CN111490362A - Terminal-equipped electric wire, method for manufacturing terminal-equipped electric wire, and terminal provided in terminal-equipped electric wire - Google Patents
Terminal-equipped electric wire, method for manufacturing terminal-equipped electric wire, and terminal provided in terminal-equipped electric wire Download PDFInfo
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- CN111490362A CN111490362A CN202010037583.0A CN202010037583A CN111490362A CN 111490362 A CN111490362 A CN 111490362A CN 202010037583 A CN202010037583 A CN 202010037583A CN 111490362 A CN111490362 A CN 111490362A
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Images
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/20—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/188—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping having an uneven wire-receiving surface to improve the contact
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
- H01B1/023—Alloys based on aluminium
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
- H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
- H01R43/048—Crimping apparatus or processes
- H01R43/0482—Crimping apparatus or processes combined with contact member manufacturing mechanism
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
- Manufacturing Of Electrical Connectors (AREA)
- Insulated Conductors (AREA)
Abstract
The invention provides a terminal-equipped wire, a method for manufacturing the terminal-equipped wire, and a terminal of the terminal-equipped wire, wherein the resistance between a conductor and the terminal is maintained at a low level and the electrical connection is sufficiently ensured. The terminal-equipped wire (1) is provided with a conductor (3), a wire (2), and a terminal (5) connected to the conductor (3), wherein the terminal (5) has 3 or more compressed portions in the longitudinal direction of the conductor (3), and at least one of the third and subsequent compressed portions is formed between adjacent compressed portions of the plurality of compressed portions that have been formed.
Description
Technical Field
The present invention relates to a terminal-equipped wire used for railway vehicles and the like, a method for manufacturing the terminal-equipped wire, and a terminal provided in the terminal-equipped wire.
Background
Conventionally, a conductor and a terminal formed of copper or a copper alloy have been used for a terminal-equipped wire for connecting a conductor and a terminal of an electric wire from the viewpoint of conductivity, and in recent years, a proposal for forming a conductor and a terminal with an aluminum material has been studied from the viewpoint of weight reduction. For example, patent document 1 discloses a method of connecting a terminal made of aluminum or an aluminum alloy to a conductor made of aluminum or an aluminum alloy.
Documents of the prior art
Patent document 1: japanese patent No. 6410163
However, aluminum is easier to relax than copper. Therefore, when the terminal formed of an aluminum material is connected to the conductor formed of an aluminum material, stress acting on the connection portion of the conductor and the terminal becomes small with the passage of time. Along with this, the contact force between the conductor and the terminal decreases, and there is a possibility that the resistance between these increases.
When a current flows through the conductor in a state where the resistance between the conductor and the terminal is large, heat is generated in the electric wire with the terminal, and the heat is a factor of disconnection or contact failure of the electric wire.
Disclosure of Invention
Accordingly, an object of the present invention is to provide a terminal-equipped wire, a method for manufacturing the terminal-equipped wire, and a terminal of the terminal-equipped wire, which can maintain the electrical resistance between a conductor made of an aluminum material and a terminal made of an aluminum material at a low level and can sufficiently ensure electrical connection.
According to a first aspect of the present invention, a terminal-equipped electric wire includes:
an electric wire including a conductor formed of an aluminum material and an insulating layer covering the conductor;
a terminal formed of an aluminum material and having a hollow portion into which the conductor exposed at an end portion of the wire is inserted, the terminal being connected to the conductor by compressing the hollow portion in a state in which the conductor is inserted into the hollow portion,
the terminal has three or more compression parts along the longitudinal direction of the conductor,
when the resistance ratios between the conductor and the terminal before and after the test in which the terminal-equipped wire was heated at 150 ℃ for 50 hours were R1 and R2, respectively, the increase rate of the resistance ratio calculated from the equation of ((R2-R1)/R1) × 100 (%) was 19% or less.
According to a second aspect of the present invention, there is provided a method of manufacturing a terminal-equipped wire, comprising the steps of:
preparing a wire including a conductor made of an aluminum material and an insulating layer covering the conductor, and a terminal made of an aluminum material having a hollow portion;
a step of connecting the terminal to the conductor by compressing the terminal three or more times in a state where the conductor exposed at the end of the wire is inserted into the hollow portion and forming a plurality of compressed portions in the terminal,
the step of connecting the terminal to the conductor includes a step of forming a new compressed portion between the already formed adjacent compressed portions.
According to a third aspect of the present invention, there is provided a terminal having a hollow portion into which a conductor is inserted, configured to be connected to the conductor by compressing the terminal in a state in which the conductor is inserted into the hollow portion, and,
the terminal is marked with information on the order of compression.
The effects of the present invention are as follows.
According to the present invention, it is possible to provide a terminal-equipped wire, a method for manufacturing the terminal-equipped wire, and a terminal provided in the terminal-equipped wire, which can maintain the electrical resistance between a conductor made of an aluminum material and a terminal made of an aluminum material at a low level and can sufficiently ensure electrical connection.
Drawings
Fig. 1 is a perspective view illustrating a state before a conductor is inserted into a hollow portion of a terminal, in which the terminal and the conductor of a terminal-equipped wire according to an embodiment are included.
Fig. 2 is a cross-sectional view illustrating a state after a conductor is inserted into a hollow portion of a terminal of the terminal-equipped wire according to the embodiment and before the hollow portion is compressed.
Fig. 3 is a sectional view of the terminal-equipped electric wire when the terminal of the terminal-equipped electric wire according to the embodiment is compressed 3 times, (a) is a sectional view of the terminal-equipped electric wire when the first compression is completed, (b) is a sectional view of the terminal-equipped electric wire when the second compression is completed, and (c) is a sectional view of the terminal-equipped electric wire when the third compression is completed.
Fig. 4 is a schematic configuration diagram of a terminal according to an embodiment.
Fig. 5 is a sectional view of the terminal-equipped electric wire when the terminal of the terminal-equipped electric wire is compressed 2 times, (a) is a sectional view of the terminal-equipped electric wire when the first compression is completed, and (b) is a sectional view of the terminal-equipped electric wire when the second compression is completed.
Fig. 6 is a sectional view of the terminal-equipped electric wire when the terminal of the terminal-equipped electric wire is compressed 3 times, (a) is a sectional view of the terminal-equipped electric wire when the first compression is completed, (b) is a sectional view of the terminal-equipped electric wire when the second compression is completed, and (c) is a sectional view of the terminal-equipped electric wire when the third compression is completed.
Fig. 7 is a cross-sectional view showing a portion where a compressed portion is formed when a terminal of the terminal-equipped electric wire according to the embodiment is compressed 4 times.
Fig. 8 is a cross-sectional view of the terminal-equipped electric wire in an embodiment showing a portion where a compressed portion is formed when the terminal of the terminal-equipped electric wire is compressed 5 times.
Fig. 9 is an explanatory view showing an outline of the high-temperature environment exposure test.
Fig. 10 is an explanatory diagram showing a method of measuring the resistance ratio.
In the figure: 1-terminal-equipped wire, 2-wire, 3-conductor, 4-insulation layer, 5-terminal, 6-cylindrical part, 6 a-one end part, 7-hollow part, 8-extension part, 9-bolt hole, 10, 11, 12-compression part, P1, P2, P3-compression part, 13-aluminum plate, 14-thermostatic bath.
Detailed Description
Hereinafter, a terminal-equipped wire, a method for manufacturing the terminal-equipped wire, and a terminal included in the terminal-equipped wire according to the present invention will be described with reference to the drawings.
< 1. example of the construction of electric wire with terminal
An example of the structure of the terminal-equipped wire will be described.
As shown in fig. 1, the terminal-equipped wire 1 of the present embodiment includes a wire 2 and a terminal 5. The terminal-equipped wire 1 can be used as a wiring material used in, for example, buildings, wind power generators, rail vehicles, automobiles, and the like.
(Electrical wire)
The electric wire 2 is configured as a so-called insulated wire, and includes a conductor 3 and an insulating layer 4 covering the conductor 3. The conductor 3 exposed at the end of the wire 2 is inserted into the hollow portion 7 of the terminal 5.
The conductor 3 constitutes a core wire of the electric wire 2. As the conductor 3, a twisted wire obtained by twisting a metal wire or a plurality of metal wires can be used. As the metal material constituting the conductor 3, for example, pure aluminum or an aluminum alloy (hereinafter, these are referred to as "aluminum material") can be used. Pure aluminum is a material composed of Al and unavoidable impurities. Examples of the pure aluminum include pure aluminum for electric power (ECAl). Examples of the aluminum alloy include the following Al-Zr and Al-Fe-Zr. The Al-Zr contains 0.03 to 1.5 mass% of Zr, 0.1 to 1.0 mass% of Fe and Si, and the balance is an aluminum alloy having a chemical composition consisting of Al and unavoidable impurities. Further, Al-Fe-Zr contains 0.01 to 0.10 mass% of Zr, 0.1 mass% or less of Si, 0.2 to 1.0 mass% of Fe, 0.01 mass% or less of Cu, 0.01 mass% or less of Mn, 0.01 mass% or less of Mg, 0.01 mass% or less of Zn, 0.01 mass% or less of Ti, and 0.01 mass% or less of V, and the balance is an aluminum alloy containing Al and unavoidable impurities.
In Al-Zr, "0.1 to 1.0 mass% of Fe and Si" has the following meanings. When both Fe and Si are contained, the total concentration of Fe and Si is 0.1 to 1.0 mass%. When Fe is contained and Si is not contained, the concentration of Fe is 0.1 to 1.0 mass%. When Si is contained and Fe is not contained, the concentration of Si is 0.1 to 1.0 mass%. The term "not contained" as used herein means not more than the detection limit in the high-frequency inductively coupled plasma emission spectroscopic analysis.
The insulating layer 4 is formed of an insulating material and provided so as to cover the conductor 3. As a material of the insulating layer 4, for example, a fluororesin, an olefin resin, a silicone resin, or the like can be used. The insulating layer 4 is provided over the entire length of the wire 2 in the longitudinal direction, but in the present embodiment, a predetermined length is removed from the end of the wire 2, and a part of the end of the conductor 3 is exposed.
(terminal)
The terminal 5 includes a cylindrical portion 6 and an extending portion 8, which are integrally formed. The terminal 5 is formed by press-working one end side of a tube, for example. The one end side corresponds to the extension portion 8. Alternatively, the terminal 5 is formed by drilling one end side of a cylindrical base material and pressing the other end side, for example. One end side of the drilling process corresponds to the hollow portion 7. The other end side of the press working corresponds to the extension portion 8. The hollow portion 7 has a cylindrical shape open on one side. The terminal 5 is made of an aluminum material, for example. More specifically, pure aluminum or an aluminum alloy, for example, is preferable. Pure aluminum is a material composed of Al and unavoidable impurities. For example, pure aluminum for electric power (ECAl) is cited. Examples of the aluminum alloy include the following Al-Fe-Zr. The Al-Fe-Zr contains 0.01 to 0.10 mass% of Zr, 0.1 mass% or less of Si, 0.2 to 1.0 mass% of Fe, 0.01 mass% or less of Cu, 0.01 mass% or less of Mn, 0.01 mass% or less of Mg, 0.01 mass% or less of Zn, 0.01 mass% or less of Ti, and 0.01 mass% or less of V, and the balance is an aluminum alloy containing Al and unavoidable impurities.
The cylindrical portion 6 is configured as a portion connected to the conductor 3 exposed from the end of the wire 2. In the present embodiment, the cylindrical portion 6 is formed in a cylindrical shape having a circular cross section, and a hollow portion 7 into which the conductor 3 exposed at the end of the wire 2 can be inserted is formed inside. The conductor 3 is inserted from one end 6a (inlet portion) of the cylindrical portion 6. The one end portion 6a is opened to have a size equal to or larger than the outer diameter of the conductor 3. The surface of the terminal 5 and the inner surface of the cylindrical portion 6 may be plated with Sn or Ag. In addition, the hollow portion 7 may be inserted after applying a compound to which conductive particles are added to the exposed conductor 3. The exposed conductor 3 may be inserted after the compound is applied or filled in the hollow portion 7 of the cylindrical portion 6. As the compound containing conductive particles, for example, a fluoro-based oil containing conductive particles of Ni-P or Ni-B and conductive particles obtained by mixing these can be used.
The extension portion 8 is configured as a portion to be connected to an external connection target side terminal, a bolt, or the like. In the present embodiment, the extension portion 8 is formed in a plate shape, and is provided with a bolt hole 9 into which a terminal, a bolt, or the like is inserted.
< 2. example of method for manufacturing electric wire with terminal
Next, a method for manufacturing the terminal-equipped wire 1 according to the present embodiment will be described.
The terminal-equipped electric wire 1 of the present embodiment can be manufactured by sequentially performing a step of preparing the electric wire 2 and the terminal 5, and a step of connecting the terminal 5 to the conductor 3 by compressing the terminal 5 in a state where the conductor 3 is inserted.
Hereinafter, each step will be described with reference to fig. 1 to 3.
(preparation Process)
First, the electric wire 2 having the conductor 3 and the terminal 5 are prepared. Both the conductor 3 and the terminal 5 are members made of an aluminum material. As shown in fig. 1, the insulating layer 4 of the electric wire 2 is removed by a predetermined length from the end of the electric wire 2 in the longitudinal direction, and a part of the conductor 3 is exposed. As shown in fig. 2, a part of the exposed conductor 3 of the wire 2 is inserted into a hollow portion 7 formed in the cylindrical portion 6 of the terminal 5.
(compression/connection step)
Next, as shown in fig. 3(a), the compressed portion P1 is compressed while the exposed part of the conductor 3 of the wire 2 is inserted into the hollow portion 7 of the terminal 5, thereby forming the compressed portion 10. Then, as shown in fig. 3(b), the compressed portion P3 is compressed to form the compressed portion 12. Finally, as shown in fig. 3(c), the compression portion 11 is formed by compressing the compression portion P2 between the compression portion P1 and the compression portion P3, and the terminal 5 is connected to the conductor 3.
These compressions are performed by, for example, applying a predetermined pressure to the compression points P1 to P3 over the entire circumference of the cylindrical portion 6 in the circumferential direction using a compression jig, and compressively deforming (plastically deforming) the cylindrical portion 6. In the present embodiment, the compression parts 10 to 12 have a hexagonal cross-sectional shape in a cross section perpendicular to the longitudinal direction (axial direction) of the conductor 3. The compression parts 10 to 12 are formed so as not to overlap each other by being positionally displaced with respect to the axial direction of the cylindrical part 6 (the longitudinal direction of the conductor 3 inserted into the hollow part 7). As described above, the terminal 5 is press-connected to the conductor 3 to obtain the terminal-equipped wire 1.
< 3 > Effect of the present embodiment
According to the present embodiment, one or more of the following effects can be obtained.
(a) Specifically, when the resistance ratio between the conductor 3 and the terminal 5 before and after the execution of an experiment (high-temperature environment exposure test) heated in an atmosphere at 150 ℃ for 50 hours is set to R1 and R2, respectively, the (electric power) resistance ratio increase rate calculated by the equation of ((R2-R1)/R1) × 100 can be suppressed to 19% or less, and the resistance ratio is a value measured by a so-called 4-terminal method described later, and is essentially synonymous with the resistance between the terminal 5 and the conductor 3.
(b) In the present embodiment, since a predetermined pressure is applied to the entire circumference of the cylindrical portion 6 in the circumferential direction when the compression portions 10 to 12 are formed, the terminal 5 can be uniformly compressed and connected to the entire circumference of the conductor 3, and the contact force between the terminal 5 and the conductor 3 can be maintained high.
< 4. modification
The present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the scope of the invention.
In the present embodiment, in forming the compressed parts 10 to 12, the compressed part P1 is compressed first and the compressed part P3 is compressed second, but the present invention is not limited to this, and the compressed part P3 may be compressed first and the compressed part P1 may be compressed second as long as the P2 between the compressed part P1 and the compressed part P3 is compressed last. Even in such a compression procedure, the increase in the resistance ratio of the terminal-equipped wire 1 can be suppressed to 19% or less.
In the present embodiment, the case where the number of the compression portions is three (the number of the compression positions is three) is described as an example, but the present invention is not limited to this, and the terminal 5 may be compressed at 4 as shown in fig. 7, or at 5 as shown in fig. 8. In the case of compression at 4, the compression part formed as the fourth is preferably formed between adjacent two of the plurality of compression parts already formed, for example, preferably compressed in the order of compression points P1, P4, P2, P3. By compressing in this order, a decrease in the contact force between the conductor 3 and the terminal 5 due to stress relaxation of the conductor 3 and the terminal 5 can be suppressed, and thus an increase in the resistance ratio of the terminal-equipped electric wire 1 can be suppressed.
In addition, even though the compression part formed as the 4 th (last) is not formed between the already formed adjacent compression parts, for example, the compression part formed as the 3 rd may be formed between the already formed adjacent compression parts in such a manner that the compression parts P1, P3, P2, P4 are compressed in order. However, the compressed part to be formed last is more preferably formed between adjacent compressed parts that have already been formed.
In addition, in the case of compressing the terminal 5 at 5 positions, the compression portion is preferably formed between adjacent two of the already formed compression portions. Particularly preferably, the compression part formed as the 5 th compression part is more preferably formed between adjacent two of the already formed compression parts. Preferably, the 3 rd and subsequent compressed parts are formed between all adjacent two compressed parts. For example, it is preferable to compress the components in the order of the compression sites P1, P5, P3, P2, and P4. By performing compression in this order, it is possible to suppress a decrease in the contact force between the conductor 3 and the terminal 5 due to stress relaxation of the conductor 3 and the terminal 5, and therefore, it is possible to suppress an increase in the resistance ratio of the terminal-equipped electric wire 1.
The aluminum material constituting the terminal 5 includes pure aluminum and an aluminum alloy, and the aluminum material constituting the conductor 3 includes pure aluminum and an aluminum alloy. Pure aluminum is a material composed of Al and unavoidable impurities. As pure aluminum, pure aluminum for electric power (ECAl) is exemplified. The aluminum alloy of the terminal 5 includes the following Al-Fe-Zr. The aluminum alloy of the conductor 3 includes the following Al-Fe-Zr and Al-Zr. The Al-Fe-Zr contains 0.01 to 0.10 mass% of Zr, 0.1 mass% or less of Si, 0.2 to 1.0 mass% of Fe, 0.01 mass% or less of Cu, 0.01 mass% or less of Mn, 0.01 mass% or less of Mg, 0.01 mass% or less of Zn, 0.01 mass% or less of Ti, and 0.01 mass% or less of V, and the balance is an aluminum alloy containing Al and unavoidable impurities. The Al-Zr contains 0.03 to 1.5 mass% of Zr, 0.1 to 1.0 mass% of Fe and Si, and the balance is an aluminum alloy having a chemical composition consisting of Al and unavoidable impurities. In the combination of the terminal 5 and the aluminum material of the conductor 3, since a decrease in the contact force between the conductor 3 and the terminal 5 due to stress relaxation of the conductor 3 and the terminal 5 can be suppressed, an increase in the resistance ratio of the terminal-equipped electric wire 1 can be suppressed.
Although not particularly limited in this embodiment, the compression ratio of the conductor 3 is preferably 50% or more and 95% or less. Here, the compression ratio is a ratio of a cross-sectional area of the conductor 3 corresponding to the non-compressed portion of the terminal 5 to a cross-sectional area of the conductor 3 corresponding to the compressed portion in a cross-section perpendicular to the longitudinal direction of the conductor 3 when the terminal 5 having the conductor 3 inserted in the hollow portion 7 is compressed, and C1 (mm) is defined as each of the cross-sectional area of the conductor 3 corresponding to the non-compressed portion of the terminal 5 and the cross-sectional area of the conductor 3 corresponding to the compressed portion (mm)2)、C2(mm2) The above compression ratio can suppress a decrease in the contact force between the conductor 3 and the terminal 5 due to stress relaxation between the conductor 3 and the terminal 5, and thus can suppress an increase in the resistance ratio of the terminal-equipped electric wire 1.
The width of each of the compression portions 10, 11, and 12 is preferably 7mm or less. With the width of the compressed portion, a decrease in the contact force between the conductor 3 and the terminal 5 due to stress relaxation of the conductor 3 and the terminal 5 can be suppressed, and therefore an increase in the resistance ratio of the terminal-equipped electric wire 1 can be suppressed. The width of the compression portion is more preferably 2mm or more and 5mm or less. When the thickness is 2mm or more and 5mm or less, the increase in the resistance ratio can be further suppressed to 19% or less. Further, the width of the compression portion is more preferably 3mm or more and 4mm or less. If the thickness is 3mm or more and 4mm or less, the increase in the resistance ratio can be further suppressed.
In the present embodiment, the compressing units 10, 11, and 12 are preferably provided at equal intervals, respectively. The compressed portions 10, 11, and 12 are provided at equal intervals, and can suppress an increase in the resistance ratio of the terminal-equipped wire 1.
In the present embodiment, the case where the compressed parts 10 to 12 are formed so as not to overlap with each other is exemplified, but the present invention is not limited thereto, and the compressed parts may be formed so as to overlap with each other slightly.
In the present embodiment, the case where the compressed parts 10 to 12 have a hexagonal cross-sectional shape in a cross section perpendicular to the longitudinal direction (axial direction) of the conductor 3 is exemplified, but the present invention is not limited thereto, and other polygonal shapes may be provided, or a circular shape may be provided.
In the present embodiment, although not particularly limited, it is preferable that information on the order of compression be given to the terminal 5. For example, as shown in fig. 4, it is preferable to label the character strings "1 st", "3 rd", and "2 nd" on the portions of the cylindrical portion 6 corresponding to the compression portions P1, P2, and P3, but the present invention is not limited thereto, and if the compression portion P2 between the compression portion P1 and the compression portion P3 is labeled with "3 rd", the compression portion P3 may be labeled with "1 st", and the compression portion P1 may be labeled with "2 nd". The information relating to the compression order is not limited to the character strings "1 st", "2 nd", and "3 rd", and any arbitrary mark may be given as long as the compression order is clear. In addition, the character string may be engraved or recorded. When information on the order of compression is given to the terminal 5, the compression portion to be formed last can be accurately formed between two adjacent compression portions among the plurality of compression portions already formed.
In the present embodiment, the terminal-equipped wire is exemplified as the terminal-equipped wire, but the present invention is not limited thereto, and can be applied to a terminal-equipped cable, for example.
Examples of the experiments
Next, the present invention will be described in more detail based on experimental examples, but the present invention is not limited to these experimental examples.
(Experimental example 1)
As shown in fig. 3(a) to (c), in experimental example 1, the terminal 5 having the conductor 3 inserted into the hollow portion 7 is compressed three times in the order of the compression sites P1, P3, and P2. The compressed portions along the longitudinal direction of the conductor 3 were 3mm in width, and three compressed portions were formed at equal intervals to obtain the terminal-equipped wire 1. The interval between adjacent compressed portions (the width of the uncompressed portion in the longitudinal direction of the conductor 3) was about 9 mm. Al-Fe-Zr having the same composition is used for the aluminum material of the terminal 5 and the conductor 3. Al-Fe-Zr contained 0.6 mass% of Fe, 0.02 mass% of Zr, 0.06 mass% of Si, 0.002 mass% of Cu, 0.002 mass% of Mn, and 0.006 mass% of Ti and V in total, with the remainder being an aluminum alloy formed of Al. The cross-sectional area of the conductor 3 is 50mm2. All the wires constituting the conductor are formed of the same material. The diameter of the wires constituting the conductor was 0.45 mm. The number of filaments was 309. As shown in fig. 9, after the terminal 5 was compressed and connected to the conductor 3, the terminal-equipped wire 1 was placed in a thermostatic bath 14 set at 150 ℃, and a high-temperature environment exposure test was performed in which the terminal-equipped wire was held in the atmosphere for 50 hours. The high-temperature environment exposure test simulates a power-on test environment. Further, assuming that the extension portion 8 is connected to an external connection target side terminal, a bolt, or the like, the aluminum plate 13 is fixed to the extension portion 8 by a bolt (not shown). Fig. 9 shows a case where an aluminum plate is fixed to the lower side of the extension portion 8, but even if the aluminum plate is fixed to the upper side of the extension portion 8, the same effect as that of the case where the aluminum plate is fixed to the lower side of the extension portion 8 can be obtained. The tests were carried out under the same conditions in experimental examples 2 to 9 shown in table 1 below.
(Experimental example 2)
As shown in table 1 below, in experimental example 2, the terminal-equipped wire 1 was manufactured in the same manner as in experimental example 1 except that the width of the compressed part was changed to 5mm, and the interval between adjacent compressed parts (the width of the uncompressed part in the longitudinal direction of the conductor 3) was changed to 7 mm.
(Experimental example 3)
As shown in table 1 below, in experimental example 3, a terminal-equipped wire 1 was produced in the same manner as in experimental example 1 except that the order of compressing the terminals 5 was changed to compressing positions P3, P1, and P2, the width of the compressing portion was set to 5mm, and the interval between adjacent compressing portions (the width of the non-compressing portion in the longitudinal direction of the conductor 3) was set to about 7 mm.
(Experimental example 4)
Experimental example 4 a terminal-equipped wire 1 was manufactured in the same manner as in experimental example 1, except that the width of the compressed portion was changed to 7mm, and the interval between adjacent compressed portions (the width of the uncompressed portion in the longitudinal direction of the conductor 3) was changed to about 4 mm.
(Experimental example 5)
As shown in fig. 5(a) and (b), in experimental example 5, the terminal 5 into which the conductor 3 is inserted in the hollow portion 7 is compressed twice in the order of the compression portions P1 and P2. The width of the compressed portion in the longitudinal direction of the conductor 3 was set to 10mm, and the terminal-equipped wire 1 was obtained.
(Experimental example 6)
As shown in table 1 below, in experimental example 6, the terminal-equipped wire 1 was manufactured in the same manner as in experimental example 1, except that the order of compressing the terminal 5 was changed to the compression positions P1, P2, and P3.
(Experimental example 7)
As shown in fig. 6(a) to (c), in experimental example 7, the terminal 5 having the conductor 3 inserted in the hollow portion 7 was compressed three times in the order of the compression portions P1, P2, and P3. The terminal-equipped wire 1 was manufactured in the same manner as in experimental example 1, except that the order of compressing the terminals 5 was changed to the compression positions P1, P2, and P3, the width of the compressed portions was changed to 5mm, and the interval between adjacent compressed portions (the width of the non-compressed portion in the longitudinal direction of the conductor 3) was set to 7 mm.
(Experimental example 8)
As shown in table 1 below, in experimental example 8, a terminal-equipped wire 1 was produced in the same manner as in example 1, except that the order of compressing the terminals 5 was changed to the compressing portions P2, P1, and P3, the width of the compressing portions was changed to 5mm, and the interval between the adjacent compressing portions (the width of the non-compressing portion in the longitudinal direction of the conductor 3) was changed to about 7 mm.
(Experimental example 9)
As shown in table 1 below, in experimental example 9, a terminal-equipped wire 1 was produced in the same manner as in example 1, except that the order of the compression terminals 5 was changed to compression portions P1, P2, and P3, the width of the compression portions was changed to 7mm, and the interval between adjacent compression portions (the width of the non-compression portion in the longitudinal direction of the conductor 3) was changed to about 4 mm.
The increase rates of the resistance ratios of the terminal-equipped electric wires 1 in the above experimental examples 1 to 9 are summarized in the following table 1.
TABLE 1
| Item | Number of times of compression | Compression sequence | Width of compression part (mm) | Compression ratio (%) | Resistance ratio increase rate (%) |
| Experimental example 1 | 3 | P1→P3→ |
3 | 90 | 9 |
| Experimental example 2 | 3 | P1→P3→ |
5 | 86 | 17 |
| Experimental example 3 | 3 | P3→P1→ |
5 | 86 | 19 |
| Experimental example 4 | 3 | P1→P3→ |
7 | 82 | 18 |
| Experimental example 5 | 2 | P1→ |
10 | 75 | 60 |
| Experimental example 6 | 3 | P1→P2→ |
3 | 90 | 45 |
| Experimental example 7 | 3 | P1→P2→ |
5 | 86 | 37 |
| Experimental example 8 | 3 | P2→P1→ |
5 | 86 | 43 |
| Experimental example 9 | 3 | P1→P2→ |
7 | 82 | 28 |
(measurement of resistance ratio increase rate)
Here, the resistance ratio increase rate is a change rate of the resistance ratio after the test was carried out with respect to the resistance ratio (initial resistance ratio) before the test (high-temperature environment exposure test) in which the terminal-equipped wire 1 was placed in the thermostatic bath 14 set at 150 ℃ and was held in the atmosphere for 50 hours, and the resistance ratio increase rate is calculated by the equation ((R2-R1)/R1) × 100 in the case where the resistance ratios between the conductor 3 and the terminal 5 before and after the test were respectively set to R1 and R2.
(measurement of resistance ratio)
Here, the resistance ratio (initial resistance ratio) R1 before the high-temperature environment exposure test of the terminal-equipped wire 1 was carried out was measured by a so-called four-terminal method. The four-terminal method will be described with reference to fig. 10.
First, a predetermined current 1A is supplied to the entire terminal-equipped wire 1, and a resistance value R0. between a point P and a point Q is measured, where the point P is one end of the cylindrical portion 6 of the terminal 5 and corresponds to the distal end portion of the inserted conductor 3, the point Q is a portion of the conductor 3 that does not contact the terminal 5, the point S is the other end of the cylindrical portion 6 of the terminal 5 and is a portion of the inlet portion into which the conductor 3 is inserted, an initial resistance ratio R1 is calculated by a formula of (R0-L2 ×α)/(L1 ×α) when the distance between the point P and the point S is L1, the distance between the point Q and the point S is L2, and the resistance value per unit length of the conductor 3 is α, a resistance value per unit length of the conductor 3 is measured in advance, or a resistance value between L2 is measured and divided by a length between L2, and the resistance value per unit length can be used.
Specifically, a predetermined current 1A is supplied to the entire terminal-equipped wire 1 after the high-temperature environment exposure test is performed, and a resistance value R between a point P and a point Q is measured, and a resistance value α per unit length of the conductor 3 is the same value as that used before and after the high-temperature environment exposure test is performed, the resistance ratio is calculated by the formula (R-L ×α)/(L1 ×α), and the resistance value is measured using a resistance meter manufactured by japanese electrical corporation.
(measurement of compression ratio)
As described above, the compression ratio is a ratio of a cross-sectional area of the conductor 3 corresponding to the non-compressed portion of the terminal 5 to a cross-sectional area of the conductor 3 corresponding to the compressed portion in a cross-section perpendicular to the longitudinal direction of the conductor 3 when the terminal 5 of the conductor 3 is inserted into the hollow portion 7, and the cross-sectional area of the conductor 3 corresponding to the non-compressed portion and the cross-sectional area of the conductor 3 corresponding to the compressed portion of the terminal 5 are each C1 (mm)2)、C2(mm2) In the case of (2), the calculation is performed by the formula of (C2/C1) × 100.
As can be seen from the above results, in experimental examples 1 to 4, the rate of increase in the resistance ratio can be suppressed by forming 3 compressed parts and forming the compressed part formed last between two adjacent compressed parts that have already been formed.
When the terminal 5 is compressed, a force is generated not only in the radial direction but also in the axial direction of the conductor 3. Therefore, there is a case where the force extending in the axial direction of the conductor 3 generated when the 3 rd compression portion is formed is suppressed by the two already formed compression portions. Therefore, when the 3 rd compression part is compressed, not only the contact force between the terminal 5 and the conductor 3 of the 3 rd compression part, the contact force between the terminal 5 and the conductor 3 between the 1 st compression part and the 3 rd compression part, but also the contact force between the terminal 5 and the conductor 3 between the 2 nd compression part and the 3 rd compression part may be increased. This may suppress an increase in the resistance ratio of the terminal-equipped wire 1.
In experimental examples 1 and 2, it was confirmed that the smaller the width of the compression portion, the lower the rate of increase in the resistance ratio. In contrast, in experimental examples 6 and 7, it was confirmed that the larger the width of the compression portion, the lower the rate of increase in the resistance ratio.
In addition, it was confirmed that the increase rate of the resistance ratio of experimental example 5 was 60% at the maximum. In examples 6 to 9, it was confirmed that the increase rate of the resistance ratio was higher than in examples 1 to 4 by forming 3 compressed parts and not forming the compressed part formed last between two adjacent compressed parts formed.
The terminal-equipped electric wire 1 in which the number of times the terminal 5 is compressed is 4 or 5 will be described based on experimental examples.
(Experimental example 10)
As shown in fig. 7, in experimental example 10, the terminal 5 into which the conductor 3 was inserted in the hollow portion 7 was compressed four times in the order of the compression points P1, P4, P2, and P3. Four compressed portions were formed at equal intervals, with the width of the compressed portion in the longitudinal direction of the conductor 3 set to 3mm, to obtain the terminal-equipped wire 1. The interval between adjacent compressed portions (the width of the uncompressed portion in the longitudinal direction of the conductor 3) was about 6 mm. Al-Fe-Zr having the same composition is used for the aluminum material of the terminal 5 and the conductor 3. Al-Fe-Zr contained 0.6 mass% of Fe, 0.02 mass% of Zr, 0.06 mass% of Si, 0.002 mass% of Cu, 0.002 mass% of Mn, and 0.006 mass% of Ti and V in total, with the remainder being an aluminum alloy formed of Al. The cross-sectional area of the conductor 3 is 50mm2. All the wires constituting the conductor are formed of the same material. The diameter of the wires constituting the conductor was 0.45 mm. The number of filaments was 309. After the terminal 5 was compressed and connected to the conductor 3, the above-described high-temperature environment exposure test was performed with the counterterminal electric wire 1 heated at 150 ℃ for 50 hours in the atmosphere. High temperature environment exposure test was also performed under the same conditions in experimental examples 11 to 22 shown in Table 2 belowAnd (6) testing. The high-temperature environment exposure test was carried out in the same manner as in examples 1 to 9. The measurement of the resistance ratio and the measurement of the compression ratio were performed by the same methods as in experimental examples 1 to 9.
(Experimental example 11)
As shown in table 2 below, experimental example 11 produced a terminal-equipped wire 1 in the same manner as experimental example 10, except that the order of compressing the terminals 5 was changed to P1, P2, P4, and P3.
(Experimental example 12)
As shown in table 2 below, experimental example 12 produced a terminal-equipped wire 1 in the same manner as in experimental example 10, except that the order of compressing the terminals 5 was changed to P1, P4, P3, and P2.
(Experimental example 13)
As shown in table 2 below, experimental example 13 produced a terminal-equipped wire 1 in the same manner as in experimental example 10, except that the order of compressing the terminals 5 was changed to P2, P1, P4, and P3.
(Experimental example 14)
As shown in table 2 below, in experimental example 14, the terminal-equipped wire 1 was manufactured in the same manner as in experimental example 10, except that the order of compressing the terminals 5 was changed to P4, P1, P2, and P3.
(Experimental example 15)
As shown in table 2 below, experimental example 15 produced a terminal-equipped wire 1 in the same manner as experimental example 10, except that the order of compressing the terminals 5 was changed to P3, P1, P4, and P2.
(Experimental example 16)
As shown in table 2 below, in experimental example 16, the terminal-equipped wire 1 was manufactured in the same manner as in experimental example 10, except that the order of compressing the terminals 5 was changed to P3, P4, P1, and P2.
(Experimental example 17)
As shown in fig. 8, in experimental example 17, the terminal 5 having the conductor 3 inserted in the hollow portion 7 was compressed five times in the order of P1, P5, P3, P2, and P4. The width of the compressed portion in the longitudinal direction of the conductor 3 was 3mm, and the interval between adjacent compressed portions (the width of the uncompressed portion in the longitudinal direction of the conductor 3) was about 4 mm. The terminal-equipped electric wires 1 were obtained by forming 5 compressed parts at equal intervals.
(Experimental example 18)
As shown in table 2 below, experimental example 18 produced a terminal-equipped wire 1 in the same manner as in experimental example 17, except that the order of compressing the terminal 5 was changed to P1, P4, P3, P5, and P2.
(Experimental example 19)
As shown in fig. 5(a) and (b), in experimental example 19, the terminal 5 into which the conductor 3 is inserted in the hollow portion 17 is compressed twice in the order of the compression portions P1 and P2. The width of the compressed portion in the longitudinal direction of the conductor 3 was set to 10mm, and the terminal-equipped wire 1 was obtained. Experimental example 19 is the same as Experimental example 5 shown in Table 1.
(Experimental example 20)
As shown in table 2 below, in experimental example 20, the terminal-equipped wire 1 was manufactured in the same manner as in experimental example 10, except that the order of compressing the terminals 5 was changed to P1, P2, P3, and P4.
(Experimental example 21)
As shown in table 2 below, experimental example 21 produced a terminal-equipped wire 1 in the same manner as in experimental example 10, except that the order of compressing the terminals 5 was changed to P1, P3, P2, and P4.
(Experimental example 22)
As shown in table 2 below, in experimental example 22, the terminal-equipped wire 1 was manufactured in the same manner as in experimental example 10, except that the order of compressing the terminals 5 was changed to P3, P1, P2, and P4.
The resistance ratio increase rates and the like of the terminal-equipped electric wires 1 in the above experimental examples 10 to 22 are summarized in table 2 below.
TABLE 2
| Item | Number of times of compression | Compression sequence | Width of compression part (mm)) | Compression ratio (%) | Resistance ratio increase rate (%) |
| Experimental example 10 | 4 | P1→P4→P2→ |
3 | 90 | 7 |
| Experimental example 11 | 4 | P1→P2→P4→ |
3 | 90 | 8 |
| Experimental example 12 | 4 | P1→P4→P3→ |
3 | 90 | 8 |
| Experimental example 13 | 4 | P2→P1→P4→ |
3 | 90 | 7 |
| Experimental example 14 | 4 | P4→P1→P2→ |
3 | 90 | 10 |
| Experimental example 15 | 4 | P3→P1→P4→ |
3 | 90 | 13 |
| Experimental example 16 | 4 | P3→P4→P1→ |
3 | 90 | 12 |
| Experimental example 17 | 5 | P1→P5→P3→P2→ |
3 | 90 | 4 |
| Experimental example 18 | 5 | P1→P4→P3→P5→ |
3 | 90 | 7 |
| Experimental example 19 | 2 | P1→ |
10 | 75 | 60 |
| Experimental example 20 | 4 | P1→P2→P3→ |
3 | 90 | 21 |
| Experimental example 21 | 4 | P1→P3→P2→ |
3 | 90 | 15 |
| Experimental example 22 | 4 | P3→P1→P2→ |
3 | 90 | 16 |
As is clear from the above results, in experimental examples 10 to 16, the increase rate of the resistance ratio can be suppressed to 13% or less by forming 4 compressed parts and forming the compressed part formed last between two adjacent compressed parts among the plurality of compressed parts that have been formed. In experimental examples 17 and 18, the increase rate of the resistance ratio was suppressed to 7% or less by forming 5 compressed parts and forming the compressed part formed last between two adjacent compressed parts among the plurality of compressed parts that have already been formed.
In experimental examples 10 to 18, it was confirmed that the increase rate of the resistance ratio was lower in 5 times than in 4 times of compression. In experimental examples 21 and 22, 4 compressed portions were formed and the compressed portion formed last was not formed between the adjacent compressed portions that had already been formed, but by forming the compressed portion formed to the 3 rd between the adjacent compressed portions that had already been formed, the increase rate of the resistance ratio could be suppressed to 16% or less.
It was also confirmed that the resistance ratio increase rate was the largest in experimental example 19 in which the compression ratio of the conductor 3 was the smallest and the number of times of compression was the smallest.
In addition, it was confirmed that the resistance ratio increase rate was the highest in experimental examples 20 to 22 in experimental example 20.
(Experimental example 23)
As shown in fig. 3(a) to (c), in experimental example 23, the terminal 5 having the conductor 3 inserted in the hollow portion 7 was compressed three times in the order of the compression sites P1, P3, and P2. The compressed portions along the longitudinal direction of the conductor 3 were set to have a width of 5mm, and three compressed portions were formed at equal intervals to obtain the terminal-equipped wire 1. The interval between adjacent compressed portions (the width of the uncompressed portion in the longitudinal direction of the conductor 3) was about 7 mm. ECAl is used for the aluminum material of the terminal 5, and Al-Fe-Zr is used for the aluminum material of the conductor 3. ECAl is a1070 equivalent ECAl. Al-Fe-Zr contained 0.6 mass% of Fe, 0.02 mass% of Zr, 0.06 mass% of Si, 0.002 mass% of Cu, 0.002 mass% of Mn, and 0.006 mass% of Ti and V in total, with the remainder being an aluminum alloy formed of Al. The cross-sectional area of the conductor 3 is 50mm2. After the terminal 5 was compressed and connected to the conductor 3, a high-temperature environment exposure test was performed on the counterterminal electric wire 1 under conditions of 150 ℃ for 50 hours in the atmosphere. The test was also performed under the same conditions in experimental example 24 shown in table 3 below. The high-temperature environment exposure test was carried out in the same manner as in examples 1 to 22. The measurement of the resistance ratio and the measurement of the compression ratio were also performed by the same methods as in experimental examples 1 to 22.
Experimental example 25 shown in table 3 is the same as experimental example 2 shown in table 1.
(Experimental example 24)
As shown in table 3 below, experimental example 24 produced the terminal-equipped wire 1 in the same manner as in experimental example 23, except that the aluminum material of the conductor 3 was changed to Al — Zr. Al-Zr contains 0.34 mass% of Zr, 0.15 mass% of Fe, 0.1 mass% of Si, and 0.03 mass% in total of Ti and V, with the remainder being an aluminum alloy made of Al. The measurement of the resistance ratio and the measurement of the compression ratio were also performed in the same manner as in examples 1 to 22.
As a result of the above, in experimental examples 23 and 24, it was confirmed that the increase in the resistance ratio can be further suppressed as compared with experimental example 25 by forming 3 compressed parts and forming the compressed part formed last between two adjacent compressed parts among the plurality of compressed parts already formed and changing the combination of the aluminum materials of the terminal 5 and the conductor 3.
A compression weight is applied to the terminal 5 having the conductor 3 inserted in the hollow portion 7, and the terminal 5 and the conductor 3 are compressed. After the compressive stress is completely removed, the terminal 5 and the conductor 3 rebound (stress relaxation) according to the young's modulus. Therefore, when the compressive load is completely removed, a load that presses the outer peripheral surface of the conductor 3 and the inner peripheral surface of the terminal 5 against each other is generated. The spring back amount is increased by increasing the tensile strength of the aluminum material constituting the conductor 3 and relatively making the tensile strength of the aluminum material constituting the terminal 5 smaller than the tensile strength of the aluminum material constituting the conductor 3. The rebound amount of experimental example 23 is larger than that of experimental example 25. In addition, in example 24, the rebound amount is larger than in example 23. The larger the spring back amount, the larger the load of mutual pressing between the outer peripheral surface of the conductor 3 and the inner peripheral surface of the terminal 5. As a result, it was confirmed that the resistance ratio increase rate can be further suppressed by increasing the spring back amount.
The increase rates of the resistance ratios of the terminal-equipped electric wires 1 in the above experimental examples 23 to 25 and the like are summarized in the following table 3.
TABLE 3
In this experimental example, the cross-sectional area of the conductor 3 was set to 50mm2However, the present embodiment is not limited to this. The effect of the present invention can be obtained regardless of the size of the cross-sectional area of the conductor 3, for example, even 50mm which has negligible influence of stress relaxation2～400mm2The conductor having a large cross-sectional area is particularly significant because the rate of increase in the resistance ratio can be maintained small.
< 5 > preferred embodiment of the present invention
Hereinafter, preferred embodiments of the present invention will be described.
(Note 1)
According to an aspect of the present invention, there is provided a terminal-equipped wire including:
an electric wire including a conductor formed of an aluminum material and an insulating layer covering the conductor; and
a terminal made of an aluminum material, having a hollow portion into which the conductor exposed at an end portion of the wire is inserted, and connected to the conductor by compressing the hollow portion in a state in which the conductor is inserted into the hollow portion,
when the resistance ratios between the conductor and the terminal before and after the test of heating the terminal-equipped wire at 150 ℃ for 50 hours were set to R1 and R2, respectively, the increase rate of the resistance ratio calculated from the equation of ((R2-R1)/R1) × 100 (%) was 19% or less.
(Note 2)
According to the terminal-equipped electric wire described in supplementary note 1, it is preferable that the aluminum material used for the conductor has a tensile strength higher than that of the aluminum material used for the terminal.
(Note 3)
The terminal-equipped electric wire according to note 1 or 2, wherein the conductor preferably contains 0.03 to 1.5 mass% of Zr, 0.1 to 1.0 mass% of Fe and Si, and the balance is an aluminum alloy containing Al and unavoidable impurities,
the terminal is pure aluminum with Al and unavoidable impurities.
(Note 4)
The terminal-equipped electric wire according to any one of supplementary notes 1 to 3, wherein the conductor preferably contains 0.01 to 0.10 mass% of Zr, 0.1 mass% or less of Si, 0.2 to 1.0 mass% of Fe, 0.01 mass% or less of Cu, 0.01 mass% or less of Mn, 0.01 mass% or less of Mg, 0.01 mass% or less of Zn, 0.01 mass% or less of Ti, and 0.01 mass% or less of V, and the balance is an aluminum alloy containing Al and unavoidable impurities,
the terminal is pure aluminum with Al and unavoidable impurities.
(Note 5)
The terminal-equipped electric wire according to any one of supplementary notes 1 to 4, wherein a width of the compressed portion in a longitudinal direction of the conductor is preferably 7mm or less.
(Note 6)
According to the terminal-equipped electric wire described in any one of supplementary notes 1 to 5, the compression portions are preferably provided at equal intervals.
(Note 7)
The terminal-equipped electric wire according to any one of supplementary notes 1 to 6, wherein the conductor preferably has a cross-sectional area of 50mm2The above.
(Note 8)
According to another aspect of the present invention, there is provided a method of manufacturing a terminal-equipped wire, including the steps of:
preparing a wire including a conductor formed of an aluminum material and an insulating layer covering the conductor, and a terminal formed of an aluminum material having a hollow portion;
a step of connecting the terminal to the conductor by compressing the terminal three or more times in a state where the conductor exposed at the end of the wire is inserted into the hollow portion and forming a plurality of compressed portions in the terminal,
the step of connecting the terminal to the conductor includes a step of forming a new compressed portion between the already formed adjacent compressed portions.
(Note 9)
According to the method of manufacturing a terminal-equipped wire described in supplementary note 8, a step of forming a new compressed portion between the already formed adjacent compressed portions is performed at the end of the step of connecting the terminal to the conductor.
(Note 10)
According to still another aspect of the present invention, there is provided a terminal including a hollow portion into which a conductor is inserted, the terminal being connected to the conductor by compressing the terminal in a state in which the conductor is inserted into the hollow portion, and,
the terminals are marked with information on the order of compression.
(Note 11)
In the terminal described in reference numeral 10, it is preferable to mark the order of compression at the compressed portion of the terminal.
(Note 12)
According to still another aspect of the present invention, there is provided a jig for connecting a terminal to a conductor by compressing the terminal at three or more places in a state where the conductor is inserted into a hollow portion of the terminal, wherein the jig compresses the terminal to finally form three or more compressed portions in a longitudinal direction of the conductor on the terminal, and at least one of the three or more compressed portions which are formed third and subsequent is formed between adjacent compressed portions among a plurality of compressed portions which have already been formed.
(Note 13)
The terminal-equipped electric wire according to any one of supplementary notes 1 to 7, preferably, the number of the compressed parts of the terminal is four or more.
(Note 14)
The terminal-equipped electric wire according to any one of supplementary notes 1 to 7, wherein the number of compressed parts of the terminal is preferably four or more, and the increase (%) in the resistance ratio is 13% or less.
(Note 15)
The terminal-equipped electric wire according to any one of supplementary notes 1 to 7, preferably, the terminal has five or more compressed parts.
(Note 16)
The terminal-equipped electric wire according to any one of supplementary notes 1 to 7, wherein the compressed portion of the terminal is preferably five or more, and the increase rate (%) in resistance ratio is 7% or less.
(Note 17)
According to the method of manufacturing a terminal-equipped wire described in supplementary note 8 or 9, the number of times of forming the compressed portion of the terminal is preferably four or more.
(Note 18)
According to the method of manufacturing a terminal-equipped wire described in supplementary note 8, it is preferable that the number of times of formation of the compressed portion of the terminal is four or more, and the step of forming the third and subsequent compressed portions is performed between the already formed adjacent compressed portions.
(Note 19)
In the terminal described in reference numeral 10 or 11, the number of the sequences is preferably four or more.
(Note 20)
In the jig according to supplementary note 12, the terminal preferably has four or more compressed portions.
(Note 21)
The jig according to supplementary note 12 is preferably configured such that the compression portions of the terminal are formed at four or more positions, and all of the compression portions formed as the third and subsequent compression portions are formed between adjacent ones of the already-formed compression portions.
Claims (10)
1. A terminated electric wire, comprising:
an electric wire including a conductor formed of an aluminum material and an insulating layer covering the conductor; and
a terminal formed of an aluminum material and having a hollow portion into which the conductor exposed at an end portion of the wire is inserted, the terminal being connected to the conductor by compressing the hollow portion in a state in which the conductor is inserted into the hollow portion,
the electric wire with terminal is characterized in that,
the terminal has three or more compression parts along the longitudinal direction of the conductor,
when the resistance ratios between the conductor and the terminal before and after the test in which the terminal-equipped wire was heated at 150 ℃ for 50 hours were R1 and R2, respectively, the increase rate of the resistance ratio calculated from the equation of ((R2-R1)/R1) × 100 (%) was 19% or less.
2. The terminal-equipped electric wire according to claim 1,
the tensile strength of the aluminum material used for the conductor is greater than that of the aluminum material used for the terminal.
3. The terminal-equipped electric wire according to claim 1 or 2,
the width of the compressed portion along the longitudinal direction of the conductor is 7mm or less.
4. The terminal-equipped electric wire according to any one of claims 1 to 3,
the compressing parts are respectively arranged at equal intervals.
5. The terminal-equipped electric wire according to any one of claims 1 to 4,
the compression part of the terminal is more than four.
6. A method for manufacturing a terminal-equipped wire, comprising the steps of:
preparing a wire including a conductor made of an aluminum material and an insulating layer covering the conductor, and a terminal made of an aluminum material having a hollow portion;
a step of connecting the terminal to the conductor by compressing the terminal three or more times in a state where the conductor exposed at the end of the wire is inserted into the hollow portion and forming a plurality of compressed portions in the terminal,
the method for manufacturing the electric wire with terminal is characterized in that,
the step of connecting the terminal to the conductor includes a step of forming a new compressed portion between the already formed adjacent compressed portions.
7. The method of manufacturing an electric wire with terminal according to claim 6,
and a step of forming a new compressed portion between the adjacent compressed portions formed at the end of the step of connecting the terminal to the conductor.
8. The method of manufacturing an electric wire with terminal according to claim 6 or 7,
the compression part of the terminal is more than four.
9. A terminal having a hollow portion into which a conductor is inserted, the terminal being characterized in that,
the terminal is connected to the conductor by compressing the terminal in a state where the conductor is inserted into the hollow portion, and,
the terminal is marked with information on the order of compression.
10. A terminal according to claim 9, wherein the terminal is characterized in that,
the compressed part of the terminal is marked with the order of compression.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2019-012444 | 2019-01-28 | ||
| JP2019012444A JP2020119865A (en) | 2019-01-28 | 2019-01-28 | Electric wire with terminal, manufacturing method of the same, and terminal included in the same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN111490362A true CN111490362A (en) | 2020-08-04 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202010037583.0A Pending CN111490362A (en) | 2019-01-28 | 2020-01-14 | Terminal-equipped electric wire, method for manufacturing terminal-equipped electric wire, and terminal provided in terminal-equipped electric wire |
Country Status (3)
| Country | Link |
|---|---|
| EP (1) | EP3687000B1 (en) |
| JP (2) | JP2020119865A (en) |
| CN (1) | CN111490362A (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP7380459B2 (en) * | 2020-07-13 | 2023-11-15 | 株式会社プロテリアル | Electric wire with terminal |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2587095A (en) * | 1947-04-08 | 1952-02-26 | Thomas & Betts Corp | Electric cable connector |
| US3912358A (en) * | 1973-06-19 | 1975-10-14 | Roger D Miller | Aluminum alloy compression type connectors for use with aluminum or copper conductors |
| CN102185185A (en) * | 2010-01-18 | 2011-09-14 | 赵卫平 | Aluminum conductor and conductive terminal connection |
| US20140073205A1 (en) * | 2012-09-07 | 2014-03-13 | Mecatraction | Method of assembling a connecting device on a stripped end section of an electric cable and assembly comprising such a device securely assembled on such a section of cable |
| JP2019009101A (en) * | 2017-06-22 | 2019-01-17 | 日立金属株式会社 | Terminal-equipped wire |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS6132717A (en) | 1984-07-26 | 1986-02-15 | Ashida Seisakusho:Kk | Method and apparatus for curing treatment of heat resistant fiber composite |
| JP5446506B2 (en) * | 2009-06-26 | 2014-03-19 | 日本精機株式会社 | Manufacturing method of organic EL element |
| JP5972069B2 (en) | 2012-06-25 | 2016-08-17 | 東京電力ホールディングス株式会社 | Compression sleeve, connection method between electric wire and compression sleeve, connection structure between electric wire and compression sleeve |
| US9837727B2 (en) * | 2012-09-14 | 2017-12-05 | Saint-Gobain Glass France | Pane having an electrical connection element |
| KR20170057243A (en) * | 2014-09-22 | 2017-05-24 | 후루카와 덴키 고교 가부시키가이샤 | Terminal-equipped electrical wire |
-
2019
- 2019-01-28 JP JP2019012444A patent/JP2020119865A/en active Pending
-
2020
- 2020-01-14 CN CN202010037583.0A patent/CN111490362A/en active Pending
- 2020-01-15 EP EP20151904.8A patent/EP3687000B1/en active Active
-
2022
- 2022-03-24 JP JP2022048246A patent/JP7347570B2/en active Active
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2587095A (en) * | 1947-04-08 | 1952-02-26 | Thomas & Betts Corp | Electric cable connector |
| US3912358A (en) * | 1973-06-19 | 1975-10-14 | Roger D Miller | Aluminum alloy compression type connectors for use with aluminum or copper conductors |
| CN102185185A (en) * | 2010-01-18 | 2011-09-14 | 赵卫平 | Aluminum conductor and conductive terminal connection |
| US20140073205A1 (en) * | 2012-09-07 | 2014-03-13 | Mecatraction | Method of assembling a connecting device on a stripped end section of an electric cable and assembly comprising such a device securely assembled on such a section of cable |
| JP2019009101A (en) * | 2017-06-22 | 2019-01-17 | 日立金属株式会社 | Terminal-equipped wire |
Also Published As
| Publication number | Publication date |
|---|---|
| JP2020119865A (en) | 2020-08-06 |
| EP3687000B1 (en) | 2023-08-30 |
| JP2022075941A (en) | 2022-05-18 |
| JP7347570B2 (en) | 2023-09-20 |
| EP3687000A1 (en) | 2020-07-29 |
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Address after: Tokyo, Japan Applicant after: Bomeilicheng Co.,Ltd. Address before: Tokyo, Japan Applicant before: HITACHI METALS, Ltd. |