JP2007305314A - Cable with terminal, manufacturing method therefor, ultrasonic welding method for joining terminal and cable, and ultrasonic welder - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a cable having a terminal that is made of a material different from that of the cable and is joined to the cable in a highly reliable state, to provide a manufacturing method for the cable, to provide an efficient ultrasonic welding method for obtaining the cable, and to provide an ultrasonic welder which does not give unnecessary mechanical damage to the material of an aluminum twisted wire upon welding to maintain the overall strength of the aluminum twisted wire. <P>SOLUTION: The core wire (aluminum twisted wire 12) and the terminal 11 of the aluminum cable 13 are welded by ultrasonic wave via a clad plate 100 to provide the cable 10 having the terminal 11. The clad plate 100 is disposed between the aluminum twisted wire 12 and the terminal 11, and has an aluminum layer facing the aluminum twisted wire 12 and a copper layer facing the terminal 11. The ultrasonic welding is carried out using the ultrasonic welder having a horn chip with the front end face that is inclined against the horizontal plane of the aluminum twisted wire 12. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a cable with a connection terminal, a method for manufacturing the same, and an ultrasonic welding method and an ultrasonic welder between the connection terminal and the cable, and in particular, a material different from a cable used as an automobile cable or a battery cable. The present invention relates to a cable with a connection terminal in which a connection terminal made of is joined in a highly reliable joining state, a manufacturing method thereof, an efficient ultrasonic welding method for the cable, and an ultrasonic welding machine for use in the welding.

  In recent years, there has been a great interest in environmental harmony and resource energy savings, and electric vehicles and hybrid vehicles have been developed and put into practical use in place of conventional gasoline vehicles. As a material that replaces copper that has been used for conductors of automobile harnesses, aluminum conductors are attracting attention from the viewpoints of improving fuel efficiency due to weight reduction, steel recyclability, and flexibility. For this reason, aluminum materials are used for hybrid vehicles, electric vehicle power harnesses, and battery cables.

  FIG. 23 is a perspective view of a conventional aluminum cable with a terminal. FIG. 24 is an exploded perspective view of a conventional aluminum cable with a terminal before welding. FIG. 25 is a view showing a state before welding a conventional aluminum cable with a terminal. FIG. 25 (a) is a side view thereof, FIG. 25 (b) is a top view thereof, and FIG. It is sectional drawing of the AA in FIG.

  The terminal-attached aluminum cable 90 includes the connection terminal 11 and the aluminum cable 13. The aluminum cable 13 is obtained by twisting a plurality of aluminum strands 2 to form an aluminum stranded wire 12 and covering the outer periphery of the aluminum stranded wire 12 with the insulating layer 1.

  The connection terminal 11 is for fixing the ring-shaped connection part 4 for connecting the object, the plate-like base part 5 having a concave cross section for joining the aluminum stranded wire 12, and the aluminum cable 13 (the end thereof). And a fixed piece 8. The plate-like base 5 has a pair of side walls 9, and an exposed aluminum stranded wire 12 is disposed therebetween. In general, the connection terminal 11 is made of a copper plate material.

  For example, an ultrasonic welding method is used as a method of joining the connection terminal 11 and the aluminum cable 13 (see, for example, Patent Documents 1 to 3).

  FIG. 26 is a drawing showing one step of a conventional ultrasonic welding method, in which FIG. (A) is a side view thereof, FIG. (B) is a top view thereof, and FIG. (C) is an AA view of FIG. It is sectional drawing of a line.

As shown in FIGS. 26A to 26C, the back surface of the plate-like base portion 5 is placed on the anvil 113 of the ultrasonic welder, and the end surface of the horn chip 115 is pressed against the upper surface of the aluminum stranded wire 12. Apply ultrasonic vibration. By pressing the horn chip 115 and ultrasonic vibration, the aluminum strand 2 is plastically deformed and the aluminum stranded wire 12 is flattened, and the interface between the aluminum strand 2 and the plate-like base 5 is slid and welded together. Is completed.
JP 54-43588 A JP 2004-71372 A JP 2004-95293 A

  However, according to the conventional ultrasonic welding method, when ultrasonically welding the connection terminal 11 made of copper and the aluminum stranded wire 12 made of aluminum, welding between different kinds of materials is performed. Compared with the case of welding, ultrasonic application energy must be set large and ultrasonic vibration must be applied for a long time.

  As a result, the deformation of the aluminum strand 2 is increased, and the mechanical strength of the entire aluminum stranded wire 12 is reduced. In particular, an ultrasonic wave application region (a portion crushed by pressing by the horn chip 115) in the aluminum stranded wire 12 and In the vicinity of the boundary with the non-applied region (the portion that maintains the outer shape of the aluminum stranded wire 12 without being in contact with the horn chip 115), there is a possibility that the aluminum wire 2 may be disconnected (see FIG. 23).

  Also, with respect to the crimp terminal (connection terminal 11), by increasing the ultrasonic wave application energy, the connection terminal 11 comes into contact with the anvil 113 of the ultrasonic welding machine, and wear due to ultrasonic vibration occurs. Will cause damage.

  Accordingly, an object of the present invention is to provide a cable with a connection terminal in which a connection terminal made of a different material from the cable is joined in a highly reliable joined state, a manufacturing method thereof, and a cable made of a different material and the connection terminal. It is also an object of the present invention to provide an ultrasonic welding method that does not require application of excessive ultrasonic energy (efficiently) and can provide a highly reliable joining state in ultrasonic welding.

  In addition, the object of the present invention is to maintain the strength of the entire aluminum stranded wire without causing extra mechanical damage to the material itself even in ultrasonic welding between a cable made of a different material and a connection terminal. It is to provide an ultrasonic welding machine capable of performing the above.

  In order to achieve the above object, the present invention provides a cable in which the outer periphery of a core wire is covered with an insulating layer, and a connection terminal that is electrically connected to the core wire that is exposed by peeling off the insulating layer at a terminal portion of the cable. A cable with a connection terminal, comprising: a first metal layer joined to the core wire; and a composite material having a second metal layer joined to the connection terminal, wherein the first metal layer is the core wire. And the second metal layer is made of the same material as that of the connection terminal.

  The “same material” as used in the present invention refers to a material mainly composed of the same simple metal or an alloy thereof. For example, when the core wire is aluminum or an aluminum alloy, the first metal layer is composed mainly of aluminum or an aluminum alloy. Here, the main component means a case where the content exceeds 50% by mass, but it is desirable that the content is 80% by mass or more. More preferably, it is 90% by mass or more, and most preferably contains the same simple metal or its alloy in an amount of 95-100% by mass.

  In order to achieve the above object, the present invention provides a cable in which the outer periphery of the core wire is covered with an insulating layer, and a connection that is electrically connected to the core wire exposed by peeling off the insulating layer at the end of the cable. A method of manufacturing a cable with a connection terminal comprising a terminal, wherein the connection between the core wire and the connection terminal faces the core wire disposed between the core wire and the connection terminal, and the core wire. This is performed by ultrasonic welding through a composite material having a first metal layer made of the same material and a second metal layer facing the connection terminal and made of the same material as the connection terminal. The manufacturing method of the cable with a connection terminal characterized by this is provided.

  Further, in order to achieve the above object, the present invention provides the core wire that is obtained by peeling off and exposing the insulating layer in the terminal portion of the cable in which the outer periphery of the core wire is covered with the insulating layer, the connection terminal, the core wire and the A first metal layer that is disposed between the connection terminals and faces the core wire and is made of the same material as the core wire, and a second metal layer that faces the connection terminal and is made of the same material as the connection terminal. An ultrasonic welding method in which ultrasonic welding is performed by an ultrasonic welder through a composite material having a metal layer of a horn tip provided on the ultrasonic welder with respect to a horizontal plane of the core wire Provided is an ultrasonic welding method characterized by applying ultrasonic vibration in an inclined state to perform ultrasonic welding.

  In order to achieve the above object, the present invention is for ultrasonic welding the connecting wire and the core wire, which is exposed by peeling off the insulating layer at the end portion of the cable whose outer periphery is covered with an insulating layer. The ultrasonic welder is characterized in that a tip surface of a horn tip provided in the ultrasonic welder has an inclination angle with respect to a horizontal plane of the core wire.

  According to the present invention, it is possible to obtain a cable with a connection terminal in which connection terminals made of different materials from the cable are joined in a highly reliable joining state. Also, in ultrasonic welding between a cable made of different materials and a connection terminal, there is no need to apply excessive ultrasonic energy (efficiently), and an ultrasonic welding method capable of obtaining a highly reliable joining state. Can be obtained. Furthermore, even in ultrasonic welding between cables made of different materials and connection terminals, the ultrasonic welding machine can maintain the strength of the entire aluminum stranded wire without causing extra mechanical damage to the material itself. Can be obtained.

[First embodiment of the present invention]
(Configuration of cable with terminal)
FIG. 1 is a perspective view of an aluminum cable with a terminal according to the first embodiment of the present invention. FIG. 2 is an exploded perspective view of the aluminum cable with terminal according to the first embodiment of the present invention before welding. 3 is a drawing showing a state before welding the aluminum cable with a terminal according to the first embodiment of the present invention, where FIG. 3 (a) is a side view thereof, and FIG. 3 (b) is a top view thereof. FIG. 7C is a cross-sectional view taken along line AA in FIG.

  The terminal-attached aluminum cable 10 includes a connection terminal 11, an aluminum cable 13, and a clad plate 100 interposed between the connection terminal 11 and the aluminum cable 13.

  The connection terminal 11 includes a ring-shaped connection portion 4 for connecting an object, a plate-shaped base portion 5 having a concave cross section for ultrasonic welding the aluminum stranded wire 12 via the clad plate 100, and an aluminum cable 13 And a fixing piece 8 for fixing the end portion). The plate-like base 5 has a pair of side walls 9 between which a clad plate 100 and an exposed aluminum stranded wire 12 disposed thereon are arranged. The connection terminal 11 is made of a material such as copper or a copper alloy (for example, phosphor bronze). Any material mainly composed of copper or a copper alloy can be preferably used. Here, the main component means a case where the content exceeds 50% by mass, but it is desirable that the content is 80% by mass or more. More desirably, the content is 90% by mass or more, and most preferably 95 to 100% by mass.

  In particular, the difference from the conventional terminal-attached aluminum cable 90 is that a copper layer 98 (hereinafter sometimes referred to as a Cu layer 98) containing copper as a main component and aluminum as a main component on the plate-like base 5. The clad plate 100 is provided with an aluminum layer 99 (hereinafter sometimes referred to as an Al layer 99). The material of the Cu layer (Cu film) 98 is Cu or a Cu alloy (for example, Cu—Sn alloy, Cu—Zr alloy, Cu—Cr—Sn—Zn alloy, Cu—Ni—Fe—P alloy, etc.). Thus, the material of the Al layer (Al film) 99 is made of Al or an Al alloy (for example, Al—Fe alloy, Al—Zr alloy, Al—Fe—Zr alloy, etc.).

  The clad plate 100 is disposed such that the Cu layer 98 is located on the side facing the plate-like base 5 of the connection terminal 11 and the Al layer 99 is located on the side in contact with the aluminum stranded wire 12.

  FIG. 4 shows a side view of a single cable used for the cable with terminal according to the embodiment of the present invention. The aluminum cable 13 has a structure in which a plurality of aluminum wires 2 (or aluminum alloy wires) are twisted to form an aluminum stranded wire 12 and the outer periphery of the aluminum stranded wire 12 is covered with the insulating layer 1. It may be a single wire conductor. The core wire can be suitably used as long as it has aluminum or an aluminum alloy as a main component. Here, the main component means a case where the content exceeds 50% by mass, but it is desirable that the content is 80% by mass or more. More desirably, the content is 90% by mass or more, and most preferably 95 to 100% by mass.

  FIG. 5 shows a sectional view of a single cable used for the cable with terminal according to the embodiment of the present invention. The aluminum cable 13 that can be used in the present invention is not particularly limited. For example, in addition to 19 stranded wires (FIG. (A)), 38 stranded wires, 64 stranded wires, 137 stranded wires, 184 wires A stranded wire, 287 stranded wire, etc. can be used (FIGS. (B) to (f)).

  It is not restricted to the aluminum twisted wire structure shown in FIG. 5, An aluminum flat wire may be sufficient. Alternatively, an aluminum cable having a structure in which one unit is formed by preparing a plurality of strands, a plurality of units are prepared, and the unit group is twisted together may be used.

  In the 19 strands, for example, the diameter of the aluminum strand 2 is about 1.0 mm, the diameter of the strand 12 is about 5.0 mm, and the outer diameter of the aluminum cable 13 is about 8.0 mm. Things are desirable.

(Manufacturing method of cable with terminal)
FIG. 6 is a drawing showing one step of the ultrasonic welding method according to the first embodiment of the present invention, wherein FIG. 6 (a) is a side view thereof, FIG. 6 (b) is a top view thereof, and FIG. These are sectional drawings of the AA line of figure (b).

  First, as shown in FIGS. 3A to 3C, an end portion of the aluminum cable 13 is fixed to the fixing piece 8 of the connection terminal 11, and the clad plate 100 disposed on the plate-like base portion 5 having a concave section is arranged. On the Al layer 99, the aluminum strand 12 which peeled the insulating layer 1 and exposed outside is arrange | positioned. The clad plate 100 can be made by laminating a copper plate and an aluminum plate and rolling them.

  In this state, as shown in FIGS. 6A to 6C, the back surface of the plate-like base portion 5 is placed on the anvil 73 of the ultrasonic welder, and the horn tip 75 is placed on the upper surface of the aluminum stranded wire 12. Ultrasonic vibration is applied by pressing the end face. By pressing the horn chip 75 and ultrasonic vibration, the aluminum strand 2 is plastically deformed and the aluminum stranded wire 12 is crushed substantially flat, and the interface between the aluminum strand 2 and the plate-like base 5 is interposed via the clad plate 100. Then, the ultrasonic welding is completed.

  In this way, the clad plate 100 is disposed on the plate-like base portion 5 having a concave cross section, and the aluminum stranded wire 12 is disposed on the clad plate 100 and ultrasonic welding is performed, so that the connection terminal 11 made of copper and the aluminum made of aluminum. Also in ultrasonic welding between different types of materials with the strand 2, the same kind of material is used at the interface of ultrasonic welding (Cu layer 98 at the interface with the connection terminal 11, and Al layer 99 at the interface with the aluminum stranded wire 12. )become. For this reason, an excessive ultrasonic application energy is not given and a highly reliable joining state can be obtained in a short time.

  As a result, even in the ultrasonic welding between different materials, the ultrasonic welding can be completed while maintaining the strength of the entire aluminum stranded wire 12 without causing extra mechanical damage to the raw material itself.

  The space and size formed by the shape of the concave cross section of the plate-like base 5 are appropriately determined according to the shape and size of the aluminum stranded wire 12, but there is a gap between the plate-like base 5 and the aluminum stranded wire 12. It is preferable to adhere so that it may not be formed.

(Ultrasonic welding machine)
Next, the case where the connection terminal 11 and the aluminum strand wire 12 (aluminum strand 2) are welded using the ultrasonic welding machine according to the present embodiment to produce a welded portion will be described.

  FIG. 20 is a diagram showing a schematic configuration of the ultrasonic welder according to the embodiment of the present invention. As shown in FIG. 20, the ultrasonic welding machine 70 according to the present embodiment is mainly composed of a main body 70 a and an ultrasonic oscillator 77. The main body 70 a is composed of a horn support 72 and an anvil 73 provided on the base 71, and a horn chip 75 is provided at the tip of an ultrasonic horn 74 that extends horizontally from the horn support 72.

FIG. 21 is an enlarged view of the main part X of FIG. 20 during ultrasonic welding.
As for the horn chip | tip 75, the front end surface (lower surface in FIG. 21) 75a inclines only the predetermined angle with respect to the horizontal surface (F) of a to-be-welded body (the aluminum strand wire 12 and the plate-shaped base part 5). The inclination angle θ of the distal end surface 75a is appropriately determined according to the size of the aluminum stranded wire 12, and increases as the size of the aluminum stranded wire 12 increases. For example, the inclination angle θ is 0 to 30 ° (excluding 0), preferably 10 to 20 °. The tip surface 75a referred to here is a surface obtained by averaging the inclinations of the entire tip of the horn chip 75.

  An object to be welded is placed on the anvil 73 of the ultrasonic welder 70 having such an apparatus configuration, and the tip surface 75a of the horn tip 75 is brought into contact with the object to be welded, so that the ultrasonic oscillator 77 oscillates. The ultrasonic vibration thus applied is applied to the workpiece.

  Here, FIG. 22 is a figure which shows the site | part corresponded in FIG. 21 about the conventional ultrasonic welding machine. When a conventional ultrasonic welding machine is used in which the front end surface 115a of the horn chip 115 is flat (indicated by the above-mentioned inclination angle, 0 °), the region Z (the ultrasonic application region and the non-application region in the aluminum stranded wire 12) In the vicinity of the boundary portion, the aluminum stranded wire 12 is crushed (or completely extended), and the aluminum element wire 2 is disconnected.

  On the other hand, in the ultrasonic welding method using the ultrasonic welding machine 70 according to the present embodiment, as shown in FIG. 21, the tip surface 75a of the horn tip 75 is inclined at an angle θ with respect to the workpiece. The contact is made in the state, and ultrasonic waves are applied. For this reason, in the region Y (near the boundary between the ultrasonic wave application region and the non-application region in the aluminum stranded wire 12), the aluminum stranded wire 12 is prevented from being crushed. As a result, there is no possibility that the aluminum strand 2 is disconnected in the aluminum stranded wire 12 during ultrasonic welding.

(Effect of the first embodiment of the present invention)
According to the present embodiment, the following effects can be obtained.
(1) The connection terminal 11 according to the present embodiment is formed by disposing the clad material 100 composed of the Cu layer 98 and the Al layer 99 on the plate-like base 5 so that the Cu layer 98 faces the lower surface. Since the Al layer 99 is positioned so that the Al layer 99 faces the surface on the contact portion side with the stranded wire 12, since the connection is made between the same kind of materials in the ultrasonic welded portion, the applied energy at the time of ultrasonic welding is reduced. Can be small. As a result, it is possible to prevent the conductor strength of the aluminum element wire 2 from being lowered, thereby improving the connectivity. In other words, even in ultrasonic welding between different materials, the same kind of materials (copper and aluminum) are used at the interface of ultrasonic welding, so it does not give excessive ultrasonic energy and is reliable in a short time. As a result, even in ultrasonic welding between different kinds of materials, the strength of the entire aluminum stranded wire 12 can be maintained without causing extra mechanical damage to the material itself.

(2) When using a clad plate 100 formed by laminating and rolling a copper plate and an aluminum plate, the interface between the copper plate and the aluminum plate becomes stronger, so that the connection terminal 11 and the aluminum stranded wire 12 are further improved in connectivity.

(3) The plate-like base 5 has side walls 9 that are substantially perpendicular to the left and right ends thereof, and is formed in a concave cross section. Since this side wall 9 constrains the aluminum stranded wire 12 during ultrasonic welding, the aluminum stranded wire 12 does not come apart when ultrasonically welding an aluminum conductor composed of the stranded wire 12 of the Al strand 2. .

(4) Although the ring-shaped connection part 4 in a connection terminal is connected to the connector terminal of a connection object goods (for example, battery etc.), this connector terminal is often made of Cu. Since the Al layer (Al film) 99 is not formed on the ring-shaped connection portion 4 of the connection terminal 11 according to the present embodiment, the ring-shaped connection portion 4 of the connection terminal 11 and the connector terminal are of the same type. Contact between materials. Therefore, in the ring-shaped connection portion 4 of each terminal, there is no possibility that potential difference corrosion between different metals occurs.

(5) Since the tip end surface 75a of the horn tip 75 is brought into contact with the body to be welded at an angle θ and is applied with ultrasonic waves, the twisted aluminum wire that is generated as the deformation of the aluminum strand increases. The overall mechanical strength is prevented from lowering, and in particular, near the boundary between the ultrasonic application region and the non-application region in the aluminum stranded wire 12, the aluminum stranded wire 12 is prevented from being crushed. As a result, an effect of preventing disconnection of the aluminum strand 2 in the aluminum stranded wire 12 can be obtained during ultrasonic welding.

[Second Embodiment of the Present Invention]
(Configuration of cable with terminal)
FIG. 7 is a perspective view of an aluminum cable with a terminal according to the second embodiment of the present invention. FIG. 8 is an exploded perspective view of the aluminum cable with terminal according to the second embodiment of the present invention before welding. Moreover, FIG. 9 is drawing which shows the state before welding the aluminum cable with a terminal which concerns on the 2nd Embodiment of this invention, a figure (a) is the side view, and FIG.9 (b) is the top view. FIG. 7C is a cross-sectional view taken along line AA in FIG.

  The difference between the cable 20 with a terminal according to the second embodiment and the cable 10 with a terminal according to the first embodiment is that a clad plate 101 having a side wall is used instead of the clad plate 100 according to the first embodiment. It is in point to use.

  The clad plate 101 has side walls in contact with the inner surface of the side wall 9 of the plate-like base 5 on both side surfaces thereof.

(Manufacturing method of cable with terminal)
FIG. 10 is a drawing showing one step of the ultrasonic welding method according to the second embodiment of the present invention, wherein FIG. 10 (a) is a side view thereof, FIG. 10 (b) is a top view thereof, and FIG. These are sectional drawings of the AA line of figure (b).

  The cable 20 with a terminal can be manufactured in the same manner as in the first embodiment except that the clad plate 101 having a side wall is used instead of the clad plate 100 in the first embodiment. The clad plate 101 can be produced, for example, by laminating and rolling a copper plate and an aluminum plate, cutting the produced composite plate material into a required size, and bending both ends to form side walls.

(Effect of the second embodiment of the present invention)
According to the present embodiment, in addition to the effects of the first embodiment of the present invention, the following effects can be obtained.
(1) Since the connection region between the connection terminal 11 and the aluminum stranded wire 12 is the three planes of the plate-like base portion 5 and the side wall 9, a sufficient contact area between the connection terminal 11 and the aluminum stranded wire 12 also in the side wall portion. Can be secured, and connectivity can be improved.

[Third embodiment of the present invention]
(Configuration of cable with terminal)
FIG. 11 is a perspective view of an aluminum cable with a terminal according to the third embodiment of the present invention. FIG. 12 is an exploded perspective view of the aluminum cable with terminal according to the third embodiment of the present invention before welding. FIG. 13 is a drawing showing a state before welding an aluminum cable with a terminal according to a third embodiment of the present invention, where FIG. 13 (a) is a side view thereof, and FIG. 13 (b) is a top view thereof. FIG. 7C is a cross-sectional view taken along line AA in FIG.

  The cable 30 with a terminal according to the third embodiment is different from the cable 10 with a terminal according to the first embodiment in that a cap-like clad cap is used instead of the flat clad plate 100 in the first embodiment. 102 is used.

  The clad cap 102 has a cap shape having an inner diameter large enough to fit the tip of the aluminum stranded wire 12, and has an outer layer made of a Cu layer 98 and an inner layer made of an Al layer 99. In the drawing, the cross section has a perfect circle shape, but is not limited thereto, and may be a polygonal shape such as a quadrangle, an elliptical shape, or the like.

(Manufacturing method of cable with terminal)
FIG. 14 is a drawing showing one step of the ultrasonic welding method according to the third embodiment of the present invention, wherein FIG. 14 (a) is a side view thereof, FIG. 14 (b) is a top view thereof, and FIG. These are sectional drawings of the AA line of figure (b).

  The terminal-attached cable 30 can be manufactured in the same manner as in the first embodiment except that a cap-like clad cap 102 is used instead of the clad plate 100 in the first embodiment. The clad cap 102 is formed, for example, by laminating and rolling a copper plate and an aluminum plate, then punching the produced composite plate material into a required size and shape with a press, and bending it into a cap shape with the Al layer 99 inside. It can be produced by processing.

(Effect of the third embodiment of the present invention)
According to the present embodiment, in addition to the effects of the first embodiment of the present invention, the following effects can be obtained.
(1) By placing the aluminum conductor (aluminum stranded wire 12) in the clad cap 102, it uniformly contacts the horn chip 75 that transmits ultrasonic vibrations, so that the work can be performed under certain conditions.
(2) By placing the aluminum conductor (aluminum stranded wire 12) in the clad cap 102, water does not enter from the front end side of the conductor, and different metal corrosion is less likely to occur.

[Fourth embodiment of the present invention]
(Configuration of cable with terminal)
FIG. 15 is a perspective view of an aluminum cable with a terminal according to the fourth embodiment of the present invention. FIG. 16 is an exploded perspective view of the aluminum cable with a terminal according to the fourth embodiment of the present invention before welding. FIG. 17 is a drawing showing a state before welding an aluminum cable with a terminal according to a fourth embodiment of the present invention, where FIG. 17 (a) is a side view thereof, and FIG. 17 (b) is a top view thereof. FIG. 7C is a cross-sectional view taken along line AA in FIG.

  The cable with a terminal 40 according to the fourth embodiment is different from the cable with a terminal 10 according to the first embodiment in that a pipe-like clad pipe is used instead of the flat clad plate 100 in the first embodiment. 103 is used.

  The clad pipe 103 has a pipe shape having an inner diameter large enough to fit the tip of the aluminum stranded wire 12, and has an outer layer made of a Cu layer 98 and an inner layer made of an Al layer 99. In the drawing, the cross section has a perfect circle shape, but is not limited thereto, and may be a polygonal shape such as a quadrangle, an elliptical shape, or the like.

(Manufacturing method of cable with terminal)
FIG. 18 is a drawing showing one step of the ultrasonic welding method according to the fourth embodiment of the present invention, wherein FIG. 18 (a) is a side view thereof, FIG. 18 (b) is a top view thereof, and FIG. These are sectional drawings of the AA line of figure (b).

  The terminal-attached cable 40 can be manufactured in the same manner as in the first embodiment except that the pipe-like clad pipe 103 is used instead of the clad plate 100 in the first embodiment. The clad pipe 103 is formed by, for example, laminating and rolling a copper plate and an aluminum plate, then forming the produced composite plate material into a circular shape so that the Al layer 99 is on the inside by a roll forming machine, and joining both ends by ultrasonic waves. It can produce by doing.

(Effect of the fourth embodiment of the present invention)
According to the present embodiment, in addition to the effects of the first embodiment of the present invention, the following effects can be obtained.
(1) By placing the aluminum conductor (aluminum stranded wire 12) in the clad pipe 103, it uniformly contacts the horn chip 75 that transmits ultrasonic vibrations, so that the work can be performed under certain conditions.

[Fifth embodiment of the present invention]
(Configuration of cable with terminal)
FIG. 19 is a perspective view of an aluminum cable with a terminal according to the fifth embodiment of the present invention. The cable with a terminal according to the fifth embodiment of the present invention is one example of use of the aluminum cable with a terminal according to the first to fourth embodiments.

  In the usage example shown in FIG. 19, after the ultrasonic welding of the aluminum cable 13 and the connection terminal 11 is finished, the entire portion corresponding to the welded portion is covered with the heat shrinkable tube 51. For example, a heat-shrinkable tube 51 having a length that completely covers this part is prepared, and after this part is covered, hot-blowing is performed to shrink the heat-shrinkable tube 51 so that it is in close contact with this part. As shown, an insulating coating is formed. As the heat shrinkable tube 51, for example, Sumitube (registered trademark) (manufactured by Sumitomo Electric Fine Polymer Co., Ltd.) can be used.

(Effects of the fifth embodiment of the present invention)
According to the present embodiment, the following effects can be obtained.
Since the ultrasonic welded portion between the aluminum cable 13 and the connection terminal 11 is covered with the heat shrinkable tube 51 to be kept watertight, potential difference corrosion between different kinds of metals due to water intrusion from the gap between the copper plate and the aluminum plate is prevented. Can be prevented.

  In addition, although description was abbreviate | omitted in description of the said 1st-4th embodiment of this invention, generally the aluminum cable 13 used for this invention is demonstrated below as shown in FIG. It has a structure.

  First, the outer periphery of the insulating layer 1 is covered with a cylindrical braided wire (braided shield layer) 52, and the outer periphery of the braided wire 52 is covered with an outermost layer insulator (sheath) 53. Part of the outermost layer insulator (sheath) 53 is peeled off, and the braided wire (braided shield layer) 52 is exposed (exposed shield) from the end portion of the aluminum cable 13.

  The ground connection terminal (connector member) 54 and the crimp sleeve 55 are inserted over the exposure shield. Here, the ground connection terminal (connector member) 54 includes a cylindrical portion (not shown) extending in the longitudinal direction and a flange portion, and the crimping sleeve 55 is positioned on the cylindrical portion.

  Thereafter, the cylindrical portions of the exposure shield, the crimp sleeve 55, and the ground connection terminal 54 are integrally compression-molded from above the crimp sleeve 55 to form a polygonal cross section (here, a hexagon) as shown in FIG. Mold. Here, the compression sleeve 55 is compression-molded in order to secure a contact area between the exposed shield and the cylindrical portion of the ground connection terminal 54 and increase electrical contact. This is because the cylindrical portion of the ground connection terminal 54 and the cylindrical portion of the ground connection terminal 54 are joined together to ensure the mechanical strength of the exposed shield at the crimp sleeve 55 portion.

[Other Embodiments of the Present Invention]
(1) In the above embodiment, the core wire has been described with respect to the cable made of aluminum or aluminum alloy and the connection terminal made of copper or copper alloy. However, the present invention is also applicable when the cable and the connection terminal are made of other dissimilar metals. Is possible.

(2) In the above embodiment, the case where the aluminum (or aluminum alloy) stranded wire and the connection terminal made of copper (or copper alloy) are welded by ultrasonic welding has been described, but other welding methods, For example, it can be applied to resistance welding, laser welding, and arc welding.

(3) In the above embodiment, the structure in which the tip surface 75a of the horn tip 75 of the ultrasonic welder 70 is inclined over the entire surface has been explained. A structure in which the corner of the horn tip is chamfered (R-shaped) at a position corresponding to the vicinity of the boundary between the collapsed portion) and the non-applied region (the portion that maintains the outer shape of the aluminum stranded wire without being in contact with the horn tip). If so, the tip surface of the horn tip may be substantially flat. Even in such a structure, the aluminum stranded wire 12 is prevented from being crushed in the vicinity of the boundary between the ultrasonic application region and the non-application region in the aluminum stranded wire 12 (region Y in FIG. 21). At this time, in the aluminum stranded wire 12, there is no possibility that the aluminum strand 2 is broken.

  Next, although this invention is demonstrated based on an Example, this invention is not limited to these Examples.

[Example 1] (First embodiment / flat clad plate type)
A copper plate and an aluminum plate were laminated and rolled to produce a composite plate material (clad plate 100) having a thickness of 0.4 mm. In this composite plate material (cladding plate 100), the layer thickness of the Cu layer 98 was 0.25 mm, and the layer thickness of the Al layer 99 was 0.15 mm. This composite plate material (cladding plate 100) was cut into a strip-shaped test piece having a width of 8 mm and a length of 10 mm.

  In a state where the test piece is disposed on the bottom surface of the plate-like base portion 5 having a concave cross section of the copper connection terminal 11 having a thickness of 1.0 mm, an aluminum stranded wire 12 (aluminum strand 2 on the test piece and in the plate-like base portion 5). ) Was placed.

  Using the ultrasonic welding machine 70 shown in FIG. 20, a horn tip 75 is pressed against the upper surface of the aluminum stranded wire 12 to apply ultrasonic vibration for a predetermined time, and the aluminum stranded wire 12 is placed on the plate-like base 5 with a test piece. Via ultrasonic welding.

  As the aluminum stranded wire 12, an aluminum conductor obtained by twisting 19 aluminum strands having an outer diameter of φ1.0 mm was used. As the horn tip 75 (male shape) in the ultrasonic welder 70, a tip having an inclined tip surface (inclination angle of 5 °) was used, and the tip surface size was 10 mm × 8 mm. The ultrasonic welding conditions were a frequency of 40 kHz, a pressure of 0.1 to 0.4 MPa, and an ultrasonic wave application energy of 1 to 3000 J.

[Example 2] (first embodiment / flat clad plate type)
A copper plate and an aluminum plate were laminated and rolled to produce a composite plate material (clad plate 100) having a thickness of 0.4 mm. In this composite plate material (cladding plate 100), the layer thickness of the Cu layer 98 was 0.2 mm, and the layer thickness of the Al layer 99 was 0.2 mm. The same aluminum conductor and ultrasonic welder as in Example 1 were used, and the ultrasonic welding conditions were also ultrasonically welded under the same conditions as in Example 1.

Example 3 (Second Embodiment / Flat Clad Plate Type with Side Wall)
A copper plate and an aluminum plate were laminated and rolled to produce a composite plate material having a thickness of 0.4 mm. In this composite plate material, the layer thickness of the Cu layer 98 was 0.2 mm, and the layer thickness of the Al layer 99 was 0.2 mm.

  This composite plate was cut into a strip-shaped test piece having a width of 14 mm and a length of 10 mm. Both ends in the width direction of these test pieces were bent inward by approximately 90 ° with a width of 3 mm, and a clad plate 101 having side walls (see FIG. 9) was produced.

  In a state where the test piece is arranged on the bottom surface of the plate-like base 5 having a concave cross section of the connection terminal 11, the aluminum stranded wire 12 is arranged on the test piece and in the plate-like base 5.

  Using the ultrasonic welding machine 70 shown in FIG. 20, the horn chip 75 is pressed against the upper surface of the aluminum stranded wire 12 to apply ultrasonic vibration for a predetermined time, and the aluminum stranded wire 12 is placed on the plate-like base via a test piece. And ultrasonic welding.

  The used aluminum conductor (aluminum stranded wire 12), horn tip, ultrasonic welding conditions, and the like were the same as in Example 1.

Example 4 (Second Embodiment / Flat Clad Plate Type with Side Wall)
A copper plate and an aluminum plate were laminated and rolled to produce a composite plate material having a thickness of 0.4 mm. In this composite plate material, the layer thickness of the Cu layer 98 was 0.2 mm, and the layer thickness of the Al layer 99 was 0.2 mm. For other ultrasonic welding conditions and the like, ultrasonic welding and the like were performed in the same manner as in Example 3.

[Example 5] (Third Embodiment / Clad Cap Type)
A copper plate and an aluminum plate were laminated and rolled to produce a composite plate material having a thickness of 0.4 mm. In this composite plate material, the layer thickness of the Cu layer 98 was 0.25 mm, and the layer thickness of the Al layer 99 was 0.15 mm.

  This composite plate material was punched out with a press machine, and a cap-type test piece (clad cap 102) formed integrally by bending so that the Al layer 99 was inside was prepared. The test piece had a length of 15 mm, a width of 7 mm, and an opening diameter of 6 mm.

  With the cap-type test piece (clad cap 102) covered on the terminal side of the aluminum stranded wire 12, the cap-type test piece (clad cap 102) is placed on the bottom surface of the plate-like base portion 5 having a concave cross section of the connection terminal 11. Arranged.

  Using the ultrasonic welding machine 70 shown in FIG. 20, the horn chip 75 is pressed from above the cap-type test piece (clad cap 102) to apply ultrasonic vibration for a predetermined time, and the aluminum stranded wire 12 is formed into a plate shape. Ultrasonic welding was performed on the base 5 through a test piece.

  The aluminum conductor (aluminum stranded wire 12) and the ultrasonic welder were the same as those in Example 1, and the ultrasonic welding conditions were also ultrasonically welded under the same conditions as in Example 1.

[Example 6] (Third Embodiment / Clad Cap Type)
A copper plate and an aluminum plate were laminated and rolled to produce a composite plate material having a thickness of 0.4 mm. In this composite plate material, the layer thickness of the Cu layer 98 was 0.2 mm, and the layer thickness of the Al layer 99 was 0.2 mm. For other ultrasonic welding conditions and the like, ultrasonic welding and the like were performed in the same manner as in Example 5.

[Example 7] (Fourth Embodiment / Clad Pipe Type)
A copper plate and an aluminum plate were laminated and rolled to produce a composite plate material having a thickness of 0.4 mm. In this composite plate material, the layer thickness of the Cu layer 98 was 0.25 mm, and the layer thickness of the Al layer 99 was 0.15 mm.

  This composite plate material is formed into a circular shape with a roll forming machine so that the Al layer 99 is on the inside, and both ends are joined by ultrasonic waves to produce a clad pipe 103, which is cut out to a predetermined length to obtain a tubular test. I got a piece. This tubular test piece had a length of 15 mm, a width of 7 mm, and an opening diameter of 6 mm.

  With the tubular test piece inserted into the terminal side of the aluminum stranded wire 12, the tubular test piece was disposed on the bottom surface of the plate-like base portion 5 having a concave cross section of the connection terminal 11.

  Using the ultrasonic welding machine 70 shown in FIG. 20, the horn tip 75 is pressed from above the tubular test piece to apply ultrasonic vibration for a predetermined time, and the aluminum test piece 12 is attached to the plate-like base 5 with the tubular test piece. Via ultrasonic welding.

  The aluminum conductor (aluminum stranded wire 12), ultrasonic welder, and the like were the same as in Example 1, and the ultrasonic welding conditions were also ultrasonically welded under the same conditions as in Example 1.

[Example 8] (Fourth Embodiment / Clad Pipe Type)
A copper plate and an aluminum plate were laminated and rolled to produce a composite plate material having a thickness of 0.4 mm. This composite plate material had a Cu layer thickness of 0.2 mm and an Al layer thickness of 0.2 mm. For other ultrasonic welding conditions and the like, ultrasonic welding and the like were performed in the same manner as in Example 7.

[Comparative Example 1]
By rolling using only a copper plate, a plate material having a thickness of 1.0 mm was produced. Using this plate material, ultrasonic welding or the like was performed under the same conditions as in Example 1.

[Evaluation of connectivity, etc.]
About the aluminum cable with a connection terminal produced in Examples 1-8 and the comparative example 1, evaluation, such as the connectivity of the welding part after ultrasonic welding, was performed. The evaluation results (ultrasonic application energy, tensile strength, peel strength (peeling strength), lightness, corrosivity, vibration test, and overall evaluation thereof) are shown in Table 1. The tensile strength was tested by pulling in the length direction of the conductor, and the peel strength (peeling strength) was tested by pulling in the direction perpendicular to the length of the conductor by 90 °. Further, the corrosivity was tested by a salt spray test, and the vibration test was performed at an acceleration of 88 m / s ² , an excitation time of 3 hours (standard value) and 9 hours, and an excitation frequency of 20 to 200 Hz. .

  Regarding the energy applied to the ultrasonic wave, the energy required for welding is higher than 2600J, and the energy required for welding is lower than 2600J. The tensile strength is expressed by the actual tensile strength (MPa) and the relative value when the base material strength (120 MPa) of the aluminum conductor (aluminum stranded wire 12) used is 1.0. The peel strength was expressed as a relative value when the base material strength (120 MPa) of the aluminum conductor (aluminum stranded wire 12) used was 1.0 (“0.5” = 60 MPa). Regarding lightness, corrosivity, vibration test, and comprehensive evaluation, “Good” indicates “Good” and “Inadequate” indicates “Good”.

  As shown in Table 1, the welded portion of the terminal-attached aluminum cable produced in Comparative Example 1 has a tensile strength of 120 MPa (relative value is 1.0) and a peel strength of 0.5 (relative value), which is sufficient. It had tensile strength and peel strength. However, since the welding of the plate material (Cu) and the aluminum conductor in Comparative Example 1 is between different materials, the ultrasonic energy required for welding was high. Further, in Comparative Example 1, since the plate material is composed only of Cu, the lightness was insufficient as compared with the clad material of Cu and Al. Moreover, although the standard value in a vibration test is satisfied, when it implemented for 9 hours, the crack generate | occur | produced and it was inadequate compared with Examples 1-8. Based on the above, the overall evaluation was insufficient.

  On the other hand, as in Comparative Example 1, the welded portion of the terminal-attached aluminum cable produced in Examples 1 to 8 has a tensile strength of 120 MPa (relative value is 1.0) and a peel strength of 0.5 (relative value). ) And had sufficient tensile strength and peel strength. Moreover, since the welding on both front and back surfaces of the composite plate material in Examples 1 to 8 was welding between the same kind of materials, ultrasonic application energy required for welding was low. Furthermore, since the composite plate material is composed of a composite material of Al and Cu, compared with the case of Comparative Example 1 composed of Cu alone, the light weight is good and the vibration test result is also good. . From the above, the overall evaluation was also good.

(Examination of whether or not the horn tip is inclined)
Two composite plate materials (samples) of various shapes prepared in Examples 1 to 8 were prepared. Each sample was subjected to ultrasonic welding with the aluminum stranded wire 12 using an ultrasonic welding machine in which the tip surface of the horn tip was inclined (inclination angle 5 °) (Examples 1 to 8).

  Each other sample was subjected to ultrasonic welding with an aluminum stranded wire using an ultrasonic welding machine having a flat tip surface of the horn tip (Comparative Examples 2 to 9).

  The presence or absence of Al wire breakage in each weld after ultrasonic welding was evaluated. The evaluation results are shown in Table 2.

  As shown in Table 2, no Al wire breakage was observed in the welds in Examples 1 to 8. On the other hand, in the welded parts in Comparative Examples 2 to 9, Al wire breakage was observed. Therefore, it was confirmed that when the tip end surface of the horn tip was brought into contact with the object to be welded and ultrasonic waves were applied, the Al conductor did not break in the aluminum conductor.

It is a perspective view of the aluminum cable with a terminal concerning the 1st embodiment of the present invention. It is a disassembled perspective view before welding of the aluminum cable with a terminal which concerns on the 1st Embodiment of this invention. It is drawing which shows the state before welding the aluminum cable with a terminal which concerns on the 1st Embodiment of this invention, (a) is the side view, (b) is the top view, (c) is (b) It is sectional drawing of AA in FIG. The side view of the cable single-piece | unit used for the cable with a terminal which concerns on embodiment of this invention is shown. Sectional drawing of the cable single-piece | unit used for the cable with a terminal which concerns on embodiment of this invention is shown. It is drawing which shows 1 process of the ultrasonic welding method which concerns on the 1st Embodiment of this invention, (a) is the side view, (b) is the top view, (c) is A- of (b). It is sectional drawing of A line. It is a perspective view of the aluminum cable with a terminal which concerns on the 2nd Embodiment of this invention. It is a disassembled perspective view before welding of the aluminum cable with a terminal which concerns on the 2nd Embodiment of this invention. It is drawing which shows the state before welding the aluminum cable with a terminal which concerns on the 2nd Embodiment of this invention, (a) is the side view, (b) is the top view, (c) is (b). It is sectional drawing of AA in FIG. It is drawing which shows 1 process of the ultrasonic welding method which concerns on the 2nd Embodiment of this invention, (a) is the side view, (b) is the top view, (c) is A- of (b). It is sectional drawing of A line. It is a perspective view of the aluminum cable with a terminal which concerns on the 3rd Embodiment of this invention. It is a disassembled perspective view before welding of the aluminum cable with a terminal which concerns on the 3rd Embodiment of this invention. It is drawing which shows the state before welding the aluminum cable with a terminal which concerns on the 3rd Embodiment of this invention, (a) is the side view, (b) is the top view, (c) is (b). It is sectional drawing of AA in FIG. It is drawing which shows 1 process of the ultrasonic welding method which concerns on the 3rd Embodiment of this invention, (a) is the side view, (b) is the top view, (c) is A- of (b). It is sectional drawing of A line. It is a perspective view of the aluminum cable with a terminal which concerns on the 4th Embodiment of this invention. It is a disassembled perspective view before welding of the aluminum cable with a terminal which concerns on the 4th Embodiment of this invention. It is drawing which shows the state before welding the aluminum cable with a terminal which concerns on the 4th Embodiment of this invention, (a) is the side view, (b) is the top view, (c) is (b) It is sectional drawing of AA in FIG. It is drawing which shows 1 process of the ultrasonic welding method which concerns on the 4th Embodiment of this invention, (a) is the side view, (b) is the top view, (c) is A- of (b). It is sectional drawing of A line. It is a perspective view of the aluminum cable with a terminal which concerns on the 5th Embodiment of this invention. It is a figure showing a schematic structure of an ultrasonic welding machine concerning an embodiment of the invention. It is an enlarged view of the principal part X of FIG. 20 in the case of ultrasonic welding. It is a figure which shows the site | part corresponded to FIG. 21 about the conventional ultrasonic welding machine. It is a perspective view of the conventional aluminum cable with a terminal. It is a disassembled perspective view before the welding of the conventional aluminum cable with a terminal. It is drawing which shows the state before welding the conventional aluminum cable with a terminal, (a) is the side view, (b) is the top view, (c) is sectional drawing of the AA in (b). is there. It is drawing which shows 1 process of the conventional ultrasonic welding method, (a) is the side view, (b) is the top view, (c) is sectional drawing of the AA line of (b).

Explanation of symbols

1: Insulating layer 2: Aluminum wire (aluminum conductor)
4: Ring-shaped connection portion 5: Plate-shaped base portion 8: Fixed piece 9: Side walls 10, 20, 30, 40, 50, 90: Aluminum cable with terminal 11: Connection terminal 12: Aluminum stranded wire (aluminum conductor)
13: Aluminum cable 51: Heat shrinkable tube 52: Braided wire 53: Outermost layer insulator 54: Ground connection terminal 55: Crimp sleeve 70: Ultrasonic welding machine 70a: Main body 71: Base 72: Horn support 73: Anvil 74: ultrasonic horn 75: horn chip 75a: tip surface 77: ultrasonic oscillator 98: Cu layer 99: Al layer 100: clad plate 101: (with side wall) clad plate 102: clad cap 103: clad pipe 113: anvil 115 : Horn chip 115a: Tip surface

Claims (13)

A cable in which an outer periphery of a core wire is covered with an insulating layer; a connection terminal electrically connected to the core wire exposed by peeling off the insulating layer at a terminal portion of the cable; and a first metal bonded to the core wire A cable with a connection terminal comprising a layer and a composite material having a second metal layer bonded to the connection terminal,
The cable with a connection terminal, wherein the first metal layer is made of the same material as the core wire, and the second metal layer is made of the same material as the connection terminal.   The cable with connection terminals according to claim 1, wherein the bonding between the core wire and the first metal layer and the connection between the connection terminal and the second metal layer are performed by ultrasonic welding.   The cable with connection terminals according to claim 1, wherein the connection terminals are mainly composed of copper or a copper alloy.   The cable with connection terminals according to claim 1, wherein the core wire is mainly composed of aluminum or an aluminum alloy.   The cable with connection terminals according to claim 1, wherein the core wire is a stranded wire conductor made of an aluminum wire or an aluminum alloy wire.   2. The composite material according to claim 1, wherein the composite material is a composite plate material produced by laminating and rolling the material plate of the first metal layer and the material plate of the second metal layer. Cable with connection terminal.   The cable with connection terminals according to claim 1, wherein the composite material has side walls at both ends in the width direction.   The cable with connection terminals according to claim 1, wherein the composite material has a cylindrical shape.   The cable with connection terminals according to claim 1, wherein the composite material has a cap shape.   The cable with connection terminals according to any one of claims 1 to 9, wherein the entire joined portion is covered with a heat-shrinkable tube in a watertight manner. A method of manufacturing a cable with a connection terminal, comprising: a cable having an outer periphery of a core wire covered with an insulating layer; and a connection terminal electrically connected to the core wire exposed by peeling off the insulating layer at a terminal portion of the cable. There,
The connection between the core wire and the connection terminal is arranged between the core wire and the connection terminal, the first metal layer facing the core wire and made of the same kind of material as the core wire, and the connection terminal A method for manufacturing a cable with connection terminals, characterized in that the method is performed by ultrasonic welding through a composite material that faces and has a second metal layer made of the same kind of material as the connection terminals. The said core wire and surface which arrange | positioned the said core wire which peeled and exposed the said insulating layer in the terminal part of the cable which coat | covered the outer periphery of the core wire with the insulating layer, and the connecting terminal between the said core wire and the said connecting terminal And ultrasonic waves through a composite material having a first metal layer made of the same kind of material as the core wire and a second metal layer facing the connecting terminal and made of the same kind of material as the connecting terminal. An ultrasonic welding method in which ultrasonic welding is performed by a welding machine,
An ultrasonic welding method comprising applying ultrasonic vibration in a state where a tip surface of a horn tip provided in the ultrasonic welder is inclined with respect to a horizontal plane of the core wire, and performing ultrasonic welding. An ultrasonic welding machine for ultrasonically welding the core wire, which is exposed by peeling off the insulating layer in the end portion of the cable whose outer periphery is coated with an insulating layer, and a connection terminal,
The ultrasonic welding machine, wherein a tip surface of a horn tip provided in the ultrasonic welding machine has an inclination angle with respect to a horizontal plane of the core wire.

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