Electric wire with terminal and method for producing the same

Patent metadata

Field	Value
Publication number	US-9281101-B2
Application number	US-201214362299-A
Country	US
Kind code	B2
Filing date	Nov 30, 2012
Priority date	Dec 8, 2011
Publication date	Mar 8, 2016
Grant date	Mar 8, 2016

Abstract

An electric wire with a terminal may include an insulated electric wire that may include an insulating coating of polyolefin based resin, an adhesive layer that may be formed over an entire circumference of a surface of the insulating coating, and a waterproofing resin portion that may be formed by insert molding. The waterproofing resin portion may cover a region between the adhesive layer of the insulated electric wire and a portion where the metal terminal is connected to a core wire. The adhesive layer may include a composition of a copolymer of ethylene and glycidyl methacrylate and a phenol based curing agent. The waterproofing resin portion may include aromatic nylon.

First claim

The invention claimed is:

1. An electric wire with a terminal comprising:
an insulated electric wire comprising:
a conductive core wire; and
an insulating coating of polyolefin based resin that covers a circumference of the core wire;

a metal terminal electrically connected to the core wire at an end portion of the insulated electric wire;
an adhesive layer that comprises a composition of a copolymer of ethylene, glycidyl methacrylate, and a phenol based curing agent, and is formed over an entire circumference of a surface of the insulating coating at an end portion of the insulated electric wire; and
a waterproofing resin portion that comprises aromatic nylon and is formed by insert molding using, as an insert portion, a protected region, wherein
the protected region comprises a region that is at least disposed between a portion of the insulated electric wire where the adhesive layer is formed and a portion where the metal terminal is connected to the core wire,
the waterproofing resin portion covers protected region, and
the adhesive layer bonds an outside surface of the insulating coating to an inside surface of the waterproofing resin portion.

2. The electric wire with a terminal according to claim 1 , wherein the adhesive layer comprises a material in which a rate of elongation is at least 104.7% in an environment at −40° C. when tested in accordance with JIS K6251.

3. The electric wire with a terminal according to claim 2 , wherein an adhesive strength of the insulating coating and the adhesive layer is 183 kPa or more in an environment at 150° C. when tested in accordance with JIS K6850.

4. The electric wire with a terminal according to claim 1 , wherein an adhesive strength of the insulating coating and the adhesive layer is 183 kPa or more in an environment at 150° C. when tested in accordance with JIS K6850.

5. The electric wire with a terminal according to claim 1 , wherein the phenol based curing agent comprises at least one of a novolac type phenol resin or a resol type phenol resin.

6. The electric wire with a terminal according to claim 1 , wherein the glycidyl methacrylate is a bifunctional monomer comprising an acrylic group and an epoxy group.

7. The electric wire with a terminal according to claim 1 , wherein the water proof resin portion has a thickness of approximately 1.0 mm.

8. The electric wire with a terminal according to claim 1 , wherein the adhesive layer has an elasticity that copes with a difference in thermal expansion between the insulating coating and the waterproofing resin portion.

9. A method for producing an electric wire with a terminal comprising:
connecting a metal terminal to an end portion of an insulated electric wire;
wrapping an adhesive layer comprising a composition of a copolymer of ethylene, glycidyl methacrylate, and a phenol based curing agent around an entire circumference of an insulating coating at the end portion of the insulated electric wire;
bonding the adhesive layer wrapped around the end portion of the insulated electric wire to the insulating coating of the insulated electric wire by heating; and
shaping by insert molding, using a protected region in the insulated electric wire as an insert portion, a resin material comprising aromatic nylon into a waterproofing resin portion, wherein
a shape of the waterproofing resin portion covers the protected region, and
the adhesive layer bonds an outside surface of the insulating coating to an inside surface of the waterproofing resin portion.

10. The method for producing an electric wire with a terminal according to claim 9 , wherein the metal terminal and the end portion of the insulated electric wire are connected by welding or crimping.

11. The method for producing an electric wire with a terminal according to claim 9 , wherein during the wrapping, a terminal portion of the adhesive layer wrapped around the insulating coating is temporarily fixed to another portion of the adhesive layer by heating.

12. The method for producing an electric wire with a terminal according to claim 9 , wherein during shaping, the protected region is disposed at a predetermined position inside a metal mold for shaping the waterproofing resin portion, and
wherein the resin material is injected in a molten state from a resin supplying device to the metal mold thereby shaping the waterproof resin portion into the shape of the waterproofing resin portion that covers the protected region.

13. The method for producing an electric wire with a terminal according to claim 12 , wherein the adhesive layer is hardened before the insert molding is temporarily softened by heat of the resin in the molten state and the adhesive layer is welded to the waterproofing resin portion.

14. The method for producing an electric wire with a terminal according to claim 9 , wherein the adhesive layer comprises a sheet-like shape.

15. The method for producing an electric wire with a terminal according to claim 9 , wherein the adhesive layer comprises a material in which a rate of elongation is at least 104.7% in an environment at −40° C. when tested in accordance with JIS K6251.

16. The method for producing an electric wire with a terminal according to claim 15 , wherein an adhesive strength of the insulating coating and the adhesive layer is 183 kPa or more in an environment at 150° C. when tested in accordance with JIS K6850.

17. The method for producing an electric wire with a terminal according to claim 9 , wherein an adhesive strength of the insulating coating and the adhesive layer is 183 kPa or more in an environment at 150° C. when tested in accordance with JIS K6850.

18. The method for producing an electric wire with a terminal according to claim 9 , wherein the phenol based curing agent comprises at least one of a novolac type phenol resin or a resol type phenol resin.

19. The method for producing an electric wire with a terminal according to claim 9 , wherein the adhesive layer has an elasticity that copes with a difference in thermal expansion between the insulating coating and the waterproofing resin portion.

Assignees

• Autonetworks Technologies Ltd
• Sumitomo Wiring Systems
• Sumitomo Electric Industries

Inventors

• TACHI Kentaro
• Nakamura Tetsuya
• Matsui Katsufumi
• Fukumoto Kouji
• Suetani Masaharu
• Hashimoto Daisuke
• HIROOKA Toshiya

Classifications

• H01B13/08

  by winding · CPC title

• B29L2031/3462

  Cables · CPC title

• B29C45/14639

  for obtaining an insulating effect, e.g. for electrical components · CPC title

• H01B3/308

  Wires with resins · CPC title

• H01B3/447

  from acrylic compounds · CPC title