JP2004063204A - Joining structure of conductor wire - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide structure simply joining electric wire and a terminal without requiring structure of the terminal or complicated working in the joining of a core wire of the electric wire and the terminal. <P>SOLUTION: In joining of the electric wire having conductor wire covered with an insulating material, a bobbin on which the conductor wire is wound, and the terminal to which the conductor wire is joined, the end wire part of the conductor wire is wound multiple times in a superimposed state, the end wire part is melted by heat of laser beams, and the end wire part and the terminal are joined. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a structure in which an electric wire is joined to a terminal, and is applied to, for example, a sensor using an electric wire or various actuators including a motor.
[0002]
[Prior art]
Conventionally, in joining a wire and a terminal used in a sensor or actuator, the heating electrode is brought into contact with the terminal to be welded and the end line of the wire by fusing, which is a type of resistance welding, and instantaneously energized. Then, the contact portion is overheated, and the insulating film on the surface of the electric wire is melted and peeled off by the heat generated at that time, thereby joining the core wire and the terminal of the electric wire. The electric wire has copper as a main component and is coated with an insulating resin film. The terminals are generally tin-zinc plated on brass. Separately, the connection of the covered wire is disclosed in Japanese Patent Laid-Open No. 2000-77844. In this publication, a YAG laser beam oscillated by a YAG laser oscillator is guided to an emission unit through an optical fiber, and the YAG laser beam is applied to an electric wire winding portion by an optical lens (collimator lens, condenser lens) built in the emission unit. Focus and irradiate. Here, the optical axis of the YAG laser light is aligned with the portion inside the wire winding portion of the commutator blade portion, and the optical axis of the YAG laser light is from the commutator blade portion with respect to the normal line at the incident point of the commutator blade portion. The content of inclining 5 to 15 ° inward is disclosed.
[0003]
[Problems to be solved by the invention]
However, the above known technique has the following problems. In the case of joining the end line portion of the electric wire and the terminal by fusing, the heating electrode of the fusing machine is brought into contact with the insulating coating on the surface of the electric wire or the terminal. For this reason, unnecessary materials (such as part of electric wires such as insulating coatings and plating residue on the terminal surface) melted by processing adhere to the heating electrode, so that the heating electrode of the fusing machine becomes dirty and the processing quality tends to fluctuate. Therefore, it is necessary to frequently clean the heating electrode, and the processing conditions and electrode maintenance must be managed in detail. As a result, the processing condition management is severe and the cost is high. In addition, the technique disclosed in Japanese Patent Application Laid-Open No. 2000-77844 described above is a method in which a wire around a wire is directly irradiated with a laser beam and joined. In this case, a laser beam is directly applied to the wire to be joined. Because the amount of heat of the laser light is large, it is difficult to manage the amount of heat, and measures such as tilting the optical axis of the laser with respect to the object to be irradiated to reduce the amount of heat emitted per unit area are made. When heated to a state where the coating is burned out, not only the insulation coating of the electric wire but also the core wire of the electric wire is melted. Therefore, strict processing condition management is required to obtain stable bonding. Furthermore, since the core wire of the electric wire is exposed to high heat by being directly irradiated with laser light, the crystal structure of the core wire is coarsened and the strength of the joint portion is reduced.
[0004]
Therefore, the present invention has been made in view of the above-described problems, and it is easy to join an electric wire and a terminal without requiring a structure of the terminal or complicated processing in joining the core wire (conductive wire) and the terminal of the electric wire. It is a technical problem to provide a structure that can be performed in a simple manner.
[0005]
[Means for Solving the Problems]
Technical measures taken to solve the above problems are:
In joining of electric wires having a conductive wire covered with an insulating material, a bobbin around which the conductive wire is wound, and a terminal to which the conductive wire is joined,
The end line part of the conducting wire is wound on the terminal a plurality of times, and the end line part is melted by the heat of the laser beam to join the end line part and the terminal. Structure.
[0006]
In a conventional wire-terminal connection structure having an insulation coating, the heating electrode is directly brought into contact with the insulation coating of the wire by fusing, and the insulation coating is peeled off by the heat of the heating electrode, so that the conductor (core wire) of the wire The terminal is joined, or the electric wire is irradiated with laser light directly to melt the insulating coating of the electric wire, and the electric wire lead (core wire) and the terminal are joined. Instead of the above prior art, laser light is irradiated to the end line portion of the electric wire (conductive wire covered with the insulating material) wound in a superimposed manner on the terminal, and the electric insulation film of the electric wire located in the superimposed state is put inside the wire. The lead wires and the terminals are joined by melting the lead wires located and peeling off the insulating coating of the electric wires located in the lower part wound by the heat of the melted lead wires. With the above configuration, the electric wire on the upper surface (position closest to the laser beam) that is wound in an overlapping manner is melted by the heat from the laser beam, and at the same time, the conductor wire positioned below the molten conductor wire is covered. The insulating material being peeled off from the conducting wire joins the terminal, the conducting wire from which the insulating material has been peeled off, and the molten conducting wire. As described above, since the lower conductor receives the heat of the melted upper conductor and only the insulating coating is melted, the coarsening of the metal structure of the conductor (core wire) of the electric wire can be suppressed. And since joining of a conducting wire and a terminal can be achieved with a simple configuration without changing the component configuration, the manufacturing cost can be suppressed.
[0007]
Still further, the technical measures taken in claim 2 are:
The conducting wire has a joining structure of conducting wires disposed in a recess formed in the terminal.
[0008]
The electric wire used for the configuration shown in claim 1 is arranged in the concave portion of the terminal so that the conductive wire melted by the irradiated laser beam gathers at a predetermined position of the terminal. Of the conducting wires wound in an overlapping manner, the electric wire arranged closest to the laser beam is first melted. At this time, the concave portion is formed so that the molten conductor is optimally flowed at a position where the lower conductor and the terminal are joined, and the predetermined joining purpose is achieved.
[0009]
Further, the technical measures taken in claim 3 are:
The concave portion has a conductive wire joining structure having a substantially V-shape or a substantially U-shape.
[0010]
Regarding the recess configuration of the terminal shown in claim 2, preferably the laser beam is unnecessary for the electric wire disposed in the lower portion of the upper surface electric wire (conductive wire coated with an insulating material) disposed in the concave portion. The electric wire is arranged so that no energy is transmitted, but the groove shape of the concave portion is substantially V-shaped or substantially U-shaped so that the molten wire is optimally arranged on the upper portion of the electric wire of the concave portion. And
[0011]
Further, the technical means taken in claim 4 is:
In a joining structure of a conducting wire having a conducting wire covered with an insulating material, a bobbin around which the conducting wire is wound, and a terminal to which the conducting wire is joined,
An end line portion of the conducting wire located adjacent to the terminal is wound by being overlapped with the terminal by a linear member, and the linear member has the same main component as the conducting wire. It is made into the joining structure of the conducting wire by which it melts with the heat by a laser beam and the said end line part and the said terminal are joined.
[0012]
In the configuration of the first aspect, the conductive wire is wound around the terminal, but the same effect can be achieved even if the electric wire and the terminal are fixed by a member different from the electric wire. Then, after the electric wire located adjacent to the terminal is wound in advance with a linear member, the linear member is melted with laser light, thereby joining the lead wire of the end line portion and the terminal.
[0013]
Further, the technical means taken in claim 5 is:
The linear member has a conductive wire joining structure whose main component is a copper alloy or a nickel-based alloy.
[0014]
As the linear member for winding the electric wire around the terminal, a copper alloy or a nickel-based alloy is used. Therefore, it is possible to stably join the conductive wire in the end line portion and the terminal.
[0015]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings. Note that the joining of the lead wire and the terminal of the present invention can be generally applied to electromagnetic application products such as sensors and actuators such as motors among electrical and electronic parts. In the following description, an example of an electromagnetic coil will be described. FIG. 1 is a schematic plan view showing a joining structure of a conductor and a terminal covered with the insulating material of the present invention. As shown in FIG. 1, a conducting wire 3 covered with an insulating film 2 is wound around the bobbin 6 so as to overlap with the bobbin 6 in several layers. This insulating coating 2 uses resins having different heat resistances depending on the application. For applications used for synthetic resins such as polyester, polyurethane, epoxy, polyamide, and other parts that require heat resistance, polyesterimide resin is used. Alternatively, polyamideimide resin or the like is used. The terminal 4 of the present invention can be applied to any material having conductivity other than the materials described in the prior art. Therefore, the number of parts can be reduced by designing such that, for example, a part of the parts forming the magnetic circuit is used as a terminal using an iron-based material. Therefore, the parts configuration of the electromagnetic application product including the sensor and the motor can be simplified, so that the cost can be reduced.
[0016]
FIG. 2 is a schematic sectional view showing the arrangement of the electric wire 1 and the terminal 4 in AA in the end line portion 5 of the electric wire 1 in FIG. 2A shows that the electric wire 1 is wound around the terminal 4 a plurality of times. FIG. 2B shows the electric wire 1 below the end line portion 5 wound by the laser beam. The insulating coating 2 melts and peels, and the electric wire 1 above the end wire portion 5 shows a state in which the conductive wire inside the insulating coating 2 melts and melts and is joined to the terminal 4 and the conductive wire 3 below the end wire portion 5. . FIG. 3 shows another example of the recess 7 of the terminal 4 in FIG. About the shape of the recessed part 7, it is devised so that the electric wire 1 may overlap and be wound, and the electric wire 1 arrange | positioned at the lower part of the recessed part 7 is devised so that a laser beam may not be irradiated directly. Therefore, the electric wire 1 superimposed on the end line part 5 is arrange | positioned so that it may be piled up and wound. As long as it has a cross-sectional shape that achieves the above object, it is not limited to a substantially Y shape or a substantially U shape.
[0017]
Next, an example of processing for joining the electric wire and the terminal will be described. A general YAG laser is used as the laser light source, and the laser light is guided using a fiber from a laser light source unit (not shown) so that the laser light is less likely to diverge. For example, when the electric wire covered with polyamide-imide resin, which is a heat resistant resin, is 0.25 mm, the distance until the electric wire 1 is irradiated with the laser light is about 70 mm. At this time, the diameter of the fiber is 0.4 mm, and the end of the electric wire to be melted for about 4 milliseconds is irradiated. At this time, the output of the laser welder is about 2.9 joules. Since the above conditions vary depending on the material and wire diameter of the insulating coating of the electric wires to be joined, optimum processing conditions are examined according to the wire material of the electric wires to be used. In the laser bonding by the fiber used in the present invention, the spot diameter is as small as about 0.6 mm, so that it can be applied to a sensor having a thin wire diameter of about 0.3 mm or a terminal of a small coil product. As described above, the spot diameter of the laser beam applied to the electric wire is about twice as large as the wire diameter. Enables joining of conductors and terminals. The object can be similarly achieved even if the upper wire in FIG. 2A is arranged as an auxiliary material in place of the above-described end wire portion. In this case, since the material used as the auxiliary material is a material capable of joining the material used for the terminal and the electric wire, copper, a copper alloy, or a nickel-based alloy is preferable.
[0018]
【The invention's effect】
As described above, according to the present invention, non-contact bonding can be performed by melting the end portion of an electric wire using a laser beam in bonding a conductive wire having an insulating film and a terminal. With the above configuration, it is possible to stably connect the electric wire and the terminal without significantly changing the components. Moreover, the stable connection of a conducting wire and a terminal is similarly attained by the method of connecting an electric wire and a terminal using an auxiliary member. Compared with the process using fusing according to the prior art and other methods using laser light, with the configuration in which the end of the wire of the present invention is overlapped and wound, and the electric wire is additionally arranged in the recess provided in the terminal. Thus, it is possible to ensure a simple and stable connection quality. Therefore, the present technology has a simple structure and lower cost than the conventional technology, and has a great effect.
[Brief description of the drawings]
FIG. 1 is a schematic plan view showing an example of joining of an electric wire and a terminal in an embodiment of the present invention.
FIG. 2 is a schematic side view showing the joining of an electric wire and a terminal in the AA cross section of FIG. 1;
FIG. 3 is a schematic side view showing an example of the shape of a recess of a terminal in another embodiment of the present invention.
[Explanation of symbols]
1: Electric wire 2: Insulating coating 3: Conducting wire 4: Terminal 5: End wire portion 6: Bobbin 7: Recessed portion

Claims (5)

A conducting wire coated with an insulating material, a bobbin around which the conducting wire is wound,
In joining of electric wires having a terminal to which the conducting wire is joined,
The end line portion of the conducting wire is wound around the terminal a plurality of times, and the end line portion is melted by the heat of the laser beam to join the end line portion and the terminal. Characteristic wire connection structure. The conducting wire is disposed in a recess formed in the terminal;
The joining structure of the conducting wire according to claim 1. The recess has a substantially V-shape or a substantially U-shape;
The conductor joining structure according to claim 2, wherein: A conducting wire coated with an insulating material, a bobbin around which the conducting wire is wound,
In the joining structure of the conducting wire having the terminal to which the conducting wire is joined,
An end line portion of the conducting wire located adjacent to the terminal is wound by being overlapped with the terminal by a linear member, and the linear member has the same main component as the conducting wire. Being melted by heat from laser light, the end line part and the terminal being joined,
Conductive wire joint structure characterized by The linear member is mainly composed of a copper alloy or a nickel-based alloy,
The conductor joining structure according to claim 3.

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