EP3940895A1 - Electric wire with terminal and method for manufacturing the same - Google Patents

Electric wire with terminal and method for manufacturing the same Download PDF

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Publication number
EP3940895A1
EP3940895A1 EP21184373.5A EP21184373A EP3940895A1 EP 3940895 A1 EP3940895 A1 EP 3940895A1 EP 21184373 A EP21184373 A EP 21184373A EP 3940895 A1 EP3940895 A1 EP 3940895A1
Authority
EP
European Patent Office
Prior art keywords
conductor
terminal
compression
compressed
electric wire
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP21184373.5A
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German (de)
English (en)
French (fr)
Inventor
Tetsuro Sato
Tsuyoshi Fujita
Yuju Endo
Ryo Inoue
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Proterial Ltd
Original Assignee
Hitachi Metals Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hitachi Metals Ltd filed Critical Hitachi Metals Ltd
Publication of EP3940895A1 publication Critical patent/EP3940895A1/en
Pending legal-status Critical Current

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Classifications

    • 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
    • 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
    • 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
    • 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
    • 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

Definitions

  • the present invention relates to an electric wire with terminal and a method for manufacturing the same.
  • WO98/54790 is one of the prior art documents related to the invention of the present application.
  • Patent Document 1 WO98/54790
  • the stress acting on a connecting portion between the conductor and the terminal decreases over time, which in turn reduces the contact force between the conductor and the terminal and may increase the electric resistance between the conductor and the terminal.
  • the stress relaxation in aluminum is more likely to occur than the stress relaxation in copper, and the above problems are more likely to arise when a terminal made of aluminum is connected to a conductor made of aluminum. With a high electric resistance between the conductor and the terminal, passing electric current through the conductor generates heat in the electric wire with terminal, which may cause an electric wire break or poor contact.
  • the object of the present invention is to provide an electric wire with terminal that can maintain a low electric resistance between the conductor and the terminal, and to ensure adequate electrical connections, and a method for manufacturing the same.
  • An electric wire with terminal (1) comprising:
  • a method for manufacturing an electric wire with terminal (1) comprising an electric wire (2) including a conductor (3) and an insulating layer (4) covering the conductor (3), and a terminal (5) including a hollow portion (7) into which the conductor (3) exposed at an end portion of the electric wire (2) is inserted, wherein the terminal (5) is connected to the conductor (3) by compressing the hollow portion (7) with the conductor (3) being inserted into the hollow portion (7), the method comprising:
  • an electric wire with terminal that can maintain a low electric resistance between the conductor and the terminal, and to ensure adequate electrical connections, and a method for manufacturing the same.
  • FIG. 1 A is a cross-sectional view of an electric wire with terminal in a preferred embodiment of the present invention
  • FIG. 1 B is an enlarged view of a section A of the electric wire with terminal in FIG. 1 A
  • an electric wire with terminal 1 includes an electric wire 2 and a terminal 5.
  • the electric wire with terminal 1 can be used as a wiring material for buildings, wind generators, railcars (rolling stocks), automobiles, and so on.
  • the electric wire 2 includes a conductor 3 and an insulating layer 4 covering the conductor 3.
  • a metal wire, a stranded wire made of plural metal strands (elementary wires) stranded together, or a composite stranded wire made of plural stranded wires stranded together may be used.
  • the metal materials for forming the conductor e.g., pure aluminum or aluminum alloys (hereafter referred to as "aluminum material" may be used. Pure aluminum is a material composed of Al and inevitable impurities.
  • pure aluminum e.g., pure aluminum for electrical purpose (ECA1) may be used.
  • aluminum alloys e.g., Al-Zr, Al-Fe-Zr, etc. as below may be used.
  • Al-Zr is aluminum alloy with a chemical composition composed of 0.03 to 1.5 mass% (% by mass) of Zr, 0.1 to 1.0 mass% of Fe and Si, and the balance of Al and inevitable impurities.
  • Al-Fe-Zr is aluminum alloy with a chemical composition composed of 0 .
  • 0.1 to 1.0 mass% of Fe and Si means that when both Fe and Si are included, a total concentration of Fe and Si is 0.1 to 1.0 mass%, when Fe is included but Si is not included, a concentration of Fe is 0 . 1 to 1.0 mass%, and when Si is included but Fe is not included, a concentration of Si is 0 . 1 to 1.0 mass%.
  • not included means that, for example, the concentration is less than or equal to the detection limit of the high-frequency inductively coupled plasma emission spectroscopy.
  • An insulating layer 4 is composed of, e.g., fluorine resin, olefin resin, silicone resin or the like. Although the insulating layer 4 is provided over an entire length in a longitudinal direction of the electric wire 2, in the present embodiment, the insulating layer 4 is removed from the electric wire 2 for a given length from an end portion of the electric wire 2, and an end portion of the conductor 3 is partially exposed (Hereinafter, also referred to as "the exposed conductor 3 ").
  • the terminal 5 includes a tubular portion 6 having a hollow portion 7 and an extending portion 8, which are formed integrally (as one piece).
  • the terminal 5, for example, may include a plate-like extending portion 8 which is formed by press-machining one end of a pipe.
  • the terminal 5, for example, may include the tubular portion 6 formed by boring one end of a cylindrical base material and the extending portion 8 formed by pressing the other end of the cylindrical base material.
  • the hollow portion 7 has a cylindrical shape opened at one side.
  • the terminal 5 is composed of, e.g., aluminum material. More specifically, pure aluminum or aluminum alloy is preferred, for example. Pure aluminum is a material composed of A1 and inevitable impurities. As pure aluminum, e.g., pure aluminum for electrical purpose (ECA1) may be used. As aluminum alloy, e.g., Al-Fe-Zr as below may be used. Al-Fe-Zr is aluminum alloy with a chemical composition composed of 0 .
  • the tubular portion 6 is formed in a tubular shape having a circular cross section, within which the hollow portion 7 is formed.
  • the hollow portion 7 is configured in such a manner that the conductor 3 exposed at the end portion of the electric wire 2 can be inserted into the hollow portion 7.
  • the tubular portion 6 is opened in such a manner that an inner diameter N (mm) of the tubular portion 6 has a size ranging from a size corresponding (equivalent) to an outer diameter of the conductor 3 to 90% to 95% of the outer diameter of the conductor 3.
  • N mm
  • the conductor 3 exposed at the end portion of the electric wire 2 is inserted into the hollow portion 7.
  • a thickness A (mm) of the tubular portion 6 is determined from a ratio of a cross-sectional area of the tubular portion 6 corresponding to a non-compressed portion 11 of the terminal 5 and a cross-sectional area of the conductor 3 corresponding to the non-compressed portion 11 of the terminal 5, in a cross section normal to the longitudinal direction of the conductor 3, when the terminal 5 with the hollow portion 7 into which the conductor 3 is inserted is compressed.
  • the thickness A (mm) of the tubular portion 6 is determined by the formula (T/S), where the cross-sectional area of the tubular portion 6 at the non-compressed portion 11 of the terminal 5 is T (mm 2 ) and the cross-sectional area of the conductor 3 at the non-compressed portion 11 of the terminal 5 is S (mm 2 ).
  • the range of this ratio (T/S) is preferably 1.0 or more and 3.0 or less. If this ratio (T/S) is less than 0, the thickness A of the tubular portion 6 will be small and the compression may cause the tubular portion 6 to stretch and break.
  • T/S the tubular portion 6 will be mainly compressed and the conductor 3 will not be sufficiently compressed, which may result in insufficient mechanical joints.
  • the thickness A of the tubular portion 6 can be derived from the cross-sectional area T of the tubular portion 6 and the inner diameter N of the tubular portion 6, which can be calculated from the ratio (T/S) of the cross-sectional area T of the tubular portion 6 corresponding to the non-compressed portion 11 of the terminal 5 and the cross-sectional area S of the conductor 3 corresponding to the non-compressed portion 11 of the terminal 5.
  • a surface of the terminal 5 and an inner surface of the tubular portion 6 may be Sn-plated or Ag-plated. It is possible to apply a compound with conductive particles to the exposed conductor 3 and then insert the exposed conductor 3 into the hollow portion 7. Alternatively, the hollow portion 7 of the tubular portion 6 may be coated or filled with the compound before inserting the exposed conductor 3. As the compound with conductive particles, fluorine oil or silicone oil including conductive particles of Ni-P or Ni-B, Ni, or Zn solely or in combination may be used.
  • the terminal 5 is connected to the conductor 3 by compressing the hollow portion 7 (the tubular portion 6 ) with the conductor 3 being inserted in the hollow portion 7.
  • the extending portion 8 is configured as a part to be connected to a terminal, bolt, and the like of an external counterpart.
  • the extending portion 8 is formed in a plate shape and provided with a bolt hole 9, into which a bolt used for connection with an external terminal is inserted.
  • the tubular portion 6 of the terminal 5 has at least three compressed portions 10 in the longitudinal direction of the conductor 3. Although the case in which the three compressed portions 10 are formed will be explained herein, the number of the compressed portions 10 may be four or more.
  • the tubular portion 6 includes a portion located between the adjacent compressed portions 10, and such a portion is called as "non-compressed portion 11".
  • the compressed portion 10 is a part configured to be compressed by compression dies 20, as described below, and has a substantially flat surface along the longitudinal direction.
  • the non-compressed portion 11 is a portion that is configured not to be compressed by the compression dies 20 and has a larger outer diameter than the outer diameter of the compressed portion 10.
  • a tapered part is formed by compression (press deformation) with the use of the compression dies 20, and this tapered part is included in the non-compressed portion 11. Details of the compressed portion 10 and the non-compressed portion 11 will be described below.
  • each compression die 20 is, e.g., in a transverse view, a half-circle shape, a butt shape, hexagonal shape, and the like.
  • a compression ratio of the conductor 3 is 50% or more and 95% or less.
  • the "compression ratio” is a ratio of a cross-sectional area of the conductor 3 corresponding to the non-compressed portion 11 of the terminal 5 and a cross-sectional area of the conductor 3 corresponding to the compressed portion 10 in the cross section normal to the longitudinal direction of the conductor 3 when the terminal 5 with the conductor 3 inserted in the hollow portion 7 is compressed.
  • this compression ratio is calculated by the formula (D/S) ⁇ 100, where the cross-sectional area of the conductor 3 corresponding to the non-compressed portion 11 of the terminal 5 is S (mm 2 ) and the cross-sectional area of the conductor 3 corresponding to the compressed portion 10 of the terminal 5 is D (mm 2 ).
  • the cross-sectional area of the conductor 3 can be calculated by the product of the cross-sectional area of each metal strand and the number of metal strands.
  • a preparation step for preparing the electric wire 2 and the terminal 5 is firstly performed.
  • the materials for the conductor 3 and the terminal 5 should be selected in such a manner that the tensile strength of the material used for the conductor 3 is greater than the tensile strength of the material used for the terminal 5 (by e.g., 20 MPa or more).
  • ECA1 is used as the material for the terminal 5
  • Al-Fe-Zr tensile strength difference: about 24 MPa or more
  • Al-Zr tensile strength difference: about 46 MPa or more
  • the tensile strength of the material can be adjusted depending on the heat treatment condition and the degree of machining during the manufacturing process.
  • the insulating layer 4 of the electric wire 2 is removed for a predetermined length from the terminal along the longitudinal direction of the electric wire 2, thereby exposing a part of the conductor 3. Then, the exposed part of the conductor 3 of the electric wire 2 is inserted into the hollow portion 7 formed in the tubular portion 6 of the terminal 5.
  • connection step of connecting the terminal 5 to the conductor 3 is performed by compressing the tubular portion 6 of the terminal 5 at least three times to form at least three compressed portions 10 at the terminal 5 with the conductor 3 inserted in the hollow portion 7.
  • the tubular portion 6 of the terminal 5 is compressed three times to form three compressed portions 10 on the terminal 5 will be described below.
  • connection step first, as shown in FIG. 2 A , a portion near an extending portion 8 -side end portion of the tubular portion 6 (a near-end portion of the conductor 3 ) is pressed by the compression dies 20, so that the tubular portion 6 is compressed to form a first compressed portion 101. Then, as shown in FIG. 2 B , a portion near an opening-side end of the hollow portion 7 (on an insulating layer 4 -side) in the tubular portion 6 is pressed by the compression dies 20, so that the tubular portion 6 is compressed to form a second compressed portion 102.
  • the connection step includes a step of forming the third compressed portion (another compressed portion) 103 between the already-formed adjacent first and second compressed portions 101, 102. Between the first compressed portion 101 and the third compressed portion 103, and between the third compressed portion 103 and the second compressed portion 102, respectively, non-compressed portions 11 will be formed.
  • the first compressed portion 101 is firstly formed then the second compressed portion 102 is formed is explained.
  • the first compressed portion 101 may be formed.
  • the first compressed portion 101 and the second compressed portion 102 may be formed at the same time. In this case, the compression of the tubular portion 6 of the terminal 5 is performed at least two times to form at least three compressed portions 10 at the terminal 5.
  • the first to third compressed portions 101 to 103 are formed by compressing the tubular portion 6 (press-deformation, plastic deformation) by applying a predetermined pressure all around the tubular portion 6 in a circumferential direction using the compression dies 20.
  • each of the first to third compressed portions 101 to 103 has a hexagonal cross section that is perpendicular to the longitudinal direction (axial direction) of the conductor 3.
  • the behavior of the terminal 5 and the conductor 3 when forming the compressed portion 10 will be explained below.
  • the effect of this pressure causes both the terminal 5 (the tubular portion 6 ) and the conductor 3 to extend along the longitudinal direction.
  • the terminal 5 because the tensile strength of the material used for the terminal 5 is smaller than the tensile strength of the material used for the conductor 3, the terminal 5 deforms more largely, and the difference in elongation between the terminal 5 and the conductor 3 is ⁇ L.
  • an initial state is the state where the first and second compressed portions 101, 102 are formed.
  • a middle position between the first and the second compressed portions 101, 102 is pressed by the compression dies 20, the terminal 5 will extend to be longer by ⁇ L than the conductor 3 due to the applied pressure.
  • the contact force (axial contact force) between the terminal 5 and conductor 3 is generated at each of the first and second compressed portions 101, 102, so that the contact resistance between the terminal 5 and the conductor 3 can be reduced.
  • This elongation difference ⁇ L between the terminal 5 and the conductor 3 increases the contact force (axial contact force) between the terminal 5 and the conductor 3 and reduces the contact resistance between the terminal 5 and the conductor 3.
  • the contact force between the terminal 5 and the conductor 3 will reduces due to changes in time.
  • the relaxation (loosening) of the contact force in the radial direction is supported by the contact force in the axial direction, by providing a force that allows the terminal 5 and the conductor 3 to pull each other not only in the radial direction but also in the longitudinal direction.
  • the resistance value between the terminal 5 and the conductor 3 is suppressed from increasing over time.
  • the compression elongation strain can be increased, and the contact force (axial contact force) between the terminal 5 and the conductor 3 can be increased, so that the contact resistance between the terminal 5 and the conductor 3 can be further reduced.
  • a compression width W which is a length in the longitudinal direction of the compressed portion 10, can be set to an appropriate width according to the conductor cross-sectional area.
  • the compression width W can be controlled by adjusting the size of the compression dies 20 to be used, and the compression interval L can be controlled by adjusting the positions of the respective compressed portions 101 to 103 (along the longitudinal direction of the conductor 3 ).
  • the inventors conducted experiments to examine the effects of the compression width W and the compression interval L.
  • the compression load by the compression dies 20 was constant at 12 t
  • the compression interval L (mm) was constant at 7 mm
  • the compression width W (mm) was changed.
  • samples of the electric wire 2 including the conductor 3 having the conductor cross-sectional areas of 50 mm 2 and 250 mm 2 , respectively, were used.
  • the compression ratio of 60 % to 95 % was set for the sample with the conductor cross-sectional area of 50 mm 2
  • the compression ratio of 70% to 95% was set for the sample with the conductor cross-sectional area of 250 mm 2 .
  • the inner diameter N of the tubular portion 6 of the terminal 5 was 10.2 mm, and the thickness A of the tubular portion 6 was 3.0 mm.
  • the inner diameter N of the tubular portion 6 of the terminal was 21.8 mm, and the thickness A of the tubular portion 6 was 5.2 mm (in the following experiments, the terminal 5 should have the same size).
  • each of the samples for high-temperature environmental exposure testing was prepared by attaching an aluminum plate 13 to the extending portion 8 with a bolt (not shown), assuming that the extending portion 8 of the electric wire with terminal 1 configured to be connected to the conductor 3 by compressing the terminal 5 would be connected by a bolt or the like to a terminal of the external counterpart.
  • the high-temperature environment exposure test was performed in such a manner that the sample for the high-temperature environmental exposure test was placed in a thermostatic chamber 14 set at 200°C and held for 100 hours in the atmosphere, and the sample was taken out from the thermostatic chamber 14 every 10 hours for detaching and attaching the bolt.
  • the high-temperature environmental exposure test simulated the energizing test environment.
  • the ratio of electric resistance was measured before and after the high-temperature environmental exposure test, and the resistance ratio-increase rate was calculated from the ratio of electric resistance before and after the test.
  • the resistance ratio-increase rate (%) can be calculated from the formula ((R 2 -R 1 )/R 1 ) ⁇ 100, where the electric resistance ratios between the conductor 3 and the terminal 5 before and after (i.e. after 100 hours hold) the high-temperature environmental exposure test are R 1 and R 2 , respectively.
  • the electric resistance ratio (initial resistance ratio) R 1 was measured using the so-called "four-terminal method" prior to the high-temperature environmental exposure test of the electric wire with terminal 1.
  • the four-terminal method will be explained below with referring to FIG. 5 .
  • the entire electric wire with terminal 1 is supplied with a constant current 1 A and the electric resistance value R 0 between a point P and a point Q is measured.
  • the point P is one end of the tubular portion 6 of the terminal 5, and is a part corresponding to the end portion of the inserted conductor 3.
  • the point Q is a part of the conductor 3 that is not in contact with the terminal 5.
  • a point S is the other end of the tubular portion 6 of the terminal 5, and a part at the entrance where the conductor 3 is inserted.
  • the initial resistance ratio R 1 (%) is calculated using the formula ⁇ (R 0 -L 2 ⁇ ⁇ )/(L 1 ⁇ ⁇ ) ⁇ ⁇ 100, where a distance between the point P and the point S is L 1 , a distance between the point Q and the point S is L 2 , and the electric resistance value per unit length of the conductor 3 is ⁇ .
  • the electric resistance value per unit length of the conductor 3 may be measured in advance, or the electric resistance value between the point Q and the point S may be measured and divided by the length L 2 to be used as the electric resistance value per unit length.
  • the electric resistance ratio R 2 after the high-temperature environmental exposure test was measured using the same four-terminal method as when the electric resistance ratio (initial resistance ratio) was measured before the test, after cooling the electric wire with terminal 1 to room temperature.
  • the electric resistance value R between the point P and the point Q is measured by supplying a constant current 1 A to the entire electric wire with terminal 1 after the high-temperature environmental exposure test.
  • the electric resistance value ⁇ per unit length of the conductor 3 should remain the same before and after the high-temperature environmental exposure test.
  • the electric resistance ratio R 2 (%) is calculated as ⁇ (R-L 2 ⁇ ⁇ )/(L 1 ⁇ ⁇ ) ⁇ ⁇ 100 .
  • the electric resistance value was measured using an ohmmeter made by Hioki Electric Co., Ltd.
  • the experimental results of the electric resistance ratio R 2 after the high-temperature environmental exposure test (after 100 hours hold) are shown in FIG. 6 A .
  • the sample with the conductor 3 having the cross-sectional area of 50 mm 2 showed that the electric resistance ratio R 2 decreases with the compression width W being larger, but when the compression width W is too large, the electric resistance ratio R 2 changes to increase, and there is a certain compression width W where the electric resistance ratio R 2 becomes the minimum value.
  • the sample of the conductor 3 having the cross-sectional area of 250 mm 2 the electric resistance ratio R 2 decreases with the compression width W being larger.
  • the compression width W of the sample with the conductor 3 having the cross-sectional area of 50 mm 2 was set to 3 mm
  • the compression width W of the sample with conductor 3 having the cross-sectional area of 250 mm 2 was set to 7 mm
  • the compression load by the compression dies 20 was set to 12 t at constant
  • the compression interval L was varied, to measure the electric resistance ratio R 2 after the high-temperature environmental exposure test.
  • FIG. 6 B shows the results of the experiment.
  • FIG. 6 B includes a region where the compression interval L is negative, which represents an overlapping state of the compressed portions 10.
  • FIG. 6 C shows an overlapping state.
  • the compression widths W of the first compressed portion 101, second compressed portion 102, and third compressed portion 103 pressed by the compression dies 20 are overlapping by the compression interval L.
  • the value of the compression interval L is negative.
  • FIG. 7 A is a graph showing the compression width W on the horizontal axis and the resistance ratio-increase rate on the vertical axis.
  • the compression interval L of both the sample with the conductor 3 having the cross-sectional area of 50 mm 2 and the sample with the conductor 3 having the cross-sectional area of 250 mm 2 was set to 7 mm at constant, the compression load by the compression dies 20 was set to 12 t at constant, while the compression width W was varied, to measure the resistance ratio-increase rate before and after the high-temperature environmental exposure test. As shown in FIG.
  • FIG. 7 B is a graph showing the compression interval L on the horizontal axis and the resistance ratio-increase rate on the vertical axis.
  • the compression width W of the sample with the conductor 3 having the cross-sectional area of 50 mm 2 was set to 3 mm at constant
  • the compression width W of the sample with conductor 3 having the cross-sectional area of 250 mm 2 was set to 7 mm at constant
  • the compression load by the compression dies 20 was set to 12 t at constant
  • the compression interval L was varied, to the resistance ratio-increase rate before and after the high-temperature environmental exposure test.
  • the resistance ratio-increase rate basically decreases with the compression interval L being smaller, but when the compression interval L is too small, the resistance ratio-increase rate changes to increase, and there is a certain compression interval L where the resistance ratio-increase rate becomes the minimum value.
  • FIG. 7 B includes a region where the compression interval L is negative, which represents an overlapping state of compressed portions 10.
  • the overlapping state in FIG. 7 B is similar to the overlapping state shown in FIG. 6 C .
  • the compression widths W of the first compressed portion 101, second compressed portion 102, and third compressed portion 103 pressed by the compression dies 20 are overlapping by the compression interval L.
  • FIG. 8 A is a graph showing the cross-sectional area S (mm 2 ) of the conductor 3 on the horizontal axis and the compression width W (mm) of the conductor 3 on the vertical axis.
  • FIG. 8 B is a graph showing the cross-sectional area S (mm 2 ) of the conductor 3 on the horizontal axis and the compression interval L (mm) of the conductor 3 on the vertical axis.
  • the inventors found the compression width W (mm) and the compression interval L (mm) that satisfy the electric resistance ratio R 2 after the high-temperature environmental exposure test being less than 100 % under conditions where the cross-sectional area of the conductor 3 is 38 mm 2 or more and 500 mm 2 or less.
  • the region expressed by the formula (1) is shown as a hatched area in FIG. 8 A .
  • the region expressed by the formula (2) is shown as a hatched area in FIG. 8 B .
  • the cross-sectional area S of the conductor 3 is 50 mm 2 , it is possible to select the compression width W to be 3 mm or more and 7 mm or less, and the compression interval L to be - 1 mm or more and 11 mm or less.
  • the electric resistance ratio R 2 after the high-temperature environmental exposure test would be not more than 100 %.
  • the inventors further found better compression width W (mm) and compression interval L (mm). If both the conditions (1) and (2) as below are met, the selectable range will be smaller than the case where the compression width W and the compression interval L meet the target specifications for achieving that the electric resistance ratio R 2 after the high-temperature environmental exposure test would be 100 % or less:
  • FIG. 9 A is a graph showing the cross-sectional area S (mm 2 ) of the conductor 3 on the horizontal axis and the compression width W (mm) of the conductor 3 on the vertical axis.
  • FIG. 9 B is a graph showing the cross-sectional area S (mm 2 ) of the conductor 3 on the horizontal axis and the compression interval L (mm) of the conductor 3 on the vertical axis.
  • the inventors found the compression width W (mm) and the compression interval L (mm) that meet both the target specifications that (1) the electric resistance ratio R 2 after the high-temperature environmental exposure test is 100 % or less, and (2) the resistance ratio-increase rate should be 20 % or less, under conditions where the cross-sectional area of the conductor 3 is 38 mm 2 or more and 500 mm 2 or less.
  • the region expressed by the formula (3) is shown as a hatched area in FIG. 9 A .
  • the region expressed by the formula (4) is shown as a hatched area in FIG. 9 B .
  • the cross-sectional area S of the conductor 3 is 50 mm 2 , it is possible to select the compression width W to be 3 mm or more and 6 mm or less, and the compression interval L to be - 1 mm or more and 9 mm or less.
  • the electric resistance ratio R 2 after the high-temperature environmental exposure test would be not more than 100 % and the resistance ratio-increase rate is 20 % or less.
  • the electric wire with terminal 1 is expressed by the formulas (1) and (2) that define the relationship of the compression width W (mm) and the compression interval L (mm) with respect to the cross-sectional area S (mm 2 ) of the conductor 3: 0.01 ⁇ S + 2.5 ⁇ W ⁇ 0.07 ⁇ S + 3.5 and ⁇ 1.0 ⁇ L ⁇ 0.145 ⁇ S + 3.75
  • the resistance ratio-increase rate may be more than 20 % depending on the compression width W and the compression interval L.
  • the compression width W (mm) and the compression interval L (mm) preferably meets the following formulas (3), (4) of the conductor cross-sectional area S (mm 2 ): 0.01 ⁇ S + 2.5 ⁇ W ⁇ 0.035 ⁇ S + 4.25 and ⁇ 1.0 ⁇ L ⁇ 0.09 ⁇ S + 4.5
  • the cross-sectional area S of the conductor 3 should be 38 mm 2 or more and 500 mm 2 or less.
  • the tensile strength of the material used for the conductor 3 is greater than the tensile strength of the material used for the terminal 5, and the terminal 5 has three or more compressed portions 10 in the longitudinal direction of the conductor 3, wherein the cross-sectional area of the conductor 3 is S (mm 2 ), the compression width which is the length in the longitudinal direction of the compressed portion 10 is W (mm), and the compression interval which is the length in the longitudinal direction of the non-compressed portion 11 located between the adjacent compressed portions 10 is L (mm), wherein the compression width W (mm) and the compression interval L (mm), respectively, satisfy the formulas (1) and (2): 0.01 ⁇ S + 2.5 ⁇ W ⁇ 0.07 ⁇ S + 3.5 and ⁇ 1.0 ⁇ L ⁇ 0.145 ⁇ S + 3.75
  • the compression width W (mm) and the compression interval L (mm) satisfy the following formulas (3) and (4): 0.01 ⁇ S + 2.5 ⁇ W ⁇ 0.035 ⁇ S + 4.25 and ⁇ 1.0 ⁇ L ⁇ 0.09 ⁇ S + 4.5

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
EP21184373.5A 2020-07-13 2021-07-07 Electric wire with terminal and method for manufacturing the same Pending EP3940895A1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP2020119682A JP7380459B2 (ja) 2020-07-13 2020-07-13 端子付電線

Publications (1)

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EP3940895A1 true EP3940895A1 (en) 2022-01-19

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Application Number Title Priority Date Filing Date
EP21184373.5A Pending EP3940895A1 (en) 2020-07-13 2021-07-07 Electric wire with terminal and method for manufacturing the same

Country Status (3)

Country Link
EP (1) EP3940895A1 (zh)
JP (2) JP7380459B2 (zh)
CN (1) CN113937515A (zh)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1998054790A1 (en) 1997-05-26 1998-12-03 The Whitaker Corporation Crimp connection for large conductors
JP4976230B2 (ja) * 2007-08-03 2012-07-18 株式会社三英社製作所 スリーブを用いた電線の接続方法
EP3687000A1 (en) * 2019-01-28 2020-07-29 Hitachi Metals, Ltd. Electric wire with terminal, method for manufacturing the same, and terminal for electric wire with terminal

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2006149102A (ja) 2004-11-19 2006-06-08 Chugoku Electric Power Co Inc:The 電線接続用圧縮スリーブ
JP6410163B1 (ja) 2017-06-22 2018-10-24 日立金属株式会社 端子付き電線
JP7228087B2 (ja) 2018-08-13 2023-02-24 株式会社プロテリアル 端子付電線

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1998054790A1 (en) 1997-05-26 1998-12-03 The Whitaker Corporation Crimp connection for large conductors
JP4976230B2 (ja) * 2007-08-03 2012-07-18 株式会社三英社製作所 スリーブを用いた電線の接続方法
EP3687000A1 (en) * 2019-01-28 2020-07-29 Hitachi Metals, Ltd. Electric wire with terminal, method for manufacturing the same, and terminal for electric wire with terminal

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CN113937515A (zh) 2022-01-14
JP2022016764A (ja) 2022-01-25
JP2023169336A (ja) 2023-11-29

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