JP2022015510A - Terminal-equipped wire, and manufacturing method and design method thereof - Google Patents

Abstract

To provide a terminal-equipped wire that can eliminate the harmful effects of increased electrical resistance at a terminal, and improve the flexibility and bending property, and a manufacturing method and a design method thereof.SOLUTION: In a terminal-equipped wire 10A, exposed conductive wires 3 at both ends of a plurality of wires 1 (1A, 1B, 1C) whose outer periphery of a conductive wire 3 is covered with an insulating coating 2 are ultrasonically bonded, and a copper 4 which is a conductive metal is crimped to joint portions 6 at both ends thereof, and terminals 5 are respectively formed to the joint portions.SELECTED DRAWING: Figure 1

Description

The present invention relates to an electric wire with a terminal, a method for manufacturing an electric wire with a terminal, and a method for designing an electric wire with a terminal.

In recent years, for example, in the automobile industry, due to the increasing demand for hybrid automobiles, electric automobiles, and the like, digitization has further progressed, and electric wires with terminals have been used more and more.

For example, in the conventional method for manufacturing an electric wire with a terminal disclosed in Patent Document 1, a preliminary step of roughening the surface of the wire constituting the conductive wire is performed, an oxide film is removed, and then ultrasonic bonding is performed. A joint is formed, a conductive metal is crimped to this joint, and a terminal is formed at the end of the electric wire to eliminate the harmful effects of an increase in electrical resistance at the terminal due to the oxide film.

Japanese Unexamined Patent Publication No. 2009-23179

However, in the conventional electric wires with terminals including those disclosed in Patent Document 1, in order to pass a large current, the outer diameter of the electric wire becomes larger by that amount, and the flexibility and flexibility are lowered. For example, there are cases where it is difficult to pass through a narrow space such as a hybrid vehicle or an electric vehicle.

Against this background, there is a demand for the development of electric wires with terminals that can eliminate the harmful effects of increased electrical resistance in the terminals and improve flexibility and flexibility.

An object of the present invention is an electric wire with a terminal, a method for manufacturing an electric wire with a terminal, and a method for designing an electric wire with a terminal, which can eliminate harmful effects due to an increase in electrical resistance at the terminal and can improve flexibility and flexibility. Is to provide.

In the electric wire with a terminal of the present invention, the exposed conductive wires at both ends of a plurality of electric wires whose outer periphery is covered with an insulating coating are ultrasonically bonded, and the conductive metal is bonded to the joints at both ends. Is crimped to form terminals respectively.

According to the electric wire with a terminal of the present invention as described above, it is possible to eliminate the harmful effect due to the increase in electric resistance in the terminal, and to improve the flexibility and flexibility.

It is a top view which shows the electric wire with a terminal which concerns on one Embodiment of this invention. It is a side view of the electric wire with a terminal of FIG. In the insulation coating removal step of the method for manufacturing a terminald electric wire according to an embodiment of the present invention, (a) is a plan view showing an electric wire before the insulation coating is removed, and (b) is an electric wire after the insulation coating is removed. It is a top view which shows. FIG. 5 is a side view showing a state in which a conductive wire at a tip portion of a plurality of electric wires is set in a concave portion of a horn in the ultrasonic bonding step of the method for manufacturing an electric wire with a terminal of the present embodiment. A side surface showing a state in which a conductive wire at the tip of a plurality of electric wires is set in a concave portion of a horn, and then an anvil is closed for bonding in the ultrasonic bonding step of the method for manufacturing a wire with a terminal of the present embodiment. It is a figure. FIG. 5 is a side view showing a state in which bonding of conductive wires at the tips of a plurality of electric wires in a device is completed in the ultrasonic bonding step of the method for manufacturing a wire with a terminal of the present embodiment. It is a top view which shows the electric wire with terminal of the single electric wire which is the comparison target in the design method of the electric wire with terminal of this embodiment.

Hereinafter, an embodiment of the present invention will be described with reference to FIGS. 1 to 7. 1 and 2 are explanatory views for explaining the structure of the electric wire with terminal 10A of the present embodiment, and FIGS. 3 to 7 are a method of manufacturing the electric wire with terminal and the electric wire with terminal of the present embodiment. It is explanatory drawing for demonstrating a design method.

In the electric wire 10A with terminals of the present embodiment, the exposed conductive wires 3 at both ends of the plurality of electric wires 1 (1A, 1B, 1C) whose outer periphery of the conductive wire 3 is covered with the insulating coating 2 are ultrasonically bonded. Copper 4 (conductive metal) is crimped to the bonding portions 6 at both ends thereof, and terminals 5 and 5 are formed, respectively.

Although not shown, the conductive wire 3 in the plurality of electric wires 1 (1A, 1B, 1C) is composed of a plurality of strands made of aluminum. Further, the conductive wires 3 in the plurality of electric wires 1 (1A, 1B, 1C) have the same diameter and are ultrasonically bonded by arranging them in a direction orthogonal to the length direction thereof (described later). Further, the copper 4 forming the terminals 5 and 5 has a first caulking piece 4a, 4a and a second caulking piece 4b, 4b, and the joint portion 6 is crimped by the first caulking piece 4a, 4a. The ends of the electric wires 1 (1A, 1B, 1C) covered with the insulating coating 2 by the second caulking pieces 4b, 4b are crimped and crimped.

Next, with reference to FIGS. 3 to 7, a method of manufacturing a terminal-attached electric wire of the present embodiment to which the terminal-attached electric wire design method of the present embodiment is applied will be described.

In the method for manufacturing an electric wire with a terminal of the present embodiment, as shown in FIGS. 3 (a) and 3 (b), a plurality of electric wires 1 (1A, 1B, 1C) are used by using a jig or an apparatus (not shown). ), The insulating coating 2 at both ends is removed. Here, the radial cross-sectional area of the conductive wire 3 in the plurality of electric wires 1 (1A, 1B, 1C) is that of the conductive wire 30 in the terminal-attached electric wire 10B of the single electric wire 10 through which the same current flows as shown in FIG. The cross-sectional area of 0.3 mm ² is equally divided into the same 0.1 mm ² .

Subsequently, as shown in FIG. 4, the conductive wire 3 at the tip of the plurality of electric wires 1 (1A, 1B, 1C) from which the insulating coating 2 has been removed is connected to the horn 11 and the gliding jaw 13 in the ultrasonic bonding device 100. It is loaded into the recess consisting of 13. Then, as shown in FIG. 5, when the erbil 12 is pushed as shown by the white arrow, the conductive wire 3 of the electric wire 1 (1A, 1B, 1C) has the same diameter at the tip of the anvil 12. Contact everything. In this state, when ultrasonic waves are applied in the axial direction of the plurality of electric wires 1 (1A, 1B, 1C) and vibrated, the tips of the plurality of electric wires 1 (1A, 1B, 1C) are shown in FIG. The conductive wire 3 of the portion is crimped to form a joined portion 6.

Finally, by pressurizing with a jig or device (not shown), the first caulking pieces 4a, 4a of the copper 4 are caulked to the joint portion 6, and the second caulking pieces 4b, 4b of the copper 4 are insulated coatings 2. When the end of the electric wire 1 (1A, 1B, 1C) covered with is crimped and crimped, terminals 5 and 5 are formed at both ends of the electric wire 1 (1A, 1B, 1C).

According to the above-mentioned electric wire with a terminal 10A of the present embodiment, since ultrasonic bonding is used, the oxide film of the bonding portion 6 can be removed, the harmful effects due to the increase in electric resistance at the terminal can be eliminated, and the overall thickness can be reduced. Therefore, flexibility and flexibility can be improved.

Further, in the electric wire 10A with a terminal of the present embodiment, since the conductive wire 3 in the plurality of electric wires 1 (1A, 1B, 1C) is composed of a plurality of strands, the flexibility and flexibility are further improved. Can be done.

Further, in the electric wire 10A with a terminal of the present embodiment, since the conductive wire 3 in the plurality of electric wires 1 (1A, 1B, 1C) is made of aluminum, it is excellent in lightness and recyclability. The conductive wire 3 may be made of another conductive wire metal such as copper. Further, the copper 4 forming the terminal 5 may be made of another conductive metal such as aluminum.

Further, in the electric wire 10A with a terminal of the present embodiment, the conductive wires 3 in the plurality of electric wires 1 (1A, 1B, 1C) have the same diameter and are ultrasonically bonded by arranging them in a direction orthogonal to the length direction thereof. Therefore, during ultrasonic bonding, pressure and ultrasonic vibration are efficiently transmitted to the conductive wire 3, the bonding strength of the bonding portion 6 can be further increased, and more stable bonding can be achieved.

Further, in the electric wire 10A with terminals of the present embodiment, the copper 4 which is a conductive metal has a first caulking piece 4a, 4a and a second caulking piece 4b, 4b, and these caulking pieces 4a, 4a, 4b. , 4b crimps and crimps the ends of the wire 1 (1A, 1B, 1C) covered with the joint 6 and the insulating coating 2, so that the terminals 5, 5 and the wire 1 (1A, 1B, 1C) are crimped. ) Can be increased.

According to the method for manufacturing a terminal-attached electric wire of the present embodiment, the terminal-attached electric wire 10A of the present embodiment described above can be efficiently manufactured.

According to the method for designing a terminal-attached electric wire of the present embodiment, a thick single electric wire such as a terminal-attached electric wire 10B having poor flexibility and flexibility can be used as a terminal-attached electric wire having excellent flexibility and flexibility. It can be designed by replacing it with 10A. The radial cross-sectional area of the conductive wire 30 in the terminal-equipped electric wire 10B to be compared is set to 0.3 mm ² , but the cross-sectional area is not limited to this, and the radial cross-sectional area is 0.5 mm ² , 0. It may be set in various ways such as 75 mm ² .

As described above, the embodiment for carrying out the present invention has been described in detail with reference to the drawings, but the specific configuration is not limited to this embodiment and does not deviate from the gist of the present invention. The design modification of is included in the present invention.

10A Wire with terminal 10B Wire with terminal of single wire 1,1A, 1B, 1C Wire 2 Insulation coating 3 Conductive wire 4 Copper (conductive metal)
4a First caulking piece (caulking piece)
4b 2nd caulking piece (caulking piece)
5 terminals

Claims (7)

The exposed conductive wires at both ends of a plurality of electric wires whose outer circumferences are covered with an insulating coating are ultrasonically bonded, and a conductive metal is crimped to the joints at both ends to form terminals. An electric wire with a terminal that is characterized by being made. The electric wire with a terminal according to claim 1, wherein the conductive wire in the plurality of electric wires is composed of a plurality of strands. The electric wire with a terminal according to claim 1 or 2, wherein the conductive wire in the plurality of electric wires is made of aluminum. The invention according to any one of claims 1 to 3, wherein the conductive wires in the plurality of electric wires have the same diameter and are ultrasonically bonded by arranging them in a direction orthogonal to the length direction thereof. Electric wire with terminals. The conductive metal has a crimped piece, and the joint portion and the end portion of the electric wire covered with the insulating coating are crimped and crimped by the crimped piece, respectively. The electric wire with a terminal according to any one of 4. Insulation coating removal process to remove the insulation coating at both ends of multiple wires,
An ultrasonic bonding step of ultrasonically bonding conductive wires at both ends of an electric wire from which the insulating coating has been removed to form a bonded portion.
A terminal forming step of crimping a conductive metal to the joints formed at both ends of the electric wire to form terminals at both ends of the electric wire.
A method for manufacturing an electric wire with a terminal, which is characterized by having. With a terminal of a single electric wire through which the same current flows, the total cross-sectional area of the total cross-sectional area of the conductive wire in the plurality of electric wires in the terminal-attached electric wire according to any one of claims 1 to 5 in the radial direction is added. A method for designing an electric wire with a terminal, which is characterized by having the same radial cross-sectional area of the conductive wire in the electric wire.

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