JP2010073638A - Aluminum wire, and aluminum wire terminal crimping method - Google Patents

Aluminum wire, and aluminum wire terminal crimping method Download PDF

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JP2010073638A
JP2010073638A JP2008242809A JP2008242809A JP2010073638A JP 2010073638 A JP2010073638 A JP 2010073638A JP 2008242809 A JP2008242809 A JP 2008242809A JP 2008242809 A JP2008242809 A JP 2008242809A JP 2010073638 A JP2010073638 A JP 2010073638A
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terminal
conductor
electric wire
wire
solder
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JP5158874B2 (en
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Toshiyuki Hashimoto
利行 橋本
Hitomi Sato
仁美 佐藤
Hiroyuki Tsukada
浩之 塚田
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Furukawa Electric Co Ltd
Furukawa Automotive Systems Inc
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Furukawa Automotive Systems Inc
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Abstract

<P>PROBLEM TO BE SOLVED: To provide an aluminum wire hardly causing cutting of an element wire along a bell-mouth part of a crimped terminal and excellent in durability, and to provide an aluminum wire terminal crimping method. <P>SOLUTION: In the aluminum wire 10 with the connection terminal 100 crimped on a conductor 11, solder 15 is applied onto a longitudinal predetermined part of the conductor over the entire circumferential periphery and the solder-applied part abuts on the bell-mouth part 111 of the connection terminal which is crimped on the conductor, thereby providing the aluminum wire and the aluminum wire terminal crimping method hardly causing cutting of the element wire along the bell-mouth part of the crimped terminal and excellent in durability. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

本発明は、例えば車両のワイヤーハーネスに使用されるアルミ電線及びアルミ電線の端子圧着方法に関する。   The present invention relates to an aluminum electric wire used for, for example, a vehicle wiring harness and a terminal crimping method for the aluminum electric wire.

近年、例えば車両に銅電線の代わりにアルミ電線でできたワイヤーハーネスが用いられるようになっている。この理由は、第１にアルミ電線の方が銅電線よりも軽量のため車両の軽量化を図ることができると共に、ワイヤーハーネス組付け時の作業性やワイヤーハーネスの車両への取付け性向上を図ることにある。また、第２に車両のリサイクル時に従来の銅電線がボディに残って銅と鉄との分離が行い難かったのに対し、銅電線の代わりにアルミ電線を用いることでアルミが車両に残ってもリサイクル時に鉄とアルミの分離が行い易くなるのでリサイクル性に優れることにある。また、第３にアルミ電線の方が銅電線よりもコスト的に廉価なことにある。   In recent years, for example, wire harnesses made of aluminum wires instead of copper wires have been used in vehicles. This is because, firstly, the aluminum wire is lighter than the copper wire, so that the weight of the vehicle can be reduced, and the workability when assembling the wire harness and the attachment of the wire harness to the vehicle are improved. There is. Second, when the vehicle is recycled, the conventional copper wire remains in the body, making it difficult to separate the copper and iron, but by using an aluminum wire instead of the copper wire, aluminum remains in the vehicle. Since it becomes easy to separate iron and aluminum during recycling, it is excellent in recyclability. Third, aluminum wires are cheaper than copper wires.

一方、アルミ電線は導体に酸化被膜を形成し易いため、接続端子を圧着した際に、導体と端子間、あるいは導体を構成する撚り線の素線間での金属的な接合が不完全になりやすい。その状態で温度サイクル等の環境変化を与えると、端子圧着部の電気抵抗が上昇し、溶断が発生するなど、端子圧着部での電気的特性が維持できない。これを防ぎ、アルミ電線の端子圧着部の電気的特性を安定に維持するために、アルミ電線導体部の圧縮率が、圧着部分のアルミ電線導体部断面積／圧着前のアルミ電線導体部断面積の比率で５０〜７０％の範囲にする方法が開示されている（例えば、特許文献１参照）。   On the other hand, since an aluminum wire tends to form an oxide film on a conductor, when the connection terminal is crimped, the metallic connection between the conductor and the terminal or between the strands of the stranded wire constituting the conductor becomes incomplete. Cheap. If an environmental change such as a temperature cycle is given in this state, the electrical resistance of the terminal crimping part increases, and the electrical characteristics at the terminal crimping part cannot be maintained. In order to prevent this and maintain stable electrical characteristics of the terminal crimping part of the aluminum wire, the compression ratio of the aluminum wire conductor part is the cross-sectional area of the aluminum wire conductor part of the crimped part / the cross-sectional area of the aluminum wire conductor part before crimping. Has been disclosed (see, for example, Patent Document 1).

図９は、従来のアルミ電線１０’に端子２００を圧着した状態を示す平面図（図９（ａ））及び側面図（図９（ｂ））である。また、図１０（ａ）は、上述のようにして端子２００をアルミ電線１０’に圧着した状態の端子付きアルミ電線の圧着断面図である。また、図１０（ｂ）は、銅電線２０に端子２００を圧着した状態の圧着断面図である。   FIGS. 9A and 9B are a plan view (FIG. 9A) and a side view (FIG. 9B) showing a state where the terminal 200 is crimped to the conventional aluminum electric wire 10 '. FIG. 10A is a crimping sectional view of the aluminum electric wire with a terminal in a state where the terminal 200 is crimped to the aluminum electric wire 10 'as described above. FIG. 10B is a cross-sectional view of a crimped state in which the terminal 200 is crimped to the copper electric wire 20.

ここで、端子２００の圧着高さはクリンプハイト値と呼ばれ、図１０においてクリンプハイト値Ｈａ，Ｈｂとして示すように、端子２００と電線１０’，２０の圧着圧縮率（減面率）は一般的に、このクリンプハイト値によって管理されている。   Here, the crimping height of the terminal 200 is called a crimp height value, and the crimp compression rate (area reduction) between the terminal 200 and the electric wires 10 ′ and 20 is generally shown in FIG. 10 as the crimp height values Ha and Hb. Therefore, it is managed by this crimp height value.

そして、図１０（ａ）に示す断面例Ａのようにクリンプハイト値が小さいものは導体断面積が小さく、高圧縮状態で圧着されている。反対に図１０（ｂ）に示す断面例Ｂのようにクリンプハイト値が大きいものは導体断面積が大きく、低圧縮状態で圧着されている。   And the thing with a small crimp height value like the cross-sectional example A shown to Fig.10 (a) has a small conductor cross-sectional area, and is crimped | bonded by the highly compressed state. On the other hand, the one with a large crimp height value such as the cross-sectional example B shown in FIG. 10B has a large conductor cross-sectional area and is crimped in a low compression state.

例えば、クリンプハイト値が小さい断面例Ａでの圧縮率が７０％とすると、断面例Ａは、アルミ電線１０’への端子圧着構造として好ましい機械的及び電気的特性を有する端子圧着構造に相当する。一方、断面例Ａに比べてクリンプハイト値（導体断面積）が大きい断面例Ｂでは、圧縮率が７０％より大きく、断面例Ｂは通常の銅電線２０への端子圧着構造に相当する。   For example, when the compression rate in the cross-section example A with a small crimp height value is 70%, the cross-section example A corresponds to a terminal crimp structure having mechanical and electrical characteristics preferable as a terminal crimp structure to the aluminum electric wire 10 ′. . On the other hand, in the cross-sectional example B where the crimp height value (conductor cross-sectional area) is larger than that in the cross-sectional example A, the compressibility is larger than 70%, and the cross-sectional example B corresponds to a terminal crimping structure to a normal copper wire 20.

即ち、圧縮率とは、電線導体の端子圧着前の断面積を１００％としたときの減面率をいい、圧着後のクリンプハイト値や導体断面積が小さいほうが、高圧縮となる。そして、高圧縮ほど圧縮率は小さな数字となる。   That is, the compression ratio refers to a surface area reduction ratio when the cross-sectional area of the electric wire conductor before terminal crimping is 100%, and the smaller the crimp height value and the conductor cross-sectional area after crimping, the higher the compression. And the higher the compression, the smaller the compression rate.

従来における銅電線２０への端子圧着構造は、実際は目標の圧縮率になるクリンプハイト値によって管理されているが、端子の種類や電線径によって若干異なるものの結果的に圧着圧縮率がほぼ７５〜９５％の範囲内にて管理されている。   The conventional terminal crimping structure to the copper wire 20 is actually managed by the crimp height value that is the target compression rate, but the crimp compression rate is approximately 75 to 95 as a result, although it varies slightly depending on the type of terminal and the wire diameter. % Is managed within the range.

一方、アルミ電線１０’を現状の管理値にて圧着すると、高温や低温を要する環境試験において抵抗値の上昇が発生し、安定した電気接続を維持することができない。しかしながら、アルミ電線１０’に限って最適な管理値を５０〜７０％の範囲に特定することで、環境試験をクリアし、安定した電気接続を図ることができる点が特許文献１の実施例に詳細に記載されている。
実特開２００５−１７４８９６（段落（００２９）、図４） On the other hand, when the aluminum wire 10 ′ is crimped at the current control value, an increase in resistance value occurs in an environmental test that requires high or low temperature, and stable electrical connection cannot be maintained. However, in the embodiment of Patent Document 1, it is possible to clear an environmental test and achieve stable electrical connection by specifying an optimal management value in the range of 50 to 70% only for the aluminum electric wire 10 ′. It is described in detail.
Japanese Unexamined Patent Publication No. 2005-174896 (paragraph (0029), FIG. 4)

ここで、アルミ電線１０’に端子２００を圧着する際に圧縮率を５０〜７０％としてアルミ電線１０’の変形を大きくすると、図１１（ａ）及び図１１（ａ）の点線Ｐで示す部分を拡大した図１１（ｂ）に示すように、特に端子２００のベルマウス部２１１付近でアルミ電線１０’の素線の局所的な変形が大きくなり、素線が破断し易くなるという問題がある。なお、ここでベルマウス部２１１とは、図１１（ｂ）に示すようにワイヤーバレル２１０の電線側端部で、端子圧着前には存在しないが端子圧着後に側面視でテーパ状をなす部分を指す。   Here, when the terminal 200 is crimped to the aluminum electric wire 10 ′, when the compression rate is 50 to 70% and the deformation of the aluminum electric wire 10 ′ is increased, the portion indicated by the dotted line P in FIGS. 11A and 11A As shown in FIG. 11 (b), the local deformation of the strand of the aluminum electric wire 10 ′ increases particularly near the bell mouth portion 211 of the terminal 200, and the strand is likely to break. . Here, the bell mouth portion 211 is an end portion on the electric wire side of the wire barrel 210 as shown in FIG. 11B, and a portion that does not exist before terminal crimping but has a tapered shape in side view after terminal crimping. Point to.

このような問題が生じるのは、ベルマウス部２１１にあたる部分の導体が圧着によって変形した部分と変形を受けない部分の遷移部分になるので、素線が局所的に強く伸ばされるなど局所的な変形が起こり易く、圧縮変形が大きいと
ベルマウス部２１１で素線が破断し易くなることに起因していると考えられる。 Such a problem occurs because the portion of the conductor corresponding to the bell mouth portion 211 becomes a transition portion between a portion deformed by crimping and a portion not subjected to deformation, so that the local deformation such as the strand is strongly stretched locally. If the compression deformation is large, it is considered that the wire is easily broken at the bell mouth portion 211.

また、端子２００のアルミ電線１０’への圧着時だけでなく、特にこのアルミ電線１０’を車両のワイヤーハーネスの振動部位に利用すると、車両走行中にアルミ電線１０’が常に振動を受けるので、ベルマウス部での破断が生じ易くなる。   Further, not only when the terminal 200 is crimped to the aluminum electric wire 10 ′, but particularly when this aluminum electric wire 10 ′ is used as a vibration part of the wire harness of the vehicle, the aluminum electric wire 10 ′ is constantly vibrated during traveling of the vehicle. Breakage at the bell mouth portion is likely to occur.

本発明は、圧着された端子のベルマウス部で素線が破断し難い耐久性に優れたアルミ電線及びアルミ電線の端子圧着方法を提供することを目的とする。   An object of the present invention is to provide an aluminum wire excellent in durability in which a strand is not easily broken at a bell mouth portion of a crimped terminal, and a terminal crimping method of the aluminum wire.

上述の課題を解決するために本発明の請求項１に係るアルミ電線は、
導体に接続端子が圧着されたアルミ電線であって、
前記導体の長手方向における所定の一部分に、周方向全周に亘ってハンダが塗布され、
前記ハンダが塗布された部分が、前記導体に圧着された接続端子のベルマウス部に当たっていることを特徴としている。 In order to solve the above-mentioned problem, an aluminum electric wire according to claim 1 of the present invention is
An aluminum electric wire with a connection terminal crimped to a conductor,
Solder is applied to a predetermined part in the longitudinal direction of the conductor over the entire circumference,
The portion to which the solder is applied is in contact with a bell mouth portion of a connection terminal crimped to the conductor.

請求項１に係るアルミ電線によると、ベルマウス部で導体がハンダにより補強されているので、このベルマウス部における導体の破断が起こり難くなる。これは、ハンダの塗布により導体とハンダを合わせた断面積が単純に増加しているためだけでなく、素線同士がハンダにより接合されていることで導体の変形時の引っ張り応力を隣り合う素線同士で分担することや、ハンダにより素線表面に圧縮応力が付加されていることなどのメカニズムによりベルマウス部の導体が補強されるためであると考えられる。   According to the aluminum electric wire according to the first aspect, since the conductor is reinforced by the solder in the bell mouth portion, the conductor is hardly broken in the bell mouth portion. This is not only due to the fact that the cross-sectional area of the conductor and the solder is simply increased by the application of solder, but also because the strands are joined together by solder so that the tensile stress at the time of deformation of the conductor is adjacent to the element. This is considered to be because the conductor of the bell mouth portion is reinforced by a mechanism such as sharing between the wires or a compressive stress being applied to the surface of the strand by solder.

また、本発明の請求項２に係るアルミ電線は、請求項１に記載のアルミ電線において、
前記導体が絶縁材からなる被覆部で被覆されると共に、当該電線の端部で当該被覆部が除去され、
前記被覆部が除去され露出した部分の前記導体の長手方向における所定の一部分に、周方向全周に亘ってハンダが塗布され、
前記ハンダが塗布された部分が、前記導体に圧着された接続端子のベルマウス部に当たっていることを特徴としている。 Moreover, the aluminum electric wire which concerns on Claim 2 of this invention is the aluminum electric wire of Claim 1,
The conductor is covered with a covering portion made of an insulating material, and the covering portion is removed at the end of the wire,
Solder is applied over the entire circumference in a predetermined part of the conductor in the longitudinal direction of the exposed portion where the covering portion is removed,
The portion to which the solder is applied is in contact with a bell mouth portion of a connection terminal crimped to the conductor.

請求項２に係るアルミ電線によると、アルミ電線が絶縁被覆された被覆線であっても被覆の端部を除去した部分に端子を圧着した場合に請求項１と同様の作用が得られる。   According to the aluminum electric wire which concerns on Claim 2, even if it is a covered wire with which the aluminum electric wire was insulation-coated, the effect | action similar to Claim 1 is acquired when a terminal is crimped | bonded to the part which remove | eliminated the edge part of the coating | cover.

また、本発明の請求項３に係るアルミ電線の端子圧着方法は、
アルミ電線に接続端子を圧着するアルミ電線の端子圧着方法であって、
導体の長手方向における所定の一部分に、周方向全周に亘ってハンダフラックスを塗布し、
前記導体の少なくともハンダフラックスが塗布された部分を溶融したハンダに浸漬して、前記ハンダフラックスが塗布された部分に前記ハンダを塗布し、
前記ハンダが塗布された部分が、前記導体に圧着される接続端子のワイヤーバレルの電線側端部に当たるように当該接続端子を圧着することを特徴としている。 Moreover, the terminal crimping method of the aluminum electric wire which concerns on Claim 3 of this invention is the following.
A method for crimping an aluminum wire by crimping a connection terminal on the aluminum wire,
Apply solder flux to a predetermined part in the longitudinal direction of the conductor over the entire circumference,
Dipping at least a portion of the conductor to which the solder flux is applied in molten solder, and applying the solder to the portion to which the solder flux is applied,
The connecting terminal is crimped so that the soldered portion is in contact with the wire side end of the wire barrel of the connecting terminal to be crimped to the conductor.

請求項３に係るアルミ電線の端子圧着方法によると、請求項１及び請求項２のような端子のベルマウス部にあたる導体の部分の破断が生じ難い圧着端子付きアルミ電線を容易に製造できるようになる。   According to the terminal crimping method for an aluminum electric wire according to claim 3, it is possible to easily manufacture an aluminum electric wire with a crimping terminal that does not easily break the portion of the conductor corresponding to the bell mouth portion of the terminal as in claims 1 and 2. Become.

本発明によると、アルミ電線を端子に圧着する際に圧縮率を小さくして安定な電気接続を図りつつ、圧着された端子のベルマウス部で素線が破断し難い耐久性に優れたアルミ電線及びアルミ電線の端子圧着方法を提供することができる。   According to the present invention, when an aluminum wire is crimped to a terminal, the compression rate is reduced to achieve stable electrical connection, and the wire is not easily broken at the bell mouth portion of the crimped terminal and has excellent durability. And the terminal crimping method of an aluminum electric wire can be provided.

以下、本発明の一実施形態に係るアルミ電線及びアルミ電線の端子圧着方法について図面に基づいて詳細に説明する。最初に本発明の一実施形態に係るアルミ電線について説明する。   Hereinafter, an aluminum electric wire and an aluminum electric wire terminal crimping method according to an embodiment of the present invention will be described in detail based on the drawings. First, an aluminum electric wire according to an embodiment of the present invention will be described.

図１は、本発明の一実施形態に係るアルミ電線１０を示す側面図である。また、図２は、本発明の一実施形態に係るアルミ電線１０に接続端子（以下、単に「端子」とする）１００を圧着した状態を示す平面図（図２（ａ））及び側面図（図２（ｂ））である。また、図３は、図２における端子１００のベルマウス部近傍のみを部分的に拡大して示す側面図である。また、図４は、アルミ電線１０に圧着する前の端子１００の平面図（図４（ａ））及び側面図（図４（ｂ））である。   FIG. 1 is a side view showing an aluminum electric wire 10 according to an embodiment of the present invention. 2 is a plan view (FIG. 2 (a)) and a side view (side view) showing a state in which a connection terminal (hereinafter simply referred to as “terminal”) 100 is crimped to an aluminum electric wire 10 according to an embodiment of the present invention. FIG. 2 (b)). FIG. 3 is a side view partially enlarged showing only the vicinity of the bell mouth portion of the terminal 100 in FIG. FIG. 4 is a plan view (FIG. 4A) and a side view (FIG. 4B) of the terminal 100 before being crimped to the aluminum electric wire 10.

本発明の一実施形態にかかるアルミ電線１０は、図１に示すアルミ電線１０の導体部１１に端子１００が圧着されるアルミ電線であって、導体部１１が絶縁材からなる被覆部１２で被覆されると共に、アルミ電線１０の端部で被覆部１２が除去されている。そして、被覆部１２が除去され露出した部分の導体部１１の長手方向における所定の一部分に、周方向全周に亘ってハンダ１５が塗布されている。そして、このハンダ１５が塗布された部分が、図２及び図３に示すように導体部１１に圧着された端子１００のベルマウス部（ワイヤーバレルの電線側端部で、端子圧着前には存在しないが端子圧着後に側面視でテーパ状をなす部分）１１１に当たるようになっている。   An aluminum wire 10 according to an embodiment of the present invention is an aluminum wire in which a terminal 100 is crimped to a conductor portion 11 of the aluminum wire 10 shown in FIG. 1, and the conductor portion 11 is covered with a covering portion 12 made of an insulating material. In addition, the covering portion 12 is removed at the end of the aluminum electric wire 10. Then, solder 15 is applied to a predetermined part in the longitudinal direction of the conductor portion 11 at the exposed portion where the covering portion 12 is removed, over the entire circumference. And the part which this solder | pewter 15 was apply | coated exists in the bell mouth part of the terminal 100 crimped | bonded to the conductor part 11 as shown in FIG.2 and FIG.3 (the electric wire side edge part of a wire barrel, before terminal crimping) However, after the terminal is crimped, it comes into contact with the portion 111 having a tapered shape in a side view.

端子１００は、図２及び図４に示すように、電線接続部１００Ａと端子接続部１００Ｂによって構成されている。そして、電線接続部１００Ａは、導体部１１を圧着するワイヤーバレル１１０と、アルミ電線１０を樹脂被覆ごと圧着するインシュレーションバレル１２０によって構成されている。また、ワイヤーバレル１１０は断面略Ｕ字型をなし、いわゆるオープンバレルタイプの端子を形成している。   As shown in FIGS. 2 and 4, the terminal 100 includes an electric wire connecting portion 100A and a terminal connecting portion 100B. And 100 A of electric wire connection parts are comprised by the insulation barrel 120 which crimps | bonds the aluminum electric wire 10 with the resin coating | cover with the wire barrel 110 which crimps | bonds the conductor part 11. FIG. The wire barrel 110 has a substantially U-shaped cross section and forms a so-called open barrel type terminal.

続いて、上述したアルミ電線への端子圧着方法について説明する。なお、図５は、アルミ電線の導体部に全体的にハンダを施す一般的なアルミハンダ方法を示した工程図である。また、図６は、アルミ電線の導体部をフラックスを使用せずにハンダ槽に浸漬した前後の状態を示す工程図である。図５及び図６からアルミ電線の導体部にハンダフラックスを塗布した部分にだけハンダが塗布されていることが分かる。また、図７は、本発明の一実施形態に係るアルミ電線へのハンダの塗布方法を説明する工程図である。   Then, the terminal crimping method to the aluminum electric wire mentioned above is demonstrated. FIG. 5 is a process diagram showing a general aluminum soldering method in which solder is entirely applied to a conductor portion of an aluminum electric wire. FIG. 6 is a process diagram showing a state before and after the conductor portion of the aluminum electric wire is immersed in a solder bath without using a flux. 5 and 6 that the solder is applied only to the portion where the solder flux is applied to the conductor portion of the aluminum electric wire. FIG. 7 is a process diagram for explaining a method of applying solder to an aluminum electric wire according to an embodiment of the present invention.

最初に導体部１１が絶縁材からなる被覆部１２で被覆されると共に、アルミ電線１０の端部で被覆部１２が除去されて導体部１１が露出したアルミ電線１０を用意する。   First, the conductor portion 11 is covered with a covering portion 12 made of an insulating material, and the aluminum wire 10 is prepared in which the covering portion 12 is removed at the end of the aluminum wire 10 and the conductor portion 11 is exposed.

次いで、図７（ａ）に示すように、アルミ電線１０の長手方向における所定の一部分に、周方向全周に亘ってハンダフラックス１５ａを塗布する。ここで、ハンダフラックス１５ａは、アルミニウム又はアルミニウム合金に適用できるハンダフラックスなら如何なるものでも良く、特定のハンダフラックスに限定されない。   Next, as shown in FIG. 7A, a solder flux 15a is applied to a predetermined part in the longitudinal direction of the aluminum electric wire 10 over the entire circumference. Here, the solder flux 15a may be any solder flux applicable to aluminum or an aluminum alloy, and is not limited to a specific solder flux.

次いで、図７（ｂ）に示すように、導体部１１の少なくともハンダフラックス１５ａが塗布された部分を溶融したハンダ液５０に浸漬する。   Next, as shown in FIG. 7B, at least a portion of the conductor portion 11 to which the solder flux 15a is applied is immersed in a molten solder solution 50.

これによって、図７（ｃ）に示すように、アルミ電線１０のハンダフラックス１５ａが塗布された部分にのみハンダ１５が塗布される。   As a result, as shown in FIG. 7C, the solder 15 is applied only to the portion of the aluminum electric wire 10 where the solder flux 15a is applied.

そして、ハンダ１５が塗布された部分が、導体部１１に圧着される端子１００のベルマウス部１１１に当たるように端子１００を導体部１１に圧着する。   And the terminal 100 is crimped | bonded to the conductor part 11 so that the part to which the solder | pewter 15 was apply | coated contacts the bellmouth part 111 of the terminal 100 crimped | bonded to the conductor part 11. FIG.

以下に、このアルミ電線への端子圧着工程について説明する。図８は本発明の一実施形態に係るアルミ電線への端子圧着前の状態から端子圧着後の状態までを（ａ）〜（ｄ）の順で示す工程図であり、左側は端子を側方から見た状態で右側はアルミ電線を被覆部方向から見た状態で示している。   Below, the terminal crimping | compression-bonding process to this aluminum electric wire is demonstrated. FIG. 8 is a process diagram showing, in order from (a) to (d), a state before crimping a terminal to an aluminum electric wire according to an embodiment of the present invention, and a state after crimping the terminal. The right side when viewed from the side shows the aluminum wire as viewed from the direction of the covering portion.

最初に、図８（ａ）に示すように、端子１００を基台８０に固定し、アルミ電線１０を端子１００の適所に位置決めする。即ち、アルミ電線１０の導体部１１をワイヤーバレル１１０で挟まれた領域に位置決めすると共に、被覆部１２をインシュレーションバレル１２０で挟まれた領域に位置決めする。この際、アルミ電線１０に圧着されるワイヤーバレル１１０の端子圧着後にベルマウス部１１１として形成されるワイヤーバレル１１０の電線側端部に上述したアルミ電線１０のハンダ１５が当たるように位置決めする。   First, as shown in FIG. 8A, the terminal 100 is fixed to the base 80, and the aluminum electric wire 10 is positioned at an appropriate position of the terminal 100. That is, the conductor portion 11 of the aluminum electric wire 10 is positioned in the region sandwiched between the wire barrels 110 and the covering portion 12 is positioned in the region sandwiched between the insulation barrels 120. At this time, positioning is performed so that the above-described solder 15 of the aluminum electric wire 10 contacts the electric wire side end portion of the wire barrel 110 formed as the bell mouth portion 111 after the terminal of the wire barrel 110 to be crimped to the aluminum electric wire 10 is crimped.

この状態で、端子長手方向で見て特別な形状の圧着溝を有する圧着治具９０を端子１００の上方から接近させる（図８（ａ）の端子圧着方向を示す矢印Ｘ参照）。なお、圧着治具９０には圧着するワイヤーバレル１１０及びインシュレーションバレル１２０に対応する圧着部が形成されている。即ち、端子１００のワイヤーバレル１１０に対応する位置に端子圧着部９１が形成され、端子１００のインシュレーションバレル１２０に対応する位置には端子圧着部９２が形成されている。ここで、この圧着治具９０を図示しないアクチュエータによって端子側に向かって下降させる（図８（ｂ）参照）。この下降動作によって、各バレル１１０，１２０の端部が圧着治具９０の圧着部の各圧着溝に沿ってしだいに屈曲され、やがては、圧着治具９０において各バレル端部がアルミ電線１０の中心軸線方向に変形（カール）する（図８（ｃ）参照）。   In this state, the crimping jig 90 having a specially shaped crimping groove as viewed in the terminal longitudinal direction is approached from above the terminal 100 (see arrow X indicating the terminal crimping direction in FIG. 8A). The crimping jig 90 is formed with crimping portions corresponding to the wire barrel 110 and the insulation barrel 120 to be crimped. That is, a terminal crimping portion 91 is formed at a position corresponding to the wire barrel 110 of the terminal 100, and a terminal crimping portion 92 is formed at a position corresponding to the insulation barrel 120 of the terminal 100. Here, the crimping jig 90 is lowered toward the terminal side by an actuator (not shown) (see FIG. 8B). By this descending operation, the ends of the barrels 110 and 120 are gradually bent along the crimping grooves of the crimping portion of the crimping jig 90, and eventually the barrel ends of the crimping jig 90 are attached to the aluminum wire 10. It deforms (curls) in the direction of the central axis (see FIG. 8C).

そして、圧着治具９０を更に下降することによってワイヤーバレル先端がアルミ電線１０の導体部１１の撚り線間に押し込まれていく。これと同時に、アルミ電線１０の被覆部１２にもインシュレーションバレル１２０が圧着される。この際、アルミ電線に圧着されるワイヤーバレル１１０のベルマウス部１１１に上述したアルミ電線１０のハンダ１５が当たるように圧着する。   Then, by further lowering the crimping jig 90, the tip of the wire barrel is pushed between the strands of the conductor portion 11 of the aluminum electric wire 10. At the same time, the insulation barrel 120 is also crimped to the covering portion 12 of the aluminum electric wire 10. Under the present circumstances, it crimps | bonds so that the solder 15 of the aluminum electric wire 10 mentioned above may contact the bellmouth part 111 of the wire barrel 110 crimped | bonded to an aluminum electric wire.

また、このように端子１００をアルミ電線１０の導体部１１に圧着するにあたって、圧着部分のアルミ電線導体部断面積／圧着前のアルミ電線導体部断面積で規定されるアルミ電線導体部の圧縮率（減面率）が５０〜７０％の範囲内になるように端子１００をアルミ電線１０に圧着する。この端子圧着作業が終わると、圧着治具９０を上昇させて端子圧着作業を完了する（図８（ｄ）参照）。   Further, when the terminal 100 is crimped to the conductor portion 11 of the aluminum electric wire 10 in this way, the compression ratio of the aluminum electric wire conductor portion defined by the cross-sectional area of the aluminum electric wire conductor portion of the crimped portion / the cross-sectional area of the aluminum electric wire conductor portion before the crimping. The terminal 100 is crimped to the aluminum electric wire 10 so that the (area reduction) is in the range of 50 to 70%. When this terminal crimping operation is finished, the crimping jig 90 is raised to complete the terminal crimping operation (see FIG. 8D).

このようにして圧着された端子付きのアルミ電線１０は、導体部１１がベルマウス部１１１でハンダ１５により補強されているので、端子１００のベルマウス部１１１における導体部１１の破断が起こり難くなる。これは、ハンダ１５の塗布により導体部１１とハンダ１５を合わせた断面積が単純に増加しているためだけでなく、素線同士がハンダ１５により接合されていることで、導体部１１の変形時の引っ張り応力を隣り合う素線同士で分担することや、ハンダ１５により素線表面に圧縮応力が付加されていることなどのメカニズムによりベルマウス部１１１の導体部１１が補強されるためであると考えられる。   In the aluminum electric wire 10 with a terminal crimped in this way, the conductor portion 11 is reinforced by the solder 15 at the bell mouth portion 111, so that the conductor portion 11 in the bell mouth portion 111 of the terminal 100 is hardly broken. . This is not only because the cross-sectional area of the conductor portion 11 and the solder 15 is simply increased by the application of the solder 15, but also because the wires are joined together by the solder 15. This is because the conductor portion 11 of the bell mouth portion 111 is reinforced by a mechanism such as sharing the tensile stress at the time between adjacent strands or applying a compressive stress to the surface of the strand by the solder 15. it is conceivable that.

以下、このようなアルミ電線１０の端子圧着方法を用いてアルミ電線１０に端子１００を実際に圧着してみたので、その結果について実施例として説明する。   Hereinafter, since the terminal 100 was actually crimped | bonded to the aluminum electric wire 10 using such a terminal crimping method of the aluminum electric wire 10, the result is demonstrated as an Example.

具体的には、導体部１１がアルミニウム又はアルミニウム合金からなるアルミ電線１０の端部の被覆部１２を一部除去した。そして、被覆部１２が除去された導体部１１の根元付近に刷毛でハンダフラックスを塗布した（図７（ａ）参照）。この際、ハンダフラックス１５ａは被覆除去部の長手方向には短い範囲で、周方向には全周にわたって塗布されるよう、アルミ電線１０を軸を中心に自転させながら、フラックスを含ませた細い刷毛を当てて帯状に一周塗布した。   Specifically, the conductor 12 was partially removed from the covering 12 at the end of the aluminum electric wire 10 made of aluminum or an aluminum alloy. And solder flux was apply | coated with the brush near the base of the conductor part 11 from which the coating | coated part 12 was removed (refer Fig.7 (a)). At this time, the solder flux 15a is applied in a short range in the longitudinal direction of the coating removal portion, and the thin brush containing the flux while rotating the aluminum electric wire 10 around the axis so as to be applied over the entire circumference in the circumferential direction. Was applied once in a strip shape.

その後、被覆除去部である導体部１１をハンダ槽のハンダ液に浸漬した（図７（ｂ）参照）。これにより、ハンダフラックス１５ａを塗布した部分のみの酸化皮膜が除去され、ハンダ１５が付着した。また、それ以外の部分では、導体部１１の表面にアルミ酸化皮膜が残っているので、ハンダ１５は付着せず、素線のままとなった。この結果、導体部１１の根元付近に鉢巻き状にハンダ１５が付着したアルミ電線１０が得られた（図７（ｃ）参照）。   Then, the conductor part 11 which is a coating removal part was immersed in the solder liquid of a solder tank (refer FIG.7 (b)). As a result, the oxide film only on the portion where the solder flux 15a was applied was removed, and the solder 15 adhered. Moreover, since the aluminum oxide film remained on the surface of the conductor part 11 in the part other than that, the solder 15 did not adhere and it remained with the strand. As a result, the aluminum electric wire 10 with the solder 15 attached in a headband shape near the base of the conductor portion 11 was obtained (see FIG. 7C).

このアルミ電線１０を端子１００と共に圧着機の金型にセットした。ここで、ハンダ１５がワイヤーバレル１１０のベルマウス部１１１にかかるように、端子１００に対してアルミ電線１０の長手方向の位置を定めた。   The aluminum electric wire 10 was set together with the terminal 100 in a die of a crimping machine. Here, the position in the longitudinal direction of the aluminum electric wire 10 was determined with respect to the terminal 100 such that the solder 15 was placed on the bell mouth portion 111 of the wire barrel 110.

次いで、上述した圧着方法でアルミ電線１０に端子１００を圧着した。この際、圧縮率５０〜７０％でアルミ電線１０に端子１００のワイヤーバレル１１０を圧着してもベルマウス部１１１で芯線の破断は起こらなかった。また、電気接続性は良好で、信頼性試験によっても安定した導通を示した。   Subsequently, the terminal 100 was crimped | bonded to the aluminum electric wire 10 with the crimping method mentioned above. At this time, even if the wire barrel 110 of the terminal 100 was crimped to the aluminum electric wire 10 at a compression rate of 50 to 70%, the core wire did not break at the bell mouth portion 111. In addition, the electrical connectivity was good and stable conduction was shown by a reliability test.

なお、本発明を実施するにあたって、接続端子は、電線を加締めて電気的及び機械的に接続するタイプの端子であれば良く、端子の形状は限定されない。また、端子が導体を加締めるバレル部の形状は、上述した実施形態ではワイヤーバレルがオープンバレルであったが、この代わりにクローズドバレルであっても良い。また、上述した実施形態では端子にインシュレーションバレルが備わっていたが、必ずしもインシュレーションバレルが端子に備わっていなくても良い。また、アルミ電線は、導体がアルミニウム又はアルミニウム合金であれば良く、その種類は限定されない。また、ハンダは、アルミニウム又はアルミニウム合金にハンダ付け可能なものであれば、その種類は限定されない。   In carrying out the present invention, the connection terminal may be any type of terminal that is electrically and mechanically connected by crimping an electric wire, and the shape of the terminal is not limited. Moreover, although the wire barrel was an open barrel in the above-described embodiment, the shape of the barrel portion where the terminal caulks the conductor may be a closed barrel instead. In the above-described embodiment, the terminal is provided with the insulation barrel, but the insulation barrel is not necessarily provided in the terminal. In addition, the type of the aluminum electric wire is not limited as long as the conductor is aluminum or an aluminum alloy. Moreover, the kind of solder will not be limited if it can be soldered to aluminum or an aluminum alloy.

なお、本発明において、ハンダはアルミ電線の導体部の長手方向所定の一部分に亘り、かつ周方向に全周に塗布するようになっており、これは狭義には鉢巻き状に塗布するという意味であるが、上述の実施形態のようにアルミ電線の狭い帯状にハンダを鉢巻き状に塗布することに限定されず、導体部の長手方向一部であって周方向に全周であれば如何なる形態であっても良い。   In the present invention, the solder is applied to a predetermined part in the longitudinal direction of the conductor portion of the aluminum electric wire and applied to the entire circumference in the circumferential direction, which means that the solder is applied in a headband shape in a narrow sense. However, it is not limited to applying the solder to the narrow band shape of the aluminum electric wire as in the above-described embodiment, and any form as long as it is a part of the conductor portion in the longitudinal direction and the entire circumference in the circumferential direction. There may be.

このように導体部の長手方向一部と限定した理由は、端子のワイヤーバレルを加締めるアルミ電線の領域全体に（即ち、少なくとも加締めで変形する部分の全長に亘って）ハンダが塗布されると、変形部で素線間の長手方向へのずれが拘束されて圧縮時の挙動が不安定になり、安定した圧着ができなくなるためである。また、変形部全体で断面積が増大することから、圧着力が大きくなるためでもある。   The reason why the conductor portion is limited to a part in the longitudinal direction is that the solder is applied to the entire region of the aluminum electric wire that crimps the wire barrel of the terminal (that is, at least over the entire length of the portion deformed by crimping). This is because the deformation is restrained in the longitudinal direction between the strands at the deformed portion, the behavior during compression becomes unstable, and stable crimping cannot be performed. Moreover, since the cross-sectional area increases in the entire deformed portion, the crimping force is increased.

なお、ハンダを塗布する厚さによって、上記の補強の度合いを調整することも可能である。また、ハンダフラックスの塗布方法は、本実施形態では上述の実施例のような電線を自転させながら電線の長手方向の一部にのみ刷毛やノズルを当てて塗布する方法であったが、このような方法には限定されない。また、アルミ電線の導体部のハンダ槽への浸漬時に、超音波等の振動を加えても良い。   It should be noted that the degree of reinforcement described above can be adjusted by the thickness to which the solder is applied. Further, in this embodiment, the solder flux is applied by applying a brush or a nozzle to only a part of the longitudinal direction of the electric wire while rotating the electric wire as in the above-described example. The method is not limited. Moreover, you may add vibrations, such as an ultrasonic wave, at the time of the immersion to the solder tank of the conductor part of an aluminum electric wire.

本発明の一実施形態に係るアルミ電線を示す側面図である。It is a side view which shows the aluminum electric wire which concerns on one Embodiment of this invention. 本発明の一実施形態に係るアルミ電線に端子を圧着した状態を示す平面図（図２（ａ））及び側面図（図２（ｂ））である。It is a top view (Drawing 2 (a)) and a side view (Drawing 2 (b)) which show the state where a terminal was crimped to an aluminum electric wire concerning one embodiment of the present invention. 図２における端子のベルマウス部近傍のみを部分的に拡大して示す側面図である。It is a side view which expands and shows only the bellmouth part vicinity of the terminal in FIG. 本発明の一実施形態に係るアルミ電線に圧着する前の端子を示す平面図（図４（ａ））及び側面図（図４（ｂ））である。It is the top view (Drawing 4 (a)) and side view (Drawing 4 (b)) which show the terminal before crimping to the aluminum electric wire concerning one embodiment of the present invention. アルミ電線に全体的にハンダを施す方法を（ａ）〜（ｃ）の順に示す工程図である。It is process drawing which shows the method of soldering the whole aluminum wire in order of (a)-(c). アルミ電線にフラックスを塗布しない状態でこのアルミ電線をはんだ槽に浸漬する前後の状態を（ａ）〜（ｂ）の順に示す工程図である。It is process drawing which shows the state before and behind immersing this aluminum electric wire in a solder tank in the state which does not apply | coat a flux to an aluminum electric wire in order of (a)-(b). 本発明の一実施形態に係るアルミ電線へのハンダの塗布方法を（ａ）〜（ｃ）の順に示す工程図である。It is process drawing which shows the application | coating method of the solder to the aluminum electric wire which concerns on one Embodiment of this invention in order of (a)-(c). 本発明の一実施形態に係るアルミ電線への端子圧着前の状態から端子圧着後の状態までを（ａ）〜（ｄ）の順に示す工程図であり、左側は端子を側方から見た状態で右側はアルミ電線を被覆部方向から見た状態で示している。It is process drawing which shows from the state before terminal crimping to the state after terminal crimping to the aluminum electric wire which concerns on one Embodiment of this invention to the state after terminal crimping in order of (a)-(d), The state which looked at the terminal from the left side The right side shows the aluminum wire as viewed from the direction of the covering. 従来のアルミ電線に端子を圧着した状態を示す平面図（図９（ａ））及び側面図（図９（ｂ））である。It is the top view (Drawing 9 (a)) and the side view (Drawing 9 (b)) which show the state where a terminal was crimped to the conventional aluminum electric wire. 従来のアルミ電線に端子を圧着した状態の端子圧着部の断面図（図１０（ａ））及び従来の銅電線に端子を圧着した状態の端子圧着部の断面図（図１０（ｂ））である。In sectional drawing (FIG. 10 (a)) of the terminal crimping part in the state which crimped the terminal to the conventional aluminum electric wire, and sectional drawing (FIG.10 (b)) of the terminal crimping part in the state which crimped the terminal to the conventional copper electric wire. is there. 従来のアルミ電線に端子を圧着させた場合に生じる不具合を説明する側面図（図１１（ａ））及び図１１（ａ）の点線Ｐの部分を拡大した部分的拡大図（図１１（ｂ））である。A side view (FIG. 11 (a)) and a partially enlarged view (FIG. 11 (b)) enlarging a portion indicated by a dotted line P in FIG. ).

符号の説明Explanation of symbols

１０，１０’ アルミ電線
１１ 導体部
１２ 被覆部
１５ ハンダ
１５ａ ハンダフラックス
２０ 銅電線
５０ ハンダ液
８０ 基台
９０ 圧着治具
９１，９２ 端子圧着部
１００ （接続）端子
１００Ａ 電線接続部
１００Ｂ 端子接続部
１１０ ワイヤーバレル
１１１ ベルマウス部
１２０ インシュレーションバレル
２００ 端子
２１０ ワイヤーバレル
２１１ ベルマウス部
Ｈａ，Ｈｂ クリンプハイト値 DESCRIPTION OF SYMBOLS 10,10 'Aluminum electric wire 11 Conductor part 12 Covering part 15 Solder 15a Solder flux 20 Copper electric wire 50 Solder liquid 80 Base 90 Crimping jig 91,92 Terminal crimping part 100 (connection) terminal 100A Wire connection part 100B Terminal connection part 110 Wire barrel 111 Bell mouth part 120 Insulation barrel 200 Terminal 210 Wire barrel 211 Bell mouth part Ha, Hb Crimp height value

Claims (3)

導体に接続端子が圧着されたアルミ電線であって、
前記導体の長手方向における所定の一部分に、周方向全周に亘ってハンダが塗布され、
前記ハンダが塗布された部分が、前記導体に圧着された接続端子のベルマウス部に当たっていることを特徴とするアルミ電線。 An aluminum electric wire with a connection terminal crimped to a conductor,
Solder is applied to a predetermined part in the longitudinal direction of the conductor over the entire circumference,
An aluminum electric wire characterized in that a portion to which the solder is applied is in contact with a bell mouth portion of a connection terminal crimped to the conductor. 前記導体が絶縁材からなる被覆部で被覆されると共に、当該電線の端部で当該被覆部が除去され、
前記被覆部が除去され露出した部分の前記導体の長手方向における所定の一部分に、周方向全周に亘ってハンダが塗布され、
前記ハンダが塗布された部分が、前記導体に圧着された接続端子のベルマウス部に当たっていることを特徴とする、請求項１に記載のアルミ電線。 The conductor is covered with a covering portion made of an insulating material, and the covering portion is removed at the end of the wire,
Solder is applied over the entire circumference in a predetermined part of the conductor in the longitudinal direction of the exposed portion where the covering portion is removed,
The aluminum wire according to claim 1, wherein the soldered portion is in contact with a bell mouth portion of a connection terminal that is crimped to the conductor. アルミ電線に接続端子を圧着するアルミ電線の端子圧着方法であって、
導体の長手方向における所定の一部分に、周方向全周に亘ってハンダフラックスを塗布し、
前記導体の少なくともハンダフラックスが塗布された部分を溶融したハンダに浸漬して、前記ハンダフラックスが塗布された部分に前記ハンダを塗布し、
前記ハンダが塗布された部分が、前記導体に圧着される接続端子のワイヤーバレルの電線側端部に当たるように当該接続端子を圧着することを特徴とするアルミ電線の端子圧着方法。

A method for crimping an aluminum wire by crimping a connection terminal on the aluminum wire,
Apply solder flux to a predetermined part in the longitudinal direction of the conductor over the entire circumference,
Dipping at least a portion of the conductor to which the solder flux is applied in molten solder, and applying the solder to the portion to which the solder flux is applied,
A terminal crimping method for an aluminum electric wire, wherein the connection terminal is crimped so that a portion to which the solder is applied hits an electric wire side end of a wire barrel of the connection terminal crimped to the conductor.

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