Abstract: To provide a connection structure that can be crimped and connected in a desired crimping shape to the electric wire tip portion of an insulated wire without causing the deformation into an unintended crimping shape of the crimping portion of a crimp terminal. When crimping a conductor crimping portion (30a) of crimp terminal (10) to an electric wire tip portion (200a) of insulated wire (200), outer peripheral contact portions (613, 613) of a lower blade (61) of a crimping device (60A) and an outer peripheral contact portion (623) of an upper blade (62) are point-contacted to an outer periphery of a conductor crimping portion (30a) in a perpendicular cross section in a direction perpendicular to a longitudinal direction X and to a crimping direction Z so as to be left-right symmetrical with respect to a reference plane formed by the longitudinal direction (x) and the crimping direction (Z).

Abstract: The terminal connection strip includes: a carrier formed in a strip shape; and a plurality of terminal fitting which project from at least one edge side of the carrier in a width direction. The terminal fitting includes a crimping section which connects by crimping at least a conductor tip of an insulated wire provided with the conductor tip where a conductor is covered with an insulating cover and the conductor is exposed by peeling off the insulating cover on a distal end side of the insulated wire to the terminal fitting. The crimping section is formed into a hollow shape which allows the insertion of at least the conductor tip from a proximal end side of the crimping section and allows the crimping section to surround the conductor tip.

Abstract: When molds (31a), (31b) are caused to mesh so that a crimping portion (5) is compressed, the crimping portion (5) is crimped to conductive wires (25) and a cover portion (27). A conductor crimping portion (7) is completely compressed by the molds (31a), (31b). A cover crimping portion (9) preliminarily compresses the cover portion (27). Next, temporarily compressed terminal-equipped electrical wires are disposed between different molds. When the molds are caused to mesh so that the crimping portion (5) is compressed, the cover crimping portion (9) is forcefully compressed. In other words, the cover crimping portion (9) is subjected to final compression. In other words, the present invention is provided with a first compression step for preliminarily compressing the cover portion (27) and a second compression step for forcefully compressing the covering part.

Abstract: Under compression by molds (31a, 31b), a wire (25), a covered area (27), and a crimping portion (5) are compressed and their cross-sectional areas decrease. Here, A1 is the cross-sectional area of the wire (25) after compression. That is, A1 is the sum of the cross-sectional area of the each strand after compression. Also, 131 is the cross-sectional area of the covered area (27) after compression. In the present invention, the compression rate for the wire (25) is set between 50% and 80%. Also, the compression rate for the covered area (27) is set between 40% and 90%. The amount of compression by the molds (31a, 31b) is set so that the compression rates are within these ranges. In the present invention, the compression rate is calculated by: (cross-sectional area after compression)/(cross-sectional area before compression). That is, 80% compression rate means that the cross-sectional area has decreased by 20% due to compression. That is, the relationships of 80%?(A1/A0)?50% and 90%?(B1/B0)?40% are satisfied.

Abstract: When molds (31a), (31b) are caused to mesh so that a crimping portion (5) is compressed, the crimping portion (5) is crimped to conductive wires (25) and a cover portion (27). A conductor crimping portion (7) is completely compressed by the molds (31a), (31b). A cover crimping portion (9) preliminarily compresses the cover portion (27). Next, temporarily compressed terminal-equipped electrical wires are disposed between different molds. When the molds are caused to mesh so that the crimping portion (5) is compressed, the cover crimping portion (9) is forcefully compressed. In other words, the cover crimping portion (9) is subjected to final compression. In other words, the present invention is provided with a first compression step for preliminarily compressing the cover portion (27) and a second compression step for forcefully compressing the covering part.

Abstract: A method of manufacturing an electrical wire connecting structure in which a terminal having a tube-shaped portion and a conductor portion of a covered electrical wire are crimped at the tube-shaped portion, and the tube-shaped portion has a conductor crimping portion corresponding to the conductor portion, and a cover crimping portion corresponding to a cover portion of the covered electrical wire, the method comprising the steps of a) forming the tube-shaped portion, b) inserting the covered electrical wire into a corresponding space, c) crimping a welded portion of the conductor, and d) compressing the cover crimping portion.

Abstract: A transition portion (4) has a surface (14) that is formed extending upward. The surface (14) is a surface formed extending upward so as to face a bottom portion (6a). Specifically, the transition portion (4) has a cross-sectional shape in which upper edge portions of side portions (8a) are bent inward. As the surface (14) approaches a main terminal body (3) from a sealing portion (22), the surface (14) gradually separates away from the bottom portion (6a) and the edge portions of the surface (14) gradually open outward and connect to side portions (8b) of the main terminal body (3). The surface (14) is formed so as to be curved upward, in a cross-section, from the end portion of the sealing portion (22).

Abstract: Under compression by molds (31a, 31b), a wire (25), a covered area (27), and a crimping portion (5) are compressed and their cross-sectional areas decrease. Here, A1 is the cross-sectional area of the wire (25) after compression. That is, A1 is the sum of the cross-sectional area of the each strand after compression. Also, 131 is the cross-sectional area of the covered area (27) after compression. In the present invention, the compression rate for the wire (25) is set between 50% and 80%. Also, the compression rate for the covered area (27) is set between 40% and 90%. The amount of compression by the molds (31a, 31b) is set so that the compression rates are within these ranges. In the present invention, the compression rate is calculated by: (cross-sectional area after compression)/(cross-sectional area before compression). That is, 80% compression rate means that the cross-sectional area has decreased by 20% due to compression. That is, the relationships of 80%?(A1/A0)?50% and 90%?(B1/B0)?40% are satisfied.

Abstract: A crimp terminal has a crimp portion that is formed by bending a plate material into a hollow shape and that has at one end thereof an opening capable of accommodating and crimping a conductor portion of a coated wire. The crimp terminal includes a first weld portion obtained by bringing two edge portions of the crimp portion in close proximity to each other and joining by laser welding, and a second weld portion obtained by forming a lapped portion by overlapping of a transition portion formed at an opposite end of the crimp portion to the opening, and closing the lapped portion by laser welding. A welding trajectory in the second weld portion is constituted by a curve, a plurality of straight lines, or a discontinuously formed line.

Abstract: A transition portion (4) has a surface (14) that is formed extending upward. The surface (14) is a surface formed extending upward so as to face a bottom portion (6a). Specifically, the transition portion (4) has a cross-sectional shape in which upper edge portions of side portions (8a) are bent inward. As the surface (14) approaches a main terminal body (3) from a sealing portion (22), the surface (14) gradually separates away from the bottom portion (6a) and the edge portions of the surface (14) gradually open outward and connect to side portions (8b) of the main terminal body (3). The surface (14) is formed so as to be curved upward, in a cross-section, from the end portion of the sealing portion (22).

Abstract: The height (F) of a protruding portion (7) is less than the thickness of a crimping portion (5) before crimping. If the height of the protruding portion (7) is greater than the thickness of the crimping portion, then a recess is prone to form in the inner surface of the crimping portion (5). In other words, because there is more metal flowing outwards, a recess corresponding to the metal flow is prone to form on the inner surface side. If such a recess does form, adhesion with a covered area (27) is likely to deteriorate. This is problematic because such a gap would be a path allowing the ingress of moisture. On the other hand, if the height of the protruding portion (7) is less than the thickness of the crimping portion (5) before crimping, then when the crimping portion (5) is compressed during crimping, the amount of metal flowing towards the protruding portion (7) diminishes, making it possible to suppress the formation of a receding portion on the inner surface of the crimping portion (5).

Abstract: A covered conductive wire is configured by covering a conductive wire with an insulating cover portion. The conductive wire is formed of an aluminum-based material, for example. A crimping portion includes a cover crimping portion for crimping the cover portion of the covered conductive wire, and a conductor crimping portion for crimping a portion of the conductive wire that is exposed when the cover portion is removed at the tip portion of the covered conductive wire. It is possible to use polyvinyl chloride and/or a non-halogen member, for example, for the cover portion of the covered conductive wire, and a plasticizer, filler, stabilizer, or the like is compounded as needed. A material that shrinks by a factor of 7% or less after being allowed to stand for 120 hours at a high temperature of 120° C. is used for this cover portion.

Abstract: Provided is an electrical wire-connecting structure, and a manufacturing method thereof, with which it is easy to ensure watertightness between a crimping terminal and an insulated electrical wire. A crimping terminal (11) having a tubular portion (25) is prepared in which a first cylindrical portion (52) into which a core wire portion (14) of an electrical wire (13) is inserted is formed with a smaller diameter than a second cylindrical portion (54) into which an insulation covering portion (15) of the electrical wire (13) is inserted, and an inner diameter of the second cylindrical portion (54) is in the range of 1.0 to 1.7 times an outer diameter of the insulation covering portion (15). The electrical wire (13) is inserted into the tubular portion (25), and the second cylindrical portion (54) and the insulation covering portion (15) are compressively crimped.

Abstract: A covered conductive wire is configured by covering a conductive wire with an insulating cover portion. The conductive wire is formed of an aluminum-based material, for example. A crimping portion includes a cover crimping portion for crimping the cover portion of the covered conductive wire, and a conductor crimping portion for crimping a portion of the conductive wire that is exposed when the cover portion is removed at the tip portion of the covered conductive wire. It is possible to use polyvinyl chloride and/or a non-halogen member, for example, for the cover portion of the covered conductive wire, and a plasticizer, filler, stabilizer, or the like is compounded as needed. A material that shrinks by a factor of 7% or less after being allowed to stand for 120 hours at a high temperature of 120° C. is used for this cover portion.

Abstract: A crimp-connection structural body, a wire harness, a method of manufacturing a crimp-connection structural body, and a manufacturing device are provided. The crimp-connection structural body includes an insulated wire formed by covering a conductor by an insulating cover, and a crimp terminal having a crimp section allowing connection by crimp of a conductor exposed portion formed by exposing the conductor. The crimp section is formed of a closed-barrel-type crimp section, and a cross-sectional shape of the crimp section in a radial direction is formed into an approximately recessed cross-sectional shape having a crimp recessed portion formed by indenting by inclined portions inclined from positions spaced-apart from each other by a predetermined distance. The predetermined distance is set to 90% or less of an entire width of the crimp section. An opposedly facing angle made by the inclined portions is set to a value which ranges from 10° to 120° inclusive.

Abstract: A conductor wire crimping portion (7) has depressions (13a, 13b, 13c) that are disposed at prescribed intervals in the axial direction and that are linear locking portions. The depressions (13a, 13b, 13c) are continuously depressed grooves on the inner surface of a crimping portion (5). On an upper die (30a), at a portion corresponding to the conductor wire crimping portion (7), a straight portion is formed, and in the front-back direction thereof, tapered portions are formed. More specifically, the upper die (30a) is formed to have an inverted trapezoid shape, a middle portion of which protrudes in the crimping direction. Consequently, at each boundary between the straight portion and the tapered portion, a die angled portion (32) is formed. At an area corresponding to the straight portion of the upper die (30a), the depression (13a) is provided, and at an area corresponding to the die angled section (32), the depression (13b) is provided.

Abstract: In a terminal connection method of inserting a wire tip of an insulated wire, which is formed by stripping a front end of an insulating cover to expose an aluminum core wire, into a pressure-bonding section of a female crimp terminal to pressure bond the insulated wire to the female crimp terminal via the pressure-bonding section, signs are formed on the outer circumferential face of an insulated tip of the insulating cover at a distance of an internal length of the pressure-bonding section from a conductor tip face of the conductor tip, and the wire tip is inserted up to the signs in the pressure-bonding section to pressure-bond the wire tip to the pressure-bonding section.

Abstract: The terminal connection strip includes: a carrier formed in a strip shape; and a plurality of terminal fitting which project from at least one edge side of the carrier in a width direction. The terminal fitting includes a crimping section which connects by crimping at least a conductor tip of an insulated wire provided with the conductor tip where a conductor is covered with an insulating cover and the conductor is exposed by peeling off the insulating cover on a distal end side of the insulated wire to the terminal fitting. The crimping section is formed into a hollow shape which allows the insertion of at least the conductor tip from a proximal end side of the crimping section and allows the crimping section to surround the conductor tip.

Abstract: The terminal connection strip includes: a carrier formed in a strip shape; and a plurality of terminal fitting which project from at least one edge side of the carrier in a width direction. The terminal fitting includes a crimping section which connects by crimping at least a conductor tip of an insulated wire provided with the conductor tip where a conductor is covered with an insulating cover and the conductor is exposed by peeling off the insulating cover on a distal end side of the insulated wire to the terminal fitting. The crimping section is formed into a hollow shape which allows the insertion of at least the conductor tip from a proximal end side of the crimping section and allows the crimping section to surround the conductor tip.

Abstract: Provided is an electrical wire-connecting structure, and a manufacturing method thereof, with which it is easy to ensure watertightness between a crimping terminal and an insulated electrical wire. A crimping terminal (11) having a tubular portion (25) is prepared in which a first cylindrical portion (52) into which a core wire portion (14) of an electrical wire (13) is inserted is formed with a smaller diameter than a second cylindrical portion (54) into which an insulation covering portion (15) of the electrical wire (13) is inserted, and an inner diameter of the second cylindrical portion (54) is in the range of 1.0 to 1.7 times an outer diameter of the insulation covering portion (15). The electrical wire (13) is inserted into the tubular portion (25), and the second cylindrical portion (54) and the insulation covering portion (15) are compressively crimped.