JP2017216122A - 端子付き電線の製造方法 - Google Patents
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- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
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- H01R4/20—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve
- H01R4/203—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve having an uneven wire-receiving surface to improve the contact
- H01R4/206—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve having an uneven wire-receiving surface to improve the contact with transversal grooves or threads
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
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- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
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- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
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- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/187—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping combined with soldering or welding
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- H—ELECTRICITY
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- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
- H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
- H01R4/625—Soldered or welded connections
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- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
- H01R43/0207—Ultrasonic-, H.F.-, cold- or impact welding
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
- H01R43/048—Crimping apparatus or processes
- H01R43/0488—Crimping apparatus or processes with crimp height adjusting means
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
- H01R43/048—Crimping apparatus or processes
- H01R43/05—Crimping apparatus or processes with wire-insulation stripping
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21F—WORKING OR PROCESSING OF METAL WIRE
- B21F15/00—Connecting wire to wire or other metallic material or objects; Connecting parts by means of wire
- B21F15/02—Connecting wire to wire or other metallic material or objects; Connecting parts by means of wire wire with wire
- B21F15/06—Connecting wire to wire or other metallic material or objects; Connecting parts by means of wire wire with wire with additional connecting elements or material
- B21F15/08—Connecting wire to wire or other metallic material or objects; Connecting parts by means of wire wire with wire with additional connecting elements or material making use of soldering or welding
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
- H01R43/048—Crimping apparatus or processes
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49174—Assembling terminal to elongated conductor
Abstract
【解決手段】端子(31)は、芯線束(13)が載置される基底部(42)と、基底部(42)から延設される一対の圧着片(43)と、を有し、端子圧着機(51)は、基底部(42)を支持する支持面(53)を有するアンビル(52)と、アンビル(52)に対面する2つの円弧面状のアーチ溝(57)を有するクリンパ(55)と、を有し、接合芯線(13A)は、圧着前において、軸線に直交する断面の幅(X)が、アーチ溝(57)の幅(W)から端子(31)の厚さ(T)の2倍を減じた値以下であり、且つ、断面の高さ(Y)が、圧着の完了時における支持面(53)とアーチ溝(57)との最大距離(H)から端子(31)の厚さ(T)の2倍を減じた値以上である。
【選択図】図5
Description
(1)
複数の導体芯線が束ねられた芯線束を有する電線に端子が圧着された端子付き電線の製造方法であって、
前記芯線束に対して超音波接合処理を施すことによって前記複数の導体芯線が互いに接合された接合芯線を形成する工程と、端子圧着機を用いて前記接合芯線に前記端子を圧着する工程と、を含み、
前記端子は、
前記接合芯線が載置されることになる基底部、及び、前記接合芯線を挟むように前記基底部から延設される一対の圧着片、を有し、
前記端子圧着機は、
前記基底部を支持することになる支持面を有するアンビル、及び、前記支持面から離れる向きに突出すると共に前記接合芯線の長さ方向に延び且つ幅方向に並ぶ2つの円弧面から構成されたアーチ溝であって前記一対の圧着片を前記接合芯線に向けて湾曲させることになるアーチ溝を有するクリンパ、を有すると共に、前記支持面と前記円弧面とに挟まれる空間の形状が所定の圧着形状となる圧着完了状態まで前記アンビルと前記クリンパとを近付けることによって前記圧着を行い、
前記接合芯線は、
前記圧着の前における該接合芯線の軸線に直交する断面の幅が、前記アーチ溝の幅から前記端子の厚さの2倍を減じた値以下であり、且つ、前記圧着の前における前記断面の高さが、前記圧着完了状態における前記支持面と前記円弧面との最大距離から前記端子の厚さの2倍を減じた値以上である、ように形成される、
端子付き電線の製造方法であること。
(2)
上記(1)に記載の製造方法において、
前記複数の導体芯線が、
アルミニウム又はアルミニウム合金から形成されている、
端子付き電線の製造方法であること。
以下、図面を参照しながら、本発明の実施形態に係る端子付き電線の製造方法について説明する。
図1(a)に示すように、電線11の端部の絶縁被覆14を皮剥きし、導体芯線12を束ねた芯線束13を所定長さだけ露出させる。露出させる芯線束13の所定長さは、端子31を圧着するのに十分な長さであればよい。
図1(b)に示すように、電線11の端部で露出させた芯線束13を超音波接合することにより、複数の導体芯線12が互いに接合された接合芯線13Aを形成する。具体的には、図3に示すように、露出させた芯線束13を超音波接合機20の成形空間Sに配置させ、グライディングジョー23をアンビルプレート22に近接する方向(図3中の矢印A方向)へ移動させるとともにアンビル24をホーン21に近接する方向(図3中の矢印B方向)へ移動させ、成形空間S内の芯線束13を両側及び上下から押圧する。そして、この状態にて、ホーン21を超音波振動させる。これにより、成形空間Sにおいて、導体芯線12の表面に形成された酸化皮膜が破壊されながら、導体芯線12同士が互いに接合する。これにより、図2(b)に示すように、断面形状が幅Xかつ高さYである矩形状の接合芯線13Aが形成される。このようにして形成された接合芯線13Aでは、導体芯線12同士が接合されて一体化(単線化)しており、導体芯線12同士が良好に導通した状態となっている。
図1(d)に示すように、端子圧着機51を用いて接合芯線13Aに端子31を圧着する。具体的には、まず、図5(b)に示すように、アンビル52の支持面53に端子31を載せて支持させ、この端子31に電線11の端部を配置させる。ここで、圧着前の端子31は、基底部42から延設された導体圧着片43同士の内面側の間隔が、クリンパ55のアーチ溝57の幅Wから端子31の厚さTの2倍を減じた値(基準幅=W−2T)よりも十分に大きくなっている。よって、電線11の接合芯線13Aを端子31の導体圧着部41へ配置させる際、幅Xが基準幅以下(X≦W−2T)である接合芯線13Aは、端子31の導体圧着片43に引っ掛かることなく、導体圧着部41内に配置されることになる。
なお、本発明は上記各実施形態に限定されることはなく、本発明の範囲内において種々の変形例を採用できる。例えば、本発明は、上述した実施形態に限定されるものではなく、適宜、変形、改良、等が可能である。その他、上述した実施形態における各構成要素の材質、形状、寸法、数、配置箇所、等は本発明を達成できるものであれば任意であり、限定されない。
(1)
複数の導体芯線(12)が束ねられた芯線束(13)を有する電線(11)に端子(31)が圧着された端子付き電線(1)の製造方法であって、
前記芯線束(13)に対して超音波接合処理を施すことによって前記複数の導体芯線が互いに接合された接合芯線(13A)を形成する工程と、端子圧着機(51)を用いて前記接合芯線(13A)に前記端子(31)を圧着する工程と、を含み、
前記端子(31)は、
前記接合芯線(13A)が載置されることになる基底部(42)、及び、前記接合芯線を挟むように前記基底部から延設される一対の圧着片(43)、を有し、
前記端子圧着機(51)は、
前記基底部(42)を支持することになる支持面(53)を有するアンビル(52)、及び、前記支持面(53)から離れる向きに突出すると共に前記接合芯線の長さ方向に延び且つ幅方向に並ぶ2つの円弧面(57a)から構成されたアーチ溝(57)であって前記一対の圧着片(43)を前記接合芯線(13A)に向けて湾曲させることになるアーチ溝(57)を有するクリンパ(55)、を有すると共に、前記支持面(53)と前記円弧面(57a)とに挟まれる空間の形状が所定の圧着形状となる圧着完了状態まで前記アンビルと前記クリンパとを近付けることによって前記圧着を行い、
前記接合芯線(13A)は、
前記圧着の前における該接合芯線(13A)の軸線に直交する断面の幅(X)が、前記アーチ溝の幅(W)から前記端子の厚さ(T)の2倍を減じた値以下(X≦W−2T)であり、且つ、前記圧着の前における前記断面の高さ(Y)が、前記圧着完了状態における前記支持面と前記円弧面との最大距離(H)から前記端子の厚さ(T)の2倍を減じた値以上(Y≧H−2T)である、ように形成される、
端子付き電線の製造方法。
(2)
上記(1)に記載の製造方法において、
前記複数の導体芯線(12)が、
アルミニウム又はアルミニウム合金から形成されている、
端子付き電線の製造方法。
11 電線
12 導体芯線
13 芯線束
13A 接合芯線
31 端子
42 基底部
43 導体圧着片(圧着片)
51 端子圧着機
52 アンビル
53 支持面
55 クリンパ
57 アーチ溝
X 接合芯線の幅
Y 接合芯線の高さ
W アーチ溝の幅
T 端子の厚さ
H 最大距離
Claims (2)
- 複数の導体芯線が束ねられた芯線束を有する電線に端子が圧着された端子付き電線の製造方法であって、
前記芯線束に対して超音波接合処理を施すことによって前記複数の導体芯線が互いに接合された接合芯線を形成する工程と、端子圧着機を用いて前記接合芯線に前記端子を圧着する工程と、を含み、
前記端子は、
前記接合芯線が載置されることになる基底部、及び、前記接合芯線を挟むように前記基底部から延設される一対の圧着片、を有し、
前記端子圧着機は、
前記基底部を支持することになる支持面を有するアンビル、及び、前記支持面から離れる向きに突出すると共に前記接合芯線の長さ方向に延び且つ幅方向に並ぶ2つの円弧面から構成されたアーチ溝であって前記一対の圧着片を前記接合芯線に向けて湾曲させることになるアーチ溝を有するクリンパ、を有すると共に、前記支持面と前記円弧面とに挟まれる空間の形状が所定の圧着形状となる圧着完了状態まで前記アンビルと前記クリンパとを近付けることによって前記圧着を行い、
前記接合芯線は、
前記圧着の前における該接合芯線の軸線に直交する断面の幅が、前記アーチ溝の幅から前記端子の厚さの2倍を減じた値以下であり、且つ、前記圧着の前における前記断面の高さが、前記圧着完了状態における前記支持面と前記円弧面との最大距離から前記端子の厚さの2倍を減じた値以上である、ように形成される、
端子付き電線の製造方法。 - 請求項1に記載の製造方法において、
前記複数の導体芯線が、
アルミニウム又はアルミニウム合金から形成されている、
端子付き電線の製造方法。
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2016108900A JP6574736B2 (ja) | 2016-05-31 | 2016-05-31 | 端子付き電線の製造方法 |
DE102017209028.6A DE102017209028A1 (de) | 2016-05-31 | 2017-05-30 | Herstellungsverfahren für Elektrokabel mit Klemme |
US15/608,354 US10483657B2 (en) | 2016-05-31 | 2017-05-30 | Manufacturing method for electric wire having terminal |
CN201710400839.8A CN107453182B (zh) | 2016-05-31 | 2017-05-31 | 具有端子的电线的制造方法 |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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JP6646872B2 (ja) * | 2016-03-09 | 2020-02-14 | 株式会社オートネットワーク技術研究所 | 端子付き電線の製造方法及び端子付き電線 |
CN107342466B (zh) * | 2017-06-05 | 2019-07-16 | 吉林省中赢高科技有限公司 | 一种铜端子与铝导线的接头及其超声波焊接方法 |
DE102017124693B3 (de) * | 2017-10-23 | 2018-11-29 | Lisa Dräxlmaier GmbH | Verfahren zum stoffschlüssigen Fügen einer elektrischen Leitung an ein elektrisches Kontaktteil |
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US11664608B2 (en) * | 2020-03-20 | 2023-05-30 | Lear Corporation | Electrical assembly and method |
CN112103458B (zh) * | 2020-09-23 | 2022-11-11 | 长春富超威硕科技有限公司 | 防氧化快速接线电瓶 |
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JP2011090804A (ja) * | 2009-10-20 | 2011-05-06 | Autonetworks Technologies Ltd | 端子金具付き電線および端子金具付き電線の製造方法 |
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