JP2016177986A

JP2016177986A - Wire with terminal and method of manufacturing the same

Info

Publication number: JP2016177986A
Application number: JP2015057183A
Authority: JP
Inventors: 耕一郎山下; Koichiro Yamashita
Original assignee: Fujikura Ltd
Current assignee: Fujikura Ltd
Priority date: 2015-03-20
Filing date: 2015-03-20
Publication date: 2016-10-06

Abstract

PROBLEM TO BE SOLVED: To enhance connection reliability of a core wire and a terminal, by suppressing the movement of the core wire effectively at the time of terminal connection.SOLUTION: A wire with a terminal includes a covered electric wire where a core wire composed of a conductive material is covered with a coat composed of an insulating material, and a terminal for connection with the core wire at the terminal of the covered electric wire. The terminal includes a connection with the core wire, having a first width in a first direction intersecting the axial direction of the covered electric wire, and an insertion part extending from the connection and having a second width smaller than the first width. The insertion part is inserted between the core wire and the coat.SELECTED DRAWING: Figure 1

Description

この発明は、端子が接続された端子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 to which a terminal is connected and a method for manufacturing the electric wire.

従来より、被覆電線の先端（芯線）を超音波溶接により接続端子に接続した端子付き電線が知られている（特許文献１を参照）。
特許文献１に開示された端子付き電線の製造方法では、被覆電線の先端の被覆を剥離して芯線を露出する工程と、この芯線を端子金具の芯線溶接部に配置する工程と、芯線を加圧した状態で超音波を付与し、端子金具の芯線溶接部に芯線を溶接する工程とから被覆電線の先端に端子金具を接続する。 Conventionally, a terminal-attached electric wire in which a tip (core wire) of a covered electric wire is connected to a connection terminal by ultrasonic welding is known (see Patent Document 1).
In the method of manufacturing a terminal-attached electric wire disclosed in Patent Document 1, a step of peeling the sheath at the end of the covered electric wire to expose the core wire, a step of arranging the core wire in the core wire welded portion of the terminal fitting, and adding the core wire The terminal metal fitting is connected to the tip of the covered electric wire from the step of applying ultrasonic waves in a pressed state and welding the core wire to the core wire welding portion of the terminal metal fitting.

特開２０１１−４４３７１号公報JP 2011-44371 A

ところで、例えば三相交流電線のように、複数の被覆電線を束ねた束電線を使用する場合、断面扇形形状の３本の被覆電線を組み合わせて全体を断面円形状となすことで、束電線全体をコンパクト化（細径化）することができる。そのため、断面扇形形状の被覆電線など、断面非円形状の被覆電線が着目されている。
このような断面非円形状の電線を製造する場合、断面円形状の丸形電線を押圧変形して断面非円形に成形する製造方法がある。この場合、断面円形状の丸形電線を製造するときに、被覆の外周長（一周の長さ）を、通常の断面円形状よりも大きくする必要がある。すなわち、円の周長は面積が一定の図形の周長で最小であるため、被覆内の芯線を断面円形状から断面非円形状に押圧変形させるために、被覆が芯線外周に密着していない丸形被覆電線を製造する必要がある。 By the way, when using a bundled electric wire in which a plurality of coated electric wires are bundled, for example, a three-phase AC electric wire, the entire bundled electric wires are formed by combining three covered electric wires having a sectoral cross section into a circular cross section. Can be made compact (thinner diameter). For this reason, a covered electric wire having a non-circular cross section, such as a covered electric wire having a fan-shaped cross section, has attracted attention.
When manufacturing such a non-circular cross-section electric wire, there is a manufacturing method in which a circular electric wire having a circular cross-section is pressed and deformed to form a non-circular cross-section. In this case, when manufacturing a round electric wire having a circular cross section, it is necessary to make the outer peripheral length (length of one round) of the coating larger than the normal circular cross section. That is, since the circumference of the circle is the smallest in the circumference of a figure with a constant area, the sheath is not in close contact with the outer circumference of the core wire in order to press-deform the core wire in the sheath from the circular cross-sectional shape to the non-circular cross-sectional shape. It is necessary to manufacture a round covered electric wire.

また例えば、耐熱性樹脂などの弾性が低い材料で新鮮を被覆する場合、被覆電線の可撓性を維持するため、被覆が芯線外周に密着していない被覆電線を製造する必要がある。 In addition, for example, when covering fresh with a material having low elasticity such as a heat resistant resin, in order to maintain the flexibility of the covered electric wire, it is necessary to manufacture a covered electric wire whose covering is not in close contact with the outer periphery of the core wire.

しかしながら、芯線と被覆の間に隙間があると、端子金具に被覆電線の先端を超音波溶着により接続するとき、意図せず芯線が動いてしまうことがある。この場合、超音波の振動エネルギーが芯線及び端子間に伝わらずに逃げてしまい、端子の接続信頼性が劣ってしまうこととなる。 However, if there is a gap between the core wire and the coating, the core wire may move unintentionally when the tip of the coated wire is connected to the terminal fitting by ultrasonic welding. In this case, the vibration energy of the ultrasonic waves escapes without being transmitted between the core wire and the terminal, resulting in poor connection reliability of the terminal.

この発明は、上記事情に鑑みてなされたもので、端子接続時の芯線の動きを効果的に抑制することで、芯線と端子との接続信頼性を高めることができる端子付き電線及びその製造方法を提供することを目的とする。 The present invention has been made in view of the above circumstances, and by effectively suppressing the movement of the core wire at the time of terminal connection, an electric wire with a terminal capable of improving the connection reliability between the core wire and the terminal and a method for manufacturing the same The purpose is to provide.

本発明に係る端子付き電線は、導電材からなる芯線を絶縁材からなる被覆で覆った被覆電線と、前記被覆電線の端末部において前記芯線に接続される端子とを備え、前記端子は、前記芯線に接続され前記被覆電線の軸方向と交差する第１方向における第１の幅を有する接続部と、前記接続部から延び前記第１の幅より小さい第２の幅を有する挿入部とを備え、前記挿入部は、前記芯線と前記被覆との間に挿入されることを特徴とする。 An electric wire with a terminal according to the present invention includes a covered electric wire in which a core wire made of a conductive material is covered with a coating made of an insulating material, and a terminal connected to the core wire at a terminal portion of the covered electric wire, A connection portion having a first width in a first direction connected to the core wire and intersecting an axial direction of the covered electric wire; and an insertion portion extending from the connection portion and having a second width smaller than the first width. The insertion portion is inserted between the core wire and the covering.

本発明に係る端子付き電線によれば、被覆電線の端末部において芯線に接続される端子が、芯線に接続され被覆電線の軸方向と交差する第１方向における第１の幅を有する接続部と、接続部から延び第１の幅より小さい第２の幅を有する挿入部とを備え、挿入部が被覆電線の芯線と被覆との間に挿入されるので、芯線と端子の接続部とを接続する際に芯線が動くことを抑制することができる。これにより、芯線と端子とを密着させて確実に接続することができ、端子の接続信頼性を高めることができる。 According to the terminal-attached electric wire according to the present invention, the terminal connected to the core wire in the terminal portion of the covered electric wire has a first width in the first direction that is connected to the core wire and intersects the axial direction of the covered electric wire; An insertion portion extending from the connection portion and having a second width smaller than the first width, and the insertion portion is inserted between the core wire and the sheath of the covered electric wire, so that the core wire and the terminal connection portion are connected. It is possible to suppress the movement of the core wire when doing so. Thereby, a core wire and a terminal can be contact | adhered and it can connect reliably, and the connection reliability of a terminal can be improved.

本発明の一実施形態においては、前記接続部は、前記芯線に超音波溶着により接続されている。 In one Embodiment of this invention, the said connection part is connected to the said core wire by ultrasonic welding.

本発明の他の実施形態においては、前記挿入部は、前記第１方向と交差する第２方向の厚みが、前記接続部から離れるに従って小さくなるように構成されている。 In another embodiment of the present invention, the insertion portion is configured such that the thickness in the second direction intersecting the first direction decreases as the distance from the connection portion increases.

本発明の更に他の実施形態においては、前記挿入部は、前記第１方向と交差する第２方向の厚みが、前記接続部より小さくなるように構成されている。 In still another embodiment of the present invention, the insertion portion is configured such that a thickness in a second direction intersecting the first direction is smaller than that of the connection portion.

本発明の更に他の実施形態においては、前記挿入部は、前記第２の幅が、前記接続部から離れるに従って小さくなるように構成されている。 In still another embodiment of the present invention, the insertion portion is configured such that the second width decreases as the distance from the connection portion increases.

本発明の更に他の実施形態においては、前記挿入部は、前記被覆電線の芯線と接する上面部が、前記電線の軸方向を中心とする凹曲面円弧状に形成されている。 In still another embodiment of the present invention, in the insertion portion, an upper surface portion in contact with the core wire of the covered electric wire is formed in a concave curved circular arc shape centering on the axial direction of the electric wire.

本発明に係る端子付き電線の製造方法は、導電材からなる芯線を絶縁材からなる被覆で覆った被覆電線を用意する工程と、前記被覆電線の端末部において前記芯線と接続され前記被覆電線の軸方向と交差する第１方向における第１の幅を有する接続部、及びこの接続部から延び前記第１の幅より小さい第２の幅を有する挿入部を備える端子を用意する工程と、前記被覆電線の被覆を除去して芯線を口出しする工程と、前記被覆電線の芯線と被覆との間に、前記端子の挿入部を挿入する工程と、前記被覆電線の芯線と前記端子の接続部とを接続する工程とを備えたことを特徴とする。 The method for manufacturing a terminal-attached electric wire according to the present invention includes a step of preparing a covered electric wire in which a core wire made of a conductive material is covered with a coating made of an insulating material, and a terminal portion of the covered electric wire that is connected to the core wire and Providing a terminal having a connection portion having a first width in a first direction intersecting the axial direction, and an insertion portion extending from the connection portion and having a second width smaller than the first width; Removing the coating of the electric wire to lead out the core wire, inserting the insertion portion of the terminal between the core wire and the coating of the coated electric wire, and connecting the core wire of the coated electric wire and the terminal And a connecting step.

本発明に係る端子付き電線の製造方法によれば、簡易な工程にて、上記作用効果を奏する端子付き電線を製造することができる。 According to the manufacturing method of the electric wire with a terminal concerning the present invention, the electric wire with a terminal which has the above-mentioned operation effect can be manufactured in a simple process.

本発明の一実施形態においては、前記接続する工程では、前記芯線と前記接続部とを超音波溶着により接続する。 In one embodiment of the present invention, in the connecting step, the core wire and the connecting portion are connected by ultrasonic welding.

本発明によれば、端子の挿入部が被覆電線の芯線と被覆との間に挿入されるので、芯線と端子の接続部とを接続する際に芯線が動くことを抑制し、芯線と端子とを密着させて確実に接続して、端子の接続信頼性を高めることができる。 According to the present invention, since the insertion portion of the terminal is inserted between the core wire and the sheath of the covered electric wire, the movement of the core wire is suppressed when connecting the core wire and the connection portion of the terminal. It is possible to improve the connection reliability of the terminals by making sure that they are firmly connected.

本発明の一実施形態に係る端子付き電線の端末部を示す断面図である。It is sectional drawing which shows the terminal part of the electric wire with a terminal concerning one embodiment of the present invention. 同端子付き電線の端子を示す外観斜視図である。It is an external appearance perspective view which shows the terminal of the electric wire with a terminal. 同端子付き電線の製造工程を示すフローチャートである。It is a flowchart which shows the manufacturing process of the electric wire with a terminal. 同端子付き電線を製造工程毎に示す側面図である。It is a side view which shows the electric wire with a terminal for every manufacturing process. 同端子付き電線に適用される端子のバリエーションを示す外観斜視図である。It is an external appearance perspective view which shows the variation of the terminal applied to the electric wire with the terminal.

以下、添付の図面を参照して、この発明の実施の形態に係る端子付き電線及びその製造方法を詳細に説明する。 Hereinafter, a terminal-attached electric wire and a method for manufacturing the same according to embodiments of the present invention will be described in detail with reference to the accompanying drawings.

図１は、本発明の一実施形態に係る端子付き電線を示す断面図、図２は端子付き電線の端子を示す外観斜視図である。また、図３は、端子付き電線の製造工程を示すフローチャート、図４は端子付き電線を製造工程毎に示す側面図である。図１に示すように、端子付き電線１は、被覆電線１０と、この被覆電線１０の端末部１５の芯線１１に接続された端子２０を備えて構成されている。 FIG. 1 is a sectional view showing a terminal-attached electric wire according to an embodiment of the present invention, and FIG. 2 is an external perspective view showing a terminal of the terminal-attached electric wire. Moreover, FIG. 3 is a flowchart which shows the manufacturing process of the electric wire with a terminal, FIG. 4 is a side view which shows the electric wire with a terminal for every manufacturing process. As shown in FIG. 1, the terminal-attached electric wire 1 includes a covered electric wire 10 and a terminal 20 connected to the core wire 11 of the terminal portion 15 of the covered electric wire 10.

被覆電線１０は、銅、アルミニウムなどの導電材からなる芯線１１が、絶縁樹脂などの絶縁材１２に覆われた構造を備えている。芯線１１は、例えば複数の素線を撚ったものである。被覆１２は、いわゆるチューブ押出し方式により芯線１１の周りを覆うように形成される。 The covered electric wire 10 has a structure in which a core wire 11 made of a conductive material such as copper or aluminum is covered with an insulating material 12 such as an insulating resin. The core wire 11 is formed by twisting a plurality of strands, for example. The coating 12 is formed so as to cover the core wire 11 by a so-called tube extrusion method.

この被覆電線１０は、可撓性を備えて構成されている。従って、易屈曲性を高めるために、芯線１１と被覆１２との間に若干の隙間が生じ得る程度に、芯線１１の外周に被覆１２が覆われている。そして、このように構成されているため、被覆電線１０はその断面形状に拘わらず容易に変形し易い特性も備えている。 The covered electric wire 10 is configured with flexibility. Therefore, in order to increase the flexibility, the coating 12 is covered on the outer periphery of the core wire 11 to such an extent that a slight gap can be generated between the core wire 11 and the coating 12. And since it is comprised in this way, the covered electric wire 10 is also equipped with the characteristic which is easy to deform | transform regardless of the cross-sectional shape.

さらに本実施形態に係る被覆電線１０は、端末部１５及びその近傍においては断面形状が円形状となっているが、端末部１５及びその近傍を除く主要部分の断面形状は非円形状の、例えば断面扇型形状となるように形成された電線である。
具体的には、断面扇形形状の３本の被覆電線を組み合わせて全体が断面円形状となる束電線のうちの１本であり、主要部分は、例えば１２０°の中心角を有する断面扇形形状に押圧変形され、端末部１５は断面円形状が維持されている、部分的に断面形状を相違させた被覆電線である。 Further, in the covered electric wire 10 according to the present embodiment, the cross-sectional shape is circular in the terminal portion 15 and the vicinity thereof, but the cross-sectional shape of the main part excluding the terminal portion 15 and the vicinity thereof is noncircular, for example, It is an electric wire formed so as to have a cross-sectional fan shape.
Specifically, it is one of bundled electric wires that are formed into a circular cross-section by combining three covered electric wires having a cross-sectional fan shape, and the main part has a cross-sectional fan shape having a central angle of 120 °, for example. The terminal portion 15 is a covered electric wire that is partially deformed in cross-section and is pressed and deformed so that the circular cross-section is maintained.

そして、被覆電線１０の主要部分において、１２０°の中心角を有する断面扇形形状に押圧変形させるために、被覆電線１０は、一般的な断面円形状の被覆電線の被覆の外周長に比べて、約１．１３倍の外周長を有する被覆１２で芯線１１の外周が覆われている。
このため、断面円形状の端末部１５及びその近傍では、芯線１１と被覆１２との密着具合が緩く、被覆電線１０の芯線１１と被覆１２との間には隙間が生じている。 And in the main part of the covered electric wire 10, in order to press and deform into a cross-sectional sector shape having a central angle of 120 °, the covered electric wire 10 is compared with the outer peripheral length of the covering of a general covered circular electric wire, The outer periphery of the core wire 11 is covered with a coating 12 having an outer peripheral length of about 1.13 times.
For this reason, in the terminal portion 15 having a circular cross section and in the vicinity thereof, the close contact between the core wire 11 and the covering 12 is loose, and a gap is generated between the core wire 11 and the covering 12 of the covered electric wire 10.

なお本実施形態に係る被覆電線１０は、主要部分が断面扇形形状に押圧変形され、３本の電線を束ねて束電線全体が断面円形状となるように束ねられているため、束電線全体としてコンパクト化（細径化）を図ることができる。 In addition, since the covered wire 10 according to the present embodiment is pressed and deformed so that the main portion has a cross-sectional sector shape, and the three electric wires are bundled so that the entire bundled wire has a circular cross-section, Compactness (thinning in diameter) can be achieved.

一方、図２に示すように、端子２０は、金属母材を打ち抜き加工等して形成される。端子２０は、被覆電線１０の端末部１５の芯線１１と電気的に接続される板状の電線接続部２１と、この電線接続部２１から先端側（前方）に延びて外部要素と接触させるための電気接触部２２とを有している。また、端子２０は、電線接続部２１から後端側（後方）に延びる片状の挿入部２３を有している。これら電線接続部２１、電気接触部２２及び挿入部２３は、一体的に構成されている。 On the other hand, as shown in FIG. 2, the terminal 20 is formed by punching a metal base material. The terminal 20 is a plate-like electric wire connecting portion 21 electrically connected to the core wire 11 of the terminal portion 15 of the covered electric wire 10, and extends from the electric wire connecting portion 21 to the front end side (front) so as to be in contact with an external element. Electrical contact portion 22. Further, the terminal 20 has a piece-like insertion portion 23 extending from the electric wire connection portion 21 to the rear end side (rear side). The electric wire connection portion 21, the electrical contact portion 22, and the insertion portion 23 are integrally configured.

電線接続部２１は、被覆電線２０の芯線１１の端末部１５を載置するのに必要十分な、被覆電線１０の軸方向に沿った長さＬ１及びこの軸方向と交差する方向（第１方向）の幅Ｗ１を有する。電気接触部２２は、電線接続部２１から連続し、図示しない相手方の端子や補機等と接触して電気的に結合される部分である。 The electric wire connecting portion 21 has a length L1 along the axial direction of the covered electric wire 10 that is necessary and sufficient for placing the terminal portion 15 of the core wire 11 of the covered electric wire 20 and a direction intersecting the axial direction (first direction). ) Width W1. The electrical contact portion 22 is a portion that is continuous from the wire connection portion 21 and is electrically coupled by contacting with a terminal, an auxiliary machine, or the like of the other party not shown.

なお、本実施形態に係る端子２０は、例えばバッテリー端子のような棒状の端子と接続されることが想定されたものである。このため、端子２０は、被覆電線１０の軸方向に延びる平板状をなしている。そして、電気接触部２２の先端側には、例えば棒状の端子が挿通される貫通穴２２ａが形成されている。 The terminal 20 according to the present embodiment is assumed to be connected to a rod-shaped terminal such as a battery terminal. For this reason, the terminal 20 has a flat plate shape extending in the axial direction of the covered electric wire 10. And the through-hole 22a in which a rod-shaped terminal is penetrated is formed in the front end side of the electrical contact part 22, for example.

挿入部２３は、上述したような被覆電線１０の芯線１１と被覆１２との間に生じた隙間に挿入されるものである。挿入部２３は、芯線１１の端末部１５と端子２０の電線接続部２１との接続時に、両者を安定的に密着させ得る長さＬ２に形成されている。また、挿入部２３は、上記隙間に挿入し易いように、電線接続部２１の幅Ｗ１よりも十分狭くなるような幅Ｗ２に形成されている。 The insertion portion 23 is inserted into a gap formed between the core wire 11 and the covering 12 of the covered electric wire 10 as described above. The insertion portion 23 is formed to have a length L2 that allows the terminal portion 15 of the core wire 11 and the electric wire connection portion 21 of the terminal 20 to be in close contact with each other. Further, the insertion portion 23 is formed to have a width W2 that is sufficiently narrower than the width W1 of the wire connection portion 21 so that the insertion portion 23 can be easily inserted into the gap.

そして、挿入部２３は、少なくともその先端部分において、被覆電線１０の軸方向及び前記第１方向と交差する方向（第２方向）の厚みＴ２が、電線接続部２１の厚みＴ１に比べて薄くなるように形成されている。より好適には、上記隙間への挿入部２３の挿入容易性を向上させるべく、厚みＴ２は、挿入方向先端側に向かって徐々に薄くなるように形成されている。 The insertion portion 23 has a thickness T2 in the axial direction of the covered electric wire 10 and a direction intersecting the first direction (second direction) at least at the tip portion thereof, which is smaller than the thickness T1 of the electric wire connection portion 21. It is formed as follows. More preferably, in order to improve the ease of insertion of the insertion portion 23 into the gap, the thickness T2 is formed so as to gradually decrease toward the distal end side in the insertion direction.

挿入部２３が芯線１１と被覆１２との間の隙間に挿入された状態で、電線接続部２１が端末部１５に接続されることで、端子２０が被覆電線１０に電気的に接続される。端末部１５と電線接続部２１との接続は、抵抗溶接や圧着等の種々の接続方式を採用することができるが、超音波溶着によるものが好適である。 The terminal 20 is electrically connected to the covered electric wire 10 by connecting the wire connecting portion 21 to the terminal portion 15 in a state where the insertion portion 23 is inserted into the gap between the core wire 11 and the covering 12. The connection between the terminal portion 15 and the electric wire connection portion 21 can employ various connection methods such as resistance welding and crimping, but is preferably by ultrasonic welding.

このように構成された端子２０を備えた端子付き電線１によれば、端子２０の挿入部２３が被覆電線１０の芯線１１と被覆１２との間に挿入されているので、超音波溶着の際に芯線１１が動くことが抑制される。すなわち、超音波溶着の振動エネルギーが、芯線１１が動くことによって被覆電線１０の軸方向に逃げることを抑えることができる。 According to the terminal-attached electric wire 1 including the terminal 20 configured as described above, since the insertion portion 23 of the terminal 20 is inserted between the core wire 11 and the covering 12 of the covered electric wire 10, the ultrasonic welding is performed. The movement of the core wire 11 is suppressed. That is, the vibration energy of ultrasonic welding can be prevented from escaping in the axial direction of the covered electric wire 10 due to the movement of the core wire 11.

このため、芯線１１の端末部１５と端子２０の電線接続部２１とを確実に接続することができ、端子２０の被覆電線１０に対する接続信頼性を高めることができる。なお、本発明に係る端子付き電線１の端子２０の電気接触部２２における具体的な形状や構造は限定されるものではなく、いわゆる雌雄嵌合可能な形状を有する構成であってもよい。 For this reason, the terminal part 15 of the core wire 11 and the electric wire connection part 21 of the terminal 20 can be connected reliably, and the connection reliability with respect to the covered electric wire 10 of the terminal 20 can be improved. In addition, the specific shape and structure in the electrical contact part 22 of the terminal 20 of the electric wire with a terminal 1 according to the present invention are not limited, and a configuration having a so-called male / female fitting shape may be used.

次に、本実施形態に係る端子付き電線１の製造工程について説明する。なお、以降において、既に説明した内容については同一の符号を附して説明を割愛したり、図示を省略したりする場合があるとする。ここでは、図３のフローチャートに従って、図４を参照しながら製造工程を説明する。 Next, the manufacturing process of the electric wire 1 with a terminal which concerns on this embodiment is demonstrated. In the following, it is assumed that the contents already described are denoted by the same reference numerals and description thereof is omitted or illustration is omitted. Here, according to the flowchart of FIG. 3, the manufacturing process will be described with reference to FIG.

まず、図４（ａ）に示すように、芯線１１を被覆１２で覆った被覆電線１０を用意する（ステップＳ１００）。また、上述したような電線接続部２１、電気接触部２２及び挿入部２３を有する端子２０を用意する（ステップＳ１０２）。これらステップＳ１００及びＳ１０２の順序は逆でもよい。 First, as shown to Fig.4 (a), the covered electric wire 10 which covered the core wire 11 with the coating | cover 12 is prepared (step S100). Moreover, the terminal 20 which has the electric wire connection part 21, the electrical contact part 22, and the insertion part 23 which were mentioned above is prepared (step S102). The order of these steps S100 and S102 may be reversed.

次に、図４（ｂ）に示すように、被覆電線１０の被覆１２を所定の長さで除去し、芯線１１を口出しする（ステップＳ１０４）。その後、図４（ｃ）に示すように、被覆電線１０に対して端子２０を図中矢印で示す方向に移動させ、挿入部２３を芯線１１と被覆１２との間の隙間に挿入する（ステップＳ１０６）。 Next, as shown in FIG. 4B, the covering 12 of the covered electric wire 10 is removed by a predetermined length, and the core wire 11 is extracted (step S104). Thereafter, as shown in FIG. 4C, the terminal 20 is moved with respect to the covered electric wire 10 in the direction indicated by the arrow in the figure, and the insertion portion 23 is inserted into the gap between the core wire 11 and the covering 12 (step). S106).

最後に、図４（ｄ）に示すように、芯線１１の端末部１５と端子２０の電線接続部２１とを、例えば一対の超音波溶着用治具２９ａ，２９ｂにより図中矢印で示すように上下方向から挟み込んで、超音波溶着により接続する（ステップＳ１０８）。このようにして、端子付き電線１を製造する。本実施形態に係る製造工程では、上記のような簡易な工程で、端子付き電線１を容易に製造することができる。 Finally, as shown in FIG. 4D, the terminal portion 15 of the core wire 11 and the wire connecting portion 21 of the terminal 20 are, for example, indicated by arrows in the figure by a pair of ultrasonic welding jigs 29a and 29b. They are sandwiched from above and below and connected by ultrasonic welding (step S108). Thus, the electric wire 1 with a terminal is manufactured. In the manufacturing process according to the present embodiment, the terminal-attached electric wire 1 can be easily manufactured by the simple process as described above.

図５は、端子付き電線に適用される端子のバリエーションを示す外観斜視図である。上述した端子付き電線１における挿入部２３は、次に示すように構成されてもよい。すなわち、図５（ａ）に示すように、挿入部２３は、上述した厚みＴ２及び幅Ｗ２が、挿入方向先端側に向かって徐々に薄く且つ徐々に狭くなるテーパ状に形成されてもよい。 FIG. 5 is an external perspective view showing a variation of the terminal applied to the electric wire with terminal. The insertion part 23 in the electric wire 1 with a terminal mentioned above may be comprised as shown next. That is, as shown in FIG. 5A, the insertion portion 23 may be formed in a tapered shape in which the above-described thickness T2 and width W2 are gradually thinner and gradually narrower toward the distal end side in the insertion direction.

また、図５（ｂ）に示す挿入部２３は、図５（ａ）に示した構成に加え、被覆電線１０の隙間に挿入された際に芯線１１と接する上面部２３ａが、被覆電線１０の軸方向を中心とする凹曲面円弧状に形成されたものである。なお、上面部２３ａのみならず、挿入部２３全体が凹曲面円弧状に形成されてもよい。すなわち、図５（ｂ）に示すように、挿入部２３は、上述した厚みＴ２及び幅Ｗ２が挿入方向先端側に向かって徐々に薄く狭くなるテーパ状、且つ上面部２３ａが凹曲面円弧状に形成されている。 In addition to the configuration shown in FIG. 5A, the insertion portion 23 shown in FIG. 5B has an upper surface portion 23 a that comes into contact with the core wire 11 when inserted into the gap of the covered wire 10. It is formed in a concave curved surface arc shape centering on the axial direction. In addition, not only the upper surface part 23a but the whole insertion part 23 may be formed in a concave curved circular arc shape. That is, as shown in FIG. 5B, the insertion portion 23 has a tapered shape in which the above-described thickness T2 and width W2 are gradually thinned toward the distal end in the insertion direction, and the upper surface portion 23a has a concave curved arc shape. Is formed.

更に、図５（ｃ）に示す挿入部２３は、図２に示した挿入部２３の全体が上記のような凹曲面円弧状に形成されたものである。従って、この場合は、挿入部２３は、上述した幅Ｗ２は変化しないが、上面部２３ａが凹曲面円弧状に形成され、且つ挿入方向先端側に向かって上述した厚みＴ２が徐々に薄くなる形状に形成されている。 Further, the insertion portion 23 shown in FIG. 5C is formed by forming the entire insertion portion 23 shown in FIG. Therefore, in this case, the insertion portion 23 has a shape in which the above-described width W2 does not change, but the upper surface portion 23a is formed in a concave curved arc shape, and the above-described thickness T2 gradually decreases toward the distal end side in the insertion direction. Is formed.

その他、挿入部２３は、図５（ｄ），（ｅ），（ｆ）及び（ｇ）に示すように、挿入方向先端側に向かって上述した厚みＴ２が変化しない構成であってもよい。すなわち、図５（ｄ）に示す挿入部２３は、図５（ａ）に示した挿入部２３の厚みＴ２が変化しないものを示している。 In addition, as shown in FIGS. 5D, 5 </ b> E, 5 </ b> F, and 5 </ b> G, the insertion portion 23 may be configured such that the thickness T <b> 2 described above does not change toward the distal end side in the insertion direction. That is, the insertion portion 23 shown in FIG. 5D shows the one in which the thickness T2 of the insertion portion 23 shown in FIG.

また、図５（ｅ）に示す挿入部２３は、図５（ｂ）に示した挿入部２３の厚みＴ２が変化しないものであり、図５（ｆ）に示す挿入部２３は、図５（ｃ）に示した挿入部２３の厚みＴ２が変化しないものである。更に、図５（ｇ）に示す挿入部２３は、最もシンプルな構成で、上述した厚みＴ２及び幅Ｗ２が変化せず一定となったものである。このように、本実施形態に係る端子２０の挿入部２３は、被覆電線１０の芯線１１と被覆１２との間の隙間に挿入されることを考慮すれば、種々の形態を取り得る。 Moreover, the insertion part 23 shown in FIG.5 (e) does not change the thickness T2 of the insertion part 23 shown in FIG.5 (b), The insertion part 23 shown in FIG.5 (f) is FIG. The thickness T2 of the insertion portion 23 shown in c) does not change. Furthermore, the insertion portion 23 shown in FIG. 5 (g) has the simplest configuration, and the above-described thickness T2 and width W2 are constant and unchanged. Thus, the insertion part 23 of the terminal 20 according to the present embodiment can take various forms in consideration of being inserted into the gap between the core wire 11 and the covering 12 of the covered electric wire 10.

以上、本発明のいくつかの実施の形態を説明したが、これらの実施の形態は、例として提示したものであり、発明の範囲を限定することは意図していない。これら新規な実施の形態は、その他の様々な形態で実施されることが可能であり、発明の要旨を逸脱しない範囲で、種々の省略、置き換え、変更を行うことができる。これら実施の形態やその変形は、発明の範囲や要旨に含まれると共に、特許請求の範囲に記載された発明とその均等の範囲に含まれる。 As mentioned above, although several embodiment of this invention was described, these embodiment is shown as an example and is not intending limiting the range of invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the scope of the invention. These embodiments and modifications thereof are included in the scope and gist of the invention, and are included in the invention described in the claims and the equivalents thereof.

１端子付き電線
１０被覆電線
１１芯線
１２被覆
１５端末部
２０端子
２１電線接続部
２２電気接触部
２３挿入部
２３ａ上面部 DESCRIPTION OF SYMBOLS 1 Electric wire with a terminal 10 Covered electric wire 11 Core wire 12 Coating | coated 15 Terminal part 20 Terminal 21 Electric wire connection part 22 Electrical contact part 23 Insertion part 23a Upper surface part

Claims

導電材からなる芯線を絶縁材からなる被覆で覆った被覆電線と、
前記被覆電線の端末部において前記芯線に接続される端子と
を備え、
前記端子は、前記芯線に接続され前記被覆電線の軸方向と交差する第１方向における第１の幅を有する接続部と、前記接続部から延び前記第１の幅より小さい第２の幅を有する挿入部とを備え、
前記挿入部は、前記芯線と前記被覆との間に挿入される
ことを特徴とする端子付き電線。 A covered electric wire in which a core wire made of a conductive material is covered with a coating made of an insulating material;
A terminal connected to the core wire at a terminal portion of the covered electric wire,
The terminal is connected to the core wire and has a connection portion having a first width in a first direction intersecting the axial direction of the covered electric wire, and has a second width that extends from the connection portion and is smaller than the first width. With an insertion part,
The insertion portion is inserted between the core wire and the covering.

前記接続部は、前記芯線に超音波溶着により接続されている
ことを特徴とする請求項１記載の端子付き電線。 The said connection part is connected to the said core wire by ultrasonic welding. The electric wire with a terminal of Claim 1 characterized by the above-mentioned.

前記挿入部は、前記第１方向と交差する第２方向の厚みが、前記接続部から離れるに従って小さくなるように構成されている
ことを特徴とする請求項１又は２記載の端子付き電線。 The electric wire with a terminal according to claim 1 or 2, wherein the insertion portion is configured such that a thickness in a second direction intersecting the first direction decreases as the distance from the connection portion increases.

前記挿入部は、前記第１方向と交差する第２方向の厚みが、前記接続部より小さくなるように構成されている
ことを特徴とする請求項１又は２記載の端子付き電線。 The electric wire with a terminal according to claim 1 or 2, wherein the insertion portion is configured such that a thickness in a second direction intersecting the first direction is smaller than that of the connection portion.

前記挿入部は、前記第２の幅が、前記接続部から離れるに従って小さくなるように構成されている
ことを特徴とする請求項１〜４のいずれか１項記載の端子付き電線。 The said insertion part is comprised so that said 2nd width may become small as it leaves | separates from the said connection part. The electric wire with a terminal of any one of Claims 1-4 characterized by the above-mentioned.

前記挿入部は、前記被覆電線の芯線と接する上面部が、前記電線の軸方向を中心とする凹曲面円弧状に形成されている
ことを特徴とする請求項１〜５のいずれか１項記載の端子付き電線。 The upper surface part which contact | connects the core wire of the said covered electric wire is formed in the said insertion part in the concave curved-surface arc shape centering on the axial direction of the said electric wire. The any one of Claims 1-5 characterized by the above-mentioned. Electric wire with terminal.

導電材からなる芯線を絶縁材からなる被覆で覆った被覆電線を用意する工程と、
前記被覆電線の端末部において前記芯線と接続され前記被覆電線の軸方向と交差する第１方向における第１の幅を有する接続部、及びこの接続部から延び前記第１の幅より小さい第２の幅を有する挿入部を備える端子を用意する工程と、
前記被覆電線の被覆を除去して芯線を口出しする工程と、
前記被覆電線の芯線と被覆との間に、前記端子の挿入部を挿入する工程と、
前記被覆電線の芯線と前記端子の接続部とを接続する工程とを備えた
ことを特徴とする端子付き電線の製造方法。 Preparing a covered electric wire in which a core wire made of a conductive material is covered with a coating made of an insulating material;
A connecting portion having a first width in a first direction that is connected to the core wire at the terminal portion of the covered electric wire and intersects an axial direction of the covered electric wire, and a second extending from the connecting portion and smaller than the first width. Preparing a terminal with an insertion portion having a width;
Removing the coating of the covered electric wire and extracting the core wire;
Inserting the terminal insertion portion between the core wire of the covered electric wire and the covering; and
The manufacturing method of the electric wire with a terminal characterized by including the process of connecting the core wire of the said covered electric wire, and the connection part of the said terminal.

前記接続する工程では、前記芯線と前記接続部とを超音波溶着により接続する
ことを特徴とする請求項７記載の端子付き電線の製造方法。 The method of manufacturing an electric wire with a terminal according to claim 7, wherein in the connecting step, the core wire and the connecting portion are connected by ultrasonic welding.