Manufacturing method for terminal-integrated conductors and terminal-integrated conductors

Abstract

To provide a low-cost method for manufacturing a terminal-integrated conductor with excellent electrical conductivity, and to provide a terminal-integrated conductor. [Solution] A method for manufacturing a terminal-integrated conductor, wherein in a part of a strand bundle 2 which is a bundle of multiple conductor strands 20, the conductor strands 20 are ultrasonically joined together, so that the ultrasonically joined joint portion 3 becomes at least a part of the terminal portion 11, and the part of the strand bundle 2 other than the terminal portion 11 becomes the conductor portion 12. A terminal-integrated conductor 1 having a conductor portion 12 which is a strand bundle in which multiple conductor strands are bundled together, and a terminal portion 11 provided in at least a part of the longitudinal direction of the conductor portion 12, wherein at least a part of the terminal portion 11 has a joint portion 3 in which the conductor strands 20 are solid-phase joined together in a part of the strand bundle 2.

Description

Technical Field

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

Background Art

[0002] For example, as a power cable or the like that is connected to an electric motor or the like and transmits supply power, there is one having a wire composed of a bundle of a large number of conductor strands and a terminal provided at one end of the wire. That is, in such a wired terminal, a terminal that is a separate component from the wire is joined to one end of the wire. Such a wired terminal is likely to be disadvantageous in terms of cost because the terminal is a separate component from the wire.

[0003] On the other hand, the wired terminal disclosed in Patent Document 1 forms a flat conductor in which a large number of conductor strands are integrally fixed by soldering, and this flat conductor is terminated. In this case, a terminal as a separate component becomes unnecessary.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, as described above, the wired terminal disclosed in Patent Document 1 forms a terminal by integrally fixing a large number of conductor strands by soldering. Therefore, the electrical conductivity in the terminal tends to be relatively high, and there is room for improvement from the viewpoints of power loss, Joule heat, etc.

[0006] The present invention has been made in view of such problems, and aims to provide a method for manufacturing a low-cost terminal-integrated wire and a terminal-integrated wire that are excellent in electrical conductivity.

Means for Solving the Problems

[0007] One aspect of the present invention relates to a method for manufacturing a terminal-integrated conductor, wherein in a part of a bundle of multiple conductor strands, the conductor strands are ultrasonically joined together, so that the ultrasonically joined joint is at least part of the terminal portion, and the portion of the bundle of strands other than the terminal portion is the conductor portion.

[0008] Another aspect of the present invention is a conductor portion consisting of a bundle of multiple conductor strands, A terminal portion provided in at least a part of the longitudinal direction of the conductor portion, A terminal-integrated conductor having, At least a portion of the terminal portion is a terminal-integrated conductor having a joint in which the conductor strands are solid-bonded to each other in a portion of the strand bundle. [Effects of the Invention]

[0009] In the above-described method for manufacturing a terminal-integrated conductor, the conductor strands are ultrasonically joined together in a portion of the wire bundle, so that the ultrasonically joined joint becomes at least part of the terminal. This makes it possible to easily form the terminal without using any other components besides the wire bundle. Terminal-integrated conductors can be manufactured at low cost. Furthermore, there is no need to include any material other than the conductor strands in part of the terminal. Therefore, it is possible to prevent high electrical resistance at the terminal and obtain a terminal-integrated conductor with excellent electrical conductivity.

[0010] In the above-described terminal-integrated conductor, at least a portion of the terminal section has a joint where conductor strands are solid-state bonded to each other in a portion of the strand bundle. As a result, the terminal section is formed by a strand bundle continuous with the strand bundle that constitutes the conductor section. Therefore, a low-cost terminal-integrated conductor can be obtained. Furthermore, at least a portion of the terminal section has a joint where conductor strands are solid-state bonded to each other. Therefore, it is possible to prevent high electrical resistance in the terminal section and obtain a terminal-integrated conductor with excellent electrical conductivity.

[0011] As described above, according to the above embodiment, it is possible to provide a method for manufacturing a terminal-integrated conductor and a terminal-integrated conductor that have excellent electrical conductivity and are low cost. [Brief explanation of the drawing]

[0012] [Figure 1] An explanatory diagram of a method for manufacturing a terminal-integrated conductor in Embodiment 1, which is an explanatory diagram of a bundle of wire strands. [Figure 2] This is an explanatory diagram of a method for manufacturing a terminal-integrated conductor in Embodiment 1, and is an explanatory diagram of a pre-molded body. [Figure 3] This is an explanatory diagram of a method for manufacturing a terminal-integrated conductor in Embodiment 1, and is an explanatory diagram of ultrasonic bonding. [Figure 4] This is an explanatory diagram of a method for manufacturing a terminal-integrated conductor in Embodiment 1, showing the state in which a joint has been formed. [Figure 5] This is an explanatory diagram of a method for manufacturing a terminal-integrated conductor in Embodiment 1, showing the state after the terminal portion has been press-formed. [Figure 6] Diagram illustrating the terminal-integrated conductor in Embodiment 1. [Figure 7] This is an explanatory diagram of a method for manufacturing a terminal-integrated conductor in Embodiment 2, showing the state in which a joint has been formed. [Figure 8] This is an explanatory diagram of a method for manufacturing a terminal-integrated conductor in Embodiment 3, and is an explanatory diagram of a bundle of wire strands. [Figure 9] This is an explanatory diagram of a method for manufacturing a terminal-integrated conductor in Embodiment 3, showing the state in which a joint has been formed. [Figure 10] This is an explanatory diagram of a method for manufacturing a terminal-integrated conductor in Embodiment 3, showing the state after the terminal portion has been press-formed. [Figure 11] This is an explanatory diagram of a method for manufacturing a terminal-integrated conductor in Embodiment 3, showing the state after a through hole has been drilled. [Figure 12] This is an explanatory diagram of a method for manufacturing a terminal-integrated conductor in Embodiment 4, showing the state after the terminal portion has been bent. [Figure 13] View taken along line XIII in Figure 12. [Figure 14] Explanatory drawing of a terminal-integrated conducting wire in Embodiment 5.

Mode for Carrying Out the Invention

[0013] In the method for manufacturing the terminal-integrated conducting wire, after forming the joint portion, the terminal portion can also be press-worked. In this case, flattening of the surface of the terminal portion can be achieved.

[0014] Also, when forming the terminal portion, a preform is formed by bending a part of the strand bundle into a loop to provide an intersection where a plurality of locations in the extending direction of the strand bundle intersect, and at the intersection, the conductor strands can be ultrasonically joined to each other. In this case, an annular terminal portion can be easily formed.

[0015] Also, after forming the joint portion, a through-hole can be drilled in the joint portion. In this case, a through-hole can be easily and accurately formed.

[0016] Also, after forming the joint portion, the joint portion can be bent. In this case, bending can be easily and accurately performed.

[0017] In the terminal-integrated conducting wire, the terminal portion can be formed by bending a part of the strand bundle into a loop. In this case, for example, it is easy to fasten the terminal portion to another terminal with a fastening member such as a bolt or a screw.

[0018] Also, a through-hole can be formed inside the joint portion. In this case, for example, it is easy to fasten the terminal portion to another terminal with a fastening member such as a bolt or a screw.

[0019] Also, the joint portion can be bent. In this case, a bent portion can be easily and highly accurately formed.

[0020] Furthermore, it is preferable that the conductor strands are made of copper, aluminum, or an alloy thereof.

[0021] (Embodiment 1) A method for manufacturing a terminal-integrated conductor and an embodiment of the terminal-integrated conductor will be described with reference to the drawings. First, as shown in Figures 1 to 6, the manufacturing method for the terminal-integrated conductor of this embodiment involves ultrasonically joining the conductor strands 20 together in a portion of the strand bundle 2, which is a bundle of multiple conductor strands 20. This makes the ultrasonically joined joint portion 3 part of the terminal portion 11, while the portion of the strand bundle 2 other than the terminal portion 11 becomes the conductor portion 12.

[0022] In this embodiment, when forming the terminal portion 11, as shown in Figures 1 and 2, a portion of the wire bundle 2 is bent into an annular shape to pre-form an intersection portion 22 where multiple points in the extending direction of the wire bundle 2 intersect. This molded body is called a pre-formed body 10. Then, as shown in Figures 3 and 4, the conductor wires 20 are ultrasonically joined together at the intersection portion 22.

[0023] More specifically, the manufacturing method of the terminal-integrated conductor 1 of this embodiment will be described. First, a conductor consisting of a bundle of wires 2, as shown in Figure 1, is prepared. This conductor is covered with an insulating coating 4, such as polyvinyl chloride or polyethylene, with a portion of it exposed from the insulating coating 4. In particular, in this embodiment, the ends of the conductor are exposed from the insulating coating.

[0024] Furthermore, the wire bundle 2 is a bundle of multiple conductor wires 20, and in this embodiment, it is a stranded wire formed by twisting multiple conductor wires 20 together. The wire bundle 2 is not limited to a stranded wire; for example, it may be a bundle of multiple conductor wires arranged in parallel with each other. Also, the conductor wires 20 can be made of, for example, copper, aluminum, or an alloy thereof. Furthermore, the number of conductor wires 20 constituting the wire bundle 2 is not particularly limited as long as there are multiple wires, but for example, it can be 10 or more, or 20 or more.

[0025] Next, a portion of the wire bundle 2 shown in Figure 1 is bent into an annular shape. For example, the wire bundle 2 is bent into an annular shape by winding it around a roughly cylindrical bobbin (not shown). At this time, as shown in Figure 2, multiple intersections 22 are created where the wire bundle 2 intersects at multiple points in the direction of extension. This forms the pre-molded body 10 in the state shown in Figure 2.

[0026] Next, as shown in Figures 3 and 4, the conductor strands 20 are ultrasonically bonded together at the intersection 22. In this embodiment, only the intersection 22, or only the intersection 22 and its surroundings, are ultrasonically bonded. The ultrasonic bonding is performed using an ultrasonic bonding device. The ultrasonic bonding device has an anvil 51 and a horn 52 arranged opposite each other. The mounting surface 511 of the anvil 51 and the pressing surface 521 of the horn 52 each have an uneven surface formed with numerous fine irregularities.

[0027] The intersection 22 of the pre-formed body 10 is sandwiched between the anvil 51 and the horn 52 of the ultrasonic bonding device. In other words, the intersection 22 of the pre-formed body 10 is placed on the mounting surface 511 of the anvil 51, and the intersection 22 is pressed by the horn 52 placed on top of it. As a result, the intersection 22, in which a part 2a of the wire bundle 2 and another part 2b of the wire bundle 2 overlap, is placed on the anvil 51, and the intersection 22 is pressed toward the anvil 51 by the horn 52.

[0028] In this state, ultrasonic vibrations are applied to the wire bundle 2 at the intersection 22 via the horn 52. The direction of the ultrasonic vibrations at this time is mainly perpendicular to the direction of pressurization. As a result, the wire bundles 2 at the intersection 22 are joined together. This joining is formed by solid-state joining between the conductor wires 20 that make up the wire bundle 2. That is, the oxide film that was present on the surface of the conductor wires 20 is removed by friction caused by ultrasonic vibrations. Then, as the exposed metals on the surface of the conductor wires 20 come into close proximity, interatomic attractive forces act on them, and they are joined in a solid state. This solid-state joining occurs between the conductor wires 20 in part 2a of the wire bundle 2 and the conductor wires 20 in another part 2b of the wire bundle 2 that intersect each other at the intersection 22, and also between multiple conductor wires 20 at the same location (i.e., parts 2a and 2b of the wire bundle 2).

[0029] In this way, the intersection 22 is solid-state bonded by ultrasonic bonding, forming a joint 3 as shown in Figure 4. As a result, a terminal-integrated conductor 1 is obtained in which a part of the strand bundle 2 forms an annular portion and the intersection 22 is fixed. In other words, as shown in Figure 4, the annular portion including the intersection 22 that has become joint 3 becomes the terminal portion 11, and the other portion becomes the conductor portion 12. The portion covered by the insulating coating 4 is also part of the conductor portion 12.

[0030] In this embodiment, after forming the joint portion 3, the terminal portion 11 is press-formed. In other words, the terminal portion 11 including the joint portion 3 is press-formed. During the press working process, when forming the joint 3, the terminal portion 11 is pressurized in the same direction as the pressurized direction applied by the anvil 51 and horn 52 of the ultrasonic bonding device. This pressurization direction is approximately the same as the through-direction of the through-hole 110 in the terminal portion 11.

[0031] As a result, as shown in Figure 5, the terminal portion 11 is flattened and its width increases in the direction perpendicular to the pressurizing direction. Here, width refers to the width of the body portion in the radial direction of the annular portion. The protruding portion 119, which was the tip of the wire bundle 2 and extends beyond the annular portion, is cut off as needed. This results in a terminal-integrated conductor 1 as shown in Figure 6. Note that the cutting of the protruding portion 119 can be done before press processing (as shown in Figure 4) or simultaneously with press processing.

[0032] Next, the terminal-integrated conductor 1 of this form will be described. As shown in Figure 6, the terminal-integrated conductor 1 of this embodiment has a conductor section 12 consisting of a bundle of multiple conductor strands 20, and a terminal section 11 provided on at least a portion of the longitudinal direction of the conductor section 12. In other words, the conductor section 12 and the terminal section 11 are integrally formed. At least a portion of the terminal section 11 has a joint section 3 in which the conductor strands 20 are solid-state joined to each other in a portion of the bundle of strands 2.

[0033] The conductor portion 12 is covered with an insulating film 4, and at least one end of it is exposed from the insulating film 4. A terminal portion 11 is formed continuously with the end of the conductor portion 12 that is exposed from the insulating film 4. In this embodiment, the conductor portion 12 is a stranded wire formed by twisting together a plurality of conductor strands 20. The conductor portion 12 is not limited to a stranded wire; for example, it may be a bundle of a plurality of conductor strands arranged in parallel with each other.

[0034] The terminal portion 11 is formed by bending a part of the wire bundle 2 into an annular shape. The terminal portion 11 has a through hole 110 formed inside the annular portion. In this embodiment, this through hole 110 is not formed by drilling or the like, but is formed inside the annular portion of the wire bundle 2 as a result of bending a part of the wire bundle 2 into an annular shape and solid-state bonding the joint portion 3, as described above.

[0035] Furthermore, in this embodiment, the joint portion 3 is limited to the intersection portion 22 of the terminal portion 11, or only the surrounding area. In other words, in this embodiment, the parts of the terminal portion 11 other than the intersection portion 22 are not solid-state joined to each other.

[0036] Furthermore, the main surfaces 111 of the terminal portion 11 that face the direction of penetration of the through hole 110 and are facing opposite directions from each other are substantially flat surfaces. In other words, in this embodiment, as described above, the terminal portion 11 is press-formed, and the main surfaces 111 are substantially flat surfaces. Also, the thickness of the terminal portion 11 in the direction of penetration of the through hole 110 is smaller than the diameter of the conductor portion 12. In this embodiment, the conductor portion 12 is flexible.

[0037] Next, we will explain the effects and benefits of this embodiment. In the manufacturing method of the terminal-integrated conductor 1 described above, the conductor strands 20 are ultrasonically joined together in a portion of the strand bundle 2, so that the ultrasonically joined joint 3 becomes at least a part of the terminal portion 11. This makes it possible to easily form the terminal portion 11 without using any other parts besides the strand bundle 2. Therefore, the terminal-integrated conductor 1 can be manufactured at low cost. Furthermore, it is not necessary to include any material other than the conductor strands 20 in a portion of the terminal portion 11. That is, for example, the terminal-integrated conductor 1 can be formed using only copper or a copper alloy, or only aluminum or an aluminum alloy. Therefore, it is possible to prevent the electrical resistance at the terminal portion 11 from becoming high and to obtain a terminal-integrated conductor 1 with excellent electrical conductivity.

[0038] Furthermore, in forming the terminal portion 11, a pre-molded body 10 (Figure 2) is formed as described above, and the conductor strands 20 are ultrasonically joined at the intersection 22. This makes it possible to easily form the annular terminal portion 11.

[0039] Furthermore, after forming the joint 3, the terminal portion 11 can be press-formed to flatten its surface. As a result, the electrical resistance between the terminal portion 11 and other terminals or fastening members connecting the terminal portion 11 can be reduced. Also, during ultrasonic bonding, the irregularities of the mounting surface 511 of the anvil 51 and the pressure surface 521 of the horn 52 are transferred to the surface of the joint 3. These transferred irregularities can be flattened by press-forming.

[0040] In the above-described terminal-integrated conductor 1, at least a portion of the terminal section 11 has a joint 3 in which the conductor strands 20 are solid-state bonded to each other in a portion of the strand bundle 2. As a result, the terminal section 11 is formed by a strand bundle 2 that is continuous with the strand bundle 2 that constitutes the conductor section 12. Therefore, a low-cost terminal-integrated conductor 1 can be obtained. Furthermore, at least a portion of the terminal section 11 has a joint 3 in which the conductor strands 20 are solid-state bonded to each other. Therefore, it is possible to prevent the electrical resistance in the terminal section 11 from becoming high and to obtain a terminal-integrated conductor 1 with excellent electrical conductivity.

[0041] In the terminal-integrated conductor 1, the terminal portion 11 is formed by bending a part of the wire bundle 2 into a ring shape. Therefore, the terminal portion 11 can be easily fastened to other terminals using fastening members such as bolts or screws.

[0042] As described above, this embodiment provides a low-cost method for manufacturing a terminal-integrated conductor with excellent electrical conductivity, and a terminal-integrated conductor.

[0043] (Embodiment 2) This embodiment is a modified form of Embodiment 1, and as shown in Figure 7, it is a terminal-integrated conductor 1 and a method for manufacturing the same, in which the conductor strands 20 are solid-bonded to each other over substantially the entire terminal portion 11.

[0044] The manufacturing method of this embodiment is the same as in Embodiment 1, in which, after forming the pre-molded body 10 (see Figure 2), ultrasonic bonding is performed on the entire portion that will become the terminal portion 11, including not only the intersection portion 22 but also the annular portion. That is, the entire portion that will become the terminal portion 11 of the pre-molded body 10 is sandwiched between the anvil 51 and the horn 52 of the ultrasonic bonding device, and ultrasonic bonding is performed.

[0045] As a result, as shown in Figure 7, the conductor strands 20 are solid-bonded to each other throughout the entire terminal portion 11. In other words, in this embodiment, the entire terminal portion 11 is the joint portion 3. From the state shown in Figure 7, pressing and cutting off the protruding portion 119 can be performed as appropriate, similar to Embodiment 1.

[0046] Otherwise, it is the same as in Embodiment 1. Note that, among the reference numerals used in Embodiment 2 and later, those that are the same as those used in the previously described embodiments represent the same components, etc., as in the previously described embodiments, unless otherwise specified.

[0047] In this embodiment, the conductor strands 20 are solid-state bonded to each other throughout the terminal portion 11, which further reduces the electrical resistance in the terminal portion 11. Furthermore, it has the same effects and advantages as Embodiment 1.

[0048] (Embodiment 3) This embodiment, as shown in Figures 8 to 11, is a method for manufacturing a terminal-integrated conductor 1, in which a joint 3 is formed and then a through hole 110 is drilled in the joint 3.

[0049] In this embodiment, no process is performed to pre-form a portion of the wire bundle 2 into a ring shape. For example, the ends of the wire bundle 2 shown in Figure 8 are joined ultrasonically to form the joint 3 shown in Figure 9. In this embodiment, the wire bundle 2 is not a stranded wire, but a bundle of substantially straight conductor wires 20. However, a stranded wire can also be used as the wire bundle 2 in this embodiment.

[0050] Ultrasonic bonding solid-states the conductor strands 20 at one end of the strand bundle 2, and they become flattened, forming a terminal portion 11. The unevenness of the mounting surface 511 of the anvil 51 and the unevenness of the pressing surface 521 of the horn 52 are transferred to this terminal portion 11. By performing press processing on this terminal portion 11, the unevenness is flattened as shown in Figure 10. It is also possible to widen the main surface of the terminal portion 11 or to adjust the shape of the terminal portion 11.

[0051] Furthermore, as shown in Figure 11, a through hole 110 is drilled in the terminal portion 11. This creates a through hole on the inside of the joint portion 3. The drilling of the through-hole 110 can also be performed together with the press working described above. Other aspects are the same as in Embodiment 1.

[0052] In this embodiment, a compact terminal section 11 can be easily formed. Furthermore, it has the same effects and advantages as Embodiment 1.

[0053] In this embodiment, the outer shape of the terminal portion 11, as viewed from the direction normal to the main surface, is approximately rectangular. However, it can also be a polygonal shape other than a quadrilateral, a circular shape, or the like.

[0054] (Embodiment 4) This embodiment is a terminal-integrated conductor 1 in which the joint portion 3 is bent, as shown in Figures 12 and 13. In manufacturing the terminal-integrated conductor 1 of this embodiment, the joint portion 3 is formed and then bent. That is, similar to Embodiment 3, after ultrasonic bonding and press working, for example, as shown in Figure 10, a part of the terminal portion 11 is bent.

[0055] This results in a terminal-integrated conductor 1 having a terminal portion 11 equipped with a bent portion 112. In this embodiment, a vertical portion 113 continuous via the bent portion 112 is erected so as to be substantially perpendicular to the main surface of the terminal portion 11. Other aspects are the same as in Embodiment 1.

[0056] The terminal portion 11 of the terminal-integrated conductor 1 in this embodiment is suitable, for example, when welding to the mating terminal to be connected. In other words, it is conceivable to weld the vertical portion 113 to the mating terminal. Furthermore, it has the same effects and advantages as Embodiment 1.

[0057] (Embodiment 5) This embodiment, as shown in Figure 14, is a terminal-integrated conductor 1 in which a terminal portion 11 is formed between multiple conductor portions 12. The terminal-integrated conductor 1 shown in Figure 14 has terminal portions 11 at both ends in the longitudinal direction, as well as terminal portions 11 between the terminal portions 11 at both ends.

[0058] The same method as in Embodiment 3 can be used when manufacturing such a terminal-integrated conductor 1. For example, first, a bundle of wires 2 covered with an insulating film 4 is prepared. Then, both ends of the bundle of wires 2 are exposed from the insulating film 4, and desired parts of the bundle of wires 2 other than the ends are exposed from the insulating film 4. Then, the conductor wires 20 are ultrasonically joined together at each of the exposed parts of the bundle of wires 2. Subsequently, press working and drilling of the through hole 110 are performed in the same manner as in Embodiment 3.

[0059] Furthermore, as a variation of this embodiment, the terminal portion 11 can be formed using the method shown in Embodiment 1 or Embodiment 2. Also, similar to Embodiment 4, a part of the terminal portion 11 can be bent.

[0060] In the terminal-integrated conductor of this disclosure, the shape of the terminal portion is not limited to those described above, but other shapes are also conceivable.

[0061] The present invention is not limited to the embodiments described above, and can be applied to various embodiments without departing from its spirit. [Explanation of Symbols]

[0062] 1 Terminal integrated conductor 10 Pre-molded body 2 Wire bundle 20 Conductor strands 22 Intersection 3 Joint

Claims

1. A method for manufacturing a terminal-integrated conductor, comprising ultrasonically joining a portion of a bundle of multiple conductor strands, thereby making the ultrasonically joined joint a terminal portion, and the portion of the bundle other than the terminal portion a conductor portion.

2. A method for manufacturing a terminal-integrated conductor according to claim 1, wherein the terminal portion is press-formed after the joint portion has been formed.

3. A method for manufacturing a terminal-integrated conductor according to claim 1 or 2, wherein, in forming the terminal portion, a part of the strand bundle is bent into an annular shape to form a pre-formed pre-molded body that has intersections where multiple points in the extending direction of the strand bundle intersect, and the conductor strands are ultrasonically joined at the intersections.

4. A method for manufacturing a terminal-integrated conductor according to claim 1 or 2, wherein after forming the joint, a through hole is drilled in the joint.

5. A method for manufacturing a terminal-integrated conductor according to claim 1 or 2, wherein the joint is formed and then the joint is bent.

6. A conductor section consisting of a bundle of multiple conductor strands, A terminal portion provided in at least a part of the longitudinal direction of the conductor portion, A terminal-integrated conductor having, A terminal-integrated conductor wherein at least a portion of the terminal portion has a joint in which the conductor strands are solid-bonded to each other in a portion of the strand bundle.

7. The terminal portion is formed by bending a part of the strand bundle into a ring shape, as described in claim 6.

8. The terminal-integrated conductor according to claim 6 or 7, wherein a through hole is formed on the inside of the joint portion.

9. The terminal-integrated conductor according to claim 6 or 7, wherein the joint portion is bent.

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