Method of manufacturing electrical wire connecting structure and electrical wire connecting structure

Patent metadata

Field	Value
Publication number	US-2016172811-A1
Application number	US-201615051943-A
Country	US
Kind code	A1
Filing date	Feb 24, 2016
Priority date	Feb 24, 2013
Publication date	Jun 16, 2016
Grant date	—

Abstract

In an electrical wire connecting structure and a method of manufacturing the electrical wire connecting structure, a terminal having a tube-shaped portion of 2.0 mm in inner diameter is prepared for an electrical wire having a conductor cross-sectional area of 0.72 to 1.37 mm 2 , the electrical wire 13 is inserted into an electrical wire insertion port of the tube-shaped portion of the electrical wire, and the tube-shaped portion and the core wire portion of the electrical wire are compressed to be crimp-connected to each other. Furthermore, a terminal having a tube-shaped portion of 3.0 mm in inner diameter is prepared for an electrical wire having a conductor cross-sectional area of 1.22 to 2.65 mm 2 , the electrical wire is inserted into the electrical wire insertion port of the tube-shaped portion 25 of the electrical wire, and the tube-shaped portion and the core wire portion of the electrical wire are compressed to be crimp-connected to each other.

First claim

1 . A method of manufacturing an electrical wire connecting structure in which a terminal having a tube-shaped portion and a conductor portion of a covered electrical wire are crimped at the tube-shaped portion, and the tube-shaped portion has a conductor crimping portion corresponding to the conductor portion, and a cover crimping portion corresponding to a cover portion of the covered electrical wire, comprising:
welding end faces of a terminal forming piece to each other to form the tube-shaped portion, and closing an end portion side opposite to an electrical wire insertion port of the tube-shaped portion, thereby preparing said terminal having the tube-shaped portion, wherein the terminal is formed as a closed cylindrical body that is closed from the end portion side opposite to the electrical wire insertion port except for the electrical wire insertion port, and wherein the tube-shaped portion has an inner diameter of 1.5 to 2.0 mm; inserting, into the electrical wire insertion port of the tube-shaped portion, the covered electrical wire, wherein an area of the conductor portion in a cross-section vertical to a longitudinal direction of the covered electrical wire ranges from 0.72 to 1.37 mm 2 ; crimping a welded portion of the conductor crimping portion in one direction; and applying a same pressure to a whole periphery of the cover portion to compress the cover crimping portion, wherein the conductor crimping portion has a crimping mark on which the welded portion is crimped in said one direction, and which is concaved into the conductor portion from the welded portion, wherein the cover crimping portion has uniform elastic repulsive force over the whole periphery of the cover portion upon applying said same pressure to said whole periphery of the cover portion, wherein the tube-shaped portion is formed as a stepped tube having plural tube aperture diameters, and wherein each of the plural aperture diameters corresponds to a thickness of a cover portion of the covered electrical wire.

2 . A method of manufacturing an electrical wire connecting structure in which a terminal having a tube-shaped portion and a conductor portion of a covered electrical wire are crimped at the tube-shaped portion, and the tube-shaped portion has a conductor crimping portion corresponding to the conductor portion, and a cover crimping portion corresponding to a cover portion of the covered electrical wire, comprising:
welding end faces of a terminal forming piece to each other to form the tube-shaped portion, and closing an end portion side opposite to an electrical wire insertion port of the tube-shaped portion, thereby preparing said terminal having the tube-shaped portion, wherein the terminal is formed as a closed cylindrical body that is closed from the end portion side opposite to the electrical wire insertion port except for the electrical wire insertion port, and wherein the tube-shaped portion has an inner diameter of 2.2 to 3.0 mm; inserting, into the electrical wire insertion port of the tube-shaped portion, the covered electrical wire, wherein an area of the conductor portion in a cross-section vertical to a longitudinal direction of the covered electrical wire ranges from 1.22 to 2.65 mm 2 ; crimping a welded portion of the conductor crimping portion in one direction; and applying a same pressure to a whole periphery of the cover portion to compress the cover crimping portion, wherein the conductor crimping portion has a crimping mark on which the welded portion is crimped in said one direction, and which is concaved into the conductor portion from the welded portion, wherein the cover crimping portion has uniform elastic repulsive force over the whole periphery of the cover portion upon applying said same pressure to said whole periphery of the cover portion, wherein the tube-shaped portion is formed as a stepped tube having plural tube aperture diameters, and wherein each of the plural aperture diameters corresponds to a thickness of a cover portion of the covered electrical wire.

3 . The method of manufacturing the electrical wire connecting structure according to claim 1 , wherein the end portion side opposite to the electrical wire insertion port of the tube-shaped portion is closed by welding.

4 . The method of manufacturing the electrical wire connecting structure according to claim 1 , wherein the closed cylindrical body is formed by press working and laser welding.

5 . The method of manufacturing the electrical wire connecting structure according to claim 1 , wherein the tube-shaped portion is formed so as to have a larger tube aperture diameter as approaching to the electrical wire insertion port.

6 . The method of manufacturing the electrical wire connecting structure according to claim 1 , wherein a compressibility of the conductor portion is 75%±5%.

7 . The method of manufacturing the electrical wire connecting structure according to claim 2 , wherein the end portion side opposite to the electrical wire insertion port of the tube-shaped portion is closed by welding.

8 . The method of manufacturing the electrical wire connecting structure according to claim 2 , wherein the closed cylindrical body is formed by press working and laser welding.

9 . The method of manufacturing the electrical wire connecting structure according to claim 2 , wherein the tube-shaped portion is formed so as to have a larger tube aperture diameter as approaching to the electrical wire insertion port.

10 . The method of manufacturing the electrical wire connecting structure according to claim 2 , wherein a compressibility of the conductor portion is 75%±5%.

Assignees

• Furukawa Electric Co Ltd
• Furukawa Automotive Sys Inc

Inventors

• Tachibana Akira
• Mitose Kengo
• Susai Kyota
• Tateyama Takao
• Kawamura Yukihiro
• TONOIKE Takashi
• Kozawa Masakazu
• Yamada Takuro

Classifications

• H01R4/62 Primary

  Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors (H01R4/68 takes precedence) · CPC title

• H01R4/187

  combined with soldering or welding · CPC title

• H01R4/183 Primary

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

• H01R43/0488

  with crimp height adjusting means · CPC title

• Y10T29/49183

  of ferrule about conductor and terminal · CPC title