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

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

• an aluminum electric wire including an electric conductor part including numerous strands and a coating part coated on the electric conductor part;
• a terminal having an open wire barrel to be directly crimped onto said electrical conductor part of said aluminum electric-wire and an insulation barrel to be directly crimped onto said coating part of said aluminum electric-wire, said wire barrel having an aluminum-electric-wire retaining crimp barrel and an aluminum-electric-wire conducting crimp barrel;
• wherein said aluminum-electric-wire conducting crimp barrel and said aluminum-electric-wire retaining crimp barrel are formed integrally with each other as said wire barrel,
• said aluminum-electric-wire retaining crimp barrel is formed at a position neighboring to said insulation barrel,
• said aluminum-electric-wire conducting crimp barrel is formed at a side opposite to said insulation barrel with respect to said aluminum-electric-wire retaining crimp barrel,
• said aluminum-electric-wire conducting crimp barrel is crimped onto said aluminum electric-wire at a height lower than that of said aluminum-electric-wire retaining crimp barrel when viewed in the terminal crimping direction in a state where both of said crimp barrels are crimped onto said aluminum electric-wire,
• said aluminum-electric-wire retaining crimp barrel having a higher value of compressed ratio than said aluminum-electric-wire conducting crimp barrel so as to ensure crimping of said aluminum-electric-wire by said terminal, said compressed ratio defined by (cross-sectional area of aluminum electric-wire's conductor part at crimped portion)/(cross-sectional area of aluminum electric-wire's conductor part before crimping), and
• said value of compressed ratio of said aluminum-electric-wire conducting crimp barrel is enough to break an oxide film of said electric-wire's conductor part.

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

• an aluminum electric-wire;
• an aluminum-electric-wire's coating part crimping insulation barrel;
• and
• an electrical-conductor crimping barrel having different front and rear heights;
• wherein said aluminum electric-wire's conductor crimping barrel is open and formed at a position neighboring to said insulation barrel;
• and said electrical-conductor crimping barrel has an oblique structure having a height increased in a direction departing from said insulation barrel, before said terminal is crimped, so that the portion having the smaller barrel height is crimped onto said aluminum electric-wire at a smaller biting depth and the portion having the larger barrel height is crimped onto said aluminum electric-wire at a larger biting depth, and so that said electrical-conductor crimping barrel is brought to have a contacting extent with wire-elements constituting said aluminum electric-wire and the wire-elements have a compressed ratio, in which both of the contacting extent and the compressed ratio are varied in the terminal-wise longitudinal direction relative to said aluminum electric-wire.

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

• an aluminum electric wire including an electrical conductor part comprising numerous strands and a coating part coated on the electrical conductor part;
• a terminal having an open wire barrel to be crimped onto said electrical conductor part of said aluminum electric-wire;
• and
• wherein the compressed ratio of said aluminum electric-wires s conductor part by said wire barrel is within a range of 40 to less than 50%, in terms of the ratio of (cross-sectional area of aluminum electric-wire's conductor part at crimped portion)/(cross-sectional area of aluminum electric-wire's conductor part before crimping).

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

• an aluminum electric wire including an electrical conductor part comprising numerous strands and a coating part coated on the electrical conductor part;
• a terminal having an open wire barrel to be crimped onto said electrical conductor part of said aluminum electric-wire;
• and
• wherein the cross-sectional area of said aluminum electric-wire's conductor part to be crimped is 1.5 mm2 or more, and the compressed ratio of said aluminum electric-wire's conductor part by said wire barrel is within a range of 40 to less than 50% in terms of the ratio of (cross-sectional area of aluminum electric-wire's conductor part at crimped portion)/(cross-sectional area of aluminum electric-wire's conductor part before crimping).

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

• an aluminum electric wire including an electrical conductor part comprising numerous strands and a coating part coated on the electrical conductor part;
• a terminal having an open wire barrel to be crimped onto said electrical conductor part of said aluminum electric-wire;
• and
• wherein the cross-sectional area of said aluminum electric-wire's conductor part to be crimped is 1.5 mm2 or more, and the compressed ratio of said aluminum electric-wire's conductor part by said wire barrel has an upper limit value of less than 50% in terms of the ratio of the (cross-sectional area of aluminum electric-wire's conductor part at crimped portion)/(cross-sectional area of aluminum electric-wire's conductor part before crimping), and a lower limit value where the terminal crimping strength becomes 100N.