JP2016225074A - Aluminum electric wire, harness, and method for producing harness - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a technique for dealing with dissimilar metal contact corrosion (electric corrosion) by a totally new constitution.SOLUTION: There is provided an aluminum electric wire 2, including: a core wire 4 made of aluminum or an aluminum alloy, formed with an oxide film 7 thicker than a natural oxide film at the outer circumferential face 6; and an insulation covering 5 of covering the core wire 4. Also provided is a harness 1 including: the aluminum electric wire 2 including the core wire 4 made of aluminum or an aluminum alloy, formed with the oxide film 7 thicker than a natural oxide film at the outer circumferential face 6 and the insulation covering 5 of covering the core wire 4; and a crimp terminal 3 made of copper or a copper alloy, crimped to the core wire 4 of the aluminum electric wire 2. Also provided is a method for producing the harness 1, comprising: a coating step (S130) where the crimp terminal 3 made of copper or a copper alloy is coated with corrosion prevention treatment agent; and a connection step (S160) where the core wire 4 of the aluminum electric wire 2 having the core wire 4 made of aluminum or an aluminum alloy, formed with the oxide film 7 thicker than the natural oxide film at the outer circumferential face 6 and the insulation covering 5 of covering the core wire 4 is crimped with the crimp terminal 3.SELECTED DRAWING: Figure 3

Description

  The present invention relates to an aluminum electric wire, a harness, and a method for manufacturing the harness.

  Patent document 1 is disclosing the electric wire 102 with a terminal provided with the electric wire 100 and the terminal 101 attached to the electric wire 100, as shown in FIG. 7 of this application. The electric wire 100 includes a core wire 103 and an insulating material 104 that covers the outer periphery of the core wire 103. The core wire 103 is made of aluminum or an aluminum alloy for the purpose of reducing the weight of the vehicle. The terminal 101 is made of general copper or copper alloy. With the above configuration, when the terminal 101 is crimped to the exposed core wire 103 of the electric wire 100, there is a possibility that dissimilar metal contact corrosion occurs. Therefore, in Patent Document 1, the terminal 101 is previously covered with a water stop material made of a hydrophobic material before pressure bonding.

JP2013-235716A

  An object of the present invention is to provide a technique for dealing with contact corrosion of different metals (electric corrosion) with a completely new configuration.

According to the first aspect of the present invention, there is provided an aluminum electric wire having an aluminum or aluminum alloy core wire having an outer peripheral surface formed with an oxide film thicker than a natural oxide film, and an insulating coating covering the core wire. Is done.
The oxide film is an anodized film.
The oxide film is an aluminum oxide hydrate film.
The aluminum oxide hydrate film is a boehmite film or a bayerite film.
According to a second aspect of the present invention, an aluminum electric wire having an aluminum or aluminum alloy core wire in which an oxide film thicker than a natural oxide film is formed on the outer peripheral surface, and an insulating coating covering the core wire; A copper or copper alloy terminal crimped or pressure-contacted to the core wire of the aluminum electric wire;
A harness is provided.
The oxide film is an anodized film.
The oxide film is an aluminum oxide hydrate film.
The aluminum oxide hydrate film is a boehmite film or a bayerite film.
According to the third aspect of the present invention, an application step of applying an anticorrosive treatment agent to a copper or copper alloy terminal, and an aluminum or aluminum alloy made of an oxide film thicker than a natural oxide film on the outer peripheral surface There is provided a method of manufacturing a harness including a connecting step of crimping or press-contacting the terminal to the core wire of an aluminum electric wire having a core wire and an insulating coating covering the core wire.

  According to the present invention, since the oxide film thicker than the natural oxide film is formed on the outer peripheral surface of the core wire, it is possible to suppress contact corrosion of different metals.

It is a disassembled perspective view of a harness. It is a perspective view of a harness. It is sectional drawing of the strand which comprises a core wire. It is an example of the flowchart regarding the manufacturing process of a harness. It is a perspective view which shows a mode that an aluminum electric wire is attached to a press-contact terminal. It is an example of the flowchart regarding the manufacturing process of a harness. It is a figure equivalent to FIG.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. In this embodiment, by forming an oxide film thicker than the natural oxide film on the outer peripheral surface of the core wire of the aluminum electric wire, even if the core wire of the aluminum electric wire is crimped or pressed to a copper or copper alloy terminal, the electrolytic corrosion is suppressed. I can do it.

  FIG. 1 shows an exploded perspective view of the harness 1, and FIG. 2 shows a perspective view of the harness 1. As shown in FIGS. 1 and 2, the harness 1 includes an aluminum electric wire 2 and a crimp terminal 3 (terminal) attached to an end 2 </ b> A of the aluminum electric wire 2.

  The aluminum electric wire 2 has a core wire 4 and an insulating coating 5 that covers the core wire 4.

  The core wire 4 is made of aluminum or an aluminum alloy. By making the core wire 4 made of aluminum or an aluminum alloy, the weight of the core wire 4 can be reduced to about one third as compared to a general copper or copper alloy core wire, and the material cost is reduced. It can be halved. As shown in FIG. 1, in the present embodiment, the core wire 4 is a stranded wire formed by twisting a plurality of strands p. As shown in FIG. 3, an oxide film 7 thicker than the natural oxide film is formed on the outer peripheral surface 6 of each element wire p. The oxide film 7 is uniformly formed over the entire length of each strand p. The oxide film 7 is, for example, an anodized film or an aluminum oxide hydrate film. The aluminum oxide hydrate film is, for example, a boehmite film or a bayerite film.

  The anodized film is an oxide film that can be artificially thick and firmly formed, and can be formed by anodized film treatment. Anodized film treatment means that an aluminum product is immersed in an electrolytic solution (sulfuric acid, oxalic acid, other organic acids), and direct current, alternating current, or alternating current is passed through the aluminum product as an anode. This is a process to form an oxide film on the surface of the product.

  The aluminum oxide hydrate film is an artificially thick and strong oxide film that can be formed by hydration. Hydration is a process for forming an oxide film on the surface of an aluminum product by immersing the aluminum product in high-temperature pure water for a predetermined time. In addition, when the water temperature of the pure water in which an aluminum product is immersed is 80 degree | times or more, for example, the oxide film formed on the surface of an aluminum product turns into a boehmite film | membrane, and when it is less than 80 degree | times, it becomes a bayerite film | membrane.

  In addition, the film thickness of the natural oxide film naturally formed on the surface of aluminum or aluminum alloy is generally several tens to several hundreds of nanometers.

  In the present embodiment, the core wire 4 is a stranded wire formed by twisting a plurality of strands p, but the core wire 4 may be a single wire. When the core wire 4 is a single wire, the oxide film 7 is formed on the outer peripheral surface 6 of the core wire 4. In this case, the oxide film 7 is formed on the outer peripheral surface 6 of the core wire 4 over the entire length.

  The insulating coating 5 is made of an insulating synthetic resin such as polyvinyl chloride. When the core wire 4 is a stranded wire, the insulating coating 5 is formed so as to cover the core wire 4 after forming the oxide film 7 on the outer peripheral surface 6 of each strand p. Further, when the core wire 4 is a single wire, the insulating coating 5 is formed so as to cover the core wire 4 after forming the oxide film 7 on the outer peripheral surface 6 of the core wire 4.

  On the other hand, the crimp terminal 3 is made of copper or a copper alloy. By making the crimp terminal 3 copper or a copper alloy, the crimp terminal 3 can be provided with a spring property. The crimp terminal 3 is tin-plated or nickel-plated, for example. Since tin plating has a natural potential close to that of aluminum as compared with nickel plating, tin plating can be further expected to have an electrolytic corrosion suppression effect. As shown in FIG. 1, the crimp terminal 3 includes a contact portion 10, a conductor barrel 11, and an insulation barrel 12.

  The contact portion 10 is configured as a female terminal. That is, the contact portion 10 includes a rectangular tube portion 13 and a contact spring piece 14 accommodated in the rectangular tube portion 13. When the male terminal is inserted into the rectangular tube portion 13, the contact spring piece 14 contacts the male terminal with a predetermined contact pressure while being elastically deformed. The crimp terminal 3 may be a male terminal.

  The conductor barrel 11 is a portion that is crimped to the core wire 4 exposed at the end 2 </ b> A of the aluminum electric wire 2.

  The insulation barrel 12 is a portion that is crimped to the insulating coating 5 in the vicinity of the end 2 </ b> A of the aluminum electric wire 2.

  Next, the manufacturing process of the harness 1 will be described with reference to FIG.

  As shown in FIG. 4, the manufacturing process of the harness 1 includes a member manufacturing process (S100) and a harness assembling process (S110). The member production step (S100) is a step of individually producing the aluminum electric wire 2 and the crimp terminal 3 which are components of the harness 1. The harness assembling step (S110) is a step of manufacturing the harness 1 by combining the aluminum electric wire 2 and the crimp terminal 3.

  In the member manufacturing step (S100), first, a roll made of copper or copper alloy is obtained (S120), a plating process is performed on the roll, and the crimp terminal 3 having a predetermined shape is manufactured by pressing, An anticorrosion treatment agent is applied to the crimp terminal 3 (S130). The step of applying the anticorrosion treatment agent to the crimp terminal 3 can be incorporated in the press line of the crimp terminal 3. The anticorrosive treatment agent is preferably applied to the crimp terminal 3 by dipping or spraying, for example. Examples of the anticorrosive treatment agent include fluorine-based and silicon-based water repellent treatment agents, and contact oils in which a rust preventive additive is added to a base mineral oil or synthetic oil.

  In the member manufacturing step (S100), first, a wire made of aluminum or an aluminum alloy is obtained (S140), and the wire p having a predetermined diameter is manufactured by rolling the wire, and the outer periphery of the wire p After forming the oxide film 7 on the surface 6, the plurality of strands p are twisted and covered with the insulating coating 5, thereby producing the aluminum electric wire 2.

  Next, in the harness assembling step (S110), the aluminum electric wire 2 is cut as necessary, and the insulating coating 5 is removed by a specified length (S150). Then, the core wire 4 of the aluminum electric wire 2 is crimped to the crimp terminal 3 (S160). That is, the conductor barrel 11 of the crimp terminal 3 is crimped to the core wire 4 of the aluminum wire 2, and the insulation barrel 12 of the crimp terminal 3 is crimped to the insulating coating 5 of the aluminum wire 2. When the conductor barrel 11 is crimped to the core wire 4 of the aluminum wire 2, the oxide film 7 formed on the outer peripheral surface 6 of each wire p of the core wire 4 is torn, and the conductor barrel 11 and the core wire 4 of the aluminum wire 2 are oxidized film. 7 will be in direct contact with no interposition. The harness 1 is completed through the above steps.

  As mentioned above, although embodiment of this invention was described, the said embodiment has the following characteristics.

  The aluminum electric wire 2 includes an aluminum or aluminum alloy core wire 4 having an outer peripheral surface 6 formed with an oxide film 7 thicker than a natural oxide film, and an insulating coating 5 that covers the core wire 4. According to the above configuration, since the oxide film 7 is covered with the insulating coating 5, the oxide film 7 is not easily broken by an unintended external force, and thus the oxide film 7 can be set thin. Thereby, the oxide film 7 can be easily broken at the time of crimping the core wire 4, and the anticorrosion effect by the oxide film 7 can be expected at a place other than the crimped part.

  The harness 1 includes an aluminum electric wire 2 having an aluminum or aluminum alloy core wire 4 having an outer peripheral surface 6 formed with an oxide film 7 thicker than a natural oxide film, and an insulating coating 5 covering the core wire 4, and an aluminum electric wire And a crimp terminal 3 made of copper or a copper alloy that is crimped to the core wire 4 of the second core. According to the above configuration, since the oxide film 7 thicker than the natural oxide film is formed on the outer peripheral surface 6 of the core wire 4, it is possible to suppress the dissimilar metal contact corrosion between the core wire 4 and the crimp terminal 3. .

  A number of techniques have been reported for breaking the natural oxide film on the core wire of an aluminum wire and reducing the contact resistance with the terminal.

  In the above embodiment, the harness 1 includes the aluminum electric wire 2 and the crimp terminal 3. However, instead of this, as shown in FIG. 5, the harness 1 may include an aluminum wire 2 and a press contact terminal 15 made of copper or copper alloy that is press-contacted to the aluminum wire 2. When the aluminum wire 2 is inserted into the slit of the press contact terminal 15, the insulation coating 5 of the aluminum wire 2 is locally cut by the press contact terminal 15, and as a result, the core wire 4 of the aluminum wire 2 is directly connected to the press contact terminal 15. Touch. Even in this case, since the oxide film 7 thicker than the natural oxide film is formed on the outer peripheral surface 6 of the core wire 4, dissimilar metal contact corrosion between the core wire 4 and the press contact terminal 15 can be suppressed.

  Examples of the oxide film 7 include an anodized film and an aluminum oxide hydrate film.

  Moreover, as an aluminum oxide hydrate film | membrane, a boehmite film | membrane or a bayerite film | membrane is mentioned, for example.

  Moreover, as shown in FIG. 4, the manufacturing method of the harness 1 has the coating process (S130) which apply | coats an anticorrosion treatment agent to the crimp terminal 3 made from copper or a copper alloy, and the outer peripheral surface 6 is thicker than a natural oxide film. A connecting step (S160) of crimping the crimp terminal 3 to the core wire 4 of the aluminum electric wire 2 having the core wire 4 made of aluminum or aluminum alloy on which the film 7 is formed and the insulating coating 5 covering the core wire 4; . According to the above method, since the oxide film 7 thicker than the natural oxide film is formed on the outer peripheral surface 6 of the core wire 4, it is possible to suppress the dissimilar metal contact corrosion between the core wire 4 and the crimp terminal 3. . In addition, since the anticorrosion treatment agent is applied to the crimping terminal 3 in advance before the crimping terminal 3 is crimped to the core wire 4, the anticorrosion treatment agent is applied to the crimping terminal 3 after the crimping terminal 3 is crimped to the core wire 4. In comparison, the working efficiency of the coating process is good.

  In addition, since the crimp terminal 3 is normally cut with a press after tin plating or the like, copper or a copper alloy is exposed on the end face of the crimp terminal 3. Therefore, it is particularly preferable to apply an anticorrosive treatment agent to the end face of the crimp terminal 3 from the viewpoint of suppressing electrolytic corrosion.

  Next, another manufacturing process of the harness 1 will be described with reference to FIG.

  As shown in FIG. 6, the manufacturing process of the harness 1 includes a member manufacturing process (S200) and a harness assembling process (S210). The member production step (S200) is a step of individually producing the aluminum electric wire 2 and the crimp terminal 3 which are components of the harness 1. The harness assembling step (S210) is a step of producing the harness 1 by combining the aluminum electric wire 2 and the crimp terminal 3.

  In the member manufacturing step (S200), first, a roll made of copper or copper alloy is obtained (S220), a plating process is performed on the roll, and press forming is performed to manufacture a crimp terminal 3 having a predetermined shape ( S230).

  In the member production step (S200), first, a wire made of aluminum or an aluminum alloy is obtained (S240), and the wire p having a predetermined diameter is produced by rolling the wire, and the outer periphery of the wire p After forming the oxide film 7 on the surface 6, the plurality of strands p are twisted and covered with the insulating coating 5, thereby producing the aluminum electric wire 2.

  Next, in the harness assembling step (S210), the aluminum electric wire 2 is cut as necessary, and the insulating coating 5 is removed by a specified length (S250). And after apply | coating an anticorrosion treatment agent to the crimp terminal 3, the core wire 4 of the aluminum electric wire 2 is crimped | bonded to the crimp terminal 3 (S260). That is, the conductor barrel 11 of the crimp terminal 3 is crimped to the core wire 4 of the aluminum wire 2, and the insulation barrel 12 of the crimp terminal 3 is crimped to the insulating coating 5 of the aluminum wire 2. When the conductor barrel 11 is crimped to the core wire 4 of the aluminum wire 2, the oxide film 7 formed on the outer peripheral surface 6 of each wire p of the core wire 4 is torn, and the conductor barrel 11 and the core wire 4 of the aluminum wire 2 are oxidized film. 7 will be in direct contact with no interposition. The harness 1 is completed through the above steps.

  The step of applying the anticorrosive treatment agent to the crimp terminal 3 can be incorporated in a crimp line for crimping the core wire 4 of the aluminum electric wire 2 to the crimp terminal 3. Examples of the anticorrosive treatment agent include a fluorine-based or silicon-based water repellent treatment agent, contact oil obtained by adding a rust-preventive additive to a base mineral oil or synthetic oil, or contact grease. When the anticorrosive treatment agent is a fluorine-based or silicon-based water repellent treatment agent or a contact oil in which a rust-preventive additive is added to the base mineral oil or synthetic oil, the anticorrosion treatment agent is, for example, immersed or It is applied to the crimp terminal 3 by spraying. When the anticorrosion treatment agent is grease, the anticorrosion treatment agent is applied to the crimp terminal 3 by, for example, a dispenser.

  Moreover, the effect of suppressing electrolytic corrosion can also be expected by subjecting the crimp terminal 3 to oxidation treatment or sulfuration treatment.

1 Harness 2 Aluminum wire 2A End 3 Crimp terminal (terminal)
4 Core wire 5 Insulation coating 6 Outer peripheral surface 7 Oxide film 10 Contact part 11 Conductor barrel 12 Insulation barrel 13 Square tube part 14 Contact spring piece 15 Pressure contact terminal (terminal)
p strand

Claims (9)

An aluminum electric wire having an aluminum or aluminum alloy core wire having an outer peripheral surface formed with an oxide film thicker than a natural oxide film, and an insulating coating covering the core wire. The aluminum electric wire according to claim 1,
The oxide film is an anodized film.
Aluminum wire. The aluminum electric wire according to claim 1,
The oxide film is an aluminum oxide hydrate film.
Aluminum wire. An aluminum electric wire according to claim 3,
The aluminum oxide hydrate film is a boehmite film or a bayerite film.
Aluminum wire. An aluminum wire having an aluminum or aluminum alloy core wire having an oxide film thicker than a natural oxide film formed on the outer peripheral surface, and an insulating coating covering the core wire;
A copper or copper alloy terminal crimped or pressure-contacted to the core wire of the aluminum electric wire;
Harness equipped with. The harness according to claim 5,
The oxide film is an anodized film.
Harness. The harness according to claim 5,
The oxide film is an aluminum oxide hydrate film.
Harness. The harness according to claim 7,
The aluminum oxide hydrate film is a boehmite film or a bayerite film.
Harness. An application step of applying an anticorrosive treatment agent to a copper or copper alloy terminal;
A connecting step of crimping or press-contacting the terminal to the core wire of an aluminum electric wire having an aluminum or aluminum alloy core wire having an oxide film thicker than a natural oxide film on the outer peripheral surface, and an insulating coating covering the core wire When,
including,
A method for manufacturing a harness.

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