BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
[0001] The present invention relates to an electric wire with terminal, a method for manufacturing
the same, and a terminal for the electric wire with terminal.
2. DESCRIPTION OF THE RELATED ART
[0002] Conventionally, for an electric wire with terminal which is formed by connecting
a terminal and a conductor of the electric wire, a conductor and a terminal each being
made of copper or copper alloy has been used in view of electrical conductivity. Recently,
it is considered to use a conductor and a terminal each being made of an aluminum
material in view of weight reducing. For example, Japanese Patent No.
6410163 discloses connecting a terminal made of aluminum or aluminum alloy to a conductor
made of aluminum or aluminum alloy.
[0003] [Patent Document
1] Japanese Patent No.
6410163
SUMMARY OF THE INVENTION
[0004] However, aluminum tends to cause stress relaxation in comparison to copper. Thus,
when the terminal made of an aluminum material is connected to the conductor made
of an aluminum material, the stress caused at a connection between the conductor and
the terminal decreases as time advances. In accordance with this, contact force between
the conductor and the terminal may decrease and electric resistance between the conductor
and the terminal may increase. When electric current flows through the conductor while
the electric resistance between the conductor and the terminal is large, the electric
wire with terminal generates heat so that the heat may cause electric wire breaking
or loose connection.
[0005] It is an object of the invention to provide an electric wire with terminal that maintains
low electric resistance between the conductor made of an aluminum material and the
terminal made of an aluminum material and ensures enough electric connection, the
method for manufacturing the same, and a terminal for the electric wire with terminal.
[0006] According to the first embodiment of the invention, an electric wire with terminal
comprises: an electric wire comprising a conductor comprising an aluminum material
and an insulation layer coating the conductor; and a terminal comprising an aluminum
material and including a hollow portion into which the conductor exposed from an end
of the electric wire is inserted, which is connected to the conductor by compressing
the hollow portion while the conductor is inserted into the hollow portion, wherein
the terminal comprises three or more compressed portions along a longitudinal direction
of the conductor, and wherein a resistance ratio growth rate (%) obtained by a formula
((R
2-R
1)/R
1)×
100 is not more than
19% wherein R
1 represents an electric resistance ratio between the conductor and the terminal before
performing a test that keeps the electric wire with terminal at
150°C in air for
50 hours, and R
2 represents an electric resistance ratio between the conductor and the terminal after
performing the test.
[0007] According to the second embodiment of the invention, a method for manufacturing an
electric wire with terminal comprises: preparing an electric wire comprising a conductor
comprising an aluminum material and an insulation layer coating the conductor, and
a terminal comprising an aluminum material and including a hollow portion; and connecting
the terminal to the conductor by forming a plurality of compressed portions on the
terminal by compressing the terminal three or more times while the conductor exposed
from an end of the electric wire is inserted into the hollow portion, wherein said
connecting the terminal to the conductor comprises forming a further compressed portion
between adjacent compressed portions which are already formed.
[0008] According to the third embodiment of the invention, a terminal comprises a hollow
portion into which a conductor is inserted, wherein the terminal is configured to
be connected to the conductor by compressing the terminal while the conductor is inserted
into the hollow portion, and wherein information as to a terminal compression order
is given on the terminal.
Points of the invention
[0009] According to an embodiment of the invention, an electric wire with terminal, the
method for manufacturing the same, and a terminal of the electric wire with terminal
can be provided that maintain low electric resistance between the conductor made of
an aluminum material and the terminal made of an aluminum material and ensure enough
electric connection.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010]
FIG. 1 is a perspective view showing a terminal and a conductor of an electric wire with
terminal according to the embodiment, which shows a state before the conductor is
inserted into a hollow portion of the terminal;
FIG. 2 is a cross-sectional view showing an electric wire with terminal according to the embodiment,
which shows a state after the conductor is inserted into the hollow portion of the
terminal and before the hollow portion is compressed;
FIGS. 3A to 3C are cross-sectional views showing an electric wire with terminal according to the
embodiment of which the terminal is compressed three times, wherein FIG. 3A shows a cross-sectional view showing an electric wire with terminal when the first
compression is finished, FIG. 3B shows a cross-sectional view showing the electric wire with terminal when the second
compression is finished, and FIG. 3C shows a cross-sectional view showing the electric wire with terminal when the third
compression is finished;
FIG. 4 is a block diagram showing a terminal according to the embodiment; and
FIGS. 5A and 5B are cross-sectional views showing an electric wire with terminal which is compressed
two times, wherein FIG. 5A shows a cross-sectional view showing an electric wire with terminal when the first
compression is finished, and FIG. 5B shows a cross-sectional view showing the electric wire with terminal when the second
compression is finished;
FIGS. 6A to 6C are cross-sectional views showing an electric wire with terminal according to the
embodiment of which the terminal is compressed three times, wherein FIG. 6A shows a cross-sectional view showing an electric wire with terminal when the first
compression is finished, FIG. 6B shows a cross-sectional view showing the electric wire with terminal when the second
compression is finished, and FIG. 6C shows a cross-sectional view showing the electric wire with terminal when the third
compression is finished;
FIG. 7 is a cross-sectional view showing portions where compressed portions are formed when
a terminal of an electric wire with terminal according to the embodiment is compressed
four times;
FIG. 8 is a cross-sectional view showing portions where compressed portions are formed when
a terminal of an electric wire with terminal according to the embodiment is compressed
five times;
FIG. 9 is a diagram showing a summary of high temperature exposure test; and
FIG. 10 is a diagram showing a measuring method of electric resistance ratio.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0011] Next, an electric wire with terminal, a method for manufacturing the same, and a
terminal of the electric wire with terminal according to the present invention will
be described in reference to the appended drawings.
<1. Example of an electric wire with terminal>
[0012] An example of an electric wire with terminal will be explained as follows.
[0013] Referring to
FIG. 1, an electric wire with terminal
1 according to the present embodiment comprises an electric wire
2 and a terminal
5. For example, the electric wire with terminal
1 may be used as a wiring member to be used for buildings, aero generators, railroad
cars, and automobiles.
(Electric wire)
[0014] The electric wire
2 is configured as so-called insulated electric wire. The electric wire
2 comprises a conductor
3 and an insulation layer
4 that coats the conductor
3. An exposed part of the conductor
3 exposed at an end of the electric wire
2 is inserted into a hollow portion
7 of the terminal
5.
[0015] The conductor
3 constitutes a core wire of the electric wire
2. A stranded wire stranding metal wires or a plurality of metal strands may be used
as the conductor
3. As a metal material for the conductor
3, e.g., pure aluminum or aluminum alloy (hereinafter, these materials are collectively
referred to as "aluminum material") are used. Pure aluminum is a material comprising
Al and inevitable impurities or consisting of Al and inevitable impurities. As the
pure aluminum, e.g., electric conductor grade aluminum (ECA1) may be used. As the
aluminum alloy, e.g., Al-Zr, Al-Fe-Zr and the like as below may be used. Al-Zr is
aluminum alloy having a chemical composition comprising or consisting of
0.03 to
1.5% by mass of Zr,
0.1 to
1.0% by mass of Fe and Si, and the balance being Al and inevitable impurities. Al-Fe-Zr
is aluminum alloy having a chemical composition comprising or consisting of
0.01 to
0.10% by mass of Zr, not more than
0.1% by mass of Si,
0.2 to
1.0% by mass of Fe, not more than
0.01% by mass of Cu, not more than
0.01% by mass of Mn, not more than
0.01% by of Mg, not more than
0.01% by mass of Zn, not more than
0.01% by mass of Ti, and not more than
0.01% by mass of V, and the balance being Al and inevitable impurities.
[0016] In Al-Zn, "
0.1 to
1.0% by mass of Fe and Si" means as follows. If Al-Zn includes both of Fe and Si, a total
concentration of Fe and Si is
0.1 to
1.0% by mass. If Al-Zn includes Fe and does not include Si, a concentration of Fe is
0.1 to
1.0% by mass. If Al-Zn includes Si and does not include Fe, a concentration of Si is
0.1 to
1.0% by mass. In this case, e.g., "does not include" means the concentration is not more
than the detection limit of the high frequency inductively coupled plasma emission
spectroscopy.
[0017] The insulation layer
4 is made of an electrically insulating material. The insulation layer
4 is provided to coat the conductor
3. Resin such as fluorine resins, olefin resins, and silicone resins may be used as
the material of the insulation layer
4. Although the insulation layer
4 is arranged over a whole length in the longitudinal direction of the electric wire
2, in the present embodiment, the insulation layer
4 is removed in a predetermined length from the end of the electric wire
2. Thus, a portion of the end of the conductor
3 is exposed.
(Terminal)
[0018] The terminal
5 comprises a cylindrical portion
6 and an extended portion
8, which are integrally, i.e. as one piece, formed. For example, the terminal
5 is formed by pressing one end side of a pipe. The one end side corresponds to the
extended portion
8. Alternatively, the terminal
5 is e.g., formed by drilling one end side of a cylindrical base material and pressing
the other end. Drilled one end side corresponds to the hollow portion
7. Further, the pressed another end side corresponds to the extended portion
8. The hollow portion
7 has a cylindrical shape that is opened at the one end side. The terminal
5 is made of e.g. an aluminum material. More specifically, the terminal
5 is preferably made of e.g., pure aluminum or aluminum alloy. As the pure aluminum,
e.g., electric conductor grade aluminum (ECAl) may be used. As the aluminum alloy,
e.g., Al-Fe-Zr and the like as below may be used. Al-Fe-Zr is aluminum alloy having
a chemical composition comprising or consisting of
0.01 to
0.10% by mass of Zr, not more than
0.1% by mass of Si,
0.2 to
1.0% by mass of Fe, not more than
0.01% by mass of Cu, not more than
0.01% by mass of Mn, not more than
0.01% by of Mg, not more than
0.01% by mass of Zn, not more than
0.01% by mass of Ti, and not more than
0.01% by mass of V, and the balance being A1 and inevitable impurities.
[0019] The cylindrical portion
6 is configured as a portion to be connected to the terminal
3 which is exposed from the end of electric wire
2. In the present embodiment, the cylindrical portion
6 is formed in a cylindrical shape having a cross section in a circular shape. Inside
of the cylindrical portion
6 forms the hollow portion
7 into which the conductor
3 exposed from the end of electric wire
2 can be inserted. The conductor
3 is inserted from one end portion
6a (entrance) of the cylindrical portion
6. The one end portion
6a has an opening having an inner diameter not less than an outside diameter of the
conductor
3. Further, a surface of the terminal
5 and an inner surface of the cylindrical portion
6 may be plated with Sn or Ag. Furthermore, the exposed conductor
3 may be inserted into the hollow portion
7 after applying a compound including electrically conductive particles. Furthermore,
the exposed conductor
3 may be inserted into the hollow portion
7 after applying or filling the compound including electrically conductive particles
on the hollow portion
7 of the cylindrical portion
6. For example, electrically conductive particles made of Ni-P or Ni-B, or fluorine-based
oil including electrically conductive particles of a mixture of Ni-P and Ni-B may
be used as the compound with electrically conductive particles.
[0020] The extended portion
8 is configured as a portion connected to a terminal or a bolt or the like of an external
connection counterpart. In the present embodiment, the extended portion
8 is formed in plate shape and provided with a bolt hole
9 into which e.g., the terminal or the bolt of the external connection counterpart
is inserted.
<2. Example of the method for manufacturing an electric wire with terminal>
[0021] Next, the method for manufacturing the electric wire with terminal
1 according to the present embodiment will be explained as follows.
[0022] The electric wire with terminal
1 according to the present embodiment can be manufactured by sequentially performing
preparing the electric wire
2 and the terminal
5, connecting the terminal
5 with the conductor
3 by pressing the terminal
5 while the conductor
3 is inserted into the terminal
5. Each step will be explained as follows with referring to
FIGS. 1, 2 and
3A to
3C.
(Preparation step)
[0023] Firstly, the electric wire
2 having the conductor
3 and the terminal
5 is prepared. Each of the conductor
3 and the terminal
5 is made of the aluminum material. As shown in
FIG. 1, the insulation layer
4 configuring the electric wire
2 is removed at a predetermined length from an end of the electric wire
2 in the longitudinal direction, and a part of the conductor
3 is exposed. Thereafter, as shown in
FIG. 2, the exposed part of the conductor
3 of the electric wire
2 is inserted into the hollow portion
7 formed in the cylindrical portion
6 of the terminal
5.
(Compression and Connection step)
[0024] Next, as shown in
FIG. 3A, a compressed portion
10 is formed by compressing a compression part P
1 while the exposed part of the conductor
3 of the electric wire
2 is inserted into the hollow portion
7 of the terminal
5. Then, as shown in
FIG. 3B, a compressed portion
12 is formed by compressing a compression part P
3. Finally, as shown in
FIG. 3C, the terminal
3 is connected to the terminal
5 by forming a compressed portion
11 by compressing a compression part P
2 formed between the compression part P
1 and compression part P
3.
[0025] This compression is achieved by compression deforming (plastic deforming) the cylindrical
portion
6 by compressing along the entire circumference of the cylindrical portion
6 in a circumference direction at the compression parts P
1 to P
3 of the cylindrical portion
6 by using e.g., a compression jig. In the present embodiment, the compressed portions
10 to
12 have hexagonal cross-sectional shapes in cross-section perpendicular to the longitudinal
direction (axial direction) of the conductor
3. Further, the compressed portions
10 to
12 are formed to be shifted in an axial direction of the cylindrical portion
6 (the longitudinal direction of the conductor
3 which is inserted into the hollow portion
7), i.e., so as not to overlap respectively. As described above, the electric wire
with terminal
1 can be obtained by compressively connecting the terminal
5 to the conductor
3.
<3. Effect of the present embodiment>
[0026] According to the present embodiment, one or more effects described below can be achieved.
- (a) In the present embodiment, it is possible to suppress the decrease in contact
force between the conductor 3 and the terminal 5 caused by stress relaxation between the conductor 3 and the terminal 5, so that low electric resistance between the conductor 3 and the terminal 5 can be maintained. Thus, it is possible to suppress the increase of an electric resistance
ratio of the electric wire with terminal 1 under a predetermined level and to ensure
enough electric connection. Specifically, an electric resistance ratio growth rate
that is obtained by the formula ((R2-R1)/R1)×100 can be controlled to be not more than 19%, wherein R1 represents the electric resistance ratio between the conductor 3 and the terminal 5 before performing a test that keeps the electric wire with terminal 1 in a constant temperature at 150°C in air (the high temperature exposure test), and R2 represents the electric resistance ratio between the conductor 3 and the terminal 5 after performing the test. Here, the electric resistance ratio is measured by the
four-terminal sensing described below. The electric resistance ratio is substantially
the same as the electric resistance between the terminal 5 and the conductor 3. A calculation method of the electric resistance ratio will be described below.
- (b) In the present embodiment, since a predetermined pressure is applied over the
entire circumference in the circumference direction of the cylindrical portion 6 at the time of forming the compressed portions 10 to 12, it is possible to compressively connect the terminal 5 to the entire circumference of the conductor 3 equally and to maintain high contact force between the terminal 5 and the conductor 3.
<4. Variations>
[0027] As described above, although the embodiment of the present invention is described
in detail, the invention is not intended to be limited to the embodiment, and the
various kinds of modifications can be implemented without departing from the gist
of the invention.
[0028] In the present embodiment, although the compression part P
1 is compressed firstly and the compression part P
3 is compressed after the compression part P
1 is compressed when the compressed portions
10 to
12 are formed, the present invention is not limited thereto, and the compression part
P
3 may be compressed firstly and the compression part P
1 is compressed after the compression part P
3 is compressed if the compression part P
2 arranged between the compression part P
1 and the compression part P
3 is compressed finally. Such a compression order can control the electric resistance
ratio under to be not more than
19%.
[0029] In the present embodiment, although the terminal
5 having three compressed portions (having three compression parts) is described as
an example, the present invention is not limited thereto, and the terminal
5 may be compressed at four points as shown in
FIG. 7 or at five points as shown in
FIG. 8. When the terminal
5 is compressed at the four points, it is preferable to locate the compressed portion
to be formed by the fourth compression between adjacent two ones of the compressed
portions which have been already formed. For example, it is preferable to compress
the terminal
5 in order of the compression parts P
1, P
4, P
2, and P
3. Since such a compression order can suppress the decrease in contact force between
the conductor
3 and the terminal
5 caused by the stress relaxation between the conductor
3 and the terminal
5, it is possible to suppress the increase in electric resistance ratio of the electric
wire with terminal
1.
[0030] Moreover, even if the compressed portion formed by the fourth compression (final
compression) is not located between the adjacent compressed portions which have been
already formed, the compressed portion formed by the third compression may be located
between the adjacent compressed portions which have been already formed such that
the compressed portions are compressed in order of the compression parts e.g., P
1, P
3, P
2, and P
4. Meanwhile, it is preferable to locate the compressed portion to be formed by the
final compression between the adjacent compressed portions which have been already
formed.
[0031] When the terminal
5 is compressed at the five points, it is preferable to form the compressed portion
between the adjacent two compressed portions from a plurality of compressed portions
which was already formed. Especially, it is preferable to locate the compressed portion
which is formed by the fifth compression between adjacent two ones of the compressed
portions which have been already formed. Furthermore, it is preferable to locate all
the compressed portions to be formed by or after the third compression between the
adjacent two ones of the compressed portions which have been already formed. For example,
it is preferable to compress the terminal
5 in order of the compression parts P
1, P
5, P
3, P
2, and P
4. Since such a compression order can suppress the decrease in contact force between
the conductor
3 and the terminal
5 caused by the stress relaxation between the conductor
3 and the terminal
5, it is possible to suppress the increase in the electric resistance ratio of the electric
wire with terminal
1.
[0032] The aluminum material constituting the terminal
5 may comprise pure aluminum or aluminum alloy. The aluminum material constituting
the conductor
3 may comprise pure aluminum or aluminum alloy. The pure aluminum is comprising or
consisting of A1 and inevitable impurities. As the pure aluminum, e.g., electric conductor
grade aluminum (ECA1) may be used. As the aluminum alloy for the terminal
5, e.g., Al-Fe-Zr and the like as below may be used. As the aluminum alloy for the conductor
3, e.g., Al-Fe-Zr, Al-Zr and the like as below may be used. Al-Fe-Zr is aluminum alloy
having a chemical composition comprising or consisting essentially of
0.01 to
0.10% by mass of Zr, not more than
0.1% by mass of Si,
0.2 to
1.0% by mass of Fe, not more than
0.01% by mass of Cu, not more than
0.01% by mass of Mn, not more than
0.01% by of Mg, not more than
0.01% by mass of Zn, not more than
0.01% by mass of Ti, and not more than
0.01% by mass of V, and the balance being A1 and inevitable impurities. Al-Zr is aluminum
alloy having a chemical composition comprising or consisting of
0.03 to
1.5% by mass of Zr,
0.1 to
1.0% by mass of Fe and Si, and the balance being Al and inevitable impurities. Since
such a combination of the aluminum materials for the terminal
5 and the conductor
3 can suppress the decrease in contact force between the conductor
3 and the terminal
5 caused by the stress relaxation between the conductor
3 and the terminal
5, it is possible to suppress the increase in the electric resistance ratio of the electric
wire with terminal
1.
[0033] A compression ratio of the conductor
3 is preferably not less than
50% and not more than
95%, although it is not limited in the present embodiment. Herein, the compression ratio
is defined as a ratio of a cross-sectional area of the conductor
3 corresponding to a compressed portion of the terminal
5 to a cross-sectional area of the conductor
3 corresponding to a non-compressed portion of the terminal
5 in cross section perpendicular to a longitudinal direction of the conductor
3 when the terminal
5 with the hollow portion
7 into which the conductor
3 is inserted is compressed. The compression ratio is obtained by a formula (C
2/C
1)×
100 wherein C
1 (mm
2) represents the cross-sectional area of the conductor
3 corresponding to the non-compressed portion of the terminal
5 and C
2 (mm
2) represents the cross-sectional area of the conductor
3 corresponding to the compressed portion of the terminal
5. When the compression ratio falls within the above range, it is possible to suppress
the decrease in contact force between the conductor
3 and the terminal
5 caused by the stress relaxation between the conductor
3 and the terminal
5, it is possible to suppress the increase in the electric resistance ratio of the electric
wire with terminal
1.
[0034] Further, the width of the compressed portions
10 to
12 is preferably not more than
7 mm. When the width falls within the above range, it is possible to suppress the decrease
in contact force between the conductor
3 and the terminal
5 caused by the stress relaxation between the conductor
3 and the terminal
5, so that it is possible to suppress the increase in the electric resistance ratio
of the electric wire with terminal
1. Furthermore, the width of the compressed portion is more preferably not less than
2 mm and not more than
5 mm. Further, when the width of the compressed portion is more preferably not less
than
2 mm and not more than
5 mm, the electric resistance ratio can be controlled to be not more than
19%. Furthermore, the width of the compressed portion is more preferably not less than
3 mm and not more than
4 mm. When the width of the compressed portion is not less than
3 mm and not more than
4 mm, it is possible to further suppress the increase in the electric resistance ratio.
[0035] Furthermore, although the present invention is not limited thereto, it is preferable
to arrange the compressed portions
10 to
12 respectively at a regular interval. Arrangement of the compressed portions
10 to
12 at the regular interval can suppress the increase in the electric resistance ratio.
[0036] In the present embodiment, although the example in which the compressed portions
10 to
12 are formed so as not to be overlapped respectively is explained, the present invention
is not limited thereto, and the compressed portions may be provided to be partially
overlapped respectively.
[0037] In the present embodiment, although the example in which the compressed portions
10 to
12 have hexagonal cross sections in a cross section perpendicular to the longitudinal
direction (axial direction) of the conductor
3 is explained, the present invention is not limited thereto, and the compressed portions
10 to
12 may have cross sections having the other polygonal shape or the circular shape.
[0038] In the present embodiment, although the present invention is not limited thereto,
it is preferable to provide the information as to the compression order on the terminal
5. For example, as shown in
FIG. 4, although it is preferable to respectively arrange characters (letters) "first", "third",
or "second" at points corresponding to the compression parts P
1, P
2, and P
3 of the cylindrical portion
6, the present invention is not limited thereto, and the character "first" may be provided
at the compression part P
3 and the character "second" may be provided at the compression part P
1, if the character "third" is provided at the compression part P
2 arranged between the compression part P
1 and the compression part P
3. Meanwhile, the information as to the compression order is not limited to the characters
such as "first", "second", or "third". Any information may be provided if the compression
order can be identified. Further, the characters may be punched or described. As the
information as to the compression order is provided at the terminal
5, the compressed portion to be formed lastly can be securely formed between the adjacent
two ones of the compressed portions which have been already formed.
[0039] In the present embodiment, although the electric wire with terminal is explained
as the example, the present invention is not limited thereto. For example, the present
invention can be applied to a cable with a terminal.
[Experimental examples]
[0040] Next, the present invention will be explained in more detail based on experimental
examples. However, the present invention is not limited to the experimental examples.
(Experimental example 1)
[0041] As shown in
FIGS. 3A to
3C, in the experimental example
1, the terminal
5 of the conductor
3 which was inserted into the hollow portion
7 was compressed three times in order of the compression parts P
1, P
3, and P
2. The electric wire with terminal
1 was obtained by setting the width of the compressed portion along the longitudinal
direction of the conductor
3 at
3 mm and forming three compressed portions at a regular interval. The interval between
the adjacent compressed portions (a width of the non-compressed portion along the
longitudinal direction of the conductor
3) was approximately
9 mm. Al-Fe-Zr having the same composition was used as the aluminum materials for the
terminal
5 and the conductor
3. Al-Fe-Zr is aluminum alloy having a chemical composition comprising or consisting
of
0.6% by mass of Fe,
0.02% by mass of Zr,
0.06% by mass of Si,
0.002% by mass of Cu,
0.002% by mass of Mn and
0.006% by mass of total of Ti and V, and the balance being A1 and inevitable impurities.
A cross-sectional area of the conductor
3 was
50 mm
2. All metal strands for forming the conductor was the same material. A diameter of
the metal strand forming the conductor was
0.45 mm. The number of the metal strands was
309. As shown in
FIG. 9, in the high temperature exposure test, the electric wire with terminal
1 after compressing the terminal 5 and connecting with the terminal
3 was placed and kept in a thermostatic chamber
14 at
150°C in the air for
50 hours. The high temperature exposed test simulated the current test environment.
Further, an aluminum plate
13 was fixed on the extended portion
8 by a bolt (not shown) with assuming as if the extended portion
8 was connected to a terminal or a bolt of the external connection counterpart.
FIG. 9 shows the case in which the aluminum plate is fixed on a lower side of the extended
portion
8. Even if the aluminum plate is fixed on an upper side of the extended portion
8, the same effect as the case in which the aluminum plate is fixed on a lower side
of the extended portion
8 can be obtained. According to the experimental examples
2 to
9 shown in Table
1, the high temperature exposure test was performed under the same condition.
(Experimental example 2)
[0042] As shown in Table
1, in the experimental example
2, the electric wire with terminal
1 was made in the same manner as the electric wire with terminal
1 in the experimental example
1, except that the width of the compressed portion was
5 mm, and the interval between the adjacent compressed portions (the width of the non-compressed
portion along the longitudinal direction of the conductor
3) was approximately
7 mm.
(Experimental example 3)
[0043] As shown in Table
1, in the experimental example
3, the electric wire with terminal
1 was made in the same manner as the electric wire with terminal
1 in the experimental example
1, except that the order of the compression parts was P
3, P
1, and P
2, the width of the compressed portion was
5 mm, and the interval between the adjacent compressed portions (the width of the non-compressed
portion along the longitudinal direction of the conductor
3) was approximately
7 mm.
(Experimental example 4)
[0044] As shown in Table
1, in the experimental example
4, the electric wire with terminal
1 was made in the same manner as the electric wire with terminal
1 in the experimental example
1, except that the width of the compressed portion was
7 mm, and the interval between the adjacent compressed portions (the width of the non-compressed
portion along the longitudinal direction of the conductor
3) was approximately
4 mm.
(Experimental example 5)
[0045] As shown in
FIGS. 5A and
5B, in the experimental example
5, the terminal
5 of the conductor
3 which was inserted into the hollow portion
7 was compressed two times in order of the compression parts P
1 and P
2. The electric wire with terminal
1 was obtained by setting the width of the compressed portion along the longitudinal
direction of the conductor
3 at
10 mm.
(Experimental example 6)
[0046] As shown in Table
1, in the experimental example
6, the electric wire with terminal
1 was made in the same manner as the electric wire with terminal
1 in the experimental example
1, except that the order of the compression parts was P
1, P
2, and P
3.
(Experimental example 7)
[0047] As shown in
FIGS. 6A to
6C, in the experimental example
1, the terminal
5 of the conductor
3 which was inserted into the hollow portion
7 was compressed three times in order of the compression parts P
1, P
2, and P
3. The electric wire with terminal
1 was made in the same manner as the electric wire with terminal
1 in the experimental example
1, except that the order of the compression parts was P
1, P
2, and P
3, the width of the compressed portion was set at
5 mm, and the interval between the adjacent compressed portions (the width of the non-compressed
portion along the longitudinal direction of the conductor
3) was set at approximately
7 mm.
(Experimental example 8)
[0048] As shown in Table
1, in the experimental example
8, the electric wire with terminal
1 was made in the same manner as the electric wire with terminal
1 in the experimental example
1, except that the order of the compression parts was P
2, P
1, and P
3, the width of the compressed portion was
5 mm, and the interval between the adjacent compressed portions (the width of the non-compressed
portion along the longitudinal direction of the conductor
3) was approximately
7 mm.
(Experimental example 9)
[0049] As shown in Table
1, in the experimental example
9, the electric wire with terminal
1 was made in the same manner as the electric wire with terminal
1 in the experimental example
1, except that the order of the compression parts was P
1, P
2, and P
3, the width of the compressed portion was
7 mm, and the interval between the adjacent compressed portions (the width of the non-compressed
portion along the longitudinal direction of the conductor
3) was approximately
4 mm.
[0050] The resistance ratio growth rate and the like of the electric wire with terminal
1 in the above experimental examples
1 to
9 is summarized in Table
1.
[Table
1]
Items |
Number of times of compressions |
Compression order |
Width of compressed portion (mm) |
Compression ratio (%) |
Resistance ratio growth rate (%) |
Experimental example 1 |
3 |
P1→P3→P2 |
3 |
90 |
9 |
Experimental example 2 |
3 |
P1→P3→P2 |
5 |
86 |
17 |
Experimental example 3 |
3 |
P3→P1→P2 |
5 |
86 |
19 |
Experimental example 4 |
3 |
P1→P3→P2 |
7 |
82 |
18 |
Experimental example 5 |
2 |
P1→P2 |
10 |
75 |
60 |
Experimental example 6 |
3 |
P1→P2→P3 |
3 |
90 |
45 |
Experimental example 7 |
3 |
P1→P2→P3 |
5 |
86 |
37 |
Experimental example 8 |
3 |
P2→P1→P3 |
5 |
86 |
43 |
Experimental example 9 |
3 |
P1→P2→P3 |
7 |
82 |
28 |
(Measuring the resistance ratio growth rate)
[0051] The resistance ratio growth rate herein is defined by a change rate of the electric
resistance ratio (initial resistance ratio) before the electric wire with terminal
1 was placed and kept in a thermostatic chamber
14 at
150°C in the air for
50 hours (the high temperature exposure test) to the electric resistance ratio after
performing the high temperature exposure test. The resistance ratio growth rate is
obtained by a formula ((R
2-R
1)/R
1)×
100 wherein R
1 represents the electric resistance ratio between the conductor
3 and the conductor
5 before performing the high temperature exposure test, and R
2 represents the electric resistance ratio between the conductor
3 and the conductor
5 after performing the high temperature exposure test.
(Measuring the electric resistance ratio)
[0052] In this case, the electric resistance ratio R
1 (the initial resistance ratio) of the electric wire with terminal
1 before performing the high temperature exposure test was measured by so-called four-terminal
sensing. The four-terminal sensing method will be explained as follows with referring
to
FIG. 10.
[0053] Firstly, constant current of
1A is fed to the whole of the electric wire with terminal
1 and an electric resistance value R
0 between the point P and the point Q is measured. In this case, the point P is a part
which is an end of the cylindrical portion
6 of the terminal
5 and corresponds to a tip end of the conductor
3 inserted into the hollow portion
7. The point Q is a part of the conductor
3 which does not contact the terminal
5. The point S is an entrance of the terminal
5 that is the other end of the cylindrical portion
6 into which the conductor
3 is inserted. The initial resistance ratio R
1 is obtained by a formula (R
0 - L
2×α)/(L
1 ×α) wherein L
1 represents the distance between the point P and the point S, L
2 represents the distance between the point Q and the point S, and α represents an
electric resistance value of the conductor
3 per unit length. The electric resistance value of the conductor
3 per unit length may be previously measured. Alternatively, the electric resistance
value of the conductor
3 per unit length may be defined by measuring the electric resistance value in the
length L
2 and dividing the measured value by the length L
2.
[0054] The electric resistance ratio R
2 after performing the high temperature exposure test was measured by the four-terminal
sensing after cooling down the electric wire with terminal
1 to a room temperature, in the same manner as measuring the electric resistance ratio
before performing the high temperature exposure test (initial electric resistance
ratio). Specifically, the constant current of
1A is fed to the whole of the electric wire with terminal 1 and the electric resistance
value R between the point P and the point Q is measured. The electric resistance value
α of the conductor
3 per unit length is constant and the same value before and after performing the high
temperature exposure test. The electric resistance ratio R
2 is obtained by a formula (R-L
2×α)/(L
1×α). The resistance value will be measured by the resistance meter made by HIOKI E.E.
Corporation.
(Measuring compression ratio)
[0055] As described above, the compression ratio is defined by a ratio of a cross-sectional
area of the conductor
3 corresponding to a compressed portion of the terminal
5 to a cross-sectional area of the conductor
3 corresponding to a non-compressed portion of the terminal
5 in cross section perpendicular to a longitudinal direction of the conductor
3 when the terminal
5 with the hollow portion
7 into which the conductor
3 is inserted is compressed. The compression ratio is obtained by a formula (C
2/C
1)×
100 wherein C1 (mm
2) represents the cross-sectional area of the conductor
3 corresponding to the non-compressed portion of the terminal
5, and C
2 (mm
2) represents the cross-sectional area of the conductor
3 corresponding to the compressed portion of the terminal
5.
[0056] From the results described above, it was confirmed that the resistance ratio growth
rate can be controlled by forming three compressed portions of which the compressed
portion formed for the last time is located between the adjacent two ones which have
been already formed.
[0057] When the terminal
5 is compressed, the force is generated not only in a radial direction of the conductor
3 but also in the axial direction of the conductor
3. Thus, the extending force of the conductor
3 in the axial direction, which is caused at the time of forming the third compressed
portion, may be suppressed by the two compressed portions which have been already
formed. Therefore, as the third compressed portion is compressed, in addition to the
increase in a contact force between the conductor
3 and the terminal
5 in the third compressed portion, there may be the increase in a contact force between
the conductor
3 and the terminal
5 in a portion between the first compressed portion and the third compressed portion
as well as a contact force between the conductor
3 and the terminal
5 in a portion between the second compressed portion and the third compressed portion.
Thus, the increase in the resistance ratio of the electric wire with terminal
1 may be suppressed.
[0058] Furthermore, it was confirmed that the resistance ratio growth rate decreases in
accordance with the decrease in the width of the compressed portion in the experimental
examples
1 and
2. Meanwhile, it was confirmed that the resistance ratio growth rate decreases in accordance
with the increase in the width of the compressed portion in the experimental examples
6 and
7.
[0059] Furthermore, it was confirmed that the resistance ratio growth rate of the experimental
example
5 is
60%, which is the highest rate. It was confirmed that the resistance ratio growth rates
in the experimental examples
6 to
9 is higher than the resistance ratio growth rates in the experimental examples
1 to
4. In the experimental examples
6 to
9, three compressed portions of which the last compressed portion is not located between
the adjacent two ones which have been already formed.
[0060] Next, the electric wire with terminal
1 of which the number of times for compressing the terminal
5 is four or five will be explained based on the experimental examples as follows.
(Experimental example 10)
[0061] As shown in
FIG. 7, in the experimental example
10, the terminal
5 of the conductor
3 inserted into the hollow portion
7 was compressed for four times in order of the compression parts P
1, P
4, P
2, and P
3. The electric wire with terminal
1 was obtained by setting the width of the compressed portion along the longitudinal
direction of the conductor
3 at
3 mm, and forming four compressed portions at a regular interval. The interval between
the adjacent compressed portions (the width of the non-compressed portion along the
longitudinal direction of the conductor
3) was approximately
6 mm. Al-Fe-Zr having the same composition was used as the aluminum material for the
terminal
5 and the conductor
3. Al-Fe-Zr is aluminum alloy having a chemical composition consisting of
0.6% by mass of Fe,
0.02% by mass of Zr,
0.06% by mass of Si,
0.002% by mass of Cu,
0.002% by mass of Mn and
0.006% by mass of total of Ti and V, and the balance being Al and inevitable impurities.
A cross-sectional area of the conductor
3 was
50 mm
2. All metal strands for forming the conductor were made of the same material. A diameter
of the metal strand for forming the conductor was
0.45 mm. The number of the metal strands was
309. In the high temperature exposure test, the electric wire with terminal
1 after compressing the terminal
5 and connecting to the terminal
3 was placed and kept in a thermostatic chamber
14 at
150°C in the air for
50 hours. In the experimental examples
11 to
22 shown in Table
2, the high temperature exposure test was performed under the same condition. The high
temperature exposure test was performed in the same method as in the experimental
examples
1 to
9. Further, the electric resistance ratio and the compression ratio were measured by
the same methods as in the experimental examples
1 to
9.
(Experimental example 11)
[0062] As shown in Table
2, in the experimental example
11, the electric wire with terminal
1 was made in the same manner as the electric wire with terminal
1 in the experimental example
10, except that the order of the compression parts was P
1, P
2, P
4, and P
3.
(Experimental example 12)
[0063] As shown in Table
2, in the experimental example
12, the electric wire with terminal
1 was made in the same manner as the electric wire with terminal
1 in the experimental example
10, except that the order of the compression parts was P
1, P
4, P
3, and P
2.
(Experimental example 13)
[0064] As shown in Table
2, in the experimental example
13, the electric wire with terminal
1 was made in the same manner as the electric wire with terminal
1 in the experimental example
10, except that the order of the compression parts was P
2, P
1, P
4, and P
3.
(Experimental example 14)
[0065] As shown in Table
2, in the experimental example
14, the electric wire with terminal
1 was made in the same manner as the electric wire with terminal
1 in the experimental example
10, except that the order of the compression parts was P
4, P
1, P
2, and P
3.
(Experimental example 15)
[0066] As shown in Table
2, in the experimental example
15, the electric wire with terminal
1 was made in the same manner as the electric wire with terminal
1 in the experimental example
10, except that the order of the compression parts was P
3, P
1, P
4, and P
2.
(Experimental example 16)
[0067] As shown in Table
2, in the experimental example
16, the electric wire with terminal
1 was made in the same manner as the electric wire with terminal
1 in the experimental example
10, except that the order of the compression parts was P
3, P
4, P
1, and P
2.
(Experimental example 17)
[0068] As shown in
FIG. 8, in the experimental example
17, the terminal
5 of the conductor
3 which was inserted into the hollow portion
7 was compressed for five times in order of the compression parts P
1, P
5, P
3, P
2, and P
4. The width of the compressed portion along the longitudinal direction of the conductor
3 was
3 mm. The interval between the adjacent compressed portions (the width of the non-compressed
portion along the longitudinal direction of the conductor
3) was approximately
4 mm. The electric wire with terminal
1 was obtained by forming five compressed portions at a regular interval.
(Experimental example 18)
[0069] As shown in Table
2, in the experimental example
18, the electric wire with terminal
1 was made in the same manner as the electric wire with terminal
1 in the experimental example
17, except that the order of the compression parts was P
1, P
4, P
3, P
5, and P
2.
(Experimental example 19)
[0070] As shown in
FIGS. 5A and
5B, in the experimental example
5, the terminal
5 of the conductor
3 inserted into the hollow portion
7 was compressed for two times in order of the compression parts P
1 and P
2. The electric wire with terminal
1 was obtained by setting the width of the compressed portion along the longitudinal
direction of the conductor
3 at
10 mm. The experimental example
19 was in same with the experimental example
5 shown in Table
1.
(Experimental example 20)
[0071] As shown in Table
2, in the experimental example
20, the electric wire with terminal
1 was made in the same manner as the electric wire with terminal
1 in the experimental example
10, except that the order of the compression parts was P
1, P
2, P
3, and P
4.
(Experimental example 21)
[0072] As shown in Table
2, in the experimental example
21, the electric wire with terminal
1 was made in the same manner as the electric wire with terminal
1 in the experimental example
10, except that the order of the compression parts was P
1, P
3, P
2, and P
4.
(Experimental example 22)
[0073] As shown in Table
2, in the experimental example
22, the electric wire with terminal
1 was made in the same manner as the electric wire with terminal
1 in the experimental example
10, except that the order of the compression parts was P
3, P
1, P
2, and P
4.
[0074] The resistance ratio growth rate and the like of the electric wire with terminal
1 in the above experimental examples
10 to
22 is summarized in Table
2.
[Table
2]
Items |
Number of times of Compression |
Compression order |
Width of compressed portion (mm) |
Compression ratio (%) |
Resistance ratio growth rate (%) |
Experimental example 10 |
4 |
P1→P4→P2→P3 |
3 |
90 |
7 |
Experimental example 11 |
4 |
P1→P2→P4→P3 |
3 |
90 |
8 |
Experimental example 12 |
4 |
P1→P4→P3→P2 |
3 |
90 |
8 |
Experimental example 13 |
4 |
P2→P1→P4→P3 |
3 |
90 |
7 |
Experimental example 14 |
4 |
P4→P1→P2→P3 |
3 |
90 |
10 |
Experimental example 15 |
4 |
P3→P1→P4→P2 |
3 |
90 |
13 |
Experimental example 16 |
4 |
P3→P4→P1→P2 |
3 |
90 |
12 |
Experimental example 17 |
5 |
P1→P5→P3→P2 →P4 |
3 |
90 |
4 |
Experimental example 18 |
5 |
P1→P4→P3→P5 →P2 |
3 |
90 |
7 |
Experimental example 19 |
2 |
P1→P2 |
10 |
75 |
60 |
Experimental example 20 |
4 |
P1→P2→P3→P4 |
3 |
90 |
21 |
Experimental example 21 |
4 |
P1→P3→P2→P4 |
3 |
90 |
15 |
Experimental example 22 |
4 |
P3→P1→P2→P4 |
3 |
90 |
16 |
[0075] As described above, in the experimental examples
10 to
16, it was confirmed that the resistance ratio growth rate can be controlled to be not
more than
13% by forming the four compressed portions and forming the last compressed portion
between the adjacent two ones of the compressed portions which have been already formed.
In the experimental examples
17 and
18, it was confirmed that the resistance ratio growth rate can be controlled to be not
more than
7% by forming the five compressed portions and forming the last compressed portion
between the adjacent two ones of the compressed portions which have been already formed.
[0076] In the experimental examples
10 to
18, it was confirmed that the resistance ratio growth rate when the terminal
5 is compressed for five times is lower than the resistance ratio growth rate when
the terminal
5 is compressed for four times. In the experimental examples
21 and
22, it was confirmed that the resistance ratio growth rate can be controlled to be not
more than
16% by forming the four compressed portions and forming the third compressed portion
between the adjacent two ones of the compressed portions which have been already formed,
although the last compressed portion is not formed between the adjacent two ones of
the compressed portions which have been already formed and.
[0077] Furthermore, it was confirmed that the resistance ratio growth rate is the highest
in the experimental example
19 in which the compression ratio and the number of times of compression of the conductor
3 are the lowest. Furthermore, it was confirmed that the resistance ratio growth rate
in the experimental example
20 is the highest among the experimental examples
20 to
22.
(Experimental example 23)
[0078] As shown in
FIGS. 3A to
3C, in the experimental example
23, the terminal
5 of the conductor
3 inserted into the hollow portion
7 was compressed for three times in order of the compression parts P
1, P
3, and P
2. The electric wire with terminal
1 was obtained by setting the width of the compressed portion along the longitudinal
direction of the conductor
3 at
5 mm, and forming three compressed portions at a regular interval. The interval between
the adjacent compressed portions (the width of the non-compressed portion along the
longitudinal direction of the conductor
3) was approximately
7 mm. ECA1 was used for the aluminum material of the terminal
5. Al-Fe-Zr was used for the aluminum material of the conductor
3. ECA1 is a pure aluminum satisfying standard A
1070. Al-Fe-Zr is aluminum alloy having a chemical composition consisting of
0.6% by mass of Fe,
0.02% by mass of Zr,
0.06% by mass of Si,
0.002% by mass of Cu,
0.002% by mass of Mn and
0.006% by mass of total of Ti and V, and the balance being A1 and inevitable impurities.
A cross-sectional area of the conductor
3 was
50 mm
2. In the high temperature exposure test, the electric wire with terminal
1 after compressing the terminal
5 and connecting to the terminal
3 was placed and kept in a thermostatic chamber
14 at
150°C in the air for
50 hours. In the experimental example
24 shown in Table
3, the high temperature exposure test was performed under the same condition. The high
temperature exposure test was performed in the same method as in the experimental
examples
1 to
22. Further, the electric resistance ratio and the compression ratio were measured by
the same methods as in the experimental examples
1 to
22. Furthermore, the experimental example
25 was in the same manner as the electric wire with terminal
1 in the experimental example
2 shown in Table
1.
(Experimental example 24)
[0079] As shown in Table
3, in the experimental example
24, the electric wire with terminal
1 was made in the same manner as the electric wire with terminal
1 in the experimental example
23, except that the aluminum material for the conductor
3 was Al-Zr. Al-Zr is aluminum alloy having a chemical composition consisting of
0.34% by mass of Zr,
0.15% by mass of Fe,
0.1% by mass of Si,
0.03% by mass of total of Ti and V, and the balance being Al and inevitable impurities.
The electric resistance ratio and the compression ratio were measured by the same
methods as in the experimental examples
1 to
22.
[0080] From the results described above, in the experimental examples
23 and
24, it was confirmed that the increase in the electric resistance ratio can be further
controlled as compared with the case in the experimental example
25, by forming three compressed portions of which the last compressed portion is formed
between the adjacent two ones of the compressed portions which have been already formed,
and changing the combination of the aluminum materials for the terminal
5 and the conductor
3.
[0081] The terminal
5 and the conductor
3 are compressed by loading a compressive load on the terminal
5 of which the conductor
3 is inserted into the hollow portion
7. The terminal
5 and the conductor
3 spring back (i.e. the stress is relaxed) in accordance with the Young's modulus after
the compressive load is completely moved away. Thus, the load that compresses the
conductor
3 and the terminal
5 each other occurs between an outer circumferential surface of the conductor
3 and an inner circumferential surface of the terminal
5 when the compressive load is completely moved away. The amount of spring back increases
in accordance with an increase in tensile strength of the aluminum material for forming
the conductor
3, and tensile strength of the aluminum material for forming the terminal
5 that is lower than the tensile strength of the aluminum material forming the conductor
3. The amount of spring back in the experimental example
23 is higher than the amount of spring back in the experimental example
25. Further, the amount of spring back in the experimental example
24 is higher than the amount of spring back in the experimental example
23. As the amount of spring back increases, the load to compress the conductor
3 and the terminal
5 each other occurred between the outer circumferential surface of the conductor
3 and the inner circumferential surface of the terminal
5 increase. As a result, it was confirmed that the resistance ratio growth rate could
be additionally controlled by increasing the amount of spring back.
[0082] The resistance ratio growth rate and the like of the electric wire with terminal
1 in the above experimental examples
23 to
25 is summarized in Table
3.
[Table
3]
Items |
Number of times of Compression |
Compression order |
Width of compressed portion (mm) |
Compression ratio (%) |
Aluminum material of terminal |
Aluminum material of conductor |
Resistance ratio growth rate (%) |
Experimental example 23 |
3 |
P1→P3→P2 |
5 |
86 |
ECA1 |
Al-Fe-Zr |
11 |
Experimental example 24 |
3 |
P1→P3→P2 |
5 |
86 |
ECA1 |
Al-Zr |
6 |
Experimental example 25 |
3 |
P1→P3→P2 |
5 |
86 |
Al-Fe-Zr |
Al-Fe-Zr |
17 |
[0083] Although the cross-sectional area of the conductor
3 was set at
50 mm
2 in the present experimental examples, the present invention is not limited thereto.
The effect of the present invention can be obtained regardless of the cross-sectional
area of the conductor
3. For example, it is significant to maintain the low resistance ratio growth rate although
the conductor has a cross-sectional area of
50 to
400 mm
2 which cannot ignore the effect of stress relaxation.
[5. Preferred embodiment of the present invention]
[0084] The preferred embodiment of the present invention will be noted as follows.
(Note 1)
[0085] According to an embodiment of the invention, an electric wire with terminal comprises:
an electric wire comprising a conductor comprising an aluminum material and an insulation
layer coating the conductor; and
a terminal comprising an aluminum material and including a hollow portion into which
the conductor exposed from an end of the electric wire is inserted, which is connected
to the conductor by compressing the hollow portion while the conductor is inserted
into the hollow portion,
wherein the terminal comprises three or more compressed portions along a longitudinal
direction of the conductor, and wherein a resistance ratio growth rate (%) obtained
by a formula ((R2-R1)/R1)×100 is not more than 19% wherein R1 represents an electric resistance ratio between the conductor and the terminal before
performing a test that keeps the electric wire with terminal at 150°C in air for 50 hours, and R2 represents an electric resistance ratio between the conductor and the terminal after
performing the test.
(Note 2)
[0086] Preferably, in the electric wire with terminal according to Note
1, a tensile strength of the aluminum material for the conductor is higher than a tensile
strength of the aluminum material for the terminal.
(Note 3)
[0087] Preferably, in the electric wire with terminal according to Notes
1 or
2, the conductor is aluminum alloy comprising or consisting of
0.03 to
1.5% by mass of Zr,
0.1 to
1.0% by mass of Fe and Si, and the balance being Al and inevitable impurities.
(Note 4)
[0088] Preferably, in the electric wire with terminal according to any one of Notes
1 to
3, the conductor is aluminum alloy comprising or consisting of
0.01 to
0.10% by mass of Zr, not more than
0.1% by mass of Si,
0.2 to
1.0% by mass of Fe, not more than
0.01% by mass of Cu, not more than
0.01% by mass of Mn, not more than
0.01% by of Mg, not more than
0.01% by mass of Zn, not more than
0.01% by mass of Ti and not more than
0.01% by mass of V, and the balance being Al and inevitable impurities, and the terminal
comprising pure aluminum composed of A1 arid inevitable impurities.
(Note 5)
[0089] Preferably, in the electric wire with terminal according to any one of Notes
1 to
4, a width of the compressed portion of the conductor along the longitudinal direction
is not more than
7 mm.
(Note 6)
[0090] Preferably, in the electric wire with terminal according to any one of Notes
1 to
5, the compressed portions are respectively arranged at a regular interval.
(Note 7)
[0091] Preferably, in the electric wire with terminal according to any one of Notes
1 to
6, a cross-sectional area of the conductor is not less than
50 mm
2.
(Note 8)
[0092] According to the other embodiment of the invention, a method for manufacturing an
electric wire with terminal comprises:
preparing an electric wire comprising a conductor made of an aluminum material and
an insulation layer coating the conductor and a terminal made of an aluminum material
having a hollow portion; and
connecting the terminal to the conductor by forming a plurality of compressed portions
on the terminal by compressing the terminal three or more times while the conductor
exposed from an end of the electric wire is inserted into the hollow portion,
wherein said connecting the terminal to the conductor comprises forming a further
compressed portion between adjacent compressed portions which are already formed.
(Note 9)
[0093] In the method for manufacturing the electric wire with terminal according to Note
8, said forming of the further compressed portion between the adjacent compressed portions
which are already formed may be performed as a last step in said connecting the terminal
to the conductor.
(Note 10)
[0094] According to another embodiment of the invention, a terminal comprises a hollow portion
into which a conductor is inserted,
wherein the terminal is configured to be connected to the conductor by compressing
the terminal while the conductor is inserted into the hollow portion, and
wherein information as to an order for compression is given on the terminal.
(Note 11)
[0095] Preferably, in the terminal according to Note
10, the order for compression is given at a part to be compressed of the terminal.
(Note 12)
[0096] According to the other embodiment of the invention, a jig for connecting a terminal
to a conductor by compressing the terminal at three or more parts while the conductor
is inserted into a hollow portion of the terminal is provided in which the jig is
configured to compress the terminal to form three or more compressed portions at the
terminal along the longitudinal direction of the conductor, and to form at least one
of the compressed portions formed on after a third compression between adjacent ones
of the compressed portions which are already formed.
(Note 13)
[0097] Preferably, in the electric wire with terminal according to any one of Notes
1 to
7, the number of the compressed portions is four or more.
(Note 14)
[0098] Preferably, in the electric wire with terminal according to any one of Notes
1 to
7, the number of the compressed portions is four or more, and the resistance ratio growth
rate (%) is not more than
13%.
(Note 15)
[0099] Preferably, in the electric wire with terminal according to any one of Notes
1 to
7, the number of the compressed portions is five or more.
(Note 16)
[0100] Preferably, in the electric wire with terminal according to any one of Notes
1 to
7, the number of the compressed portions is five or more, and the resistance ratio growth
rate (%) is not more than
7%.
(Note 17)
[0101] Preferably, in the method for manufacturing the electric wire with terminal according
to Note
8 or
9, the terminal is compressed four or more times.
(Note 18)
[0102] Preferably, in the method for manufacturing the electric wire with terminal according
to Note
8, the terminal is compressed four or more times, and forming a compressed portion by
or after a third compression is performed between adjacent compressed portions which
are already formed.
(Note 19)
[0103] Preferably, in the terminal according to Note
10 or
11, the number of the order for compression is four or more.
(Note 20)
[0104] Preferably, in the jig according to Note
12, the number of the compressed portions is four or more.
(Note 21)
[0105] Preferably, in the jig according to Note
12, the number of the compressed portions is four or more, and all compressed portions
formed by or after a third compression are located between adjacent ones of the compressed
portions which are already formed.
[0106] Although the invention has been described with respect to the specific embodiments
for complete and clear disclosure, the appended claims are not to be thus limited
but are to be construed as embodying all modifications and alternative constructions
that may occur to one skilled in the art which fairly fall within the basic teaching
herein set forth.