Method for manufacturing a wire with terminals, and a wire with terminals

Abstract

The present invention provides a method for manufacturing a wire with terminals, and a wire with terminals, that can optimize the application of ultraviolet-curing resin to the corrosion-protected area. [Solution] The method for manufacturing the terminal-equipped electric wire 100 includes a coating step of applying an ultraviolet-curable resin to the parts of the terminal-equipped electric wire to be protected from corrosion, an assembly step of assembling an insulating resin cover 10 to the opening of the crimp terminal 1 to cover the exposed core wire, and an irradiation step of irradiating the crimp terminal 1 with ultraviolet light. In the coating step, the ultraviolet-curable resin is applied to the core wire tip, groove-shaped part, and peripheral edge of the opening, which are the parts to be protected from corrosion. The resin cover is formed to fit the peripheral edge of the opening. In the assembly step, the resin cover is bonded to the peripheral edge of the opening to which the ultraviolet-curable resin has been applied.

Description

Technical Field

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[0001] The present invention relates to a method for manufacturing a wire with a terminal and a wire with a terminal.

Background Art

[0002] Conventionally, in a method for manufacturing a wire with a terminal, for example, after crimping a crimp terminal to an exposed portion of a core wire provided at the end of the wire, an ultraviolet curable resin (UV (Ultraviolet) curable resin) or the like is applied to the portion where the core wire is exposed with respect to the crimp terminal, thereby ensuring corrosion protection performance (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the conventional method for manufacturing a wire with a terminal, there is room for further improvement from the viewpoint of more appropriate application of the ultraviolet curable resin, such as the position of the nozzle for injecting the UV curable resin may shift with respect to the crimp terminal.

[0005] An object of the present invention is to provide a method for manufacturing a wire with a terminal and a wire with a terminal that can optimize the application of the ultraviolet curable resin to the corrosion protection target site.

Means for Solving the Problems

[0006] To achieve the above objective, the present invention provides a method for manufacturing a terminal-equipped electric wire, comprising: an electric wire including a conductive core wire and an insulating coating portion covering the outside of the core wire and providing insulation; a terminal connection portion electrically connected to a mating terminal; a core wire crimp portion crimped to the core wire exposed at the end of the electric wire; a coating portion crimped to the insulating coating portion; and a crimp terminal provided at the connection portion between the core wire crimp portion and the coating crimp portion, including an opening through which a part of the core wire is exposed; a coating step of applying an ultraviolet-curable resin to the part to be protected from corrosion; and an assembly step after the coating step of assembling an insulating resin cover over the opening to cover the exposed portion of the core wire; and the assembly The process includes an irradiation step of irradiating the crimp terminal with ultraviolet light after the attachment step, wherein the corrosion protection target portion includes the tip of the core wire exposed toward the terminal connection portion from the core wire crimp portion, a groove-shaped portion formed in the core wire crimp portion and extending along the axial direction of the electric wire, and the peripheral edge of the opening, and the resin cover is formed to match the peripheral edge of the opening among the corrosion protection target portion, wherein the coating step involves applying the ultraviolet-curable resin to the tip of the core wire, the groove-shaped portion of the core wire crimp portion, and the peripheral edge of the opening, and the assembly step involves bonding the resin cover to the peripheral edge of the opening to which the ultraviolet-curable resin has been applied. [Effects of the Invention]

[0007] The method for manufacturing a wire with terminals and the wire with terminals according to the present invention have the effect of enabling the proper application of ultraviolet-curable resin to the corrosion-protected parts. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is a plan view showing a schematic configuration of a wire with terminals according to an embodiment. [Figure 2] Figure 2 is a schematic side view showing the state of a wire with terminals according to the embodiment. [Figure 3] Figure 3 is a flowchart showing an example of a method for manufacturing a wire with terminals according to an embodiment. [Figure 4] Figure 4 is a plan view showing the state of a wire with terminals before the coating process in the wire manufacturing method. [Figure 5] Figure 5 is a schematic side view showing the state of a wire with terminals during the coating process in the manufacturing method of wires with terminals. [Figure 6] Figure 6 is a plan view showing the state of a wire with terminals during the assembly process of a wire with terminals manufacturing method. [Figure 7] Figure 7 is a schematic side view showing the state of a wire with terminals during the assembly process of a wire with terminals manufacturing method. [Figure 8] Figure 8 is a schematic side view showing the state of a wire with terminals during the irradiation process in the wire manufacturing method. [Modes for carrying out the invention]

[0009] Embodiments of the present invention will be described in detail below with reference to the drawings. However, the present invention is not limited to the embodiments described below. That is, the components in the embodiments described below include those that are easily conceivable by those skilled in the art, or that are substantially the same, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention.

[0010] In the following explanation, the X direction in the diagram will be referred to as the "axial direction X," the Y direction as the "width direction Y," and the Z direction as the "height direction Z." Here, the "axial direction X," "width direction Y," and "height direction Z" are mutually orthogonal. The axial direction X is the direction along the axis Xa and corresponds to the direction of extension of the electric wire W to which the crimp terminal 1, described later, is provided. One of the axial directions X will be referred to as the first axial direction X1, and the other as the second axial direction X2. In the following explanation, the direction of rotation with respect to the axial direction X will be referred to as the "circumferential direction." Unless otherwise specified, the directions used in the following explanation represent the directions when each part is assembled together.

[0011] [Embodiment] The manufacturing method for the terminal-equipped wire according to this embodiment is for manufacturing the terminal-equipped wire 100 shown in Figures 1 and 2. Below, we will first describe the basic configuration of the terminal-equipped wire 100 shown in Figures 1, 2 and 4, and then describe the manufacturing method for the terminal-equipped wire in detail.

[0012] The terminal-equipped wire 100 is applicable, for example, to wire harnesses used in vehicles. Here, a wire harness is a component made by bundling multiple wires W used for power supply and signal communication to connect various devices mounted on a vehicle, and connecting the multiple wires W to each device with connectors or the like. The terminal-equipped wire 100 comprises a wire W, a crimp terminal 1 crimped to the end of the wire W, an insulating resin cover 10 assembled to the crimp terminal 1 and fixed with an ultraviolet-curable resin UVR, and a cured resin part 70 made of cured ultraviolet-curable resin UVR. Here, the ultraviolet-curable resin UVR hardens when irradiated with ultraviolet light.

[0013] As shown in Figure 4, the electric wire W is composed of, for example, a conductive core wire W1 and an insulating coating W2 that covers the outside of the core wire W1. The electric wire W is an insulated electric wire in which the core wire W1 is covered with the insulating coating W2. In this embodiment, the core wire W1 is a core wire made by bundling together multiple strands of a conductive metal, such as aluminum or an aluminum alloy, but it may also be a stranded core wire made by twisting together multiple strands. The insulating coating W2 is an electric wire coating that covers the outer circumference of the core wire W1. The insulating coating W2 is formed by extruding an insulating resin material (such as PP, PVC, or cross-linked PE; appropriately selected considering abrasion resistance, chemical resistance, heat resistance, etc.). In the electric wire W, the insulating coating W2 is stripped off at least one end of the core wire W1, so that one end of the core wire W1 is exposed from the end of the insulating coating W2, and a crimp terminal 1 is crimped to the exposed end of the core wire W1. Here, the electric wire W is formed to extend with approximately the same diameter in the direction of linear extension, the cross-sectional shape of the core wire W1 (cross-sectional shape in the direction intersecting the direction of extension) is approximately circular, and the cross-sectional shape of the insulating coating W2 is approximately annular, resulting in an overall approximately circular cross-sectional shape.

[0014] Next, the crimp terminal 1 will be described with reference to Figures 1, 2, and 4. The crimp terminal 1 is a terminal fitting formed to be insertable into, for example, an insulating resin connector. The crimp terminal 1 comprises a terminal connection part 2, a first connecting part 3, a core wire crimping part 4, a second connecting part 5, and a sheath crimping part 6. The crimp terminal 1 is arranged and interconnected in the order of terminal connection part 2, first connecting part 3, core wire crimping part 4, second connecting part 5, and sheath crimping part 6 along the axial direction X, from the first axial direction X1 side toward the second axial direction X2 side. The terminal connection part 2, first connecting part 3, core wire crimping part 4, second connecting part 5, and sheath crimping part 6 are all integrally constructed from a conductive metal, such as copper, copper alloy, aluminum, aluminum alloy, etc., and are tin-plated or otherwise treated. The crimp terminal 1 is formed by pressing and bending a single sheet of metal, which has been punched out in shapes corresponding to each part, such as the terminal connection part 2, the first connecting part 3, the core wire crimping part 4, the second connecting part 5, and the insulation crimping part 6, so that each part is formed three-dimensionally as a single unit.

[0015] The terminal connection part 2 is, for example, the part that is electrically connected to the mating terminal 200. The terminal connection part 2 is shown as a female terminal shape and is electrically connected to the mating terminal 200, which has a male terminal shape.

[0016] The first connecting portion 3 is interposed between the terminal connection portion 2 and the core wire crimping portion 4, and is the portion that connects the terminal connection portion 2 and the core wire crimping portion 4. In the crimp terminal 1, the terminal connection portion 2 and the core wire crimping portion 4 are electrically connected via the first connecting portion 3, and the terminal connection portion 2 and the core wire W1 of the electric wire W are electrically connected and electrically conductive via the core wire crimping portion 4.

[0017] The first connecting section 3 is composed of a bottom wall 30, a pair of side walls 31, and an opening 32. The bottom wall 30 is connected to the terminal connection section 2 on the first axial direction X1 side and to the bottom wall 40 of the core wire crimping section 4 on the second axial direction X2 side. The bottom wall 30 extends along the axial direction X and is the base portion of the first connecting section 3, whose cross-sectional shape, as viewed from the axial direction X, is roughly bucket-shaped in the pre-crimping state before the crimping terminal 1 is crimped to the electric wire W.

[0018] The side wall 31 is connected to the terminal connection part 2 on the first axis direction X1 side and is connected to the caulking piece 41 of the core wire crimping part 4 on the second axis direction X2 side. The side wall 31 is provided so as to rise along the height direction Z on both sides in the width direction Y of the bottom wall 30.

[0019] The opening 32 is formed between the terminal connection part 2 and the core wire crimping part 4 in the axial direction X and between a pair of side walls 31 facing each other in the width direction Y in a crimped state where the core wire crimping part 4 is crimped to the core wire W1 and the covering crimping part 6 is crimped to the insulating covering part W2. The opening 32 opens in one of the height directions Z orthogonal to the axial direction X in the above crimped state, and inside the opening 32, the tip part W1a of the core wire is exposed. The tip part W1a of the core wire is the tip part of the core wire W1 exposed from the core wire crimping part 4 toward the terminal connection part 2 side. The tip part W1a of the core wire is exposed through the opening 32. The core wire W has a tip part W1a of the core wire protruding from the core wire crimping part 4 toward the terminal connection part 2 side along the axial direction X in the above crimped state.

[0020] The core wire crimping part 4 is a part that is crimped to the exposed part of the core wire W1 provided at the terminal of the electric wire W and electrically connects the electric wire W and the crimping terminal 1. The core wire crimping part 4 includes a bottom wall 40 and a pair of caulking pieces (barrel pieces) 41. The core wire crimping part 4 is caulked and crimped to the core wire W1 by the bottom wall 40 and the pair of caulking pieces 41.

[0021] The bottom wall 40 is connected to the terminal connection part 2 on one side in the axial direction X and is connected to the covering crimping part 6 on the other side in the axial direction X. Specifically, the bottom wall 40 is connected to the bottom wall 30 of the first connection part 3 on the first axis direction X1 side and is connected to the bottom wall 50 of the second connection part 5 on the second axis direction X2 side. The bottom wall 40 extends along the axial direction X and is a part that becomes the base of the core wire crimping part 4 formed in a substantially U shape in the state before crimping.

[0022] The pair of crimping pieces 41, together with a part of the bottom wall 40, constitute the core wire crimping section 4. Each of the pair of crimping pieces 41 extends from both side edges of the bottom wall 40 along the direction around the axis Xa of the electric wire W. The pair of crimping pieces 41 are wrapped around the core wire W1 and crimped, and the length from the base on the bottom wall 40 side to the tip is set so that when crimped, the tip ends do not overlap with each other. The core wire crimping section 4 is crimped and fastened to the core wire W1 by wrapping the outside of the core wire W1, which is placed between the pair of crimping pieces 41, with the bottom wall 40 and the pair of crimping pieces 41. The core wire crimping section 4 is not limited to the above form; for example, a crimping method called overlap crimping may be used. In this overlap crimping method, the pair of crimping pieces 41 are wrapped around the core wire W1 and crimped, and when crimped, the tip ends overlap with each other.

[0023] The core wire crimping section 4 is crimped to the core wire W1 by crimping the core wire W1, which is placed on the bottom wall 40, with the crimping piece 41. The core wire crimping section 4 has a groove-shaped portion 45 formed in the core wire crimping section 4 and extending along the axial direction X of the electric wire W. The groove-shaped portion 45 is curved along the direction around the axis Xa of the electric wire W and is formed between the crimping pieces 41 facing the width direction Y of the bottom wall 40.

[0024] The second connecting portion 5 is interposed between the core wire crimping portion 4 and the insulation crimping portion 6, and is the portion that connects the core wire crimping portion 4 and the insulation crimping portion 6. The second connecting portion 5 is composed of a bottom wall 50, a pair of side walls 51, and an opening 52. The bottom wall 50 is connected to the core wire crimping portion 4 on the first axial direction X1 side and to the bottom wall 60 of the insulation crimping portion 6 on the second axial direction X2 side. The bottom wall 50 extends along the axial direction X and is the base portion of the second connecting portion 5, with a cross-sectional shape that is roughly barrel-shaped when viewed from the axial direction X in the pre-crimping state.

[0025] The side wall 51 is connected to the crimping piece 41 of the core wire crimping section 4 on the first axial direction X1 side, and to the crimping piece 61 of the covering crimping section 6 on the second axial direction X2 side. The side wall 51 is provided rising along the height direction Z on both sides of the width direction Y of the bottom wall 50.

[0026] The opening 52 is formed between the core wire crimping portion 4 and the insulation crimping portion 6 in the axial direction X, and between a pair of side walls 51 facing each other in the width direction Y, in the crimped state in which the core wire crimping portion 4 is crimped to the core wire W1 and the insulation crimping portion 6 is crimped to the insulation insulation portion W2. In the crimped state, the opening 52 opens in one direction in the height direction Z perpendicular to the axial direction X, and the core wire exposed portion W1b is exposed inside the opening 52. The direction in which the opening 52 opens is the same as the direction in which the opening 32 described above opens. The core wire exposed portion W1b is the portion exposed between the core wire crimping portion 4 and the insulation crimping portion 6. In other words, in the crimped state, the core wire W1 has a core wire exposed portion W1b that extends along the axial direction X and is exposed from the opening 52.

[0027] The insulated crimping portion 6 is the part that is fixed to the insulating coating portion W2 of the electric wire W by being crimped and fastened to the insulating coating portion W2. The insulated crimping portion 6 is provided on the second axial direction X2 side of the crimp terminal 1, in this case, on the side opposite to the terminal connection portion 2. The insulated crimping portion 6 is composed of a bottom wall 60 and a pair of crimping pieces 61. The insulated crimping portion 6 is crimped and fastened to the insulating coating portion W2 by the bottom wall 60 and the pair of crimping pieces 61.

[0028] The bottom wall 60 is connected to the bottom wall 50 of the second connecting portion 5 on the first axial direction X1 side. The bottom wall 60 extends along the axial direction X and, in the pre-crimping state, forms the base of the covering crimping portion 6 which is formed in a substantially U shape.

[0029] The pair of crimping pieces 61, together with a part of the bottom wall 60, constitute the coating crimping section 6. Each of the pair of crimping pieces 61 extends from both side edges of the bottom wall 60 along the direction around the axis Xa of the electric wire W. The pair of crimping pieces 61 are wrapped around the insulating coating section W2 and crimped, and the length from the base on the bottom wall 60 side to the tip is set so that when crimped, the tip ends do not overlap with each other. The coating crimping section 6 is formed by the bottom wall 60 and the pair of crimping pieces 61 wrapping around the outside of the insulating coating section W2, which is positioned between the pair of crimping pieces 61, and crimping and fastening it to the insulating coating section W2. The coating crimping section 6 is not limited to the above form; for example, a crimping method called overlap crimping may be used. In this overlap crimping method, the pair of crimping pieces 61 are wrapped around the insulating coating section W2 and crimped, and when crimped, the tip ends overlap with each other.

[0030] The resin cover 10 is formed from an insulating resin material or the like so as to be attachable to the part of the crimp terminal 1 that needs corrosion protection, and is a corrosion-preventive member for protecting the crimp terminal 1 from corrosion. The resin cover 10 is formed to match the peripheral edge 52a of the opening 52 and is assembled to the opening 52 to cover the exposed portion of the core wire W1. That is, the peripheral edge 10a of the resin cover 10 is formed to match the peripheral edge 52a of the opening 52 in the axial direction X, width direction Y, and height direction Z. Here, the exposed portion of the core wire W1 is the core wire exposed portion W1b.

[0031] The resin cover 10 is molded to match the shape of the peripheral edge 52a of the opening 52. When viewed from the height direction Z, the width of the resin cover 10 is molded to be approximately the same as or slightly smaller than the width of the peripheral edge 52a (see Figures 1 and 6). Furthermore, when viewed from the width direction Y, the cross-sectional shape of the resin cover 10 is formed to be approximately trapezoidal, and the height of the bottom side on the second axial direction X2 side is molded to be approximately the same as or slightly smaller than the height of the peripheral edge 52a on the second axial direction X2 side (see Figures 2 and 7). The resin cover 10 is bonded to the peripheral edge 52a of the opening 52 with an ultraviolet-curable resin UVR to close the opening 52, and is fixed to the crimp terminal 1 by curing the ultraviolet-curable resin UVR by ultraviolet irradiation.

[0032] The cured resin portion 70 is formed when the ultraviolet-curable resin UVR applied to the corrosion-protected portion AT of the crimp terminal 1 is cured. The corrosion-protected portion AT in this embodiment is the portion of the crimp terminal 1 to which corrosion protection processing is to be applied, and as shown in Figure 4, it includes, for example, the core wire tip portion W1a, the groove-shaped portion 45, and the peripheral portion 52a of the opening 52. The cured resin portion 70 includes a first cured resin portion 71, a second cured resin portion 72, and a third cured resin portion 73.

[0033] The first cured resin portion 71 is a part of the corrosion-protected area AT that is formed to cover the core wire tip W1a. The first cured resin portion 71 is formed inside the opening 32. The first cured resin portion 71 is formed, for example, continuously with the second cured resin portion 72 along the axial direction X.

[0034] The second cured resin portion 72 is a part of the corrosion-protected area AT that is formed to cover the groove-shaped portion 45. The second cured resin portion 72 is formed in a strip shape along the axial direction X when viewed from the height direction Z. The second cured resin portion 72 is formed to be continuous with the first cured resin portion 71 on the first axial direction X1 side and continuous with the second cured resin portion 72 on the second axial direction X2 side.

[0035] The third cured resin portion 73 is the part of the corrosion-protected area AT that adheres and fixes the resin cover 10 to the peripheral edge 52a of the opening 52. As shown in Figure 4, when the crimped terminal 1 in the crimped state is viewed from the height direction Z, the peripheral edge 52a of the opening 52 is composed of the end faces a and f of the core wire crimping portion 4 on the second axial direction X2 side, the end faces c and d of the covering crimping portion 6 on the first axial direction X1 side, and the end faces b and e of the pair of side walls 51 in the height direction Z. Specifically, the end faces a and f of the core wire crimping portion 4 on the second axial direction X2 side are the end faces on the second axial direction X2 side of the pair of crimping pieces 41 crimped to the core wire W1. The end faces c and d of the covering crimping portion 6 on the first axial direction X1 side are the end faces on the first axial direction X1 side of the pair of crimping pieces 61 crimped to the insulating covering portion W2. The end faces a and f of the core wire crimping portion 4 on the second axial direction X2 side, the end faces c and d of the covering crimping portion 6 on the first axial direction X1 side, and the end faces b and e of the pair of side walls 51 in the height direction Z are all processed ends from when the crimping terminal 1 was punched out during manufacturing. The third cured resin portion 73 is formed interposed between the peripheral edge 52a of the opening 52 and the peripheral edge 10a of the resin cover 10.

[0036] Next, the manufacturing method of the terminal-equipped wire 100 of this embodiment (terminal-equipped wire manufacturing method) will be explained based on the flowchart in Figure 3, with reference to other figures as appropriate. The manufacturing method of the terminal-equipped wire 100 described below may be performed manually by workers using various devices, equipment, jigs, etc., or it may be performed automatically by various manufacturing equipment.

[0037] The wire manufacturing method with terminals according to this embodiment includes a crimping step (step S1), a coating step (step S2), an assembly step (step S3), and an irradiation step (step S4). In this embodiment, the steps for manufacturing the wire W, which are performed before the crimping step, the stripping step for stripping the insulating coating W2 from the end of the wire W to expose the core wire W1, and the manufacturing step for the crimp terminal 1 are omitted.

[0038] First, as part of the crimping process (step S1), the worker places the core wire W1 on the core wire crimping section 4 and the insulating coating section W2 on the coating crimping section 6 of the crimping terminal 1 before it is crimped, and then crimps the pair of crimping pieces 41 of the core wire crimping section 4 and the pair of crimping pieces 61 of the coating crimping section 6 to crimp the crimping terminal 1 to the electric wire W.

[0039] Next, as part of the coating process (step S2), the worker applies the ultraviolet-curing resin UVR to the areas of the corrosion-protected portion AT of the crimped terminal-attached wire 100 (see Figure 5). Specifically, in the coating process (step S2), the worker applies the ultraviolet-curing resin UVR to the core wire tip W1a, the grooved portion 45, and the peripheral portion 52a of the opening 52, which are the areas to be coated. When applying the ultraviolet-curing resin UVR to the peripheral portion 52a of the opening 52, the resin is applied clockwise or counterclockwise along the peripheral portion 52a when viewed from the height direction Z of the crimped terminal 1. For example, if coating is started from one end face a in the width direction Y of the end faces a and f on the second axial direction X2 side of the core wire crimping section 4, the UV-curable resin UVR is applied clockwise along the peripheral portion 52a in the following order: end face b of the side wall 51 on one side in the width direction Y, one end face c and the other end face d of the end faces c and d on the first axial direction X1 side of the covering crimping section 6, end face e of the other side wall 51 in the width direction Y, and the other end face f of the end faces a and f on the second axial direction X2 side of the core wire crimping section 4. For example, in the coating process (step S2), the UV-curable resin UVR is applied by intermittently ejecting droplets from a nozzle such as a dispenser using a coating device 300 (not shown). The coating device can apply the UV-curable resin UVR to any target area by moving the nozzle relative to the target area along the axial direction X and the width direction Y.

[0040] Next, after the coating process (step S2), the worker performs an assembly process (step S3) in which the resin cover 10 is assembled to the opening 52 of the corrosion-protected part AT to cover the exposed core wire W1b (see Figures 6 and 7). Specifically, the worker adheres the resin cover 10 to the peripheral edge 52a of the opening 52, which was coated with the ultraviolet-curable resin UVR in the coating process (step S2). Specifically, the end face of the peripheral edge 10a of the resin cover 10 is adhered to the end face of the peripheral edge 52a, which is composed of the end faces a and f on the second axial direction X2 side of the core wire crimping part 4, the end faces c and d on the first axial direction X1 side of the covering crimping part 6, and the end faces b and e in the height direction Z of the pair of side walls 51, via the ultraviolet-curable resin UVR.

[0041] Next, after the assembly process (step S3), the worker performs an irradiation process (step S4) in which ultraviolet light (UV) is irradiated onto the crimp terminal 1 to cure the UV-curable resin UVR (see Figure 8). Specifically, the worker uses an irradiation device 400, which has a UV-LED (Light Emitting Diode) as a light source, to irradiate the crimp terminal 1 with ultraviolet light and cure the UV-curable resin UVR applied to the crimp terminal 1. For example, the irradiation device 400 has the light source positioned on the opposite side of the bottom wall 40 in the height direction Z, and the process is completed by irradiating the crimp terminal 1 with ultraviolet light from the light source.

[0042] In conventional methods for manufacturing wires with terminals, corrosion protection is ensured by applying UV-curable resin UVR to the exposed portion of the core wire W1 on the crimp terminal using a nozzle and allowing it to harden. However, if the relative position of the crimp terminal and the nozzle is misaligned, it becomes difficult to apply the UV-curable resin UVR to the desired position. Therefore, it is conceivable to increase the amount of UV-curable resin UVR applied in order to minimize the exposure of the core wire W1. In this case, if the UV-curable resin UVR drips and hardens on the surface of the side wall 51 or bottom wall 50, the width in the width direction Y and the height in the height direction Z of the crimp terminal will increase, which may prevent the assembler from inserting the crimp terminal into the connector cavity.

[0043] Therefore, in the manufacturing method of the terminal-equipped wire 100 of this embodiment, a resin cover 10 formed to cover the core wire exposed portion W1b is assembled to the opening 52 and bonded with an ultraviolet-curing resin UVR. This makes it possible to reliably cover the core wire exposed portion W1b with respect to the peripheral portion 52a of the opening 52, which has a complex shape. Furthermore, the manufacturing method of the terminal-equipped wire 100 does not require a large amount of ultraviolet-curing resin UVR to be applied, and it is possible to reduce the dripping of ultraviolet-curing resin UVR to unnecessary parts.

[0044] As described above, in the manufacturing method of the terminal-equipped wire 100 according to this embodiment, in the coating step (step S2), an ultraviolet-curable resin UVR is applied to the part AT of the terminal-equipped wire 100 that is to be protected from corrosion. Then, in the assembly step (step S3), an insulating resin cover 10, which is formed to match the opening 52 of the crimp terminal 1, is assembled to the part AT that is to be protected from corrosion, and the exposed core wire portion W1b is covered. In this coating step (step S2), the ultraviolet-curable resin UVR is applied to the core wire tip portion W1a, the grooved portion 45, and the peripheral portion 52a of the opening 52. Then, in the assembly step (step S3), the resin cover 10 is bonded to the peripheral portion 52a of the opening 52 that has been coated with the ultraviolet-curable resin UVR.

[0045] With the above configuration, the manufacturing method for the terminal-equipped wire 100 allows for a reduction in the amount of UV-curable resin UVR applied compared to conventional manufacturing methods, and suppresses the dripping of UV-curable resin UVR onto the side walls 51 and bottom wall 50 of the crimp terminal 1. As a result, the manufacturing method for the terminal-equipped wire 100 reduces the exposure of the core wire W1 at the crimp terminal 1, reduces the dripping of UV-curable resin UVR onto unnecessary parts, and optimizes the application of UV-curable resin UVR to the corrosion-protected part AT.

[0046] Furthermore, in the method for manufacturing the terminal-equipped wire 100, and in the terminal-equipped wire 100 itself, the groove-shaped portion 45 is formed between crimping pieces 41 that are curved along the direction of the axis Xa of the wire W and facing the width direction Y of the bottom wall 40. As a result, the method for manufacturing the terminal-equipped wire 100 and the terminal-equipped wire 100 itself can be subjected to corrosion protection treatment even if there is a core wire W1 exposed in the groove-shaped portion 45.

[0047] Furthermore, the manufacturing method of the terminal-equipped wire 100 and the terminal-equipped wire 100 of this embodiment can suppress a decrease in the insertability of the crimp terminal 1 into the connector by reducing the dripping of the ultraviolet-curable resin UVR into unnecessary parts.

[0048] In the above description, the resin cover 10 is injection-molded from an insulating resin material to match the shape of the peripheral edge 52a of the opening 52, but it is not limited to this, and may also be made by punching out an insulating sheet-like resin material to match the shape of the peripheral edge 52a of the opening 52. Furthermore, when the resin cover 10 is assembled and fixed in the opening 52, a gap is created between it and the exposed core wire portion W1b. Therefore, in order to fill this gap, an anticorrosive agent or the like may be applied to the back surface of the resin cover 10 or the exposed core wire portion W1b before assembling the resin cover 10 to the opening 52.

[0049] It should be noted that the method for manufacturing a wire with a terminal and the wire with a terminal 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.

[0050] The wire manufacturing method with terminals and the wire with terminals according to this embodiment may be constructed by appropriately combining the components of the embodiments and modified examples described above. [Explanation of symbols]

[0051] 1. Crimp terminals 2 Terminal connection section 3 1st connection part 4. Core wire crimping section 5 Second connection part 6 Covering crimp part 10 Resin cover 52 Opening 100 terminal wire 200 Mating terminal AT corrosion protection target parts UVR Ultraviolet curing resin W electric wire W1 core wire W1a Core wire tip W2 Insulation coating

Claims

1. A wire with a terminal having a conductive core wire and an insulating coating portion that covers the outside of the core wire and provides insulation, a terminal connection portion that is electrically connected to a mating terminal, a core wire crimp portion that is crimped to the core wire exposed at the end of the wire, a coating crimp portion that is crimped to the insulating coating portion, and a crimp terminal provided at the connection portion between the core wire crimp portion and the coating crimp portion and including an opening in which a part of the core wire is exposed, a coating step of applying an ultraviolet-curing resin to the part to be protected from corrosion, Following the coating step, an assembly step is performed in which an insulating resin cover is assembled to the opening to cover the exposed portion of the core wire, The assembly step is followed by an irradiation step of irradiating the crimp terminal with ultraviolet light, The corrosion protection target portion includes the tip of the core wire exposed toward the terminal connection portion from the core wire crimping portion, the groove-shaped portion formed in the core wire crimping portion and extending along the axial direction of the electric wire, and the peripheral edge of the opening. The resin cover is formed to match the peripheral edge of the opening among the parts to be protected from corrosion. In the coating step, the ultraviolet-curable resin is applied to the tip of the core wire, the grooved portion of the core wire crimping portion, and the peripheral edge of the opening. In the assembly process, the resin cover is bonded to the peripheral edge of the opening to which the UV-curable resin has been applied. A method for manufacturing an electric wire with terminals, characterized by the following features.

2. The core wire crimping portion is, The device comprises a bottom wall connected to the terminal connection portion on one side in the axial direction and connected to the covering crimp portion on the other side in the axial direction, and a pair of crimping pieces extending from both side edges of the bottom wall along the direction around the axis of the electric wire, and the core wire placed on the bottom wall is crimped to the core wire by crimping with the crimping pieces. The groove-shaped portion is Formed between the crimping pieces that curve along the axial direction of the electric wire and face the width direction of the bottom wall. A method for manufacturing an electric wire with a terminal as described in claim 1.

3. A wire comprising a conductive core wire and an insulating coating portion that covers the outside of the core wire and has insulating properties, A crimp terminal comprising: a terminal connection portion electrically connected to a mating terminal; a core wire crimp portion crimped to the core wire exposed at the end of the wire; a coating crimp portion crimped to the insulating coating portion; and a connecting portion between the core wire crimp portion and the coating crimp portion, including an opening through which a portion of the core wire is exposed. An insulating resin cover is formed to match the peripheral edge of the opening of the crimp terminal crimped to the electric wire, and is assembled to the opening to cover the exposed portion of the core wire. It comprises a cured resin part in which an ultraviolet-curable resin has been cured, The cured resin portion is A first cured resin portion is formed to cover the tip of the core wire that is exposed from the core wire crimping portion toward the terminal connection portion, A second cured resin portion is formed to cover a groove-shaped portion formed in the core wire crimping portion and extending along the axial direction of the electric wire, The resin includes a third cured resin part that adheres and fixes the resin cover and the peripheral edge of the opening. A wire with terminals characterized by the following features.

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