JP2017168400A

JP2017168400A - Terminal-attached electric cable and method for manufacturing the same

Info

Publication number: JP2017168400A
Application number: JP2016055047A
Authority: JP
Inventors: 宏介蓮井; Kosuke Hasui; 博須藤; Hiroshi Sudo; 茂雄松藤; Shigeo Matsufuji; 勇人青井; Isato Aoi; 幸康坂本; Yukiyasu Sakamoto
Original assignee: Sumitomo Wiring Systems Ltd; AutoNetworks Technologies Ltd; Sumitomo Electric Industries Ltd
Current assignee: Sumitomo Wiring Systems Ltd; AutoNetworks Technologies Ltd; Sumitomo Electric Industries Ltd
Priority date: 2016-03-18
Filing date: 2016-03-18
Publication date: 2017-09-21

Abstract

PROBLEM TO BE SOLVED: To increase the connection reliability when press-connecting, by a terminal, a first electric cable including a first core wire which is a collection of a plurality of first elemental wires formed by copper or the like, and a second electric cable including a second core wire formed by a metal of a different kind from that of the first elemental wires.SOLUTION: A terminal-attached electric cable 10 comprises: a first electric cable 20 including a first core wire 22 which is a collection of a plurality of first elemental wires 23 formed by copper or the like, and a first coating, in which a first core wire bared portion 22a is formed by baring a part of the first core wire 22 in its extending direction, and the first elemental wires 23 are bonded together in at least a part of the first core wire bared portion 22a; a second electric cable 30 including a second core wire 32 formed by a metal of a difference kind from hat of the first elemental wires 23 and a second coating, in which a second core wire bared portion 32a is formed by baring a part of the second core wire 32 in its extending direction; and a terminal 40 press-fit to the first core wire bared portion 22a and the second core wire bared portion 32a.SELECTED DRAWING: Figure 3

Description

この発明は、複数の電線を、端子で圧着接続する技術に関する。 The present invention relates to a technique for crimping and connecting a plurality of electric wires with terminals.

特許文献１は、銅電線とアルミニウム電線とが少なくとも一部が重ねられて配置されて、接続部材によって圧着されており、前記接続部材は、圧縮量の異なる多段で構成されている銅電線とアルミニウム電線との接続構造を開示している。 In Patent Document 1, a copper electric wire and an aluminum electric wire are arranged so that at least a part thereof is overlapped and crimped by a connecting member, and the connecting member is composed of a multi-stage copper electric wire and aluminum having different compression amounts. The connection structure with an electric wire is disclosed.

特許文献２は、端子金具の圧着部に、圧着に伴って芯線が喰い込むセレーションを形成する技術を開示している。 Patent document 2 is disclosing the technique which forms the serration which a core wire bites into the crimping part of a terminal metal fitting with crimping | compression-bonding.

特開２０１５−１３３２８６号公報JP-A-2015-133286 特開２０１０−２７４６３号公報JP 2010-27463 A

しかしながら、アルミニウム電線を構成する芯線の表面には、強固な酸化皮膜が形成されている。このため、特許文献１に開示の技術においても、銅電線とアルミニウム電線との接続が、アルミニウム芯線の酸化皮膜によって妨げられ、銅電線とアルミニウム電線との接続信頼性を確保することが困難となる。 However, a strong oxide film is formed on the surface of the core wire constituting the aluminum electric wire. For this reason, also in the technique disclosed in Patent Document 1, the connection between the copper electric wire and the aluminum electric wire is hindered by the oxide film of the aluminum core wire, and it becomes difficult to ensure the connection reliability between the copper electric wire and the aluminum electric wire. .

また、特許文献２に開示の技術では、セレーションは、芯線のうち圧着部に接する部分で酸化皮膜を突破るに過ぎないため、銅電線とアルミニウム電線とが混在する場合等、両者の接続信頼性を確保することは困難である。 Moreover, in the technique disclosed in Patent Document 2, since serration only breaks through the oxide film at the portion of the core wire that contacts the crimped portion, the connection reliability between the copper wire and the aluminum wire is mixed. It is difficult to ensure.

そこで、本発明は、銅又は銅合金により形成された複数の第１素線の集合体である第１芯線を含む第１電線と、前記第１素線とは異種金属で形成された第２芯線とを含む第２電線とを、端子で圧着接続する際に、その接続信頼姓を向上させることを目的とする。 Accordingly, the present invention provides a first electric wire including a first core wire that is an aggregate of a plurality of first strands formed of copper or a copper alloy, and a second wire in which the first strand is formed of a dissimilar metal. It is an object of the present invention to improve the connection reliability of a second electric wire including a core wire when crimping and connecting with a terminal.

上記課題を解決するため、第１の態様に係る端子付電線は、銅又は銅合金により形成された複数の第１素線の集合体である第１芯線と、前記第１芯線の周囲を覆う第１被覆とを含み、前記第１芯線の延在方向の一部が露出されて第１芯線露出部が形成されると共に、前記第１芯線露出部の少なくとも一部で前記複数の第１素線同士が接合されている第１電線と、前記第１素線とは異種金属により形成された第２芯線と、前記第２芯線の周囲を覆う第２被覆とを含み、前記第２芯線の延在方向の一部が露出されて第２芯線露出部が形成されている第２電線と、前記第１芯線露出部と前記第２芯線露出部とに圧着された端子と、を備える。 In order to solve the above-described problem, a terminal-attached electric wire according to a first aspect covers a first core wire that is an assembly of a plurality of first strands formed of copper or a copper alloy, and the periphery of the first core wire. And a first core wire exposed portion is formed by exposing a part of the extending direction of the first core wire, and the plurality of first elements are formed by at least a part of the first core wire exposed portion. A first electric wire to which the wires are joined; a second core wire formed of a dissimilar metal with the first strand; and a second coating covering the periphery of the second core wire; A second electric wire in which a part of the extending direction is exposed to form a second core wire exposed portion; and a terminal crimped to the first core wire exposed portion and the second core wire exposed portion.

第２の態様は、第１の態様に係る端子付電線であって、前記第１芯線露出部の少なくとも一部で前記複数の第１素線同士は超音波接合されているものである。 A 2nd aspect is an electric wire with a terminal which concerns on a 1st aspect, Comprising: The said some 1st strand is ultrasonically joined by at least one part of the said 1st core wire exposed part.

第３の態様は、第１又は第２の態様に係る端子付電線であって、前記第１芯線露出部の少なくとも一部の表面が凹凸形状に形成されているものである。 A 3rd aspect is an electric wire with a terminal concerning the 1st or 2nd aspect, Comprising: At least one part surface of the said 1st core wire exposed part is formed in uneven | corrugated shape.

第４の態様は、第１から第３のいずれか１つの態様に係る端子付電線であって、前記第１芯線露出部の断面積が、前記第１芯線露出部の延在方向において変化しているものである。 A 4th aspect is an electric wire with a terminal which concerns on any one 1st to 3rd aspect, Comprising: The cross-sectional area of the said 1st core wire exposed part changes in the extension direction of the said 1st core wire exposed part. It is what.

第５の態様は、第１から第４のいずれか１つの態様に係る端子付電線であって、前記第２芯線はアルミニウム又はアルミニウム合金により形成されているものである。 A fifth aspect is a terminal-attached electric wire according to any one of the first to fourth aspects, wherein the second core wire is formed of aluminum or an aluminum alloy.

上記課題を解決するため、第６の態様に係る端子付電線の製造方法は、(a)銅又は銅合金により形成された複数の第１素線の集合体である第１芯線と、前記第１芯線の周囲を覆う第１被覆とを含み、前記第１芯線の延在方向の一部が露出されて第１芯線露出部が形成された第１電線を準備する工程と、(b)前記第１芯線露出部の少なくとも一部で前記複数の第１素線同士を接合する工程と、(c)前記第１素線とは異種金属により形成された第２芯線と、前記第２芯線の周囲を覆う第２被覆とを含み、前記第２芯線の延在方向の一部が露出されて第２芯線露出部が形成されている第２電線を準備する工程と、(d)前記第１芯線露出部と前記第２芯線露出部とに端子を圧着する工程と、を備える。 In order to solve the above-described problem, a method of manufacturing a terminal-attached electric wire according to a sixth aspect includes (a) a first core wire that is an aggregate of a plurality of first strands formed of copper or a copper alloy; A step of preparing a first electric wire including a first coating covering a periphery of one core wire, wherein a part of the first core wire in an extending direction is exposed to form a first core wire exposed portion; and (b) A step of joining the plurality of first strands at at least a part of the exposed portion of the first core wire; and (c) a second core wire formed of a dissimilar metal with the first strand; and A step of preparing a second electric wire including a second coating covering the periphery, wherein a part of the extending direction of the second core wire is exposed to form a second core wire exposed portion; and (d) the first And crimping a terminal to the core wire exposed portion and the second core wire exposed portion.

第１から第６の態様によると、第１芯線は、銅又は銅合金により形成された複数の第１素線の集合体であり、この第１芯線の延在方向の一部が露出されて第１芯線露出部が形成されると共に、第１芯線露出部の少なくとも一部で前記複数の第１素線同士が接合されている。このため、第１芯線露出部は、第１素線がばらばらな状態で存在する場合よりも、変形し難くなる。そして、この第１芯線露出部と第２芯線露出部とに端子を圧着すると、第１芯線露出部が第２芯線露出部の表面の酸化皮膜等を破壊することができ、両者を良好に電気的に接続することができる。これにより、銅又は銅合金により形成された複数の第１素線の集合体である第１芯線を含む第１電線と、前記第１素線とは異種金属で形成された第２芯線とを含む第２電線とを、端子で圧着接続する際に、その接続信頼姓を向上させることができる。 According to the first to sixth aspects, the first core wire is an aggregate of a plurality of first strands formed of copper or a copper alloy, and a part of the extending direction of the first core wire is exposed. A first core wire exposed portion is formed, and the plurality of first strands are joined to each other at least at a part of the first core wire exposed portion. For this reason, a 1st core wire exposed part becomes difficult to deform | transform compared with the case where a 1st strand exists in a disperse | distributed state. And if a terminal is crimped | bonded to this 1st core wire exposed part and the 2nd core wire exposed part, the 1st core wire exposed part can destroy the oxide film etc. of the surface of a 2nd core wire exposed part, and both are electrically connected. Can be connected. Accordingly, the first electric wire including the first core wire which is an aggregate of a plurality of first strands formed of copper or a copper alloy, and the second core wire formed of a dissimilar metal with the first strand. When the second electric wire to be included is crimped and connected with a terminal, the connection reliability can be improved.

第２の態様によると、複数の第１素線同士を簡易に接合することができる。 According to the 2nd aspect, several 1st strands can be joined easily.

第３の態様によると、第１芯線露出部の凹凸形状によって、第２芯線露出部の表面の酸化皮膜等を有効に破壊することができる。 According to the 3rd aspect, the oxide film etc. on the surface of a 2nd core wire exposure part can be destroyed effectively by the uneven | corrugated shape of a 1st core wire exposure part.

第４の態様によると、第１芯線露出部の断面積が、前記第１芯線露出部の延在方向において変化しているため、第１芯線露出部と第２芯線露出部とに端子を圧着する際に、その断面積の変化に応じて圧縮量を変更することができる。 According to the fourth aspect, since the cross-sectional area of the first core wire exposed portion is changed in the extending direction of the first core wire exposed portion, the terminal is crimped to the first core wire exposed portion and the second core wire exposed portion. In doing so, the amount of compression can be changed in accordance with the change in the cross-sectional area.

第５の態様によると、少なくとも一部で複数の第１素線同士が接合された第１芯線露出部によって、アルミニウム又はアルミニウム合金により形成された第２芯線露出部の表面に形成された強固な酸化皮膜を破壊することができる。 According to the fifth aspect, the first core wire exposed portion formed by joining a plurality of first strands at least in part is formed on the surface of the second core wire exposed portion formed of aluminum or aluminum alloy. The oxide film can be destroyed.

実施形態に係る端子付電線を示す概略斜視図である。It is a schematic perspective view which shows the electric wire with a terminal which concerns on embodiment. 図１のＩＩ−ＩＩ線における概略断面図である。It is a schematic sectional drawing in the II-II line of FIG. 図２のＩＩＩ−ＩＩＩ線における概略断面図である。It is a schematic sectional drawing in the III-III line of FIG. 圧着前の端子を示す概略斜視図である。It is a schematic perspective view which shows the terminal before crimping. 端子付電線の製造方法例を示す説明図である。It is explanatory drawing which shows the example of a manufacturing method of an electric wire with a terminal. 端子付電線の製造方法例を示す説明図である。It is explanatory drawing which shows the example of a manufacturing method of an electric wire with a terminal. 第１芯線露出部に形成された凹凸形状の一例を示す概略斜視図である。It is a schematic perspective view which shows an example of the uneven | corrugated shape formed in the 1st core wire exposed part. 第１芯線露出部に形成された凹凸形状の他の例を示す概略斜視図である。It is a schematic perspective view which shows the other example of the uneven | corrugated shape formed in the 1st core wire exposed part. 第１芯線露出部に形成された凹凸形状のさらに他の例を示す概略斜視図である。It is a schematic perspective view which shows the further another example of the uneven | corrugated shape formed in the 1st core wire exposed part. 端子付電線の製造方法例を示す説明図である。It is explanatory drawing which shows the example of a manufacturing method of an electric wire with a terminal. 端子付電線の製造方法例を示す説明図である。It is explanatory drawing which shows the example of a manufacturing method of an electric wire with a terminal. 変形例に係る第１芯線露出部を示す概略斜視図である。It is a schematic perspective view which shows the 1st core wire exposed part which concerns on a modification. 同上の変形例に係る端子付電線を示す概略断面図である。It is a schematic sectional drawing which shows the electric wire with a terminal which concerns on the modification same as the above. 他の変形例に係る端子付電線を示す概略平面図である。It is a schematic plan view which shows the electric wire with a terminal which concerns on another modification. さらに他の変形例に係る端子付電線を示す概略平面図である。It is a schematic plan view which shows the electric wire with a terminal which concerns on another modification.

以下、実施形態に係る端子付電線及びその製造方法について説明する。図１は端子付電線１０を示す概略斜視図であり、図２は図１のＩＩ−ＩＩ線における概略断面図であり、図３は図２のＩＩＩ−ＩＩＩ線における概略断面図である。 Hereinafter, the electric wire with a terminal concerning the embodiment and its manufacturing method are explained. 1 is a schematic perspective view showing a terminal-attached electric wire 10, FIG. 2 is a schematic cross-sectional view taken along line II-II in FIG. 1, and FIG. 3 is a schematic cross-sectional view taken along line III-III in FIG.

＜端子付電線について＞
端子付電線１０は、第１電線２０と、第２電線３０と、端子４０とを備える。 <About electric wires with terminals>
The electric wire with terminal 10 includes a first electric wire 20, a second electric wire 30, and a terminal 40.

第１電線２０は、第１芯線２２と、第１被覆２４とを備える。 The first electric wire 20 includes a first core wire 22 and a first coating 24.

第１芯線２２は、複数の第１素線２３の集合体により構成されている。通常、第１芯線２２は、複数の第１素線２３を撚り合せた撚り合せ線である。複数の第１素線２３は、撚り合わされていなくてもよい。第１素線２３は、銅又は銅合金によって形成された線状部材である。 The first core wire 22 is composed of an assembly of a plurality of first strands 23. Usually, the first core wire 22 is a stranded wire obtained by twisting a plurality of first strands 23. The plurality of first strands 23 may not be twisted together. The 1st strand 23 is a linear member formed with copper or a copper alloy.

第１被覆２４は、第１芯線２２の周囲を覆う絶縁性の部分である。第１被覆２４は、例えば、樹脂等の絶縁材料を第１芯線２２の周囲に押出被覆することによって形成される。 The first coating 24 is an insulating part that covers the periphery of the first core wire 22. The first coating 24 is formed, for example, by extrusion coating an insulating material such as a resin around the first core wire 22.

第１電線２０の延在方向の一部、ここでは、第１電線２０の端部で、第１被覆２４が除去されており、この部分に、上記第１芯線２２が露出した第１芯線露出部２２ａが形成されている。第１芯線露出部２２ａの少なくとも一部、ここでは、第１芯線露出部２２ａの先端寄りの部分で、複数の第１素線２３同士が接合されている。第１素線２３同士の接合は、超音波接合により行うことが好ましい。 The first covering 24 is removed at a part in the extending direction of the first electric wire 20, here the end of the first electric wire 20, and the first core wire 22 is exposed at this portion. A portion 22a is formed. The plurality of first strands 23 are joined to each other at least at a part of the first core wire exposed portion 22a, here, at a portion near the tip of the first core wire exposed portion 22a. The bonding between the first strands 23 is preferably performed by ultrasonic bonding.

第１芯線露出部２２ａの少なくとも一部の表面は凹凸形状に形成されている。凹凸形状は、第１芯線露出部２２ａの表面の一部が凹み、他の部分が相対的に凸形状をなしている場合、及び、第１芯線露出部２２ａの表面の一部が凸形状をなし、他の部分が相対的に凹んでいる場合を含む。ここでは、第１芯線露出部２２ａの表面のうち第２芯線露出部３２ａと接触する側の部分に、部分的に凹む凹部２２ｂが複数形成されている。第１芯線露出部２２ａの表面に形成された凹凸形状の例については後でさらに詳細に説明する。なお、第１素線２３同士の接合は、その他、抵抗溶接、半田付けにより行われていてもよい。 At least a part of the surface of the first core wire exposed portion 22a is formed in an uneven shape. In the uneven shape, a part of the surface of the first core wire exposed part 22a is recessed and the other part is relatively convex, and a part of the surface of the first core wire exposed part 22a is convex. None, including cases where other parts are relatively recessed. Here, a plurality of concave portions 22b that are partially recessed are formed in the portion of the surface of the first core wire exposed portion 22a that is in contact with the second core wire exposed portion 32a. An example of the uneven shape formed on the surface of the first core wire exposed portion 22a will be described in more detail later. In addition, the joining of the first strands 23 may be performed by resistance welding or soldering.

第２電線３０は、第２芯線３２と、第２被覆３４とを備える。 The second electric wire 30 includes a second core wire 32 and a second coating 34.

第２芯線３２は、複数の第２素線３３の集合体により構成されている。通常、第２芯線３２は、複数の第２素線３３を撚り合せた撚り合せ線である。複数の第２素線３３は、撚り合わされていなくてもよい。第２素線３３は、第１素線２３とは異種金属により形成された線状部材である。なお、ここで、２つの金属が異種金属であるとは、当該２つの金属に含まれる主成分の金属が異なる場合をいう。従って、第１素線２３及び第２素線３３の少なくとも一方が合金で形成されている場合を想定すると、第１素線２３を形成する金属と、第２素線３３を形成する金属との間で、主成分以外に添加された金属が共通していても、両者は異種金属である。ここでは、第２素線３３は、アルミニウム又はアルミニウム合金により形成されている。なお、第２素線は、複数の素線の集合体である必要は無く、単芯線によって構成されていてもよい。 The second core wire 32 is constituted by an assembly of a plurality of second strands 33. Normally, the second core wire 32 is a stranded wire obtained by twisting a plurality of second strands 33. The plurality of second strands 33 may not be twisted together. The second strand 33 is a linear member formed of a different metal from the first strand 23. Note that here, the two metals are dissimilar metals means that the main metals contained in the two metals are different. Accordingly, assuming that at least one of the first strand 23 and the second strand 33 is formed of an alloy, the metal that forms the first strand 23 and the metal that forms the second strand 33 Even though the metals added in addition to the main component are common, both are dissimilar metals. Here, the second strand 33 is formed of aluminum or an aluminum alloy. In addition, the 2nd strand does not need to be an aggregate | assembly of a some strand, and may be comprised with the single core wire.

第２被覆３４は、第２芯線３２の周囲を覆う絶縁性の部分である。第２被覆３４は、例えば、樹脂等の絶縁材料を第２芯線３２の周囲に押出被覆することによって形成される。 The second coating 34 is an insulating part that covers the periphery of the second core wire 32. The second coating 34 is formed, for example, by extrusion coating an insulating material such as a resin around the second core wire 32.

第２電線３０の延在方向の一部、ここでは、第２電線３０の端部で、第２被覆３４が除去されており、この部分に、上記第２芯線３２が露出した第２芯線露出部３２ａが形成されている。第２芯線露出部３２ａにおいて、複数の第２素線３３は、上記第１芯線露出部２２ａと同様に、超音波接合等によって接合されていてもよいし、接合されていなくてもよい。 The second coating 34 is removed at a part in the extending direction of the second electric wire 30, here the end of the second electric wire 30, and the second core wire 32 is exposed at this portion. A portion 32a is formed. In the second core wire exposed portion 32a, the plurality of second strands 33 may be joined by ultrasonic joining or the like, similarly to the first core wire exposed portion 22a.

端子４０は、金属等によって形成された部材であり、第１芯線露出部２２ａと第２芯線露出部３２ａとが束ねられた状態で、第１芯線露出部２２ａと第２芯線露出部３２ａとに圧着されている。 The terminal 40 is a member formed of metal or the like, and is connected to the first core wire exposed portion 22a and the second core wire exposed portion 32a in a state where the first core wire exposed portion 22a and the second core wire exposed portion 32a are bundled. It is crimped.

より具体的には、端子４０は、図４に示すように、金属板を適宜打抜き屈曲加工等することにより形成された部材であり、底部４２とその底部４２の両側部に設けられた一対の圧着片４４とを備えている。端子４０を構成する金属板は、例えば、銅又は銅合金により形成される。端子４０の表面には、錫メッキ等のメッキが形成される場合がある。 More specifically, as shown in FIG. 4, the terminal 40 is a member formed by appropriately punching and bending a metal plate or the like, and includes a pair of bottom portions 42 and both sides of the bottom portion 42. And a crimping piece 44. The metal plate which comprises the terminal 40 is formed with copper or a copper alloy, for example. A plating such as tin plating may be formed on the surface of the terminal 40 in some cases.

底部４２は、湾曲した方形板状に形成されている。一対の圧着片４４は、底部４２の両側部から底部４２の一方主面側に延出する方形板状に形成されている。そして、底部４２上に第１芯線露出部２２ａ及び第２芯線露出部３２ａを配設した状態で、一対の圧着片４４を内向きに塑性変形させると、底部４２と一対の圧着片４４との間で第１芯線露出部２２ａと第２芯線露出部３２ａとが圧着状態で保持される。また、端子４０の延在方向において複数箇所で、圧縮量を変更してもよい。 The bottom 42 is formed in a curved rectangular plate shape. The pair of crimping pieces 44 are formed in a square plate shape that extends from both side portions of the bottom portion 42 to one main surface side of the bottom portion 42. When the pair of crimping pieces 44 are plastically deformed inward with the first core wire exposed portion 22a and the second core wire exposed portion 32a disposed on the bottom portion 42, the bottom portion 42 and the pair of crimping pieces 44 The first core wire exposed portion 22a and the second core wire exposed portion 32a are held in a compressed state. Further, the compression amount may be changed at a plurality of locations in the extending direction of the terminal 40.

また、端子４０の内側の表面には凹凸形状が形成されていてもよい。 In addition, an uneven shape may be formed on the inner surface of the terminal 40.

＜端子付電線の製造方法について＞
上記端子付電線１０の製造方法例について説明する。 <About manufacturing method of electric wire with terminal>
The example of a manufacturing method of the said electric wire 10 with a terminal is demonstrated.

まず、図５に示すように、上記第１芯線２２と、第１被覆２４とを含み、第１芯線２２の延在方向の一部が露出されて第１芯線露出部２２ａが形成された第１電線２０を準備する（工程(a)）。 First, as shown in FIG. 5, the first core wire 22 and the first coating 24 are included, and the first core wire 22 is partially exposed in the extending direction to form a first core wire exposed portion 22a. One electric wire 20 is prepared (step (a)).

次に、図６に示すように、超音波接合用のアンビル６０、ホーン６２間で、第１芯線露出部２２ａの少なくとも一部で複数の第１素線２３同士を接合する（工程(b)）。 Next, as shown in FIG. 6, between the anvil 60 for ultrasonic bonding and the horn 62, the plurality of first strands 23 are bonded to each other by at least a part of the first core wire exposed portion 22a (step (b)). ).

この際、アンビル６０及びホーン６２の少なくとも一方（抵抗溶接の場合には電圧印加用の一対のチップの少なくとも一方）として、第１芯線露出部２２ａに接触する部分に、当該第１芯線露出部２２ａに形成される凹凸形状に対して逆の凹凸形状が形成されたものを用いる。すると、第１芯線露出部２２ａの複数の第１素線２３同士が超音波接合されつつ、アンビル６０又はホーン６２の凹凸形状が転写され、当該第１芯線露出部２２ａに凹凸形状として凹部２２ｂが形成される。 At this time, as at least one of the anvil 60 and the horn 62 (at least one of a pair of tips for applying voltage in the case of resistance welding), the first core wire exposed portion 22a is in contact with the first core wire exposed portion 22a. In this example, a concave and convex shape opposite to the concave and convex shape formed is used. Then, the concave and convex shape of the anvil 60 or the horn 62 is transferred while the plurality of first strands 23 of the first core wire exposed portion 22a are ultrasonically bonded, and the concave portion 22b is formed as the concave and convex shape on the first core wire exposed portion 22a. It is formed.

ここでは、第１芯線露出部２２ａのうちアンビル６０又はホーン６２で押圧される面に、凹部２２ｂが形成されている。図７に示す例では、扁平な角柱状に形成される第１芯線露出部の一方の面に、多角形（ここでは、平行四辺形）に凹む凹部２２ｂが縦横に並ぶように形成されている。その他、図８に示すように、扁平な角柱状に形成される第１芯線露出部１２２ａの一方の面に、その幅方向に対して斜め方向に沿った溝状の凹部１２２ｂが複数並列状に形成されていてもよい。また、図９に示すように、扁平な角柱状に形成される第１芯線露出部２２２ａの一方の面に、その延在方向に沿った溝状の凹部２２２ｂが複数並列状に形成されていてもよい。第１芯線露出部の少なくとも一部の面に形成された凹凸形状は、その他、網目状又は網点状の凸部又は凹部が形成された構成等であってもよい。なお、第１芯線露出部２２ａの少なくとも一部に凹凸形状が形成されていればよいが、当該凹凸形状が形成される部分は、第１芯線露出部２２ａと第２芯線露出部３２ａとの端子４０を圧着した状態で、第２芯線露出部３２ａに接触する部分である。 Here, the recessed part 22b is formed in the surface pressed with the anvil 60 or the horn 62 among the 1st core wire exposed parts 22a. In the example shown in FIG. 7, concave portions 22 b that are recessed in a polygonal shape (here, a parallelogram) are formed on one surface of the first core wire exposed portion formed in a flat prismatic shape so as to be aligned vertically and horizontally. . In addition, as shown in FIG. 8, a plurality of groove-like recesses 122b extending in a diagonal direction with respect to the width direction are arranged in parallel on one surface of the first core wire exposed portion 122a formed in a flat prismatic shape. It may be formed. Further, as shown in FIG. 9, a plurality of groove-like recesses 222b along the extending direction are formed in parallel on one surface of the first core wire exposed portion 222a formed in a flat prismatic shape. Also good. The concavo-convex shape formed on at least a part of the surface of the first core wire exposed portion may be a configuration in which a net-like or dot-like convex or concave portion is formed. In addition, although the uneven | corrugated shape should just be formed in at least one part of the 1st core wire exposed part 22a, the part in which the said uneven | corrugated shape is formed is a terminal of the 1st core wire exposed part 22a and the 2nd core wire exposed part 32a. This is a portion that contacts the second core wire exposed portion 32a in a state where 40 is crimped.

なお、複数の第１素線２３同士を超音波接合、抵抗溶接又は半田等で接合した後に、別途プレス金型等で、第１芯線露出部２２ａに凹凸形状を形成してもよい。 In addition, after joining several 1st strand 23 by ultrasonic bonding, resistance welding, or solder, you may form uneven | corrugated shape in the 1st core wire exposed part 22a with a press die separately.

これとは別に、図１０に示すように、第２芯線３２と、第２被覆３４とを含み、第２芯線３２の延在方向の一部が露出されて第２芯線露出部３２ａが形成された第２電線３０を準備する（工程(c)）。 Apart from this, as shown in FIG. 10, the second core wire 32 and the second coating 34 are included, and a part of the extending direction of the second core wire 32 is exposed to form a second core wire exposed portion 32a. The second electric wire 30 is prepared (step (c)).

なお、工程(a)、(b)の前に工程(c)が実施されてもよい。 Step (c) may be performed before steps (a) and (b).

この後、図１１に示すように、端子圧着用のアンビル５０上に、端子４０を載置し、当該端子４０内に第１芯線露出部２２ａ及び第２芯線露出部３２ａを配設する。この際、第１芯線露出部２２ａの凹部２２ｂが第２芯線露出部３２ａ側を向くようにする。そして、端子圧着用のクリンパ５２をアンビル５０上の端子４０に向けて押して、一対の圧着片４４を第１芯線露出部２２ａ及び第２芯線露出部３２ａに向けてかしめ変形させる。これにより、第１芯線露出部２２ａ及び第２芯線露出部３２ａに端子４０が圧着される。この際、第１芯線露出部２２ａ及び第２芯線露出部３２ａも端子４０を介して圧縮される。ここで、銅又は銅合金で形成された複数の第１素線２３が接合された第１芯線露出部２２ａは、アルミニウム又はアルミニウム合金で形成された第２芯線露出部３２ａよりも変形し難い。このため、第２芯線露出部３２ａの表面の被膜、特に、アルミニウム又はアルミニウム合金の表面に形成された被膜が、第１芯線露出部２２ａにより破壊され、特に、凹凸形状によって有効に破壊される。これにより、第２芯線露出部３２ａの表面の被膜が破壊された状態で、第１芯線露出部２２ａと第２芯線露出部３２ａとが接触した状態となる。これにより、第１芯線露出部２２ａと第２芯線露出部３２ａとは低い電気抵抗で接触した状態となる。これにより、第１電線２０の第１芯線露出部２２ａと第２電線３０の第２芯線露出部３２ａとが端子４０によって圧着接続された端子付電線１０が製造される。 Thereafter, as shown in FIG. 11, the terminal 40 is placed on the terminal crimping anvil 50, and the first core wire exposed portion 22 a and the second core wire exposed portion 32 a are disposed in the terminal 40. At this time, the concave portion 22b of the first core wire exposed portion 22a faces the second core wire exposed portion 32a. Then, the crimper 52 for terminal crimping is pushed toward the terminal 40 on the anvil 50, and the pair of crimping pieces 44 are crimped and deformed toward the first core wire exposed portion 22a and the second core wire exposed portion 32a. Thereby, the terminal 40 is crimped | bonded to the 1st core wire exposed part 22a and the 2nd core wire exposed part 32a. At this time, the first core wire exposed portion 22 a and the second core wire exposed portion 32 a are also compressed through the terminal 40. Here, the 1st core wire exposed part 22a where the some 1st strand 23 formed with copper or copper alloy was joined is harder to deform | transform than the 2nd core wire exposed part 32a formed with aluminum or aluminum alloy. For this reason, the coating on the surface of the second core wire exposed portion 32a, in particular, the coating formed on the surface of aluminum or an aluminum alloy is destroyed by the first core wire exposed portion 22a, and particularly effectively destroyed by the uneven shape. Thereby, the first core wire exposed portion 22a and the second core wire exposed portion 32a are in contact with each other in a state where the coating on the surface of the second core wire exposed portion 32a is destroyed. Thereby, the 1st core wire exposed part 22a and the 2nd core wire exposed part 32a will be in the state contacted by low electrical resistance. As a result, the terminal-attached electric wire 10 in which the first core wire exposed portion 22a of the first electric wire 20 and the second core wire exposed portion 32a of the second electric wire 30 are crimp-connected by the terminal 40 is manufactured.

＜効果等＞
以上のように構成された端子付電線１０及びその製造方法によると、第１芯線２２は、銅又は銅合金により形成された複数の第１素線２３の集合体であり、この第１芯線２２の延在方向の一部が露出されて第１芯線露出部２２ａが形成されると共に、第１芯線露出部２２ａの少なくとも一部で複数の第１素線２３同士が接合されている。このため、第１芯線露出部２２ａは、第１素線２３がばらばらな状態で存在する場合よりも変形し難い。そして、この第１芯線露出部２２ａと第２芯線露出部３２ａとに端子４０を圧着すると、第１芯線露出部２２ａが第２芯線露出部３２ａの表面の被膜を破壊することができ、両者を良好に電気的に接続することができる。これにより、銅又は銅合金により形成された複数の第１素線２３の集合体である第１芯線２２を含む第１電線２０と、第１素線２３とは異種金属で形成された第２芯線３２を含む第２電線３０とを、端子４０で圧着接続する際に、その接続信頼姓を向上させることができる。 <Effects>
According to the terminal-attached electric wire 10 configured as described above and the manufacturing method thereof, the first core wire 22 is an aggregate of a plurality of first strands 23 formed of copper or a copper alloy, and the first core wire 22. The first core wire exposed portion 22a is formed by exposing a part of the extending direction of the first core wire 23, and the plurality of first strands 23 are joined to each other by at least a part of the first core wire exposed portion 22a. For this reason, the 1st core wire exposed part 22a is harder to deform | transform than the case where the 1st strand 23 exists in a disperse | distributed state. Then, when the terminal 40 is crimped to the first core wire exposed portion 22a and the second core wire exposed portion 32a, the first core wire exposed portion 22a can destroy the coating on the surface of the second core wire exposed portion 32a, Good electrical connection can be achieved. Thereby, the 1st electric wire 20 containing the 1st core wire 22 which is an aggregate | assembly of the some 1st strand 23 formed with copper or copper alloy, and the 1st strand 23 are the 2nd formed with a dissimilar metal. When the second electric wire 30 including the core wire 32 is crimped and connected with the terminal 40, the connection reliability can be improved.

また、第１素線２３同士が超音波接合されているため、それらの接合を簡易に行うことができる。 In addition, since the first strands 23 are ultrasonically bonded to each other, the bonding can be easily performed.

さらに、第１芯線露出部２２ａの表面の少なくとも一部は凹凸形状に形成されているため（ここでは凹部２２ｂが形成されているため）、その凹凸形状によって第２芯線露出部３２ａの表面の酸化皮膜等を有効に破壊することができ、第１電線２０と第２電線３０との接続信頼姓を向上させることができる。 Furthermore, since at least a part of the surface of the first core wire exposed portion 22a is formed in a concavo-convex shape (here, the concave portion 22b is formed), the surface of the second core wire exposed portion 32a is oxidized by the concavo-convex shape. A film | membrane etc. can be destroyed effectively and the connection last name of the 1st electric wire 20 and the 2nd electric wire 30 can be improved.

特に、第２芯線露出部３２ａがアルミニウム又はアルミニウム合金により形成されている場合には、その表面に強固な酸化皮膜が形成されるため、上記のように、第１芯線露出部２２ａによって当該酸化皮膜を破壊できる構成は有効である。 In particular, when the second core wire exposed portion 32a is formed of aluminum or an aluminum alloy, a strong oxide film is formed on the surface of the second core wire exposed portion 32a. Therefore, as described above, the oxide film is formed by the first core wire exposed portion 22a. It is effective to have a configuration that can destroy

＜変形例＞
上記実施形態を前提として、各種変形例について説明する。 <Modification>
Based on the above embodiment, various modifications will be described.

上記実施形態では、第１芯線露出部２２ａに凹凸形状が形成されている例で説明したが、かかる凹凸形状は形成されていなくてもよい。凹凸形状が形成されていなくても、複数の第１素線同士が接合されることにより、第１芯線露出部は、第２芯線露出部よりも変形し難くなるため、端子の圧着時に第２芯線露出部の表面に形成された被膜を破壊することができるからである。 In the said embodiment, although the uneven | corrugated shape was formed in the 1st core wire exposure part 22a, this uneven | corrugated shape does not need to be formed. Even if the concavo-convex shape is not formed, the first core wire exposed portion is less likely to be deformed than the second core wire exposed portion when the plurality of first strands are joined together. This is because the film formed on the surface of the core wire exposed portion can be destroyed.

また、図１２及び図１３に示す変形例では、上記第１芯線露出部２２ａに対応する第１芯線露出部３２２ａの断面積（第１芯線露出部３２２ａの延在方向に対して直交する方向における断面積）が、その延在方向において変化している。より具体的には、第１芯線露出部３２２ａ等に端子４０を圧着する前の状態において、第１芯線露出部３２２ａの先端側部分３２２ａｐがその基端側部分３２２ａｑよりも細くなっている。なお、ここでは、先端側部分３２２ａｐ及び基端側部分３２２ａｑの両方に凹凸形状として凹部３４６が形成されている。そして、当該第１芯線露出部３２２ａと、第２芯線露出部３２ａに対応する第２芯線露出部３３２ａとに端子４０を圧着した状態で、第１芯線露出部３２２ａの先端側部分３２２ａｐの断面積は、その基端側部分３２２ａｑの断面積よりも小さい。ここで、端子４０を圧着する前の状態では、第２芯線露出部３３２ａの断面積は、その延在方向においてほぼ一定である。このため、端子４０を圧着すると、第１芯線露出部３２２ａ及び第２芯線露出部３３２ａの先端側では、第２芯線露出部３３２ａの圧縮量は比較的小さい。一方、第１芯線露出部３２２ａ及び第２芯線露出部３３２ａの基端側では、第２芯線露出部３３２ａの圧縮量は比較的大きい。このため、端子４０の延在方向において、第２芯線露出部３３２ａ等の圧縮量を変化させることができる。これにより、例えば、第２芯線露出部３３２ａの基端側では、当該第２芯線露出部３３２ａを大きく圧縮させて有効に酸化皮膜を破壊し電気抵抗を小さくする一方、第２芯線露出部３３２ａの先端側では、当該第２芯線露出部３３２ａの圧縮量を小さくすることで、そのダメージを少なくして引っ張り強度の向上を図ることができる。 12 and 13, the cross-sectional area of the first core wire exposed portion 322a corresponding to the first core wire exposed portion 22a (in the direction orthogonal to the extending direction of the first core wire exposed portion 322a). (Cross-sectional area) changes in the extending direction. More specifically, the distal end portion 322ap of the first core wire exposed portion 322a is thinner than the proximal end portion 322aq before the terminal 40 is crimped to the first core wire exposed portion 322a or the like. Here, the concave portion 346 is formed as an uneven shape in both the distal end portion 322ap and the proximal end portion 322aq. Then, in a state where the terminal 40 is crimped to the first core wire exposed portion 322a and the second core wire exposed portion 332a corresponding to the second core wire exposed portion 32a, the cross-sectional area of the tip side portion 322ap of the first core wire exposed portion 322a Is smaller than the cross-sectional area of the base end portion 322aq. Here, in a state before the terminal 40 is crimped, the cross-sectional area of the second core wire exposed portion 332a is substantially constant in the extending direction. For this reason, when the terminal 40 is crimped, the amount of compression of the second core wire exposed portion 332a is relatively small on the distal end side of the first core wire exposed portion 322a and the second core wire exposed portion 332a. On the other hand, the compression amount of the second core wire exposed portion 332a is relatively large on the proximal end side of the first core wire exposed portion 322a and the second core wire exposed portion 332a. For this reason, the compression amount of the second core wire exposed portion 332a and the like can be changed in the extending direction of the terminal 40. Thereby, for example, on the base end side of the second core wire exposed portion 332a, the second core wire exposed portion 332a is greatly compressed to effectively destroy the oxide film and reduce the electrical resistance, while the second core wire exposed portion 332a On the distal end side, by reducing the amount of compression of the second core wire exposed portion 332a, the damage can be reduced and the tensile strength can be improved.

また、上記実施形態では、端子４０が第１芯線２２と第２芯線３２とを接続するためのスプライス専用の端子である例で説明したが、必ずしもその必要は無い。図１４に示すように、端子４４０として、第１芯線露出部２２ａ及び第２芯線露出部３２ａに接続される電線接続部４４２と、相手側に接続される相手側接続部４４８とが一体形成された構成のものを用いてもよい。なお、電線接続部４４２自体は、上記端子４０と同様構成である。また、ここでは、相手側接続部４４８が車体の金属ボディ等にネジ等によって接続される丸形端子であることを想定している。 Moreover, although the said embodiment demonstrated the example which is the terminal only for the splice for connecting the 1st core wire 22 and the 2nd core wire 32 in the said embodiment, the need does not necessarily exist. As shown in FIG. 14, as the terminal 440, an electric wire connection portion 442 connected to the first core wire exposed portion 22a and the second core wire exposed portion 32a and a counterpart connection portion 448 connected to the counterpart side are integrally formed. You may use the thing of the structure. The wire connecting portion 442 itself has the same configuration as the terminal 40 described above. Here, it is assumed that the counterpart connection portion 448 is a round terminal connected to a metal body or the like of the vehicle body by a screw or the like.

また、上記実施形態では、第１電線２０の端部の第１芯線露出部２２ａと、第２電線３０の端部の第２芯線露出部３２ａとを端子４０で接続する例で説明したが、図１５に示すように、第１電線２０に対応する第１電線５２０の延在方向中間部に、第１芯線露出部５２２ａが形成されると共に当該その第１素線５２３同士が接合され、この第１芯線露出部５２２ａと第２芯線露出部３２ａとが、端子４０で接続される構成であってもよい。 Moreover, although the said embodiment demonstrated the example which connects the 1st core wire exposed part 22a of the edge part of the 1st electric wire 20, and the 2nd core wire exposed part 32a of the edge part of the 2nd electric wire 30 with the terminal 40, As shown in FIG. 15, the first core wire exposed portion 522a is formed at the intermediate portion in the extending direction of the first electric wire 520 corresponding to the first electric wire 20, and the first strands 523 are joined to each other. The first core wire exposed portion 522a and the second core wire exposed portion 32a may be connected by the terminal 40.

また、上記実施形態では、１つの第１電線２０と１つの第２電線３０とに、端子４０を圧着する例で説明したが、３つ以上の電線に端子が圧着される構成であってもよい。この場合、追加的な３本目以降の電線については、第１電線２０と同様構成であってもよいし、第２電線３０と同様構成であってもよい。 Moreover, although the example which crimps | bonds the terminal 40 to one 1st electric wire 20 and one 2nd electric wire 30 was demonstrated in the said embodiment, even if it is the structure by which a terminal is crimped | bonded to three or more electric wires. Good. In this case, the additional third and subsequent electric wires may have the same configuration as the first electric wire 20 or the same configuration as the second electric wire 30.

以上のようにこの発明は詳細に説明されたが、上記した説明は、すべての局面において、例示であって、この発明がそれに限定されるものではない。例示されていない無数の変形例が、この発明の範囲から外れることなく想定され得るものと解される。 As described above, the present invention has been described in detail. However, the above description is illustrative in all aspects, and the present invention is not limited thereto. It is understood that countless variations that are not illustrated can be envisaged without departing from the scope of the present invention.

１０端子付電線
２０、５２０第１電線
２２第１芯線
２２ａ、１２２ａ、２２２ａ、３２２ａ、５２２ａ第１芯線露出部
２２ｂ、１２２ｂ、２２２ｂ凹部
２３、５２３第１素線
２４第１被覆
３０第２電線
３２第２芯線
３２ａ、２３２ａ、３３２ａ第２芯線露出部
３４第２被覆
４０、４４０端子
３２２ａｐ先端側部分
３２２ａｑ基端側部分
３４６凹部
４４２電線接続部 10 Electric wire with terminal 20, 520 First electric wire 22 First core wire 22a, 122a, 222a, 322a, 522a First core wire exposed portion 22b, 122b, 222b Recess 23, 523 First strand 24 First coating 30 Second electric wire 32 Second core wire 32a, 232a, 332a Second core wire exposed portion 34 Second coating 40, 440 Terminal 322ap Tip side portion 322aq Base end side portion 346 Concave portion 442 Electric wire connection portion

Claims

銅又は銅合金により形成された複数の第１素線の集合体である第１芯線と、前記第１芯線の周囲を覆う第１被覆とを含み、前記第１芯線の延在方向の一部が露出されて第１芯線露出部が形成されると共に、前記第１芯線露出部の少なくとも一部で前記複数の第１素線同士が接合されている第１電線と、
前記第１素線とは異種金属により形成された第２芯線と、前記第２芯線の周囲を覆う第２被覆とを含み、前記第２芯線の延在方向の一部が露出されて第２芯線露出部が形成されている第２電線と、
前記第１芯線露出部と前記第２芯線露出部とに圧着された端子と、
を備える端子付電線。 A first core wire that is an aggregate of a plurality of first strands formed of copper or a copper alloy, and a first coating that covers the periphery of the first core wire, and a part of the extending direction of the first core wire Are exposed to form a first core wire exposed portion, and a first electric wire in which the plurality of first strands are joined to each other in at least a part of the first core wire exposed portion,
The first strand includes a second core wire formed of a dissimilar metal and a second coating covering the periphery of the second core wire, and a second part of the second core wire in the extending direction is exposed and second A second electric wire having a core wire exposed portion formed thereon;
A terminal crimped to the first core wire exposed portion and the second core wire exposed portion;
An electric wire with a terminal.

請求項１に記載の端子付電線であって、
前記第１芯線露出部の少なくとも一部で前記複数の第１素線同士は超音波接合されている、端子付電線。 It is an electric wire with a terminal according to claim 1,
The electric wire with a terminal, wherein the plurality of first strands are ultrasonically bonded to each other at least at a part of the exposed portion of the first core wire.

請求項１又は請求項２に記載の端子付電線であって、
前記第１芯線露出部の少なくとも一部の表面が凹凸形状に形成されている、端子付電線。 It is an electric wire with a terminal according to claim 1 or claim 2,
The electric wire with a terminal, wherein at least a part of the surface of the first core wire exposed portion is formed in an uneven shape.

請求項１から請求項３のいずれか１項に記載の端子付電線であって、
前記第１芯線露出部の断面積が、前記第１芯線露出部の延在方向において変化している、端子付電線。 It is an electric wire with a terminal given in any 1 paragraph of Claims 1-3,
The electric wire with a terminal, wherein a cross-sectional area of the first core wire exposed portion changes in an extending direction of the first core wire exposed portion.

請求項１から請求項４のいずれか１項に記載の端子付電線であって、
前記第２芯線はアルミニウム又はアルミニウム合金により形成されている、端子付電線。 It is an electric wire with a terminal given in any 1 paragraph of Claims 1-4,
The second core wire is a terminal-attached electric wire formed of aluminum or an aluminum alloy.

(a)銅又は銅合金により形成された複数の第１素線の集合体である第１芯線と、前記第１芯線の周囲を覆う第１被覆とを含み、前記第１芯線の延在方向の一部が露出されて第１芯線露出部が形成された第１電線を準備する工程と、
(b)前記第１芯線露出部の少なくとも一部で前記複数の第１素線同士を接合する工程と、
(c)前記第１素線とは異種金属により形成された第２芯線と、前記第２芯線の周囲を覆う第２被覆とを含み、前記第２芯線の延在方向の一部が露出されて第２芯線露出部が形成されている第２電線を準備する工程と、
(d)前記第１芯線露出部と前記第２芯線露出部とに端子を圧着する工程と、
を備える端子付電線の製造方法。 (a) a first core wire that is an aggregate of a plurality of first strands formed of copper or a copper alloy, and a first coating that covers the periphery of the first core wire, the extending direction of the first core wire A step of preparing a first electric wire in which a part of the first core wire is exposed and a first core wire exposed portion is formed;
(b) joining the plurality of first strands at least at a part of the first core wire exposed portion;
(c) The first strand includes a second core wire formed of a dissimilar metal and a second coating covering the periphery of the second core wire, and a part of the extending direction of the second core wire is exposed. Preparing a second electric wire on which the second core wire exposed portion is formed;
(d) a step of crimping a terminal to the first core wire exposed portion and the second core wire exposed portion;
The manufacturing method of the electric wire with a terminal provided with.