JP2018116919A - Flat wire connecting structure, flat wire connecting method and flat wire forming jig - Google Patents

Abstract

Provided are a flat conductor connecting structure, a flat conductor connecting method, and a flat conductor forming jig capable of suppressing an increase in contact resistance. A connecting structure for a rectangular conducting wire includes a connecting member having a cylindrical portion and a plate-like first rectangular conducting wire, and the first rectangular conducting wire follows the shape of the inner peripheral surface of the cylindrical portion. It has a first tip portion that is curved and accommodated in the hollow portion of the cylindrical portion, the central axis of the outer peripheral surface of the first tip portion is parallel to the longitudinal direction of the first flat wire, and the first tip portion is The outer peripheral surface of the first tip portion is crimped to the cylindrical portion in a state where the outer peripheral surface is in contact with the inner peripheral surface of the cylindrical portion. [Selection] Figure 1

Description

  The present invention relates to a connecting structure for a flat conducting wire, a connecting method for a flat conducting wire, and a forming jig for the flat conducting wire.

  As a method of connecting the flat conductive wires to the terminals or connecting the flat conductive wires to each other, a connection method by pressure bonding is known. For example, when a flat conducting wire is crimped to a crimp terminal, the tip of the flat conducting wire is inserted into a cylindrical connecting tube portion of the crimp terminal. Next, the connecting pipe portion is partially crushed by the crimping tool, so that the flat conducting wire is sandwiched between the connecting pipe portions and crimped.

  Patent Document 1 discloses another method for connecting a flat wire to a crimp terminal. In the connection method of Patent Document 1, the end portion of the flat conducting wire is bent by a line extending in the longitudinal direction of the flat conducting wire and inserted into the cylindrical connecting pipe portion of the crimp terminal. Next, the entire connecting pipe portion is crushed, whereby the flat conductor wire is connected to the crimp terminal. In this way, by crimping the rectangular conductor in advance, a crimp terminal having an inner diameter of the cylindrical portion smaller than the width of the rectangular conductor can be used.

JP 2004-319157 A

  In the connection method of Patent Document 1, since the end portion of the flat conductor wire is bent in advance, the flat conductor wire and the crimp terminal are in contact with each other only with a dot or a line before the crimp terminal is crushed, and the contact between the two. Resistance is great. Moreover, in the connection method of patent document 1, since it is necessary to crush the whole connection pipe part, the crimping tool which crushes a connection pipe part partially cannot be used. If a crimping tool is used in the connection method of Patent Document 1, the connecting pipe portion is only partially crushed, so that it is difficult to contact the flat wire and the crimping terminal over a large area, and the contact resistance may increase. was there.

  The present invention has been made in view of the above circumstances, and an object thereof is to provide a flat wire connecting structure, a flat wire connecting method, and a flat wire forming jig capable of suppressing an increase in contact resistance. That is.

  The connection structure of the flat conducting wire according to an embodiment of the present invention includes a connecting member having a cylindrical portion and a plate-like first flat conducting wire, and the first flat conducting wire is provided on the inner peripheral surface of the cylindrical portion. Curved along the shape and having a first tip portion accommodated in the hollow portion of the cylindrical portion, the central axis of the outer peripheral surface of the first tip portion is parallel to the longitudinal direction of the first rectangular conducting wire, The 1 tip portion is pressure-bonded to the cylindrical portion in a state where the outer peripheral surface of the first tip portion is in contact with the inner peripheral surface of the cylindrical portion.

  According to such a structure, since the front-end | tip part of a 1st flat conducting wire is curving in the shape along the internal peripheral surface of a connection member, a 1st curved part and a connection member can be surface-contacted easily, both It is prevented that the contact resistance increases.

  The connecting method of the flat conducting wire which concerns on one Embodiment of this invention is a connecting method of the connecting member which has a flat conducting wire and a cylindrical part, Comprising: The 1st front-end | tip part of a plate-shaped 1st flat conducting wire is connected to the flat conducting wire. A bending step of bending the cylindrical portion into a shape along the inner peripheral surface of the cylindrical portion with the longitudinal direction as the central axis; a flat lead wire inserting step of inserting the curved first tip portion into the hollow portion of the cylindrical portion; A crimping step of crimping the first tip portion and the tubular portion in a state where the outer peripheral surface of the tip portion is in contact with the inner peripheral surface.

  According to such a method, the distal end portion of the first flat conducting wire is curved into a shape along the inner peripheral surface of the cylindrical portion, so that the first flat conducting wire and the connecting member can be in surface contact easily. It is prevented that both contact resistances increase.

  A flat wire forming jig according to an embodiment of the present invention is a forming jig for forming a front end portion of a flat wire into a shape suitable for crimping connection using a connecting member having a cylindrical portion. And a sandwiching portion that sandwiches the tip of the flat conducting wire between the die portion, the die portion has a flat surface, and the flat surface comes into contact with the tip of the flat conducting wire to A support part to be supported, and a molding part having a molding surface formed by recessing a part of the support part, and the sandwiching part uses the tip portion of the flat wire supported by the support part as a molding surface. The pressing surface has a pressing portion, and the molding surface has a shape along the inner peripheral surface of the cylindrical portion.

  According to such a structure, when the front-end | tip part of a flat conducting wire is pressed on a shaping | molding surface, it will curve to the shape along the internal peripheral surface of a cylindrical part. Therefore, the flat conductor and the connecting member can be easily brought into surface contact, and the contact resistance between the two is prevented from increasing.

  ADVANTAGE OF THE INVENTION According to this invention, the connection structure of the flat conducting wire which can suppress the increase in contact resistance, the connecting method of a flat conducting wire, and the shaping | molding jig of a flat conducting wire are provided.

FIG. 1 is a view showing a process of connecting two rectangular conductors and one round wire according to an embodiment of the present invention. FIG. 2 is a diagram showing a process of forming a flat conductor using the forming jig according to the embodiment of the present invention. FIG. 3 is a view showing a process of forming a flat conductor using the forming jig according to the embodiment of the present invention. FIG. 4 is a diagram showing a process of crimping two flat conductor wires and a round wire to a sleeve using the crimping tool according to the embodiment of the present invention. FIG. 5 is a view showing a connection structure between a flat wire and a crimp terminal according to a modification of the embodiment of the present invention.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. The embodiment described below is an example in which the present invention is applied to a crimping connection between two flat conductive wires 10 and 20 and one cylindrical conductive wire (round wire) 30.

  FIG. 1 is a view showing a process of connecting two flat conductors 10 and 20 and one round wire 30. Two rectangular conductors 10 and 20 and one round wire 30 are crimped together with a cylindrical sleeve 40 which is a connecting member.

  Fig.1 (a) shows the state before each member is connected. The sleeve 40 has a cylindrical shape in a state before the two rectangular conductive wires 10 and 20 and one round wire 30 are connected. The sleeve 40 is formed of a material that can be deformed by applying an external force. The material used for the sleeve 40 is, for example, a metal material such as copper or aluminum.

  The flat conducting wires 10 and 20 have a long thin plate shape. Each of the rectangular conductive wires 10 and 20 is formed of a conductive metal material such as copper or aluminum. The round wire 30 is formed of a conductive metal material such as copper or aluminum, and the periphery thereof is covered with an insulating material (for example, a resin material). The round wire 30 may be a single conducting wire or a stranded wire in which a plurality of thin conducting wires are twisted.

  The width of the flat conducting wire 10 and the width of the flat conducting wire 20 are larger than the inner diameter of the sleeve 40. Therefore, the rectangular conducting wires 10 and 20 cannot be inserted into the sleeve 40 as they are. In the present embodiment, the rectangular conductive wires 10 and 20 are molded so as to be insertable into the sleeve 40 as shown in FIG. It should be noted that the present invention can also be applied to the connection of a flat wire having a width smaller than the inner diameter of the sleeve 40.

  In the following description, the longitudinal direction of the flat conducting wires 10 and 20 is defined as the Z-axis direction, the thickness direction of the flat conducting wires 10 and 20 is defined as the X-axis direction, and the width direction of the flat conducting wires 10 and 20 is defined as the Y-axis direction. The X axis, Y axis, and Z axis are orthogonal to each other.

  FIG. 2 is a diagram showing a process of forming the flat conducting wires 10 and 20 using the forming jig 100. FIG. 2A shows a state before the flat conducting wires 10 and 20 are molded. FIG. 2B shows a state in which the flat conducting wires 10 and 20 are formed. FIG.2 (c) shows the state after the flat conducting wires 10 and 20 are shape-processed.

  FIG. 3 is a cross-sectional view illustrating a process of forming the flat conducting wires 10 and 20 using the forming jig 100. FIG. 3A shows a state before the flat conducting wires 10 and 20 are molded. FIG. 3B shows a state in which the flat conducting wires 10 and 20 are molded. FIG.3 (c) shows the state after the flat conducting wires 10 and 20 are shape-processed.

  The forming jig 100 includes a mold part 50 and a sandwiching part 60 that sandwiches the flat conducting wires 10 and 20 between the mold part 50. A groove 51 is formed on the upper surface side of the mold portion 50 in a substantially rectangular shape in plan view and parallel to the Z-axis direction. The width of the groove 51 in the Y-axis direction is larger than the width of the flat conductors 10 and 20, and the depth of the groove 51 in the X-axis direction is substantially the same as the sum of the thicknesses of the two flat conductors 10 and 20. Therefore, the end portion 11 of the flat conducting wire 10 and the end portion 21 of the flat conducting wire 20 can be fitted into the groove 51. Further, one end of the groove 51 in the Z-axis direction is closed by a wall 57, and the other end 52 is not closed. Therefore, when the end portions 11 and 21 of the flat conducting wires 10 and 20 are fitted into the grooves 51, portions other than the end portions 11 and 21 of the flat conducting wires 10 and 20 pass through the other end 52 of the groove 51 in the Z-axis direction. It protrudes outside the groove 51. Note that the length of the groove 51 in the Z-axis direction is larger than the length of the sleeve 40 in the Z-axis direction.

  A support portion 56 having a flat surface is formed on the bottom surface of the groove 51. When the flat conducting wires 10 and 20 are fitted in the grooves 51, the flat conducting wires 10 and 20 are supported by the support portion 56. Part of the support portion 56 is provided with a molding portion 55 formed by denting the support portion 56. The concave curved molding surface 54 of the molding part 55 is a circumferential surface having substantially the same curvature as the inner circumferential surface 41 (see FIG. 1) of the sleeve 40. The central axis of the molding surface 54 of the molding part 55 is parallel to the Z axis. The length of the molding portion 55 in the Z-axis direction is the same as the length of the groove 51. The width of the molding portion 55 in the Y-axis direction is smaller than the widths of the flat conducting wires 10 and 20 and the width of the groove 51 in the Y-axis direction. Moreover, the shaping | molding part 55 is formed near the center in the Y-axis direction of the support part 56 formed in two places in the Y-axis direction. Therefore, when the flat conducting wires 10 and 20 are fitted into the grooves 51, the flat conducting wires 10 and 20 are supported by the support portion 56 and do not enter the molding portion 55.

  Further, the peripheral edge portion 55A of the molding portion 55 is chamfered with a curved surface. Therefore, when the flat conducting wires 10 and 20 are placed in the groove 51, the flat conducting wires 10 and 20 are prevented from being damaged by coming into contact with the peripheral portion 55A. Further, when the end portions 11 and 21 of the flat conducting wires 10 and 20 are molded, strain concentrated on the end portion (near the peripheral portion 55A) of the forming portion is alleviated, and the flat conducting wires 10 and 20 may be cracked. Is prevented.

  The wall 57 of the mold part 50 is an example of an abutting part of the present invention. The side wall 58 is an example of the contact portion of the present invention. When forming the flat conducting wires 10 and 20, the flat conducting wires 10 and 20 are stacked in the X-axis direction and supported by the support portion 56, the side end 12 of the flat conducting wire 10 in the Z-axis direction, and the Z of the flat conducting wire 20. The side end 22 in the axial direction is abutted against the other wall 57 of the groove 51 in the Z-axis direction. Thereby, the flat conducting wires 10 and 20 are positioned in the Z-axis direction. Further, the side ends 13 and 23 of the flat conductors 10 and 20 in the Y-axis direction abut against the side wall 58 of the groove 51 in the Y-axis direction, so that the movement of the flat conductors 10 and 20 in the Y-axis direction is restricted.

The clamping part 60 has a pressing part 61 for pressing the flat conductors 10 and 20 into the molding part 55. The pressing part 61 has a pressing surface 62 having a convex curved surface. The pressing surface 62 has a circumferential surface, and the curvature thereof is set based on the curvature of the molding surface 54 and the thickness of the flat conductors 10 and 20. Specifically, when the curvature radius of the molding surface 54 is R50 and the thicknesses of the flat conductors 10 and 20 are T10 and T20, the curvature radius R60 of the circumferential surface of the pressing surface 62 satisfies the following formula 1. Is set.
[Equation 1]
R60 = R50− (T10 + T20)
Further, the length of the pressing surface 62 in the Z-axis direction is the same as the length of the molding portion 55 in the Z-axis direction.

  The sandwiching portion 60 is pressed from the upper side in the X-axis direction against the flat conducting wires 10 and 20 fitted in the groove 51. Since the flat conducting wires 10 and 20 are made of a material that can be deformed by an external force, when the sandwiching portion 60 is pressed against the flat conducting wires 10 and 20, as shown in FIGS. 2B and 3B, The flat conducting wires 10 and 20 are curved in a semi-cylindrical shape. Specifically, the end portion 11 of the flat conducting wire 10 is molded into a shape along the molding surface 54 of the molding portion 55. Further, the end portion 21 of the flat conducting wire 20 is molded into a shape along the concave curved surface 14 of the end portion 11 of the curved flat conducting wire 10. Note that the lengths of the pressing surface 62 and the molding surface 54 in the Z-axis direction are set longer than the length of the sleeve 40. Therefore, the length in the Z-axis direction of the end portions 11 and 21 of the formed flat conducting wires 10 and 20 is also longer than the length of the sleeve 40.

  Further, the curvature of the pressing surface 62 of the pressing portion 61 is set so as to satisfy Formula 1. Therefore, in a state in which the pressing portion 61 is pressed against the flat conducting wires 10 and 20, the forming portion 55 and the flat conducting wire 10, the flat conducting wire 10 and the flat conducting wire 20, and the flat conducting wire 20 and the pressing portion 61 are in contact with each other without a substantial gap.

  When the holding portion 60 is pulled away from the flat conductors 10 and 20, the end portions 11 and 21 of the respective flat conductors 10 and 20 are curved into a semi-cylindrical shape as shown in FIGS. 2 (c) and 3 (c). Held in a state.

  As a result, the convex curved surface of the curved end portion 11 of the flat wire 10 (hereinafter, the curved end portion 11 is also referred to as the curved portion 11) has substantially the same shape as the inner peripheral surface 41 of the sleeve 40, and the flat wire. A convex surface of the 20 curved end portions 21 (hereinafter, the curved end portion 21 is also referred to as the curved portion 21) has an outer peripheral surface shape having substantially the same radius of curvature as the concave curved surface 14 of the curved portion 11 of the flat wire 10; Become.

  The curved portions 11 and 21 of the flat conducting wires 10 and 20 are inserted into the hollow portion of the sleeve 40. FIG. 1C shows a state in which the curved portions 11 and 21 of the flat conducting wires 10 and 20 are inserted into the hollow portion of the sleeve 40. The curved portions 11 and 21 of the flat conducting wires 10 and 20 have a dimension in the Y-axis direction smaller than the inner diameter of the sleeve 40 and can be easily inserted into the hollow portion of the sleeve 40.

  Further, the round wire 30 is inserted into the hollow portion of the sleeve 40. Specifically, the round wire 30 is inserted into the hollow portion of the sleeve 40 so as to face the concave curved surface 24 of the curved portion 21 of the flat conducting wire 20.

  When the ends (curved portions) 11 and 21 and the round wire 30 of the two rectangular conductors 10 and 20 are accommodated in the sleeve 40, a part of the sleeve 40 is crushed by the crimping tool 200, and the rectangular conductors 10 and 20 and the round wire 30 are crimped to the sleeve 40.

  FIG. 4 is a view showing a process of crimping the flat conducting wires 10, 20 and the round wire 30 to the sleeve 40 using the crimping tool 200. FIG. 4A shows a state before the flat conducting wires 10 and 20 and the round wire 30 are crimped. FIG. 4B shows a state where the rectangular conducting wires 10 and 20 and the round wire 30 are crimped.

  The crimping tool 200 includes a receiving mold 70 on which the sleeve 40 is placed and a pressing mold 80 having a protrusion 81. The receiving die 70 has a groove 71 extending in parallel with the Z-axis direction. When the sleeve 40 is disposed in the groove 71, the wall surface of the groove 71 and the outer peripheral surface 42 of the sleeve 40 come into contact with each other, and the movement of the sleeve 40 in the groove 71 is restricted.

  As shown in FIG. 4A, the sleeve 40 is disposed in the groove 71 such that the flat conductive wires 10 and 20 are disposed on the receiving mold 70 side and the round wire 30 is disposed on the push mold 80 side. . In a state before the flat conducting wires 10 and 20 and the round wire 30 are crimped, there is a gap between the conducting wires 10, 20 and 30, and the conducting wires 10, 20 and 30 are not fixed.

  When the pressing die 80 is pressed against the sleeve 40 from the positive side of the X axis, a part of the sleeve 40 is crushed by the protrusion 81 as shown in FIG. When a part of the sleeve 40 is crushed, a crushed portion (opposing portion) 43 of the sleeve 40 protrudes toward the inside of the sleeve 40. The round wire 30 is pressed against the flat conducting wire 20 by the protruding facing portion 43. Further, the flat conducting wire 20 is pressed against the flat conducting wire 10, and the flat conducting wire 10 is pressed against a part (contact portion) 44 of the inner peripheral surface 41 of the sleeve 40. Thereby, the three of the flat conducting wire 10, the flat conducting wire 20, and the round wire 30 are electrically connected. Further, the three conductors 10, 20, 30 are sandwiched and fixed by two portions (opposing portion 43 and contact portion 44) facing each other on the inner peripheral surface 41 of the sleeve 40. As a result, the three conducting wires 10, 20, 30 are pressure-bonded to the sleeve 40.

  FIG. 1 (d) shows a state after the two rectangular conductive wires 10, 20 and one round wire 30 are pressed onto the sleeve 40. As shown in FIG. 1D, the sleeve 40 is partially crushed in the Z-axis direction. Thus, by using the crimping tool 200 that crushes a part of the sleeve 40 instead of the entire length, the force required to crush the sleeve 40 is reduced, and the crimping of the conductors 10, 20, 30 to the sleeve 40 is reduced. Becomes easy. In addition, in order to make the crimping | compression-bonding of 10, 20, and 30 of each conducting wire firmer, the sleeve 40 may be crushed over the full length in a Z-axis direction.

  Thus, according to the present embodiment, the end portions 11 and 21 of the flat conducting wires 10 and 20 are bent in advance by the forming jig 100. Therefore, the flat conductors 10 and 20 can be inserted into the sleeve 40 having an inner diameter smaller than the width of the flat conductors 10 and 20, and the connecting portion of the flat conductors 10 and 20 can be downsized. In addition, as the width of the flat conductors 10 and 20 increases, the dimension of the end parts 11 and 21 in the Y-axis direction changes before and after the end parts 11 and 21 of the flat conductors 10 and 20 are bent. Becomes larger. Therefore, the effect that the connecting portion can be reduced in size by bending the end portions 11 and 21 becomes more prominent as the widths of the flat conductors 10 and 20 are larger.

  Further, the end 11 of the flat conducting wire 10 is curved in advance along the inner peripheral surface 41 of the sleeve 40. Further, the end portion 21 of the flat conducting wire 20 is previously bent into a shape along the curved end portion (curving portion) 11 of the flat conducting wire 10. Further, the end portions 11 and 21 of the flat conductive wires 10 and 20 are curved over the entire length in the Z-axis direction in the sleeve 40. Therefore, when the flat conducting wires 10 and 20 are pressure-bonded to the sleeve 40, it is not necessary to deform the flat conducting wires 10 and 20, so that the crimping is easy.

  Further, since the end portion 11 of the flat conducting wire 10 is formed into a shape along the inner peripheral surface 41 of the sleeve 40, the flat conducting wire 10 and the sleeve 40 are brought into contact with each other on the surface. Furthermore, since the end portion 21 of the flat conducting wire 20 is formed into a shape along the end portion (curved portion) 11 of the flat conducting wire 10, the flat conducting wire 10 and the flat conducting wire 20 are in contact with each other. Thereby, it can prevent that the contact resistance between the flat conducting wire 10 and the sleeve 40 and the contact resistance between the flat conducting wire 10 and the flat conducting wire 20 become high.

  Further, the wider the width of the flat conductors 10 and 20, the larger the contact area between them, thereby preventing an increase in contact resistance. In the present embodiment, the flat conductors 10 and 20 having a width larger than the inner diameter of the sleeve 40 can be crimped to the sleeve 40 by bending the end portions 11 and 21 of the flat conductors 10 and 20. Therefore, in the present embodiment, the increase in contact resistance can be suppressed by increasing the widths of the two rectangular conductive wires 10 and 20 without increasing the inner diameter of the sleeve 40.

  Further, the lengths of the curved portions 11 and 21 of the flat conducting wires 10 and 20 in the Z-axis direction are longer than the length of the sleeve 40. Therefore, the flat conducting wire 10 and the sleeve 40 and the flat conducting wire 10 and the flat conducting wire 20 can be brought into surface contact over the entire length in the sleeve 40. Thereby, it can prevent more reliably that the contact resistance between the flat conducting wire 10 and the sleeve 40, and the contact resistance between the flat conducting wire 10 and the flat conducting wire 20 become high.

  In addition, when a manufacturing error is included in the dimensions of the forming jig 100, there may occur a case where the shape of the curved portion 11 of the flat wire 10 does not completely match the shape of the inner peripheral surface 41 of the sleeve 40. Further, when the clamping part 60 of the forming jig 100 is pressed against the flat conductors 10 and 20 and then pulled away, the bending parts 11 and 21 of the flat conductors 10 and 20 are elastically deformed, and the bending part 11 of the flat conductor 10 is deformed. There may be a case where the shape does not completely match the inner peripheral surface 41 of the sleeve 40 or a case where the shapes of the curved portion 11 of the flat conducting wire 10 and the curved portion 21 of the flat conducting wire 20 do not completely match. However, even in that case, since the curved portions 11 and 21 of the flat conducting wires 10 and 20 are curved, when the flat conducting wires 10 and 20 are crimped by using the crimping tool 200, the flat conducting wires 10 and 20 are used. The two can be brought into contact with each other over a large area without greatly deforming.

  Moreover, in this embodiment, since the end parts 11 and 21 of the rectangular conducting wires 10 and 20 are curved, the empty space (end part 21) in the hollow part after the end parts 11 and 21 are inserted into the hollow part of the sleeve 40. The area sandwiched between the concave curved surface 24 and the inner peripheral surface 41 of the sleeve 40 can be increased. Thereby, the round wire 30 can be easily inserted into the hollow portion of the sleeve 40. Moreover, since the empty space in the hollow part after insertion of the round wire 30 becomes small by inserting the round wire 30 in the hollow part of the cylindrical part 140, it is easy to contact conducting wires. Thereby, it can prevent that the contact resistance between conducting wires increases. Furthermore, since the empty space in the hollow portion is reduced, the deformation amount of the sleeve 40 when the sleeve 40 is crushed by the crimping tool 200 to crimp the conductors 10, 20, and 30 is reduced, and the crimping is facilitated.

  Further, the end portions 11 and 21 of the flat conductors 10 and 20 are curved to increase the empty space in the hollow portion of the sleeve 40 (the region sandwiched between the concave curved surface 24 of the end portion 21 and the inner peripheral surface 41 of the sleeve 40). Accordingly, the round wire 30 having a larger outer diameter can be inserted into the hollow portion. By using the round wire 30 having a large outer diameter, the contact area between the round wire 30 and the flat rectangular wire 20 and the contact area between the round wire 30 and the inner peripheral surface 41 are increased. Fixing by pressure bonding can be further strengthened. Moreover, when the contact area of the round wire 30 and the flat conducting wire 20 becomes large, it can prevent more reliably that the contact resistance between both becomes large.

  The above is the description of the exemplary embodiments of the present invention. Embodiments of the present invention are not limited to those described above, and various modifications are possible within the scope of the technical idea of the present invention. For example, the embodiment of the present invention also includes contents appropriately combined with embodiments or the like clearly shown in the specification or obvious embodiments.

(Modification)
For example, in the above-described embodiment, the two flat conductive wires 10 and 20 are crimped to the sleeve 40, but the embodiment of the present invention is not limited to this configuration. For example, the number of flat conductor wires crimped to the sleeve 40 may be one or three or more. In this case, the radius of curvature of the pressing surface 62 of the pressing portion 61 of the forming jig 100 is changed according to the number and thickness of the rectangular conductive wires.

  Further, in the above-described embodiment, the two flat conductive wires 10 and 20 and the round wire 30 are crimped to the sleeve 40 so that the respective conductive wires 10, 20 and 30 are electrically connected. Is not limited to this configuration. For example, the rectangular conductive wires 10 and 20 may be electrically connected to the crimp terminal instead of the sleeve 40.

  FIG. 5 shows a connection structure when connecting the flat conducting wires 10 and 20 to the crimp terminal 140. The crimp terminal 140 has a cylindrical portion 141 and a terminal portion 142. The cylindrical portion 141 and the terminal portion 142 are integrally formed, and are formed of a conductive metal material such as copper. The end portions 11 and 21 of the flat conducting wires 10 and 20 are inserted into the hollow portion of the cylindrical portion 141 and are crimped. Thereby, the flat conducting wires 10 and 20 are electrically connected to the terminal portion 142 via the cylindrical portion 141. In this case, it is not necessary to insert the round wire 30 in the hollow part of the cylindrical part 141 like the above-mentioned embodiment.

  In the configuration illustrated in FIG. 5, the round wire 30 may be further inserted into the hollow portion of the cylindrical portion 141 before the cylindrical portion 141 is crushed by the crimping tool 200. In this case, in order to prevent the round wire 30 from interfering with the terminal portion 142, the round wire 30 is inserted from the end of the cylindrical portion 141 in the Z-axis direction from the side where the terminal portion 142 is not provided. The The cylindrical portion 141 is crushed by the crimping tool 200 in a state where the two rectangular conductive wires 10 and 20 and the round wire 30 are inserted. Thereby, the three conducting wires 10, 20, 30 are electrically connected to the terminal portion 142 via the cylindrical portion 141. Moreover, since the empty space in a hollow part becomes small by inserting the round wire 30 in the hollow part of the cylindrical part 140, conducting wire becomes easy to contact. Thereby, it can prevent that the contact resistance between conducting wires increases. Furthermore, since the empty space in the hollow part of the cylindrical part 140 becomes small, the amount of deformation of the cylindrical part 140 when the cylindrical part 140 is crushed by the crimping tool 200 to crimp the conducting wires 10, 20, 30 is reduced. Smaller and easier to crimp.

  In the configuration shown in FIG. 5, a spacer member may be further inserted into the hollow portion of the tubular portion 141 before the tubular portion 141 is crushed by the crimping tool 200. The spacer member has a rod shape having a length substantially the same as the length of the cylindrical portion 141 in the Z-axis direction. The spacer member is formed of a conductive metal material such as copper, for example. The spacer member is inserted into the hollow portion of the tubular portion 141 so as to face the concave curved surface 24 of the curved portion 21 of the flat conducting wire 20. Thereby, the deformation amount of the cylindrical part 141 at the time of crimping | bonding the flat conducting wires 10 and 20 to the cylindrical part 141 can be suppressed to the same extent as the case where the round wire 30 is inserted.

  In the above-described embodiment, the two rectangular conductive wires 10 and 20 are inserted into the sleeve 40 from the same side in the Z-axis direction, but the embodiment of the present invention is not limited to this configuration. For example, the two flat conductors 10 and 20 may be inserted into the sleeve 40 from opposite directions.

  In the above-described embodiment, the sleeve 40 has a cylindrical shape, but the embodiment of the present invention is not limited to this configuration. For example, the cross section in the XY plane of the sleeve 40 may be elliptical. In this case, the molding surface 54 of the mold part 50 of the molding jig 100 and the pressing surface 62 of the pressing part 61 are formed in a shape along the inner peripheral surface of the sleeve 40.

  Moreover, in the above-mentioned embodiment, the two flat conducting wires 10 and 20 are stacked and placed on the mold part 50, and two are simultaneously molded, but the embodiment of the present invention is not limited to this configuration. For example, the two flat conductors 10 and 20 may be molded separately. In this case, the shape of the flat conducting wire 10 and the shape of the flat conducting wire 20 may not completely match. However, even in that case, since the end portions 11 and 21 of the flat conductors 10 and 20 are formed to be curved, when the flat conductors 10 and 20 are crimped using the crimping tool 200, the flat conductors 10 and 20 are flat. The conductors 10 and 20 can be brought into contact with each other over a wide area without greatly deforming the conductors 10 and 20.

  Moreover, in the above-mentioned embodiment, although the width | variety of the two flat conducting wires 10 and 20 is larger than the internal diameter of the sleeve 40, embodiment of this invention is not limited to this structure. For example, the width of one or both of the two rectangular conductive wires 10 and 20 may be smaller than the inner diameter of the sleeve 40.

  Further, in the above-described embodiment, in the state before the sleeve 40 is crushed by the crimping tool 200, as shown in FIG. Although 10, 20, and 30 are not fixed, embodiment of this invention is not limited to this structure. For example, the round wire 30 with a large diameter may be used so that a clearance gap may become small between each conducting wire 10,20,30. As a specific configuration example, the outer diameter of the round wire 30 is set to a size that matches the inner diameter of the bending portion 21. Thereby, in a state before the sleeve 40 is crushed, the conductors are easily brought into contact with each other on the surface, and each conductor is prevented from moving in the sleeve 40 due to friction between the conductors. Moreover, by using the round wire 30 with a large diameter, the contact area between the round wire 30 after the crushing of the sleeve 40 and the flat conducting wire 20 is increased, and the contact resistance between them can be suppressed.

  Moreover, in the above-mentioned embodiment, although each conducting wire 10, 20, and 30 is connected to the sleeve 40 only by crimping, embodiment of this invention is not limited to this structure. For example, after each conducting wire 10, 20, 30 is crimped to the sleeve 40, the connection between the conducting wires or the connection between the flat conducting wire 10 and the sleeve 40 may be reinforced by soldering or welding. Thereby, each lead wire 10, 20, and 30 is more firmly fixed, and the increase in contact resistance can be further suppressed.

10 Flat conductor 11 End (curved part)
20 Flat conductor 21 End (curved part)
30 round wire 40 sleeve 50 mold part 60 clamping part 70 receiving mold 80 pressing mold 100 forming jig 200 crimping tool

Claims (19)

It is a connection structure for flat conductors,
A connecting member having a tubular portion;
A plate-shaped first flat conductor,
The first flat conducting wire is curved along the shape of the inner peripheral surface of the cylindrical portion, and has a first tip portion accommodated in the hollow portion of the cylindrical portion,
The central axis of the outer peripheral surface of the first tip is parallel to the longitudinal direction of the first flat wire,
The first tip portion is pressure-bonded to the cylindrical portion in a state where the outer peripheral surface of the first tip portion is in contact with the inner peripheral surface of the cylindrical portion.
Connection structure. The width of the first flat conducting wire is larger than the inner diameter of the cylindrical portion,
The connection structure according to claim 1. The first tip portion is curved along the shape of the inner peripheral surface of the tubular portion over the entire length in the longitudinal direction within the hollow portion of the tubular portion.
The connection structure according to claim 1 or 2. The cylindrical part is
A contact portion in contact with the outer peripheral surface of the first tip portion;
A facing portion facing the contact portion across the first tip portion;
Have
The facing portion protrudes toward the first tip portion.
The connection structure according to any one of claims 1 to 3. Further comprising a second flat conductor,
The second flat wire has a second tip portion inserted on the opposite side of the contact portion with respect to the first flat wire in the hollow portion of the cylindrical portion,
The second tip is crimped to the tubular portion in contact with the first tip of the first flat conducting wire;
The connection structure according to claim 4. The second flat conductive wire is a plate having a width larger than the inner diameter of the cylindrical portion,
The second tip is curved along the inner peripheral surface of the first tip of the first flat conducting wire.
The connection structure according to claim 5. The tip further comprises a conducting wire inserted into the hollow part of the cylindrical part,
The conducting wire is crimped to the cylindrical portion in a state of being in contact with the facing portion.
The connection structure according to any one of claims 4 to 6. A connecting method between a flat conductor and a connecting member having a cylindrical part,
A bending step of bending the first tip portion of the plate-like first flat conducting wire into a shape along the inner peripheral surface of the cylindrical portion with the longitudinal direction of the flat conducting wire as a central axis;
A flat wire insertion step of inserting the curved first tip portion into the hollow portion of the tubular portion;
A crimping step of crimping the first tip portion and the tubular portion in a state where the outer peripheral surface of the first tip portion is in contact with the inner peripheral surface;
including,
Connection method. The crimping process includes
An arrangement step of arranging the cylindrical portion in a receiving mold;
A crushing step of crushing a part of the cylindrical portion arranged in the receiving mold with a pressing mold;
Including
The receiving mold has a groove parallel to the longitudinal direction,
In the arranging step, the cylindrical portion is arranged in the groove,
The pressing die has a protrusion that can be inserted into the groove from a direction orthogonal to the longitudinal direction,
In the crushing step, a part of the cylindrical portion is crushed by the protrusion.
The connection method according to claim 8. The cylindrical part is
A contact portion in contact with the outer peripheral surface of the first tip portion;
A facing portion facing the contact portion across the first tip portion;
Have
In the crushing step, the facing portion is crushed toward the first tip.
The connection method according to claim 8 or 9. A conductor insertion step of inserting the leading end portion of the conducting wire into the hollow portion of the connecting member so as to face the curved inner peripheral surface of the first leading end portion;
The connection method according to any one of claims 8 to 10. A second rectangular conductor inserting step of inserting the second distal end portion of the second rectangular conducting wire into the hollow portion of the connecting member so as to face the inner peripheral surface of the curved first distal end portion;
In the crimping step, the second tip is crimped in contact with the first tip.
The connection method according to any one of claims 8 to 11. The second flat wire has a plate shape,
The bending step includes
Stacking the first tip and the second tip;
The connection method according to claim 12, further comprising a step of bending the first tip portion and the second tip portion in an overlapped state together. A forming jig for forming the tip of the flat conducting wire into a shape suitable for crimping connection using a connecting member having a cylindrical part,
Mold part,
A sandwiching part that sandwiches the tip of the flat conducting wire with the mold part;
Have
The mold part is
A support portion that has a flat surface and supports the flat conducting wire by contacting the flat surface with the tip of the flat conducting wire;
A molded part having a molding surface, formed by recessing a part of the support part;
Have
The clamping part has a pressing part that presses the leading end part of the flat conducting wire supported by the support part toward the molding surface,
The molding surface has a shape along the inner peripheral surface of the cylindrical portion.
Molding jig. The length in the longitudinal direction of the flat conductor of the molded part is longer than the length in the longitudinal direction of the cylindrical part,
The forming jig according to claim 14. The mold part has an abutting part that abuts on a side end in a width direction of a tip part of the flat conducting wire supported by the support part and restricts movement of the flat conducting wire in the width direction.
The forming jig according to claim 14 or 15. The mold portion has an abutting portion against which a side end in the longitudinal direction of the distal end portion of the flat wire supported by the supporting portion is abutted.
The forming jig according to any one of claims 14 to 16. The pressing portion of the sandwiching portion has a convex curved surface having a shape along the concave curved surface of the distal end portion when the distal end portion of the flat wire is pressed against the molding surface and curved.
The forming jig according to any one of claims 14 to 17. The rectangular conducting wire is obtained by laminating a plurality of the rectangular conducting wires in the thickness direction of the plurality of rectangular conducting wires.
The forming jig according to any one of claims 14 to 18.

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