Yazaki Corporation

Tomoya Sato

Naoki Ito

Yasunori Nabeta

Hiroshi Aoki

Kazuhide Takahashi

Hiroya Kousaka

A manufacturing method of an electric wire with terminal includes a crimping step of crimping first and second fastening portions of a terminal to a conductor core wire and an insulating coating, while moving a crimping jig in a predetermined movement direction. The crimping jig includes first and second crimpers configured to crimp the first and second fastening portions, such that a width of the first fastening portion after crimping is larger than a width of the second fastening portion after crimping. The second crimper includes a fastening surface configured to fasten the second fastening portion at the time of crimping, a side surface facing the first crimper, and an inclined surface expanding in a width direction as approaching the first crimper so as to chamfer a boundary portion between the fastening surface and the side surface. The inclined surface faces an intermediate portion in the crimping step.

Manufacturing method of electric wire with terminal, manufacturing device of electric wire with terminal, and electric wire with terminal

A terminal-wire bonding method includes: arranging a first core at a second end of a first terminal-wire having a first terminal connected with the first core exposed from an insulating sheath at a first end, onto a side of an anvil and a second core at a second end of a second terminal-wire having a second terminal connected with the second core exposed, at a first end, from an insulating sheath longer than the insulating sheath of the first terminal-wire, onto a side of a horn; and bonding the first core at the second end and the second core at the second end together by ultrasonic bonding between the horn and the anvil.

Terminal-wire bonding method and bonded terminal-wire

A wire bonding method includes: arranging a first core including a plurality of strands exposed from an insulating sheath of a first wire, onto a side of an anvil and a second core including a plurality of strands exposed from an insulating sheath of a second wire, onto a side of a horn for ultrasonic bonding, the second core being larger in sectional area than the first core; and bonding the first core and the second core together by ultrasonic bonding between the horn and the anvil.

Wire bonding method and bonded wire

A bonding method for a conductor of an electric wire including a conductor formed of a plurality of strands and a sheath covering the conductor such that the conductor is exposed to a predetermined length. The bonding method includes bonding the strands to each other, the strands being spaced apart from the sheath by a predetermined length. An outer diameter of a middle portion of the conductor between a bonded portion and a portion covered with the sheath gradually decreases toward the bonded portion. A maximum value of an intersection angle between an upper surface of the bonded portion or a longitudinal direction of the electric wire and the strands of the middle portion is smaller than a predetermined angle. The predetermined angle is an angle at which breakage of the strands is prevented when the bonding is performed.

Bonding method for conductor of electric wire and electric wire

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.

Electric wire with terminal and method of manufacturing the same

An ultrasonic bonding method of a conductor of an electric wire includes ultrasonically bonding strands forming a conductor of at least one electric wire using an anvil and horns. A first vibration mode of at least one of the horns is different from a second vibration mode of the other horns.

Ultrasonic bonding method of conductor of electric wire, ultrasonic bonding apparatus for conductor of electric wire and electric wire

An electric wire with terminal includes: an electric wire including a core wire having a plurality of element wires, and a covering that covers the core wire in a state in which an end portion of the core wire is exposed; and a crimp terminal including a core wire crimping portion crimped to the core wire in a state in which a distal end of the core wire protrudes to the outside. A distal end of the core wire has a bonding portion at which element wires are bonded together, and the bonding portion is formed by shearing and deforming distal ends of the element wires.

Electric wire with terminal and method of manufacturing electric wire with terminal

A terminal-equipped electric wire includes at least one electric wire and a terminal including a wire barrel and installed on the electric wire. The electric wire includes a sheath; a conductor having a covered portion covered by the sheath and an exposed portion exposed due to absence of the sheath over a predetermined length at a part of the electric wire in a longitudinal direction of the electric wire; and a bonded portion formed over a predetermined length at a part of the exposed portion, the bonded portion at which strands of the conductor are bonded. An end of the wire barrel on a sheath side is closer to the sheath than an end of the bonded portion on the sheath side. The wire barrel covers at least a part of the bonded portion.

Terminal-equipped electric wire and method of manufacturing terminal-equipped electric wire

A method for manufacturing a terminal-equipped electric wire includes forming, in an electric wire, a bonded portion in which strands of a conductor exposed due to absence of a sheath are bonded to each other. A terminal including a wire barrel portion is fixed to the electric wire such that the wire barrel portion covers at least a part of the bonded portion. A sectional shape of the bonded portion before the fixing of the terminal is formed in such a shape that a variable range of a value of a distance between a geometric center of a cross section of the bonded portion and the wire barrel portion falls within a range of 0.71 to 1.29 when rotating the bonded portion by an arbitrary angle while engaging the bonded portion with the wire barrel portion within the wire barrel portion.

Method for manufacturing terminal-equipped electric wire, and terminal-equipped electric wire

A bonding method for a conductor of an electric wire includes a conductor formed of a plurality of strands and a sheath covering the conductor such that the conductor is exposed to a predetermined length. The bonding method ultrasonically bonds the plurality of strands of the electric wire to each other using an anvil and a horn. When the strands are ultrasonically bonded to each other by clamping a part of the conductor exposed from the sheath between the anvil and the horn throughout a predetermined length and ultrasonically vibrating the horn, a distance from the anvil or the horn to the sheath of the electric wire is shorter than a length of the strands when the strand vibrates in a primary mode by ultrasonic vibration.

A method for manufacturing an electric wire with a terminal includes forming a bonded part in which outer peripheral surfaces of strands are bonded to one another on an end portion of a core wire having the strands, in an electric wire in which the end portion is exposed from a covering; installing the bonded part onto a crimp terminal including a bottom part and a pair of caulking pieces extending from the bottom part and facing each other; crimping the caulking pieces to the bonded part, by sandwiching the crimp terminal and the electric wire between a first mold supporting the crimp terminal and a second mold moving relative to the first mold; and cutting a tip end portion projecting to outside from the caulking pieces in the bonded part by a cutting unit, while the caulking pieces are pressing the bonded part toward the bottom part.

Electric wire with terminal and method for manufacturing electric wire with terminal

A terminal-bonded cable includes a terminal including: a conductor-bonded portion and a sheath-contacted portion; and a cable including a conductor constituted by a plurality of strands, a sheath which covers the conductor, an exposed conductor portion in which the conductor is partially exposed from the sheath in the length direction, and a bond portion which is formed in a part of the exposed conductor portion and in which strands are bonded to each other. The bond portion is bonded to the conductor-bonded portion. The sheath is in contact with the sheath-contacted portion. The conductor-bonded portion protrudes in a thickness direction from the sheath-contacted portion.

Terminal-bonded cable

A terminal-equipped electric wire has an electric wire including a bonded portion formed over a predetermined length at a part of a conductor exposed due to absence of a sheath over a predetermined length at a part of the electric wire in a longitudinal direction and in which strands of the conductor are bonded to each other; and a terminal including a wire barrel portion, the wire barrel portion covering at least a part of the bonded portion. The wire barrel portion includes a load release portion configured to reduce stress applied to the conductor.

Terminal-equipped electric wire and method for manufacturing terminal-equipped electric wire

A terminal-equipped electric wire includes a terminal and an electric wire. The terminal includes a conductor bonding part and a sheath supporting part. The electric wire includes a conductor formed of a plurality of strands and a sheath covering the conductor such that the conductor is exposed to a predetermined length. The conductor exposed from the sheath is bonded to the conductor bonding part, and the sheath is supported by the sheath supporting part and is fixed in the terminal. The sheath supporting part is in a state where there is no permanent distortion with respect to a state when the terminal is present alone.

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Shizuoka, Japan

Tomoya Sato