Electrical wires, conductors, insulated wires, and wire harnesses

The electric wire conductor with a lower and upper twisted layer structure and controlled interlayer voids addresses the issue of welding defects in aluminum conductors, enhancing bonding and appearance through loose strand separation during ultrasonic welding.

JP7882369B2Active Publication Date: 2026-06-30SUMITOMO WIRING SYSTEMS LTD
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Patent Information

Authority / Receiving Office
JP · JP
Patent Type
Patents
Current Assignee / Owner
SUMITOMO WIRING SYSTEMS LTD
Filing Date
2025-02-27
Publication Date
2026-06-30

AI Technical Summary

Technical Problem

Ultrasonic welding of aluminum conductors to connector terminals often results in bending of individual wires at the welded portion, leading to unsightly appearance and low adhesion force, considered a welding defect.

Method used

The electric wire conductor is designed with a lower twisted layer and an upper twisted layer, where the interlayer voids between these layers occupy 63% or less of the total void space, and the upper twist pitch is larger than the lower twist pitch, promoting loose strands during welding to prevent bending and enhance adhesion.

Benefits of technology

This design significantly reduces the occurrence of welding defects by ensuring efficient energy transmission and firm bonding between the wire conductor and the connection terminal, maintaining a superior appearance and increased bonding force.

✦ Generated by Eureka AI based on patent content.

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Patent Text Reader

Abstract

To provide a wire conductor that is made of aluminum or an aluminum alloy, and is not likely to, when it is ultrasonically welded to a connection terminal, cause a welding defect in a welded portion, and also to provide an insulated wire and a wire harness including the wire conductor.SOLUTION: A wire conductor 1 includes: a lower strand layer 11 in which a plurality of sub-strands 10, each formed by twisting together a plurality of bare wires 1a made of aluminum or an aluminum alloy, are bundled and twisted together; and an upper strand layer 12 in which a plurality of the sub-strands 10 are twisted around an outer circumference of the lower strand layer 11; wherein, in a cross section orthogonal to the axial direction, a proportion of an area occupied by a gap G1 formed between the lower strand layer 11 and the upper strand layer 12 to an area of gaps not occupied by the bare wires 1a is 63% or less.SELECTED DRAWING: Figure 1
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