WO2011118416A1 - Electric wire with terminal fitting and production method for same - Google Patents

Electric wire with terminal fitting and production method for same Download PDF

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Publication number
WO2011118416A1
WO2011118416A1 PCT/JP2011/055760 JP2011055760W WO2011118416A1 WO 2011118416 A1 WO2011118416 A1 WO 2011118416A1 JP 2011055760 W JP2011055760 W JP 2011055760W WO 2011118416 A1 WO2011118416 A1 WO 2011118416A1
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WO
WIPO (PCT)
Prior art keywords
electric wire
terminal fitting
wire
adherend
core wire
Prior art date
Application number
PCT/JP2011/055760
Other languages
French (fr)
Japanese (ja)
Inventor
悟史 森川
和将 小林
拓次 大塚
洋樹 下田
Original Assignee
株式会社オートネットワーク技術研究所
住友電装株式会社
住友電気工業株式会社
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Application filed by 株式会社オートネットワーク技術研究所, 住友電装株式会社, 住友電気工業株式会社 filed Critical 株式会社オートネットワーク技術研究所
Publication of WO2011118416A1 publication Critical patent/WO2011118416A1/en

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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
    • H01R43/02—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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/10—Sockets for co-operation with pins or blades
    • H01R13/11—Resilient sockets
    • H01R13/113—Resilient sockets co-operating with pins or blades having a rectangular transverse section
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • 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
    • H01R4/10—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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/40—Securing contact members in or to a base or case; Insulating of contact members
    • H01R13/42—Securing in a demountable manner
    • H01R13/422—Securing in resilient one-piece base or case, e.g. by friction; One-piece base or case formed with resilient locking means
    • H01R13/4223—Securing in resilient one-piece base or case, e.g. by friction; One-piece base or case formed with resilient locking means comprising integral flexible contact retaining fingers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • 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
    • H01R4/10—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
    • H01R4/183—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 for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H01R4/184—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 for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
    • H01R4/185—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 for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion combined with a U-shaped insulation-receiving portion

Definitions

  • the present invention relates to an electric wire with a terminal fitting and a manufacturing method thereof.
  • An aluminum electric wire has, for example, a structure in which a core wire made of a twisted wire obtained by twisting a plurality of aluminum strands is covered with an insulating coating, and when a harness is formed, a terminal fitting is generally connected to the end of the electric wire.
  • the terminal end of the aluminum wire is peeled off to expose the end of the core wire, and the wire barrel (electric wire connecting portion) provided on the terminal fitting is crimped to the exposed end of the core wire.
  • an insulation barrel provided behind the wire barrel is crimped and connected to the terminal of the insulation coating remaining together (for example, see Patent Document 1).
  • electrolytic corrosion has been prevented by applying an anticorrosive agent made of silicone rubber, a chelating agent or the like to the crimped portion of the wire barrel.
  • the present invention has been completed based on the above situation, and an object of the present invention is to reliably prevent electrolytic corrosion at the connection portion between the electric wire and the terminal fitting without using an anticorrosive agent.
  • the electric wire with a terminal fitting of the present invention is an electric wire in which a metal core wire is covered with an insulation coating, a terminal fitting provided with an electric wire connecting portion that is made of a metal different from the core wire and is connected to the core wire, A thin adherend that is made of a metal that has a similar ionization tendency to that of the terminal fitting, and that can be applied to the end of the insulation coating remaining from the end of the core wire exposed by peeling off the insulation coating of the wire.
  • the adherend is joined to the core wire of the electric wire by ultrasonic welding, and the electric wire connecting portion of the terminal fitting is crimped to the adherend.
  • the adherend is attached to the end of the insulation coating remaining from the end of the exposed core wire in the electric wire, and the adherend is joined to the core wire by ultrasonic welding, and the adherend generates heat at that time. As a result, it is welded to the insulation coating.
  • An electrical connection between the core wire and the terminal fitting is taken by crimping the wire connecting portion of the terminal fitting to the adherend. In the crimped portion of the wire connecting portion, the metals that are close to ionization are in contact with each other, so even if moisture adheres, electrolytic corrosion hardly occurs. On the other hand, the dissimilar metals are in contact with each other between the inner surface of the adherend and the core wire.
  • the adherend is welded to the insulating coating and sealed inside the contact portion, that is, the inner side of the adherend. As a result, inundation is prevented, so that electrolytic corrosion does not occur at the contact portion. As a result, it is possible to reliably prevent electrolytic corrosion at the connection portion between the electric wire and the terminal fitting without using an anticorrosive agent.
  • FIG. 1 is a schematic view showing an ultrasonic welding process according to an embodiment of the present invention.
  • FIG. 2 is a perspective view of the female terminal fitting.
  • FIG. 3 is a side view of a state in which a female terminal fitting is crimped to the end of an aluminum electric wire.
  • FIG. 4 is a side sectional view showing the operation of inserting the aluminum electric wire with the female terminal fitting into the female housing.
  • FIG. 5 is a side sectional view when the insertion is completed.
  • the terminal metal fitting 20 (henceforth, female terminal metal fitting 20) is connected to the terminal of the aluminum electric wire 10.
  • the aluminum electric wire 10 has a core wire 11 formed of a twisted wire obtained by twisting a plurality of strands 12 made of aluminum or aluminum alloy, and an insulating coating 13 made of synthetic resin is formed around the core wire 11. The structure is covered with.
  • the female terminal fitting 20 is formed by pressing a copper alloy plate, and as shown in FIG. 2, has a substantially rectangular tube shape that is electrically connected to a mating male terminal fitting (not shown).
  • a wire barrel 25 and an insulation barrel 26 are provided behind the terminal connection portion 21.
  • the front wire barrel 25 corresponds to the wire connecting portion of the present invention.
  • An elastic contact piece 23 is provided inside the terminal connection portion 21 so as to be folded back from the front edge of the bottom plate 22, and the tab of the mating male terminal fitting described above is connected to the terminal connection portion 21 from the front. By inserting and elastically contacting the elastic contact piece 23, the male terminal fitting and the female terminal fitting 20 are electrically connected.
  • the wire barrel 25 is of an open barrel type, and a pair of left and right wide barrel pieces 25A are formed so as to be opposed to each other from the left and right side edges of the bottom plate 22.
  • the wire barrel 25 is caulked and crimped to the end of the core wire 11 of the aluminum electric wire 10, and the so-called overlap type is formed by embedding the outer periphery of the core wire 11 from both the left and right sides while overlapping the protruding ends of both barrel pieces 25A. It can be squeezed.
  • the insulation barrel 26 is also of an open barrel type, and a pair of left and right barrel pieces 26A which are narrower and taller than the barrel piece 25A on the wire barrel 25 side are also opposed to each other from the left and right side edges of the bottom plate 22. In this way, it is formed to rise.
  • the insulation barrel 26 is caulked and crimped to the remaining end of the insulating coating 13 of the aluminum electric wire 10 and is caulked in an overlapping manner in the same manner.
  • the manufacturing process of the electric wire with a terminal metal fitting which concerns on this embodiment is demonstrated.
  • the terminal of the insulation coating 13 of the aluminum electric wire 10 is peeled off, and the terminal of the core wire 11 is exposed over a predetermined length.
  • a thin adherend 30 is attached from the exposed end of the core wire 11 to the end of the insulation coating 13 in the aluminum electric wire 10.
  • the adherend 30 is formed by winding a copper foil around a plurality of layers, and the front side is formed in a closed state.
  • the first half of the adherend 30 is joined to the core wire 11 by ultrasonic welding.
  • the front region 30A attached to the core wire 11 in the adherend 30 is received on the anvil X constituting the ultrasonic welding machine, while the upper surface side of the front region 30A is received by the horn Y.
  • Apply pressure while applying lateral vibration As a result, impurities on the bonding surface of the adherend 30 and the core wire 11 are removed by friction due to ultrasonic vibration, while atomic diffusion is induced by heating due to frictional heat, and a solid-phase welding state is generated on the bonding surface. Is done. That is, the outer peripheral surface of the core wire 11 and the inner peripheral surface of the adherend 30 are joined to establish an electrical connection.
  • the outer peripheral surface of the insulating coating 13 is welded to the inner peripheral surface of the adherend 30 by receiving the heat. Thereby, the space between the opening edge of the rear end of the adherend 30 and the outer peripheral surface of the insulating coating 13 is sealed so as not to be submerged.
  • the female terminal fitting 20 is crimped and connected to the adherend 30 by a crimping device.
  • the crimping device is provided with an anvil and a crimper, and the front region 30A attached to the core wire 11 of the adherend 30 with respect to the wire barrel 25 of the female terminal fitting 20 is also attached to the insulation barrel 26.
  • the rear region 30B attached to the insulating coating 13 in the adherend 30 is set in a state where it is arranged, and as shown in FIGS. 3 and 4, both barrels 25 and 26 are connected to the anvil and crimper. And are crimped together in an overlap type.
  • the insulation coating 13 and the adherend 30 are welded to each other due to the residual heat of ultrasonic welding. However, even if a situation where the mutual welding is weak occurs, the insulation barrel 26 is finally subjected to the overlap pressure bonding. Insufficient adhesion (welding force) can be covered. The reason why the overlap pressure bonding is adopted is to prevent breakage of the adherend 30.
  • the inner peripheral surface of the wire barrel 25 and the outer peripheral surface of the adherend 30 are brought into close contact with each other, and electrical connection is established.
  • the insulation barrel 26 is wound around the outer periphery of the adherend 30 at the position close to the opening edge and crimped and crimped, so that the gap between the opening edge of the adherend 30 and the outer peripheral surface of the insulating coating 13 is more reliable. Closed.
  • the operation for connecting the female terminal fitting 20 to the terminal of the aluminum electric wire 10 according to the present embodiment is completed.
  • a plurality of aluminum wires 10 with female terminal fittings 20 formed as described above are gathered to form a harness.
  • the female terminal fitting 20 at the end of the aluminum wire 10 is a female housing. 5 is inserted from the rear into the corresponding cavity 51 formed in 50, and is received and retained by the lance 52 as shown in FIG. 5, and is wired at a predetermined location of the vehicle.
  • the corresponding female terminal fitting 20 and the male terminal fitting are electrically connected to each other.
  • the crimped portion between the wire barrel 25 and the adherend 30 of the female terminal fitting 20 is in contact with the copper alloy and copper. Eating is difficult.
  • the dissimilar metals are in contact with each other between the inner surface of the adherend 30 and the core wire 11 of the aluminum electric wire 10, but the outer surface of the insulating coating 13 is welded and sealed to the adherend 30, thereby making contact. Since water intrusion into the portion, that is, the adherend 30 is prevented, electrolytic corrosion does not occur at the contact portion. As a result, it is possible to reliably prevent electrolytic corrosion at the connecting portion between the aluminum electric wire 10 and the female terminal fitting 20 without using an anticorrosive.
  • both the wire barrel 25 and the insulation barrel 26 are caulked and crimped to the adherend 30.
  • the existing female terminal fitting 20 provided with the wire barrel 25 and the insulation barrel 26 can be applied as it is without preparing a new structure.
  • the insulation barrel 26 is caulked and crimped to the outer periphery at a position close to the opening edge of the adherend 30, so that the seal between the opening edge of the adherend 30 and the outer peripheral surface of the insulating coating 13 is more reliably achieved. Can be taken to.
  • the present invention is not limited to the embodiments described with reference to the above description and drawings.
  • the following embodiments are also included in the technical scope of the present invention.
  • the adherend is not limited to one formed by wrapping the copper foil exemplified in the above embodiment around a plurality of layers. If ultrasonic welding is possible, for example, a thin cap shape made of copper or copper alloy It may be.
  • the metal foil constituting the adherend when the electric wire is an aluminum electric wire and the terminal fitting is made of a copper alloy is as follows. Also good. That is, the material of the foil needs to be a metal having a smaller ionization tendency than aluminum, and preferably has a similar ionization tendency to the terminal fitting material (copper alloy), such as zinc, iron, nickel and tin. . (3) Similarly, the material of the thin cap constituting the adherend when the electric wire is an aluminum electric wire and the terminal fitting is made of a copper alloy is ionized rather than aluminum other than copper or copper alloy shown above. Zinc, iron, nickel, tin, and lead are examples of metals that have a small tendency and that have a similar ionization tendency to the terminal fitting material (copper alloy).
  • both the wire barrel and the insulation are used for pressure bonding to the cap.
  • only the wire barrel may be provided without providing the insulation barrel.
  • the form of the wire barrel is not limited to the overlap form exemplified in the above embodiment, and the pair of left and right barrel pieces may be arranged so as to be shifted in the axial direction of the core wire. There may be only one piece. Furthermore, it may be a closed barrel type formed in a cylindrical shape in advance before caulking. In short, it is preferable that when the barrel is caulked, it does not break by piercing the adherend.
  • the female terminal fitting is exemplified as the terminal fitting to be connected to the terminal of the aluminum electric wire, but other terminals such as a male terminal fitting having a male tab or an LA terminal having an eyeball-shaped connecting portion. It may be a metal fitting.
  • the present invention is not limited to the case where a copper alloy terminal fitting is connected to the aluminum electric wire exemplified in the above embodiment, and the core wire of the electric wire and the terminal fitting connected thereto are formed of different metals. In general, it can be widely applied.
  • the technology disclosed in the present specification relates to an electric wire with a terminal fitting, and an electric wire connection in which a metal core wire is covered with an insulating coating, and the core wire is made of a different kind of metal and connected to the same core wire.
  • a terminal fitting provided with a portion, and a metal having an ionization tendency close to that of the terminal fitting, the insulation covering of the electric wire being peeled off and exposed from the end of the core wire left exposed
  • a thin-walled adherend that can be attached, the adherend is joined to the core wire of the electric wire by ultrasonic welding, and the wire connection portion of the terminal fitting is crimped to the adherend (Means 1).
  • the electric wire may be an aluminum electric wire provided with a core wire made of aluminum or aluminum alloy, while the terminal fitting may be made of a copper alloy (means 2). According to the configuration of the means 2, even when an aluminum electric wire with a high possibility of electrolytic corrosion is used, the occurrence of electrolytic corrosion can be effectively prevented.
  • the adherend may be formed by winding a copper foil around a plurality of layers (means 3).
  • the wire connecting portion is composed of two sets of front and rear barrels, and the barrel on the front side is attached to the end of the electric wire among the cores. It is good also as what is crimped and crimped
  • the existing terminal metal fitting provided with the wire barrel and the insulation barrel can be applied as it is. Further, the seal between the adherend and the insulating coating is more reliably taken.
  • the technology disclosed in this specification together with the configurations of the means 1 to 4 is provided at the terminal of the core wire in the electric wire in which the metal core wire is covered with an insulating coating, and on the metal terminal fitting different from the core wire.
  • a method of manufacturing an electric wire with a terminal fitting to which the electric wire connecting portion is connected, and peeling the end of the insulation coating of the electric wire to expose the end of the core wire, and the exposed electric wire in the electric wire A step of attaching a thin adherend made of a metal having an ionization tendency close to that of the terminal fitting from the end of the core wire to the end of the insulation coating, and joining the adherend to the core wire by ultrasonic welding And the step of crimping the wire connection portion of the terminal fitting to the adherend are sequentially performed (means 5). According to the manufacturing method of the means 5, the electric wire with a terminal metal fitting of this invention can be manufactured reliably.

Abstract

Disclosed is an aluminum electric wire (10) with a female terminal fitting (20) comprising an electric wire (10) with a metal core (11) covered by an insulation sheath (13); a terminal fitting (20) provided with an electric wire connecting section (25) that is connected to the core (11) and made from a different type of metal than the core (11); and a thin adherend (30) made of metal that has similar ionization tendencies to the terminal fitting (20) and that is attachable from an end where the core (11) has been exposed by the peeling away of the insulation sheath (13) on the electric wire (10) to an end where the insulation sheath (13) remains intact. The adherend (30) is formed by winding copper foil in a plurality of layers. The adherend (30) is bonded to the core (11) of the electric wire (10) by ultrasonic welding and the electric wire connecting section (25) of the terminal fitting (20) is crimped to the adherend (30).

Description

端子金具付き電線及びその製造方法Electric wire with terminal fitting and manufacturing method thereof
　本発明は、端子金具付き電線及びその製造方法に関する。 The present invention relates to an electric wire with a terminal fitting and a manufacturing method thereof.
　近年、自動車のワイヤハーネス等の分野においても、軽量化等を目的としてアルミ電線を使用するようになった。アルミ電線は例えば、複数本のアルミ素線を撚り合わせた撚り線からなる芯線を絶縁被覆で覆った構造であって、ハーネス化される場合は一般に、電線の端末に端子金具が接続される。具体的には、アルミ電線の被覆の端末が皮剥きされて芯線の端末が露出され、この露出された芯線の端末に対して、端子金具に設けられたワイヤバレル（電線接続部）が圧着され、併せて残った絶縁被覆の端末に、ワイヤバレルの後方に設けられたインシュレーションバレルが圧着されて接続されるようになっている（例えば、特許文献１参照）。 In recent years, aluminum wires have been used in the field of automobile wire harnesses for the purpose of weight reduction. An aluminum electric wire has, for example, a structure in which a core wire made of a twisted wire obtained by twisting a plurality of aluminum strands is covered with an insulating coating, and when a harness is formed, a terminal fitting is generally connected to the end of the electric wire. Specifically, the terminal end of the aluminum wire is peeled off to expose the end of the core wire, and the wire barrel (electric wire connecting portion) provided on the terminal fitting is crimped to the exposed end of the core wire. In addition, an insulation barrel provided behind the wire barrel is crimped and connected to the terminal of the insulation coating remaining together (for example, see Patent Document 1).
　ところで電線を端子金具に導通接続させるに当たり、電線の芯線と端子金具とが異種の金属によって形成されている場合には、特に両者の接触部分に水分が介在すると、両金属が水中にイオンとして溶け込んで電気化学的反応により腐食が進行する電食が発生することが知られている。端子金具は強度上の問題等で銅合金製とするのが一般的であるため、上記のように電線にアルミ電線を使用すると、正に電食が問題となる。具体的には、ワイヤバレルが芯線に圧着された部分において、埃や砂が侵入して混じった塩分が付着しさらに水分が付着すると、接触部分が電解質溶液に浸漬された状態となって、イオン化傾向が大きい金属であるアルミニウムが溶解する、すなわち電食が進むおそれがある。
　そこで従来では、ワイヤバレルの圧着部分に、シリコーンゴム、キレート剤等からなる防食剤を塗布することで、電食を防止するようにしていた。 By the way, when conducting the electrical connection of the electric wire to the terminal fitting, when the core wire of the electric wire and the terminal fitting are formed of different kinds of metals, especially when water is present at the contact portion between the two, the two metals dissolve as ions in the water. It is known that galvanic corrosion occurs due to electrochemical reaction. Since terminal fittings are generally made of a copper alloy due to problems in strength and the like, if an aluminum electric wire is used as the electric wire as described above, electrolytic corrosion becomes a problem. Specifically, at the portion where the wire barrel is crimped to the core wire, when dust or sand enters and the mixed salt adheres and moisture further adheres, the contact portion becomes immersed in the electrolyte solution, and ionization occurs. There is a possibility that aluminum which is a metal having a large tendency is dissolved, that is, electrolytic corrosion proceeds.
Conventionally, therefore, electrolytic corrosion has been prevented by applying an anticorrosive agent made of silicone rubber, a chelating agent or the like to the crimped portion of the wire barrel.
特開２００５－５０７３６号公報Japanese Patent Laying-Open No. 2005-50736
　しかしながら上記した防食剤を塗布する方法では、バレルの圧着形状によって塗布条件を変える必要がある、塗布層の厚さにばらつきが出て品質が安定しない、塗布層の剥がれに注意が必要、さらにはメンテナンス時に簡単にリペアできない等、数々の問題があり、新たな対策の出現が切望されていた。
　本発明は上記のような事情に基づいて完成されたものであって、その目的は、防食剤を使用することなく電線と端子金具との接続部分の電食を確実に防止するところにある。 However, in the above-described method of applying the anticorrosive agent, it is necessary to change the application conditions depending on the pressure-bonding shape of the barrel, the thickness of the application layer varies, the quality is not stable, the care of peeling of the application layer is necessary, and There were a number of problems, such as inability to easily repair during maintenance, and the emergence of new countermeasures was anxious.
The present invention has been completed based on the above situation, and an object of the present invention is to reliably prevent electrolytic corrosion at the connection portion between the electric wire and the terminal fitting without using an anticorrosive agent.
　本発明の端子金具付き電線は、金属製の芯線を絶縁被覆で覆った電線と、前記芯線とは異種の金属製であって同芯線と接続される電線接続部を設けた端子金具と、前記端子金具とイオン化傾向が近い金属製であって、前記電線の絶縁被覆が皮剥きされて露出された前記芯線の端末から残された絶縁被覆の端末に亘って被着可能な薄肉の被着体と、が具備され、前記被着体が前記電線の前記芯線に対して超音波溶接により接合され、前記被着体に前記端子金具の前記電線接続部が圧着されている。 The electric wire with a terminal fitting of the present invention is an electric wire in which a metal core wire is covered with an insulation coating, a terminal fitting provided with an electric wire connecting portion that is made of a metal different from the core wire and is connected to the core wire, A thin adherend that is made of a metal that has a similar ionization tendency to that of the terminal fitting, and that can be applied to the end of the insulation coating remaining from the end of the core wire exposed by peeling off the insulation coating of the wire. The adherend is joined to the core wire of the electric wire by ultrasonic welding, and the electric wire connecting portion of the terminal fitting is crimped to the adherend.
　電線における露出した芯線の端末から残された絶縁被覆の端末に亘って被着体が被着され、この被着体が超音波溶接により芯線に接合され、そのとき被着体が発熱することに伴い絶縁被覆に対して溶着される。この被着体に端子金具の電線接続部が圧着されることにより、芯線と端子金具との間の電気的接続が取られる。
　電線接続部の圧着部分では、イオン化傾向の近い金属同士の接触となるために、仮に水分が付着したとしても電食は起き難い。一方、被着体の内面と芯線との間は異種金属同士の接触となるが、この接触部分すなわち被着体の内側には、同被着体が絶縁被覆に対して溶着されてシールされることによって浸水が阻止されるから、同接触部分に電食が発生するには至らない。結果、防食剤を使用することなく電線と端子金具との接続部分の電食を確実に防止できる。 The adherend is attached to the end of the insulation coating remaining from the end of the exposed core wire in the electric wire, and the adherend is joined to the core wire by ultrasonic welding, and the adherend generates heat at that time. As a result, it is welded to the insulation coating. An electrical connection between the core wire and the terminal fitting is taken by crimping the wire connecting portion of the terminal fitting to the adherend.
In the crimped portion of the wire connecting portion, the metals that are close to ionization are in contact with each other, so even if moisture adheres, electrolytic corrosion hardly occurs. On the other hand, the dissimilar metals are in contact with each other between the inner surface of the adherend and the core wire. The adherend is welded to the insulating coating and sealed inside the contact portion, that is, the inner side of the adherend. As a result, inundation is prevented, so that electrolytic corrosion does not occur at the contact portion. As a result, it is possible to reliably prevent electrolytic corrosion at the connection portion between the electric wire and the terminal fitting without using an anticorrosive agent.
　本発明によれば、防食剤を使用することなく電線と端子金具との接続部分の電食を確実に防止することができる。 According to the present invention, it is possible to reliably prevent electrolytic corrosion at the connection portion between the electric wire and the terminal fitting without using an anticorrosive agent.
図１は本発明の一実施形態に係る超音波溶接工程を示す概略図である。FIG. 1 is a schematic view showing an ultrasonic welding process according to an embodiment of the present invention. 図２は雌端子金具の斜視図である。FIG. 2 is a perspective view of the female terminal fitting. 図３はアルミ電線の端末に雌端子金具を圧着した状態の側面図である。FIG. 3 is a side view of a state in which a female terminal fitting is crimped to the end of an aluminum electric wire. 図４は雌端子金具付きのアルミ電線を雌ハウジングに挿入する動作を示す側断面図である。FIG. 4 is a side sectional view showing the operation of inserting the aluminum electric wire with the female terminal fitting into the female housing. 図５は挿入完了時の側断面図である。FIG. 5 is a side sectional view when the insertion is completed.
　１０…アルミ電線（電線）
　１１…芯線
　１３…絶縁被覆
　２０…雌端子金具（端子金具）
　２２…底板
　２５…ワイヤバレル（電線接続部）
　２５Ａ…バレル片
　２６…インシュレーションバレル
　２６Ａ…バレル片
　３０…被着体
　３０Ａ…前側領域
　３０Ｂ…後側領域
　Ｘ…アンビル
　Ｙ…ホーン 10 ... Aluminum wire (wire)
DESCRIPTION OF SYMBOLS 11 ... Core wire 13 ... Insulation coating 20 ... Female terminal metal fitting (terminal metal fitting)
22 ... Bottom plate 25 ... Wire barrel (wire connection part)
25A ... barrel piece 26 ... insulation barrel 26A ... barrel piece 30 ... adherend 30A ... front region 30B ... rear region X ... anvil Y ... horn
　＜実施形態＞
　本発明の一実施形態を図１ないし図５によって説明する。この実施形態では、アルミ電線１０に適用した場合を例示しており、図３に示すように、アルミ電線１０の端末には、雌側の端子金具２０（以下、雌端子金具２０）が接続されている。
　アルミ電線１０は、図１に示すように、アルミニウムまたはアルミニウム合金製の素線１２を複数本を撚り合せた撚り線によって芯線１１が形成され、この芯線１１の回りが合成樹脂製の絶縁被覆１３で覆われた構造となっている。 <Embodiment>
An embodiment of the present invention will be described with reference to FIGS. In this embodiment, the case where it applies to the aluminum electric wire 10 is illustrated, and as shown in FIG. 3, the terminal metal fitting 20 (henceforth, female terminal metal fitting 20) is connected to the terminal of the aluminum electric wire 10. ing.
As shown in FIG. 1, the aluminum electric wire 10 has a core wire 11 formed of a twisted wire obtained by twisting a plurality of strands 12 made of aluminum or aluminum alloy, and an insulating coating 13 made of synthetic resin is formed around the core wire 11. The structure is covered with.
　雌端子金具２０は、銅合金製の板材をプレス加工することで形成され、図２に示すように、相手の雄端子金具（図示せず）と電気的に接続される略角筒形をなす端子接続部２１の後方に、ワイヤバレル２５とインシュレーションバレル２６とが設けられた構造である。前側のワイヤバレル２５が本発明の電線接続部に相当する。
　端子接続部２１の内部には、底板２２の前縁から折り返されるようにして弾性接触片２３が設けられており、同端子接続部２１に対して上記した相手の雄端子金具のタブが前方から挿入され、弾性接触片２３と弾性的に接触することにより、雄端子金具と雌端子金具２０とが電気的に接続されるようになっている。 The female terminal fitting 20 is formed by pressing a copper alloy plate, and as shown in FIG. 2, has a substantially rectangular tube shape that is electrically connected to a mating male terminal fitting (not shown). A wire barrel 25 and an insulation barrel 26 are provided behind the terminal connection portion 21. The front wire barrel 25 corresponds to the wire connecting portion of the present invention.
An elastic contact piece 23 is provided inside the terminal connection portion 21 so as to be folded back from the front edge of the bottom plate 22, and the tab of the mating male terminal fitting described above is connected to the terminal connection portion 21 from the front. By inserting and elastically contacting the elastic contact piece 23, the male terminal fitting and the female terminal fitting 20 are electrically connected.
　ワイヤバレル２５はオープンバレル形式であって、左右一対の幅広のバレル片２５Ａが、底板２２の左右の側縁から互いに対向するようにして立ち上がり形成されている。ワイヤバレル２５は、アルミ電線１０の芯線１１の端末にかしめ圧着されるものであって、両バレル片２５Ａの突出端を重ね合わせつつ芯線１１の外周を左右両側から抱き込むようにして、いわゆるオーバラップ型にかしめられるようになっている。 The wire barrel 25 is of an open barrel type, and a pair of left and right wide barrel pieces 25A are formed so as to be opposed to each other from the left and right side edges of the bottom plate 22. The wire barrel 25 is caulked and crimped to the end of the core wire 11 of the aluminum electric wire 10, and the so-called overlap type is formed by embedding the outer periphery of the core wire 11 from both the left and right sides while overlapping the protruding ends of both barrel pieces 25A. It can be squeezed.
　インシュレーションバレル２６は、同じくオープンバレル形式であって、ワイヤバレル２５側のバレル片２５Ａよりも幅狭で背が高い左右一対のバレル片２６Ａが、同じく底板２２の左右の側縁から互いに対向するようにして立ち上がり形成されている。このインシュレーションバレル２６は、アルミ電線１０の残された絶縁被覆１３の端末にかしめ圧着されるものであって、同様にオーバラップ型にかしめられるようになっている。 The insulation barrel 26 is also of an open barrel type, and a pair of left and right barrel pieces 26A which are narrower and taller than the barrel piece 25A on the wire barrel 25 side are also opposed to each other from the left and right side edges of the bottom plate 22. In this way, it is formed to rise. The insulation barrel 26 is caulked and crimped to the remaining end of the insulating coating 13 of the aluminum electric wire 10 and is caulked in an overlapping manner in the same manner.
　続いて、本実施形態に係る端子金具付き電線の製造工程を説明する。
　図１に示すように、アルミ電線１０の絶縁被覆１３の端末が皮剥きされて、芯線１１の端末が所定長さに亘って露出状態とされる。このアルミ電線１０における露出した芯線１１の端末から残された絶縁被覆１３の端末に亘り、薄肉の被着体３０が被着される。被着体３０は具体的には、銅箔を複数層に巻き付けることで形成され、前面側は閉じた状態に形成されている。 Then, the manufacturing process of the electric wire with a terminal metal fitting which concerns on this embodiment is demonstrated.
As shown in FIG. 1, the terminal of the insulation coating 13 of the aluminum electric wire 10 is peeled off, and the terminal of the core wire 11 is exposed over a predetermined length. A thin adherend 30 is attached from the exposed end of the core wire 11 to the end of the insulation coating 13 in the aluminum electric wire 10. Specifically, the adherend 30 is formed by winding a copper foil around a plurality of layers, and the front side is formed in a closed state.
　次に、被着体３０の前半部分を超音波溶接により芯線１１に接合する。具体的には、被着体３０における芯線１１に被着された前側領域３０Ａが、超音波溶接機を構成するアンビルＸに載せられて受けられる一方、同前側領域３０Ａの上面側をホーンＹにより横振動を与えながら加圧する。これにより、被着体３０と芯線１１の接合面は、超音波振動による摩擦によって表面の不純物が除去される一方、摩擦熱による加熱によって原子拡散が誘起され、接合面に固相溶接状態が生成される。すなわち、芯線１１の外周面と被着体３０の内周面とが接合されて、電気的接続が取られる。
　また、上記の超音波溶接に伴い被着体３０の後側領域３０Ｂも加熱されるため、その熱を受けて、絶縁被覆１３の外周面が被着体３０の内周面に溶着される。これにより、被着体３０における後端の開口縁と絶縁被覆１３の外周面との間が、浸水不能にシールされる。 Next, the first half of the adherend 30 is joined to the core wire 11 by ultrasonic welding. Specifically, the front region 30A attached to the core wire 11 in the adherend 30 is received on the anvil X constituting the ultrasonic welding machine, while the upper surface side of the front region 30A is received by the horn Y. Apply pressure while applying lateral vibration. As a result, impurities on the bonding surface of the adherend 30 and the core wire 11 are removed by friction due to ultrasonic vibration, while atomic diffusion is induced by heating due to frictional heat, and a solid-phase welding state is generated on the bonding surface. Is done. That is, the outer peripheral surface of the core wire 11 and the inner peripheral surface of the adherend 30 are joined to establish an electrical connection.
Further, since the rear region 30 </ b> B of the adherend 30 is also heated with the ultrasonic welding described above, the outer peripheral surface of the insulating coating 13 is welded to the inner peripheral surface of the adherend 30 by receiving the heat. Thereby, the space between the opening edge of the rear end of the adherend 30 and the outer peripheral surface of the insulating coating 13 is sealed so as not to be submerged.
　アルミ電線１０の端末に被着体３０が被着されたら、圧着装置により、被着体３０に対して雌端子金具２０が圧着接続される。詳細には、圧着装置にはアンビルとクリンパとが設けられ、雌端子金具２０のワイヤバレル２５に対して被着体３０における芯線１１に被着された前側領域３０Ａが、またインシュレーションバレル２６に対して、被着体３０における絶縁被覆１３に被着された後側領域３０Ｂがそれぞれ配された状態でセットされ、図３及び図４に示すように、両バレル２５，２６は、アンビルとクリンパとの間で挟圧されて共にオーバラップ型にかしめられる。
　絶縁被覆１３と被着体３０とは超音波溶接の余熱によって相互に溶着するが、万が一相互の溶着が弱い事態が生じたとしても、最後にインシュレーションバレル２６のオーバラップ圧着があるから、固着力（溶着力）の不足をカバーすることができる。オーバラップ圧着としたのは、被着体３０の破断防止に配慮したためである。 When the adherend 30 is attached to the end of the aluminum electric wire 10, the female terminal fitting 20 is crimped and connected to the adherend 30 by a crimping device. Specifically, the crimping device is provided with an anvil and a crimper, and the front region 30A attached to the core wire 11 of the adherend 30 with respect to the wire barrel 25 of the female terminal fitting 20 is also attached to the insulation barrel 26. On the other hand, the rear region 30B attached to the insulating coating 13 in the adherend 30 is set in a state where it is arranged, and as shown in FIGS. 3 and 4, both barrels 25 and 26 are connected to the anvil and crimper. And are crimped together in an overlap type.
The insulation coating 13 and the adherend 30 are welded to each other due to the residual heat of ultrasonic welding. However, even if a situation where the mutual welding is weak occurs, the insulation barrel 26 is finally subjected to the overlap pressure bonding. Insufficient adhesion (welding force) can be covered. The reason why the overlap pressure bonding is adopted is to prevent breakage of the adherend 30.
　これにより、特にワイヤバレル２５の内周面と被着体３０の外周面とが密着して電気的接続が取られる。また、被着体３０の開口縁に寄った位置の外周にインシュレーションバレル２６が巻き付いてかしめ圧着されることで、被着体３０の開口縁と絶縁被覆１３の外周面との間がより確実に閉鎖される。
　以上により、本実施形態に係るアルミ電線１０の端末に雌端子金具２０を接続する作業が終了する。 Thereby, in particular, the inner peripheral surface of the wire barrel 25 and the outer peripheral surface of the adherend 30 are brought into close contact with each other, and electrical connection is established. Further, the insulation barrel 26 is wound around the outer periphery of the adherend 30 at the position close to the opening edge and crimped and crimped, so that the gap between the opening edge of the adherend 30 and the outer peripheral surface of the insulating coating 13 is more reliable. Closed.
Thus, the operation for connecting the female terminal fitting 20 to the terminal of the aluminum electric wire 10 according to the present embodiment is completed.
　上記のように形成された雌端子金具２０付きのアルミ電線１０が、複数本纏められてハーネスが構成され、例えば図４に示すように、当該アルミ電線１０の端末の雌端子金具２０が雌ハウジング５０に形成された対応するキャビティ５１内に後方から挿入されて、図５に示すように、ランス５２により抜け止めされて収容され、車両の所定箇所に配線されて、同雌ハウジング５０が相手の雄ハウジングと嵌合されることにより、対応する雌端子金具２０と雄端子金具同士が電気的に接続されるところとなる。 A plurality of aluminum wires 10 with female terminal fittings 20 formed as described above are gathered to form a harness. For example, as shown in FIG. 4, the female terminal fitting 20 at the end of the aluminum wire 10 is a female housing. 5 is inserted from the rear into the corresponding cavity 51 formed in 50, and is received and retained by the lance 52 as shown in FIG. 5, and is wired at a predetermined location of the vehicle. By fitting with the male housing, the corresponding female terminal fitting 20 and the male terminal fitting are electrically connected to each other.
　以上のように本実施形態によれば、雌端子金具２０のワイヤバレル２５と被着体３０との圧着部分では、銅合金と銅との接触となるために、仮に水分が付着したとしても電食は起き難い。一方、被着体３０の内面とアルミ電線１０の芯線１１との間は、異種金属同士の接触となるが、絶縁被覆１３の外面が被着体３０に溶着してシールされることで、接触部分すなわち被着体３０内への浸水は阻止されるから、同接触部分に電食が発生するには至らない。結果、防食剤を使用することなくアルミ電線１０と雌端子金具２０との接続部分の電食を確実に防止することができる。 As described above, according to this embodiment, the crimped portion between the wire barrel 25 and the adherend 30 of the female terminal fitting 20 is in contact with the copper alloy and copper. Eating is difficult. On the other hand, the dissimilar metals are in contact with each other between the inner surface of the adherend 30 and the core wire 11 of the aluminum electric wire 10, but the outer surface of the insulating coating 13 is welded and sealed to the adherend 30, thereby making contact. Since water intrusion into the portion, that is, the adherend 30 is prevented, electrolytic corrosion does not occur at the contact portion. As a result, it is possible to reliably prevent electrolytic corrosion at the connecting portion between the aluminum electric wire 10 and the female terminal fitting 20 without using an anticorrosive.
　この実施形態では、雌端子金具２０を被着体３０に接続するのに、ワイヤバレル２５とインシュレーションバレル２６の両方を被着体３０に対してかしめ圧着するようにしているから、雌端子金具として新たな構造のものを準備することなく、ワイヤバレル２５とインシュレーションバレル２６とを備えた既存の雌端子金具２０をそのまま適用することが可能である。
　また、インシュレーションバレル２６が被着体３０の開口縁に寄った位置の外周にかしめ圧着されることで、被着体３０の開口縁と絶縁被覆１３の外周面との間のシールをより確実に取ることができる。 In this embodiment, in order to connect the female terminal fitting 20 to the adherend 30, both the wire barrel 25 and the insulation barrel 26 are caulked and crimped to the adherend 30. Thus, the existing female terminal fitting 20 provided with the wire barrel 25 and the insulation barrel 26 can be applied as it is without preparing a new structure.
Further, the insulation barrel 26 is caulked and crimped to the outer periphery at a position close to the opening edge of the adherend 30, so that the seal between the opening edge of the adherend 30 and the outer peripheral surface of the insulating coating 13 is more reliably achieved. Can be taken to.
　＜他の実施形態＞
　本発明は上記記述及び図面によって説明した実施形態に限定されるものではなく、例えば次のような実施形態も本発明の技術的範囲に含まれる。
　（１）被着体としては、上記実施形態に例示した銅箔を複数層に巻き付けて形成したものに限らず、超音波溶接が可能であれば、例えば銅または銅合金製の薄肉のキャップ形状のものであってもよい。 <Other embodiments>
The present invention is not limited to the embodiments described with reference to the above description and drawings. For example, the following embodiments are also included in the technical scope of the present invention.
(1) The adherend is not limited to one formed by wrapping the copper foil exemplified in the above embodiment around a plurality of layers. If ultrasonic welding is possible, for example, a thin cap shape made of copper or copper alloy It may be.
　（２）電線がアルミ電線であり、端子金具が銅合金製である場合における被着体を構成する金属箔としては、上記実施形態に例示した銅箔以外に、以下のようなものであってもよい。すなわち箔の材質としては、アルミニウムよりもイオン化傾向が小さい金属である必要があり、かつ端子金具の材質（銅合金）とイオン化傾向が近い方が好ましく、例えば亜鉛、鉄、ニッケル及びすずが挙げられる。
　（３）同じく電線がアルミ電線であり、端子金具が銅合金製である場合における被着体を構成する薄肉のキャップの材質としては、上記に示した銅または銅合金以外に、アルミニウムよりもイオン化傾向が小さい金属であって、かつ端子金具の材質（銅合金）とイオン化傾向が近いものであるところの、亜鉛、鉄、ニッケル、すず及び鉛が挙げられる。 (2) The metal foil constituting the adherend when the electric wire is an aluminum electric wire and the terminal fitting is made of a copper alloy, in addition to the copper foil exemplified in the above embodiment, is as follows. Also good. That is, the material of the foil needs to be a metal having a smaller ionization tendency than aluminum, and preferably has a similar ionization tendency to the terminal fitting material (copper alloy), such as zinc, iron, nickel and tin. .
(3) Similarly, the material of the thin cap constituting the adherend when the electric wire is an aluminum electric wire and the terminal fitting is made of a copper alloy is ionized rather than aluminum other than copper or copper alloy shown above. Zinc, iron, nickel, tin, and lead are examples of metals that have a small tendency and that have a similar ionization tendency to the terminal fitting material (copper alloy).
　（４）上記実施形態では、キャップに圧着するのにワイヤバレルとインシュレーションの両方を用いたが、インシュレーションバレルを設けることなくワイヤバレルのみを備えるようにしてもよい。
　（５）ワイヤバレルの形式としては、上記実施形態に例示したオーバラップ形式に限らず、左右一対のバレル片が、芯線の軸線方向にずれて配された形式のものであってもよく、バレル片が１本だけのものであってもよい。さらには、かしめ前に予め筒形に形成されたクローズドバレル形式であってもよい。要は、バレルがかしめられたときに、被着体に突き刺さる等でこれを破損しないものが好ましい。 (4) In the above embodiment, both the wire barrel and the insulation are used for pressure bonding to the cap. However, only the wire barrel may be provided without providing the insulation barrel.
(5) The form of the wire barrel is not limited to the overlap form exemplified in the above embodiment, and the pair of left and right barrel pieces may be arranged so as to be shifted in the axial direction of the core wire. There may be only one piece. Furthermore, it may be a closed barrel type formed in a cylindrical shape in advance before caulking. In short, it is preferable that when the barrel is caulked, it does not break by piercing the adherend.
　（６）上記実施形態では、アルミ電線の端末に接続する端子金具として雌端子金具を例示したが、雄タブを備えた雄端子金具、あるいは目玉状の接続部を有するＬＡ端子等の他の端子金具であってもよい。
　（７）本発明は、上記実施形態に例示したアルミ電線に銅合金製の端子金具を接続する場合に限らず、電線の芯線とこれに接続される端子金具とが異種の金属によって形成されている場合全般に広く適用することが可能である。 (6) In the above embodiment, the female terminal fitting is exemplified as the terminal fitting to be connected to the terminal of the aluminum electric wire, but other terminals such as a male terminal fitting having a male tab or an LA terminal having an eyeball-shaped connecting portion. It may be a metal fitting.
(7) The present invention is not limited to the case where a copper alloy terminal fitting is connected to the aluminum electric wire exemplified in the above embodiment, and the core wire of the electric wire and the terminal fitting connected thereto are formed of different metals. In general, it can be widely applied.
　（課題を解決するための手段）
　本明細書で開示された技術は端子金具付き電線に関するものであり、金属製の芯線を絶縁被覆で覆った電線と、前記芯線とは異種の金属製であって同芯線と接続される電線接続部を設けた端子金具と、前記端子金具とイオン化傾向が近い金属製であって、前記電線の絶縁被覆が皮剥きされて露出された前記芯線の端末から残された絶縁被覆の端末に亘って被着可能な薄肉の被着体と、が具備され、前記被着体が前記電線の前記芯線に対して超音波溶接により接合され、前記被着体に前記端子金具の前記電線接続部が圧着されているところに特徴を有する（手段１）。 (Means for solving the problem)
The technology disclosed in the present specification relates to an electric wire with a terminal fitting, and an electric wire connection in which a metal core wire is covered with an insulating coating, and the core wire is made of a different kind of metal and connected to the same core wire. A terminal fitting provided with a portion, and a metal having an ionization tendency close to that of the terminal fitting, the insulation covering of the electric wire being peeled off and exposed from the end of the core wire left exposed A thin-walled adherend that can be attached, the adherend is joined to the core wire of the electric wire by ultrasonic welding, and the wire connection portion of the terminal fitting is crimped to the adherend (Means 1).
　手段１の構成に加えて、前記電線が、アルミニウムまたはアルミニウム合金製の芯線を備えたアルミ電線である一方、前記端子金具が銅合金製であるものとしてもよい（手段２）。
　手段２の構成によれば、電食する可能性が高いアルミ電線を使用した場合にも、電食の発生を有効に防ぐことができる。
　手段２に構成に加えて、前記被着体は、銅箔を複数層に巻き付けることで形成されているものとしてもよい（手段３）。 In addition to the configuration of the means 1, the electric wire may be an aluminum electric wire provided with a core wire made of aluminum or aluminum alloy, while the terminal fitting may be made of a copper alloy (means 2).
According to the configuration of the means 2, even when an aluminum electric wire with a high possibility of electrolytic corrosion is used, the occurrence of electrolytic corrosion can be effectively prevented.
In addition to the configuration of the means 2, the adherend may be formed by winding a copper foil around a plurality of layers (means 3).
　手段１ないし手段３のいずれかの構成に加えて、前記電線接続部が前後２組のバレルから構成され、前側の前記バレルが、前記電線の端末に被着された被着体のうち前記芯線の端末に被着された領域にかしめ圧着され、後側の前記バレルが、前記被着体のうち前記絶縁被覆の端末に被着された領域にかしめ圧着されているものとしてもよい（手段４）。
　手段４の構成によれば、ワイヤバレルとインシュレーションバレルとを備えた既存の端子金具をそのまま適用することができる。また、被着体と絶縁被覆間のシールがより確実に取られる。 In addition to the structure of any one of the means 1 to 3, the wire connecting portion is composed of two sets of front and rear barrels, and the barrel on the front side is attached to the end of the electric wire among the cores. It is good also as what is crimped and crimped | bonded by crimping to the area | region adhered to the terminal of this, and the said barrel of the rear side being crimped and crimped | bonded to the area | region adhered to the terminal of the said insulation coating among the said to-be-adhered bodies. ).
According to the structure of the means 4, the existing terminal metal fitting provided with the wire barrel and the insulation barrel can be applied as it is. Further, the seal between the adherend and the insulating coating is more reliably taken.
　手段１ないし手段４の構成とともに、本明細書で開示された技術は、金属製の芯線を絶縁被覆で覆った電線における前記芯線の端末に、前記芯線とは異種の金属製の端子金具に設けられた電線接続部が接続された端子金具付き電線を製造する方法に関するものであり、前記電線の絶縁被覆の端末を皮剥きして前記芯線の端末を露出する工程と、前記電線における露出した前記芯線の端末から残された絶縁被覆の端末に亘り、前記端子金具とイオン化傾向が近い金属からなる薄肉の被着体を被着する工程と、前記被着体を超音波溶接により前記芯線に接合する工程と、前記被着体に前記端子金具の前記電線接続部を圧着する工程とが順次に行われるところに特徴を有する（手段５）。
　手段５の製造方法によれば、本発明の端子金具付き電線を、確実に製造することができる。 The technology disclosed in this specification together with the configurations of the means 1 to 4 is provided at the terminal of the core wire in the electric wire in which the metal core wire is covered with an insulating coating, and on the metal terminal fitting different from the core wire. A method of manufacturing an electric wire with a terminal fitting to which the electric wire connecting portion is connected, and peeling the end of the insulation coating of the electric wire to expose the end of the core wire, and the exposed electric wire in the electric wire A step of attaching a thin adherend made of a metal having an ionization tendency close to that of the terminal fitting from the end of the core wire to the end of the insulation coating, and joining the adherend to the core wire by ultrasonic welding And the step of crimping the wire connection portion of the terminal fitting to the adherend are sequentially performed (means 5).
According to the manufacturing method of the means 5, the electric wire with a terminal metal fitting of this invention can be manufactured reliably.

Claims (5)

  1. 　金属製の芯線を絶縁被覆で覆った電線と、
    　前記芯線とは異種の金属製であって同芯線と接続される電線接続部を設けた端子金具と、
    　前記端子金具とイオン化傾向が近い金属製であって、前記電線の絶縁被覆が皮剥きされて露出された前記芯線の端末から残された絶縁被覆の端末に亘って被着可能な薄肉の被着体と、が具備され、
    　前記被着体が前記電線の前記芯線に対して超音波溶接により接合され、前記被着体に前記端子金具の前記電線接続部が圧着されている端子金具付き電線。     An electric wire having a metal core wire covered with an insulation coating;
    A terminal fitting provided with an electric wire connecting portion made of a metal different from the core wire and connected to the core wire,
    A thin-walled deposit that is made of a metal that is close to ionization to the terminal fitting and that can be deposited over the end of the insulation coating left from the end of the core wire exposed by peeling off the insulation coating of the electric wire. A body,
    An electric wire with a terminal fitting, wherein the adherend is joined to the core wire of the electric wire by ultrasonic welding, and the wire connecting portion of the terminal fitting is crimped to the adherend.
  2. 　前記電線が、アルミニウムまたはアルミニウム合金製の芯線を備えたアルミ電線である一方、前記端子金具が銅合金製である請求の範囲第１項に記載の端子金具付き電線。 The electric wire with terminal fitting according to claim 1, wherein the electric wire is an aluminum electric wire having a core wire made of aluminum or aluminum alloy, and the terminal fitting is made of copper alloy.
  3. 　前記被着体は、銅箔を複数層に巻き付けることで形成されている請求の範囲第２項に記載の端子金具付き電線。 The electric wire with a terminal fitting according to claim 2, wherein the adherend is formed by winding a copper foil around a plurality of layers.
  4. 　前記電線接続部が前後２組のバレルから構成され、前側の前記バレルが、前記電線の端末に被着された被着体のうち前記芯線の端末に被着された領域にかしめ圧着され、後側の前記バレルが、前記被着体のうち前記絶縁被覆の端末に被着された領域にかしめ圧着されている請求の範囲第１項ないし請求の範囲第３項のいずれか一項に記載の端子金具付き電線。 The electric wire connecting portion is composed of two front and rear barrels, and the front barrel is caulked and crimped to a region of the adherend attached to the end of the electric wire and attached to the end of the core wire. 4. The barrel according to claim 1, wherein the barrel on the side is crimped and crimped to a region of the adherend that is attached to the end of the insulating coating. Electric wire with terminal fittings.
  5. 　金属製の芯線を絶縁被覆で覆った電線における前記芯線の端末に、前記芯線とは異種の金属製の端子金具に設けられた電線接続部が接続された端子金具付き電線を製造する方法であって、
    　前記電線の絶縁被覆の端末を皮剥きして前記芯線の端末を露出する工程と、
    　前記電線における露出した前記芯線の端末から残された絶縁被覆の端末に亘り、前記端子金具とイオン化傾向が近い金属からなる薄肉の被着体を被着する工程と、
    　前記被着体を超音波溶接により前記芯線に接合する工程と、
    　前記被着体に前記端子金具の前記電線接続部を圧着する工程と、
    が順次に行われる端子金具付き電線の製造方法。     This is a method of manufacturing an electric wire with a terminal fitting in which an electric wire connecting portion provided on a metal terminal fitting different from the core wire is connected to an end of the core wire in an electric wire in which a metallic core wire is covered with an insulating coating. And
    Peeling the end of the insulation coating of the electric wire to expose the end of the core wire; and
    A step of attaching a thin adherend made of a metal having a close ionization tendency to the terminal fitting, over the end of the insulation coating left from the exposed end of the core wire in the electric wire;
    Joining the adherend to the core wire by ultrasonic welding;
    Crimping the wire connecting portion of the terminal fitting to the adherend;
    Is a method for manufacturing electric wires with terminal fittings.
PCT/JP2011/055760 2010-03-25 2011-03-11 Electric wire with terminal fitting and production method for same WO2011118416A1 (en)

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