Electric wire with terminal and method of manufacturing the same

Patent metadata

Field	Value
Publication number	US-10879631-B2
Application number	US-201916507980-A
Country	US
Kind code	B2
Filing date	Jul 10, 2019
Priority date	Jul 13, 2018
Publication date	Dec 29, 2020
Grant date	Dec 29, 2020

Abstract

An electric wire with a terminal and manufacturing method thereof is provided. In the electric wire with the terminal, the protective member, the core wire, and the terminal fitting are integrally connected to each other by ultrasonic vibration applied via the protective member from an ultrasonic horn in a state in which the core wire is sandwiched between the protective member and the terminal fitting. Therefore, there is no possibility that the ultrasonic horn directly presses the core wire, and the edge (particularly, the rear edge) of the pressing portion of the ultrasonic horn is direct in contact with the core wire. Thereby, at the time of ultrasonic bonding, stress concentration due to the edge (particularly the rear edge) of the pressing portion of the ultrasonic horn with respect to the core wire can be relaxed, and disconnection of the core wire can be suppressed.

First claim

What is claimed is:

1. An electric wire with a terminal in which a core wire exposed from an end of the electric wire and the terminal are connected by ultrasonic bonding, the electric wire with the terminal comprising:
a plate shaped protective member for protecting the core wire having a rear end portion bent along the core wire,
wherein the core wire is integrally connected to the protective member and the terminal by ultrasonic vibration applied in a pressurized state from an ultrasonic horn via the protective member in a state of being sandwiched between the protective member and the terminal.

2. The electric wire with the terminal according to claim 1 ,
wherein the dimension of the protective member is set to be equal to or larger than the diameter of the strand of the core wire in the pressurization direction.

3. The electric wire with the terminal according to claim 1 ,
wherein the protective member is formed of the same material as the core wire.

4. The electric wire with the terminal according to claim 1 ,
wherein a dimension of the protective member is set to be substantially same as a dimension of a distal end portion of the ultrasonic horn that is in contact with the protective member in a direction orthogonal to the core wire and orthogonal to a pressurization direction.

5. The electric wire with the terminal according to claim 4 ,
wherein the dimension of the protective member is equal to or larger than the dimension of the distal end portion of the ultrasonic horn that is in contact with the protective member minus a diameter of a strand of the core wire, and is equal to or smaller than the dimension of the distal end portion of the ultrasonic horn in the direction orthogonal to the core wire and orthogonal to the pressurization direction.

6. The electric wire with the terminal according to claim 1 ,
wherein the dimension of the protective member is ⅔ or more of the dimension of the distal end portion of the ultrasonic horn that is in contact with the protective member, and is smaller than the dimension of the distal end portion of the ultrasonic horn in the direction orthogonal to the core wire and orthogonal to the pressurization direction.

7. The electric wire with the terminal according to claim 6 ,
wherein the protective member has a chamfered portion at an edge of a side surface of the protective member facing the core wire.

8. An electric wire with a terminal in which a core wire exposed from an end of the electric wire and the terminal are connected by ultrasonic bonding, the electric wire with the terminal comprising:
a protective member for protecting the core wire,
wherein the core wire is integrally connected to the protective member and the terminal by ultrasonic vibration applied in a pressurized state from an ultrasonic horn via the protective member in a state of being sandwiched between the protective member and the terminal, and
wherein the dimension of the protective member is set to be larger than the dimension of the distal end portion of the ultrasonic horn that is in contact with the protective member in at least one of the direction orthogonal to the core wire and orthogonal to the pressurization direction and a direction parallel to the core wire.

9. A method of manufacturing an electric wire with a terminal in which a core wire exposed from an end of the electric wire and the terminal are connected by ultrasonic bonding, the method comprising:
placing the terminal on an anvil, disposing the core wire on the terminal, and disposing a plate shaped protective member on the core wire; and
integrally connecting the protective member, the core wire and the terminal by applying ultrasonic vibration by an ultrasonic horn disposed on the anvil via the protective member in a state in which the core wire is pressed against the terminal via the protective member and a rear end portion of the protective member is bent along the core wire.

Assignees

• Yazaki Corp

Inventors

• Sato Tomoya
• Ito Naoki

Classifications

• H01R43/0207 Primary

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

• H01R4/023

  between cables or wires and terminals · CPC title

• H01R4/646 Primary

  for cables or flexible cylindrical bodies · CPC title

• H01R11/11 Primary

  End pieces or tapping pieces for wires, supported by the wire and for facilitating electrical connection to some other wire, terminal or conductive member (H01R11/01 takes precedence) · CPC title