Insulation cold-pressed terminal, wire assembling method and wire harness assembly

Abstract

The invention relates to an insulating cold-pressed terminal, a wire assembling method and a wire harness assembly, which fundamentally solves the industrial problem that a double-wire-diameter wire is not matched with a standard terminal by expanding the inner aperture of a pre-insulating sleeve, lengthening the axial length of the pre-insulating sleeve and arranging a guide structure, and realizes multiple remarkable beneficial effects. Potential safety hazards and quality risks are thoroughly eliminated, the expanded inner hole allows a double-wire insulating layer to penetrate easily in a lossless mode, the lengthened insulating sleeve can completely cover a conductor crimping area, the risk of short circuit caused by copper wire exposure is fundamentally eradicated, and electrical safety is fundamentally guaranteed. The built-in locking structure is meshed with the insulation skin to provide excellent pulling resistance and vibration resistance, the texture structure ensures high-reliability connection with the conductor, finally, the appearance of the product is neat and uniform, the performance is stable and reliable, and the comprehensive quality is remarkably improved.

Description

TECHNICAL FIELD

[0001] The application relates to an insulated cold-press terminal, a wire assembly method and a wire harness assembly, and belongs to the technical field of cables. BACKGROUND

[0002] In the field of electrical connection, a cold-press terminal is a basic element for realizing reliable connection of a wire and a device terminal. The cold-press terminal fixes a wire conductor in a metal barrel through mechanical pressure connection, and provides insulation protection and strain relief by using an external pre-insulated sleeve. In the industry, standard components such as UL1015 series wires and E-shaped tubular pre-insulated terminals are generally used to achieve compatibility and economy.

[0003] However, in actual production and assembly, especially in the scene of pressing a large-diameter wire and a small-diameter wire (for example, 6AWG and 18AWG) to the same terminal, the combination of standard components exposes significant technical defects. The primary problem is that the standard wire such as UL1015 has an insulation layer thickness and an overall outer diameter that meet its own specifications, which are often larger than those of other series of the same specification. When such wire is matched with the most suitable standard terminal (such as E16-12) recommended by the industry, the combined outer diameter is slightly larger than the inner hole diameter of the pre-insulated sleeve of the terminal, resulting in difficulty in threading the wire insulation into the terminal.

[0004] To overcome this assembly problem, the existing technology is forced to use an extremely non-standard process: lengthening the exposed length of the conductor so that the insulation ends outside the pre-insulated sleeve port, and additionally adding a positioning heat shrink sleeve to compensate for the insulation defect of the exposed conductor and assist in fixation. This temporary measure has multiple disadvantages: first, the excessively long exposed copper wire greatly increases the risk of short circuit, posing a serious safety hazard; second, the additional heat shrink sleeve process step is complicated, greatly reducing the processing efficiency and increasing the production cost; third, the appearance of the finished wire harness is not neat and consistent, affecting the product aesthetics and professionalism. In addition, this forced matching method has questionable mechanical reliability, and in a vibration or pulling environment, the cable is prone to come loose from the pressure connection point.

[0005] Therefore, there is an urgent need in the art for an innovative terminal structure design that can fundamentally solve the pressing problem of dual-diameter wires, especially when matched with thick-insulation standard wires, while ensuring electrical safety and reliable connection, improving assembly efficiency and product quality. SUMMARY

[0006] The application aims to provide an insulated cold-press terminal, a wire assembly method and a wire harness assembly to solve the above problems.

[0007] To achieve the above object, the present application provides the following technical solutions: An insulated cold-press terminal, comprising a conductor made of metal material, one end of the conductor being a connecting part for connecting external equipment, the other end being an open-type press contact barrel for press contacting a wire, an insulating sleeve made of insulating material being sleeved outside the press contact barrel, a guide structure being arranged at the entrance of the insulating sleeve close to the wire insertion end, the inner hole diameter of the insulating sleeve close to the conductor being configured to be capable of simultaneously accommodating and penetrating the insulating sheaths of the first wire and the second wire, the wire diameter of the first wire being greater than the wire diameter of the second wire, the inner wall of the insulating sleeve being provided with a locking structure for engaging with the wire insulating sheath to provide an axial locking force, and the inner wall of the press contact barrel of the conductor being provided with a texture structure for engaging with the wire conductor to provide electrical conductivity and anti-pulling force.

[0008] Further, the guide structure is a horn mouth, a chamfer or a round corner formed at the entrance of the insulating sleeve.

[0009] Further, the locking structure is any one or a combination of a plurality of the following structures: a piercing engagement structure, a friction clamping structure and a geometric interlocking structure.

[0010] Further, the piercing engagement structure is a continuous distribution of sharp tooth rings in a ring direction or a spiral direction or is an array distribution of convex points.

[0011] Further, the friction clamping structure is a knurled surface, a straight line, a ring line or a roughened surface.

[0012] Further, the geometric interlocking structure refers to that the inner hole cross section of the insulating sleeve is non-circular and is configured to match the external profile of the combined double-wire group inserted side by side.

[0013] Further, the texture structure is a sawtooth pattern, a convex point or a knurl.

[0014] The present application also provides a wire assembly method using the above-mentioned insulated cold-press terminal, comprising the following steps: Peeling off a section of the insulating sheath of the first wire and the second wire to expose the conductors; Inserting the insulating sheath portions of the first wire and the second wire from the guide structure into the inner hole of the insulating sleeve in parallel until the exposed conductor portions of the two wires completely enter the press contact barrel of the conductor; Simultaneously press contacting the press contact barrel and the insulating sleeve outside the press contact barrel using a press contact tool, so that the texture structure engages with the conductors and the locking structure engages with the insulating sheaths of the two wires.

[0015] Further, the press contact die used has a first press contact tooth opening matching the conductor diameter of the first wire and a second press contact tooth opening matching the conductor diameter of the second wire.

[0016] The application also provides a wire harness assembly, which comprises first and second conductors with different diameters, and a pre-insulated cold-press terminal as described above assembled by the above-mentioned conductor assembling method.

[0017] The application has the beneficial effects that the application fundamentally solves the industry problem of mismatch between double-wire-diameter conductors and standard terminals by enlarging the inner hole diameter of the pre-insulated sleeve, lengthening the axial length of the sleeve and arranging a guide structure, realizes multiple significant beneficial effects, completely eliminates safety hazards and quality risks, the enlarged inner hole allows the double-wire insulation layer to easily and non-destructively pass in, and the lengthened insulation sleeve can completely cover the conductor crimping area, fundamentally eliminates the short circuit risk caused by copper wire exposure, and fundamentally guarantees electrical safety; the built-in locking structure engages with the insulation skin to provide excellent anti-pulling and anti-vibration capabilities, the texture structure ensures high reliable connection with the conductor, and finally makes the product appearance neat and uniform, the performance stable and reliable, and the comprehensive quality significantly improved.

[0018] The above description is only a summary of the technical solutions of the application, in order to more clearly understand the technical means of the application and can be implemented according to the content of the description, the following is a preferred embodiment of the application and is described in detail below with the help of the accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS

[0019] Figure 1 A structure schematic view of an insulated cold-press terminal according to an embodiment of the application; Figure 2 A structure schematic view of an insulated cold-press terminal according to an embodiment of the application; Figure 1 A sectional structure schematic view of a locking structure in the middle; Figure 3 A sectional structure schematic view of a locking structure in the middle; Figure 2 An enlarged schematic view of A part of the structure. DETAILED DESCRIPTION

[0020] The specific embodiments of the application will be further described in detail below with the help of the accompanying drawings and embodiments. The following embodiments are used to illustrate the application, but not to limit the scope of the application.

[0021] In the description of the application, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the application and simplifying the description, and therefore cannot be understood as indicating or implying that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the application. In addition, the terms "first", "second", "third" are only for descriptive purposes and cannot be understood as indicating or implying relative importance.

[0022] In the description of the present application, it should be noted that unless otherwise explicitly specified and limited, the terms "mounting", "connection", "linking" should be understood in a broad sense, for example, it can be fixed connection, or detachable connection, or integral connection; it can be mechanical connection, or electrical connection; it can be direct connection, or indirect connection through intermediate medium, or internal communication of two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0023] Please refer to Figures 1 to 3 In an embodiment of the present application, an insulating cold-press terminal 100 is provided, which comprises a conductive body 10 made of metal material, one end of the conductive body 10 being a connecting portion for connecting external equipment, and the other end being an open-type press contact cylinder for press contacting a wire; and a pre-insulating sleeve 20 made of insulating material is sleeved outside the press contact cylinder.

[0024] The axial length of the pre-insulating sleeve 20 is set to be lengthened, the pre-insulating sleeve 20 is provided with a guide structure 21 at the entrance close to the wire insertion end, and the insulating inner hole diameter of the pre-insulating sleeve 20 is set to be enlarged, the inner hole diameter of the insulating sleeve close to the conductive body is configured to be able to simultaneously accommodate and pass through the insulating outer sheaths of the first wire and the second wire, wherein the wire diameter of the first wire is larger than that of the second wire.

[0025] The inner wall of the pre-insulating sleeve 20 is provided with a locking structure for engaging with the wire insulating outer sheath to provide an axial locking force, and the inner wall of the press contact cylinder of the conductive body 10 is provided with a textured structure for engaging with the wire conductor to provide electrical conductivity and anti-pulling force.

[0026] In an embodiment, the guide structure 21 is a horn mouth, a chamfer or a round corner formed at the entrance of the pre-insulating sleeve 20. Preferably, the guide structure 21 is a horn mouth, and the opening angle thereof is 30-60 degrees, which facilitates the smooth insertion of the double-wire-diameter wire.

[0027] In an embodiment, the locking structure is any one or a combination of the following structures: a piercing engagement structure, a friction holding structure, and a geometric interlocking structure. Preferably, the combination of the piercing engagement structure and the friction holding structure is adopted, which not only ensures the initial fixing effect, but also provides a sustained locking force.

[0028] In an embodiment, the piercing engagement structure is a continuous ring or spiral of sharp teeth or an array of protrusions. Preferably, a plurality of continuous ring of sharp teeth is used, each sharp tooth 23 comprises a cover 231, a limiting body 232 and a piercing body 233, which are decreasing in size from outside to inside, and a fixed groove 22 is provided on the pre-insulated sleeve 20 to match the shape of the sharp tooth 23, wherein the cover 231 and the limiting body 232 are made of elastically deformable material, and the piercing body 233 is made of non-deformable material, which ensures effective penetration of the insulating sheath, and in addition, barbs 234 can be provided on the piercing body to prevent the sharp tooth 23 from separating from the insulating sheath.

[0029] In an embodiment, the frictional engagement structure is knurling, straight lines, ring lines or roughened surface. Preferably, a ring structure is used, with a groove depth of 0.05-0.15mm and a groove pitch of 0.3-0.8mm, which provides sufficient friction.

[0030] In an embodiment, the geometric interlocking structure refers to the cross-section of the inner hole of the pre-insulated sleeve 20 being non-circular, which is configured to match the outer profile of the double wire combination inserted side by side. Preferably, the cross-section of the inner hole is elliptical or rounded rectangular, with the long axis being 0.1-0.5mm larger than the outer diameter of the double wires inserted side by side.

[0031] In an embodiment, the texture structure is a sawtooth pattern, protrusions or knurling. Preferably, a sawtooth pattern is used, with a tooth depth of 0.05-0.2mm and a tooth pitch of 0.3-0.6mm, which ensures good engagement with the conductor.

[0032] The application also provides a wire assembly method using the pre-insulated cold press terminal 100 as described above, comprising the following steps: Peeling off a section of the insulating sheath from the end of the first wire and the second wire to expose the conductor; Inserting the insulating sheath of the first wire and the second wire side by side from the guide structure 21 into the inner hole of the pre-insulated sleeve 20 until the exposed conductor portions of the two wires completely enter the press-in barrel of the conductive body 10; Using a press-in tool to simultaneously press-in the press-in barrel and the pre-insulated sleeve 20 outside the press-in barrel, so that the texture structure engages with the conductor and the locking structure engages with the insulating sheath of the two wires.

[0033] In an embodiment, the press-in die used has a first press-in jaw opening matching the diameter of the first wire conductor and a second press-in jaw opening matching the diameter of the second wire conductor. Preferably, the first press-in jaw opening is suitable for 6AWG wire, and the second press-in jaw opening is suitable for 18AWG wire.

[0034] The application also provides a wire harness assembly, which comprises first and second wires with different diameters and the pre-insulated cold-press terminal 100 as described above assembled by the wire assembling method.

[0035] The technical features of the above-described embodiments can be combined in any manner. For the sake of brevity, not all possible combinations of the technical features in the above-described embodiments are described, but it should be understood that any combination of the technical features is within the scope of the present disclosure as long as the combination does not result in contradictions.

[0036] The above-described embodiments only express several implementation manners of the present application, and the description is relatively specific and detailed, but it should not be understood as a limitation on the scope of the patent. It should be pointed out that, for those skilled in the art, several modifications and improvements can be made without departing from the concept of the present application, and these are within the protection scope of the present application. Therefore, the protection scope of the patent of the present application should be subject to the appended claims.

Claims

1. An insulated cold-pressed terminal, comprising a conductor made of a metal material, one end of the conductor being a connection portion for connecting to an external device, and the other end being an open crimping barrel for crimping a wire, the outer surface of the crimping barrel being provided with a pre-insulating sleeve made of an insulating material, characterized in that: The pre-insulating sleeve is provided with a guide structure near the entrance of the wire insertion end, and the inner aperture of the insulating sleeve near the conductor is configured to simultaneously accommodate and pass through the insulating sheaths of the first wire and the second wire. The wire diameter of the first wire is larger than the wire diameter of the second wire. The inner wall of the pre-insulating sleeve is provided with a locking structure for engaging with the insulating sheath of the wire to provide axial locking force, and the inner wall of the crimping barrel of the conductor is provided with a structure for engaging with the wire conductor to provide conductivity and pull-out resistance.

2. The insulated cold-pressed terminal according to claim 1, wherein: The guide structure is a bell mouth, chamfer or rounded corner formed at the inlet end of the pre-insulation sleeve.

3. The insulated cold-pressed terminal according to claim 1, wherein: The locking structure is any one or more combinations of a piercing engagement structure, a frictional clamping structure, and a geometric interlocking structure.

4. The insulated cold-pressed terminal according to claim 3, wherein: The piercing meshing structure is a sharp tooth ring distributed continuously in an annular or spiral direction or a convex point distributed in an array.

5. The insulated cold-pressed terminal according to claim 3, wherein: The friction-holding structure is a surface with knurling, straight lines, annular lines or roughening treatment.

6. The insulated cold-pressed terminal according to claim 3, wherein: The geometric interlocking structure means that the cross section of the inner hole of the pre-insulating sleeve is non-circular and is configured to match the outer contour of the double-conductor combination inserted side by side.

7. The insulated cold-pressed terminal according to claim 1, wherein: The texture structure is a serrated pattern, convex dots or knurling.

8. A method for assembling a wire using the pre-insulated cold-pressed terminal according to any one of claims 1 to 7, characterized in that: The following steps are involved: Strip off a section of insulation from the ends of the first wire and the second wire to expose the conductors; Inserting the insulating outer sheath portions of the first and second conductors in parallel from the guide structure into the inner hole of the pre-insulating sleeve until the exposed conductor portions of the two conductors are completely inserted into the crimping barrel of the conductor; The crimping barrel and the pre-insulating sleeve outside the crimping barrel are crimped simultaneously using a crimping tool so that the texture structure engages with the conductor and the locking structure engages with the insulation skins of the two wires.

9. The wire assembly method according to claim 8, wherein: The crimping die used has a first crimping tooth opening that matches the diameter of the first wire conductor and a second crimping tooth opening that matches the diameter of the second wire conductor.

10. A wiring harness assembly, characterized in that: The wiring harness assembly includes a first wire and a second wire having different wire diameters, and a pre-insulated cold-pressed terminal according to any one of claims 1 to 7 assembled by the wire assembly method according to claim 8 or 9.

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