Manufacturing device for electric wire with terminal and electric wire with terminal

Abstract

To provide a manufacturing device for electric wire with terminal that can improve the joining condition between an electric wire and a terminal and the electric wire with terminal.SOLUTION: A manufacturing device 1A for electric wire with terminal includes a horn 3A which has a processing surface 31 that contacts and applies pressure to a braided wire end W1A in a clamped state where a joining object body is clamped between an anvil 2A and the horn 3A. The processing surface 31 includes an inclined surface 31c on which the braided wire end W1A is inclined from a high-density portion OC to a low-density portion DP in the width direction Y during joining as an inclined region. The inclined surface 31c connects a top surface 31b and each base end surface 31a and is inclined toward the anvil 2A side from the base end surface 31a to the top surface 31b in the width direction Y as the inclined region.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present invention relates to an apparatus for manufacturing an electric wire with a terminal and an electric wire with a terminal. [Background technology]

[0002] Conventionally, in devices that use an anvil and a horn to join an electric wire and a terminal with ultrasonic vibration, for example, the electric wire is cut to a specified length, the coating at the end of the wire is stripped to a specified length, the stripped core wire of the electric wire is placed on the joint portion of the terminal that has been set in advance on the anvil, the joint portion and the core wire are clamped and pressure is applied between the anvil and the horn, and the horn ultrasonically vibrates to join the joint portion and the core wire (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2017-188373 A Summary of the Invention [Problem to be solved by the invention]

[0004] When joining an electric wire and a terminal using a conventional joining device, during the pressurizing stage, overcrowded areas where the multiple strands that make up the core are overcrowded and undercrowded areas where the strands are undercrowded are generated. As a result, in the conventional manufacturing device for electric wires with terminals, the joining of the overcrowded areas in the core is good, but the joining of the undercrowded areas is not good, which may cause variations in the joining state of the electric wire and the terminal, leaving room for improvement.

[0005] An object of the present invention is to provide an apparatus for manufacturing an electric wire with terminal, and an electric wire with terminal, which can improve the joining state between an electric wire and a terminal. [Means for solving the problem]

[0006] In order to achieve the above-mentioned object, the manufacturing apparatus for an electric wire with a terminal according to the present invention comprises an anvil on which a joined object, which is formed by bringing a joint portion of a terminal and a conductor portion of an electric wire into contact with each other, is placed, a horn that is arranged facing the anvil in the vertical direction, sandwiching the joined object, and joins the conductor portion to the joint portion in the joined object by ultrasonic vibration, and a pair of holding members that clamp the joined object held by the anvil and the horn in a width direction perpendicular to the axial direction of the electric wire and the vertical direction, wherein the joint portion has a joining surface that contacts the conductor portion and joins the conductor portion when the joined object is clamped by the anvil and the horn, the horn has a processing surface that contacts the conductor portion when clamped and applies pressure to the conductor portion, and the processing surface has an inclined region that inclines with respect to the width direction during joining from an overcrowded portion where the conductor portion becomes overcrowded to an undercrowded portion where the conductor portion becomes undercrowded. Effect of the Invention

[0007] ADVANTAGEOUS EFFECT OF THE DISCLOSURE According to the manufacturing apparatus for an electric wire with terminal and the electric wire with terminal of the present invention, it is possible to improve the joining state between the electric wire and the terminal. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a schematic diagram showing an electric wire with terminal manufactured by the manufacturing apparatus for an electric wire with terminal according to the first embodiment. [Diagram 2] FIG. 2 is a schematic cross-sectional view of the electric wire with terminal of FIG. [Diagram 3] FIG. 3 is a schematic diagram showing the manufacturing apparatus for the electric wire with terminal according to the first embodiment. [Figure 4] FIG. 4 is a schematic diagram showing the manufacturing apparatus for an electric wire with a terminal in a state different from that in FIG. [Diagram 5] FIG. 5 is a schematic diagram showing an electric wire with terminal manufactured by the manufacturing apparatus for an electric wire with terminal according to the second embodiment. [Figure 6]FIG. 6 is a schematic cross-sectional view of the electric wire with terminal of FIG. [Figure 7] FIG. 7 is a schematic diagram showing a manufacturing apparatus for an electric wire with a terminal according to the second embodiment. [Figure 8] FIG. 8 is a schematic diagram showing the manufacturing apparatus for an electric wire with a terminal in a state different from that in FIG. [Figure 9] FIG. 9 is a schematic diagram showing an electric wire with terminal manufactured by the manufacturing apparatus for an electric wire with terminal according to the third embodiment. [Figure 10] FIG. 10 is a schematic cross-sectional view of the electric wire with terminal of FIG. [Figure 11] FIG. 11 is a schematic diagram showing a manufacturing apparatus for an electric wire with a terminal according to the third embodiment. [Figure 12] FIG. 12 is a schematic diagram showing the manufacturing apparatus for an electric wire with a terminal according to the third embodiment in a state different from that in FIG. [Figure 13] FIG. 13 is a schematic diagram showing a conventional manufacturing apparatus for an electric wire with a terminal, the manufacturing apparatus being intended for an electric wire having a core wire. [Figure 14] FIG. 14 is a schematic diagram showing a conventional manufacturing apparatus for an electric wire with a terminal, the manufacturing apparatus being intended for an electric wire having a braided wire. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, the embodiments of the present invention will be described in detail with reference to the drawings. Note that the present invention is not limited to the following embodiments. In other words, the components in the following embodiments include those that a person skilled in the art can easily imagine or that are substantially the same, and various omissions, substitutions, and modifications can be made without departing from the gist of the invention.

[0010] In the following description, for convenience, of the illustrated X, Y, and Z directions, the X direction will be referred to as the "axial direction X," the Y direction will be referred to as the "width direction Y," and the Z direction will be referred to as the "vertical direction Z." The axial direction X, the width direction Y, and the vertical direction Z are mutually perpendicular. The axial direction X corresponds to the direction along the axis O of the electric wire W. The width direction Y and the vertical direction Z are included in the directions perpendicular to the axial direction X.

[0011] [First embodiment] First, an electric wire with terminal WA and a manufacturing apparatus 1A for the electric wire with terminal WA according to the first embodiment will be described with reference to Figs. 1 to 4. The electric wire with terminal WA shown in Fig. 1 is composed of an electric wire W extending along an axial direction X and a terminal 10A, and is applied to, for example, a wire harness arranged in a vehicle. Here, the wire harness is, for example, a collective component in which a plurality of electric wires W used for power supply and signal communication are bundled together to connect each device mounted on the vehicle, and the plurality of electric wires W are connected to each device by terminals 10A, connectors, etc.

[0012] The electric wire W is formed into a tubular shape by braiding a plurality of wires S as a conductor portion (see FIG. 3), and has a braided wire W1 extending along the axial direction X. The wires S are made of a conductive metal such as aluminum, an aluminum alloy, copper, or a copper alloy. The braided wire W1 has a braided wire end W1A at least on one end in the axial direction X.

[0013] The braided wire end W1A is a portion formed by forming an end of the braided wire W1 in the axial direction X by a manufacturing apparatus 1A for an electric wire with terminal WA, which will be described later, and joined to the terminal 10A. As shown in Fig. 2, the cross-sectional shape of the braided wire end W1A when viewed from the axial direction X is not a simple rectangular shape, but is formed in a concave shape with the upper end concave downward. The braided wire end W1A has a processing surface 21 formed on the upper side and a joining surface 22 formed on the lower side and joined to the terminal 10A.

[0014] The processed surface 21 is a surface of the braided wire end W1A that is processed by the manufacturing apparatus 1A for the electric wire with terminal WA. As shown in FIG. 2, the processed surface 21 is formed such that the cross-sectional shape viewed from the axial direction X is concave toward the joining surface 22 side. The processed surface 21 includes a pair of base end surfaces 21a, a bottom surface 21b located between the pair of base end surfaces 21a, and a pair of inclined surfaces 21c that respectively connect the bottom surface 21b and each base end surface 21a. The pair of base end surfaces 21a are portions located on both sides of the width direction Y of the processed surface 21. The bottom surface 21b is a portion located on the center side of the width direction Y of the processed surface 21, and is a portion that is concave from the position of the base end surface 21a toward the joining surface 22 side. The pair of inclined surfaces 21c are portions that are inclined toward the joining surface 22 side from each base end surface 21a toward the bottom surface 21b with respect to the width direction Y.

[0015] The joining surface 22 is a surface of the braided wire end W1A that is joined to the terminal 10A by the manufacturing apparatus 1A for the electric wire with terminal WA.

[0016] The terminal 10A is made of a conductive metal such as copper, a copper alloy, aluminum, an aluminum alloy, etc. The terminal 10A has a joint 11A to which the braided wire end W1A in the axial direction X of the braided wire W1 is joined, and a connection portion 18 provided on the opposite side of the joint 11A in the axial direction X. The terminal 10A is formed such that each portion is integrally formed by, for example, pressing and bending a single sheet metal punched into a shape corresponding to each portion such as the joint 11A, the connection portion 18, etc.

[0017] As shown in Fig. 2, the joint portion 11A is formed to have a rectangular, flat cross-sectional shape as viewed from the axial direction X. The joint portion 11A has a joint surface 11Aa formed on the upper side and to which the braided wire end W1A is joined, and a placement surface 11Ab formed on the lower side. The joint surface 11Aa and the placement surface 11Ab are both flat surfaces extending in the axial direction X and the width direction Y. The joint surface 11Aa is a portion of the braided wire end W1A to which the braided wire end W1A is joined by the manufacturing apparatus 1A for the electric wire with terminal WA. The placement surface 11Ab is a portion that comes into contact with the placement surface 41 of the anvil 2A when the joint portion 11A of the terminal 10A is placed on the anvil 2A.

[0018] The connection portion 18 is a portion to be connected to a mating terminal, etc. The connection portion 18 in the embodiment is formed in an annular shape that can be fastened to, for example, a cylindrical terminal.

[0019] Next, the manufacturing apparatus 1A and manufacturing method for the terminal-fitted electric wire WA according to the first embodiment will be described with reference to FIGS.

[0020] A manufacturing apparatus 1A for manufacturing an electric wire with terminal WA (hereinafter simply referred to as "manufacturing apparatus 1A") processes an end of a braided wire W1 in the axial direction X and joins it to a joint portion 11A of a terminal 10A. The manufacturing apparatus 1A includes an anvil 2A, a horn 3A, and a pair of holding members 4, which join the braided wire end W1A to the terminal 10A. Note that in the illustrated manufacturing apparatus 1A, support members for supporting the anvil 2A, the horn 3A, and the pair of holding members 4, as well as mechanisms for moving them, are omitted.

[0021] The anvil 2A and the horn 3A are disposed opposite each other in the vertical direction Z, with one anvil 2A fixed in position and the other horn 3A configured to be freely movable in the vertical direction Z. By moving the downward side of the horn 3A relative to the anvil 2A, the manufacturing apparatus 1A can clamp the joined body, which is formed by bringing the joint portion 11A and the unprocessed braided wire end portion W1A into contact with each other, in the vertical direction Z and apply pressure to the joined body.

[0022] The anvil 2A has a mounting surface 41 formed on the upper side on which the joint portion 11A of the terminal 10A is placed. The shape of the mounting surface 41 is formed according to the shape of the mounting surface 11Ab of the joint portion 11A. The mounting surface 41 in this embodiment is a uniform flat surface without any irregularities according to the shape of the mounting surface 11Ab.

[0023] The horn 3A is formed on the lower side and has a processing surface 31 for processing the braided wire end W1A of the braided wire W1. The processing surface 31 comes into contact with the braided wire end W1A in a state in which the joined body is clamped between the anvil 2A and the horn 3A, and applies ultrasonic vibration to the braided wire end W1A while applying pressure to the braided wire end W1A.

[0024] The processing surface 31 has an inclined region that inclines from an overcrowded portion OC where the braided wire end W1A becomes overcrowded to a sparse portion DP where the braided wire end W1A becomes sparse in the width direction Y when the braided wire end W1A is joined to the joining portion 11A in a clamped state in which the workpiece is clamped by the anvil 2A and the horn 3A. Specifically, the processing surface 31 has a pair of base end faces 31a facing the overcrowded portion OC, a top face 31b facing the sparse portion DP, and inclined faces 31c that respectively connect the top face 31b and each base end face 31a.

[0025] The pair of base end faces 31a are portions located on both sides of the processing surface 31 in the width direction Y. Each of the pair of base end faces 31a is a flat surface. The top face 31b is located toward the center of the processing surface 31 in the width direction Y, and is a portion that protrudes from the position of the base end faces 31a toward the anvil 2A side (downward side). The top face 31b is a flat surface. The inclined face 31c is a portion that is an inclined region that inclines toward the anvil 2A side from the base end faces 31a toward the top face 31b with respect to the width direction Y.

[0026] The pair of holding members 4 are disposed opposite to each other in the width direction Y and configured to be movable in the up-down direction Z. The pair of holding members 4 sandwich the joint portion 11A between themselves and the anvil 2A in the up-down direction Z, and restrict the movement of the joint portion 11A.

[0027] The manufacturing apparatus 1A clamps the object to be joined in the vertical direction Z between the anvil 2A and the horn 3A, and applies ultrasonic vibrations and pressure to the unprocessed braided wire end W1A using the horn 3A, ultrasonically joining the braided wire end W1A to the joining portion 11A.

[0028] Next, a method for manufacturing the electric wire with terminal WA using the manufacturing apparatus 1A having the above configuration will be described. Note that, although in this embodiment, an operator mainly performs the work described below, the work may be automatically performed by the manufacturing apparatus 1A.

[0029] First, the worker places the terminal 10A on the anvil 2A in the manufacturing device 1A. At this time, the joint 11A of the terminal 10A is placed on the placement surface 41 with the joint surface 11Aa facing the horn 3A side, and the placement surface 11Ab contacts the placement surface 41. Next, the worker moves the pair of holding members 4 toward the anvil 2A side, and the pair of holding members 4 and the anvil 2A respectively clamp both ends of the joint 11A in the width direction Y, thereby fixing the terminal 10A to the anvil 2A. Next, the worker places the braided wire end W1A of the braided wire W1 on the joint surface 11Aa of the joint 11A, and then moves the horn 3A from above the braided wire end W1A toward the anvil 2A (FIG. 3). The manufacturing device 1A moves the horn 3A from the initial position toward the anvil 2A, and applies ultrasonic vibration to the braided wire end W1A while applying pressure F with the horn 3A (FIG. 4). Through the above steps, the electric wire with terminal WA shown in FIG. 1 is manufactured.

[0030] As described above, in the manufacturing apparatus 1A for electric wire with terminal WA according to the first embodiment, the processing surface 31 of the horn 3A has an inclined surface 31c as an inclined region, in which the braided wire end W1A is inclined from the overcrowded portion OC to the undercrowded portion DP in the width direction Y when joined. In addition, in the manufacturing apparatus 1A for electric wire with terminal WA, the processing surface 31 has a pair of base end surfaces 31a located on both sides of the processing surface 31 in the width direction Y facing the overcrowded portion OC, and a top surface 31b located at the center of the processing surface 31 in the width direction Y facing the undercrowded portion DP and protruding from the position of the base end surface 31a toward the anvil side. The inclined surface 31c connects the top surface 31b and each base end surface 31a, and inclines toward the anvil 2A side from the base end surface 31a to the top surface 31b in the width direction Y as an inclined region.

[0031] When processing the braided wire W1 using the conventional horn 301 shown in FIG. 14, a difference occurs in the movement of the wires S due to the pressure F applied from the processing surface 301a of the horn 301 and vibration between the outer periphery on both sides in the width direction Y where the braided wires S are dense and the center where the braided wires S overlap in the vertical direction, so that the wires S become overcrowded in the outer periphery to form an overcrowded portion OC, and the wires S become sparse in the center to form a sparse portion DP. In other words, the braided wire W1 has overcrowded portions OC on both sides in the width direction Y and sparse portions DP on the center side in the width direction Y. As a result, a pressure difference occurs between the overcrowded portion OC and the sparse portion DP on the braided wire end with respect to the joint, which may cause a difference in the joint state. In addition, in the conventional manufacturing device, a long vibration time is required because there is a risk of a difference in the joint state between the joint 11A and the braided wire end W1A.

[0032] In the manufacturing apparatus 1A for the electric wire with terminal WA, the top surface 31b protruding toward the anvil 2A side from the pair of base end surfaces 31a presses the sparsely populated area DP, and the pair of base end surfaces 31a recessed toward the horn 3A side from the top surface 31b presses the overcrowded area OC, thereby adjusting the pressure on the entire braided wire end W1A. As a result, the braided wire end W1A is less likely to have the overcrowded area OC and the sparsely populated area DP, which suppresses the joining variation between the joining portion 11A and the braided wire end W1A, and improves the joining condition of the braided wire W1 and the terminal 10A. In addition, the manufacturing apparatus 1A improves the joining condition of the braided wire W1 and the terminal 10A, thereby shortening the processing time required for joining. As a result, it is possible to join the braided wire W1 and the terminal 10A at a lower cost, and it is possible to suppress the stress on the joining portion due to vibration, thereby improving the reliability of the electrical connection.

[0033] The electric wire with terminal WA according to the first embodiment includes a cylindrical braided wire W1 and a terminal 10A having a joint portion 11A joined to a braided wire end portion W1A of the braided wire W1. The braided wire end portion W1A has a joint surface 22 joined to the terminal 10A and a processed surface 21 formed on the opposite side of the joint surface 22. The processed surface 21 has a pair of base end surfaces 21a located on both sides in the width direction Y, a bottom surface 21b located on the central side and recessed from the base end surface 21a toward the joint surface 22, and an inclined surface 21c connecting the bottom surface 21b and each base end surface 21a and inclining from each base end surface 21a toward the joint surface 22 toward the bottom surface 21b.

[0034] The electric wire with terminal WA has the above-mentioned configuration, which suppresses the variation in the joint between the joint portion 11A and the braided wire end portion W1A and improves the joint state between the braided wire W1 and the terminal 10A, thereby improving the reliability of the electrical connection at the joint portion of the electric wire with terminal WA.

[0035] [Second embodiment] Next, an electric wire with terminal WB and a manufacturing apparatus 1B for the electric wire with terminal WB according to a second embodiment will be described with reference to Figs. 5 to 8. The electric wire with terminal WB according to the second embodiment is different from the electric wire with terminal WA according to the first embodiment in the shape of the joint surface 23 of the braided wire end W1B and the joint portion 11B of the terminal 10B. Furthermore, the manufacturing apparatus 1B for the electric wire with terminal WB according to the second embodiment is different from the manufacturing apparatus 1A for the electric wire with terminal WA according to the first embodiment in the shape of the mounting surface 42 of the anvil 2B. In the second embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof will be omitted.

[0036] The braided wire end W1B is an example of a conductor portion, and is a portion formed by forming an end portion of the braided wire W1 in the axial direction X by a manufacturing apparatus 1B for a terminal-attached electric wire WB described later, and joined to the terminal 10B. As shown in Fig. 6, the braided wire end W1B does not have a simple rectangular cross-sectional shape as viewed from the axial direction X, but is formed so that the central portion is recessed downward. The braided wire end W1B has a processed surface 21 formed on the upper side, and a joining surface 23 formed on the lower side and joined to the terminal 10B.

[0037] The joining surface 23 is a surface of the braided wire end W1B joined to the terminal 10B by the manufacturing apparatus 1B of the electric wire with terminal WB. As shown in FIG. 6, the joining surface 23 is formed such that the cross-sectional shape viewed from the axial direction X is convex toward the joining portion 11B side. The joining surface 23 includes a pair of base end surfaces 23a, a top surface 23b located between the pair of base end surfaces 23a, and a pair of inclined surfaces 23c connecting the top surface 23b and each of the base end surfaces 23a. The pair of base end surfaces 23a are portions located on both sides of the joining surface 23 in the width direction Y. The top surface 23b is a portion located on the center side of the joining surface 23 in the width direction Y and protruding from the position of the base end surface 23a toward the joining portion 11B side. The pair of inclined surfaces 23c are portions inclined toward the terminal 10B side from each base end surface 23a toward the top surface 23b with respect to the width direction Y.

[0038] The terminal 10B has a joint 11B to which the braided wire end W1B is joined, and a connection portion 18 provided on the opposite side of the joint 11B in the axial direction X. The terminal 10B is formed integrally with each portion by, for example, pressing and bending a single sheet metal punched into a shape corresponding to each portion, such as the joint 11B and the connection portion 18. The cross-sectional shape of the terminal 10B as viewed from the axial direction X is formed in a concave shape in accordance with the processing surface 31 and a mounting surface 42 described later, and it can be said that the joint surface 11Ba and the mounting surface 11Bb each have a step including an inclined surface.

[0039] 6, the joint 11B has a cross-sectional shape as viewed from the axial direction X that is recessed downwardly in the same manner as the braided wire end W1B, with the central portion being recessed downwardly. The joint 11B has a joint surface 11Ba formed on the upper side and to which the braided wire end W1B is joined, and a placement surface 11Bb formed on the lower side.

[0040] The joining surface 11Ba is a surface to which the braided wire end W1B is joined by the manufacturing apparatus 1B for the electric wire with terminal WB. As shown in Fig. 6, the joining surface 11Ba has a cross-sectional shape when viewed from the axial direction X that is concave toward the mounting surface 11Bb. The joining surface 11Ba has a pair of base end surfaces 13a located on both sides in the width direction Y, a bottom surface 13b located on the central side and concave from the base end surfaces 13a toward the mounting surface 11Bb, and an inclined surface 13c that connects the bottom surface 13b and each base end surface 13a and inclines from each base end surface 13a toward the mounting surface 11Bb.

[0041] The mounting surface 11Bb is a portion that comes into contact with the mounting surface 42 of the anvil 2B when the joint portion 11B of the terminal 10B is placed on the anvil 2B. The mounting surface 11Bb has a cross-sectional shape as viewed from the axial direction X that is convex downward (outside the body to be joined) as shown in Fig. 6. The mounting surface 11Bb has a pair of base end surfaces 12a located on both sides in the width direction Y, a top surface 12b located on the central side and protruding from the position of the base end surfaces 12a, and inclined surfaces 12c that connect the top surface 12b and each base end surface 12a, and incline downward (outside the body to be joined) from each base end surface 13a.

[0042] Next, a manufacturing apparatus 1B and a manufacturing method for an electric wire with terminal WB according to a second embodiment will be described with reference to FIGS.

[0043] The anvil 2B has a mounting surface 42 formed on the upper side on which the joint portion 11B of the terminal 10B is placed. The mounting surface 42 is formed in a shape corresponding to the shape of the mounting surface 11Bb of the joint portion 11B. The mounting surface 42 in this embodiment has a pair of base end surfaces 42a facing the pair of base end surfaces 31a and located on both sides of the mounting surface 42 in the width direction Y, a bottom surface 42b facing the top surface 31b and located on the center side of the mounting surface 42 in the width direction Y, and a pair of inclined surfaces 42c connecting the bottom surface 42b and each base end surface 42a, respectively, and inclining from each base end surface 42a to the bottom surface 42b toward the anvil 2B with respect to the width direction Y.

[0044] Next, a method for manufacturing the electric wire with terminal WB using the manufacturing apparatus 1B having the above configuration will be described. Note that, although in this embodiment, an operator mainly performs the work described below, the work may be automatically performed by the manufacturing apparatus 1B.

[0045] First, the worker places the terminal 10B on the anvil 2B in the manufacturing device 1B. At this time, the joint portion 11B of the terminal 10B is placed on the placement surface 42 with the joining surface 11Ba facing the horn 3A side, and the placement surface 11Bb contacts the placement surface 42. Next, the worker moves the pair of holding members 4 toward the anvil 2B side, and the pair of holding members 4 and the anvil 2B respectively clamp both ends of the joint portion 11B in the width direction Y, thereby fixing the terminal 10B to the anvil 2B. Next, the worker places the braided wire end W1B of the braided wire W1 on the joining surface 11Ba of the joint portion 11B, and then moves the horn 3A from above the braided wire end W1B toward the anvil 2B (FIG. 7). The manufacturing device 1B moves the horn 3A from the initial position toward the anvil 2B side, and applies ultrasonic vibration to the braided wire end W1B while applying pressure F with the horn 3A (FIG. 8). Through the above steps, the electric wire with terminal WB shown in FIG. 5 is manufactured.

[0046] As described above, in the manufacturing apparatus 1B for the electric wire with terminal WB according to the second embodiment, the processing surface 31 of the horn 3A has an inclined surface 31c as an inclined region in which the braided wire end W1A is inclined from the dense portion OC toward the sparse portion DP in the width direction Y during joining. In addition, in the manufacturing apparatus 1B for the electric wire with terminal WB, the processing surface 31 has a pair of base end surfaces 31a and a top surface 31b, and the inclined surface 31c connects the top surface 31b and each base end surface 31a, respectively, and inclines as an inclined region from the base end surface 31a toward the top surface 31b toward the anvil 2A in the width direction Y. In addition, in the manufacturing apparatus 1B for the electric wire with terminal WB, the anvil 2B has a mounting surface 42 formed opposite the processing surface 31 and on which the joint portion 11B is placed, and the mounting surface 42 has the pair of base end surfaces 42a, a bottom surface 42b, and a pair of inclined surfaces 42c described above.

[0047] The manufacturing apparatus 1B of the electric wire with terminal WB can achieve the same effects as those of the manufacturing apparatus 1A of the electric wire with terminal WB by virtue of the above-mentioned configuration.

[0048] The electric wire with terminal WB according to the second embodiment includes a cylindrical braided wire W1 and a terminal 10B having a joint portion 11B joined to a braided wire end portion W1B of the braided wire W1. The braided wire end portion W1B has a joint surface 23 joined to the terminal 10B and a processed surface 21 formed on the opposite side of the joint surface 23.

[0049] The electric wire with terminal WB according to the second embodiment can achieve the same effects as those of the electric wire with terminal WB described above due to the above-mentioned configuration.

[0050] [Third embodiment] Next, an electric wire with terminal WC and a manufacturing apparatus 1C for the electric wire with terminal WC according to a third embodiment will be described with reference to Figs. 9 to 12. In the electric wire with terminal WC according to the third embodiment, the electric wire W is a coated electric wire instead of a braided wire W1, and the shape of the joint portion 11C of the terminal 10C is different from that of the electric wire with terminal WA according to the first embodiment. In addition, the manufacturing apparatus 1C for the electric wire with terminal WC according to the third embodiment is different from the manufacturing apparatus 1A for the electric wire with terminal WA according to the first embodiment in the shapes of the processing surface 32 of the horn 3C and the mounting surface 43 of the anvil 2C. In the third embodiment, the same components as those in the first and second embodiments are denoted by the same reference numerals, and detailed description thereof will be omitted.

[0051] As shown in Fig. 1 and Fig. 2, the electric wire W includes a core wire W2 and an insulating covering W3 that has insulating properties and covers the outside of the core wire W2. The electric wire W is an insulated electric wire in which the core wire W2 is covered with the insulating covering W3. The electric wire W generally has flexibility, but is not limited to this.

[0052] As shown in Fig. 1, the electric wire W includes a core wire W2 formed by bundling a plurality of wires S as a conductor portion, and an insulating coating W3 having insulating properties and covering the outside of the core wire W2. The electric wire W is a coated electric wire in which the core wire W2 is coated with the insulating coating W3. The electric wire W extends along the axial direction X and is formed so as to extend with approximately the same diameter in the axial direction X. The electric wire W has a circular cross-sectional shape in a direction perpendicular to the axial direction X.

[0053] The core wire W2 is, for example, a bundle of wires S made of a conductive metal, such as aluminum, an aluminum alloy, copper, a copper alloy, etc. The core wire W2 may be a twisted core wire made by twisting together a plurality of wires W11. The electric wire W has the insulating coating W3 stripped off from at least one end in the axial direction X, and the core wire W2 is exposed from the end of the insulating coating W3 to form an exposed core portion W2A.

[0054] The insulating coating W3 is formed, for example, by extrusion molding an insulating resin material (such as PP (polypropylene), PVC (polyvinyl chloride), cross-linked PE (polyethylene), etc., which is appropriately selected taking into consideration abrasion resistance, chemical resistance, heat resistance, etc.) The insulating coating W3 is formed into a substantially circular ring shape whose cross-sectional shape in a direction perpendicular to the axial direction X is aligned in the circumferential direction.

[0055] The exposed core portion W2A is an example of a conductor portion, and is a portion where an end portion of the core W2 in the axial direction X is shaped and joined to the terminal 10C by a manufacturing apparatus 1C for an electric wire with terminal WC described later. As shown in Fig. 10, the cross-sectional shape of the exposed core portion W2A when viewed from the axial direction X is not a simple rectangular shape, but is formed so that the central portion is recessed upward. The exposed core portion W2A has a processed surface 24 formed on the upper side and a joining surface 25 formed on the lower side and joined to the terminal 10C.

[0056] The processed surface 24 is a surface in the exposed core portion W2A that is processed by the manufacturing apparatus 1C for an electric wire with terminal WC. As shown in Fig. 10, the processed surface 24 has a cross-sectional shape as viewed from the axial direction X that is formed into an inverted V shape facing upward. The processed surface 24 has a vertex 24a located at the center side in the width direction Y of the exposed core portion W2A, and a pair of inclined surfaces 24b located on both sides of the vertex 24a in the width direction Y and inclined downward from the vertex 24a toward both ends in the width direction Y.

[0057] The joint surface 25 is a surface of the exposed core portion W2A that is joined to the terminal 10C by the manufacturing apparatus 1C for the electric wire with terminal WC. As shown in Fig. 10, the joint surface 25 has a cross-sectional shape as viewed from the axial direction X that is formed into an inverted V shape facing upward. The joint surface 25 has a bottom point 25a located at the center side in the width direction Y of the exposed core portion W2A, and a pair of inclined surfaces 25b located on both sides of the bottom point 25a in the width direction Y and inclined downward from the bottom point 25a toward both ends in the width direction Y.

[0058] The terminal 10C has a joint portion 11C to which the exposed core portion W2A is joined, and a connection portion 18 provided on the opposite side of the joint portion 11C in the axial direction X. The terminal 10C is formed such that each portion is integrally formed by, for example, pressing and bending a single sheet of metal punched into a shape corresponding to each portion, such as the joint portion 11C, the connection portion 18, etc.

[0059] 6, the joint portion 11C has a cross-sectional shape as viewed from the axial direction X that is formed into an inverted V shape with the central portion recessed upward, similar to the exposed core portion W2A. The joint portion 11C has a mounting surface 14 formed on the lower side and a joint surface 15 formed on the upper side to which the exposed core portion W2A is joined.

[0060] The mounting surface 14 is a portion that comes into contact with a mounting surface 43 of the anvil 2C when the joint portion 11C of the terminal 10C is placed on the anvil 2C described later. The mounting surface 14 has a cross-sectional shape that is formed into an inverted V shape facing downward when viewed from the axial direction X, as shown in Fig. 10. The mounting surface 14 has a bottom point 14a located at the center of the mounting surface 14 in the width direction Y, and a pair of inclined surfaces 14b located on both sides of the bottom point 14a in the width direction Y and inclined downward from the bottom point 14a toward both ends in the width direction Y.

[0061] The joint surface 15 is a surface of the terminal 10C to which the exposed core portion W1C is joined by the manufacturing apparatus 1C for the electric wire with terminal WC. As shown in Fig. 10, the joint surface 15 has a cross-sectional shape that is an inverted V shape facing downward when viewed from the axial direction X. The joint surface 15 has a vertex 15a located at the center of the joint surface 15 in the width direction Y, and a pair of inclined surfaces 15b located on both sides of the vertex 15a in the width direction Y and inclined downward from the vertex 15a toward both ends in the width direction Y.

[0062] Next, a manufacturing apparatus 1C and a manufacturing method for an electric wire with a terminal WC according to a third embodiment will be described with reference to FIGS.

[0063] The anvil 2C has a mounting surface 43 formed on the upper side on which the joint portion 11C of the terminal 10C is placed. The mounting surface 43 is formed in a shape corresponding to the shape of the mounting surface 14 of the joint portion 11C. The mounting surface 43 in this embodiment has a vertex 43a facing the bottom point 14a and located at the center side of the mounting surface 43 in the width direction Y, and a pair of inclined surfaces 43b facing a pair of inclined surfaces 14b and located on both sides of the vertex 43a in the width direction Y, and inclined from the vertex 43a toward the anvil 2C side (downward side) toward both ends in the width direction Y.

[0064] The horn 3C is formed on the lower side and has a processing surface 32 for processing the exposed core wire portion W2A. When the workpiece is clamped between the anvil 2C and the horn 3C, the processing surface 32 comes into contact with the exposed core wire portion W2A and applies ultrasonic vibration while applying pressure to the exposed core wire portion W2A.

[0065] The processing surface 32 has an inclined region that inclines from an overcrowded portion OC where the exposed core portion W2A becomes overcrowded to an undercrowded portion DP where the exposed core portion W2A becomes undercrowded in the width direction Y when the exposed core portion W2A is joined to the joint portion 11C in a clamped state in which the joined body is clamped by the anvil 2C and the horn 3C. Specifically, the processing surface 32 has a bottom point 32a facing the overcrowded portion OC and a pair of inclined surfaces 32b facing the undercrowded portion DP. The bottom point 32a is a portion located on the center side of the processing surface 32 in the width direction Y. The bottom point 32a is a portion that is recessed toward the horn 3C side. The pair of inclined surfaces 32b are located on both sides of the bottom point 32a in the width direction Y, and are portions that incline from the bottom point 32a toward the anvil 2C side toward both ends in the width direction Y as an inclined region.

[0066] Next, a method for manufacturing the electric wire with terminal WC using the manufacturing apparatus 1C having the above configuration will be described. Note that, although in this embodiment, the worker mainly performs the work described below, the work may be automatically performed by the manufacturing apparatus 1C.

[0067] First, the worker places the terminal 10C on the anvil 2C in the manufacturing device 1C. At this time, the joint portion 11C of the terminal 10C is placed on the placement surface 43 with the joint surface 15 facing the horn 3C side, and the placement surface 14 contacts the placement surface 43. Next, the worker moves the pair of holding members 4 toward the anvil 2C, and the pair of holding members 4 and the anvil 2C clamp both ends of the joint portion 11C in the width direction Y, thereby fixing the terminal 10C to the anvil 2C. Next, the worker places the core exposed portion W2A on the joint surface 15 of the joint portion 11C, and then moves the horn 3C from above the core exposed portion W2A toward the anvil 2C (FIG. 11). The manufacturing device 1C applies ultrasonic vibration to the core exposed portion W2A while applying pressure F to the core exposed portion W2A with the horn 3C while moving the horn 3C from the initial position toward the anvil 2C (FIG. 12). Through the above steps, the electric wire with terminal WA shown in FIG. 9 is manufactured.

[0068] As described above, the manufacturing apparatus 1C of the electric wire with terminal WC according to the third embodiment has the processing surface 32 in which the horn 3C contacts and presses the exposed core portion W2A when the object to be joined is clamped by the anvil 2C and the horn 3C. The processing surface 32 has an inclined surface 32b as an inclined region, in which the exposed core portion W2A is inclined between the overcrowded portion OC and the sparse portion DP with respect to the width direction Y during joining. In addition, the manufacturing apparatus 1C of the electric wire with terminal WC has a processing surface 32 facing the overcrowded portion OC and located at the center of the processing surface 32 in the width direction Y, and has a bottom point 32a that is recessed toward the opposite side to the anvil 2C, and a pair of inclined surfaces 32b facing the sparse portion DP and located on both sides of the bottom point 32a in the width direction Y, and inclined from the bottom point 32a toward both ends in the width direction Y as an inclined region.

[0069] When processing exposed core portion W2A using conventional horn 300 shown in FIG. 13, overcrowded portion OC and sparse portion DP are generated in exposed core portion W2A during the pressurizing stage. In the overcrowded portion OC, the wires S are overlapped in the pressurizing direction, and pressure is applied preferentially. As a result, a pressure difference occurs in the overcrowded portion OC compared to the sparse portion DP, which may cause variations in the bonding state. Furthermore, with conventional manufacturing equipment, a long vibration time is required because there is a risk of differences in the bonding state between joint 11A and braided wire end W1A.

[0070] The manufacturing device 1C of the electric wire with terminal WC and the electric wire with terminal WC are configured as described above, and when the coated electric wire W and the terminal 10C are joined, the wires S in the dense area OC move along the inclined surface 32b toward the sparse area DP by the pressure transmitted from the horn 3C. As a result, the exposed core wire portion W2A has a uniform thickness L with the wires S evenly arranged. This suppresses the unevenness of the joint between the joint portion 11C and the exposed core wire portion W2A, and improves the joint state between the electric wire W and the terminal 10C. Furthermore, the manufacturing device 1C improves the joint state between the electric wire W and the terminal 10C, thereby shortening the processing time required for the joint. As a result, it is possible to suppress the stress on the joint portion due to vibration, and improve the reliability of the electrical connection. [Explanation of symbols]

[0071] Manufacturing apparatus for the wire WA with a 1A terminal 2A anvil 3A horn 4 Holding member 10A terminal 11A joint part 11Aa joint surface 11Ab placed surface 21 Work surface 21a Base end surface 21b Bottom surface 21c Inclined surface 22 Joint surface 31 Machined surface 41 Placing surface W Wire WA Wire with a terminal W1 Braided wire W1A End part of the braided wire S Strand

Claims

1. an anvil on which a workpiece is placed, the workpiece being configured by bringing a joint portion of a terminal into contact with a conductor portion of an electric wire; horns disposed on the anvil so as to face each other in a vertical direction with the workpiece therebetween, and which join the conductive portion to the joining portion of the workpiece by ultrasonic vibration; a pair of holding members that hold the workpieces held by the anvil and the horn in a width direction perpendicular to the axial direction of the electric wires and the up-down direction, The joint is a joining surface that comes into contact with the conductor portion and joins the workpiece to the conductor portion when the workpiece is sandwiched between the anvil and the horn, The horn is a processed surface that contacts the conductor portion in the clamped state and applies pressure to the conductor portion; The processed surface is The conductive portion has an inclined region that is inclined from an overcrowded portion to an undercrowded portion in the width direction when the conductive portion is joined. A manufacturing apparatus for an electric wire with terminal.

2. the electric wire includes a braided wire formed into a tubular shape by braiding a plurality of wires as the conductor portion, the overcrowded portions are located on both sides in the width direction, and the sparsely populated portion is located on a central side in the width direction, The processed surface is a pair of base end surfaces located on both sides of the processing surface in the width direction facing the overcrowded portion; A top surface is located on the center side of the width direction of the processing surface facing the depopulated portion and protrudes from the position of the base end surface toward the anvil side; the top surface and each of the base end surfaces are connected to each other, and the inclined region has an inclined surface that is inclined toward the anvil side from the base end surface to the top surface in the width direction. The manufacturing apparatus for an electric wire with terminal according to claim 1 .

3. the electric wire includes a braided wire formed into a tubular shape by braiding a plurality of wires as the conductor portion, the overcrowded portions are located on both sides in the width direction, and the sparsely populated portion is located on a central side in the width direction, The processed surface is a pair of horn-side base end surfaces located on both sides of the processing surface in the width direction, the pair facing the overcrowded portion; a horn-side top surface located on the center side of the width direction of the processing surface facing the sparsely populated portion and protruding from the position of the horn-side base end surface toward the anvil side; a pair of horn-side inclined surfaces that connect the horn-side top surface and each of the horn-side base end surfaces, and that incline toward the anvil side from each of the horn-side base end surfaces toward the horn-side top surface in the width direction as the inclined region; The joining surface is a pair of terminal-side base end surfaces located on both sides of the joining surface in the width direction and facing the overcrowded portion; a terminal-side bottom surface that is located on a central side of the joining surface in the width direction opposite to the sparsely populated portion and recessed from the position of the terminal-side base end surface toward the anvil side; a pair of terminal side inclined surfaces that connect the terminal side bottom surface and each of the terminal side base end surfaces, and that incline toward the anvil side from the terminal side base end surface toward each of the terminal side bottom surfaces in the width direction, The anvil is a mounting surface formed opposite the processing surface and on which the joint is placed, The placement surface is a pair of anvil-side base end surfaces facing the pair of horn-side base end surfaces and positioned on both sides of the placement surface in the width direction; an anvil-side bottom surface that faces the horn-side top surface, is located at the center of the mounting surface in the width direction, and is recessed from the position of the anvil-side base end surface toward an opposite side to the horn; a pair of anvil side inclined surfaces that connect the anvil side bottom surface and each of the anvil side base end surfaces, and that are inclined from each of the anvil side base end surfaces to the anvil side bottom surface in the width direction toward the opposite side to the horn; The manufacturing apparatus for an electric wire with terminal according to claim 1 .

4. the electric wire includes a core wire formed by bundling a plurality of wires as the conductor portion, the overcrowded portion is located at a center side in the width direction, and the sparsely populated portions are located on both sides in the width direction, The processed surface is a horn-side bottom point located at a center side in the width direction of the processing surface facing the overcrowded portion and recessed toward an opposite side to the anvil; A pair of horn-side inclined surfaces are located on both sides of the horn-side bottom point in the width direction facing the depopulated portion, and inclined from the horn-side bottom point toward both ends in the width direction as the inclined region toward the anvil side, The joining surface is a terminal-side apex located at a center side of the joining surface in the width direction opposite to the crowded portion and protruding toward the horn side; a pair of terminal-side inclined surfaces located on both sides of the terminal-side apex in the width direction, facing the depopulated portion, and inclined from the terminal-side apex toward both ends in the width direction toward the anvil side, The anvil is a mounting surface formed opposite the processing surface and on which the joint is placed, The placement surface is an anvil-side apex that faces the horn-side bottom point, is located at the center of the width direction of the placement surface, and protrudes toward the horn side; a pair of anvil-side inclined surfaces that face the pair of horn-side inclined surfaces, are positioned on both sides of the anvil-side apex in the width direction, and are inclined from the anvil-side apex toward both ends in the width direction in a direction opposite to the horn; The manufacturing apparatus for an electric wire with terminal according to claim 1 .

5. an electric wire formed into a tubular shape by braiding a plurality of wires and having a braided wire extending along an axial direction; a terminal having a joint portion joined to an end portion of the braided wire in the axial direction of the braided wire, The braided wire end portion is a joining surface that contacts the joining portion and joins to the joining portion; a work surface formed on the opposite side of the joining surface, The workpiece surface is A pair of base end surfaces located on both sides in a width direction of the work surface; a bottom surface located at a center side of the processing surface in the width direction and recessed from the base end surface toward the joining surface; an inclined surface that connects the bottom surface and each of the base end surfaces and is inclined toward the joint surface from each of the base end surfaces toward the bottom surface in the width direction; A terminal-attached electric wire.

6. an electric wire including a core wire formed by bundling a plurality of wires extending along an axial direction, and a coating that covers the core wire with an end of the core wire exposed as an exposed core wire portion; a terminal having a joint portion joined to the exposed core portion, The exposed core wire portion is a core-side joint surface that comes into contact with the joint portion and is joined to the joint portion; a processed surface formed on the opposite side of the core wire side joining surface, The joint is a terminal-side joint surface facing the core-side joint surface and joined to the core-side joint surface, The work surface, the core wire side joint surface, and the terminal side joint surface are An apex located at a center side in a width direction of the joint portion and protruding toward the work surface side; A pair of inclined surfaces are located on both sides of the apex in the width direction and inclined from the apex to both ends in the width direction in a direction opposite to the apex. A terminal-attached electric wire.

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