Wire with terminals

Abstract

The object of the present invention is to improve the electrical connection stability between the core wire and the terminal fitting. The terminal wire includes: a wire (10) having a core wire (11) consisting of multiple bare wires (11a) covered with a sheath (12); and a terminal fitting (20) assembled to the wire, the terminal fitting having a core wire connector (22) physically and electrically connected to the core wire, the core wire connector having: a bottom (22a); a pair of cantilevered sidewall portions (22b, 22b) erected from the bottom and spaced apart from each other; and at least one pair of crimping bodies (24, 24) spaced apart from each other between the pair of sidewall portions, and the sheath of the wire inserted from the opening (22c) between the free ends (22b1, 22b1) of each pair of sidewall portions is cut to crimp the outermost bare wire of the core wire, and a fusion portion (11b) is provided on the wire to fuse all the bare wires of the core wire together.

Description

TECHNICAL FIELD

[0001] The present application relates to a terminal-equipped electric wire. BACKGROUND

[0002] In the past, a terminal-equipped electric wire has been known, which is provided with an electric wire in which a core wire composed of a plurality of bare wires is covered with a sheath, and a terminal fitting assembled to the electric wire. For example, in the terminal-equipped electric wire, a pair of crimping bodies provided to the terminal fitting is crimped to the core wire, thereby physically and electrically connecting the core wire and the terminal fitting. Such a terminal-equipped electric wire is disclosed in, for example, Patent Document 1.

[0003] PRIOR ART DOCUMENTS

[0004] PATENT DOCUMENTS

[0005] Patent Document 1: Japanese Patent Application Laid-Open No. 61-112575 SUMMARY

[0006] PROBLEMS TO BE SOLVED BY THE INVENTION

[0007] However, in the conventional terminal-equipped electric wire, since the pair of crimping bodies is crimped to the core wire from the outer surface side, the more the number of bare wires constituting the core wire, the more the number of bare wires (non-contact bare wires) not directly contacting the crimping bodies increases relative to the number of bare wires (contact bare wires) directly contacting the crimping bodies. Also, in the core wire, the non-contact bare wires are indirectly electrically connected to the crimping bodies via the contact bare wires. Therefore, in the conventional terminal-equipped electric wire, the electrical resistance between the bare wires of the core wire becomes high, which can cause an increase in electrical resistance at the connection portion between the core wire and the terminal fitting. Therefore, the conventional terminal-equipped electric wire has room for improvement in improving the electrical connection stability of the core wire and the terminal fitting.

[0008] Therefore, an object of the present application is to provide a terminal-equipped electric wire capable of improving the electrical connection stability of a core wire and a terminal fitting.

[0009] MEANS FOR SOLVING THE PROBLEMS

[0010] To achieve the above object, the terminal-equipped electric wire according to the present application is characterized by comprising: an electric wire in which a core wire composed of a plurality of bare wires is covered with a sheath; and a terminal fitting assembled to the electric wire, the terminal fitting having a core wire connecting body physically and electrically connected to the core wire, the core wire connecting body having a bottom, a pair of cantilever-shaped side wall portions provided upright from the bottom and arranged opposite to each other at a spacing, and at least one set of a pair of crimping bodies arranged opposite to each other at a spacing between the pair of side wall portions and cutting the sheath of the electric wire inserted from an opening between free ends of the pair of side wall portions to crimp the bare wire of the outermost layer of the core wire, the electric wire being provided with a fusion portion in which all the bare wires of the core wire are fused to each other.

[0011] Effects of Invention

[0012] In the core wire of the terminal-equipped electric wire according to the present application, since all the bare wires are directly connected by the fusion portion, the increase in the resistance between the bare wires can be suppressed. Therefore, the terminal-equipped electric wire according to the present application can suppress the increase in the resistance at the connection portion between the core wire and the core wire connecting body, and thus can improve the electrical connection stability of the core wire and the terminal fitting.

[0013] In addition, in the electric wire, in the case where the bare wire is formed of aluminum or an aluminum alloy, an oxide film is formed on the surface of the bare wire. However, in the core wire, all the bare wires are fused to each other in a state where the oxide film has been removed when the fusion portion is formed. Therefore, in the core wire, even in the case where the bare wire is formed of aluminum or an aluminum alloy, the increase in the resistance between the bare wires can be suppressed. Moreover, in the process of pressing the electric wire, the pair of crimping bodies remove the oxide film of the bare wire of the outermost layer of the core wire while rubbing the surface of the bare wire. Therefore, the core wire connecting body can bring the pair of crimping bodies into contact with the bare wire of the outermost layer of the core wire in a state where the oxide film is not present. Therefore, the terminal-equipped electric wire according to the present application can suppress the increase in the resistance at the connection portion between the core wire and the core wire connecting body even in the case where the bare wire is formed of aluminum or an aluminum alloy.

[0014] Thus, the terminal-equipped electric wire according to the present application can suppress the increase in the resistance at the connection portion between the core wire and the core wire connecting body, and thus can improve the electrical connection stability of the core wire and the terminal fitting. BRIEF DESCRIPTION OF DRAWINGS

[0015] Figure 1 is an exploded perspective view of the terminal-equipped electric wire according to the embodiment.

[0016] Figure 2 is a perspective view of the terminal-equipped electric wire according to the embodiment.

[0017] Figure 3This is a top view of the terminald wire of the embodiment, viewed from the open side of the terminal fitting.

[0018] Figure 4 yes Figure 3 A schematic diagram of the XX-line cross-section.

[0019] Figure 5 This is an explanatory diagram showing an example of the process for forming the welded section.

[0020] Figure 6 This is an explanatory diagram showing another example of the process for forming the welded section.

[0021] Symbol Explanation

[0022] 1. Wire with terminals

[0023] 10. Wires

[0024] 10a End portion

[0025] 10b end face

[0026] 11-core wire

[0027] 11a bare wire

[0028] 11b Welded section

[0029] 11c exposed

[0030] 12. Covered with skin

[0031] 20 terminal accessories

[0032] 22-core connector

[0033] 22a Bottom

[0034] 22b Sidewall portion

[0035] 22b1 Free End

[0036] 22c Opening

[0037] 24 Press-fit body Detailed Implementation

[0038] Hereinafter, embodiments of the terminald wire according to the present invention will be described in detail with reference to the accompanying drawings. It should be noted that the present invention is not limited to these embodiments.

[0039] [Implementation Method]

[0040] based on Figures 1 to 6 One embodiment of the terminal wire involved in this invention will be described.

[0041] Figures 1 to 4The symbol 1 indicates a terminal-equipped electric wire of the embodiment. The terminal-equipped electric wire 1 has a physical connection and an electrical connection between an electric wire 10 and a terminal fitting 20 assembled to the electric wire 10.

[0042] The terminal-equipped electric wire 1 can be a terminal-equipped electric wire in which the terminal fitting 20 is connected to the end of the electric wire 10, or a terminal-equipped electric wire in which the terminal fitting 20 is connected to a part between both end portions of the electric wire 10. In addition, the terminal-equipped electric wire 1 can be a terminal-equipped electric wire in which at least one terminal fitting 20 is connected to one electric wire 10, or a terminal-equipped electric wire in which a plurality of electric wires 10 are connected with at least one terminal fitting 20 and electrically connected via the terminal fitting 20. For example, the terminal fitting 20 is connected to the end of at least one electric wire 10 in a case where the terminal fitting 20 is formed to be physically and electrically connected to a counterpart terminal fitting by fitting connection to the counterpart terminal fitting, or by screwing to an electrical connection portion on a counterpart side. In addition, for example, the terminal fitting 20 is connected to the end of the electric wire 10 or a part between both end portions of the electric wire 10 in a case where the terminal fitting 20 is formed as a joint terminal that electrically connects a plurality of electric wires 10. The terminal fitting 20 in this case can be a joint terminal that physically and electrically connects a plurality of electric wires 10 and electrically connects all the electric wires 10 via itself, or a joint terminal that physically and electrically connects at least two of the plurality of electric wires 10 in one group, and is provided for each group. In the terminal-equipped electric wire 1 shown here, one terminal fitting 20 that is fitting-connected to a counterpart terminal fitting is connected to the end of one electric wire 10.

[0043] The electric wire 10 has a core wire 11 composed of a plurality of bare wires 11a and a sheath 12 that covers the core wire 11 Figure 1 , Figure 3 and Figure 4 The electric wire 10 shown here has a core wire 11 that is a bundle of a plurality of bare wires 11a composed of a conductive metal wire, and a cylindrical sheath 12 that covers the core wire 11 in a concentric manner from the outer surface side. The bare wire 11a is formed of, for example, aluminum, aluminum alloy, copper, or copper alloy.

[0044] The core wire 11 can be a core wire in which a plurality of bare wires 11a having their axial directions aligned with each other are bundled in a cylindrical shape, or can be a stranded wire in which a plurality of bare wires 11a bundled in a cylindrical shape are stranded. Further, the core wire 11 as the stranded wire can be one in which all of the bare wires 11a bundled in a cylindrical shape are stranded together, can be one in which one bare wire 11a is placed at the center and the remaining plurality of bare wires 11a are wound around the one bare wire 11a, or can be one in which a plurality of bare wire groups in which a plurality of bare wires 11a are twisted are formed, the plurality of bare wire groups are bundled in a cylindrical shape, and the plurality of bare wire groups are stranded together. Regardless of which of the above forms the core wire 11 adopts, the core wire 11 is one in which a plurality of bare wires 11a are disposed in the outermost layer and a plurality of bare wires 11a are disposed inside the plurality of bare wires 11a in the outermost layer.

[0045] The terminal fitting 20 is formed of an electrically conductive material such as metal. The terminal fitting 20 shown here is formed by press forming a metal plate as a base material. The terminal fitting 20 has a terminal connecting body 21 that is physically and electrically connected to a terminal connecting body (not shown) of a counterpart terminal fitting, a core wire connecting body 22 that is physically and electrically connected to the core wire 11 at the end of the electric wire 10, and a sheath connecting body 23 that is physically connected to the sheath 12 at the end of the electric wire 10. Figures 1 to 3

[0046] For example, one of the terminal connecting body 21 of the terminal fitting 20 and the terminal connecting body of the counterpart terminal fitting is formed in a female terminal shape, and the other thereof is formed in a male terminal shape, and they are inserted and fitted into each other. In this example, the terminal connecting body 21 of the terminal fitting 20 is formed in a female terminal shape, and the terminal connecting body of the counterpart terminal fitting is formed in a male terminal shape.

[0047] The core wire connecting body 22 has a bottom portion 22a, and a pair of cantilever-shaped side wall portions 22b, 22b disposed in opposition to each other at a distance from the bottom portion 22a. Figure 1 Figure 2 Figure 4 The end of the electric wire 10 is accommodated in a space surrounded by the bottom portion 22a and the pair of side wall portions 22b, 22b. In the core wire connecting body 22 shown here, the pair of rectangular side wall portions 22b, 22b are provided upright from both ends of the rectangular bottom portion 22a. In the core wire connecting body 22, the end of the electric wire 10 is inserted from an opening 22c between the free ends 22b1, 22b1 of the pair of side wall portions 22b, 22b in the space surrounded by the bottom portion 22a and the pair of side wall portions 22b, 22b. Figure 1 Figure 2 Figure 4

[0048] ​​​​​​Further, the core wire connector 22 has at least one set of a pair of crimping bodies 24, 24 which are arranged in opposition to each other at a spacing between a pair of side wall portions 22b, 22b, and which cut and crimp the outermost bare wire 11a of the core wire 11 after insertion of the electric wire 10 from the opening 22c into the core wire connector 22. Figures 1 to 4 The core wire connector 22 shown here has two sets of the pair of crimping bodies 24, 24. The two sets of the pair of crimping bodies 24, 24 are arranged at a spacing from each other in the axial direction of the electric wire 10 assembled in the core wire connector 22.

[0049] The pair of crimping bodies 24, 24 can be a structure in which one crimping body protrudes from one side wall portion 22b toward the other side wall portion 22b and the other crimping body protrudes from the other side wall portion 22b toward the one side wall portion 22b. The crimping bodies 24 shown here are formed as tab bodies in which a portion of the side wall portion 22b is bent by 90 degrees from the side wall portion 22b.

[0050] The pair of crimping bodies 24, 24 have crimping end portions 24a, 24a which are arranged in opposition to each other at a spacing in the direction of the opposed arrangement of the pair of side wall portions 22b, 22b, and between which the electric wire 10 is pressed in. Figure 4 In the pair of crimping bodies 24, 24, the core wire 11 is held by the respective crimping end portions 24a, 24a, and pressing force is applied from the respective crimping end portions 24a, 24a to the outermost bare wire 11a of the core wire 11, so as to be physically and electrically connected to the outermost bare wire 11a. Therefore, in the pair of crimping bodies 24, 24, the spacing of the respective crimping end portions 24a, 24a is made narrower than the diameter of the core wire 11. The crimping end portion 24a can be formed as a flat surface along the insertion direction of the electric wire 10 from the opening 22c, or as a blade-shaped crimping blade. The crimping end portion 24a shown here is formed as a flat surface having a thickness equivalent to the plate thickness of the base material.

[0051] Further, the pair of crimping bodies 24, 24 have core wire introduction portions at the end portions on the opening 22c side, which are insertion starting points when the electric wire 10 is pressed between the respective crimping end portions 24a, 24a, and which are wider in lateral width than the spacing of the respective crimping end portions 24a, 24a. For example, the pair of crimping bodies 24, 24 have inclined portions 24b, 24b at the end portions on the opening 22c side, which are connected to the crimping end portions 24a, 24a and expand the spacing of each other as they approach from the boundary with the crimping end portions 24a, 24a toward the opening 22c side. Figure 4). The core wire introduction portion is formed by the respective inclined portions 24b, 24b. The inclined portion 24b can be formed as a flat surface having a thickness equivalent to the plate thickness of the base material, or can be formed as a blade-shaped crimping blade. The inclined portion 24b shown here is formed as a crimping blade.

[0052] The electric wire 10 is inserted from the opening 22c into the space surrounded by the bottom portion 22a and the pair of side wall portions 22b, 22b. Along with this, the pair of crimping bodies 24, 24 cut the sheath 12 of the electric wire 10 to be crimped by the respective inclined portions 24b, 24b, and expose the outermost bare wire 11a of the core wire 11 in the sheath 12. The electric wire 10 is further crimped deeper, and the exposed outermost bare wire 11a of the core wire 11 rubs along the respective crimping end portions 24a, 24a while the electric wire 10 is crimped between the respective crimping end portions 24a, 24a. Thus, in the electric wire 10, the core wire 11 is in a crimped state between the respective crimping end portions 24a, 24a, and the outermost bare wire 11a of the core wire 11 is physically and electrically connected to the terminal fitting 20 via the respective crimping end portions 24a, 24a.

[0053] Thus, the core wire connecting body 22 brings the pair of crimping bodies 24, 24 into direct contact with the outermost bare wire 11a of the core wire 11 ( Figure 4 ). Therefore, the core wire connecting body 22 cannot in principle come into direct contact with the bare wires 11a of the core wire 11 other than the outermost bare wire. Also, the core wire connecting body 22 does not bring the pair of crimping bodies 24, 24 into direct contact with all of the outermost bare wires 11a. That is, in the core wire 11, there are roughly the outermost bare wire (hereinafter referred to as "contact bare wire") 11a that is in direct contact with the crimping body 24 and is electrically connected thereto, and the remaining bare wires (hereinafter referred to as "non-contact bare wire") 11a that are electrically connected to the crimping body 24 indirectly via the contact bare wire 11a. Also, in the core wire 11, even if the number of bare wires 11a increases, the increased portion does not come into direct contact with the crimping body 24, and the more the number of bare wires 11a increases, the higher the increase rate of the non-contact bare wire 11a compared to the increase rate of the contact bare wire 11a, and as a result, the electrical resistance between the bare wires of the core wire 11 increases.

[0054] Therefore, in the electric wire 1 with terminal, the electrical connection stability of the core wire 11 to the terminal fitting 20 is improved by reducing the electrical resistance between the bare wires of the core wire 11. Here, the electrical resistance between the bare wires of the core wire 11 is reduced by physically and electrically connecting all of the bare wires of the core wire 11 to each other. Therefore, in the electric wire 10, a fusion portion 11b ( Figures 1 to 3 and Figure 5 ) is provided in which all of the bare wires of the core wire 11 are fused to each other.

[0055] Thus, in the core wire 11, all the bare wires 11a are directly connected by the fusion splice 11b, and therefore, the resistance between the bare wires can be suppressed from rising. Thus, the terminal-equipped electric wire 1 of the present embodiment can suppress the resistance from rising at the connecting portion between the core wire 11 and the core wire connecting body 22.

[0056] In addition, in the electric wire 10, in the case where the bare wire 11a is formed of aluminum or an aluminum alloy, an oxide film is formed on the surface of the bare wire 11a. However, in the core wire 11, all the bare wires are fused to each other in a state where the oxide film has been removed when the fusion splice 11b is formed. Thus, in the core wire 11, even in the case where the bare wire 11a is formed of aluminum or an aluminum alloy, the resistance between the bare wires can be suppressed from rising. Moreover, in the process of pressing the electric wire 10, the pair of crimping bodies 24, 24 wipe the surface of the outermost bare wire 11a of the core wire 11 with the respective crimping end portions 24a, 24a while removing the oxide film of the bare wire 11a. Thus, the core wire connecting body 22 can cause the pair of crimping bodies 24, 24 to contact the outermost bare wire 11a of the core wire 11 without passing through the oxide film. Thus, the terminal-equipped electric wire 1 of the present embodiment can suppress the resistance from rising at the connecting portion between the core wire 11 and the core wire connecting body 22 even in the case where the bare wire 11a is formed of aluminum or an aluminum alloy.

[0057] Specifically, the fusion splice 11b can be provided at the tip end of the electric wire 10, or between the both end portions of the electric wire 10. In addition, the fusion splice 11b can be formed in a state where the core wire 11 is covered with the sheath 12, or can be formed to the core wire 11 before being covered with the sheath 12. For example, in the case where the fusion splice 11b is provided at the tip end of the electric wire 10, the fusion splice 11b is provided to the exposed portion of the core wire 11 at the tip end portion 10a of the tip end of the electric wire 10. In this case, the fusion splice 11b is formed to the exposed portion of the core wire 11 in a state where the core wire 11 is covered with the sheath 12. In addition, for example, in the case where the fusion splice 11b is provided between the both end portions of the electric wire 10, the fusion splice 11b is formed to the core wire 11 before being covered with the sheath 12.

[0058] The fusion splice 11b is formed, for example, by irradiating laser light to a portion of all the bundled bare wires 11a in the core wire 11, and fusing all the bare wires of the core wire 11 to each other by the laser light irradiation.

[0059] The fusion splice 11b shown here is provided to the exposed portion of the core wire 11 at the tip end portion 10a of the electric wire 10. Figure 5 For example, the core wire 11 shown here is covered with the sheath 12 up to the end surface 10b in the axial direction of the tip end portion 10a of the electric wire 10. Moreover, the core wire 11 has an exposed surface 11c exposed at the end surface 10b of the tip end portion 10a of the electric wire 10.Figure 5 (See the upper and middle diagrams). Therefore, the welded section 11b shown here is formed by irradiating the exposed surface 11c of the core wire 11 with a laser, thereby fusing all the bare wires together using the laser irradiation of the exposed surface 11c of the core wire 11. Figure 5 (See the middle and lower figures). That is, the welded section 11b is a laser welded section formed by laser irradiation of the exposed surface 11c of the core wire 11. The laser irradiation can be performed on a single wire 10 disposed on the fixture, or on multiple wires 10 arranged in the fixture sequentially.

[0060] The skin-covered connector 23 is composed of a bottom 23a and a pair of cylindrical portions 23b, 23b protruding from both ends of the bottom 23a. Figure 1 and Figure 2 In this sheathed connector 23, for example, the end of the wire 10 is opened from the opening 23c between the free ends 23b1, 23b1 of each of the cylindrical portions 23b, 23b1. Figure 1 The sheath 12 is inserted and placed on the inner wall surface (bottom surface) of the bottom 23a. For example, the sheath connector 23 is wound around the end of the wire 10 while the individual cylindrical portions 23b, 23b are pressurized and deformed.

[0061] As shown above, the terminal wire 1 of this embodiment suppresses the resistance rise at the connection portion between the core wire 11 and the core wire connector 22, thereby improving the electrical connection stability between the core wire 11 and the terminal accessory 20.

[0062] Furthermore, in the wire 10 shown here, when forming the welded portion 11b, the outer sheath 12 is not partially peeled off; instead, a laser is irradiated onto the exposed surface 11c of the end face 10b of the terminal portion 10a. Therefore, in this wire 1 with terminals, it is not necessary to perform the stripping operation of the outer sheath 12, thus reducing the increase in processing steps.

[0063] However, in some cases, in the wire 10, the core wire 11 is exposed in a cylindrical shape at the end 10a by stripping the sheath 12 from the end 10a. Figure 6 (See the upper and middle figures). The terminald wire 1 of this embodiment can also be applied to wires 10 having exposed portions of such columnar core wires 11. For example, for this wire 10, before assembling it to the terminal fitting 20, it is positioned in a clamp, and a laser is irradiated from the outer peripheral side onto the exposed portions of the columnar core wires 11, causing all the bare wires to fuse together. Figure 6 (See the middle and lower figures). Alternatively, for example, in this wire 10, after assembly with the terminal fitting 20, the terminal fitting 20 can be used as a clamp to irradiate the exposed portion of the columnar core wire 11 from the outer peripheral side with a laser, so that all the bare wires are fused together.

[0064] In addition, in the case of connecting a plurality of electric wires 10, the terminal fitting according to the present application can, for example, extend the length of the crimping end portions 24a, 24a of each of the pair of crimping bodies 24, 24 according to the number of electric wires 10 to be connected, and connect the plurality of electric wires 10 to at least one set of the pair of crimping bodies 24, 24. In addition, in the case of connecting a plurality of electric wires 10, the terminal fitting according to the present application can, for example, provide at least one set of the pair of crimping bodies 24, 24 for each electric wire 10.

Claims

1. An electric wire with a terminal, characterized by comprising: Possessing: an electric wire formed by covering a core wire composed of a plurality of bare wires with a sheath; and a terminal fitting assembled to the electric wire, the terminal fitting has a core wire connecting body physically and electrically connected to the core wire, the core wire connecting body has a bottom, a pair of cantilever-shaped side wall portions standing from the bottom and disposed opposite each other at a spaced interval, and at least one set of a pair of crimping bodies disposed opposite each other at a spaced interval between the pair of cantilever-shaped side wall portions and cutting the sheath of the electric wire inserted from an opening between free ends of the pair of cantilever-shaped side wall portions to crimp the bare wires of the outermost layer of the core wire, and the core wire is covered with the sheath to an end surface in an axial direction of a terminal portion of the electric wire and exposes a surface to the end surface, the electric wire is provided with a fusion portion in which all the bare wires of the core wire including the terminal portion of the exposed surface are fused to each other, the pair of crimping bodies crimp the bare wires of the outermost layer of the core wire in which the fusion portion is not provided.

2. The electric wire with a terminal according to claim 1, wherein the fusion portion is a laser fusion portion in which all the bare wires are fused to each other by laser irradiation to the exposed surface of the core wire.

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