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

Patent metadata

Field	Value
Publication number	US-9444212-B2
Application number	US-201414477571-A
Country	US
Kind code	B2
Filing date	Sep 4, 2014
Priority date	Feb 24, 2013
Publication date	Sep 13, 2016
Grant date	Sep 13, 2016

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

The invention claimed is:

1. 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, wherein the terminal has a closed cylindrical body that is closed from an end portion side opposite to an electrical wire insertion port of the tube-shaped portion except for the electrical wire insertion port by welding end faces of a terminal forming piece to each other to form the tube-shaped portion and closing the end portion side opposite to the electrical wire insertion port of the tube-shaped portion, the tube-shaped portion has an inner diameter ranging from 1.5 to 2.0 mm, the covered electric wire has the conductor portion whose area in cross-section vertical to a longitudinal direction of the covered electrical wire ranges from 0.72 to 1.37 mm 2 ,
wherein the conductor crimping portion has a crimping mark in which a welded portion is crimped in one direction and which is concaved into the conductor portion from the welded portion, and wherein the cover crimping portion has uniform elastic repulsive force over a whole periphery of the cover portion by applying a same pressure to the whole periphery of the cover portion,
wherein the tube-shaped portion is a stepped tube having plural tube aperture diameters, and
wherein the stepped tube has the plural aperture diameters each of which corresponds to a thickness of a cover portion of the covered electrical wire.

2. 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.

3. The electrical wire connecting structure according to claim 1 , wherein the tube-shaped portion is configured to have a larger tube aperture diameter as approaching to the electrical wire insertion port.

4. The electrical wire connecting structure according to claim 1 , wherein the tube-shaped portion is formed of a copper or copper alloy base material.

5. The electrical wire connecting structure according to claim 1 , wherein the tube-shaped portion comprises a metal member formed by laminating a layer of any one of tin, nickel, silver and gold on a copper or copper alloy base material.

6. The electrical wire connecting structure according to claim 1 , wherein the conductor portion of the covered electrical wire is formed of aluminum or aluminum alloy.

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

Assignees

• Furukawa Electric Co Ltd
• Furukawa Automotive Systems Inc

Inventors

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

Classifications

• Y10T29/49183

  of ferrule about conductor and terminal · CPC title

• H01R43/0488

  with crimp height adjusting means · CPC title

• H01R43/048 Primary

  Crimping apparatus or processes (H01R43/042 takes precedence) · CPC title

• 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