JP2017098109A - Terminal-equipped wire and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To suppress increase in welding energy and manufacturing cost even when the total cross-sectional area of a core wire of a coated electric wire connected to a terminal increases.SOLUTION: The terminal-equipped wire includes: a coated wire formed by coating a core wire made of a conductive material with a coating made of an insulating material; and a terminal connected to the core wire. The coated electric wire has a bent portion in which a part of the core wire is bent rearward from its tip end side. The terminal includes: a welding portion welded to the core wire by ultrasonic welding; and a crimping portion provided near the welding portion and crimping the bent portion.SELECTED DRAWING: Figure 1

Description

  The present invention relates to an electric wire with a terminal to which a terminal is connected and a method for manufacturing the electric wire.

Conventionally, a terminal-attached electric wire in which the tip (core wire) of a covered electric wire is connected to a connection terminal by ultrasonic welding is known (for example, see Patent Document 1 below).
In the manufacturing method of the electric wire with a terminal indicated by patent documents 1, after a welding process by ultrasonic welding, a pair of side walls of a terminal metal fitting are bent and a core wire welding part is covered with a core wire, and a terminal is provided in a covered electric wire. It is connected.

JP 2003-338327 A

  By the way, when the tip of the covered electric wire is connected to the terminal fitting by ultrasonic welding, if the conductor cross-sectional area of the covered electric wire, that is, the total cross-sectional area of the core wire is large, larger welding energy is required. For this reason, a large-scale welding apparatus is needed, and there exists a problem that the manufacturing cost of the electric wire with a terminal will become high.

  The present invention has been made in view of the above circumstances, and an electric wire with a terminal capable of suppressing an increase in welding energy and manufacturing cost even when the total cross-sectional area of a core wire of a covered electric wire connected to a terminal is increased, and its manufacture It aims to provide a method.

  An electric wire with a terminal according to the present invention includes a covered electric wire in which a core wire made of a conductive material is covered with a coating made of an insulating material, and a terminal connected to the core wire, and the covered electric wire includes a part of the core wire. A bent portion that is bent backward from the distal end side, and the terminal is welded to the core wire by ultrasonic welding, and a crimping portion that is provided near the welded portion and crimps the bent portion It is characterized by having.

  According to the terminal-attached electric wire according to the present invention, the covered electric wire has a bent portion where a part of the core wire is bent backward from the tip side, and the terminal is welded to the core wire by ultrasonic welding; Since it has a crimping part that is provided near the welded part and crimps the bent part, the conductor cross-sectional area of the core wire welded to the welded part can be reduced. Thereby, even if the total cross-sectional area of the core wire connected to a terminal becomes large, the increase in welding energy can be suppressed and the increase in manufacturing cost can also be suppressed. Even if the conductor cross-sectional area of the core wire is reduced, the bent portion is crimped by the crimping portion, so that necessary electrical connection is ensured.

  In one Embodiment of this invention, the said crimping | compression-bonding part crimps | bonds the said bending part on the said coating | cover.

  In another embodiment of the present invention, the crimping portion is an open barrel having a plate-like portion continuous from the welded portion and a pair of barrel pieces crimped toward the plate-like portion.

  In still another embodiment of the present invention, the crimping portion is crimped in a state where the bent portion is disposed on the plate surface side of the plate-like portion.

  In still another embodiment of the present invention, the crimping part crimps the bent part in a state of being sandwiched between the pair of barrel pieces.

  The method for manufacturing a terminal-attached electric wire according to the present invention includes a step of removing the coating on the distal end side of a covered electric wire in which a core wire made of a conductive material is covered with a coating made of an insulating material, and extracting the core wire, and a part of the core wire Forming the bent portion backward from the tip side thereof, a step of welding the core wire and the welded portion of the terminal by ultrasonic welding, and the bent portion provided in the vicinity of the welded portion. And a step of crimping by the crimping portion.

  According to the manufacturing method of the electric wire with a terminal concerning the present invention, the electric wire with a terminal which has the above-mentioned operation effect can be manufactured in a simple process.

  In one Embodiment of this invention, the said crimping process WHEREIN: The said bending part is crimped | bonded on the said coating | cover.

  In another embodiment of the present invention, the crimping portion comprises an open barrel having a plate-like portion continuous from the welded portion and a pair of barrel pieces crimped toward the plate-like portion. In the step, the crimping is performed in a state where the bent portion is disposed on the plate surface side of the plate-like portion.

  In still another embodiment of the present invention, the crimping portion comprises an open barrel having a plate-like portion continuous from the welded portion and a pair of barrel pieces crimped toward the plate-like portion, In the step of crimping, the bent portion is crimped in a state of being sandwiched between the pair of barrel pieces.

  According to the present invention, the covered electric wire has a bent portion obtained by bending a part of the core wire, and the crimping portion of the terminal crimps the bent portion, so that the conductor cross-sectional area of the core wire welded to the welded portion of the terminal is reduced. Even if the total cross-sectional area of the core wire is increased, an increase in welding energy and an increase in manufacturing cost can be suppressed.

It is a figure which shows the electric wire with a terminal which concerns on the 1st Embodiment of this invention. It is a flowchart which shows the manufacturing process of the electric wire with a terminal. It is a flowchart which shows the connection process in the manufacturing process. It is a side view which shows the electric wire with a terminal for every manufacturing process. It is a figure which shows the modification of the electric wire with a terminal. It is a figure which shows the other modification of the electric wire with the terminal. It is a perspective view which shows the electric wire with a terminal which concerns on the 2nd Embodiment of this invention.

  Hereinafter, a terminal-attached electric wire and a method for manufacturing the same according to an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

[First Embodiment]
1A and 1B are diagrams showing a terminal-attached electric wire 1 according to a first embodiment of the present invention, in which FIG. 1A shows a perspective view, and FIG. 1B shows an AA in FIG. 'A cross-sectional view is shown. Moreover, FIG. 2 is a flowchart which shows the manufacturing process of the electric wire 1 with a terminal, and FIG. 3 is a flowchart which shows the connection process in this manufacturing process. Further, FIG. 4 is a side view showing the terminal-attached electric wire 1 for each manufacturing process.

  As shown in FIGS. 1A and 1B, the terminal-attached electric wire 1 according to the first embodiment includes a covered electric wire 10 and a core wire exposed portion 13 of the core wire 11 in a terminal portion on the distal end side of the covered electric wire 10. And a terminal 20 connected to the terminal. The covered electric wire 10 includes a core wire 11 formed by twisting together a plurality of elongated wires such as copper and aluminum, and a coating 12 made of an insulating resin that covers the periphery of the core wire 11 and insulates and protects the core wire 11 from the outside. ing.

  The coating 12 is formed so as to cover the periphery of the core wire 11 by, for example, extrusion molding. In the core wire exposed portion 13, the coating 12 is peeled (removed), and the core wire 11 is exposed to the outside in the core wire exposed portion 13. And the core wire exposure part 13 has the to-be-welded part 13a welded to the welding part 21 of the terminal 20 mentioned later, and the bending part 13b by which one part is bend | folded back from the front end side of a terminal part. Yes.

  On the other hand, the terminal 20 is formed by punching and bending a metal base material. The terminal 20 has a plate-like welded portion 21 welded by ultrasonic welding to the welded portion 13a of the core wire exposed portion 13 of the covered electric wire 10, and a connected member (front) extending from the welded portion 21 to the front end side (front). And a connecting portion 22 for contacting the external connecting element).

  Further, the terminal 20 includes a crimping portion 23 that crimps the bent portion 13 b of the core wire exposed portion 13 on the rear end (base end) side (rear side) in the vicinity of the welded portion 21. The crimping part 23 is a pair of plate-like parts 23a (see FIG. 1 (b)) continuous from the welded part 21 and a pair of crimps that are erected on both side edges of the plate-like part 23a toward the plate-like part 23a. It consists of an open barrel structure having barrel pieces 24a, 24b.

  The pair of barrel pieces 24a and 24b have, for example, the same thickness as the plate thickness of the welded portion 21 and the connecting portion 22, and are referred to as the longitudinal direction of the terminal 20 (that is, the axial direction of the core wire 11, hereinafter referred to as the “axial direction”). ) To have a predetermined width. In the first embodiment, these barrel pieces 24 a and 24 b are intended to crimp the bent portion 13 b of the core wire exposed portion 13 on the coating 12 in the crimping portion 23.

  For this reason, the width of the barrel pieces 24a and 24b can be made as narrow as possible as long as the bent portion 13b can be sandwiched together with the covering 12 as compared with a general wire barrel or insulation barrel. . The welded portion 21, the connecting portion 22, and the crimping portion 23 of these terminals 20 are integrally formed.

  The welded portion 21 has a length along the axial direction and a width along the plate surface intersecting the axial direction, which are necessary and sufficient to place the welded portion 13a of the core wire exposed portion 13. The connecting portion 22 is a portion that is continuous from the welded portion 21 and is electrically connected to contact with an unillustrated counterpart terminal or auxiliary machine.

  Since the terminal 20 according to the first embodiment is assumed to be connected to a rod-shaped terminal such as a battery terminal, for example, the terminal 20 has a flat plate shape extending in the axial direction of the covered electric wire 10. And the through-hole 22a in which a rod-shaped terminal is inserted is formed in the front end side of the connection part 22, for example. In addition, the specific shape and structure in the connection part 22 of the terminal 20 of the electric wire 1 with a terminal which concern on this invention are not limited. For this reason, the connection part 22 may have a configuration having a so-called male / female fitting shape.

  The crimping portion 23 is for crimping the bent portion 13b after ultrasonic welding between the welded portion 13a of the core wire exposed portion 13 and the welded portion 21 (or prior to ultrasonic welding). In 1st Embodiment, as above-mentioned, the crimping | compression-bonding part 23 crimps | bonds the bending part 13b with the core wire 11 and the coating | cover 12 on the coating | cover 12. FIG.

  That is, the pair of barrel pieces 24a and 24b in the crimping portion 23 sandwich the terminal portion (core wire 11 and coating 12) of the covered electric wire 10 disposed between the plate-like portion 23a and the barrel pieces 24a and 24b. It crimps so that the bending part 13b arrange | positioned between may be inserted | pinched. In the example shown in FIGS. 1 (a) and (b), the bent portion 13b is arranged on the barrel piece 24a arranged on the covering 12, and the barrel piece 24b is arranged on the bent piece 13b. Yes.

  Thereby, in the crimping | compression-bonding part 23, the bending part 13b is crimped | bonded between the barrel pieces 24a and 24b, and the core wire 11 and the coating | cover 12 are crimped | bonded by the barrel pieces 24a and 24b. Thus, after the welded part 13 a and the welded part 21 are ultrasonically welded, the bent part 13 b is crimped by the crimping part 23, whereby the terminal 20 is electrically connected to the covered electric wire 10.

  According to the electric wire with terminal 1 configured as described above, the core wire exposed to be welded to the welded portion 21 even when the diameter of the covered electric wire 10 connected to the terminal 20 is increased and the total cross-sectional area of the core wire 11 is increased. The conductor cross-sectional area of the portion 13 can be adjusted and reduced. That is, the conductor cross-sectional area of the welded portion 13 a can be made smaller than the conductor cross-sectional area of the original core wire exposed portion 13 by adjusting the amount of the bent portion 13 b of the core wire exposed portion 13.

  As a result, an increase in welding energy required for ultrasonic welding can be suppressed even when the total cross-sectional area of the core wire 11 of the covered electric wire 10 is increased, such as a so-called thick wire. It is possible to suppress the enlargement of the manufacturing cost and suppress the increase in manufacturing cost. In addition, in the electric wire 1 with a terminal, even if it reduces the conductor cross-sectional area of the to-be-welded part 13a welded to the welding part 21 of the terminal 20, ie, the conductor cross-sectional area of the core wire exposed part 13 to be welded, the bent part 13b. Is crimped to the terminal 20 by the crimping portion 23, the required electrical connection can be ensured, and the connection reliability is not inferior.

  Next, the manufacturing process of the terminal-attached electric wire 1 according to the first embodiment will be described. Here, according to the flowcharts of FIGS. 2 and 3, the manufacturing process will be described with reference to FIG. In the following description including FIG. 2 to FIG. 4, the same constituent elements as those in the first embodiment are denoted by the same reference numerals, and hence redundant description is omitted below.

  According to the flowchart of FIG. 2, first, a covered electric wire in which the core wire 11 is covered with the covering 12 is prepared as shown in FIG. Next, as shown in FIG. 4B, the coating 12 having a predetermined length is removed from the tip of the terminal portion on the tip side of the covered electric wire 10, and the core wire 11 is extracted (step S100) to expose the core wire. Part 13 is formed. And as shown in FIG.4 (c), a part of core wire exposure part 13 is bend | folded back from the front end side, and the bending part 13b is formed (step S102). By this step S102, the remaining portion of the core wire exposed portion 13 becomes the welded portion 13a.

  Next, a separately prepared terminal 20 having the welded portion 21, the connecting portion 22, and the crimping portion 23 as described above is prepared (step S104), and the welded portion 21 of the terminal 20 as shown in FIG. Then, the welded portion 13 a and the coating 12 of the covered electric wire 10 are placed and set on the crimping portion 23. Finally, the terminal-attached electric wire 1 according to the first embodiment is manufactured through a connection step (step S106) for connecting the terminal 20 to the covered electric wire 10.

  The connecting step in step S106 is performed as shown in the flowchart of FIG. 3, for example. First, as shown in FIG.4 (e), the terminal 20 with which the covered electric wire 10 was set is mounted on the base 19 of an ultrasonic welding apparatus. Then, while pressing the horn 18 from above the welded portion 13a on the welded portion 21 in the direction indicated by the arrow A in the figure, it is vibrated finely in the direction indicated by the arrow B in the figure to perform ultrasonic welding (step S200). . Thereby, the welded part 13a of the core wire exposed part 13 and the welded part 21 of the terminal 20 are connected.

  Next, as shown in FIG. 4 (f), the barrel piece 24a of the crimping portion 23 is crimped onto the coating 12, and the bent portion 13b is placed on the barrel piece 24a. Further, as shown in FIG. 4G, the barrel piece 24b is caulked on the bent portion 13b placed on the barrel piece 24a, and the barrel pieces 24a and 24b are directed toward the plate-like portion 23a as a whole. By crimping, the bent portion 13b is crimped on the covering 12 (step S202). In this way, the terminal 20 is connected to the covered electric wire 10.

  The order of the ultrasonic welding process in step S200 and the crimping process in step S202 may be interchanged. Moreover, in the crimping | compression-bonding process of step S202, the caulking order of the barrel pieces 24a and 24b may be reversed. In the manufacturing process according to the first embodiment, the terminal-attached electric wire 1 can be easily manufactured by the simple process as described above.

[Modified example of electric wire 1 with terminal]
FIG. 5 is a view showing a modification of the terminal-attached electric wire 1 of the first embodiment, FIG. 5 (a) shows a perspective view, and FIG. 5 (b) shows BB ′ in FIG. 5 (a). A line sectional view is shown. The terminal-attached electric wire 1 according to the first embodiment may have the following configuration. That is, as shown in FIGS. 5A and 5B, the pair of barrel pieces 24 a and 24 b of the crimping portion 23 are bent on the coating 12 and placed directly on the bent portion 13 b and the core 11 and the coating. 12 is crimped toward the plate-like portion 23a so as to be crimped together. Even if comprised in this way, the increase in welding energy and manufacturing cost can be suppressed, and the electric wire 1 with a terminal which ensured electrical connection can be obtained.

[Other variations of the electric wire 1 with terminals]
6A and 6B are diagrams showing another modification of the terminal-attached electric wire 1 according to the first embodiment, in which FIG. 6A shows a side view and FIG. 6B shows a C- in FIG. C 'line sectional drawing is shown. The terminal-attached electric wire 1 according to the first embodiment may further have the following configuration. That is, as shown in FIGS. 6A and 6B, the pair of barrel pieces 24a and 24b of the crimping portion 23 are in direct contact with the cover 12, and are folded on the plate surface side of the plate-like portion 23a. The bent portion 13 b is crimped so as to be crimped together with the core wire 11 and the coating 12. Even if comprised in this way, the increase in welding energy and manufacturing cost can be suppressed, and the electric wire 1 with a terminal which ensured electrical connection can be obtained.

  In the modification shown in FIGS. 5 and 6, the pair of barrel pieces 24 a and 24 b (open barrel) of the crimping portion 23 is configured to be crimped so that the bent portion 13 b is crimped together with the core wire 11 and the coating 12. When the bent portion 13b is crimped together with the core wire 11 and the covering 12, it may be configured to be crimped by one closed barrel (closed barrel) instead of the pair of barrel pieces 24a and 24b.

[Second Embodiment]
FIG. 7 is a perspective view showing a terminal-attached electric wire according to the second embodiment of the present invention. As shown in FIG. 7, in the electric wire with terminal 1A according to the second embodiment, the bent portion 13b of the core wire exposed portion 13 is bent so that the tip thereof faces the core wire exposed base end portion 13c side, and the core wire is exposed. It is formed in the region of the portion 13, and is crimped in the region of the core wire exposed portion 13 by the pair of barrel pieces 24 a and 24 b of the crimping portion 23 and is crimped to the terminal 20. This is different from the above-described first embodiment in which the bent portion 13 b is crimped on the coating 12 by the crimping portion 23. Other configurations related to the second embodiment are the same as those of the first embodiment. Even if comprised in this way, it is possible to show the effect similar to 1st Embodiment.
In addition, in the crimping | compression-bonding part 23 of the electric wire 1A with a terminal which concerns on 2nd Embodiment, it replaces with a pair of barrel pieces 24a and 24b, and is a bending part of the core wire exposure part 13 by one closed barrel (closed barrel). You may comprise so that 13b may be crimped within the area | region of the core wire exposed part 13. FIG.

  As mentioned above, although several embodiment of this invention was described, these embodiment is shown as an example and is not intending limiting the range of invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the scope of the invention. These embodiments and modifications thereof are included in the scope and gist of the invention, and are included in the invention described in the claims and the equivalents thereof.

DESCRIPTION OF SYMBOLS 1 Electric wire with a terminal 10 Covered electric wire 11 Core wire 12 Cover 13 Core wire exposed part 13a Welded part 13b Bending part 13c Core wire exposed base end part 18 Horn 19 Base 20 Terminal 21 Welded part 22 Connection part 22a Through-hole 23 Crimped part 23a Plate shape Part 24a, 24b Barrel piece

Claims (9)

A covered electric wire in which a core wire made of a conductive material is covered with a coating made of an insulating material;
A terminal connected to the core wire,
The covered electric wire has a bent portion obtained by bending a part of the core wire backward from the tip side thereof,
The said terminal has the welding part welded to the said core wire by ultrasonic welding, and the crimping part which crimps the said bending part provided in the vicinity of the said welding part. The electric wire with a terminal characterized by the above-mentioned. The electric wire with a terminal according to claim 1, wherein the crimping part crimps the bent part on the coating. 3. The terminal according to claim 1, wherein the crimping portion includes an open barrel having a plate-like portion continuous from the welded portion and a pair of barrel pieces crimped toward the plate-like portion. With electric wire. The electric wire with a terminal according to claim 3, wherein the crimping part is crimped in a state where the bent part is disposed on a plate surface side of the plate-like part. The electric wire with a terminal according to claim 3, wherein the crimp portion is crimped in a state where the bent portion is sandwiched between the pair of barrel pieces. Removing the coating on the front end side of the covered electric wire in which the core wire made of a conductive material is covered with a coating made of an insulating material, and extracting the core wire;
A step of bending a part of the core wire backward from the tip side to form a bent part;
Welding the welded portion of the core wire and the terminal by ultrasonic welding;
A method of crimping the bent portion with a crimping portion provided in the vicinity of the welded portion. The method for producing a terminal-attached electric wire according to claim 6, wherein in the step of crimping, the bent portion is crimped on the coating. The crimping part is composed of an open barrel having a plate-like part continuous from the welded part and a pair of barrel pieces crimped toward the plate-like part,
The method for manufacturing an electric wire with a terminal according to claim 6 or 7, wherein in the step of crimping, crimping is performed in a state where the bent portion is disposed on a plate surface side of the plate-like portion. The crimping part is composed of an open barrel having a plate-like part continuous from the welded part and a pair of barrel pieces crimped toward the plate-like part,
The method of manufacturing a terminal-attached electric wire according to claim 6 or 7, wherein in the step of crimping, the bent portion is crimped in a state of being sandwiched between the pair of barrel pieces.

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