JP2019160569A

JP2019160569A - Terminal-equipped wire

Info

Publication number: JP2019160569A
Application number: JP2018045896A
Authority: JP
Inventors: 拓也川口; Takuya Kawaguchi
Original assignee: Fujikura Ltd
Current assignee: Fujikura Ltd
Priority date: 2018-03-13
Filing date: 2018-03-13
Publication date: 2019-09-19

Abstract

To provide a terminal-equipped wire with effectively suppressed element wire disconnection due to galvanic corrosion and improved electric reliability.SOLUTION: A terminal-equipped wire 1 comprises: an electric wire 10 in which an insulation material covers a conductor 15 structured by a plurality of element wires made of aluminum; a cap member 30 made of aluminum covering an outer periphery of a conductive exposure part 16 formed in the electric wire 10; and a terminal 20 made of copper attached to the electric wire 10. This terminal 20 includes a conductive crimping part 21 fastening the conductive exposure part 16 from the outer periphery of the cap member 30. In the conductive crimping part 21, a high crimping part 24 fastening the conductive exposure part 16 and the cap member 30 is contained so that a compression rate of the conductive exposure part 16 and the cap member 30 becomes 60% to 70% in a ratio of a cross sectional area after the fastening/the cross sectional area before the fastening.SELECTED DRAWING: Figure 3

Description

本発明は、端子付電線に関し、特に端子と電線の導体とが異種金属から形成された端子付電線に関するものである。 The present invention relates to a terminal-attached electric wire, and more particularly to a terminal-attached electric wire in which a terminal and a conductor of the electric wire are formed from different metals.

電線に端子を接続した端子付電線として、アルミニウムまたはアルミニウム合金からなる複数の素線から構成された導体に絶縁材が被覆された電線と、銅又は銅合金からなる端子とを接続したものが知られている。電線の導体と端子とが異種金属から形成されたこのような端子付電線では、導体と端子との接続部分が被水すると、イオン化傾向が大きい卑な金属（アルミニウムまたはアルミニウム合金）からなる導体が電解質溶液（塩水など）に溶出して腐食（ガルバニック腐食）し、その結果、導体において素線切れが生じて電気的信頼性が低下する可能性があった。 As a terminal-attached electric wire in which a terminal is connected to an electric wire, an electric wire in which an insulating material is coated on a conductor made of a plurality of strands made of aluminum or an aluminum alloy and a terminal made of copper or a copper alloy are connected. It has been. In such an electric wire with a terminal in which the conductor and the terminal of the electric wire are formed of different metals, when the connection portion between the conductor and the terminal is exposed to water, a conductor made of a base metal (aluminum or aluminum alloy) having a large ionization tendency Elution into an electrolyte solution (salt water or the like) causes corrosion (galvanic corrosion). As a result, the conductor may be broken and the electrical reliability may be lowered.

このようなガルバニック腐食の進行速度は、異種金属間の電位差や表面積比などに左右されることが知られている。すなわち、上述の卑な金属とイオン化傾向が小さい貴な金属との間の電位差が大きいほど、また、貴な金属に対する卑な金属の表面積が小さいほど、卑な金属の腐食が進行する。そこで、導体と端子とが異種金属から形成された端子付電線において、電線の導体露出部の外周に、イオン化傾向がこれら金属の中間となる金属材料から構成されたキャップ部材を被せ、その外周から端子を圧着したものが知られている（例えば、特許文献１）。 It is known that the progress speed of such galvanic corrosion depends on a potential difference between different metals, a surface area ratio, and the like. That is, the corrosion of the base metal proceeds as the potential difference between the above-mentioned base metal and the noble metal having a low ionization tendency increases, and as the surface area of the base metal relative to the noble metal decreases. Therefore, in the electric wire with a terminal in which the conductor and the terminal are formed of different metals, the outer periphery of the conductor exposed portion of the electric wire is covered with a cap member made of a metal material whose ionization tendency is intermediate between these metals. One obtained by crimping a terminal is known (for example, Patent Document 1).

しかしながら、このような構成では、異種金属間（端子とキャップ部材との間、キャップ部材と素線（導体）との間）の電位差は小さくなるものの、キャップ部材に対する素線の表面積比が非常に小さいため、キャップ部材の内部に水が浸入すると、ガルバニック腐食による素線切れが生じて電気的信頼性が低下する可能性があった。 However, in such a configuration, although the potential difference between dissimilar metals (between the terminal and the cap member and between the cap member and the strand (conductor)) is small, the surface area ratio of the strand to the cap member is very high. Since it is small, when water enters the cap member, there is a possibility that wire breakage due to galvanic corrosion occurs and electrical reliability is lowered.

特開２０１３−０９３２６１号公報JP 2013-093261 A

本発明は、このような従来技術の問題点に鑑みてなされたもので、ガルバニック腐食による素線切れを効果的に抑制し、電気的信頼性を向上させた端子付電線を提供することを目的とする。 The present invention has been made in view of such problems of the prior art, and it is an object of the present invention to provide a terminal-attached electric wire that effectively suppresses wire breakage due to galvanic corrosion and has improved electrical reliability. And

本発明の一態様によれば、ガルバニック腐食による素線切れを効果的に抑制し、電気的信頼性を向上させた端子付電線が提供される。この端子付電線は、アルミニウムまたはアルミニウム合金からなる複数の素線から構成される導体に絶縁材が被覆され、導体露出部と絶縁材被覆部とを含む電線と、上記素線と同じ材料からなり、上記導体露出部の外周を覆うキャップ部材と、上記素線と異なる材料からなり、上記キャップ部材の外周から上記導体露出部を加締める導体圧着部を有する端子とを備える。そして、上記導体圧着部には、上記導体露出部及び上記キャップ部材の圧縮率が、加締め後の断面積／加締め前の断面積の比率で６０％〜７０％の範囲となるように、上記導体露出部及び上記キャップ部材を加締める強圧着部が含まれる。 According to one aspect of the present invention, there is provided a terminal-attached electric wire that effectively suppresses wire breakage due to galvanic corrosion and improves electrical reliability. This electric wire with a terminal is made of the same material as the above-mentioned wire, and an electric wire including a conductor exposed portion and an insulating material covering portion, with a conductor composed of a plurality of strands made of aluminum or an aluminum alloy covered with an insulating material. A cap member that covers the outer periphery of the exposed conductor portion, and a terminal that is made of a material different from that of the element wire and includes a conductor crimping portion that caulks the exposed conductor portion from the outer periphery of the cap member. And in the said conductor crimping | compression-bonding part, the compression ratio of the said conductor exposed part and the said cap member becomes the range of 60%-70% by the ratio of the cross-sectional area after caulking / cross-sectional area before caulking. A strong pressure bonding part for caulking the conductor exposed part and the cap member is included.

このような端子付電線によれば、強圧着部において、金属部材同士が金属融合し、端子とキャップ部材との導通、キャップ部材と素線との導通及び素線間の導通が確保される。また、素線と同じ材料からなるキャップ部材によって導体露出部が覆われ、素線に異種金属が接触しないように構成されているため、キャップ部材の内部に水が浸入しても、ガルバニック腐食による素線切れが発生せず、電気的信頼性を向上させることができる。 According to such a terminal-attached electric wire, the metal members are fused with each other in the strong pressure bonding portion, and conduction between the terminal and the cap member, conduction between the cap member and the strand, and conduction between the strands are ensured. In addition, the conductor exposed portion is covered with a cap member made of the same material as the element wire so that different metals do not come into contact with the element wire. Therefore, even if water enters the cap member, it is caused by galvanic corrosion. Wire breakage does not occur, and electrical reliability can be improved.

ここで、上記端子付電線において、上記端子は、上記キャップ部材の外周から上記絶縁材被覆部を加締める被覆材圧着部を更に有してもよい。これにより、端子と電線の固定強度が増大するだけでなく、キャップ部材の開口が塞がれてキャップ部材の内部への水の浸入を抑制することができる。 Here, in the electric wire with terminal, the terminal may further include a covering material crimping portion that caulks the insulating material covering portion from the outer periphery of the cap member. Thereby, not only the fixing strength of the terminal and the electric wire is increased, but also the opening of the cap member is blocked, and the intrusion of water into the cap member can be suppressed.

また、上記端子付電線において、上記強圧着部が、上記導体圧着部の中間部分に形成されていてもよい。これにより、キャップ部材の外周から導体圧着部を圧着するとき、導体圧着部の端部でキャップ部材に損傷をあたえることを抑制することができる。 Moreover, the said electric wire with a terminal WHEREIN: The said strong crimping | compression-bonding part may be formed in the intermediate part of the said conductor crimping | compression-bonding part. Thereby, when crimping | bonding a conductor crimping | compression-bonding part from the outer periphery of a cap member, it can suppress giving a damage to a cap member in the edge part of a conductor crimping | compression-bonding part.

さらに、上記端子付電線において、上記キャップ部材の外周面にスズめっき層が形成されていてもよい。これにより、キャップ部材のカルバニック腐食を抑制することができる。 Furthermore, in the electric wire with terminal, a tin plating layer may be formed on the outer peripheral surface of the cap member. Thereby, carbonic corrosion of the cap member can be suppressed.

本発明によれば、ガルバニック腐食による素線切れを効果的に抑制し、電気的信頼性を向上させた端子付電線を提供することができる。 ADVANTAGE OF THE INVENTION According to this invention, the wire with a terminal which suppressed the strand cut | disconnection by galvanic corrosion effectively, and improved electrical reliability can be provided.

図１は、本発明の一実施形態における端子付電線を示す平面図である。FIG. 1 is a plan view showing a terminal-attached electric wire according to an embodiment of the present invention. 図２は、図１に示される端子付電線の側面図である。FIG. 2 is a side view of the terminal-attached electric wire shown in FIG. 図３は、図１のＡ−Ａ線断面図である。3 is a cross-sectional view taken along line AA in FIG. 図４は、図２のＢ−Ｂ線切断部端面図である。FIG. 4 is an end view taken along the line BB in FIG. 図５は、図２のＣ−Ｃ線切断部端面図である。FIG. 5 is an end view taken along the line CC of FIG. 図６は、圧縮率と接続抵抗の上昇値との関係を示すグラフである。FIG. 6 is a graph showing the relationship between the compression ratio and the increase value of the connection resistance. 図７は、図１に示される端子付電線の製造方法を示す図である。FIG. 7 is a diagram showing a method for manufacturing the terminal-attached electric wire shown in FIG. 図８は、図１に示される端子付電線の製造方法を示す図である。FIG. 8 is a diagram showing a method for manufacturing the terminal-attached electric wire shown in FIG.

以下、本発明に係る端子付電線の実施形態について図１から図８を参照して詳細に説明する。なお、図１から図８において、同一又は相当する構成要素には、同一の符号を付して重複した説明を省略する。また、図１から図８においては、各構成要素の縮尺や寸法が誇張されて示されている場合や一部の構成要素が省略されている場合がある。 Hereinafter, embodiments of the electric wire with terminal according to the present invention will be described in detail with reference to FIGS. 1 to 8. 1 to 8, the same or corresponding components are denoted by the same reference numerals, and redundant description is omitted. Moreover, in FIG. 1 to FIG. 8, there are cases where the scales and dimensions of each component are exaggerated and some components are omitted.

図１は本発明の一実施形態における端子付電線１を示す平面図、図２は端子付電線１を示す側面図、図３は図１のＡ−Ａ線断面図、図４は図２のＢ−Ｂ線切断部端面図、図５は図２のＣ−Ｃ線切断部端面図である。 1 is a plan view showing a terminal-attached electric wire 1 according to an embodiment of the present invention, FIG. 2 is a side view showing the terminal-attached electric wire 1, FIG. 3 is a cross-sectional view taken along the line AA in FIG. FIG. 5 is an end view of the cutting section taken along the line B-B, and FIG.

図１から図３に示すように、端子付電線１は、電線１０と、電線１０の先端部（＋Ｘ方向側の端部）に装着されたキャップ部材３０と、キャップ部材３０の外周から電線１０を加締めることにより電線１０に固定された端子２０とを備えている。 As shown in FIGS. 1 to 3, the terminal-attached electric wire 1 includes an electric wire 10, a cap member 30 attached to a tip portion (an end portion on the + X direction side) of the electric wire 10, and an electric wire 10 from the outer periphery of the cap member 30. And a terminal 20 fixed to the electric wire 10 by crimping.

電線１０は、アルミニウム又はアルミニウム合金からなる複数の素線から構成された導体１５と、導体１５の外周を被覆する絶縁材とから構成されている。そして、導体１５を被覆する絶縁材の一部が除去され、導体１５が露出された導体露出部１６と、導体１５が絶縁材で被覆された絶縁材被覆部１１とを含んでいる。導体露出部１６は、電線１０の先端部に形成されており、その全長がキャップ部材３０に覆われている。 The electric wire 10 is composed of a conductor 15 composed of a plurality of strands made of aluminum or an aluminum alloy, and an insulating material covering the outer periphery of the conductor 15. A part of the insulating material covering the conductor 15 is removed, and the conductor exposed portion 16 where the conductor 15 is exposed and the insulating material covering portion 11 where the conductor 15 is covered with the insulating material are included. The conductor exposed portion 16 is formed at the distal end portion of the electric wire 10, and the entire length thereof is covered with the cap member 30.

キャップ部材３０は、導体１５（素線）と同様に、イオン化傾向が卑なアルミニウム又はアルミニウム合金からなる。そしてキャップ部材３０は、＋Ｘ方向側の端部が端面３１により塞がれ、−Ｘ方向側の端部に開口３５が形成された、有底筒状の構成を有している（図３参照）。電線１０の導体露出部１６は、開口３５からキャップ部材３０の内部に挿入されており、導体露出部１６の先端から絶縁材被覆部１１の一部までがこのキャップ部材３０に覆われている。 The cap member 30 is made of aluminum or aluminum alloy having a low ionization tendency, like the conductor 15 (element wire). The cap member 30 has a bottomed cylindrical configuration in which the end on the + X direction side is closed by the end surface 31 and the opening 35 is formed on the end on the −X direction side (see FIG. 3). ). The conductor exposed portion 16 of the electric wire 10 is inserted into the cap member 30 through the opening 35, and the cap member 30 covers from the tip of the conductor exposed portion 16 to a part of the insulating material covering portion 11.

端子２０は、イオン化傾向が貴な銅又は銅合金からなり、電線１０と接続される電線接続部と、相手方端子（図略）と接続される端子接続部とを含んでいる。本実施形態の端子２０は、電線接続部として、端子２０のＸ方向中央に位置する導体圧着部２１と、−Ｘ方向側端部に位置する被覆材圧着部２５とを有している。また端子接続部として、＋Ｘ方向側端部に位置するボックス部２７を有し、ボックス部２７の内部には弾性片２７Ａが設けられている（図３参照）。そして、このボックス部２７に挿入された相手方端子（図略）が弾性片２７Ａに圧接することにより、端子２０と相手方端子との電気的接続が図られる。 The terminal 20 is made of copper or a copper alloy having a preferential ionization tendency, and includes a wire connection portion connected to the electric wire 10 and a terminal connection portion connected to a counterpart terminal (not shown). The terminal 20 of the present embodiment includes a conductor crimping portion 21 located at the center in the X direction of the terminal 20 and a covering material crimping portion 25 located at the −X direction side end as the wire connecting portion. In addition, the terminal connecting portion includes a box portion 27 located at the end on the + X direction side, and an elastic piece 27A is provided inside the box portion 27 (see FIG. 3). And the other party terminal (not shown) inserted in this box part 27 press-contacts to the elastic piece 27A, and the electrical connection of the terminal 20 and the other party terminal is achieved.

端子２０の被覆材圧着部２５は、端子２０の底部２６の−Ｙ方向側縁部から延出する被覆圧着片２５Ａと、底部２６の＋Ｙ方向側縁部から延出する被覆圧着片２５Ｂとを含んでいる。これら一対の被覆圧着片２５Ａ，２５Ｂ（すなわち、被覆材圧着部２５）は、キャップ部材３０の外周から電線１０の絶縁材被覆部１１を加締めて該絶縁材被覆部１１を圧着している。 The covering crimping portion 25 of the terminal 20 includes a covering crimping piece 25A extending from the −Y direction side edge of the bottom portion 26 of the terminal 20 and a covering crimping piece 25B extending from the + Y direction side edge of the bottom portion 26. Contains. The pair of coated crimping pieces 25 A and 25 B (that is, the coating material crimping portion 25) crimps the insulating material coating portion 11 by crimping the insulating material coating portion 11 of the electric wire 10 from the outer periphery of the cap member 30.

端子２０の導体圧着部２１は、端子２０の底部２６の−Ｙ方向側縁部から延出する導体圧着片２１Ａと、底部２６の＋Ｙ方向側縁部から延出する導体圧着片２１Ｂとを含んでいる。これら一対の導体圧着片２１Ａ，２１Ｂ（すなわち、導体圧着部２１）は、キャップ部材３０の外周から電線１０の導体露出部１６を加締めて該導体露出部１６を圧着している。 The conductor crimping portion 21 of the terminal 20 includes a conductor crimping piece 21A extending from the −Y direction side edge of the bottom portion 26 of the terminal 20 and a conductor crimping piece 21B extending from the + Y direction side edge of the bottom portion 26. It is out. The pair of conductor crimping pieces 21 A and 21 B (that is, the conductor crimping portion 21) crimps the conductor exposed portion 16 of the electric wire 10 by crimping the conductor exposed portion 16 from the outer periphery of the cap member 30.

図１から図５に示すように、端子２０の導体圧着部２１は、中間部分に位置する第３の部分２４と、第３の部分２４の＋Ｘ方向側に位置する第１の部分２２と、第３の部分２４の−Ｘ方向側に位置する第２の部分２３とを含んでいる。なお、底部２６を基準とした第３の部分２４の最大高さ（Ｚ方向の最大長さ）は、第１の部分２２及び第２の部分２３の底部２６を基準とした最大高さよりも小さくなっている。このように導体圧着部２１の第３の部分２４が低くなっているのは、第３の部分２４が第１の部分２２及び第２の部分２３に比べて大きな力で導体露出部１６を加締めていることに起因する。このような第３の部分２４は、導体露出部１６及びキャップ部材３０の圧縮率が「加締め後の断面積／加締め前の断面積」の比率で６０〜７０％の範囲となるように導体露出部１６を加締めている。すなわち、図３及び図５に示すように、第３の部分２４は、第１の部分２２及び第２の部分２３に比べて大きな力で導体露出部１６を圧着する（強圧着する）強圧着部である。一方、図３及び図４に示すように、第１の部分２２及び第２の部分２３は第３の部分よりも弱い力（通常の力）で導体露出部１６を圧着する部分である。以下、第１の部分２２及び第２の部分２３をそれぞれ通常圧着部２２及び通常圧着部２３と記載し、第３の部分２４を強圧着部２４と記載する。 As shown in FIGS. 1 to 5, the conductor crimping portion 21 of the terminal 20 includes a third portion 24 located in the intermediate portion, a first portion 22 located on the + X direction side of the third portion 24, and And a second portion 23 located on the −X direction side of the third portion 24. The maximum height (the maximum length in the Z direction) of the third portion 24 with respect to the bottom portion 26 is smaller than the maximum height with respect to the bottom portions 26 of the first portion 22 and the second portion 23. It has become. Thus, the third portion 24 of the conductor crimping portion 21 is lowered because the third portion 24 applies the conductor exposed portion 16 with a greater force than the first portion 22 and the second portion 23. Due to tightening. Such a third portion 24 has a compression ratio of the conductor exposed portion 16 and the cap member 30 in a range of 60 to 70% in a ratio of “cross-sectional area after crimping / cross-sectional area before crimping”. The conductor exposed portion 16 is caulked. That is, as shown in FIG. 3 and FIG. 5, the third portion 24 is a strong pressure-bonding (strongly pressure-bonded) conductor exposed portion 16 with a larger force than the first portion 22 and the second portion 23. Part. On the other hand, as shown in FIGS. 3 and 4, the first portion 22 and the second portion 23 are portions for crimping the conductor exposed portion 16 with a weaker force (normal force) than the third portion. Hereinafter, the first portion 22 and the second portion 23 are referred to as a normal pressure-bonding portion 22 and a normal pressure-bonding portion 23, respectively, and the third portion 24 is referred to as a strong pressure-bonding portion 24.

ここで、図６は、導体の断面積が０．５ｍｍ²の電線に端子を様々な圧縮率で圧着したときの接続抵抗の上昇値（ｍΩ）を示すグラフである。図６からは、７０％の圧縮率を境として接続抵抗の上昇が顕著になっていることが分かる。すなわち、強圧着部２４における圧縮率を７０％以下としたのは、このようにすることで、強圧着部２４において電線１０との間で良好な導通を確保することができるためである。一方、強圧着部２４における圧縮率を６０％以上としたのは、圧縮率が６０％よりも小さくなるような強い力で加締めると、強圧着部２４における把持力が低下してしまうため（具体的には、４０Ｎの引っ張り力に抗しきれなくなるため）である。 Here, FIG. 6 is a graph showing an increase in connection resistance (mΩ) when a terminal is crimped to an electric wire having a conductor cross-sectional area of 0.5 mm ² at various compression rates. From FIG. 6, it can be seen that the increase in the connection resistance becomes remarkable at the compression rate of 70%. That is, the reason why the compression rate in the strong pressure bonding portion 24 is set to 70% or less is that, in this way, it is possible to ensure good conduction between the strong pressure bonding portion 24 and the electric wire 10. On the other hand, the reason why the compression ratio in the strong pressure bonding portion 24 is set to 60% or more is that when the caulking is performed with a strong force such that the compression ratio is smaller than 60%, the gripping force in the strong pressure bonding portion 24 is reduced ( Specifically, it is impossible to resist the tensile force of 40N).

このように、本実施形態における端子付電線１によれば、導体露出部１６及びキャップ部材３０の圧縮率が「加締め後の断面積／加締め前の断面積」の比率で６０〜７０％の範囲となる強圧着部２４が導体圧着部２１に設けられているため、端子２０とキャップ部材３０との間、キャップ部材３０と導体１５との間、及び導体１５の各素線間において良好な導通を確保することができる。 Thus, according to the electric wire with terminal 1 in the present embodiment, the compression ratio of the conductor exposed portion 16 and the cap member 30 is 60 to 70% in the ratio of “cross-sectional area after caulking / cross-sectional area before caulking”. Since the strong pressure-bonding portion 24 in the range of is provided in the conductor pressure-bonding portion 21, it is good between the terminal 20 and the cap member 30, between the cap member 30 and the conductor 15, and between each strand of the conductor 15. Continuity can be ensured.

また、本実施形態によれば、図３に示すように、導体露出部１６は全長にわたって、導体１５（素線）と同じ材料からなるキャップ部材３０に覆われるため、導体１５のカルバニック腐食を効果的に防止することができる。具体的には、キャップ部材３０によって導体露出部１６が覆われ、端子２０はキャップ部材３０の外周から導体露出部１６を加締めているため、導体露出部１６（導体１５）と端子２０とが直接接触することがなく、さらに導体露出部１６はキャップ部材３０内で被水しにくい。そして、導体露出部１６（導体１５）の代わりに、導体露出部１６を覆うキャップ部材３０が端子２０と直接接触することとなるが、このキャップ部材３０と端子２０との接続部分が被水したとしても、キャップ部材３０の表面積は導体１５の素線自体の表面積に比べて極めて大きいため、キャップ部材３０に生じるガルバニック腐食の進行を抑えることができる。また、キャップ部材３０の外周面に腐食が生じたとしても、電線１０と端子２０との電気的接続信頼性に影響を与えることがない。 Further, according to the present embodiment, as shown in FIG. 3, the conductor exposed portion 16 is covered with the cap member 30 made of the same material as the conductor 15 (elementary wire) over the entire length, so that the carbonic corrosion of the conductor 15 is effective. Can be prevented. Specifically, the conductor exposed portion 16 is covered by the cap member 30, and the terminal 20 caulks the conductor exposed portion 16 from the outer periphery of the cap member 30, so that the conductor exposed portion 16 (conductor 15) and the terminal 20 are connected. There is no direct contact, and the exposed conductor 16 is less likely to get wet in the cap member 30. Then, instead of the conductor exposed portion 16 (conductor 15), the cap member 30 covering the conductor exposed portion 16 is in direct contact with the terminal 20, but the connection portion between the cap member 30 and the terminal 20 is covered with water. Even so, since the surface area of the cap member 30 is extremely larger than the surface area of the strands of the conductor 15, the progress of galvanic corrosion occurring in the cap member 30 can be suppressed. Even if corrosion occurs on the outer peripheral surface of the cap member 30, the electrical connection reliability between the electric wire 10 and the terminal 20 is not affected.

さらに、キャップ部材３０の開口３５からキャップ部材３０の内部に水が浸入したとしても、キャップ部材３０は導体１５（素線）と同一の材料からなるため、素線にガルバニック腐食が生じることがなく、素線切れの発生が防止され、端子付電線の電気的信頼性が向上する。なお、図１及び図２に示すように、本実施形態によれば、端子２０の被覆材圧着部２５によってキャップ部材３０の開口３５近傍が圧着されるため、端子２０と電線１０との間の固定強度が増大するとともに、キャップ部材３０の開口３５が塞がれてキャップ部材３０内部への水の浸入が抑制される。 Furthermore, even if water enters the cap member 30 from the opening 35 of the cap member 30, the cap member 30 is made of the same material as the conductor 15 (element wire), so that galvanic corrosion does not occur on the element wire. The occurrence of wire breakage is prevented, and the electrical reliability of the electric wire with terminal is improved. As shown in FIGS. 1 and 2, according to the present embodiment, the vicinity of the opening 35 of the cap member 30 is crimped by the covering material crimping portion 25 of the terminal 20, and therefore, between the terminal 20 and the electric wire 10. As the fixing strength increases, the opening 35 of the cap member 30 is closed, and water intrusion into the cap member 30 is suppressed.

次に、このような端子付電線１の製造方法の一例について図７及び図８を参照して説明する。この製造方法では、アルミニウム又はアルミニウム合金からなる複数の素線から構成された導体１５の外周に絶縁材が被覆された電線１０と、導体１５（素線）と同じ材料からなる有底筒状のキャップ部材３０と、銅又は銅合金からなる端子２０とを用意する。なお、電線１０の先端の被覆材は除去されて導体露出部１６が形成されている。また本製造方法において、導体露出部１６はキャップ部材３０の全長よりも短い長さに形成されている。 Next, an example of the manufacturing method of such a terminal-attached electric wire 1 will be described with reference to FIGS. In this manufacturing method, the electric wire 10 in which the outer periphery of the conductor 15 composed of a plurality of strands made of aluminum or an aluminum alloy is coated with an insulating material, and the bottomed cylindrical shape made of the same material as the conductor 15 (strand). A cap member 30 and a terminal 20 made of copper or a copper alloy are prepared. The covering material at the tip of the electric wire 10 is removed to form a conductor exposed portion 16. In the manufacturing method, the conductor exposed portion 16 is formed to have a length shorter than the entire length of the cap member 30.

まず、図７に示すように、電線１０の導体露出部１６をキャップ部材３０の開口３５からキャップ部材３０の内部に挿入し、導体露出部１６の先端１６Ｂをキャップ部材３０の端面３１の内面に突き当てる。これにより、導体露出部１６の全長がキャップ部材３０によって覆われたキャップ付電線２が形成される。 First, as shown in FIG. 7, the conductor exposed portion 16 of the electric wire 10 is inserted into the cap member 30 through the opening 35 of the cap member 30, and the tip 16 B of the conductor exposed portion 16 is placed on the inner surface of the end surface 31 of the cap member 30. Strike. Thereby, the capped electric wire 2 in which the entire length of the conductor exposed portion 16 is covered with the cap member 30 is formed.

その後、図８に示すように、キャップ付電線２のキャップ部材３０が端子２０の電線接続部（導体圧着部２１と被覆材圧着部２５）に配置されるようにキャップ付電線２を端子２０上に載置してこれらを圧着装置にセットし、キャップ付電線２に端子２０を圧着することによって端子付電線１を製造する。より具体的には、電線１０に装着されているキャップ部材３０の端面３１が端子２０の導体圧着部２１よりも＋Ｘ方向側に配置され、キャップ部材３０の開口３５が端子２０の被覆材圧着部２５よりも−Ｘ方向側に配置されるように、キャップ付電線２を端子２０上に載置した後、圧着装置によって、このキャップ付電線２に対して、端子２０の導体圧着部２１と被覆材圧着部２５とをそれぞれ圧着し、端子付電線１を製造する。 Thereafter, as shown in FIG. 8, the cap-equipped electric wire 2 is placed on the terminal 20 so that the cap member 30 of the cap-equipped electric wire 2 is disposed at the electric wire connection portion (conductor crimping portion 21 and covering material crimping portion 25) of the terminal 20. The terminal-attached electric wire 1 is manufactured by placing them on a crimping device and crimping the terminal 20 on the cap-equipped electric wire 2. More specifically, the end surface 31 of the cap member 30 attached to the electric wire 10 is arranged on the + X direction side of the conductor crimping portion 21 of the terminal 20, and the opening 35 of the cap member 30 is the covering material crimping portion of the terminal 20. After placing the capped electric wire 2 on the terminal 20 so as to be arranged on the −X direction side from 25, the conductor crimping portion 21 and the covering of the terminal 20 are covered with the capped electric wire 2 by a crimping device. The material crimping portions 25 are respectively crimped to manufacture the terminal-attached electric wire 1.

本製造方法では、２回の加締め工程によって、端子２０の導体圧着部２１をキャップ付電線２に圧着する。具体的には、キャップ部材３０の外周から導体露出部１６を加締めるように、導体圧着部２１全体で圧着する第１の加締め工程と、第１の加締め工程の後に、導体圧着部２１の中間部分をさらに強い力で圧着する第２の加締め工程とを含む。これにより、強圧着部２４と該強圧着部２４の両側に位置する通常圧着部２２，２３とを含む導体圧着部２１が形成される（図２及び図３参照）。 In this manufacturing method, the conductor crimping part 21 of the terminal 20 is crimped to the electric wire 2 with a cap by two caulking steps. Specifically, after the first caulking step and the first caulking step, the conductor crimping portion 21 is crimped on the entire conductor crimping portion 21 so that the conductor exposed portion 16 is caulked from the outer periphery of the cap member 30. And a second caulking step for crimping the intermediate portion with a stronger force. Thereby, the conductor crimping | compression-bonding part 21 containing the normal crimping parts 22 and 23 located in the both sides of this strong crimping part 24 and this strong crimping | compression-bonding part 24 is formed (refer FIG.2 and FIG.3).

そして、第２の加締め工程では、導体露出部１６及びキャップ部材３０の圧縮率が、「第２の加締め工程後の断面積／第１の加締め工程前の断面積」の比率で６０〜７０％の範囲になるように、導体圧着部２１の中間部分を強圧着し、強圧着部２４を形成する（図５）。このような強圧着により、キャップ部材３０及びキャップ部材３０内の導体１５が強く押しつぶされ、これにより、キャップ部材３０を形成するアルミニウム及び導体１５の素線を形成するアルミニウムが大きく展延してアルミニウムの酸化被膜が破壊され、金属融合する。その結果、導体１５を構成する素線間の導通が図られるとともに、導体１５とキャップ部材３０との間の導通が図られる。 In the second caulking step, the compression ratio of the conductor exposed portion 16 and the cap member 30 is 60 in a ratio of “cross-sectional area after the second caulking step / cross-sectional area before the first caulking step”. The intermediate part of the conductor crimping part 21 is strongly crimped so as to be in the range of ˜70%, thereby forming the strong crimping part 24 (FIG. 5). By such strong pressure bonding, the cap member 30 and the conductor 15 in the cap member 30 are strongly crushed, whereby the aluminum forming the cap member 30 and the aluminum forming the strands of the conductor 15 are greatly expanded to form aluminum. The oxide film is destroyed and the metal is fused. As a result, conduction between the strands constituting the conductor 15 is achieved, and conduction between the conductor 15 and the cap member 30 is achieved.

また第２の加締め工程において、導体圧着部２１の中間部分を強圧着して強圧着部２４を形成することで、強圧着の際に導体圧着部２１のエッジ部分２９がキャップ部材３０に食い込んでキャップ部材３０が破損してしまうことが防止される。 In the second caulking step, the intermediate portion of the conductor crimping portion 21 is strongly crimped to form the strong crimping portion 24, so that the edge portion 29 of the conductor crimping portion 21 bites into the cap member 30 during strong crimping. This prevents the cap member 30 from being damaged.

なお、上述の実施形態では、端子２０が導体圧着部２１と被覆材圧着部２５とを有し、被覆材圧着部２５がキャップ部材３０の外周から絶縁材被覆部１１を加締めることで、キャップ部材３０の開口３５を塞いでいるが、これに限定されるものではない。例えば、絶縁材被覆部１１のキャップ部材３０で覆われてない部分を被覆材圧着部２５で加締めてもよいし、被覆材圧着部２５を有さない端子２０を使用してもよい。このような構成では、キャップ部材の開口から水が浸入する可能性があるが、キャップ部材が導体（素線）と同じ材料から形成され、導体（素線）には異種金属が接触しないため、上述の実施形態と同様に、ガルバニック腐食による素線切れを防止することができる。 In the above-described embodiment, the terminal 20 includes the conductor crimping portion 21 and the covering material crimping portion 25, and the covering material crimping portion 25 crimps the insulating material covering portion 11 from the outer periphery of the cap member 30, thereby Although the opening 35 of the member 30 is blocked, the present invention is not limited to this. For example, a portion of the insulating material covering portion 11 that is not covered with the cap member 30 may be crimped by the covering material crimping portion 25, or the terminal 20 that does not have the covering material crimping portion 25 may be used. In such a configuration, water may enter from the opening of the cap member, but the cap member is formed of the same material as the conductor (element wire), and the dissimilar metal does not contact the conductor (element wire). Similar to the above-described embodiment, it is possible to prevent wire breakage due to galvanic corrosion.

また、上述の実施形態では、キャップ部材３０が導体露出部１６の全長を覆っているが、これに限定されるものではない。例えば、電線の導体露出部の全長をキャップ部材が覆ってなくてもよい。このような構成では、導体露出部が被水する可能性があるが、端子はキャップ部材の外周から加締められているため導体露出部に端子が直接接触していない。そのため、導体（素線）には異種金属が接触せず、ガルバニック腐食による素線切れを防止することができる。 Moreover, in the above-mentioned embodiment, although the cap member 30 has covered the full length of the conductor exposed part 16, it is not limited to this. For example, the cap member may not cover the entire length of the conductor exposed portion of the electric wire. In such a configuration, there is a possibility that the exposed conductor portion will get wet, but since the terminal is crimped from the outer periphery of the cap member, the terminal is not in direct contact with the exposed conductor portion. Therefore, a dissimilar metal does not contact a conductor (element wire), and the strand break by galvanic corrosion can be prevented.

なお、他の実施形態として、キャップ部材（アルミニウム又はアルミニウム合金）の外周面にスズめっき層を形成してもよい。スズはアルミニウムに比べて銅との間のイオン化傾向の差が小さいため、キャップ部材の外周から端子（銅）を圧着接続する端子付き電線において、キャップ部材の表面にガルバニック腐食が生じることが抑制され、端子付電線１の耐久性が向上する。 As another embodiment, a tin plating layer may be formed on the outer peripheral surface of the cap member (aluminum or aluminum alloy). Since tin has a smaller difference in ionization tendency from copper than aluminum, in a wire with a terminal that crimps and connects a terminal (copper) from the outer periphery of the cap member, the occurrence of galvanic corrosion on the surface of the cap member is suppressed. The durability of the terminal-attached electric wire 1 is improved.

これまで本発明の好ましい実施形態について説明したが、本発明は上述の実施形態に限定されず、その技術的思想の範囲内において種々異なる形態にて実施されてよいことは言うまでもない。 The preferred embodiments of the present invention have been described above, but the present invention is not limited to the above-described embodiments, and it goes without saying that the present invention may be implemented in various forms within the scope of the technical idea.

なお、本明細書において使用した位置関係を示す用語は、図示した実施形態との関連において使用されているのであり、これに限定されるものではない。 In addition, the term which shows the positional relationship used in this specification is used in connection with illustrated embodiment, It is not limited to this.

１端子付電線
２キャップ付電線
１０電線
１１絶縁材被覆部
１５導体
１６導体露出部
２０端子
２１導体圧着部
２１Ａ，２１Ｂ導体圧着片
２２，２３通常圧着部
２４強圧着部
２５被覆材圧着部
２５Ａ，２５Ｂ被覆圧着片
２６底部
２７ボックス部
３０キャップ部材
３１端面
３５開口 DESCRIPTION OF SYMBOLS 1 Electric wire with a terminal 2 Electric wire with a cap 10 Electric wire 11 Insulation material covering part 15 Conductor 16 Conductor exposed part 20 Terminal 21 Conductor crimping part 21A, 21B Conductor crimping piece 22,23 Normal crimping part 24 Strong crimping part 25 Covering material crimping part 25A, 25B Coated crimping piece 26 Bottom 27 Box part 30 Cap member 31 End face 35 Opening

Claims

アルミニウムまたはアルミニウム合金からなる複数の素線から構成される導体に絶縁材が被覆され、導体露出部と絶縁材被覆部とを含む電線と、
前記素線と同じ材料からなり、前記導体露出部の外周を覆うキャップ部材と、
前記素線と異なる材料からなり、前記キャップ部材の外周から前記導体露出部を加締める導体圧着部を有する端子と、
を備え、
前記導体圧着部には、前記導体露出部及び前記キャップ部材の圧縮率が、加締め後の断面積／加締め前の断面積の比率で６０〜７０％の範囲となるように、前記導体露出部及び前記キャップ部材を加締める強圧着部が含まれることを特徴とする端子付電線。 An electric conductor comprising a conductor composed of a plurality of strands made of aluminum or an aluminum alloy and coated with an insulating material, including an exposed conductor portion and an insulating material covering portion;
A cap member made of the same material as the strand and covering the outer periphery of the conductor exposed portion;
A terminal made of a material different from the element wire, and having a conductor crimping portion for caulking the conductor exposed portion from the outer periphery of the cap member;
With
In the conductor crimping portion, the conductor exposure portion and the cap member have a compression ratio such that the ratio of the cross-sectional area after crimping / the cross-sectional area before crimping is in the range of 60 to 70%. The terminal-attached electric wire is characterized in that a strong pressure-bonding part for crimping the part and the cap member is included.

前記端子は、前記キャップ部材の外周から前記絶縁材被覆部を加締める被覆材圧着部を更に有することを特徴とする請求項１に記載の端子付電線。 The electric wire with a terminal according to claim 1, wherein the terminal further includes a covering material crimping portion for caulking the insulating material covering portion from an outer periphery of the cap member.

前記強圧着部は、前記導体圧着部の中間部分に形成されていることを特徴とする請求項１または２に記載の端子付電線。 The terminal-attached electric wire according to claim 1 or 2, wherein the strong crimping portion is formed at an intermediate portion of the conductor crimping portion.

前記キャップ部材の外周面にスズめっき層が形成されていることを特徴とする請求項１から３のいずれか一項に記載の端子付電線。 The electric wire with a terminal according to any one of claims 1 to 3, wherein a tin plating layer is formed on an outer peripheral surface of the cap member.