JP6549923B2 - Electric wire with terminal, method of manufacturing the same, and wire harness - Google Patents

Description

  The present invention relates to an electric wire with a terminal formed by crimp connection of an electric wire and a terminal, a method of manufacturing the same, and a wire harness incorporating the electric wire with a terminal.

  2. Description of the Related Art Conventionally, for example, in a wire harness mounted on a vehicle, a terminal-attached electric wire having a connection structure in which a terminal is crimped and crimped to an electric wire is used. In the terminal-equipped electric wire of this type, when a liquid containing moisture adheres to the connection between the exposed wire and the inner wall of the terminal, oxidation of the surface of the connection and its vicinity proceeds, causing an increase in electrical resistance or the occurrence of corrosion. It may happen.

  Recently, in order to reduce the weight of the wire harness, for example, an electric wire with a terminal in which a wire made of an aluminum alloy and a terminal made of a copper alloy are combined has been developed. Thus, a highly waterproof connection structure is proposed by a closed barrel type terminal provided with a cylindrical crimped portion with a bottom, as one form of a terminal-attached electric wire in which metals of different types are in contact with each other (for example, patent Reference 1).

JP, 2014-164913, A

  By the way, according to the intensive studies of the inventor, when the closed barrel type terminal is crimped from two directions facing each other, the repulsive force (that is, the crimping force) that the covering material of the wire gives to the terminal depends on the circumferential direction of the wire. It was found to be significantly different. Due to the “anisotropy of the pressure bonding force”, in one terminal-attached wire, a portion where the adhesion between the wire and the terminal is relatively high and a portion where the adhesion between the terminals is relatively coexist.

  As a result, a slight gap may occur at a portion where the adhesion between the wire and the terminal is relatively low, and liquid from the outside may intrude into the connection portion through the gap. In particular, in the case of the electric wire whose covering material is thinned, the influence may become large. That is, the terminal-equipped electric wire of this type still has room for improvement from the viewpoint of water blocking.

  The present invention has been made in view of the above-described problems, and can improve the waterproofness between the wire and the terminal while adopting a very simple structure even in the case where the pressing force anisotropy is present. An object of the present invention is to provide an electric wire with a terminal, a method of manufacturing the same, and a wire harness.

  The “terminal-attached electric wire” according to the present invention has a conductive wire and an insulating covering material for covering the wire, and an exposed portion in which the distal end side of the wire is exposed is formed by peeling the covering material. And a terminal having a cylindrical crimping portion, at least the exposed portion being inserted into the crimping portion and crimped and connected to the electric wire, from the open end of the crimping portion to the peeling end of the covering material One or more roughened areas having a larger surface roughness than the other areas are formed on a part of the outer peripheral surface of the covering material in the range of It straddles along at least one of two imaginary lines on the outer circumferential surface facing each other along the circumferential direction, and is formed at the peeling end or a position around the peeling end.

  As described above, since the roughened area is provided on a part of the outer peripheral surface of the covering material in the range from the open end of the crimped portion to the peeling end of the covering material, the wettability in the roughened area becomes low. Water repellency is high. Thereby, it is possible to prevent the liquid from the outside from infiltrating into the peeling end through the gap between the electric wire and the terminal by capillary action.

  Anisotropy of the crimping force tends to appear in line symmetry to the axial center of the wire. Therefore, the liquid penetrates by providing the roughened region at a position straddling in the circumferential direction at least one of the two imaginary lines on the outer peripheral surface, which face each other across the axial center of the electric wire. It can be reliably placed at the likely site. Specifically, the positions of the two imaginary lines may be made to coincide with the portion where the relative crimping force is minimized.

  In addition, there is a tendency for the peeling end side having a step of the electric wire due to the presence or absence of the covering material to be compressed more strongly than the opening end side having no step of the electric wire. In other words, regarding the gap generated between the electric wire and the terminal, the peeling end side tends to be smaller than the opening end side. Therefore, by providing this roughened area at a position at or near the exfoliation end of the covering material, it is possible to maximize the water blocking effect by the water repellency.

  As described above, even when anisotropy of the pressure bonding force exists, it is possible to improve the water blocking property between the wire and the terminal while adopting a very simple structure.

  Moreover, it is preferable that the said roughening area | region has a symmetrical shape which makes one of the said two virtual lines a central line. Thus, even when the path is deviated obliquely from the direction along the virtual line, it is possible to effectively secure a margin for the amount of deviation of the path. Alternatively, the same applies to the margin with respect to the amount of deviation of the direction when the wire is inserted into the crimping part.

  Moreover, it is preferable that the said roughening area | region is two and it is formed axisymmetrically with respect to the axial center of the said electric wire. Thereby, it is possible to efficiently cover the range in the circumferential direction where there is a high possibility that the liquid infiltrates, and it is possible to reduce the number of steps for forming the roughened area by that amount.

  Further, the number of the roughened regions is one, and it is preferable that the roughened region be formed in a ring shape. As a result, it is possible to reliably cover the portion where the liquid is likely to infiltrate without particularly being aware of the insertion direction of the electric wire.

  Moreover, it is preferable that the said roughening area | region is formed with the width | variety of 100 micrometers or more along the axial center direction of the said electric wire. At the same time or separately from this, the roughened region is formed with a width of 30% or more of the length of the covering material from the opening end to the peeling end along the axial center direction of the electric wire. Is preferred. By securing a sufficient width along the axial direction, it is possible to prevent the liquid that has infiltrated to the position of the roughened area from passing through the roughened area as it is.

  Moreover, it is preferable that the said roughening area | region is 90 degree | times or more in the contact angle with respect to the 5 mass% concentration salt water. As a result, an effective water blocking effect can be obtained even for seawater having a composition similar to that of the above-mentioned brine.

  Moreover, it is preferable that the said roughening area | region is formed by performing laser processing to a part of said outer peripheral surface. This makes it possible to process the surface shape as desired and to obtain the desired surface roughness.

  Moreover, it is preferable that the crimp direction of the said electric wire is orthogonal to the virtual plane which includes the said two virtual lines. Generally speaking, the crimping force is maximized at circumferential positions equal to the crimping direction, and the crimping force is minimized at circumferential positions furthest from the crimping direction. When the crimping direction is orthogonal to the imaginary plane, the positions of the two imaginary lines coincide with the portion where the crimping force is minimized.

  Moreover, it is preferable that the said wire consists of aluminum or aluminum alloy. As a result, the weight of the wire can be reduced, and the weight of the entire wire with terminal can also be achieved.

  The “method for producing an electric wire with a terminal” according to the present invention includes a conductive wire and an insulating covering material for covering the wire, and an exposed portion where the distal end side of the wire is exposed by peeling of the covering material. A method of manufacturing a terminal-equipped electric wire, comprising: a wire in which is formed; and a cylindrical crimped portion, at least the exposed portion being inserted into the crimped portion, and a terminal crimped and connected to the wire; The method further includes a forming step of forming one or more roughened areas having a larger surface roughness than the other areas on the outer peripheral surface of the covering material before press-connecting the electric wire, and in the forming step, the electric wire is crimped. At the time of connection, there are two virtual lines on the outer peripheral surface which are in the range from the open end of the crimped portion to the peeling end of the covering material and are opposed to each other across the axial center of the electric wire While straddling at least one side along the circumferential direction, the peeling end or Forming the roughed portion on the portion corresponding to the position of the periphery of the release end.

  Further, in the forming step, when the electric wire is crimped and connected, a mark for determining the direction of the electric wire is further formed at a position corresponding to the position on the outer peripheral surface and at the proximal end side than the open end. It is preferable to do. Even when the position of the roughened area can not be visually recognized from the outside of the crimped portion when inserting the wire, the position of the orientation determination mark can be used as a clue to guide the wire in the correct direction.

  Further, in the forming step, it is preferable that the roughened area and the orientation determination mark be formed by performing laser processing on a part of the outer peripheral surface. By forming the roughened area and the orientation determination mark in the same process, preparation for starting processing can be performed only once, and the production efficiency of the terminal-equipped wire can be improved.

  The "wire harness" according to the present invention is formed by bundling a plurality of any of the terminal-attached electric wires described above.

  According to the electric wire with a terminal according to the present invention, the method for manufacturing the same, and the wire harness, even when anisotropy of the pressure bonding force is present, the water blocking property between the electric wire and the terminal is adopted while adopting a very simple structure. Can be improved.

It is a perspective view of the electric wire with a terminal concerning this embodiment. It is a partially expanded longitudinal cross-sectional view of the electric wire with a terminal shown in FIG. It is sectional drawing along the axial center of the electric wire shown in FIG. It is an expanded view of the covering material which makes the outer peripheral surface of an electric wire. It is the schematic explaining the water stop effect by roughening area | region. It is a flowchart explaining the manufacturing method of the electric wire with a terminal shown in FIG. It is the schematic explaining the formation process of step S2. It is the schematic explaining the crimping | compression-bonding process of step S4. It is a perspective view of the wire harness incorporating the electric wire with a terminal shown in FIG. It is an expanded view of the coating material which concerns on a modification.

  Preferred embodiments of the present invention will be described with reference to the drawings. The embodiments described below are examples, and various embodiments can be adopted within the scope of the present invention.

<Overall Configuration of Terminal Attached Wire 1>
FIG. 1 is a perspective view of a terminal-equipped wire 1 according to this embodiment. More specifically, FIG. 1 (a) is an overall perspective view after crimp connection of the electric wire 2 and the terminal 3 and FIG. 1 (b) is an exploded perspective view before crimp connection of the electric wire 2 and the terminal 3 .

  FIG. 2 is a partially enlarged vertical sectional view of the terminal-attached electric wire 1 shown in FIG. 1, and specifically shows a crimped shape of the crimped portion 31 crimped and connected to the electric wire 2. FIG. 3 is a cross-sectional view along the axial center 23 of the electric wire 2 shown in FIG. 1, and specifically shows the cross-sectional shape of the electric wire 2 at a position corresponding to roughened regions 22b and 22c described later.

  As shown in FIGS. 1 to 3, the terminal-equipped electric wire 1 basically includes an electric wire 2 and a terminal 3. The electric wire 2 has a conductive wire 21 and an insulating covering material 22 for covering the wire 21.

  The wire 21 is a stranded wire formed by twisting a plurality of strands 21a. The wire 21a is made of, for example, a metal material made of aluminum, an aluminum alloy, copper or a copper alloy. The form of the wire 21 is not limited to a stranded wire and may be a single wire.

  As long as the covering material 22 is a material which insulates the wire 21 from the outside, the kind of material is not limited. The covering material 22 is made of, for example, an insulating resin containing polyvinyl chloride (PVC) or crosslinked polyethylene.

  By part of the covering material 22 being peeled off, the electric wire 2 is formed with an exposed portion 2a in which the distal end side of the wire 21 is exposed. In addition, the site | part except the exposed part 2a which comprises the electric wire 2, ie, the site | part which remains without peeling of the coating material 22, is called "the coating | coated part 2b." Further, the end surface formed by the peeling of the covering material 22, that is, the position of the boundary surface between the exposed portion 2a and the covering portion 2b is referred to as "peeling end 22a".

  Hereinafter, for convenience of description, the extending direction of the terminal 3 is defined as “X direction”, the crimped side of the terminal 3 as “arrow X 1 side”, and the non-crimped side of the terminal 3 as “arrow X 2 side”. The X direction will be described on the premise that it coincides with the direction along the axial center 23 of the electric wire 2 (hereinafter referred to as the axial direction).

  The terminal 3 is a closed barrel type female crimp terminal, and has a substantially cylindrical crimp portion 31 and a box portion 32 having a hollow square pole shape. Between the crimped portion 31 and the box portion 32, a transition portion 33 of a predetermined length, which mechanically and electrically connects the two, is located. The crimping portion 31, the box portion 32 and the transition portion 33 integrally constitute the terminal 3. The terminal 3 is made of a copper alloy strip such as brass whose surface is tin-plated (Sn-plated).

  The crimping part 31 is a part to which the electric wire 2 in which at least the exposed part 2a is inserted is crimped. The crimped portion 31 is formed in a continuous shape in the entire circumferential direction, specifically, in a bottomed cylindrical shape. Hereinafter, in the crimping part 31, the part to be crimped to the covering material 22 may be referred to as "coated crimping part 31a", and the part to be crimped to the exposed part 2a may be referred to as "conductor crimping part 31b".

  The arrow X1 side of the coated crimping portion 31a forms an opening 31d, and the arrow X2 side of the conductor crimping portion 31b forms a closed bottom 31c. Since there is a difference in level of the thickness of the covering material 22 between the exposed portion 2a and the covering portion 2b, the conductor crimping portion 31b tends to be strongly compressed. Thereby, the transition part from the covering pressure-bonding part 31a to the conductor pressure-bonding part 31b has a shape in which the conductor pressure-bonding part 31b is strongly pressed.

  The bottom portion 31 c is deformed so as to crush in a substantially flat plate shape on the arrow X 2 side, and has a flat shape in which predetermined portions facing in the vertical direction overlap each other. Also, a butt portion 31f is provided extending substantially parallel to the X direction from the bottom portion 31c to the position of the opening 31d.

  The box portion 32 receives insertion of an insertion tab provided on a male crimp terminal (not shown). The box portion 32 has a bottom surface portion 32a, side surface portions 32b and 32c, and a top surface portion 32d. The resilient contact piece 32e is formed by bending the bottom portion 32a inward toward the arrow X1 side, and contacts the above-mentioned insertion tab when inserting the male crimp terminal.

<External Features of Coating Material 22>
Two roughened regions 22b and 22c are formed along the circumferential direction on a part of the outer peripheral surface of the covering material 22 corresponding to the covering pressure-bonding part 31a. Here, the “roughened area” means an area having a larger surface roughness as compared to other areas in the range from the open end 31 e to the peeling end 22 a. The “opening end 31e” refers to the position of the boundary surface between the crimped portion 31 and the covering material 22 on the arrow X1 side.

  "Surface roughness" is a physical quantity defined in JIS B 0601 (1994), JIS B 0031 (1994). That is, the roughened regions 22b and 22c have an arithmetic average roughness (Ra), a maximum height (Ry), a ten-point average roughness (Rz), an average interval of unevenness (Sm), and an average interval of local crests (S) And at least one of the load length ratios (tp) may be considered as a relatively large area.

  The two roughened regions 22b and 22c have the same shape, and more specifically, a rectangular shape in plan view, and are formed at positions symmetrical with respect to the axial center 23 of the electric wire 2.

  FIG. 4 is a developed view of the covering material 22 forming the outer peripheral surface of the electric wire 2, and for convenience of description, the position is expressed using a two-dimensional graph. The horizontal axis of the graph is the relative position X (unit: μm) in the axial center direction with respect to the peeling end 22a, the position of the peeling end 22a is 0 μm, and the arrow X1 side is a positive direction. The vertical axis of the graph is the angle θ in the circumferential direction (unit: degree), the position of the butting portion 31f is 0 degree (360 degrees), and the clockwise direction is a positive direction by looking at the electric wire 2 from the arrow X2 side. .

  The roughened area 22b is disposed at a position separated by a gap G [μm] (positive value or zero value) from the peeling end 22a and centered on θ = 90 degrees. In the roughened area 22b, the width in the axial direction is Wa [μm], and the width in the circumferential direction (angular distance) is Wc [degree (θ)] (positive value). That is, the roughened area 22 b is in the range of G to (G + Wa) [μm] in the axial direction, and in the range of (90−Wc / 2) to (90 + Wc / 2) [degrees] in the circumferential direction.

  The roughened area 22c is disposed at a position separated from the peeling end 22a by a gap G [μm] and centered on θ = 270 degrees. The roughened area 22c has a width in the axial direction of Wa [μm] and a width in the circumferential direction (angular distance) of Wc [degree (θ)]. That is, the roughened area 22c is in the range of G to (G + Wa) [μm] in the axial direction, and in the range of (270−Wc / 2) to (270 + Wc / 2) [degrees] in the circumferential direction.

  If the distance between the peeling end 22a and the opening end 31e is defined as L, G = 0.1 L [μm], Wa = 0.4 L [μm], and Wc = 90 degrees in this example. The roughened regions 22b and 22c are formed at positions closer to the peeling end 22a than the opening end 31e, that is, at positions around the peeling end 22a or the peeling end 22a. The position of the exfoliation end 22a means G = 0 μm, and the peripheral position means about 0 <G ≦ 100 [μm].

  By the way, a circular mark (hereinafter, adjustment mark 22m) is formed at the position of θ = 0 ° and X = L + ΔX [μm], that is, the position closer to the arrow X1 than the opening end 31e. The adjustment marks 22 m correspond to “orientation marks” for adjusting the circumferential direction (angle θ) of the electric wire 2 when the electric wire 2 is inserted into the crimping portion 31.

<Waterstopping effect by roughened regions 22b and 22c>
The terminal-equipped wire 1 according to this embodiment is configured as described above. Specifically, the terminal-equipped electric wire 1 includes the conductive wire 21 and the insulating covering material 22 covering the wire 21, and the exposed portion 2 a where the distal end side of the wire 21 is exposed by peeling of the covering material 22. And a crimped portion 31 having a bottomed cylindrical shape, and at least the exposed portion 2a is inserted into the crimp portion 31 so as to include a terminal 3 crimped and connected to the electric wire 2.

  When caulking the closed barrel type terminal 3 from two crimping directions P1 (FIG. 8) facing each other, the repulsive force (that is, the crimping force) that the covering material 22 of the electric wire 2 gives to the terminal 3 depends on the circumferential direction of the electric wire 2 May differ significantly. Due to the “anisotropy of the pressure bonding force”, a portion with relatively high adhesion between the electric wire 2 and the terminal 3 and a low portion coexist in one electric wire with a terminal 1. As a result, a slight gap 26 is generated in a portion where the adhesion between the electric wire 2 and the terminal 3 is relatively low, and there is a possibility that moisture W from the outside may infiltrate through the gap 26.

  Therefore, in this embodiment, part of the outer peripheral surface of the covering material 22 in the range from the open end 31e of the crimped portion 31 to the peeling end 22a of the covering material 22 has a larger surface roughness than the other regions. A plurality of roughened regions 22b and 22c (two in FIG. 4) are formed. The water blocking effect of the roughened regions 22b and 22c will be described with reference to FIG.

  FIG. 5 corresponds to a partially enlarged cross-sectional view showing the boundary between the covering material 22 and the crimped portion 31. Specifically, FIG. 5 (a) shows a portion where the roughened regions 22b and 22c are not present, and FIG. 5 (b) shows a portion where the roughened regions 22b and 22c are present.

  As shown to Fig.5 (a), it is assumed that the clearance gap 26 of 1 micrometer order exists between the coating material 22 and the crimping | compression-bonding part 31. As shown in FIG. For example, in the case where the covering material 22 is polyvinyl chloride, the contact angle with a 5 mass% concentration salt water is about 68 degrees, and the wettability is high. That is, since the water repellency of the covering material 22 is low, the penetration of the water W due to the capillary phenomenon may not be sufficiently prevented.

  Here, the "contact angle" is the angle between the tangent and the solid surface when the tangent of the solid, liquid and gas (generally air, hereinafter referred to as air) is drawn to the curved surface of the liquid. (See “JIS R 3257, test method for wettability of substrate glass surface”).

  As shown in FIG. 5 (b), roughened areas 22 b and 22 c are formed on a part of the outer peripheral surface of the covering material 22. For example, the contact angle with respect to 5 mass% concentration salt water is 90 degrees or more (more preferably 96 degrees or more), and the wettability is low. That is, since the water repellency of the covering material 22 is high, the penetration of the water W due to the capillary phenomenon can be sufficiently prevented. In particular, an effective water blocking effect can be obtained for seawater having a composition similar to that of the above-mentioned brine.

  The roughened regions 22 b and 22 c may be formed by performing laser processing on a part of the outer peripheral surface of the covering material 22. This makes it possible to process the surface shape as desired and to obtain the desired surface roughness.

<Arrangement and Shape of Roughened Regions 22b and 22c>
The anisotropy of the pressure bonding force tends to appear in line symmetry to the axial center 23 of the wire 2. Therefore, a position where the roughened regions 22b and 22c are straddled along at least one of two imaginary lines 24 and 25 (FIG. 4) on the outer peripheral surface facing each other with the axis 23 in between along the circumferential direction. By providing it, it can arrange | position reliably in the site | part with high possibility that the water | moisture-content W may infiltrate. Specifically, the positions of the two imaginary lines 24 and 25 may be made to coincide with the portion where the relative pressure bonding force is minimized.

  In addition, the peeling end 22a side having the step of the electric wire 2 due to the presence or absence of the covering material 22 tends to be compressed more strongly than the opening end 31e side having no step of the electric wire 2. In other words, regarding the gap 26 generated between the electric wire 2 and the terminal 3, the peeling end 22 a side tends to be smaller than the opening end 31 e side. Therefore, by providing the roughened regions 22b and 22c at a position of the peeling end 22a of the covering material 22 or its periphery, it is possible to exert the water blocking effect by the water repellency to the maximum.

  As described above, according to this electric wire with terminal 1, even when anisotropy of the pressure bonding force is present, the waterproofness between the electric wire 2 and the terminal 3 can be achieved while adopting a very simple structure. It can improve.

  Returning to FIG. 4, the roughened area 22b (22c) may have a symmetrical shape with one of the two imaginary lines 24 (25) as a center line. As a result, even when the path is deviated obliquely from the direction along the virtual lines 24 and 25, it is possible to effectively secure a margin for the amount of deviation of the path. Alternatively, the same applies to the margin with respect to the amount of deviation of the direction when the electric wire 2 is inserted into the crimping portion 31.

  Further, two roughened regions 22 b and 22 c may be formed in line symmetry with respect to the axial center 23. Thereby, it is possible to efficiently cover the range in the circumferential direction where there is a high possibility that the moisture W infiltrates, and it is possible to reduce the number of steps for forming the roughened regions 22 b and 22 c by that amount.

  The roughened regions 22b and 22c may be formed with a width (Wa) of 100 μm or more along the axial center direction (X direction) of the electric wire 2. In addition to or in addition to this, the roughened regions 22b and 22c have a width (Wa) of 30% or more of the length (L) of the covering material 22 from the opening end 31e to the peeling end 22a along the X direction. ) May be formed. By securing the width (Wa) sufficiently, it is possible to prevent the moisture W which has infiltrated to the position of the roughened areas 22b and 22c from passing through the roughened areas 22b and 22c as it is.

  Further, the width (Wc) along the circumferential direction may be any value of 0 <Wc <180, and it is preferable to satisfy 60 ≦ Wc ≦ 120 [θ]. It is preferable that the boundary position (G) on the peeling end 22a side satisfy 0 ≦ G ≦ 100 [μm] as an absolute value and 0 ≦ G ≦ 0.3 L as a relative value. The boundary position (G + Wa) on the side of the opening end 31e is preferably less than L [μm], and more preferably 0.5 L [μm] or less.

<Method of Manufacturing Terminal-Coated Electric Wire 1>
Subsequently, a method of manufacturing the above-described terminal-attached electric wire 1 will be described in detail with reference to the flowchart of FIG. 6 and FIGS. 7 and 8.

  In the "preparation process" which is step S1 of FIG. 6, the electric wire 2 and the terminal 3 to be crimped and connected are prepared. Specifically, the distal end side of the covering material 22 is peeled off by a predetermined length to produce the electric wire 2 in which the exposed portion 2a is formed.

At the same time, the metal plate punched into a predetermined shape is bent into a tubular shape, and the end portions are welded using a fiber laser or the like to form a butt portion 31f. Thereafter, one end of the cylindrical portion is crushed to form the bottom portion 31c, and the portion is welded and sealed so as to close the portion. Thereby, the terminal 3 provided with the bottomed cylindrical crimp part 31 is shape | molded.
The bottom portion 31 c may not be formed on the terminal 3. If the bottom 31c is not formed, one end of the terminal 3 opposite to the side receiving the wire 2 is sealed with a predetermined sealing material (for example, an insulating resin material) after receiving the wire 2 Good.

  In the “forming step” which is Step S2 of FIG. 6, roughened regions 22b and 22c and an adjustment mark 22m are formed on the outer peripheral surface of the covering material 22. Hereinafter, this will be described in detail with reference to FIG.

  As shown to Fig.7 (a), the electric wire 2 prepared by step S1 is not processed with respect to the outer peripheral surface of the coating material 22. As shown in FIG. First, by setting a laser processing apparatus (not shown), the irradiation unit included in the laser processing apparatus is directed to the corresponding position of the roughened area 22 b. Thereafter, the surface is roughened to have a larger surface roughness than that before the irradiation, for example, by sweeping and irradiating the laser beam under the conditions of an output of 15 W and a sweep speed of 2000 [mm / s].

  As shown in FIG. 7B, this processing process forms a roughened area 22b having a relatively large surface roughness as compared to other parts, and having a rectangular shape in plan view. By the same procedure, another roughened area 22c is formed. The roughened regions 22 b and 22 c may be formed by a known micro-machining method including sand blasting other than laser machining.

  Thereafter, by setting the laser processing apparatus, the irradiation unit included in the laser processing apparatus is directed to the corresponding position of the mark 22m. After that, for example, by irradiating the laser beam under the condition of a sweep speed of 1000 [mm / s], the marking process is performed such that the color changes to a color (for example, black or gray) higher in visibility than before irradiation. Ru.

  As shown in FIG. 7C, by this processing, the adjustment mark 22m having a relatively high visibility and a circular shape in a plan view is formed as compared to the other parts. Here, when the electric wire 2 is crimped and connected, the adjustment mark 22m is formed on the outer peripheral surface of the covering material 22 at a position corresponding to the position on the arrow X1 side (base end side) than the opening end 31e. Do. Even when the positions of the roughened regions 22b and 22c can not be visually recognized from the outside of the crimped portion 31 when inserting the electric wire 2, the position of the adjustment mark 22m can be used as a clue to guide the electric wire 2 in the correct direction. .

  Preferably, roughened regions 22b and 22c and adjustment marks 22m are formed by laser processing. By forming within the same process, preparation for starting processing can be performed only once, and the production efficiency of the terminal-equipped wire 1 can be improved.

  When forming the adjustment mark 22m, other processing except for the above-described laser processing may be adopted. For example, printing processing may be applied other than sand blasting processing, or a baking pot (iron) heated to a predetermined temperature may be pressed against the outer peripheral surface of the covering material 22 and discolored by the heat of the baking pot. Furthermore, the number of adjustment marks 22m may be set to a plurality, and the shape may be set to a shape that is easy to distinguish, for example, a triangle, a square, a star, a rhombus, an ellipse, or x. In addition, the order of formation of the roughened regions 22b and 22c and the adjustment mark 22m may be different.

  In the "insertion process" which is step S3 of FIG. 6, the electric wire 2 processed in step S2 is inserted into the terminal 3 in a predetermined direction by a predetermined length. Specifically, after bringing the exposed portion 2a of the electric wire 2 close to the opening 31d of the terminal 3, it is confirmed whether or not the adjustment mark 22m formed on the covering member 22 is in the correct position. Specifically, it is checked whether the circumferential position (angle θ) of the adjustment mark 22m of the electric wire 2 and the butting portion 31f of the terminal 3 match.

  If the positions of the two do not match, after the electric wire 2 is rotated in the direction to make the difference between the two smaller, the consistency of the positions is confirmed again. On the other hand, when both positions correspond, the exposed part 2a of the electric wire 2 is inserted from the opening part 31d of the terminal 3, maintaining the positional relationship.

  The adjustment mark 22 m also functions as a positioning mark for adjusting the insertion amount of the electric wire 2. Specifically, the insertion amount may be determined according to the position (relative position X) in the axial direction of the adjustment mark 22m and the opening end 31e.

  In the "crimping process" which is step S4 of FIG. 6, the wire 2 inserted in step S3 is crimped. Hereinafter, this will be described in detail with reference to FIG.

  As shown in FIG. 8, the electric wire 2 and the terminal 3 before crimp connection are set to the crimp die 4b, and the crimp die 4a above the crimp die 4b is lowered. Then, the electric wire 2 and the terminal 3 are crimped and connected by caulking the crimped portion 31 of the terminal 3 from the crimping direction P1. Here, the crimping direction P1 is substantially orthogonal to the imaginary plane 27 including the two imaginary lines 24 and 25. In this case, the crimping force is maximized at circumferential positions (θ = 0 degrees, 180 degrees) corresponding to the crimping direction P1, and circumferential positions (θ = 90 degrees, 270 degrees) corresponding to the side direction P2. The crimping force is minimized at.

  Thus, the manufacture of the terminal-equipped wire 1 ends with steps S1 to S4. According to this manufacturing method, a plurality of roughened areas 22b and 22c having a larger surface roughness than the other areas are formed on the outer peripheral surface of the covering material 22 before press-connecting the electric wire 2 (see FIG. Step S2) is provided. In the forming step, when the electric wire 2 is crimped and connected, two virtual lines 24 on the outer peripheral surface, which are in the range from the open end 31e to the peeling end 22a and face each other with the axis 23 interposed therebetween, While straddling along at least one side of 25 in the circumferential direction, roughened regions 22b and 22c are formed in the portion corresponding to the position of the exfoliation end 22a or its periphery. Thereby, the electric wire 1 with a terminal which exhibits the above-mentioned effect can be manufactured.

<Example of application>
Then, the application example of this electric wire 1 with a terminal is demonstrated. FIG. 9 is a perspective view of a wire harness 100 incorporating the terminal-equipped wire 1 shown in FIG.

  The wire harness 100 includes a connection structure 104A, 104B, 104C, which is composed of terminal-attached electric wires 1, 1, 1,... And connectors 102, 102, 102,. ‥‥have. And wire harness 100 combines each connection structure 104A (B, C, ...) with the member which is not illustrated, and after bundling with winding tape 106, it is a set electric wire which arranges collective connector 108 at the end. is there.

  As described above, by bundling a plurality of terminal-attached electric wires 1, a wire harness 100 capable of achieving both weight reduction and high water repellency can be obtained. For example, if the wire harness 100 is mounted on a vehicle, the weight of the vehicle can be significantly reduced, and fuel efficiency can be improved.

<Modification>
FIG. 10 is a development view of the covering material 122 according to the modification, and as in FIG. 4, the position is expressed using a two-dimensional graph. This is different from the above-described embodiment (the covering material 22 in FIG. 4) in that only one roughened region 22d is formed along a circumferential direction on a part of the outer peripheral surface of the covering material 122.

  The roughened area 22d is spaced from the peeling end 22a by a gap G [μm]. The roughened area 22d has a width in the axial direction of Wa [μm] and a width in the circumferential direction of Wc = 360 degrees. That is, the roughened area 22 b is in the range of G to (G + Wa) [μm] in the axial direction, and in the range of 0 to 360 degrees in the circumferential direction.

  As described above, the number of roughened regions 22 d is one, and may be formed annularly. Thereby, without particularly being aware of the insertion direction of the electric wire 2, it is possible to reliably cover a portion where the possibility of the water W entering is high.

<Supplement>
By the way, the method to grasp | ascertain the crimp direction P1 (refer FIG. 8) of the terminal 3 is demonstrated.

[1] The most reliable means is to attend the pressure bonding step (step S4 in FIG. 6). Instead of this, as shown below, the crimp direction P1 may be estimated by analyzing the terminal-equipped electric wire 1 after production.

[2] Depending on the shape of the crimping portion 31, the crimping direction P1 may be able to be estimated. For example, in the case where the metal plate is bent into a tubular shape and the end portions are welded, the crimping direction P1 can be estimated from the position of the butt portion 31f.

[3] The crimping direction P1 can be estimated by the cross-sectional shape of the electric wire 2. This is because the cross-sectional shape of the electric wire 2 is anisotropically deformed through the process of crimping the electric wire 2 and the terminal 3. Specifically, the crimping direction P1 corresponds to the direction in which the thickness of the electric wire 2 becomes the minimum value among the angular directions passing through the axial center 23. For example, when the cross-sectional shape of the electric wire 2 is an ellipse, it can be estimated that the crimping direction P1 is the short axis direction.

[4] The crimping direction P1 can be estimated from the location of the burrs in the crimping portion 31. This is because the crimped portion 31 is plastically deformed along the boundary surface of the pair of crimp molds 4a and 4b (FIG. 8) through the crimping process of the electric wire 2 and the terminal 3. Specifically, the pressure bonding direction P1 corresponds to the normal direction of the virtual plane 27 including two burrs. It should be noted that a place where the burrs are polished may be used instead of the place where the burrs are generated.

  Specific examples of the present invention will be described below, but the present invention is not particularly limited to these examples.

In each of the following Examples 1 to 5 and Comparative Example 1, a salt spray test and corrosion evaluation were carried out using a terminal-equipped electric wire provided with a terminal and an electric wire. In addition, the detail of the metal base material used for the terminal is as follows.
A copper alloy plate FAS-680 (0.25 mm in thickness, H material) manufactured by Furukawa Electric Co., Ltd. was used as the metal base of the terminal. The alloy composition of FAS-680 is 2.0 to 2.8% by mass of nickel (Ni), 0.45 to 0.6% by mass of silicon (Si), and 0.4 to 0.55 of zinc (Zn) Mass%, 0.1 to 0.25 mass% of tin (Sn), and 0.05 to 0.2 mass% of magnesium (Mg) are contained, with the balance being copper (Cu) and unavoidable impurities. The Vickers hardness of FAS-680 is about 200 Hv. In addition, the metal member to which the tin plating was given was used as a metal-plating part at least in the part of the metal base material in which a welding part is formed.

  As a core wire of the aluminum electric wire, aluminum alloy MSAl (wire, wire diameter 0.43 mm) manufactured by Furukawa Electric Co., Ltd. was used. The alloy composition of MSAl is about 0.2% iron (Fe), about 0.2% copper (Cu), about 0.1% magnesium (Mg), and about 0.04% silicon (Si) The balance is aluminum (Al) and unavoidable impurities. The wire was 2.5 sq, 19 strands, using MSAl. Moreover, the coating material of the electric wire used the ethylene vinyl acetate copolymer as halogen-free resin. The covering material is formed by extrusion so that the outer diameter of the wire is 2.4 mm, and the thickness of the covering material is 150 μm. Two roughened regions were formed at positions around the θ = 90 degrees and 270 degrees on the outer peripheral surface of the covering material.

  In this state, the electric wire was inserted into the crimped portion of the terminal, and the crimped portion covering the covering material was crimped and connected by strongly compressing using a crimp type.

The salt spray test and the corrosion evaluation were carried out according to the following procedure.
The terminal-attached electric wire was inserted into the cavity, the electric wire side was facing the ceiling, and the terminal side was facing the ground, and the cavity was set in the test device so that the cavity floats in the air. The salt spray test adjusted 5 mass% salt water to 35 degreeC, and sprayed continuously for 96 hours.
Thereafter, the terminal was disassembled, and the state of corrosion (deterioration) of the conductor in the crimped portion was visually confirmed and evaluated.
In each of Examples 1 to 5 and Comparative Example 1, tests and evaluations were carried out on 10 terminal-attached electric wires.

Hereinafter, in Examples 1 to 5 and Comparative Example 1, the gap G in the axial direction of the peeling end and the roughening region, the width Wa in the axial direction of the roughening region, the circumferential width Wc of the roughening region, and the peeling end The distance L between the and the open end is shown.
Example 1
G: 50 μm
Wa: 100 μm
Wc: 90 degrees L: 2000 μm
(Example 2)
G: 50 μm
Wa: 150 μm
Wc: 90 degrees L: 2000 μm
(Example 3)
G: 50 μm
Wa: 200 μm
Wc: 90 degrees L: 2000 μm
(Example 4)
G: 50 μm
Wa: 500 μm
Wc: 90 degrees L: 2000 μm
(Example 5)
G: 50 μm
Wa: 1000 μm
Wc: 90 degrees L: 2000 μm
(Comparative example 1)
G: 0 μm
Wa: 0 μm
Wc: 0 degree L: 2000 μm

The test results and evaluations of the above-described Examples 1 to 5 and Comparative Example 1 are shown in Table 1.
In this Table 1, corrosion test observation evaluation was divided into three steps and evaluated. The corrosion state of the conductor in the crimped portion was visually evaluated in three stages of ○, Δ, and ×.
○ · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · corrosion

  As shown in Table 1, when the width Wa of the roughened area was 0 μm as in Comparative Example 1, corrosion was observed in all of the ten terminal-equipped electric wires tested. That is, it was found that the water blocking effect can not be obtained only by the crimp connection.

  On the other hand, when the width Wa of the roughened area is 100 μm as in Example 1, no corrosion is observed in 7 out of 10, and a terminal-attached wire with no corrosion can be obtained with high probability. did it. In the case where the width Wa of the roughened region is 150 μm, 200 μm, 500 μm, and 1000 μm as in Examples 2 to 5, no corrosion was observed in all ten of the ten terminal-attached electric wires.

1 terminal-attached electric wire 2 electric wire 2a exposed portion 3 terminal 21 wire rod 22, 122 covering material 22b, 22c, 22d roughened area 22m mark for adjustment (mark for direction determination)
22a Peeling end 23 Axis 24/25 Virtual line 31 Crimping portion 31e Opening end 100 Wire harness

Claims (13)

An electric wire having a conductive wire and an insulating covering material for covering the wire, and an exposed portion in which the distal end side of the wire is exposed by peeling of the covering material;
A terminal-equipped electric wire comprising: a cylindrical crimped portion; and a terminal having at least the exposed portion inserted into the crimped portion to be crimped and connected to the electric wire,
One or more roughened areas having a larger surface roughness than the other areas are formed on a part of the outer peripheral surface of the covering material in the range from the open end of the crimped portion to the peeling end of the covering material And
The roughened region straddles at least one of two imaginary lines on the outer peripheral surface, which are opposed to each other across the axial center of the electric wire, and the peeling end or the peeling end It is formed in the surrounding position ,
An electric wire with a terminal, characterized in that a mark for determining the direction of the electric wire is formed on the outer peripheral surface at a position corresponding to a position on the proximal side of the open end .   The electric wire with a terminal according to claim 1, wherein the roughened region has a symmetrical shape centering on any one of the two imaginary lines.   The electric wire with a terminal according to claim 1 or 2, wherein the number of the roughened regions is two, and is formed in line symmetry with respect to the axial center of the electric wire.   The electric wire with a terminal according to claim 1 or 2, wherein the roughened area is one and is formed in an annular shape.   The electric wire with a terminal according to any one of claims 1 to 4, wherein the roughened area is formed with a width of 100 μm or more along the axial center direction of the electric wire.   The said roughening area | region is formed with the width | variety of 30% or more of the length of the said covering material from the said open end to the said exfoliation end along the axial center direction of the said electric wire, It is characterized by the above-mentioned. The electric wire with a terminal as described in any one of to 5.   The terminal-coated wire according to any one of claims 1 to 6, wherein the roughened region has a contact angle of 90 degrees or more with respect to a 5 mass% concentration salt water.   The electric wire with a terminal according to any one of claims 1 to 7, wherein the roughened area is formed by performing laser processing on a part of the outer peripheral surface.   The terminal-attached electric wire according to any one of claims 1 to 8, wherein a crimping direction of the electric wire is orthogonal to an imaginary plane including the two imaginary lines.   The said electric wire consists of aluminum or aluminum alloy, The electric wire with a terminal of any one of Claim 1 to 9 characterized by the above-mentioned. An electric wire having a conductive wire and an insulating covering material for covering the wire, and an exposed portion in which the distal end side of the wire is exposed by peeling of the covering material;
A method of manufacturing a terminal-equipped electric wire comprising: a cylindrical crimping portion; and at least the exposed portion being inserted into the crimping portion to form a crimp-connected terminal with the electric wire.
The method further includes a forming step of forming one or more roughened areas having a larger surface roughness as compared to other areas on the outer peripheral surface of the covering material before crimp-connecting the electric wire.
In the forming step, when the electric wire is crimped and connected,
The circumferential direction is at least one of two imaginary lines on the outer circumferential surface which are in the range from the open end of the crimped portion to the peeling end of the covering material and are opposed to each other across the axial center of the electric wire. Forming the roughened region at a position corresponding to the position of the exfoliation end or the periphery of the exfoliation end , and further on the outer peripheral surface and at a position proximal to the open end. A manufacturing method of a terminal-equipped electric wire, characterized in that a mark for determining the direction of the electric wire is formed at a corresponding portion . Wherein in the forming step, the manufacturing method of an electric wire with terminal according to claim 11, characterized in that forming each of the marks for determining the roughened area and the orientation by performing laser processing on a part of the outer peripheral surface.   A wire harness comprising a plurality of terminal-attached electric wires according to any one of claims 1 to 10 bundled together.

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