Method for manufacturing electric wire

• US 10,453,581 B2
• Filed: 09/11/2017
• Issued: 10/22/2019
• Est. Priority Date: 10/25/2010
• Status: Active Grant

• Current Assignee: Yazaki Corporation
• Original Assignee: Yazaki Corporation
• Inventors: Ishibashi, Kenichi, Mochizuki, Kazumi, Kondo, Yasunobu
• Primary Examiner(s): Vo, Peter Dungba
• Assistant Examiner(s): Carley, Jeffrey T
• Application Number:
  US15/700,963
• Publication Number:
  US 20170372811A1
• Time in Patent Office: 771 Days
• CPC Class Codes: C22C 21/00 Alloys based on aluminium
• CPC Class Codes: C22F 1/04 of aluminium or alloys based thereon
• CPC Class Codes: H01B 1/023 Alloys based on aluminium
• CPC Class Codes: H01B 7/0009 Details relating to the conductive cores

Abstract

A method of manufacturing an electric wire includes providing wire rods made of aluminum alloy, forming aluminum alloy wires by drawing the wire rods to a final wire diameter without heat treatment, and forming a conductor by twisting together the aluminum alloy wires with a twist pitch of 7 to 36 times a predetermined diameter of the conductor. A composition of the aluminum alloy contains 0.1 to less than 1.0% by weight of Fe, 0 to 0.08% by weight of Zr, 0.02 to 2.8% by weight of Si, and 0.05 to 0.63% by weight of Cu and/or 0.03 to 0.45% by weight of Mg, with the remainder being Al and unavoidable impurities.

Claims

1. A method for manufacturing an electric wire comprising a conductor, the method comprising:

providing wire rods made of aluminum alloy, a composition of the aluminum alloy containing a predetermined amount of Al, 0.1 to less than 1.0% by weight of Fe, 0 to 0.08% by weight of Zr, 0.02 to 2.8% by weight of Si, and at least one of Cu and Mg, where the amount of Cu is 0.05 to 0.63% by weight and the amount of Mg is 0.03 to 0.45% by weight;

forming aluminum alloy wires by drawing, without heat treatment, the wire rods to a final wire diameter; and

forming the conductor by twisting the aluminum alloy wires together with a twist pitch of 7 to 36 times a predetermined diameter of the conductor,

wherein the aluminum alloy wires have an elongation of 10% or more after forming the aluminum alloy wires.

2. The method according to claim 1, wherein the final wire diameter is 0.32 mm.

3. The method according to claim 1, wherein the aluminum alloy wires have a tensile strength of 80 MPa or more, after forming the aluminum alloy wires.

5. The method according to claim 1, wherein the composition of the aluminum alloy contains 0.02 to 0.08% by weight of Zr.

6. The method according to claim 1, wherein the composition of the aluminum alloy contains 0.04 to 0.6% by weight of Cu and Mg.

7. The method according to claim 6, wherein the composition of the aluminum alloy contains 0.1 to 0.4% by weight of Cu and Mg.

8. The method according to claim 3, wherein the aluminum alloy wires have an electric conductivity of 57.5% IACS or more.

9. The method according to claim 1, further comprising annealing the drawn wire rods after the drawing of the wire rods to the final wire diameter.

10. The method according to claim 2, wherein the wire rods are drawn, without heat treatment, from a diameter of 9.5 mm to the final wire diameter by having said composition of the aluminum alloy.

4. A method for manufacturing an electric wire comprising a conductor, the method comprising:

providing wire rods made of aluminum alloy, a composition of the aluminum alloy containing a predetermined amount of Al, 0.1 to less than 1.0% by weight of Fe, 0 to 0.08% by weight of Zr, 0.02 to 2.8% by weight of Si, and at least one of Cu and Mg, where the amount of Cu is 0.05 to 0.63% by weight and the amount of Mg is 0.03 to 0.45% by weight;

forming aluminum alloy wires by drawing, without heat treatment, the wire rods to a final wire diameter; and

forming the conductor by twisting the aluminum alloy wires together with a twist pitch of

10 to 30 times a predetermined diameter of the conductor.

11. The method according to claim 4, wherein the final wire diameter is 0.32 mm.

12. The method according to claim 11, wherein the wire rods are drawn, without heat treatment, from a diameter of 9.5 mm to the final wire diameter by having said composition of the aluminum alloy.