JP2020035635A - Terminal-equipped wire and manufacturing method thereof - Google Patents
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本発明は例えば自動車等に用いられる端子付き電線およびその製造方法に関するものである。 The present invention relates to a terminal-equipped electric wire used for, for example, an automobile, and a method for manufacturing the same.
従来、自動車、ＯＡ機器、家電製品等の分野では、電力線や信号線として、電気導電性に優れた銅系材料からなる電線が使用されている。特に、自動車分野においては、車両の高性能化、高機能化が急速に進められており、車載される各種電気機器や制御機器が増加している。したがって、これに伴い、使用される端子付き電線も増加する傾向にある。 2. Description of the Related Art Conventionally, in the fields of automobiles, office automation equipment, home electric appliances, and the like, electric wires made of a copper-based material having excellent electric conductivity have been used as power lines and signal lines. In particular, in the field of automobiles, high performance and high functionality of vehicles are being rapidly promoted, and various electric devices and control devices mounted on vehicles are increasing. Accordingly, the number of electric wires with terminals used tends to increase accordingly.
一方、環境問題が注目される中、自動車の軽量化が要求されている。したがって、ワイヤハーネスの使用量増加に伴う重量増加が問題となる。このため、従来使用されている銅線に代えて、軽量なアルミニウム電線が注目されている。 On the other hand, with the focus on environmental issues, there is a demand for lighter vehicles. Therefore, there is a problem of an increase in weight due to an increase in the use amount of the wire harness. For this reason, attention has been paid to lightweight aluminum electric wires in place of conventionally used copper wires.
ここで、このような電線同士を接続する際や機器類等の接続部においては、接続用端子が用いられる。しかし、アルミニウム電線を用いた端子付き電線であっても、接続部の信頼性等のため、端子部には、電気特性に優れる銅が使用される場合がある。このような場合には、アルミニウム電線と銅製の端子とが接合されて使用される。 Here, a connection terminal is used at the time of connecting such electric wires or at a connection portion of devices or the like. However, even in the case of an electric wire with a terminal using an aluminum electric wire, copper having excellent electric characteristics may be used for the terminal portion in some cases due to the reliability of the connection portion. In such a case, an aluminum electric wire and a copper terminal are used by being joined.
しかし、異種金属を接触させると、標準電極電位の違いから、いわゆる電食が発生する恐れがある。特に、アルミニウムと銅との標準電極電位差は大きいため、接触部への水の飛散や結露等の影響により、電気的に卑であるアルミニウム側の腐食が進行する。このため、接続部における電線と端子との接続状態が不安定となり、接触抵抗の増加や線径の減少による電気抵抗の増大、更には断線が生じて電装部品の誤動作、機能停止に至る恐れがある。このため、電線と端子との接続部を防食材で被覆する方法が提案されている。 However, when different metals are brought into contact with each other, so-called electrolytic corrosion may occur due to a difference in the standard electrode potential. In particular, since the standard electrode potential difference between aluminum and copper is large, corrosion of the electrically-noble aluminum side progresses due to the effects of water scattering and dew condensation on the contact portion. For this reason, the connection state between the electric wire and the terminal in the connection portion becomes unstable, and the electric resistance increases due to an increase in the contact resistance and a decrease in the wire diameter. is there. For this reason, a method has been proposed in which the connection between the electric wire and the terminal is covered with an anticorrosive material.
例えば、防食材の粘度を下げることで、効率よく導線の素線間等に防食材を浸透させるために、製造工程において、樹脂を加温して一時的に低粘度として、防食材を塗布する方法が提案されている（特許文献１）。 For example, by lowering the viscosity of the anticorrosion material, in order to efficiently penetrate the anticorrosion material between the wires of the conductive wire, in the manufacturing process, the resin is heated to temporarily reduce the viscosity, and the anticorrosion material is applied. A method has been proposed (Patent Document 1).
図５（ａ）は、導線圧着部１０７において、導線１１３を圧着した状態を示す概念図である。導線圧着部１０７を金型で圧縮して導線１１３を圧着すると、その先端部には、導線１１３との間に隙間１０１が生じる場合がある。 FIG. 5A is a conceptual diagram showing a state in which the conductor 113 is crimped in the conductor crimping part 107. When the conductor crimping portion 107 is compressed with a mold to crimp the conductor 113, a gap 101 may be formed between the leading end and the conductor 113.
この状態で、図５（ｂ）に示すように、導線圧着部１０７の先端から露出する導線１１３を覆うように防食材１１７を塗布すると、発明者らは、図５（ｃ）に示すように、この隙間１０１や導線１１３の素線間に残っていた空気によって、気泡１０２が生じるおそれがあることを見出した。このような気泡１０２が生じると、この部位の防食材１１７の厚みが薄くなり、硬化時等において防食材１１７が破裂して導線１１３が露出するおそれがある。このため、防食性が低下するという問題がある。 In this state, as shown in FIG. 5B, when the anticorrosion material 117 is applied so as to cover the conductive wire 113 exposed from the tip of the conductive wire crimping portion 107, the inventors can obtain the structure as shown in FIG. 5C. It has been found that air bubbles 102 may be generated by the air remaining between the gap 101 and the strands of the conductive wire 113. When such bubbles 102 are generated, the thickness of the anticorrosion material 117 at this portion becomes thin, and the anticorrosion material 117 may rupture at the time of curing or the like, and the conductive wire 113 may be exposed. For this reason, there is a problem that the anticorrosion property is reduced.
これに対し、特許文献１のように防食材を低粘度とすることで、気泡を抜けやすくする方法はあるが、特許文献１のように粘度調整を行うためには、環境温度を調整する追加設備が必要となり、製造工程が長くなるなどコスト増を招く。 On the other hand, there is a method of easily removing air bubbles by making the anticorrosive material low in viscosity as in Patent Literature 1. However, in order to adjust the viscosity as in Patent Literature 1, an additional method of adjusting the environmental temperature is required. Equipment is required, resulting in an increase in cost such as a long manufacturing process.
本発明は、このような問題に鑑みてなされたもので、製造性を損なうことなく、導線圧着部から露出する導線を確実に防食材で覆い、防食性を確保することが可能な端子付き電線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 such a problem, and without impairing manufacturability, an electric wire with a terminal that can surely cover a conductor exposed from a conductor crimping portion with an anticorrosion material and ensure anticorrosion properties. It is an object of the present invention to provide a method for producing the same.
前述した目的を達するために本発明は、被覆導線と端子とが接続される端子付き電線の製造方法であって、被覆導線の先端部の被覆部を除去し、導線露出部を形成する電線加工工程と、前記導線露出部を、端子の導線圧着部で圧着して、導線と前記端子とを接続する電線・端子接続工程と、前記導線圧着部の先端から露出する前記導線の出代部に対し、前記導線圧着部を避けるように防食材を塗布する第１防食材塗布工程と、前記第１防食材塗布工程で塗布した防食材を、前記導線の先端部近傍に浸透させる防食材浸透工程と、前記導線の出代部に防食材を浸透させた後、前記第１防食材塗布工程で塗布した防食材を覆うようにさらに防食材を塗布する第２防食材塗布工程と、塗布された防食材を硬化させる樹脂硬化工程と、を具備することを特徴とする端子付き電線の製造方法である。 In order to achieve the above-mentioned object, the present invention relates to a method of manufacturing a terminal-attached electric wire in which a covered conductor and a terminal are connected, the method comprising: removing a covering portion at a tip portion of the covered conductor to form a conductor exposed portion. A wire / terminal connecting step of crimping the conductor exposed portion with a conductor crimping portion of a terminal to connect the conductor and the terminal, and a protruding portion of the conductor exposed from a tip of the conductor crimping portion. On the other hand, a first anticorrosion material application step of applying an anticorrosion material so as to avoid the conductor crimping portion, and an anticorrosion material infiltration step of permeating the anticorrosion material applied in the first anticorrosion material application step near the tip of the conductor. A second anticorrosive material applying step of further applying an anticorrosive material so as to cover the anticorrosive material applied in the first anticorrosive material applying step, after the anticorrosive material has been permeated into the protruding portion of the conductive wire; A resin curing step of curing the anticorrosive material. It is a manufacturing method of the electric wire with terminal, characterized.
前記防食材浸透工程と並行して、前記導線の出代部以外の部位であって、前記導線圧着部を覆うように、防食材を塗布する第３防食材塗布工程を有してもよい。 In parallel with the anticorrosion material infiltration step, a third anticorrosion material application step of applying an anticorrosion material to a portion other than the protruding portion of the conductor and covering the conductor crimping portion may be provided.
前記第１防食材塗布工程の後に、前記導線の出代部の前方の防食材を仮硬化させる防食材仮硬化工程を含んでもよい。 After the first anticorrosion material applying step, an anticorrosion material temporary hardening step of temporarily hardening the anticorrosion material in front of the protruding portion of the conductive wire may be included.
本発明によれば、導線圧着部の先端から露出する導線の出代部に対し、導線圧着部を避けるように防食材を塗布するため、導線と導線圧着部との隙間が防食材で覆われることがない。また、導線の素線間等に防食材を浸透させることで、導線の素線間や隙間を防食材で埋めることができるため、気泡が生じることを抑制することができる。このため、気泡に起因した防食性の低下を抑制することができる。 ADVANTAGE OF THE INVENTION According to this invention, since the anticorrosion material is apply | coated to the protruding part of the conductor exposed from the front-end | tip of a conductor crimp part so that a conductor crimp part may be avoided, the clearance gap between a conductor and a conductor crimp part is covered with an anticorrosion material. Nothing. In addition, by penetrating the anticorrosive material between the wires of the conductive wire or the like, the space between the wires of the conductive wire or the gap can be filled with the anticorrosive material, so that generation of bubbles can be suppressed. For this reason, it is possible to suppress a decrease in the anticorrosion property caused by the bubbles.
また、防食材を浸透させている間に、導線の出代部以外の部位であって、導線圧着部を覆うように、防食材を塗布することで、防食材の塗布時間を短縮することができる。 In addition, while the anticorrosion material is infiltrated, the anticorrosion material is applied so as to cover the conductor crimping portion at a portion other than the protruding portion of the conductor, thereby shortening the application time of the anticorrosion material. it can.
また、防食材を塗布した後、導線の出代部の前方の防食材を仮硬化させることで、防食材が端子本体側に流出することを抑制することができる。 Further, after the anticorrosion material is applied, the anticorrosion material in front of the protruding portion of the conductive wire is temporarily cured, so that the anticorrosion material can be prevented from flowing out to the terminal body side.
本発明によれば、製造性を損なうことなく、導線圧着部から露出する導線を確実に防食材で覆い、防食性を確保することが可能な端子付き電線の製造方法を提供することができる。 ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the electric wire with a terminal which can cover a conductor exposed from a conductor crimping part reliably with an anticorrosion material and ensure anticorrosion property can be provided, without impairing manufacturability.
以下、図面を参照しながら、本発明の実施形態について説明する。図１は、端子付き電線１０を示す斜視図であり、図２は断面図である。なお、図１は、防食材１７を透視した図である。なお、防食材１７は、後述する第１防食材１７ａ、第２防食材１７ｂ、第３防食材１７ｃの総称である。端子付き電線１０は、端子１と被覆導線１１が接続されて構成される。 Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a perspective view showing an electric wire with terminal 10, and FIG. 2 is a sectional view. FIG. 1 is a perspective view of the anticorrosion material 17. In addition, the anticorrosion material 17 is a general term for a first anticorrosion material 17a, a second anticorrosion material 17b, and a third anticorrosion material 17c described later. The electric wire with terminal 10 is configured by connecting the terminal 1 and the covered conductor 11.
被覆導線１１は、アルミニウムまたはアルミニウム合金製である導線１３と、導線１３を被覆する被覆部１５からなる。すなわち、被覆導線１１は、被覆部１５と、その先端から露出する導線１３とを具備する。導線１３は、例えば、複数の素線が撚り合わせられた撚り線である。 The covered conductor 11 includes a conductor 13 made of aluminum or an aluminum alloy, and a covering portion 15 covering the conductor 13. That is, the covered conductor 11 includes the covered portion 15 and the conductor 13 exposed from the tip. The conducting wire 13 is, for example, a stranded wire in which a plurality of strands are twisted.
端子１は、オープンバレル型であり、銅または銅合金製である。端子１には被覆導線１１が接続される。端子１は、端子本体３と圧着部５とがトランジション部４を介して連結されて構成される。圧着部５と端子本体３の間に位置するトランジション部４は、上方が開口する。 The terminal 1 is an open barrel type and is made of copper or a copper alloy. The terminal 1 is connected to a covered conductor 11. The terminal 1 is configured by connecting a terminal body 3 and a crimping portion 5 via a transition portion 4. The upper part of the transition part 4 located between the crimping part 5 and the terminal body 3 is open.
端子本体３は、所定の形状の板状素材を、断面が矩形の筒体に形成したものである。端子本体３は、内部に、板状素材を矩形の筒体内に折り込んで形成される弾性接触片を有する。端子本体３は、前端部から雄型端子などが挿入されて接続される。なお、以下の説明では、端子本体３が、雄型端子等の挿入タブ（図示省略）の挿入を許容する雌型端子である例を示すが、本発明において、この端子本体３の細部の形状は特に限定されない。例えば、雌型の端子本体３に代えて例えば雄型端子の挿入タブを設けてもよい。また、端子本体３は、雄雌の嵌合タイプではなく、一般的な丸形端子や先開形端子であってもよい。 The terminal body 3 is formed by forming a plate-shaped material having a predetermined shape into a tubular body having a rectangular cross section. The terminal body 3 has an elastic contact piece formed by folding a plate-shaped material into a rectangular cylinder inside. The terminal body 3 is connected by inserting a male terminal or the like from the front end. In the following description, an example is shown in which the terminal body 3 is a female terminal that allows insertion of an insertion tab (not shown) such as a male terminal. However, in the present invention, the shape of the details of the terminal body 3 is described. Is not particularly limited. For example, an insertion tab for a male terminal may be provided instead of the female terminal body 3. Further, the terminal body 3 is not a male and female fitting type, but may be a general round terminal or open-ended terminal.
圧着部５は、被覆導線１１と圧着される部位であり、圧着前においては、端子１の長手方向に垂直な断面形状が略Ｕ字状のバレル形状を有する。端子１の圧着部５は、被覆導線１１の先端側に被覆部１５から露出する導線１３を圧着する導線圧着部７と、被覆導線１１の被覆部１５を圧着する被覆圧着部９と、導線圧着部７と被覆圧着部９の間のバレル間部８からなる。 The crimping part 5 is a part to be crimped to the covered conductor 11, and has a barrel shape in which a cross section perpendicular to the longitudinal direction of the terminal 1 is substantially U-shaped before crimping. The crimping part 5 of the terminal 1 includes a conductor crimping part 7 for crimping the conductor 13 exposed from the covering part 15 on the tip end side of the covering conductor 11, a covering crimping part 9 for crimping the covering part 15 of the covering conductor 11, and a conductor crimping part. It consists of an inter-barrel section 8 between the section 7 and the covering crimp section 9.
導線圧着部７の内面の一部には、幅方向（長手方向に垂直な方向）に、図示を省略したセレーションが設けられる。このようにセレーションを形成することで、導線１３を圧着した際に、導線１３の表面の酸化膜を破壊しやすく、また、導線１３との接触面積を増加させることができる。 Serrations (not shown) are provided in a part of the inner surface of the wire crimping portion 7 in the width direction (direction perpendicular to the longitudinal direction). By forming the serrations in this manner, when the conductor 13 is crimped, the oxide film on the surface of the conductor 13 can be easily broken, and the contact area with the conductor 13 can be increased.
被覆導線１１の先端は、被覆部１５が剥離され、内部の導線１３が露出する。被覆導線１１の被覆部１５は、端子１の被覆圧着部９によって圧着される。また、被覆部１５が剥離されて露出する導線１３は、導線圧着部７により圧着される。導線圧着部７において、導線１３と端子１とが電気的に接続される。なお、被覆部１５の端面は、被覆圧着部９と導線圧着部７の間のバレル間部８に位置する。 The covering portion 15 is peeled off from the tip of the covered conductor 11, and the inside conductor 13 is exposed. The covering portion 15 of the covering conductor 11 is crimped by the covering crimping portion 9 of the terminal 1. The conductive wire 13 from which the covering portion 15 is peeled off and exposed is crimped by the conductor crimping portion 7. In the wire crimping portion 7, the wire 13 and the terminal 1 are electrically connected. In addition, the end face of the covering portion 15 is located in the inter-barrel portion 8 between the covering crimping portion 9 and the wire crimping portion 7.
本発明では、少なくとも、バレル間部８から導線圧着部７の先端の導線１３が露出する部位までが防食材１７で覆われている。したがって、導線１３は、防食材１７によって外部に露出しない。なお、防食材１７は、例えば、アクリレート系の光硬化樹脂である。 In the present invention, at least a portion from the inter-barrel portion 8 to a portion where the conductive wire 13 at the tip of the conductive wire crimping portion 7 is exposed is covered with the anticorrosive material 17. Therefore, the conductive wire 13 is not exposed to the outside by the anticorrosion material 17. The anticorrosion material 17 is, for example, an acrylate-based photocurable resin.
次に、端子付き電線１０の製造方法について説明する。まず、被覆導線１１の先端部の被覆部１５を除去し、導線露出部を形成する（電線加工工程）。次に、導線露出部を、端子１の導線圧着部７で圧着して、導線１３と端子１とを接続する（電線・端子接続工程）。 Next, a method of manufacturing the electric wire with terminal 10 will be described. First, the covering portion 15 at the end of the covered conductor 11 is removed to form a conductor exposed portion (electric wire processing step). Next, the exposed portion of the conductor is crimped by the conductor crimping portion 7 of the terminal 1 to connect the conductor 13 to the terminal 1 (wire / terminal connection step).
次に、図３（ａ）に示すように、導線圧着部７の先端から端子本体３側に露出する導線１３の出代部に対して、例えばディスペンサ等によって第１防食材１７ａを塗布する（第１防食材塗布工程）。この際、第１防食材１７ａは、導線圧着部７を避けるように塗布される。すなわち、導線圧着部７の先端部の上面には、第１防食材１７ａは付着せず、導線１３の出代部のみに接触するように第１防食材１７ａが塗布される。 Next, as shown in FIG. 3A, a first anticorrosion material 17a is applied to a protruding portion of the conductive wire 13 exposed from the distal end of the conductive wire crimping portion 7 toward the terminal body 3 by, for example, a dispenser or the like ( First anticorrosive material application step). At this time, the first anticorrosion material 17a is applied so as to avoid the wire crimping portion 7. That is, the first anticorrosive material 17a is not applied to the upper surface of the distal end portion of the conductive wire crimping portion 7, and the first anticorrosive material 17a is applied so as to be in contact with only the protruding portion of the conductive wire 13.
第１防食材塗布工程の後に、図３（ｂ）に示すように、導線１３の出代部の前方の第１防食材１７ａを部分的に仮硬化させ、仮硬化部１８を形成する（防食材仮硬化工程）。仮硬化部１８は、第１防食材１７ａの端子本体３側の一部に部分的に光を照射することで形成することができる。なお、仮硬化部１８は、完全に硬化していてもよく、完全に硬化していなくてもよい。いずれにせよ、導線１３と付着している部分の第１防食材１７ａに流動性が残ればよい。 After the first anticorrosive material application step, as shown in FIG. 3B, the first anticorrosive material 17a in front of the protruding portion of the conductive wire 13 is partially pre-cured to form a pre-cured portion 18 (anti-corrosion). Food temporary curing process). The temporary hardened portion 18 can be formed by partially irradiating a part of the first anticorrosive material 17a on the terminal main body 3 side. The temporary curing section 18 may be completely cured, or may not be completely cured. In any case, it is sufficient that fluidity remains in the portion of the first anticorrosive material 17a attached to the conductive wire 13.
また、防食材仮硬化工程は、必要に応じ行えばよく、後述する防食材浸透工程において、第１防食材１７ａの端子本体３への流出が少ない場合には不要である。例えば、第１防食材１７ａの塗布時の粘度が１０００ｍＰａ・ｓ以下である場合に、防食材仮硬化工程を行うことが効果的である。 In addition, the anticorrosion material temporary curing step may be performed as needed, and is unnecessary when the outflow of the first anticorrosion material 17a to the terminal body 3 is small in the anticorrosion material infiltration step described later. For example, when the viscosity of the first anticorrosion material 17a at the time of application is 1000 mPa · s or less, it is effective to perform the anticorrosion material temporary curing step.
その後、図３（ｃ）に示すように、第１防食材塗布工程で塗布した第１防食材１７ａを、導線１３の先端部近傍に浸透させる（防食材浸透工程）。この際、第１防食材１７ａは、導線１３の素線間と、導線１３と導線圧着部７の先端部の隙間１２に浸透する。なお、浸透時間は、例えば０．３〜２．４秒が望ましく、より望ましくは１〜２．４秒とする。浸透時間が十分でないと、隙間１２が埋まらずに気泡が生成され、浸透時間が長すぎると、サイクルタイムが長くなりすぎて生産性が悪化する。 Thereafter, as shown in FIG. 3C, the first anticorrosion material 17a applied in the first anticorrosion material application step is made to penetrate into the vicinity of the distal end of the conductive wire 13 (corrosion prevention material permeation step). At this time, the first anticorrosion material 17a penetrates between the strands of the conductor 13 and the gap 12 between the conductor 13 and the tip of the conductor crimping portion 7. The permeation time is, for example, preferably from 0.3 to 2.4 seconds, and more preferably from 1 to 2.4 seconds. If the permeation time is not sufficient, the gap 12 will not be filled, and air bubbles will be generated. If the permeation time is too long, the cycle time will be too long and the productivity will deteriorate.
防食材浸透工程おいて、導線１３の出代部に第１防食材１７ａを浸透させた後、第１防食材１７ａを覆うようにさらに第２防食材を塗布し（第２防食材塗布工程）、導線圧着部７の先端部において、十分な防食材の厚みを確保する。この際、第２防食材は、第１防食材１７ａと同一の粘度の樹脂を用いてもよいが、第１防食材１７ａよりも粘度の高い樹脂を用いてもよい。 In the anticorrosion material infiltration step, after the first anticorrosion material 17a is made to penetrate into the protruding portion of the conductive wire 13, a second anticorrosion material is further applied so as to cover the first anticorrosion material 17a (second anticorrosion material application step). In addition, a sufficient thickness of the anticorrosion material is ensured at the distal end of the wire crimping portion 7. At this time, as the second anticorrosion material, a resin having the same viscosity as that of the first anticorrosion material 17a may be used, or a resin having a higher viscosity than the first anticorrosion material 17a may be used.
なお、前述したように、防食材浸透工程が完了しないと、第２防食材を塗布することができないため、その間は手待ち時間となる。このため、図４（ａ）に示すように、防食材浸透工程と並行して、導線１３の出代部以外の部位であって、バレル間部８から導線圧着部７を覆うように、第３防食材１７ｃを塗布してもよい（第３防食材塗布工程）。このようにすることで、防食材浸透工程における待ち時間を有効に利用して他の部位に防食材を塗布することができる。 As described above, since the second anticorrosive material cannot be applied until the anticorrosive material infiltration step is completed, a hand waiting time is required during that time. For this reason, as shown in FIG. 4A, in parallel with the anticorrosive material infiltration step, a portion other than the protruding portion of the conductor 13, and covering the conductor crimping portion 7 from the inter-barrel portion 8, is formed. A third anticorrosion material 17c may be applied (third anticorrosion material application step). In this way, the anticorrosion material can be applied to other parts by effectively utilizing the waiting time in the anticorrosion material infiltration step.
この場合には、図４（ｂ）に示すように、第３防食材１７ｃを塗布した後であって、防食材浸透工程が完了した後に第２防食材１７ｂを導線圧着部７の先端部近傍に塗布し、導線圧着部７の先端部近傍の防食材１７の厚みを確保する。 In this case, as shown in FIG. 4B, after the third anticorrosion material 17c is applied, and after the anticorrosion material infiltration step is completed, the second anticorrosion material 17b is placed near the distal end of the wire crimping portion 7. To secure the thickness of the anticorrosion material 17 near the tip of the wire crimping portion 7.
最後に、塗布された防食材１７（第１防食材１７ａ、第２防食材１７ｂ、第３防食材１７ｃ）に光を照射して完全に硬化させる（樹脂硬化工程）。以上により、端子付き電線１０を得ることができる。 Finally, the applied anticorrosion material 17 (first anticorrosion material 17a, second anticorrosion material 17b, third anticorrosion material 17c) is irradiated with light to be completely cured (resin curing step). Thus, the electric wire with terminal 10 can be obtained.
なお、本発明において、防食材１７を塗布するとは、防食材１７の液滴を対象部に接触させる方法や、防食材１７の液滴を供給部から打ち出して（滴下させて）対象部に付着させる方法など、対象部に防食材１７が付着した状態を得る方法の全てを含むものとする。例えば、防食材１７の液滴を対象部に対して、メカニカルディスペンサで接触させて塗布してもよく、ジェットディスペンサで供給部から打ち出して塗布してもよい。 In the present invention, the application of the anticorrosion material 17 means that the droplets of the anticorrosion material 17 are brought into contact with the target portion, or the droplets of the anticorrosion material 17 are ejected from the supply section (dropped) and adhere to the target portion. The method includes all methods for obtaining a state in which the anticorrosion material 17 is attached to the target portion, such as a method for causing the anticorrosion material 17 to adhere to the target portion. For example, the liquid droplets of the anticorrosion material 17 may be applied to the target portion by bringing the liquid droplets into contact with a mechanical dispenser, or may be applied from a supply portion by a jet dispenser.
また、各工程における防食材１７の塗布は、一か所ではなく、複数個所であってもよい。例えば、第１防食材塗布工程において、導線圧着部７の上部にかからず、導線１３の先端部にかかるように複数個所に第１防食材１７ａを塗布してもよい。 Further, the application of the anticorrosion material 17 in each step may be performed at a plurality of places instead of one place. For example, in the first anticorrosion material application step, the first anticorrosion material 17a may be applied to a plurality of locations so as not to cover the top portion of the conductor crimping portion 7 but to cover the tip of the conductor 13.
なお、第１防食材１７ａ、第２防食材１７ｂ及び第３防食材１７ｃは、それぞれの形成タイミングが異なるため、その境界を、断面研磨後に光学顕微鏡や偏光顕微鏡で識別が可能である。 Since the first anticorrosion material 17a, the second anticorrosion material 17b, and the third anticorrosion material 17c have different formation timings, their boundaries can be identified by an optical microscope or a polarizing microscope after section polishing.
以上説明したように、本実施形態によれば、第１防食材１７ａを導線圧着部７の上部にかからないように塗布するため、導線圧着部７と導線１３との隙間１２に溜まっていた空気による気泡の発生を抑制することができる。また、第２防食材１７ｂを塗布する前に十分に浸透時間を確保するため、第２防食材１７ｂを塗布した際の気泡の発生も抑制することができるとともに、第２防食材１７ｂによって導線圧着部７の先端部近傍の防食材１７の厚みを確保することができる。 As described above, according to the present embodiment, since the first anticorrosive material 17a is applied so as not to cover the upper part of the wire crimping portion 7, the first anticorrosive material 17a is formed by the air accumulated in the gap 12 between the wire crimping portion 7 and the wire 13. Generation of air bubbles can be suppressed. In addition, in order to sufficiently secure the penetration time before applying the second anticorrosive material 17b, it is possible to suppress the generation of air bubbles when the second anticorrosive material 17b is applied, and to crimp the lead wire using the second anticorrosive material 17b. The thickness of the anticorrosion material 17 near the distal end of the portion 7 can be ensured.
なお、このような効果は、特に、電線径の小さい場合に有効である。例えば、０．３ｓｑ〜２．５ｓｑの電線の場合には、隙間１２に樹脂が浸透しにくく、気泡も抜けにくいが、上記の方法によれば、気泡の発生を抑制することができる。 Such an effect is particularly effective when the diameter of the electric wire is small. For example, in the case of a 0.3 sq to 2.5 sq electric wire, the resin hardly penetrates into the gap 12 and the air bubbles hardly escape, but according to the above method, the generation of air bubbles can be suppressed.
また、第１防食材塗布工程の後に、第１防食材１７ａを仮硬化させることで、第１防食材１７ａが端子本体３側に流れてしまい、十分に第１防食材１７ａを導線１３側に浸透させることができなくなることを抑制することができる。 In addition, after the first anticorrosive material application step, the first anticorrosive material 17a is temporarily cured, so that the first anticorrosive material 17a flows toward the terminal body 3 and the first anticorrosive material 17a is sufficiently transferred to the conductor 13 side. It is possible to suppress the inability to infiltrate.
また、防食材浸透工程と並行して、第３防食材１７ｃを塗布することで、浸透時間を有効に利用し、タクトタイムを短縮することができる。 Further, by applying the third anticorrosion material 17c in parallel with the anticorrosion material permeation step, the permeation time can be effectively used, and the tact time can be reduced.
浸透時間と防食材の粘度等の条件を調整して、各種の端子付き電線を製造し、各種の評価を行った。防食材としては、紫外線硬化性のアクリレート系樹脂を用いた。第１防食材塗布工程→第２防食材塗布工程→樹脂硬化工程を行い、硬化後の浸透性（気泡の有無）と、膜厚について外観を確認し、導線部分の樹脂の膜厚が５０μｍ以上のものを合格とした。また、製造にかかる時間について評価した。 By adjusting the conditions such as the penetration time and the viscosity of the anticorrosive material, various types of electric wires with terminals were manufactured, and various evaluations were made. As the anticorrosion material, an ultraviolet curable acrylate resin was used. First anticorrosive material application step → Second anticorrosive material application step → Resin curing step, and confirm the appearance of the cured resin (with or without air bubbles) and the film thickness. Passed. The time required for production was evaluated.
各条件において、１０個のサンプルを作成し、上記の評価を行った。この際、１０個全てが基準をクリアしたものを○とし、合格数が１〜９個であったものを△とし、全て不合格であった物を×とした。浸透性、膜厚および目標タクトの全てについて評価し、その最低の評価を当該条件の評価として表１に示した。 Under each condition, 10 samples were prepared and the above evaluation was performed. At this time, those in which all of the 10 samples passed the standard were rated as ○, those in which the number of passed samples was 1 to 9 were rated as Δ, and those in which all the samples failed were rated as ×. All of the permeability, the film thickness, and the target tact were evaluated, and the lowest evaluation was shown in Table 1 as the evaluation of the condition.
浸透時間を２．５秒以上とすると、目標とするタクトタイムを超えてしまうため全て不合格となった。一方、浸透時間が０．１秒では、十分に樹脂が浸透せずに気泡が確認された。このため、浸透時間は、０．３〜２．４秒であることが望ましい。 When the permeation time was set to 2.5 seconds or more, all of the samples were rejected because the target tact time was exceeded. On the other hand, when the permeation time was 0.1 second, the resin was not sufficiently permeated, and bubbles were confirmed. For this reason, the permeation time is desirably 0.3 to 2.4 seconds.
また、粘度によっては、浸透時間を長くすることで膜厚不足が見られた。これに対しては、第１防食材の仮硬化工程を追加することで膜厚不足が解消された。 Further, depending on the viscosity, shortage of the film thickness was observed by increasing the permeation time. In response to this, the lack of film thickness was solved by adding a temporary curing step of the first anticorrosive material.
以上、添付図を参照しながら、本発明の実施の形態を説明したが、本発明の技術的範囲は、前述した実施の形態に左右されない。当業者であれば、特許請求の範囲に記載された技術的思想の範疇内において各種の変更例または修正例に想到し得ることは明らかであり、それらについても当然に本発明の技術的範囲に属するものと了解される。 As described above, the embodiments of the present invention have been described with reference to the accompanying drawings. However, the technical scope of the present invention is not affected by the above-described embodiments. It is clear that a person skilled in the art can conceive various changes or modifications within the scope of the technical idea described in the claims, and these naturally fall within the technical scope of the present invention. It is understood to belong.
１………端子
３………端子本体
４………トランジション部
５………圧着部
７………導線圧着部
８………バレル間部
９………被覆圧着部
１０………端子付き電線
１１………被覆導線
１２………隙間
１３………導線
１５………被覆部
１７………防食材
１７ａ………第１防食材
１７ｂ………第２防食材
１７ｃ………第２防食材
１８………仮硬化部
１０１………隙間
１０２………気泡
１０７………導線圧着部
１１３………導線
１１７………防食材
1 Terminal 3 Terminal body 4 Transition part 5 Crimp part 7 Wire crimp part 8 Barrel part 9 Cover crimp part 10 with terminals Electric wire 11 ... Insulated conductor 12 ... Gap 13 ... Conductor 15 ... Coating part 17 ... Corrosion protection material 17a ... First corrosion protection material 17b ... Second corrosion protection material 17c ... 2 Anticorrosion material 18 Temporarily cured portion 101 Gap 102 Air bubble 107 Conductive wire crimping portion 113 Conductive wire 117 Anticorrosive material
Claims (3)
被覆導線の先端部の被覆部を除去し、導線露出部を形成する電線加工工程と、
前記導線露出部を、端子の導線圧着部で圧着して、導線と前記端子とを接続する電線・端子接続工程と、
前記導線圧着部の先端から露出する前記導線の出代部に対し、前記導線圧着部を避けるように防食材を塗布する第１防食材塗布工程と、
前記第１防食材塗布工程で塗布した防食材を、前記導線の先端部近傍に浸透させる防食材浸透工程と、
前記導線の出代部に防食材を浸透させた後、前記第１防食材塗布工程で塗布した防食材を覆うようにさらに防食材を塗布する第２防食材塗布工程と、
塗布された防食材を硬化させる樹脂硬化工程と、
を具備することを特徴とする端子付き電線の製造方法。 A method for manufacturing a terminal-equipped electric wire in which a coated conductor and a terminal are connected,
An electric wire processing step of removing the covering portion at the tip of the covered conductor and forming a conductor exposed portion,
An electric wire / terminal connecting step of crimping the conductor exposed portion with a conductor crimping portion of a terminal to connect the conductor and the terminal,
A first anticorrosion material applying step of applying an anticorrosion material to the protruding portion of the conductor exposed from the tip of the conductor crimping portion so as to avoid the conductor crimping portion,
An anticorrosion material penetrating step of permeating the anticorrosion material applied in the first anticorrosion material application step near the tip of the conductive wire;
A second anticorrosion material applying step of further applying an anticorrosion material so as to cover the anticorrosion material applied in the first anticorrosion material application step after infiltrating the anticorrosion material into the protruding portion of the conductive wire;
A resin curing step of curing the applied anticorrosion material,
A method for manufacturing an electric wire with a terminal, comprising:
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| JP2022118198A (en) | 2022-08-12 |
| JP7421844B2 (en) | 2024-01-25 |
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