Electric wire with terminals, method for manufacturing electric wire with terminals, and auxiliary materials

Abstract

The objective is to provide a wire with a terminal that can properly secure the wire and the terminal, a method for manufacturing a wire with a terminal, and auxiliary materials. [Solution] The terminal-equipped electric wire 1 comprises an electric wire W extending in the axial direction X, with its outer circumference covered by a covering portion W2 and a conductor portion W1 exposed at its tip; a terminal 50 having a plate-shaped connecting portion 51 that electrically connects to the conductor portion W1; and an auxiliary material 10 having a beam portion 11 and two plate-shaped joining plate portions 12a and 12b rising opposite each other from the beam portion 11. The connecting portion 51 and the conductor portion W1 are positioned between the two joining plate portions 12a and 12b, and the auxiliary material 10 is welded and joined together with the connecting portion 51 and the conductor portion W1.

Description

Technical Field

[0001] The present invention relates to a wire with terminals, a method for manufacturing the wire with terminals, and an auxiliary material.

Background Art

[0002] As a technology related to a conventional wire with terminals, a method for manufacturing the wire with terminals, and an auxiliary material, for example, Patent Document 1 discloses a wire with terminals in which a conductor portion of a wire is welded to a terminal substrate portion to electrically connect the terminal and the wire. In this wire with terminals, a pair of side walls erected on both sides of the welding portion of the terminal substrate portion has a corner portion with a cross-sectional R shape with respect to the welding portion.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, such a wire with terminals electrically connects the conductor portion of the wire and the terminal by welding, and fixes the terminal to the wire, but there is room for further improvement in the fixing of the wire and the terminal.

[0005] The present invention has been made in view of the above circumstances, and an object thereof is to provide a wire with terminals, a method for manufacturing the wire with terminals, and an auxiliary material that can properly fix the wire and the terminal.

Means for Solving the Problems

[0006] To achieve the above objective, the terminal-equipped electric wire of the present invention comprises an electric wire extending in a first direction, with its outer circumference covered by a covering portion and its tip exposed as a conductor; a terminal having a plate-shaped connecting portion that electrically connects to the conductor; and an auxiliary material having a beam portion and two plate-shaped joining plate portions rising opposite each other from the beam portion. The connecting portion and the conductor are positioned between the two joining plate portions, and the auxiliary material is welded together with the connecting portion and the conductor.

[0007] To achieve the above objective, the present invention provides a method for manufacturing a wire with a terminal, comprising: a preparation step of preparing a wire extending in a first direction, having an outer circumference covered with a covering portion and a conductor portion exposed at its tip; a terminal having a plate-shaped connecting portion electrically connected to the conductor portion; and an auxiliary material having a beam portion and two plate-shaped joining plate portions rising opposite each other from the beam portion; an insertion step of inserting the conductor portion of the wire and the connecting portion of the terminal into an insertion portion formed by spacing the joining plate portions of the auxiliary material in a second direction perpendicular to the first direction, thereby positioning the conductor portion and the connecting portion between the joining plate portions; and a joining step of performing ultrasonic bonding after the insertion step by supporting the outer surface of one of the joining plate portions with an anvil and pressing a horn against the outer surface of the other joining plate portion.

[0008] To achieve the above objective, the auxiliary material of the present invention comprises a beam portion and an auxiliary material having two plate-shaped joining plate portions rising opposite to the beam portion, wherein the two joining plate portions are arranged between the two joining plate portions, the conductor portion of an electric wire extending in a first direction and having its outer circumference covered with a covering portion and its tip exposed with a conductor portion, and the connecting portion of a terminal having a plate-shaped connecting portion that electrically connects to the conductor portion, and the connecting portion and the conductor portion together are configured to enable ultrasonic bonding, and each joining plate portion has a plurality of protrusions extending in the second direction on its inner surface facing each other, at least one of the plurality of protrusions corresponds to the connecting portion, and at least one of the plurality of protrusions corresponds to the conductor portion. [Effects of the Invention]

[0009] The wire with terminals, the method for manufacturing the wire with terminals, and the auxiliary material according to the present invention have the effect of being able to properly fix the wire and the terminal. [Brief explanation of the drawing]

[0010] [Figure 1] Figure 1 is a plan view showing a wire with terminals according to an embodiment. [Figure 2] Figure 2 is a side view showing a wire with terminals according to an embodiment. [Figure 3] Figure 3 is a cross-sectional view taken along line III-III in Figure 1. [Figure 4] Figure 4 is a perspective view of the auxiliary material according to the embodiment. [Figure 5] Figure 5 is a flowchart illustrating the steps of the manufacturing method for terminal-equipped electric wires according to the embodiment. [Figure 6] Figure 6 is a perspective view showing the joining process in the manufacturing method of a terminal-equipped electric wire according to the embodiment. [Modes for carrying out the invention]

[0011] Embodiments of the present invention will be described in detail below with reference to the drawings. However, the present invention is not limited by these embodiments. Furthermore, some of the components in the following embodiments may be easily substituted or substantially identical to those that are easily substituted by those skilled in the art.

[0012] [Embodiment] As shown in Figures 1 to 3, the terminal-equipped wire 1 is applied to a wire harness routed in a vehicle or the like. Here, a wire harness is, for example, a bundle of multiple wires W used for power supply and signal communication to connect various devices mounted on a vehicle, and the multiple wires W are connected to each device using connectors or the like. The terminal-equipped wire 1 of this embodiment comprises a wire W, a terminal 50, and an auxiliary material 10 provided at the point where the wire W and the terminal 50 connect.

[0013] In the following explanation, the direction in which the electric wire W extends is referred to as the axial direction X (first direction), and the directions perpendicular to the axial direction X and perpendicular to each other are referred to as the width direction Y (second direction) and the vertical direction Z. The vertical direction Z refers to the direction in which the plate surface of the plate-shaped connecting portion 51 of the terminal 50 is facing. Furthermore, one side of the axial direction X is referred to as side X1, and the other side as side X2. Similarly, in the width direction Y, one side is referred to as Y1 and the other side as Y2, and in the vertical direction Z, one side is referred to as Z1 and the other side as Z2.

[0014] As shown in Figures 1 to 3, the terminal-equipped electric wire 1, which is formed in a roughly U-shape when viewed from the axial direction X, has a plate-shaped connecting portion 51 of the terminal 50 and a conductor portion W1 of the electric wire W positioned between the auxiliary members 10. The end face 51a of the connecting portion 51 (the other end face X2 in the axial direction X) and the tip end W1a of the conductor portion W1 are butted together at a butt joint 40, and the auxiliary member 10 and the connecting portion 51 and the auxiliary member 10 and the conductor portion W1 are welded together. Note that although the auxiliary member 10 and the connecting portion 51 and the auxiliary member 10 and the conductor portion W1 are joined by welding, the butt joint 40 where the end face 51a of the connecting portion 51 and the tip end W1a of the conductor portion W1 are butted together (in other words, the connecting portion 51 and the conductor portion W1 at the butt joint 40) are not joined.

[0015] The electric wire W is composed of a conductive linear conductor W1 and an insulating sheath W2 that covers the outside of the conductor W1. The electric wire W is an insulated electric wire in which the conductor W1 is covered with the sheath W2. The conductor W1 is composed of a core wire made by bundling multiple strands of a conductive metal such as copper, copper alloy, aluminum, or aluminum alloy, or a twisted core wire made by twisting multiple strands together. The sheath W2 is an electric wire sheath that covers the outer circumference of the conductor W1. The sheath W2 is formed by extruding an insulating resin material such as PP (Polypropylene), PVC (Polyvinyl Chloride), or cross-linked PE (Polyethylene). The insulating resin material that constitutes the sheath W2 is appropriately selected with consideration for abrasion resistance, chemical resistance, heat resistance, etc. At its tip, the sheath W2 is stripped off, and the tip of the conductor W1 is exposed from the tip of the sheath W2. In the wire with terminal 1, the connection portion 51 of the terminal 50 is connected to the end of the wire W where the conductor portion W1 is exposed. In the embodiment, in the portion of the wire W where the conductor portion W1 is covered by the covering portion W2, the conductor portion W1 has a substantially circular cross-sectional shape in the width direction Y, and the covering portion W2 has a substantially annular shape, so the overall shape is substantially circular, and the diameter is substantially the same in the axial direction X.

[0016] The terminal 50 has a plate-shaped connecting portion 51 that electrically connects to the conductor portion W1. The connecting portion 51 extends from one side X2 to the other side X2 of the terminal body 52, which has a hole for connecting to other equipment, etc. The terminal 50 is a terminal fitting in which the entire unit, including the connecting portion 51 and the terminal body 52, is made of a conductive metal such as copper, copper alloy, aluminum, or aluminum alloy, and its surface is tin-plated or otherwise coated. The terminal 50 is formed three-dimensionally as a single piece by pressing and bending a single sheet of metal, which has been punched out of conductive metal into shapes corresponding to each component.

[0017] As shown in FIG. 3, the auxiliary member 10 has a beam portion 11 and two plate-like joint plate portions 12 that rise up from the beam portion 11 in opposite directions. In the ultrasonic bonding in the present embodiment, the auxiliary member 10 is preferably made of the same material as the material of the conductor portion W1 of the electric wire W. For example, it is integrally formed of a conductive metal such as copper, a copper alloy, aluminum, an aluminum alloy, or the like. More specifically, as shown in FIG. 4, the beam portion 11 of the auxiliary member 10 is formed in a substantially long rectangular plate shape with the axial direction X as the longitudinal direction and the plate surface facing the width direction Y. The two joint plate portions 12 are formed to have the same length in the axial direction X as the beam portion 11. Of the two joint plate portions 12, the joint plate portion 12a is provided on one side Z1 in the vertical direction Z, and the joint plate portion 12b is provided on the other side Z2 in the vertical direction Z. The joint plate portions 12a and 12b have a plurality of convex portions 12c extending in the width direction Y on the inner surfaces 12a1 and 12b1 facing each other. The convex portion 12c extends from the end portion on one side Y1 in the width direction Y of the joint plate portion 12 (the surface on the other side Y2 in the width direction Y of the beam portion 11) to the vicinity of the end portion on the other side Y2 of the joint plate portion 12 (see also FIG. 3). The convex portion 12c has an arc-shaped cross section in the axial direction X. In the present embodiment, two convex portions 12c are provided on each of the joint plate portions 12a and 12b at a predetermined interval in the axial direction X. Further, each convex portion 12c of the joint plate portion 12a and each convex portion 12c of the joint plate portion 12b are arranged such that the axial centers CL1 and CL2 in the vertical direction Z of the opposing convex portions 12c coincide (see also FIG. 2). In other words, each convex portion 12c on one side X1 in the axial direction X of the joint plate portion 12a and the joint plate portion 12b coincides at the axial center CL1, and each convex portion 12c on the other side X2 in the axial direction X of the joint plate portion 12a and the joint plate portion 12b coincides at the axial center CL2. Thereby, the joint plate portions 12a and b, the connection portion 51, and the conductor portion W1 are joined in a balanced manner.

[0018] In the auxiliary member 10 formed in a substantially U shape when viewed from the axial direction X, the portion where the two joint plate portions 12a and 12b are separated at the end portion on the other side Y2 in the width direction Y is the insertion portion 13. As will be described later, the connection portion 51 of the terminal 50 to be joined to the auxiliary member 10 and the conductor portion W1 of the electric wire W are inserted from the insertion portion 13.

[0019] Also, as shown in FIG. 2, among the plurality of convex portions 12c provided on each of the joint plate portions 12a and 12b, the convex portion 12c1 on one side X1 in the axial direction X is disposed at a position corresponding to the connection portion 51 of the terminal 50, and is joined by ultrasonic bonding so as to bite into the connection portion 51. Similarly, the convex portion 12c2 on the other side X2 in the axial direction X in the joint plate portions 12a and 12b is disposed at a position corresponding to the conductor portion W1, and is joined by ultrasonic bonding so as to bite into the conductor portion W1.

[0020] Next, a method for manufacturing the electric wire 1 with a terminal will be described based on the flowchart of FIG. 5. Preparation step (step S10); Prepare the electric wire W, the terminal 50, and the auxiliary material 10. The electric wire W has its outer periphery covered with the covering portion W2, and at the tip, the covering portion W2 is peeled off to expose the conductor portion W1.

[0021] Insertion step (step S20); The conductor portion W1 of the electric wire W and the connection portion 51 of the terminal 50 are inserted into the auxiliary material 10 from the insertion portion 13 of the auxiliary material 10. The conductor portion W1 and the connection portion 51 are inserted from the other side Y2 to the one side Y1 in the width direction Y where the insertion portion 13 is located. Here, the connection portion 51 and the conductor portion W1 are in a state where the end face 51a in the axial direction X of the connection portion 51 and the end portion W1a at the tip of the conductor portion W1 are abutted against each other. In other words, in the insertion step (step S20), the end face 51a of the connection portion 51 and the end portion W1a at the tip of the conductor portion W one side Y1 in the width direction Y where the insertion portion 13 is located. Here, the connection portion 51 and the conductor portion W1 are in a state where the end face 51a in the axial direction X of the connection portion 51 and the end portion W1a at the tip of the conductor portion W1 are abutted against each other. In other words, in the insertion step (step S20), the end face 51a of the connection portion 51 and the end portion W1a at the tip of the conductor portion W1 are abutted against each other to form the butted portion 40. The abutment of the end face 51a and the end portion W1a at the tip of the conductor portion W1 may be performed before insertion into the auxiliary material, or after inserting the connection portion 51 and the electric wire W into the auxiliary material 10 respectively, or while inserting, the end face 51a and the end portion W1a at the tip of the conductor portion W1 may be abutted against each other.

[0022] Furthermore, when the covering portion W2 is removed, the outer shape of the cross-section in the width direction Y of the conductor portion W1 is formed to be circular. Therefore, before inserting the conductor portion W1 into the auxiliary material 10, temporary shaping may be performed as needed to allow insertion into the auxiliary material 10. The temporary shaping process for the conductor portion W1 can be, for example, a single-wire process in which the core wires of the conductor portion W1 are ultrasonically joined to form a roughly plate-like single wire. Even without performing the temporary shaping process, if the conductor portion W1 can be inserted into the auxiliary material 10 by, for example, widening the joining plate portions 12a and 12b of the auxiliary material 10, then temporary shaping is not necessary.

[0023] Furthermore, the connecting portion 51 is inserted into the auxiliary material 10 so as to be in a position corresponding to the protrusion 12c1 on one side X1 in the axial direction X of the joining plate portions 12a and 12b. Similarly, the conductor portion W1 is inserted into the auxiliary material 10 so as to be in a position corresponding to the protrusion 12c2 on the other side X2 in the axial direction X of the joining plate portions 12a and 12b. In this embodiment, by positioning the end face 51a of the connecting portion 51 and the tip of the conductor portion W1 at an intermediate position in the axial direction X of the joining plate portions 12a and 12b, the protrusion 12c1 corresponds to the connecting portion 51 and the protrusion 12c2 corresponds to the conductor portion W1.

[0024] As shown in Figure 2, the distance a from the axis CL1 of the protrusion 12c1 to the end face 51a (end W1a of the conductor W1) and the distance b from the axis CL2 of the protrusion 12c2 to the end face 51a (end W1a of the conductor W1) can be appropriately set according to the shape of the terminal 50 and the electric wire W. Furthermore, when inserting the connection part 51 and the conductor W1 into the insertion part 13, the gap between the insertion part 13 can be widened by bending the joint plate part 12a to one side Z1 in the vertical direction Z and bending the joint plate part 12b to the other side Z2 in the vertical direction Z, thereby facilitating the insertion of the connection part 51 and the conductor W1.

[0025] After the joining process (step S20); insertion process (step S20) is completed, the auxiliary material 10, the connection portion 51 of the terminal 50 inserted between the joining plate portions 12a and 12b of the auxiliary material 10, and the conductor portion W1 of the electric wire W are ultrasonically joined using the ultrasonic joining device 100 shown in Figure 6. Here, the ultrasonic joining device 100 is provided with a horn 110 on one side Z1 in the vertical direction Z and an anvil 120 on the other side Z2. The horn 110 vibrates ultrasonically in the axial direction X as indicated by the arrow S, and can pressurize the objects to be joined between the anvil 120 and the horn from one side Z1 to the other side Z2 in the vertical direction Z.

[0026] The auxiliary material 10, with the connecting portion 51 and the conductor portion W1 sandwiched between it, has its outer surface 12b2 of the joining plate portion 12b supported by the anvil 120, and the horn 110 is pressed against the outer surface 12a2 of the joining plate portion 12a. The horn 110 then vibrates ultrasonically in the axial direction X while pressing against the outer surface 12a2 of the joining plate portion 12a. In this way, the joining plate portions 12a and 12b of the auxiliary material 10 and the connecting portion 51 and conductor portion W1 inserted into the auxiliary material 10 are ultrasonically joined, and the connecting portion 51 of the terminals 50 that are abutted at the butt joint portion 40 and the conductor portion W1 of the electric wire W are electrically connected. At this time, the connecting portion 51 and the conductor portion W1 at the butt joint portion 40 are not joined.

[0027] The terminal-equipped electric wire 1 described above comprises an electric wire W extending in the axial direction X, which is the first direction, with its outer circumference covered by a covering portion W2 and a conductor portion W1 exposed at its tip; a terminal 50 having a plate-shaped connecting portion 51 that electrically connects to the conductor portion W1; and an auxiliary member 10 having a beam portion 11 and two plate-shaped joining plate portions 12a and 12b rising opposite each other from the beam portion 11. The connecting portion 51 and the conductor portion W1 are positioned between the two joining plate portions 12a and 12b, and the auxiliary member 10 is welded and joined together with the connecting portion 51 and the conductor portion W1.

[0028] As a result, the connecting plate portions 12a and 12b of the auxiliary material 10 are joined to the connection portion 51 of the terminal 50, and the connecting plate portions 12a and 12b are joined to the conductor portion W1, so that a wire with a terminal 1 can be provided that can properly fix the wire W and the terminal 50.

[0029] If the auxiliary material 10 is omitted, that is, if the end face 51a of the connection portion 51 of the terminal 50 and the tip end W1a of the conductor portion W1 of the electric wire W are brought together and the horn 110 is pressed against this joined portion to perform ultrasonic bonding, the end face 51a is perpendicular to the vibration direction (arrow S) of the horn 110, which is the axial direction X, so bonding is not promoted and good ultrasonic bonding may not be possible. On the other hand, if the conductor portion W1 is positioned so that it rests on one side Z1 of the connection portion 51 of the terminal 50 in the vertical direction Z, then the horn 110 can be pressed against one side Z1 of the conductor portion W1 to perform good ultrasonic bonding. However, in this case, the connection portion 51 and the conductor portion W1 overlap when bonded, so the height of the bonded portion in the vertical direction Z becomes high.

[0030] Therefore, as in this embodiment, the connecting portion 51 and the conductor portion W1 are sandwiched between the joining plate portions 12 of the roughly U-shaped auxiliary material 10, one joining plate portion 12b is supported by the anvil 120, and the horn 110 is pressed against the other joining plate portion 12a to perform ultrasonic bonding. As a result, each of the two joining plate portions 12a and 12b is ultrasonically bonded to the connecting portion 51 and the conductor portion W1, enabling an electrical connection between the connecting portion 51 and the conductor portion W1, and reducing the height of the bonded portion compared to the case where the connecting portion 51 and the conductor portion W1 are stacked and ultrasonically bonded.

[0031] Furthermore, each joining plate portion 12a, 12b has a plurality of protrusions 12c extending in the width direction Y on its opposing inner surfaces 12a1, 12b1, with at least one of the plurality of protrusions 12c1 corresponding to the connecting portion 51, and at least one other of the plurality of protrusions 12c2 corresponding to the conductor portion W1.

[0032] The protrusion 12c increases the surface area of ​​the inner surfaces 12a1 and 12b1 of the joining plate portion 12 that contact the connection portion 51 and the conductor portion W1. Consequently, the contact resistance between the connection portion 51 and the conductor portion W1 and the joining plate portion 12 is stabilized, and the mechanical strength of the ultrasonic bonding can be increased. Furthermore, even when a large current is applied to the electric wire W, the increased contact area between the connection portion 51 and the conductor portion W1 and the auxiliary material 10 (joining plate portion 12) allows for proper heat dissipation from the auxiliary material 10, thereby reducing the temperature rise.

[0033] Furthermore, the protrusion 12c of the auxiliary material 10 has an arc-shaped cross-section in the axial direction X. As a result, since the cross-section of the protrusion 12c in the axial direction X is arc-shaped, it is possible to eliminate a surface perpendicular to the direction of ultrasonic vibration of the horn 110 (arrow S), thereby reducing the occurrence of areas where ultrasonic bonding does not occur between the joining plate portion 12, the connecting portion 51, and the conductor portion W1.

[0034] The manufacturing method for the terminal-equipped electric wire 1 comprises a preparation step (step S10) of preparing the electric wire W, the terminal 50, and the auxiliary material 10; an insertion step (step S20) of inserting the conductor portion W1 of the electric wire W and the connection portion 51 of the terminal 50 into the insertion portion 13 formed by the joint plate portions 12a and 12b of the auxiliary material 10 being spaced apart in the width direction Y, and butting the end face 51a of the connection portion 51 with the tip (end W1a) of the conductor portion W1 to position the conductor portion W1 and the connection portion 51 between the joint plate portions 12a and 12b; and a joining step (step S30) of performing ultrasonic joining by supporting the outer surface 12b2 of one joint plate portion 12b with an anvil 120 and pressing a horn 110 against the outer surface 12a2 of the other joint plate portion 12a.

[0035] Furthermore, the auxiliary member 10 comprises a beam portion 11 and two plate-shaped connecting plate portions 12a and 12b rising opposite each other from the beam portion 11. Between the two connecting plate portions 12a and 12b, a terminal 50 is positioned which has a plate-shaped connecting portion 51 that electrically connects to the conductor portion W1 of an electric wire W, which extends in the axial direction X, has its outer circumference covered with a covering portion W2 and has a conductor portion W1 exposed at its tip. The connecting portion 51 and the conductor portion W1 are configured to enable ultrasonic bonding. Each connecting plate portion 12a and 12b has a plurality of protrusions 12c extending in the width direction Y on its opposing inner surfaces 12a1 and 12b1. At least one of the multiple protrusions 12c1 corresponds to the connecting portion 51, and at least one of the multiple protrusions 12c2 corresponds to the conductor portion W1.

[0036] As a result, the auxiliary material 10 and the connecting part 51 and the auxiliary material 10 and the conductor part W1 can be welded and joined by ultrasonic bonding, thereby providing a method for manufacturing a wire with a terminal 1 and an auxiliary material 10 that can properly fix the wire W and the terminal 50.

[0037] It should be noted that the wire with terminals, the method for manufacturing the wire with terminals, and the auxiliary materials according to the embodiments of the present invention described above are not limited to the embodiments described above, and various modifications are possible within the scope of the claims.

[0038] In the above description, the protrusions 12c are formed with a total of four protrusions in two sets, but this is not limited to this, and multiple protrusions can be formed. Multiple protrusions 12c are arranged such that at least one corresponds to the connecting portion 51 and at least one corresponds to the conductor portion W1, and the number of protrusions 12c corresponding to the connecting portion 51 and the number of protrusions 12c corresponding to the conductor portion W1 do not have to be the same. Furthermore, the auxiliary material 10, the connecting portion 51, and the conductor portion W1 are not limited to being welded and joined by ultrasonic welding, but may be welded and joined by other processes such as resistance welding or laser welding. In addition, although the connecting portion 51 and the conductor portion W1 at the butt joint 40 are not joined, depending on the output of the ultrasonic welding and the type of welding, a part or all of the butt joint 40 where the connecting portion 51 and the conductor portion W1 are butted together may be joined. Alternatively, the joining process can be performed by inserting the connecting portion 51 and the conductor portion W1 between the joining plate portions 12a and 12b with the end face 51a of the connecting portion 51 and the tip end W1a of the conductor portion W1 separated (i.e., without forming a butt joint 40).

[0039] The terminal-equipped wire, the method for manufacturing the terminal-equipped wire, and the auxiliary material according to this embodiment may be constructed by appropriately combining the components of the embodiments and modified examples described above. [Explanation of symbols]

[0040] 1: Wire with terminals 10: Auxiliary materials 11:Beam part 12,12a,12b: Joint plate part 12a1,12b1: Inner surface 12a2,12b2: External surface 12c, 12c1, 12c2: Convex part 13: Insertion part 50: Terminals 51: Connection part 51a: End face 110: Horn 120: Anvil W: Electric wire W1: Conductor part W2: Covering part X: Axis direction (first direction) Y: Width direction (2nd direction)

Claims

1. A wire extending in a first direction, with its outer circumference covered by a covering and its tip having an exposed conductor, A terminal having a plate-shaped connecting portion that is electrically connected to the aforementioned conductor portion, An auxiliary member having a beam section and two plate-shaped connecting plate sections rising opposite to the beam section, Equipped with, The connecting portion and the conductor portion are arranged between the two joining plates. The auxiliary material is welded and joined together with the connecting portion and the conductor portion. Electrical wire with terminals.

2. Each of the aforementioned joining plate portions has a plurality of protrusions on its inner surface facing each other, extending in a second direction perpendicular to the first direction, The terminal wire according to claim 1, wherein at least one of the plurality of protrusions is positioned at a location corresponding to the connection portion, and at least one of the plurality of protrusions is positioned at a location corresponding to the conductor portion.

3. The terminal-equipped wire according to claim 2, wherein the protrusion has an arc-shaped cross-section in the first direction.

4. A preparation step of preparing an electric wire extending in a first direction, with its outer circumference covered by a covering portion and its tip exposed as a conductor, a terminal having a plate-shaped connecting portion that electrically connects to the conductor, and an auxiliary material having a beam portion and two plate-shaped joining plate portions rising opposite each other from the beam portion, Insertion step: Insert the conductor portion of the electric wire and the connecting portion of the terminal into the insertion portion formed by the joint plate portion of the auxiliary material being spaced apart in a second direction perpendicular to the first direction, and position the conductor portion and the connecting portion between the joint plate portion, After the insertion step, a bonding step is performed in which the outer surface of one of the bonding plate portions is supported by an anvil, and a horn is pressed against the outer surface of the other bonding plate portion to perform ultrasonic bonding, A method for manufacturing an electric wire with terminals.

5. The beam section, The auxiliary member comprises two plate-shaped connecting plate portions that rise opposite to each other from the beam portion, The two joining plates are arranged such that the conductor portion of an electric wire, which extends in a first direction and whose outer circumference is covered with a covering portion and whose tip is exposed, and the connecting portion of a terminal having a plate-shaped connecting portion that electrically connects to the conductor portion are positioned between the two joining plates, and the connecting portion and the conductor portion together are configured to enable ultrasonic bonding. Each of the aforementioned joining plate portions has a plurality of protrusions on its inner surface facing each other, extending in a second direction perpendicular to the first direction, At least one of the multiple protrusions corresponds to the connecting portion, and at least one of the multiple protrusions corresponds to the conductor portion. Auxiliary material.

Images