JP2021163732A - Electric wire with terminal, wiring harness, and manufacturing method for electric wire with terminal - Google Patents

Abstract

To provide an electric wire with a terminal, or the like, which suppresses a manufacturing cost, and has an excellent anti-corrosive performance.SOLUTION: In at least one part of an inner face of a conductive wire crimping part 7, a plurality of serrations 19 are provided in a width direction (in a direction vertical to a longitudinal direction). In at least tip end part of a conductive wire 13 exposed from a coated part 15, a first element wire integrated part 13a to which both element wires are welded and integrated is formed. Also, an element wire bundle part 13b to which both the element wires are not welded and integrated is formed between the element wire integrated part 13a and the coated part 15. In the conductive wire crimping part 7, the conductive wire 13 is crimped. At the time, near a tip end part of the conductive wire crimping part 7, at least one part of the element wire integrated part 13a is crimped. More specifically, the element wire integrated part 13a is crimped with the conductive wire crimping part 7 in at least a range from the tip end part of the conductive wire crimping part 7 to the serration 19 on the foremost side of the conductive wire crimping part 7.SELECTED DRAWING: Figure 2

Description

The present invention relates to, for example, a method for manufacturing a terminal-attached electric wire, a wire harness, and a terminal-attached electric wire used in an automobile or the like.

After the crimp terminal is connected to the conductor, the covered electric wire is bundled into a wire harness and distributed for power supply of an automobile or the like. To connect the crimp terminal to the coated wire, the insulating coating on the end portion of the coated wire is removed to expose the conductor, and then the exposed portion of the conductor is crimped by the crimp portion of the crimp terminal. By crimping, the wire constituting the conductor comes into contact with the crimping portion of the crimping terminal, and conduction between the coated electric wire and the crimping terminal can be obtained.

However, especially in wire harnesses used in automobiles, wires made of aluminum (including aluminum alloy) are often used for weight reduction. A stronger oxide film is formed on the surface of the aluminum wire as compared with the copper or copper alloy wire. Such an oxide film causes deterioration of the conductivity between the coated electric wire and the terminal.

For example, when the conductor of a coated electric wire and the crimp terminal are connected, the portion where the crimp terminal and the conductor are in direct contact with each other is likely to obtain continuity, but the contact portion between the strands is not strongly compressed to form an oxide film. It is not destroyed and it is difficult to obtain good continuity. Such an effect becomes particularly remarkable when the number of wires constituting the conductor is large and the number of wires not in direct contact with the crimp terminal is large, and the resistance value of the crimp portion tends to be high. Further, in the case of a thick (large diameter) covered electric wire, this problem tends to be remarkable. Here, the thick material means that the conductor is mainly 3 sq or more in thickness in the case of a covered electric wire used for an automobile.

In order to reduce the resistance between the wires constituting the conductor, a method of strongly compressing the pressure-bonded portion to break the oxide film can be considered. However, there is a problem that the wire is cut due to excessive compression and the crimped portion of the crimping terminal is greatly extended.

On the other hand, a method of bonding strands by ultrasonic bonding has been proposed (Patent Document 1). However, when the strands are bonded by ultrasonic bonding, the bonding portion of the strands is greatly extended and deformed by the pressure applied to the strands. As a result, when the crimp terminals are connected, the conductor may not fit within a predetermined range, and problems such as protrusion from the crimp portion or difficulty in obtaining a good crimp shape may occur.

Similarly, a method of joining the strands with solder has been proposed (Patent Document 2). However, when the strands are joined by soldering, there is a problem that the cost of soldering increases and the solder adhesion distance varies depending on the surface condition of the strands. In addition, since the solder is a metal different from the wire, the adhesion of moisture causes corrosion of dissimilar metals, which will be described later, and the impact causes cracks in the solder and the solder to fall off. It was hard to expect.

Further, when bonded by ultrasonic bonding, the cross-sectional shape of the bonded portion becomes substantially rectangular, and when bonded by soldering, the cross-sectional shape becomes an indefinite shape such as an ellipse depending on the soldered state. Therefore, when the joint portion or the solder portion is arranged in the crimping portion of the terminal and crimped, there is a problem that the stability in the crimping portion is poor and it is difficult to crimp to a desired crimping shape.

On the other hand, a method of joining the strands by laser welding or arc welding has also been proposed (Patent Document 3). By integrating the strands by laser welding or arc welding, the stability is better when placed at the crimping part of the terminal compared to ultrasonic bonding or solder bonding, and the desired crimping shape can be obtained. It becomes easier to crimp.

Japanese Patent No. 5428722 Japanese Unexamined Patent Publication No. 2010-225529 Japanese Patent No. 6373077

On the other hand, when the metal materials constituting each of the terminal and the conductor of the electric wire are different metal materials, if an electrolytic solution such as water adheres to the connection portion between the terminal and the conductor, the standard electrode potentials of the two are different. , Corrosion current flows between a metal with high ionization tendency (base metal) and a metal with low ionization tendency (noble metal). As a result, the base metal becomes a metal ion, is dissolved in the solution, and is corroded. This is called galvanic corrosion (corrosion), which is a corrosion phenomenon that occurs when dissimilar metal materials are brought into contact with each other in an aqueous electrolyte solution.

Therefore, for example, when aluminum comes into direct contact with a nobler metal (such as copper) in an aqueous electrolyte solution for a long period of time, a local battery is formed, and the aluminum dissolves in the liquid and is ionized. Therefore, when an aqueous electrolyte solution such as salt water and air (oxygen) enter the contact portion between aluminum and copper, the corrosion of the aluminum is further accelerated.

In particular, since the standard electrode potential difference between aluminum and copper is large, if water splashes or dew condensation occurs on the contact part between the two due to running in rainy weather or car washing, corrosion on the electrically base aluminum side progresses. do. For this reason, the connection state between the electric wire and the terminal at the connection part becomes unstable, and there is a risk that the electrical resistance increases due to the increase in contact resistance and the decrease in wire diameter, and further, the disconnection occurs, resulting in malfunction or malfunction of the electrical component. be.

On the other hand, the rear end of the terminal is made of an aluminum material, the tip of the terminal is made of a copper material, the rear end of the terminal and the tip of the terminal are joined, and the joint is sealed with an insulator. The connection terminals and the like configured in this way have been proposed. However, this method has a problem that the structure and the manufacturing process become complicated.

On the other hand, in Patent Document 1 described above, the tips of the strands are integrated by arc welding or laser welding. However, in Patent Document 1, the portion to be crimped by the crimping portion is basically a non-integrated wire portion or only a small part of the wire integrated portion. That is, most of the wire-integrated portion is located outside the crimping portion, and the unintegrated wire-strand portion is located near the end of the crimping portion. Therefore, there is a problem that the electrolytic solution or air (oxygen) easily permeates the inside of the crimping portion from the gap of the wire portion, and contact corrosion of different metals inside the crimping portion is likely to occur.

For example, at the tip of the crimping portion, even if a part of the wire-integrated portion is crimped, the distance from the tip of the crimping portion to the internal strand is short. For this reason, if corrosion progresses at the joint surface between the wire-integrated portion and the terminal, the internal wire-wire portion is exposed in a short period of time. Therefore, the electrolytic solution and oxygen rapidly permeate into the gaps between the wire portions that appear, and as described above, the conductivity is lost at an early stage. On the other hand, if an attempt is made to improve the anticorrosion property by coating with a resin, the structure and the manufacturing process become complicated, and there is a problem that a large amount of resin is used, which is costly, especially for a thick material of 3 sq or more.

On the other hand, the inventors have found that, in particular, a thick wire of 3 sq or more has a thicker conductor and a smaller copper / aluminum surface area ratio than a wire of less than 3 sq, so that corrosion proceeds slowly. .. Therefore, it is presumed that the conduction durability of a thick electric wire can be improved by delaying the corrosion even if the costly resin sealing is not performed. However, even if it is a thick electric wire, it cannot be said that the conventional electric wire with a terminal has sufficient durability, and an electric wire with a terminal that can secure stable continuity for a longer period of time is available. It is required.

The present invention has been made in view of such a problem, and an object of the present invention is to provide an electric wire with a terminal having excellent corrosion resistance while suppressing a manufacturing cost.

In order to achieve the above-mentioned object, the first invention is an electric wire with a terminal in which a terminal and a coated wire are connected, and the covered wire is a wire composed of a plurality of strands and a covered portion covering the wire. The terminal has a wire crimping portion to which the wire is crimped, the coated portion at the tip of the coated wire is peeled off to expose the wire, and the covered wire is at least the wire. The tip portion has a first wire integrated portion in which the wires are welded and integrated, and a wire bundle portion between the first wire integrated portion and the end portion of the covering portion. Serrations are provided on at least a part of the inner surface of the lead wire crimping portion, and at least in the range from the tip end portion of the lead wire crimping portion to the serration on the tip end side of the lead wire crimping portion, the first wire integrated portion It is an electric wire with a terminal characterized in that it is crimped by the wire crimping portion.

The coated conductor has a second wire integrated portion in which the wires are welded and integrated between the first wire integrated portion and the end portion of the coated portion, and the conductor crimping portion. At the rear end portion, the second wire integrated portion may be crimped.

It is desirable that the wire bundle portion is located between the first wire bundle portion and the second wire bundle portion, and the wire bundle portion is not exposed at the front and rear ends of the conductor crimping portion.

In this case, it is desirable that the second wire-integrated portion is crimped by the lead wire crimping portion within a length range of at least 1 mm or more from the rear end of the lead wire crimping portion.

It is desirable that the first wire integrated portion is crimped by the lead wire crimping portion within a range of at least 1 mm or more from the tip of the lead wire crimping portion.

Assuming that the length of the first wire unifying portion is L, the first wire unifying portion is crimped by the conductor crimping portion within a length range of at least L / 2 or more from the tip of the conductor crimping portion. It is desirable that it is done.

At least, the first wire integrated portion exposed from the lead wire crimping portion may be coated with a resin.

According to the first invention, a first wire-integrated portion in which the wires are welded and integrated is formed at the tip of the conductor, and the portion is a serration (concave-convex groove / protrusion) of the conductor crimping portion. ) Is crimped. Therefore, at the time of crimping, the first wire integrated portion bites into the serration and the conductivity between the terminal and the conductor is exhibited. As a result, the wire bundle portion does not exist between the end of the wire crimping portion and the serration, and is filled with the first wire integrated portion, so that the arrival of moisture to the serration is delayed. It can be made to maintain continuity for a long period of time.

Further, a second wire-integrated portion in which the wires are welded and integrated is formed between the first wire-integrated portion and the end of the covering portion, and at the rear end of the conductor crimping portion, the first wire is integrated. By crimping the two-wire integrated portion, it is possible to delay the infiltration of water from the rear of the conductor crimping portion and the progress of corrosion.

In particular, the wire bundle portion is located between the first wire unifying portion and the second wire unifying portion so that the wire bundle portion is not exposed to the front and rear ends of the wire crimping portion. The continuity can be reliably maintained for a long period of time.

Further, if the second wire crimping portion is crimped by the conductor crimping portion within a length range of at least 1 mm or more from the rear end of the conductor crimping portion, the distance from the end of the conductor crimping portion to the wire bundle portion. Is sufficient, so that the conductivity can be maintained for a long period of time.

Similarly, if the first wire crimping portion is crimped by the conductor crimping portion within a length range of at least 1 mm or more from the tip of the conductor crimping portion, the distance from the end of the conductor crimping portion to the wire bundle portion. Is sufficient, so that the conductivity can be maintained for a long period of time.

In particular, assuming that the length of the first wire unifying portion is L, the first wire unifying portion is crimped by the conductor crimping portion within a range of at least L / 2 or more from the tip of the conductor crimping portion. Then, since the distance from the end of the conductor crimping portion to the wire bundle portion is sufficient, the conductivity can be maintained for a long period of time.

Further, by covering the first wire integrated portion exposed from the wire crimping portion with a resin, the corrosion resistance can be more reliably improved. Even in this case, a sufficient effect can be obtained even with a small amount of resin applied as compared with the conventional electric wire with a terminal.

The second invention is a wire harness characterized in that a plurality of electric wires with terminals according to the first invention are bundled.

According to the second invention, it is possible to obtain a wire harness in which a plurality of electric wires are joined.

The third invention is to manufacture an electric wire with a terminal in which a conductor composed of a plurality of strands, a coated conductor composed of a covering portion covering the conductor, and a terminal having a wire crimping portion to which the conductor is crimped are connected. In the method, the coated conductor is a first wire integrated portion in which the wires are welded and integrated with each other at at least the tip of the conductor exposed from the tip of the covered portion, and the first wire. The first wire is integrated so as to have a wire bundle portion between the integrated portion and the end portion of the covering portion, serrations are provided on at least a part of the inner surface of the conductor crimping portion, and the serrations are applied. This is a method for manufacturing an electric wire with a terminal, which comprises crimping the conducting wire with the conducting wire crimping portion in a state where the chemical portion is arranged.

The conductor is crimped by the conductor crimping portion in a state where the first wire integrating portion is arranged so that the maximum diameter portion of the first wire unifying portion before crimping is applied to the conductor crimping portion. Is desirable.

According to the third invention, it is possible to easily obtain an electric wire with a terminal capable of ensuring conductivity for a long period of time.

In particular, by crimping the conductor with the conductor crimping portion in a state where the first wire integrating portion is arranged so that the maximum diameter portion of the first wire integrating portion is applied to the conductor crimping portion, the wire integrating portion is formed. Can be reliably compressed together with the conductor crimping portion to suppress the occurrence of a gap between the conductor crimping portion and the wire-integrated portion after crimping.

According to the present invention, it is possible to provide an electric wire with a terminal and the like, which can suppress the manufacturing cost and have excellent corrosion resistance.

The perspective view which shows the electric wire 10 with a terminal. (A) is a cross-sectional view showing an electric wire 10 with a terminal, and (b) is an enlarged view of the vicinity of the tip of the wire crimping portion 7 of (a). An exploded perspective view of the electric wire 10 with a terminal. (A) and (b) are diagrams showing a manufacturing process of the electric wire 10 with a terminal. (A) and (b) are diagrams showing a manufacturing process of the electric wire 10 with a terminal. An exploded perspective view of another electric wire with a terminal. The figure which shows the manufacturing process of another electric wire with a terminal. (A) and (b) are diagrams showing the manufacturing process of other electric wires with terminals.

(First Embodiment)
Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a perspective view showing an electric wire 10 with a terminal, and FIG. 2A is a cross-sectional view. The terminal-equipped electric wire 10 is configured by connecting the terminal 1 and the coated conductor wire 11.

The coated conductor 11 includes a conductor 13 made of aluminum or an aluminum alloy, and a covering portion 15 that covers the conductor 13. The conductor 13 is, for example, a stranded wire in which a plurality of strands are twisted together. At the tip of the coated conductor 11, the coated portion 15 is peeled off, and the internal conductor 13 is exposed.

The terminal 1 is made of copper or a copper alloy. The terminal 1 is configured by connecting the terminal body 3 and the crimping portion 5. The terminal body 3 is a round terminal and is provided with a bolt fastening portion. The terminal body 3 may be a female terminal into which a male terminal or the like is inserted from the front end portion, or may be an insertion tab for the male terminal.

The crimping portion 5 of the terminal 1 is an open barrel type, and before crimping, the crimping portion 5 has a barrel shape having a substantially U-shaped cross section perpendicular to the longitudinal direction of the terminal 1. The crimping portion 5 of the terminal 1 is a wire crimping portion 7 for crimping the conducting wire 13, a covering crimping portion 9 for crimping the covering portion 15 of the coated conducting wire 11, and a barrel-to-barrel portion between the conducting wire crimping portion 7 and the covering crimping portion 9. It consists of eight.

That is, the coated portion 15 of the coated conductor 11 is crimped by the coated crimping portion 9 of the terminal 1, and the conducting wire 13 exposed by peeling the covering portion 15 is crimped by the conducting wire crimping portion 7. In the conductor crimping portion 7, the conductor 13 and the terminal 1 are electrically connected. The end face of the covering portion 15 is located at the barrel-to-barrel portion 8 between the covering crimping portion 9 and the lead wire crimping portion 7.

FIG. 2B is an enlarged view of the vicinity of the tip end portion (terminal body 3 side) of the lead wire crimping portion 7. A plurality of serrations 19 are provided in the circumferential direction on at least a part of the inner surface of the wire crimping portion 7. By forming the serrations 19 in this way, when the conductor 13 is crimped, the oxide film on the surface of the conductor 13 is easily broken, and the contact area with the conductor 13 can be increased.

A first wire-integrated portion 13a in which the wires are welded and integrated is formed at least at the tip of the conductor 13 exposed from the covering portion 15. Further, a wire bundle portion 13b in which the wires are not welded and integrated is formed between the wire integrated portion 13a and the end portion of the covering portion 15. That is, in the coated conductor 11, at least at the tip of the conductor 13, the first wire-integrated portion 13a in which the wires are welded and integrated, and the ends of the wire-integrated portion 13a and the covering portion 15 It has a wire bundle portion 13b between them.

The wire-integrated portion 13a is formed by, for example, laser welding or arc welding. At this time, in the case of laser welding, the strands are melted and integrated by irradiating the laser from a direction perpendicular to the longitudinal direction of the lead wire 13 in the vicinity of the tip portion of the lead wire 13. Further, in the case of arc welding, an arc is discharged from the tip side of the conducting wire 13 in a direction parallel to the longitudinal direction of the conducting wire 13, and the strands are melted and integrated.

As described above, in the conductor crimping portion 7, the conductor 13 is crimped. At this time, at least a part of the wire unifying portion 13a is crimped in the vicinity of the tip portion of the lead wire crimping portion 7. More specifically, at least in the range from the tip of the conductor crimping portion 7 to the serration 19 on the most tip side of the conductor crimping portion 7, the wire integrated portion 13a is crimped by the conductor crimping portion 7. That is, the conductor 13 is crimped with at least a part of the wire-integrated portion 13a applied to the serration 19 on the most advanced side.

Normally, during crimping, when the conductor 13 is pushed into the serration 19, the oxide film on the surface is destroyed, so that the conduction between the conductor 13 and the conductor crimping portion 7 can be ensured more reliably. Therefore, it is necessary to suppress the corrosion of the contact portion between the serration 19 and the conducting wire 13 in order to ensure the continuity between the two for a long period of time.

In the present embodiment, the area from the tip of the wire crimping portion 7 to the serration 19 on the most advanced side is composed of the wire integrated portion 13a. As described above, if the wires are not integrated with each other, moisture rapidly permeates the gaps and the like, and corrosion progresses to the inside at an early stage. The strands are integrated up to the serration 19 on the tip side, and there is no gap between the strands. Therefore, even if corrosion occurs at the contact portion between the conductor 13 and the conductor crimping portion 7 at the tip of the conductor crimping portion 7, it takes a considerable amount of time for the corrosion to proceed to serration 19. Therefore, continuity between the two can be ensured for a long period of time.

Here, the length (A in the figure) in the range from the tip of the lead wire crimping portion 7 to the rear end of the wire unifying portion 13a (the end on the covering crimping portion 9 side) is 1 mm or more. Is desirable. That is, it is desirable that the wire-integrated portion 13a is crimped by the lead wire crimping portion 7 within a length range of at least 1 mm or more from the tip of the lead wire crimping portion 7.

Further, the length (A in the figure) in which the wire-integrated portion 13a is crimped by the lead wire crimping portion 7 is at least L with respect to the total length (L in the figure) from the tip of the wire-integrated portion 13a. It is desirable that the length is in the range of / 2 or more. In this way, by lengthening the crimping length of the wire-integrated portion 13a to a predetermined value or longer, the length from the tip of the conductor crimping portion 7 to the wire bundle portion 13b can be secured, and the conductor wire 13 can be secured for a long period of time. And the conductive wire crimping portion 7 can be ensured in conductivity, and the durability can be further improved.

As shown in the drawing, a part of the wire unifying portion 13a may protrude from the tip of the conductor crimping portion 7, or all of the wire unifying portion 13a is inside the conductor crimping portion 7. It may be crimped. Further, the wire-integrated portion 13a does not have to cover the entire serration 19 on the most advanced side, and a part of the end portion of the wire-integrated portion 13a becomes a part of the serration 19 on the most advanced side. It just needs to be on. Further, the wire-integrated portion 13a may be applied to a plurality of serrations 19.

If the whole is to be the wire-integrated portion 13a, the whole will be spheroidized due to surface tension, and crimping will be difficult. Further, since the wire bundle portion 13b is easier to be deformed than the wire bundle integrated portion 13a, by crimping the wire bundle portion 13b, the conductor 13 is easily deformed at the time of crimping and crimped in a desired shape. can do.

Next, a method of manufacturing the electric wire 10 with terminals will be described. FIG. 3 is a perspective view showing the terminal 1 and the coated conductor 11 before crimping. As described above, the terminal 1 is an open barrel type terminal connected to the coated conductor wire 11. The terminal 1 has a terminal body 3 and a crimping portion 5, and the crimping portion 5 is a barrel-to-barrel portion 8 between a lead wire crimping portion 7, a coated crimping portion 9, and a conducting wire crimping portion 7 and a covering crimping portion 9. It consists of. A plurality of serrations 19 are formed on the lead wire crimping portion 7 so as to be continuous in a predetermined range in the width direction (circumferential direction).

First, the coated portion 15 having a predetermined length at the tip of the coated conducting wire 11 is peeled off to expose the internal conducting wire 13. Next, a wire-integrated portion 13a is formed at the tip of the conducting wire 13. The wire-integrated portion 13a is formed by, for example, laser welding or arc welding. The wire-integrated portion 13a may not be completely spherical as shown in the drawing, as long as the wires are welded and integrated. At this time, the wire bundle portion 13b is formed between the wire integrated portion 13a and the end portion of the covering portion 15.

Next, as shown in FIGS. 4A and 4B, the exposed conductor 13 is arranged at the position of the conductor crimping portion 7, and the covering portion 15 is arranged at the position of the covering crimping portion 9. That is, the end portion of the covering portion 15 is located at the inter-barrel portion 8. At this time, the conductor 13 is arranged in the conductor crimping portion 7 so that at least a part of the wire integrated portion 13a is applied to the serration 19 on the most advanced side. Further, the conductor 13 is led so that the maximum diameter portion 14 (the portion having the widest width in the direction perpendicular to the longitudinal direction of the conductor 13) of the wire integrated portion 13a before crimping is located inside the conductor crimping portion 7. It is arranged in the crimping portion 7.

In this way, by crimping in this state so that a part of the wire-integrated portion 13a is applied to the serration 19, after crimping, in the range from the tip of the lead wire crimping portion 7 to the serration 19 on the most advanced side. , The wire-integrated portion 13a can be reliably arranged.

Further, by arranging the conductor 13 in the conductor crimping portion 7 so that the maximum diameter portion 14 of the wire unifying portion 13a before crimping is located inside the conductor crimping portion 7, the wire unifying portion is crimped. 13a can be reliably crimped by the conductor crimping portion 7. At this time, a gap is unlikely to occur between the wire-bonded integrated portion 13a and the wire crimping portion 7 after crimping.

For example, if an attempt is made to crimp only the rear end side (near the boundary with the wire bundle portion 13b) of the substantially spherical wire unifying portion 13a from the maximum diameter portion 14, the wire unifying portion 13a will be crimped at the time of crimping. There is a risk of moving so as to escape to the tip end side of the conductor crimping portion 7. Therefore, it is difficult to compress and deform the wire-integrated portion 13a into the compressed shape of the wire crimping portion 7. For this reason, a gap is likely to occur between the wire-bonded integrated portion 13a and the wire crimping portion 7 after crimping. In the present embodiment, by crimping the maximum diameter portion 14 of the wire-integrated portion 13a, the maximum diameter portion 14 does not easily escape toward the tip of the wire crimping portion 7 at the time of crimping, and the wire-integrated portion 13a is reliably connected to the wire. It can be deformed inside the crimping portion 7 to be deformed into the compressed shape of the conducting wire crimping portion 7.

Further, in the substantially spherical wire integration portion 13a, the maximum diameter portion 14 is usually located at a substantially center of the strand integration portion 13a (a substantially center in the longitudinal direction of the conductor 13). Therefore, by crimping the maximum diameter portion 14 of the wire unifying portion 13a with the conductor crimping portion 7, when the length of the wire unifying portion 13a after crimping is set to L, the tip of the conductor crimping portion 7 The wire integrated portion 13a can be crimped in a length range of at least L / 2 or more. More preferably, the maximum diameter portion 14 of the wire-integrated portion 13a before crimping is crimped in a state where the wire-integrated portion 13a is arranged in the conductor crimping portion 7 so as to cover the serration 19 on the most advanced side. Is desirable.

In this state, as shown in FIG. 5A, the lead wire crimping portion 7 and the covering crimping portion 9 are crimped. As described above, the electric wire 10 with a terminal is formed. Further, by bundling and integrating a plurality of electric wires 10 with terminals, it is possible to obtain a wire harness in which a plurality of electric wires are joined.

As described above, reliability can be ensured for a sufficiently long period of time as it is, but further, as shown in FIG. 5B, at least the wire-integrated portion exposed from the lead wire crimping portion 7. 13a may be coated with the resin coating portion 17. The resin coating portion 17 is, for example, a photocurable resin, a moisture-curable resin, or the like, and can be obtained by curing the resin after coating. By doing so, the corrosion resistance can be further improved.

In this embodiment, since the wire-integrated portion 13a is crimped, it takes time for the corrosion to progress to the inside. Therefore, a very small amount (thin) of the resin-coated portion 17 is sufficiently effective as compared with the case where the conventional electric wire with terminals is coated with resin to ensure the corrosion resistance only with the resin. Further, the resin coating portion 17 may be arranged in the inter-barrel portion 8, or the tip of the electric wire may be coated with the resin only in the inter-barrel portion 8 without the resin coating.

As described above, according to the present embodiment, the wire integrated portion 13a is formed at the tip end portion of the conductor wire 13, and the portion is crimped so as to cover the serration 19 of the conductor wire crimping portion 7. , The arrival of corrosion on the serrations 19 can be delayed. As a result, continuity can be maintained for a long period of time.

Further, a wire bundle portion 13b in which the wires are not welded and integrated is formed between the wire integrated portion 13a and the end portion of the covering portion 15, and the wire bundle portion 13b is crimped by the conductor crimping portion 7. NS. At the time of crimping, the wire bundle portion 13b is easily deformed, so that the conductor wire 13 can be more reliably crimped by following the shape of the conductor crimping portion 7.

Further, since the wire-integrated portion 13a is crimped by the conductor crimping portion 7 within a range of a predetermined length or more from the tip of the conductor crimping portion 7, the wire crimping portion 7 is crimped from the end of the wire crimping portion 7 to the wire bundle portion 13b. A sufficient distance can be secured and conductivity can be maintained for a long period of time.

Further, by covering the wire-integrated portion 13a exposed from the lead wire crimping portion 7 with the resin coating portion 17, the corrosion resistance can be more reliably improved.

(Second Embodiment)
Next, the second embodiment will be described. FIG. 6 is a diagram showing a method of manufacturing an electric wire with a terminal according to the second embodiment. In the following description, the same reference numerals as those in FIGS. 1 to 5 will be given to the configurations that perform the same functions as those in the first embodiment, and duplicate description will be omitted.

The second embodiment is different from the first embodiment in that the wire-integrated portions 13a and 13c are formed in the conductor wire 13 exposed from the covering portion 15. In the second embodiment, the coated conductor 11 has a second wire-integrated portion 13c in which the wires are welded and integrated between the wire-integrated portion 13a and the end of the covering portion 15. .. That is, the wire bundle portion 13b is located between the wire unifying portion 13a and the wire unifying portion 13c. The wire-integrated portion 13c is also formed in the same manner as the wire-integrated portion 13a.

Next, as shown in FIG. 7, the conductor 13 is arranged in the conductor crimping portion 7 so that at least a part of the wire-integrated portion 13a covers the serration 19 on the most advanced side. Further, as described above, the conductor 13 is arranged in the conductor crimping portion 7 so that the maximum diameter portion 14 of the wire unifying portion 13a before crimping is located inside the conductor crimping portion 7.

At this time, at least a part of the wire-integrated portion 13c is arranged so as to cover the wire crimping portion 7. Desirably, the conductor 13 is arranged in the conductor crimping portion 7 so that at least a part of the wire integrated portion 13c is applied to the serration 19 on the rearmost end side. Further, it is more desirable that the conductor 13 is arranged in the conductor crimping portion 7 so that the maximum diameter portion 14a of the wire unifying portion 13c before crimping is located inside the conductor crimping portion 7.

That is, the distance between the wire unifying portion 13a and the wire unifying portion 13c before crimping (the length of the wire bundle portion 13b) is shorter than the length of the wire crimping portion 7, and more preferably, the state-of-the-art serration 19 It is shorter than the interval of the serration 19 at the end. Further, more preferably, the distance between the maximum diameter portion 14 of the wire-integrated portion 13a and the maximum diameter portion 14a of the wire-integrated portion 13c before crimping is such that the distance between the tip end portion of the most advanced serration 19 and the end end serration 19 Shorter than the length to the rear end.

In this state, as shown in FIG. 8A, the lead wire crimping portion 7 and the covering crimping portion 9 are crimped. Therefore, at the tip of the conductor crimping portion 7, the wire unifying portion 13a is crimped, at the rear end of the conductor crimping portion 7, the wire unifying portion 13c is crimped, and the wire bundle portion 13b is crimped with the conductor. It is not exposed at the front and rear ends of the part 7. It is desirable that the wire-integrated portion 13c is crimped by the wire crimping portion 7 within a length range of at least 1 mm or more from the rear end of the wire crimping portion 7. That is, it is desirable that the wire-integrated portion 13c is also crimped within the same length range as the wire-integrated portion 13a.

As described above, the electric wire 10a with a terminal is formed. Further, even in this case, as shown in FIG. 8B, at least the wire-integrated portions 13a and 13c exposed from the conductor crimping portion 7 may be covered with the resin coating portion 17, or the conductor crimping portion 7 may be covered. Only one of the wire-integrated portions 13a and 13c exposed from the wire may be coated with the resin coating portion 17.

According to the second embodiment, the same effect as that of the first embodiment can be obtained. Further, by forming the wire-integrated portion 13c, the wire-integrated portions 13a and 13c can be crimped at the front and rear ends of the conductor crimping portion 7, and the wire bundled portion 13b is placed outside the conductor crimping portion 7. It is possible to suppress exposure. Therefore, the corrosion resistance can be improved more reliably.

Although the embodiment of the present invention has been described above with reference to the attached drawings, the technical scope of the present invention does not depend on the above-described embodiment. It is clear that a person skilled in the art can come up with various modifications or modifications within the scope of the technical ideas described in the claims, and these are naturally within the technical scope of the present invention. It is understood that it belongs.

For example, the present invention is particularly effective for a thick (3 sq or more) coated electric wire, but is naturally applicable to a coated electric wire having a smaller diameter.

1 ………… Terminal 3 ………… Terminal body 5 ………… Crimping part 7 ………… Lead wire crimping part 8 ………… Barrel inter-barrel part 9 ………… Covered crimping part 10, 10a ………… Wire with terminal 11 …… ... Covered wire 13 ......... Wire 13a, 13c ......... Wire integrated part 13b ......... Wire bundled part 14, 14a ......... Maximum diameter part 15 ......... Covered part 17 ......... Resin coated part 19 ... ...... Serration

Claims (10)

An electric wire with terminals that connects terminals and coated conductors.
The coated conductor is composed of a conductor composed of a plurality of strands and a covering portion covering the conductor.
The terminal has a conductor crimping portion to which the conductor is crimped.
The coated portion at the tip of the coated conductor is peeled off to expose the conductor.
The coated conductor is formed between a first wire integrated portion in which the wires are welded and integrated, and an end portion between the first wire integrated portion and the coated portion at least at the tip of the conductor. Has a wire bundle part of
Serrations are provided on at least a part of the inner surface of the wire crimping portion.
With a terminal, at least in the range from the tip of the conductor crimping portion to the serration on the tip side of the conductor crimping portion, the first wire integrated portion is crimped by the conductor crimping portion. Electrical wire. The coated wire has a second wire integrated portion in which the wires are welded and integrated between the first wire integrated portion and the end portion of the coated portion, and the wire crimping portion. The electric wire with a terminal according to claim 1, wherein the second wire integrated portion is crimped at the rear end portion. The wire bundle portion is located between the first wire unifying portion and the second wire unifying portion, and the wire bundle portion is not exposed at the front and rear ends of the lead wire crimping portion. The electric wire with a terminal according to claim 2. 2. Electric wire with terminals. Any of claims 1 to 4, wherein the first wire-integrated portion is crimped by the lead wire crimping portion within a range of at least 1 mm or more from the tip of the lead wire crimping portion. Wire with terminal described in. Assuming that the length of the first wire integrated portion is L, the first wire integrated portion is crimped by the lead wire crimping portion within a range of at least L / 2 or more from the tip of the lead wire crimping portion. The electric wire with a terminal according to any one of claims 1 to 5, wherein the electric wire is provided. The electric wire with a terminal according to any one of claims 1 to 6, wherein at least the first wire integrated portion exposed from the lead wire crimping portion is coated with a resin. A wire harness according to any one of claims 1 to 7, wherein a plurality of electric wires with terminals are bundled. A method for manufacturing an electric wire with a terminal, in which a conductor composed of a plurality of strands, a coated conductor composed of a covering portion covering the conductor, and a terminal having a wire crimping portion to which the conductor is crimped are connected.
The coated conductor is a first wire integrated portion in which the wires are welded and integrated, and the first wire integrated portion and the above, at least at the tip of the conductor exposed from the tip of the coated portion. It has a wire bundle between the end of the covering and
Serrations are provided on at least a part of the inner surface of the wire crimping portion.
A method for manufacturing an electric wire with a terminal, which comprises crimping the conductor wire with the conductor wire crimping portion in a state where the first wire integrated portion is arranged so as to cover the serration. The conductor is crimped by the conductor crimping portion in a state where the first wire integrating portion is arranged so that the maximum diameter portion of the first wire crimping portion before crimping is applied to the conductor crimping portion. 9. The method for manufacturing an electric wire with a terminal according to claim 9.

Images