JP7421844B2 - Electric wire with terminal and its manufacturing method - Google Patents
Electric wire with terminal and its manufacturing method Download PDFInfo
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- 238000005260 corrosion Methods 0.000 claims description 91
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- 238000002788 crimping Methods 0.000 claims description 69
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Description
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。 TECHNICAL FIELD The present invention relates to an electric wire with a terminal used in, 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。 Conventionally, electric wires made of copper-based materials with excellent electrical conductivity have been used as power lines and signal lines in fields such as automobiles, OA equipment, and home appliances. In particular, in the automobile field, the performance and functionality of vehicles are rapidly increasing, and the number of various electrical devices and control devices mounted on vehicles is increasing. Therefore, along with this, there is a tendency for the number of electric wires with terminals to be used to increase.
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 environmental issues attracting attention, there is a demand for lighter automobiles. Therefore, an increase in weight due to an increase in the amount of wire harness used becomes a problem. For this reason, lightweight aluminum electric wires are attracting attention 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, connection terminals are used when connecting such electric wires to each other or at connection parts of devices and the like. However, even in the case of an electric wire with a terminal using an aluminum electric wire, copper, which has excellent electrical properties, is sometimes used for the terminal part in order to ensure the reliability of the connection part. In such cases, aluminum wires and copper terminals are used together.
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 dissimilar metals are brought into contact, so-called electrolytic corrosion may occur due to the difference in standard electrode potential. In particular, since the standard electrode potential difference between aluminum and copper is large, corrosion on the electrically base aluminum side progresses due to the influence of water splashing and dew condensation on the contact portion. As a result, the connection between the wire and the terminal at the connection point becomes unstable, increasing contact resistance, increasing electrical resistance due to a decrease in wire diameter, and even breaking the wire, which may lead to malfunction or stoppage of electrical components. be. For this reason, a method has been proposed in which the connection portion between the electric wire and the terminal is coated with 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, in the manufacturing process, in order to reduce the viscosity of the anticorrosive and allow the anticorrosion to penetrate between the strands of conductor wires, etc., the resin is heated to temporarily lower the viscosity before being 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 conducting wire 113 is crimped in the conducting wire crimping section 107. When the conducting wire crimping portion 107 is compressed with a mold and the conducting wire 113 is crimped, a gap 101 may be created between the leading end portion and the conducting wire 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. 5(b), the inventors applied corrosion protection 117 to cover the conducting wire 113 exposed from the tip of the conducting wire crimping part 107, as shown in FIG. 5(c). It has been found that air remaining in the gap 101 and between the strands of the conducting wire 113 may cause bubbles 102. When such bubbles 102 are generated, the thickness of the corrosion protection 117 in this area becomes thinner, and there is a risk that the corrosion protection 117 will burst during hardening and the conductive wire 113 will be exposed. For this reason, there is a problem that the corrosion resistance 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 making the anticorrosive material low in viscosity to make it easier for air bubbles to come out, as in Patent Document 1, but in order to adjust the viscosity as in Patent Document 1, it is necessary to adjust the environmental temperature. This requires equipment, lengthens the manufacturing process, and increases costs.
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及びその製造方法を提供することを目的とする。 The present invention has been made in view of these problems, and provides an electric wire with a terminal that can secure corrosion resistance by reliably covering the conductor exposed from the conductor crimping part with corrosion protection without impairing manufacturability. The purpose is to provide a method for producing the same.
前述した目的を達するために第１の発明は、被覆導線と端子とが接続される端子付き電線であって、被覆導線の先端部の被覆部が除去された導線露出部が、前記端子の導線圧着部で圧着されており、前記導線圧着部と前記端子本体との間のトランジション部の開口する側を上方とすると、前記導線圧着部の先端から露出する導線の出代部に対し、前記導線圧着部の上部に付着しないように設けられた第１防食材と、前記第１防食材の少なくとも一部を覆うように前記導線圧着部の少なくとも先端部近傍に設けられ、前記第１防食材との境界が顕微鏡で観察可能な第２防食材と、を具備し、前記第１防食材が、前記導線と前記導線圧着部との隙間に浸透されていることを特徴とする端子付き電線である。 In order to achieve the above-mentioned object, a first invention provides an electric wire with a terminal in which a covered conductor and a terminal are connected, wherein an exposed portion of the conductor from which the coating at the tip of the covered conductor is removed is connected to the conductor of the terminal. The lead wire is crimped at the crimping part, and if the opening side of the transition part between the lead wire crimping part and the terminal main body is set upward, the lead wire is a first corrosion-proofing member provided so as not to adhere to the upper part of the crimping part; and a first corrosion-proofing member provided at least in the vicinity of the tip of the conductor crimping part so as to cover at least a portion of the first corrosion-proofing part; a second corrosion-proofing material whose boundary is observable with a microscope , and the first corrosion-proofing material is infiltrated into a gap between the conductive wire and the conductive wire crimping part. .
前記導線の出代部以外の部位であって、前記導線圧着部の少なくとも一部を覆うように設けられる第３防食材をさらに有し、前記第２防食材が、前記第１防食材及び前記第３防食材の少なくとも一部を覆うように設けられてもよい。 It further includes a third corrosion-proofing part provided so as to cover at least a part of the conductor crimping part at a part other than the protruding part of the conductor, and the second corrosion-proofing part covers the first corrosion-proofing part and the It may be provided so as to cover at least a portion of the third anticorrosive material.
第２の発明は、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、前記導線圧着部の後端側に第３防食材を塗布する第３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防食材塗布工程及び前記第３防食材塗布工程で塗布した防食材の少なくとも一部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、を具備し、前記防食材浸透工程では、所定時間の浸透時間によって、前記第１防食材塗布工程で塗布した防食材を前記導線と前記導線圧着部の先端部との隙間に浸透させるとともに、前記第３防食材塗布工程で塗布した防食材を前記導線と前記導線圧着部の後端部との隙間に浸透させることを特徴とする端子付き電線の製造方法である。
A second invention is a method for manufacturing an electric wire with a terminal in which a covered conductor and a terminal are connected, which includes an electric wire processing step of removing a covering portion at a tip of the covered conductor to form an exposed portion of the conductor;
A wire/terminal connecting step in which the exposed conductor portion is crimped with a conductor crimping portion of a terminal to connect the conductor and the terminal, and the protruding portion of the conductor exposed from the tip of the conductor crimping portion is a first anti-corrosion coating step of applying an anti-corrosion coating to avoid the conductor crimping portion; a third anti-corrosion coating step of applying a third anti-corrosion coating to the rear end side of the conductor crimping portion; and the first anti-corrosion coating step. An anti-corrosion infiltration step in which the anti-corrosion applied in the step is infiltrated into the vicinity of the tip of the conductive wire, and after the anti-corrosion is infiltrated into the protruding portion of the conductor, the first anti-corrosion coating step and the third anti-corrosion coating step are performed. The method further comprises: a second anti-corrosion coating step of further applying an anti-corrosion coating to cover at least a portion of the anti-corrosion coating applied in the anti-corrosion coating step; and a resin curing step of curing the applied anti-corrosion coating; In the penetration step, the corrosion protection applied in the first corrosion protection application step is allowed to penetrate into the gap between the conductive wire and the tip end of the conductor wire crimping part for a predetermined penetration time, and in the third corrosion protection application step. This method of manufacturing an electric wire with a terminal is characterized in that the applied anticorrosive material is allowed to penetrate into a gap between the conductive wire and the rear end portion of the conductive wire crimping portion.
第１、第２の発明によれば、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。 According to the first and second inventions, since the anticorrosion is applied to the protruding part of the conductor exposed from the tip of the conductor crimping part so as to avoid the conductor crimping part, the gap between the conductor and the conductor crimping part is reduced. Not covered with anti-corrosive material. In addition, by infiltrating the corrosion-proofing material between the strands of the conducting wire, the spaces between the strands of the conducting wire and the gaps can be filled with the corrosion-proofing material, thereby suppressing the formation of air bubbles. Therefore, deterioration in corrosion resistance due to bubbles can be suppressed.
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。 Additionally, while the corrosion protection is permeating, it is possible to shorten the application time by applying the corrosion protection to areas other than the protruding portion of the conductor so as to cover the conductor crimping part. can.
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及びその製造方法を提供することができる。 According to the present invention, it is possible to provide an electric wire with a terminal and a method for manufacturing the same, which can reliably cover the conductor exposed from the conductor crimping portion with anticorrosive material and ensure corrosion resistance 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。 Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a perspective view showing an electric wire 10 with a terminal, and FIG. 2 is a sectional view. Note that FIG. 1 is a perspective view of the anticorrosive material 17. Note that the corrosion protection material 17 is a general term for a first corrosion protection material 17a, a second corrosion protection material 17b, and a third corrosion protection material 17c, which will be described later. The electric wire 10 with a terminal is configured by connecting a terminal 1 and a covered conductive wire 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 conductive wire 11 includes a conductive wire 13 made of aluminum or an aluminum alloy, and a covering portion 15 that covers the conductive wire 13. That is, the covered conductive wire 11 includes a covered portion 15 and a conductive wire 13 exposed from the tip thereof. The conducting wire 13 is, for example, a stranded wire in which a plurality of wires are twisted together.
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 of an open barrel type and made of copper or copper alloy. A covered conductor wire 11 is connected to the terminal 1 . The terminal 1 is constructed by connecting a terminal body 3 and a crimp section 5 via a transition section 4 . The transition portion 4 located between the crimp portion 5 and the terminal body 3 is open at the top.
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 main body 3 is formed from a plate-like material having a predetermined shape into a cylindrical body having a rectangular cross section. The terminal main body 3 has an elastic contact piece formed by folding a plate-like material into a rectangular cylinder. A male terminal or the like is inserted into the terminal body 3 from the front end and connected thereto. In the following description, an example will be shown in which the terminal main body 3 is a female terminal that allows insertion of an insertion tab (not shown) such as a male terminal, but in the present invention, the detailed shape of the terminal main body 3 is not particularly limited. For example, instead of the female terminal body 3, an insertion tab for a male terminal may be provided. Further, the terminal main body 3 may be a general round terminal or a tip-open terminal instead of a male-female fitting type.
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 portion 5 is a portion that is crimped to the covered conductive wire 11, and before crimping, the cross section perpendicular to the longitudinal direction of the terminal 1 has a substantially U-shaped barrel shape. The crimping part 5 of the terminal 1 includes a conductor crimping part 7 for crimping the conductor 13 exposed from the sheathing part 15 on the distal end side of the sheathed conductor 11 , a covering crimping part 9 for crimping the sheathing part 15 of the sheathed conductor 11 , and a conductor crimping part 9 for crimping the sheathing part 15 of the sheathed conductor 11 . 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 on a part of the inner surface of the conductive wire crimping portion 7 in the width direction (direction perpendicular to the longitudinal direction). By forming the serrations in this manner, when the conducting wire 13 is crimped, the oxide film on the surface of the conducting wire 13 is easily destroyed, and the contact area with the conducting wire 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 conductive wire 11, and the internal conductive wire 13 is exposed. The covering portion 15 of the covered conducting wire 11 is crimped by the covering crimping portion 9 of the terminal 1 . Further, the conducting wire 13 exposed by peeling off the covering portion 15 is crimped by the conducting wire crimping portion 7 . In the conductor crimping section 7, the conductor 13 and the terminal 1 are electrically connected. Note that the end surface of the covering portion 15 is located in the inter-barrel portion 8 between the covering crimping portion 9 and the conductor 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 the portion from the inter-barrel portion 8 to the 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 due to the corrosion protection 17. Note that the corrosion protection material 17 is, for example, an acrylate-based photocuring 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 for manufacturing the electric wire 10 with a terminal will be described. First, the covering portion 15 at the tip of the covered conducting wire 11 is removed to form an exposed portion of the conducting wire (wire processing step). Next, the exposed portion of the conductor wire is crimped with the conductor crimping portion 7 of the terminal 1 to connect the conductor wire 13 and 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. 3(a), the first anticorrosive material 17a is applied to the protruding portion of the conductor 13 exposed from the tip of the conductor crimping part 7 to the terminal body 3 side using, for example, a dispenser ( (first anticorrosive coating step). At this time, the first anticorrosive material 17a is applied so as to avoid the conductor crimping portion 7. That is, the first anti-corrosion 17a is not attached to the upper surface of the tip of the conductor crimping portion 7, but is applied so as to contact only the protruding portion of the conductor 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 coating step, as shown in FIG. 3(b), the first anticorrosive 17a in front of the protruding portion of the conductive wire 13 is partially hardened to form a temporarily hardened portion 18 (preventive). food material temporary curing process). The temporarily hardened portion 18 can be formed by partially irradiating light onto a portion of the first corrosion-proofing material 17a on the terminal main body 3 side. Note that the temporarily hardened portion 18 may or may not be completely hardened. In any case, it is sufficient that fluidity remains in the portion of the first corrosion-proofing material 17a adhering to the conducting 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。 Further, the anticorrosive temporary curing step may be performed as necessary, and is not necessary if the first anticorrosive 17a flows out into the terminal main body 3 in a small amount in the anticorrosive infiltration step described below. For example, when the viscosity of the first corrosion protection material 17a upon application is 1000 mPa·s or less, it is effective to perform the corrosion protection 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. 3(c), the first anticorrosive material 17a applied in the first anticorrosion coating step is allowed to penetrate into the vicinity of the tip of the conducting wire 13 (anticorrosive penetration step). At this time, the first anticorrosive material 17a penetrates between the strands of the conducting wire 13 and into the gap 12 between the conducting wire 13 and the tip of the conducting wire crimping portion 7. Note that the penetration time is preferably, for example, 0.3 to 2.4 seconds, more preferably 1 to 2.4 seconds. If the infiltration time is insufficient, air bubbles will be generated without filling the gaps 12, and if the infiltration time is too long, the cycle time will become too long and 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 anti-corrosion infiltration step, after the first anti-corrosion 17a is infiltrated into the protruding portion of the conductor 13, a second anti-corrosion is further applied to cover the first anti-corrosion 17a (second anti-corrosion coating step). , ensure a sufficient thickness of corrosion protection at the tip of the conductor crimping portion 7. At this time, for the second corrosion protection, a resin having the same viscosity as that of the first corrosion protection 17a may be used, but a resin having a higher viscosity than the first corrosion protection 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。 Note that, as described above, the second anti-corrosion coating cannot be applied until the anti-corrosion infiltration process is completed, so there is a waiting time during that time. For this reason, as shown in FIG. 4(a), in parallel with the anticorrosive infiltration step, a third portion is formed at a portion other than the protruding portion of the conductive wire 13 from the inter-barrel portion 8 to cover the conductive wire crimping portion 7. A third anti-corrosion coating 17c may also be applied (third anti-corrosion coating step). By doing this, the waiting time in the anti-corrosive penetration step can be effectively utilized to apply the anti-corrosive to other parts.
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. 4(b), after the third anti-corrosion 17c is applied and the anti-corrosion penetration process is completed, the second anti-corrosion 17b is applied to the vicinity of the tip of the wire crimping part 7. to ensure the thickness of the anticorrosive 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 coated anti-corrosion 17 (first anti-corrosion 17a, second anti-corrosion 17b, third anti-corrosion 17c) is irradiated with light to be completely cured (resin curing step). Through the above steps, the electric wire 10 with a terminal 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, applying the anti-corrosion 17 refers to a method of bringing droplets of the anti-corrosion 17 into contact with the target part, or a method of ejecting (dropping) droplets of the anti-corrosion 17 from a supply unit and adhering them to the target part. This includes all methods of obtaining a state in which the anticorrosion 17 is attached to the target part, such as a method of causing the corrosion resistant material 17 to adhere to the target part. For example, droplets of the anti-corrosion 17 may be applied to the target area by contacting them with a mechanical dispenser, or may be applied by ejecting them from a supply section using 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。 Furthermore, the anticorrosion 17 may be applied to multiple locations instead of one location in each step. For example, in the first anticorrosion coating step, the first anticorrosion 17a may be applied to a plurality of locations so as not to cover the upper part of the conductor crimping part 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。 Note that since the first corrosion protection material 17a, the second corrosion protection material 17b, and the third corrosion protection material 17c are formed at different timings, their boundaries can be identified using an optical microscope or a polarizing microscope after cross-sectional 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 explained above, according to the present embodiment, since the first anticorrosion 17a is applied so as not to cover the upper part of the conductor crimping part 7, the air accumulated in the gap 12 between the conductor crimping part 7 and the conductor 13 Generation of bubbles can be suppressed. In addition, since sufficient penetration time is secured before applying the second anti-corrosive material 17b, it is possible to suppress the generation of air bubbles when the second anti-corrosive material 17b is applied, and the second anti-corrosive material 17b is used for crimping the conductor. The thickness of the anticorrosive material 17 near the tip 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。 Note that such an effect is particularly effective when the wire diameter is small. For example, in the case of an electric wire of 0.3 sq to 2.5 sq, it is difficult for the resin to penetrate into the gap 12 and it is difficult for air bubbles to escape, but the above method can suppress the generation of air bubbles.
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, by temporarily curing the first corrosion-proofing material 17a after the first corrosion-proofing process, the first corrosion-proofing material 17a flows toward the terminal body 3 side, and the first corrosion-proofing material 17a is sufficiently applied to the conducting wire 13 side. This can prevent the inability to penetrate.
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 anti-corrosion 17c in parallel with the anti-corrosion penetration step, the penetration time can be effectively utilized and the takt time can be shortened.
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。 Various electric wires with terminals were manufactured by adjusting conditions such as penetration time and viscosity of the anticorrosive material, and various evaluations were conducted. As the anticorrosion material, UV-curable acrylate resin was used. Perform the first anti-corrosion coating process → second anti-corrosion coating process → resin curing process, and check the appearance for permeability (presence or absence of bubbles) and film thickness after curing, and check that the resin film thickness at the conductor wire portion is 50 μm or more. Those were considered to have passed the test. In addition, the time required for manufacturing 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 created and the above evaluation was performed. In this case, a case in which all 10 items cleared the standard was marked as ○, a case in which 1 to 9 items passed was marked as △, and a case in which all of them failed was marked as ×. All of the permeability, film thickness, and target tact were evaluated, and the lowest evaluation is shown in Table 1 as the evaluation under the conditions.
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 penetration time was set to 2.5 seconds or more, the target takt time was exceeded, so all samples were rejected. On the other hand, when the penetration time was 0.1 seconds, the resin did not penetrate sufficiently and bubbles were observed. Therefore, the penetration time is preferably 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。 Furthermore, depending on the viscosity, film thickness was found to be insufficient when the penetration time was increased. In contrast, the lack of film thickness was resolved by adding a temporary curing step for the first anticorrosion barrier.
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。 Although the embodiments of the present invention have been described above with reference to the accompanying drawings, the technical scope of the present invention is not limited to the embodiments described above. It is clear that those skilled in the art can come up with various changes and modifications within the scope of the technical idea stated in the claims, and these naturally fall within the technical scope of the present invention. It is understood that it belongs.
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 section 5...Crimping section 7...Conductor crimping section 8...Inter-barrel section 9...Sheathing crimping section 10...With terminal Electric wire 11...Coated conductor 12...Gap 13...Conductor 15...Coating portion 17...Corrosion-proofing 17a...First corrosion-proofing 17b...Second corrosion-proofing 17c...No. 2 Anti-corrosion 18...Temporary hardening section 101...Gap 102...Bubbles 107...Conductor crimping section 113...Conductor 117...Anti-corrosion
Claims (3)
被覆導線の先端部の被覆部が除去された導線露出部が、前記端子の導線圧着部で圧着されており、
前記導線圧着部と前記端子本体との間のトランジション部の開口する側を上方とすると、
前記導線圧着部の先端から露出する導線の出代部に対し、前記導線圧着部の上部に付着しないように設けられた第１防食材と、
前記第１防食材の少なくとも一部を覆うように前記導線圧着部の少なくとも先端部近傍に設けられ、前記第１防食材との境界が顕微鏡で観察可能な第２防食材と、
を具備し、
前記第１防食材が、前記導線と前記導線圧着部との隙間に浸透されていることを特徴とする端子付き電線。 An electric wire with a terminal in which a covered conductor and a terminal are connected,
An exposed portion of the conductor from which the coating at the tip of the covered conductor has been removed is crimped with a conductor crimping portion of the terminal,
When the opening side of the transition part between the conductor crimping part and the terminal main body is defined as the upper side,
a first anti-corrosion barrier provided on a projecting portion of the conductor exposed from the tip of the conductor crimping portion so as not to adhere to an upper portion of the conductor crimping portion;
a second corrosion-proofing material, which is provided near at least the tip of the conductive wire crimping part so as to cover at least a portion of the first corrosion-proofing part, and whose boundary with the first corrosion-proofing part is observable with a microscope ;
Equipped with
An electric wire with a terminal, characterized in that the first anticorrosive material penetrates into a gap between the conductive wire and the conductive wire crimping portion.
前記第２防食材が、前記第１防食材及び前記第３防食材の少なくとも一部を覆うように設けられたことを特徴とする請求項１記載の端子付き電線。 further comprising a third corrosion-proofing portion provided to cover at least a portion of the conductive wire crimping portion at a portion other than the protruding portion of the conductive wire;
The electric wire with a terminal according to claim 1, wherein the second corrosion protection material is provided so as to cover at least a portion of the first corrosion protection material and the third corrosion protection material.
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、
前記導線圧着部の後端側に第３防食材を塗布する第３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防食材塗布工程及び前記第３防食材塗布工程で塗布した防食材の少なくとも一部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、
を具備し、
前記防食材浸透工程では、所定時間の浸透時間によって、前記第１防食材塗布工程で塗布した防食材を前記導線と前記導線圧着部の先端部との隙間に浸透させるとともに、前記第３防食材塗布工程で塗布した防食材を前記導線と前記導線圧着部の後端部との隙間に浸透させることを特徴とする端子付き電線の製造方法。 A method for manufacturing an electric wire with a terminal in which a covered conductor and a terminal are connected, the method comprising:
a wire processing step of removing a covering portion at the tip of the covered conductor to form an exposed portion of the conductor;
a wire/terminal connecting step of crimping the exposed conductor portion with a conductor crimping portion of a terminal to connect the conductor and the terminal;
a first anti-corrosion coating step of applying anti-corrosion to the protruding portion of the conductor exposed from the tip of the conductor crimping portion so as to avoid the conductor crimping portion;
a third anticorrosive coating step of applying a third anticorrosion to the rear end side of the conductor crimping part;
an anti-corrosion infiltration step in which the anti-corrosion applied in the first anti-corrosion application step is infiltrated into the vicinity of the tip of the conductor;
After infiltrating the protruding portion of the conductor wire with corrosion protection, further applying corrosion protection so as to cover at least a part of the corrosion protection applied in the first corrosion protection coating step and the third corrosion protection coating step. 2. Anticorrosive coating process,
a resin curing process to harden the applied anticorrosion;
Equipped with
In the anti-corrosion penetrating step, the anti-corrosion coated in the first anti-corrosion application step is allowed to penetrate into the gap between the conductive wire and the tip of the conductive wire crimping part for a predetermined penetration time, and the third anti-corrosion coating A method for manufacturing an electric wire with a terminal, characterized in that the anticorrosion applied in the coating step is allowed to penetrate into a gap between the conductive wire and the rear end of the conductive wire crimping part.
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| JP2012028021A (en) | 2010-07-20 | 2012-02-09 | Auto Network Gijutsu Kenkyusho:Kk | Electric wire with terminal |
| JP2016225171A (en) | 2015-06-01 | 2016-12-28 | 株式会社フジクラ | Manufacturing method of wire with terminal, and wire with terminal |
| JP2017212089A (en) | 2016-05-25 | 2017-11-30 | 古河電気工業株式会社 | Wire with terminal |
| JP2018077949A (en) | 2016-11-07 | 2018-05-17 | 古河電気工業株式会社 | Method for manufacturing terminal-attached electric wire |
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| US7960652B2 (en) | 2008-10-02 | 2011-06-14 | Delphi Technologies, Inc. | Sealed cable and terminal crimp |
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| JP2012028021A (en) | 2010-07-20 | 2012-02-09 | Auto Network Gijutsu Kenkyusho:Kk | Electric wire with terminal |
| JP2016225171A (en) | 2015-06-01 | 2016-12-28 | 株式会社フジクラ | Manufacturing method of wire with terminal, and wire with terminal |
| JP2017212089A (en) | 2016-05-25 | 2017-11-30 | 古河電気工業株式会社 | Wire with terminal |
| JP2018077949A (en) | 2016-11-07 | 2018-05-17 | 古河電気工業株式会社 | Method for manufacturing terminal-attached electric wire |
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