Electrical cable and wiring harness equipped with a connector

Abstract

It is an object to provide a terminal-equipped electric wire that can achieve sufficient bonding strength in the connection between the end portion of an electric wire and a terminal component, and to provide a wire harness including such a terminal-equipped electric wire. In a terminal-equipped electric wire 11, a fused connection portion 113 for connecting an exposed conductor portion 111d of an electric wire 111 and a joining portion 112b of a terminal component 112 to each other has a shape such that, in a cross section passing through an extension center axis X11 of the exposed conductor portion 111d and intersecting a layout surface 112b-1 of the joining portion 112b, a contour line 113a of the fused connection portion 113 does not pass through an inner side of an arcuate surface A11.having a center A111 at an end portion located near an edge on an extension side of the electric wire, wherein the arcuate surface A11 has a radius R11, which is a length obtained by subtracting a thickness L12 of one of the plurality of wires 111a from a distance L11 between the center A111 and an outer surface of the exposed conductor portion 111d.

Description

Technical field

[0001] The present invention relates to an electrical line equipped with a connection, comprising an electrical line of which an end section is connected to a connection component, and a cable harness comprising such an electrical line equipped with a connection. background

[0002] Traditionally, electrical cables equipped with a terminal have been widespread, comprising electrical conductors whose end sections are connected to terminal components (see, for example, Patent Document 1). In the electrical cable equipped with a terminal described in Patent Document 1, the end section of the electrical conductor is connected to the terminal component by crimping. However, there are also electrical cables connected with a terminal that comprise electrical conductors whose end sections are fused to terminal components, for example, by laser welding. State of the art patent document

[0003] Patent Document 1: JP2007-59304A Summary of the invention: From the invention to the problem to be solved

[0004] Regarding fusion-jointed electrical conductors equipped with a terminal, it is not always clear what type of connection state is required between the end section of an electrical conductor and a terminal component to obtain sufficient adhesion strength, and there is currently potential for improvement in adhesion strength.

[0005] Therefore, in view of the problems described above, an objective of the present invention is to provide an electrical conductor equipped with a connector that can achieve sufficient adhesion strength in the connection between the end section of an electrical conductor and a connector component, and to provide a cable harness comprising such an electrical conductor equipped with a connector. Solution to the task

[0006] To achieve the above objective, an electrical conductor equipped with a terminal comprises: an electrical conductor produced by sheathing a conductor section formed by a plurality of twisted strands with a resin sheath, the electrical conductor comprising an exposed conductor section at an end section where the conductor section extends in a state exposed by the resin sheath; a terminal component made of a conductive metal and equipped with a joining section on which the exposed conductor section is arranged and fused; and a fused connecting section in which the exposed conductor section and the joining section are at least partially fused and integrated to connect the exposed conductor section and the joining section, the fused connecting section having a shape such thatthat in a cross-section passing through an extension center axis of the exposed conductor section and intersecting an arrangement surface of the joining section for the exposed conductor section, a contour line of the fused joining section does not pass through an inside of an arc-shaped surface having a center at an end section on the arrangement surface in the cross-section near an edge of the arrangement surface on an extension side of the electrical conductor, wherein the arc-shaped surface has a radius that is a length in a direction perpendicular to the arrangement surface obtained by subtracting a thickness from one of the plurality of conductors from a distance between the center and an outer surface of the exposed conductor section.

[0007] To achieve the above objective, the cable harness also comprises a plurality of previously described electrically equipped conductors and a connector housing, which is a housing element made of insulating resin, with which the plurality of electrically equipped conductors are combined, wherein the connector housing is equipped with a plurality of connection receiving chambers, each formed in a tube shape, wherein connection components of the plurality of electrically equipped conductors are received in a one-to-one relationship in the respective connection receiving chambers. Advantageous effects of the invention

[0008] According to the electrical line equipped with a connector and the cable harness as described above, sufficient adhesive strength can be achieved in the connection between the end section of an electrical line and a connector component. Brief description of the drawings Fig. Figure 1 is a perspective exploded view showing a cable harness according to one embodiment. Fig. 2 is an enlarged view showing an exposed section of a conductor in Fig. The electrical conductor shown in Figure 1 is arranged on an arrangement surface of a joining section of a connecting component. Fig. Figure 3 is a three-view projection that shows the electrical conductor and the connecting component, as in Fig. 2 shown. Fig. 4 is a schematic view showing the shape of the [unclear text]. Fig. 2 and Fig. 3 represents the fused connection section shown. The Fig. 5A and Fig. Figure 5B presents a comparative example, shown in a side view and a partial cross-sectional view, similar to Fig. 4, is shown, in comparison to the form of the in Fig. 4 shown fused connection section. Detailed description of the preferred embodiment

[0009] The following describes an embodiment of an electrical line and cable harness equipped with a connector.

[0010] Fig. Figure 1 is a perspective exploded view showing a cable harness according to one embodiment. Fig. 2 is an enlarged view showing an exposed section of a conductor in Fig. The electrical conductor shown in Figure 1 is arranged on an arrangement surface of a joining section of a connecting component. Fig. Figure 3 is a three-view projection that shows the electrical conductor and the connecting component, as in Fig. 2 shown.

[0011] The wiring harness 1 according to the present embodiment is intended to be mounted, for example, on an automobile or the like, in order to connect various devices, and comprises a plurality of electrical conductors 11 equipped with a terminal and a connector housing 12. Each electrical conductor 11 equipped with a terminal has a terminal component 112, which serves as a socket terminal and is fused to an end section of the electrical conductor 111, for example, by laser welding. The connector housing 12 is a housing element made of insulating resin in the form of a rectangular block, to which a plurality of electrical conductors 11 equipped with a terminal are connected.The connector housing 12 is equipped with a plurality of connection receiving chambers 121, each of which is formed in a tube shape, and the connection components 112 of the plurality of electrical lines 11 equipped with a connection are received in a one-to-one relationship in the respective connection receiving chambers 121.

[0012] The electrical conductor 111 of the electrical conductor 11, which is equipped with a terminal, is a sheathed electrical conductor produced by sheathing a conductor section 111b, formed from a plurality of twisted conductors 111a, with a resin sheath 111c. The electrical conductor 111 has an exposed conductor section 111d at an end section, where the conductor section 111b extends in an exposed state from the resin sheath 111c.

[0013] The connecting component 112, which serves as the socket connector, is a component manufactured by sheet metal processing, equipped with: a connecting section 112a, made of a conductive metal in a rectangular tube shape, to which a mating plug connector is attached; and a joining section 112b, on which the exposed conductor section 111d of the electrical conductor 111 is arranged and fused together. The joining section 112b is a metal plate section that extends in a flat plate shape from the base plate section of the connecting section 112a on the opposite side from the connection side. The exposed conductor section 111d, which is arranged on the joining section 112b, is fused together with the joining section 112b.As a result, at least a portion of the exposed conductor section 111d and the joining section 112b are melted and integrated to form a fused connecting section 113 that joins the exposed conductor section 111d and the joining section 112b. In this case, the fused connecting section 113 is formed in the shape described below.

[0014] Fig. 4 is a schematic view showing the shape of the [unclear text]. Fig. 2 and Fig. 3 represents the fused connection section shown. Fig. Figure 4 is a side view and a partial cross-section, from the direction of arrow V11 in Fig. 2 seen, and represents the fused connection section 113 of the electrical conductor 11 connected to a terminal, i.e., a connection part between the exposed conductor section 111d of the electrical conductor 111 and the joining section 112b of the terminal component 112. In this case, the partial cross-section is a cross-section that passes through the extension center axis X11 of the exposed conductor section 111d and intersects the arrangement surface 112b-1 of the joining section 112b for the exposed conductor section 111d.

[0015] As in Fig. As shown in Figure 4, the fused connection section 113 is configured such that a contour line 113a in the cross-section does not pass through the inside of an arcuate surface A11, as explained below. The arcuate surface A11 has a center A111 at an end section, located on the mounting surface 112b-1 in the cross-section of the fused connection section 113 near the edge of the mounting surface 112b-1 on the side of the electrical conductor extension. The arcuate surface A11 is a surface in an arc shape with a radius R11, as explained below, around the center A111. The radius R11 of the arc-shaped surface A11 is a distance in the perpendicular direction D11 of the arrangement surface 112b-1, which is obtained by subtracting a thickness L12 of a conductor 111a from a distance L11 between the center A111 and the outer surface of the exposed conductor section 111d.

[0016] Furthermore, the contour line 113a of the fused connection section 113 in the above cross-section extends towards the arrangement surface 112b-1 on the opposite side to the side of the electrical conductor's extension by following a convex curve 113a-1 in the opposite direction, and then reaches the arrangement surface 112b-1 by following a concave shape 113a-2 with a rounded corner. Likewise, a distance L13 between the center A111 and the nearest point 113a-3 on the contour line 113a, which is closest to the center A111, is 70% or more of an outer diameter L14 of the conductor section 111b. Furthermore, a joining length L15 along the extension center axis X11 of the fused connection section 113 with the arrangement surface 112b-1 is longer than the outer diameter L14 of the conductor section 111b.

[0017] The electrical conductor 11 equipped with a connector and the cable harness 1 according to the embodiment described above can provide the effects described below. In the present embodiment, the exposed conductor section 111d at the end section of the electrical conductor 111 and the joining section of the connector 112 are joined by the fused connecting section 113, in which the exposed conductor section 111d and the joining section 112b are at least partially fused and integrated. Furthermore, the contour line 113a of the fused connecting section 113 in the above cross-section has a shape that does not pass through the inner side of the arc-shaped surface A11 around the center A111 with radius R11, which is obtained by subtracting the thickness L12 of a conductor 111a from the distance L11 between the center A111 and the outer surface of the exposed conductor section 111d.This arc-shaped area A11 indicates for the exposed conductor section 111d that the fused connection section 113 has a sufficient volume and joining length L15 for connection with the arrangement surface 112b-1 to provide adequate adhesion strength.

[0018] The Fig. 5A and Fig. 5B presents a comparative example in a side view and a partial cross-sectional view. Fig. Figure 4 presents, in comparison to the shape of the fused connection section, as in Fig. 4 shown. Fig. 5A represents a first comparative example and Fig. 5B presents a second comparative example. In the Fig. 5A and Fig. 5B are components that are equivalent to those in Fig. The four shown have the same reference symbol as those in Fig. 4 are provided only if they are necessary for the explanation, and duplicate explanations for these equivalent components are subsequently omitted.

[0019] In the Fig. In the first comparative example shown in Figure 5A, the fused connection section 513 collapses and flows. As a result, the fused connection section 513 has such a shape that a contour line 513a passes through the inside of the arcuate surface A11 in the cross-section of the fused connection section 513. The fused connection section 513 in this first comparative example lacks the volume to provide adequate bond strength. Furthermore, in this first comparative example, due to the collapse of the fused connection section 513, the distance L53 from the nearest point 513a-3 on the contour line 513a to the center A111 is less than 70% of the outer diameter L14 of the conductor section 111b.The fused connection section 513 in the first comparison example also has an insufficient volume in such a way that the distance L53 from the nearest point 513a-3 on the contour line 513a to the center A111 is short.

[0020] In the Fig.In the second comparative example shown in Figure 5B, the wettability of a fused connection section 613 with the arrangement surface 112b-1 of the joining section 112b is insufficient, resulting in a gap between the fused connection section 613 and the arrangement surface 112b-1. A contour line 613a runs through the gap in cross-section through the inside of the arcuate surface A11. In this second comparative example, the fused connection section 613 has a breakout in the gap, and the volume required to exert sufficient adhesion is insufficient. Furthermore, in this second comparative example, the edge of the gap is a nearest point 613a-3, and the distance L63 from this nearest point 613a-3 to the center A111 is less than 70% of the outer diameter L14 of the conductor section 111b.Furthermore, the distance L63 from the nearest point 613a-3 to the center A111 is also a joining length L65 of the fused connection section 613 for connection with the arrangement surface 112b-1 along the extension center axis X11, and this joining length L65 is shorter than the outer diameter L14 of the conductor section 111b. The fused connection section 613 according to the second comparative example even exhibits a lower adhesive strength due to the short distance L63 and the short joining length L65 between the nearest point 613a-3 and the center A111.

[0021] In contrast, according to the embodiment described above, the contour line 113a of the fused connection section 113 does not pass through the inside of the arcuate surface A11 in the cross-section and can therefore ensure sufficient volume and joining length L15. Furthermore, by providing the fused connection section 113, as explained above, sufficient adhesive strength can be obtained for the connection between the end section of the electrical conductor 111 and the connecting component 112.

[0022] In the present embodiment, the contour line 113a reaches the mounting surface 112b-1 by following the convex curve 113a-1 and the concave shape 113a-2 with a rounded corner. In this configuration, the fused connection section 113 has sufficient volume because the contour line 113a follows the convex curve 113a-1. Furthermore, since the contour line 113a reaches the mounting surface 112b-1 by following the concave shape 113a-2 with a rounded corner, the fused connection section 113 is integrated with the mounting surface 112b-1 with sufficient uniform continuity. In light of these points, the above configuration also improves the bond strength between the end section of the electrical conductor 111 and the connecting component 112.

[0023] Furthermore, in the present embodiment, the distance L13 between the center A111 and the nearest point 113a-3 on contour line 113a, which is closest to the center A111, has a length that is 70% or more of the outer diameter L14 of the conductor section 111b. In this configuration, the distance L13 between the center A111 of the arc-shaped surface A11 and the nearest point 113a-3 on contour line 113a indicates the extent of volume reduction when the fused connection section 113 has a partially indented shape. Furthermore, if the distance L13 is set to a length that is 70% or more of the outer diameter L14 of the conductor section 111b, volume reduction is mitigated and the bond strength between the end section of the electrical conductor 111 and the terminal component 112 can be further improved.

[0024] Furthermore, in the present embodiment, the joining length L15 of the fused connection section 113 for connection with the mounting surface 112b-1 is longer than the outer diameter L14 of the conductor section 111b. According to this configuration, a sufficient length as joining length L15 can be obtained between the fused connection section 113 and the mounting surface 112b-1, and therefore the adhesive strength between the end section of the electrical conductor 111 and the connecting component 112 can be further improved.

[0025] The embodiment described above merely shows typical forms of the electrically connected cable and the wiring harness. The electrically connected cable and the wiring harness are not limited to this and can be modified in various ways.

[0026] For example, in the embodiment described above, the wiring harness 1, which is mounted on an automobile or the like to connect various devices, is given as an example of a wiring harness. However, the wiring harness is not limited to this, and the specific object to which it is mounted is not specifically limited.

[0027] Furthermore, in the embodiment described above, the electrical conductor 11, which has a connection and comprises the electrical conductor 111 whose end section is joined to the connector 112 of the socket type, is given as an example of an electrical conductor equipped with a connection. However, the electrical conductor equipped with a connection is not limited to this and can have a plug-type connector that is connected to an end section of the electrical conductor, or it can be joined with a connection other than a plug-type connector, such as a round connector.

[0028] Furthermore, in the embodiment described above, the connector housing 12, which has a rectangular, block-like appearance and is equipped with the plurality of connection receiving chambers 121, is provided as an example of a connector housing for a cable harness. However, the connector housing is not limited to this, and its specific external shape can be any form, as long as the connection components of the multiple electrically equipped conductors are received in a one-to-one relationship in the respective connection receiving chambers.

[0029] In the embodiment described above, the fused connection section 113, which has the contour line 113a reaching the mounting surface 112b-1 by following the convex curve 113a-1 and the concave shape 113a-2 with a rounded corner, is given here as an example of a fused connection section. However, the fused connection section is not limited to this, and the specific shape of the contour line is not important as long as it has a shape that does not pass through the inside of the arc-shaped surface, as explained above. The bond strength between the end section of the electrical conductor 111 and the terminal component 112 can, however, be further improved, as described above, with the contour line 113a following the convex curve 113a-1 and the concave shape 113a-2 with a rounded corner.

[0030] Furthermore, in the embodiment described above, the fused connection section 113, in which the distance L13 between the center A111 and the nearest point 113a-3 on the contour line 113a is 70% or more of the outer diameter L14 of the conductor section 111b, is given as an example of a fused connection section. However, the fused connection section is not limited to this, and as long as the fused connection section has a shape that does not extend through the inside of the arc-shaped region, as explained above, the distance between the center and the nearest point of the contour line may be less than 70% of the outer diameter of the connector section.However, as described above, the bond strength between the end section of the electrical conductor 111 and the connector component 112 can be further improved if the distance L13 between the center A111 and the nearest point 113a-3 of the contour line 113a is set to 70% or more of the outer diameter L14 of the connector section 111b.

[0031] Furthermore, in the embodiment described above, the joining length L15 of the fused connection section 113 for connection with the mounting surface 112b-1 is longer than the outer diameter L14 of the conductor section 111b. However, the fused connection section is not limited to this, and the joining length can be shorter than the outer diameter of the conductor section. As described above, however, the bond strength between the end section of the electrical conductor 111 and the connecting component 112 can be further improved if the joining length L15 is longer than the outer diameter L14 of the connector section 111b. List of reference symbols 1 wiring harness 11 electrical line equipped with a connection 12 connector housings 111 electrical line 111a Adler 111b ladder section 111c Resin coating 111d exposed conductor section 112 Connecting component 112a Connecting section 112b Joining section 112b-1 Arrangement area 113 fused connection section 113a Contour line 113a-1 convex curve 113a-2 concave shape with rounded corner 113a-3 next point 121 Connection reception chamber A11 arc-shaped area A111 Mitte D11 vertical direction L11 Distance between the center and outer surface of the exposed conductor section L12 Thickness of a vein L13 Distance between center and nearest point on the contour line L14 Outer diameter of the conductor section L15 joining length R11 radius X11 Extension center axis QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] JP 2007-59304A

[0003]

Claims

[1] Electrical line (11) equipped with a terminal, comprising: an electrical conductor (111) produced by sheathing a conductor section (111b) formed by a plurality of twisted conductors (111a) with a resin sheath (111c), wherein the electrical conductor (111) comprises an exposed conductor section (111d) at an end section where the conductor section (111b) extends in a state exposed by the resin sheath (111c); a connecting component (112) made of a conductive metal and equipped with a joining section (112b) on which the exposed conductor section (111d) is arranged and fused together; and a fused connecting section (113) in which the exposed conductor section (111d) and the joining section (112b) are at least partially fused and integrated to connect the exposed conductor section (111d) and the joining section (112b), wherein the fused connecting section (113) has a shape such that, in a cross-section passing through an extension center axis (X11) of the exposed conductor section (111d) and intersecting an arrangement surface (112b-1) of the joining section (112b) for the exposed conductor section (111d), a contour line (113a) of the fused connecting section (113) does not pass through an inside of an arc-shaped surface (A11) that has a center at an end section on the arrangement surface (112b-1) in the cross-section near an edge of the arrangement surface (112b-1) on a extension side of the electrical conductor, wherein the arc-shaped surface (A11) has a radius,which is a length in a perpendicular direction to the arrangement surface (112b-1) obtained by subtracting a thickness (L12) from one of the plurality of conductors (111a) from a distance (L11) between the center and an outer surface of the exposed conductor section (111d). [2] The electrical conductor (11) equipped with a terminal according to claim 1, wherein the contour line (113a) extends towards the arrangement surface (112b-1) on a side opposite to the extension side of the electrical conductor by following a convex curve (113a-1) in the direction of the opposite side and then reaching the arrangement surface (112b-1) by following a concave shape (113a-2) with a rounded corner. [3] The electrical conductor (11) equipped with a terminal according to claim 1, wherein a distance (L13) between the center and the nearest point on the contour line (113a) that is closest to the center is 70% or more of an outer diameter (L14) of the conductor section (111b). [4] The electrical conductor (11) equipped with a connection according to claim 1, wherein a joining length (L15) of the fused connecting section (113) for connection with the arrangement surface (112b-1) along the extension center axis (X11) is longer than an outer diameter (L14) of the conductor section (111b). [5] Wiring harness (1), comprising: a plurality of electrical conductors (11) equipped with a connection according to any one of claims 1 to 4; and a connector housing (12), which is a housing element made of insulating resin, with which the plurality of electrical conductors (11) equipped with a connection are combined, wherein the connector housing (12) is equipped with a plurality of connection receiving chambers (121), each of which is formed in a tube shape, wherein connection components (112) of the plurality of electrical conductors (11) equipped with a connection are received in a one-to-one relationship in the respective connection receiving chambers (121).

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