JP2016177956A - Cable with connecting terminal and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide cable with a connecting terminal which can be formed with a simple method even if core wire is any thickness.SOLUTION: A connecting terminal 21 connected to a companion part 15 is formed to multiple core wire 19 exposed from insulation coating 17 of a cable end 29. The connecting terminal 21 puts the multiple core wire 19 and the folded multiple core wire 19 together and welds and solidifies, and a through hole 25 is formed at the welded and solidified site.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a connection electric wire and a method for manufacturing the electric wire, and more particularly to an electric wire with a connection terminal in which connection terminals are formed on a plurality of core wire portions exposed from an insulating coating of an electric wire terminal and a method for manufacturing the electric wire.

  A vehicle such as an automobile is equipped with a wire harness in which a plurality of electric wires are bundled. In this type of electric wire, a plurality of core wires are exposed from the insulation coating of the end of the electric wire, and a terminal fitting connected to the mating terminal is crimped to the exposed core wire.

  However, since the terminal fitting to be crimped to the wire end has a pair of barrel pieces that are crimped so as to wrap the wire end, when the wire diameter becomes large like a high-voltage cable, the component becomes large and the component The cost increases and the number of crimping operations increases.

  On the other hand, in Patent Document 1, a plurality of core wires exposed from the insulation coating of the electric wire terminal are pressed while rotating a rotating brush, and each core wire is entangled irregularly and formed into a dumpling shape, followed by press molding. Thus, a method of manufacturing an electric wire in which a perforated connection terminal is formed is disclosed. According to this, since it becomes possible to integrally form the connection terminal at the electric wire terminal, a separate terminal fitting is not required, and the component cost can be reduced.

JP 2000-57855 A

  However, in the case of Patent Document 1, if the core wire is relatively thin, the rotating brush can be pressed to entangle the core wires irregularly. However, with a relatively thick core wire such as a high-voltage cable, the strength of each core wire is low. Since it is high, the core wires cannot be entangled irregularly.

  This invention is made | formed in view of such a problem, and makes it a subject to provide the electric wire with a connection terminal which can be formed with a simple method irrespective of the thickness of a core wire, and its manufacturing method.

  First, when the present inventors performed resistance welding on a plurality of core wires exposed from the insulating coating and extending in parallel to each other, it was confirmed that the surfaces of adjacent core wires were welded and integrated.

  However, if the core wires extending in parallel are welded in this way, when drilling is performed, the strength in the length direction of the core wire and the direction intersecting with this direction is insufficient, and the separation between the core wires (both the variations) There was a concern that this would occur.

  Therefore, as a result of intensive studies on the electric wires with connection terminals that suppress such peeling between the core wires and solve the above-mentioned problems, the inventors have invented the following. That is, in the electric wire with connection terminal of the present invention, a plurality of core wires exposed from the insulation coating of the electric wire terminal are formed with connection terminals to be connected to the mating component, and the connection terminals include a plurality of core wires and a plurality of these folded back. The core wire is overlapped and welded and solidified, and a through hole is formed in the welded and solidified portion.

  As described above, both the step of folding the plurality of core wires and the step of welding and solidifying the plurality of core wires folded and overlapped can be easily performed regardless of the diameter of the core wires. Therefore, according to the present invention, a connection terminal can be easily formed even in an electric wire having a relatively thick core wire, such as a high-voltage cable.

  In addition, by folding and solidifying a plurality of core wires in this way, the folded portion can be given strength, and the cross-sectional area in the direction intersecting the length direction of each core wire can be increased approximately twice. The binding force between the core wires can be increased. Thereby, since the intensity | strength of a connection terminal can be raised, peeling between core wires when performing a drilling process can be suppressed.

  In this case, the connection terminal can form a through hole along the overlapping surface of the plurality of core wires and the plurality of core wires folded back. According to this, since the strength of the folded portions of the plurality of core wires can be effectively used, it is possible to effectively suppress peeling between the core wires after drilling.

  Moreover, it is preferable that the connection terminal has a plurality of core wires divided into a plurality of bundles, and these bundles are intertwined. Since the core wires can intersect with each other by entwining a plurality of bundles in this way, the strength of the connection terminal after welding and solidification can be increased around the intersecting portion. Further, even if the core wire is relatively thick, it is possible to easily entangle the bundles of the core wires.

  Further, in the method of manufacturing the electric wire with connection terminal according to the present invention, the plurality of core wires exposed from the insulation coating are folded, and the plurality of folded core wires are overlapped with the plurality of core wires to be welded and solidified, and then drilling is performed. It is characterized by giving. Here, the welding and solidification is preferably the resistance welding method when the core wire material is copper or a copper alloy, and the ultrasonic welding method is preferable when the core wire material is aluminum or an aluminum alloy.

  According to the present invention, an electric wire with a connection terminal can be formed by a simple method regardless of the thickness of the core wire.

It is an appearance perspective view of an electric wire with a connection terminal to which the present invention is applied. It is a figure explaining the process of peeling off insulation coating from an electric wire terminal. It is a figure explaining the welding process of the core wire exposed from the electric wire terminal. It is a figure explaining the drilling process of the core wire exposed from the electric wire terminal. It is the front view and sectional drawing of the connecting terminal in which the through hole was formed. It is an external appearance perspective view of the other electric wire with a connection terminal to which this invention is applied. It is a figure explaining the process of twisting the some core wire exposed from the insulation coating. It is a figure explaining the process of weaving the some core wire exposed from the insulation coating.

  Hereinafter, a first embodiment of an electric wire with connection terminals to which the present invention is applied will be described with reference to the drawings. The electric wire 11 with connection terminal (hereinafter, abbreviated as an electric wire 11) of the present embodiment is used for an electric wire constituting a wire harness mounted on an electric vehicle, a hybrid car, or the like, for example, and an electric such as a battery, an inverter, or a motor. Although it is wired between apparatuses, it is applicable not only to this example but to various electric wires. In FIG. 1, the example which connects the electric wire 11 to the other party component 15 mounted in the other party electrical equipment 13 is shown.

  As shown in FIG. 1, the electric wire 11 is formed in a circular cross section, and a resin insulating coating 17 is formed so as to cover the plurality of core wires 19. The terminal portion of the electric wire 11 is stripped of the insulating coating 17 to expose a plurality of core wires 19.

  In the electric wire 11 of the present embodiment, each core wire 19 is formed by forming a stranded wire obtained by spirally twisting a large number of copper alloy metal strands, but the core wire 19 is not formed by a stranded wire. Also good.

  A connection terminal 21 in which the exposed core wire 19 is solidified in a rectangular shape is formed at the terminal portion of the electric wire 11. The connection terminal 21 is a part that electrically and mechanically connects the electric wire 11 and the counterpart component 15. The connection terminal 21 is welded and solidified so that the exposed plurality of core wires 19 are folded back and the plurality of core wires 19 and the plurality of folded core wires 19 are overlapped. The end surfaces 23 on both sides in the overlapping direction of the plurality of core wires 19 are substantially flat surfaces.

  A through hole 25 having a circular cross section that penetrates in the direction in which the plurality of core wires 19 are folded is formed in the central portion of the connection terminal 21. The connection terminal 21 is fixed to the counterpart component 15 by inserting the counterpart component 15 through the through hole 25 and tightening the nut 27.

  The electric wire 11 of this embodiment can be manufactured by the following methods, for example. First, as shown in FIG. 2, the insulation coating 17 a of the terminal portion 29 of the electric wire 11 is peeled off to expose the core wire 19. At this time, the core wire 19 is cut or peeled off so that there is no remaining coating.

  Subsequently, the plurality of core wires 19 exposed from the insulating coating 17 are folded back so that the plurality of core wires 19 and the plurality of folded core wires 19 overlap each other. In this embodiment, it arrange | positions so that the front-end | tip of several folded core wires 19 may be located ahead of the front-end | tip of the insulation coating 17. FIG.

  Next, as shown in FIG. 3, the plurality of core wires 19 folded back of the electric wire 11 are subjected to a welding process by a resistance welding method. In the resistance welding method, a plurality of core wires 19 that are folded on each other are sandwiched between a pair of flat plate electrodes 31, and a current is passed between the electrodes 31 while the power supply 33 is turned on and pressurized (in the direction of the arrow). Thereby, each core wire 19 will generate heat | fever when an electric current flows, and the adjacent core wires 19 will be welded. As a result, the plurality of core wires 19 and the plurality of folded core wires 19 are joined to each other by welding the core wires 19 on the overlapping surfaces and integrated into a block shape. Further, both end surfaces 23 in contact with the electrode 31 become substantially flat surfaces following the electrode surface.

  The energization time of the resistance welding method is usually several seconds. For example, when the current value is constant, if the energization time is too short, the adhesive force between the core wires 19 is insufficient, and if the energization time is too long, Discoloration may occur due to welding. Accordingly, the processing conditions such as the current value and the energization time are appropriately set within a range in which insufficient strength after welding does not occur according to the thickness of the core wire 19 of the electric wire 11.

  For welding the core wire 19, a desired welding means is employed depending on the material of the core wire 19. In this embodiment, since the core wire 19 is formed of copper or a copper alloy, a resistance welding method is adopted. However, when the core wire 19 is formed of aluminum or an aluminum alloy, an ultrasonic welding method or the like is preferable. It is.

  Next, drilling is performed on the terminal portion 29 where each core wire 19 is welded and solidified. In this drilling process, the through holes 25 are formed in the direction in which the plurality of core wires 19 and the plurality of folded core wires 19 overlap. That is, the through hole 25 is formed so as to penetrate the both end faces 23 of the terminal portion 29. In this drilling process, a drilling machine or the like is used, and the terminal portion 29 is fixed with a jig or the like. As shown in FIG. 4, a circular through hole 25 is formed at the center in the width direction of the terminal portion 29 as shown in FIG. The Note that after the drilling process, burrs and the like that rise from the periphery of the through hole 23 are removed.

  When connecting the electric wire 11 with connection terminal of the present embodiment to the mating component 15, as described above, the mating component 15 is inserted into the through hole 25 of the connection terminal 21 and tightened with the nut 27. At the time of tightening 27, it is preferable to use a torque wrench or the like. Thereby, it is possible to avoid an excessive stress from acting on the connection terminal 21.

  As described above, according to the present embodiment, there are two processes, that is, the process of folding the plurality of core wires 19 exposed from the insulating coating 17 and the process of welding the folded core cables 19 in a state of being folded. Thus, the connection terminal 21 is formed, and in any process, regardless of the wire diameter or the like of the core wire 19, it can be performed with simple equipment, and automation is also easy. Therefore, according to this embodiment, the connection terminal 21 can be formed easily and inexpensively even for an electric wire having a relatively large wire diameter, such as a high-voltage cable.

  Further, in the present embodiment, since the plurality of core wires 19 exposed from the insulating coating 17 are folded and welded, the folded portion of the core wire 19 can be given high strength, and the core wire 19 can be welded without being folded back. Compared with the case of solidifying, the cross-sectional area in the direction intersecting with the length direction of each core wire 19 (direction in which adjacent core wires 19 are welded) can be increased approximately twice to increase the binding force between the core wires 19. . Thereby, since the intensity | strength of the terminal part 29 can be raised, the peeling between the core wires 19 when performing a drilling process can be suppressed.

  In addition, both end surfaces 23 in which the through holes 25 are formed are desired to have a predetermined flatness in order to ensure desired workability and drilling accuracy. Is a surface with which the electrode 31 abuts in the welding step, and a predetermined flatness is secured along the electrode surface. Therefore, as in the present embodiment, by providing the through holes 25 in the direction in which the plurality of core wires 19 are folded, the both end surfaces 23 can be drilled without performing planar processing such as grinding, and the manufacturing process. Can be simplified.

  Next, another embodiment of the electric wire with connection terminal to which the present invention is applied will be described. However, since each of the following embodiments is basically the same as the first embodiment, only differences from the first embodiment will be described.

  The electric wire 41 with connection terminal of the second embodiment is different from the electric wire 11 with connection terminal of the first embodiment in that, as shown in FIG. 6, a plurality of core wires 19 and a plurality of core wires 19 that are folded back. The through hole 45 is formed along the overlapping surface 43.

  According to the present embodiment, the through hole 45 is provided along the overlapping direction (vertical direction in FIG. 6) of the folded portion 47 where each core wire 19 is folded, so that the high strength of the folded portion 47 can be effectively used. it can. Therefore, it is possible to effectively suppress peeling between the core wires 19 when drilling is performed. However, in the present embodiment, both end surfaces 49 where the through holes 45 are formed are not surfaces on which the electrodes 31 in the welding process come into contact. There is a need.

  Next, 3rd Embodiment of the electric wire with a connecting terminal to which this invention is applied is described. The third embodiment is different from the first and second embodiments in that a plurality of core wires 19 exposed from the insulating coating 17 are divided into a plurality of bundles, and these bundles are intertwined. It is.

  For example, as shown in FIG. 7, the plurality of core wires 19 exposed from the insulating coating 17 are divided into two bundles 51a and 51b, and these bundles 51a and 51b are repeatedly twisted and then folded. .

  Alternatively, for example, as shown in FIG. 8, the plurality of core wires 19 exposed from the insulating coating 17 are divided into three bundles 52a, 52b, and 52c, and these bundles 52a, 52b, and 52c are divided into three bundles. Knit into a knitted shape, make it one, and then fold it back. In any case, the welding process in the folded state is the same as in the first embodiment.

  According to the present embodiment, all the exposed core wires 19 are divided into a plurality of bundles, and these are simply twisted or knitted a plurality of times along the length direction of the core wires 19. Regardless of the size, the core wire 19 can be entangled with a simple operation. Such an operation can be easily automated by attaching the tip of each bundle to the arm and rotating the arm around the length direction of the core wire 19, for example.

  Further, when the core wire 19 in which the bundles are entangled in this manner is welded, the portion where the bundles are entangled and intersected with each other can obtain higher strength than the portion that does not intersect, so the strength of the terminal portion 29 can be increased. It is possible to further suppress peeling between the core wires 19 when drilling is performed.

DESCRIPTION OF SYMBOLS 11,41 Electric wire with a connection terminal 15 Mating part 17 Insulation coating 19 Core wire 21 Connection terminal 23,49 End surface 25,45 Through-hole 29 Terminal part 43 Overlapping surface 47 Folding part

Claims (4)

Connection terminals to be connected to the mating parts are formed on the plurality of core wires exposed from the insulation coating of the wire terminal,
The connection terminal is an electric wire with a connection terminal in which a plurality of the core wires and a plurality of the core wires folded back are overlapped and welded and solidified, and through holes are formed in the welded and solidified portions.   The said connection terminal is an electric wire with a connection terminal of Claim 1 in which the said through-hole is formed along the overlapping surface of the said some core wire and the several said core wire which turned | folded these back.   The said connection terminal is an electric wire with a connection terminal of Claim 1 or 2 by which the said some core wire is divided | segmented into several bundles, and these bundles are intertwined. In the method of manufacturing a wire with a connection terminal in which a connection terminal connected to a counterpart component is formed on a plurality of core wires exposed from the insulation coating of the wire terminal,
A plurality of the core wires exposed from the insulating coating are folded back, and the plurality of the core wires that are folded are overlapped with the plurality of core wires to be welded and solidified, and then subjected to perforation processing. Manufacturing method.

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