Wire with terminal and manufacturing method therefor

Patent metadata

Field	Value
Publication number	US-10128628-B2
Application number	US-201515533858-A
Country	US
Kind code	B2
Filing date	Dec 3, 2015
Priority date	Dec 15, 2014
Publication date	Nov 13, 2018
Grant date	Nov 13, 2018

Abstract

A method for manufacturing a terminal-attached electric wire including an electric wire including a core wire having plurality of strand wires, and a female terminal including wire barrels crimped around the core wire. The method includes a first step of applying ultrasonic vibrations to the core wire, and a second step of crimping the wire barrels in a region of the core wire to which ultrasonic vibrations have been applied. The first step includes applying ultrasonic vibrations to the core wire while leaving a compression margin for the crimping by the second step such that the resistance between the electric wire and the female terminal is stabilized until the strand wires of the terminal-attached electric wire are severed when the core wire of the terminal-attached electric wire is further compressed after the second step.

First claim

The invention claimed is:

1. A method for manufacturing a terminal-attached electric wire including an electric wire including a core wire having a plurality of strand wires, and a terminal including a crimp portion crimped around the core wire,
the method comprising:
a first step of applying ultrasonic vibrations to the core wire; and
a second step of crimping the crimp portion in a region of the core wire in which the ultrasonic vibrations have been applied,
wherein the first step includes applying ultrasonic vibrations to the core wire according to a first compression ratio that is between 85% and 95%, inclusive, so as to leave a compression margin for the crimping in the second step such that resistance between the electric wire and the terminal is stabilized until the strand wires of the terminal-attached electric wire are severed when the core wire of the terminal-attached electric wire is further compressed after the second step, and the second step includes crimping the crimp portion according to a second compression ratio that is between 50% and 80%, inclusive, wherein the first compression ratio is defined as the quotient of a cross sectional area of the core wire after the first step divided by a cross sectional area of the core before the first step, multiplied by 100%, and the second compression ratio is defined as the quotient of a cross sectional area of the core wire after the second step divided by a cross sectional area of the core wire before the first step, multiplied by 100%.

2. The method for manufacturing a terminal-attached electric wire according to claim 1 , wherein the strand wires include aluminum or an aluminum alloy.

3. The method for manufacturing a terminal-attached electric wire according to claim 1 , wherein:
the plurality of strand wires include 20 or more strand wires; and
in a state in which the crimp portion is crimped on the core wire, the 20 or more strand wires are crimped on the crimp portion.

4. A terminal-attached electric wire comprising:
an electric wire including a core wire having a plurality of strand wires; and
a terminal including a crimp portion crimped around the core wire,
wherein:
the terminal-attached electric wire is manufactured by executing a first step of applying ultrasonic vibrations to the core wire, and a second step of crimping the crimp portion in a region of the core wire to which ultrasonic vibrations have been applied;
the first step includes applying ultrasonic vibrations to the core wire according to a first compression ratio that is between 85% and 95%, inclusive, while leaving a compression margin for the crimping by the second step such that resistance between the electric wire and the terminal is stabilized until the strand wires of the terminal-attached electric wire are severed when the core wire of the terminal-attached electric wire is compressed, and the second step includes crimping the crimp portion according to a second compression ratio that is between 50% and 80%, inclusive, wherein the first compression ratio is defined as the quotient of a cross sectional area of the core wire after the first step divided by a cross sectional area of the core before the first step, multiplied by 100%, and the second compression ratio is defined as the quotient of a cross sectional area of the core wire after the second step divided by a cross sectional area of the core wire before the first step, multiplied by 100%.

Assignees

• Autonetworks Technologies Ltd
• Sumitomo Wiring Systems
• Sumitomo Electric Industries
• Toyota Motor Co Ltd

Inventors

• Ootsuka Takuji
• Hirai Hiroki
• Ono Junichi
• Miyamoto Kenji
• Oota Toshiya
• Nakashima Takahito
• Kobayashi Hiroshi

Classifications

• H01R43/048

  Crimping apparatus or processes (H01R43/042 takes precedence) · CPC title

• H01R4/62

  Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors (H01R4/68 takes precedence) · CPC title

• H01R4/185

  combined with a U-shaped insulation-receiving portion · CPC title

• H01R43/28

  for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26 · CPC title

• H01R43/0207 Primary

  Ultrasonic-, H.F.-, cold- or impact welding · CPC title