Conductor connection structure and method for manufacturing the same

Abstract

To provide a conductor connection structure that enables a conductor and an electric wire to be easily joined to each other when the conductor and the electric wire are butt-joined, and a manufacturing method therefor.SOLUTION: A conductor connection structure includes an electric wire 10 having a core wire bundle 30 and a conductor 40 having a plate-shaped end portion, the core wire bundle has a core wire protruding piece 32, the conductor has a conductor protruding piece 42, the core wire protruding piece and the conductor protruding piece are overlapped with each other in a thickness direction of the conductor, a first joint portion 51 is formed by joining the tip of the core wire protruding piece to the base end portion of the conductor, a second joint portion 52 is formed by joining the tip of the conductor protruding piece to the base end portion of the core wire bundle, and the first joint portion and the second joint portion are provided at different positions from each other in plan view. A method manufacturing for a conductor connection structure includes a step of overlapping a core wire protruding piece and a conductor protruding piece, a step of joining the tip of a core wire protruding piece to a base end portion of the conductor to form a first joint portion, and a step of joining the tip of a conductor protruding piece to a base end portion of the core wire bundle to form a second joint portion.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a conductor connection structure and a method for manufacturing the conductor connection structure.

Background Art

[0002] Automobiles are equipped with a wide variety of electronic devices, and wire harnesses are routed to transmit power, control signals, etc. to the electronic devices. A wire harness includes a plurality of electric wires and connectors, and is connected to an electronic device or another wire harness by fitting the connector to the connector of the electronic device or the connector of another wire harness.

[0003] Generally, a wire with a terminal (a wire with a conductor) constituting such a wire harness includes an electric wire and a terminal fitting (conductor) attached to the end of the electric wire (see Patent Document 1).

[0004] Patent Document 1 discloses a wire with a terminal including an electric wire in which a conductor portion made of a material mainly composed of a first metal is coated with an insulating material, and a terminal made of a material mainly composed of a second metal different from the first metal and connected to the conductor portion exposed at one end of the electric wire. In the wire with a terminal, an alloy layer containing the first metal and the second metal is further formed across the conductor portion and the terminal on the entire outer peripheral edge of the contact portion between the conductor portion and the terminal. Specifically, in a state where the conductor portion including a plurality of strands and the terminal are butted against each other, the contact portion between the conductor portion and the terminal is joined by a laser welder. The joint portion between the conductor portion and the terminal thus formed becomes an alloy layer, and the conductor portion and the terminal are electrically connected and firmly joined.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] In Patent Document 1, a plate-shaped terminal and a substantially rectangular parallelepiped-shaped conductor part are joined in a butted state. Therefore, in order to ensure electrical continuity between the terminal and the conductor part, it is necessary to melt the entire butted part. However, since the conductor part formed in a substantially rectangular parallelepiped shape is an aggregate of fine wires, it is easily melted locally and is likely to melt and fall off. Therefore, the range of condition setting when fusion-joining the terminal and the conductor part becomes narrow, which has been a factor in reducing the yield.

[0007] The present invention has been made in view of the problems of such conventional technologies. And an object of the present invention is to provide a conductor connection structure capable of easily joining a conductor such as a terminal and an electric wire when they are butted and joined, and a method for manufacturing the conductor connection structure.

Means for Solving the Problems

[0008] The conductor connection structure according to an aspect of the present invention includes an electric wire having a core wire bundle composed of a plurality of strands, and a conductor having a plate-shaped end portion. The core wire bundle has a core wire protruding piece that extends from the base end portion of the core wire bundle toward the conductor along the surface of the core wire bundle. The conductor has a conductor protruding piece that extends from the base end portion of the conductor toward the core wire bundle along the surface of the conductor. The core wire protruding piece and the conductor protruding piece are overlapped in the thickness direction of the conductor. A first joint portion is formed by joining the tip of the core wire protruding piece and the base end portion of the conductor. A second joint portion is formed by joining the tip of the conductor protruding piece and the base end portion of the core wire bundle. The first joint portion and the second joint portion are provided at different positions when viewed in plan.

[0009] A method for manufacturing a conductor connection structure according to another aspect of the present invention is a method for manufacturing a conductor connection structure formed by joining an electric wire including a core wire bundle composed of a plurality of strands and a conductor having a plate-shaped end portion. The manufacturing method includes a step of preparing the electric wire including the core wire bundle having a core wire protruding piece extending along the surface of the core wire bundle from the base end portion of the core wire bundle, and the conductor having a conductor protruding piece extending along the surface of the conductor from the base end portion of the conductor; a step of overlapping the core wire protruding piece and the conductor protruding piece in the thickness direction of the conductor; a step of joining the tip of the core wire protruding piece and the base end portion of the conductor to form a first joint portion; and a step of joining the tip of the conductor protruding piece and the base end portion of the core wire bundle to form a second joint portion. The first joint portion and the second joint portion are provided at different positions when viewed in plan.

Effects of the Invention

[0010] According to the present invention, it is possible to provide a conductor connection structure and a method for manufacturing the conductor connection structure that can easily join a conductor such as a terminal and an electric wire when they are butted and joined.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Embodiments for Carrying Out the Invention

[0012] Hereinafter, the conductor connection structure according to this embodiment and the manufacturing method of the conductor connection structure will be described in detail with reference to the drawings. Note that the dimensional ratios in the drawings are exaggerated for the convenience of explanation and may be different from the actual ratios.

[0013] [Conductor Connection Structure] As shown in FIGS. 1 and 2, the wire 1 with a conductor to which the conductor connection structure according to this embodiment is applied includes a wire 10 and a conductor 40 connected to the tip of the wire 10. In this specification and the drawings, the direction in which the wire 10 and the conductor 40 are arranged is indicated by an arrow Y, the direction orthogonal to the arrow Y (vertical direction) is indicated by an arrow Z, and the direction orthogonal to both the arrow Y and the arrow Z (left - right direction) is indicated by an arrow X. Also, among the wire 10 and the conductor 40, the conductor 40 side is referred to as "front", and the opposite wire 10 side is referred to as "rear".

[0014] The wire 10 is a covered wire including a plurality of strands 21 and an insulator covering portion 22 that covers the periphery of the plurality of strands 21. The strands 21 can be made of, for example, a conductive metal material such as copper, copper alloy, aluminum, or aluminum alloy. The insulator covering portion 22 is formed of a resin material having flexibility and electrical insulation. And at one end of the wire 10, the insulator covering portion 22 is removed and a part of the strands 21 is exposed.

[0015] The wire 10 is formed by shaping the exposed plurality of strands 21 and includes a core wire bundle 30 that is substantially rectangular in plan view. And a tapered surface 23 is formed between the plurality of strands 21 provided with the insulator covering portion 22 around and the core wire bundle 30. Note that the thickness of the core wire bundle 30 along the Z - direction is smaller than the diameter of the bundle of the plurality of strands 21 provided with the insulator covering portion 22 around, and the width of the core wire bundle 30 along the X - direction is larger than the diameter of the bundle of the plurality of strands 21 provided with the insulator covering portion 22 around.

[0016] The core wire bundle 30 includes a core wire protruding piece 32 that extends forward from the base end portion 31 of the core wire bundle 30 toward the conductor 40 located in front along the surface 301 of the core wire bundle 30. And, as shown in FIG. 1, the core wire protruding piece 32 is provided across the entire width direction (X direction) of the core wire bundle 30. Thus, since the core wire bundle 30 includes the core wire protruding piece 32, the core wire bundle 30 has a substantially L-shaped cross section when viewed from the side.

[0017] The conductor 40 is a member made of a conductive metal and at least the end portions are plate-shaped. The conductor 40 is formed by processing a plate material made of a conductive metal material such as copper, copper alloy, aluminum or aluminum alloy. Note that the conductor 40 may be composed of a single-layer metal plate or may be composed of a laminated plate formed by laminating a plurality of thin metal plates.

[0018] The conductor 40 may be a substantially rectangular parallelepiped plate-shaped member or may be, for example, a bus bar. In the present embodiment, the thickness of the conductor 40 along the Z direction is substantially the same as the thickness of the core wire bundle 30, and the width of the conductor 40 along the X direction is substantially the same as the width of the core wire bundle 30. Note that on the front side of the conductor 40, a leaf spring, a protrusion, a through hole, or the like for suppressing disengagement when inserted into a connector or the like may be formed. Also, the thickness of the conductor 40 is not particularly limited, but can be, for example, 3 mm to 6 mm.

[0019] The conductor 40 includes a conductor protruding piece 42 that extends rearward from the base end portion 41 of the conductor 40 toward the core wire bundle 30 located behind along the surface 401 of the conductor 40. And, similar to the core wire protruding piece 32, the conductor protruding piece 42 is provided across the entire width direction (X direction) of the conductor 40. Thus, since the conductor 40 includes the conductor protruding piece 42, the conductor 40 has a substantially L-shaped cross section when viewed from the side.

[0020] The thickness of the core wire protruding piece 32 along the Z direction and the thickness of the conductor protruding piece 42 along the Z direction can be made substantially the same. And the sum of the thickness of the core wire protruding piece 32 and the thickness of the conductor protruding piece 42 is substantially the same as the thickness of the core wire bundle 30 and is further substantially the same as the thickness of the conductor 40.

[0021] Also, the protruding lengths of the core wire protruding piece 32 and the conductor protruding piece 42 along the Y direction can be made substantially the same. Specifically, as shown in FIG. 3(c), in the Y direction, the length from the base end face 311 of the base end portion 31 of the core wire bundle 30 to the tip face 321 of the core wire protruding piece 32 is the protruding length of the core wire protruding piece 32. Further, as shown in FIG. 4(b), in the Y direction, the length from the base end face 411 of the base end portion 41 of the conductor 40 to the tip face 421 of the conductor protruding piece 42 is the protruding length of the conductor protruding piece 42. And the protruding lengths of the core wire protruding piece 32 and the conductor protruding piece 42 can be made substantially the same.

[0022] In the wire with conductor 1 of the present embodiment, the core wire protruding piece 32 and the conductor protruding piece 42 are overlapped in the thickness direction (Z direction). That is, the overlapping surfaces 322 of the core wire protruding piece 32 and the overlapping surfaces 422 of the conductor protruding piece 42 are in contact with each other.

[0023] Furthermore, a first joint portion 51 is formed by joining the tip of the core wire protruding piece 32 and the base end portion 41 of the conductor 40. That is, as will be described later, the first joint portion 51 is formed by joining the interface between the tip face 321 of the core wire protruding piece 32 and the base end face 411 of the conductor 40 in a state where they are in contact with each other. Similarly, a second joint portion 52 is formed by joining the tip of the conductor protruding piece 42 and the base end portion 31 of the core wire bundle 30. That is, the second joint portion 52 is formed by joining the interface between the tip face 421 of the conductor protruding piece 42 and the base end face 311 of the core wire bundle 30 in a state where they are in contact with each other.

[0024] As will be described later, the first joint 51 can be formed by laser-welding the contact portion between the tip surface 321 of the core wire protruding piece 32 and the base end surface 411 of the conductor 40. Similarly, the second joint 52 can be formed by laser-welding the contact portion between the tip surface 421 of the conductor protruding piece 42 and the base end surface 311 of the core wire bundle 30. Therefore, it is preferable that the first joint 51 and the second joint 52 are composed of an alloy of the metal constituting the core wire bundle 30 and the metal constituting the conductor 40. By configuring the first joint 51 and the second joint 52 with such an alloy, the conductivity between the core wire bundle 30 and the conductor 40 can be enhanced.

[0025] Here, in the electric wire 1 with a conductor, the first joint 51 and the second joint 52 are provided at different positions when viewed in plan. By forming the first joint 51 and the second joint 52 at different positions in this way, as will be described later, the melting and dropping during welding are prevented, so that welding defects are suppressed and the core wire bundle 30 and the conductor 40 can be easily connected. Specifically, in the electric wire 1 with a conductor, it is preferable that the first joint 51 and the second joint 52 are displaced from each other along the longitudinal direction (Y direction) of the electric wire 10. With such a configuration, it is possible to improve the conduction between the core wire bundle 30 and the conductor 40 in the Y direction while suppressing the melting and dropping during welding.

[0026] As shown in FIG. 1, it is preferable that the first joint 51 and the second joint 52 are formed over the entire width direction (X direction) of the core wire bundle 30 and the conductor 40. Further, as shown in FIG. 2, it is preferable that the depth D in the Z direction of the first joint 51 exceeds the thickness T of the core wire protruding piece 32. Similarly, it is preferable that the depth in the Z direction of the second joint 52 exceeds the thickness of the conductor protruding piece 42. With such a configuration, it is possible to improve the conduction between the core wire bundle 30 and the conductor 40 in the Y direction. Note that, as shown in FIG. 2, the overlapping surface 322 of the core wire protruding piece 32 and the overlapping surface 422 of the conductor protruding piece 42, which are located between the first joint 51 and the second joint 52, may not be joined.

[0027] As described above, the conductor connection structure of this embodiment includes an electric wire 10 having a core wire bundle 30 composed of a plurality of strands 21, and a conductor 40 having a plate-shaped end portion. The core wire bundle 30 has a core wire protruding piece 32 that extends from the base end portion 31 of the core wire bundle 30 toward the conductor 40 along the surface 301 of the core wire bundle 30. The conductor 40 has a conductor protruding piece 42 that extends from the base end portion 41 of the conductor 40 toward the core wire bundle 30 along the surface 401 of the conductor 40. The core wire protruding piece 32 and the conductor protruding piece 42 are overlapped in the thickness direction (Z direction) of the conductor 40. A first joint portion 51 is formed by joining the tip of the core wire protruding piece 32 and the base end portion 41 of the conductor 40, and a second joint portion 52 is formed by joining the tip of the conductor protruding piece 42 and the base end portion 31 of the core wire bundle 30. The first joint portion 51 and the second joint portion 52 are provided at different positions when viewed in plan.

[0028] In the above conductor connection structure, when the electric wire 10 and the conductor 40 are butted and joined, the core wire protruding piece 32 is provided on the core wire bundle 30, the conductor protruding piece 42 is provided on the conductor 40, and when these are overlapped and joined, the first joint portion 51 and the second joint portion 52 are formed at different positions from each other. With such a configuration, melting and dropping during welding are prevented, so that welding defects are suppressed and the core wire bundle 30 and the conductor 40 can be easily connected, while ensuring good electrical continuity between the core wire bundle 30 and the conductor 40.

[0029] In the conductor connection structure of this embodiment, the first joint portion 51 and the second joint portion 52 may be displaced from each other along the longitudinal direction of the electric wire 10. With such a configuration, it is possible to suppress melting and dropping during welding while ensuring good electrical continuity between the core wire bundle 30 and the conductor 40 in the longitudinal direction of the electric wire 10.

[0030] In the conductor connection structure of this embodiment, the depth D of the first joint portion 51 exceeds the thickness T of the core wire protruding piece 32, and the depth of the second joint portion 52 may exceed the thickness of the conductor protruding piece 42. With such a configuration, it is possible to ensure good electrical continuity between the core wire bundle 30 and the conductor 40 in the longitudinal direction of the electric wire 10.

[0031] [Method for manufacturing a conductor connection structure] Next, a method for manufacturing a conductor connection structure according to the present embodiment will be described.

[0032] In the manufacturing method of the present embodiment, first, an electric wire 10 having a core wire protruding piece 32 is produced. Specifically, as shown in FIG. 3(a), the insulator covering portion 22 at one end of the electric wire 10 is removed to expose a part of a plurality of strands 21. Next, as shown in FIG. 3(b), a notch is provided at the lower part of the tip of the exposed plurality of strands 21 to provide a step at the tip of the bundle of strands 21. That is, a step is provided at the tip of the bundle of strands 21 by cutting short about half of the strands 21 located below in the bundle of strands 21 whose overall shape is flat or cylindrical.

[0033] Then, as shown in FIG. 3(c), the notched bundle of strands 21 is formed. Specifically, the tip of the bundle of strands 21 is ultrasonically welded or resistance welded to join the respective strands 21 to form a core wire bundle 30 and a core wire protruding piece 32.

[0034] Note that the forming method of the core wire bundle 30 and the core wire protruding piece 32 is not limited to the above method. For example, after exposing the bundle of strands 21 from one end of the electric wire 10, the tip of the bundle of strands 21 is welded, and then the core wire bundle 30 and the core wire protruding piece 32 may be formed by notching the lower part of the tip of the welded bundle of strands 21.

[0035] Next, a conductor 40 having a conductor protruding piece 42 is produced. Specifically, as shown in FIG. 4(a), after preparing a plate-like member 40A, as shown in FIG. 4(b), a notch is provided above the tip of the plate-like member 40A to form a conductor protruding piece 42.

[0036] Note that, as described above, it is preferable that the protruding length of the core wire protruding piece 32 along the Y direction and the protruding length of the conductor protruding piece 42 along the Y direction are substantially the same. Also, it is preferable that the thickness of the core wire protruding piece 32 along the Z direction and the thickness of the conductor protruding piece 42 along the Z direction are substantially the same.

[0037] Next, as shown in FIG. 5(a), the tip surface 321 of the core wire protruding piece 32 is opposed to the base end surface 411 of the conductor 40, and further, the tip surface 421 of the conductor protruding piece 42 is opposed to the base end surface 311 of the core wire bundle 30. Next, as shown in FIG. 5(b), the core wire bundle 30 and the conductor 40 are abutted along the Y direction. Thereby, the tip surface 321 of the core wire protruding piece 32 is brought into contact with the base end surface 411 of the conductor 40, and the tip surface 421 of the conductor protruding piece 42 is brought into contact with the base end surface 311 of the core wire bundle 30. Further, the overlapping surface 322 of the core wire protruding piece 32 and the overlapping surface 422 of the conductor protruding piece 42 are also brought into contact.

[0038] Then, by joining the contact portion between the tip surface 321 of the core wire protruding piece 32 and the base end surface 411 of the conductor 40, a first joint portion 51 is formed. Specifically, as shown in FIG. 5(c), a welding laser beam 61 is irradiated from a laser welding machine 60 toward the interface between the tip surface 321 of the core wire protruding piece 32 and the base end surface 411 of the conductor 40. Thereby, the periphery of the tip surface 321 of the core wire protruding piece 32 and the periphery of the base end surface 411 of the conductor 40 are heated and melted by the laser beam 61. Then, by stopping the irradiation of the laser beam 61, the periphery of the tip surface 321 of the core wire protruding piece 32 and the periphery of the base end surface 411 of the conductor 40 are cooled and solidified, thereby forming the first joint portion 51.

[0039] Here, when the aggregate of fine wires is laser welded, the fine wires may be locally melted and melted away. However, in the manufacturing method of the present embodiment, since the base end portion 41 of the conductor 40 and the conductor protruding piece 42 exist below the interface between the tip surface 321 of the core wire protruding piece 32 and the base end surface 411 of the conductor 40, the base end portion 41 of the conductor 40 and the conductor protruding piece 42 serve as a backing metal. Therefore, even when the laser beam 61 is irradiated to the tip surface 321 of the core wire protruding piece 32 and the base end surface 411 of the conductor 40, the molten metal is held by the base end portion 41 and the conductor protruding piece 42, so that the molten metal is prevented from melting away on the side opposite to the irradiation surface of the laser beam 61.

[0040] After the first joint portion 51 is formed, the second joint portion 52 is formed by joining the contact portion between the tip surface 421 of the conductor protruding piece 42 and the base end surface 311 of the core wire bundle 30. Specifically, as shown in FIG. 5(d), a welding laser beam 61 is irradiated from the laser welding machine 60 toward the interface between the tip surface 421 of the conductor protruding piece 42 and the base end surface 311 of the core wire bundle 30. Note that the interface between the tip surface 421 of the conductor protruding piece 42 and the base end surface 311 of the core wire bundle 30 is located behind the interface between the tip surface 321 of the core wire protruding piece 32 and the base end surface 411 of the conductor 40 in the Y direction. Thereby, the periphery of the tip surface 421 of the conductor protruding piece 42 and the periphery of the base end surface 311 of the core wire bundle 30 are heated and melted by the laser beam 61. Then, by stopping the irradiation of the laser beam 61, the periphery of the tip surface 421 of the conductor protruding piece 42 and the periphery of the base end surface 311 of the core wire bundle 30 are cooled and solidified, thereby forming the second joint portion 52.

[0041] Here, since the base end portion 31 of the core wire bundle 30 and the core wire protruding piece 32 exist above the interface between the tip surface 421 of the conductor protruding piece 42 and the base end surface 311 of the core wire bundle 30, the base end portion 31 of the core wire bundle 30 and the core wire protruding piece 32 serve as a backing metal. Therefore, even when the laser beam 61 is irradiated onto the tip surface 421 of the conductor protruding piece 42 and the base end surface 311 of the core wire bundle 30, the molten metal is held by the base end portion 31 and the core wire protruding piece 32, so that the molten metal is suppressed from melting and falling off.

[0042] In this way, after butting the core wire bundle 30 of the electric wire 10 against the conductor 40 and forming the first joint portion 51 and the second joint portion 52, the electric wire 1 with a conductor to which the conductor connection structure is applied can be obtained.

[0043] As described above, it is preferable that the depth D of the first joint portion 51 exceeds the thickness T of the core wire protruding piece 32, but it is not necessary to set the depth from the surface 301 of the core wire bundle 30 to the surface 401 of the conductor 40. Similarly, it is preferable that the depth of the second joint portion 52 exceeds the thickness of the conductor protruding piece 42, but it is not necessary to set the depth from the surface 401 of the conductor 40 to the surface 301 of the core wire bundle 30. That is, the welding depth with respect to the contact portion between the core wire bundle 30 and the conductor 40 aims for about half of the plate thickness of the conductor 40. Therefore, in the manufacturing method of the present embodiment, even a laser welding machine 60 with a low laser output can perform the joining.

[0044] Note that the laser beam 61 used for laser welding only needs to be able to heat the irradiated site and melt the core wire bundle 30 and the conductor 40. The type of the laser beam 61 (such as a carbon dioxide laser, a YAG laser, a semiconductor laser, etc.) and the medium of the laser beam 61 (gas, solid) can be appropriately selected as needed.

[0045] In the manufacturing method of the present embodiment, the core wire protruding piece 32 and the conductor protruding piece 42 serve as a backing metal, and a penetrating weld from the surface 301 of the core wire bundle 30 to the surface 401 of the conductor 40 is not performed. Therefore, since the melting and dropping of the molten metal are suppressed, it is difficult to generate protrusions due to the melting and dropping. Such protrusions penetrate through an insulating tape or tube, etc., and cause a circuit short. However, in the manufacturing method of the present embodiment, the generation of such protrusions is suppressed, so that a circuit short caused by the protrusions can be prevented.

[0046] Thus, the manufacturing method of this embodiment is a manufacturing method of a conductor connection structure formed by joining an electric wire 10 including a core wire bundle 30 composed of a plurality of strands 21 and a conductor 40 having a plate-shaped end portion. The manufacturing method includes: preparing an electric wire 10 including a core wire bundle 30 having a core wire protruding piece 32 extending along the surface 301 of the core wire bundle 30 from the base end portion 31 of the core wire bundle 30, and a conductor 40 having a conductor protruding piece 42 extending along the surface 401 of the conductor 40 from the base end portion 41 of the conductor 40; a step of overlapping the core wire protruding piece 32 and the conductor protruding piece 42 in the thickness direction (Z direction) of the conductor 40; a step of joining the tip of the core wire protruding piece 32 and the base end portion 41 of the conductor 40 to form a first joint portion 51; and a step of joining the tip of the conductor protruding piece 42 and the base end portion 31 of the core wire bundle 30 to form a second joint portion 52. The first joint portion 51 and the second joint portion 52 are provided at different positions when viewed in plan.

[0047] In the above manufacturing method, when the electric wire 10 and the conductor 40 are butted and joined, the core wire protruding piece 32 is provided on the core wire bundle 30, and the conductor protruding piece 42 is provided on the conductor 40. When these are overlapped and joined, the first joint portion 51 and the second joint portion 52 are formed at different positions from each other. Therefore, since the core wire protruding piece 32 and the conductor protruding piece 42 serve as a backing metal, the melting and dropping of the molten metal can be suppressed. As a result, welding conditions with a margin for melting and dropping can be set, and the management range of the welding conditions can also be increased. Therefore, the productivity of the conductor connection structure can be improved. Further, since the melting and dropping of the molten metal are suppressed, welding can be performed under stronger conditions, and as a result, insufficient welding can also be suppressed.

[0048] Furthermore, in the above manufacturing method, since the generation of protrusions due to melting and dropping can be suppressed, it is possible to minimize the thickness of the protective tape, tube, etc. for insulation.

[0049] In the method for manufacturing the conductor connection structure of the present embodiment, the first joint 51 and the second joint 52 may be displaced from each other along the longitudinal direction of the electric wire 10. With such a configuration, it is possible to improve the electrical continuity between the core wire bundle 30 and the conductor 40 in the longitudinal direction of the electric wire 10 while suppressing the melting and dropping during welding.

[0050] In the method for manufacturing the conductor connection structure of the present embodiment, the depth D of the first joint 51 exceeds the thickness T of the core wire protruding piece 32, and the depth of the second joint 52 may exceed the thickness of the conductor protruding piece 42. With such a configuration, it is possible to suppress the melting and dropping of the molten metal while improving the electrical continuity between the core wire bundle 30 and the conductor 40 in the longitudinal direction of the electric wire 10.

[0051] In the method for manufacturing the conductor connection structure of the present embodiment, the first joint 51 and the second joint 52 may be formed by laser welding. In the present embodiment, since the core wire protruding piece 32 and the conductor protruding piece 42 serve as backing metals, the yield can be improved even in laser welding.

[0052] Note that, in the manufacturing method of the present embodiment, the forming methods of the first joint 51 and the second joint 52 are not limited to laser welding, and may be ultrasonic bonding or resistance welding. However, since ultrasonic bonding machines and resistance welding machines are expensive, and the first joint 51 and the second joint 52 can be formed even by a laser welding machine with a low laser output, laser welding is preferred in the manufacturing method of the present embodiment. Also, in the case of laser welding, since the laser output required for welding can be reduced, cost reduction can be achieved by reducing the equipment cost.

[0053] As described above, the present embodiment has been described, but the present embodiment is not limited to these, and various modifications are possible within the scope of the gist of the present embodiment.

Description of Reference Numerals

[0054] 1 Electric wire with conductor 10 Electric wire 21 Strand 30 Core wire bundle 31 Base end portion of the core wire bundle 32 Core wire protruding piece 40 Conductor 41 Base end portion of the conductor 42 Conductor protruding piece 51 First joint 52 Second joint 301 Surface of the core wire bundle 311 Base end face of the core wire bundle 321 Tip end face of the core wire bundle 401 Surface of the conductor 411 Base end face of the conductor 421 Tip end face of the conductor

Claims

1. An electric wire including a core wire bundle composed of a plurality of strands, A conductor having a plate-shaped end portion, Comprising, The core wire bundle has a core wire protruding piece extending from the base end portion of the core wire bundle toward the conductor along the surface of the core wire bundle, The conductor has a conductor protruding piece extending from the base end portion of the conductor toward the core wire bundle along the surface of the conductor, The core wire protruding piece and the conductor protruding piece are overlapped in the thickness direction of the conductor, A first joint portion is formed by joining the tip of the core wire protruding piece and the base end portion of the conductor, A second joint portion is formed by joining the tip of the conductor protruding piece and the base end portion of the core wire bundle, The first joint portion and the second joint portion are provided at different positions when viewed in plan, a conductor connection structure.

2. The first joint portion and the second joint portion are displaced from each other along the longitudinal direction of the electric wire, the conductor connection structure according to claim 1.

3. The depth of the first joint portion exceeds the thickness of the core wire protruding piece, and the depth of the second joint portion exceeds the thickness of the conductor protruding piece, the conductor connection structure according to claim 1 or 2.

4. A method for manufacturing a conductor connection structure formed by joining an electric wire including a core wire bundle composed of a plurality of strands and a conductor having a plate-shaped end portion, A step of preparing the electric wire including the core wire bundle having a core wire protruding piece extending from the base end portion of the core wire bundle along the surface of the core wire bundle, and the conductor having a conductor protruding piece extending from the base end portion of the conductor along the surface of the conductor, A step of overlapping the core wire protruding piece and the conductor protruding piece in the thickness direction of the conductor, A step of joining the tip of the core wire protruding piece and the base end portion of the conductor to form a first joint portion, A step of joining the tip of the conductor protruding piece and the base end portion of the core wire bundle to form a second joint portion, Having, The first joint portion and the second joint portion are provided at different positions when viewed in plan, a method for manufacturing a conductor connection structure.

5. The first joint portion and the second joint portion are displaced from each other along the longitudinal direction of the electric wire, the method for manufacturing a conductor connection structure according to claim 4.

6. The depth of the first joint portion exceeds the thickness of the core wire protruding piece, and the depth of the second joint portion exceeds the thickness of the conductor protruding piece, the method for manufacturing a conductor connection structure according to claim 4 or 5.

7. The method for manufacturing the conductor connection structure according to claim 4 or 5, wherein the first joint portion and the second joint portion are formed by laser welding.

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