Method for connecting insulated wires

Patent metadata

Field	Value
Publication number	US-10038292-B2
Application number	US-201514843040-A
Country	US
Kind code	B2
Filing date	Sep 2, 2015
Priority date	Sep 3, 2014
Publication date	Jul 31, 2018
Grant date	Jul 31, 2018

Abstract

A method for connecting a plurality of insulated wires to each other is provided. Each of the insulated wires has a conductor portion and an insulating coating covering the conductor portion. The insulating coating is made of an insulating material. The method includes stripping the insulating coating of each of the insulated wires to expose the conductor portion such that the insulating coating is removed from a section of the insulated wire along a direction in which the insulated wire extends and at a location away from an end portion of the insulated wire, and connecting the conductor portions of the insulated wires. The connecting includes crimping a crimp joint terminal onto the exposed conductor portions to join the exposed conductor portions, and after the crimping, welding the conductor portions by applying pressure and electric current or ultrasonic vibration to the crimp joint terminal.

First claim

What is claimed is:

1. A method for connecting a plurality of insulated wires to each other, each of the insulated wires having a conductor portion and an insulating coating covering the conductor portion, the insulating coating being made of an insulating material, the method comprising:
stripping the insulating coating of each of the insulated wires to expose the conductor portion such that the insulating coating is removed from a section of the insulated wire along a direction in which the insulated wire extends and at a location away from an end portion of the insulated wire; and
connecting the conductor portions of the insulated wires, the connecting comprising crimping a crimp joint terminal onto the exposed conductor portions to join the exposed conductor portions, and after the crimping, welding the conductor portions by applying pressure and electric current or ultrasonic vibration to the crimp joint terminal,
wherein the insulated wires comprises aluminum electric wires and copper electric wires, wherein the conductor portion of the aluminum electric wire is made of aluminum or aluminum alloy, and the conductor portion of the copper electric wire is made of copper or copper alloy, and
wherein the connecting the conductor portions comprises laying the conductor portion of the aluminum electric wire over at least a portion of a through hole formed in the crimp joint terminal, the through-hole being configured to break an oxide film of the exposed conductor portion when the crimp joint terminal is crimped.

2. The method according to claim 1 , wherein the stripping comprises adjusting the sections of the insulated wires, from which the insulated coatings are removed, to be substantially equal to each other in the direction in which the insulated wires extend, and
wherein the connecting the conductor portions comprises aligning the sections of the insulated wires, from which the insulating coatings are removed, at both ends of the respective sections.

3. The method according to claim 1 , wherein the through hole is formed in a portion of the crimp joint terminal forming a bottom portion of the crimp joint terminal after the crimping.

4. The method according to claim 1 , wherein in the crimp join terminal a portion of the aluminum electric wires is arranged beneath a portion of the copper electric wires.

5. The method according to claim 1 , wherein the connecting the conductor portions comprises laying, among the aluminum electric wires and the copper electric wires, the aluminum electric wire over the portion of the through hole.

Assignees

• Yazaki Corp

Inventors

• Matsuoka Syogo
• KATOU Sanae
• Shimizu Ayako

Classifications

• H01R43/0207 Primary

  Ultrasonic-, H.F.-, cold- or impact welding · CPC title

• Y10T29/49213

  Metal · CPC title

• H01R4/183

  for cylindrical elongated bodies, e.g. cables having circular cross-section (H01R4/01 takes precedence) · CPC title

• H01R4/187

  combined with soldering or welding · CPC title

• H01R4/625

  Soldered or welded connections · CPC title