Manufacturing method of electric wire with terminal

Abstract

To provide a wire with a terminal capable of easily checking whether multiple compressed parts have been compressed in the desired compression order after production.SOLUTION: The wire with a terminal includes: a wire having a conductor; and a terminal connected to the conductor by being compressed with the conductor inserted. The terminal has three or more compressions along the length of the conductor, and in the three or more compression portions, protruding parts with a different protruding amount depending on the order of compression are formed as part of the terminal, respectively.SELECTED DRAWING: Figure 1

Description

[Technical field]

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

[0002] Conventionally, there has been disclosed an electric wire with a terminal in which a conductor is inserted in the terminal and the terminal is compressed multiple times to form multiple compressed parts, thereby connecting the terminal to the conductor. In this case, for example, it is known that if a new compressed part is formed between adjacent compressed parts that have already been formed, the electrical resistance between the conductor and the terminal can be maintained low even after a long time has passed since compression (see Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2020-119865 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, in a conventional electric wire with a terminal, after production, it is not easy to check whether the multiple compressed portions have been compressed in a desired compression order.

[0005] An object of the present invention is to provide an electric wire with a terminal that makes it possible to easily check whether a plurality of compressed portions have been compressed in a desired compression order after production. [Means for solving the problem]

[0006] According to a first aspect of the present invention, An electric wire having a conductor; a terminal connected to the conductor by being compressed in an inserted state; A terminal-attached electric wire comprising: The terminal has three or more compression portions along a longitudinal direction of the conductor, In each of the three or more compressed portions, a protruding portion having a different protruding amount depending on the order of compression is formed as a part of the terminal. A terminated wire is provided.

[0007] According to a second aspect of the present invention, A step of preparing an electric wire having a conductor and a terminal into which the conductor is inserted; a step of compressing the terminal three or more times along a longitudinal direction of the conductor with the conductor inserted into the terminal, thereby forming three or more compressed portions in the terminal, thereby connecting the terminal to the conductor; A method for producing an electric wire with a terminal, comprising: The step of connecting the terminal to the conductor includes a step of forming protruding portions having different protruding amounts in the three or more compressed portions according to the order of compression. A method for manufacturing a terminal-fitted electric wire is provided. Effect of the Invention

[0008] According to the present invention, it is possible to provide an electric wire with a terminal that allows easy confirmation after manufacture as to whether a plurality of compressed portions have been compressed in a desired compression order. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a perspective view illustrating a terminal 5 and a conductor 3 of a terminal-attached electric wire 1 according to an embodiment of the present invention, illustrating a state before the conductor is inserted into a hollow portion 7 of the terminal 5. As shown in FIG. [Diagram 2] FIG. 2 is a cross-sectional view illustrating a state after a conductor 3 is inserted into a hollow portion 7 of a terminal 5 of a terminal-attached electric wire 1 according to one embodiment of the present invention and before the hollow portion 7 is compressed. [Diagram 3] FIG. 3 is a cross-sectional view of the terminal-attached electric wire 1 according to one embodiment of the present invention when the terminal 5 of the terminal-attached electric wire 1 is compressed three times. [Figure 4]Fig. 4(a) is a diagram showing a state before the terminal 5 is compressed by the hexagonal die 50 in a cross section perpendicular to the longitudinal direction of the conductor 3. Fig. 4(b) is a diagram showing a state after the terminal 5 is compressed by the hexagonal die 50 in a cross section perpendicular to the longitudinal direction of the conductor 3. [Diagram 5] Fig. 5(a) shows the state after the terminal 5 has been compressed by the hexagonal die 50 in a cross-sectional view perpendicular to the longitudinal direction of the conductor 3 in the compression portion 10. Fig. 5(b) shows the state after the terminal 5 has been compressed by the hexagonal die 50 in a cross-sectional view perpendicular to the longitudinal direction of the conductor 3 in the compression portion 12. Fig. 5(c) shows the state after the terminal 5 has been compressed by the hexagonal die 50 in a cross-sectional view perpendicular to the longitudinal direction of the conductor 3 in the compression portion 11. [Figure 6] Fig. 6(a) is a diagram showing the cross-sectional width dimensions of the terminal 5 at the compressed portions P1, P2, and P3 when a conductor 3 with a cross-sectional area of ​​50 sq. is used. Fig. 6(b) is a diagram showing the cross-sectional width dimensions of the terminal 5 at the compressed portions P1, P2, and P3 when a conductor 3 with a cross-sectional area of ​​200 sq. is used. Fig. 6(c) is a diagram showing the cross-sectional width dimensions of the terminal 5 at the compressed portions P1, P2, and P3 when a conductor 3 with a cross-sectional area of ​​250 sq. is used. [Figure 7] Fig. 7(a) is a diagram showing the protrusion ratio of the terminal 5 at the compressed portion P2 when a conductor 3 with a cross-sectional area of ​​50 sq. is used. Fig. 7(b) is a diagram showing the protrusion ratio of the terminal 5 at the compressed portion P2 when a conductor 3 with a cross-sectional area of ​​200 sq. is used. Fig. 7(c) is a diagram showing the protrusion ratio of the terminal 5 at the compressed portion P2 when a conductor 3 with a cross-sectional area of ​​250 sq. is used. [Figure 8] FIG. 8 shows a state after the terminal 5 has been compressed by a hexagonal die 50 in a cross section perpendicular to the longitudinal direction of the conductor 3 at the compressed portion 11. [Figure 9]Fig. 9(a) is a diagram showing the standard values ​​of the terminal 5 at the compressed portion P2 when a conductor 3 with a cross-sectional area of ​​50 sq. is used. Fig. 9(b) is a diagram showing the standard values ​​of the terminal 5 at the compressed portion P2 when a conductor 3 with a cross-sectional area of ​​200 sq. is used. Fig. 9(c) is a diagram showing the standard values ​​of the terminal 5 at the compressed portion P2 when a conductor 3 with a cross-sectional area of ​​250 sq. is used. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] <One embodiment of the present invention> (1) Manufacturing Example of Terminal-Attached Wire 1 In this embodiment, for example, three compressed portions 10, 11, and 12 are formed in the terminal 5 into which the conductor 3 is inserted, thereby manufacturing the terminal-attached electric wire 1 for connecting the terminal 5 to the conductor 3. Hereinafter, an example of a manufacturing method of the terminal-attached electric wire 1 will be described.

[0011] The terminal-attached electric wire 1 of this embodiment is manufactured by sequentially carrying out the steps of preparing the electric wire 2 and the terminal 5, compressing the terminal 5 with the conductor 3 inserted therein, and connecting the terminal 5 to the conductor 3.

[0012] (preparation process) First, prepare the electric wire 2 and the terminal 5. Below, the electric wire 2 and the terminal 5 will be described, and then each process will be described.

[0013] (Electric wire) The electric wire 2 is configured as, for example, an insulated electric wire, and includes a conductor 3 and an insulating layer 4 that covers the outer periphery of the conductor 3.

[0014] The conductor 3 constitutes the core wire of the electric wire 2. The conductor 3 is made of a single metal wire or a stranded wire made by twisting together a plurality of metal wires. The conductor 3 is made of, for example, pure aluminum or an aluminum alloy (hereinafter, these are referred to as "aluminum material").

[0015] The insulating layer 4 is provided so as to cover the lateral periphery, i.e., the outer periphery, of the conductor 3. The insulating layer 4 is made of, for example, a fluorine-based resin, an olefin-based resin, or a silicone-based resin.

[0016] (Terminal) The terminal 5 comprises a tubular portion 6 and an extending portion 8, which are integrally formed. The terminal 5 is, for example, formed by pressing one end of a pipe. This one end corresponds to the extending portion 8. Alternatively, the terminal 5 is, for example, formed by drilling one end of a cylindrical base material and pressing the other end. The drilled one end corresponds to the hollow portion 7. The pressed other end corresponds to the extending portion 8. The hollow portion 7 has a cylindrical shape that is open on one side. The terminal 5 is made of, for example, an aluminum material.

[0017] The cylindrical portion 6 is configured as a portion to be connected to the conductor 3 exposed from the end of the electric wire 2. In this embodiment, the cylindrical portion 6 is formed in a cylindrical shape with a circular cross section, and the inside forms a hollow portion 7 into which the conductor 3 exposed at the end of the electric wire 2 can be inserted.

[0018] The extension portion 8 is configured as a portion to be connected to an external connection counterpart terminal, bolt, etc. In this embodiment, the extension portion 8 is formed in a plate shape and is provided with a bolt hole 9 into which an external terminal, bolt, etc. is inserted.

[0019] After preparing the electric wire 2 and the terminal 5, as shown in Fig. 1, a predetermined length of the insulating layer 4 is removed from an end of the electric wire 2 in the longitudinal direction to expose a part of the conductor 3. Then, as shown in Fig. 2, the exposed part of the conductor 3 of the electric wire 2 is inserted into the hollow portion 7 formed in the tubular portion 6 of the terminal 5.

[0020] (Compression and connection process) Next, as shown in FIG. 3, in a state where an exposed part of the conductor 3 of the electric wire 2 is inserted into the hollow portion 7 of the terminal 5, the compressed portion P1 is compressed to form the compressed portion 10. Thereafter, the compressed portion P3 is compressed to form the compressed portion 12. Finally, the compressed portion P2 between the compressed portion P1 and the compressed portion P3 is compressed to form the compressed portion 11, thereby connecting the terminal 5 to the conductor 3. The compression jig (hexagonal die 50) used in forming the compressed portions 10 to 12 is preferably sized and shaped so that the compression ratio of the conductor 3 is 50% or more and 95% or less. Here, the compression ratio is the ratio of the cross-sectional area of ​​the conductor 3 corresponding to the non-compressed portion of the terminal 5 to the cross-sectional area of ​​the conductor 3 corresponding to the compressed portion in a cross section perpendicular to the longitudinal direction of the conductor 3 when the terminal 5 with the conductor 3 inserted into the hollow portion 7 is compressed. The cross-sectional areas of the conductor 3 corresponding to the non-compressed portion of the terminal 5 and the cross-sectional areas of the conductor 3 corresponding to the compressed portion are respectively defined as C1 (mm 2 ), C2(mm 2 ) is calculated using the formula (C2 / C1) × 100.

[0021] These compressions are performed, for example, by using a compression tool to apply a predetermined pressure to the compressed portions P1 to P3 over the entire circumference of the tubular portion 6 in the circumferential direction, thereby compressively deforming (plastically deforming) the tubular portion 6. The same compression tool is used when forming the compressed portions 10 to 12.

[0022] In this way, by forming the final (third) compressed portion 12 between the adjacent compressed portions 10 and 12 that have already been formed, the electrical resistance between the conductor 3 and the terminal 5 can be maintained low for a long period of time after compression.

[0023] However, even if the terminals are compressed in this order, in a conventional electric wire with a terminal, it may be difficult to easily check whether the compressed parts are compressed in the desired order after compression. Therefore, in this embodiment, the terminal 5 is compressed using a hexagonal die 50 having housing grooves 50A and 50B, for example, as shown in Figures 4(a) and (b).

[0024] The configuration of the hexagonal die 50 will be described below, and the compression and connection process of the terminal 5 using the hexagonal die 50 will be described in more detail.

[0025] 4(a) shows the state before the terminal 5 is compressed by the hexagonal die 50 in a cross section perpendicular to the longitudinal direction of the conductor 3. The hexagonal die 50 is composed of a pair of die bodies 20, 30 facing each other. The cylindrical portion 6 of the terminal 5 is disposed between the die bodies 20, 30, and the die bodies 20, 30 are butted against each other to compress the compressed regions P1-P3, thereby forming the compressed portions 10-12. When the die bodies 20, 30 are butted against each other, the two surfaces where the die body 20 and the die body 30 come into contact with each other are referred to as butt surfaces 41, 42 of the die bodies 20, 30, respectively.

[0026] The die body 20 has a pressing portion 21 that compresses one of the two semi-circumferential surface portions that constitute the entire outer circumferential surface of the cylindrical portion 6. Similarly, the die body 30 has a pressing portion 31 that compresses the other semi-circumferential surface portion of the cylindrical portion 6. The pressing portion 21 has three pressing surfaces 21a, 21b, and 21c that contact one semi-circumferential surface of the cylindrical portion 6 when the die bodies 20 and 30 are butted together. Similarly, the pressing portion 31 has three pressing surfaces 31a, 31b, and 31c that contact the other semi-circumferential surface of the cylindrical portion 6 when the die bodies 20 and 30 are butted together. The three pressing surfaces 21a, 21b, and 21c of the die body 20 are continuously provided along the circumferential direction of the terminal 5 to be placed (see arrow A in FIG. 4(a)), and adjacent pressing surfaces are configured to have a required angle (for example, 120°). Similarly, the three pressing surfaces 31a, 31b, and 31c on the die body 30 are provided continuously along the circumferential direction of the terminal 5 to be placed (see arrow A in FIG. 4(a)), and adjacent pressing surfaces are configured to have a required angle (e.g., 120°). Hereinafter, pressing surface 21a and pressing surface 31c, pressing surface 21b and pressing surface 31b, and pressing surface 21c and pressing surface 31a will each be referred to as a pair of pressing surfaces.

[0027] As shown in FIG. 4(b), an accommodation groove 50A for accommodating the protruding portion 5a generated when forming the compressed portion is provided between the butt surface 41 of the die body 20, 30 of the hexagonal die 50 and the pair of pressing surfaces 21a, 31c. Similarly, an accommodation groove 50B for accommodating the protruding portion 5b generated when forming the compressed portions 10 to 12 is provided between the butt surface 42 of the die body 20, 30 of the hexagonal die 50 and the pair of pressing surfaces 21c, 31a. The accommodation grooves 50A, 50B are configured to be large enough to accommodate the protruding portions 5a, 5b. The details of the protruding portions 5a, 5b will be described later.

[0028] The compression and connection process of the terminal 5 using the above-mentioned hexagonal die 50 will be described. The terminal 5 (cylindrical portion 6) is set between the die body 20 and the die body 30, which are arranged facing each other with a predetermined distance between them. Then, for example, the die body 20 is moved in the direction (compression direction) of the white arrow shown in FIG. 4(a) to butt the die body 20 and the die body 30 together. As a result, the six pressing surfaces 21a, 21b, 21c, 31a, 31b, and 31c press the outer circumferential surface of the terminal 5, plastically deforming the terminal 5 radially inward, and crimping and connecting the terminal 5 and the conductor 3. At this time, a part of the terminal 5 protrudes radially outward to form the protruding portions 5a and 5b. The protruding portions 5a and 5b are accommodated in the accommodation grooves 50A and 50B, respectively. The protruding portions 5a and 5b are formed when a part of the terminal 5 is plastically deformed in a direction substantially perpendicular to the direction of compression when the terminal 5 is crimped (compressed) by the die bodies 20 and 30.

[0029] By performing such compression at the compressed portions P1 to P3, the terminal 5 is crimp-connected to the conductor 3, and the electric wire with terminal 1 can be obtained.

[0030] (2) Example of the configuration of terminal-attached wire 1 An example of the configuration of the terminal-attached electric wire 1 obtained by the above-mentioned manufacturing method will be described below.

[0031] The terminal 5 has three compressed portions 10-12 formed at different positions with respect to the axial direction of the tubular portion 6 (the length direction of the conductor 3 inserted in the hollow portion 7) so as not to overlap each other. The compressed portions 10-12 have a substantially hexagonal cross-sectional shape in a cross section perpendicular to the longitudinal direction (axial direction) of the conductor 3. The compressed portion 11 is formed near the center of the tubular portion 6 in the axial direction, and the compressed portions 10 and 12 are formed so as to sandwich the compressed portion 11 from both sides.

[0032] 5(a), (b), and (c) show the state after the terminal 5 is compressed by the hexagonal die 50 in a cross section perpendicular to the longitudinal direction of the conductor 3 at the compression portions P1, P3, and P2, respectively. When the terminal 5 is compressed, a force is generated not only in the radially inward direction of the terminal 5 (conductor 3) but also in the longitudinal direction (axial direction). The force that causes the terminal 5 to extend in the longitudinal direction when the third compressed portion 11 is formed is suppressed by the two compressed portions 10 and 12 that have already been formed. Therefore, the suppressed force that causes the terminal 5 to extend in the longitudinal direction is converted to the radially outward direction of the terminal 5, and is reflected as the protrusion amount of the protruding portions 5a and 5b. Specifically, as shown in Figures 5(a) to (c), the amount of protrusion of the protruding portions 5a, 5b in the third compressed portion 11 formed between the compressed portions 10, 12 is greater than the amount of protrusion of the protruding portions 5a, 5b in the first and second compressed portions 10, 12, where the force exerted on the terminal 5 in the longitudinal direction during compression is not significantly restricted.

[0033] As described above, the amount of protrusion of the protruding portions 5a, 5b differs depending on the compressed portions 10-12 and the order of compression. The receiving grooves 50A, 50B are configured to be large enough to accommodate the protruding portions 5a, 5b, so that the cross-sectional width dimension (hereinafter simply referred to as the "cross-sectional width dimension") of the terminal 5 including the protruding portions of the protruding portions 5a, 5b in a cross-sectional view perpendicular to the longitudinal direction of the terminal 5 (conductor 3) reflects the amount of protrusion of the protruding portions 5a, 5b. Specifically, as shown in Figs. 5(a)-(c), the cross-sectional width dimension of the compressed portion P2 (compressed portion 11) in which the amount of protrusion of the protruding portions 5a, 5b is large is larger than the cross-sectional width dimensions of the compressed portion P1 (compressed portion 10) and compressed portion P3 (compressed portion 12) in which the amount of protrusion of the protruding portions 5a, 5b is small.

[0034] (3) Effects of this embodiment According to this embodiment, one or more of the following advantages are achieved.

[0035] (a) The terminals 5 in the three compressed portions 10-12 are each formed with the protruding portions 5a, 5b having different protruding amounts depending on the order of compression. Therefore, simply by checking the protruding amounts of the protruding portions 5a, 5b of the compressed portions 10-12, it is possible to easily check whether the compression has been performed in the desired compression order.

[0036] (b) When the terminal 5 is compressed in the desired compression order, i.e., when the terminal 5 is compressed in the order of compression portions P1, P3, P2, the amount of protrusion of the protruding portions 5a, 5b in the compressed portion 11 is formed to be greater than the amount of protrusion of the protruding portions 5a, 5b in the compressed portions 10, 12 which are formed to sandwich the compressed portion 11 from both sides. Therefore, by simply visually checking and measuring the amount of protrusion of these protruding portions 5a, 5b, it is possible to easily and reliably check whether the terminal 5 has been compressed in the desired compression order.

[0037] (4) Variations Although the embodiment of the present invention has been specifically described above, the present invention is not limited to the above-mentioned embodiment, and various modifications can be made without departing from the gist of the present invention.

[0038] In the above embodiment, in forming the compressed portions 10 to 12, the compressed portion P1 is compressed first, and then the compressed portion P3 is compressed, but this is not limited thereto, and the compressed portion P3 may be compressed first, and then the compressed portion P1 may be compressed, as long as the P2 between the compressed portions P1 and P3 is compressed last. Even in this case, the same effect as the above embodiment can be obtained.

[0039] In the above-described embodiment, an example is given in which there are three compressed portions (three compressed locations), but this is not limiting, and for example, the terminal 5 may be compressed in four or five locations. When compressing four locations, it is preferable that the fourth compressed portion be formed between two adjacent compressed portions of the multiple compressed portions already formed. Furthermore, when compressing the terminal 5 in five locations, it is preferable that the fifth compressed portion be formed between two adjacent compressed portions of the multiple compressed portions already formed. Even in these cases, substantially the same effects as the above-described embodiment can be obtained.

[0040] Although not particularly limited in the above embodiment, it is preferable that the compressed portions 10 to 12 are provided at equal intervals.

[0041] In the above-described embodiment, the compressed portions 10 to 12 have an approximately hexagonal cross-sectional shape in a cross section perpendicular to the longitudinal direction (axial direction) of the conductor 3, but this is not limited to this and may have another polygonal shape or may have a circular shape.

[0042] In the above embodiment, the electric wire with terminal has been described as an example, but the present invention is not limited to this and can also be applied to, for example, a cable with terminal.

[0043] In the above embodiment, the electric wire 2 has been described as an insulated electric wire including the conductor 3 and the insulating layer 4 covering the outer periphery of the conductor 3, but the present invention is not limited thereto, and for example, a so-called bare electric wire not including the insulating layer 4 covering the outer periphery of the conductor 3 may be used. Even in this case, substantially the same effects as those of the above embodiment can be obtained. EXAMPLES

[0044] Next, the present invention will be described in more detail based on experimental examples, but the present invention is not limited to these experimental examples.

[0045] (Experimental Example 1) In Experimental Example 1, a plurality of terminals 5 with conductors 3 inserted therein were prepared and compressed by a pair of die bodies 20 and 30 in the order of compressed parts P1, P3, P2, compressed parts P3, P1, P2, compressed parts P2, P1, P3, and compressed parts P2, P3, P1, to obtain Samples 1, 2, 3, and 4. The terminals 5 and the conductors 3 were made of aluminum material having the same composition. After the samples 1 to 4 were produced, the cross-sectional width dimensions of the compressed parts P1, P2, and P3 were measured in a cross-sectional view perpendicular to the longitudinal direction of the terminals 5 (conductors 3). The compression tool used to form the compressed parts P1, P2, and P3 was the same, and a hexagonal die was used so that the compression ratio of the conductors 3 was 80 to 90%.

[0046] The measurement results of the cross-sectional width dimensions at the compressed portions P1, P2, and P3 are shown in Figures 6(a) to (c). Figures 6(a) to (c) show the results when using conductors 3 with cross-sectional areas of 50 sq., 200 sq., and 250 sq., respectively. The horizontal axis of Figures 6(a) to (c) shows the compressed portions of terminal 5, with the left side showing compressed portion P1, the middle showing compressed portion P2, and the right side showing compressed portion P3. The vertical axis of Figures 6(a) to (c) shows the length of the cross-sectional width dimensions at each compressed portion. The cross-sectional width dimensions of Sample 1 are shown by dotted lines, the cross-sectional width dimensions of Sample 2 by solid lines, the cross-sectional width dimensions of Sample 3 by dashed lines, and the cross-sectional width dimensions of Sample 4 by long dashed lines.

[0047] The relationship between sample numbers and compression order is summarized in Table 1 below.

[0048] [Table 1]

[0049] As shown in Figures 6(a) to (c), it was confirmed that regardless of the thickness of the conductor 3 used, the cross-sectional width dimension of the compressed portion P2 of samples 1 and 2, in which the last compressed portion 11 is formed between two adjacent compressed portions 10 and 12 that have already been formed, is significantly larger than the cross-sectional width dimensions of the compressed portions P1 and P3.

[0050] (Experimental Example 2) In Experimental Example 2, a terminal 5 with a conductor 3 inserted therein was prepared, and compressed by a pair of die bodies 20 and 30 in the order of compressed parts P1, P3, P2, P3, P1, P2, P1, P2, P3, P3, P2, P1, P2, P1, P3, P2, P3, P1, to obtain Samples 5, 6, 7, 8, 9, and 10. Four pieces of each of Samples 5 to 10 were produced. The terminal 5 and the conductor 3 were made of aluminum material with the same composition as in Experimental Example 1. The compression jig and compression ratio were the same as in Experiment 1.

[0051] The relationship between sample numbers and compression order is summarized in Table 2 below.

[0052] [Table 2]

[0053] After producing Samples 5 to 10, the cross-sectional width dimensions of compressed portions P1, P2, and P3 in a cross-sectional view perpendicular to the longitudinal direction of terminal 5 (conductor 3) were designated as A, B, and C, respectively (see Figs. 5(a) to (c)), and the protrusion ratio (%) of B was calculated. Specifically, the protrusion ratio (%) of B is the protrusion ratio of the cross-sectional width dimension of compressed portion P2 to the cross-sectional width dimension of compressed portions P1 and P3, and was calculated by the formula {(2×B-(A+C)) / (2×B)}×100.

[0054] The calculation results are shown in Figures 7(a) to (c). Figures 7(a) to (c) show the results when using conductors 3 with cross-sectional areas of 50 sq., 200 sq., and 250 sq., respectively. The horizontal axis of Figures 7(a) to (c) shows the sample number. The vertical axis of Figures 7(a) to (c) shows the protrusion ratio (%) of B.

[0055] 7(a) to (c), it was confirmed that the protrusion ratio (%) of B in Samples 5 and 6, in which the last compressed portion 11 is formed between two already formed adjacent compressed portions 10 and 12, was greater than 4.2% regardless of the thickness of the conductor 3 used. It was confirmed that the protrusion ratio (%) of B in the other Samples 7 to 10 was 4.2% or less.

[0056] (Experimental Example 3) In Experimental Example 3, a terminal 5 with a conductor 3 inserted therein was prepared, and compressed by a pair of die bodies 20 and 30 in the order of compressed parts P1, P3, P2, P3, P1, P2, P1, P2, P3, P3, P2, P1, P2, P1, P1, P3, P2, P3, P1, to obtain Samples 11, 12, 13, 14, 15, and 16. One each of Samples 11 to 16 was produced. The terminal 5 and the conductor 3 were made of aluminum material with the same composition as in Experimental Example 1. The compression jig and compression ratio were the same as in Experiment 1.

[0057] The relationship between sample numbers and compression order is summarized in Table 3 below.

[0058] [Table 3]

[0059] The protrusion ratio of B is correlated with the distance between the pressing surface 21b of the die body 20 and the pressing surface 31b of the die body 30 and the size of the accommodation grooves 50A, 50B. In a cross-sectional view perpendicular to the longitudinal direction of the terminal 5 (conductor 3), the protrusion ratio of B increases as the cross-sectional height dimension X (see FIG. 8), which is the distance between the upper end and the lower end of the compressed portion P2, decreases (the compression increases). In addition, in a cross-sectional view perpendicular to the longitudinal direction of the terminal 5 (conductor 3), if the height dimensions of the protruding portions 5a, 5b are t1, t2 (see FIG. 8), the protrusion ratio of B increases as t1, t2 decreases. Therefore, the height ratio of B X / T (However, the calculation was performed using T = (t1 + t2) / 2), and the protrusion ratio of B / height ratio of B (hereinafter referred to as the standard value) was calculated.

[0060] The calculation results are shown in Figures 9(a) to (c). Figures 9(a) to (c) show the results when using conductors 3 with cross-sectional areas of 50 sq., 200 sq., and 250 sq., respectively. The horizontal axis of Figures 9(a) to (c) shows the sample number. The vertical axis of Figures 9(a) to (c) shows the standard value.

[0061] As shown in Figures 9(a) to (c), it was confirmed that the standard value of samples 11 and 12, in which the last compressed portion 11 is formed between two adjacent compressed portions 10 and 12 already formed, is 0.7 or more, regardless of the thickness of the conductor 3 used. It was confirmed that the standard values ​​of the other samples 13 to 16 are less than 0.7. (5) Preferred embodiments of the present invention Preferred aspects of the present invention will be described below.

[0062] (Appendix 1) According to one aspect of the present invention, An electric wire having a conductor; a terminal connected to the conductor by being compressed in an inserted state; A terminal-attached electric wire comprising: The terminal has three or more compression portions along a longitudinal direction of the conductor, In each of the three or more compressed portions, a protruding portion having a different protruding amount depending on the order of compression is formed as a part of the terminal. A terminated wire is provided.

[0063] (Appendix 2) Preferably, The terminal has three compression portions along the longitudinal direction of the conductor. The terminal-equipped electric wire according to claim 1 is provided.

[0064] (Appendix 3) Preferably, Among the three or more compression sections, one compression section and two compression sections sandwiching the one compression section from both sides are a protruding amount of the protruding portion in the one compressed portion is larger than a protruding amount of the protruding portion in the two compressed portions; There is provided an electric wire with a terminal according to claim 1 or 2.

[0065] (Appendix 4) Preferably, each of the three or more compression portions is formed by compressing the terminal from opposing directions with a pair of dies; The plurality of protruding portions are each formed in a direction perpendicular to a compression direction of the pair of dies, In a cross-sectional view perpendicular to the longitudinal direction of the conductor, When the cross-sectional width dimensions of the terminal including the protruding portion of the protruding shape portion in the two compressed portions are A and C, respectively, and the cross-sectional width dimension of the terminal including the protruding portion of the protruding shape portion in the compressed portion formed between the two compressed portions is B, the protrusion ratio (%) of B calculated by the formula {(2×B-(A+C)) / (2×B)}×100 is greater than 4.2%; The terminal-equipped electric wire according to claim 3 is provided.

[0066] (Appendix 5) Preferably, each of the three or more compression portions is formed by compressing the terminal from opposing directions with a pair of dies; The plurality of protruding portions are each formed in a direction perpendicular to a compression direction of the pair of dies, In a cross-sectional view perpendicular to the longitudinal direction of the conductor, The cross-sectional width dimensions of the terminal including the protruding portion of the protruding portion in the two compressed portions are A and C, respectively, and the cross-sectional width dimension of the terminal including the protruding portion of the protruding portion in the compressed portion formed between the two compressed portions is B. The standard value calculated from the height ratio when the height dimension of the protruding portion of the protruding portion in the compressed portion formed between the two compressed portions is T and the cross-sectional height dimension of the terminal is X is 0.7 or more. 2. An electric wire with terminal as described in Appendix 3. However, the protrusion ratio (%) = {(2 × B - (A + C)) / (2 × B)} × 100, and the height ratio Rate=X / T and the standard value is protrusion ratio / height ratio.

[0067] (Appendix 6) According to another aspect of the present invention, A step of preparing an electric wire having a conductor and a terminal into which the conductor is inserted; a step of compressing the terminal three or more times along a longitudinal direction of the conductor with the conductor inserted into the terminal, thereby forming three or more compressed portions in the terminal, thereby connecting the terminal to the conductor; A method for producing an electric wire with a terminal, comprising: The step of connecting the terminal to the conductor includes a step of forming protruding portions having different protruding amounts in the three or more compressed portions according to the order of compression. A method for manufacturing a terminal-fitted electric wire is provided.

[0068] (Appendix 7) Preferably, The step of connecting the terminal to the conductor is performed using a compression die having an accommodation groove for accommodating the protruding portion generated when the compression portion is formed. A method for producing an electric wire with a terminal as described in Appendix 6 is provided.

[0069] (Appendix 8) Preferably, The step of connecting the terminal to the conductor includes a step of forming a new compressed portion between compressed portions already formed on both ends of the conductor in the longitudinal direction. A method for producing an electric wire with a terminal according to claim 6 or 7 is provided. [Explanation of symbols]

[0070] 1. Wire with terminal 2 electric wire 3 Conductors 5 Terminal 10,11,12 Compression section P1, P2, P3 compression points

Claims

1. A first step of preparing an electric wire having a conductor and a terminal into which the conductor is inserted; a second step of compressing the terminal three times along a longitudinal direction of the conductor using a hexagonal die while the conductor is inserted into the terminal, thereby forming first, second and third compressed portions in the terminal, thereby connecting the terminal to the conductor; a third step of checking the order of compression of the first to third compression units; having the third step includes a step of confirming the protrusion amounts of the protruding portions in the first to third compressed portions, and examining the order from the confirmation results; A manufacturing method for electric wire with terminal.

2. The second step includes a step of forming the third compressed portion between the first and second compressed portions after forming the first and second compressed portions; the third step includes a step of checking whether a protruding amount of the protruding portion in the third compressed portion is larger than a protruding amount of the protruding portion in the first and second compressed portions, and checking whether the third compressed portion is formed after forming the first and second compressed portions. A method for producing the electric wire with terminal according to claim 1.

3. Each of the plurality of protruding portions is formed in a direction perpendicular to the compression direction of the hexagonal die, In a cross-sectional view perpendicular to the longitudinal direction of the conductor, When the cross-sectional width dimensions of the terminal including the protruding portion of the protruding shape portion in the first and second compression portions are A and C, respectively, and the cross-sectional width dimension of the terminal including the protruding portion of the protruding shape portion in the third compression portion is B, a protrusion ratio (%) calculated by the formula {(2×B−(A+C)) / (2×B)}×100 is greater than 4.2%; A method for producing the terminal-attached electric wire according to claim 2.

4. The hexagonal die has an accommodation groove for accommodating the protruding portion generated when forming the first to third compression portions. A method for producing the terminal-attached electric wire according to any one of claims 1 to 3.

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