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JP7597178B2 - Manufacturing method of electric wire with terminal - Google Patents
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JP7597178B2 - Manufacturing method of electric wire with terminal - Google Patents

Manufacturing method of electric wire with terminal Download PDF

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JP7597178B2
JP7597178B2 JP2023155579A JP2023155579A JP7597178B2 JP 7597178 B2 JP7597178 B2 JP 7597178B2 JP 2023155579 A JP2023155579 A JP 2023155579A JP 2023155579 A JP2023155579 A JP 2023155579A JP 7597178 B2 JP7597178 B2 JP 7597178B2
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conductor
terminal
compressed
compression
electric wire
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JP2023169336A (en
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哲朗 佐藤
剛司 藤田
裕寿 遠藤
亮 井上
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Proterial Ltd
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048—Crimping apparatus or processes
    • H01R43/0482—Crimping apparatus or processes combined with contact member manufacturing mechanism
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048—Crimping apparatus or processes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/20—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping using a crimping sleeve
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Manufacturing Of Electrical Connectors (AREA)

Description

本発明は、端子付き電線の製造方法に関する。 The present invention relates to a method for manufacturing an electric wire with a terminal.

従来、電線の導体と端子とが接続されてなる端子付電線は、導電性等の観点から、銅又は銅合金で形成された導体と端子が用いられてきたが、近年、軽量化等の観点から、導体と端子とをアルミニウム材料（アルミニウムまたはアルミニウム合金）で形成することが検討されている。 Conventionally, terminal-attached electric wires, in which the conductor of an electric wire is connected to a terminal, have used conductors and terminals made of copper or copper alloys from the viewpoint of electrical conductivity, etc., but in recent years, from the viewpoint of weight reduction, etc., it has been considered to form the conductor and terminals from aluminum materials (aluminum or aluminum alloys).

なお、この出願の発明に関連する先行技術文献情報としては、特許文献１がある。 Prior art related to the invention of this application includes Patent Document 1.

国際公開第９８／５４７９０号WO 98/54790

端子付電線では、導体と端子との接続部分に作用する応力が時間の経過とともに小さくなり、これに伴い導体と端子との間の接触力が下がり、これらの間の電気抵抗が増加するおそれがある。特に、アルミニウムは銅と比較して応力緩和が生じやすく、アルミニウム材料からなる端子をアルミニウム材料からなる導体に接続した場合には、上述の課題が生じやすい。導体と端子との間の電気抵抗が大きい状態で、導体に電流を流すと端子付電線に発熱が生じ、この発熱は電線断線や接触不良の要因になり得る。 In electric wires with terminals, the stress acting on the connection between the conductor and the terminal decreases over time, which reduces the contact force between the conductor and the terminal, and there is a risk of the electrical resistance between them increasing. In particular, aluminum is more susceptible to stress relaxation than copper, and the above-mentioned problems are likely to occur when a terminal made of aluminum material is connected to a conductor made of aluminum material. When the electrical resistance between the conductor and the terminal is high, passing a current through the conductor generates heat in the electric wire with terminals, and this heat can lead to wire breakage or poor contact.

そこで、本発明は、導体と端子との間の電気抵抗を低く維持して、電気的接続を十分確保できる端子付電線の製造方法を提供することを目的とする。 Therefore, the present invention aims to provide a method for manufacturing a terminal-attached electric wire that can maintain low electrical resistance between the conductor and the terminal and ensure sufficient electrical connection.

本発明は、上記課題を解決することを目的として、導体、及び前記導体を被覆する絶縁層を含む電線と、前記電線の端部で露出する前記導体が挿入される筒状部を有し、前記筒状部内に前記導体が挿入された状態で前記筒状部が圧縮されることにより、前記導体に接続される端子と、を備えた端子付電線の製造方法であって、前記導体に用いられる材料の引張強度が、前記端子に用いられる材料の引張強度よりも大きい前記電線及び前記端子を準備する準備工程と、前記筒状部内に前記電線の端部で露出する前記導体を挿入させた状態で前記端子を３回以上圧縮して前記端子に３つ以上の圧縮部を形成することにより、前記端子を前記導体に接続する接続工程と、を備え、前記接続工程は、第１の圧縮部および第２の圧縮部を形成したあとに、当該第１および第２の圧縮部の間に第３の圧縮部を形成する工程を含み、該工程において、前記導体の断面積をＳ（ｍｍ２）とし、前記第１乃至第３の圧縮部の前記長手方向に沿った長さである圧縮幅をＷ（ｍｍ）とし、前記第１乃至第３の圧縮部間に位置する非圧縮部の前記長手方向に沿った長さである圧縮間隔をＬ（ｍｍ）とした場合に、前記圧縮幅Ｗの値、前記圧縮間隔Ｌの値が、それぞれ下式（１），（２）
０．０１×Ｓ＋２．５≦Ｗ≦０．０７×Ｓ＋３．５ ・・・（１）
－１．０≦Ｌ≦０．１４５×Ｓ＋３．７５ ・・・（２）
の関係式を満足するように、前記第３の圧縮部を形成する、端子付電線の製造方法を提供する。 In order to solve the above-mentioned problems, the present invention provides a method for manufacturing a terminal-attached electric wire comprising: an electric wire including a conductor and an insulating layer covering the conductor; and a terminal having a tubular portion into which the conductor exposed at an end of the electric wire is inserted, the tubular portion being compressed with the conductor inserted into the tubular portion to connect the conductor, the method comprising: a preparation step of preparing the electric wire and the terminal, the tensile strength of a material used for the conductor being greater than the tensile strength of a material used for the terminal; and a connection step of compressing the terminal three or more times with the conductor exposed at the end of the electric wire inserted into the tubular portion to form three or more compressed portions in the terminal, thereby connecting the terminal to the conductor, the connection step including a step of forming a third compressed portion between the first and second compressed portions after forming a first compressed portion and a second compressed portion, the step of reducing the cross-sectional area of the conductor to S ( mm2 ), a compression width that is a length of the first to third compressed portions along the longitudinal direction is W (mm), and a compression interval that is a length of a non-compressed portion located between the first to third compressed portions along the longitudinal direction is L (mm), the value of the compression width W and the value of the compression interval L are expressed by the following formulas (1) and (2), respectively.
0.01×S+2.5≦W≦0.07×S+3.5...(1)
-1.0≦L≦0.145×S+3.75...(2)
The third compressed portion is formed so as to satisfy the following relational expression:

本発明によれば、導体と端子との間の電気抵抗を低く維持して、電気的接続を十分確保できる端子付電線の製造方法を提供できる。 The present invention provides a method for manufacturing a terminal-attached electric wire that maintains low electrical resistance between the conductor and the terminal and ensures sufficient electrical connection.

（ａ）は本発明の一実施の形態に係る端子付電線の断面図であり、（ｂ）はそのＡ部拡大図である。1A is a cross-sectional view of an electric wire with a terminal according to an embodiment of the present invention, and FIG. （ａ）～（ｃ）は、端子付電線の製造方法を説明する図である。4A to 4C are diagrams illustrating a method for manufacturing an electric wire with a terminal. （ａ），（ｂ）は、第３の圧縮部を形成する際の端子と導体の挙動を説明する図である。6A and 6B are diagrams illustrating the behavior of a terminal and a conductor when a third compressed portion is formed. 高温環境暴露試験の概要を示す説明図である。FIG. 1 is an explanatory diagram showing an overview of a high-temperature environment exposure test. 抵抗比の測定方法を示す説明図である。FIG. 4 is an explanatory diagram showing a method for measuring a resistance ratio. 圧縮幅Ｗを変化させた際の高温環境暴露試験後の電気抵抗比Ｒ２の測定結果である。13 shows the measurement results of the electrical resistance ratio R2 after a high temperature environment exposure test when the compression width W was changed. 圧縮間隔Ｌを変化させた際の高温環境暴露試験後の電気抵抗比Ｒ２の測定結果を示すグラフ図である。FIG. 11 is a graph showing the measurement results of the electrical resistance ratio R2 after a high-temperature environment exposure test when the compression interval L is changed. オーバーラップ状態を示した図である。FIG. 13 is a diagram showing an overlapping state. （ａ）は、圧縮幅Ｗを変化させた際の高温環境暴露試験後の抵抗比増加率の測定結果、（ｂ）は、圧縮間隔Ｌを変化させた際の高温環境暴露試験後の抵抗比増加率の測定結果を示すグラフ図である。FIG. 1A is a graph showing the measurement results of the resistance ratio increase rate after a high-temperature environmental exposure test when the compression width W is changed, and FIG. 1B is a graph showing the measurement results of the resistance ratio increase rate after a high-temperature environmental exposure test when the compression interval L is changed. （ａ）は、高温環境暴露試験後の電気抵抗比Ｒ２が１００％以下の領域を示す導体断面積Ｓと圧縮幅Ｗとの関係を示すグラフ図であり、（ｂ）は、高温環境暴露試験後の電気抵抗比Ｒ２が１００％以下の領域を示す導体断面積Ｓと圧縮間隔Ｌとの関係を示すグラフ図である。1A is a graph showing the relationship between the conductor cross-sectional area S and the compression width W, which indicate the region where the electrical resistance ratio R2 after a high-temperature environmental exposure test is 100% or less, and FIG. 1B is a graph showing the relationship between the conductor cross-sectional area S and the compression interval L, which indicate the region where the electrical resistance ratio R2 after a high-temperature environmental exposure test is 100% or less. （ａ）は、高温環境暴露試験後の電気抵抗比Ｒ２が１００％以下、且つ抵抗比増加率が２０％以下となる領域を示す導体断面積Ｓと圧縮幅Ｗとの関係を示すグラフ図であり、（ｂ）は、高温環境暴露試験後の電気抵抗比Ｒ２が１００％以下、且つ抵抗比増加率が２０％以下となる領域を示す導体断面積Ｓと圧縮間隔Ｌとの関係を示すグラフ図である。1A is a graph showing the relationship between the conductor cross-sectional area S and the compression width W, which shows the region where the electrical resistance ratio R2 after a high-temperature environmental exposure test is 100% or less and the resistance ratio increase rate is 20% or less. FIG. 1B is a graph showing the relationship between the conductor cross-sectional area S and the compression interval L, which shows the region where the electrical resistance ratio R2 after a high-temperature environmental exposure test is 100% or less and the resistance ratio increase rate is 20% or less.

［実施の形態］
以下、本発明の実施の形態を添付図面にしたがって説明する。 [Embodiment]
Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings.

（端子付電線の概略構成）
図１（ａ）は、本実施の形態に係る端子付電線の断面図であり、図１（ｂ）はそのＡ部拡大図である。図１（ａ），（ｂ）に示すように、端子付電線１は、電線２と端子５とを備えている。端子付電線１は、例えば、ビル、風力発電機、鉄道車両や自動車などに用いられる配線材として用いることができる。 (General configuration of terminal-attached electric wire)
Fig. 1(a) is a cross-sectional view of an electric wire with a terminal according to the present embodiment, and Fig. 1(b) is an enlarged view of part A. As shown in Fig. 1(a) and (b), the electric wire with a terminal 1 includes an electric wire 2 and a terminal 5. The electric wire with terminal 1 can be used as a wiring material for use in buildings, wind power generators, railway cars, automobiles, etc.

電線２は、導体３と、導体３を被覆する絶縁層４と、を備えている。導体３としては、金属線、複数の金属素線を撚り合わせた撚り線、もしくは複数の撚り線を更に撚り合わせた複合撚り線を用いることができる。導体３を構成する金属材料として、例えば、純アルミニウムあるいはアルミニウム合金（以下、これらを「アルミニウム材料」という）を用いている。純アルミニウムはＡｌ及び不可避不純物から成る材料である。 The electric wire 2 includes a conductor 3 and an insulating layer 4 that covers the conductor 3. The conductor 3 may be a metal wire, a twisted wire made by twisting together multiple metal wires, or a composite twisted wire made by further twisting together multiple twisted wires. For example, pure aluminum or an aluminum alloy (hereinafter, these are referred to as "aluminum material") is used as the metal material that constitutes the conductor 3. Pure aluminum is a material made of Al and unavoidable impurities.

純アルミニウムとしては、例えば、電気用純アルミニウム（ＥＣＡｌ）が挙げられる。アルミニウム合金として、例えば、以下のＡｌ－Ｚｒ、Ａｌ－Ｆｅ－Ｚｒ等が挙げられる。Ａｌ－Ｚｒは、０．０３～１．５質量％のＺｒと、０．１～１．０質量％のＦｅ及びＳｉと、を含み、残部がＡｌと不可避不純物からなる化学組成を有するアルミニウム合金である。また、Ａｌ－Ｆｅ－Ｚｒは、０．０１～０．１０質量％のＺｒと、０．１質量％以下のＳｉと、０．２～１．０質量％のＦｅと、０．０１質量％以下のＣｕと、０．０１質量％以下のＭｎと、０．０１質量％以下のＭｇと、０．０１質量％以下のＺｎと、０．０１質量％以下のＴｉと、０．０１質量％以下のＶと、を含み、残部がＡｌと不可避不純物とを有するアルミニウム合金である。Ａｌ－Ｚｒにおいて、「０．１～１．０質量％のＦｅ及びＳｉ」とは、以下の意味を有する。Ｆｅ及びＳｉの両方を含有する場合は、Ｆｅ及びＳｉの合計濃度が０．１～１．０質量％である。Ｆｅを含有し、Ｓｉを含有しない場合は、Ｆｅの濃度が０．１～１．０質量％である。Ｓｉを含有し、Ｆｅを含有しない場合は、Ｓｉの濃度が０．１～１．０質量％である。なお、ここでの「含有しない」とは、例えば、高周波誘導結合プラズマ発光分光分析で、検出限界以下であることを意味する。 An example of pure aluminum is electrical pure aluminum (ECAl). An example of aluminum alloy is Al-Zr, Al-Fe-Zr, etc. as shown below. Al-Zr is an aluminum alloy having a chemical composition containing 0.03 to 1.5 mass% Zr, 0.1 to 1.0 mass% Fe and Si, with the balance being Al and unavoidable impurities. Also, Al-Fe-Zr is an aluminum alloy containing 0.01 to 0.10 mass% Zr, 0.1 mass% or less Si, 0.2 to 1.0 mass% Fe, 0.01 mass% or less Cu, 0.01 mass% or less Mn, 0.01 mass% or less Mg, 0.01 mass% or less Zn, 0.01 mass% or less Ti, and 0.01 mass% or less V, with the balance being Al and unavoidable impurities. In Al-Zr, "0.1 to 1.0 mass% Fe and Si" has the following meaning. When both Fe and Si are contained, the total concentration of Fe and Si is 0.1 to 1.0 mass%. When Fe is contained but Si is not contained, the Fe concentration is 0.1 to 1.0 mass%. When Si is contained but Fe is not contained, the Si concentration is 0.1 to 1.0 mass%. Here, "not contained" means that it is below the detection limit in, for example, high-frequency inductively coupled plasma atomic emission spectrometry.

絶縁層４は、例えば、フッ素系樹脂、オレフィン系樹脂、又はシリコーン系樹脂などからなる。絶縁層４は、電線２の長さ方向の全長にわたって設けられるが、本実施の形態では、電線２の端末から所定の長さだけ絶縁層４が除去され、導体３の端末の一部が露出している。 The insulating layer 4 is made of, for example, a fluorine-based resin, an olefin-based resin, or a silicone-based resin. The insulating layer 4 is provided over the entire length of the electric wire 2, but in this embodiment, a predetermined length of the insulating layer 4 is removed from the end of the electric wire 2, and a portion of the end of the conductor 3 is exposed.

端子５は、中空部７を有する筒状の筒状部６と、延在部８とを備え、これらが一体的に形成されてなる。端子５は、例えば、パイプの一端側をプレス加工して板状の延在部８を形成したものである。あるいは、端子５は、例えば、円柱の母材の一端側を穴あけ加工して筒状部６を形成すると共に、他端側をプレス加工して延在部８を形成したものである。中空部７は一方において開口した円筒形状を有する。 The terminal 5 comprises a cylindrical tubular portion 6 having a hollow portion 7, and an extension portion 8, which are integrally formed. The terminal 5 is, for example, formed by pressing one end of a pipe to form a plate-like extension portion 8. Alternatively, the terminal 5 is, for example, formed by drilling one end of a cylindrical base material to form the cylindrical portion 6, and pressing the other end to form the extension portion 8. The hollow portion 7 has a cylindrical shape that is open on one side.

端子５は、例えば、アルミニウム材料によって構成されている。より具体的には、例えば、純アルミニウムあるいはアルミニウム合金が好ましい。純アルミニウムはＡｌ及び不可避不純物から成る材料である。例えば、電気用純アルミニウム（ＥＣＡｌ）が挙げられる。アルミニウム合金として、例えば、以下のＡｌ－Ｆｅ－Ｚｒ挙げられる。Ａｌ－Ｆｅ－Ｚｒは、０．０１～０．１０質量％のＺｒと、０．１質量％以下のＳｉと、０．２～１．０質量％のＦｅと、０．０１質量％以下のＣｕと、０．０１質量％以下のＭｎと、０．０１質量％以下のＭｇと、０．０１質量％以下のＺｎと、０．０１質量％以下のＴｉと、０．０１質量％以下のＶと、を含み、残部がＡｌと不可避不純物とを有するアルミニウム
合金である。 The terminal 5 is made of, for example, an aluminum material. More specifically, for example, pure aluminum or an aluminum alloy is preferable. Pure aluminum is a material made of Al and inevitable impurities. For example, electrically pure aluminum (ECAl) can be mentioned. As an aluminum alloy, for example, the following Al-Fe-Zr can be mentioned. Al-Fe-Zr is an aluminum alloy containing 0.01 to 0.10 mass% Zr, 0.1 mass% or less Si, 0.2 to 1.0 mass% Fe, 0.01 mass% or less Cu, 0.01 mass% or less Mn, 0.01 mass% or less Mg, 0.01 mass% or less Zn, 0.01 mass% or less Ti, and 0.01 mass% or less V, with the balance being Al and inevitable impurities.

筒状部６は、断面円形の筒状に形成されており、その内部には、電線２の端部で露出する導体３を挿入可能な中空部７が形成されている。筒状部６の内径Ｎ（ｍｍ）は、導体３の外径と同等の大きさから導体３の外径の９０％～９５％程度の大きさで開口しており、この中空部７の開口から、電線２の端部で露出する導体３が挿入される。導体３を中空部７の開口から挿入する際、結束バンド等で導体３の外径を筒状部６と同等程度の内径になるまで圧縮すると、導体３に与えるダメージを少なく、また、スムーズに中空部７に導体３を挿入できる。また、筒状部６の厚さＡ（ｍｍ）は、中空部７内に導体３が挿入された端子５が圧縮されたときの、導体３の長手方向に垂直な断面における、端子５の非圧縮部１１に対応する筒状部６の断面積と端子５の非圧縮部１１に対応する導体３の断面積の比から決定される。すなわち、端子５の非圧縮部１１の筒状部６の断面積をＴ（ｍｍ２）及び端子５の非圧縮部１１の導体３の断面積をＳ（ｍｍ２）、とした場合に、（Ｔ／Ｓ）の式から決定される。その比率の範囲は１．０以上３．０以下が好ましい。１．０より小さいと、筒状部６の厚さＡが小さいため、圧縮によって筒状部６が伸びて破断するおそれがある。３．０より大きいと、筒状部６が主に圧縮され、導体５が十分に圧縮されず、十分な機械的接合が得られないおそれがある。端子５の非圧縮部１１に対応する筒状部６の断面積Ｔ（ｍｍ２）はＴ＝（（（２Ａ＋Ｎ）／２）２－（Ｎ／２）２）×πで算出される。
端子５の非圧縮部１１の筒状部６の断面積Ｔと端子５の非圧縮部１１の導体３の断面積Ｓの比から求められる筒状部６の断面積Ｔ及び筒状部６の内径Ｎが決定されれば、筒状部６の厚さＡが導出される。 The cylindrical portion 6 is formed in a cylindrical shape with a circular cross section, and a hollow portion 7 is formed inside the cylindrical portion 6 into which the conductor 3 exposed at the end of the electric wire 2 can be inserted. The inner diameter N (mm) of the cylindrical portion 6 is opened to a size equal to the outer diameter of the conductor 3 to about 90% to 95% of the outer diameter of the conductor 3, and the conductor 3 exposed at the end of the electric wire 2 is inserted from the opening of the hollow portion 7. When the conductor 3 is inserted from the opening of the hollow portion 7, if the outer diameter of the conductor 3 is compressed with a cable tie or the like until the inner diameter of the conductor 3 is approximately equal to that of the cylindrical portion 6, damage to the conductor 3 is reduced and the conductor 3 can be smoothly inserted into the hollow portion 7. The thickness A (mm) of the cylindrical portion 6 is determined from the ratio of the cross-sectional area of the cylindrical portion 6 corresponding to the non-compressed portion 11 of the terminal 5 to the cross-sectional area of the conductor 3 corresponding to the non-compressed portion 11 of the terminal 5 in a cross section perpendicular to the longitudinal direction of the conductor 3 when the terminal 5 with the conductor 3 inserted in the hollow portion 7 is compressed. That is, when the cross-sectional area of the cylindrical portion 6 of the non-compressed portion 11 of the terminal 5 is T (mm 2 ) and the cross-sectional area of the conductor 3 of the non-compressed portion 11 of the terminal 5 is S (mm 2 ), it is determined by the formula (T/S). The range of this ratio is preferably 1.0 to 3.0. If it is less than 1.0, the thickness A of the cylindrical portion 6 is small, so that the cylindrical portion 6 may stretch due to compression and break. If it is more than 3.0, the cylindrical portion 6 is mainly compressed, and the conductor 5 may not be sufficiently compressed, and a sufficient mechanical joint may not be obtained. The cross-sectional area T (mm 2 ) of the cylindrical portion 6 corresponding to the non-compressed portion 11 of the terminal 5 is calculated by T = (((2A + N)/2)2 - (N/2)2) x π.
Once the cross-sectional area T of the tubular portion 6 and the inner diameter N of the tubular portion 6, which are calculated from the ratio of the cross-sectional area T of the tubular portion 6 of the non-compressed portion 11 of the terminal 5 to the cross-sectional area S of the conductor 3 of the non-compressed portion 11 of the terminal 5, are determined, the thickness A of the tubular portion 6 can be derived.

なお、端子５の表面や筒状部６の内面は、ＳｎめっきやＡｇめっきが施されていてもよい。また、露出する導体３に導電粒子入りのコンパウンドを塗布してから、中空部７に挿入してもよい。また、筒状部６の中空部７にコンパウンドを塗布または充填してから、露出する導体３を挿入してもよい。この導電粒子入りコンパウンドとしては、例えば、Ｎｉ－ＰまたはＮｉ－Ｂ、Ｎｉ、Ｚｎからなる導電粒子やこれらを混合した導電粒子を含有するフッ素系油またはシリコーン系油を用いることができる。端子５は、中空部７内に導体３が挿入された状態で中空部７（筒状部６）が圧縮されることにより、導体３に接続されている。 The surface of the terminal 5 and the inner surface of the cylindrical portion 6 may be Sn-plated or Ag-plated. A compound containing conductive particles may be applied to the exposed conductor 3 before it is inserted into the hollow portion 7. A compound may be applied or filled into the hollow portion 7 of the cylindrical portion 6 before the exposed conductor 3 is inserted. As the compound containing conductive particles, for example, a fluorine-based oil or a silicone-based oil containing conductive particles made of Ni-P, Ni-B, Ni, or Zn, or a mixture of these, may be used. The terminal 5 is connected to the conductor 3 by compressing the hollow portion 7 (cylindrical portion 6) with the conductor 3 inserted in the hollow portion 7.

延在部８は、外部の接続相手側の端子やボルト等に接続される部分として構成されている。本実施の形態では、延在部８は、板状に形成され、外部の端子との接続に用いられるボルト等が挿入されるボルト孔９が設けられている。 The extension 8 is configured as a portion that is connected to a terminal, bolt, etc., of the other external connection partner. In this embodiment, the extension 8 is formed in a plate shape and is provided with a bolt hole 9 into which a bolt, etc., used for connecting to an external terminal is inserted.

本実施の形態に係る端子付電線１では、端子５の筒状部６には、導体３の長手方向に３つ以上の圧縮部１０が形成されている。ここでは、圧縮部１０を３つ形成する場合について説明するが、圧縮部１０の数は４つ以上であってもよい。隣り合う圧縮部１０間に位置する部分の筒状部６を非圧縮部１１と呼称する。圧縮部１０は、後述する圧縮ダイス２０によって圧縮される部分であり、長手方向に略平坦な面となっている。非圧縮部１１は圧縮ダイス２０に押圧されない部分であり、圧縮部１０よりも外径が大きい。圧縮部１０と非圧縮部１１との間には、圧縮ダイス２０の押圧による変形によってテーパ状の部分が形成されるが、このテーパ状の部分は非圧縮部１１に含まれる。圧縮部１０及び非圧縮部１１の詳細については後述する。 In the terminal-attached electric wire 1 according to the present embodiment, the cylindrical portion 6 of the terminal 5 has three or more compressed portions 10 formed in the longitudinal direction of the conductor 3. Here, the case where three compressed portions 10 are formed will be described, but the number of compressed portions 10 may be four or more. The cylindrical portion 6 located between adjacent compressed portions 10 is called the non-compressed portion 11. The compressed portion 10 is a portion compressed by the compression die 20 described later, and has a substantially flat surface in the longitudinal direction. The non-compressed portion 11 is a portion not pressed by the compression die 20, and has a larger outer diameter than the compressed portion 10. A tapered portion is formed between the compressed portion 10 and the non-compressed portion 11 due to deformation caused by pressing by the compression die 20, and this tapered portion is included in the non-compressed portion 11. Details of the compressed portion 10 and the non-compressed portion 11 will be described later.

圧縮工程では、半割構造を有する一対の圧縮ダイス２０を用いる。一対の圧縮ダイス２０は端子５の筒状部６に所定の圧力を加えて筒状部６の被加圧部を圧縮変形（塑性変形）させるためのものである。各々の圧縮ダイス２０の形状は、例えば、横断面視で、半円形状、突形状、六角形状が挙げられる。本実施の形態では特に限定されないが、導体３の圧縮比は５０％以上９５％以下であることが好ましい。ここで、圧縮比とは、中空部７内に導体３が挿入された端子５が圧縮されたときの、導体３の長手方向に垂直な断面における、端子５の非圧縮部１１に対応する導体３の断面積と圧縮部１０に対応する導体３の断面積の比である。すなわち、端子５の非圧縮部１１に対応する導体３の断面積をＳ（ｍｍ２）及び圧縮部１０に対応する導体３の断面積をＤ（ｍｍ２）、とした場合に、（Ｄ／Ｓ）×１００の式で算出される。上記の圧縮比であれば、導体３と端子５の応力緩和に起因する導体３と端子５の間の接触力低下を抑制することができるので、端子付電線１の電気抵抗比の増加を抑えることができる。なお、導体３として複数の金属素線を用いる場合は、導体３の断面積Ｓは、金属素線単体の断面積と金属素線の本数との積で算出することができる。 In the compression process, a pair of compression dies 20 having a half-split structure is used. The pair of compression dies 20 is for applying a predetermined pressure to the cylindrical portion 6 of the terminal 5 to compress and deform (plastically deform) the pressurized portion of the cylindrical portion 6. The shape of each compression die 20 may be, for example, a semicircular shape, a convex shape, or a hexagonal shape in cross section. Although not particularly limited in this embodiment, the compression ratio of the conductor 3 is preferably 50% or more and 95% or less. Here, the compression ratio is the ratio of the cross-sectional area of the conductor 3 corresponding to the non-compressed portion 11 of the terminal 5 to the cross-sectional area of the conductor 3 corresponding to the compressed portion 10 in a cross section perpendicular to the longitudinal direction of the conductor 3 when the terminal 5 with the conductor 3 inserted in the hollow portion 7 is compressed. That is, when the cross-sectional area of the conductor 3 corresponding to the non-compressed portion 11 of the terminal 5 is S (mm 2 ) and the cross-sectional area of the conductor 3 corresponding to the compressed portion 10 is D (mm 2 ), the compression ratio is calculated by the formula (D/S)×100. The above compression ratio can suppress a decrease in contact force between the conductor 3 and the terminal 5 caused by stress relaxation between the conductor 3 and the terminal 5, thereby suppressing an increase in the electrical resistance ratio of the terminal-attached electric wire 1. When a plurality of metal wires are used as the conductor 3, the cross-sectional area S of the conductor 3 can be calculated by multiplying the cross-sectional area of a single metal wire by the number of metal wires.

（端子付電線の製造方法）
端子付電線１を製造する際には、まず、電線２及び端子５を準備する準備工程を行う。この際、導体３に用いられる材料の引張強度が、端子５に用いられる材料の引張強度よりも大きくなる（例えば、２０ＭＰａ以上大きくなる）ように、導体３及び端子５の材料を選定する。例えば、端子５の材料としてＥＣＡｌを用いる場合には、これよりも引張強度が大きい材料としてＡｌ－Ｆｅ－Ｚｒ（引張強度差：２４ＭＰａ程度以上）、Ａｌ－Ｚｒ（引張強度差：４６ＭＰａ程度以上）を導体３の材料として用いることができる。また、導体３及び端子５の材料として、同じ材料を用いる場合であっても、製造工程中の熱処理条件や加工度等によっても材料の引張強度を調整することができる。 (Method of manufacturing electric wire with terminal)
When manufacturing the electric wire with terminal 1, a preparation step is first performed to prepare the electric wire 2 and the terminal 5. At this time, materials for the conductor 3 and the terminal 5 are selected so that the tensile strength of the material used for the conductor 3 is greater than that of the material used for the terminal 5 (for example, greater by 20 MPa or more). For example, when ECAl is used as the material for the terminal 5, materials having a greater tensile strength than ECAl, such as Al-Fe-Zr (tensile strength difference: about 24 MPa or more) and Al-Zr (tensile strength difference: about 46 MPa or more), can be used as the material for the conductor 3. Even when the same material is used for the conductor 3 and the terminal 5, the tensile strength of the material can be adjusted by the heat treatment conditions and the degree of processing during the manufacturing process.

準備工程では、電線２が有する絶縁層４を電線２の長さ方向の端末から所定の長さだけ取り除き、導体３の一部を露出させる。その後、端子５の筒状部６に形成された中空部７内に電線２の導体３の露出した一部を挿入する。 In the preparation process, a predetermined length of the insulating layer 4 of the electric wire 2 is removed from the longitudinal end of the electric wire 2 to expose a portion of the conductor 3. Then, the exposed portion 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.

その後、中空部７内に導体３を挿入させた状態で端子５の筒状部６を３回以上圧縮して端子に３つ以上の圧縮部１０を形成することにより、端子５を導体３に接続する接続工程を行う。ここでは、端子５の筒状部６を３回圧縮して端子に３つの圧縮部１０を形成する場合について説明する。 After that, the connection process is performed to connect the terminal 5 to the conductor 3 by compressing the tubular portion 6 of the terminal 5 three or more times while the conductor 3 is inserted in the hollow portion 7 to form three or more compressed portions 10 in the terminal. Here, we will explain the case where the tubular portion 6 of the terminal 5 is compressed three times to form three compressed portions 10 in the terminal.

接続工程では、まず、図２（ａ）に示すように、筒状部６における延在部８側の端部近傍（導体３の端部近傍）を圧縮ダイス２０により押圧し、筒状部６を圧縮して第１の圧縮部１０１を形成する。その後、図２（ｂ）に示すように、筒状部６における中空部７の開口側（絶縁層４側）の端部近傍を圧縮ダイス２０により押圧し、筒状部６を圧縮して第２の圧縮部１０２を形成する。 In the connection process, first, as shown in FIG. 2(a), the vicinity of the end of the tubular portion 6 on the extension portion 8 side (near the end of the conductor 3) is pressed by a compression die 20 to compress the tubular portion 6 and form a first compressed portion 101. Then, as shown in FIG. 2(b), the vicinity of the end of the tubular portion 6 on the opening side of the hollow portion 7 (the insulating layer 4 side) is pressed by a compression die 20 to compress the tubular portion 6 and form a second compressed portion 102.

その後、図２（ｃ）に示すように、第１の圧縮部１０１と第２の圧縮部１０２との中間の位置を圧縮ダイス２０により押圧し、筒状部６を圧縮して第３の圧縮部１０３を形成する。このように、接続工程は、既に形成した隣り合う第１及び第２の圧縮部１０１，１０２の間に新たな第３の圧縮部１０３を形成する工程を含む。第１の圧縮部１０１と第３の圧縮部１０３との間、及び、第３の圧縮部１０３と第２の圧縮部１０２との間には、それぞれ非圧縮部１１が形成されることになる。なお、ここでは、第１の圧縮部１０１を形成した後に第２の圧縮部１０２を形成する場合について説明したが、第２の圧縮部１０２を形成した後に第１の圧縮部１０１を形成してもよいし、第１の圧縮部１０１と第２の圧縮部１０２とを同時に形成してもよい。 2(c), the intermediate position between the first compressed portion 101 and the second compressed portion 102 is pressed by the compression die 20 to compress the cylindrical portion 6 to form the third compressed portion 103. In this way, the connection process includes a process of forming a new third compressed portion 103 between the adjacent first and second compressed portions 101 and 102 that have already been formed. Non-compressed portions 11 are formed between the first compressed portion 101 and the third compressed portion 103, and between the third compressed portion 103 and the second compressed portion 102. Note that, although the case where the second compressed portion 102 is formed after the first compressed portion 101 has been described here, the first compressed portion 101 may be formed after the second compressed portion 102 has been formed, or the first compressed portion 101 and the second compressed portion 102 may be formed simultaneously.

第１乃至第３の圧縮部１０１～１０３は、圧縮ダイス２０を用いて筒状部６の周方向の全周にわたって所定の圧力を加えることにより、筒状部６を圧縮変形（塑性変形）させることにより形成される。本実施の形態では、各圧縮部１０１～１０３は、導体３の長手方向（軸方向）に垂直な断面形状が六角形状となっている。各圧縮部１０１～１０３を形成することにより、端子５を導体３に圧縮接続して、端子付電線１を得ることができる。 The first to third compressed portions 101-103 are formed by compressing and deforming (plastically deforming) the cylindrical portion 6 by applying a predetermined pressure to the entire circumference of the cylindrical portion 6 using a compression die 20. In this embodiment, each of the compressed portions 101-103 has a hexagonal cross-sectional shape perpendicular to the longitudinal direction (axial direction) of the conductor 3. By forming each of the compressed portions 101-103, the terminal 5 can be compressed and connected to the conductor 3 to obtain the terminal-attached electric wire 1.

（圧縮部１０及び非圧縮部１１の詳細）
ここで、圧縮部１０を形成する際の端子５と導体３の挙動について検討する。図３（ａ）に示すように、端子５と導体３を圧縮ダイス２０により押圧すると、当該押圧の影響により、端子５（筒状部６）と導体３の両者が長手方向に伸びる。本実施の形態では、端子５に用いられる材料の引張強度が、導体３に用いられる材料の引張強度よりも小さいため、端子５の方が大きく変形し、端子５と導体３の伸び量の差はΔＬとなる。 (Details of Compression Unit 10 and Non-Compression Unit 11)
Here, the behavior of the terminal 5 and the conductor 3 when the compressed portion 10 is formed will be considered. As shown in Fig. 3(a) , when the terminal 5 and the conductor 3 are compressed by the compression die 20, both the terminal 5 (cylindrical portion 6) and the conductor 3 are stretched in the longitudinal direction due to the influence of the compression. In this embodiment, since the tensile strength of the material used for the terminal 5 is smaller than the tensile strength of the material used for the conductor 3, the terminal 5 is deformed more, and the difference in the amount of stretch between the terminal 5 and the conductor 3 is ΔL.

図３（ｂ）に示すように、第１及び第２の圧縮部１０１，１０２を形成した状態を初期状態とする。この状態で、第１及び第２の圧縮部１０１，１０２の中間の位置を圧縮ダイス２０により押圧すると、当該押圧の影響により、端子５が導体３よりΔＬ分長く伸びようとするため、第１および第２の圧縮部１０１，１０２で端子５と導体３との接触力（軸方向接触力）が発生し、両者の接触抵抗を低減できる。 As shown in FIG. 3(b), the initial state is the state in which the first and second compressed portions 101, 102 are formed. In this state, when the compression die 20 is pressed at the intermediate position between the first and second compressed portions 101, 102, the terminal 5 tends to stretch longer than the conductor 3 by ΔL due to the influence of the pressing force, and a contact force (axial contact force) between the terminal 5 and the conductor 3 is generated at the first and second compressed portions 101, 102, thereby reducing the contact resistance between the two.

この端子５と導体３の伸び量の差ΔＬの影響により、端子５と導体３との接触力（軸方向接触力）を大きくし、両者の接触抵抗を低減できる。経時変化により端子５と導体３との接触力は低減するが、本実施の形態では、径方向だけでなく長手方向（軸方向）にも端子５と導体３とがお互いに引っ張り合うような力、すなわち軸方向接触力を与えてやることで、径方向の接触力の緩みを軸方向接触力でサポートして、経時変化による端子５と導体３間の抵抗値の上昇を抑制している。 Due to the effect of the difference ΔL in the amount of stretch between the terminal 5 and the conductor 3, the contact force (axial contact force) between the terminal 5 and the conductor 3 can be increased, reducing the contact resistance between the two. The contact force between the terminal 5 and the conductor 3 decreases over time, but in this embodiment, a force that causes the terminal 5 and the conductor 3 to pull on each other not only in the radial direction but also in the longitudinal direction (axial direction), i.e., an axial contact force, is applied, so that the loosening of the radial contact force is supported by the axial contact force, suppressing the increase in the resistance value between the terminal 5 and the conductor 3 due to changes over time.

端子５と導体３との接触力（軸方向接触力）をより大きくし、接触抵抗をより低減するためには、伸びひずみをより大きくすればよい。伸びひずみεは、圧縮による伸びをΔＬとし、圧縮間隔（図３（ｂ）における長手方向に隣り合う圧縮部１０間の間隔、すなわち、非圧縮部１１の長手方向に沿った長さ）をＬとすると、下式
ε＝ΔＬ／Ｌ
で表すことができる。よって、圧縮による伸びΔＬを大きくし、圧縮間隔Ｌを小さくすることで、圧縮による伸びひずみを大きくして、端子５と導体３との接触力（軸方向接触力）をより大きくし、両者の接触抵抗をより低減することが可能になる。 In order to increase the contact force (axial contact force) between the terminal 5 and the conductor 3 and to reduce the contact resistance, the elongation strain should be increased. The elongation strain ε is expressed by the following formula: ε=ΔL/L, where ΔL is the elongation due to compression and L is the compression interval (the interval between adjacent compressed parts 10 in the longitudinal direction in FIG. 3(b) , i.e., the length of the non-compressed parts 11 along the longitudinal direction).
Therefore, by increasing the elongation ΔL due to compression and decreasing the compression interval L, the elongation strain due to compression is increased, the contact force (axial contact force) between the terminal 5 and the conductor 3 is increased, and the contact resistance between them can be further reduced.

圧縮による端子５と導体３の伸び量の差ΔＬを大きくするためには、圧縮部１０の長手方向に沿った長さである圧縮幅Ｗを導体断面積に応じた適切な幅にすればよい。圧縮幅Ｗは、使用する圧縮ダイス２０の大きさを調整することにより制御可能であり、圧縮間隔Ｌは、各圧縮部１０１～１０３の位置（導体３の長手方向に沿った位置）を調整することにより制御可能である。 To increase the difference ΔL in the amount of elongation between the terminal 5 and the conductor 3 due to compression, the compression width W, which is the length along the longitudinal direction of the compression portion 10, can be set to an appropriate width according to the cross-sectional area of the conductor. The compression width W can be controlled by adjusting the size of the compression die 20 used, and the compression interval L can be controlled by adjusting the position of each compression portion 101-103 (position along the longitudinal direction of the conductor 3).

本発明者らは、圧縮幅Ｗ及び圧縮間隔Ｌの影響を検討するため、実験を行った。まず、圧縮ダイス２０による圧縮荷重を１２ｔで一定とし、圧縮間隔Ｌ（ｍｍ）を７ｍｍで一定とし、圧縮幅Ｗ（ｍｍ）を変化させて実験を行った。実験では、導体断面積が５０ｍｍ２及び２５０ｍｍ２の導体３を有する電線２を用い、導体断面積が５０ｍｍ２の試料については圧縮比を６０％から９５％とし、導体断面積が２５０ｍｍ２の試料については圧縮比を７０％から９５％とした。導体断面積が５０ｍｍ２（直径約１０ｍｍ）の電線２を用いる場合には、端子５の筒状部６の内径Ｎ１０．２ｍｍ、厚さＡ３．０ｍｍであり、導体断面積が２５０ｍｍ２（直径約２３．６ｍｍ）の電線２を用いる場合には、端子５の筒状部６の内径Ｎ２１．８ｍｍ、厚さＡ５．２ｍｍである（以下の実験において、端子５は同じ大きさのものを用いる。）。圧縮幅Ｗ（ｍｍ）が大きくなると、導体３の圧縮比も大きくなる。 The present inventors conducted an experiment to examine the influence of the compression width W and the compression interval L. First, the experiment was conducted by setting the compression load by the compression die 20 constant at 12t, setting the compression interval L (mm) constant at 7mm, and changing the compression width W (mm ) . In the experiment, electric wires 2 having conductors 3 with conductor cross-sectional areas of 50 mm2 and 250 mm2 were used, and the compression ratio was set to 60% to 95% for the sample with the conductor cross-sectional area of 50 mm2, and 70% to 95% for the sample with the conductor cross-sectional area of 250 mm2 . When an electric wire 2 having a conductor cross-sectional area of 50 mm2 (diameter approximately 10 mm) is used, the inner diameter N of the cylindrical portion 6 of the terminal 5 is 10.2 mm and the thickness A is 3.0 mm, and when an electric wire 2 having a conductor cross-sectional area of 250 mm2 (diameter approximately 23.6 mm) is used, the inner diameter N of the cylindrical portion 6 of the terminal 5 is 21.8 mm and the thickness A is 5.2 mm (in the following experiments, terminals 5 of the same size are used). As the compressed width W (mm) increases, the compression ratio of the conductor 3 also increases.

（抵抗比増加率の測定）
次に、端子５を圧縮して導体３に接続された端子付電線１の延在部８が外部の接続相手側の端子にボルト等で接続されたことを想定し、延在部８にアルミニウム板１３をボルト（不図示）で固定することにより、高温環境暴露試験用試料を作製した。この高温環境暴露試験用試料を図４に示すように、２００℃に設定した恒温槽１４内に配置し、大気中で１００時間保持し、かつ１０時間毎に恒温槽から取り出してボルトの着脱を行う高温環境暴露試験を行った。高温環境暴露試験は通電試験環境を模擬した。なお、アルミニウム板を延在部８の下側に固定した場合を示したが、延在部８の上側に固定した場合でも、延在部８の下側に固定した場合と同様な結果が得られる。 (Measurement of resistance ratio increase rate)
Next, assuming that the terminal 5 is compressed and the extension portion 8 of the terminal-attached electric wire 1 connected to the conductor 3 is connected to an external terminal of the connection partner with a bolt or the like, an aluminum plate 13 is fixed to the extension portion 8 with a bolt (not shown) to prepare a high-temperature environment exposure test sample. As shown in FIG. 4, this high-temperature environment exposure test sample was placed in a thermostatic chamber 14 set at 200° C., held in the atmosphere for 100 hours, and taken out of the thermostatic chamber every 10 hours to perform a high-temperature environment exposure test in which the bolt was attached and detached. The high-temperature environment exposure test simulated the current flow test environment. Note that, although the case where the aluminum plate is fixed to the lower side of the extension portion 8 is shown, the same results as when the aluminum plate is fixed to the upper side of the extension portion 8 are obtained when the aluminum plate is fixed to the lower side of the extension portion 8.

高温環境暴露試験の前後での電気抵抗比を測定し、それら試験前後の電気抵抗比から抵抗比増加率を算出した。なお、抵抗比増加率（％）は、高温環境暴露試験の実施前と実施後（１００時間保持後）の導体３と端子５との間の電気抵抗比をそれぞれＲ１、Ｒ２とした場合に、（（Ｒ２－Ｒ１）／Ｒ１）×１００の式より算出することができる。 The electrical resistance ratio was measured before and after the high-temperature environmental exposure test, and the resistance ratio increase rate was calculated from the electrical resistance ratios before and after the test. The resistance ratio increase rate (%) can be calculated from the formula ((R2-R1)/R1) x 100, where R1 and R2 are the electrical resistance ratios between the conductor 3 and the terminal 5 before and after the high-temperature environmental exposure test (after 100 hours of exposure), respectively.

（電気抵抗比の測定）
ここで、端子付電線１の高温環境暴露試験実施前の電気抵抗比（初期抵抗比）Ｒ１の測定は、いわゆる４端子法により行った。４端子法について、図５を用いて説明する。 (Measurement of Electrical Resistance Ratio)
Here, the electrical resistance ratio (initial resistance ratio) R1 of the terminal-attached electric wire 1 before the high-temperature environment exposure test was measured by a so-called four-terminal method. The four-terminal method will be described with reference to FIG.

最初に、端子付電線１の全体に、定電流１Ａを供給し、点Ｐと点Ｑとの間の電気抵抗値Ｒ０を測定する。ここで、点Ｐは、端子５の筒状部６の一端であって、挿入された導体３の先端部に対応する部位である。点Ｑは、導体３のうち、端子５と接触していない部位である。点Ｓは、端子５の筒状部６の他端であって、導体３が挿入される入り口部分の部位である。初期抵抗比Ｒ１（％）は、点Ｐと点Ｓとの距離をＬ１とし、点Ｑと点Ｓとの距離をＬ２とし、導体３の単位長さ当たりの電気抵抗値をαとした場合に、｛（Ｒ０－Ｌ２×α）／（Ｌ１×α）｝×１００の式で算出される。導体３の単位長さ当たりの電気抵抗値は事前に測定するか、もしくはＬ２間の電気抵抗値を測定し、Ｌ２間の長さで除算し、単位長さ当たりの電気抵抗値として使用してもよい。 First, a constant current of 1A is supplied to the entire terminal-attached electric wire 1, and the electrical resistance value R0 between points P and Q is measured. Here, point P is one end of the cylindrical portion 6 of the terminal 5, and is a portion corresponding to the tip of the inserted conductor 3. Point Q is a portion of the conductor 3 that is not in contact with the terminal 5. Point S is the other end of the cylindrical portion 6 of the terminal 5, and is a portion of the entrance portion into which the conductor 3 is inserted. The initial resistance ratio R1 (%) is calculated by the formula {(R0-L2×α)/(L1×α)}×100, where L1 is the distance between points P and S, L2 is the distance between points Q and S, and α is the electrical resistance value per unit length of the conductor 3. The electrical resistance value per unit length of the conductor 3 may be measured in advance, or the electrical resistance value between L2 may be measured and divided by the length between L2 to use as the electrical resistance value per unit length.

また、高温環境暴露試験実施後の電気抵抗比Ｒ２の測定は、端子付電線１を室温まで冷却した後に、試験実施前の電気抵抗比（初期抵抗比）の値を測定するときと同様の上記４端子法で行った。具体的には、高温環境暴露試験実施後の端子付電線１の全体に、定電流１Ａを供給し、点Ｐと点Ｑとの間の電気抵抗値Ｒを測定する。導体３の単位長さ当たりの電気抵抗値αは、高温環境暴露試験実施前後で変化せず同じ値を用いる。電気抵抗比Ｒ２（％）は、｛（Ｒ－Ｌ２×α）／（Ｌ１×α）｝×１００の式で算出される。なお、抵抗値の測定は、日置電気株式会社製の抵抗計を使用した。高温環境暴露試験実施後（１００時間保持後）の電気抵抗比Ｒ２の実験結果を図６（ａ）に示す。 The electrical resistance ratio R2 after the high-temperature environmental exposure test was measured by the same four-terminal method as used to measure the electrical resistance ratio (initial resistance ratio) before the test after the terminal-attached electric wire 1 was cooled to room temperature. Specifically, a constant current of 1A was supplied to the entire terminal-attached electric wire 1 after the high-temperature environmental exposure test, and the electrical resistance value R between points P and Q was measured. The electrical resistance value α per unit length of the conductor 3 does not change before and after the high-temperature environmental exposure test, and the same value is used. The electrical resistance ratio R2 (%) is calculated by the formula {(R-L2×α)/(L1×α)}×100. The resistance value was measured using a resistance meter manufactured by Hioki Electric Industry Co., Ltd. The experimental results of the electrical resistance ratio R2 after the high-temperature environmental exposure test (after 100 hours of exposure) are shown in Figure 6(a).

図６（ａ）に示すように、導体３の断面積５０ｍｍ２とした試料では、圧縮幅Ｗが大きくなるほど電気抵抗比Ｒ２が低下するが、圧縮幅Ｗを大きくしすぎると電気抵抗比Ｒ２は増加に転じ、電気抵抗比Ｒ２が極小値となる圧縮幅Ｗが存在することがわかった。導体３の断面積２５０ｍｍ２とした試料では、圧縮幅Ｗが大きくなるほど電気抵抗比Ｒ２が低下することがわかった。 As shown in Fig. 6(a), in the sample with a cross-sectional area of the conductor 3 of 50 mm2, the electrical resistance ratio R2 decreases as the compression width W increases, but if the compression width W is made too large, the electrical resistance ratio R2 starts to increase, and it was found that there exists a compression width W at which the electrical resistance ratio R2 has a minimum value. In the sample with a cross-sectional area of the conductor 3 of 250 mm2, it was found that the electrical resistance ratio R2 decreases as the compression width W increases.

同様に、導体３の断面積５０ｍｍ２の圧縮幅Ｗを３ｍｍ、導体３の断面積を２５０ｍｍ２、圧縮幅Ｗを７ｍｍかつ圧縮ダイス２０による圧縮荷重を１２ｔで一定とし、圧縮間隔Ｌを変化させて高温環境暴露試験実施後の電気抵抗比Ｒ２を求めた。実験結果を図６（ｂ）に示す。導体３の断面積５０ｍｍ２とした試料では、圧縮間隔Ｌが大きくなるほど電気抵抗比Ｒ２が低下するが、圧縮間隔Ｌを大きくしすぎると電気抵抗比Ｒ２は増加に転じ、電気抵抗比Ｒ２が極小値となる圧縮間隔Ｌが存在することがわかった。導体３の断面積２５０ｍｍ２とした試料では、圧縮間隔Ｌが大きくなるほど電気抵抗比Ｒ２が低下することがわかった。また、図６（ｂ）では圧縮間隔Ｌがマイナスとなる領域も含まれているが、これは圧縮部１０がオーバーラップした状態を表している。図６（ｃ）にオーバーラップした状態を示す。圧縮ダイス２０により押圧した第１圧縮部１０１、第２圧縮部１０２、第３圧縮部１０３の圧縮幅Ｗが圧縮間隔Ｌだけ重なる。圧縮間隔Ｌは、第１圧縮部１０１の右端から第２圧縮部１０２の左端までの距離をＷＬとした場合に、Ｌ＝（ＷＬ－３Ｗ）／２で算出することができる。ここで、圧縮部１０がオーバーラップした状態の場合は、圧縮間隔Ｌの値はマイナスとなる。 Similarly, the electrical resistance ratio R2 after the high temperature environment exposure test was obtained by changing the compression interval L while keeping the compression width W of the conductor 3 at 50 mm2 , 3 mm, the cross-sectional area of the conductor 3 at 250 mm2, the compression width W at 7 mm, and the compression load by the compression die 20 at 12 t constant. The experimental results are shown in FIG. 6(b). In the sample with the cross-sectional area of the conductor 3 at 50 mm2, the electrical resistance ratio R2 decreases as the compression interval L increases, but if the compression interval L is made too large, the electrical resistance ratio R2 starts to increase, and it was found that there is a compression interval L at which the electrical resistance ratio R2 is a minimum value. In the sample with the cross-sectional area of the conductor 3 at 250 mm2 , it was found that the electrical resistance ratio R2 decreases as the compression interval L increases. In addition, FIG. 6(b) also includes an area where the compression interval L is negative, which represents a state in which the compressed portion 10 overlaps. FIG. 6(c) shows the overlapped state. The compression widths W of the first compressed portion 101, the second compressed portion 102, and the third compressed portion 103 pressed by the compression die 20 overlap by a compression interval L. The compression interval L can be calculated by L = (WL - 3W) / 2, where WL is the distance from the right end of the first compressed portion 101 to the left end of the second compressed portion 102. Here, when the compressed portions 10 are in an overlapping state, the value of the compression interval L is negative.

図７（ａ）は、横軸に圧縮幅Ｗ、縦軸に抵抗比増加率を示すグラフ図である。圧縮ダイス２０による圧縮荷重を１２ｔで一定とした上で、導体断面積５０ｍｍ２とした試料、及び導体断面積を２５０ｍｍ２とした試料の両者とも、圧縮間隔Ｌを７ｍｍと一定とし、圧縮幅Ｗを変化させて高温環境暴露試験の実施前と実施後の抵抗比増加率を求めた。図７（ａ）に示すように、両試料とも、基本的に圧縮幅Ｗが大きくなるほど抵抗比増加率が低下するが、圧縮幅Ｗを大きくしすぎると抵抗比増加率は増加に転じ、抵抗比増加率が極小値となる圧縮幅Ｗが存在することがわかった。 7(a) is a graph showing the compression width W on the horizontal axis and the resistance ratio increase rate on the vertical axis. The compression load by the compression die 20 was fixed at 12t, and the compression interval L was fixed at 7mm for both the sample with a conductor cross-sectional area of 50 mm2 and the sample with a conductor cross-sectional area of 250 mm2 , and the resistance ratio increase rate was obtained before and after the high temperature environmental exposure test by changing the compression width W. As shown in FIG. 7(a), for both samples, the resistance ratio increase rate basically decreases as the compression width W increases, but if the compression width W is made too large, the resistance ratio increase rate turns to an increase, and it was found that there is a compression width W at which the resistance ratio increase rate becomes a minimum value.

図７（ｂ）は、横軸に圧縮間隔Ｌ、縦軸に抵抗比増加率を示すグラフ図である。同様に、圧縮ダイス２０による圧縮荷重を（１２ｔ）で一定とした上で、導体３の断面積５０ｍｍ２の圧縮幅Ｗを３ｍｍ、導体３の断面積２５０ｍｍ２の圧縮幅Ｗを７ｍｍで一定とし、圧縮間隔Ｌを変化させて高温環境暴露試験の実施前と実施後の抵抗比増加率を求めた。 7B is a graph showing the compression interval L on the horizontal axis and the resistance ratio increase rate on the vertical axis. Similarly, the compression load by the compression die 20 was kept constant at (12t), the compression width W of the conductor 3 with a cross-sectional area of 50 mm2 was kept constant at 3 mm, and the compression width W of the conductor 3 with a cross-sectional area of 250 mm2 was kept constant at 7 mm, and the compression interval L was changed to obtain the resistance ratio increase rate before and after the high temperature environmental exposure test.

図７（ｂ）に示すように、導体３の断面積を５０ｍｍ２とした試料、及び導体３の断面積を２５０ｍｍ２とした試料の両者とも、基本的に圧縮間隔Ｌが小さくなるほど抵抗比増加率が低下するが、圧縮間隔Ｌを小さくしすぎると抵抗比増加率は増加に転じ、抵抗比増加率が極小値となる圧縮間隔Ｌが存在することがわかった。また、図７（ｂ）では圧縮間隔Ｌがマイナスとなる領域も含まれているが、これは圧縮部１０がオーバーラップした状態を表している。図７（ｂ）のオーバーラップした状態に関しても、図６（ｃ）に図示したオーバーラップした状態と同様な状態である。圧縮ダイス２０により押圧した第１圧縮部１０１、第２圧縮部１０２、第３圧縮部１０３の圧縮幅Ｗが圧縮間隔Ｌだけ重なる。 As shown in FIG. 7(b), in both the sample with the cross-sectional area of the conductor 3 of 50 mm2 and the sample with the cross-sectional area of the conductor 3 of 250 mm2, the resistance ratio increase rate basically decreases as the compression interval L becomes smaller, but if the compression interval L is made too small, the resistance ratio increase rate turns to increase, and it was found that there exists a compression interval L where the resistance ratio increase rate becomes a minimum value. Also, FIG. 7(b) includes an area where the compression interval L is negative, which represents a state where the compressed parts 10 overlap. The overlapped state in FIG. 7(b) is also in the same state as the overlapped state shown in FIG. 6(c). The compression widths W of the first compressed part 101, the second compressed part 102, and the third compressed part 103 pressed by the compression die 20 overlap by the compression interval L.

図８（ａ）は、横軸を導体３の断面積Ｓ（ｍｍ２）、縦軸を圧縮幅Ｗ（ｍｍ）としたグラフ図である。また、図８（ｂ）は、横軸を導体３の断面積Ｓ（ｍｍ２）、縦軸を圧縮間隔Ｌ（ｍｍ）としたグラフ図である。ここでは、導体３の断面積が３８ｍｍ２以上５００ｍｍ２以下の条件下において、高温環境暴露試験後の電気抵抗比Ｒ２が１００％以下であることを満たす圧縮幅Ｗ（ｍｍ）と圧縮間隔Ｌ（ｍｍ）を見出した。その結果、圧縮幅Ｗ（ｍｍ）は下記に示す式（１）を、圧縮間隔Ｌ（ｍｍ）は下記に示す式（２）を満たす場合に、高温環境暴露試験後の電気抵抗比Ｒ２が１００％以下であることがわかった。
０．０１×Ｓ＋２．５≦Ｗ≦０．０７×Ｓ＋３．５ ・・・（１）
－１．０≦Ｌ≦０．１４５×Ｓ＋３．７５ ・・・（２）
式（１）で示す領域は図８（ａ）の斜線部である。同様に、式（２）で示す領域は図８（ｂ）の斜線部である。例えば、導体３の断面積Ｓが５０ｍｍ２の場合、圧縮幅Ｗは３ｍｍ以上７ｍｍ以下、圧縮間隔Ｌは－１ｍｍ以上１１ｍｍ以下を選択することが可能であり、上記領域内の圧縮幅Ｗおよび圧縮間隔Ｌを使用することにより、高温環境暴露試験後の電気抵抗比Ｒ２は１００％以下となる。 8(a) is a graph in which the horizontal axis is the cross-sectional area S ( mm2 ) of the conductor 3 and the vertical axis is the compression width W (mm). Also, FIG. 8(b) is a graph in which the horizontal axis is the cross-sectional area S ( mm2 ) of the conductor 3 and the vertical axis is the compression interval L (mm). Here, under the condition that the cross-sectional area of the conductor 3 is 38 mm2 or more and 500 mm2 or less, the compression width W (mm) and compression interval L (mm) that satisfy the electrical resistance ratio R2 after the high temperature environmental exposure test being 100% or less were found. As a result, it was found that the electrical resistance ratio R2 after the high temperature environmental exposure test is 100% or less when the compression width W (mm) satisfies the following formula (1) and the compression interval L (mm) satisfies the following formula (2).
0.01×S+2.5≦W≦0.07×S+3.5...(1)
-1.0≦L≦0.145×S+3.75...(2)
The region indicated by formula (1) is the shaded area in Fig. 8(a). Similarly, the region indicated by formula (2) is the shaded area in Fig. 8(b). For example, when the cross-sectional area S of the conductor 3 is 50 mm2 , it is possible to select the compression width W to be 3 mm or more and 7 mm or less, and the compression interval L to be -1 mm or more and 11 mm or less. By using the compression width W and compression interval L within the above range, the electrical resistance ratio R2 after the high temperature environment exposure test becomes 100% or less.

さらに良好な圧縮幅Ｗ（ｍｍ）と圧縮間隔Ｌ（ｍｍ）を見出した。下記、（１）、（２）の条件をいずれも満たす場合である。上述した高温環境暴露試験後の電気抵抗比Ｒ２が１００％以下となる目標仕様を満たす圧縮幅Ｗおよび圧縮間隔Ｌの場合より選択できる範囲は小さくなる。
（１）高温環境暴露試験後の電気抵抗比Ｒ２が１００％以下であること。
（２）抵抗比増加率２０％以下であること。 Further, a more favorable compression width W (mm) and compression interval L (mm) were found when both of the following conditions (1) and (2) were satisfied. The range of options is narrower than that of the compression width W and compression interval L that satisfy the target specification in which the electrical resistance ratio R2 after the high-temperature environmental exposure test is 100% or less.
(1) The electrical resistance ratio R2 after a high-temperature environmental exposure test is 100% or less.
(2) The resistance ratio increase rate is 20% or less.

図９（ａ）は、横軸を導体３の断面積Ｓ（ｍｍ２）、縦軸を圧縮幅Ｗ（ｍｍ）としたグラフ図である。また、図９（ｂ）は、横軸を導体３の断面積Ｓ（ｍｍ２）、縦軸を圧縮間隔Ｌ（ｍｍ）としたグラフ図である。ここでは、導体３の断面積が３８ｍｍ２以上５００ｍｍ２以下の条件下において、（１）高温環境暴露試験後の電気抵抗比Ｒ２が１００％以下であること、（２）高温環境試験後の抵抗比増加率が２０％以下であることの両方の目標仕様を満たす圧縮幅Ｗ（ｍｍ）と圧縮間隔Ｌ（ｍｍ）を見出した。その結果、圧縮幅Ｗ（ｍｍ）は下記に示す式（３）を、圧縮間隔Ｌ（ｍｍ）は下記に示す式（４）を満たす場合に、（１）高温環境暴露試験後の電気抵抗比Ｒ２が１００％以下であること、（２）高温環境暴露試験前後の抵抗比増加率が２０％以下であることの両方の目標仕様を満たすことがわかった。
０．０１×Ｓ＋２．５≦Ｗ≦０．０３５×Ｓ＋４．２５ ・・・（３）
－１．０≦Ｌ≦０．０９×Ｓ＋４．５ ・・・（４）
式（３）で示す領域は図９（ａ）の斜線部である。同様に、式（４）で示す領域は図９（ｂ）の斜線部である。例えば、導体３の断面積Ｓが５０ｍｍ２の場合、圧縮幅Ｗは３ｍｍ以上６ｍｍ以下、圧縮間隔Ｌは－１ｍｍ以上９ｍｍ以下を選択することが可能であり、上記領域内の圧縮幅Ｗおよび圧縮間隔Ｌを使用することにより、高温環境暴露試験後の電気抵抗比Ｒ２は１００％以下、且つ抵抗比増加率は２０％以下となる。 FIG. 9(a) is a graph with the horizontal axis being the cross-sectional area S (mm 2 ) of the conductor 3 and the vertical axis being the compression width W (mm). FIG. 9(b) is a graph with the horizontal axis being the cross-sectional area S (mm 2 ) of the conductor 3 and the vertical axis being the compression interval L (mm). Here, under the condition that the cross-sectional area of the conductor 3 is 38 mm 2 or more and 500 mm 2 or less, a compression width W (mm) and a compression interval L (mm) that satisfy both target specifications of (1) the electrical resistance ratio R2 after the high-temperature environmental exposure test being 100% or less and (2) the resistance ratio increase rate after the high-temperature environmental exposure test being 20% or less were found. As a result, it was found that when the compression width W (mm) satisfies the following formula (3) and the compression interval L (mm) satisfies the following formula (4), both target specifications of (1) the electrical resistance ratio R2 after the high-temperature environmental exposure test being 100% or less and (2) the resistance ratio increase rate before and after the high-temperature environmental exposure test being 20% or less are satisfied.
0.01×S+2.5≦W≦0.035×S+4.25 (3)
-1.0≦L≦0.09×S+4.5...(4)
The region indicated by formula (3) is the shaded area in Fig. 9(a). Similarly, the region indicated by formula (4) is the shaded area in Fig. 9(b). For example, when the cross-sectional area S of the conductor 3 is 50 mm2 , it is possible to select the compression width W to be 3 mm or more and 6 mm or less, and the compression interval L to be -1 mm or more and 9 mm or less. By using the compression width W and compression interval L within the above range, the electrical resistance ratio R2 after the high temperature environmental exposure test is 100% or less, and the resistance ratio increase rate is 20% or less.

以上の結果より、式（１）、式（２）を満たすように圧縮幅Ｗ及び圧縮間隔Ｌを調整して圧縮部１０を形成することで、高温環境暴露試験後の電気抵抗比Ｒ２が小さく、上述の目標仕様を満たす端子付電線１が得られる。さらに好ましくは、式（３）、式（４）を満たすように圧縮幅Ｗ及び圧縮間隔Ｌを調整して圧縮部１０を形成することで、高温環境暴露試験後の電気抵抗比Ｒ２及び抵抗比増加率が小さく、上述の目標仕様を満たす端子付電線１が得られる。 From the above results, by forming the compressed portion 10 by adjusting the compression width W and compression interval L so as to satisfy formulas (1) and (2), a terminal-attached electric wire 1 having a small electrical resistance ratio R2 after the high-temperature environmental exposure test and satisfying the above-mentioned target specifications can be obtained. More preferably, by forming the compressed portion 10 by adjusting the compression width W and compression interval L so as to satisfy formulas (3) and (4), a terminal-attached electric wire 1 having a small electrical resistance ratio R2 and resistance ratio increase rate after the high-temperature environmental exposure test and satisfying the above-mentioned target specifications can be obtained.

すなわち、本実施の形態に係る端子付電線１は、圧縮幅Ｗ（ｍｍ）と圧縮間隔Ｌ（ｍｍ）が、下式（１），（２）の導体３の断面積Ｓ（ｍｍ２）との関係式で表される。
０．０１×Ｓ＋２．５≦Ｗ≦０．０７×Ｓ＋３．５ ・・・（１）
－１．０≦Ｌ≦０．１４５×Ｓ＋３．７５ ・・・（２）
この範囲内においても、圧縮幅Ｗと圧縮間隔Ｌによっては抵抗比増加率が２０％を超えることがあり、上述の目標仕様における（１）、（２）の両方満たすために、より好ましくは、圧縮幅Ｗ（ｍｍ）と圧縮間隔Ｌ（ｍｍ）が、下式（３），（４）の導体断面積Ｓ（ｍｍ２）との関係式であるとよい。
０．０１×Ｓ＋２．５≦Ｗ≦０．０３５×Ｓ＋４．２５ ・・・（３）
－１．０≦Ｌ≦０．０９×Ｓ＋４．５ ・・・（４） That is, in the terminal-attached electric wire 1 according to this embodiment, the compression width W (mm) and compression interval L (mm) are expressed by the relationship with the cross-sectional area S (mm 2 ) of the conductor 3 in the following equations (1) and (2).
0.01×S+2.5≦W≦0.07×S+3.5...(1)
-1.0≦L≦0.145×S+3.75...(2)
Even within this range, the resistance ratio increase rate may exceed 20% depending on the compression width W and compression interval L. In order to satisfy both (1) and (2) in the above-mentioned target specifications, it is more preferable that the compression width W (mm) and compression interval L (mm) are related to the conductor cross-sectional area S ( mm2 ) by the following equations (3) and (4).
0.01×S+2.5≦W≦0.035×S+4.25 (3)
-1.0≦L≦0.09×S+4.5...(4)

なお、例えば、導体３の外径が小さい場合に、圧縮幅Ｗを小さくし過ぎると、目標仕様を満たすことができないおそれが生じる。導体３の導体断面積Ｓは、例えば、３８ｍｍ２以上５００ｍｍ２以下であるとよい。 For example, when the outer diameter of the conductor 3 is small, if the compression width W is too small, the target specifications may not be satisfied. The conductor cross-sectional area S of the conductor 3 is preferably, for example, 38 mm2 or more and 500 mm2 or less.

（実施の形態の作用及び効果）
以上説明したように、本実施の形態に係る端子付電線１では、導体３に用いられる材料の引張強度が、端子５に用いられる材料の引張強度よりも大きく、端子５は、導体３の長手方向に３つ以上の圧縮部１０を有し、導体３の断面積をＳ（ｍｍ２）とし、圧縮部１０の長手方向に沿った長さである圧縮幅をＷ（ｍｍ）とし、隣り合う圧縮部１０間に位置する非圧縮部１１の長手方向に沿った長さである圧縮間隔をＬ（ｍｍ）とした場合に、圧縮幅Ｗ（ｍｍ）の値、圧縮間隔Ｌ（ｍｍ）の値が、それぞれ下式（１），（２）
０．０１×Ｓ＋２．５≦Ｗ≦０．０７×Ｓ＋３．５ ・・・（１）
－１．０≦Ｌ≦０．１４５×Ｓ＋３．７５ ・・・（２）
の関係式を満足する。さらに好ましくは、圧縮幅Ｗ（ｍｍ）の値、圧縮間隔Ｌ（ｍｍ）の
値が、それぞれ下式（３），（４）
０．０１×Ｓ＋２．５≦Ｗ≦０．０３５×Ｓ＋４．２５ ・・・（３）
－１．０≦Ｌ≦０．０９×Ｓ＋４．５ ・・・（４）
の関係式を満足する。 (Functions and Effects of the Embodiments)
As described above, in the terminal-attached electric wire 1 according to the present embodiment, the tensile strength of the material used for the conductor 3 is greater than the tensile strength of the material used for the terminal 5, the terminal 5 has three or more compressed portions 10 in the longitudinal direction of the conductor 3, and when the cross-sectional area of the conductor 3 is S ( mm2 ), the compressed width which is the length along the longitudinal direction of the compressed portion 10 is W (mm), and the compressed interval which is the length along the longitudinal direction of the non-compressed portion 11 located between adjacent compressed portions 10 is L (mm), the value of the compressed width W (mm) and the value of the compressed interval L (mm) are expressed by the following formulas (1) and (2), respectively:
0.01×S+2.5≦W≦0.07×S+3.5...(1)
-1.0≦L≦0.145×S+3.75...(2)
More preferably, the value of the compression width W (mm) and the value of the compression interval L (mm) satisfy the following relations (3) and (4), respectively.
0.01×S+2.5≦W≦0.035×S+4.25 (3)
-1.0≦L≦0.09×S+4.5...(4)
The following relation is satisfied.

このように構成することで、導体３のサイズ（外径や導体断面積）によらず、導体３と端子５との間の接触力（軸方向接触力）を高めることが可能になり、導体３と端子５との間の電気抵抗を低く維持して、電気的接続を十分確保できる端子付電線１を実現できる。 By configuring it in this way, it is possible to increase the contact force (axial contact force) between the conductor 3 and the terminal 5 regardless of the size of the conductor 3 (outer diameter and conductor cross-sectional area), and it is possible to realize a terminal-attached electric wire 1 that maintains low electrical resistance between the conductor 3 and the terminal 5 and ensures sufficient electrical connection.

（実施の形態のまとめ）
次に、以上説明した実施の形態から把握される技術思想について、実施の形態における符号等を援用して記載する。ただし、以下の記載における各符号等は、特許請求の範囲における構成要素を実施の形態に具体的に示した部材等に限定するものではない。 (Summary of the embodiment)
Next, the technical ideas grasped from the above-described embodiment will be described by using the reference numerals and the like in the embodiment. However, the reference numerals and the like in the following description do not limit the components in the claims to the members and the like specifically shown in the embodiment.

［１］導体（３）、及び前記導体（３）を被覆する絶縁層（４）を含む電線（２）と、前記電線（２）の端部で露出する前記導体（３）が挿入される中空部（７）を有し、前記中空部（７）内に前記導体（３）が挿入された状態で前記中空部（７）が圧縮されることにより、前記導体（３）に接続される端子（５）と、を備えた端子付電線（１）であって、前記導体（３）に用いられる材料の引張強度は、前記端子（５）に用いられる材料の引張強度よりも大きく、前記端子（５）は、前記導体（３）の長手方向に３つ以上の圧縮部（１０）を有し、前記導体（３）の断面積をＳ（ｍｍ２）とし、前記圧縮部（１０）の前記長手方向に沿った長さである圧縮幅をＷ（ｍｍ）とし、隣り合う前記圧縮部（１０）間に位置する非圧縮部（１１）の前記長手方向に沿った長さである圧縮間隔をＬ（ｍｍ）とした場合に、前記圧縮幅Ｗの値、前記圧縮間隔Ｌの値が、それぞれ下式（１），（２）
０．０１×Ｓ＋２．５≦Ｗ≦０．０７×Ｓ＋３．５ ・・・（１）
－１．０≦Ｌ≦０．１４５×Ｓ＋３．７５ ・・・（２）
の関係式を満足する、端子付電線（１）。 [1] A terminal-attached electric wire (1) comprising: an electric wire (2) including a conductor (3) and an insulating layer (4) covering the conductor (3); and a terminal (5) having a hollow portion (7) into which the conductor (3) exposed at an end of the electric wire (2) is inserted, the hollow portion (7) being compressed with the conductor (3) inserted into the hollow portion (7) to be connected to the conductor (3), wherein the tensile strength of a material used for the conductor (3) is greater than the tensile strength of a material used for the terminal (5), the terminal (5) has three or more compressed portions (10) in the longitudinal direction of the conductor (3), and the cross-sectional area of the conductor (3) is S ( mm2 ), a compression width that is the length of the compressed portion (10) along the longitudinal direction is W (mm), and a compression interval that is the length of a non-compressed portion (11) located between adjacent compressed portions (10) along the longitudinal direction is L (mm), the value of the compression width W and the value of the compression interval L are respectively expressed by the following formulas (1) and (2):
0.01×S+2.5≦W≦0.07×S+3.5...(1)
-1.0≦L≦0.145×S+3.75...(2)
A terminal-attached electric wire (1) that satisfies the following relational expression.

［２］前記圧縮幅Ｗの値、前記圧縮間隔Ｌの値が、それぞれ下式（３），（４）
０．０１×Ｓ＋２．５≦Ｗ≦０．０３５×Ｓ＋４．２５ ・・・（３）
－１．０≦Ｌ≦０．０９×Ｓ＋４．５ ・・・（４）
の関係式を満足する、［１］に記載の端子付電線（１）。 [2] The value of the compression width W and the value of the compression interval L are expressed by the following formulas (3) and (4), respectively.
0.01×S+2.5≦W≦0.035×S+4.25 (3)
-1.0≦L≦0.09×S+4.5...(4)
The terminal-attached electric wire (1) according to [1], which satisfies the following relational expression.

［３］前記端子（５）は、アルミニウム材料からなり、前記導体（３）は、前記端子（５）に用いられるアルミニウム材料よりも引張強度が大きいアルミニウム材料からなる、［１］または［２］に記載の端子付電線（１）。 [3] The terminal (5) is made of an aluminum material, and the conductor (3) is made of an aluminum material having a greater tensile strength than the aluminum material used for the terminal (5). The terminal-attached electric wire (1) described in [1] or [2].

［４］導体（３）、及び前記導体（３）を被覆する絶縁層（４）を含む電線（２）と、前記電線（２）の端部で露出する前記導体（３）が挿入される中空部（７）を有し、前記中空部（７）内に前記導体（３）が挿入された状態で前記中空部（７）が圧縮されることにより、前記導体（３）に接続される端子（５）と、を備えた端子付電線（１）の製造方法であって、前記導体（３）に用いられる材料の引張強度が、前記端子（５）に用いられる材料の引張強度よりも大きい前記電線（２）及び前記端子（５）を準備する準備工程と、前記中空部（７）内に前記電線（２）の端部で露出する前記導体（３）を挿入させた状態で前記端子（５）を３回以上圧縮して前記端子（５）に３つ以上の圧縮部（１０）を形成することにより、前記端子（５）を前記導体（３）に接続する接続工程と、を備え、前記接続工程は、既に形成した隣り合う圧縮部（１０）の間に新たな圧縮部（１０）を形成する工程を含むと共に、前記導体（３）の断面積をＳ（ｍｍ２）とし、前記圧縮部（１０）の前記長手方向に沿った長さである圧縮幅をＷ（ｍｍ）とし、隣り合う前記圧縮部（１０）間に位置する非圧縮部（１１）の前記長手方向に沿った長さである圧縮間隔をＬ（ｍｍ）とした場合に、前記圧縮幅Ｗの値、前記圧縮間隔Ｌの値が、それぞれ下式（１），（２）
０．０１×Ｓ＋２．５≦Ｗ≦０．０７×Ｓ＋３．５ ・・・（１）
－１．０≦Ｌ≦０．１４５×Ｓ＋３．７５ ・・・（２）
の関係式を満足するように前記圧縮部（１０）を形成する、端子付電線の製造方法。 [4] A method for manufacturing a terminal-attached electric wire (1) including an electric wire (2) including a conductor (3) and an insulating layer (4) covering the conductor (3), and a terminal (5) having a hollow portion (7) into which the conductor (3) exposed at an end of the electric wire (2) is inserted, the hollow portion (7) being compressed with the conductor (3) inserted into the hollow portion (7), wherein the tensile strength of a material used for the conductor (3) is greater than the tensile strength of a material used for the terminal (5). The method includes a preparation step of preparing the electric wire (2) and the terminal (5), and a connection step of compressing the terminal (5) three or more times while the conductor (3) exposed at the end of the electric wire (2) is inserted into the hollow portion (7) to form three or more compressed portions (10) in the terminal (5), thereby connecting the terminal (5) to the conductor (3), wherein the connection step includes a step of forming a new compressed portion (10) between adjacent compressed portions (10) that have already been formed, and the value of the compressed width W and the value of the compressed interval L are expressed by the following formulas (1) and (2), respectively, where S ( mm2 ) is the cross-sectional area of the conductor (3), W (mm) is the compressed width that is the length of the compressed portion (10) along the longitudinal direction, and L (mm) is the compressed interval that is the length of a non-compressed portion (11) located between adjacent compressed portions (10).
0.01×S+2.5≦W≦0.07×S+3.5...(1)
-1.0≦L≦0.145×S+3.75...(2)
The method for manufacturing an electric wire with a terminal, wherein the compressed portion (10) is formed so as to satisfy the following relational expression.

以上、本発明の実施の形態を説明したが、上記に記載した実施の形態は特許請求の範囲に係る発明を限定するものではない。また、実施の形態の中で説明した特徴の組合せの全てが発明の課題を解決するための手段に必須であるとは限らない点に留意すべきである。また、本発明は、その趣旨を逸脱しない範囲で適宜変形して実施することが可能である。 Although the embodiments of the present invention have been described above, the invention according to the claims is not limited to the embodiments described above. It should be noted that not all of the combinations of features described in the embodiments are necessarily essential to the means for solving the problems of the invention. The present invention can be modified as appropriate without departing from the spirit of the invention.

１…端子付電線
２…電線
３…導体
４…絶縁層
５…端子
６…筒状部
７…中空部
８…延在部
９…ボルト孔
１０…圧縮部
１０１…第１の圧縮部
１０２…第２の圧縮部
１０３…第３の圧縮部
１１…非圧縮部































 REFERENCE SIGNS LIST 1... terminal-attached electric wire 2... electric wire 3... conductor 4... insulating layer 5... terminal 6... cylindrical portion 7... hollow portion 8... extension portion 9... bolt hole 10... compressed portion 101... first compressed portion 102... second compressed portion 103... third compressed portion 11... non-compressed portion

Claims (3)

導体、及び前記導体を被覆する絶縁層を含む電線と、
前記電線の端部で露出する前記導体が挿入される筒状部を有し、前記筒状部内に前記導体が挿入された状態で前記筒状部が圧縮されることにより、前記導体に接続される端子と、
を備えた端子付電線の製造方法であって、
前記導体に用いられる材料の引張強度が、前記端子に用いられる材料の引張強度よりも大きい前記電線及び前記端子を準備する準備工程と、
前記筒状部内に前記電線の端部で露出する前記導体を挿入させた状態で前記端子を３回以上圧縮して前記端子に３つ以上の圧縮部を形成することにより、前記端子を前記導体に接続する接続工程と、を備え、
前記接続工程は、第１の圧縮部および第２の圧縮部を形成したあとに、当該第１および第２の圧縮部の間に第３の圧縮部を形成する工程を含み、該工程において、前記導体の断面積をＳ（ｍｍ２）とし、前記第１乃至第３の圧縮部の前記長手方向に沿った長さである圧縮幅をＷ（ｍｍ）とし、前記第１乃至第３の圧縮部間に位置する非圧縮部の前記長手方向に沿った長さである圧縮間隔をＬ（ｍｍ）とした場合に、前記圧縮幅Ｗの値、前記圧縮間隔Ｌの値が、それぞれ下式（１），（２），（３），（４）
０．０１×Ｓ＋２．５≦Ｗ≦０．０７×Ｓ＋３．５ ・・・（１）
－１．０≦Ｌ≦０．１４５×Ｓ＋３．７５ ・・・（２）
０．０１×Ｓ＋２．５≦Ｗ≦０．０３５×Ｓ＋４．２５ ・・・（３）
－１．０≦Ｌ≦０．０９×Ｓ＋４．５ ・・・（４）
の関係式を満足するように、前記第３の圧縮部を形成し、
前記第３の圧縮部は、前記筒状部の周方向の全周にわたって圧縮変形させた圧縮変形部である、
端子付電線の製造方法。 An electric wire including a conductor and an insulating layer covering the conductor;
a terminal having a tubular portion into which the conductor exposed at an end of the electric wire is inserted, the tubular portion being compressed with the conductor inserted into the tubular portion to be connected to the conductor;
A method for manufacturing an electric wire with a terminal, comprising:
a preparation step of preparing the electric wire and the terminal, the tensile strength of a material used for the conductor being greater than the tensile strength of a material used for the terminal;
a connecting step of inserting the conductor exposed at the end of the electric wire into the cylindrical portion, compressing the terminal three or more times to form three or more compressed portions in the terminal, thereby connecting the terminal to the conductor,
The connecting step includes a step of forming a first compressed portion and a second compressed portion, and then forming a third compressed portion between the first and second compressed portions, in which, when a cross-sectional area of the conductor is S ( mm2 ), a compressed width which is a length of the first to third compressed portions along the longitudinal direction is W (mm), and a compressed interval which is a length of a non-compressed portion located between the first to third compressed portions along the longitudinal direction is L (mm), the value of the compressed width W and the value of the compressed interval L are respectively expressed by the following formulas (1), (2) , (3), and (4):
0.01×S+2.5≦W≦0.07×S+3.5...(1)
-1.0≦L≦0.145×S+3.75...(2)
0.01×S+2.5≦W≦0.035×S+4.25 (3)
-1.0≦L≦0.09×S+4.5...(4)
The third compression portion is formed so as to satisfy the relational expression:
The third compressed portion is a compressed and deformed portion that is compressed and deformed over the entire circumferential direction of the cylindrical portion.
A manufacturing method for electric wire with terminal. 前記端子は、アルミニウム材料からなり、
前記導体は、前記端子に用いられるアルミニウム材料よりも引張強度が大きいアルミニウム材料からなる、
請求項１に記載の端子付電線の製造方法。 the terminal is made of an aluminum material;
The conductor is made of an aluminum material having a tensile strength greater than that of an aluminum material used for the terminal.
A method for producing the electric wire with terminal according to claim 1 . 前記端子の前記筒状部の断面積をＴ（ｍｍ２）とした場合に、当該筒状部の断面積Ｔと前記導体の断面積Ｓとから求められるＴ／Ｓは１．０以上３．０以下である、
請求項１または２に記載の端子付電線の製造方法。

 When the cross-sectional area of the cylindrical portion of the terminal is T (mm 2 ), T/S calculated from the cross-sectional area T of the cylindrical portion and the cross-sectional area S of the conductor is 1.0 or more and 3.0 or less.
A method for producing an electric wire with a terminal according to claim 1 or 2 .
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