JP6219039B2 - Welding method, tube terminal, tube terminal manufacturing method, electric wire connection structure, and electric wire connection structure manufacturing method - Google Patents

Description

  The present invention relates to a welding method, a tube terminal, a method for manufacturing a tube terminal, a wire connection structure, and a method for manufacturing a wire connection structure, for example, used for a wire connection structure inserted into a connector of an automobile wire harness.

  2. Description of the Related Art Conventionally, in-vehicle wiring of an automobile requires a lot of electric wiring, and therefore, a wire harness that is a collective part made by bundling a plurality of electric wires is used. Thus, in the wire harness used for a motor vehicle etc., the electric wire connection structure as a terminal with which the electric wire was connected to the multi-core connector is inserted, and the electrical connection is ensured. In the electric wire connection structure, an electric wire having a coating peeled off at a U-shaped electric wire connection portion called a wire barrel of a terminal is caulked by a method called crimping. In this type of wire connection structure, the surface of the wire from which the coating has been peeled is exposed, so that there is a problem that corrosion is likely to occur due to exposure to rainwater or the like. For this reason, in order to prevent the corrosion of the electric wire, after the electric wire is crimped to the terminal, a technique for molding the entire outer periphery of the exposed region of the electric wire and the vicinity thereof with an insulating coating member such as a resin material has been proposed ( For example, see Patent Document 1).

JP 2011-222243 A

  By the way, in the technique of patent document 1, since molding requires the operation | work which molds resin with respect to each crimping | compression-bonding part after pressure bonding, while a work becomes complicated, the process of manufacturing a wire harness increases greatly, etc. There was a problem. In addition, the crimping part is enlarged by molding, and it is necessary to increase the size of the connector housing to which each terminal is mounted, which increases the size of the connector, and the entire wire harness can be molded in a high density and small size. could not. Therefore, an electric wire connection structure has been studied in which an electric wire is inserted into a tubular electric wire connecting portion that is crushed and welded, and the electric wire connecting portion and the electric wire are pressure-bonded.

However, when crushing and welding the tip of the tubular electric wire connection portion, it is necessary to weld the overlapped portion of the metal plate, and in this case, the overlapped portion is welded while being deformed due to residual stress. There was a case.
The present invention eliminates the problems of the conventional technology described above, and can suppress the shape deformation and displacement of the welding object, the welding method, the tube terminal, the manufacturing method of the tube terminal, the wire connection structure, and the wire connection. An object of the present invention is to provide a method for manufacturing a structure.

In order to achieve the above object, the present invention is a welding method in which a single metal plate is bent to form a flat overlap portion, and the overlap portion is welded by irradiating a laser beam or an electron beam. Prior to the main welding of the overlapped portion, the overlapped portion is temporarily welded.
In the above-described configuration, the overlapped portion is formed by bending the single metal plate so as to be folded back from the left and right sides.
In the above configuration, the left and right end faces of the single metal plate bent so as to be folded back from both the left and right sides are butt welded.
Further, in the above configuration, the overlapped portion is characterized in that after welding each of the left and right overlapped portions is temporarily welded so as to straddle the left and right overlapped portions.

In order to achieve the above-mentioned object, the present invention bends the one metal plate so as to be folded back from the left and right sides to form an overlapping portion, and the overlapping portion is irradiated with a laser beam or an electron beam for welding. The welding method is characterized by performing temporary fixing welding for welding the left and right overlapping portions along the overlapping direction and main welding for welding so as to straddle the left and right metal plates of the overlapping portion .

Moreover, the present invention is characterized in that, in the above-described welding method, the temporary fixing welding is performed in each of the left and right overlapping portions .
In the above configuration, the method further comprises a step of welding the overlapped portion in a direction intersecting with the main welding and along the left and right end portions of the metal plate.
Moreover, the said structure WHEREIN: The process of welding the said overlap part in the direction along the left-right edge part of the said metal plate is a process of butt-welding the both right-and-left end surfaces of the said metal plate, It is characterized by the above-mentioned.

To achieve the above object, the present invention has a wire connecting portion of at least the tubular, at the tip of ulcers portions tube terminal that is welded wire connection portion of the tubular was ulcers of the tip The welded portion of the portion includes a temporarily welded portion and a main welded portion .

  In order to achieve the above object, the present invention provides a tube terminal manufacturing method having at least a tubular electric wire connecting portion and crushing and welding the distal end of the tubular electric wire connecting portion prior to the main welding of the distal end. The crushed portion is temporarily fixed and welded.

  According to the present invention, in the method of manufacturing a tube terminal, welding is performed so that the main welding does not overlap the temporary fixing welding.

  Further, the present invention is characterized in that, in the above-described method for manufacturing a tube terminal, the temporary welding is performed at a plurality of locations, and the primary welding is performed between the temporary welding locations.

To achieve the above object, the present invention has a wire connecting portion of at least the tubular, the tube terminal ulcers portion of the tip of the wire connecting portion of the tubular has been welded, the wire connection of the tube terminal in the electric wire connection structure is inserted into the part and a crimped electric wire, welded portions of ulcers portion of said tip, characterized in that it comprises a temporary fixing welding portion and the welded portion .

  In order to achieve the above-mentioned object, the present invention has at least a tubular electric wire connecting portion, a tube terminal welded by crushing the tip of the tubular electric wire connecting portion, and a crimping inserted into the electric wire connecting portion of the tube terminal. In the manufacturing method of the electric wire connection structure provided with the formed electric wire, the crushed portion is temporarily fixed and welded prior to the main welding of the tip.

  According to the present invention, prior to the main welding of the overlapped portion where the metal plates are folded and overlapped, the overlapped portion is temporarily fixed, so that shape deformation and displacement of the welding object during the main welding are suppressed. Can do.

It is a perspective view which shows the electric wire connection structure concerning this embodiment. It is sectional drawing which showed the longitudinal direction cross section of the electric wire connection structure. It is a perspective view which shows an electric wire connection part, (A) shows the cylindrical electric wire connection part before tip welding, (B) is a figure which shows the electric wire connection part after tip welding. It is a figure which shows the welding location of the front-end | tip of an electric wire connection part.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a perspective view showing an electric wire connection structure 10 according to the present embodiment, and FIG. 2 is a cross-sectional view showing a longitudinal section of the electric wire connection structure 10.
As shown in FIG. 1, the electric wire connection structure 10 includes a tube terminal 11 and an electric wire 13 that is pressure-bonded to the tube terminal 11. The tube terminal 11 has a female terminal fitting portion 20 and an electric wire connection portion 30, and has a transition portion 40 as a bridge between them. The tube terminal 11 is basically made of a base material made of a metal material (copper or copper alloy in this embodiment) in order to ensure conductivity and strength. In addition, the base material of the tube terminal 11 is not limited to copper or a copper alloy, and aluminum, steel, an alloy containing these as a main component, or the like can also be used.
Moreover, in order to ensure various characteristics as the terminal, the tube terminal 11 may be subjected to, for example, a plating process such as tin, nickel, silver plating, or gold on part or all of the tube terminal 11. Further, not only plating but also reflow treatment of tin or the like may be performed.

As shown in FIG. 2, the electric wire 13 is, for example, a conductor insulating layer (electric wire covering) in which an aluminum core wire 14 in which aluminum or aluminum alloy-like aluminum wires 14a are bundled is made of an insulating resin (for example, polyvinyl chloride). 15 is configured to be covered. The aluminum core wire 14 is formed by twisting the aluminum wire 14a so as to have a predetermined cross-sectional area. However, the aluminum core wire 14 is not limited to this form and may be formed by a single wire.
In addition, the metal material which comprises a core wire should just be a metal which has high electroconductivity, and it may use copper or a copper metal instead of aluminum or an aluminum alloy.

  The fitting portion 20 of the tube terminal 11 is a fitting portion of a female terminal that allows insertion of an insertion tab such as a male terminal. In the present invention, the shape of the details of the fitting portion is not particularly limited. That is, the tube terminal 11 only needs to include the electric wire connection portion 30 through at least the transition portion 40, and for example, the fitting portion may not have a fitting portion. For example, the fitting portion may be an insertion tab of a male terminal. There may be. Moreover, the shape in which the terminal end part which concerns on another form to the electric wire connection part 30 was connected may be sufficient. In this specification, in order to explain the tube terminal 11 of the present invention, an example in which a female box is provided for convenience is shown.

The electric wire connection part 30 is a part for crimping and joining the tube terminal 11 and the electric wire 13. One end of the wire connecting portion 30 has a wire insertion port 31 into which the wire 13 can be inserted, and the other end (tip) 32 is connected to the transition portion 40. As will be described in detail later, the distal end 32 of the electric wire connection portion 30 on the transition portion 40 side is sealed by welding or the like, and is formed so that moisture or the like does not enter from the transition portion 40 side.
When moisture adheres to the joint between the metal base (copper or copper alloy) of the tube terminal 11 and the aluminum core wire 14, the aluminum core wire 14 corrodes due to the difference in electromotive force (ionization tendency) between the two metals. Further, even if the tube terminal 11 and the aluminum core wire 14 are made of aluminum, their joints are easily corroded due to a subtle difference in alloy composition.

  In this configuration, the wire connection portion 30 is formed in a bottomed tubular shape, so that ingress of moisture and the like is suppressed from the outside, and corrosion of the joint portion between the tube terminal 11 and the wire 13 can be suppressed. In addition, since the electric wire connection part 30 can acquire a fixed effect with respect to corrosion if it is tubular, it does not necessarily need to be a cylinder with respect to the longitudinal direction, and may be an elliptical or rectangular tube depending on the case. . Further, the diameter does not need to be constant, and the radius may change in the longitudinal direction.

  In the electric wire connection part 30, the electric connection is ensured simultaneously by crimping the electric wire connection part 30 and crimping | bonding the metal base material and electric wire 13 which comprise the electric wire connection part 30. FIG. Thus, in the electric wire connection part 30, the base material and electric wire (core wire) of the electric wire connection part 30 are plastically deformed and couple | bonded by caulking joining. Therefore, it is necessary to design the thickness of the electric wire connecting portion 30 so that it can be caulked and joined, but since it can be joined freely by human processing or machining, it is not particularly limited. Absent.

  When the electric wire connection part 30 and the electric wire 13 are pressure-bonded, they are plastically deformed by strong compression using a jig such as an anvil and a crimper (not shown). In addition, in the electric wire connection part 30, the function of maintaining the continuity by strongly compressing the aluminum core wire 14 and the seal between the inner peripheral surface of the electric wire connection part 30 and the outer peripheral surface of the electric wire 13 by compressing the conductor insulating layer 15 And a function to maintain the sex. When crimping the wire connection portion 30 and the wire 13, it is possible to take a construction method in which the crimper is lowered from above and crimped (crimped) by applying pressure to the wire connection portion 30 set on the anvil. . In addition, when the electric wire 13 is inserted in the electric wire connection part 30, the outer periphery of the conductor insulating layer 15 is formed in the diameter dimension closely_contact | adhered to the inner periphery of the electric wire connection part 30, and between the electric wire connection part 30 and the electric wire 13 is formed. The structure in which the sealing property is maintained may be used.

  Since aluminum or aluminum alloy used for the core wire has higher contact resistance than copper and copper alloy, there is anxiety in connection. For this reason, on the inner wall surface of the electric wire connecting portion 30, an electric wire locking groove (not shown) called serration extending in the circumferential direction of the electric wire at a position in contact with the aluminum core wire 14 of the electric wire 13 inserted from the electric wire insertion port 31. Is provided. Moreover, when inserting the electric wire 13 in the electric wire connection part from the electric wire insertion port 31, the structure which the coating film is peeled off and the oxide film on the surface of the exposed aluminum core wire 14 may be broken by the electric wire locking groove.

The electric wire connecting portion 30 is formed by punching a strip (stripe) made of copper or a copper alloy into a flattened shape and bending it. In this case, the fitting part 20 may be provided integrally.
FIG. 3 is a diagram showing a model of the process of forming the wire connection portion 30. As shown in FIG. 3 (A), the wire connecting portion 30 presses a metal plate punched into a flat state and bends it into a C-shaped cross section, and butt welds a press cross section 33 facing the longitudinal direction on the upper surface side. And formed into a cylindrical shape. For butt welding of the press section, fiber laser welding is preferable, but welding methods such as electron beam welding, ultrasonic welding, and resistance welding may be used. Also, joining using a connection medium such as solder or solder may be used. In fiber laser welding, high power and continuous irradiation laser welding can be performed by focusing on a very small spot. Thereby, the butt | matching part of a press cross section can be welded reliably.

  The tip 32 connected to the transition part 40 of the wire connection part 30 formed in a cylindrical shape is crushed toward the bottom surface side of the wire connection part 30 as shown in FIG. Thereby, the tip 32 is plastically deformed in a substantially flat plate shape, and the inside of the electric wire connecting portion 30 is sealed. In the present embodiment, the upper surface side of the wire connection portion 30 is butt welded to form the cylindrical wire connection portion 30, but the present invention is not limited to this, and the butt welding is performed on the bottom surface side of the wire connection portion 30. It may be configured to do so.

The tip 32 of the crushed electric wire connection portion 30 is further welded on the line in the transverse direction and sealed.
The tubular electric wire connecting portion 30 with the tip 32 sealed is inserted from the electric wire insertion port 31 with the electric wire 13 having the tip covering removed and the aluminum core wire 14 exposed. The wire 13 can peel the conductor insulating layer 15 at the end of the wire using a wire stripper to expose the aluminum core wire 14. And the electric wire 13 is inserted in the electric wire connection part 30 in this state. The electric wire 13 may be configured to be inserted into the electric wire connection portion 30 in a step prior to sealing the tip 32 of the electric wire connection portion 30.

Next, the welding process of the front-end | tip 32 of the electric wire connection part 30 is demonstrated.
FIG. 4 is a view showing a welding portion of the tip 32 of the electric wire connecting portion 30. As shown in FIG. 4, the tip 32 of the wire connection portion 30 is such that the top surface side of the tubular wire connection portion 30 is crushed toward the bottom surface side, and the metal plate is folded and overlapped vertically. It has become. By welding the portion where the metal plates are stacked one above the other by, for example, fiber laser welding or electron beam welding, it is possible to maintain a reliable water stoppage of the tip 32.

  By the way, when the metal plate is bent and overlapped, when the fiber surface is irradiated with a fiber laser beam or electron beam and welded, the overlapped portion is deformed or displaced due to the residual stress after bending. There is a case where welding is performed in a broken state. Therefore, in this embodiment, prior to the main welding of the crushed tip 32 of the electric wire connecting portion 30 in order to prevent the overlapped portion from being deformed or welded while being displaced due to the residual stress after bending. Temporary welding.

As shown in FIG. 4 (enlarged view of portion A of the tip 32), the tip 32A is locally welded so as not to overlap the main welding point 41 welded on the line in the transverse direction. Further, the plurality of temporary fixing welds 42, 43, 44, 45 are welded.
When welding the tip 32 of the wire connection portion 30, the tip 32 of the wire connection portion 30 is crushed to seal the inside of the wire connection portion 30, and then the temporary welding locations 42, 43, 44, 45 are first welded. Perform temporary fixing welding. Then, main welding is performed in the transverse direction of the tip 32 between the temporary fixing welds 42 and 43 and the temporary fixing welds 44 and 45. In this way, prior to the main welding with a long sweep distance, the crushed tip 32 is fixed by temporary fixing welding with a short sweep distance. Accordingly, it is possible to prevent the main welding from being performed while the tip 32 is deformed or displaced due to the residual stress of the crushed portion 32A of the tip 32.

In the crushed portion 32 </ b> A of the tip 32, it is desirable that the temporary welding is performed at least at two or more places where the bending residual stress that crushes the tip 32 is large. In the present embodiment, in particular, the residual stress of the temporarily welded portions 42 and 43 in the crushed portion 32A tends to be high, and at least these two locations are temporarily welded to suppress the deformation of the tip 32 due to the residual stress. Can do.
Further, in the case where three temporary weldings are performed, for example, temporary welding may be performed at any one of the temporary welding locations 42 and 43 and the temporary welding locations 44 and 45. In this case, the primary welding location 41 is used. Is between the temporary welding locations 42 and 43 and the temporary welding locations 44 or 45. Further, in the case where four temporary weldings are performed, temporary welding is temporarily performed to the temporary welding locations 42, 43, 44, and 45, and the primary welding location 41 includes the temporary welding locations 42 and 43, and the temporary welding locations. Between 44 and 45. Thereby, prior to the main welding, deformation of the crushed tip 32 due to residual stress can be suppressed and fixed. Therefore, it is possible to suppress shape deformation and displacement due to residual stress at the tip 32.

  As described above, according to the embodiment to which the present invention is applied, in the welding method of welding the overlapped portion by irradiating the overlapped object by irradiating a laser beam or an electron beam, Prior to the main welding of the mating portion, the overlapping portion is temporarily welded. Thereby, the overlapping part can be fixed by temporary fixing welding. Therefore, it can prevent that a superposition part deform | transforms with the residual stress after a bending process, and is main-welded with the state shifted | deviated, and can suppress the shape deformation | transformation and shift | offset | difference of a welding target object.

  Further, according to the embodiment to which the present invention is applied, in order to perform welding so that the main welding does not overlap with the temporary welding, a portion having a large residual stress after bending is fixed by temporary welding, and the main welding is performed. The overlapping portion can be reliably welded. Thereby, it can prevent that a superposition part deform | transforms with the residual stress after a bending process, and is main-welded with the state shifted | deviated, and can suppress the shape deformation | transformation and shift | offset | difference of a welding target object.

  In addition, according to the embodiment to which the present invention is applied, since temporary welding is performed at a plurality of locations and main welding is performed between the respective temporary welding locations, a portion having a large residual stress after bending is reliably secured by temporary welding. Can be fixed to. And an overlap part can be reliably welded by carrying out the main welding between several temporary fix locations. Thereby, it can prevent that a superposition part deform | transforms with the residual stress after a bending process, and is main-welded with the state shifted | deviated, and can suppress the shape deformation | transformation and shift | offset | difference of a welding target object.

  Further, according to the embodiment to which the present invention is applied, in the tube terminal 11 which has at least the tubular electric wire connecting portion 30 and is crushed and welded with the distal end 32 of the tubular electric wire connecting portion 30, Prior to welding, the crushed portion 32A was temporarily welded. According to this configuration, the crushed portion 32A of the tip 32 can be fixed by temporary fixing welding. Therefore, it can prevent that the crushed part 32A deform | transforms with the residual stress after a bending process, or is main-welded in the state which shifted | deviated, and can suppress the shape deformation | transformation and deviation | shift of the front-end | tip 32 of welding object. it can.

  In addition, according to the embodiment to which the present invention is applied, the tube terminal 11 having at least a tubular wire connection portion 30, crushing and welding the tip 32 of the tubular wire connection portion 30, and the wire connection of the tube terminal 11 In the electric wire connection structure 10 including the electric wire 13 inserted and crimped into the portion 30, the crushed portion 32 </ b> A was temporarily welded prior to the main welding of the tip 32. According to this configuration, the crushed portion 32A of the tip 32 can be fixed by temporary fixing welding. Therefore, it can prevent that the crushed part 32A deform | transforms with the residual stress after a bending process, or is main-welded in the state which shifted | deviated, and can suppress the shape deformation | transformation and deviation | shift of the front-end | tip 32 of welding object. it can.

DESCRIPTION OF SYMBOLS 10 Electric wire connection structure 11 Pipe terminal 13 Electric wire 30 Electric wire connection part 32 Tip (object overlapped)
32A Crushed part (overlapping part)
41 Welding points 42, 43, 44, 45 Temporarily fixed welding points

Claims (14)

In a welding method in which a single metal plate is bent to form a flat overlapping portion, and the overlapping portion is welded by irradiation with a laser beam or an electron beam, prior to the main welding of the overlapping portion, A welding method characterized by temporarily welding the overlapped portion. The welding method according to claim 1, wherein the overlapping portion is formed by bending the single metal plate so as to be folded back from both left and right sides . The welding method according to claim 2, wherein both left and right end surfaces of the single metal plate bent so as to be folded back from both left and right sides are butt welded. 4. The welding method according to claim 2 , wherein the overlapped portion is welded by temporarily welding each of the left and right overlapped portions, and then performing main welding so as to straddle the left and right overlapped portions. . In the welding method in which the single metal plate is bent so as to be folded back from the left and right sides to form an overlapped portion, and the overlapped portion is welded by irradiation with a laser beam or an electron beam, the left and right overlapped portions are overlapped. A welding method characterized by performing temporary fixing welding for welding along a direction and main welding for welding so as to straddle the left and right metal plates of the overlapping portion . The welding method according to claim 5, wherein the temporary fixing welding is performed at each of the left and right overlapping portions. The welding method according to claim 5, further comprising a step of welding the overlapped portion in a direction intersecting with the main welding and along a left and right end portion of the metal plate. . The welding according to claim 7, wherein the step of welding the overlapped portion in a direction along the left and right end portions of the metal plate is a step of butt welding the left and right end surfaces of the metal plate. Method. At least wire connection portion of the tubular, at the tip of the ulcer portion a tube terminal welded wire connection portion of the tubular, welded portions of ulcers portion of said tip, temporarily fixed welded portion And a tube- welded portion .   In the method of manufacturing a tube terminal having at least a tubular electric wire connecting portion and crushing and welding the tip of the tubular electric wire connecting portion, the crushed portion is temporarily welded prior to the main welding of the tip. A method of manufacturing a tube terminal.   The method for manufacturing a tube terminal according to claim 10, wherein welding is performed so that the main welding does not overlap with the temporary welding.   11. The method of manufacturing a tube terminal according to claim 10, wherein the temporary fixing welding is performed at a plurality of locations, and main welding is performed between the temporary fixing welding locations. At least the tubular has a wire connecting portion, the wire connection comprising a tube terminal ulcers portions are welded at the tip of the wire connecting portion of the tubular, and a wire that has been inserted crimped to wire connecting portion of the tube terminal in structure, the weld portion of ulcers portion of said tip, the electric wire connection structure which comprises a temporary fixing welding portion and the welded portion.   A method of manufacturing an electric wire connection structure comprising at least a tubular electric wire connecting portion, a tube terminal obtained by crushing and welding the tip of the tubular electric wire connecting portion, and an electric wire inserted into the electric wire connecting portion of the tube terminal and crimped The method for manufacturing an electric wire connection structure according to claim 1, wherein the crushed portion is temporarily welded prior to the main welding of the tip.