This application claims priority from Japanese Patent Application No. 2015-233575 filed on Nov. 30, 2015, the entire contents of which are incorporated herein by reference.
The present invention relates to a connection method for a terminal fitting and a connection structure of a terminal fitting.
There has been known a connection structure in which connection plates of a plurality of terminal fittings, to which grounding electric wires have been connected, are put on top of one another, a common bolt is inserted into mounting holes provided in the connection plates to thereby bolt and fasten the connection plates to a grounding surface (such as a predetermined place of a vehicle body), so that the grounding electric wires can be conductively connected to the grounding surface in a lump through the terminal fittings put on top of one another (for example, see Patent Literature 1: JP-A-2012-190749).
[Patent Literature 1] JP-A-2012-190749
According to a related art, in a structure in which terminal fittings put on top of one another are fastened by a bolt, the terminal fittings connected to grounding electric wires respectively are put on top of one another and fastened by the bolt. Therefore, the weight increases as the number of grounding electric wires increases. In addition, the thickness of the terminal fittings put on top of one another increases as the number of grounding electric wires increases. Thus, a large space for receiving the terminal fittings has to be secured above the grounding surface. In addition, much working time is required for fastening work while adjusting the nut length or the bolt length in accordance with the terminal fittings to be put on top of one another.
In addition, in order to conductively connect a plurality of grounding electric wires in a lump, it can be also considered to use a joint connector in which connection terminals connected to the grounding electric wires are inserted into a housing accommodating joint terminals to thereby conductively connect the grounding electric wires in a lump through the joint terminals while holding the connection terminals inside the housing. However, in the case of the joint connector, a holding mechanism (such as a lock lance) for holding the connection terminals inside the housing has to be provided. It is therefore difficult to miniaturize the housing. In addition, since the housing provided with the holding mechanism is required, the cost increases inevitably.
In addition, due to fastening by a bolt, reliability in connection may deteriorate after the connection because the bolt is loosened. In this case, when the connection terminals are crimped and fastened to the terminal fittings, a firm connection structure can be obtained. However, when the connection terminals and the terminal fittings are crimped by a crimping machine, there is a fear that their postures cannot be stabilized relatively to each other but a variation may occur in crimping strength.
One or more embodiments provide a connection method for a terminal fitting capable of conductively connecting a plurality of electric wires in a lump with high reliability in connection while suppressing weight and saving space.
In an aspect (1), one or more embodiments provide a connection method for a terminal fitting, in which the terminal fitting includes a terminal body and a plurality of terminal connection portions extending from the terminal body, and a pair of fastening caulking pieces of each of connection terminals connected to end portions of electric wires are caulked and connected to a pair of fastened caulking pieces formed in a corresponding one of the terminal connection portions. The connection method is manufactured by:
folding open end portions of the fastened caulking pieces inward respectively to form folded portions and a space between the folded portions so that open end portions of the pair of fastening caulking portions enter the space; and
crushing the pair of the fastening caulking pieces to caulk the pair of the fastened caulking pieces so that the open end portions of the pair of the fastening caulking pieces enter the space.
In an aspect (2), the connection method for the terminal fitting according to the aspect (1), may be further manufactured by:
forming a retention space in each of the connection terminals by the fastening caulking pieces so that the fastened caulking pieces are inserted into the retention space; and
inserting one of the terminal connection portions into the retention space so that the open end portions of the pair of the fastened caulking pieces face to the same side as the open end portions of the pair of the fastening caulking pieces to thereby make the connection terminal retain the terminal connection portion.
In an aspect (3), the connection method for the terminal fitting according to the aspect (2), the fastening caulking pieces may include rotation regulation faces that abut against the fastened caulking pieces inserted into the retention space to thereby regulate rotation of the terminal connection portion around an axis extending in an insertion direction of the terminal connection portion.
According to the aspect (1), when the pair of the fastening caulking pieces are caulked to catch the pair of the fastened caulking pieces from outside, the open end portions of the pair of the fastening caulking pieces enter a space provided between folded parts formed at the upper ends of the pair of the fastened caulking pieces respectively, so that the fastening caulking pieces can caulk the fastened caulking pieces and the folded parts so as to catch the fastened caulking pieces and the folded parts from outside. Thus, the fastened caulking pieces including the folded parts are rounded inside the fastening caulking pieces and received therein tightly, so that the fastening connection portion can be filled with the fastened caulking pieces. In this manner, the fastening connection portion is fastened to the terminal connection portion firmly with high contact pressure, while the terminal fitting and the connection terminal can be conductively connected surely. Thus, electric resistance in the connection place can be stabilized to establish a good electric connection.
According to the aspect (2), the open end portions of the pair of the fastened caulking pieces are retained in the retention space so as to face on the same side as the open end portions of the pair of the fastening caulking pieces, and the fastening caulking pieces then caulk the fastened caulking pieces to catch the outsides thereof.
Thus, fastening work can be performed in the state where the posture of the terminal connection portion has been stabilized relatively to the connection terminal, so that workability in fastening the connection terminal to the terminal connection portion of the terminal fitting can be improved, while a variation in crimping strength can be suppressed to obtain high reliability in connection.
In addition, when the retention space is formed in the connection terminal in advance, the width size can be suppressed in comparison with a case where fastening caulking pieces are formed into a U-shape widened upward. Thus, components including a crimper can be miniaturized to save the working space during fastening by a crimping machine.
According to the aspect (3), the terminal connection portion of the terminal fitting abuts against the rotation regulation faces of the fastening caulking pieces so that the terminal connection portion can be kept in a predetermined posture with respect to the connection terminal.
Thus, without using any jig or the like for regulating rotation of the terminal connection portion, a good balance can be kept in the biting amounts of the fastening caulking pieces into the terminal connection portion, so that a variation in crimping strength can be suppressed to obtain high reliability in connection.
According to one or more embodiments, it is possible to provide a connection method for a terminal fitting capable of conductively connecting a plurality of electric wires in a lump with high reliability in connection while suppressing weight and saving space.
The invention has been described briefly above. The further details of the invention will be made clearer through with reference to the accompanying drawings.
An embodiment of the invention will be described below with reference to the drawings.
A connection method for a terminal fitting according to the embodiment of the invention will be described.
As shown in
As shown in
A rotation stopper piece 15 is formed in a part of the fixed plate portion 12. The rotation stopper piece 15 is a bent portion to be engaged with a step or a hole portion around the grounding surface to which the terminal body 11 is fastened by a bolt. When the rotation stopper piece 15 is engaged with the step or the hole portion around the grounding surface, the rotation stopper piece 15 regulates rotation of the terminal fitting 10 relative to the grounding surface.
Two support wall portions 16 each having an arc shape in planar view are formed at the circumferential edge of the fixed plate portion 12. With respect to the fixed plate portion 12, the support wall portions 16 are provided erectly on the side of the upper surface which is a one-side surface. In addition, in the electric wire connection portion body 19, a connection plate portion 14 having an arc shape in planar view is formed in an approximately half circumferential part of the circumferential edge of the fixed plate portion 12. With respect to the fixed plate portion 12, the connection plate portion 14 is provided erectly on the side of the upper surface which is a one-side surface. The connection plate portion 14 is disposed along the outer circumferential surfaces of the support wall portions 16.
A plurality of lock pieces 16a are formed at the upper edge of each support wall portion 16. The lock pieces 16a are folded back toward the outer surface of the connection plate portion 14 so that the opposite ends of the connection plate portion 14 can be locked by the lock pieces 16a. Thus, the connection plate portion 14 is supported by the support wall portions 16.
In this manner, in the terminal fitting 10, the parts where the connection plate portion 14 is locked by the lock pieces 16a of the support wall portions 16 serve as coupling portions 20. That is, the terminal fitting 10 includes a plurality of coupling portions 20 so that the terminal body 11 and the electric wire connection portion body 19 can be coupled with each other by the coupling portions 20.
Each terminal connection portion 21 is formed integrally with the connection plate portion 14 of the terminal body 11. A plurality of terminal connection portions 21 are provided in upper edge parts of the connection plate portion 14. Specifically, four terminal connection portions 21 are formed in the connection plate portion 14. The terminal connection portions 21 are extended, within one and the same plane, from the circumferential edge of the fixed plate portion 12 so as to project radially.
As shown in
As shown in
As shown in
As shown in
As shown in
In order to connect the grounding electric wire D to the connection terminal 30, the jacket 2 is removed to expose the conductor portion 1 in an end portion of the grounding electric wire D. Then, the end portion of the grounding electric wire D is disposed on the electric wire connection portion 31 of the connection terminal 30, and the conductor caulking portion 33 is caulked while the coating caulking portion 34 is caulked. After that, the connection terminal 30 is separated from the carrier 35. Thus, the grounding electric wire D is conductively connected to the connection terminal 30.
As shown in
Thus, a retention space S surrounded by the fastening caulking pieces 32a is formed in the fastening connection portion 32 of the connection terminal 30. The opposite side faces of the retention space S are formed into substantially vertical faces due to the fastening caulking pieces 32a provided erectly upward. The opposite side faces serve as rotation regulation faces 36. In addition, a bottom face 37 forming the retention space S is bent to swell downward slightly.
The retention space S of the fastening connection portion 32 is formed to be a little larger than the outer shape of the terminal connection portion 21 in front view. Thus, the terminal connection portion 21 can be inserted into the retention space S (see
Next, description will be made about the connection method for the terminal fitting in which the connection terminal 30 is caulked and fastened to the terminal connection portion 21 of the terminal fitting 10.
As shown in
(Temporarily Fixing Step)
As shown in
In addition, the bottom face 37 of the retention space S is bent downward in a concave shape. Accordingly, the terminal connection portion 21 inserted into the retention space S has a stable posture on the bottom face 37. Particularly, the bottom portion of the terminal connection portion 21 is bent to swell outward so that the terminal connection portion 21 can be fitted into the bottom face 37 of the retention space S to be thereby stabilized.
(Mounting Step)
As shown in
(Fastening Step)
The crimping machine 41 is actuated to start crimping and move down the crimper 43 of the crimping machine 41. Thus, the fastening connection portion 32 is guided into the concave part by the guide faces 43a of the crimper 43. Still on this occasion, the terminal connection portion 21 is kept in the predetermined posture inside the retention space S with respect to the connection terminal 30. After that, the pressing faces 43b of the crimper 43 abut against the upper portions of the fastening caulking pieces 32a of the fastening connection portion 32. As a result, the fastening caulking pieces 32a are crushed to start caulking.
Then, as shown in
Thus, as shown in
When the terminal connection portions 21 of the terminal fitting 10 and the connection terminals 30 are fastened and connected in the aforementioned steps, the grounding electric wires D are conductively connected to the terminal fitting 10 in a lump. When the terminal fitting 10 is fixed to the grounding surface of the vehicle by a bolt, the grounding electric wires D are grounded.
As has been described above, according to the connection method for the terminal fitting according to the embodiment, the terminal connection portion 21 is inserted into the retention space S surrounded by the fastening caulking pieces 32a of the connection terminal 30 so that the terminal connection portion 21 can be retained by the connection terminal 30. Thus, the fastening caulking pieces 32a can be caulked and fastened in the state where the terminal connection terminal 21 has been retained by the connection terminal 30. As a result, the terminal connection portion 21 can be kept in a stable posture when it is being caulked and fastened. Thus, a variation in crimping strength can be suppressed to obtain high reliability in connection.
In addition, according to the connection method for the terminal fitting according to the embodiment, the terminal connection portion 21 is inserted into and retained by the retention space S formed in advance in the connection terminal 30, and the fastening caulking pieces 32a are crushed and fastened to caulk and catch the outer sides of the opposite side portions of the terminal connection portion 21 inside the retention space S. Thus, the fastening work can be performed in the state where the posture of the terminal connection portion 21 has been stabilized with respect to the connection terminal 30. In this manner, the workability can be improved, and a variation in crimping strength can be suppressed to obtain high reliability in connection. In addition, due to the retention space S formed in advance in the connection terminal 30, the width size can be suppressed in comparison with a case where the fastening caulking pieces 32a are formed into a U-shape widened upward. Thus, components including the crimper 43 can be miniaturized to save the working space during fastening by the crimping machine 41. For example, as shown in
In addition, the terminal connection portion 21 inserted into the retention space S is retained by the connection terminal 30 in the state where the terminal connection portion 21 is regulated from rotating around the axis extending in the insertion direction by the rotation regulation faces 36 constituted by the opposite side faces of the retention space S. Thus, the terminal connection portion 21 can be kept in a more stable posture with respect to the connection terminal 30, so that the accuracy of caulking and fastening can be enhanced.
In addition, the terminal connection portion 21 inserted into the retention space S is retained in a stable state due to the bottom face 37 of the retention space S bent downward. Thus, the terminal connection portion 21 can be kept in a more stable posture with respect to the connection terminal 30, so that the accuracy of fastening can be enhanced.
In addition, according to the embodiment, when a plurality of grounding electric wires D are connected to the terminal fitting 10, the grounding electric wires D can be conductively connected to the terminal fitting 10 in a lump. It is therefore unnecessary to stack terminal fittings 10. Accordingly, in comparison with a background-art structure in which terminal fittings connected to grounding electric wires respectively are stacked and fastened for conductive connection, increase in weight of the terminal fitting 10 can be suppressed even when the number of grounding electric wires D increases. In addition, since it is not necessary to stack terminal fittings 10, the thickness of the terminal fitting 10 does not increase even when the number of electric wires D to be conductively connected increases. Thus, space saving can be attained. In addition, since the connection terminals 30 are fastened to the terminal connection portions 21 of the terminal fitting 10, it is possible to dispense with a special holding mechanism for holding the connection terminals 30. Thus, reduction in size and cost can be attained in comparison with a joint connector in which a holding mechanism for holding terminals has to be provided in a housing.
In addition, due to the structure in which separate connection terminals 30 are fastened and connected to the terminal fitting 10, the connection terminals 30 to which grounding electric wires D different in size have been connected can be fastened and conductively connected to the terminal connection portions 21. That is, grounding electric wires D having various sizes can be dealt with without changing the connection forms between the terminal connection portions 21 of the terminal fitting 10 and the fastening connection portions 32 of the connection terminals 30. In addition, when terminal fittings 10 differing in number of terminal connection portions 21 are prepared, it is possible to easily deal with increase or decrease in number of grounding electric wires D to be conductively connected.
Here, for example, a plurality of grounding electric wires D can be conductively connected in a lump in a terminal fitting in which a plurality of connection portions to which the grounding electric wires D can be connected are formed integrally. However, such a terminal fitting has to be prepared in accordance with the number of grounding electric wires D to be connected. In addition, a terminal fitting having connection portions corresponding to the grounding electric wires D has to be prepared in accordance with a change in size of the grounding electric wires D.
On the other hand, according to the connection method for the terminal fitting according to the embodiment, a change in number or size of grounding electric wires D to be conductively connected can be dealt with by a required minimum variation of terminal fittings 10.
In addition, due to the structure in which connection terminals 30 are caulked and fastened to a plurality of terminal connection portions 21 of the terminal fitting 10, the connection terminals 30 can be fastened to the terminal connection portions 21 in accordance with necessity. Thus, the number of grounding electric wires D to be conductively connected in a lump can be increased or decreased easily within the range of the number of terminal connection portions 21.
In addition, the engagement walls 22 that can be engaged with the fastening caulking pieces 32a are formed in the opposite side portions of the terminal connection portion 21. Accordingly, when the fastening caulking pieces 32a of the connection terminal 30 are caulked to the terminal connection portion 21, the fastening caulking pieces 32a are engaged with the engagement walls 22 of the terminal connection portion 21. Thus, the fastening caulking pieces 32a are surely crimped on the terminal connection portion 21 so that the connection strength of the connection terminal 30 to the terminal connection portion 21 can be further enhanced. It is therefore possible to stabilize electric resistance at the connection place to thereby improve the electric connection.
Further, the pair of the fastening caulking pieces 32a enter the space G provided between the folded portions 22a formed respectively at the upper ends of the pair of engagement walls 22. When the fastening caulking pieces 32a are caulked to catch the engagement walls 22 and the folded portions 22a from outside, the engagement walls 22 including the folded portions 22a are rounded inside the fastening caulking pieces 32a and received therein tightly. Thus, the fastening connection portion 32 is filled with the terminal connection portion 21. In this manner, the fastening connection portion 32 is fastened to the terminal connection portion 21 firmly with high contact pressure, so that the reliability in connection of the connection terminal 30 to the terminal connection portion 21 is improved.
In addition, the terminal connection portions 21 according to the embodiment are extended radially within one and the same plane. Accordingly, it is possible to provide a large number of terminal connection portions 21 while suppressing the area occupied by the terminal fitting 10 as much as possible. Thus, a large number of grounding electric wires D can be connected in a lump.
In addition, in the connection structure of the terminal fitting according to the embodiment, the electric wire connection portion body 19 coupled with the terminal body 11 through the coupling portion 20 is separated for the sake of disassembly. In this manner, the grounding electric wires D can be separated from the terminal body 11 in a lump. Thus, good recycling efficiency can be obtained.
In addition, the locking force with which the coupling portion 20 coupling the terminal body 11 with the electric wire connection portion body 19 is locked by the locking pieces 16a can be adjusted. For example, the locking force can be adjusted in accordance with the diameters of grounding electric wires D, the number of the grounding electric wires D to be connected, the wiring condition of the grounding electric wires D, etc. Thus, connection strength during wiring can be secured surely while good separation performance during disassembly can be also secured. Thus, durability and recycling efficiency can be made compatible. For example, the coupling strength between the terminal body 11 and the electric wire connection portion body 19 can be adjusted within a range from strength required as connection strength to strength allowing separation (for example, from 100 N to 500 N).
Incidentally, the terminal connection portion 21 in the aforementioned embodiment is formed into a U-shape in section due to the engagement walls 22 provided in the opposite side portions thereof, and the folded portions 22a bent inward and folded like an arc are formed in the upper end portions of the engagement walls 22. However, the sectional shape of the terminal connection portion 21 is not limited to the aforementioned one.
Incidentally, in the aforementioned embodiment, grounding electric wires D of on-vehicle circuits (accessories) are connected to the terminal fitting 10 so that the grounding electric wires D can be grounded in a lump. However, electric wires to be connected to the terminal fitting 10 are not limited to the grounding ones.
In addition, the rotation stopper piece 15 is not provided in the terminal body 11 of the terminal fitting 10 but a step or a rotation stopper piece that can abut against the terminal fitting 10 to thereby serve as a rotation stopper when the terminal fitting 10 is attached to the grounding surface may be provided on the grounding surface side.
Incidentally, the invention is not limited to the aforementioned embodiment, but deformations, improvements, etc. can be made suitably. In addition, materials, shapes, dimensions, numbers, arrangement places, etc. of respective constituent elements in the aforementioned embodiment are not limited. Any materials, any shapes, any dimensions, any numbers, any arrangement places, etc. may be used as long as the invention can be attained.
Here, the features of the aforementioned embodiment of the connection structure and the connection method for the terminal fitting according to the invention will be summarized and listed briefly in the following paragraphs [1] to [4].
[1] A connection method for a terminal fitting, in which the terminal fitting (10) includes a terminal body (11) and a plurality of terminal connection portions (21) extending from the terminal body, and a pair of fastening caulking pieces (32a) of each of connection terminals (30) connected to end portions of electric wires (grounding electric wires D) are caulked and connected to a pair of fastened caulking pieces (engagement walls 22) formed in a corresponding one of the terminal connection portions, the connection method comprising:
folding open end portions of the fastened caulking pieces inward respectively to form folded portions (22a) and a space (G) between the folded portions so that open end portions of the pair of fastening caulking portions enter the space; and
crushing the pair of the fastening caulking pieces to caulk the pair of the fastened caulking pieces so that the open end portions of the pair of the fastening caulking pieces enter the space.
[2] The connection method for the terminal fitting according to [1], further comprising:
forming a retention space (S) in each of the connection terminals by the fastening caulking pieces so that the fastened caulking pieces are inserted into the retention space (S); and inserting one of the terminal connection portions into the retention space so that the open end portions of the pair of the fastened caulking pieces face to the same side as the open end portions of the pair of the fastening caulking pieces to thereby make the connection terminal retain the terminal connection portion.
[3] The connection method for the terminal fitting according to [2],
wherein the fastening caulking pieces include rotation regulation faces (36) that abut against the fastened caulking pieces inserted into the retention space to thereby regulate rotation of the terminal connection portion around an axis extending in an insertion direction of the terminal connection portion.
[4] A connection structure for a terminal fitting comprising:
the terminal fitting (10) including a terminal body (11) and a plurality of terminal connection portions (21) extending from the terminal body; and
connection terminals (30) connected to end portions of electric wires (grounding electric wires D),
wherein each of the connection terminals include a pair of fastening caulking pieces (32a),
wherein open end portions of a pair of fastened caulking pieces (engagement walls 22) formed in each of the terminal connection portions are folded inward respectively to form folded portions (22a) and a space (G) between the folded portions so that open end portions of the pair of fastening caulking portions enter the space,
wherein the pair of the fastening caulking pieces are caulked with the pair of the fastened caulking pieces and the open end portions of the pair of the fastening caulking pieces enter the space, and
wherein the terminal fitting is connected to the electric wires through the connection terminals.
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Entry |
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Chinese Office Action for the related Chinese Patent Application No. 201611080994.8 dated Jul. 3, 2018. |
Number | Date | Country | |
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20170155200 A1 | Jun 2017 | US |