JP2016225051A

JP2016225051A - Terminal connection structure for wire end, and manufacturing method thereof

Info

Publication number: JP2016225051A
Application number: JP2015108075A
Authority: JP
Inventors: 明正田村; Akimasa Tamura; 淳史川畑; Atsushi Kawabata; 一左森; Kazusuke Mori; 一洋松井; Kazuhiro Matsui
Original assignee: Tabuchi Electric Co Ltd
Current assignee: Tabuchi Electric Co Ltd
Priority date: 2015-05-28
Filing date: 2015-05-28
Publication date: 2016-12-28
Anticipated expiration: 2035-05-28
Also published as: JP6545530B2

Abstract

【課題】電線と接続用端子との半田付け部分７とその周辺に対して外部環境への対策を施しつつ、機械的強度の増強を容易かつ安価に行った電線端部の端子接続構造を提供する。
【解決手段】外部の導体に電気的に取り付けられるコネクタ部２と、絶縁被覆を有し複数の芯線が束ねられてなる電線５の端部の絶縁被覆５ｄが除去された部分５ｃが半田付けにより接続された電線接続部３とを有する接続用端子を備え、半田付け部分７、または、半田付け部分７およびこれに隣接する絶縁被覆端部５ａの部分の外周に、耐熱性を有する筒状部材１０、熱により収縮し筒状部材１０の外周を覆う熱収縮チューブ２０Ａ、および筒状部材１０の内方に充填された樹脂８０を有する積層部３０と、積層部３０に隣接する隣接部分３ｂの部分の外周が熱収縮チューブ２０Ａに覆われることにより、熱収縮チューブ２０Ａと電線５の絶縁被覆５ｂの部分との間が封止された封止部４０とを備えた。
【選択図】図３Provided is a terminal connection structure for an end portion of a wire which is easily and inexpensively increased in mechanical strength while taking measures against the external environment for a soldered portion 7 between the wire and a connection terminal and its periphery. To do.
A connector portion 2 electrically attached to an external conductor and a portion 5c from which an insulating coating 5d is removed from an end portion of an electric wire 5 having an insulating coating and a plurality of core wires bundled together are soldered. A cylindrical member having a heat resistance on the outer periphery of the soldering portion 7 or the soldering portion 7 and the insulating coating end portion 5a adjacent thereto, the connecting terminal having the connected electric wire connecting portion 3 10. A heat shrinkable tube 20A that shrinks by heat and covers the outer periphery of the tubular member 10, a laminated portion 30 having a resin 80 filled inside the tubular member 10, and an adjacent portion 3b adjacent to the laminated portion 30 The outer periphery of the portion was covered with the heat-shrinkable tube 20 A, thereby providing a sealing portion 40 in which the space between the heat-shrinkable tube 20 A and the portion of the insulating coating 5 b of the electric wire 5 was sealed.
[Selection] Figure 3

Description

本発明は、外部の導体に電気的に接続する電線端部の端子接続構造およびその製造方法に関するものである。 The present invention relates to a terminal connection structure of an end portion of an electric wire that is electrically connected to an external conductor, and a manufacturing method thereof.

従来、電源用途などの電線を外部の電源や回転機等の端子台（導体）に電気的に接続する際には、ビニル等からなる外側の絶縁被覆を剥がして当該電線の端部に接続用端子を接合し、例えばこの接続用端子を端子台のねじ孔にねじ体で取り付ける。自動車の製造分野では、近年の車体軽量化の一環で、こうした電源用電線に、例えば軽量なアルミニウムを使用することが求められてきている。このアルミニウム製電線は、多くの場合、絶縁のための高耐熱エナメル被膜が施された複数のアルミニウム細線の芯線からなり、例えば接続用端子に電線端部のエナメル被膜を除去した状態で半田付けされる。接続用端子の材質は、銅または銅合金であることが多く、アルミニウム製電線を材質の異なる接続用端子に半田付けする場合には、外部環境からの影響による電蝕の発生を抑制する必要がある。そこで、電線端部と接続用端子との半田付け接合部では、電蝕抑制効果のある半田を使用したり、接続用端子に錫めっきを施す。 Conventionally, when an electric wire for a power source is electrically connected to an external power source or a terminal block (conductor) such as a rotating machine, the outer insulation coating made of vinyl or the like is peeled off to connect to the end of the electric wire. The terminals are joined and, for example, this connection terminal is attached to the screw hole of the terminal block with a screw body. In the automobile manufacturing field, as part of the recent reduction in body weight, it has been required to use, for example, lightweight aluminum for such power supply wires. In many cases, this aluminum wire consists of a plurality of thin aluminum wires coated with a heat-resistant enamel coating for insulation, and is soldered to the connection terminal with the enamel coating at the end of the wire removed. The The material of the connection terminal is often copper or copper alloy, and when soldering aluminum wires to connection terminals of different materials, it is necessary to suppress the occurrence of electrolytic corrosion due to the influence of the external environment. is there. Therefore, at the soldered joint between the end of the electric wire and the connection terminal, solder having an electrolytic corrosion suppressing effect is used, or tin is applied to the connection terminal.

他の外部環境からの影響として、例えばエナメル被膜が除去されたアルミ細線表面への塩分による侵蝕が知られている。また他に、アルミ細線に酸化被膜が経時的に形成されて接触抵抗が発生することが知られており、接触抵抗の形成により電線と接続用端子間の電気抵抗が増大する。特許文献１には、こうした接触抵抗の発生を防止するため、アルミ電線と接続用端子とを圧着した後、当該圧着した部分に半田を含浸させて固化させる技術が開示されている。 As an influence from other external environment, for example, corrosion by salt on the surface of an aluminum fine wire from which the enamel coating has been removed is known. In addition, it is known that an oxide film is formed over time on an aluminum fine wire and contact resistance is generated, and the electrical resistance between the electric wire and the connection terminal increases due to the formation of the contact resistance. Patent Document 1 discloses a technique in which, in order to prevent the occurrence of such contact resistance, an aluminum electric wire and a connection terminal are crimped and then the crimped portion is impregnated with solder and solidified.

特開２０１０−０２０９８０号公報JP 2010-020980 A

しかし、車載用途に適合させる場合には、こうした対策だけでは不十分である。アルミニウム細線は、銅細線と比べて、引っ張り強度および曲げ強度が著しく低いことが知られている。上記従来技術は、接触抵抗を形成する外部環境への対策はなされているが、アルミニウム電線のこうした機械的強度への対応が考慮されていない。 However, such measures alone are not sufficient when adapted to in-vehicle applications. It is known that the aluminum fine wire has significantly lower tensile strength and bending strength than the copper fine wire. In the above prior art, measures against the external environment forming the contact resistance are taken, but the correspondence to the mechanical strength of the aluminum electric wire is not considered.

そこで、本発明の目的は、電線と接続用端子との半田付け部分とその周辺に対して外部環境への対策を施しつつ、半田付け部分とその周辺の機械的強度の増強を容易かつ安価に行った電線端部の端子接続構造およびその製造方法を提供することである。 Accordingly, an object of the present invention is to easily and inexpensively increase the mechanical strength of the soldered portion and its surroundings while taking measures against the external environment for the soldered portion of the electric wire and the connection terminal and its surroundings. It is providing the terminal connection structure of the performed electric wire edge part, and its manufacturing method.

前記目的を達成するために、本発明にかかる電線端部の端子接続構造は、絶縁被覆を有し複数の芯線が束ねられてなる電線の端部を外部の導体に電気的に接続する構造であって、
前記導体に取り付けられるコネクタ部と、電線の端部の前記絶縁被覆が除去された部分が半田付けにより接続された電線接続部とを有する接続用端子を備え、
前記半田付けされた半田付け部分の外周に、または、前記半田付け部分および前記半田付け部分に隣接する前記電線の絶縁被覆の部分の外周に、耐熱性を有する筒状部材、熱により収縮し前記筒状部材の外周を覆う熱収縮チューブ、および前記筒状部材の内方に充填された樹脂を有する積層部が設けられ、
さらに、前記積層部に隣接する前記電線の絶縁被覆の部分の外周が熱により収縮した前記熱収縮チューブに覆われることにより、当該収縮した熱収縮チューブと前記積層部に隣接する電線の絶縁被覆の部分との間を封止する封止部が設けられている。
芯線は、単線であっても、撚り線であってもよい。 In order to achieve the above object, the terminal connection structure of the wire end according to the present invention is a structure for electrically connecting the end of the wire having an insulating coating and a plurality of core wires bundled to an external conductor. There,
A connector portion attached to the conductor, and a connection terminal having a wire connection portion to which a portion of the end portion of the electric wire from which the insulating coating has been removed is connected by soldering,
On the outer periphery of the soldered soldered portion, or on the outer periphery of the soldered portion and the insulating coating portion of the electric wire adjacent to the soldered portion, a heat-resistant tubular member, which shrinks due to heat, A heat shrinkable tube that covers the outer periphery of the tubular member, and a laminated portion having a resin filled inside the tubular member;
Furthermore, the outer periphery of the insulating coating portion of the electric wire adjacent to the laminated portion is covered with the heat-shrinkable tube that is shrunk by heat, so that the insulating coating of the electric wire adjacent to the heat-shrinkable tube and the laminated portion is contracted. A sealing portion that seals between the portions is provided.
The core wire may be a single wire or a stranded wire.

この構成によれば、半田付け部分の外周、または、半田付け部分および半田付け部分に隣接する電線の絶縁被覆の部分の外周が当該樹脂に覆われているので、半田付け部分とその周辺に対して外部環境への対策を施しつつ、半田付け部分とその周辺の機械的強度の増強を行うことができる。さらに、この構成によれば、上記の各外周に、耐熱性を有する筒状部材、熱により収縮し前記筒状部材の外周を覆う熱収縮チューブを有して、筒状部材の内方に樹脂が充填されているので、市販の耐熱性シートのような汎用品を用いて筒状部材を形成して、熱により収縮した熱収縮チューブでこの筒状部材の外周を覆うことにより、樹脂が内方に充填される構造体（以下、ハウジングという）を容易かつ安価に構成することができる。すなわち、当該ハウジングを構成するために、高価な金型を製造する費用や手間が削減できる。このように、この構成によれば、半田付け部分とその周辺の機械的強度の増強を容易かつ安価に行うことができる。 According to this configuration, the outer periphery of the soldering part or the outer periphery of the soldering part and the insulating coating part of the electric wire adjacent to the soldering part is covered with the resin. As a result, the mechanical strength of the soldered portion and its surroundings can be increased while taking measures against the external environment. In addition, according to this configuration, the outer peripheral member has a heat-resistant tubular member and a heat-shrinkable tube that shrinks due to heat and covers the outer periphery of the tubular member, and the resin is disposed inside the tubular member. Since a cylindrical member is formed using a general-purpose product such as a commercially available heat-resistant sheet, and the outer periphery of the cylindrical member is covered with a heat-shrinkable tube that is contracted by heat, the resin is contained inside. A structure (hereinafter referred to as a housing) filled in the direction can be easily and inexpensively configured. That is, since the housing is configured, the cost and labor for manufacturing an expensive mold can be reduced. As described above, according to this configuration, it is possible to easily and inexpensively increase the mechanical strength of the soldered portion and its periphery.

前記積層部内の前記樹脂は、前記接続用端子の長手方向に対して、前記封止部寄りの第１の樹脂部分と、その他の部分の第２の樹脂部分とを有していることが好ましい。この構成は、例えば液状の樹脂を用いて前記封止部寄りの第１の樹脂部分を先に形成してから、その他の部分の第２の樹脂部分を形成することで実現される。ここで、絶縁被覆端部内部の芯線間に浸潤する量は、隙間部内の液状の樹脂の量に従って増加する。一方、電線の絶縁被覆端部の内部に存在する芯線には、第１の樹脂部分からの樹脂のみが浸潤する。よって、芯線間には、当初は全体のうちの一部の樹脂のみが浸潤するので、第１の樹脂部分が硬化してから第２の樹脂部分を形成することで、絶縁被覆端部の内部に存在する芯線間に浸潤する樹脂を比較的少なくしつつ、最終的に樹脂全部で筒状部材の内方を充填することができる。さらに、第１の樹脂部分の樹脂の量は、第２の樹脂部分の樹脂の量よりも少ない方が、絶縁被覆端部の内部に存在する芯線間に浸潤する樹脂を一層少なくすることができるので好ましい。 It is preferable that the resin in the laminated portion has a first resin portion near the sealing portion and a second resin portion in other portions with respect to the longitudinal direction of the connection terminal. . This configuration is realized, for example, by first forming the first resin portion near the sealing portion using a liquid resin and then forming the second resin portion of the other portion. Here, the amount of infiltration between the core wires inside the insulating coating end portion increases according to the amount of liquid resin in the gap portion. On the other hand, only the resin from the first resin portion is infiltrated into the core wire existing inside the insulating coating end of the electric wire. Therefore, since only a part of the resin infiltrates between the core wires at first, the second resin portion is formed after the first resin portion is cured, so that the inside of the insulating coating end portion is formed. It is possible to finally fill the inside of the tubular member with all the resin while relatively reducing the amount of resin infiltrating between the core wires existing in the tube. Furthermore, the amount of the resin in the first resin portion is smaller than the amount of the resin in the second resin portion, so that the amount of the resin infiltrating between the core wires existing inside the insulating coating end portion can be further reduced. Therefore, it is preferable.

上記の各構成では、既に述べた様に、前記電線の絶縁被覆端部の内部に存在する前記芯線間に、前記樹脂を有する。よって、電線の絶縁被覆端部、すなわち前記半田付け部分に隣接する前記電線の絶縁被覆の部分の内部に存在する芯線間において、外部環境への耐性を向上させ、かつ機械的強度を増強することができる。 In each of the above-described configurations, as already described, the resin is provided between the core wires existing inside the insulating coating end of the electric wire. Therefore, the resistance to the external environment is improved and the mechanical strength is enhanced between the core wires existing inside the end portion of the insulating coating of the electric wire, that is, the portion of the insulating coating of the electric wire adjacent to the soldered portion. Can do.

本発明にかかる電線端部の端子接続構造の製造方法は、絶縁被覆を有し複数の芯線が束ねられてなる電線の端部を外部の導体に電気的に接続する構造であって、前記導体に取り付けられるコネクタ部と、電線の端部の前記絶縁被覆が除去された部分が半田付けにより接続された電線接続部とを有する接続用端子とを備えた構造の製造方法であって、
筒状部材の内部の所定位置に、前記電線が取り付けられた前記接続用端子を位置させる端子位置設定小工程、および熱収縮チューブの内部に所定深さまで前記筒状部材を挿入する筒状部材挿入小工程を含む第１工程と、
前記熱収縮チューブを加熱して、前記筒状部材の周りの熱収縮チューブを収縮させて、当該収縮した熱収縮チューブと前記筒状部材との間を密着して、前記筒状部材に開口部と、前記筒状部材内部に前記開口部につながり少なくとも前記半田付けされた半田付け部分を内包する隙間部とを形成し、かつ、前記電線の絶縁被覆周りの前記熱収縮チューブを収縮させて、当該収縮した熱収縮チューブとこれに対向する前記電線の絶縁被覆との間が封止された封止部を形成する第２工程と、
前記開口部から前記隙間部内に液状の樹脂を注入して硬化させる第３工程とを、
この順番に有する。
ここで、前記「液状の樹脂」には、液体のほか、浸潤性を有する泥状もしくは半固形の樹脂が含まれる。 The method for manufacturing a terminal connection structure for an end portion of an electric wire according to the present invention is a structure for electrically connecting an end portion of an electric wire having an insulation coating and a plurality of core wires bundled to an external conductor, A connection portion having a connector portion, and a connection terminal having a wire connection portion to which a portion of the end portion of the electric wire from which the insulation coating has been removed is connected by soldering,
A small terminal position setting step for positioning the connection terminal to which the electric wire is attached at a predetermined position inside the cylindrical member, and a cylindrical member insertion for inserting the cylindrical member to a predetermined depth inside the heat shrinkable tube A first step including a small step;
The heat-shrinkable tube is heated, the heat-shrinkable tube around the tubular member is shrunk, and the contracted heat-shrinkable tube and the tubular member are in close contact with each other, and an opening is formed in the tubular member. And forming a gap portion inside the cylindrical member connected to the opening and containing at least the soldered soldered portion, and shrinking the heat shrinkable tube around the insulating coating of the wire, A second step of forming a sealed portion in which a space between the contracted heat-shrinkable tube and the insulating coating of the electric wire facing the tube is sealed;
A third step of injecting and curing a liquid resin from the opening into the gap,
Have in this order.
Here, the “liquid resin” includes a liquid or a mud-like or semi-solid resin having infiltrating properties.

ここで、端子位置設定小工程には、筒状部材の内部の所定位置に、電線が取り付けられた接続用端子を位置させる工程であれば、例えば、ｉ．汎用の耐熱性シートを丸めるなどして、筒状部材を形成してから、筒状部材の内部の所定位置まで当該接続用端子を挿入する工程や、ｉｉ．汎用の耐熱性シートを巻回するなどして、当該接続用端子の周りに筒状部材を形成し、筒状部材内部の所定位置に当該接続用端子を存在させる工程が含まれうる。端子位置設定小工程がｉ．の工程の場合、筒状部材挿入小工程において、形成された筒状部材を熱収縮チューブの内部に所定深さまで挿入してから、筒状部材の内部の所定位置まで当該接続用端子を挿入する順番と、形成された筒状部材の内部の所定位置まで当該接続用端子を挿入してから、筒状部材挿入小工程において、この接続用端子が挿入された筒状部材を熱収縮チューブの内部に所定深さまで挿入する順番とを取りうる。端子位置設定小工程がｉｉ．の工程の場合、当該接続用端子の周りに筒状部材を形成してから、筒状部材挿入小工程において、この接続用端子を内部に含む筒状部材を熱収縮チューブの内部に所定深さまで挿入する順番を取りうる。 Here, in the terminal position setting small process, if the connection terminal to which the electric wire is attached is positioned at a predetermined position inside the cylindrical member, for example, i. A step of inserting the connecting terminal to a predetermined position inside the cylindrical member after forming the cylindrical member by rolling a general-purpose heat-resistant sheet, ii. A step of forming a cylindrical member around the connection terminal by winding a general-purpose heat-resistant sheet and causing the connection terminal to exist at a predetermined position inside the cylindrical member may be included. The terminal position setting sub-process is i. In the case of this step, in the tubular member insertion sub-step, the formed tubular member is inserted into the heat-shrinkable tube to a predetermined depth, and then the connection terminal is inserted to a predetermined position inside the tubular member. After inserting the connecting terminal to the predetermined position inside the formed cylindrical member in order, the cylindrical member into which the connecting terminal is inserted is inserted into the heat shrinkable tube in the small step of inserting the cylindrical member. The order of insertion up to a predetermined depth can be taken. The terminal position setting sub-process is ii. In the case of this step, after forming the cylindrical member around the connection terminal, in the cylindrical member insertion sub-process, the cylindrical member including the connection terminal is inserted into the heat-shrinkable tube to a predetermined depth. The order of insertion can be taken.

この製造方法によれば、第２工程で形成された、筒状部材内部に少なくとも半田付け部分を内包する隙間部内に、第３工程において、液状の樹脂が注入されるので、半田付け部分の外周、または、半田付け部分および半田付け部分に隣接する電線の絶縁被覆の部分の外周が樹脂に覆われるので、半田付け部分とその周辺に対して外部環境への対策を施しつつ、半田付け部分とその周辺の機械的強度の増強を行うことができる。さらに、この製造方法によれば、内部に樹脂が充填されるハウジングを、熱収縮チューブの内部に筒状部材を挿入した後、熱収縮チューブを加熱することで形成しているから、筒状部材として一般的な耐熱性シートのような汎用品を使用できるので、ハウジングを容易かつ安価に構成することができ、当該ハウジングを構成するために、高価な金型を製造するなどの費用や手間が削減できる。このように、半田付け部分とその周辺の機械的強度の増強を容易かつ安価に行うことができる。 According to this manufacturing method, since the liquid resin is injected in the third step into the gap portion formed in the second step and containing at least the soldering portion inside the cylindrical member, the outer periphery of the soldering portion Or, since the outer periphery of the soldering portion and the insulation coating portion of the electric wire adjacent to the soldering portion is covered with resin, the soldering portion The surrounding mechanical strength can be increased. Furthermore, according to this manufacturing method, the housing filled with the resin is formed by inserting the tubular member into the heat shrinkable tube and then heating the heat shrinkable tube. As a general-purpose product such as a general heat-resistant sheet can be used, the housing can be configured easily and inexpensively. In order to configure the housing, the cost and labor of manufacturing an expensive mold are reduced. Can be reduced. In this way, the mechanical strength of the soldered portion and its surroundings can be easily and inexpensively increased.

前記第３工程は、前記液状の樹脂の注入すべき量の一部を前記開口部から前記隙間部内に注入して硬化させる初期注入小工程と、その後に続く、前記開口部から前記隙間部内に残りの量の液状の樹脂を注入して硬化させる本注入小工程とを含むことが好ましい。上述のように、絶縁被覆端部の内部の芯線間に浸潤する量は、隙間部内の液状の樹脂の量に従って増加する。一方、電線の絶縁被覆端部の内部に存在する芯線には、初期注入小工程の液状の樹脂のみが浸潤する、すなわち、当初は全体のうちの一部の樹脂のみが芯線間に浸潤するので、この樹脂が硬化してから、本注入小工程を行うことで、絶縁被覆端部の内部に存在する芯線間に浸潤する樹脂を比較的少なくしつつ、最終的に樹脂全部で筒状部材の内方を充填することができる。さらに、初期注入小工程における樹脂の注入すべき一部の量は、本注入小工程における残りの量よりも少ない方が、絶縁被覆端部の内部に存在する芯線間に浸潤する樹脂を一層少なくすることができるので好ましい。 In the third step, an initial injection small step of injecting a part of the amount of the liquid resin to be injected into the gap portion from the opening portion and curing, followed by the subsequent step from the opening portion into the gap portion. And a main injection small step of injecting and curing the remaining amount of liquid resin. As described above, the amount of infiltration between the core wires inside the insulating coating end portion increases according to the amount of liquid resin in the gap portion. On the other hand, only the liquid resin in the initial injection small process is infiltrated into the core wire existing inside the insulation coating end portion of the electric wire, that is, only a part of the resin infiltrate between the core wires at the beginning. After the resin is cured, the main injection small process is performed, so that the resin that infiltrates between the core wires existing inside the insulating coating end is relatively reduced, and finally the entire resin is made of the cylindrical member. The inside can be filled. Furthermore, the amount of resin to be injected in the initial injection small process is smaller than the remaining amount in the main injection small process, and the amount of resin that infiltrates between the core wires existing inside the insulating coating end is further reduced. This is preferable.

本発明に係る電線端部の端子接続構造およびその製造方法は、電線と接続用端子との半田付け部分とその周辺に対して外部環境への対策を施しつつ、半田付け部分とその周辺の機械的強度の増強を容易かつ安価に行うことができる。 The terminal connection structure for the end of the electric wire according to the present invention and the method for manufacturing the same include a soldering portion and its peripheral machine while taking measures against the external environment with respect to the soldering portion between the electric wire and the connection terminal and its periphery. The mechanical strength can be easily and inexpensively increased.

本発明の第１実施形態に係る加熱前の電線端部の端子接続構造を示す斜視図である。It is a perspective view which shows the terminal connection structure of the electric wire edge part before a heating which concerns on 1st Embodiment of this invention. 加熱後の同端子接続構造を示す斜視図である。It is a perspective view which shows the same terminal connection structure after a heating. 加熱後の同端子接続構造を示す側面図である。It is a side view which shows the same terminal connection structure after a heating. 本発明の第１実施形態に係る電線端部の端子接続構造の製造方法における第１工程を示す概略図である。It is the schematic which shows the 1st process in the manufacturing method of the terminal connection structure of the electric wire edge part which concerns on 1st Embodiment of this invention. 同製造方法における第１工程の変形例を示す概略図である。It is the schematic which shows the modification of the 1st process in the manufacturing method. 同製造方法における第２工程を示す側面図である。It is a side view which shows the 2nd process in the manufacturing method. 同製造方法における第３工程を示す斜視図である。It is a perspective view which shows the 3rd process in the manufacturing method. 接続用端子の変形例を示す分解斜視図であるIt is a disassembled perspective view which shows the modification of the terminal for a connection. 接続用端子の変形例を示す斜視図である。It is a perspective view which shows the modification of the terminal for a connection.

以下、本発明の実施形態を図面に基づいて説明する。なお、各図において同一の符号は、同一または相当部分を示し、特段変更等の説明がない限り、適宜その説明を省略する。 Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the drawings, the same reference numerals indicate the same or corresponding parts, and the description thereof will be omitted as appropriate unless otherwise specified.

図１に、第１実施形態に係る加熱前の電線端部の端子接続構造を表す斜視図を示し、図２に、同端子接続構造の加熱後の斜視図を示し、図３に、図２の側面図を示す。図１の接続用端子１は、電線５を外部の導体（不図示）に電気的に接続させるため、電線５の端部に取り付けられる。電線５は、例えばアルミニウムまたはアルミニウム合金製の単線または撚り線からなる芯線を複数束ねたものからなり、複数束ねた芯線の外周にビニルシート、織物等からなる絶縁被覆５ｄを有している。また各芯線は、エナメル被膜が施されている。接続用端子１は、芯線と異なる材質例えば銅または黄銅のような銅合金の板材からなり、本実施形態では、電線接続用端子１の表面全体に錫めっき処理が施されている。これにより、接続用端子１と電線５が異なる材質で、互いに接合されても、電蝕発生が回避される。 FIG. 1 is a perspective view showing a terminal connection structure of an electric wire end portion before heating according to the first embodiment, FIG. 2 is a perspective view after heating of the terminal connection structure, FIG. The side view of is shown. The connection terminal 1 in FIG. 1 is attached to the end of the electric wire 5 in order to electrically connect the electric wire 5 to an external conductor (not shown). The electric wire 5 is made of a bundle of a plurality of core wires made of, for example, aluminum or an aluminum alloy, and has an insulating coating 5d made of a vinyl sheet, a woven fabric or the like on the outer periphery of the bundled core wires. Each core wire is provided with an enamel coating. The connection terminal 1 is made of a plate material made of a copper alloy such as copper or brass, which is different from the core wire. In this embodiment, the entire surface of the wire connection terminal 1 is subjected to tin plating. Thereby, even if the connection terminal 1 and the electric wire 5 are made of different materials and joined to each other, the occurrence of electrolytic corrosion is avoided.

接続用端子１は、外部の導体、例えばねじ孔を有する端子台（不図示）にねじ止めされて取り付けられるコネクタ部２と、上述のように芯線を複数束ねた電線５が半田付けされる電線接続部３とを備える。コネクタ部２と電線接続部３は、各図に示す接続用端子１および電線５の長手方向Ｘと合致した方向に沿って並んでいる。電線接続部３の前方に位置するコネクタ部２の中央には、外部の不図示の端子台にねじ止めされるための取付孔２１が、表裏の主面と直交する上下方向に貫通して設けられている。電線接続部３は、かしめられて電線５を保持する２つのかしめ片６、６を有している。かしめ片６は、本実施形態では、電線接続部３の電線５が取り付けられる側に突出した、電線接続部３と同一部材の板状の突片である。なお、かしめ片６は１つであってもよい。２つのかしめ片６、６が、電線５の端部の絶縁被覆５ｄが除去された部分（被覆除去部分という）５ｃを抱持するようにかしめられて、２つのかしめ片６、６および電線接続部３と被覆除去部分５ｃとが半田付けされる。半田付けの際には、各芯線の半田付けされる接合部のエナメル被膜や酸化被膜等は除去される。この電線５が半田付けされた部分である半田付け部分７により、電線接続部３と電線５とが、電気的かつ機械的に接続される。 The connection terminal 1 includes an external conductor, for example, a connector portion 2 that is screwed and attached to a terminal block (not shown) having a screw hole, and an electric wire in which a plurality of core wires 5 are soldered as described above. And a connection unit 3. The connector part 2 and the electric wire connection part 3 are lined up along the direction which matched the longitudinal direction X of the terminal 1 for a connection and the electric wire 5 which are shown to each figure. At the center of the connector portion 2 located in front of the wire connection portion 3, a mounting hole 21 for being screwed to an external terminal block (not shown) is provided penetrating in the vertical direction perpendicular to the front and back main surfaces. It has been. The electric wire connecting portion 3 has two caulking pieces 6 and 6 that are caulked to hold the electric wires 5. In this embodiment, the caulking piece 6 is a plate-like protruding piece that is the same member as the wire connecting portion 3 and protrudes to the side where the electric wire 5 of the wire connecting portion 3 is attached. One caulking piece 6 may be provided. The two caulking pieces 6, 6 are caulked so as to hold a portion 5 c from which the insulating coating 5 d at the end of the electric wire 5 is removed (referred to as a coating removing portion) 5 c, and the two caulking pieces 6, 6 and the electric wire connection The part 3 and the coating removal part 5c are soldered. At the time of soldering, the enamel film, the oxide film, and the like of the joint portion to be soldered of each core wire are removed. The wire connection portion 3 and the wire 5 are electrically and mechanically connected by a soldering portion 7 that is a portion to which the wire 5 is soldered.

本実施形態の接続用端子１は、半田付け部分７、および半田付け部分７に隣接する電線５の絶縁被覆５ｄの部分すなわち電線５の絶縁被覆５ｄの端部（以下、絶縁被覆端部という）５ａの外周は、隙間をあけて耐熱性を有する筒状部材１０に囲まれている。この筒状部材１０に囲まれる部分は、半田付け部分７の外周のみであってもよいが、少なくとも半田付け部分７および絶縁被覆端部５ａの外周を含む方が、後述の樹脂８０により半田付け部分７および絶縁被覆端部５ａの両方の外周を覆うことができ、両外周の外部環境への対策面、機械的強度面から望ましい。この筒状部材１０に囲まれる部分は、後述の積層部３０の部分に相当する。また、筒状部材１０の外周、および積層部３０に隣接する電線５の絶縁被覆５ｄの部分（以下、隣接部分という）５ｂが、隙間をあけて、加熱により収縮する前の熱収縮チューブ２０に囲まれている。熱収縮チューブ２０の素材としては、例えばエチレンプロピレンゴム、ポリ塩化ビニル等を採用しうる。 The connection terminal 1 of the present embodiment includes a soldering portion 7 and a portion of the insulating coating 5d of the electric wire 5 adjacent to the soldering portion 7, that is, an end portion of the insulating coating 5d of the electric wire 5 (hereinafter referred to as an insulating coating end portion). The outer periphery of 5a is surrounded by a cylindrical member 10 having heat resistance with a gap. The portion surrounded by the cylindrical member 10 may be only the outer periphery of the soldering portion 7, but at least the outer periphery of the soldering portion 7 and the insulating coating end 5 a is soldered by a resin 80 described later. The outer periphery of both the part 7 and the insulation coating end 5a can be covered, which is desirable from the viewpoint of measures against external environment and mechanical strength of both outer periphery. A portion surrounded by the tubular member 10 corresponds to a portion of a laminated portion 30 described later. In addition, the outer periphery of the cylindrical member 10 and the insulating coating 5d portion (hereinafter referred to as an adjacent portion) 5b of the electric wire 5 adjacent to the laminated portion 30 are formed in the heat-shrinkable tube 20 before being contracted by heating with a gap. being surrounded. As a material of the heat shrinkable tube 20, for example, ethylene propylene rubber, polyvinyl chloride or the like can be adopted.

この状態で、ヒートガン（不図示）の熱風等により、熱収縮チューブ２０が加熱されて熱収縮チューブ２０が収縮し、図２に示すような、熱収縮した熱収縮チューブ２０Ａが筒状部材１０との間を密着して筒状部材１０を覆う状態となる。この時、図３に明示するように、筒状部材１０のコネクタ部２側は、熱収縮した熱収縮チューブ２０Ａに覆われることなく開口しており、開口部３１が形成されている。また、筒状部材１０の内部には、開口部３１につながり少なくとも半田付け部分７を内包する空間である隙間部３２が形成されている。隙間部３２には、例えば、電線接続部３のみ、半田付け部分７のみ、電線接続部３および絶縁被覆端部５ａ、または半田付け部分７および絶縁被覆端部５ａを含ませることができるが、本実施形態では、電線接続部３および絶縁被覆端部５ａが内包されている。一方、この加熱後の状態では、収縮した熱収縮チューブ２０Ａとこれに対向する電線５の絶縁被覆５ｄとの間が封止されて、すなわち、筒状部材１０で覆われていない電線５の隣接部分５ｂの部分の外周が、熱により収縮した熱収縮チューブ２０Ａに覆われることにより、熱収縮した熱収縮チューブ２０Ａと電線５の隣接部分５ｂの部分との間が密着して封止されて、封止部４０を形成している。以上により、電線５が取り付けられた接続用端子１が、電線５の隣接部分５ｂに密着した熱収縮チューブ２０Ａを介して、この熱収縮チューブ２０Ａが前述のとおり密着する筒状部材１０と一体化し、樹脂８０が内方に充填される構造体であるハウジングＨが形成される。 In this state, the heat-shrinkable tube 20 is heated by the hot air of a heat gun (not shown) and the heat-shrinkable tube 20 is shrunk, and the heat-shrinkable heat-shrinkable tube 20A as shown in FIG. It will be in the state which closely_close | closes and covers the cylindrical member 10. At this time, as clearly shown in FIG. 3, the connector part 2 side of the cylindrical member 10 is opened without being covered by the heat-shrinkable heat-shrinkable tube 20A, and an opening 31 is formed. Further, inside the cylindrical member 10, a gap portion 32 that is a space connected to the opening portion 31 and containing at least the soldering portion 7 is formed. The gap portion 32 can include, for example, only the electric wire connection portion 3, only the soldering portion 7, only the electric wire connection portion 3 and the insulating covering end portion 5a, or the soldering portion 7 and the insulating covering end portion 5a. In this embodiment, the electric wire connection part 3 and the insulation coating edge part 5a are included. On the other hand, in the state after the heating, the space between the contracted heat-shrinkable tube 20A and the insulating coating 5d of the electric wire 5 opposed thereto is sealed, that is, adjacent to the electric wire 5 not covered with the cylindrical member 10. The outer periphery of the portion 5b is covered with a heat-shrinkable tube 20A that is shrunk by heat, so that the heat-shrinkable tube 20A that has been heat-shrinked and the portion of the adjacent portion 5b of the electric wire 5 are tightly sealed. The sealing part 40 is formed. As described above, the connecting terminal 1 to which the electric wire 5 is attached is integrated with the tubular member 10 to which the heat-shrinkable tube 20A is in close contact as described above via the heat-shrinkable tube 20A in close contact with the adjacent portion 5b of the electric wire 5. A housing H that is a structure in which the resin 80 is filled inward is formed.

本実施形態の接続用端子１では、半田付け部分７および絶縁被覆端部５ａの外周は、半田付け部分７および絶縁被覆端部５ａを含む側である隙間部３２の内方に充填された樹脂８０に覆われている。すなわち、ハウジングＨの内方に、樹脂８０が充填されている。よって、樹脂８０の層、筒状部材１０の層、および熱収縮した熱収縮チューブ２０Ａの層が、少なくとも半田付け部分７および絶縁被覆端部５ａの外周に、内側から外側に向けて隙間無くこの順番で並び、積層部３０を形成している。この時、封止部４０は、積層部３０に隣接し、熱収縮した熱収縮チューブ２０Ａを積層部３０と共有している。 In the connection terminal 1 of the present embodiment, the outer periphery of the soldered portion 7 and the insulating coating end 5a is filled with resin inside the gap portion 32 on the side including the soldering portion 7 and the insulating coating end 5a. 80. That is, the resin 80 is filled in the housing H. Therefore, the layer of the resin 80, the layer of the cylindrical member 10, and the layer of the heat-shrinkable tube 20A that has been heat-shrinked are at least on the outer periphery of the soldering portion 7 and the insulating coating end portion 5a without gaps from the inside to the outside. Arranged in order, the stacked portion 30 is formed. At this time, the sealing portion 40 is adjacent to the laminated portion 30 and shares the heat-shrinkable tube 20 A that has undergone heat shrinkage with the laminated portion 30.

積層部３０の樹脂８０すなわち隙間部３２内の樹脂８０は、長手方向Ｘに対して、封止部４０寄りの第１の樹脂部分８１と、その他の部分の第２の樹脂部分８２とを有している。第１の樹脂部分８１および第２の樹脂部分８２では、例えば後述の電線端部の端子接続構造の製造方法における第３工程によって、封止部４０寄りの第１の樹脂部分８１を先に形成してから、その他の部分の第２の樹脂部分８２を形成する。このとき、電線５の絶縁被覆端部５ａの内部に存在する芯線間には、第１の樹脂部分の樹脂８０が浸潤している。この構造により、絶縁被覆端部５ａの内部に存在する芯線間において、外部環境への耐性を向上させ、かつ機械的強度を増強することができる。一方、前記第３工程による第１の樹脂部分８１および第２の樹脂部分８２を有する構造により、絶縁被覆端部５ａの内部に存在する芯線間に浸潤する樹脂を比較的少なくしつつ、最終的に樹脂全部で筒状部材１０の内方を充填することができる。この点については、後で詳述する。 The resin 80 in the laminated portion 30, that is, the resin 80 in the gap portion 32, has a first resin portion 81 near the sealing portion 40 and a second resin portion 82 in the other portion in the longitudinal direction X. doing. In the first resin portion 81 and the second resin portion 82, the first resin portion 81 near the sealing portion 40 is formed first by, for example, a third step in a method for manufacturing a terminal connection structure for an end portion of an electric wire described later. Then, the second resin portion 82 of the other portion is formed. At this time, the resin 80 of the first resin portion is infiltrated between the core wires existing inside the insulating coating end portion 5 a of the electric wire 5. With this structure, the resistance to the external environment can be improved and the mechanical strength can be enhanced between the core wires existing inside the insulating coating end 5a. On the other hand, with the structure having the first resin portion 81 and the second resin portion 82 in the third step, the resin infiltrating between the core wires existing inside the insulating coating end portion 5a is relatively reduced, and finally The inside of the cylindrical member 10 can be filled with all the resin. This point will be described in detail later.

以上の様に、本実施形態の接続用端子１は、半田付け部分７の外周、または、半田付け部分７および絶縁被覆端部５ａの外周が樹脂８０に覆われているので、半田付け部分７とその周辺に対して外部環境への対策を施しつつ、半田付け部分７とその周辺の機械的強度の増強を行うことができる。さらに、この構成では、上記の各外周に、耐熱性を有する筒状部材１０と、熱により収縮し筒状部材１０の外周を覆う熱収縮チューブ２０Ａとを有して、筒状部材１０の内方に樹脂８０が充填されている。したがって、市販の耐熱性シートのような汎用品を用いて筒状部材１０を形成して、熱により収縮した熱収縮チューブ２０Ａでこの筒状部材１０の外周を覆うことにより、ハウジングＨを容易かつ安価に構成することができる。すなわち、当該ハウジングＨを構成するために、高価な金型を製造する費用や手間が削減できる。このように、この構成によれば、半田付け部分７とその周辺の機械的強度の増強を容易かつ安価に行うことができる。 As described above, the connection terminal 1 of the present embodiment has the outer periphery of the soldering portion 7 or the outer periphery of the soldering portion 7 and the insulating coating end portion 5 a covered with the resin 80. In addition, the mechanical strength of the soldered portion 7 and its periphery can be increased while taking measures against the external environment with respect to the periphery thereof. Further, in this configuration, the outer periphery of each of the tubular members 10 includes the tubular member 10 having heat resistance and the heat-shrinkable tube 20A that shrinks by heat and covers the outer periphery of the tubular member 10. The resin 80 is filled in the direction. Therefore, the tubular member 10 is formed using a general-purpose product such as a commercially available heat-resistant sheet, and the outer periphery of the tubular member 10 is covered with the heat-shrinkable tube 20A contracted by heat. It can be configured at low cost. That is, since the housing H is configured, the cost and labor for manufacturing an expensive mold can be reduced. As described above, according to this configuration, the mechanical strength of the soldering portion 7 and its periphery can be easily and inexpensively increased.

次に、本発明の第１実施形態の製造方法について説明する。図４に、本実施形態に係る電線端部の端子接続構造の製造方法における第１工程を表す概略図を示し、図５に、この第１工程の変形例を表す概略図を示す。また、図６に、第１工程に続く第２工程を表す側面図を示し、図７に、第２工程に続く第３工程を表す斜視図を示す。図４に示すように、同端子接続構造の製造方法における第１工程では、まず汎用品を使用して筒状部材１０を形成してから（形成工程Ａ１）、筒状部材１０の内部に所定位置で、電線５が取り付けられた接続用端子１を位置させ（端子位置設定小工程Ａ２）、さらに熱収縮チューブ２０の内部に所定深さまで筒状部材１０を挿入させる（筒状部材挿入小工程Ｂ）。 Next, the manufacturing method of 1st Embodiment of this invention is demonstrated. FIG. 4 shows a schematic diagram representing a first step in the method of manufacturing a terminal connection structure for an electric wire end according to the present embodiment, and FIG. 5 shows a schematic diagram showing a modification of the first step. FIG. 6 is a side view showing the second step following the first step, and FIG. 7 is a perspective view showing the third step following the second step. As shown in FIG. 4, in the first step in the manufacturing method of the terminal connection structure, first, the cylindrical member 10 is formed using a general-purpose product (forming step A 1), and then the inside of the cylindrical member 10 is predetermined. At the position, the connection terminal 1 to which the electric wire 5 is attached is positioned (terminal position setting small process A2), and the tubular member 10 is further inserted into the heat shrinkable tube 20 to a predetermined depth (tubular member insertion small process). B).

形成工程Ａ１では、例えば、汎用の耐熱性シート１０Ａを丸めて、筒状部材１０を形成する。耐熱性シート１０Ａでは、所望の隙間部３２の容積や形状を形成することができるように、シートの材質、厚さ、寸法、形状およびその巻き数が決定される。具体的には、汎用の耐熱性シート１０Ａとして、メタ系アラミド繊維である難燃性のノーメックス（デュポン社の登録商標）繊維のシートを使用し、その厚さは０．３８ｍｍであり、寸法は７０ｍｍ×１５０ｍｍである。さらに、この耐熱性シート１０Ａを長尺方向で２回巻きして円筒状とし、この円筒の外周面において、当該円筒の軸方向の中央部および両端部付近の３ヶ所で粘着テープを２周巻きつけて仮止めして、筒状部材１０を形成する。端子位置設定小工程Ａ２における、接続用端子１が挿入される筒状部材１０の内部の所定位置として、例えば、図３に示すコネクタ部２が筒状部材１０の外部に存在し、かつ、電線接続部３のみ、半田付け部分７のみ、電線接続部３および絶縁被覆端部５ａ、または半田付け部分７および絶縁被覆端部５ａが筒状部材１０の内部に存在するような位置とすることができる。 In the formation step A1, for example, the general-purpose heat-resistant sheet 10A is rolled to form the tubular member 10. In the heat resistant sheet 10A, the material, thickness, dimension, shape, and number of windings of the sheet are determined so that the desired volume and shape of the gap portion 32 can be formed. Specifically, as a general-purpose heat-resistant sheet 10A, a sheet of flame retardant Nomex (registered trademark of DuPont), which is a meta-aramid fiber, is used, and its thickness is 0.38 mm. It is 70 mm x 150 mm. Further, the heat-resistant sheet 10A is wound twice in the longitudinal direction to form a cylindrical shape, and the adhesive tape is wound twice on the outer peripheral surface of the cylinder at three locations near the center and both ends in the axial direction of the cylinder. The cylindrical member 10 is formed by attaching and temporarily fixing. As the predetermined position inside the cylindrical member 10 into which the connecting terminal 1 is inserted in the terminal position setting sub-process A2, for example, the connector portion 2 shown in FIG. Only the connecting portion 3, only the soldering portion 7, the wire connecting portion 3 and the insulating coating end portion 5 a, or the soldering portion 7 and the insulating coating end portion 5 a are located in the cylindrical member 10. it can.

筒状部材挿入小工程Ｂにおける、筒状部材１０を挿入させる熱収縮チューブ２０の内部の所定深さとしては、引っ張り動作や曲げ動作等に耐えうる機械的強度を有する最低限の長さの封止部４０が確保でき、かつ、筒状部材１０に熱収縮チューブ２０Ａが密着して機械的強度が確保できればよい。例えば、筒状部材１０を熱収縮チューブ２０の内側に挿入した状態で、図４に示す長手方向Ｘと平行な軸を有する熱収縮チューブ２０内部において、熱収縮チューブ２０の後方から電線５を引き出し、筒状部材１０の前方端縁と熱収縮チューブ２０の前方端縁とを一致させるように筒状部材１０を前方寄りに配置させる。なお、筒状部材１０の前方端縁と熱収縮チューブ２０の前方端縁とは、厳密に一致させなくてもよく、筒状部材１０の前方端部が熱収縮チューブ２０から若干長だけ飛び出していたり、熱収縮チューブ２０の前方端部が筒状部材１０から若干長だけ飛び出していてもよい。ここで、熱収縮チューブ２０の長さは、上記の所定深さを実現できる最小の長さとなっている。 The predetermined depth inside the heat-shrinkable tube 20 into which the cylindrical member 10 is inserted in the cylindrical member insertion sub-process B is a minimum length seal having mechanical strength that can withstand pulling and bending operations. The stop part 40 can be ensured, and the heat-shrinkable tube 20 A may be in close contact with the tubular member 10 to ensure the mechanical strength. For example, in a state where the cylindrical member 10 is inserted inside the heat shrinkable tube 20, the electric wire 5 is pulled out from the rear of the heat shrinkable tube 20 inside the heat shrinkable tube 20 having an axis parallel to the longitudinal direction X shown in FIG. 4. The cylindrical member 10 is disposed closer to the front so that the front end edge of the cylindrical member 10 and the front end edge of the heat shrinkable tube 20 coincide with each other. The front end edge of the cylindrical member 10 and the front end edge of the heat shrinkable tube 20 do not have to be exactly matched, and the front end portion of the tubular member 10 protrudes from the heat shrinkable tube 20 by a little length. Alternatively, the front end of the heat-shrinkable tube 20 may protrude slightly from the cylindrical member 10. Here, the length of the heat-shrinkable tube 20 is the minimum length that can realize the predetermined depth.

上で説明を行った図４に示す第１工程では、形成工程Ａ１、端子位置設定小工程Ａ２、筒状部材挿入小工程Ｂの順番であったが、形成工程Ａ１で筒状部材１０を形成した後に、筒状部材挿入小工程Ｂで形成工程Ａ１での筒状部材１０を熱収縮チューブ２０の内部に所定深さまで挿入してから、端子位置設定小工程Ａ２で筒状部材１０の内部の所定位置まで接続用端子１を挿入する順番とすることもできる。さらに、図４に示す第１工程に代えて、図５に示す第１工程とすることもできる。すなわち、図５に示す第１工程では、まず筒状部材１０の内部の前記所定位置で、電線５が取り付けられた接続用端子１が位置するように、図３の電線接続部３の周りのみ、半田付け部分７の周りのみ、電線接続部３および絶縁被覆端部５ａの周り、または半田付け部分７および絶縁被覆端部５ａの周りに汎用品を使用して筒状部材１０を形成してから（端子位置設定小工程Ａ）、図５の熱収縮チューブ２０の内部に所定深さまで筒状部材１０を挿入させる（筒状部材挿入小工程Ｂ）。端子位置設定小工程Ａでは、例えば、汎用の耐熱性シート１０Ａを丸めるなどして、筒状部材１０を形成する。この筒状部材１０の形成の方法は、具体的には、形成工程Ａ１で既に述べた方法を使用することができる。 In the first step shown in FIG. 4 described above, the forming step A1, the terminal position setting substep A2, and the cylindrical member insertion substep B are in this order, but the cylindrical member 10 is formed in the forming step A1. After the cylindrical member 10 in the forming step A1 is inserted to the inside of the heat-shrinkable tube 20 to a predetermined depth in the cylindrical member insertion substep B, the inside of the cylindrical member 10 in the terminal position setting substep A2 is performed. The order in which the connection terminals 1 are inserted up to a predetermined position can also be used. Furthermore, it can replace with the 1st process shown in FIG. 4 and can also be set as the 1st process shown in FIG. That is, in the first step shown in FIG. 5, first, only around the wire connection portion 3 of FIG. 3 so that the connection terminal 1 to which the wire 5 is attached is located at the predetermined position inside the tubular member 10. The cylindrical member 10 is formed using a general-purpose product only around the soldering portion 7, around the wire connection portion 3 and the insulating coating end portion 5 a, or around the soldering portion 7 and the insulating coating end portion 5 a. (Terminal position setting small process A), the cylindrical member 10 is inserted into the heat shrinkable tube 20 of FIG. 5 to a predetermined depth (cylindrical member insertion small process B). In the terminal position setting sub-process A, the cylindrical member 10 is formed by, for example, rolling a general-purpose heat-resistant sheet 10A. Specifically, the method already described in the forming step A1 can be used as the method of forming the cylindrical member 10.

次に、同製造方法における第２工程について説明する。第２工程は、ヒートガン（不図示）の熱風等により、熱収縮チューブ２０を加熱して、図６中の矢印で示すように熱収縮チューブ２０を収縮させる工程である。上述の第１工程後には、筒状部材１０が熱収縮チューブ２０（図中の２点鎖線）の内部の所定深さまで挿入された状態となっている。この状態で、筒状部材１０の周りの熱収縮チューブ２０を加熱することにより、積層部３０の部分に相当する当該部分の熱収縮チューブ２０が収縮し、収縮した熱収縮チューブ２０Ａ（実線）が筒状部材１０に密着する。このとき、筒状部材１０の長手方向Ｘの後方側（図６の左側）は閉じられるが前方側は開口したままであり開口部３１が形成され、筒状部材１０内部にこの開口部３１につながる空間すなわち隙間部３２が形成される。この隙間部３２内部には、既に述べた様に、少なくとも半田付け部分７が内包され、本実施形態では、電線接続部３および絶縁被覆端部５ａが内包されている。 Next, the 2nd process in the manufacturing method is explained. The second step is a step of heating the heat-shrinkable tube 20 with hot air or the like of a heat gun (not shown) to shrink the heat-shrinkable tube 20 as indicated by an arrow in FIG. After the first step, the cylindrical member 10 is inserted to a predetermined depth inside the heat-shrinkable tube 20 (two-dot chain line in the figure). In this state, by heating the heat-shrinkable tube 20 around the cylindrical member 10, the heat-shrinkable tube 20 of the portion corresponding to the portion of the laminated portion 30 is shrunk, and the shrunk heat-shrinkable tube 20 A (solid line) is The cylindrical member 10 is in close contact. At this time, the rear side in the longitudinal direction X of the cylindrical member 10 (the left side in FIG. 6) is closed, but the front side remains open and an opening 31 is formed, and the opening 31 is formed inside the cylindrical member 10. A space to be connected, that is, a gap 32 is formed. As described above, at least the soldering portion 7 is included in the gap portion 32, and in this embodiment, the electric wire connection portion 3 and the insulating coating end portion 5a are included.

一方、電線５の隣接部分５ｂ周りの熱収縮チューブ２０を加熱することにより、当該部分の熱収縮チューブ２０を収縮させ、収縮した熱収縮チューブ２０Ａ（実線）と電線５の隣接部分５ｂとの間が封止された封止部４０を形成する。以上のように、第２工程により、電線５の隣接部分５ｂおよび筒状部材１０が１つの熱収縮チューブ２０Ａと各々密着することで、電線５が取り付けられた接続用端子１が熱収縮チューブ２０Ａを介して筒状部材１０と一体化し、前述の様にハウジングＨが形成される。なお、伸展性や反発力を有する耐熱性シート１０Ａを丸めて筒状部材１０を形成した場合には、加熱により熱収縮チューブ２０が収縮しても当該収縮の力に抗して拡張しようとするので、筒状部材１０の開口部３１の直径が著しく減少したり、筒状部材１０が変形したりするなどの可能性は低いことから、所望の形状または大きさのハウジングＨを維持しうる。 On the other hand, by heating the heat-shrinkable tube 20 around the adjacent portion 5b of the electric wire 5, the heat-shrinkable tube 20 of the portion is contracted, and between the contracted heat-shrinkable tube 20A (solid line) and the adjacent portion 5b of the electric wire 5 The sealing part 40 sealed with is formed. As described above, the adjacent portion 5b of the electric wire 5 and the cylindrical member 10 are in close contact with one heat shrinkable tube 20A by the second step, so that the connection terminal 1 to which the electric wire 5 is attached becomes the heat shrinkable tube 20A. The housing H is integrated with the cylindrical member 10 as described above. When the tubular member 10 is formed by rolling the heat-resistant sheet 10A having extensibility and repulsion, even if the heat-shrinkable tube 20 contracts due to heating, it tries to expand against the contraction force. Therefore, since the possibility that the diameter of the opening 31 of the cylindrical member 10 is remarkably reduced or the cylindrical member 10 is deformed is low, the housing H having a desired shape or size can be maintained.

次に、同製造方法における第３工程について説明する。図７には、開口部３１から隙間部３２内部を臨む向きのハウジングＨの斜視図が示されている。この第３工程は、開口部３１から隙間部３２内に液状の樹脂８０を注入して硬化させる工程である。本実施形態では、隙間部３２内部には電線接続部３および絶縁被覆端部５ａが内包されているので、液状の樹脂８０の注入すべき量は、隙間部３２の容積から電線接続部３および絶縁被覆端部５ａの体積を減じた量にほぼ等しい。ここで、樹脂８０が、エポキシ樹脂などの熱硬化性樹脂の場合は、加熱して硬化させ、ビニル系ポリマーや縮合系ポリマーなどの熱可塑性樹脂の場合は、冷却して硬化させる。本実施形態では、第３工程は、初期注入小工程と、その後に続く本注入小工程に分かれている。初期注入小工程では、液状の樹脂８０の注入すべき量の一部を前記開口部から前記隙間部内に注入して硬化させる。この初期注入小工程により、前記第１の樹脂部分８１が形成される。次に、本注入小工程では、開口部３１から隙間部内３２に残りの量の液状の樹脂８０を注入し硬化させる。本注入小工程により、前記第２の樹脂部分８２が形成される。 Next, the 3rd process in the manufacturing method is explained. FIG. 7 shows a perspective view of the housing H facing the gap 32 from the opening 31. The third step is a step of injecting and curing the liquid resin 80 from the opening 31 into the gap portion 32. In the present embodiment, since the wire connection portion 3 and the insulating coating end portion 5a are included in the gap portion 32, the amount of liquid resin 80 to be injected is determined from the volume of the gap portion 32 and the wire connection portion 3 and It is almost equal to the amount obtained by reducing the volume of the insulating coating end 5a. Here, when the resin 80 is a thermosetting resin such as an epoxy resin, it is cured by heating, and when it is a thermoplastic resin such as a vinyl polymer or a condensation polymer, it is cured by cooling. In the present embodiment, the third process is divided into an initial injection small process and a subsequent main injection small process. In the initial injection small process, a part of the liquid resin 80 to be injected is injected into the gap from the opening and cured. By the initial injection small process, the first resin portion 81 is formed. Next, in this small injection step, the remaining amount of liquid resin 80 is injected from the opening 31 into the gap portion 32 and cured. The second resin portion 82 is formed by the main injection small process.

液状の樹脂８０の粘度が低い程、ハウジングＨ中の隙間部３２内に液状の樹脂８０を注入する第３工程により、電線５の絶縁被覆端部５ａの内部に存在する芯線間に、液体の樹脂８０が浸潤する。よって、この樹脂８０が硬化することで、絶縁被覆端部５ａの内部に存在する芯線間において、外部環境への耐性を向上させ、かつ機械的強度を増強することができる。しかし、絶縁被覆端部５ａ内部の芯線間に浸潤する量は、隙間部３２内の液状の樹脂８０の量に従って増加することから、隙間部３２内すべてを液状の樹脂８０で満たすと、樹脂８０の大きな重量による押下げ力によって、絶縁被覆端部５ａ内部の芯線間に浸潤する量が不必要に多くなり、この不必要に浸潤した樹脂８０の分だけ無駄が生じる。そこで、第３工程を、初期注入小工程と、その後に続く本注入小工程に分けることで、絶縁被覆端部５ａの内部に存在する芯線には、初期注入小工程で形成された第１の樹脂部分８１からの液状の樹脂のみが浸潤して、当初は全体量のうちの一部の樹脂のみが浸潤するので、絶縁被覆端部５ａの内部に存在する芯線間に浸潤する樹脂を比較的少なくしつつ、この第１の樹脂部分８１が硬化してから、本注入小工程で第２の樹脂部分８２を形成することで、最終的に樹脂全部で筒状部材１０の内部を充填することができる。 As the viscosity of the liquid resin 80 is lower, the liquid resin 80 is injected into the gap portion 32 in the housing H by the third step, and the liquid between the core wires existing inside the insulating coating end 5a of the electric wire 5 is reduced. Resin 80 infiltrates. Therefore, by hardening this resin 80, it is possible to improve the resistance to the external environment and enhance the mechanical strength between the core wires existing inside the insulating coating end 5a. However, the amount of infiltration between the core wires inside the insulating coating end 5a increases according to the amount of the liquid resin 80 in the gap 32. Therefore, when the entire gap 32 is filled with the liquid resin 80, the resin 80 The pressing force due to the large weight unnecessarily increases the amount of infiltrating between the core wires inside the insulating coating end 5a, and waste is caused by the unnecessary infiltrating resin 80. Therefore, by dividing the third step into an initial injection small process and a subsequent main injection small process, the core wire existing inside the insulating coating end 5a is formed in the first injection small process. Since only the liquid resin from the resin portion 81 is infiltrated and only a part of the total amount of resin is infiltrated at first, the resin infiltrating between the core wires existing inside the insulating coating end 5a is relatively After the first resin portion 81 is hardened, the second resin portion 82 is formed in the main injection small process so that the interior of the cylindrical member 10 is finally filled with all the resin. Can do.

以上の様に、本実施形態に係る電線端部の端子接続構造の製造方法によれば、第２工程で形成された、筒状部材１０内部に少なくとも半田付け部分７を内包する隙間部３２内に、第３工程において、液状の樹脂８０が注入される。これにより、半田付け部分７の外周、または、半田付け部分７および半田付け部分７に隣接する電線の隣接部分５ｂの部分の外周が樹脂８０によって覆われるので、半田付け部分７とその周辺に対して外部環境への対策を施しつつ、半田付け部分７とその周辺の機械的強度の増強を行うことができる。さらに、この製造方法によれば、開口部３１と隙間部３２とが形成されて樹脂が充填されるハウジングＨを、第１工程およびその後の第２工程によって、熱収縮チューブ２０内に筒状部材１０を含み、筒状部材１０の内部に接続用端子１を含む状態で、熱収縮チューブ２０を加熱することで形成する。ここで、汎用品等を使用して筒状部材１０を形成することで、ハウジングＨを容易かつ安価に構成することができ、ハウジングＨを構成するために、高価な金型を製造するなどの費用や手間が削減できる。このように、半田付け部分７とその周辺の機械的強度の増強を容易かつ安価に行うことができる。 As described above, according to the method for manufacturing the terminal connection structure of the end portion of the electric wire according to the present embodiment, the gap portion 32 is formed in the second step and includes at least the soldering portion 7 inside the cylindrical member 10. In the third step, liquid resin 80 is injected. As a result, the outer periphery of the soldering portion 7 or the outer periphery of the soldering portion 7 and the adjacent portion 5b of the electric wire adjacent to the soldering portion 7 is covered with the resin 80. Thus, the mechanical strength of the soldered portion 7 and its surroundings can be increased while taking measures against the external environment. Further, according to this manufacturing method, the housing H in which the opening 31 and the gap 32 are formed and filled with the resin is formed in the tubular member in the heat shrinkable tube 20 by the first step and the subsequent second step. 10 and is formed by heating the heat-shrinkable tube 20 in a state in which the connection terminal 1 is included inside the cylindrical member 10. Here, by forming the cylindrical member 10 using a general-purpose product or the like, the housing H can be configured easily and inexpensively, and an expensive mold is manufactured to configure the housing H. Costs and labor can be reduced. Thus, the mechanical strength of the soldered portion 7 and its periphery can be increased easily and inexpensively.

図８は、接続用端子１の変形例を示す電線５の取り付け前の分解斜視図であり、図９は、同変形例の電線５の取り付け後を示す斜視図である。この変形例では、接続用端子１Ａが上記のかしめ片６に相当する第１のかしめ片６１および第２のかしめ片６２を各々２つずつ備えている点が、上記の第１実施形態における接続用端子１と異なっている。なお、両かしめ片６１、６２は各々１つであってもよい。第１および第２のかしめ片６１、６２は前記長手方向Ｘに沿って、所定間隔に離間して設けられており、第１のかしめ片６１の方が電線５の端部側（コネクタ部２に近い側）に配置されている。本変形例でも、接続用端子１は、電線５と異なる材質であるため、既に述べた様に電線５との電蝕を回避するための表面処理（錫めっき処理）がなされている。 FIG. 8 is an exploded perspective view of the modified example of the connecting terminal 1 before the electric wire 5 is attached, and FIG. 9 is a perspective view of the modified example after the electric wire 5 is attached. In this modification, the connection terminal 1A includes two first caulking pieces 61 and two second caulking pieces 62 corresponding to the caulking pieces 6 described above. It is different from the terminal 1 for use. In addition, each of the two caulking pieces 61 and 62 may be one. The first and second caulking pieces 61 and 62 are provided at predetermined intervals along the longitudinal direction X, and the first caulking piece 61 is on the end side of the electric wire 5 (connector portion 2). It is arranged on the side close to). Also in this modified example, since the connection terminal 1 is made of a material different from that of the electric wire 5, the surface treatment (tin plating treatment) for avoiding electric corrosion with the electric wire 5 is performed as described above.

ここで本変形例では、第１のかしめ片６１、６１は、電線５を抱持するようにかしめられて電線５を外力が加わった応力下で保持し、第２のかしめ片６２、６２は、かしめられて電線５を外力が加わらない無応力下で覆っている。電線５は、より詳しくは、電線接続部３上の接続面３ｂに接触して半田付けされ、かつ、かしめられた２つの第２のかしめ片６２に囲まれた状態で、第２のかしめ片６２に半田付けされて保持される。すなわち、この変形例では、第１のかしめ片６１、６１による第１の外力が加わった応力下で、電線接続用端子１と電線５とが電気的に接合されているとともに、かしめられた２つの第２のかしめ片６２に囲まれた状態でかつ第２のかしめ片６２、６２による無応力下で、接続面３ｂにおいて電線接続用端子１に電線５が半田付けされて保持され、電線接続用端子１と電線５が機械的に接合されている。 Here, in this modification, the first caulking pieces 61 and 61 are caulked so as to hold the electric wire 5 and hold the electric wire 5 under a stress applied with an external force, and the second caulking pieces 62 and 62 are The electric wire 5 is covered under no stress where no external force is applied. More specifically, the electric wire 5 is in contact with the connecting surface 3b on the electric wire connecting portion 3 and soldered, and is surrounded by the two second caulking pieces 62 that are caulked. 62 is soldered and held. That is, in this modification, the wire connecting terminal 1 and the wire 5 are electrically joined and caulked 2 under the stress applied with the first external force by the first caulking pieces 61, 61. The wire 5 is soldered and held on the wire connection terminal 1 on the connection surface 3b in a state surrounded by the two second caulking pieces 62 and under no stress by the second caulking pieces 62, 62, and the electric wire connection The terminal 1 and the electric wire 5 are mechanically joined.

この端子接続構造では、図９における、電線５の第１のかしめ片６１、６１の部分５１の断面積Ａ１、第２のかしめ片６２、６２の部分５２の断面積Ａ２、第１、第２のかしめ片６１、６１、６２、６２以外の部分５３の断面積Ａ３には、Ａ１＜Ａ２≒Ａ３の関係がある。ここで前述と同様に、半田付けの際には、各芯線のエナメル被膜や酸化被膜等は除去される。以上の構成により、第２のかしめ片６２、６２が主に機械的強度を負担して、第１のかしめ片６１、６１は、機械的な負担がほとんど掛からず、主に電気的接合を負担する。 In this terminal connection structure, the cross-sectional area A1 of the portion 51 of the first caulking pieces 61 and 61 of the electric wire 5 and the cross-sectional area A2 of the portion 52 of the second caulking pieces 62 and 62 in FIG. The cross-sectional area A3 of the portion 53 other than the caulking pieces 61, 61, 62, 62 has a relationship of A1 <A2≈A3. Here, in the same manner as described above, the enamel film and the oxide film of each core wire are removed during soldering. With the above configuration, the second caulking pieces 62 and 62 mainly bear the mechanical strength, and the first caulking pieces 61 and 61 hardly bear the mechanical burden and mainly bear the electrical connection. To do.

本変形例では、電線接続用端子１と電線５が異なる材質であっても、簡単な構造で、電蝕発生を回避しながら、工程数の増加を回避して、電線５と電線接続用端子１を機械的に強固に接合するとともに、電気的に安定した状態で接合することができる。なお本変形例では、半田付け部分７に相当する部分は第２のかしめ片６２、６２周りであるが、筒状部材１０で囲まれる部分は、第２のかしめ片６２、６２周りに第１のかしめ片６１、６１周りが含まれることが好ましく、概略的には電線接続部３全体であることが好ましい。 In this modification, even if the wire connection terminal 1 and the wire 5 are made of different materials, the structure is simple and avoids the occurrence of galvanic corrosion while avoiding an increase in the number of processes, and the wire 5 and the wire connection terminal. 1 can be bonded mechanically firmly and in an electrically stable state. In this modification, the portion corresponding to the soldering portion 7 is around the second caulking pieces 62 and 62, but the portion surrounded by the tubular member 10 is the first caulking piece 62 and 62 around the first caulking pieces 62 and 62. It is preferable that the caulking pieces 61 and 61 are included, and it is generally preferable that the entire wire connecting portion 3 is included.

本発明は、以上の実施形態に限定されるものではなく、本発明の要旨を逸脱しない範囲内で、種々の追加、変更または削除が可能である。したがって、そのようなものも本発明の範囲内に含まれる。例えば、上記各実施形態では、電線にアルミニウムまたはアルミニウム合金を使用したが、電線として、高周波電流時の近接効果軽減のためにアルミ撚り線や銅撚り線に強磁性薄膜層等が被膜された磁性めっき線（ＦＰＷ）や、軽量で引っ張り強度および折り曲げ強度等が向上した銅クラッドアルミ線（ＣＣＡＷ）を使用することもできる。こうした構成も本発明の範囲内に含まれる。 The present invention is not limited to the above-described embodiments, and various additions, modifications, or deletions are possible within the scope not departing from the gist of the present invention. Therefore, such a thing is also included in the scope of the present invention. For example, in each of the above embodiments, aluminum or an aluminum alloy is used for the electric wire. However, as the electric wire, a magnetic film in which a ferromagnetic thin film layer or the like is coated on an aluminum stranded wire or a copper stranded wire to reduce the proximity effect at the time of high-frequency current. It is also possible to use a plated wire (FPW) or a copper clad aluminum wire (CCAW) that is lightweight and has improved tensile strength and bending strength. Such a configuration is also included in the scope of the present invention.

１：接続用端子
２：コネクタ部
３：電線接続部
５：電線
５ａ：絶縁被覆端部
５ｂ：隣接部分
５ｃ：被覆除去部分
５ｄ：絶縁被覆
７：半田付け部分
１０：筒状部材
２０，２０Ａ：熱収縮チューブ
３０：積層部
４０：封止部
８０：樹脂
８１：第１の樹脂部分
８２：第２の樹脂部分 1: Connection terminal 2: Connector portion 3: Wire connection portion 5: Electric wire 5a: Insulation coating end 5b: Adjacent portion 5c: Cover removal portion 5d: Insulation coating 7: Soldering portion 10: Cylindrical members 20, 20A: Heat-shrinkable tube 30: laminated portion 40: sealing portion 80: resin 81: first resin portion 82: second resin portion

Claims

It is a structure for electrically connecting an end of an electric wire formed by bundling a plurality of core wires having an insulating coating to an external conductor,
A connector portion attached to the conductor, and a connection terminal having a wire connection portion to which a portion of the end portion of the electric wire from which the insulating coating has been removed is connected by soldering,
On the outer periphery of the soldered soldered portion, or on the outer periphery of the soldered portion and the insulating coating portion of the electric wire adjacent to the soldered portion, a heat-resistant tubular member, which shrinks due to heat, A heat shrinkable tube that covers the outer periphery of the tubular member, and a laminated portion having a resin filled inside the tubular member;
Furthermore, the outer periphery of the insulating coating portion of the electric wire adjacent to the laminated portion is covered with the heat-shrinkable tube that is shrunk by heat, so that the insulating coating of the electric wire adjacent to the heat-shrinkable tube and the laminated portion is contracted. A sealing part for sealing between the parts was provided,
Terminal connection structure at the end of the wire.

It is the terminal connection structure of the electric wire end part according to claim 1,
The resin in the laminated portion has a first resin portion closer to the sealing portion and a second resin portion of the other portion with respect to the longitudinal direction of the connection terminal.
Terminal connection structure at the end of the wire.

It is a terminal connection structure of the electric wire end part according to claim 1 or 2,
Between the core wires present inside the insulating coating end of the electric wire, the resin is included,
Terminal connection structure at the end of the wire.

A structure in which an end portion of an electric wire having an insulating coating and a plurality of core wires bundled together is electrically connected to an external conductor, and a connector portion attached to the conductor and the insulating coating on the end portion of the electric wire A method of manufacturing a structure including a connection terminal having a wire connection portion to which the removed portion is connected by soldering,
A small terminal position setting step for positioning the connection terminal to which the electric wire is attached at a predetermined position inside the cylindrical member, and a cylindrical member insertion for inserting the cylindrical member to a predetermined depth inside the heat shrinkable tube A first step including a small step;
The heat-shrinkable tube is heated, the heat-shrinkable tube around the tubular member is shrunk, and the contracted heat-shrinkable tube and the tubular member are in close contact with each other, and an opening is formed in the tubular member. And forming a gap portion inside the cylindrical member connected to the opening and containing at least the soldered soldered portion, and shrinking the heat shrinkable tube around the insulating coating of the wire, A second step of forming a sealed portion in which a space between the contracted heat-shrinkable tube and the insulating coating of the electric wire facing the tube is sealed;
A third step of injecting and curing a liquid resin from the opening into the gap,
The manufacturing method of the terminal connection structure of the electric wire edge part which has in this order.

It is a manufacturing method of the terminal connection structure of the electric wire end part according to claim 4,
In the third step, an initial injection small step of injecting a part of the amount of the liquid resin to be injected into the gap portion from the opening portion and curing, followed by the subsequent step from the opening portion into the gap portion. And a main injection small process for injecting and curing the remaining amount of liquid resin,
A method for manufacturing a terminal connection structure at an end of an electric wire.