点は１０８３℃であるのに対し、アルミニウムの融点は６６０℃であるので、金属回収しやすい利点もあるからである。   This is because aluminum has a conductivity of about 60% as compared with copper, but the weight only needs to be 1/3, so that significant weight reduction can be expected. Further, the melting point of copper is 1083 ° C., whereas the melting point of aluminum is 660 ° C., so that there is an advantage that the metal can be easily recovered.

自動車用のワイヤーハーネスの電線をアルミニウム電線にした場合、特にアルミニウムやアルミニウム合金製の導体部の表面に、強固で電気抵抗の大きい酸化被膜が存在することが、端子を接続する上での問題となることがある。   When the wire of an automobile wire harness is made of an aluminum wire, there is a problem in connecting terminals that there is a strong oxide film with high electrical resistance, especially on the surface of the conductor made of aluminum or aluminum alloy. May be.

図２はアルミニウム電線２１とアルミニウム端子３０を圧着接続する場合の一般的な例を示している（例えば、特許文献１参照）。端子３０は、前部に孔３１ａ付きの接続板部３１を持ち、後部に圧着部３２を持つ。圧着部３２は、底板３３と、該底板３３の幅方向両側縁から上に延設された一対の圧着片３４、３４とを持つＵ字形状をなしており、内面にセレーション３５を有する。アルミニウム電線２１は、撚線等よりなる導体部２２の外周を絶縁被覆２３で覆ったもので、端子３０を圧着する際には、皮剥きした電線２１の端末の露出導体２２を底板３３の上に挿入し、両側の圧着片３４を加締装置で内側に曲げて、導体部３２を包み込むように加締める。それにより、導体部２２に端子３０を圧着接続することができる。   FIG. 2 shows a general example in the case where the aluminum wire 21 and the aluminum terminal 30 are crimped and connected (see, for example, Patent Document 1). The terminal 30 has a connection plate part 31 with a hole 31a at the front part and a crimping part 32 at the rear part. The crimping portion 32 has a U-shape having a bottom plate 33 and a pair of crimping pieces 34, 34 extending upward from both lateral edges of the bottom plate 33, and has a serration 35 on the inner surface. The aluminum electric wire 21 is obtained by covering the outer periphery of a conductor portion 22 made of stranded wire or the like with an insulating coating 23. When crimping the terminal 30, the exposed conductor 22 at the end of the peeled electric wire 21 is placed on the bottom plate 33. The crimping pieces 34 on both sides are bent inward by a crimping device and crimped so as to wrap the conductor portion 32. Thereby, the terminal 30 can be crimped to the conductor portion 22.

このように、従来では、圧着部３２の内面にセレーション３５を形成することによって、圧着時に導体部２２の表面の酸化被膜を破壊するようにしている。また、導体部２２の表面の酸化被膜を破壊する効果を一層増すために、このセレーション３５を斜めに形成することも、特許文献１において提案されている。   Thus, conventionally, by forming serrations 35 on the inner surface of the crimping part 32, the oxide film on the surface of the conductor part 22 is destroyed during crimping. Further, in order to further increase the effect of destroying the oxide film on the surface of the conductor portion 22, it is proposed in Patent Document 1 to form the serration 35 obliquely.

また、導体部の表面の酸化被膜を破壊しながら端子を圧着する方法として、特許文献２には、電線の導体部と端子の圧着部にそれぞれ電極を介して外部電源を接続すると共に、電極と外部電源との間にパルス電流を発生させるパルス電流発生回路を接続し、いずれか一方の電極にパルス電流を印加することで、導体部と圧着部の界面に存在する酸化皮膜を破壊して、導体部と圧着部を直に接触させる電線接続方法が提案されている。   In addition, as a method of crimping the terminal while destroying the oxide film on the surface of the conductor portion, Patent Document 2 discloses that an external power source is connected to the conductor portion of the electric wire and the crimp portion of the terminal through the electrodes, By connecting a pulse current generation circuit that generates a pulse current between the external power supply and applying a pulse current to one of the electrodes, the oxide film present at the interface between the conductor part and the crimping part is destroyed, An electric wire connection method has been proposed in which a conductor portion and a crimping portion are in direct contact with each other.

この方法によれば、導体部の表面の酸化皮膜を、パルス電流による衝撃作用と電気化学作用の両作用で破壊することができ、露出した導体部の素地と端子を直に接触させることができて、接触抵抗を低減できることになっている。
特開２００３−２４９２８４号公報 特開２００３−２７２７２８号公報 According to this method, the oxide film on the surface of the conductor can be destroyed by both the impact action and the electrochemical action by the pulse current, and the exposed conductor base and the terminal can be brought into direct contact with each other. Thus, the contact resistance can be reduced.
JP 2003-249284 A JP 2003-272728 A

ところで、上述した２つの従来技術は、いずれも電線の導体部と端子の圧着部の接触面間に存在する酸化被膜を除去しながら、端子と導体部の接触抵抗を低減することを主な目的とするものであって、電線の導体部を構成する素線と素線の接触面間に存在する酸化被膜の問題を十分に解消するまでには至らなかった。即ち、導体部を構成する素線と素線の接触面にも酸化被膜が存在するが、特に太物電線の場合は、この素線間の酸化被膜が障害となって、端子を圧着した際の電気接続抵抗が小さくならないという問題があった。   By the way, the two prior arts mentioned above are mainly intended to reduce the contact resistance between the terminal and the conductor part while removing the oxide film existing between the contact surfaces of the conductor part of the electric wire and the crimping part of the terminal. Therefore, the problem of the oxide film existing between the contact surfaces of the wires constituting the conductor portion of the electric wire has not been sufficiently solved. In other words, an oxide film is also present on the contact surface between the wires constituting the conductor part, but particularly in the case of thick wires, the oxide film between the wires becomes an obstacle and the terminal is crimped. There was a problem that the electrical connection resistance of the was not reduced.

本発明は、上記事情を考慮し、電線の導体部と端子の電気接続抵抗の低減を図れるようにした圧着方法を提供することを目的とする。   In view of the above circumstances, an object of the present invention is to provide a crimping method capable of reducing the electrical connection resistance between a conductor portion of a wire and a terminal.

請求項１の発明の電線に対する端子の圧着方法は、端子の圧着部を、多数の素線の束よりなる電線の導体部に対して、外側から包み込むように圧着する電線に対する端子の圧着方法において、前記多数の素線の束の最中心部に位置する素線と、前記導体部を外側から包み込む前記圧着部との間に電流を流すことで、前記素線と素線の接触面間および前記素線と端子の接触面間の抵抗によるジュール熱により、前記素線の表面を溶融させながら、前記端子の圧着部を前記導体部に圧着することを特徴とする。   The method for crimping a terminal to an electric wire according to the invention of claim 1 is a method for crimping a terminal against an electric wire, wherein the crimping portion of the terminal is crimped so as to be wrapped from the outside with respect to the conductor portion of the electric wire formed of a bundle of many strands. , By passing an electric current between the strand located at the center of the bundle of the multiple strands and the crimping portion that wraps the conductor portion from the outside, between the contact surfaces of the strand and the strand, and The crimping portion of the terminal is crimped to the conductor portion while the surface of the strand is melted by Joule heat due to resistance between the contact surfaces of the strand and the terminal.

請求項２の発明は、請求項１に記載の電線に対する端子の圧着方法であって、前記素線が、アルミニウムあるいはアルミニウム合金よりなる非メッキ素線であることを特徴とする。   A second aspect of the invention is a method for crimping a terminal against an electric wire according to the first aspect, wherein the strand is a non-plated strand made of aluminum or an aluminum alloy.

請求項１の発明によれば、多数の素線の束の最中心部に位置する素線と、電線の導体部を外側から包み込む圧着部との間に電流を流しながら、端子を電線の導体部に圧着するので、ジュール熱による発熱により、素線の接触表面を溶融させながら、素線間および素線と端子間を接合することができ、酸化被膜の影響を防止して低い電気接続抵抗で端子と電線を接続することができる。   According to the first aspect of the present invention, the terminal is connected to the conductor of the electric wire while an electric current flows between the element wire positioned at the most central portion of the bundle of the many electric wires and the crimping portion that wraps the conductor portion of the electric wire from the outside. Because the heat generated by Joule heat melts the contact surface of the strands, the strands and between the strands and the terminals can be joined, preventing the influence of the oxide film and low electrical connection resistance The terminal and the electric wire can be connected with.

請求項２の発明によれば、アルミニウム電線と端子を圧着する場合に特に有効性を発揮することができる。即ち、アルミニウム電線の場合は、アルミニウムあるいはアルミニウム合金製の素線の表面に強固な酸化被膜が存在し、それが接続抵抗を小さくする上での阻害要因となっているが、素線の表面を溶融させながら圧着するので、その酸化被膜の影響を排除しながら、小さい電気接続抵抗で端子とアルミニウム電線を接続することができる。   According to the invention of claim 2, the effectiveness can be exhibited particularly when the aluminum electric wire and the terminal are crimped. That is, in the case of an aluminum electric wire, a strong oxide film exists on the surface of the aluminum or aluminum alloy wire, which is an obstacle to reducing the connection resistance. Since crimping is performed while melting, the terminal and the aluminum electric wire can be connected with a small electrical connection resistance while eliminating the influence of the oxide film.

以下、本発明の実施形態を図１（ａ）、（ｂ）を参照して説明する。   Embodiments of the present invention will be described below with reference to FIGS. 1 (a) and 1 (b).

本実施形態の圧着方法は、自動車に使用するワイヤーハーネス用のアルミニウム電線に対して銅製またはアルミ製の端子（アルミ電線用圧着端子）を圧着する場合の方法である。図１（ａ）に示すように、アルミニウム電線の導体部１は、アルミニウムまたはアルミニウム合金製の非メッキ素線２を複数本撚り合わせることで構成されている。   The crimping method of this embodiment is a method in the case of crimping a copper or aluminum terminal (aluminum wire crimping terminal) to an aluminum wire for a wire harness used in an automobile. As shown to Fig.1 (a), the conductor part 1 of the aluminum electric wire is comprised by twisting together the non-plating strand 2 made from aluminum or aluminum alloy.

端子の圧着部３を電線の導体部１に対して圧着する場合は、断面Ｕ字状の圧着部３内に導体部１を収容し、一対の圧着片４、４を外側から内側に丸めるように加締めることで、導体部１を包み込みながら圧着部３を圧着することができる。   When crimping the crimping part 3 of the terminal to the conductor part 1 of the electric wire, the conductor part 1 is accommodated in the crimping part 3 having a U-shaped cross section, and the pair of crimping pieces 4 and 4 are rounded from the outside to the inside. By crimping, the crimping part 3 can be crimped while wrapping the conductor part 1.

その圧着の際に、本実施形態の圧着方法では、多数の素線２の束の最中心部に位置する素線２ａと、導体部１を外側から包み込む圧着部３との間に直流電流を流す。そうすることで、図１（ｂ）に示すように、素線２と素線２の接触面間および素線２と端子の接触面間の抵抗Ｒによるジュール熱により、素線２の表面を溶融させながら、端子の圧着部３を導体部１に圧着させる。   At the time of the crimping, in the crimping method of the present embodiment, a direct current is applied between the strand 2a located at the center of the bundle of many strands 2 and the crimping portion 3 that wraps the conductor portion 1 from the outside. Shed. By doing so, as shown in FIG. 1 (b), the surface of the strand 2 is caused by Joule heat due to resistance R between the contact surfaces of the strands 2 and 2 and between the contact surfaces of the strand 2 and the terminals. The terminal crimping part 3 is crimped to the conductor part 1 while being melted.

例えば、素線２間の抵抗が約３００ｍΩ、ジュール熱によるアルミニウムの溶融電圧が３００ｍＶの場合、通電電流は０．３Ｖ／０．３Ω＝１Ａとなる。従って、１Ａの電流を流しながら圧着を行う。   For example, when the resistance between the strands 2 is about 300 mΩ and the melting voltage of aluminum by Joule heat is 300 mV, the energization current is 0.3 V / 0.3Ω = 1 A. Accordingly, pressure bonding is performed while a current of 1 A is passed.

そうすることにより、ジュール熱により、素線２の接触表面を溶融させながら、素線２間および素線２と端子（圧着部３）間を接合することができ、酸化被膜の影響を防止して、低い電気接続抵抗で端子と電線を接続することができる。特に太物のアルミニウム電線の場合は、素線２同士の接触面間に存在する酸化被膜による接触抵抗が問題となるが、その接触抵抗を低減できることになり、端子と電線の電気接続抵抗の減少を図ることができる。   By doing so, while the contact surface of the strand 2 is melted by Joule heat, the strand 2 and the strand 2 and the terminal (crimp part 3) can be joined, and the influence of the oxide film is prevented. Thus, the terminal and the electric wire can be connected with a low electrical connection resistance. Especially in the case of a thick aluminum electric wire, the contact resistance due to the oxide film existing between the contact surfaces of the strands 2 becomes a problem, but the contact resistance can be reduced, and the electrical connection resistance between the terminal and the electric wire is reduced. Can be achieved.

本発明の実施形態の説明図で、（ａ）は端子を圧着するときの端子の圧着部と電線の導体分の関係を示す斜視図、（ｂ）は素線間および素線と端子間の接触抵抗によるジュール熱の発生原理を説明するための拡大模式図である。BRIEF DESCRIPTION OF THE DRAWINGS It is explanatory drawing of embodiment of this invention, (a) is a perspective view which shows the crimping | compression-bonding part of a terminal when crimping a terminal, and the relationship between the conductors of an electric wire, (b) is between strands and between strands and a terminal. It is an expansion schematic diagram for demonstrating the generation | occurrence | production principle of Joule heat by contact resistance. 一般的な端子の圧着方法の説明図である。It is explanatory drawing of the crimping method of a general terminal.

符号の説明Explanation of symbols

１ 導体部
２ 素線
２ａ 最中心部の素線
３ 端子の圧着部
４ 圧着片
Ｒ 表面接触抵抗 DESCRIPTION OF SYMBOLS 1 Conductor part 2 Wire 2a The wire of the center most part 3 Crimp part of a terminal 4 Crimp piece R Surface contact resistance

Claims (2)

端子の圧着部を、多数の素線の束よりなる電線の導体部に対して、外側から包み込むように圧着する電線に対する端子の圧着方法において、
前記多数の素線の束の最中心部に位置する素線と、前記導体部を外側から包み込む前記圧着部との間に電流を流すことで、前記素線と素線の接触面間および前記素線と前記端子の接触面間の抵抗によるジュール熱により、前記素線の表面を溶融させながら、前記端子の圧着部を前記導体部に圧着することを特徴とする電線に対する端子の圧着方法。 In the crimping method of the terminal against the electric wire to be crimped so that the crimping portion of the terminal is wrapped from the outside with respect to the conductor portion of the electric wire consisting of a bundle of many strands,
By passing an electric current between the strand located at the most central portion of the bundle of the plurality of strands and the crimping portion that wraps the conductor portion from the outside, between the contact surfaces of the strand and the strand, and the A method for crimping a terminal against an electric wire, wherein the crimping portion of the terminal is crimped to the conductor portion while the surface of the strand is melted by Joule heat due to resistance between the contact surface of the strand and the terminal. 請求項１に記載の電線に対する端子の圧着方法であって、
前記素線が、アルミニウムあるいはアルミニウム合金よりなる非メッキ素線であることを特徴とする電線に対する端子の圧着方法。 A method for crimping a terminal to an electric wire according to claim 1,
A method for crimping a terminal against an electric wire, wherein the element wire is a non-plated element wire made of aluminum or an aluminum alloy.
JP2008075711A 2008-03-24 2008-03-24 Crimping method of terminal to electric wire Expired - Fee Related JP5039619B2 (en)

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PCT/JP2009/054946 WO2009119352A1 (en) 2008-03-24 2009-03-13 Method for crimping terminal on wire

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