JP7398971B2 - Heater wire crimping structure and crimping method - Google Patents

Description

The present invention relates to a heater wire crimping structure and a crimping method.

As a heater wire crimping structure, a structure 100 as shown in FIG. 6 is known. In this structure 100, the end of the heater wire 101 and the end of the lead wire 102 are arranged in the same direction and are crimped and bonded together using a crimping member 103. The coating near the tip of both the heater wire 101 and the lead wire 102 has been peeled off, and conductor portions 101b and 102b extend from the tips of the coating portions 101a and 102a where the coating remains. The crimping member 103 includes a pair of barrels (insulation barrels) 104a and 104b (see FIG. 7) that grip the covering parts 101a and 102, and a pair of barrels (wire insulation barrels) that are crimped onto the conductor parts 101b and 102b to connect them. barrel) 105a, 105b (see FIG. 8).

The pair of barrels 105a and 105b that connect the conductor parts 101b and 102b are crimped by overlapping the tip of the other barrel 105b over the tip of one barrel 105a and crimping, as shown in FIG. .
On the other hand, the pair of barrels 104a and 104b that grip the covering parts 101a and 102a are held in a substantially heart shape, as shown in FIG.

Patent Document 1 discloses an improved example of a crimping tool for overlap crimping. Patent Document 2 discloses that the conductor portion of the heater wire and the conductor portion of the lead wire are placed one above the other in a U-shaped crimping member with the lead wire facing upward, and the left and right barrels are placed inside. A structure is disclosed in which the conductor parts are connected to each other by bending and deforming the barrels so that the tips of both barrels bite into the conductor parts. The covering part is not crimped, but is held inside the housing and sealed waterproof.

Patent No. 2812128 JP 2015-8042 Publication

In the structures shown in FIGS. 6 to 8, a gap S is created between the heater wire 101 and the barrels 104a, 104b of the crimping member 103 for the covering portions 101a, 102a (see FIG. 7). Therefore, if the two wires arranged in parallel are twisted over a long period of time, the heater wire 101 will be repeatedly subjected to a load and may break.

The present invention reduces the load applied to the heater wire due to twisting, etc. in the structure of crimping the heater wire and the lead wire, thereby suppressing disconnection, and easily realizing a highly durable heater wire crimping structure and its structure. Our goal is to provide a crimping method that can be used.

The heater wire crimping structure and crimping method of the present invention are as follows.
(1) A heater wire crimping structure in which ends of heater wires arranged in the same direction and ends of lead wires are crimped with a crimping member,
The crimping member includes a covering crimping part that crimps both the covering parts of the heater wire and the lead wire, and a conductor crimping part that crimps both the conductor parts of the heater wire and the lead wire from which the covering part has been removed, which are arranged in parallel in the same direction. The covering crimping part has a pair of barrels for crimping both the covering parts, and the pair of barrels are crimped onto the surfaces of the both covering parts with their tips overlapping each other. Wire crimp structure.
(2) The heater wire crimping structure according to (1), wherein the tip of the lower barrel of the pair of overlapping barrels contacts or bites into the sheath of the lead wire.
(3) The heater wire crimping structure according to (1) or (2), wherein the conductor crimping part has a pair of barrels for crimping both the conductor parts.
(4) A heater wire crimping method in which the ends of the heater wires arranged in the same direction and the ends of the lead wires are crimped with a crimping member, the method comprising:
A covered crimping part having a pair of barrels for crimping both the covering parts of the heater wire and the lead wire, and a conductor crimping part for crimping both the conductor parts of the heater wire and the lead wire from which the covering part has been removed are arranged in parallel in the same direction. Prepare the crimping member,
When crimping the sheathing part and both conductor parts by placing the sheathing part of the heater wire and the lead wire in parallel in the sheathing crimping part and by arranging both the conductor parts of the heater wire and the lead wire in parallel in the conductor crimping part. ,
The covering crimping part bends and deforms one barrel of a pair of barrels toward the covering part, and then bends and deforms the other barrel toward the other barrel, so that both barrels are in a state where their tips overlap each other. Here's how to crimp the heater wire onto the sheath.
(5) The heating wire crimping method according to (4), wherein the one barrel is bent and deformed toward the sheathing portion of the lead wire, and the tip of the barrel contacts or bites into the sheathing portion of the lead wire.
(6) When bending and deforming the barrels, pressurize both barrels with a tool that has a gently sloped part that deforms one barrel and a steeply sloped part that deforms the other barrel (4 ) or the heater wire crimping method described in (5).

In the heater wire crimping structure of the present invention, the barrels crimped to the heater wire and lead wire sheathing portions are overlapped with each other, and the lead wire sheathing portion and the heater wire sheathing portion are crimped to each other. Therefore, the range of contact between the covering portion of each wire and the barrel is wide, and the gap between the inner surface of the barrel and the surface of the covering portion is small. As a result, movement of the heater wire within the barrel is suppressed and torsional durability is improved. According to the crimping method of the present invention, the crimping structure described above can be easily obtained.

FIG. 1 is a plan view of a crimp structure according to an embodiment of the present invention. 2 is a sectional view taken along the line II-II in FIG. 1. FIG. 2 is a sectional view taken along line III-III in FIG. 1. FIG. FIG. 2 is a perspective view showing an example of a crimping member used in the crimping method of the present invention. (a) to (d) are process diagrams showing one embodiment of the crimping method of the present invention. FIG. 2 is a plan view showing an example of a conventional crimp structure. 7 is a sectional view taken along the line VII-VII in FIG. 6. FIG. 7 is a sectional view taken along line VIII-VIII in FIG. 6. FIG.

The crimping structure 10 shown in FIG. 1 includes an end 11a of a heater wire 11 and an end 12a of a lead wire 12 that are arranged parallel to each other in the same direction, and a crimping member 13 that crimps and connects them.
The heater wire 11 consists of a central conducting wire 11b and a covering 11c covering the conducting wire 11b. As shown in FIG. 1, the coating 11c is peeled off at the tip of the heater wire 11 to form a conductor portion 11d with the conductor 11b exposed. The portion where the coating 11c remains is the coating portion 11e. In this embodiment, the conductive wire 11b is a twisted wire in which a plurality of thin wires (conductive wires) are twisted around one flexible core wire (for example, aramid fiber yarn such as Kevlar (registered trademark) yarn). The number of thin wires to be twisted is preferably 4 to 6. Note that the cross-sectional area of the conducting wire 11b is made small in order to increase the electrical resistance. On the other hand, the coating 11c has a considerable thickness in order to ensure insulation performance.

As shown in FIG. 2, the lead wire 12 includes a conducting wire 12b made of a twisted wire made of a large number of thin wires, and a covering 12c covering the conducting wire 12b. The number of thin wires to be twisted is preferably about 15 to 20, for example, but is not limited to this number. Generally, the outer diameter of the lead wire 12 is somewhat larger than the outer diameter of the heater wire 11, but it may be approximately the same, and there is no problem even if the heater wire 11 is thicker.

The crimping member 13 includes a covering crimping part 14 that crimps the covering parts 11e and 12e of the heater wire 11 and the lead wire 12, and a conductor crimping part 15 that crimps the conductor parts 11d and 12d of the heater wire 11 and the lead wire 12. , and a connecting portion 16 that connects them. The covering crimping section 14 has a pair of barrels 14a and 14b for crimping the covering sections 11e and 12e. The conductor crimping section 15 has a pair of barrels 15a and 15b for crimping the conductor sections 11d and 12d.
FIG. 4 shows the crimping member 13 before crimping. As shown in the figure, the crimping member 13 has a U-shaped covering crimping part 14 and a conductor crimping part 15 connected by a connecting part 16. The center line of the circular arc portion of both crimp parts 14 and 15 is common. However, the radius of curvature of the arc portion of the covering crimping portion 14 is larger than that of the conductor crimping portion 15 by the thickness of the coverings 11c and 12c.
Note that the bottom of the U-shape may not be arcuate but may be flat. The pressure bonding member 13 is obtained by integrally molding a plate material of a highly conductive and ductile metal such as aluminum by press working or the like.

Returning to FIG. 3, the conductor crimping part 15 is a part that crimps the conductor part 11d of the heater wire 11 and the conductor part 12d of the lead wire 12 together in a parallel state, and includes a pair of left and right barrels 15a and 15b (wire barrels). has. The ends of the barrels 15a and 15b are stacked vertically to crimp the conductor portions 11d and 12d, which is a so-called overlap crimping structure. Before crimping, the left and right barrels 15a and 15b extend upward in parallel to each other (see FIG. 4). In this embodiment, the tip of the barrel 15a on the conductor portion 11d side of the heater wire is located on the lower side, and the tip of the barrel 15b on the conductor portion 12d side of the lead wire overlaps thereon. However, since the conductor 11d of the heater wire is thin, the barrel 15a on the conductor portion 11d side covers not only the conductor portion 11d but also the conductor portion 12d of the lead wire.
In addition, contrary to the above, the barrel 15b on the lead wire side can also be placed on the lower side.

The conductor crimping portion 15 and the conductor portions 11d and 12d crimped thereby may be somewhat flat due to being pressed vertically, and may have an oval or oval shape that is elongated from side to side.
In this embodiment, as shown in FIG. 1, the conductor 12b of the lead wire is integrally crimped with the conductor 11b of the heater wire 11 with its tip folded back.

In the covering crimping section 14, as shown in FIG. 2, a pair of barrels 14a and 14b crimping both the covering sections 11e and 12e of the heater wire 11 and the lead wire 12. That is, the pair of barrels 14a and 14b are pressed onto the surfaces of both the coatings 11c and 12c in an overlapping structure in which their tips are vertically overlapped. The cover crimping portion 14 has a cross section that is approximately oval or elliptical. Although both the heater wire 11 and the lead wire 12 maintain their original circular cross-sectional shapes, their cross-sections may be deformed into a substantially elliptical or substantially elliptical shape by crimping.

Also in the covering crimping part 14, the tip 14a1 of the barrel 14a on the heater wire 11 side is located on the lower side, and the tip 14b1 of the barrel 14b on the lead wire 12 side overlaps thereon. The reason why the barrel 14a on the side of the heater wire 11 is placed on the lower side is because the heater wire 11 is somewhat thinner than the lead wire 12, so that the wound shape is stable. In this embodiment, the tip 14a1 of the barrel 14a on the side of the heater wire 11 is in contact with the coating 12c of the lead wire 12. The tip 14a1 of the barrel 14a may bite into the coating 12c.

The reason why the tip 14a1 of the barrel 14a contacts or bites into the sheath 12c of the lead wire 12 is to help maintain the integrity of the lead wire 12 and the crimp member 13. This is also to prevent gaps from forming between the barrel 14a and the coatings 11c and 12c of the wires 11 and 12 as much as possible.
Note that, contrary to the above, the tip end portion 14b1 of the barrel 14b may be located on the lower side, and the tip end portion 14a1 of the barrel 14a on the lead wire 12 side may be crimped so as to overlap thereon. However, since the sheath 12c of the lead wire 12 has a larger diameter than the sheath 11c of the heater wire 11, it is preferable that the tip 14a1 of the barrel 14a bites into the sheath 12c of the lead wire 12.

The cover crimping part 14 configured as described above has the curved left and right barrels 14a and 14b tightly holding the heater wire 11 and the lead wire 12, and is different from the conventional one (see FIG. 7). There are few gaps. Therefore, even if the two wires are repeatedly twisted during long-term use, the load applied to the heater wire 11, especially the conductor wire 11b, is small, and there is little risk of breakage. Since the conductor crimping portion 15 is the same as the conventional one, it can exhibit the same conductivity and strength.

Next, an embodiment of the crimping method for forming the above-mentioned crimping structure will be described with reference to FIGS. 5(a) to 5(d). FIGS. 5(a) to 5(d) show the processing procedure of the covering crimping portion 14, which is a feature of the present invention. Note that the processing procedure for the conductor crimping portion 15 is almost the same as that for the covering crimping portion 14.
First, a lower die 21 and an upper die 22 as lower and upper crimping tools, the crimping member 13 as materials, the heater wire 11, and the lead wire 12 are prepared. The coatings 11c and 12c at the tips of the heater wire 11 and the lead wire 12 are peeled off in advance. The lower mold 21 supports the pressing force, and the upper mold 22 has the function of deforming the barrel.

The lower mold 21 is provided with a recess 21a on the upper surface thereof, the shape of which matches the shape of the conductor crimping portion after molding. The upper mold 22 is provided with a recess 22a on its lower surface. The recess 22a for processing the conductor crimping part has a first slope 22b that slopes upward at a relatively gentle angle, a second slope 22c that slopes upward at a gentler angle, and a second slope 22c that slopes upward at a gentler angle. The third inclined surface 22d slopes downward at a steep angle from the end.

In the preparation stage shown in FIG. 5A, a combination of the pressure bonding member 13, the heater wire 11, and the lead wire 12 is placed on the lower mold 21. The heater wire 11 and the lead wire 12 are arranged in parallel in the same direction, the respective covering parts 11e and 12e are inserted between the barrels 14a and 14b of the covering crimping part 14, and the conductor parts 11d and 12d are inserted into the conductor crimping part 15 ( (see FIG. 4) between the barrels 15a and 15b.

In this state, the upper mold 22 is lowered toward the lower mold 21, as shown in FIG. 5(b). At this time, the first inclined surface 22b gradually comes into contact with the lower part from the tip of the lower barrel (here, the barrel 14a on the heater wire side), causing the barrel 14a to curve inward. Furthermore, as shown in FIG. 5(c), the upper die 22 is lowered to curve the barrel 14b inward, with the third inclined surface 22d facing upward.

When the upper mold 22 is further lowered, the barrel 14a with the first inclined surface on the lower side is curved so as to cover the heater wire 11 and the lead wire 12, and then the second The inclined surface 22c overlaps the upper barrel 14b on the lower barrel 14a, and finally both barrels 14a, 14b are formed into an oval shape as a whole with respect to the covering portions 11e, 12e of the two lines 11, 12. Crimp it so that it becomes . At this time, it is preferable that the tip 14a1 of the lower barrel 14a be brought into contact with or bit into the coating 12c of the wire 12 on the upper barrel 14b side.

Although the preferred embodiments have been described above, the present invention is not limited to the above embodiments, and various modifications and improvements can be made. For example, in the above embodiment, the barrel 14a of the covering crimping part 14 on the heater wire 11 side and the barrel 15a of the conductor crimping part 15 on the heater wire 11 side are both on the lower side, but one is on the lower side and the other is on the lower side. It can also be placed on the top side. However, processing is easier if they are on the same side. Furthermore, the crimping method is completed in one machining process using one set of tools 21 and 22. However, machining may be performed in multiple steps while changing tools. Further, although the conductor portions 11d and 12d are usually crimped at the same time as the covering portions 11e and 12e, they may be crimped in a separate process.

10 Crimp structure 11 Heater wire 11a (heater wire) end 11b Conductor wire 11c Covering 11d Conductor portion 11e Covering portion 12 Lead wire 12a (lead wire) end 12b Conductor 12c Covering 12d Conductor portion 12e Covering portion 13 Crimp member 14 Covering Crimping part 14a, 14b Barrel 14a1, 14b1 Barrel tip 15 Conductor crimping part 15a, 15b Barrel 16 Connecting part 21 Lower die (lower crimping tool)
21a Recess 22 Upper mold (upper crimping tool)
22a recess 22b first slope 22c second slope 22d third slope

Claims (6)

A heater wire crimping structure in which ends of heater wires arranged in the same direction and ends of lead wires are crimped with a crimping member,
The crimping member includes a covering crimping part that crimps both the covering parts of the heater wire and the lead wire, and a conductor crimping part that crimps both the conductor parts of the heater wire and the lead wire from which the covering part has been removed. are arranged in parallel in the direction,
The covering crimping part has a pair of barrels for crimping both the covering parts,
The pair of barrels is configured such that, with their tip ends overlapping each other, a contact area between both the covering parts and the barrel is wide, and a gap between the inner surface of the barrel and the surface of the covering part is small. The heater wire is crimped to the surface of both coated parts. 2. The heater wire crimping structure according to claim 1, wherein, of the distal ends of the pair of overlapping barrels, the distal end of the barrel located on the lower side contacts or bites into the covering portion of the lead wire. The heater wire crimping structure according to claim 1 or 2, wherein the conductor crimping part has a pair of barrels for crimping both the conductor parts. A method for crimping heater wires in which ends of heater wires and ends of lead wires arranged in parallel in the same direction are crimped with a crimping member, the method comprising:
A covering crimping part having a pair of barrels that crimps both the covering parts of the heater wire and the lead wire is the same as a conductor crimping part that crimps both the conductor parts of the heater wire and the lead wire from which the covering part has been removed. Prepare crimping members arranged in parallel in the direction,
Both the covering parts of the heater wire and the lead wire are arranged in parallel in the covering crimping part, and the conductor parts of the heater wire and the lead wire are arranged in parallel in the conductor crimping part, and both the covering parts are arranged in parallel in the covering crimping part . In crimping the part and both conductor parts,
The covering crimping section bends and deforms one of the pair of barrels toward the covering section, then bends and deforms the other barrel toward the one barrel, and bends and deforms both barrels toward the tip end. a heater that is pressure-bonded to the surfaces of both the coating parts so that the contact areas between the coating parts and the barrel are wide and the gap between the inner surface of the barrel and the surface of the coating parts is small, with the heaters overlapped with each other; How to crimp wire. 5. The heater wire crimping method according to claim 4, wherein the one barrel is bent and deformed toward the sheathing portion of the lead wire, and the tip end of the barrel contacts or bites into the sheathing portion of the lead wire. Claim: When bending and deforming the barrels, both barrels are pressurized with a tool having a gently sloped part that deforms the one barrel and a steeply sloped part that deforms the other barrel. 4. The heater wire crimping method according to 4 or 5.