JP2005333092A - Connecting method of led element and illumination device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of directly connecting LED elements to a bundle of electric wires having insulating coating without electric wire cutting and soldering. <P>SOLUTION: The tops of lead terminals of the LED elements are processed, a cutting portion is formed at each of the tops of the lead terminals, the bundle of the insulation coated electric wires are laterally arranged and bound, the cutting portions of the lead terminals and the bundle of the laterally arranged and bound electric wires are adjacently disposed so as to allow them to traverse or intersect with each other, the cutting portions are allowed to pass through the insulating coating of the bundle of the electric wires to electrically connect the core conductive sections of the electric wires, thereby the LED elements and the bundle of the electric wires are retained under this condition. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method of directly connecting an LED element to an electric wire bundle having an insulation coating without cutting an electric wire between the LED elements and without performing soldering. The present invention also relates to an illumination device in which a large number of LED elements formed by such a connection method are mounted and connected to a bundle of wires having an insulating coating at regular intervals.

  Recently, illumination as a light art that is illuminated, directed, and lit up with countless light bulbs in city nights has become a big topic, including Kobe (Millenario), Marunouchi (Tokyo Milenario), Roppongi Hills, From Odaiba / Shiodome to Sapporo in the north, Yokohama, Nagoya, Osaka, Kyushu in the south, redevelopment district opening, hotels, station buildings, stores, resorts, theme parks, ski resorts, Christmas events, etc. Illumination spots and events are being competed in Tsutsuura nationwide as weapons and means that are indispensable for attracting customers or revitalizing towns. Now it is no exaggeration to say that illumination by illumination and entertainment at night without production cannot be realized.

  Thousands and tens of thousands of light bulbs form illumination tunnels with dazzling designs and patterns, graceful curves of light trees, towering light structures, and so on. Invite to the dream world, fantasy space. The story is just a glance, and the countless spectators who visit it, such as the famous tunnel of light and the Millenario, are also intimidating. Despite all the desperate attention, it's not unreasonable that many people shoot with digital cameras and videos that face the flow while pushing and face upwards.

  However, when this illumination is constantly performed constantly, people's eyes will also become fertile, so the number of decorative light bulbs and the general illumination is rather poor, and the disappointment of the audience is also great, which is counterproductive. Become. That is, in full-scale illumination, one of the most important factors is the density of the light bulb array, which is usually 3000 even when decorating a huge number of light bulbs (for example, deciduous trees 8 meters high and 3 meters wide). It is necessary to upgrade the number of decorative light bulbs year by year, and the organizers will never get tired.

  As such an illumination device, a device in which a decorative light bulb is attached to a wire bundle at regular intervals is commonly used. For example, as a standard unit, 5000 decorative light bulbs that are connected and held in advance to a covered wire bundle at regular intervals are provided in a reel-wound state. Recently, instead of conventional incandescent lamp type decorative bulbs, various semiconductor LEDs (light emitting diodes) have the characteristics of high brightness, power saving, low heat generation, long life, In addition, it has been used favorably because it emits light with a unique transparency, and it is speculated that this tendency will intensify.

  However, it is not always easy to connect such a large number of decorative light bulbs (usually several thousand lamps are necessary as described above) to a wire bundle having an insulating coating. For example, FIG. 1 shows a connection method in which a light bulb is connected in series to a wire bundle. As is apparent from the drawing, the wire bundle is temporarily cut at each light bulb mounting position of the wire bundle (more precisely, Cut one of the wire bundles), and insert a light bulb between them to make an electrical connection. As can be easily imagined, in order to connect the light bulb, at both cut surfaces of the wire bundle, the insulation of the wire bundle is peeled off to expose the core conductor, and this is connected to the lead wire of the light bulb respectively. It is necessary to attach or crimp. Since this operation is basically a manual operation, it can easily be imagined that enormous man power is required to attach, for example, 5000 light bulbs to a covered electric wire. On the other hand, FIG. 2 shows the method of attaching the bulb in the case of parallel connection, but the operation is basically the same as the series connection method, in which both the attachment points of the wire bundle are cut, the insulation coating is peeled off, The bundles are connected by soldering or crimping in a bridging manner. Similarly, the amount of work becomes enormous in proportion to the number of light bulbs.

  In order to solve such a problem, the present inventor previously connected the insulation-coated wire bundle and the light bulb through a selection hand section (connecting metal section) having a piercing arc and a lead wire locking portion. The method to perform was proposed (refer patent document 1). That is, two metal pieces having a piercing arc and a lead wire locking portion are used, the piercing arc is pierced into the insulation coating of the electric wire and connected to the core conductor portion, and the lead wire locking portion is connected to the lead of the bulb. By connecting the wire, the light bulb and the electric wire are connected through the connecting metal piece. Split sockets are used to hold insulated wires and connecting metal pieces. Certainly, according to this method, workability was significantly improved as compared with the prior art. However, in addition to the split socket, it is necessary to always prepare and use a plurality of metal pieces having a specific shape for the connection between the insulated wire and the bulb lead wire. In addition, the metal section must be embedded and held by a means such as driving into a socket, and the operation is extremely complicated and troublesome. Moreover, this method is applied to a normal incandescent lamp type decorative bulb, and there is also a problem that it is difficult to apply it as it is to an LED element which has been attracting attention recently.

Japanese Patent No. 2777726 (Claims (Claims 1 to 8), FIGS. 5 to 17)

  It is an object of the present invention to use an LED element in a wire bundle having an insulation coating without cutting an electric wire between the LED elements and without performing soldering, and also using a metal piece for connection or the like. Rather than providing a way to connect directly. Another object of the present invention is to provide an illumination device in which a large number of LED elements formed by such a connection method are mounted and connected to an electric wire having an insulating coating at a constant interval.

  According to the present invention, the following LED device direct mounting / connecting method to an electric wire bundle having an insulating coating and an illumination device in which a large number of LED elements are directly mounted / connected to an electric wire bundle having an insulating coating are provided. Is done.

[1]
A method of connecting at least an LED element having two lead terminals to an electric wire bundle in which a core conductor portion is insulation-coated,
Processing the tip of the lead terminal of the LED element, forming a blade portion at the tip of the lead terminal,
Row and restrain the wire bundle covered with insulation;
The step of arranging the blade portion at the tip of the lead terminal and the row-constrained wire bundle close to each other so as to cross or cross each other. In the positional relationship, the blade portion is penetrated through the insulation coating of the wire bundle, A method of directly attaching and connecting an LED element to an electric wire bundle, comprising the step of electrically connecting and the step of holding the LED element and the electric wire bundle in this state.

[2]
A method of connecting at least an LED element having two lead terminals to an electric wire bundle in which a core conductor portion is insulation-coated,
Processing the tip of the lead terminal of the LED element, forming a blade portion at the tip of the lead terminal,
Fixing the LED element so that the blade portion is in a predetermined position where the wire bundle should be restrained;
The step of disposing the fixed blade portion and the wire bundle close to each other so as to cross or cross each other In the positional relationship, the blade portion penetrates through the insulating coating of the wire bundle and is electrically connected to the core conductor portion of the wire. And a method of directly attaching and connecting the LED element to the electric wire bundle, comprising the step of holding the LED element and the electric wire bundle in this state.

[3]
[1] The connection method according to [1] or [2], wherein a direction of the blade edge surface of the tip blade portion of the lead terminal of the LED element is parallel to the longitudinal direction of the wire bundle and the blade portion is inserted into the insulating coating. .

[4]
A holder used in the method according to any one of items [1] to [3], wherein the holder includes a constraining groove for rowing and constraining a bundle of electric wires, substantially passing through the center of the holder, and an LED element body It has a holding opening that opens to the outside holding at least the lower part, the opening and the restraining groove communicate with each other by a guide groove, and the guide groove has a blade at the tip from the bottom of the opening Each lead terminal of the LED element is led to the central restraining groove portion, the guide groove is configured to intersect or cross the restraining groove portion of the wire bundle, and the holder further includes the restraining groove portion. It consists of an upper split holder and a lower split holder that divide in half. The LED element body is held in the holding opening, and the tip edge of the lead terminal penetrates the wire bundle restrained by the restraining groove. In the connected state The upper split type holder and the lower split-type holder, LED elements connected holding holder for holding the LED element in the wire bundle to coalesce and integrated.

[5]
An illumination device in which a plurality of LED elements are directly mounted and electrically connected to an electric wire bundle having an insulating coating at intervals,
Preparing at least a plurality of LED elements having two lead terminals,
Processing the tip of the lead terminal of each LED element, forming a blade portion at the tip of the lead terminal,
The portions of the wire bundle with insulation coating that should be connected to the respective LED elements are respectively arranged in rows / restraints at intervals,
The adjacent lead wire tips and the row-constrained wire bundles are arranged close to each other so as to cross or cross each other,
A plurality of LEDs characterized in that each of the blade portions penetrates through the insulating coating in the positional relationship and is electrically connected to the core conductor portion of the wire bundle, and thus maintains this state for each LED element. An illumination device in which elements are directly mounted and electrically connected to a bundle of wires having an insulating coating at intervals.

[6]
An illumination device in which a plurality of LED elements are directly mounted and electrically connected to an electric wire bundle having an insulating coating at intervals,
Preparing at least a plurality of LED elements having two lead terminals,
Processing the tip of the lead terminal of each LED element, forming a blade portion at the tip of the lead terminal,
Each LED element is fixed in such a manner that its blade portion is in a predetermined position where the electric wire is to be restrained,
The blade portion and the row-constrained wire bundle are arranged close to each other so as to cross or cross each other,
In the positional relationship, the respective blade portions are penetrated through the insulation coating of the wire bundle and are electrically connected to the core conductor portion of the wire bundle, and thus this state is maintained for each LED element. An illumination device in which a plurality of LED elements are directly mounted and electrically connected to a wire bundle having an insulating coating at intervals.

[7]
[4] An illumination device in which a plurality of LED elements are directly mounted and electrically connected to an electric wire bundle having an insulating coating at intervals with the LED element connection holding holder according to the item [4].

[8]
Item [5] or [6], wherein the LED element connection holding holder according to [4] is used to connect and electrically connect a plurality of LED elements directly to a wire bundle having an insulating coating at intervals. Illumination equipment.

Hereinafter, preferred examples of embodiments of the present invention will be described in detail with reference to the drawings.
(Lead terminal of LED element)
FIG. 3A is an explanatory diagram showing the appearance of the LED element 1. In the main body 2 of the LED element, although not shown, LED light emitting chips such as R (red), G (green), and B (blue) are installed on the lead frame at the center, and the periphery is epoxy resin. It is sealed and stored with a sealing material such as. One of the lead terminals 4 connected to the element is a cathode of R, G, B, etc., and the other is a common (positive electrode). (Note that in the case of full color, at least three LED chips (R, G, B) are required, and therefore there are a total of four lead terminals. However, here, for convenience of explanation, a single color (two lead terminals) is required. The case will be described as an example, however, in the case of a full color or the like, it can be processed in the same manner in principle according to the following description.)

  The lead terminal 4 is made of a conductive metal material for lead wires (for example, pure silver, silver clad, pure copper, copper-tin based material (tinned copper, phosphor bronze), copper-zinc based material (brass, brass), copper- A silver-based material or the like is preferably used.) Is punched into a square bar shape, a round bar shape, a cane shape, a column shape, a long side shape, a flat plate shape, a strip shape, a line shape, or the like. The terminal cross section may be circular (in the case of a conical blade, etc.), but is usually rectangular, preferably quadrangular, particularly preferably square.

(Blade formation)
In this invention, as shown in FIG.3 (b), the front-end | tip of the lead terminal 4 of such an LED element is processed, and the blade part 6 is formed in the front-end | tip of the said lead terminal.
This is the greatest feature of the present invention. According to the knowledge of the present inventor, the formed blade portion 6 is a very sharp blade portion and easily penetrates the insulation coating of the wire bundle. It is possible to form a connection with the core conductor of the electric wire. In the first place, the tip of the thin lead terminal 4 that weakly extends downward from the main body of a small element such as an LED element, and appears to bend or bend immediately after being inadvertently touched, is relatively thick. It would be completely unpredictable to those skilled in the art to form such a sharp blade that can penetrate the insulating coating layer of a hard wire. (At this time, the length of the lead terminal is cut to an appropriate length (for example, at the position of the line k in FIG. 3A) or cut in accordance with the size of the holder described later. In addition, it is also a preferable aspect that the blade portion is formed.The figure shows a case where the blade portion is formed by cutting the length of such a lead terminal short.)

  FIG. 4 shows an example of the shape of the blade portion 6 formed at the tip of the lead terminal 4, wherein (a) is a single blade, (b) is a double blade, and (c) is a curved shape (convex). It is a double-edged blade (or conical blade). If desired, the blade may be further formed in a saw shape or a pyramid shape, or a protrusion may be formed on a part of the blade to prevent it from coming off. In consideration of the penetrating force, it is most preferable to use a single-edged blade portion shown in FIG. FIG. 4 schematically shows the blade edge surface 6 ′ when each blade portion is viewed from the tip.

  FIG. 5 is a diagram for explaining the types of arrangement or combination of two blade portions when the blade portions are formed at the tips of two adjacent lead terminals with a single-blade blade portion as a base. In the drawings, in each of the cases (a) to (c), the positional relationship between the two blade edge surfaces 6 'and 6' when the lead terminal (blade portion) is viewed from the tip is also shown.

  That is, (a) shows a case where the blade portion is arranged in parallel with the blade edge surfaces 6 ′ and 6 ′ facing in the same direction (right side in the figure), and (b) shows the blade edge surface 6 ′, When 6 'is arranged to face each other inward, (c) shows the case where the blade surfaces 6' and 6 'of the blade portion are arranged to face each other. FIG. 5 shows that the distance between the two cutting edge surfaces 6 'and 6' is that (c) is the longest, (a) is the middle, and (b) is the shortest.

  Any of the above-described arrangement methods of the blade portion can basically achieve the object of the present invention. Among these, the blade portion is arranged as shown in (b) on the cutting edge surface 6 ′. , 6 ′ is most preferable to have the shortest distance. That is, according to this arrangement, the insulation coating (substantially annular cross section) of the bundle of electric wires constrained in a row as described later is directed from the outside to the inside (that is, the center of the core portion) (or In some cases, it penetrates further in this direction (inwardly with respect to each other), so that it can reach the core part of the center most reliably and can form a stable connection. .

  On the other hand, in the case of parallel arrangement in the same direction of (a) with respect to the blade portion, the blade edge surface is directed in one direction (in this case, on the right side) (or in some cases, further Since it tries to penetrate the insulation coating (while slightly deforming in the direction (right side)), the blade part may slightly deviate from the center part of the core part of the electric wire. In addition, when the cutting edge surface of (c) is directed outward, the cutting edge surfaces each attempt to penetrate the insulating coating toward the outer side (or while slightly deforming outward in some cases) The blade portion may slightly deviate outward from the center portion of the core portion of the electric wire.

  The processing for forming the blade portion of the lead terminal includes plastic processing such as press processing, compression processing and crushing processing; cutting or grinding processing such as file processing, grinding wheel processing, and abrasive processing; laser cutting processing, gold cutting saw Known processing means such as a cutting process such as a cutting process, a gas cutting process, and an electric cutting process may be arbitrarily applied singly or in combination. Especially, the shaping | molding of the blade part shown, for example to Fig.5 (a)-(c) can be easily performed by press work or crushing.

(Penetration and connection of blade part to wire bundle)
In the present invention, the leading end of the lead terminal of the LED element thus formed with the blade portion is penetrated into the wire bundle to be electrically connected.
6 to 8 are diagrams for illustrating a process in the case where this connection is performed using a holder (also referred to as a housing), and FIG. 6 illustrates a holder for holding the LED element and the wire bundle. 7, when a wire bundle is first constrained to the holder and the blade portion of the LED element is inserted and connected to the holder, FIG. 8 shows that the LED element is fixed to the holder first and this is fixed. The case where the wire bundle is brought close to the blade portion of the LED and the blade portion is penetrated and connected to the wire bundle is shown.

(holder)
In order to carry out the connection method of the present invention, specifically, an LED element connection holding holder (hereinafter referred to as “connection holding holder” or simply “holder”) as shown in FIG. i) Row and restraint of the wire bundle, (ii) Fixing of the LED element having the lead terminal formed with the blade portion, (iii) Penetration / connection of the blade portion to the wire bundle, and (iv) The wire bundle in the connected state It is preferable to perform a process such as holding and fixing the LED element.

6A and 6B show the holder 10, wherein FIG. 6A is a plan view, FIG. 6B is a side view, FIG. 6C is a bottom view, and FIG. 6D is a cross-sectional view taken along the line AA in FIG.
The holder 10 will be described with reference to FIG. 6. The holder passes through substantially the center of the holder 10 and opens outward to hold at least the lower part of the LED element body and the restraining groove 12 for rowing and restraining the wire bundle. A holding opening 14 is provided. On the inner peripheral wall surface in the opening, it is preferable that a holding protrusion 15 is formed in a ring shape or at a distance as a pressing means for securely fixing the held LED element. The annular holding projection 15 has a waterproof effect that increases the airtightness between the LED element and the holder and prevents moisture, raindrops, etc. from entering the holder.

  The opening 14 and the restraining groove 12 communicate with each other through a guide groove 16. The guide groove 16 guides each lead terminal 4 of the LED element 1 having the blade portion 6 formed at the tip thereof from the opening bottom portion 14 ′ to the restraining groove portion 12 at the center of the holder. As shown in the figure, the cross-sectional shape of the guide groove is preferably a shape and size corresponding to the cross-sectional shape of the lead terminal, and the lead terminal is received and restrained smoothly and accurately with little play. It is desirable to guide to the groove (specifically, to the central part of the bundle of electric wires being constrained). (The drawing shows a case where the guide groove cross section is formed in a square shape on the assumption that a lead terminal having a square cross section is received and smoothly guided to the restraining groove portion). Further, since the lead terminal is press-fitted downward while being held in the guide groove, it is prevented from being bent due to buckling during press-fitting. In addition, the said guide groove 16 is comprised so that it may cross | intersect or cross | intersect the said wire bundle restraint groove part 12 at about 90 degrees, as clear from figure (a) and (d).

  The holder 10 includes an upper split holder 10A and a lower split holder 10B that divide the restraining groove into halves, and both are preferably joined to each other by a joint 17 such as a hinge. Therefore, the constraining groove 12 is composed of two halves of the upper constraining groove 12A and the lower constraining groove 12B when the holder is opened and separated.

  The upper split-shaped holder 10A and the lower split-shaped holder 10B are provided with a ridge 18 and a groove 18 ', a protrusion 19 and a recess 19' at opposite positions, and the two split holders are closed. In this case, it is also preferable that the protruding line penetrates into the recessed groove and the protruding part penetrates into the recessed part, and the both are fitted to each other so that the two split holders are completely united and integrated. Furthermore, it is also possible to apply the adhesive to the surface of the split surface and / or the opposing ridges or grooves to make the split holders united and integrated more completely. Further, the upper split holder and the lower split holder may be configured to be completely separated without being joined by a hinge or the like.

  In this state, as shown in detail in FIGS. 7 to 8 below, the main body 2 of the LED element is held in the holding opening 14 of the holder, and the leading edge 6 of the lead terminal 4 is restrained by the restraining groove. The state in which the upper split holder 10A and the lower split holder 10B are closed and joined at a joint portion such as a hinge, and the LED element 1 is connected to the electric wire bundle, with the electric wire bundle 30 penetrating and connected. Can be held in. The above-mentioned holder has such a function, and is particularly preferably a holder for holding an LED element connection.

The material of the holder is not particularly limited, but injection molding, compression molding, blow molding, extrusion molding using a thermoplastic resin that can be easily molded, such as polyethylene, polypropylene, polybutadiene, polystyrene, soft polyvinyl chloride, methacrylic resin, etc. Or the like.
By using such a holder, the present invention can be implemented as shown in FIGS.

(Connection method 1)
FIG. 7 shows a case where a bundle of wires is first restrained on the holder, and the blade portion of the LED element is brought close to the holder to be penetrated and connected.
That is, as shown in (a), the holder 10 is used to connect the LED element 1 having the two lead terminals 4 and 4 to the wire bundle 30 in which the core conductor portion 28 is covered with insulation.

  As already described, the blade portions 6 and 6 are formed at the tips of the lead terminals 4 and 4 of the LED element 1, respectively. In this case, in consideration of the use outdoors, it is preferable that the lead terminal of the element is subjected to a waterproof treatment or a drip-proof treatment in advance.

  First, as shown in (b), the wire bundles 30 that are covered with insulation are arranged in a row and restrained in the restraining groove portion 12 of the holder, more precisely, the upper restraining groove portion 12A of the upper split holder 10A. In this case, more preferably, it is also desirable to apply an adhesive to the groove or the electric wire bundle, and to more accurately and reliably restrict the electric wire bundle to the restricting groove by an adhesive force.

(In addition, the actual operation is set upside down in the figure, the upper restraint groove 12A of the upper split holder 10A is set upward, the electric wire bundle is placed on the restraint groove and restrained, and the LED element is (It is also possible to perform an operation of pushing upward from below the restraining groove 12A.)

  As already described, in the holder, the restraining groove portion 12 and the guide groove 16 that guides the lead terminal to the restraining groove portion are formed so as to cross each other or intersect at an angle of approximately 90 °. Thus, the blade portion at the tip of the lead terminal and the wire bundle that is constrained in a row in the groove portion are inevitably arranged so as to cross or cross each other in a state where they are close to each other.

  Next, as shown in (c), in a state where the wire bundle 30 is restrained by the restraining groove (upper half restraint groove) 12A of the upper split holder 10A, the lower split holder 10B is closed, and the wire bundle is Fully restrained and fixed in the restraint groove. In this case, in the next step (d), the leading edge portion of the lead terminal penetrates the insulation coating and is connected to the core conductor portion, so that at least the insulation coating portion of the wire bundle that penetrates is partially insulated. In view of use outdoors, it is preferable to apply a waterproof treatment to the portion by applying a waterproof liquid, spraying a waterproof spray, or the like.

  As described above, as shown in (c), the lead terminal 4 of the LED element is inserted into the guide groove 16 in a state where the wire bundle 30 is restrained by the restraining groove portion 12, and the lead wire 4 is pushed downward. The blade portion 6 at the tip of the terminal is inserted through the insulating coating of the wire bundle 30 and is electrically connected to the core conductor portion 28 of the wire. According to the knowledge of the present inventors, by performing this pushing for a short time or momentarily with impact or impact, the blade portion easily penetrates into the insulation coating and reaches the core conductor portion 28, A connection is made. Specifically, for example, it is preferable that the LED element is instantaneously driven by a small air cylinder. Alternatively, a pliers-type hand tool may be used to instantaneously press-fit the LED element and the holder.

  Thus, as shown in (d), the LED element 1 and the wire bundle 30 are held in this state by the holder 10, and the LED element is directly mounted and connected to the wire bundle.

(Connection method 2)
FIG. 8 shows a case in which the LED element is first fixed to the holder, the wire bundle is brought close to the fixed blade portion, and the blade portion is penetrated and connected to the wire bundle.
Also in this case, as shown in (a), using the holder 10, the LED element 1 having the two lead terminals 4, 4 is connected to the wire bundle 30 in which the core conductor portion 28 is covered with insulation.

  As already described, the blade portions 6 and 6 are formed at the tips of the lead terminals 4 and 4 of the LED element 1, respectively. Similarly, in consideration of the use outdoors, it is preferable that the lead terminal of the element is subjected to waterproof treatment or drip-proof treatment in advance.

  First, as shown in (a) and (b), the LED element 1 is inserted or pressed into the guide groove 16 with the two lead terminals 4 and 4 inserted therein, and the blade portions 6 and 6 are formed. The element body 2 is fixed to the holding opening 14 so that the wire bundle 30 is in a predetermined position to be restrained. Fixing is reliably performed by the holding projection 15 provided in the opening.

(Note that the actual operation is performed in the same manner as described in FIG. 7, with the top and bottom of the figure turned upside down, and the upper restraint groove 12A of the upper split holder 10A is set upward. The two lead terminals 4 and 4 are inserted into the guide groove 16 and pushed, and the blade portions 6 and 6 face upward so that the wire bundle 30 is to be restrained. It is also possible to fix the element body 2 to the holding opening 14.)

  As already described, in the holder used in the present invention, the constraining groove 12 and the guide groove 16 for guiding the lead terminal to the constraining groove are formed so as to cross each other or intersect at an angle of approximately 90 °. Therefore, the blade portion 6 at the tip of the lead terminal guided to the guide groove in (b) and the wire bundle 30 that is row-constrained in the groove portion inevitably cross or intersect each other. It will be arranged like this.

  Next, as shown in (c), the lower split holder 10B is closed in a state where the wire bundle 30 is arranged in the vicinity of the restraining groove (upper half restraint groove) 12A of the upper split holder 10A. As a result, the wire bundle is press-fitted or pushed in contact with the tip edge portion of the lead terminal while being restrained and fixed in the restraining groove portion (lower restraining groove portion) of the lower split holder 10B, and further the insulation coating of the wire bundle is applied. The tip blade portion penetrates and crimps, and the connection with the core conductor portion is completed.

(In addition, as is clear from the figure, the wire bundle is restrained and fixed with an adhesive in the lower restraining groove portion of the lower split holder 10B, and in this state, the split holder is closed, Thus, the wire bundle is completely restrained and fixed in the restraining groove, and is connected to the LED element held and fixed in the opening.

  According to the knowledge of the present inventors, as in the case of the connection method 1, the lower split holder is hit and quickly closed, so that the insulating coating is pushed into the blade portion in a short time or instantaneously. The blade portion is easily penetrated into the insulating coating, reaches the core conductor portion, and is connected. As described above, also in this case, specifically, it is preferable that the LED element is instantaneously driven by, for example, a small air cylinder. Alternatively, a pliers-type hand tool may be used to instantaneously press-fit the LED element and the holder.

  Thus, as described in FIG. 7, as shown in FIG. 7, the LED element 1 and the wire bundle 30 are held in this state by the holder 10, and the LED element is directly attached to the wire bundle. It is connected. The connection method of the present invention can be most effectively applied to the connection of the LED elements, but any other decoration can be used as long as it has a lead terminal capable of forming a blade at the tip. The same can be applied to incandescent lamps and the like.

  Also, from the beginning, use a holder that combines the upper and lower split holders. For example, in the bundle of wires, first insert only a number of holders through the constraining groove and put them in a daisy chain. By driving the lead terminals of the LED elements one after another from the bottom guide groove of the holding opening of the holder, the blades of the ELD elements are inserted into the respective insulation coating layers one after another in each holder mounted in a daisy chain. It can be connected to the core conductor part.

(Direction of the edge surface)
FIG. 9 shows a preferable positional relationship between the edge surfaces 6 'and 6' of the blade portion of the lead terminal and the wire bundle when a single blade or a double blade portion is formed. That is, as shown in (a), the direction of the blade edge surfaces 6 ′ and 6 ′ at the tip of the lead terminal of the LED element is made parallel to the longitudinal direction L of the constrained wire bundle 30, and the blade portion penetrates into the insulating coating. (The positional relationship of the blade edge surface with respect to the wire bundle is indicated by a dotted line), the blade portion smoothly penetrates into the insulation coating, and the core conductor wire portion and the blade edge surface are in the same direction (longitudinal direction) (that is, As the direction of the contact area is the largest), the contact area does not change and the electrical connection is ensured even if the edge surface is slightly deviated laterally. .

  On the other hand, as shown in (b), when the direction of the blade edge surfaces 6 ', 6' is not parallel to the longitudinal direction L of the wire bundle but crosses or is orthogonal, the blade portion is insulated. It does not penetrate smoothly into the inside, and the longitudinal direction of the core conductor part intersects with the blade edge surface, so if the blade edge surface is shifted laterally, the contact area between both easily changes, so connection May be unstable and lack certainty. The term “parallel” as used herein means that the cutting edge surface and the longitudinal direction L of the wire bundle are preferably completely or substantially coincident with each other, but are not limited to this, and the contact area between the two is substantially the same as described above. It means that it may have some angle that does not change.

(Illumination device)
FIG. 10 shows the appearance of an illumination device 50 formed by connecting the LED element 1 of the present invention and the insulated wire bundle 30 by the connection method of the present invention described above.
As a precaution, the configuration of such an illumination device is as follows:

  This illumination device is an illumination device in which a plurality of LED elements are directly mounted and electrically connected to a wire bundle having an insulation coating at intervals, and is formed by the method shown in FIG. 7, for example. There,

Preparing at least a plurality of LED elements 1 having two lead terminals,
Processing the tip of the lead terminal of each LED element, forming a blade portion at the tip of the lead terminal,
Each part of the wire bundle with the insulation coating to be connected to the LED element is arranged in a row and constrained with an interval,
Place the blade portion at the tip of each lead terminal and the row-constrained wire bundle close to each other so as to cross or cross each other,
In the positional relationship, the respective blade portions are penetrated through the insulating coating to be electrically connected to the core conductor portion of the electric wire bundle, and thus the LED elements are maintained in this state. It is an illumination device that is directly attached to and electrically connected to a wire bundle having a gap.

  Here, as shown in FIG. 10, when LED elements are mounted at intervals in the wire bundle, the mark is printed on the wire bundle at a fixed pitch at the element mounting position with paint or the like. It is preferable (of course a white mark is used for the black wire bundle). For example, as shown in FIG. 11, this mark has a length of m1 at a point of 1 cm from the reference point S, an m5 mark at a point of 5 cm, and an m10 mark at a point of 10 cm. By setting the marking according to the size (for example, a mark having a width of m1 = 1 cm, m5 = 2 cm, m10 = 5 cm), the operator does not need to measure the mounting position of the element each time. By looking at this marking, the mounting position (for example, 3 cm interval, 5 cm interval, etc.) can be easily confirmed, and workability is remarkably improved.

  Further, the illumination device in which such a plurality of LED elements are directly mounted and electrically connected to a wire bundle having an insulating coating at intervals may be based on the method shown in FIG.

Preparing at least a plurality of LED elements having two lead terminals,
Processing the tip of the lead terminal of each LED element, forming a blade portion at the tip of the lead terminal,
The LED element is fixed so that the blade portion is in a predetermined position where the wire bundle is to be restrained,
The blade portion and the row-constrained wire bundle are arranged close to each other so as to cross or cross each other,
In the positional relationship, the respective blade portions are penetrated through the insulation coating of the wire bundle and are electrically connected to the core conductor portion of the wire bundle, and thus this state is maintained for each LED element. It is an illumination device in which a plurality of LED elements are directly mounted and electrically connected to a wire bundle having an insulating coating at intervals.

  In the illumination apparatus of the present invention, each LED element mounted on the wire bundle penetrates with the blade edge surface all parallel to the longitudinal direction L of the wire bundle as shown in FIG. Because it is connected (and more easily using the marking of the mounting position described above), many LED elements do not have different orientations as in conventional illumination devices. Are all substantially the same.

  That is, as shown in FIG. 10, the illumination device according to the present invention as a whole has all LED elements aligned on the wire bundle in the same direction. When setting in a station building or forming a light tunnel or the like, an aesthetically perfect illumination can be formed.

  According to the connection method of the present invention, an LED element can be directly connected to an electric wire having an insulating coating without cutting the electric wire between the LED elements and without performing any soldering.

  In addition, since the connection method of the present invention does not require a member such as a metal piece for connection, the number of parts is small, the processing time is short, the processing is simple, and management is easy. Therefore, the method of the present invention can easily automate all the steps.

  Furthermore, the illumination device, which is a product obtained by the connection method of the present invention, is very easy to maintain. That is, in the connection method (parallel crimping method), even if one LED element has a defect, it is only necessary to replace that element, and this replacement maintenance is also performed by a manual tool (hand tool) as described above. ) Can be performed very easily in a short time.

  Furthermore, since the illumination device formed by the connection method of the present invention can easily have a waterproof structure and / or a drip-proof structure, it is suitable for outdoor use throughout the year regardless of rainy season or winter season. is there.

  As described above, the connection method of the present invention and the resulting illumination device have superior characteristics as compared with the conventional one, and the industrial applicability thereof is extremely high. I do not get.

It is explanatory drawing of the connection method which connects the conventional light bulb in series with an electric wire bundle. It is explanatory drawing of the attachment method of the light bulb in the case of the conventional parallel connection. It is explanatory drawing of an LED element, (a) is an external appearance, (b) shows the state which formed the blade part in the front-end | tip of a lead terminal. It is explanatory drawing which shows an example of the shape of the blade part formed in the front-end | tip of a lead terminal. It is a figure explaining the kind of arrangement of two blade parts. It is explanatory drawing of the holder for hold | maintaining an LED element and an electric wire bundle. It is explanatory drawing in the case of constraining an electric wire bundle to a holder and penetrating and connecting the blade part of an LED element close to this. It is explanatory drawing in the case of fixing an LED element to a holder and penetrating and connecting an electric wire bundle close to this fixed blade part. It is a figure which shows the preferable positional relationship of the blade edge | tip surface at the time of forming the blade part of a single blade or a double blade, and an electric wire bundle. It is explanatory drawing which shows the external appearance of the apparatus for illumination formed by the connection method of this invention. It is explanatory drawing which shows the state which attached | subjected the mark which shows the mounting position of an LED element to an electric wire bundle.

Explanation of symbols

1 LED element 2 Element body
4 Lead terminal 6 Blade portion 6 'Blade face 10 Holder 10A Upper split holder 10B Lower split holder 12 Restraint groove portion 12A Upper restraint groove portion 12B Lower restraint groove portion 14 Holding opening portion 14' Opening bottom portion 15 Holding projection 16 Guide groove 17 Upper portion Junction, such as hinge, between the split holder and the lower split holder 18 ridge 18 'groove 19 ridge 19' recess 28 core conductor 30 wire bundle 50 illumination device L longitudinal direction of wire bundle

Claims (8)

A method of connecting at least an LED element having two lead terminals to an electric wire bundle in which a core conductor portion is insulation-coated,
Processing the tip of the lead terminal of the LED element, forming a blade portion at the tip of the lead terminal,
Row and restrain the wire bundle covered with insulation;
The step of arranging the blade portion at the tip of the lead terminal and the row-constrained wire bundle close to each other so as to cross or cross each other. In the positional relationship, the blade portion is penetrated through the insulation coating of the wire bundle, A method of directly attaching and connecting an LED element to an electric wire bundle, comprising the step of electrically connecting and the step of holding the LED element and the electric wire bundle in this state. A method of connecting at least an LED element having two lead terminals to an electric wire bundle in which a core conductor portion is insulation-coated,
Processing the tip of the lead terminal of the LED element, forming a blade portion at the tip of the lead terminal,
Fixing the LED element so that the blade portion is in a predetermined position where the wire bundle should be restrained;
The step of disposing the fixed blade portion and the wire bundle close to each other so as to cross or cross each other In the positional relationship, the blade portion penetrates through the insulating coating of the wire bundle and is electrically connected to the core conductor portion of the wire. And a method of directly attaching and connecting the LED element to the electric wire bundle, comprising the step of holding the LED element and the electric wire bundle in this state.   The connection method according to claim 1 or 2, wherein the edge portion of the leading edge portion of the lead terminal of the LED element is parallel to the longitudinal direction of the wire bundle and the blade portion penetrates into the insulating coating.   It is a holder used for the method in any one of Claims 1-3, Comprising: The constraining groove part for row | line | row and constraining a wire bundle, and at least the lower part of a LED element main body are penetrated substantially through the center part. A holding opening that opens outward, and the opening and the restraining groove communicate with each other through a guide groove. The lead terminal is led to the central restraint groove, and the guide groove is configured to intersect or cross the restraint groove of the wire bundle, and the holder further divides the restraint groove in half. It consists of an upper split holder and a lower split holder that hold the body of the LED element in the holding opening, and further, the leading edge of the lead terminal penetrates and is connected to the wire bundle restrained by the restraining groove The upper part Shape holder and the lower split-shaped holder, LED element connection holding holder for holding the LED element in the wire bundle to coalesce and integrated. An illumination device in which a plurality of LED elements are directly mounted and electrically connected to an electric wire bundle having an insulating coating at intervals,
Preparing at least a plurality of LED elements having two lead terminals,
Processing the tip of the lead terminal of each LED element, forming a blade portion at the tip of the lead terminal,
The portions of the wire bundle with insulation coating that should be connected to the respective LED elements are respectively arranged in rows / restraints at intervals,
Place the blade portion at the tip of each lead terminal and the row-constrained wire bundle close to each other so as to cross or cross each other,
A plurality of LEDs characterized in that the respective blade portions are penetrated through the insulating coating in the positional relationship and are electrically connected to the core conductor portions of the wire bundle, and thus this state is maintained for each LED element. An illumination device in which elements are directly mounted and electrically connected to a bundle of wires having an insulating coating at intervals. An illumination device in which a plurality of LED elements are directly mounted and electrically connected to an electric wire bundle having an insulating coating at intervals,
Preparing at least a plurality of LED elements having two lead terminals,
Processing the tip of the lead terminal of each LED element, forming a blade portion at the tip of the lead terminal,
Each LED element is fixed in such a manner that its blade portion is in a predetermined position where the wire bundle is to be restrained,
The blade portion and the row-constrained wire bundle are arranged close to each other so as to cross or cross each other,
In the positional relationship, each blade portion is inserted through the insulation coating of the wire bundle and electrically connected to the core conductor portion of the electric wire, and thus this state is maintained for each LED element. A device for illumination in which the LED elements are directly attached to and electrically connected to a bundle of wires having an insulating coating at intervals.   An illumination device in which a plurality of LED elements are directly mounted and electrically connected to an electric wire bundle having an insulating coating at intervals with the LED element connection holding holder according to claim 4.   The illumination device according to claim 5 or 6, wherein the LED element connection holding holder according to claim 4 is electrically connected by directly mounting a plurality of LED elements on a wire bundle having an insulating coating at intervals.

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