JP2016045984A

JP2016045984A - Crimp terminal, connection structure, connector, wire harness, method of manufacturing crimp terminal and method of manufacturing connection structure

Info

Publication number: JP2016045984A
Application number: JP2014166936A
Authority: JP
Inventors: 紳悟川田; Shingo Kawata; 昭頼橘; Akira Tachibana; 賢悟水戸瀬; Kengo Mitose
Original assignee: Furukawa Electric Co Ltd; Furukawa Automotive Systems Inc
Current assignee: Furukawa Electric Co Ltd; Furukawa Automotive Systems Inc
Priority date: 2014-08-19
Filing date: 2014-08-19
Publication date: 2016-04-04
Anticipated expiration: 2034-08-19
Also published as: JP6452344B2

Abstract

PROBLEM TO BE SOLVED: To provide a crimp terminal that can suppress occurrence of corrosion at a contact portion between a conductor and a crimp portion, prevent increase of connection resistance and maintain electrical connection reliability over a long term.SOLUTION: A crimp terminal 40 has a connector portion 10 which is electrically connected to an external terminal 2, and a cylindrical crimp portion 30 which is provided to the connector portion through a transition portion 20 and crimped to an electrical wire 3. The cylindrical crimp portion 30 is a cylindrical member which is closed at the transition portion 20 side, and has a covered crimp portion 32 which is crimped to an insulation cover of the electrical wire 3, a diameter-decreasing portion 33 which decreases in diameter from an insertion port 31 side to the transition portion 20 side, and a conductor crimp portion 34 which is crimped to a conductor of the electrical wire 3. The conductor crimp portion 34 has an outer peripheral portion 34a comprising a metal base body formed of copper or copper alloy, and plural metal projecting portions 34c which are formed on the inner peripheral surface 34b of the outer peripheral portion by sputtered metal which is sputtered when metal is molten.SELECTED DRAWING: Figure 1

Description

本発明は、車両用ワイヤーハーネスの接続を行うコネクタ等に装着される圧着端子、接続構造体、コネクタ、ワイヤーハーネス、並びに圧着端子の製造方法及び接続構造体の製造方法に関し、特に、電線に取り付けられる銅あるいは銅合金製の圧着端子、接続構造体、該接続構造体を有するコネクタ、ワイヤーハーネス、並びに圧着端子の製造方法及び接続構造体の製造方法に関する。 The present invention relates to a crimp terminal, a connection structure, a connector, a wire harness, a method for manufacturing a crimp terminal, and a method for manufacturing a connection structure, particularly to an electric wire. The present invention relates to a crimp terminal made of copper or a copper alloy, a connection structure, a connector having the connection structure, a wire harness, a method of manufacturing a crimp terminal, and a method of manufacturing a connection structure.

従来、自動車用ワイヤーハーネス（組電線）などにおける電線と圧着端子との接続は、オープンバレル型と呼ばれる圧着端子で電線を加締めて圧着する圧着接続が一般的である。自動車用ワイヤーハーネスでは、当該ワイヤーハーネスに用いられる電線の導体（芯線）材料が、銅、銅合金、アルミニウム、あるいはアルミニウム合金等の金属で形成されており、このような金属からなる導体の外周を、該導体と同種あるいは異種金属からなる圧着端子の圧着部で囲むようにして加締めることにより、圧着端子と導体とが機械的、電気的に接続される。 Conventionally, the connection between an electric wire and a crimp terminal in an automobile wire harness (assembled electric wire) or the like is generally a crimp connection in which an electric wire is crimped by a crimp terminal called an open barrel type. In the automotive wire harness, the conductor (core wire) material of the electric wire used in the wire harness is formed of a metal such as copper, copper alloy, aluminum, or aluminum alloy, and the outer periphery of the conductor made of such metal is used. The crimping terminal and the conductor are mechanically and electrically connected by crimping the crimping terminal so as to surround the crimping terminal made of the same kind or different metal as the conductor.

このとき、導体の外周表面に自然酸化等によって金属酸化膜が形成されると、導体と圧着部との間に金属酸化膜が介在することにより、導体と圧着部の間の接続抵抗が大きくなるという問題がある。そこで、圧着端子の圧着部の内側に、セレーションと呼ばれる複数の凹部を設け、圧着時に凹部の開口縁部が導体の金属酸化膜を破ることにより、導体と圧着部の接続抵抗を低減する技術が提案されている（特許文献１）。 At this time, if a metal oxide film is formed on the outer peripheral surface of the conductor by natural oxidation or the like, the metal oxide film is interposed between the conductor and the crimping portion, thereby increasing the connection resistance between the conductor and the crimping portion. There is a problem. Therefore, there is a technology that reduces the connection resistance between the conductor and the crimping part by providing a plurality of recesses called serrations inside the crimping part of the crimping terminal, and the opening edge of the recess breaks the metal oxide film of the conductor during crimping. It has been proposed (Patent Document 1).

また、オープンバレル型圧着端子では、その構造上、導体と圧着端子の接触部に外界からの水分等が比較的付着し易く、当該接触部に水分等が付着すると、導体や圧着端子を構成する金属表面の酸化が進行し、接触部における電気抵抗が上昇してしまう。また、導体と圧着端子に用いられる金属が異なる場合、異種金属間腐食が進行するという問題がある。そこで、圧着端子にレーザ溶接にて一端が閉塞された筒状圧着部を設け、該筒状圧着部に導体を挿入して圧着する構造を採用し、電線導体を外界から遮断する技術が提案されている。この技術によれば、導体と圧着端子の接触部への水分の付着を防止することができ、導体や圧着端子を構成する金属の酸化や腐食を低減することが可能となっている（特許文献２）。 Moreover, in the open barrel type crimp terminal, due to its structure, moisture and the like from the outside are relatively easily attached to the contact portion between the conductor and the crimp terminal, and when the moisture and the like adhere to the contact portion, the conductor and the crimp terminal are configured. The oxidation of the metal surface proceeds and the electrical resistance at the contact portion increases. Moreover, when the metal used for a conductor and a crimp terminal differs, there exists a problem that corrosion between different metals advances. Therefore, a technique has been proposed in which a crimping terminal is provided with a cylindrical crimping part whose one end is closed by laser welding, a conductor is inserted into the cylindrical crimping part and crimped, and the wire conductor is cut off from the outside. ing. According to this technology, it is possible to prevent moisture from adhering to the contact portion between the conductor and the crimp terminal, and to reduce oxidation and corrosion of the metal constituting the conductor and the crimp terminal (Patent Document). 2).

特開２０１０−３４６７号公報JP 2010-3467 A 特開２０１４−１１６３２３号公報JP 2014-116323 A

しかしながら、上記従来の圧着端子構造では、微視的に見れば導体と圧着部の間に多くの空隙が存在しており、熱衝撃によって空隙が拡張することによる接続抵抗の増大が懸念される。また、水分等が存在する腐食環境下では、導体及び圧着部が同種あるいは異種金属である場合に、それらの接触部の隙間で腐食が生じ（隙間腐食）、この隙間腐食によって接続抵抗が増大するという懸念がある。 However, in the above-described conventional crimp terminal structure, there are many gaps between the conductor and the crimp part when viewed microscopically, and there is a concern that the connection resistance is increased due to the gap being expanded by thermal shock. Also, in a corrosive environment where moisture or the like is present, when the conductor and the crimping part are the same or different metals, corrosion occurs in the gap between the contact parts (gap corrosion), and the connection resistance increases due to this crevice corrosion. There is a concern.

本発明の目的は、導体と圧着部の接触部での腐食発生を抑制して、接続抵抗の増大を防止することができ、ひいては長期に亘って電気的な接続信頼性を維持することができる圧着端子、接続構造体、コネクタ、ワイヤーハーネス、並びに圧着端子の製造方法及び接続構造体の製造方法を提供することにある。 An object of the present invention is to suppress the occurrence of corrosion at the contact portion between the conductor and the crimping portion, thereby preventing an increase in connection resistance, and thus maintaining electrical connection reliability over a long period of time. It is providing the manufacturing method of a crimp terminal, a connection structure, a connector, a wire harness, a crimp terminal, and a connection structure.

上記目的を達成するべく、本発明の要旨構成は以下の通りである。
（１）外部端子と電気的に接続されるコネクタ部と、電線の導体と圧着される導体圧着部とを備える圧着端子であって、
前記導体圧着部は、金属基体と、前記金属基体の主面のうち前記電線の導体と圧接される側の面に形成された複数の突起部とを有し、
該突起部は、前記電線の導体と圧接される側のからの高さが１μｍ〜１２０μｍであることを特徴とする、圧着端子。
（２）前記突起部は、前記金属基体とは異なる主成分の金属からなることを特徴とする、上記（１）記載の圧着端子。
（３）前記突起部は、Ｃｕ、Ｎｉ、Ｓｉ、Ｚｎ、Ｓｎ、Ｍｇ、Ｃｒ、Ｆｅ、Ａｌからなる群から選択される１又は２以上の金属元素を主成分とすることを特徴とする、上記（１）または（２）に記載の圧着端子。
（４）前記複数の突起部は、互いに異なる主成分の金属で構成される第１突起部と第２突起部を有することを特徴とする、上記（１）乃至（３）のいずれかに記載の圧着端子。
（５）前記第１突起部は、前記金属基体よりも軟質であり且つ前記電線の導体よりも硬質であり、
前記第２突起部は、前記金属基体よりも軟質であり且つ前記電線の導体よりも軟質であることを特徴とする、上記（４）記載の圧着端子。
（６）前記導体圧着部は、前記コネクタ部側の端部が閉塞されてなる筒状圧着部を構成することを特徴とする、上記（１）乃至（５）のいずれかに記載の圧着端子。
（７）前記筒状圧着部は、レーザ溶接によってその長手方向と略同一の方向に沿って形成された帯状溶接部を有し、
前記複数の突起部は、前記レーザ溶接前に予め形成された第１突起部と、前記レーザ溶接を行う際に発生するスパッタにより形成された第２突起部とで構成されることを特徴とする、上記（６）記載の圧着端子。
（８）前記突起部は、金属の溶融時に飛散するスパッタ、あるいは前記電線の導体と圧接される側の面に固着させた金属粉または金属粒であることを特徴とする、上記（１）乃至（７）のいずれかに記載の圧着端子。
（９）前記電線の導体と圧接される側の面の平面視において、前記複数の突起部の面積占有率が３〜９８％であることを特徴とする、上記（１）乃至（８）のいずれかに記載の圧着端子。
（１０）前記導体圧着部は、前記電線の導体と圧接される側の面に凹部を有し、前記凹部に前記突起部を有することを特徴とする、上記（１）乃至（９）のいずれかに記載の圧着端子。
（１１）前記突起部は、前記金属基体よりも軟質であることを特徴とする、上記（１）乃至（１０）のいずれかに記載の圧着端子。
（１２）前記突起部は、前記金属基体よりも硬質であることを特徴とする、上記（１）乃至（１０）のいずれかに記載の圧着端子。
（１３）前記導体圧着部がオープンバレル型の圧着部であることを特徴とする、上記（１）乃至（５）のいずれか、あるいは上記（８）乃至（１２）のいずれかに記載の圧着端子。
（１４）上記（１）乃至（１３）のいずれかに記載の圧着端子に、電線の導体、又は該導体を複数本撚り合わせて得られる導体撚線が圧着により接続されてなることを特徴とする接続構造体。
（１５）前記複数の突起部の少なくとも一部が、前記電線の導体と圧接される側の面と、前記電線の導体又は前記導体撚線の外周面との間に形成された空隙の少なくとも一部を埋めていることを特徴とする、上記（１４）記載の接続構造体。
（１６）前記導体圧着部の長手方向に垂直な断面における前記導体圧着部の空隙率が、１％以下であることを特徴とする、上記（１５）記載の接続構造体。
（１７）上記（１４）乃至（１６）のいずれかに記載の接続構造体におけるコネクタ部をコネクタハウジング内に収容してなることを特徴とするコネクタ。
（１８）上記（１４）乃至（１６）のいずれかに記載の接続構造体を少なくとも１本備えたことを特徴とするワイヤーハーネス。
（１９）外部端子と電気的に接続されるコネクタ部と、電線の導体と圧着される導体圧着部とを備える圧着端子の製造方法であって、
前記導体圧着部における金属基体の主面のうち前記電線の導体と圧接される側の面に、複数の突起部を形成する突起部形成工程を有することを特徴とする、圧着端子の製造方法。
（２０）前記突起部形成工程は、前記電線の導体と圧接される側の面にスパッタを付着させるものであることを特徴とする、上記（１９）記載の圧着端子の製造方法。
（２１）板状体を折り曲げ加工するとともに、その一部を突き合わせて突き合わせ部を形成する工程と、
前記突き合わせ部にレーザ溶接を施すとともに該レーザ溶接時に発生するスパッタにより突起部を形成する工程と、
を有する、上記（２０）記載の圧着端子の製造方法。
（２２）板状体に第１突起部を形成する、第１の突起部形成工程と、
前記板状体を折り曲げ加工するとともに、その一部を突き合わせて突き合わせ部を形成する工程と、
前記突き合わせ部にレーザ溶接を施すとともに該レーザ溶接時に発生するスパッタにより第２突起部を形成する第２の突起部形成工程と、
を有することを特徴とする、上記（１９）記載の圧着端子の製造方法。
（２３）外部端子と電気的に接続されるコネクタ部と、電線の導体と圧着される導体圧着部とを備える圧着端子と、前記圧着端子に圧着により接続される電線とを備える接続構造体の製造方法であって、
前記圧着端子として、前記導体圧着部における金属基体の主面のうち電線の導体と圧接される側の面に形成された複数の突起部を有し、かつ該突起部は、前記導体圧着部の圧着面からの高さが１μｍ〜１２０μｍであるものを用い、
前記圧着端子の導体圧着部を、前記電線の導体に対して圧着することで、前記圧着端子と前記電線とを固定するとともに、前記電線の導体と圧接された側の面と前記電線の導体との間の空隙の少なくとも一部を前記突起部で埋めることを特徴とする、接続構造体の製造方法。 In order to achieve the above object, the gist of the present invention is as follows.
(1) A crimping terminal including a connector part that is electrically connected to an external terminal, and a conductor crimping part that is crimped to a conductor of an electric wire,
The conductor crimping portion includes a metal base and a plurality of protrusions formed on a surface of the main surface of the metal base that is in pressure contact with the conductor of the electric wire,
The protrusion is a crimp terminal having a height of 1 μm to 120 μm from the side pressed against the conductor of the electric wire.
(2) The crimp terminal according to (1), wherein the protrusion is made of a metal having a main component different from that of the metal substrate.
(3) The protrusion has a main component of one or more metal elements selected from the group consisting of Cu, Ni, Si, Zn, Sn, Mg, Cr, Fe, and Al. The crimp terminal as described in said (1) or (2).
(4) The plurality of projecting portions include a first projecting portion and a second projecting portion which are made of different main component metals, and are described in any one of (1) to (3) above. Crimp terminal.
(5) The first protrusion is softer than the metal base and harder than the conductor of the electric wire,
The crimp terminal according to (4) above, wherein the second protrusion is softer than the metal base and softer than the conductor of the electric wire.
(6) The crimp terminal according to any one of the above (1) to (5), wherein the conductor crimping part constitutes a cylindrical crimping part in which an end on the connector part side is closed. .
(7) The tubular crimping portion has a belt-like welded portion formed by laser welding along a direction substantially the same as the longitudinal direction thereof,
The plurality of protrusions include a first protrusion formed in advance before the laser welding and a second protrusion formed by sputtering generated when the laser welding is performed. The crimp terminal according to (6) above.
(8) The above-mentioned (1) to (1), wherein the protrusion is spatter that scatters when the metal is melted, or metal powder or metal particles fixed to a surface that is in pressure contact with the conductor of the electric wire. The crimp terminal according to any one of (7).
(9) The area occupancy ratio of the plurality of protrusions is 3 to 98% in a plan view of the surface of the wire that is in pressure contact with the conductor of the above (1) to (8) The crimp terminal in any one.
(10) Any of (1) to (9) above, wherein the conductor crimping portion has a recess on a surface that is in pressure contact with the conductor of the electric wire, and has the projection on the recess. Crimp terminal according to crab.
(11) The crimp terminal according to any one of (1) to (10), wherein the protrusion is softer than the metal base.
(12) The crimp terminal according to any one of (1) to (10), wherein the protrusion is harder than the metal base.
(13) The crimping according to any one of (1) to (5) or (8) to (12) above, wherein the conductor crimping portion is an open barrel crimping portion. Terminal.
(14) The crimp terminal according to any one of (1) to (13), wherein a conductor of an electric wire or a conductor stranded wire obtained by twisting a plurality of the conductors is connected by crimping. Connection structure to be
(15) At least one of the plurality of protrusions is at least one of gaps formed between a surface on the side pressed against the conductor of the electric wire and an outer peripheral surface of the conductor of the electric wire or the conductor stranded wire. The connection structure according to (14) above, wherein a portion is buried.
(16) The connection structure according to (15), wherein a void ratio of the conductor crimping portion in a cross section perpendicular to the longitudinal direction of the conductor crimping portion is 1% or less.
(17) A connector characterized in that the connector portion of the connection structure according to any one of (14) to (16) is housed in a connector housing.
(18) A wire harness comprising at least one connection structure according to any one of (14) to (16).
(19) A method of manufacturing a crimp terminal comprising a connector part electrically connected to an external terminal, and a conductor crimp part to be crimped to a conductor of an electric wire,
A method of manufacturing a crimp terminal, comprising: a protrusion forming step of forming a plurality of protrusions on a surface of the main surface of the metal base in the conductor crimping portion that is in pressure contact with the conductor of the electric wire.
(20) The method for manufacturing a crimp terminal according to the above (19), wherein the protrusion forming step is to attach spatter to a surface of the wire that is in pressure contact with the conductor.
(21) Bending the plate-like body and forming a butt portion by abutting a part thereof;
A step of performing laser welding on the butt portion and forming a protrusion by sputtering generated during the laser welding;
The manufacturing method of the crimp terminal of said (20) description which has this.
(22) a first protrusion forming step of forming a first protrusion on the plate-like body;
A step of bending the plate-like body and forming a butt portion by abutting a part thereof;
A second protrusion forming step of performing laser welding on the butted portion and forming a second protrusion by sputtering generated during the laser welding;
The method for producing a crimp terminal according to the above (19), characterized by comprising:
(23) A connection structure including: a connector part electrically connected to an external terminal; a crimp terminal including a conductor crimp part to be crimped to a conductor of an electric wire; and an electric wire connected to the crimp terminal by crimping. A manufacturing method comprising:
The crimping terminal has a plurality of protrusions formed on a surface of the main surface of the metal base in the conductor crimping portion that is in pressure contact with the conductor of the electric wire, and the projection is formed of the conductor crimping portion. Use the one whose height from the pressure bonding surface is 1 μm to 120 μm,
By crimping the conductor crimping portion of the crimp terminal to the conductor of the electric wire, the crimp terminal and the electric wire are fixed, and the surface of the electric wire conductor and the side of the electric wire and the conductor of the electric wire are fixed. A method for manufacturing a connection structure, wherein at least a part of a gap between the protrusions is filled with the protrusions.

本発明によれば、導体圧着部は、金属基体の主面のうち電線の導体と圧接される側の面に、金属製の複数の突起部を有するので、導体圧着部が導体と圧着される際、導体圧着部と導体の間の空隙が突起部で埋められ、導体圧着部と導体の間の空隙を減少することができる。これにより、熱衝撃による空隙の拡張を抑制することができ、また、導体圧着部と導体の接触部での隙間腐食を抑制することができる。したがって、電線圧着後の初期状態、高温環境下或いは腐食環境下のいずれにおいても、導体圧着部−導体間の接続抵抗を低減しつつ、隙間腐食を抑制することができ、長期に亘って電気的な接続信頼性を維持することができる。また、電線の導体と圧接される側の面からの突起部の高さが１μｍ〜１２０μｍであるので、導体圧着部への電線の挿入容易性を確保しつつ、導体圧着部と導体の間の空隙を突起部で確実に埋めることが可能となる。 According to the present invention, the conductor crimping portion has a plurality of metal projections on the surface of the main surface of the metal base that is in pressure contact with the conductor of the electric wire, so the conductor crimping portion is crimped with the conductor. At this time, the gap between the conductor crimping portion and the conductor is filled with the protrusion, and the gap between the conductor crimping portion and the conductor can be reduced. Thereby, the expansion | swelling of the space | gap by a thermal shock can be suppressed, and the crevice corrosion in the contact part of a conductor crimping | compression-bonding part and a conductor can be suppressed. Therefore, it is possible to suppress crevice corrosion while reducing the connection resistance between the conductor crimping part and the conductor in the initial state after crimping the wire, in a high-temperature environment or in a corrosive environment, and it can be electrically Connection reliability can be maintained. In addition, since the height of the protruding portion from the surface of the wire that is in pressure contact with the conductor is 1 μm to 120 μm, it is easy to insert the wire into the conductor crimping portion, and between the conductor crimping portion and the conductor. It is possible to reliably fill the gap with the protrusion.

また、複数の突起部は、金属基体の電線の導体と圧接される側の面に、溶接スパッタの付着によって形成されるので、複数の突起部を金属基体に容易に且つ強固に固着することができ、接続抵抗を確実に低減することができる。 In addition, since the plurality of protrusions are formed on the surface of the metal base that is in pressure contact with the conductor of the electric wire by welding sputtering, the plurality of protrusions can be easily and firmly fixed to the metal base. The connection resistance can be reliably reduced.

更に、突起部が金属基体よりも軟質な材料で形成されるので、電線圧着時に、複数の突起部が導体圧着部と導体の間で塑性変形し易くなり、導体圧着部と導体の間の空隙を大幅に減少することができ、特に、導体圧着部の長手方向に垂直な断面における導体圧着部−導体間の空隙率を大幅に低下させることができる。 Furthermore, since the protrusions are made of a softer material than the metal base, a plurality of protrusions are easily plastically deformed between the conductor crimping part and the conductor during wire crimping, and the gap between the conductor crimping part and the conductor. In particular, the void ratio between the conductor crimping part and the conductor in the cross section perpendicular to the longitudinal direction of the conductor crimping part can be greatly reduced.

本発明の実施形態に係る圧着端子を有する接続構造体の構成を概略的に示す斜視図であり、（ａ）は全体斜視図、（ｂ）は図１の線Ａ−Ａに沿う接続構造体の断面図である。It is a perspective view which shows roughly the structure of the connection structure which has a crimp terminal which concerns on embodiment of this invention, (a) is a whole perspective view, (b) is the connection structure along line AA of FIG. FIG. 本実施形態に係る圧着端子の製造方法を示すフローチャートである。It is a flowchart which shows the manufacturing method of the crimp terminal which concerns on this embodiment. （ａ）〜（ｅ）は、圧着端子の製造方法を説明する平面図である。(A)-(e) is a top view explaining the manufacturing method of a crimp terminal. （ａ）は、図２における第１突起部を形成する工程を示す図であり、（ｂ）は、当該工程によって金属基体に形成された第１突起部を示す側面図である。(A) is a figure which shows the process of forming the 1st projection part in FIG. 2, (b) is a side view which shows the 1st projection part formed in the metal base | substrate by the said process. （ａ）は、図２におけるレーザ溶接工程を説明する斜視図であり、（ｂ）は、図２の製造方法によって製造された圧着端子の構成を示す斜視図である。(A) is a perspective view explaining the laser welding process in FIG. 2, (b) is a perspective view which shows the structure of the crimp terminal manufactured by the manufacturing method of FIG. 図５のレーザ溶接工程によって筒状体に形成された第２突起部を示す側面図である。It is a side view which shows the 2nd projection part formed in the cylindrical body by the laser welding process of FIG. 本実施形態の変形例としてのオープンバレル型の圧着端子を示す斜視図であり、（ａ）は電線圧着前、（ｂ）は電線圧着後の状態を示す図である。It is a perspective view which shows the open barrel type crimp terminal as a modification of this embodiment, (a) is a figure before electric wire crimping, (b) is a figure which shows the state after electric wire crimping. 本実施形態に係る圧着端子の他の変形例を示す図であり、（ａ）は全体斜視図、（ｂ）はセレーション（凹部）が形成された筒状圧着部の部分拡大断面図である。It is a figure which shows the other modification of the crimp terminal which concerns on this embodiment, (a) is a whole perspective view, (b) is the elements on larger scale of the cylindrical crimp part in which the serration (recessed part) was formed. 本実施形態に係る圧着端子の他の変形例を示す斜視図である。It is a perspective view which shows the other modification of the crimp terminal which concerns on this embodiment. 本実施形態に係る圧着端子の他の変形例を示す斜視図である。It is a perspective view which shows the other modification of the crimp terminal which concerns on this embodiment.

以下、本発明の実施形態を、図面を参照しながら詳細に説明する。 Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

図１は、本実施形態に係る圧着端子を有する接続構造体の構成を概略的に示す図であり、（ａ）は全体斜視図、（ｂ）は図１の線Ａ−Ａに沿う接続構造体の断面図である。なお、図１における接続構造体および圧着端子は、その一例を示すものであり、本発明に係るそれぞれの部分の構成は、図１のものに限られないものとする。 1A and 1B are diagrams schematically showing a configuration of a connection structure having a crimp terminal according to the present embodiment, wherein FIG. 1A is an overall perspective view, and FIG. 1B is a connection structure taken along line AA in FIG. It is sectional drawing of a body. In addition, the connection structure and the crimp terminal in FIG. 1 show an example, and the configuration of each part according to the present invention is not limited to that in FIG.

本実施形態の接続構造体１は、圧着端子４０と電線３とが電気的・機械的にされてなる。より具体的には、銅あるいは銅合金の基体で一体形成され、金属製の導体（芯線）を有し、この導体の周囲を絶縁被覆で覆った電線３に取り付けられる。この接続構造体を１本または複数本束ね、必要に応じて端子部分をコネクタハウジングに収納するなどして、ワイヤーハーネス（組電線）となる。以降、この端子部分（圧着端子４０）について説明する。 The connection structure 1 according to the present embodiment includes a crimp terminal 40 and an electric wire 3 that are electrically and mechanically formed. More specifically, it is integrally formed with a copper or copper alloy substrate, has a metal conductor (core wire), and is attached to an electric wire 3 whose periphery is covered with an insulating coating. One or a plurality of the connection structures are bundled, and a terminal portion is accommodated in the connector housing as necessary, thereby forming a wire harness (assembled wire). Hereinafter, the terminal portion (crimp terminal 40) will be described.

圧着端子４０は、外部端子２と電気的に接続されるコネクタ部１０と、該コネクタ部とトランジション部２０を介して設けられ、電線３と圧着される筒状圧着部３０とを備えている。本実施形態では、コネクタ部１０と筒状圧着部３０とが一体成形されるが、コネクタ部と筒状圧着部を別体で成形し、これらを連結することで圧着端子を作製してもよい。 The crimp terminal 40 includes a connector part 10 that is electrically connected to the external terminal 2, and a cylindrical crimp part 30 that is provided via the connector part and the transition part 20 and is crimped to the electric wire 3. In this embodiment, the connector part 10 and the cylindrical crimp part 30 are integrally formed. However, the connector part and the cylindrical crimp part may be formed separately and connected to each other to produce a crimp terminal. .

また、圧着端子４０は、金属基体からなり、この金属基体を金属材料（銅、アルミニウム、鉄、またはこれらを主成分とする合金等）からなる母材のみで構成してもよいが、導電性と強度を確保するために母材上に金属を主成分とするめっき層を形成してもよい。ここでめっき層は母材の一部あるいは全部に適宜設けられるものであり、接点特性や耐環境性の観点からすずや銀、金等の貴金属が好ましい。めっき層は１層以上あっても良く、例えば鉄（Ｆｅ）やニッケル（Ｎｉ）、コバルト（Ｃｏ）またはこれらを主成分とする合金等の下地をさらに設けてもよい。このめっき層の厚さは、母材の保護及びコスト等を考慮し、合計で０．３μｍ〜３．０μｍである。めっき層が母材の一部に設けられる場合、当該めっき層は、ストライプやスポットなどの形状で形成される。 The crimp terminal 40 is made of a metal substrate, and the metal substrate may be composed of only a base material made of a metal material (copper, aluminum, iron, or an alloy containing these as a main component). In order to secure the strength, a plating layer containing a metal as a main component may be formed on the base material. Here, the plating layer is appropriately provided on a part or all of the base material, and from the viewpoint of contact characteristics and environmental resistance, a noble metal such as tin, silver or gold is preferable. There may be one or more plating layers, and for example, a base such as iron (Fe), nickel (Ni), cobalt (Co), or an alloy containing these as a main component may be further provided. The thickness of the plating layer is 0.3 μm to 3.0 μm in total in consideration of protection of the base material and cost. When the plating layer is provided on a part of the base material, the plating layer is formed in a shape such as a stripe or a spot.

コネクタ部１０は、例えば雄型圧着端子等の挿入タブの挿入を許容するボックス部である。本発明において、このボックス部の細部の形状は特に限定されない。例えば、図１０に示すように、本発明の圧着端子の他の実施形態として、雄型圧着端子の長尺状の接続部１１３ａ（挿入タブ）を有する構造であってもよい。すなわち、コネクタ部１０は、外部端子と係止あるいは嵌合して電気的に接続し得るものであれば、いかなる形状を有していてもよい。本実施形態では、本発明の圧着端子を説明するために便宜的に雌型圧着端子の例を示している。 The connector portion 10 is a box portion that allows insertion of an insertion tab such as a male crimp terminal. In the present invention, the detailed shape of the box portion is not particularly limited. For example, as shown in FIG. 10, as another embodiment of the crimp terminal of the present invention, a structure having an elongated connection portion 113a (insert tab) of a male crimp terminal may be used. In other words, the connector portion 10 may have any shape as long as it can be electrically connected by locking or fitting with an external terminal. In this embodiment, in order to explain the crimp terminal of the present invention, an example of a female crimp terminal is shown for convenience.

筒状圧着部３０は、トランジション部２０側が閉塞された筒部材であって、電線３が挿入される挿入口３１と、電線３の絶縁被覆と圧着される被覆圧着部３２と、挿入口３１側からトランジション部２０側に向かって縮径する縮径部３３と、電線３の導体と圧着される導体圧着部３４とを有している。この筒状圧着部３０は、例えば溶接により一端が閉塞された筒状に形成される。より具体的には、平面展開した金属基体を立体的にプレス加工することで、断面が略Ｃ字型となる筒状体が形成され、この筒状体の開放部分（突き合わせ部）がレーザ溶接される。溶接は筒状体の長手方向に行われるので、その長手方向と略同一の方向に帯状溶接部（溶接ビード）が形成されながら筒状圧着部が形成される。また、筒状圧着部を形成する溶接の後、トランジション部側の筒状圧着部の端部も溶接によって封止されるのが好ましい。この封止は圧着端子の長手方向に対して垂直な方向に行われる。この封止によって、トランジション部２０側から水分等が浸入するのを防止する。 The cylindrical crimping part 30 is a cylindrical member with the transition part 20 side closed, and includes an insertion port 31 into which the electric wire 3 is inserted, a coated crimping part 32 to be crimped to the insulation coating of the electric wire 3, and the insertion port 31 side. A diameter-reducing portion 33 that is reduced in diameter toward the transition portion 20 side, and a conductor crimping portion 34 that is crimped to the conductor of the electric wire 3. The cylindrical crimp part 30 is formed in a cylindrical shape whose one end is closed by welding, for example. More specifically, a cylindrical body having a substantially C-shaped cross section is formed by three-dimensionally pressing a metal substrate that is spread on a plane, and an open portion (butting portion) of the cylindrical body is laser-welded. Is done. Since the welding is performed in the longitudinal direction of the tubular body, the tubular crimping portion is formed while the strip-like welded portion (weld bead) is formed in the substantially same direction as the longitudinal direction. Moreover, it is preferable that the end part of the cylindrical crimp part on the transition part side is also sealed by welding after welding for forming the cylindrical crimp part. This sealing is performed in a direction perpendicular to the longitudinal direction of the crimp terminal. This sealing prevents moisture and the like from entering from the transition portion 20 side.

筒状圧着部３０では、導体が露出した電線端部を挿入口３１に挿入した状態で筒状圧着部３０を加締めることで、被覆圧着部３２、縮径部３３および導体圧着部３４が塑性変形して電線３の絶縁被覆および導体と圧着され、これにより、筒状圧着部３０と電線３の導体とが電気的に接続される。導体圧着部３４の一部には、強加工によって、凹部３５が形成されてもよい。 In the tubular crimping portion 30, the coated crimping portion 32, the reduced diameter portion 33, and the conductor crimping portion 34 are plasticized by caulking the tubular crimping portion 30 with the end of the wire exposed from the conductor inserted into the insertion port 31. It deforms and is crimped to the insulation coating and the conductor of the electric wire 3, whereby the cylindrical crimp portion 30 and the conductor of the electric wire 3 are electrically connected. A recess 35 may be formed in a part of the conductor crimping portion 34 by strong processing.

なお、トランジション部２０は、コネクタ部１０と筒状圧着部３０の橋渡しとなる部分である。立体的に形成されていても、平面的に形成されていても良い。圧着端子長方向の折り曲げに対する機械的強度の観点からは、長手方向の断面２次モーメントが大きくなるように設計すると良い。 The transition portion 20 is a portion that serves as a bridge between the connector portion 10 and the cylindrical crimp portion 30. It may be formed three-dimensionally or two-dimensionally. From the viewpoint of mechanical strength against bending in the crimp terminal length direction, it is preferable to design the second moment of the cross section in the longitudinal direction to be large.

導体圧着部３４は、図１（ｂ）に示すように、銅あるいは銅合金からなる金属基体からなる外周部３４ａと、該外周部の主面のうち電線３の導体３ａと圧着される側の面、すなわち内周面３４ｂに、金属の溶融時に飛散するスパッタによって形成された金属製の複数の突起部３４ｃとを有している。複数の突起部３４ｃは、上記帯状溶接部を形成するためのレーザ溶接を行う前に予め形成された突起部３４ｃ−１（第１突起部）と、上記レーザ溶接を行う際に発生するスパッタの付着によって形成される突起部３４ｃ−２（第２突起部）とで構成される。なお、説明の便宜上、突起部３４ｃ−１と突起部３４ｃ−２の形状、寸法が異なるが、各突起部の形状、寸法はこれに限られない。また、複数の突起部３４ｃの表面は、薄い酸化膜で覆われていてもよい。 As shown in FIG. 1 (b), the conductor crimping portion 34 includes an outer peripheral portion 34a made of a metal base made of copper or a copper alloy, and a conductor 3a of the electric wire 3 on the side to be crimped to the main surface of the outer peripheral portion. The surface, that is, the inner peripheral surface 34b has a plurality of metal protrusions 34c formed by sputtering that is scattered when the metal is melted. The plurality of protrusions 34c includes a protrusion 34c-1 (first protrusion) that is formed in advance before laser welding for forming the belt-like welded portion, and spatter generated when the laser welding is performed. It is comprised by the protrusion part 34c-2 (2nd protrusion part) formed by adhesion. For convenience of explanation, the shapes and dimensions of the protrusions 34c-1 and 34c-2 are different, but the shapes and dimensions of the protrusions are not limited thereto. The surfaces of the plurality of protrusions 34c may be covered with a thin oxide film.

導体圧着部３４が導体３ａと圧着された状態において、突起部３４ｃ−１は、所定の金属からなる導体３ａの外周面３ｂに食い込んだ状態で固定される。一方、突起部３４ｃ−２は、圧着により、外周部３４ａの内周面３４ｂと、導体３ａの外周面３ｂとの間の空隙３４ｄに埋め込まれる。 In a state where the conductor crimping portion 34 is crimped to the conductor 3a, the protruding portion 34c-1 is fixed in a state of being bitten into the outer peripheral surface 3b of the conductor 3a made of a predetermined metal. On the other hand, the protrusion 34c-2 is embedded in the gap 34d between the inner peripheral surface 34b of the outer peripheral portion 34a and the outer peripheral surface 3b of the conductor 3a by pressure bonding.

すなわち本実施形態では、第１突起部である突起部３４ｃ−１は、導体３ａの外周面３ｂに形成される金属酸化膜を破ることで、接続抵抗の上昇を低減する役割を果たす。また、第２突起部である突起部３４ｃ−２は、導体圧着部３４の内周面３４ｂと導体３ａの外周面３ｂとの間の空隙３４ｄに埋め込まれることで、接続抵抗を低減し且つすきま腐食の発生を抑制する役割を果たす。上記のような役割を果たすべく、突起部３４ｃ−１，３４ｃ−２は、それぞれ外周部３４ａよりも軟質であるのが好ましい。また、突起部３４ｃ−１は、導体３ａよりも硬質であり、突起部３４ｃ−２は、導体３ａよりも軟質であるのが好ましい。 That is, in the present embodiment, the protrusion 34c-1 that is the first protrusion plays a role of reducing the increase in connection resistance by breaking the metal oxide film formed on the outer peripheral surface 3b of the conductor 3a. Further, the protrusion 34c-2, which is the second protrusion, is embedded in the gap 34d between the inner peripheral surface 34b of the conductor crimping portion 34 and the outer peripheral surface 3b of the conductor 3a, thereby reducing the connection resistance and the clearance. It plays a role in suppressing the occurrence of corrosion. In order to play the role as described above, the protrusions 34c-1 and 34c-2 are preferably softer than the outer peripheral part 34a. Moreover, it is preferable that the protrusion part 34c-1 is harder than the conductor 3a, and the protrusion part 34c-2 is softer than the conductor 3a.

但し、第１突起部である突起部３４ｃ−１は、接続抵抗の上昇を低減する役割を果たすものに限られず、第２突起部である突起部３４ｃ−２のように、接続抵抗を低減し且つすきま腐食の発生を抑制する役割を果たしてもよい。すなわち、突起部３４ｃ−１，突起部３４ｃ−２の双方が、導体３ａよりも軟質であってもよい。 However, the protrusion 34c-1 that is the first protrusion is not limited to the role that reduces the increase in connection resistance, and the connection resistance is reduced like the protrusion 34c-2 that is the second protrusion. In addition, it may play a role of suppressing the occurrence of crevice corrosion. That is, both the protrusion 34c-1 and the protrusion 34c-2 may be softer than the conductor 3a.

突起部３４ｃ−１は、これらの役割を果たすべく、外周部３４ｃを構成する金属基体と同種又は異種の材料が選択される。具体的には、この突起部３４ｃ−１は、Ｃｕ、Ｎｉ、Ｓｉ、Ｚｎ、Ｓｎ、Ｍｇ、Ｃｒ、Ｆｅ、Ａｌからなる群から選択される１又は２以上の金属元素を主成分とする。ここで「主成分とする」とは、上記金属元素が５０ｍｏｌ％以上を占める、という意味である。 The protrusion 34c-1 is made of the same or different material as the metal substrate constituting the outer peripheral portion 34c in order to fulfill these roles. Specifically, the protrusion 34c-1 is mainly composed of one or more metal elements selected from the group consisting of Cu, Ni, Si, Zn, Sn, Mg, Cr, Fe, and Al. Here, “main component” means that the metal element occupies 50 mol% or more.

好ましくは、突起部３４ｃ−１は、Ｓｎ、Ｓｎ合金、Ｃｕ、Ｃｕ合金、Ｆｅ、Ｆｅ合金のうちのいずれかの材料からなる。そして、突起部３４ｃ−１の材料を上記金属群から適宜選択することで、突起部３４ｃ−１を、外周部３４ｃよりも軟質であることを条件として、導体よりも硬質或いは軟質とすることが可能となる。例えば、導体圧着部３４の金属基体が銅合金からなり、突起部３４ｃ−１がＳｎ又はＳｎ合金からなり、導体３ａがアルミニウム又はアルミニウム合金からなる場合、突起部３４ｃ−１を、外周部３４ｃよりも軟質であって且つ導体３ａよりも軟質とすることができる。 Preferably, the protrusion 34c-1 is made of any material of Sn, Sn alloy, Cu, Cu alloy, Fe, and Fe alloy. Then, by appropriately selecting the material of the protrusion 34c-1 from the metal group, the protrusion 34c-1 can be made harder or softer than the conductor on the condition that it is softer than the outer peripheral part 34c. It becomes possible. For example, when the metal base of the conductor crimping portion 34 is made of a copper alloy, the protrusion 34c-1 is made of Sn or an Sn alloy, and the conductor 3a is made of aluminum or an aluminum alloy, the protrusion 34c-1 is moved from the outer peripheral portion 34c. Can be made softer than the conductor 3a.

突起部３４ｃ−２は、上記レーザ溶接を行って帯状溶接部６２を形成することにより、外周部３４ａの内周面３４ｂに形成されるため、基本的には外周部３４ａと同種の材料からなる。この場合、突起部３４−２は、その材料組成自体は外周部３４ｃと同一であるが、レーザ溶接時の熱により焼なまされるため、外周部３４ｃよりも軟質となる。これにより、突起部３４ｃ−２を、外周部３４ａよりも軟質であって且つ導体３ａよりも軟質とすることが可能となる。 Since the protrusion 34c-2 is formed on the inner peripheral surface 34b of the outer peripheral portion 34a by forming the belt-like welded portion 62 by performing the above laser welding, it is basically made of the same kind of material as the outer peripheral portion 34a. . In this case, the protrusion 34-2 has the same material composition as that of the outer peripheral portion 34c, but is softer than the outer peripheral portion 34c because it is annealed by heat during laser welding. Thereby, it becomes possible to make the projection part 34c-2 softer than the outer peripheral part 34a and softer than the conductor 3a.

このように本実施形態では、複数の突起部３４ｃは、（１）導体圧着部３４の内周面３４ｂと導体３ａの外周面３ｂとの間の空隙３４ｄの少なくとも一部を埋めることを必須の役割とし、（２）導体の被膜を破る役割を選択的に与えることができる。換言すれば、少なくとも上記（１）の役割を果たすことができれば、導体圧着部３４の材料、突起部３４ｃの材料、電線の導体の材料、並びに突起部３４ｃの形成方法を適宜選択することができる。 As described above, in the present embodiment, it is essential that the plurality of protrusions 34c fill (1) at least part of the gap 34d between the inner peripheral surface 34b of the conductor crimping portion 34 and the outer peripheral surface 3b of the conductor 3a. And (2) a role of breaking the conductor coating can be selectively given. In other words, as long as at least the role (1) can be fulfilled, the material of the conductor crimping portion 34, the material of the protruding portion 34c, the material of the conductor of the electric wire, and the method of forming the protruding portion 34c can be appropriately selected. .

上記（１）及び（２）の役割を果たすためには、導体圧着部（圧着端子）、導体及び突起部の相対的な硬さを考慮する必要がある。表１に、本実施形態における導体圧着部の材料及び硬さ（ビッカーズ硬さ）、電線の導体の材料及び硬さ、並びに突起部の材料及び硬さの例を示す。

In order to fulfill the roles (1) and (2), it is necessary to consider the relative hardness of the conductor crimping portion (crimp terminal), the conductor, and the protrusion. Table 1 shows examples of the material and hardness of the conductor crimping portion (Vickers hardness), the material and hardness of the conductor of the electric wire, and the material and hardness of the protrusion in this embodiment.

表１に示すように、圧着端子、導体及び突起部の各材料の例として、表中Ｎｏ．１〜８のものを挙げることができる。中でも、突起部の材料として挙げられるＳｎ又はＳｎ合金は、軟質であり、好適に使用される。各材料の組み合わせ例として、圧着端子の硬さをＨｖ１、導体の硬さをＨｖ２、突起部の硬さをＨｖ３とすると、Ｈｖ１＞Ｈｖ２の関係を満たすことを前提とし、複数の突起部の一部の硬さＨｖ３が、Ｈｖ２よりも大きい値となるような組み合わせを選択することができる。なお、表１の組み合わせは例示であり、本発明における各材料の組み合わせは、これに限られるものではない。 As shown in Table 1, as examples of each material of the crimp terminal, the conductor, and the protrusion, No. The thing of 1-8 can be mentioned. Especially, Sn or Sn alloy mentioned as a material of a projection part is soft, and is used suitably. As an example of combination of materials, assuming that the hardness of the crimp terminal is Hv1, the hardness of the conductor is Hv2, and the hardness of the protrusion is Hv3, it is assumed that the relationship of Hv1> Hv2 is satisfied. A combination can be selected such that the hardness Hv3 of the part is greater than Hv2. In addition, the combination of Table 1 is an illustration and the combination of each material in this invention is not restricted to this.

なお、突起部３４ｃの突起部３４ｃ−１と３４ｃ−２とは同じ組成のものとすることももちろん可能である。例えば、帯状溶接部６２を形成する際に形成される突起部３４ｃ−２だけでは隙間腐食を防止する機能を十分果たせない場合に、突起部３４ｃ−２と同一組成であり且つ同一の硬さを有する突起部３４ｃ−１があらかじめ形成されていることにより、突起部３４ｃ全体の量を増加させることができる。これにより、突起部３４ｃによる隙間腐食防止機能をより確実に発揮できるようになる点で好ましい。 Of course, the protrusions 34c-1 and 34c-2 of the protrusion 34c may have the same composition. For example, when only the protrusion 34c-2 formed when forming the belt-like welded part 62 cannot sufficiently fulfill the function of preventing crevice corrosion, the protrusion 34c-2 has the same composition and the same hardness. By forming the protrusion 34c-1 to be formed in advance, the amount of the entire protrusion 34c can be increased. Thereby, it is preferable at the point which can exhibit the crevice corrosion prevention function by the projection part 34c more reliably.

また上記実施形態において、導体３ａおよび圧着端子４０の材質は問わないが、異種金属、たとえば導体３ａがアルミまたはアルミ合金であり圧着端子４０が銅または銅合金である場合等、異種金属である場合には、より効果を発揮することができる。 Moreover, in the said embodiment, although the material of the conductor 3a and the crimp terminal 40 is not ask | required, when different metals, for example, when the conductor 3a is aluminum or an aluminum alloy and the crimp terminal 40 is copper or a copper alloy, they are different metals, for example. Can be more effective.

すなわち水分が存在する環境下では異種金属間の電位差による腐食も生じ得るため、突起部３４ｃによって隙間を埋めることにより、筒状圧着部３０内への水分の侵入が抑制され、隙間腐食だけでなく異種金属間腐食の進行をも防ぐ効果が発揮されることになる。 That is, in an environment where moisture exists, corrosion due to a potential difference between different metals may also occur. Therefore, by filling the gap with the protrusion 34c, moisture intrusion into the cylindrical crimp portion 30 is suppressed, and not only crevice corrosion. The effect of preventing the progress of corrosion between different metals will be exhibited.

図２は、図１の圧着端子の製造方法を示すフローチャートであり、図３（ａ）〜（ｅ）は、図１の圧着端子の製造方法を説明する平面図である。なお、図３は板材４１（圧着端子原板）から圧着端子が製造される様子を板材のＮＤ方向（板面に対して垂直な方向）から見た図である。 FIG. 2 is a flowchart showing a method of manufacturing the crimp terminal of FIG. 1, and FIGS. 3A to 3E are plan views illustrating the method of manufacturing the crimp terminal of FIG. FIG. 3 is a view of a state in which the crimp terminal is manufactured from the plate material 41 (crimp terminal original plate) as seen from the ND direction (direction perpendicular to the plate surface) of the plate material.

先ず、銅または銅合金の金属基体からなる板材を圧延して、所定厚さ、例えば０．２５ｍｍの板材４１を作製する（ステップＳ２１）。このとき、基体のＲＤ方向（圧延方向）は、金属基体からなる板材の長手方向のことを指す（図３（ａ））。また、必要に応じて、母材からなる板材４１全体にめっき層を設けて金属基体を形成し、あるいは母材からなる板材４１をマスクした状態で任意の部分にめっき層を設けて金属基体を形成する。めっき層はめっき処理で設けられ、めっき層の材料として、例えばすず、銀、金めっきなどが挙げられる。 First, a plate material made of a copper or copper alloy metal substrate is rolled to produce a plate material 41 having a predetermined thickness, for example, 0.25 mm (step S21). At this time, the RD direction (rolling direction) of the substrate refers to the longitudinal direction of the plate material made of the metal substrate (FIG. 3A). Further, if necessary, a metal layer is formed by providing a plating layer on the entire plate 41 made of a base material, or a metal layer is formed by providing a plating layer on an arbitrary portion in a state where the plate 41 made of the base material is masked. Form. The plating layer is provided by a plating process, and examples of the material of the plating layer include tin, silver, and gold plating.

この金属基体からなる板材４１を、プレス加工（１次プレス）にて、複数の圧着端子が平面展開した状態となるように、繰り返し形状で打ち抜く（ステップＳ２２）。本プレス加工では、各被処理体を片端で支持するいわゆる片持ち型の被処理体が作製され、送り穴４２ｂが等間隔で形成されたキャリア部４２ａに、コネクタ部用板状体４３と、圧着部用板状体４４が一体で形成されている（図３（ｂ））。このとき、繰り返し形状の構成単位となる板状部位（圧着端子原板）は、ＲＤ方向に関して所定ピッチで配列されており、後に形成される筒状圧着部の長手方向がＲＤ方向に対して略垂直（ＴＤ方向）となるように打ち抜かれる。なお、本プレス加工後に母材にめっき層を設けて金属基体としてもよい。すなわち、プレス加工後にめっき処理を施してもよい。 The plate material 41 made of this metal substrate is punched in a repetitive shape by pressing (primary pressing) so that a plurality of crimp terminals are in a flattened state (step S22). In this press working, a so-called cantilevered object to be processed that supports each object to be processed at one end is produced, and a connector part plate 43 and a carrier part 42a in which feed holes 42b are formed at equal intervals, A plate-like body 44 for the crimping part is integrally formed (FIG. 3B). At this time, the plate-like portions (crimp terminal base plates) that are the structural units of the repetitive shape are arranged at a predetermined pitch in the RD direction, and the longitudinal direction of the cylindrical crimp portion formed later is substantially perpendicular to the RD direction. It is punched so as to be (TD direction). Note that a metal layer may be provided by providing a plating layer on the base material after the press working. That is, you may perform a plating process after press work.

次に、繰り返し形状の構成単位となる各板状部位の表面に、複数の突起部３４ｃ−１（第１突起部）を形成する（図３（ｃ）、ステップＳ２３）。具体的には、図４（ａ）に示すように、キャリア部４２ａに形成された送り穴４２ｂにローラ５１，５２の突起部５１ａ，５２ａを挿入して位置決めを行いつつ、上記片持ち型の被処理体をローラ５１，５２で搬送する。その後、ローラ５１，５２の回転を一時的に停止し、各板状部位の金属と同種又は異種の金属からなるスパッタ用板材５４を準備し、レーザ照射装置５３を用いてレーザ光Ｌ１を上方からスパッタ用板材５４に照射する。レーザ照射によってスパッタ用板材５４から発生したスパッタ５５は、圧着部用板状体４４の表面に分散して飛着し、該表面に固着する。これにより圧着部用板状体４４の表面の一部に、突起部３４ｃ−１が形成される（図４（ｂ））。なお、圧着部用板状体４４の表面に突起部３４ｃ−１を形成する方法は、スパッタ付着に限られず、上記（１）あるいは（２）の役割を果たすことを条件として、種々の方法を採用しうる。たとえば、突起部３４ｃ−１とする金属粒や金属粉を圧着部用板状体４４の表面にふりかけ、炉内で高温で熱処理し、圧着部用板状体４４表面に固着させてもよい。また、Ｓｎめっきが施された板状体に金属粉を乗せ、リフロー処理を施すことで金属粉と基材が一体となる突起部を形成してもよいし（拡散接合）、金属粉が載置された板状体にプレスを施すことで金属粉と基材を一体化させ、突起部を形成してもよい。 Next, a plurality of projecting portions 34c-1 (first projecting portions) are formed on the surface of each plate-like portion serving as a repetitive unit (FIG. 3C, step S23). Specifically, as shown in FIG. 4 (a), the protrusions 51a and 52a of the rollers 51 and 52 are inserted into the feed holes 42b formed in the carrier portion 42a for positioning, and the cantilever type The object to be processed is conveyed by rollers 51 and 52. Thereafter, the rotation of the rollers 51 and 52 is temporarily stopped to prepare a sputtering plate 54 made of the same or different metal from the metal in each plate-like portion, and the laser beam L1 is emitted from above using the laser irradiation device 53. Irradiate the sputtering plate 54. Sputters 55 generated from the sputtering plate material 54 by laser irradiation are dispersed and scattered on the surface of the pressure-bonding portion plate 44, and are fixed to the surface. As a result, a protrusion 34c-1 is formed on a part of the surface of the pressure-bonding portion plate 44 (FIG. 4B). Note that the method of forming the protrusion 34c-1 on the surface of the pressure-bonding portion plate 44 is not limited to sputter adhesion, and various methods can be used on the condition that the role (1) or (2) is fulfilled. Can be adopted. For example, the metal particles or metal powder used as the protrusions 34 c-1 may be sprinkled on the surface of the crimping part plate 44 and heat-treated in a furnace at a high temperature to adhere to the surface of the crimping part plate 44. Alternatively, a metal powder may be placed on the plate-like body on which Sn plating has been applied, and a reflow process may be performed to form a protrusion where the metal powder and the base material are integrated (diffusion bonding), or the metal powder may be mounted. The protrusion may be formed by integrating the metal powder and the base material by pressing the placed plate-like body.

次に、繰り返し形状の構成単位となる各板状部位に曲げ加工を施して（２次プレス）、コネクタ部４５と、筒状圧着部とするための圧着部用筒状体４６とを形成する（ステップＳ２４）。このとき、圧着部用筒状体４６の長手方向に垂直な断面は、隙間がごく微小な略Ｃ字型となっている。この隙間を介した基体の端面同士を突き合わせ部４７と呼ぶ（図３（ｄ））。 Next, bending is performed on each plate-like portion serving as a structural unit of a repetitive shape (secondary press) to form a connector portion 45 and a crimping portion tubular body 46 for forming a tubular crimp portion. (Step S24). At this time, the cross section perpendicular to the longitudinal direction of the crimping part tubular body 46 is substantially C-shaped with a very small gap. The end faces of the base body through this gap are called butted portions 47 (FIG. 3D).

その後、圧着部用筒状体４６の上方から例えばレーザ光を照射し、突き合わせ部４７に沿って図中の矢印Ｂ方向に掃引し、当該部分にレーザ溶接を施す（図３（ｅ）、ステップＳ２５）。これにより突き合わせ部４７が溶着し、筒状圧着部４８が形成される。また本ステップにより、溶接痕として帯状溶接部（溶接ビード）が形成され、更に、筒状圧着部４８の内周面に突起部３４ｃ−２が形成される。このレーザ溶接は、後述するファイバレーザを用いて実行される。レーザ溶接機は、溶接中の焦点位置を立体的に調整可能なものを用いることで、筒状体の縮径部などを立体的に溶接することができる。 Thereafter, for example, a laser beam is irradiated from above the crimping portion cylindrical body 46, and is swept in the direction of arrow B in the drawing along the abutting portion 47, and laser welding is performed on the portion (FIG. 3 (e), step S25). As a result, the butted portion 47 is welded, and the cylindrical crimping portion 48 is formed. In addition, by this step, a belt-like welded portion (weld bead) is formed as a welding mark, and further, a protrusion 34 c-2 is formed on the inner peripheral surface of the tubular crimping portion 48. This laser welding is performed using a fiber laser described later. The laser welding machine can three-dimensionally weld the reduced diameter portion of the cylindrical body by using a laser welding machine that can adjust the focal position during welding three-dimensionally.

図５（ａ）、（ｂ）は、図２におけるステップＳ２５のレーザ溶接工程を説明する斜視図である。 5A and 5B are perspective views for explaining the laser welding process in step S25 in FIG.

図５（ａ）に示すように、本実施形態では、例えばファイバレーザ溶接装置６１が使用され、レーザ出力３００〜５００Ｗ、掃引速度９０〜１８０ｍｍ／ｓｅｃ、スポット径約２０μｍにて、圧着部用筒状体４６の突き合わせ部４７が溶接される。このとき、レーザ光Ｌ２が突き合わせ部４７に沿って照射されることで、突き合わせ部４７と略同一位置に帯状溶接部６２が形成される。したがって、帯状溶接部６２は、圧着部用筒状体４６の長手方向（軸方向）に沿って形成される。 As shown in FIG. 5 (a), in this embodiment, for example, a fiber laser welding apparatus 61 is used, a laser output of 300 to 500 W, a sweep speed of 90 to 180 mm / sec, a spot diameter of about 20 μm, and a crimping section cylinder. The butted portion 47 of the body 46 is welded. At this time, the laser beam L <b> 2 is irradiated along the abutting portion 47, so that the belt-like welded portion 62 is formed at substantially the same position as the abutting portion 47. Therefore, the belt-like welded part 62 is formed along the longitudinal direction (axial direction) of the crimping part tubular body 46.

また、突き合わせ部４７の溶接時には、突き合わせ部４７から発生したスパッタが圧着部用筒状体４６の内部空間に飛散する。そして、このスパッタが圧着部用板状体４６の内周面に分散して飛着し、該内周面に固着する。上述したように、ステップＳ２３で圧着部用板状体４４の表面の一部に複数の突起部３４ｃ−１が形成されているため、突き合わせ部４７の溶接によって作製される筒状圧着部４８の内周面のうち、突起部３４ｃ−１が形成された部分では、図６に示すように、突起部３４ｃ−１，３４ｃ−２の双方がランダムに点在する。 Further, when welding the butt portion 47, spatter generated from the butt portion 47 is scattered in the internal space of the crimping portion tubular body 46. And this spatter | spatter is disperse | distributed to the internal peripheral surface of the plate-shaped body 46 for crimping | compression-bonding parts, and it adheres to this internal peripheral surface. As described above, since the plurality of protrusions 34c-1 are formed on a part of the surface of the crimping part plate 44 in step S23, the cylindrical crimping part 48 produced by welding the butting part 47 is used. In the portion of the inner peripheral surface where the protrusions 34c-1 are formed, both the protrusions 34c-1 and 34c-2 are randomly scattered as shown in FIG.

また、図５（ｂ）に示すように、帯状溶接部６２を形成する溶接の後、筒状圧着部のトランジション部側の端部（電線挿入口と反対側の端部）も溶接によって封止した、端部溶接部６４を形成するのが好ましい。この封止は圧着端子の長手方向（筒状圧着部の長手方向）に対して垂直な方向に行われる。この溶接は、金属基体が折り重なった部分を、折り重なった部分の上から溶接するものである。この封止による端部溶接部６４の形成によって、筒状圧着部のトランジション部側の端部が閉塞される。 Further, as shown in FIG. 5B, after welding for forming the belt-like welded portion 62, the end portion on the transition portion side of the cylindrical crimp portion (the end portion on the side opposite to the wire insertion port) is also sealed by welding. The end welded portion 64 is preferably formed. This sealing is performed in a direction perpendicular to the longitudinal direction of the crimp terminal (longitudinal direction of the tubular crimp portion). In this welding, a portion where the metal base is folded is welded from above the folded portion. By forming the end welded part 64 by this sealing, the end part on the transition part side of the cylindrical crimping part is closed.

図３に示す工程により、図５（ｂ）に示すように、被覆圧着部４８ａ及び導体圧着部４８ｂで構成され、且つ長手方向と略同一の方向に沿って形成された帯状溶接部６２を有する筒状圧着部４８と、トランジション部６３を介して一体成形されるコネクタ部４５とを備える圧着端子６０が作製される。筒状圧着部４８のうち、電線の導体と圧着される部分、特に導体圧着部４８ｂの内周面には、突起部３４ｃ−１，３４ｃ−２の双方が形成される。 As shown in FIG. 5 (b), the process shown in FIG. 3 includes a belt-like welded portion 62 that is composed of a coated crimping portion 48a and a conductor crimping portion 48b, and is formed along substantially the same direction as the longitudinal direction. A crimp terminal 60 including a cylindrical crimp part 48 and a connector part 45 that is integrally formed via a transition part 63 is produced. Both protrusions 34c-1 and 34c-2 are formed on a portion of the cylindrical crimp portion 48 that is crimped to the conductor of the electric wire, particularly on the inner peripheral surface of the conductor crimp portion 48b.

突起部３４ｃは、導体圧着部４８ｂの内周面、すなわち電線の導体と圧着される側の面からの高さが１μｍ〜１２０μｍであるのが好ましく、より好ましくは３μｍ〜１００μｍである。また、導体圧着部４８ｂの内周面の平面視、具体的には、ファイバレーザ掃引直下の５００μｍ×５００μｍ（＝０．２５ｍｍ^２）内の視野において、上記高さの範囲内にある複数の突起部３４ｃの面積占有率は、表面積の３〜９８％であるのが好ましく、より好ましくは５〜９５％である。また、同一視野内における複数の突起部３４ｃの最大高さが１μｍ〜１２０μｍであるのが好ましく、より好ましくは３μｍ〜１００μｍである。これにより、導体圧着部４８ｂへの電線の挿入容易性を確保しつつ、突起部３４ｃの上記役割を実現することができる。 The protrusion 34c preferably has a height of 1 μm to 120 μm, more preferably 3 μm to 100 μm, from the inner peripheral surface of the conductor crimping portion 48b, that is, the surface to be crimped to the conductor of the electric wire. Further, in the plan view of the inner peripheral surface of the conductor crimping portion 48b, specifically, in the field of view within 500 μm × 500 μm (= 0.25 mm ² ) immediately below the fiber laser sweep, a plurality of protrusions within the above height range The area occupation ratio of the part 34c is preferably 3 to 98% of the surface area, and more preferably 5 to 95%. Moreover, it is preferable that the maximum height of the some projection part 34c within the same visual field is 1 micrometer-120 micrometers, More preferably, they are 3 micrometers-100 micrometers. Thereby, the said role of the protrusion part 34c is realizable, ensuring the insertion ease of the electric wire to the conductor crimping | compression-bonding part 48b.

また、上記工程にて作製された圧着端子を、絶縁被覆を剥いで導体３ａを露出させた電線３の端部に圧着することにより、接続構造体が作製される。このとき、導体圧着部４８ｂの内周面と電線３の導体３ａとの間に突起部３４ｃ−１，３４ｃ−２を介在させた状態で、導体圧着部４８ｂと電線３の導体３ａとを圧着する。本圧着により、突起部３４ｃ−１は導体３ａに食い込み、突起部３４ｃ−２は、導体圧着部４８ｂの内周面と電線の導体との間の空隙に埋め込まれる（図１（ｂ））。この接続構造体において、導体圧着部４８ｂの長手方向に垂直な断面における導体圧着部の空隙率Ｒは、１％以下であるのが好ましく、より好ましくは、０．５％以下である。また、止水性を考慮した場合、上記空隙率Ｒは、０．１％以下であるのが好ましい。 Moreover, a connection structure is produced by crimping the crimp terminal produced at the said process to the edge part of the electric wire 3 which stripped insulation coating and exposed the conductor 3a. At this time, the conductor crimping portion 48b and the conductor 3a of the electric wire 3 are crimped with the protrusions 34c-1 and 34c-2 interposed between the inner peripheral surface of the conductor crimping portion 48b and the conductor 3a of the electric wire 3. To do. By the main crimping, the protrusion 34c-1 bites into the conductor 3a, and the protrusion 34c-2 is embedded in the gap between the inner peripheral surface of the conductor crimping part 48b and the conductor of the electric wire (FIG. 1B). In this connection structure, the void ratio R of the conductor crimping portion in the cross section perpendicular to the longitudinal direction of the conductor crimping portion 48b is preferably 1% or less, and more preferably 0.5% or less. Further, when considering the water stoppage, the porosity R is preferably 0.1% or less.

上述したように、本実施形態によれば、導体圧着部３４の内周面３４ｂに金属製の突起部３４ｃ−１，３４ｃ−２が設けられる。よって、導体圧着部４８ｂが導体３ａと圧着される際、突起部３４ｃ−１が導体３ａの金属酸化膜を破ることができ、接続抵抗を低減することができる。また、導体圧着部３４と導体３ａの間の空隙３４ｄが突起部３４ｃ−２で埋められるので、導体圧着部３４と導体３ａの間の空隙を減少することができる。これにより、熱衝撃による空隙の拡張を抑制することができ、導体３ａと導体圧着部３４の接続抵抗を低減することができる。また、水分等が存在する環境下においても、導体圧着部３４と導体３ａの接触部での隙間腐食を抑制することができる。したがって、電線圧着後の初期状態、高温環境下或いは腐食環境下のいずれにおいても、導体圧着部−導体間の接続抵抗を低減しつつ、隙間腐食を抑制することができ、長期に亘って電気的な接続信頼性を維持することができる。 As described above, according to the present embodiment, the metal protrusions 34 c-1 and 34 c-2 are provided on the inner peripheral surface 34 b of the conductor crimping portion 34. Therefore, when the conductor crimping portion 48b is crimped to the conductor 3a, the protrusion 34c-1 can break the metal oxide film of the conductor 3a, and the connection resistance can be reduced. Further, since the gap 34d between the conductor crimping portion 34 and the conductor 3a is filled with the protrusion 34c-2, the gap between the conductor crimping portion 34 and the conductor 3a can be reduced. Thereby, the expansion | swelling of the space | gap by a thermal shock can be suppressed and the connection resistance of the conductor 3a and the conductor crimping | compression-bonding part 34 can be reduced. Moreover, crevice corrosion at the contact portion between the conductor crimping portion 34 and the conductor 3a can be suppressed even in an environment where moisture or the like is present. Therefore, it is possible to suppress crevice corrosion while reducing the connection resistance between the conductor crimping part and the conductor in the initial state after crimping the wire, in a high-temperature environment or in a corrosive environment, and it can be electrically Connection reliability can be maintained.

また、突起部３４ｃ−１，３４ｃ−２は、導体圧着部３４の内周面３４ｂにスパッタの付着によって形成されるので、突起部３４ｃ−１，３４ｃ−２を導体圧着部３４に容易に且つ強固に固着することができ、接続抵抗を確実に低減することができる。 Further, since the protrusions 34c-1 and 34c-2 are formed on the inner peripheral surface 34b of the conductor crimping portion 34 by sputtering, the protrusions 34c-1 and 34c-2 can be easily attached to the conductor crimping portion 34. It can be firmly fixed and the connection resistance can be reliably reduced.

更に、突起部３４ｃ−２が金属基体よりも軟質な材料で形成されるので、電線圧着時に、突起部３４ｃ−２が導体圧着部３４と導体３ａの間で塑性変形し易くなり、導体圧着部３４と導体３ａの間の空隙３４ｄを大幅に減少することができる。特に、従来の筒状圧着部を有する圧着端子と電線とで構成される接続構造体と比較して、導体圧着部−導体間の空隙率Ｒを大幅に低下させることができる。 Furthermore, since the protrusion 34c-2 is formed of a softer material than the metal substrate, the protrusion 34c-2 is easily plastically deformed between the conductor crimping part 34 and the conductor 3a when the electric wire is crimped. The gap 34d between the conductor 34 and the conductor 3a can be greatly reduced. In particular, the void ratio R between the conductor crimping part and the conductor can be significantly reduced as compared with a connection structure composed of a crimping terminal having a conventional cylindrical crimping part and an electric wire.

以上、上記実施形態に係る圧着端子およびその製造方法について述べたが、本発明は記述の実施形態に限定されるものではなく、本発明の技術思想に基づいて各種の変形および変更が可能である。 As mentioned above, although the crimp terminal concerning the said embodiment and its manufacturing method were described, this invention is not limited to description embodiment, Various deformation | transformation and a change are possible based on the technical idea of this invention. .

例えば、図１では圧着端子４０が筒状圧着部３０を有するが（クローズドバレル型圧着端子）、複数の突起部をオープンバレル型圧着端子に形成してもよい。具体的には圧着端子７０は、図７（ａ）に示すように、外部端子と電気的に接続されるコネクタ部１０’と、該コネクタ部とトランジション部２０’を介して一体的に設けられ、電線３と圧着される電線圧着部８０とを備えている。電線圧着部８０は、トランジション部２０’を介してコネクタ部１０’と連結され、電線３の導体３ａに圧着される導体圧着部８１と、該導体圧着部と一体成形され、電線３の絶縁被覆３ｃに圧着される被覆圧着部８２とを備えている。 For example, although the crimp terminal 40 has the cylindrical crimp part 30 in FIG. 1 (closed barrel type crimp terminal), you may form a some protrusion in an open barrel type crimp terminal. Specifically, as shown in FIG. 7A, the crimp terminal 70 is integrally provided via a connector portion 10 ′ electrically connected to an external terminal, and the connector portion and the transition portion 20 ′. The electric wire 3 and the electric wire crimping portion 80 to be crimped are provided. The wire crimping portion 80 is connected to the connector portion 10 ′ via the transition portion 20 ′, and is integrally formed with the conductor crimping portion 81 that is crimped to the conductor 3 a of the electric wire 3. And a cover crimping portion 82 to be crimped to 3c.

導体圧着部８１は、銅あるいは銅合金からなる金属基体からなる、断面略Ｕ字型のベース部８１ａと、該ベース部の主面のうち電線３の導体３ａと圧着される側の面、すなわち内側面８１ｂに形成された金属製の複数の突起部８１ｃとを有している。被覆圧着部８２は、断面略Ｕ字型であり、銅あるいは銅合金からなる金属基体からなる。 The conductor crimping portion 81 includes a base portion 81a having a substantially U-shaped cross section made of a metal base made of copper or a copper alloy, and a surface of the main surface of the base portion that is to be crimped to the conductor 3a of the electric wire 3; And a plurality of metal protrusions 81c formed on the inner surface 81b. The covering crimping part 82 has a substantially U-shaped cross section and is made of a metal substrate made of copper or a copper alloy.

オープンバレル型の圧着端子７０の製造方法は、図２の製造方法におけるステップＳ２５が省略されること以外は、図２の製造方法と基本的に同じである。具体的には、先ず、銅または銅合金の金属基体からなる板材を圧延して、所定厚さの板材を作製する。また、必要に応じて、母材からなる板材全体或いは板材の一部にめっき層を設けて金属部材を形成する。次に、この金属基体からなる板材を、プレス加工（１次プレス）にて、複数の圧着端子が平面展開した状態となるように、繰り返し形状で打ち抜く。次いで、繰り返し形状の構成単位となる各板状部位における圧着部用板状体の表面に、複数の突起部を形成する。このとき、各板状部位の金属と同種又は異種の金属からなるスパッタ用板材を準備し、レーザ照射装置を用いてレーザ光を上方からスパッタ用板材に照射し、スパッタ用板材から発生したスパッタを圧着部用板状体の表面の一部（導体圧着部に相当する部分）に飛着させることにより、圧着部用板状体に複数の突起部が形成される。その後、繰り返し形状の構成単位となる各板状部位に曲げ加工を施して（２次プレス）、コネクタ部と電線圧着部とを形成する。 The manufacturing method of the open barrel type crimp terminal 70 is basically the same as the manufacturing method of FIG. 2 except that step S25 in the manufacturing method of FIG. 2 is omitted. Specifically, first, a plate material made of a copper or copper alloy metal substrate is rolled to produce a plate material having a predetermined thickness. In addition, if necessary, a metal layer is formed by providing a plating layer on the entire plate made of the base material or a part of the plate. Next, the plate material made of the metal substrate is punched in a repetitive shape by pressing (primary pressing) so that a plurality of crimp terminals are in a flattened state. Next, a plurality of protrusions are formed on the surface of the pressure-bonding plate at each plate-shaped portion that is a structural unit having a repetitive shape. At this time, a sputtering plate made of the same or different metal as the metal of each plate-like part is prepared, and the sputtering plate is irradiated with laser light from above using a laser irradiation device, and the sputtering generated from the sputtering plate is made. A plurality of protrusions are formed on the pressure-bonding-plate-like body by landing on a part of the surface of the pressure-bonding-plate-shaped body (a portion corresponding to the conductor pressure-bonding portion). After that, bending is performed on each plate-like portion serving as a repetitive unit (secondary press) to form a connector portion and a wire crimping portion.

上記のように作製された圧着端子７０を、絶縁被覆３ｃを剥いで導体３ａを露出させた電線３の端部に圧着することにより、接続構造体１’が形成される（図７（ｂ））。このとき、導体圧着部８１に形成された複数の突起部８１ｃは、図１の突起部３４ｃ−１と同様の役割を果たし、所定金属からなる導体３ａの外表面に食い込んだ状態で固定される。但し、複数の突起部が導体３ａよりも軟質となるようにスパッタ用板材の材料を選択し、当該スパッタ用板材から発生したスパッタを圧着部用板状体の表面に飛着させることができる。これにより、導体圧着部８１に形成された複数の突起部８１ｃは、図１の突起部３４ｃ−２と同様の役割を果たし、ベース部８１ａの内側面８１ｂと、導体３ａの外周面３ｂとの間の空隙に埋め込まれる。 The connection structure 1 ′ is formed by crimping the crimp terminal 70 manufactured as described above to the end of the electric wire 3 where the conductor 3a is exposed by peeling off the insulating coating 3c (FIG. 7B). ). At this time, the plurality of projecting portions 81c formed on the conductor crimping portion 81 play the same role as the projecting portion 34c-1 in FIG. 1, and are fixed in a state of being bitten into the outer surface of the conductor 3a made of a predetermined metal. . However, the material of the sputtering plate material can be selected so that the plurality of protrusions are softer than the conductor 3a, and the sputter generated from the sputtering plate material can be landed on the surface of the pressure bonding plate. Thereby, the plurality of protrusions 81c formed on the conductor crimping part 81 play a role similar to that of the protrusion 34c-2 in FIG. 1, and the inner surface 81b of the base part 81a and the outer peripheral surface 3b of the conductor 3a Embedded in the gap between.

また、オープンバレル型の圧着端子７０の製造方法では、図２のステップＳ２５が省略されるため、レーザ溶接時のスパッタによる突起部の形成は行われない。よって、圧着端子７０の製造方法において、異なる材料からなるスパッタ用板材を２つ準備し、第１スパッタ用板材にレーザ光を照射して圧着部用板状体の表面に複数の第１突起部を形成し、次いで、第２スパッタ用板材にレーザ光を照射して同圧着部用板状体に複数の第２突起部を形成してもよい。これにより、図６に示すような、上記（１）及び（２）の双方の役割を果たす複数の突起部を形成することができる。 Further, in the manufacturing method of the open barrel type crimp terminal 70, step S25 of FIG. 2 is omitted, and thus no projection is formed by sputtering during laser welding. Therefore, in the method of manufacturing the crimp terminal 70, two sputtering plate materials made of different materials are prepared, and the first sputtering plate material is irradiated with laser light to form a plurality of first protrusions on the surface of the crimp-bonding plate member. Then, the second sputtering plate material may be irradiated with laser light to form a plurality of second protrusions on the pressure-bonding plate member. Thereby, as shown in FIG. 6, the some projection part which plays both the said (1) and (2) can be formed.

図８は、本実施形態に係る圧着端子の他の変形例を示す図であり、（ａ）は全体斜視図、（ｂ）はセレーション（凹部）が形成された筒状圧着部の部分拡大断面図である。尚、図８の圧着端子は、筒状圧着部にセレーションを形成したこと以外は、図５（ｂ）の圧着端子と基本的に同じであるので、以下に異なる部分を説明する。 FIG. 8 is a view showing another modified example of the crimp terminal according to the present embodiment, wherein (a) is an overall perspective view, and (b) is a partially enlarged cross-section of a cylindrical crimp part in which serrations (recesses) are formed. FIG. The crimp terminal shown in FIG. 8 is basically the same as the crimp terminal shown in FIG. 5B except that serrations are formed in the cylindrical crimp part, and different parts will be described below.

図８（ａ）において、圧着端子９０は、被覆圧着部９２及び導体圧着部９３で構成され、且つ長手方向と略同一の方向に沿って形成された帯状溶接部（不図示）を有する筒状圧着部９１と、トランジション部６３を介して一体成形されるコネクタ部４５とを備える。筒状圧着部９１のうち、電線の導体と圧着される部分、特に導体圧着部９３の内周面９３ａには、突起部９５ａ，９５ｂが形成されている（図８（ｂ））。また、導体圧着部９３の内周面９３ａには、長手方向に対して略直角な方向に沿って延出する溝９４が設けられている。この溝９４の内側面９４ａにも、突起部９５ａ，９５ｂが形成されている。このように、導体圧着部９３の内周面９３ａに溝９４が形成されることにより、圧着時に溝９４の上縁部が電線３の導体３ａに食い込み、導体３ａの金属酸化膜を破ることができる。また、導体圧着部９３の内周面９３ａ及び溝９４の内側面９４ａに突起部９５ａ，９５ｂが形成されることにより、導体３ａの金属酸化膜をより破り易くなり、且つ導体圧着部９３と導体３ａとの間の間隙を減少することができる。 In FIG. 8A, a crimp terminal 90 is formed of a coated crimp portion 92 and a conductor crimp portion 93, and has a tubular shape having a belt-like welded portion (not shown) formed along substantially the same direction as the longitudinal direction. A crimping portion 91 and a connector portion 45 that are integrally formed via a transition portion 63 are provided. Protrusions 95a and 95b are formed on a portion of the tubular crimping portion 91 that is crimped to the conductor of the electric wire, particularly on the inner peripheral surface 93a of the conductor crimping portion 93 (FIG. 8B). Further, the inner peripheral surface 93a of the conductor crimping portion 93 is provided with a groove 94 that extends along a direction substantially perpendicular to the longitudinal direction. Protrusions 95 a and 95 b are also formed on the inner side surface 94 a of the groove 94. Thus, by forming the groove 94 on the inner peripheral surface 93a of the conductor crimping portion 93, the upper edge portion of the groove 94 may bite into the conductor 3a of the electric wire 3 during crimping and break the metal oxide film of the conductor 3a. it can. Further, since the protrusions 95a and 95b are formed on the inner peripheral surface 93a of the conductor crimping portion 93 and the inner side surface 94a of the groove 94, the metal oxide film of the conductor 3a is more easily broken, and the conductor crimping portion 93 and the conductor It is possible to reduce the gap with 3a.

なお、導体圧着部９３に溝９４を設けることで導体と圧着部の接続抵抗を十分に低減することができれば、導体の金属酸化膜を破る役割を果たす突起部９５ａを設けなくてもよい。すなわち、導体圧着部９３の内周面９３ａ及び溝９４の内側面９４ａに、導体圧着部９３と導体３ａとの間の間隙を減少する役割を果たす突起部９５ｂのみを設けてもよい。また、上記変形例では導体圧着部９３の内周面９３ａに溝９４が形成されるが、これに限らず、所定パターンで形成された凹部或いは凸部が平面方向にならんで形成されてもよい。 In addition, if the connection resistance between the conductor and the crimping part can be sufficiently reduced by providing the groove 94 in the conductor crimping part 93, it is not necessary to provide the protruding part 95a that plays the role of breaking the metal oxide film of the conductor. That is, only the protrusion 95b that serves to reduce the gap between the conductor crimping portion 93 and the conductor 3a may be provided on the inner peripheral surface 93a of the conductor crimping portion 93 and the inner side surface 94a of the groove 94. In the above modification, the groove 94 is formed on the inner peripheral surface 93a of the conductor crimping portion 93. However, the present invention is not limited to this, and the concave portion or the convex portion formed in a predetermined pattern may be formed along the plane direction. .

例えば、導体圧着部が導体に圧着される前の状態で、凹部が導体の長手方向に対して交差する交差方向に間隔を空けて並んで形成されてもよい。また、上記凹部の上縁部は四角形状であり、上記凹部の上縁部を構成する少なくとも一つの辺が、導体の長手方向に対して８５°〜９５°の角度で交差する交差辺であってもよい。また、上記交差辺の長さ寸法は、交差方向に関して隣り合う凹部の交差辺同士の間隔以上であり、且つ、導体の長手方向に隣接して位置する複数の凹部の交差辺同士は、上記長手方向にオーバーラップして形成されてもよい。また、上記交差方向における凹部のピッチ間隔は、０．１ｍｍ〜０．８ｍｍであってもよい。更に、上記交差方向に関して隣り合う凹部同士の間隔は、０．１ｍｍ以上であり、且つ交差方向における凹部のピッチ間隔Ｐ１の１／２以下であってもよい。 For example, in a state before the conductor crimping portion is crimped to the conductor, the recesses may be formed side by side in the intersecting direction intersecting the longitudinal direction of the conductor. The upper edge of the recess is a quadrangle, and at least one side constituting the upper edge of the recess is an intersecting side that intersects with the longitudinal direction of the conductor at an angle of 85 ° to 95 °. May be. Further, the length dimension of the intersecting side is not less than the interval between the intersecting sides of the recesses adjacent to each other in the intersecting direction, and the intersecting sides of the plurality of recesses located adjacent to each other in the longitudinal direction of the conductor It may be formed to overlap in the direction. Further, the pitch interval of the recesses in the intersecting direction may be 0.1 mm to 0.8 mm. Furthermore, the space | interval of adjacent recessed parts regarding the said crossing direction may be 0.1 mm or more, and may be 1/2 or less of the pitch space | interval P1 of the recessed part in a crossing direction.

また、図１では圧着端子４０が電線３と圧着された状態を示しているが、図９に示すように、電線と圧着される前の状態で、圧着端子１００が筒状圧着部に段差形状を有していてもよい。具体的には、筒状圧着部１０１は、トランジション部２０側が閉塞された筒部材であって、不図示の電線の絶縁被覆と圧着される被覆圧着部１０３と、挿入口１０２側からトランジション部２０側に向かって縮径する縮径部１０４と、電線の導体と圧着される導体圧着部１０５と、挿入口１０２側からトランジション部２０側に向かって更に縮径し、その端部が溶接により閉塞される縮径部１０６とを有していてもよい。本構成においては、導体圧着部１０５の内周面に複数の突起部が形成される。 1 shows a state in which the crimp terminal 40 is crimped to the electric wire 3, but as shown in FIG. 9, the crimp terminal 100 has a stepped shape in the cylindrical crimp portion before being crimped to the electric wire. You may have. Specifically, the cylindrical crimping portion 101 is a cylindrical member closed on the transition portion 20 side, and includes a coated crimping portion 103 to be crimped to an insulation coating of an unillustrated electric wire, and the transition portion 20 from the insertion port 102 side. A diameter-reducing portion 104 that is reduced in diameter toward the side, a conductor crimping portion 105 that is crimped to the conductor of the electric wire, and a diameter that is further reduced from the insertion port 102 side toward the transition portion 20 side, and the end portion is closed by welding. The diameter-reduced portion 106 may be included. In this configuration, a plurality of protrusions are formed on the inner peripheral surface of the conductor crimping portion 105.

このように筒状圧着部１０１が段差形状を有することで、電線端部の絶縁被覆を除去して当該端部を筒状圧着部１０１に挿入したとき、電線の絶縁被覆が縮径部１０４で係止され、これにより被覆圧着部１０３の直下に絶縁被覆が位置し、導体圧着部１０５の直下に導体が位置する。したがって、電線端部の位置決めを容易に行うことができ、被覆圧着部１０３と絶縁被覆との圧着、および導体圧着部１０５と導体の圧着を確実に行うことが可能となり、良好な止水性および電気的接続を両立して、優れた密着性を実現することができる。また、導体圧着部１０５の内周面に複数の突起部が形成されるので、圧着時に導体の金属酸化膜を破りつつ導体圧着部１０５と導体との間の空隙を埋めることができ、接続抵抗の増大を抑制しつつ、隙間腐食の発生を抑制することができる。 Thus, when the cylindrical crimping part 101 has a stepped shape, when the insulation coating at the end of the electric wire is removed and the end is inserted into the cylindrical crimping part 101, the insulating coating of the electric wire is reduced by the reduced diameter part 104. As a result, the insulation coating is located immediately below the coating crimping portion 103, and the conductor is located directly below the conductor crimping portion 105. Therefore, the end of the electric wire can be easily positioned, the crimping between the coated crimping portion 103 and the insulating coating, and the crimping between the conductor crimping portion 105 and the conductor can be performed reliably, and good water stopping and electrical It is possible to achieve excellent adhesiveness while achieving simultaneous connection. Further, since a plurality of protrusions are formed on the inner peripheral surface of the conductor crimping portion 105, the gap between the conductor crimping portion 105 and the conductor can be filled while breaking the metal oxide film of the conductor during crimping, and the connection resistance It is possible to suppress the occurrence of crevice corrosion while suppressing the increase of.

また、図１の圧着端子ではコネクタ部１０がボックス型の雌型圧着端子であるが、これに限らず、図１０で示すようにコネクタ部が雄型圧着端子であってもよい。具体的には、圧着端子１１０が、不図示の電線と圧着される筒状圧着部１１１と、該筒状圧着部とトランジション部１１２を介して一体的に設けられ、不図示の外部端子と電気的に接続されるコネクタ部１１３とを備え、筒状圧着部１１１の内周面に複数の突起部が形成されてもよい。コネクタ部１１３は、長尺状の接続部１１３ａを有しており、当該接続部が外部端子である不図示の雌型圧着端子に長手方向に沿って挿入されることで、雌型圧着端子と電気的に接続される。本構成によっても、電線圧着時に導体の金属酸化膜を破りつつ、筒状圧着部１１１と導体との間の空隙を埋めることができ、接続抵抗の増大を抑制しつつ、隙間腐食の発生を抑制することができる。 Further, in the crimp terminal shown in FIG. 1, the connector portion 10 is a box-type female crimp terminal. However, the present invention is not limited to this, and the connector portion may be a male crimp terminal as shown in FIG. Specifically, the crimp terminal 110 is integrally provided via a cylindrical crimp part 111 to be crimped to an electric wire (not shown), the cylindrical crimp part and the transition part 112, and an external terminal (not shown) is electrically connected. A plurality of protrusions may be formed on the inner peripheral surface of the tubular crimping part 111. The connector portion 113 has a long connecting portion 113a, and the connecting portion is inserted along a longitudinal direction into a female crimp terminal (not shown) that is an external terminal, so that the female crimp terminal and Electrically connected. Even with this configuration, it is possible to fill the gap between the tubular crimping part 111 and the conductor while breaking the metal oxide film of the conductor when crimping the wire, and suppress the occurrence of crevice corrosion while suppressing an increase in connection resistance. can do.

以下、本発明の実施例を説明する。
（実施例１）
先ず、圧着端子の金属基体として，厚さ０．２５ｍｍの銅合金板材（古河電気工業社製、「ＦＡＳ−６８０」）を用いた。ＦＡＳ−６８０の合金組成は、ニッケル（Ｎｉ）を２．０〜２．８質量％，シリコン（Ｓｉ）を０．４５〜０．６質量％，亜鉛（Ｚｎ）を０．４〜０．５５質量％，すず（Ｓｎ）を０．１〜０．２５質量％，およびマグネシウム（Ｍｇ）を０．０５〜０．２質量％含有し、残部が銅（Ｃｕ）および不可避不純物である。また、最表層にすずめっきが施された金属部材を用いた。上記金属部材に打ち抜き加工を施し、Ｆクリンプ（オープンバレル型）用の圧着端子原板を作製した。 Examples of the present invention will be described below.
Example 1
First, a 0.25 mm-thick copper alloy plate material (“FAS-680” manufactured by Furukawa Electric Co., Ltd.) was used as the metal base of the crimp terminal. The alloy composition of FAS-680 is nickel (Ni) 2.0-2.8 mass%, silicon (Si) 0.45-0.6 mass%, zinc (Zn) 0.4-0.55. It contains 0.1% to 0.25% by mass of tin (Sn) and 0.05 to 0.2% by mass of magnesium (Mg), with the balance being copper (Cu) and inevitable impurities. Moreover, the metal member by which tin plating was given to the outermost layer was used. The metal member was punched to produce a crimp terminal original plate for F crimp (open barrel type).

最表層がすずめっきで覆われたＦＡＳ−６８０のスパッタ用板材にファイバレーザを照射し、上記圧着端子原板の導体圧着部に相当する部分にスパッタを付着させた。レーザ光源として、古河電気工業製、５００ＷＣＷファイバレーザＡＳＦ１Ｊ２３３（波長１０８４ｎｍシングルモード発振レーザ光）を用い、ガルバノスキャナ(非テレセントリック)を用いた掃引照射、レーザ光出力、掃引速度、掃引回数を変数として目的の突起部物高さ、面積占有率を得るよう調整した。 The FAS-680 sputtering plate material whose outermost layer was covered with tin plating was irradiated with a fiber laser, and the spatter was deposited on the portion corresponding to the conductor crimping portion of the crimp terminal original plate. As a laser light source, a 500 W CW fiber laser ASF1J233 (single-mode oscillation laser light with a wavelength of 1084 nm) manufactured by Furukawa Electric Co., Ltd. is used, and sweep irradiation using a galvano scanner (non-telecentric), laser light output, sweep speed, and number of sweeps are used as variables. Adjustments were made to obtain the desired protrusion height and area occupancy.

アルミニウム電線の芯線（導体）は、線径φ０．４３ｍｍのアルミニウム導体（古河電気工業社製、アルミ合金ＭＳＡｌ）を用いた。ＭＳＡｌの合金組成は、鉄（Ｆｅ）を約０．２％、銅（Ｃｕ）を約０．２％、マグネシウム（Ｍｇ）を約０．１％、シリコン（Ｓｉ）を約０．０４％、残部がアルミニウム（Ａｌ）および不可避不純物である。ＭＳＡｌを用いて、２．５ｓｑ、１９本撚りの導体撚線を作製した。 As the core wire (conductor) of the aluminum electric wire, an aluminum conductor (manufactured by Furukawa Electric Co., Ltd., aluminum alloy MSAl) having a wire diameter of φ0.43 mm was used. The alloy composition of MSAl is about 0.2% iron (Fe), about 0.2% copper (Cu), about 0.1% magnesium (Mg), about 0.04% silicon (Si), The balance is aluminum (Al) and inevitable impurities. A 2.5 sq, 19-stranded conductor stranded wire was prepared using MSAl.

上記圧着端子原板に曲げ加工を施して作製した圧着端子に上記導体撚線を圧着して接続構造体とし、圧着端子と導体撚線を圧着した状態で、初期状態、サーマル試験（＋１２０℃の高温環境及び−４０℃の低温環境を、交互に１０００サイクル繰返し実行）、また、塩水噴霧試験（５質量％塩水、３５℃、９６時間放置）後の接続抵抗を抵抗測定機（日置電機社製、Ｈｉｏｋｉ３５６０ＡＣＭｉｌｌｉｏｈｍＨｉＴｅｓｔｅｒ）を用いて測定した。 The conductor stranded wire is crimped to a crimp terminal prepared by bending the crimp terminal base plate to form a connection structure, and the initial state, thermal test (high temperature of + 120 ° C.) with the crimp terminal and conductor stranded wire crimped. Environment and low temperature environment of −40 ° C. are alternately repeated 1000 cycles), and connection resistance after a salt spray test (5 mass% salt water, 35 ° C., left for 96 hours) is a resistance measuring machine (manufactured by Hioki Electric Co., Ltd., Measured using a HIOKI 3560 AC Milliom HiTester.

抵抗値が１．３ｍΩ以下の場合を極めて良好「◎」とし、１．４〜１．６ｍΩの場合を良好「○」、１．７〜１．９ｍΩの場合をほぼ良好「△」、２．０ｍΩ以上の場合を不良「×」とした。また、導体圧着部の金属部材表面からの突起部物の高さ、及びレーザ照射部直下の５００μｍ×５００μｍ（＝０．２５ｍｍ^２）に突起部物が占める面積率を、それぞれレーザ顕微鏡（ＫＥＹＥＮＣＥ製、ＶＫ−８５００）により求めた。評価結果を表２に示す。

When the resistance value is 1.3 mΩ or less, it is marked as “Good”, when it is 1.4 to 1.6 mΩ, “Good”, when it is 1.7 to 1.9 mΩ, “Good”. A case of 0 mΩ or more was defined as a defective “x”. Further, the height of the protrusion from the surface of the metal member of the conductor crimping portion and the area ratio occupied by the protrusion in the 500 μm × 500 μm (= 0.25 mm ² ) immediately below the laser irradiation portion are respectively measured with a laser microscope (manufactured by KEYENCE). VK-8500). The evaluation results are shown in Table 2.

（実施例２）
オープンバレル型圧着端子の導体圧着部にセレーション（凹部）を形成すること以外は、実施例１と同様にして圧着端子及び接続構造体を作製した。すなわち、圧着端子原板の導体圧着部に相当する部分の面上に、プレス加工により、導体の長手方向に対して９０°の角度で交差する交差辺を有し、上記交差方向における凹部のピッチ間隔が０．６ｍｍ、更に、上記交差方向に関して隣り合う凹部同士の間隔が０．３ｍｍである複数の四角形状の凹部を形成した。次いで、圧着端子原板の導体圧着部に相当する部分の面上、及び複数の凹部の内側面に、それぞれスパッタを付着させた。その後、上記圧着端子原板に曲げ加工を施して作製した圧着端子に実施例１と同様の導体撚線を圧着して接続構造体を作製した。突起部、突起部の最大高さ及び各抵抗値の測定は、実施例１と同様の方法で行った。評価結果を表３に示す。

(Example 2)
A crimp terminal and a connection structure were produced in the same manner as in Example 1 except that serrations (concave portions) were formed in the conductor crimp portion of the open barrel crimp terminal. That is, on the surface of the portion corresponding to the conductor crimping portion of the crimp terminal original plate, there is an intersecting side that intersects the longitudinal direction of the conductor at an angle of 90 ° by pressing, and the pitch interval of the recesses in the intersecting direction Further, a plurality of quadrangular recesses having an interval of 0.3 mm between adjacent recesses in the crossing direction were formed. Subsequently, sputter | spatter was made to adhere to the surface of the part corresponded to the conductor crimping | compression-bonding part of a crimp terminal original board, and the inner surface of several recessed part, respectively. Thereafter, a conductor twisted wire similar to that of Example 1 was crimped to a crimp terminal produced by bending the crimp terminal original plate to produce a connection structure. The measurement of the protrusion, the maximum height of the protrusion, and each resistance value was performed in the same manner as in Example 1. The evaluation results are shown in Table 3.

表２の結果から、発明例１〜２１に示すように、導体圧着部の主面に形成される突起部の面積占有率を３〜９８％、突起部の最大高さを１μｍ〜１２０μｍとすれば、初期状態、サーマルショック試験、塩水噴霧試験のいずれにおいても抵抗値が１．９ｍΩ以下となり、熱衝撃による空隙の拡張を抑制することができると共に、導体圧着部と導体の接触部での隙間腐食を抑制することができることが分かった。一方、比較例１に示すように、導体圧着部に突起部を形成しない場合、初期状態での抵抗値は１．９ｍΩ以下であったものの、サーマルショック試験及び塩水噴霧試験での抵抗値はいずれも２．０ｍΩ以上となり、高温環境下及び腐食環境下で良好な抵抗値が得られないことが分かった。 From the results in Table 2, as shown in Invention Examples 1 to 21, the area occupation ratio of the protrusions formed on the main surface of the conductor crimping part is 3 to 98%, and the maximum height of the protrusions is 1 μm to 120 μm. For example, the resistance value is 1.9 mΩ or less in the initial state, the thermal shock test, and the salt spray test, and the expansion of the gap due to the thermal shock can be suppressed, and the gap between the conductor crimping portion and the contact portion of the conductor It was found that corrosion can be suppressed. On the other hand, as shown in Comparative Example 1, when no protrusion was formed on the conductor crimping portion, the resistance value in the initial state was 1.9 mΩ or less, but the resistance value in the thermal shock test and the salt spray test was Was 2.0 mΩ or more, and it was found that a good resistance value could not be obtained under a high temperature environment and a corrosive environment.

また、表３の結果から、発明例２２〜２７に示すように、導体圧着部にセレーションを形成し、且つ導体圧着部の主面及びセレーションの内側面に突起部を形成した場合において、突起部の面積占有率を５〜９８％、突起部の最大高さを３μｍ〜１２０μｍとすれば、初期状態、サーマルショック試験、塩水噴霧試験のいずれにおいても抵抗値が１．９ｍΩ以下となり、熱衝撃による空隙の拡張を抑制することができると共に、導体圧着部と導体の接触部での隙間腐食を抑制することができることが分かった。 Further, from the results of Table 3, as shown in Invention Examples 22 to 27, when the serration was formed in the conductor crimping portion and the projection was formed on the main surface of the conductor crimping portion and the inner surface of the serration, the projection portion If the area occupancy ratio is 5 to 98% and the maximum height of the protrusion is 3 μm to 120 μm, the resistance value is 1.9 mΩ or less in any of the initial state, the thermal shock test, and the salt spray test. It was found that expansion of the gap can be suppressed and crevice corrosion at the contact portion between the conductor crimping portion and the conductor can be suppressed.

１接続構造体
１’ 接続構造体
２外部端子
３電線
３ａ導体
３ｂ外周面
３ｃ絶縁被覆
１０コネクタ部
１０’ コネクタ部
２０トランジション部
２０’ トランジション部
３０筒状圧着部
３１挿入口
３２被覆圧着部
３３縮径部
３４導体圧着部
３４ａ外周部
３４ｂ内周面
３４ｃ複数の突起部
３４ｃ−１突起部
３４ｃ−２突起部
３４ｄ空隙
３５凹部
４０圧着端子
４１板材
４２ａキャリア部
４２ｂ送り穴
４３コネクタ部用板状体
４４圧着部用板状体
４５コネクタ部
４６圧着部用筒状体
４７突き合わせ部
４８筒状圧着部
４８ａ被覆圧着部
４８ｂ導体圧着部
５１ローラ
５２ローラ
５３レーザ照射装置
５４スパッタ用板材
５５スパッタ
６０圧着端子
６２帯状溶接部
６３トランジション部
６４端部溶接部
７０圧着端子
８０電線圧着部
８１導体圧着部
８１ａベース部
８１ｂ内側面
８１ｃ突起部
８２被覆圧着部
９０圧着端子
９１筒状圧着部
９２被覆圧着部
９３導体圧着部
９３ａ内周面
９４溝
９４ａ内側面
９５ａ，９５ｂ突起部
１００圧着端子
１０１筒状圧着部
１０２挿入口
１０３被覆圧着部
１０４縮径部
１０５導体圧着部
１０６縮径部
１１０圧着端子
１１１筒状圧着部
１１２トランジション部
１１３コネクタ部
１１３ａ接続部 DESCRIPTION OF SYMBOLS 1 Connection structure 1 'Connection structure 2 External terminal 3 Electric wire 3a Conductor 3b Outer peripheral surface 3c Insulation coating 10 Connector part 10' Connector part 20 Transition part 20 'Transition part 30 Cylindrical crimp part 31 Insertion port 32 Cover crimp part 33 Shrinkage Diameter portion 34 Conductor crimping portion 34a Outer peripheral portion 34b Inner circumferential surface 34c Plural projections 34c-1 Projection portion 34c-2 Projection portion 34d Air gap 35 Recess 40 Crimp terminal 41 Plate material 42a Carrier portion 42b Feed hole 43 Plate for connector portion 44 Crimping section plate 45 Connector section 46 Crimping section cylindrical body 47 Abutting section 48 Cylindrical crimping section 48a Covering crimping section 48b Conductor crimping section 51 Roller 52 Roller 53 Laser irradiation device 54 Sputtering plate material 55 Sputter 60 Crimping terminal 62 Belt welded portion 63 Transition portion 64 End welded portion 70 Crimping terminal 80 Electric wire crimping part 81 Conductor crimping part 81a Base part 81b Inner side surface 81c Protruding part 82 Covering crimping part 90 Crimping terminal 91 Cylindrical crimping part 92 Covering crimping part 93 Conductor crimping part 93a Inner peripheral surface 94 Groove 94a Inner side face 95a, 95b Protrusion part 100 Crimping terminal 101 Cylindrical crimping part 102 Insertion slot 103 Covering crimping part 104 Reduced diameter part 105 Conductor crimping part 106 Reduced diameter part 110 Crimping terminal 111 Cylindrical crimping part 112 Transition part 113 Connector part 113a Connection part

Claims

A crimping terminal comprising a connector part electrically connected to an external terminal, and a conductor crimping part to be crimped to a conductor of an electric wire,
The conductor crimping portion includes a metal base and a plurality of protrusions formed on a surface of the main surface of the metal base that is in pressure contact with the conductor of the electric wire,
The protrusion is a crimp terminal having a height from a surface on the side in pressure contact with the conductor of the electric wire of 1 μm to 120 μm.

The crimp terminal according to claim 1, wherein the protrusion is made of a metal having a main component different from that of the metal base.

2. The protrusion is characterized in that one or more metal elements selected from the group consisting of Cu, Ni, Si, Zn, Sn, Mg, Cr, Fe, and Al are the main components. Or the crimp terminal of 2.

4. The crimp terminal according to claim 1, wherein the plurality of projecting portions include a first projecting portion and a second projecting portion made of different main component metals. 5.

The first protrusion is softer than the metal base and harder than the conductor of the electric wire,
The crimp terminal according to claim 4, wherein the second protrusion is softer than the metal base and softer than the conductor of the electric wire.

The crimp terminal according to any one of claims 1 to 5, wherein the conductor crimping portion constitutes a cylindrical crimping portion in which an end portion on the connector portion side is closed.

The cylindrical crimp part has a belt-like weld part formed along the direction substantially the same as its longitudinal direction by laser welding,
The plurality of protrusions include a first protrusion formed in advance before the laser welding and a second protrusion formed by sputtering generated when the laser welding is performed. The crimp terminal according to claim 6.

8. The method according to claim 1, wherein the protrusion is spatter scattered when the metal is melted, or metal powder or metal particles fixed to a surface that is in pressure contact with the conductor of the electric wire. The crimp terminal according to item 1.

9. The area occupancy rate of the plurality of protrusions is 3 to 98% in a plan view of the surface of the electric wire that is in pressure contact with the conductor. 9. Crimp terminal.

The said conductor crimping | compression-bonding part has a recessed part in the surface by which the conductor of the said electric wire is press-contacted, and has the said projection part in the said recessed part, The any one of Claims 1 thru | or 9 characterized by the above-mentioned. Crimp terminal.

The crimp terminal according to claim 1, wherein the protrusion is softer than the metal base.

The crimp terminal according to claim 1, wherein the protrusion is harder than the metal base.

The crimp terminal according to any one of claims 1 to 5, or the crimp terminal according to any one of claims 8 to 12, wherein the conductor crimping portion is an open barrel crimping portion.

A connection structure comprising: a crimp terminal according to any one of claims 1 to 13 and a conductor of an electric wire or a conductor twisted wire obtained by twisting a plurality of the conductors connected by crimping. .

At least a part of the plurality of protrusions fills at least a part of a gap formed between the surface on the side pressed against the conductor of the electric wire and the outer peripheral surface of the conductor of the electric wire or the conductor stranded wire. The connection structure according to claim 14, wherein the connection structure is provided.

The connection structure according to claim 15, wherein the conductor crimping portion has a porosity of 1% or less in a cross section perpendicular to the longitudinal direction of the conductor crimping portion.

17. A connector comprising: a connector housing that accommodates the connector portion of the connection structure according to claim 14.

A wire harness comprising at least one connection structure according to any one of claims 14 to 16.

A method of manufacturing a crimp terminal comprising a connector part electrically connected to an external terminal, and a conductor crimp part to be crimped to a conductor of an electric wire,
A method of manufacturing a crimp terminal, comprising: a protrusion forming step of forming a plurality of protrusions on a surface of the main surface of the metal base in the conductor crimping portion that is in pressure contact with the conductor of the electric wire.

The method for manufacturing a crimp terminal according to claim 19, wherein the protrusion forming step is to attach spatter to a surface of the electric wire that is in pressure contact with the conductor.

A step of bending the plate-like body and forming a butt portion by abutting a part thereof;
A step of performing laser welding on the butt portion and forming a protrusion by sputtering generated during the laser welding;
The manufacturing method of the crimp terminal of Claim 20 characterized by having.

Forming a first protrusion on the plate-like body, a first protrusion forming step;
A step of bending the plate-like body and forming a butt portion by abutting a part thereof;
A second protrusion forming step of performing laser welding on the butted portion and forming a second protrusion by sputtering generated during the laser welding;
The method of manufacturing a crimp terminal according to claim 19, comprising:

In a manufacturing method of a connection structure comprising a connector part electrically connected to an external terminal, a crimp terminal comprising a conductor crimp part to be crimped to a conductor of an electric wire, and an electric wire connected to the crimp terminal by crimping There,
The crimp terminal has a plurality of protrusions formed on a surface of the main surface of the metal base in the conductor crimping portion that is in pressure contact with the conductor of the electric wire, and the protrusion includes the conductor of the electric wire. Use the one whose height from the surface on the pressure contact side is 1 μm to 120 μm,
By crimping the conductor crimping portion of the crimp terminal to the conductor of the electric wire, the crimp terminal and the electric wire are fixed, and the surface of the electric wire conductor and the side of the electric wire and the conductor of the electric wire are fixed. A method for manufacturing a connection structure, wherein at least a part of a gap between the protrusions is filled with the protrusions.