Terminal crimping structure and terminal crimping method onto aluminum electric-wire and producing method of alminum electric-wire with terminal

• US 20050026515A1
• Filed: 07/01/2004
• Published: 02/03/2005
• Est. Priority Date: 07/30/2003
• Status: Active Grant

• Current Assignee: Furukawa Electric Company Limited
• Original Assignee: Furukawa Electric Company Limited
• Inventors: Kaneko, Shuhei, Hashimoto, Toshiyuki
• Granted Patent: US 7,306,495 B2
• Time in Patent Office: Days
• US Class Current: 439/877
• CPC Class Codes: H01R 4/185 combined with a U-shaped insulation-receiving portion
• CPC Class Codes: H01R 43/0488 with crimp height adjusting means

Abstract

A terminal crimping structure onto aluminum electric-wire, for crimping a terminal onto an aluminum electric-wire including: an electrical conductor part comprising numerous strands; and a coating part coated on the . electrical conductor part; wherein the terminal has a wire barrel to be crimped onto the electrical conductor part of the aluminum electric-wire; and wherein the compressed ratio of the aluminum electric-wire'"'"'s conductor part by the wire barrel is within a range of 50 to 70%, in terms of the ratio of (cross-sectional area of aluminum electric-wire'"'"'s conductor part at crimped portion)/(cross-sectional area of aluminum electric-wire'"'"'s conductor part before crimping).

Claims

1. A terminal crimping structure onto aluminum electric-wire, for crimping a terminal onto an aluminum electric-wire including:

an electrical conductor part comprising numerous strands; and

a coating part coated on the electrical conductor part;

wherein said terminal has a wire barrel to be crimped onto said electrical conductor part of said aluminum electric-wire; and

wherein the compressed ratio of said aluminum electric-wire'"'"'s conductor part by said wire barrel is within a range of 50 to 70%, in terms of the ratio of (cross-sectional area of aluminum electric-wire'"'"'s conductor part at crimped portion)/(cross-sectional area of aluminum electric-wire'"'"'s conductor part before crimping).

2. A terminal crimping structure onto aluminum electric-wire, for crimping a terminal onto an aluminum electric-wire including:

an electrical conductor part comprising numerous strands; and

a coating part coated on the electrical conductor part;

wherein said terminal has a wire barrel to be crimped onto said electrical conductor part of said aluminum electric-wire; and

wherein the cross-sectional area of said aluminum electric-wire'"'"'s conductor part to be crimped is 1.5 mm² or more, and the compressed ratio of said aluminum electric-wire'"'"'s conductor part by said wire barrel is within a range of 40 to 70%, in terms of the ratio of (cross-sectional area of aluminum electric-wire'"'"'s conductor part at crimped portion)/(cross-sectional area of aluminum electric-wire'"'"'s conductor part before crimping).

3. A terminal crimping structure onto aluminum electric-wire, for crimping a terminal onto an aluminum electric-wire including:

an electrical conductor part comprising numerous strands; and

a coating part coated on the electrical conductor part;

wherein said terminal has a wire barrel to be crimped onto said electrical conductor part of said aluminum electric-wire; and

wherein the cross-sectional area of said aluminum electric-wire'"'"'s conductor part to be crimped is 1.5 mm² or more, and the compressed ratio of said aluminum electric-wire'"'"'s conductor part by said wire barrel has an upper limit value of 70% in terms of the ratio of the (cross-sectional area of aluminum electric-wire'"'"'s conductor part at crimped portion)/(cross-sectional area of aluminum electric-wire'"'"'s conductor part before crimping), and a lower limit value where the terminal crimping strength becomes 100 N.

4. A terminal crimping method onto aluminum electric-wire, for crimping a terminal onto an aluminum electric-wire including:

an electrical conductor part comprising numerous strands; and

a coating part coated on the electrical conductor part;

wherein the method comprises the steps of;

preparing the aluminum electric-wire;

preparing the terminal having a wire barrel to be crimped onto the electrical conductor part of the aluminum electric-wire; and

crimping the terminal onto the aluminum electric-wire such that the compressed ratio of said aluminum electric-wire'"'"'s conductor part by the wire barrel falls within a range of 50 to 70%, in terms of the ratio of (cross-sectional area of aluminum electric-wire'"'"'s conductor part at crimped portion)/(cross-sectional area of aluminum electric-wire'"'"'s conductor part before crimping).

5. A terminal crimping method onto aluminum electric-wire, for crimping a terminal onto an aluminum electric-wire including:

an electrical conductor part comprising numerous strands; and

a coating part coated on the electrical conductor part;

wherein the method comprises the steps of;

preparing the aluminum electric-wire in which the electrical conductor part to be crimped has a cross-sectional area of 1.5 mm² or more, and preparing the terminal having a wire barrel to be crimped onto the electrical conductor part of the aluminum electric-wire; and

crimping the terminal onto the aluminum electric-wire such that the compressed ratio of said aluminum electric-wire'"'"'s conductor part by the wire barrel falls within a range of 40 to 70%, in terms of the ratio of (cross-sectional area of aluminum electric-wire'"'"'s conductor part at crimped portion)/(cross-sectional area of aluminum electric-wire'"'"'s conductor part before crimping).

6. A terminal crimping method onto aluminum electric-wire, for crimping a terminal onto an aluminum electric-wire including:

an electrical conductor part comprising numerous strands; and

a coating part coated on the electrical conductor part;

wherein the method comprises the steps of;

preparing the aluminum electric-wire in which the electrical conductor part to be crimped has a cross-sectional area of 1.5 mm² or more, and preparing the terminal having a wire barrel to be crimped onto the electrical conductor part of the aluminum electric-wire; and

crimping the terminal onto the aluminum electric-wire such that the compressed ratio of the aluminum electric-wire'"'"'s conductor part by the wire barrel has an upper limit value of 70% in terms of the ratio of the (cross-sectional area of aluminum electric-wire'"'"'s conductor part at crimped portion)/(cross-sectional area of aluminum electric-wire'"'"'s conductor part before crimping), and a lower limit value where the terminal crimping strength becomes 100 N.

7. A producing method of aluminum electric-wire with terminal, for crimping a terminal onto an aluminum electric-wire including:

an electrical conductor part comprising numerous strands; and

a coating part coated on the electrical conductor part;

to thereby produce the aluminum electric-wire with terminal,

wherein the method comprises the steps of;

preparing the aluminum electric-wire, and preparing the terminal having a wire barrel to be crimped onto the electrical conductor part of the aluminum electric-wire; and

crimping the terminal onto the aluminum electric-wire such that the compressed ratio of said aluminum electric-wire'"'"'s conductor part by the wire barrel falls within a range of 50 to 70%, in terms of the ratio of (cross-sectional area of aluminum electric-wire'"'"'s conductor part at crimped portion)/(cross-sectional area of aluminum electric-wire'"'"'s conductor part before crimping), to thereby produce the aluminum electric-wire with terminal.

8. A producing method of aluminum electric-wire with terminal, for crimping a terminal onto an aluminum electric-wire including:

an electrical conductor part comprising numerous strands; and

a coating part coated on the electrical conductor part;

to thereby produce the aluminum electric-wire with terminal,

wherein the method comprises the steps of;

preparing the aluminum electric-wire in which the electrical conductor part to be crimped has a cross-sectional area of 1.5 mm² or more, and preparing the terminal having a wire barrel to be crimped onto the electrical conductor part of the aluminum electric-wire; and

crimping the terminal onto the aluminum electric-wire such that the compressed ratio of said aluminum electric-wire'"'"'s conductor part by the wire barrel falls within a range of 40 to 70%, in terms of the ratio of (cross-sectional area of aluminum electric-wire'"'"'s conductor part at crimped portion)/(cross-sectional area of aluminum electric-wire'"'"'s conductor part before crimping), to thereby produce the aluminum electric-wire with terminal.

9. A producing method of aluminum electric-wire with terminal, for crimping a terminal onto an aluminum electric-wire including:

an electrical conductor part comprising numerous strands; and

a coating part coated on the electrical conductor part;

to thereby produce the aluminum electric-wire with terminal,

wherein the method comprises the steps of;

preparing the aluminum electric-wire in which the electrical conductor part to be crimped has a cross-sectional area of 1.5 mm² or more, and preparing the terminal having a wire barrel to be crimped onto the electrical conductor part of the aluminum electric-wire; and

crimping the terminal onto the aluminum electric-wire such that the compressed ratio of the aluminum electric-wire'"'"'s conductor part by the wire barrel has an upper limit value of 70% in terms of the ratio of the (cross-sectional area of aluminum electric-wire'"'"'s conductor part at crimped portion)/(cross-sectional area of aluminum electric-wire'"'"'s conductor part before crimping), and a lower limit value where the terminal crimping strength becomes 100 N, to thereby produce the aluminum electric-wire with terminal.

10. A terminal crimping structure onto aluminum electric-wire, for crimping a terminal comprising:

an aluminum-electric-wire'"'"'s coating part crimping insulation barrel;

as well as an aluminum-electric-wire conducting crimp barrel and an aluminum-electric-wire retaining crimp barrel;

onto an aluminum electric-wire;

wherein said aluminum-electric-wire conducting crimp barrel and said aluminum-electric-wire retaining crimp barrel are formed integrally with each other as a wire barrel, the region of said wire barrel having a smaller height corresponds to said aluminum-electric-wire conducting crimp barrel and the region of said wire barrel having a larger height corresponds to said aluminum-electric-wire retaining crimp barrel, when viewed in the terminal crimping direction in the state where said terminal is crimped.

11. The terminal crimping structure onto aluminum electric-wire of claim 10,

wherein, after said terminal is crimped, the compressed ratio of the aluminum electric-wire'"'"'s conductor part in the region of said wire barrel having the smaller height is within a range of 50 to 70%, in terms of the ratio of (cross-sectional area of aluminum electric-wire'"'"'s conductor part at crimped portion)/(cross-sectional area of aluminum electric-wire'"'"'s conductor part before crimping).

12. The terminal crimping structure onto aluminum electric-wire of claim 10,

wherein the cross-sectional area of the aluminum electric-wire'"'"'s conductor part to be crimped with said aluminum-electric-wire conducting crimp barrel is 1.5 mm² or more, and, after said terminal is crimped, the compressed ratio of the aluminum electric-wire'"'"'s conductor part in the region of said wire barrel having the smaller height is within a range of 40 to 70%, in terms of the ratio of (cross-sectional area of aluminum electric-wire'"'"'s conductor part at crimped portion)/(cross-sectional area of aluminum electric-wire'"'"'s conductor part before crimping).

13. The terminal crimping structure onto aluminum electric-wire of claim 10,

wherein the cross-sectional area of the aluminum electric-wire'"'"'s conductor part to be crimped with said aluminum-electric-wire conducting crimp barrel is 1.5 mm² or more, and, after said terminal is crimped, the compressed ratio of the aluminum electric-wire'"'"'s conductor part in the region of said wire barrel having the smaller height has an upper limit value of 70% in terms of the ratio of the (cross-sectional area of aluminum electric-wire'"'"'s conductor part at crimped portion)/(cross-sectional area of aluminum electric-wire'"'"'s conductor part before crimping), and a lower limit value where the terminal crimping strength becomes 100 N.

14. A terminal crimping structure onto aluminum electric-wire, for crimping a terminal comprising:

an aluminum-electric-wire'"'"'s coating part crimping insulation barrel;

as well as an aluminum-electric-wire conducting crimp barrel and an aluminum-electric-wire retaining crimp barrel;

onto an aluminum electric-wire;

wherein said aluminum-electric-wire retaining crimp barrel is formed at a position neighboring to said insulation barrel, said aluminum-electric-wire conducting crimp barrel is formed at a side opposite to said insulation barrel with respect to said aluminum-electric-wire retaining crimp barrel, and said aluminum-electric-wire conducting crimp barrel is crimped onto said aluminum electric-wire at a height lower than that of said aluminum-electric-wire retaining crimp barrel when viewed in the terminal crimping direction in a state where both of said crimp barrels are crimped onto said aluminum electric-wire.

15. The terminal crimping structure onto aluminum electric-wire of claim 14,

wherein there is formed a slit between said aluminum-electric-wire conducting crimp barrel and said aluminum-electric-wire retaining crimp barrel.

16. A terminal crimping structure onto aluminum electric-wire, for crimping a terminal comprising:

an aluminum-electric-wire'"'"'s coating part crimping insulation barrel; and

an electrical-conductor crimping barrel having different front and rear heights;

onto an aluminum electric-wire;

wherein said aluminum electric-wire'"'"'s conductor crimping barrel is formed at a position neighboring to said insulation barrel; and

said electrical-conductor crimping barrel has an oblique structure having a height increased in a direction departing from said insulation barrel, before said terminal is crimped, so that the portion having the smaller barrel height is crimped onto said aluminum electric-wire at a smaller biting depth and the portion having the larger barrel height is crimped onto said aluminum electric-wire at a larger biting depth, and so that said electrical-conductor crimping barrel is brought to have a contacting extent with wire-elements constituting said aluminum electric-wire and the wire-elements have a compressed ratio, in which both of the contacting extent and the compressed ratio are varied in the terminal-wise longitudinal direction relative to said aluminum electric-wire.

17. A producing method of aluminum electric-wire with terminal, for crimping a terminal comprising:

an aluminum-electric-wire'"'"'s coating part crimping insulation barrel;

as well as an aluminum-electric-wire conducting crimp barrel and an aluminum-electric-wire retaining crimp barrel;

onto an aluminum electric-wire;

wherein said method comprises the step of;

crimping said aluminum-electric-wire conducting crimp barrel onto said aluminum electric-wire at a height lower than that of said aluminum-electric-wire retaining crimp barrel when viewed in the terminal crimping direction in a state where said aluminum-electric-wire conducting crimp barrel and said aluminum-electric-wire retaining crimp barrel are crimped onto said aluminum electric-wire, thereby producing said aluminum electric-wire crimped with said terminal.

18. A producing method of aluminum electric-wire with terminal, for crimping a terminal comprising:

an aluminum-electric-wire'"'"'s coating part crimping insulation barrel; and

an electrical-conductor crimping barrel having different front and rear heights;

onto an aluminum electric-wire;

wherein said method comprises the step of;

using said terminal, in which said aluminum electric-wire'"'"'s conductor crimping barrel is formed at a position neighboring to said insulation barrel, and in which said electrical-conductor crimping barrel has an oblique structure having a height increased in a terminal direction departing from said insulation barrel, before said terminal is crimped; and

crimping said terminal onto said aluminum electric-wire, such that the portion having the smaller barrel height is crimped onto said aluminum electric-wire at a smaller biting depth and the portion having the larger barrel height is crimped onto said aluminum electric-wire at a larger biting depth, and such that said electrical-conductor crimping barrel is brought to have a contacting extent with wire-elements constituting said aluminum electric-wire and the wire-elements have a compressed ratio, in which both of the contacting extent and the compressed ratio are varied in the terminal-wise longitudinal direction relative to said aluminum electric-wire;

thereby producing the aluminum electric-wire crimped with said terminal.