METHOD FOR MANUFACTURING TERMINAL FITTING WITH ELECTRIC WIRE

A method for manufacturing a terminal fitting with an electric wire, includes forming a wire-terminal connection section by connecting a terminal fitting to an exposed conductor section of an electric wire in which a resin cover is removed from the electric wire to expose a conductor of the electric wire, supplying a sealing material from a nozzle of a dispenser to the wire-terminal connection section to form a sealing section that covers the wire-terminal connection section. In a process of supplying the sealing material, after the supply of the sealing material by pushing of a piston of the dispenser is completed, the piston is retracted within a range of not allowing the sealing material to run down from the nozzle.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is based on Japanese Patent Application (No. 2015-235437) filed on Dec. 2, 2015, the contents of which are incorporated herein by reference. BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method for manufacturing a terminal fitting with an electric wire in which a sealing section, such as an anti-corrosion section, is formed at a connection portion of dissimilar metals in the electric wire and the terminal fitting.

2. Description of the Related Art

For example, wire harnesses are routed in a vehicle to electrically connect devices mounted in the vehicle. A wire harness includes an electric wire bundle and various kinds of connectors disposed at the terminal ends of this electric wire bundle. Each of the connectors of the wire harness has an insulating connector housing and a plurality of conductive terminal fittings accommodated in the terminal accommodating chamber of this connector housing. The terminal fittings are disposed at the terminal ends of the electric wires constituting the electric wire bundle. A copper wire (the conductor thereof is composed of strands made of copper or a copper alloy) is generally used as an electric wire. The terminal end of this copper wire is stripped and then connected to a terminal fitting by crimping. The base material of the terminal fitting is made of copper or a copper alloy as in the case of the conductor of the copper wire and is plated in some cases.

In recent years, aluminum wires are sometimes used instead of copper wires in consideration of the reduction in the weight of a vehicle and the easiness of material recycling in addition to the shortage in copper resources (an electric wire having a conductor made of aluminum or an aluminum alloy is referred to as an aluminum wire in this specification). However, it is known that the oxide coating film formed on the surface of the aluminum serving as the material of the conductor of the aluminum wire is thicker than that of the copper serving as the material of the conductor of the copper wire. It is also known that the contact resistance between the conductor and the terminal fitting (crimp terminal) in the aluminum wire tends to become relatively high. Hence, a method for raising compressibility by strongly caulking the conductor with a pair of conductor caulking pieces formed on the crimp terminal is adopted to reduce the contact resistance between the conductor of the aluminum wire and the crimp terminal. With this method, the oxide coating films of the respective strands constituting the conductor can be broken by strongly caulking the conductor of the aluminum wire. In other words, the contact resistance between the conductor and the crimp terminal can be reduced.

However, it is known that if moisture intervenes in the contact portion between the aluminum material and the copper material, in other words, in the contact portion between the dissimilar metals, both the metals, aluminum and copper, are dissolved as ions, a potential difference, for example, is generated therebetween, and electrolytic corrosion occurs. In the case that the conductor of the aluminum wire is connected to the crimp terminal made of copper or a copper alloy electrically and mechanically, since high compression crimping is performed at the portion where the conductor is crimped with the conductor caulking pieces of the crimp terminal, moisture intrusion is prevented, and as a result, the occurrence of electrolytic corrosion is avoided. However, since some portions of the conductor are in a state of being exposed at some positions along the crimped portion of the conductor crimped with the conductor caulking pieces in the direction of the terminal axis (in the extending direction of the electric wire), if moisture attaches to such portions and then reaches the above-mentioned crimped portion, the crimped portion is, as it were, in a state of being immersed in an electrolytic solution, whereby there is a danger that the aluminum, a metal having the larger ionization tendency, may be dissolved and electrolytic corrosion may progress. Hence, such anti-corrosion sections115(sealing sections) as shown inFIGS. 9A and 9Bare formed conventionally to prevent moisture from attaching to the exposed portions of the conductor and from intruding into the crimped portion (for example, refer to JP-A-2011-113708 described below).

InFIGS. 9A and 9B, the reference numeral101designates an aluminum wire and the reference numeral102designates a crimp terminal. The aluminum wire101is composed of a conductor103made of aluminum or an aluminum alloy and an insulating resin cover104for covering this conductor103. An exposed conductor section105is formed by removing the end section of the resin cover104of the aluminum wire101. On the other hand, the crimp terminal102serving as a female terminal fitting is formed into the shape shown in the figure by pressing a metal plate made of copper or a copper alloy. The crimp terminal102has an electric contact section106having a rectangular cylindrical shape, a caulking section107, and a connection section108for connecting the electric contact section106and the caulking section107. A mounting section109for allowing the exposed conductor section105to be mounted thereon, a conductor caulking piece110for caulking the exposed conductor section105mounted on this mounting section109and a cover caulking piece111for caulking the resin cover104in the vicinity of the exposed conductor section105are formed in the caulking section107.

In the above-mentioned configuration and structure, a wire-terminal connection section118is formed so as to include a conductor caulking portion112in which the exposed conductor section105is caulked with the conductor caulking piece110and a cover caulking portion113in which the resin cover104in the vicinity of the exposed conductor section105is caulked with the cover caulking piece111. In the conductor caulking portion112, however, non-caulking portions114are generated due to the relationship between the length of the exposed conductor section105and the width of the conductor caulking piece110. Hence, in the wire-terminal connection section118, the anti-corrosion sections115(sealing sections) are formed in a state of covering these non-caulking portions114. The anti-corrosion sections115are formed by dripping an anti-corrosion material117(sealing material) from each of the respective nozzles116of two dispensers and by curing the anti-corrosion material117applied by the dripping. Silicone rubber is adopted as the anti-corrosion material117.

In the above-mentioned conventional technology, the anti-corrosion material117(sealing material) is dripped from each of the nozzles116of the two dispensers and the anti-corrosion material117applied by the dripping is cured, whereby the anti-corrosion sections115are formed. However, in the conventional forming method, there is a danger that the anti-corrosion material117may run down from the respective nozzles116. In such a case, it is necessary to wipe off the anti-corrosion material117from the tip ends of the respective nozzles116after the application, thereby causing a problem of low workability. In addition, a problem of material loss also occurs because the anti-corrosion material117is wiped off.

Not only in the case that running down has occurred as described above but also even in the case that liquid buildup (wetting-up) has occurred at the tip ends of the nozzles116, wiping work is necessary (the state of liquid buildup will be explained briefly in the descriptions of the embodiments). In addition, the supply amount of the anti-corrosion material117becomes unstable due to liquid buildup.

SUMMARY OF THE INVENTION

The present invention has been made in consideration of the above-mentioned circumstances and is intended to provide a method for manufacturing a terminal fitting with an electric wire capable of improving workability and reducing material loss.

A method for manufacturing a terminal fitting with an electric wire, comprising:forming a wire-terminal connection section by connecting a terminal fitting to an exposed conductor section of an electric wire in which a resin cover is removed from the electric wire to expose a conductor of the electric wire;supplying a sealing material from a nozzle of a dispenser to the wire-terminal connection section to form a sealing section that covers the wire-terminal connection section,wherein in a process of supplying the sealing material, after the supply of the sealing material by pushing of a piston of the dispenser is completed, the piston is retracted within a range of not allowing the sealing material to run down from the nozzle.

With the above method, after the supply of the sealing material is completed, the piston of the dispenser is retracted, whereby a suction action is exerted and the sealing material is prevented from running down.

With the above method, in the process of supplying the sealing material to the wire-terminal connection section, after the supply of the sealing material by the dispenser is completed, the piston of the dispenser is retracted to prevent the sealing material from running down, thereby eliminating the need for wiping work. Furthermore, since the need for wiping off the sealing material is eliminated, material loss does not occur. Hence, the present invention exhibits the advantages of being capable of improving workability and reducing material loss.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

A terminal fitting with an electric wire includes an aluminum wire and a crimp terminal. The aluminum wire is composed of a conductor made of aluminum or an aluminum alloy and an insulating resin cover for covering this conductor. An exposed conductor section is formed by removing the resin cover of the aluminum wire. The crimp terminal has a caulking section serving as a crimping portion, and conductor caulking pieces and cover caulking pieces are formed at this caulking section. In the wire-equipped terminal, the caulking section is crimped to the exposed conductor section, whereby a wire-terminal connection section is formed. An anti-corrosion material is then supplied so as to cover the wire-terminal connection section (at an anti-corrosion material supplying step), and the anti-corrosion material is cured, whereby an anti-corrosion section is formed. At the anti-corrosion material supplying step, a dispenser for supplying the anti-corrosion material is used. After the supply of the anti-corrosion material by the pushing of the piston of the dispenser is ended, the piston is retracted within the range of not allowing the anti-corrosion material to run down from the nozzle.

Embodiments

Embodiments will be described below referring to the accompanying drawings.FIG. 1is a perspective view showing a terminal fitting with an electric wire, illustrating a manufacturing method according to the present invention. Furthermore,FIG. 2is a cross-sectional view taken on line A-A ofFIG. 1,FIG. 3is a perspective view showing the wire-equipped terminal before an anti-corrosion section is formed, andFIG. 4is a cross-sectional view taken on line B-B ofFIG. 3. Moreover,FIG. 5is a view illustrating steps in the manufacturing method according to the present invention,FIGS. 6A to 6Care views showing the dispenser shown inFIGS. 1 and 5;FIG. 6Ais a view showing a state in which an anti-corrosion material is being supplied,FIG. 6Bis a view showing a state after the supply of the anti-corrosion material is ended, andFIG. 6Cis a view, taken as an comparative example, showing a state in which running down of the anti-corrosion material has occurred. Still further,FIGS. 7A and 7Bare views showing the dispenser shown inFIGS. 1 and 5;FIG. 7Ais a view showing a state in which liquid buildup does not occur, andFIG. 7Bis a view, taken as an comparative example, showing a state in which liquid buildup has occurred.

<Configuration of the Wire-Equipped Terminal1>

InFIGS. 1 and 2, the reference numeral1designates a terminal fitting with an electric wire to be manufactured according to the present invention. The wire-equipped terminal1includes an aluminum wire2(electric wire) and a crimp terminal3(terminal fitting) disposed at the terminal end of this aluminum wire2. Furthermore, the wire-equipped terminal1is configured so as to have an anti-corrosion section4(sealing section, waterproof section) at the connection portion of dissimilar metals in the aluminum wire2and the crimp terminal3. Although the wire-equipped terminal1according to this embodiment is configured such that the crimp terminal3is disposed at the terminal end of the aluminum wire2, it may be possible that, for example, a terminal fitting having an appropriate shape is disposed at an intermediate portion of the aluminum wire2.

<Configuration and Structure of the Aluminum Wire2>

InFIGS. 1 to 4, the aluminum wire2, having a circular cross-section and having flexibility such that, when a bending force is applied to the wire, a reaction force for returning the wire to its original state is generated, is adopted. The aluminum wire2has a conductor5and a resin cover6.

The conductor5is formed by twisting a plurality of strands (not designated by numerals) each having a circular cross-section. The strands are made of aluminum or an aluminum alloy. In other words, the conductor5is made of aluminum or an aluminum alloy. The conductor5has a predetermined conductor cross-sectional area. In addition, the portion having this conductor cross-sectional area exists along the wire length of the aluminum wire2. Since the specific gravity of aluminum is 2.70 g/cm3and the specific gravity of copper to be described later is 8.96 g/cm3, the aluminum wire2is lighter in weight. In the case that the aluminum wire2is used as a long vehicle-mounted wire, it is effective, for example, in improving fuel consumption efficiency.

The standard electrode potential of aluminum in an electrochemical reaction is −1.676 V and the standard electrode potential of copper to be described later is +0.340 V. The difference between these potentials is large. Hence, if moisture intrudes and stays in the space between aluminum and copper, a battery is formed by aluminum, copper and an electrolyte aqueous solution. As a result, contact corrosion between dissimilar metals (galvanic corrosion, electrolytic corrosion) occurs at the anode of the battery, that is, the conductor5. In consideration of this problem, the anti-corrosion section4for preventing the electrolytic corrosion is required as a matter of course.

The resin cover6is a so-called insulator and is formed on the outside of the conductor5into a circular cross-sectional shape by extrusion-molding a resin material having insulation property. Known various kinds of materials can be adopted as the above-mentioned resin material. The resin material is properly selected from, for example, polymer materials, such as polyvinyl chloride resin, polyethylene resin and polypropylene resin.

A predetermined length of the resin cover6is removed from the terminal end of the aluminum wire2configured as described above, whereby an exposed conductor section7is formed.

<Structure of the Crimp Terminal3>

InFIGS. 1 to 4, the crimp terminal3is a female terminal fitting and is formed into, for example, the shape shown in the figures by pressing a metal plate whose base material is made of copper or a copper alloy (the crimp terminal may be a male terminal fitting). The surface of the base material is supposed to be plated although not shown particularly in the figures. The plating is deposited between the copper and the aluminum serving as the contact portions of the dissimilar metals. The crimp terminal3has an electric contact section8, a caulking section9and a connection section10for connecting the electric contact section8and the caulking section9.

The electric contact section8is an electrical connection portion to be connected to a mating terminal fitting, not shown, and is formed into a cylindrical shape having a rectangular cross-section. An insertion space corresponding to the tab of the mating terminal fitting is formed inside the electric contact section8. In addition, an elastic contact piece11that elastically makes contact with the tab when the tab is inserted is formed. In the electric contact section8, the reference numeral12designates an engaged section that is hooked and engaged with the lance of a connector housing, not shown.

The caulking section9is a portion electrically connected to the aluminum wire2and is formed into a portion capable of being connected by crimping because the terminal fitting according to this embodiment is the crimp terminal3. More specifically, the caulking section9is formed so as to have portions, that is, a mounting section13on which the exposed conductor section7of the aluminum wire2is mounted, a pair of conductor caulking pieces14for caulking the exposed conductor section7mounted on this mounting section13, and a pair of cover caulking pieces15for caulking the resin cover6in the vicinity of the exposed conductor section7. The mounting section13is also referred to as a bottom plate in some cases. In addition, the conductor caulking piece14is also referred to as a wire barrel in some cases. Furthermore, the cover caulking piece15is also referred to as an insulation barrel in some cases.

The pair of conductor caulking pieces14and the pair of cover caulking pieces15are disposed with a predetermined space provided therebetween in the axial direction of the terminal. Furthermore, both the pair of conductor caulking pieces14and the pair of cover caulking pieces15have a nearly V shape before caulking. Since the pair of conductor caulking pieces14is used to caulk the exposed conductor section7and the pair of cover caulking pieces15is used to caulk the resin cover6, these are formed so as to have widths and protruding lengths being different depending on the differences in the shape and the outer circumferential length of an object to be caulked.

When the exposed conductor section7is crimped to the caulking section9configured as described above, a wire-terminal connection section designated by the reference numeral16is formed. The wire-terminal connection section16is formed so as to include a conductor caulking portion17for caulking the exposed conductor section7with the pair of conductor caulking pieces14, a non-caulking portion18around this conductor caulking portion17, and a cover caulking portion19for caulking the resin cover6in the vicinity of the exposed conductor section7with the pair of cover caulking pieces15.

The connection section10is formed into a nearly trough shape extending in a predetermined length in the axial direction of the terminal. The electric contact section8is formed continuously to one end of the connection section10in the axial direction of the terminal. In addition, the caulking section9is formed continuously to the other end of the connection section10in the axial direction of the terminal.

<Configuration of the Anti-Corrosion Section4>

InFIGS. 1 and 2, the anti-corrosion section4is formed as a portion for water-tightly covering the wire-terminal connection section16to prevent electrolytic corrosion. More specifically, in the case that the arrows shown in the figures are defined to indicate the up-down, left-right and front-rear directions, the anti-corrosion section4is formed as a portion for covering the upper side of the caulking section9(the upper sides of the conductor caulking portion17and the non-caulking portion18), the lower side of the caulking section9(the lower side of the mounting section13), the left and right sides of the caulking section9, the front side of the caulking section9(the front side of the conductor caulking portion17) and the rear side of the cover caulking portion19. In other words, the anti-corrosion section4is formed as a portion for covering the front and rear sides of the wire-terminal connection section16and the entire circumference of the wire-terminal connection section16in the axial direction of the terminal.

<Method for Manufacturing the Wire-Equipped Terminal1>

InFIG. 5, the wire-equipped terminal1is manufactured through the following steps. That is to say, the wire-equipped terminal1is manufactured through wire processing step S1, wire-terminal connecting step S2, anti-corrosion material supplying step S3(sealing material supplying step, waterproof material supplying step) and anti-corrosion material curing step S4in this order. The anti-corrosion material supplying step S3and the anti-corrosion material curing step S4are steps (forming method) for forming the anti-corrosion section4.

At the wire processing step S1, the exposed conductor section7is formed at the terminal end of the aluminum wire2. More specifically, the resin cover6is removed by a predetermined length to expose the conductor5, whereby the exposed conductor section7is formed.

At the wire-terminal connecting step S2, the caulking section9of the crimp terminal3is disposed at the position of the exposed conductor section7, and then crimp connection is performed to form the wire-terminal connection section16. At the time of the crimping, pressing using the anvil and crimper of a crimping machine, that is, caulking, is performed. When the exposed conductor section7is crimped to the caulking section9, the conductor caulking portion17, the non-caulking portion18and the cover caulking portion19are formed are formed.

At the anti-corrosion material supplying step S3, an anti-corrosion material20(sealing material, waterproof material) is supplied to the wire-terminal connection section16. At the anti-corrosion material supplying step S3, an anti-corrosion material supplying device61having the configuration described below is used. The anti-corrosion material supplying device61is configured so as to include a dispenser62and a controller63for controlling this dispenser62as shown inFIGS. 1 and 5. The dispenser62has a syringe64, a piston65and a nozzle66. In the dispenser62configured as described above, when the syringe64is filled with the anti-corrosion material20and the piston65is pushed downward under the control of the controller63, a predetermined amount of the anti-corrosion material20drips from the nozzle66. The anti-corrosion material20drips until it covers the wire-terminal connection section16. In this embodiment, a liquid ultraviolet curing resin is adopted as the anti-corrosion material20.

In the manufacturing method according to the present invention, after the supply of the anti-corrosion material20is ended, the piston65is retracted under the control of the controller63within the range of not allowing the sealing material20to run down from the nozzle66. When the piston65is slightly retracted upward as shown inFIG. 6B, it is recognized according to the figure that the size of the ball of the anti-corrosion material20becomes small. Hence, such running down of the anti-corrosion material20as shown inFIG. 6Cdoes not occur (such running down occurs in the case that a force for pushing out the anti-corrosion material20remains). Furthermore, in the manufacturing method according to the present invention, liquid buildup (wetting-up) of the anti-corrosion material20does not occur at the tip end of the nozzle66as shown inFIG. 7A(FIG. 7Bshows a state in which liquid buildup has occurred). This is because the surface of the tip end of the nozzle66(or the entire surface of the nozzle) is subjected to water-repellent processing so as to have a water-repellent function (the water-repellent processing is not limited particularly, provided that the processing can provide the water-repellent function). (The reference numeral67designates a water-repellent processing section.)

InFIG. 5, at the anti-corrosion material curing step S4, ultraviolet light (UV light) is applied to the anti-corrosion material20having been supplied to the entire circumference of the wire-terminal connection section16to perform UV curing. Since the anti-corrosion material20is made of a liquid ultraviolet curing resin, the anti-corrosion material20is cured in a short time when the material receives the energy generated by the irradiation of the ultraviolet light from, for example, a UV light23. When the anti-corrosion material20is cured, the formation of the anti-corrosion section4for water-tightly covering the wire-terminal connection section16is completed. In other words, the manufacturing of the wire-equipped terminal1is completed.

<Summary of the Wire-Equipped Terminal1and the Advantages of the Manufacturing Method>

As described above referring toFIGS. 1 to 7A, the wire-equipped terminal1includes the aluminum wire2and the crimp terminal3. The aluminum wire2includes the conductor5made of aluminum or an aluminum alloy and the insulating resin cover6for covering the conductor5. The exposed conductor section7is formed by removing the resin cover6of the aluminum wire2(at the wire processing step S1). On the other hand, the crimp terminal3has the caulking section9serving as a crimping portion, and the pair of conductor caulking pieces14and the pair of cover caulking pieces15are formed at the caulking section9. In the wire-equipped terminal1, the caulking section9is crimped to the exposed conductor section7, whereby the wire-terminal connection section16is formed (at the wire-terminal connecting step S2). The anti-corrosion material20is then supplied so as to cover the wire-terminal connection section16(at the anti-corrosion material supplying step S3), and the supplied anti-corrosion material20is UV cured by the UV light23, whereby the anti-corrosion section4is formed. At the anti-corrosion material supplying step S3, the dispenser62for supplying the anti-corrosion material20is used. At the anti-corrosion material supplying step S3, after the supply of the anti-corrosion material20by the pushing of the piston65of the dispenser62is ended, the piston65is retracted within the range of not allowing the anti-corrosion material20to run down from the nozzle66.

With the present invention, the anti-corrosion material20can be prevented from running down. This can eliminate the need for wiping work. Furthermore, since the need for wiping off the anti-corrosion material20can be eliminated, material loss can be prevented. Hence, the present invention exhibits the advantages of being capable of improving workability and reducing material loss.

Moreover, with the present invention, the water-repellent function is provided on the surface of the tip end of the nozzle66of the dispenser62that is used in the anti-corrosion material supplying step S3(the water-repellent processing section67is formed), whereby liquid buildup of the anti-corrosion material20can be prevented. That is to say, the need for wiping off the liquid buildup can be eliminated, whereby material loss can be prevented. Hence, similarly to the above description, the present invention exhibits the advantages of being capable of improving workability and reducing material loss. In addition, the present invention can stabilize the supply amount of the anti-corrosion material20to the wire-terminal connection section16by preventing the liquid buildup of the anti-corrosion material20, thereby exhibiting the advantage of being capable of maintaining the quality of the formed anti-corrosion section4constant.

FIG. 8is a view showing a modification of the dispenser. A dispenser62′ serving as a modification has a syringe64, a piston65and a plurality of nozzles66. The plurality of nozzles66is connected to the syringe64via a nozzle branching section68. Although the number of the nozzles66is four inFIG. 8(four-way branched), the number of the nozzles66is not limited to four, and the number may be eight (eight-way branched) or 16 (16-way branched). The dispenser62′ has a structure in which the four nozzles66discharge an equal amount of the anti-corrosion material20simultaneously when the piston65of the dispenser62′ is pushed.

With the present invention in the case that the dispenser62′ having the above-mentioned structure is adopted, when the piston65is pushed, the four nozzles66discharge an equal amount of the anti-corrosion material20simultaneously as described above, whereby four anti-corrosion sections4can be formed at a time. In other words, the four anti-corrosion sections4can be formed without increasing the facility for supplying the material. Consequently, the present invention exhibits the advantage of being capable of contributing to the improvement in productivity.

Here, the details of the above embodiments are summarized as follows.

A method for manufacturing a terminal fitting with an electric wire, comprising:forming a wire-terminal connection section by connecting a terminal fitting to an exposed conductor section of an electric wire in which a resin cover is removed from the electric wire to expose a conductor of the electric wire;supplying a sealing material from a nozzle of a dispenser to the wire-terminal connection section to form a sealing section that covers the wire-terminal connection section,wherein in a process of supplying the sealing material, after the supply of the sealing material by pushing of a piston of the dispenser is completed, the piston is retracted within a range of not allowing the sealing material to run down from the nozzle.

By the above method, after the supply of the sealing material is completed, the piston of the dispenser is retracted, whereby a suction action is exerted and the sealing material is prevented from running down.

For example, a surface on a tip end side of the nozzle of the dispenser is subjected to water-repellent processing.

By the above method, at least the surface on the tip end side of the nozzle of the dispenser is provided with the water-repellent processing (water-repellent function), whereby liquid buildup (wetting-up) of the sealing material is prevented by the function.

For example, the dispenser has the nozzle and another nozzle, and an equal amount of the sealing material is simultaneously discharged from each of the nozzle and the another nozzle when the piston is pushed.

By the above method, the dispenser is structured so as to cause the plurality of nozzles to discharge an equal amount of the sealing material simultaneously when the piston is pushed, whereby a plurality of sealing sections can be formed at a time.

In a case that objects to be processed are limited such that the electric wire is an aluminum wire, that the terminal fitting is made of a metal different from the material of the aluminum wire, that the sealing material is an anti-corrosion material, and that the sealing section is an anti-corrosion section, the above method is characterized as described below. That is to say, “A method for manufacturing a terminal fitting with an electric wire, comprising: forming a wire-terminal connection section by connecting a terminal fitting whose base material is made of copper or a copper alloy to the position of an exposed conductor section formed by removing the insulating resin cover of an electric wire having a conductor made of aluminum or an aluminum alloy and the insulating resin cover for covering the conductor and further forming an anti-corrosion section for covering the wire-terminal connection section, wherein a dispenser is used at anti-corrosion material supplying step for supplying an anti-corrosion material to the wire-terminal connection section, and after the supply of the anti-corrosion material by the pushing of the piston of the dispenser is ended, the piston is retracted within the range of not allowing the anti-corrosion material to run down from the nozzle.”

Furthermore, in the case that objects to be processed are limited such that the sealing material is a waterproof material and that the sealing section is a waterproof section, the method is characterized as described below. That is to say, “A method for manufacturing a terminal fitting with an electric wire, comprising the steps of forming a wire-terminal connection section by connecting a terminal fitting to the position of an exposed conductor section formed by removing the resin cover of an electric wire and further forming a waterproof section for covering the wire-terminal connection section, wherein a dispenser is used at waterproof material supplying step for supplying a waterproof material to the wire-terminal connection section, and after the supply of the waterproof material by the pushing of the piston of the dispenser is ended, the piston is retracted within the range of not allowing the waterproof material to run down from the nozzle.”

With the above method, in the sealing material supplying step for supplying the sealing material to the wire-terminal connection section, after the supply of the sealing material by the dispenser that is used in the process is completed, the piston of the dispenser is retracted to prevent the sealing material from running down, thereby eliminating the need for wiping work. Furthermore, since the need for wiping off the sealing material is eliminated, material loss does not occur. Hence, the present invention exhibits the advantages of being capable of improving workability and reducing material loss.

With the above method, the surface of the tip end of the nozzle of the dispenser that is used in the sealing material supplying step is provided with the water-repellent function, whereby liquid buildup of the sealing material can be prevented. In other words, the need for wiping off the liquid buildup is eliminated, whereby material loss does not occur. Hence, the method exhibits the advantages of being capable of improving workability and reducing material loss. In addition, the present invention stabilizes the supply amount of the sealing material to the wire-terminal connection section by preventing the liquid buildup of the sealing material, thereby exhibiting the advantage of being capable of maintaining the quality of the formed sealing section constant.

The dispenser that is used in the sealing material supplying step has the nozzles being plural in number and causes the plurality of nozzles to discharge an equal amount of the sealing material simultaneously when the piston is pushed, whereby the present invention can exhibit the advantage of being capable of forming a plurality of sealing sections at a time. In other words, the plurality of sealing sections can be formed without increasing the facility for supplying the material. The present invention thus exhibits the advantage of being capable of contributing to the improvement in productivity.

The present invention can be changed variously without departing from the gist of the present invention as a matter of course.