Wire with terminal and manufacturing method for the same, and wire with connector

Abstract

To provide a wire with a terminal and a manufacturing method for the same capable of suppressing insufficient bonding by ultrasonic welding and energy loss during bonding, and to provide a wire with a connector in which such a wire with a terminal possessing these excellent features is stably coupled with a connector.SOLUTION: A wire with a terminal and a manufacturing method for the same, as well as a wire with a connector, has a terminal fitting 3 including a wire connection portion 31 and a wire 2 including a core wire 21 joined to the wire connection portion 31. The wire connection portion 31 has a bottom wall portion to which the core wire 21 is joined along a longitudinal direction TE of the wire 2 and a pair of standing wall portions 35 erected from both ends of the bottom wall portion on both sides of the core wire 21. Holding force enhancing means for increasing the holding force when a terminal fitting 3 is clamped from the outside of the pair of standing wall portions 35 is provided on an outer surfaces 35a of the pair of standing wall portions 35.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an electric wire with a terminal, a method for manufacturing the same, and an electric wire with a connector. [Background technology]

[0002] Wire harnesses have been installed in automobiles to supply power from a power source such as a battery to various electronic devices and to transmit control signals from a control device. The wire harnesses are made up of multiple electric wires with terminals, each of which has electric wires and terminals attached to the ends of the electric wires.

[0003] An electric wire with a terminal includes a core wire formed by twisting together a plurality of conductive wires and an insulating coating covering the core wire. The coating at the end of the electric wire is removed to expose the core wire, which is then welded to a terminal fitting to form the electric wire with a terminal. The welding of the core wire and the terminal fitting is performed by ultrasonic welding using an ultrasonic welding device.

[0004] Ultrasonic welding is performed by placing the core wire of an electric wire on the electric wire connection part of a terminal fitting, clamping and pressurizing it between an anvil and a horn, and then applying ultrasonic vibrations to the horn using a vibrator. The heat generated by the ultrasonic vibrations welds the electric wire connection part and the core wire together. At this time, the ultrasonic vibrations are applied so that the vibration direction (amplitude) is along the longitudinal direction of the electric wire.

[0005] However, if the core wire of the electric wire and the electric wire connection portion of the terminal fitting vibrate in synchronization with the vibration direction of the ultrasonic vibration, the friction between the core wire and the electric wire connection portion will not work sufficiently, resulting in insufficient joining or leading to energy loss during joining. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2011-18597 Summary of the Invention [Problem to be solved by the invention]

[0007] Therefore, an object of the present invention is to provide an electric wire with a terminal that can suppress insufficient joining due to ultrasonic welding and energy loss during joining, and a method for manufacturing the same. [Means for solving the problem]

[0008] The above object can be achieved by the present invention, which is described below.

[0009] <1> An electric wire with a terminal, the electric wire including a terminal fitting having an electric wire connection portion and an electric wire having a core wire joined to the electric wire connection portion, the electric wire connection portion has a bottom wall portion to which the core wire is joined along a longitudinal direction of the electric wire, and a pair of standing wall portions standing on both sides of the core wire from both ends of the bottom wall portion, The electric wire with terminal is provided with a holding force enhancing means on the outer surfaces of the pair of upright wall portions for enhancing the holding force when the terminal fitting is clamped from the outside of the pair of upright wall portions.

[0010] <2> the holding force improving means are irregularities formed on the outer surfaces of the pair of upright wall portions; <1> The terminal-attached electric wire according to claim 1.

[0011] <3> The unevenness formed on the outer surfaces of the pair of vertical wall portions is a knurled pattern. <2> The terminal-attached electric wire according to claim 1.

[0012] <4> The holding force improving means is a through hole formed in the pair of vertical wall portions. <1> The terminal-attached electric wire according to claim 1.

[0013] <5> a rubber tube that encases the area of ​​the terminal fitting including the wire connection portion together with the core wire; <1> ~ <4> 1. An electric wire with a terminal according to any one of the preceding items.

[0014] <6> a terminal fitting arrangement step in which a terminal fitting is arranged so that the bottom wall portion contacts an anvil and the pair of upright wall portions are arranged upright in a direction away from the anvil, the terminal fitting having a bottom wall portion to which the core wire is joined along the longitudinal direction of the electric wire having a core wire made of a plurality of element wires and a pair of upright wall portions standing upright from both ends of the bottom wall portion, the terminal fitting having a holding force enhancing means provided on outer surfaces of the pair of upright wall portions for enhancing holding force when clamped from outside the pair of upright wall portions; a terminal fixing step of fixing the terminal fitting by sandwiching both outer surfaces of the pair of standing wall portions with a pair of terminal fixing blocks having abutment surfaces that abut against both outer surfaces of the pair of standing wall portions; an electric wire arranging step of arranging the electric wire including the core wire so that the core wire is located in a space surrounded by the bottom wall portion and the pair of upright wall portions of the terminal fitting and in a space above the space, and so that a longitudinal direction of the electric wire and an extending direction of the pair of upright wall portions substantially coincide with each other; a welding step of inserting a horn between the pair of upright wall portions and moving it toward the anvil to sandwich and pressurize the core wire and the bottom wall portion between the anvil and the horn, thereby applying ultrasonic vibration to the horn to weld the core wire to the terminal fitting, The method for manufacturing an electric wire with a terminal, wherein the abutting surfaces of the pair of terminal fixing blocks have surfaces corresponding to the outer surfaces of the pair of upright wall portions on which the holding force enhancing means is provided.

[0015] <7> the holding force improving means are irregularities formed on the outer surfaces of the pair of upright wall portions, The abutting surfaces of the pair of terminal fixing blocks are surfaces on which protrusions and recesses are formed, into which at least a part of the protrusions and recesses formed on the outer surfaces of the pair of standing wall portions are fitted. <6> A method for manufacturing the electric wire with terminal according to claim 1.

[0016] <8> The unevenness formed on the outer surfaces of the pair of vertical wall portions is a knurled pattern, The unevenness formed on the contact surfaces of the pair of terminal fixing blocks is a knurled pattern that is the inverse of the unevenness formed on the outer surfaces. <7> A method for manufacturing the electric wire with terminal according to claim 1.

[0017] <9> <1> ~ <4> and a connector having a connector housing, the terminal fitting includes a terminal body portion connected to the wire connection portion on a side opposite to a side from which the wire extends in a longitudinal direction of the wire, The connector housing is provided with an insertion hole into which the terminal metal fitting is inserted from the side of the terminal body portion, The terminal fitting is inserted into the insertion hole and coupled to the connector. [Effects of the Invention]

[0018] According to the present invention, it is possible to provide an electric wire with a terminal that can suppress insufficient joining due to ultrasonic welding and energy loss during joining, and a method for manufacturing the same. [Brief explanation of the drawings]

[0019] [Figure 1] 1 is a perspective view of an electric wire with a terminal according to an embodiment of the present invention. [Figure 2] 2 is a cross-sectional view of the electric wire with terminal according to the embodiment of the present invention, taken along the line BB in FIG. 1. FIG. [Figure 3] 1 is a longitudinal cross-sectional view of an electric wire with a terminal during a manufacturing process and a part of a manufacturing apparatus for explaining a manufacturing method of an electric wire with a terminal according to an embodiment of the present invention. FIG. [Figure 4] FIG. 3 is a vertical cross-sectional view illustrating a state in which an electric wire is joined to a terminal fitting after a welding step, for explaining a method for manufacturing an electric wire with a terminal according to an embodiment of the present invention. [Figure 5] 1 is an enlarged cross-sectional view of only a main portion of a connector-equipped electric wire using an electric wire with terminal according to an embodiment of the present invention. [Figure 6] FIG. 10 is a perspective view of an electric wire with a terminal according to a first modified example. [Figure 7] FIG. 10 is a perspective view of an electric wire with a terminal according to a second modified example. [Figure 8] FIG. 10 is a perspective view of an electric wire with a terminal according to a third modified example. [Figure 9] FIG. 10 is a perspective view of an electric wire with a terminal according to a fourth modified example. [Figure 10] FIG. 10 is a perspective view of an electric wire with a terminal according to a fifth modified example. [Figure 11] FIG. 13 is a perspective view of an electric wire with a terminal according to a sixth modified example. DETAILED DESCRIPTION OF THE INVENTION

[0020] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An electric wire with a terminal, a manufacturing method thereof, and an electric wire with a connector according to embodiments of the present invention will be specifically described below with reference to the drawings.

[0021] [Terminal-attached wire] Fig. 1 is a perspective view of an electric wire with terminal according to an embodiment. As shown in Fig. 1, the electric wire with terminal 1 includes a terminal fitting 3 having an electric wire connecting portion 31, and an electric wire 2 having a core wire 21 joined to the electric wire connecting portion 31. Fig. 2 is a cross-sectional view of the electric wire with terminal 1 taken along the line BB in Fig. 1.

[0022] 1 and 2, the tip side (the side of the terminal body) of the electric wire with terminal 1 is indicated by an arrow T (hereinafter referred to as "tip side T"), the opposite side of the tip side T (the side from which the electric wire extends) is indicated by an arrow E (hereinafter referred to as "electric wire extension side E"), the upper side in Fig. 1 is indicated by an arrow U, the lower side by an arrow D, the right side in the width direction in Fig. 1 by an arrow R, and the left side by an arrow L (the same applies to the subsequent figures). In the following text, the longitudinal direction of the electric wire 2 is indicated by the symbol TE (hereinafter, "of the electric wire 2" will be omitted and referred to as "longitudinal direction TE"), the up-down direction by the symbol UD, and the width direction by the symbol RL.

[0023] In the electric wire with terminal 1 according to this embodiment, the electric wire 2 includes a core wire 21 and a covering layer 22 that covers the core wire 21. Near the end of the tip side T of the electric wire 2, the covering layer 22 is peeled off (stripped) to expose the core wire 21. The core wire 21 is made of a plurality of conductive wires and has a substantially round cross section. The core wire 212 is made of a conductive metal such as copper, a copper alloy, aluminum, or an aluminum alloy, and the covering layer 22 is made of an insulating synthetic resin.

[0024] In the electric wire with terminal 1 according to this embodiment, the terminal fitting 3 is formed by bending a metal plate material that has been punched into a predetermined shape, and includes an electric wire connection portion 31 to which the core wire 21 is joined, and a terminal main body portion 32 that is continuous with the electric wire connection portion 31 on the side (tip side T) opposite to the side from which the electric wire 2 extends (electric wire extension side E) in the longitudinal direction TE. The electric wire connection portion 31 and the terminal main body portion 32 are continuous with each other via a connecting portion 33.

[0025] The terminal body 32 has a connection hole 32a that is electrically connected to various electronic devices and the like, and that opens toward the tip side T in the longitudinal direction TE. On the other hand, the wire connection portion 31 has a bottom wall 34 to which the core wire 21 is joined along the longitudinal direction TE, and a pair of standing wall portions 35 that stand upright from both ends of the bottom wall 34 on both sides (the right side R and the arrow L side) of the core wire 21.

[0026] In the electric wire with terminal 1 according to this embodiment, knurled patterns are formed on the outer surfaces 35a of the pair of vertical wall portions 35. Knurled patterns are fine irregularities on a metal surface formed by knurling (also called "knurling"), and the pattern of the irregularities can be selected as appropriate. In this embodiment, a cross-hatched pattern is formed as shown in FIG. 1. Other common knurled patterns include flat, square, and diagonal patterns.

[0027] Knurling processes for forming knurled patterns on the outer surfaces 35a of the pair of vertical wall portions 35 as a workpiece include cutting, which scrapes away the surface of the workpiece, and rolling, which deforms the workpiece by applying pressure while rolling. To form the knurled patterns of the present embodiment, the latter rolling process is preferred. Rolling is a process in which a tool with the same pattern as the desired unevenness is pressed against the workpiece, transferring the shape of the tool to form the knurled patterns. On the other hand, cutting is a process in which a knurling tool is pressed against the workpiece while it is rotating on a lathe, and the workpiece is cut to form evenly spaced grooves, thereby forming unevenness on the surface. This process is suitable for forming the flat-patterned knurled patterns of the first modified example described below.

[0028] As will be described later, the knurled-like unevenness formed on the outer surfaces 35a of the pair of standing wall portions 35 increases the holding force when the terminal fitting 3 is clamped from outside (in the left-right direction RL) between the pair of standing wall portions 35. That is, when joining the core wire 21 to the wire connection portion 31 of the terminal fitting 3 by ultrasonic welding, when the pair of standing wall portions 35 are clamped from outside (in the left-right direction RL) by gathers (terminal fixing blocks) of the ultrasonic welding device, the unevenness formed on the outer surfaces 35a functions as a means for improving the holding force of the gathers. A method for manufacturing an electric wire with terminal according to this embodiment will be described below.

[0029] [Manufacturing method for electric wire with terminal] FIG. 3 is a cross-sectional view of an electric wire with terminal and a part of a manufacturing device during the manufacturing process for explaining the manufacturing method of the electric wire with terminal according to this embodiment, and corresponds to the CC cross section of the electric wire with terminal in FIG. 2 and FIG.

[0030] The method for manufacturing the electric wire with terminal 1 according to this embodiment includes a terminal fitting arrangement step, a terminal fitting fixing step, an electric wire arrangement step, and a welding step. Hereinafter, each step of the method for manufacturing the electric wire with terminal 1 according to this embodiment will be described with reference to Figs. 1 to 3.

[0031] <Terminal fitting arrangement process> 3, the terminal fitting arrangement step is a step of arranging the terminal fitting 3 in this embodiment so that the bottom wall portion 34 contacts the anvil 41 and the pair of standing wall portions 35 stand in a direction away from the anvil 41 (upward U direction). That is, the terminal fitting 3 in this embodiment is composed of the bottom wall portion 34 to which the core wire 21 is joined along the longitudinal direction TE of the electric wire 2 including the core wire 21, as shown in FIGS. 1 to 3, and the pair of standing wall portions 35 standing from both ends of the bottom wall portion 34.

[0032] Here, the term "anvil" refers to a platform on which the objects to be ultrasonically welded are placed in an ultrasonic welding device used for ultrasonic welding, and is a component that positions and fixes the objects to prevent the vibration energy from escaping, and is also called a receiving jig or receiving metal. Also, the term "horn," which will be described later, refers to a component that resonates with the vibration of a vibrator provided in the ultrasonic welding device and applies vibration and load to the objects to be welded.

[0033] <Terminal metal fitting fixing process> The terminal fitting fixing process is a process of fixing the terminal fitting 3 by clamping both outer surfaces 35a of the pair of vertical wall portions 35 with a pair of gathers (terminal fixing blocks) 43 having abutment surfaces 43a that abut against both outer surfaces 35a of the pair of vertical wall portions 35, as shown in Figure 3.

[0034] The pair of gathers 43 have knurled patterns formed on their contact surfaces 43a. In this embodiment, the knurled patterns formed on the contact surfaces 43a are the inverse of the knurled patterns (cross-hatched) formed on the outer surfaces 35a of the pair of standing wall portions 35. The contact surfaces 43a of the pair of gathers 43 have unevenness that is the inverse of the knurled patterns formed on the outer surfaces 35a of the pair of standing wall portions 35. This allows the surface shapes of the contact surfaces 43a and the outer surfaces 35a to match, thereby enabling the terminal fitting 3 to be fixed in a nearly rigid state. Therefore, the pair of gathers 43 sandwich the outer surfaces 35a of the pair of standing wall portions 35, limiting movement of the terminal fitting 3 in the left-right direction RL. Furthermore, friction between the pair of standing wall portions 35 and the pair of gathers 43 limits movement of the terminal fitting 3 in the longitudinal direction TE.

[0035] The uneven shape of the abutment surface 43a of the pair of gathers 43 may correspond to at least a part of the uneven shape of the outer surface 35a of the pair of standing wall portions 35, but it is desirable that the entire surface of the abutment surface 43a abutting against both outer surface 35a of the pair of standing wall portions 35, as in the terminal-attached wire 1 of this embodiment, corresponds to the outer surface 35a.

[0036] <Wire placement process> As shown in FIG. 3, the electric wire arrangement process is a process of arranging an electric wire 2 having a core wire 21 made up of a plurality of wires so that the core wire 21 is positioned in a space S1 surrounded by a bottom wall portion 34 and a pair of vertical wall portions 35 of the terminal fitting 3 and in a space S2 above the space S1, and so that the longitudinal direction TE and the extending direction of the pair of vertical wall portions 35 are approximately aligned.

[0037] 3, the core wire 21 has not yet been crushed, and therefore has a substantially round cross-sectional shape similar to the portion covered with the covering layer 22. Therefore, the core wire 21 cannot be contained within the space S1 surrounded by the bottom wall portion 34 and the pair of upright wall portions 35, and protrudes significantly into the space S2 above.

[0038] <Welding process> 3, in the welding process, horn 42 is inserted between the pair of upright walls 35 and moved in the direction of arrow G toward anvil 41, thereby sandwiching and pressurizing core wire 21 and bottom wall 34 between anvil 41 and horn 42. Then, ultrasonic vibration is applied to horn 42 while pressurizing core wire 21 and bottom wall 34.

[0039] Fig. 4 shows a vertical cross-sectional view of the state in which the core wire 21 of the electric wire 2 is joined to the electric wire connecting portion 31 of the terminal fitting 3 after the operation of the welding step. Fig. 4 is a vertical cross-sectional view of the same cross section as Fig. 3. As shown in Fig. 4, after the operation of the welding step, the core wire 21 and the terminal fitting 3 are in a welded state.

[0040] The ultrasonic vibrations applied to the horn 42 in the welding process vibrate in the longitudinal direction TE. Therefore, if the terminal fitting 3 is prone to movement in the longitudinal direction TE, there is a concern that the core wire 21 of the electric wire 2 and the electric wire connection portion 31 of the terminal fitting 3 may vibrate in synchronization with the vibration direction of the ultrasonic vibrations. If the core wire 21 and the electric wire connection portion 31 vibrate in synchronization with each other, friction between the core wire 21 and the electric wire connection portion 31 may not be sufficient, resulting in insufficient joining or energy loss during joining.

[0041] However, in this embodiment, when the pair of gathers 43 sandwich the outer surfaces 35a of the pair of standing wall portions 35 in the terminal fixing process, the knurled grooves formed on the outer surfaces 35a of the pair of standing wall portions 35 and the knurled grooves formed on the abutting surfaces 43a of the pair of gathers 43 coincide with each other, resulting in a strong frictional force acting on the terminal 3. Therefore, the terminal 3 is fixed to the anvil 41 in the longitudinal direction TE as well, and its movement is restricted.

[0042] In this way, the anvil 41 and the terminal fitting 3 are fixed in a nearly rigid state, eliminating the concern that the wire connection portion 31 of the terminal fitting 3 will vibrate in synchronization with the vibration direction of the ultrasonic vibrations even when ultrasonic vibrations vibrating in the longitudinal direction TE act on it. This makes it possible to efficiently generate friction at the interface between the core wire 21 and the wire connection portion 31, resulting in less likelihood of insufficient joining and less energy loss during joining.

[0043] Furthermore, even if the contact surfaces 43a of the pair of gathers 43 do not have knurling similar to the knurling formed on the outer surfaces 35a of the pair of vertical wall portions 35, the knurling formed on the outer surfaces 35a of the pair of vertical wall portions 35 alone can generate a fairly high friction force between the contact surfaces 43a and the outer surfaces 35a, so it can be expected to a certain extent that insufficient joining is less likely to occur and energy loss during joining is less likely to occur.

[0044] [Wire with connector] Next, a description will be given of an electric wire with a connector using the electric wire with terminal 1 according to this embodiment. Fig. 5 is an enlarged cross-sectional view of only a main part of an electric wire with a connector including the electric wire with terminal according to this embodiment and a connector equipped with a connector housing. In Fig. 5, the electric wire with terminal 1 is viewed from above (from the direction of arrow D), and the connector housing 5 of the connector is shown cut in a plane parallel to a plane including the longitudinal direction TE and the width direction RL.

[0045] Since the electric wire with terminal 1 is the electric wire with terminal 1 according to the above-described embodiment, all corresponding parts are denoted by the same reference numerals. Therefore, for parts not shown in Fig. 5, please refer to Figs. 1 to 4 as appropriate.

[0046] On the other hand, the connector housing 5 is a tube having a rectangular cross section, and Fig. 5 depicts only the opposing connector walls of the connector housing 5. The connector housing 5 is provided with insertion holes 53 into which the terminal fittings 3 are inserted from the terminal body 32 side (tip side T). The connector housing 5 also has a latched portion (not shown).

[0047] When the terminal fitting 3 is moved in the direction of arrow T and inserted into the insertion hole 53, the locking portion (not shown) on the terminal fitting 3 side locks into the locking portion on the connector housing 5 side, and the terminal-equipped wire 1 and the connector housing 5 are stably connected to form a connector-equipped wire.

[0048] In the electric wire with terminal 1 according to the embodiment described above, the knurled stitches formed on the outer surfaces 35a of the pair of standing wall portions 35 are in a twill pattern, but the shape of the knurled stitch pattern is not limited to this. In the present invention, knurled stitches of various shapes may be formed on the outer surfaces of the pair of standing wall portions.

[0049] In the present invention, the holding force improving means provided on the outer surfaces of the pair of vertical wall portions may be unevenness that does not come into contact with the knurled grooves, or may be a shape that is not even uneven, such as a through hole. The holding force improving means only needs to have the function of increasing the holding force when the pair of vertical wall portions are clamped from the outside.

[0050] If the holding force improving means is provided on the outer surfaces of the pair of vertical walls, the holding force when the pair of vertical walls is clamped from the outside by the gathers (terminal fixing blocks) of the ultrasonic welding device is increased, and movement of the terminal fitting in the longitudinal direction of the electric wire during ultrasonic welding can be restricted. Therefore, with the electric wire with terminal 1 according to the embodiment, insufficient joining due to ultrasonic welding and energy loss during joining can be suppressed.

[0051] Hereinafter, three modified examples (first to third modified examples) of the electric wire with terminal will be described, in which the holding force enhancing means provided on the outer surfaces of the pair of standing wall portions are different from those of the above embodiment.

[0052] (First Modification) 6 is a perspective view of an electric wire with terminal according to a first modified example. In the electric wire with terminal 101 according to this modified example, the shape of the knurled pattern formed on the outer surfaces 135a of the pair of standing wall portions 135 of the terminal fitting 103 is different from that of the electric wire with terminal 1 according to the embodiment, but the rest is the same.

[0053] Therefore, in Fig. 6 showing the electric wire with terminal 101 according to this modification, the same reference numerals as those in the above embodiment are used to designate the same components as those in the electric wire with terminal 1 according to the embodiment, and the description of the same configurations of the components will be omitted. The following mainly describes the differences. In Fig. 6, the components having a configuration unique to this modification are assigned reference numerals in the hundreds, the last two digits of which are the same as those of the corresponding components in the electric wire with terminal 1 according to the embodiment.

[0054] 6, in the electric wire with terminal 101 according to this modification, a flattened pattern is formed on the outer surface 135a of the pair of standing wall portions 135. The flattened pattern is fine unevenness arranged in parallel to each other in a straight line, and in this modification, the fine unevenness is engraved in a direction perpendicular to the longitudinal direction TE (=up-down direction UD).

[0055] In the terminal-attached electric wire 101 according to this modified example, the flat knurled grooves formed on the outer surfaces 135a of the pair of vertical wall portions 135 have rows of irregularities arranged in the vibration direction of the ultrasonic vibrations applied to the horn during the welding process during ultrasonic welding, i.e., in a direction intersecting (and even perpendicular to) the longitudinal direction TE.

[0056] Therefore, in the terminal fixing step in ultrasonic welding, when the pair of gathers (terminal fixing blocks) sandwich both outer surfaces 135a of the pair of standing wall portions 135 to fix the terminal fitting 103, a strong frictional force is generated between the outer surfaces 135a and the abutting surfaces of the gathers (terminal fixing blocks). Therefore, even when ultrasonic vibrations vibrating in the longitudinal direction TE act, there is little concern that the wire connecting portion 131 of the terminal fitting 103 will vibrate in synchronization with the vibration direction of the ultrasonic vibrations. Therefore, friction can be efficiently generated at the interface between the core wire 21 and the wire connecting portion 131 during ultrasonic welding, resulting in less insufficient joining and less energy loss during joining.

[0057] Furthermore, it is preferable that the pair of gathers (terminal fixing blocks) used for ultrasonic welding have knurled grooves with a flat pattern formed on the outer surfaces 135a of the pair of standing wall portions 135, aligned in the direction of the unevenness extending in the up-down direction UD, on the abutting surfaces that abut against the outer surfaces 135a of the pair of standing wall portions 135. By doing so, when the pair of gathers sandwich both outer surfaces 135a of the pair of standing wall portions 135 in the terminal fixing process, the knurled grooves formed on the outer surfaces 135a of the pair of standing wall portions 135 and the knurled grooves formed on the abutting surfaces of the pair of gathers coincide with each other, resulting in a stronger frictional force. Therefore, the terminal fitting 103 is firmly fixed by the anvil in the longitudinal direction TE, and its movement is restricted.

[0058] As described above, even if the knurled stitches formed on the pair of standing wall portions 135 are not crisscrossed as in the above embodiment but are flat as in this modified example, the same advantages as those of the above embodiment can be enjoyed. As for the pattern of knurled stitches formed on the outer surfaces of the pair of standing wall portions, it is preferable to have a shape in which rows of concaves and convexes are arranged in a direction intersecting (or even perpendicular to) the longitudinal direction TE as in this modified example and the above embodiment, because this increases the frictional force between the abutting surfaces of the pair of gathers (terminal fixing blocks).

[0059] (Second Modification) 7 is a perspective view of an electric wire with terminal according to a second modified example. In the electric wire with terminal 201 according to this modified example, the shape of the projections and recesses formed on the outer surfaces 235a of the pair of standing wall portions 235 of the terminal fitting 203 is different from that of the electric wire with terminal 1 according to the embodiment, but the rest is the same.

[0060] Therefore, in Fig. 7 showing an electric wire with terminal 201 according to this modification, each member having the same configuration as that of the electric wire with terminal 1 according to the above embodiment is given the same reference numeral as that of the member in the embodiment, and a description of the similar configuration of each member will be omitted. The following mainly describes the differences. In Fig. 7, members having a configuration unique to this modification are given reference numerals in the 200s, the last two digits of which are the same as those of the corresponding members in the electric wire with terminal 1 according to the embodiment.

[0061] 7, in the electric wire with terminal 201 according to this modification, rectangular recesses 235b with a bottom are provided on the outer surfaces 235a of the pair of standing wall portions 235. Meanwhile, in the terminal fitting fixing step by ultrasonic welding, the pair of gathers (terminal fixing blocks) have surfaces corresponding to the recesses 235b, i.e., protrusions (not shown) that fit into the recesses 235b, on their contact surfaces that come into contact with the outer surfaces 235a of the pair of standing wall portions 235.

[0062] In the terminal fitting fixing process in ultrasonic welding, when a pair of gathers (terminal fixing blocks) clamp both outer surfaces 235a of a pair of standing wall portions 235 to fix the terminal fitting 203, the convex portions provided on the abutment surfaces of the pair of gathers fit into the concave portions 235b provided on the outer surfaces 235a of the pair of standing wall portions 235, thereby increasing the holding force between the outer surfaces 235a of the pair of standing wall portions 235 and the abutment surfaces of the pair of gathers.

[0063] Therefore, even if ultrasonic vibrations vibrating in the longitudinal direction TE act on the terminal fitting 203, there is no risk of the wire connection portion 231 of the terminal fitting 203 vibrating in synchronization with the vibration direction of the ultrasonic vibrations. This makes it possible to efficiently generate friction at the interface between the core wire 21 and the wire connection portion 231 during ultrasonic welding, resulting in less likelihood of insufficient joining and less energy loss during joining.

[0064] As described above, even if the unevenness formed on the outer surface 235a of the pair of standing wall portions 235 is not knurled as in the above embodiment or the first modified example, but is an uneven shape of a fixed size as in this modified example, it is possible to enjoy the same benefits as in the above embodiment and the first modified example. Note that the shape of the unevenness formed on the outer surface 235a is not limited to a rectangular shape and may be various shapes, and may be a convex portion instead of a concave portion, or a shape in which concaves and convexes are combined.

[0065] (Third Modification) 8 is a perspective view of an electric wire with terminal according to a third modified example. The electric wire with terminal 301 according to this modified example differs from the electric wire with terminal 1 according to the embodiment in that a pair of standing wall portions 335 of the terminal fitting 303 is provided with through holes 335b that penetrate from the outer surface 235a to the back surface thereof.

[0066] Therefore, in Fig. 8 showing an electric wire with terminal 301 according to this modification, each member having the same configuration as that of the electric wire with terminal 1 according to the above embodiment is given the same reference numeral as that of the member in the embodiment, and a description of the similar configuration of each member will be omitted. The following mainly describes the differences. In Fig. 8, members having a configuration unique to this modification are given reference numerals in the 300s, the last two digits of which are the same as those of the corresponding members in the electric wire with terminal 1 according to the embodiment.

[0067] 8, in the electric wire with terminal 301 according to this modification, a circular, bottomless through-hole 335b is provided in the pair of standing wall portions 335. Meanwhile, in the terminal fitting fixing step by ultrasonic welding, the pair of gathers (terminal fixing blocks) have a surface corresponding to the through-hole 335b, i.e., a protrusion (not shown) that fits into the through-hole 335b, on the abutting surface that abuts against the outer surface 335a of the pair of standing wall portions 335.

[0068] In the terminal fitting fixing process in ultrasonic welding, when a pair of gathers (terminal fixing blocks) clamp both outer surfaces 335a of a pair of vertical wall portions 335 to fix the terminal fitting 303, the convex portions provided on the abutment surfaces of the pair of gathers fit into the through holes 335b provided in the pair of vertical wall portions 335, thereby increasing the holding force between the outer surfaces 335 of the pair of vertical wall portions 335 and the abutment surfaces of the pair of gathers.

[0069] Therefore, even if ultrasonic vibrations vibrating in the longitudinal direction TE act on the wire connecting portion 331 of the terminal fitting 303, there is no need to worry about the wire connecting portion 331 vibrating in synchronization with the vibration direction of the ultrasonic vibrations. This makes it possible to efficiently generate friction at the interface between the core wire 21 and the wire connecting portion 331 during ultrasonic welding, resulting in less likelihood of insufficient joining and less energy loss during joining.

[0070] As described above, even if the pair of standing wall portions 335 have through holes as in this modification, rather than the uneven shape as in the above embodiment and the first and second modifications, it is possible to enjoy the same advantages as in the above embodiment and the first and second modifications. Note that the shape of the through holes provided in the pair of standing wall portions 335 is not limited to a circular shape and may be various shapes, or may be a shape that combines a through hole with unevenness.

[0071] The above-described embodiment and three modified examples merely show examples of typical forms of the present invention, and the present invention is not limited to the above-described embodiment and modified examples. For example, in the above-described embodiment and modified examples, a configuration is described in which the connection portion of the terminal connection part with the core wire of the electric wire is exposed. However, by wrapping the area of ​​the terminal fitting including the electric wire connection portion together with the core wire in a rubber tube, the terminal crimping portion of the core wire can be waterproofed. A fourth modified example in which the area of ​​the terminal fitting including the electric wire connection portion together with the core wire is wrapped in a rubber tube will be described below.

[0072] (Fourth Modification) 9 is a perspective view of an electric wire with terminal according to a fourth modified example. An electric wire with terminal 401 according to this modified example is provided with a rubber tube 6 that encases the area including the wire connection portion 31 of the terminal fitting 3 together with the core wire 21. Note that the provision of the rubber tube 6 is different from the electric wire with terminal 1 according to the above embodiment, but the rest is the same.

[0073] 9 showing an electric wire with terminal 401 according to this modification, the same reference numerals as those in the above embodiment are used to designate the same components as those in the above embodiment, and the same configurations of the components will not be described. The configuration that is enclosed by the rubber tube 6 and cannot be seen is the same as that of the electric wire with terminal 1 according to the above embodiment, so please refer to FIGS. 1 and 2.

[0074] When the rubber tube 6 is attached so as to encase the area including the wire connection portion 31 of the terminal fitting 3 together with the core wire 21, an interior adhesive is applied to the inner surface of the rubber tube 6 so as to adhere closely to the terminal crimping portion of the core wire 21. In this modification, a cross-hatched pattern of knurled stitches is formed on the outer surfaces 35a of the pair of upright wall portions 35 of the wire connection portion 31 enclosed by the rubber tube 6, which increases the adhesive area of ​​the interior adhesive and improves watertightness.

[0075] In this modification, the rubber tube 6 is centered on the wire connection portion 31 of the terminal fitting 3, and the tip side T encloses an area extending to almost the entire area of ​​the coupling portion 33, and the wire extension side E encloses an area extending beyond the entire area where the core wire 21 is exposed to the tip of the coating layer 22. The area enclosed by the rubber tube 6 can be widened or narrowed while determining the waterproofing effect of the terminal crimping portion of the core wire 21 (the joint with the wire connection portion 31).

[0076] Even if the unevenness formed on the outer surfaces of the pair of upright wall portions of the electric wire connection part is a flat knurled pattern as in the first modified example or a recessed portion as in the second modified example, it is possible to increase the adhesion area of ​​the interior adhesive inside the rubber tube and improve watertightness. Furthermore, even if the pair of upright wall portions of the electric wire connection part are formed with through holes as in the third modified example instead of unevenness, the interior adhesive can enter the through holes and increase the adhesion area, thereby improving watertightness.

[0077] Therefore, by providing some kind of retention force improving means on the outer surfaces of the pair of upright walls of the electric wire connection part, the watertightness achieved by providing the rubber tube can be improved. The above explanation has been given on the assumption that an interior adhesive is applied to the inner surface of the rubber tube, but even in the case of a simple rubber tube without an interior adhesive, the watertightness improvement effect can be expected by providing the rubber tube.

[0078] In the above embodiment and modified examples, the shape of the terminal body is exemplified as a rectangular shape when viewed from the right side, with a rectangular connection hole 32a at the tip, but this is not limited thereto, and the present invention can be applied to terminal bodies of any shape. A fifth modified example will be described, in which the shape of the terminal body differs from that of the above embodiment.

[0079] (Fifth Modification) 10 is a perspective view of an electric wire with terminal according to a fifth modified example. An electric wire with terminal 501 according to this modified example differs from the electric wire with terminal 1 according to the above embodiment in that the shape of the terminal body 532 of the terminal fitting 503 is simply flat, but the rest is the same.

[0080] Therefore, in Fig. 10 showing an electric wire with terminal 501 according to this modification, each member having the same configuration as that of the electric wire with terminal 1 according to the above embodiment is given the same reference numeral as that of the member in the embodiment, and a description of the similar configuration of each member will be omitted. The following mainly describes the differences. In Fig. 10, members having a configuration unique to this modification are given reference numerals in the 500s with the same last two digits as those of the corresponding members in the electric wire with terminal 1 according to the embodiment.

[0081] In the terminal-equipped electric wire 501 according to this modified example, a flat terminal main body portion 532 is provided, connected to the electric wire connection portion 531, extending directly from a bottom wall portion (not shown in FIG. 10; see bottom wall portion 34 in FIGS. 2 to 4) that connects the ends of the lower sides D of a pair of vertical wall portions 35 to the tip side T.

[0082] The terminal body 532 has a flat plate portion 532a extending from the bottom wall portion and having a pair of parallel edges extending in the longitudinal direction TE, and a circular end portion 532b continuing from the flat plate portion 532a on the tip side T and having a semicircular edge. A circular opening 532c is provided in the circular end portion 532b, which is concentric with the semicircular edge. A screw or bolt can be inserted into the circular opening 532c and fastened to another fixed part, thereby electrically connecting the circular end portion to the fixed part.

[0083] In this modified example, similar to the above embodiment, the outer surfaces 35a of the pair of standing wall portions 35 are formed with a cross-like knurled pattern, and the same advantages as those of the above embodiment can be enjoyed. That is, in the terminal fixing step by ultrasonic welding, when the pair of gathers (terminal fixing blocks) sandwich both outer surfaces 35a of the pair of standing wall portions 35 to fix the terminal fitting 503, a strong frictional force is generated between the outer surfaces 35a and the abutting surfaces of the gathers (terminal fixing blocks).

[0084] Therefore, even if ultrasonic vibrations vibrating in the longitudinal direction TE act on the wire connection portion 31 of the terminal fitting 503, there is little concern that the wire connection portion 31 will vibrate in synchronization with the vibration direction of the ultrasonic vibrations. This makes it possible to efficiently generate friction at the interface between the core wire 21 and the wire connection portion 131 during ultrasonic welding, resulting in less likelihood of insufficient joining and less energy loss during joining.

[0085] In this modification, the area of ​​the terminal fitting including the wire connection portion is wrapped together with the core wire in a rubber tube, thereby making it possible to waterproof the terminal crimping portion of the core wire. In contrast to the fifth modification, a sixth modification in which the area of ​​the terminal fitting including the wire connection portion is wrapped together with the core wire in a rubber tube will be described below.

[0086] (Sixth Modification) 11 is a perspective view of an electric wire with terminal according to a sixth modified example. An electric wire with terminal 601 according to this modified example is provided with a rubber tube 6 that encases the area including the wire connection portion 31 of the terminal fitting 3 together with the core wire 21. Note that this differs from the electric wire with terminal 501 according to the fifth modified example in that it is provided with the rubber tube 6, but is otherwise similar.

[0087] 11 showing the electric wire with terminal 601 according to this modification, the same reference numerals as those in the fifth modification are used to designate the same components as those in the fifth modification, and a description of the same components will be omitted. The components that are wrapped in the rubber tube 606 and cannot be seen are the same as those in the electric wire with terminal 501 according to the fifth modification, so please refer to FIG. 10.

[0088] In this modified example, when the rubber tube 606 is attached so as to encase the area including the wire connection portion 31 of the terminal fitting 503 together with the core wire 21, the knurled pattern formed on the outer surfaces 35a of the pair of vertical wall portions 35 increases the adhesive area of ​​the interior adhesive, thereby improving watertightness.

[0089] In this modification, the rubber tube 606 encloses the wire connection portion 31 of the terminal fitting 503 at the center, and extends to the middle of the flat portion 532a on the tip side T, and extends to the area on the wire extension side E beyond the entire area where the core wire 21 is exposed and onto the tip of the coating layer 22. The area enclosed by the rubber tube 6 can be widened or narrowed while determining the waterproofing effect of the terminal crimping portion of the core wire 21 (the joint with the wire connection portion 31).

[0090] In the sixth modification, even if the irregularities formed on the outer surfaces of the pair of upright walls of the electric wire connecting part have other shapes or even if they are through holes, the same water-stopping effect can be expected, as in the fourth modification. Also, even if the tube is a simple rubber tube to which no interior adhesive is applied, the same water-stopping effect can be expected, as in the fourth modification.

[0091] In addition, those skilled in the art can implement various modifications in accordance with conventionally known knowledge without departing from the gist of the present invention. As long as such modifications still provide the configuration of the electric wire with terminal and its manufacturing method, and the electric wire with connector of the present invention, they are of course included in the scope of the present invention. [Explanation of symbols]

[0092] 1,101,201,301,401,501,601: Wires with terminals, 2: Electric wire, 3,103,203,303,503: Terminal fittings, 5: Connector housing, 6,606: Rubber tube, 21: Core wire, 22: Covering layer, 31, 131, 231, 331: Wire connection part, 32,532: Gather (terminal body), 32a: connection hole, 33: Connection part, 34: bottom wall portion, 35, 135, 235, 335: vertical wall section, 35a, 135a, 235a, 335a: outer surface, 41: Anvil, 42: Horn, 43: Terminal fixing block, 43a: contact surface, 53: Insertion hole, 235b: recess, 532a: Flat plate part, 532b: circular end, 532c: Circular opening

Claims

1. An electric wire with a terminal, the electric wire including a terminal fitting having an electric wire connection portion and an electric wire having a core wire joined to the electric wire connection portion, the electric wire connection portion has a bottom wall portion to which the core wire is joined along a longitudinal direction of the electric wire, and a pair of standing wall portions standing on both sides of the core wire from both ends of the bottom wall portion, The electric wire with terminal is provided with a holding force enhancing means on the outer surfaces of the pair of upright wall portions for enhancing the holding force when the terminal fitting is clamped from the outside of the pair of upright wall portions.

2. The electric wire with terminal according to claim 1 , wherein the holding force improving means is unevenness formed on the outer surfaces of the pair of upright wall portions.

3. The electric wire with terminal according to claim 2 , wherein the unevenness formed on the outer surfaces of the pair of upright wall portions is a knurled pattern.

4. The electric wire with terminal according to claim 1 , wherein the holding force improving means is a through hole formed in the pair of vertical wall portions.

5. The electric wire with terminal according to claim 1 , further comprising a rubber tube that encases a region of the terminal fitting including the electric wire connection portion together with the core wire.

6. a terminal fitting arrangement step in which a terminal fitting is arranged so that the bottom wall portion contacts an anvil and the pair of upright wall portions are arranged upright in a direction away from the anvil, the terminal fitting having a bottom wall portion to which the core wire is joined along the longitudinal direction of the electric wire having a core wire made of a plurality of element wires and a pair of upright wall portions standing upright from both ends of the bottom wall portion, the terminal fitting having a holding force enhancing means provided on outer surfaces of the pair of upright wall portions for enhancing holding force when clamped from outside the pair of upright wall portions; a terminal fixing step of fixing the terminal fitting by sandwiching both outer surfaces of the pair of standing wall portions with a pair of terminal fixing blocks having abutment surfaces that abut against both outer surfaces of the pair of standing wall portions; an electric wire arranging step of arranging the electric wire including the core wire so that the core wire is located in a space surrounded by the bottom wall portion and the pair of upright wall portions of the terminal fitting and in a space above the space, and so that a longitudinal direction of the electric wire and an extending direction of the pair of upright wall portions substantially coincide with each other; a welding step of inserting a horn between the pair of upright wall portions and moving it toward the anvil to sandwich and pressurize the core wire and the bottom wall portion between the anvil and the horn, thereby applying ultrasonic vibration to the horn to weld the core wire to the terminal fitting, The method for manufacturing an electric wire with a terminal, wherein the abutting surfaces of the pair of terminal fixing blocks have surfaces corresponding to the outer surfaces of the pair of upright wall portions on which the holding force enhancing means is provided.

7. the holding force improving means are irregularities formed on the outer surfaces of the pair of upright wall portions, 7. The method for manufacturing an electric wire with a terminal according to claim 6, wherein the abutment surfaces of the pair of terminal fixing blocks are surfaces on which protrusions and recesses are formed that fit into at least some of the protrusions and recesses formed on the outer surfaces of the pair of vertical wall portions.

8. The unevenness formed on the outer surfaces of the pair of vertical wall portions is a knurled pattern, The method for manufacturing an electric wire with a terminal according to claim 7, wherein the unevenness formed on the contact surfaces of the pair of terminal fixing blocks is a knurled pattern that is the inverse of the unevenness formed on the outer surfaces.

9. An electric wire with connector comprising the electric wire with terminal according to any one of claims 1 to 4 and a connector having a connector housing, the terminal fitting includes a terminal body portion connected to the wire connection portion on a side opposite to a side from which the wire extends in a longitudinal direction of the wire, The connector housing is provided with an insertion hole into which the terminal metal fitting is inserted from the side of the terminal body portion, The terminal fitting is inserted into the insertion hole and coupled to the connector.

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