JP2010182492A - Terminal, and method of connecting terminal and electric wire - Google Patents

Terminal, and method of connecting terminal and electric wire Download PDF

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JP2010182492A
JP2010182492A JP2009023765A JP2009023765A JP2010182492A JP 2010182492 A JP2010182492 A JP 2010182492A JP 2009023765 A JP2009023765 A JP 2009023765A JP 2009023765 A JP2009023765 A JP 2009023765A JP 2010182492 A JP2010182492 A JP 2010182492A
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terminal
conductor
electric wire
bonding layer
layer
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JP5346607B2 (en
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Hideyuki Sagawa
英之 佐川
Toshiyuki Horikoshi
稔之 堀越
Toru Washimi
亨 鷲見
Kazuma Kuroki
一真 黒木
Hiromitsu Kuroda
洋光 黒田
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Hitachi Cable Ltd
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Hitachi Cable Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To provide an inexpensive terminal of high connection strength, capable of reducing connection resistance between conductor wires and connection resistance between a conductor and the terminal, and to provide a method of connecting the terminal and an electric wire. <P>SOLUTION: The terminal 1 includes a bonding part 4 for electric connection by bonding to the conductor 3 of the electric wire 2, and a contact part 5 for electric connection by contact with a mating terminal formed integrally with the bonding part 4, the bonding part 4 has a fusible bonding layer 6 molten at a prescribed temperature, on a face bonded to the conductor 3 of the electric wire 2, and has a base material layer 7 not molten at the temperature, on an opposite face of the fusible bonding layer 6, and the fusible bonding layer 6 is compositely integrated preliminarily with the base material layer 7. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

本発明は、導体素線間及び導体と端子間の接続抵抗が低減でき、低コストで、接続強度が高い端子及び端子と電線の接続方法に関する。   The present invention relates to a terminal and a method of connecting a terminal and an electric wire that can reduce connection resistance between conductor wires and between a conductor and a terminal, are low in cost, and have high connection strength.

例えば、ＨＥＶ（Hybrid Electric Vehicle；ハイブリッド自動車）において、電気ケーブルを電気部材に電気的に接続するとき、端子が使用される。端子は、電気ケーブルの電線に取り付けた状態で使用される。   For example, in HEV (Hybrid Electric Vehicle), a terminal is used when an electric cable is electrically connected to an electric member. A terminal is used in the state attached to the electric wire of the electric cable.

端子と電線の接続方法に関する従来技術として、以下のものが知られている。   The following are known as prior art relating to a method of connecting a terminal and an electric wire.

特許文献１においては、Ｃｕ又はＣｕ合金からなる端子及びＡｌ又はＡｌ合金からなる端子の両方を用いて、圧着方式によりこれら端子をＡｌ導体と接続する。この接続方法は、Ｃｕ又はＣｕ合金端子のスプリングバックによるＡｌ導体との接続抵抗の増加を、Ａｌ導体とのスプリングバック特性がほぼ同じであるＡｌ又はＡｌ合金端子を用いることで抑制する。   In Patent Document 1, both terminals made of Cu or Cu alloy and terminals made of Al or Al alloy are used, and these terminals are connected to the Al conductor by a crimping method. This connection method suppresses an increase in connection resistance with the Al conductor due to springback of the Cu or Cu alloy terminal by using an Al or Al alloy terminal having substantially the same springback characteristics as the Al conductor.

特許文献２においては、Ａｌ又はＣｕ、Ｃｕ合金からなる導体とＡｌ端子との接続方法として、導体素線間及び導体と端子間の隙間にニッケルペーストを充填することにより、接続抵抗の低減及び防水性の向上を図る。   In Patent Document 2, as a method of connecting a conductor made of Al, Cu, or Cu alloy to an Al terminal, nickel paste is filled between conductor wires and between the conductor and the terminal, thereby reducing connection resistance and waterproofing. To improve performance.

特許文献３においては、端子金具の導体挟持内面と非接続導体との間に多孔質の金属シートを介在させ一括圧着する。   In Patent Document 3, a porous metal sheet is interposed between a conductor holding inner surface of a terminal metal fitting and a non-connecting conductor, and then collectively crimped.

特許文献４においては、圧着部の変形に伴って容易に塑性変形しうる導電性金属層を圧着部の内側に設ける。   In patent document 4, the electroconductive metal layer which can be easily plastically deformed with a deformation | transformation of a crimping | compression-bonding part is provided inside a crimping | compression-bonding part.

特開２００７−３０５３５６号公報JP 2007-305356 A 特開２００４−２０００９４号公報JP 2004-200094 A 特開昭５６−４８０７９号公報JP 56-48079 A 特開昭６４−１４８８３号公報JP-A 64-14883

しかしながら、特許文献１の技術では、Ｃｕ又はＣｕ合金端子とＡｌ又はＡｌ合金端子を必要とするため、部品点数が多くなると共に、圧着工程数が増加するため、コストが高くなる。また、特許文献１の技術では、導体素線間の接続抵抗は低減できない。   However, since the technique of Patent Document 1 requires a Cu or Cu alloy terminal and an Al or Al alloy terminal, the number of parts increases and the number of crimping steps increases, resulting in an increase in cost. Moreover, with the technique of patent document 1, the connection resistance between conductor strands cannot be reduced.

特許文献２の技術では、導体素線間及び導体と端子間の接続抵抗は低減できるが、使用するバインダーが液性であるため、取り扱いに難点があり、工程が煩雑となる。また、特許文献２の技術では、ペーストの導電性を確保するためには、高価なＮｉ粉末を高濃度に添加する必要があるため、材料コストが高い。   In the technique of Patent Document 2, the connection resistance between the conductor strands and between the conductor and the terminal can be reduced. However, since the binder used is liquid, there are difficulties in handling and the process becomes complicated. Moreover, in the technique of patent document 2, since it is necessary to add expensive Ni powder to high concentration in order to ensure the electroconductivity of a paste, material cost is high.

特許文献３の技術では、導体と端子間の接続抵抗の低減と接続強度の向上を目的としているが、端子金具の導体挟持内面と非接続導体との間に多孔質の金属シートを介在させ一括圧着するので、部品点数が多くなると共に圧着工程が煩雑化し、コストが高くなる。   The technique of Patent Document 3 aims to reduce the connection resistance between the conductor and the terminal and improve the connection strength. However, a porous metal sheet is interposed between the conductor holding inner surface of the terminal metal fitting and the non-connection conductor. Since the pressure bonding is performed, the number of parts increases and the pressure bonding process becomes complicated, resulting in an increase in cost.

特許文献４の技術では、導電性金属層を塑性変形させることによって、加熱工程を行うことなしに導線との電気的接触を行うことを目的としているが、圧着部の変形に伴って容易に塑性変形しうる導電性金属層を圧着部の内側に設けるので、部品点数が多くなると共に圧着工程が煩雑化し、コストが高くなる。   The technique of Patent Document 4 aims to make electrical contact with the conductor without performing a heating process by plastically deforming the conductive metal layer. However, it easily becomes plastic as the crimping part is deformed. Since the deformable conductive metal layer is provided inside the crimping portion, the number of parts is increased and the crimping process becomes complicated and the cost is increased.

そこで、本発明の目的は、上記課題を解決し、導体素線間及び導体と端子間の接続抵抗が低減でき、低コストで、接続強度が高い端子及び端子と電線の接続方法を提供することにある。   Accordingly, an object of the present invention is to provide a method for connecting a terminal and a terminal to an electric wire, which can solve the above-described problems, can reduce connection resistance between conductor wires and between a conductor and a terminal, is low in cost, and has high connection strength. It is in.

上記目的を達成するために本発明の端子は、電線の導体に接合させて電気的に接続するための接合子部と、該接合子部と一体的に形成され相手端子に接触させて電気的に接続するための接触子部とを備えた端子であって、上記接合子部は、上記電線の導体と接合される面に所定の温度で溶融する溶融性接合層を有し、該溶融性接合層の反対面に上記温度で溶融しない母材層を有し、該母材層に上記溶融性接合層があらかじめ複合一体化されているものである。   In order to achieve the above-mentioned object, the terminal of the present invention is formed by connecting a connector part to be electrically connected to a conductor of an electric wire, and an electrical terminal formed integrally with the connector part and brought into contact with a mating terminal. A terminal having a contact portion for connecting to the conductor, the joint portion having a meltable joining layer that melts at a predetermined temperature on a surface to be joined to the conductor of the electric wire, A base material layer that does not melt at the above temperature is provided on the opposite surface of the joining layer, and the meltable joining layer is combined and integrated in advance with the base material layer.

上記溶融性接合層がＺｎ−Ａｌ合金（Ａｌが０〜３０ｍａｓｓ％；０％は除く）、Ｓｎ−Ｚｎ合金（Ｚｎが０〜４０ｍａｓｓ％；０％は除く）、Ｃｄ−Ｚｎ合金（Ｚｎが０〜９０ｍａｓｓ％；０％は除く）のいずれかからなってもよい。   The meltable bonding layer is composed of a Zn-Al alloy (Al is 0 to 30 mass%; excluding 0%), a Sn-Zn alloy (Zn is 0 to 40 mass%; excluding 0%), a Cd-Zn alloy (Zn is 0). ~ 90 mass%; except 0%).

上記母材層がＡｌ又はＡｌ合金からなってもよい。   The base material layer may be made of Al or an Al alloy.

また、本発明の端子と電線の接続方法は、電線の導体に接合させて電気的に接続するための接合子部と該接合子部と一体的に形成され相手端子に接触させて電気的に接続するための接触子部とを備えた端子と、上記電線とを接続する方法であって、上記接合子部の上記電線の導体に接合される面に所定の温度で溶融する溶融性接合層を上記温度で溶融しない母材層とあらかじめ複合一体化させて設けておき、上記接合子部の溶融性接合層を上記電線の導体に臨ませ、これら溶融性接合層及び導体を上記温度以上に加熱しながら圧縮加工することにより、上記接合子部の溶融性接合層と上記電線の導体とを接合させるものである。   In addition, the method of connecting the terminal and the electric wire according to the present invention includes a connector portion for connecting and electrically connecting to the conductor of the electric wire, and the contact portion formed integrally with the connector portion. A fusible bonding layer for melting a terminal at a predetermined temperature on a surface to be bonded to a conductor of the electric wire of the connector portion, wherein the terminal includes a contact portion for connection and the electric wire. Are preliminarily combined with a base material layer that does not melt at the above temperature, the fusible bonding layer of the above-mentioned connector part is exposed to the conductor of the above-mentioned electric wire, and the above-mentioned fusible bonding layer and the conductor are brought to the above temperature or more. By compressing while heating, the fusible bonding layer of the connector part and the conductor of the electric wire are bonded.

上記圧縮加工の際に、上記接合子部を上記電線の導体の輪郭に倣う形状に整形してもよい。   During the compression processing, the connector portion may be shaped into a shape that follows the contour of the conductor of the electric wire.

上記電線の導体がＡｌ又はＡｌ合金からなってもよい。   The conductor of the electric wire may be made of Al or an Al alloy.

本発明は次の如き優れた効果を発揮する。   The present invention exhibits the following excellent effects.

（１）導体素線間及び導体と端子間の接続抵抗が低減できる。   (1) Connection resistance between conductor wires and between conductors and terminals can be reduced.

（２）低コストである。   (2) Low cost.

（３）接続強度が高い。   (3) High connection strength.

本発明の一実施形態を示す端子と電線の斜視図である。It is a perspective view of the terminal and electric wire which show one embodiment of the present invention. 本発明の一実施形態を示す端子と電線の斜視図である。It is a perspective view of the terminal and electric wire which show one embodiment of the present invention. 本発明の一実施形態を示す端子と電線の斜視図である。It is a perspective view of the terminal and electric wire which show one embodiment of the present invention. 本発明の一実施形態を示す端子と電線の斜視図である。It is a perspective view of the terminal and electric wire which show one embodiment of the present invention. 本発明の端子と電線を接続した後の接合子部の断面図である。It is sectional drawing of the connector part after connecting the terminal and electric wire of this invention.

以下、本発明の一実施形態を添付図面に基づいて詳述する。   Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

図１〜図４に示されるように、本発明に係る端子１は、電線２の導体３に接合させて電気的に接続するための接合子部４と、接合子部４と一体的に形成され相手端子（図示せず）に接触させて電気的に接続するための接触子部５とを備えた端子１であって、接合子部４は、電線２の導体３と接合される面（以下、内面という）に所定の温度で溶融する溶融性接合層６を有し、溶融性接合層６の反対面（以下、外面という）に上記温度で溶融しない母材層７を有し、母材層７に溶融性接合層６があらかじめ複合一体化されているものである。   As shown in FIGS. 1 to 4, the terminal 1 according to the present invention is formed integrally with a joint portion 4 for joining and electrically connecting to a conductor 3 of an electric wire 2, and the joint portion 4. The contact 1 is provided with a contact portion 5 to be brought into contact with and electrically connected to a mating terminal (not shown), and the joint portion 4 is a surface to be joined to the conductor 3 of the electric wire 2 ( (Hereinafter referred to as the inner surface) has a meltable bonding layer 6 that melts at a predetermined temperature, and has a base material layer 7 that does not melt at the above temperature on the opposite surface (hereinafter referred to as the outer surface) of the meltable bonding layer 6. The meltable bonding layer 6 is combined and integrated in advance with the material layer 7.

本発明の端子１は、内面に溶融性接合層６を有しており、その溶融性接合層６が外面の母材層７にあらかじめ複合一体化されていることを特徴とする。溶融性接合層６は所定の溶融温度（＝固相線の温度）で溶融する材料からなり、母材層７は溶融性接合層６の溶融温度では溶融しない材料からなる。溶融性接合層６の材料は、いわゆるろう材である。   The terminal 1 of the present invention has a meltable bonding layer 6 on the inner surface, and the meltable bonding layer 6 is preliminarily composite-integrated with a base material layer 7 on the outer surface. The meltable bonding layer 6 is made of a material that melts at a predetermined melting temperature (= solidus temperature), and the base material layer 7 is made of a material that does not melt at the melting temperature of the meltable bonding layer 6. The material of the meltable bonding layer 6 is a so-called brazing material.

本発明の端子１は、溶融性接合層６と母材層７とを複合一体化させたクラッド材を作製し、そのクラッド材を加工して端子１を製造したものである。   The terminal 1 of the present invention is produced by manufacturing a clad material in which the meltable bonding layer 6 and the base material layer 7 are integrated and processing the clad material.

本発明の端子１と電線２とを接続する方法は、接合子部４の溶融性接合層６を電線２の導体３に臨ませ、溶融性接合層６及び導体３を溶融性接合層６の溶融温度以上に加熱しながら圧縮加工することにより、溶融性接合層６と導体３とを接合、一体化させることを特徴とする。圧縮加工の方法は、プレス加工、ロータリスエージ加工などがある。例えば、所定の温度に加熱した圧縮金型を用いて熱間プレスをすることにより、圧縮加工を行うとよい。   In the method of connecting the terminal 1 and the electric wire 2 of the present invention, the fusible bonding layer 6 of the connector portion 4 faces the conductor 3 of the electric wire 2, and the fusible bonding layer 6 and the conductor 3 are connected to the fusible bonding layer 6. It is characterized in that the meltable bonding layer 6 and the conductor 3 are bonded and integrated by compressing while heating to a melting temperature or higher. Compression methods include press working and rotary swaging. For example, the compression processing may be performed by hot pressing using a compression mold heated to a predetermined temperature.

溶融性接合層６の材料は、所定の溶融温度で溶融する材料であり、Ｚｎ−Ａｌ合金（Ａｌが０〜３０ｍａｓｓ％；０％は除く）、Ｓｎ−Ｚｎ合金（Ｚｎが０〜４０ｍａｓｓ％；０％は除く）、Ｃｄ−Ｚｎ合金（Ｚｎが０〜９０ｍａｓｓ％；０％は除く）などが好ましい。   The material of the meltable bonding layer 6 is a material that melts at a predetermined melting temperature, and is a Zn-Al alloy (Al is 0 to 30 mass%; excluding 0%), a Sn-Zn alloy (Zn is 0 to 40 mass%; Cd—Zn alloy (Zn is 0 to 90 mass%; 0% is excluded) and the like are preferable.

母材層７の材料は、Ａｌ又はＡｌ合金が好ましい。   The material of the base material layer 7 is preferably Al or an Al alloy.

端子１は、溶融性接合層６と母材層７とで構成される複合材である。溶融性接合層６と母材層７を複合一体化する方法としては、冷間あるいは熱間圧着によるクラッド法、めっき法、スパッタ法などが適用でき、その他の方法でも良い。   The terminal 1 is a composite material composed of a meltable bonding layer 6 and a base material layer 7. As a method of integrating the meltable bonding layer 6 and the base material layer 7 together, a clad method, a plating method, a sputtering method, etc. by cold or hot press bonding can be applied, and other methods may be used.

母材層７の材料と溶融性接合層６の材料の組み合わせとして、母材層７の材料がＣｕに対して溶融性接合層６の材料がリン銅ろう、母材層７の材料がＡｌに対して溶融性接合層６の材料が低温用のＺｎ−Ａｌ合金、Ｓｎ−Ｚｎ合金、Ｃｄ−Ｚｎ合金などがある。また、ＡｌにＳｉ、Ｆｅ、Ｃｕ、Ｍｎ、Ｍｇ、Ｚｎのうち１種以上の元素を含む材料と、Ａｌ母材があらかじめ複合一体化されたアルミニウムブレージングシートを用いてもよい。   As a combination of the material of the base material layer 7 and the material of the fusible bonding layer 6, the material of the base material layer 7 is Cu with respect to the material of the fusible bonding layer 6 and the material of the base material layer 7 is Al. On the other hand, the material of the meltable bonding layer 6 is a low-temperature Zn—Al alloy, Sn—Zn alloy, Cd—Zn alloy, or the like. Alternatively, an aluminum brazing sheet in which a material containing one or more elements selected from Al, Si, Fe, Cu, Mn, Mg, and Zn and an Al base material are combined and integrated in advance may be used.

電線２の導体３には、Ａｌ導体、Ａｌ合金導体などが適用できる。Ｃｕ導体、Ｃｕ合金導体でもよい。比重の軽いＡｌ導体又はＡｌ合金導体を使用した場合、Ｃｕ導体又はＣｕ合金導体を使用した場合と比べて軽量化が可能である。   An Al conductor, an Al alloy conductor, or the like can be applied to the conductor 3 of the electric wire 2. A Cu conductor or a Cu alloy conductor may be used. When an Al conductor or an Al alloy conductor having a low specific gravity is used, the weight can be reduced as compared with the case where a Cu conductor or a Cu alloy conductor is used.

電線２は、複数本のＡｌ導体素線９を撚り合わせた導体３と、導体３を覆う絶縁層１０とからなる。絶縁層１０には、ポリプロピレン樹脂、ポリ塩化ビニル樹脂、ポリエチレン樹脂、フッ素系樹脂などを用いる。   The electric wire 2 includes a conductor 3 obtained by twisting a plurality of Al conductor strands 9 and an insulating layer 10 that covers the conductor 3. For the insulating layer 10, polypropylene resin, polyvinyl chloride resin, polyethylene resin, fluorine resin, or the like is used.

図１〜図４に示した端子１の接触子部５は、中央に貫通穴（ボルト穴）１１を有する円盤状に形成される。その接触子部５の一部から径方向に所定の長さ接合子部４が延びている。端子１に接続する電線２は、絶縁層１０が剥かれて導体３が所定の長さ露出される。   The contact portion 5 of the terminal 1 shown in FIGS. 1 to 4 is formed in a disk shape having a through hole (bolt hole) 11 in the center. A connector 4 having a predetermined length extends in a radial direction from a part of the contact 5. In the electric wire 2 connected to the terminal 1, the insulating layer 10 is peeled off and the conductor 3 is exposed for a predetermined length.

図１に示した端子１は、上端子片１ａと下端子片１ｂに分割形成されている。上端子片１ａと下端子片１ｂは、それぞれ接合子部４と接触子部５を有する。接合子部４は平板状に形成される。この端子１と電線２を接続する際には、上端子片１ａは溶融性接合層６が導体３に接するよう溶融性接合層６の面を下に向け、下端子片１ｂは溶融性接合層６が導体３に接するよう溶融性接合層６の面を上に向ける。上端子片１ａと下端子片１ｂで導体３を挟み、図示しない加熱圧縮手段により、上端子片１ａと下端子片１ｂを上下から加圧することにより、接合子部４を導体３の輪郭に倣う形状に整形しつつ、同時に、溶融性接合層６を固相線温度以上の温度に加熱し、溶融性接合層６を溶融させることにより、上端子片１ａと下端子片１ｂと導体３とを接合させる。加圧と加熱は同時に行ってもよいし、加圧後に加熱してもよい。   The terminal 1 shown in FIG. 1 is divided into an upper terminal piece 1a and a lower terminal piece 1b. The upper terminal piece 1a and the lower terminal piece 1b have a connector part 4 and a contact part 5 respectively. The connector part 4 is formed in a flat plate shape. When the terminal 1 and the electric wire 2 are connected, the upper terminal piece 1a faces the surface of the fusible bonding layer 6 so that the fusible bonding layer 6 is in contact with the conductor 3, and the lower terminal piece 1b is a fusible bonding layer. The surface of the meltable bonding layer 6 is directed upward so that 6 contacts the conductor 3. The conductor 3 is sandwiched between the upper terminal piece 1a and the lower terminal piece 1b, and the upper terminal piece 1a and the lower terminal piece 1b are pressed from above and below by a heating and compression means (not shown), so that the connector portion 4 follows the contour of the conductor 3. At the same time, the meltable bonding layer 6 is heated to a temperature equal to or higher than the solidus temperature while being shaped into a shape, and the meltable bonding layer 6 is melted, whereby the upper terminal piece 1a, the lower terminal piece 1b, and the conductor 3 are Join. Pressurization and heating may be performed simultaneously, or after pressurization.

図２に示した端子１は、上端子片１ａと下端子片１ｂに分割形成されており、さらに、上端子片１ａと下端子片１ｂは接合子部４の溶融性接合層６の面が凹面となるように、接合子部４が長軸に沿って導体３の外周の曲率に合わせて円弧状に曲げられている。これにより、上端子片１ａと下端子片１ｂは、導体３に対して位置ずれがし難くなり、導体３の中心線と端子１の接合子部４の中心線が重なるように位置決めすることができる。また、図２の上端子片１ａと下端子片１ｂは、導体３との接触面積が図１のものより大きい。   The terminal 1 shown in FIG. 2 is divided into an upper terminal piece 1a and a lower terminal piece 1b. Further, the upper terminal piece 1a and the lower terminal piece 1b are formed so that the surface of the meltable bonding layer 6 of the connector portion 4 is the same. The connector portion 4 is bent in an arc shape along the major axis in accordance with the curvature of the outer periphery of the conductor 3 so as to be a concave surface. Accordingly, the upper terminal piece 1a and the lower terminal piece 1b are not easily displaced with respect to the conductor 3, and can be positioned so that the center line of the conductor 3 and the center line of the connector portion 4 of the terminal 1 overlap. it can. Further, the upper terminal piece 1a and the lower terminal piece 1b of FIG. 2 have a larger contact area with the conductor 3 than that of FIG.

図３に示した端子１は、接合子部４が中空管状に形成されている。この接合子部４となる中空管１２の接触子部５側の端部は開放されている。図３の端子１と電線２を接続するとき、中空管１２の接触子部５とは反対側の端部から中空管１２内へ導体３を挿入し、図示しない加熱圧縮手段により、中空管１２を周囲から加圧しつつ、同時に、溶融性接合層６を固相線温度以上の温度に加熱し、溶融性接合層６を溶融させることにより、中空管１２と導体３とを接合させる。中空管１２の接触子部５側の端部は開放されているが、導体３の周囲で溶融性接合層６が溶融して導体素線９間に浸透するので、接触子部５側から電線２の内部に水が浸入することが防止され、防水性が向上する。   As for the terminal 1 shown in FIG. 3, the connector part 4 is formed in the hollow tubular shape. The end of the hollow tube 12 serving as the connector portion 4 on the contact portion 5 side is open. When connecting the terminal 1 and the electric wire 2 in FIG. 3, the conductor 3 is inserted into the hollow tube 12 from the end opposite to the contact portion 5 of the hollow tube 12, The hollow tube 12 and the conductor 3 are joined by simultaneously pressurizing the hollow tube 12 from the surroundings and simultaneously heating the meltable bonding layer 6 to a temperature equal to or higher than the solidus temperature to melt the meltable bonding layer 6. Let Although the end of the hollow tube 12 on the contact portion 5 side is open, the meltable bonding layer 6 melts and penetrates between the conductor strands 9 around the conductor 3, so that from the contact portion 5 side. Water is prevented from entering the inside of the electric wire 2, and waterproofness is improved.

図４に示した端子１は、接合子部４が中空管状に形成されており、さらに、接合子部４となる中空管１２の接触子部５側の端部はあらかじめ潰すなどして閉塞されている。図示しない中空管１２の反対側の端部は開放されている。図４の端子１と電線２を接続するとき、中空管１２の反対側の端部から中空管１２内へ導体３を挿入し、図示しない加熱圧縮手段により、中空管１２を周囲から加圧しつつ、同時に、溶融性接合層６を固相線温度以上の温度に加熱し、溶融性接合層６を溶融させることにより、中空管１２と導体３とを接合させる。中空管１２の接触子部５側の端部が閉塞されているため、接触子部５側から電線２の内部に水が浸入することが防止され、防水性が向上する。   In the terminal 1 shown in FIG. 4, the connector portion 4 is formed in a hollow tubular shape, and the end portion of the hollow tube 12 to be the connector portion 4 on the side of the contact portion 5 is previously closed and closed. Has been. The opposite end of the hollow tube 12 (not shown) is open. When connecting the terminal 1 and the electric wire 2 in FIG. 4, the conductor 3 is inserted into the hollow tube 12 from the opposite end of the hollow tube 12, and the hollow tube 12 is removed from the surroundings by heating compression means (not shown). At the same time, the meltable bonding layer 6 is heated to a temperature equal to or higher than the solidus temperature and the meltable bonding layer 6 is melted, thereby joining the hollow tube 12 and the conductor 3. Since the end portion of the hollow tube 12 on the contact portion 5 side is closed, water is prevented from entering the inside of the electric wire 2 from the contact portion 5 side, and waterproofness is improved.

図５に、端子１と電線２を接続した後の接合子部４の断面を示す。端子１は、接合子部４の内面に溶融性接合層６を有するため、溶融した溶融性接合層６が端子１と導体３の間に浸透して固まる。このため、接続後は、端子１と導体３が密に接合され、端子１と導体３との接続抵抗が低減されると共に、接続強度が高くなる。また、溶融した溶融性接合層６が導体素線９同士の間に浸透して固まることから、導体素線９同士間が密に接合され、導体素線９同士間の接続抵抗が低減される。したがって、導体３が接続抵抗増大の原因となる強固な酸化膜を形成するＡｌ導体又はＡｌ合金導体であったり、母材層７がＡｌ又はＡｌ合金であっても、本発明の端子１を用いれば接続抵抗が低減されるという高い効果が発揮される。   In FIG. 5, the cross section of the connector part 4 after connecting the terminal 1 and the electric wire 2 is shown. Since the terminal 1 has the fusible bonding layer 6 on the inner surface of the connector portion 4, the molten fusible bonding layer 6 penetrates between the terminal 1 and the conductor 3 and hardens. For this reason, after the connection, the terminal 1 and the conductor 3 are closely joined, the connection resistance between the terminal 1 and the conductor 3 is reduced, and the connection strength is increased. Moreover, since the meltable meltable bonding layer 6 penetrates between the conductor strands 9 and hardens, the conductor strands 9 are closely joined together, and the connection resistance between the conductor strands 9 is reduced. . Therefore, even if the conductor 3 is an Al conductor or Al alloy conductor that forms a strong oxide film that causes an increase in connection resistance, or the base material layer 7 is Al or Al alloy, the terminal 1 of the present invention can be used. Thus, a high effect of reducing the connection resistance is exhibited.

さらに、接続後の端子１と導体３との接合界面は、圧縮による接合に加え、溶融して固まった溶融性接合層６を介した強固な金属接合が形成されるため、接続強度が高くなり、機械的耐久性などの信頼性が向上する。   Furthermore, since the joint interface between the terminal 1 and the conductor 3 after the connection forms a strong metal joint via the meltable joint layer 6 which is melted and hardened in addition to the joint by compression, the connection strength is increased. Reliability such as mechanical durability is improved.

また、本発明では、溶融性接合層６が母材層７にあらかじめ複合一体化されているため、作業性に優れていると共に、ペースト材などを塗布する工程を必要とせず、低コストで端子１と電線２を接続することができる。また、端子１の圧縮と溶融性接合層６の溶融が同時に行われるため、低コストで端子１と電線２を接続することができる。   Further, in the present invention, the meltable bonding layer 6 is integrated and integrated with the base material layer 7 in advance, so that it is excellent in workability and does not require a step of applying a paste material or the like, and is low in cost. 1 and the electric wire 2 can be connected. Moreover, since the compression of the terminal 1 and the melting of the meltable bonding layer 6 are performed simultaneously, the terminal 1 and the electric wire 2 can be connected at low cost.

図１〜図３の端子１では、溶融性接合層６と母材層７とを複合一体化させたクラッド材を作製し、そのクラッド材を加工して端子１を製造しているため、端子１の片面全面に溶融性接合層６があることになり、相手端子に接触させる接触子部５にも溶融性接合層６が表れる。図１、図２の端子１では、２つの端子１で相手端子を上下から挟んで端子１と相手端子とを圧着するとき、加熱をすることにより、溶融性接合層６を溶融させて強固に接合させることができる。図３の端子１では、溶融性接合層６が相手端子に直接接するようにする。例えば、溶融性接合層６の材料をＳｎ−Ｚｎ合金とし、母材層７の材料をＡｌとしたとき、溶融性接合層６の接続抵抗がＡｌよりも低いため、相手端子への接続信頼性を高めることができる。   In the terminal 1 of FIGS. 1 to 3, since the clad material in which the fusible bonding layer 6 and the base material layer 7 are combined and integrated is manufactured, and the terminal 1 is manufactured by processing the clad material, the terminal 1 1 has the meltable bonding layer 6 on the entire surface of one surface, and the meltable bonding layer 6 appears also in the contact portion 5 that is brought into contact with the mating terminal. 1 and 2, when the terminal 1 and the mating terminal are pressure-bonded with the two terminals 1 sandwiching the mating terminal from above and below, the meltable bonding layer 6 is melted and strengthened by heating. Can be joined. In the terminal 1 of FIG. 3, the meltable bonding layer 6 is directly in contact with the mating terminal. For example, when the material of the fusible bonding layer 6 is Sn—Zn alloy and the material of the base material layer 7 is Al, the connection resistance of the fusible bonding layer 6 is lower than that of Al. Can be increased.

［実施例１］
母材層７となる純Ａｌ条（厚さ４．０ｍｍ）と溶融性接合層６となるＺｎ−Ａｌ合金条（厚さ２．５ｍｍ）を熱間圧延法により一体化させてクラッド材を作製した。このクラッド材を総板厚１．５ｍｍになるように圧延加工を行った。その圧延したクラッド材を６０ｍｍ×２５ｍｍに切り出した。このクラッド材切り出し片に、接触子部５のための貫通穴１１を加工した。その後、この貫通穴１１を加工したクラッド材切り出し片の接合子部４となる部分を湾曲加工し、図２の端子１を得た。導体３は、導体素線９であるφ１．０ｍｍの純Ａｌ素線を１９本撚り合わせたもの（導体断面積１５ｍｍ2）を用いた。端子１の溶融性接合層６が導体３と接するように上端子片１ａと下端子片１ｂで導体３を挟んだ後、Ｚｎ−Ａｌ合金の固相線温度（３８２℃）以上の３９０℃で加熱しながら、圧縮加工を行った。圧縮加工は、所定の温度に加熱した圧縮金型を用いて熱間プレスすることにより行った。 [Example 1]
A pure Al strip (thickness 4.0 mm) to be the base material layer 7 and a Zn-Al alloy strip (thickness 2.5 mm) to be the meltable bonding layer 6 are integrated by hot rolling to produce a clad material. did. This clad material was rolled so as to have a total thickness of 1.5 mm. The rolled clad material was cut out to 60 mm × 25 mm. A through hole 11 for the contact portion 5 was processed in the cut piece of the clad material. Thereafter, the portion to be the connector portion 4 of the clad material cut piece obtained by processing the through hole 11 was curved to obtain the terminal 1 of FIG. As the conductor 3, a conductor strand 9 of 19 twisted pure Al strands with a diameter of 1.0 mm (conductor cross-sectional area 15 mm 2 ) was used. After the conductor 3 is sandwiched between the upper terminal piece 1a and the lower terminal piece 1b so that the fusible bonding layer 6 of the terminal 1 is in contact with the conductor 3, it is at 390 ° C. above the solidus temperature (382 ° C.) of the Zn—Al alloy. Compression processing was performed while heating. The compression process was performed by hot pressing using a compression mold heated to a predetermined temperature.

［実施例２］
母材層７となる純Ａｌ条（厚さ４．０ｍｍ）と溶融性接合層６となるＳｎ−Ｚｎ合金条（厚さ２．５ｍｍ）を熱間圧延法により一体化させてクラッド材を作製した。このクラッド材を総板厚１．５ｍｍになるように圧延加工を行った。その圧延したクラッド材を６０ｍｍ×２５ｍｍに切り出した。このクラッド材切り出し片に、接触子部５のための貫通穴１１を加工した。その後、この貫通穴１１を加工したクラッド材切り出し片の接合子部４となる部分を湾曲加工し、図２の端子１を得た。導体３は、導体素線９であるφ１．０ｍｍの純Ａｌ素線を１９本撚り合わせたもの（導体断面積１５ｍｍ2）を用いた。端子１の溶融性接合層６が導体３と接するように上端子片１ａと下端子片１ｂで導体３を挟んだ後、Ｓｎ−Ｚｎ合金の固相線温度（１９８℃）以上の２１０℃で加熱しながら、圧縮加工を行った。 [Example 2]
A pure Al strip (thickness 4.0 mm) to be the base material layer 7 and an Sn—Zn alloy strip (thickness 2.5 mm) to be the meltable bonding layer 6 are integrated by hot rolling to produce a clad material. did. This clad material was rolled so as to have a total thickness of 1.5 mm. The rolled clad material was cut out to 60 mm × 25 mm. A through hole 11 for the contact portion 5 was processed in the cut piece of the clad material. Thereafter, the portion to be the connector portion 4 of the clad material cut piece obtained by processing the through hole 11 was curved to obtain the terminal 1 of FIG. As the conductor 3, a conductor strand 9 of 19 twisted pure Al strands with a diameter of 1.0 mm (conductor cross-sectional area 15 mm 2 ) was used. After the conductor 3 is sandwiched between the upper terminal piece 1a and the lower terminal piece 1b so that the meltable bonding layer 6 of the terminal 1 is in contact with the conductor 3, it is at 210 ° C., which is equal to or higher than the solidus temperature (198 ° C.) of the Sn—Zn alloy. Compression processing was performed while heating.

［実施例３］
母材層７となる純Ａｌ条（厚さ４．０ｍｍ）と溶融性接合層６となるＳｎ−Ｚｎ合金条（厚さ２．５ｍｍ）を熱間圧延法により一体化させてクラッド材を作製した。このクラッド材を総板厚１．５ｍｍになるように圧延加工を行った。その圧延したクラッド材を外径がφ１０ｍｍの管状に加工した。このクラッド材管を６０ｍｍの長さに切り出した後、その片端を潰して接触子部５とし、接触子部５に貫通穴１１を加工し、図４の端子１を得た。導体３は、導体素線９であるφ１．０ｍｍの純Ａｌ素線を１９本撚り合わせたもの（導体断面積１５ｍｍ2）を用いた。端子１の溶融性接合層６が導体３と接するように上端子片１ａと下端子片１ｂで導体３を挟んだ後、Ｓｎ−Ｚｎ合金の固相線温度（１９８℃）以上の２１０℃で加熱しながら、圧縮加工を行った。 [Example 3]
A pure Al strip (thickness 4.0 mm) to be the base material layer 7 and an Sn—Zn alloy strip (thickness 2.5 mm) to be the meltable bonding layer 6 are integrated by hot rolling to produce a clad material. did. This clad material was rolled so as to have a total thickness of 1.5 mm. The rolled clad material was processed into a tube having an outer diameter of φ10 mm. After this clad material tube was cut out to a length of 60 mm, one end of the clad material tube was crushed to form the contact portion 5, and the through hole 11 was processed in the contact portion 5 to obtain the terminal 1 of FIG. 4. As the conductor 3, a conductor strand 9 of 19 twisted pure Al strands with a diameter of 1.0 mm (conductor cross-sectional area 15 mm 2 ) was used. After the conductor 3 is sandwiched between the upper terminal piece 1a and the lower terminal piece 1b so that the meltable bonding layer 6 of the terminal 1 is in contact with the conductor 3, it is at 210 ° C., which is equal to or higher than the solidus temperature (198 ° C.) of the Sn—Zn alloy. Compression processing was performed while heating.

［実施例４］
母材層７となる純Ａｌ条（厚さ４．０ｍｍ）と溶融性接合層６となるＣｄ−Ｚｎ合金条（厚さ２．５ｍｍ）を熱間圧延法により一体化させてクラッド材を作製した。このクラッド材を総板厚１．５ｍｍになるように圧延加工を行った。その圧延したクラッド材を６０ｍｍ×２５ｍｍに切り出した。このクラッド材切り出し片に、接触子部５のための貫通穴１１を加工した。その後、この貫通穴１１を加工したクラッド材切り出し片の接合子部４となる部分を湾曲加工し、図２の端子１を得た。導体３は、導体素線９であるφ１．０ｍｍの純Ａｌ素線を１９本撚り合わせたもの（導体断面積１５ｍｍ2）を用いた。端子１の溶融性接合層６が導体３と接するように上端子片１ａと下端子片１ｂで導体３を挟んだ後、Ｃｄ−Ｚｎ合金の固相線温度（２６６℃）以上の２８０℃で加熱しながら、圧縮加工を行った。 [Example 4]
A pure Al strip (thickness: 4.0 mm) serving as the base material layer 7 and a Cd—Zn alloy strip (thickness: 2.5 mm) serving as the meltable bonding layer 6 are integrated by hot rolling to produce a clad material. did. This clad material was rolled so as to have a total thickness of 1.5 mm. The rolled clad material was cut out to 60 mm × 25 mm. A through hole 11 for the contact portion 5 was processed in the cut piece of the clad material. Thereafter, the portion to be the connector portion 4 of the clad material cut piece obtained by processing the through hole 11 was curved to obtain the terminal 1 of FIG. As the conductor 3, a conductor strand 9 of 19 twisted pure Al strands with a diameter of 1.0 mm (conductor cross-sectional area 15 mm 2 ) was used. After the conductor 3 is sandwiched between the upper terminal piece 1a and the lower terminal piece 1b so that the meltable bonding layer 6 of the terminal 1 is in contact with the conductor 3, it is at 280 ° C. which is equal to or higher than the solidus temperature (266 ° C.) of the Cd—Zn alloy. Compression processing was performed while heating.

［実施例５］
母材層７となる純Ｃｕ条（厚さ４．０ｍｍ）と溶融性接合層６となるＣｕ−Ｐ−Ａｇ合金条（厚さ２．５ｍｍ）を熱間圧延法により一体化させてクラッド材を作製した。このクラッド材を総板厚１．５ｍｍになるように圧延加工を行った。その圧延したクラッド材を６０ｍｍ×２５ｍｍに切り出した。このクラッド材切り出し片に、接触子部５のための貫通穴１１を加工した。その後、この貫通穴１１を加工したクラッド材切り出し片の接合子部４となる部分を湾曲加工し、図２の端子１を得た。導体３は、導体素線９であるφ１．０ｍｍの純Ｃｕ素線を１９本撚り合わせたもの（導体断面積１５ｍｍ2）を用いた。端子１の溶融性接合層６が導体３と接するように上端子片１ａと下端子片１ｂで導体３を挟んだ後、Ｃｕ−Ｐ−Ａｇ合金の固相線温度（６４５℃）以上の６６０℃で加熱しながら、圧縮加工を行った。 [Example 5]
A clad material obtained by integrating a pure Cu strip (thickness 4.0 mm) as a base material layer 7 and a Cu-P-Ag alloy strip (thickness 2.5 mm) as a meltable bonding layer 6 by hot rolling. Was made. This clad material was rolled so as to have a total thickness of 1.5 mm. The rolled clad material was cut out to 60 mm × 25 mm. A through hole 11 for the contact portion 5 was processed in the cut piece of the clad material. Thereafter, the portion to be the connector portion 4 of the clad material cut piece obtained by processing the through hole 11 was curved to obtain the terminal 1 of FIG. The conductor 3 used was a conductor strand 9 of 19 twisted pure Cu strands of φ1.0 mm (conductor cross-sectional area 15 mm 2 ). After the conductor 3 is sandwiched between the upper terminal piece 1a and the lower terminal piece 1b so that the fusible bonding layer 6 of the terminal 1 is in contact with the conductor 3, it is 660 which is equal to or higher than the solidus temperature (645 ° C.) of the Cu—P—Ag alloy. While being heated at 0 ° C., compression processing was performed.

［比較例１］
図３の端子１と同様の形状をした純Ａｌ製の端子（肉厚１．５ｍｍ）の中空管状の接合子部内に純Ａｌ導体を挿入し、圧縮加工を行った。導体は、φ１．０ｍｍの純Ａｌ素線を１９本撚り合わせたもの（導体断面積１５ｍｍ2）を用いた。 [Comparative Example 1]
A pure Al conductor was inserted into a hollow tubular connector part of a pure Al terminal (thickness 1.5 mm) having the same shape as that of the terminal 1 in FIG. The conductor used was 19 twisted pure Al strands of φ1.0 mm (conductor cross-sectional area 15 mm 2 ).

［比較例２］
図３の端子１と同様の形状をした純Ｃｕ製の端子（肉厚１．５ｍｍ）の中空管状の接合子部内に純Ｃｕ導体を挿入し、圧縮加工を行った。導体は、φ１．０ｍｍの純Ｃｕ素線を１９本撚り合わせたもの（導体断面積１５ｍｍ2）を用いた。 [Comparative Example 2]
A pure Cu conductor was inserted into a hollow tubular connector part of a pure Cu terminal (thickness 1.5 mm) having the same shape as the terminal 1 in FIG. As the conductor, 19 twisted pure Cu strands with a diameter of 1.0 mm (conductor cross-sectional area 15 mm 2 ) were used.

［従来例１］
特許文献１と同様の片面が開放型のオープンタイプの純Ｃｕ製端子（肉厚１．５ｍｍ）上に純Ｃｕ導体を設置し、圧着により、純Ｃｕ製端子と純Ｃｕ導体を接続した。さらに、純Ｃｕ製端子のスプリングバック抑制を目的としたＡｌ製端子を、上記純Ｃｕ製端子を上から覆うように圧着した。導体は、φ１．０ｍｍの純Ａｌ素線を１９本撚り合わせたもの（導体断面積１５ｍｍ2）を用いた。 [Conventional example 1]
A pure Cu conductor was placed on an open type pure Cu terminal (thickness: 1.5 mm) having an open side similar to that of Patent Document 1, and the pure Cu terminal and the pure Cu conductor were connected by pressure bonding. Further, an Al terminal intended to suppress the spring back of the pure Cu terminal was crimped so as to cover the pure Cu terminal from above. The conductor used was 19 twisted pure Al strands of φ1.0 mm (conductor cross-sectional area 15 mm 2 ).

［従来例２］
図３の端子１と同様の形状をした純Ｃｕ製の端子（肉厚１．５ｍｍ）の中空管状の接合子部内に導電性接着材（Ｎｉペースト）を注入し、その後、接合子部内に純Ａｌ導体を挿入し、圧縮加工を行った。導体は、φ１．０ｍｍの純Ａｌ素線を１９本撚り合わせたもの（導体断面積１５ｍｍ2）を用いた。 [Conventional example 2]
A conductive adhesive (Ni paste) is injected into a hollow tubular connector part of a pure Cu terminal (thickness 1.5 mm) having the same shape as that of the terminal 1 in FIG. 3, and then pure metal is injected into the connector part. An Al conductor was inserted and compression processing was performed. The conductor used was 19 twisted pure Al strands of φ1.0 mm (conductor cross-sectional area 15 mm 2 ).

表１は、上記の各実施例、比較例、従来例に基づく端子及び端子と電線の接続方法について、端子と導体の接続強度（初期値、塩水噴霧試験後の値）、接続抵抗（初期値、塩水噴霧試験後の値）、接続に関わる材料・工程を含めたコストを比較し、総合評価を行った結果を示したものである。端子と導体の接続強度の試験は、引っ張り試験機で端子と導体を掴み、引っ張り試験にて導体が破断するかまたは端子から導体が引き抜けるときの引っ張り応力を測定し、導体のみを引っ張り試験したときの引っ張り応力に対して９０％以上の引っ張り応力であれば◎、８５％以上９０％未満であれば○、７５％以上８５％未満であれば△という判定をした。接続抵抗測定は、直流４端子法を用い、接続部に１０Ａの通電条件で行った。接続抵抗が３０μΩ以下であれば◎、３０μΩより大６０μΩ以下であれば○、６０μΩより大９０μΩ以下であれば△、９０μΩより大であれば×という判定をした。これらの端子と導体の接続強度の試験と接続抵抗測定を塩水噴霧試験を行う前と行った後に実施し、初期値と塩水噴霧試験後の値とを得た。塩水噴霧試験は、ＪＩＳ Ｃ６００６８−２−１１に準拠した。   Table 1 shows the terminal and conductor connection strength (initial value, value after salt spray test), connection resistance (initial value) for the terminal and terminal-to-wire connection method based on each of the above examples, comparative examples, and conventional examples. , Values after salt spray test), and costs including materials / processes related to connection are compared and the results of comprehensive evaluation are shown. The connection strength test between the terminal and the conductor is performed when the terminal and the conductor are gripped by a tensile tester, the tensile stress is measured when the conductor is broken or pulled out of the terminal by the tensile test, and only the conductor is pulled. When the tensile stress was 90% or more with respect to the tensile stress, ◎, when it was 85% or more and less than 90%, ◯, and when it was 75% or more and less than 85%, Δ was judged. The connection resistance measurement was performed using a direct current four-terminal method with a 10 A energization condition at the connection part. When the connection resistance was 30 μΩ or less, ◎, when the connection resistance was greater than 30 μΩ and 60 μΩ or less, ◯, when the connection resistance was greater than 90 μΩ and less than Δ, and when greater than 90 μΩ, the evaluation was ×. The connection strength test and connection resistance measurement of these terminals and conductors were performed before and after the salt spray test, and the initial value and the value after the salt spray test were obtained. The salt spray test was based on JIS C60068-2-11.

Figure 2010182492
Figure 2010182492

表１によれば、溶融性接合層６と母材層７とが一体となっている本発明の端子１を導体３と接続した実施例１〜５では、初期の接続強度が高いだけでなく、塩水噴霧試験後も高い接続強度が保たれていた。さらに、接続抵抗に関しても、実施例１〜５では、初期及び塩水噴霧試験後で優れた値を示した。これは、実施例１〜５では、端子１の導体３と接合される面に溶融性接合層６を有し、溶融性接合層６の反対面に母材層７を有し、母材層７に溶融性接合層６があらかじめ複合一体化されており、溶融性接合層６及び導体３を固相線温度以上に加熱しながら圧縮加工することにより、溶融性接合層６と導体３とを金属的に接合させたためである。特に、強固な酸化膜を形成しやすいＡｌ又はＡｌ合金を母材層７に用いる場合やＡｌ導体又はＡｌ合金導体を用いる場合、端子１が溶融性接合層６を有する効果は高い。   According to Table 1, in Examples 1 to 5 in which the terminal 1 of the present invention in which the meltable bonding layer 6 and the base material layer 7 are integrated with the conductor 3, not only the initial connection strength is high. Even after the salt spray test, high connection strength was maintained. Furthermore, regarding connection resistance, Examples 1 to 5 showed excellent values after the initial stage and after the salt spray test. In Examples 1 to 5, the surface of the terminal 1 to be joined to the conductor 3 has the fusible bonding layer 6, the opposite surface of the fusible bonding layer 6 has the base material layer 7, and the base material layer The meltable bonding layer 6 is preliminarily composite-integrated with 7 and compression processing is performed while heating the meltable bonding layer 6 and the conductor 3 to a temperature equal to or higher than the solidus temperature. This is because they are joined metallically. In particular, when Al or an Al alloy that easily forms a strong oxide film is used for the base material layer 7 or when an Al conductor or an Al alloy conductor is used, the effect that the terminal 1 has the meltable bonding layer 6 is high.

これに対し、溶融性接合層６を有さない比較例１、２及び従来例１は、初期の接続強度はある程度確保できるものの、塩水噴霧試験により、端子と導体の界面に塩水成分が浸入し、Ａｌの酸化あるいは腐食を進行させ、接続強度低下を引き起こす。また、同様の理由で、接続抵抗の増加を引き起こす。従来例２のようＮｉペーストを用いた場合、接続部への塩水の浸入が防止できるので、接続強度低下、接続抵抗増加を比較的抑えることができる。   In contrast, Comparative Examples 1 and 2 and Conventional Example 1 that do not have the fusible bonding layer 6 can secure a certain degree of initial connection strength, but the salt water component penetrates into the interface between the terminal and the conductor by the salt spray test. , Al oxidation or corrosion proceeds to cause a decrease in connection strength. For the same reason, it causes an increase in connection resistance. When Ni paste is used as in Conventional Example 2, since salt water can be prevented from entering the connecting portion, a decrease in connection strength and an increase in connection resistance can be suppressed relatively.

コストに関しては、端子が金属単体からなる比較例１、２は優れている。実施例１〜５は、端子１の材料が複合材であるため、材料コストが比較例１、２より大きくなるものの、母材層７と溶融性接合層６が一体化しているため、複合材としての加工性及び取り扱い性が優れており、端子１の加工及び端子１と導体３の接続工程は簡易であり、コスト高を抑制できる。従来例１は、端子の部品点数が多いため、材料コストが高いのに加え、端子の製造コスト及び接続工程のコストが高くなる。従来例２は、端子に加え取り扱い性に難のあるＮｉペーストを用いるため、材料コスト及び接続工程のコストが著しく高くなる。また、高い導電性を確保するためには、ペースト中に高価なＮｉ粉末を高濃度で添加する必要があり、また、Ｎｉをペースト中に均一に分散させることは技術的に問題が大きい。   Regarding cost, the comparative examples 1 and 2 which a terminal consists of a metal simple substance are excellent. In Examples 1 to 5, since the material of the terminal 1 is a composite material, the material cost is higher than those of Comparative Examples 1 and 2, but the base material layer 7 and the fusible bonding layer 6 are integrated. As a result, the processing of the terminal 1 and the process of connecting the terminal 1 and the conductor 3 are simple, and the cost can be suppressed. Since Conventional Example 1 has a large number of terminal parts, the material cost is high, and the terminal manufacturing cost and the connection process cost are high. Conventional Example 2 uses Ni paste, which is difficult to handle in addition to the terminals, so that the material cost and the cost of the connection process are significantly increased. Further, in order to ensure high conductivity, it is necessary to add expensive Ni powder in the paste at a high concentration, and it is technically problematic to uniformly disperse Ni in the paste.

これらの判断により、コストの◎○×を評価し、総合評価の○△×を評価した。表１中の総合評価の欄に示される通り、接続強度、接続抵抗、コストの全てに優れた特性を示す端子及び端子と電線の接続方法は実施例１〜５である。   Based on these judgments, the cost ◎ ○ × was evaluated, and the overall evaluation △ Δ × was evaluated. As shown in the column of comprehensive evaluation in Table 1, Examples 1 to 5 are terminals and terminal-to-wire connection methods that exhibit excellent characteristics in connection strength, connection resistance, and cost.

以上説明したように、本発明によれば、導体素線間及び導体と端子間の接続抵抗が低減でき、低コストで、接続強度が高い端子及び端子と電線の接続方法を提供することができる。   As described above, according to the present invention, it is possible to reduce the connection resistance between the conductor wires and between the conductor and the terminal, and to provide a low-cost terminal and a method for connecting the terminal and the electric wire with high connection strength. .

１ 端子
２ 電線
３ 導体
４ 接合子部
５ 接触子部
６ 溶融性接合層
７ 母材層 DESCRIPTION OF SYMBOLS 1 Terminal 2 Electric wire 3 Conductor 4 Junction part 5 Contact part 6 Melting joining layer 7 Base material layer

Claims (6)

電線の導体に接合させて電気的に接続するための接合子部と、該接合子部と一体的に形成され相手端子に接触させて電気的に接続するための接触子部とを備えた端子であって、 上記接合子部は、上記電線の導体と接合される面に所定の温度で溶融する溶融性接合層を有し、該溶融性接合層の反対面に上記温度で溶融しない母材層を有し、該母材層に上記溶融性接合層があらかじめ複合一体化されていることを特徴とする端子。   A terminal provided with a connector part that is electrically connected to a conductor of an electric wire, and a contact part that is formed integrally with the connector part and is brought into contact with a mating terminal to be electrically connected The joint portion has a meltable joining layer that melts at a predetermined temperature on a surface to be joined to the conductor of the electric wire, and a base material that does not melt at the temperature on the opposite surface of the meltable joining layer A terminal having a layer, wherein the meltable bonding layer is combined and integrated in advance with the base material layer. 上記溶融性接合層がＺｎ−Ａｌ合金（Ａｌが０〜３０ｍａｓｓ％；０％は除く）、Ｓｎ−Ｚｎ合金（Ｚｎが０〜４０ｍａｓｓ％；０％は除く）、Ｃｄ−Ｚｎ合金（Ｚｎが０〜９０ｍａｓｓ％；０％は除く）のいずれかからなることを特徴とする請求項１記載の端子。   The meltable bonding layer is composed of a Zn-Al alloy (Al is 0 to 30 mass%; excluding 0%), a Sn-Zn alloy (Zn is 0 to 40 mass%; excluding 0%), a Cd-Zn alloy (Zn is 0). The terminal according to claim 1, wherein the terminal is composed of any one of ˜90 mass%; 上記母材層がＡｌ又はＡｌ合金からなることを特徴とする請求項１又は２記載の端子。   3. The terminal according to claim 1, wherein the base material layer is made of Al or an Al alloy. 電線の導体に接合させて電気的に接続するための接合子部と該接合子部と一体的に形成され相手端子に接触させて電気的に接続するための接触子部とを備えた端子と、上記電線とを接続する方法であって、
上記接合子部の上記電線の導体に接合される面に所定の温度で溶融する溶融性接合層を上記温度で溶融しない母材層とあらかじめ複合一体化させて設けておき、
上記接合子部の溶融性接合層を上記電線の導体に臨ませ、これら溶融性接合層及び導体を上記温度以上に加熱しながら圧縮加工することにより、上記接合子部の溶融性接合層と上記電線の導体とを接合させることを特徴とする端子と電線の接続方法。 A terminal provided with a connector for joining and electrically connecting to a conductor of an electric wire, and a contact for forming an electrical connection by making contact with a mating terminal formed integrally with the connector; A method for connecting the electric wire,
A meltable bonding layer that melts at a predetermined temperature is provided on a surface to be bonded to the conductor of the electric wire of the connector portion in advance and integrated with a base material layer that does not melt at the temperature,
The meltable bonding layer of the connector part is exposed to the conductor of the electric wire, and the meltable bonding layer and the conductor of the connector part are compressed and heated while being heated to the temperature or higher. A method for connecting a terminal and an electric wire, characterized by joining the conductor of the electric wire. 上記圧縮加工の際に、上記接合子部を上記電線の導体の輪郭に倣う形状に整形することを特徴とする請求項４記載の端子と電線の接続方法。   5. The method for connecting a terminal and an electric wire according to claim 4, wherein the connector portion is shaped into a shape following the contour of the conductor of the electric wire during the compression processing. 上記電線の導体がＡｌ又はＡｌ合金からなることを特徴とする請求項４又は５記載の端子と電線の接続方法。   6. The method for connecting a terminal and an electric wire according to claim 4, wherein the conductor of the electric wire is made of Al or an Al alloy.
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