JP2013127929A - Electric wire with terminal - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a technique for separating a non-plated part of a metal terminal and a core wire of an insulated electric wire.SOLUTION: An electric wire with terminal 100 includes an insulated electric wire 10, a metal terminal 20, a resin member 30 and a sealing member 40. The metal terminal 20 is formed by punching a plate member having a plated layer 22 formed thereon, and is attached to an end part of an insulation coating 12 in the insulated electric wire 10 and to an electric wire end part 10T including a core wire 11 exposed from the end part of the insulation coating 12. The plated layer 22 is formed on an electric wire support surface 21S contacted with the electric wire end part 10T. The resin member 30 is formed of a resin material having a higher melting point than a metal material of the plated layer 22. The resin member 30 is deposited on the plated layer 22 of the electric wire support surface 21S in a state that the core wire 11 of the electric wire end part 10T is pressed against and covers the electric wire support surface 21S of the metal terminal 20.

Description

  The present invention relates to a technique for attaching a metal terminal to an end portion of an insulated wire, and particularly to a technique for suppressing corrosion of an insulated wire.

  Various devices mounted in a vehicle such as an automobile may be electrically connected to each other by an insulated wire. Moreover, in order to connect an insulated wire to an apparatus or to connect insulated wires, an electric wire with a terminal in which a metal terminal is attached to an end portion of the insulated wire is used.

  In recent years, an aluminum electric wire that is lighter than a copper electric wire or the like is sometimes used to reduce the weight of the vehicle. However, in the case of an aluminum electric wire, the aluminum electric wire may be corroded by contact with a metal terminal made of copper or a copper alloy which is a different metal. Therefore, in Patent Document 1, it is proposed to suppress corrosion of the aluminum electric wire by increasing the waterproofness of the aluminum electric wire. Specifically, it is disclosed that after a metal terminal is crimped to an aluminum electric wire, an aluminum core wire exposed to the outside is covered with a resin material.

JP 2010-108828 A

  By the way, a metal terminal is generally manufactured through punching of a plate material on which a plating layer is formed. Therefore, although the plating layer is formed on the main surface, which is the front and back surfaces of the metal terminal, the plating layer may not be formed on the cut surface (end surface) of the metal terminal formed at the time of cutting. For this reason, when a part of the metal terminal is crimped to the core wire of the insulated wire as in the conventional case, the core wire having a relatively large difference in oxidation-reduction potential and the end surface of the metal terminal are in contact with each other. For this reason, there is a possibility that the core wire or the metal terminal may be corroded due to adhesion of the electrolytic substance (water, antifreezing agent, etc.).

  On the other hand, the plating layer is generally made of a metal such as tin, and corrosion caused by contact between the metal and the aluminum core wire is not a problem. In other words, the technique disclosed in Patent Document 1 exhibits a corrosion prevention effect by the resin material mainly covering the end face of the crimping portion of the metal terminal and the aluminum core wire.

  However, in the technique disclosed in Patent Document 1, it is difficult to apply a resin material to a necessary portion without a necessary thickness variation when in a fluid state, that is, to stabilize the anticorrosion performance. Therefore, there is a demand for a technique for reliably isolating the core wire of the insulated wire from the unplated non-plated portion of the metal terminal and stabilizing the anticorrosion performance.

  This invention is made in view of the said subject, and aims at providing the technique for isolating the non-plating part of a metal terminal and the core wire of an insulated wire reliably, and stabilizing corrosion prevention performance. .

  In order to solve the above-mentioned problem, the first aspect is formed by stamping an insulated wire and a plate material on which a plating layer is formed, and ends of the insulation coating and the ends of the insulation coating in the insulated wire. A metal terminal that is attached to an end portion of the electric wire including the core wire exposed from the portion and has the plating layer formed on the electric wire support surface in contact with the end portion of the electric wire, and a resin material having a higher melting point than the metal material of the plating layer And a resin member welded to the plating layer formed on the surface of the metal terminal in a state in which the core wire included in the end portion of the electric wire is covered and pressed against the electric wire support surface of the metal terminal.

  Moreover, the 2nd aspect WHEREIN: The electric wire with a terminal which concerns on a 1st aspect WHEREIN: The said resin member extends through the other side from the one side of the said electric wire end part through the front end side of the said electric wire end part. In the range, it is welded to the plating layer formed on the wire support surface.

  Moreover, a 3rd aspect is further provided with the sealing member formed with the resin material pinched | interposed between the said resin member and the said electric wire edge part in the electric wire with a terminal which concerns on the 1st or 2nd aspect.

  Moreover, the 4th aspect WHEREIN: The electric wire with a terminal which concerns on any 1 aspect from 1st to 3 WHEREIN: The part which touches the said core wire in the said metal terminal is a flat surface from the one end to the other end in the width direction. The resin member is welded to the plating layer of the wire support surface at least on both sides of the end portion of the wire.

  Further, a fifth aspect is the electric wire with terminal according to any one of the first to fourth aspects, wherein the metal material of the plating layer includes tin, and the material of the resin member includes Polyethylene terephthalate is included.

  According to the terminal-attached electric wire according to the first aspect, the resin member may isolate the core wire at the end of the electric wire from the end surfaces (cut surfaces where the plating layer is not formed) on both sides of the core wire in the metal terminal. it can. Thereby, corrosion of a core wire or a metal terminal can be suppressed effectively.

  Moreover, since the melting point of the resin member is higher than the melting point of the metal contained in the plating layer, the metal of the plating layer can be melted by heating the resin member near the melting temperature. Thereby, the shape of the resin member can be maintained to some extent when the resin member is welded to the plating layer. Therefore, it becomes easy to attach the resin member to the target position. Therefore, as compared with the conventional case where the resin member is applied in a fluidized state, the mounting position of the resin member is less likely to vary, and the anticorrosion performance of the electric wire with terminal can be stabilized.

  According to the terminal-attached electric wire according to the second aspect, the end portion of the electric wire including the core wire exposed from the insulating coating is covered with the resin member. For this reason, a core wire can be isolated from the non-plating part of a metal terminal.

  According to the terminal-attached electric wire according to the third aspect, the gap can be filled by interposing the sealing member between the resin member and the insulated electric wire. Therefore, it can suppress that an electric field substance flows into the core wire side through the clearance gap.

  According to the terminal-attached electric wire according to the fourth aspect, the creepage distance and the spatial distance between the core wire of the insulated electric wire and the end face (non-plated portion) of the metal terminal can be increased. Therefore, the core wire can be more reliably isolated from the non-plated portion of the metal terminal.

  According to the terminal-attached electric wire according to the fifth aspect, the melting point of the resin member can be made higher than the melting point of the metal material of the plating layer. Moreover, the electric wire with a terminal which has the stable anticorrosion performance can be manufactured comparatively cheaply.

It is a schematic plan view of the electric wire with a terminal concerning a 1st embodiment. It is a schematic side view of the electric wire with a terminal concerning a 1st embodiment. It is a schematic sectional drawing which shows the cut surface in the III-III line | wire shown in FIG. It is a schematic sectional drawing of the electric wire with a terminal concerning a 2nd embodiment. It is a schematic sectional drawing of the electric wire with a terminal concerning a 3rd embodiment. It is a schematic side view of the electric wire with a terminal concerning a 4th embodiment.

  Hereinafter, embodiments will be described with reference to the accompanying drawings. However, the following embodiments are examples embodying the present invention and are not examples of limiting the technical scope of the present invention.

<1. First Embodiment>
FIG. 1 is a schematic plan view of a terminal-attached electric wire 100 according to the first embodiment. FIG. 2 is a schematic side view of the terminal-attached electric wire 100 according to the first embodiment. In FIG. 2, the resin member 30 shows a cut surface cut along the axial direction of the insulated wire 10 (direction in which the insulated wire 10 extends). FIG. 3 is a schematic cross-sectional view showing a cut surface taken along line III-III shown in FIG.

  The terminal-attached electric wire 100 can be applied not only to various devices mounted on a moving vehicle such as an automobile but also to connecting an insulated wire to various devices installed indoors and outdoors. As illustrated in FIGS. 1 to 3, the terminal-attached electric wire 100 includes an insulated wire 10, a metal terminal 20, a resin member 30, and a sealing member 40.

  The insulated wire 10 has a configuration in which the outer periphery of a core wire 11 that is a conductor is covered with an insulating coating 12 by extrusion coating or the like. The core wire 11 is configured by a single wire or a stranded wire of a metal wire such as aluminum or an aluminum alloy. However, it is also conceivable that the core wire 11 is composed of other metal wires (metal wires such as copper or copper alloy). The end portion (electric wire end portion 10T) of the insulated wire 10 is a portion where the core wire 11 is exposed from the insulating coating 12.

  The metal terminal 20 is attached to the electric wire end 10T (here, including the end of the insulating coating 12 and the core wire 11 exposed from the end of the insulating coating 12). The metal terminal 20 is formed by punching a plate-like metal member (plate material) on which a plating layer is formed. Therefore, as shown in FIG. 3, the plating layer 22 is provided on the surface of the support portion 21 that supports the insulated wire 10 (the wire support surface 21 </ b> S facing the insulated wire 10 and the back side surface) of the metal terminal 20. Is formed. Further, the end surface 23S of the edge portion of the support portion 21 is a cut surface formed when a plate-like metal member is punched out, and is a non-plated portion where no plating is formed.

  As a raw material of the metal terminal 20, for example, a metal material containing copper can be used. Further, as the material of the plating layer 22, for example, a metal material containing tin can be used. The plating layer 22 is appropriately selected according to the material of the core wire 11 and the material of the metal terminal 20. Here, in order to suppress corrosion of the insulated wire 10 (specifically, the core wire 11) or the metal terminal 20, a material having a small difference between the core wire 11 or the metal terminal 20 and the oxidation-reduction potential indicating an ionization tendency is selected. It is desirable.

  The resin member 30 covers the core wire 11 included in the end portion of the insulated wire 10 while pressing it against the wire support surface 21 </ b> S of the metal terminal 20. In the example illustrated in FIG. 1, the resin member 30 covers all the core wires 11 exposed from the insulating coating 12 and a part (end portion) of the insulating coating 12.

  In this embodiment, as shown in FIGS. 1 to 3, the resin member 30 includes a ceiling portion 31 pressed against the upper portion of the electric wire end portion 10T, a wall portion 32 that hangs downward from the ceiling portion 31, and It is comprised by the skirt part 33 which spreads outside from the edge part of the wall part 32 along the electric wire support surface 21S. As shown in FIG. 1, the wall portion 32 extends from one side of the wire end portion 10 </ b> T to the other side of the wire end portion 10 </ b> T through the distal end side of the insulated wire 10 end portion. 10 is enclosed. The skirt 33 is formed along the wall 32. In addition, the resin member 30 shown in FIGS. 1-3 is an example, The shape etc. can be changed suitably.

  The resin member 30 is made of a material having a melting point higher than that of the metal material of the plating layer 22, and is preferably made of a resin material containing polyethylene terephthalate (PET). Since the plating layer 22 is formed of a metal having a melting point lower than the melting point of PET (about 264 ° C.) (for example, tin having a melting point of about 232 ° C.), the plating layer 22 is melted at the melting temperature of the resin member 30. Can also melt. Therefore, the resin member 30 and the plating layer 22 can be favorably welded. Further, by setting the heating temperature at the time of welding to a temperature close to the melting point of the resin member 30, the resin member 30 can be partially melted while the metal member of the plating layer 22 is melted. Therefore, since the resin member 30 can be welded to the metal terminal 20 while maintaining the shape of the resin member 30 to some extent, the resin member 30 can be easily attached to a target position. In the case of the terminal-attached electric wire 100, the finish of the terminal-attached electric wire 100 is less likely to vary than in the case where a fluid resin is applied as in Patent Document 1, and the anticorrosion performance can be stabilized. it can. Moreover, the electric wire 100 with a terminal can also be manufactured comparatively cheaply by making the main component of the resin member 30 into PET and making the main component of the plating layer 20 into tin.

  As means for heating and welding the resin member 30, for example, ultrasonic welding can be applied. In ultrasonic welding, members are repeatedly compressed by ultrasonic vibration, or friction is caused on the joint surfaces between the members. As a result, the temperature between the members is increased, or the members are melted by being softened by the impact force of ultrasonic waves, so that the members are welded together. When the resin member 30 is welded to the metal terminal 20, for example, by applying ultrasonic vibration from the upper surface of the bottom portion 33 of the resin member 30, the contact portion of the wire support surface 21S plating layer 22 and the bottom portion 33 is heated. Can do. Thereby, after melting the plated layer 22 and the skirt 33, the resin member 30 can be welded to the metal terminal 20 by cooling to a required temperature or leaving it at room temperature.

  As shown in FIG. 3, the support portion 21 in contact with the core wire 11 in the metal terminal 20 has a flat surface extending from one end to the other end in the width direction of the metal terminal 20 (direction orthogonal to the axial direction of the insulated wire 10). It is formed to form. For this reason, a creeping distance between the core wire 11 and the end surface 23S or a spatial distance can be increased. Therefore, the core wire 11 and the non-plated portion are more reliably isolated.

  As shown in FIGS. 1 and 2, the sealing member 40 fills a gap between the resin member 30 and the wire end portion 10 </ b> T (here, the insulating coating 12). The sealing member 40 is preferably superior in flexibility or water absorption retention than the resin member 30 and is formed of a resin material such as epoxy resin, polyamide, or butyl rubber. When a gap is formed between the resin member 30 and the wire end portion 10T, the electrolytic substance may flow into the core wire 11 from the gap, and the core wire 11 or the metal terminal 20 may be corroded. For this reason, the gap between the resin member 30 and the insulated wire 10 is filled by sandwiching the sealing member 40 having high flexibility or high water absorption retention between the resin member 30 and the insulated wire 10, so that Inflow of material is suppressed.

  As a method for sandwiching the sealing member 40 between the resin member 30 and the insulated wire 10, for example, it is conceivable to attach the sealing member 40 to the inside of the resin member 30 in advance. By welding such a resin member 30 to the metal terminal 20, the resin member 30 can be sandwiched between the resin member 30 and the insulated wire 10. When the sealing member 40 is formed of polyamide, it can be considered that the sealing member 40 is attached to the resin member 30 by thermal welding. Further, when the sealing member 40 is formed of butyl rubber, it can be considered that the sealing member 40 is attached to the resin member 30 with an adhesive or the like. Furthermore, as another method for sandwiching the sealing member 40, the sealing member 40 is attached in advance around the wire end portion 10T, and the resin member 30 is stacked thereon to weld the resin member 30 to the metal terminal 20. It is also possible.

  As described above, according to the terminal-attached electric wire 100 according to the present embodiment, the insulated wire 10 and the metal terminal 20 are fixed by the resin member 30. Therefore, since the core wire 11 of the insulated wire 10 and the non-plated portion (end surface 23S) of the metal terminal 20 can be reliably separated, the occurrence of corrosion of the insulated wire 10 or the metal terminal 20 can be suppressed.

<2. Second Embodiment>
In the terminal-attached electric wire 100 according to the first embodiment, as shown in FIG. 3, the resin member 30 is welded only to the electric wire support surface 21 </ b> S facing the insulated electric wire 10 in the surface of the metal terminal 20. . However, it is also conceivable to weld the resin member 30 to another position. In the following description, elements having the same functions as those in the first embodiment are denoted by the same reference numerals and description thereof is omitted.

  FIG. 4 is a schematic cross-sectional view of a terminal-attached electric wire 100A according to the second embodiment. In the terminal-attached electric wire 100A, the resin member 30A is disposed on both sides of the core wire 11 and the back surface of the metal terminal 20A extends across the end surface 23S as well as the plated layer 22 of the electric wire support surface 21S facing the insulated electric wire 10. It is also welded to the plating layer 22.

  Also in the terminal-attached electric wire 100A, as with the terminal-attached electric wire 100, the core wire 11 of the insulated electric wire 10 and the non-plated portion (end surface 23S) of the metal terminal 20 can be reliably isolated. In the case of the terminal-attached electric wire 100A, the end surface 23S which is a non-plated portion can be covered with the resin member 30A. Therefore, it can suppress that an electrolytic substance adheres to the end surface 23S. In addition, in the terminal-attached electric wire 100A, the resin member 30A is welded to the wire support surface 21S of the metal terminal 20A and the plating layer 22 on the back side surface thereof, but may be welded only to the plating layer 22 on the back side surface. Conceivable.

<3. Third Embodiment>
In the electric wire with terminal 100, as shown in FIG. 3, the support portion 21 of the metal terminal 20 in contact with the core wire 11 forms a flat surface from one end to the other end in the width direction. However, it is also conceivable that the support portion 21 of the metal terminal 20 has another shape.

  FIG. 5 is a schematic cross-sectional view of a terminal-attached electric wire 100B according to the third embodiment. The terminal-attached electric wire 100B includes a metal terminal 20B formed by punching and bending. The support portion 21 </ b> B of the metal terminal 20 </ b> B in contact with the core wire 11 includes a bottom plate portion 211 disposed on the lower side of the core wire 11 and a pair of wall portions 212 and 212 rising from both sides of the bottom plate portion 211. A pair of wall parts 212 and 212 are parts formed by bending process, and the plating layer 22 is formed in the surface (inner surface) facing the core wire 11, and the back surface (outer surface). The resin member 30 </ b> B is welded to the plating layer 22 on the outer surface of the wall portion 212.

  According to the terminal-attached electric wire 100B, the end surface 23S that is a non-plated portion of the wall portion 212 is covered with the resin member 30B. For this reason, it can suppress that an electrolytic substance adheres to the end surface 23S. Moreover, since the wall part 212 is provided, it becomes easy to arrange | position the core wire 11 of the insulated wire 10 on the metal terminal 20B. In the terminal-attached electric wire 100B, the resin member 30B is welded to the plating layer 22 on the outer surface of the metal terminal 20B. However, it is also conceivable to weld the resin member 30B to the plating layer 22 on the inner side surface of the wall portion 212. It is also conceivable that the resin member 30B is welded from the plating layer 22 on the inner side surface of the wall 212 to the plating layer 22 on the outer side surface through the end surface 23S.

<4. Fourth Embodiment>
In the terminal-attached electric wire 100A according to the first embodiment, the resin member 30 is attached so as to cover the entire core wire 11 exposed from the insulating coating 12 (see FIG. 1). However, it is also conceivable to attach the resin member 30 so as to cover only a part of the core wire 11.

  FIG. 6 is a schematic side view of a terminal-attached electric wire 100C according to the fourth embodiment. In the terminal-attached electric wire 100C, the resin member 30C is fixed to the electric wire support surface 21S so as to cover only a part of the core wire 11 exposed from the insulating coating 12 in the electric wire end portion 10T. The resin member 30C is welded to the electric wire support surface 21S on both sides of the electric wire end portion 10T (here, the core wire 11), similarly to the resin member 30 shown in FIG.

  Also in the terminal-attached electric wire 100A according to the present embodiment, the insulated wire 10 can be fixed to the metal terminal 20 by the resin member 30C. For this reason, the non-plating part (end surface 23S) of the metal terminal 20 and the core wire 11 can be reliably isolated.

<5. Modification>
Although the embodiment has been described above, the present invention is not limited to the above, and various modifications are possible.

  For example, in the above embodiment, the insulated wire is fixed to the metal terminal only by the resin member. However, it is also conceivable to crimp a part of the metal terminal to the insulated wire. For example, a part of the metal terminal may be crimped to the insulating coating. In this case, the core wire of the insulated wire and the non-plated portion of the metal terminal can be isolated, and the insulated wire can be firmly fixed to the metal terminal. Moreover, you may make it crimp a part of metal terminal to a core wire. In this case, it is conceivable that after the resin member is placed on the portion of the metal terminal crimped to the core wire of the insulated wire, the resin member is welded to the plating layer of the metal terminal by ultrasonic welding or the like.

  Furthermore, each structure demonstrated in the said embodiment and modification can be suitably combined or abbreviate | omitted unless a contradiction arises mutually.

100, 100A, 100B, 100C Electrical wire with terminal 10 Insulated wire 10T Wire end 11 Core wire 12 Insulation coating 20, 20A, 20B Metal terminal 21, 21B Support portion 211 Bottom plate portion 212 Wall portion 21S Wire support surface 22 Plating layer 23S End surface ( Non-plated part)
30, 30A, 30B, 30C Resin member 31 Ceiling part 32 Wall part 33 Bottom part 40 Sealing member

Claims (5)

Insulated wires,
A plate material on which a plated layer is formed is formed by stamping, and is attached to an end portion of the insulating coating in the insulated wire and an end portion of the wire including a core wire exposed from the end portion of the insulating coating, and the end portion of the wire A metal terminal having the plating layer formed on the wire support surface in contact with
It is formed of a resin material having a melting point higher than that of the metal material of the plating layer, and is formed on the surface of the metal terminal in a state of covering the core wire included in the end portion of the wire against the wire support surface of the metal terminal A resin member welded to the plating layer;
An electric wire with a terminal. In the electric wire with a terminal according to claim 1,
The resin member is welded to the plating layer formed on the electric wire support surface in a range extending from one side of the electric wire end portion to the other side through the distal end side of the electric wire end portion. , Electric wire with terminal. In the electric wire with a terminal according to claim 1 or 2,
A sealing member formed of a resin material sandwiched between the resin member and the wire end,
The electric wire with a terminal further provided. In the electric wire with a terminal given in any 1 paragraph of Claims 1-3,
The portion in contact with the core wire in the metal terminal forms a flat surface from one end to the other end in the width direction,
The terminal-attached electric wire, wherein the resin member is welded to the plating layer of the electric wire support surface at least on both sides of the electric wire end. In the electric wire with a terminal given in any 1 paragraph of Claims 1-4,
The metal material of the plating layer contains tin,
An electric wire with a terminal, wherein the material of the resin member contains polyethylene terephthalate.

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