JP2017004844A - Electric wire with terminal and manufacturing method thereof - Google Patents

Abstract

An object of the present invention is to effectively suppress the movement of a core wire when a terminal is connected, and to improve the connection reliability between the core wire and the terminal. An electric wire with a terminal includes a covered electric wire in which a core wire made of a conductive material is covered with a coating made of an insulating material, and a terminal connected to the core wire at a terminal portion of the covered electric wire, A welding portion welded to the core wire by ultrasonic welding; and a fixing portion provided in the vicinity of the welding portion and fixing the core wire. [Selection] Figure 1

Description

  The present invention relates to an electric wire with a terminal to which a terminal is connected and a method for manufacturing the electric wire.

Conventionally, an electric wire with a terminal in which a tip (core wire) of a covered electric wire is connected to a connection terminal by ultrasonic welding is known (for example, see Patent Documents 1 and 2 below).
In the method of manufacturing a terminal-attached electric wire disclosed in Patent Document 1, a step of peeling the coating at the tip of the covered electric wire to expose the core wire, a step of arranging the core wire in the core wire welding portion of the terminal fitting, An ultrasonic wave is applied in a pressed state, and the terminal fitting is connected to the tip of the covered electric wire through a process of welding the core wire to the core wire welding portion of the terminal fitting. Moreover, in the connection method of the terminal disclosed in Patent Document 2 to the electric wire, after the welding step, the pair of side walls of the terminal fitting is bent to cover the core wire welded portion together with the core wire.

JP 2011-44371 A JP 2003-338327 A

  However, when connecting the end of the covered wire to the terminal fitting by ultrasonic welding, the core wire may move unintentionally. In this case, the vibration energy of the ultrasonic waves escapes without being transmitted between the core wire and the terminal, resulting in poor connection reliability of the terminal.

  The present invention has been made in view of the above circumstances, and by effectively suppressing the movement of the core wire at the time of terminal connection, an electric wire with a terminal capable of improving the connection reliability between the core wire and the terminal, and a method for manufacturing the same. The purpose is to provide.

  An electric wire with a terminal according to the present invention includes a covered electric wire in which a core wire made of a conductive material is covered with a coating made of an insulating material, and a terminal connected to the core wire at a terminal portion of the covered electric wire, It has the welding part welded to a core wire by ultrasonic welding, and the fixing | fixed part which is provided in the vicinity of the said welding part and fixes the said core wire.

  According to the terminal-attached electric wire according to the present invention, the terminal connected to the core wire at the terminal portion of the covered electric wire is welded to the core wire by ultrasonic welding, and the fixing is provided in the vicinity of the weld to fix the core wire. Therefore, it is possible to suppress the movement of the core wire when the fixing portion fixes the core wire and welds the core wire and the welded portion of the terminal. Thereby, a core wire and a terminal can be stuck and it can weld reliably, and the connection reliability of a terminal can be improved.

  In one Embodiment of this invention, the said fixing | fixed part fixes the said core wire prior to the said ultrasonic welding.

  In another embodiment of the present invention, the welding portion is welded to a core wire exposed portion of the core wire, and the fixing portion fixes the core wire in the core wire exposed portion.

  In still another embodiment of the present invention, the welding portion is welded to a core wire exposed portion of the core wire, and the fixing portion has a penetration portion that breaks through the coating, and fixes the core wire together with the coating.

  In still another embodiment of the present invention, the fixing portion is an open barrel that is crimped.

  In still another embodiment of the present invention, the fixing portion is a closed barrel that is caulked.

  In still another embodiment of the present invention, the fixing portion is crimped until the core wire is pressed and deformed.

  In still another embodiment of the present invention, the penetrating portion is formed in a sharp shape.

  The method for manufacturing a terminal-attached electric wire according to the present invention includes a welded portion welded by ultrasonic welding to the core wire at a terminal portion of the covered electric wire in which a core wire made of a conductive material is covered with a coating made of an insulating material, A step of preparing a terminal provided in the vicinity and having a fixing portion for fixing the core wire; a step of removing the coating of the covered electric wire to lead out a core wire exposed portion; and the core wire of the covered electric wire by the fixing portion. And a step of welding the core wire exposed portion of the covered electric wire and the welded portion of the terminal by ultrasonic welding.

  According to the manufacturing method of the electric wire with a terminal concerning the present invention, the electric wire with a terminal which has the above-mentioned operation effect can be manufactured in a simple process.

  In one embodiment of the present invention, in the fixing step, the core wire is fixed by caulking the fixing portion.

  According to the present invention, since the fixing portion fixes the core wire, it is possible to suppress the movement of the core wire when welding the core wire and the welded portion of the terminal, and to firmly weld the core wire and the terminal so as to contact the terminal. Connection reliability can be improved.

It is a perspective view showing an electric wire with a terminal concerning a 1st embodiment of the present invention. It is a flowchart which shows the manufacturing process of the electric wire with a terminal. It is a side view which shows the electric wire with a terminal for every manufacturing process. It is a perspective view which shows the modification of the terminal of the electric wire with the terminal. It is a perspective view which shows the electric wire with a terminal which concerns on the 2nd Embodiment of this invention. It is a side view which shows the electric wire with a terminal for every manufacturing process. It is a perspective view which shows the modification of the terminal of the electric wire with the terminal.

  Hereinafter, a terminal-attached electric wire and a method for manufacturing the same according to an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

[First Embodiment]
FIG. 1 is a perspective view showing a terminal-attached electric wire 1 according to a first embodiment of the present invention, FIG. 1 (a) shows an exploded view, and FIG. 1 (b) shows an overall view. Moreover, FIG. 2 is a flowchart which shows the manufacturing process of the electric wire 1 with a terminal. Furthermore, FIG. 3 is a side view which shows the electric wire 1 with a terminal for every manufacturing process.

  As shown in FIGS. 1A and 1B, the terminal-attached electric wire 1 according to the first embodiment is connected to the covered electric wire 10 and the core wire exposed portion 13 of the core wire 11 in the terminal portion of the covered electric wire 10. Terminal 20. The covered electric wire 10 includes a core wire 11 formed by twisting together a plurality of elongated wires such as copper and aluminum, and a coating 12 made of an insulating resin that covers the periphery of the core wire 11 and insulates and protects the core wire 11 from the outside. ing.

  The coating 12 is formed so as to cover the periphery of the core wire 11 by, for example, a tube extrusion method. In the core wire exposed portion 13, the coating 12 is peeled (removed). This covered electric wire 10 has flexibility. Therefore, in order to improve the bendability, the outer periphery of the core wire 11 covers the outer periphery of the core wire 11 to such an extent that a slight gap may be generated between the core wire 11 and the coating 12.

  Since the covered electric wire 10 is configured as described above, the covered electric wire 10 also has a characteristic that it is easily deformed regardless of its cross-sectional shape. In the covered electric wire 10 of the first embodiment, as shown in FIG. 1A, the cross-sectional shape of the terminal portion and the vicinity thereof is circular in a state before the terminal 20 is connected.

  However, this covered electric wire 10 is formed such that the cross-sectional shape of the main portion of the electric wire excluding the terminal portion and the vicinity thereof is a non-circular shape, for example, a cross-sectional fan shape. Specifically, it is one of bundled electric wires which are formed by combining three covered electric wires 10 having a sectoral cross section and having a circular cross section as a whole.

  Here, the fan shape or the fan shape means a shape surrounded by one arc portion and two radius portions passing through both ends thereof. The angle of the central angle formed by the two radius portions may be less than 180 °, and the cross-sectional shape may be substantially a fan shape, not a strict fan shape. Therefore, the main part of the electric wire is formed in a sector shape having a central angle of about 120 °, for example. Moreover, the terminal part of the electric wire is press-deformed into a circular cross section.

  Thus, the covered electric wire 10 has a structure in which the cross-sectional shapes are partially different. In addition, the covered electric wire 10 can also employ a shape in which a main portion of the electric wire is pressed and deformed to have a cross-sectional fan shape, or a shape formed so that the whole has a circular cross-sectional shape. For example, when the main part of the electric wire has a sectoral cross-sectional shape, the covered electric wire 10 has a covering length that is about 1.13 times the outer peripheral length of a covering electric wire having a general circular cross-sectional shape. 12, the outer periphery of the core wire 11 is covered.

  For this reason, the close contact between the core wire 11 and the sheath 12 is loose at the circular cross-section of the terminal portion and its vicinity, and the core wire 11 and the sheath 12 are at the boundary between the core wire exposed portion 13 and the sheath 12 of the covered electric wire 10. There will be a gap between them. In the case of the covered electric wire 10, since the main part of the electric wire is formed in a sectoral cross section, for example, three electric wires can be bundled so that the whole bundled electric wire has a circular cross section. Can be made compact (thinner diameter).

  On the other hand, the terminal 20 is formed by punching and bending a metal base material. The terminal 20 has a plate-like welded portion 21 to be welded by ultrasonic welding to the core wire exposed portion 13 of the covered electric wire 10, and a connected member (external connection element) extending from the welded portion 21 to the front end side (front). And a connecting portion 22 for contact.

  Further, the terminal 20 includes a fixing portion 23 that fixes the core wire exposed portion 13 on the rear end side (rear side) of the welding portion 21. The fixing portion 23 has an open barrel structure having a plate-like portion 23a and a pair of barrel pieces 24a and 24b erected on both side edges of the plate-like portion 23a. The barrel pieces 24a and 24b have the same thickness T1 as the welded portion 21 and the connecting portion 22, and are formed to have a predetermined width W2.

  Since the barrel pieces 24a and 24b are intended to fix the core wire 11 in the core wire exposed portion 13 to the terminal 20 in the fixing portion 23, the width W2 of the barrel pieces 24a and 24b is formed to be extremely narrow compared to a general wire barrel. Can do. The welded portion 21, the connecting portion 22, and the fixing portion 23 are integrally formed.

  The welded portion 21 has a length L1 along the axial direction of the covered electric wire 10 and a width W1 in a direction crossing the axial direction, which are necessary and sufficient for placing the core wire exposed portion 13 of the covered electric wire 10. The connecting portion 22 is a portion that is continuous from the welded portion 21 and is electrically connected to contact with an unillustrated counterpart terminal or auxiliary machine.

  The terminal 20 according to the first embodiment is assumed to be connected to a rod-shaped terminal such as a battery terminal. For this reason, the terminal 20 has a flat plate shape extending in the axial direction of the covered electric wire 10. And the through-hole 22a in which a rod-shaped terminal is inserted is formed in the front end side of the connection part 22, for example. In addition, the specific shape and structure in the connection part 22 of the terminal 20 of the electric wire 1 with a terminal which concerns on this invention are not limited, The structure which has what is called a male and female fitting shape may be sufficient.

  The fixing portion 23 fixes the core wire 11 to the terminal 20 prior to ultrasonic welding between the core wire exposed portion 13 and the welded portion 21. In the first embodiment, the fixing portion 23 fixes the core wire 11 in the core wire exposed portion 13 to the terminal 20. That is, the pair of barrel pieces 24a and 24b in the fixing portion 23 are crimped so as to sandwich the core wire exposed portion 13 arranged between the plate-like portion 23a.

  Thereby, the core wire exposed part 13 is fixed to the terminal 20 in the fixing part 23 without a gap between the strands. In addition, the fixing | fixed part 23 may be crimped until the core wire exposure part 13 pinched | interposed is press-deformed. If it does in this way, it will become easy to discriminate | determine from the external appearance that the core part exposed part 13 was pinched | interposed by the fixing | fixed part 23, and was fixed with respect to the terminal 20.

  In this manner, the core wire exposed portion 13 is ultrasonically welded to the welded portion 21 in a state where the core wire exposed portion 13 is fixed to the terminal 20 by the fixing portion 23, whereby the terminal 20 is electrically connected to the covered electric wire 10. . According to the terminal-equipped electric wire 1 including the terminal 20 configured in this way, the fixing portion 23 of the terminal 20 is connected to the core wire exposed portion 13 before the ultrasonic welding between the welded portion 21 and the core wire exposed portion 13. Secure to.

  Therefore, the movement of the core wire 11 during ultrasonic welding between the core wire exposed portion 13 and the welded portion 21 is suppressed. That is, the vibration energy of ultrasonic welding can be prevented from escaping in the axial direction of the covered electric wire 10 due to the movement of the core wire 11. For this reason, the core wire 11 in the core wire exposure part 13 and the welding part 21 of the terminal 20 can be reliably welded by ultrasonic welding, and the connection reliability with respect to the covered electric wire 10 of the terminal 20 can be improved.

  Next, the manufacturing process of the terminal-attached electric wire 1 according to the first embodiment will be described. Here, according to the flowchart of FIG. 2, the manufacturing process will be described with reference to FIG. In the following description including FIG. 2 and FIG. 3, the same components as those in the first embodiment are denoted by the same reference numerals, and hence redundant description is omitted below.

  First, as shown in FIG. 3 (a), a covered electric wire 10 in which a core wire 11 is covered with a covering 12 is prepared, and a separately manufactured terminal having a welded portion 21, a connecting portion 22, and a fixing portion 23 as described above. 20 (not shown) is prepared (step S100). Next, as shown in FIG.3 (b), the coating | coated 12 of predetermined length is removed from the front-end | tip in the terminal part of the covered wire | conductor 10, and the core wire exposed part 13 of the core wire 11 is extracted (step S102).

  Thereafter, as shown in FIG. 3C, the core wire exposed portion 13 of the covered electric wire 10 is placed on the welded portion 21 and the fixed portion 23 of the terminal 20, and as shown in FIG. 23 barrel pieces 24a and 24b are crimped, and the core wire 11 of the core wire exposed portion 13 is fixed to the terminal 20 by the fixing portion 23 (step S104).

  Finally, as shown in FIG. 3E, the welded portion 21 of the terminal 20 is placed on the pedestal 19 of the ultrasonic welding apparatus. Then, while pressing the horn 18 in the direction indicated by the arrow A in the figure from above the core wire exposed part 13 on the welded part 21, ultrasonic welding is performed by finely vibrating in the direction indicated by the arrow B in the figure (step S106). The core wire 11 of the core wire exposed portion 13 and the welded portion 21 of the terminal 20 are connected. Thus, the electric wire 1 with a terminal which concerns on 1st Embodiment is manufactured. In the manufacturing process according to the first embodiment, the terminal-attached electric wire 1 can be easily manufactured by the simple process as described above.

[Modified Example of Terminal of First Embodiment]
FIG. 4 is a perspective view showing a modified example of the terminal 20 of the electric wire with terminal 1 of the first embodiment. The terminal 20 applied to the electric wire with terminal 1 of the first embodiment may have the following configuration. That is, as shown in FIG. 4, the terminal 20 has a closed barrel structure in which the fixing portion 23 includes a barrel ring 25 provided on the plate-like portion 23a, and the core wire exposed between the terminals 20a is disposed. The barrel ring 25 is crimped so as to sandwich the portion 13. Even if comprised in this way, the core wire exposure part 13 can be fixed to the terminal 20 in the fixing | fixed part 23 before the ultrasonic welding, without the clearance gap between strands.

[Second Embodiment]
FIG. 5 is a perspective view showing a terminal-attached electric wire 1 according to a second embodiment of the present invention, FIG. 5 (a) shows an exploded view, and FIG. 5 (b) shows an overall view. Moreover, FIG. 6 is a side view which shows the electric wire 1 with a terminal for every manufacturing process.

  As shown in FIGS. 5A and 5B, the terminal-attached electric wire 1 according to the second embodiment has a fixed portion 23 of the terminal 20 of the covered electric wire 10 provided at the tips of the barrel pieces 24a and 24b. It has penetration parts 26 a and 26 b that break through the coating 12, and fixes the core wire 11 together with the coating 12. That is, when the barrel pieces 24 a and 24 b are caulked from above the coating 12, the penetration portions 26 a and 26 b penetrate the coating 12 and reach the core wire 11.

  In the example shown in FIG. 5A, the penetrating portions 26a and 26b are directed toward the center in the width direction without changing the thickness T2 continuing from the barrel pieces 24a and 24b so that the coating 12 can be easily broken. A width W3 continuing from the barrel pieces 24a and 24b is tapered so that the tip is sharpened.

  And the barrel pieces 24a and 24b in the fixing | fixed part 23 are crimped so that the core wire 11 arrange | positioned between the plate-shaped parts 23a may be inserted | pinched with the coating | coated 12. Thereby, the core wire 11 is fixed to the terminal 20 in the fixing portion 23 without a gap between the strands and between the core wire 11 and the covering 12 without a gap.

  This is different from the above-described first embodiment in which the fixing portion 23 fixes the core wire 11 in the core wire exposed portion 13. Other configurations related to the second embodiment such as the welded portion 21, the connecting portion 22, and the covered electric wire 10 in the terminal 20 are the same as those in the first embodiment.

  In addition, in this 2nd Embodiment, when the full length of the terminal 20 and the full length of the core wire exposed part 13 cannot be taken long, the length of the core wire exposed part 13 corresponding to the length L2 of the welding part 21 of the terminal 20 is short. Even in the case, the core wire 11 can be reliably fixed to the terminal 20 together with the covering 12 by the fixing portion 23 prior to the ultrasonic welding between the core wire exposed portion 13 and the welded portion 21. Therefore, the connection reliability of the terminal 20 to the covered electric wire 10 can be improved without escape of vibration energy during ultrasonic welding.

  Next, the manufacturing process of the terminal-attached electric wire 1 according to the second embodiment will be described. Since the flowchart of the manufacturing process of the electric wire with terminal 1 in the second embodiment is the same as that of the first embodiment, here, the manufacturing process will be described with reference to FIG. 6 according to the flowchart of FIG.

  First, as shown in FIG. 6 (a), the covered electric wire 10 and the terminal 20 (not shown) are prepared (step S100), and as shown in FIG. 6 (b), the core wire exposed portion of the core wire 11 is prepared. 13 is extracted (step S102). Next, as shown in FIG. 6C, the core wire exposed portion 13 of the covered electric wire 10 is disposed on the welded portion 21 of the terminal 20, and the plate-like portion 23a of the fixing portion 23 (see FIG. 5A). A coating 12 is placed on top.

  Thereafter, as shown in the AA ′ cross-sectional views in FIGS. 6D and 6D, the barrel pieces 24 a and 24 b of the fixing portion 23, and the penetrating portions 26 a and 26 b at the distal end penetrate the coating 12. It crimps so that it may reach the core wire 11, and the core wire 11 is fixed with respect to the terminal 20 by the fixing | fixed part 23 with the coating | coated 12 (step S104).

  Finally, as shown in FIG. 6 (e), the welded portion 21 of the terminal 20 is placed on the pedestal 19 of the ultrasonic welding apparatus, and the horn 18 is directed from above the core wire exposed portion 13 in the direction indicated by the arrow A in the figure. And is subjected to ultrasonic welding by vibrating in the direction indicated by arrow B in the figure (step S106), and the core wire exposed portion 13 and the welded portion 21 are connected. In this way, the terminal-attached electric wire 1 according to the second embodiment can be easily manufactured by a simple process.

[Modified Example of Terminal of Second Embodiment]
FIG. 7 is a perspective view showing a modified example of the terminal 20 of the electric wire with terminal 1 of the second embodiment. FIG. 7 shows variations in the shapes of the penetrating portions 26 a and 26 b of the terminal 20. As for the terminal 20 applied to the electric wire 1 with a terminal of 2nd Embodiment, the shape of the penetration parts 26a and 26b at the front-end | tip of the barrel pieces 24a and 24b may be as follows, for example.

  That is, as shown in FIG. 7A, the penetrating portions 26a and 26b are formed in a tapered shape in which the width W3 is gradually narrowed so that the front end of the terminal 20 is sharp without changing the thickness T2. It may be. Further, as shown in FIG. 7B, the penetration portions 26a and 26b have the width W3 gradually so that the front end is sharp and the other rear end is sharp without changing the thickness T2. You may form in the taper shape which becomes narrow.

  Further, as shown in FIG. 7C, the penetration portions 26a and 26b are tapered so that the thickness T2 gradually decreases so that the inner ends of the barrel pieces 24a and 24b are sharp without changing the width W3. It may be formed. Further, as shown in FIG. 7 (d), the penetration portions 26a and 26b are gradually increased in thickness T2 so that the tip is pointed toward the center in the thickness direction of the barrel pieces 24a and 24b without changing the width W3. You may form in the taper shape which becomes thin.

  In addition, as shown in FIG. 7 (e), the penetrating portions 26a and 26b may be formed in a tapered shape similar to that shown in FIG. 7 (c), and a sharp tip may be formed in a sawtooth shape. . Further, as shown in FIG. 7 (f), the penetration portions 26a and 26b gradually have a thickness T2 and a width W3 such that the tips are pointed toward the center in the thickness direction and the center in the width direction of the barrel pieces 24a and 24b. It may be formed in a tapered shape that is thin and narrow. As described above, the shapes of the penetration portions 26 a and 26 b of the terminal 20 according to the second embodiment can take various shapes in consideration of breaking through the coating 12.

  As mentioned above, although several embodiment of this invention was described, these embodiment is shown as an example and is not intending limiting the range of invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the scope of the invention. These embodiments and modifications thereof are included in the scope and gist of the invention, and are included in the invention described in the claims and the equivalents thereof.

DESCRIPTION OF SYMBOLS 1 Electric wire with a terminal 10 Covered electric wire 11 Core wire 12 Coating 13 Core wire exposed part 18 Horn 19 Base 20 Terminal 21 Welded part 22 Connection part 22a Through hole 23 Fixing part 23a Plate-like part 24a, 24b Barrel piece 25 Barrel ring 26a, 26b Penetration part

Claims (10)

A covered electric wire in which a core wire made of a conductive material is covered with a coating made of an insulating material;
A terminal connected to the core wire at a terminal portion of the covered electric wire,
The said terminal has a welding part welded to the said core wire by ultrasonic welding, and a fixing part provided in the vicinity of the said welding part and fixing the said core wire. The electric wire with a terminal characterized by the above-mentioned. The electric wire with a terminal according to claim 1, wherein the fixing portion fixes the core wire prior to the ultrasonic welding. The said welding part is welded to the core wire exposed part of the said core wire, and the said fixing | fixed part fixes the said core wire in the said core wire exposed part. The electric wire with a terminal of Claim 1 or 2 characterized by the above-mentioned. 3. The terminal according to claim 1, wherein the welded portion is welded to a core wire exposed portion of the core wire, and the fixing portion has a penetration portion that breaks through the coating, and fixes the core wire together with the coating. With electric wire. The said fixing | fixed part consists of an open barrel crimped. The electric wire with a terminal of any one of Claims 1-4 characterized by the above-mentioned. The electric wire with a terminal according to any one of claims 1 to 3, wherein the fixed portion is a closed barrel that is crimped. The electric wire with a terminal according to claim 5 or 6, wherein the fixing portion is crimped until the core wire is pressed and deformed. The said penetration part is formed in the sharp shape. The electric wire with a terminal of Claim 4 characterized by the above-mentioned. A welded portion welded by ultrasonic welding to the core wire at a terminal portion of a covered electric wire in which a core wire made of a conductive material is covered with a coating made of an insulating material; Preparing a terminal to be provided;
Removing the coating of the covered electric wire and extracting the core wire exposed portion;
Fixing the core wire of the covered electric wire with the fixing portion;
The manufacturing method of the electric wire with a terminal characterized by including the process of welding the said core wire exposed part of the said covered electric wire, and the said welding part of the said terminal by ultrasonic welding. The method of manufacturing a terminal-attached electric wire according to claim 9, wherein, in the fixing step, the core wire is fixed by caulking the fixing portion.

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