JP2007134307A - Cable connection method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To prevent the fraying, breaking or the like of a core when comparatively many cables are pressure-connected to one another. <P>SOLUTION: In the cable connection method in which core wires 2 of a plurality of cables 1 are pressurized and welded or bonded and connected with one another, the plurality of cables 1 are divided into a plurality of sets each having a small number of cables 1 and a core 2 of each set having a small number of the cables 1 is temporarily connected to form a plurality of sets of temporarily connected cables 4 and temporarily connected cores 5 of a plurality of sets each having a small number of the cables 1 are actually connected to form one set of actually connected cables 6. A core 2 of a plurality of sets each having a small number of cables 1 or the temporarily connected core 5 of a plurality of sets of temporarily connected cables 4' are arranged in parallel and neighboring with one another and actual connection is carried out while the root end is bent. Sets having the same or nearly the same diameters of strands 22 of a small number of the cables 21 are temporarily connected to one another. Sets having the same or nearly the same diameters of strands 22 of a small number of the cables 21 are primarily temporarily connected to one another and each of the temporarily connected cables 26 in a first place is temporarily connected in a second place to obtain a plurality of temporarily connected cables 29. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a wire connecting method for connecting core portions of a plurality of wires to each other by ultrasonic welding, resistance welding, or the like.

  16 (a) and 16 (b) show an embodiment of a conventional wire connection method (see Patent Document 1).

  As shown in FIG. 16A, this electric wire connection method peels off the intermediate portion in the longitudinal direction of the plurality of electric wires 61 to expose the core wire portions 62 of the electric wires 61 and converges the core wire portions 62 while working the work table. 63, the ultrasonic horn 65 is pressed against each core wire portion 62 with the anvil 64, and each core wire portion 62 is heated and welded by ultrasonic vibration of the horn 65 for joint connection. is there.

  As shown in FIG. 16B, the core wire portions 62 of the plurality of electric wires 61 are integrated by welding at the central portion. A fluid insulating material is injected from a nozzle (not shown) into the core wire welded portion 62 ′ and the nearby wire insulation coating portion 66, and the insulation portion is covered with an adhesive sheet to insulate the wire connection portion. And waterproofing is achieved.

  Although the said electric wire connection method is a thing in the intermediate part of the electric wire 61, as an example which performs a connection process of the terminal part of an electric wire, the example shown to Fig.17 (a) (b) is mentioned (refer also patent document 1).

  As shown in FIG. 17A, in this electric wire connection method, the terminal portions of the plurality of electric wires 71 are peeled to expose the core wire portions 72, and each core wire portion 72 is pressed between the pair of upper and lower electrodes 73 while being pressed between the electrodes. The core wire portions 72 are heated and welded by passing an electric current through them.

  As shown in FIG. 17B, the core wire welded portion 72 ′ is integrated by welding except for a portion near the tip of the insulating coating portion 74 of each electric wire 71. The core wire welded portion 72 ′ and the subsequent wire insulation coating portion 74 are inserted into a synthetic resin cap (not shown), and a molten resin material is injected into the cap from a nozzle and cooled and solidified to connect the wires. Insulation and waterproofing of the part are achieved.

  FIG. 18 shows an example in which the core portions of the terminals of a plurality of electric wires are connected by ultrasonic welding.

The insulation covering part in the middle of each electric wire 51 is supported by the receiver 54, and the core wire part 52 is supported by the ultrasonic horn 55 in a state where the core wire part 52 of the terminal of each electric wire 51 is supported by the metal receiver 53. While being pressurized toward the receiving member 53 from above, they are ultrasonically vibrated in the longitudinal direction of the electric wire and welded together. As shown in FIG. 19, the core wire welding portion 56 of each electric wire 51 is integrated by welding except for a portion near the tip 57 a of the insulating coating 57.
JP-A-2002-369328 (FIGS. 4 to 5)

  However, in the above conventional wire connection method, for example, as shown in FIGS. 20A and 20B, when a relatively large number of wires 51 are welded while being pressed in the radial direction, the insulation of the wires 51 is performed. Since a large step L is formed between the tip 57a of the covering portion 57 and the core wire welding portion 56, a plurality of thin strands constituting each core wire portion 52 are strongly pulled and frayed or cut. Alternatively, there is a concern that a part of the core wire portion 52 is strongly pulled (pulled) in the tip direction, the tip position of the core wire portion 52 is shifted, and the tip 52a is not aligned and becomes dirty. This is not limited to the welding of each core wire portion 52 itself, and the same applies to the case where each core wire portion 52 is bonded with solder or the like while being pressed.

  In view of the above-described points, the present invention prevents fraying or cutting of the strands constituting the core wire portion or displacement due to drawing of the core wire portion when a relatively large number of wires are pressed and connected in the radial direction. An object of the present invention is to provide an electric wire connecting method that can handle the above.

  In order to achieve the above object, an electric wire connecting method according to claim 1 of the present invention is the electric wire connecting method in which the core portions of the plural electric wires are connected to each other by welding or bonding while being pressurized. Are divided into a plurality of sets of a small number of electric wires, the core wires of the small number of electric wires are temporarily connected to each set to form a plurality of sets of temporary connection wires, and the plurality of sets of temporary connection wires are temporarily connected. The parts are finally connected to each other to form a set of main connection wires.

  With the above configuration, first, the exposed core portions of a small number (at least two) of wires are temporarily connected to each other by means of ultrasonic welding, resistance welding, pressure soldering (adhesion), etc., and a plurality of sets of temporary connections are made. An electric wire is formed. Next, the temporary connection core wire portions of the plurality of sets of temporary connection wires are mutually connected by means such as ultrasonic welding, resistance welding, and pressure soldering (adhesion) to form a set of main connection wires. Temporary connection is performed with a small number of electric wires, so when each core wire part is pressurized, it is not pulled strongly in the pressing direction, and the core wire part is between the temporary connection core wire part and the tip of the insulation coating part. The thin wire constituting the wire is not frayed or cut, or the core wire portions are not pulled and displaced. Since the temporary connection core wire portions are connected to each other, the pressure applied during the main connection acts only on the temporary connection core wire portion, and the wire between the temporary connection core wire portion and the tip of the insulation coating portion is not applied. No strong tensile force is applied, and the wire is not frayed or cut at the tip of the insulation coating portion, or the temporary connection core wire portions are not pulled and displaced. The core wire portion of the electric wire may be not only at the end portion of the electric wire but also at the intermediate portion of the electric wire. A small number of wires at the time of temporary connection depends on the diameter of the wire, but it is preferably about 2 to 5 as an example, and the number of temporarily connected wires at the time of this connection is about 2 to 5 as an example It is preferable that

  The electric wire connection method according to claim 2 is the electric wire connection method according to claim 1, wherein the core wire portions of the plurality of sets of minority wires or the temporary connection core wire portions of the plurality of sets of temporary connection wires are close to each other in parallel. Thus, the main connection is performed in a state of being bent at the base side.

  With the above configuration, the core wires of a plurality of sets of a small number of electric wires are overlapped and temporarily connected from a state in which they are close to each other in parallel, and then finally connected. Alternatively, the temporary connection core wires of the plurality of sets of temporary connection wires are superposed from each other in a state of being close to each other in parallel and are finally connected. As a result, the base part of the core part of the electric wire (core part located near the tip of the insulation coating of the electric wire) or the base part of the temporary connection core part of the temporary connection electric wire (near the tip of the insulation coating of the temporary connection electric wire) A large tensile force is not applied to the located core wire portion), and wire breakage or the like is prevented.

  The wire connection method according to claim 3 is characterized in that, in the wire connection method according to claim 1 or 2, the temporary connection is performed with the diameters of the strands of the small number of wires being the same or close to each other. To do.

  With the above configuration, core portions of electric wires having the same or close strand diameter are temporarily connected to form a plurality of sets of temporary connection wires, and a plurality of sets of temporary connection wires are connected to form one main connection wire. The Since the wire diameter of each electric wire is the same or approximate in the temporary connection, thermal energy is uniformly transmitted to each wire in ultrasonic welding or thermocompression welding, and each wire is surely welded simultaneously. Moreover, since the strand diameters are the same, the strand breakage, fraying and pulling in of the core portion are unlikely to occur.

  The electric wire connection method according to claim 4 is the electric wire connection method according to claim 3, wherein primary temporary connection is performed with the diameters of the strands of the small number of electric wires being the same or close to each other, and the primary temporary connection wires are connected to each other. Are temporarily provisionally connected to obtain the plurality of sets of temporary connection wires.

  With the above configuration, core portions of wires having the same or similar wire diameter are temporarily connected temporarily to form a plurality of sets of primary temporary connection wires, and some of the plurality of sets of primary temporary connection wires are combined to The primary temporary connection core wire portions are secondarily temporarily connected to form a plurality of sets of secondary temporary connection wires. The secondary temporary connection electric wire corresponds to the temporary connection electric wire of claim 1. A plurality of sets of secondary temporary connection wires are permanently connected to form one permanent connection wire. Since the wire diameter of each electric wire is the same or approximate in the primary temporary connection, thermal energy is uniformly transmitted to each wire in ultrasonic welding or thermocompression welding, and each wire is surely welded simultaneously. Since the secondary temporary connection is to connect the block-like primary temporary connection cores as in the main connection, even if the wire diameters are different, the connectivity is not affected at all. No fraying occurs.

  The electric wire connecting method according to claim 5 is the electric wire connecting method according to any one of claims 1 to 4, wherein the core wire portion of the small number of electric wires is accommodated in a receiving groove of a receiving tool, and the receiving groove is in the receiving groove. An ultrasonic horn is inserted, the core wire portions are temporarily welded with the ultrasonic horn, the temporary connection core wire portions of the plurality of sets of temporary connection wires are received in the receiving groove of the receiving tool, and the receiving groove is received in the receiving groove. An ultrasonic horn is inserted, and the temporary connection core wire portions are finally welded with the ultrasonic horn.

With the above configuration, the core wire portion of a small number of wires is stably supported (not expanded) in the receiving groove of the receiving device in the wire radial direction, and the ultrasonic horn enters the receiving groove in this state. By pressing each core wire portion, the pressing force is prevented from escaping in the direction perpendicular to the pressing force, and ultrasonic welding is performed in a state where each core wire portion is reliably pressurized, so that temporary welding (temporary connection) is quick. And surely done. Similarly, the temporarily welded core wires of a plurality of sets of temporarily connected wires are stably supported without spreading in the wire radial direction within the receiving groove of the receiver, and in this state, the ultrasonic horn enters the receiving groove and enters each temporary wire. By pressing the welding core wire portion, the pressing force is prevented from escaping in the direction perpendicular to the pressing direction, and each temporary welding core wire portion is ultrasonically vibrated in a state where it is reliably pressurized. Is performed quickly and reliably. The receiver can be divided into a temporary connection and a main connection, but the width of the receiving groove can be adjusted so that the width of the receiving groove can be adjusted. Is also possible. Only the tip at the tip of the ultrasonic horn may be exchanged for temporary connection and main connection, and other horn portions and the ultrasonic welder itself may be used in common.

  The electric wire connection method according to claim 6 is the electric wire connection method according to claim 5, wherein the insulation coating portions of the small number of electric wires and the insulation coating portions of the plurality of sets of temporarily connected electric wires are respectively supported by a receiver. Features.

  With the above configuration, by supporting the insulation coating portions of a small number of wires and the insulation coating portions of a plurality of sets of temporary connection wires with each receiving tool, the support and positioning of the core wire portion and the temporary welding core wire portion by the receiving device are further performed. It is performed reliably and the temporary weldability and the main weldability are further improved. It is preferable to arrange the receptacle that supports the insulating coating portion in the vicinity of the receptacle that supports the core wire portion and the temporary welding core wire portion.

  As described above, according to the first aspect of the present invention, the core wires of a small number of electric wires are temporarily connected to each other, and the temporarily connected core wires are connected to each other. In this way, unreasonable force is not applied, and fraying or cutting of the wire, displacement due to pulling of the core wire portion, and the like are prevented, and the reliability of the connection between the wires is improved.

  According to the invention described in claim 2, by forming the core wire parts so as to be close to each other before the main connection, the pulling of the wire during the main connection is prevented, and the effect of the invention according to the first aspect is achieved. Is promoted.

  According to the third aspect of the present invention, since the strand diameters at the time of temporary connection are the same or close, the connectivity between the strands is good, and strand breakage and fraying can be more reliably prevented. . In addition, the strands can be efficiently welded with less heat energy, and energy consumption in ultrasonic welding and thermocompression bonding can be reduced.

  According to the fourth aspect of the present invention, particularly when there are many electric wires having different wire diameters, the wires of each electric wire can be reliably and satisfactorily connected without being broken or frayed.

  According to invention of Claim 5, the core wire part of the electric wire at the time of temporary connection and the temporary welding core wire part of the temporary connection electric wire at the time of this connection reliably ensure the pressurizing force and the exciting force of the ultrasonic horn in the receptacle. Since it can receive, temporary connection and this connection are performed reliably and the reliability of the connection of electric wires improves further.

  According to the invention described in claim 6, the core wire portion and the temporary welding core wire portion are accurately positioned by stably supporting the insulating coating portion of the electric wire or the temporary connection electric wire with the receiving tool. The effect of the invention is promoted.

  1 to 5 show an embodiment of a wire connecting method according to the present invention.

  As shown in FIGS. 1 and 5 (a), this electric wire connecting method divides a large number of electric wires 1 to be connected into a plurality of sets, and the conductive core portion of the terminal of the divided small number of electric wires 1 2 are temporarily connected (temporarily joined) to each other, and this is repeated for each set, and as shown in FIGS. 2 and 5 (b), a plurality of sets in which the required number of wires 1 are divided into several and temporarily connected The temporary connection wire 4 is configured. Next, as shown in FIG. 3, the temporary welding core wire portions (temporary connection core wire portions) 5 of the plurality of temporary connection wires 4 are finally connected (finally joined) to each other, and the main connection wires shown in FIGS. 6 is a feature.

The electric wire group 20 for temporary connection (FIG. 5A) of this example is composed of three electric wires 1, and temporary connection and main connection are performed using two electric wire groups 20, and temporary connection is made. The number of the electric wires 1 constituting the electric wire 4 is three, and two sets of temporary connection electric wires 4 are connected to obtain a set of main connection wires 6 consisting of a total of six electric wires 1. For example, the number of the electric wires 1 constituting the temporary connection electric wire 4 may be two, or may be four or more as long as the electric wire has a small diameter.

  In this example, the temporary connection and the main connection of the electric wire 1 are performed using ultrasonic horns 8 and 10, respectively. The ultrasonic horns 8 and 10 have tips 9 and 11 at their tips, and are connected to a rear ultrasonic vibrator (not shown) to vibrate ultrasonically in the longitudinal direction of the electric wire. Open 2003-126967 and Japanese Patent Application Laid-Open No. 2003-334670, etc.) and a drive means (not shown) together with the vibrator can be moved in the vertical direction. An ultrasonic welding machine (not shown) is constituted by the ultrasonic horns 8 and 10, the ultrasonic vibrator, the driving means and the like. The tips 9 and 11 at the tips of the ultrasonic horns 8 and 10 are formed to be slightly narrower than the inner widths of the receiving grooves 14 and 18 of the wire receivers 12 and 16.

  As shown in FIG. 1, the core part 2 of each divided electric wire 1 is accommodated and set in a receiving groove 14 of a metal connector (anvil) 12 for temporary connection in a state in which the core part 2 is stripped in advance and the tips are aligned. The bottom surface 14a and both side surfaces 14b of the receiving groove 14 are stably supported without spreading laterally. The insulating coating 3 in the middle portion in the longitudinal direction of each electric wire 1 is supported in a vertically long manner in a receiving groove 15 of a metal or synthetic resin receiving tool 13. Each core wire portion 2 and insulating coating portion 3 are smoothly inserted into the receiving grooves 14 and 15 from above by guide inclined surfaces 14c and 15c. Each insulation coating portion 3 is stably supported by the bottom surface 15a and both side surfaces 15b of the receiving groove 15 without lateral expansion.

  In this state, the ultrasonic horn 8 for temporary connection descends from the upper side of the receiving tool 12 and enters the vertical receiving groove 14, and the core wire portion 2 of each electric wire 1 is moved downward between the bottom surface 14 a of the receiving groove 14. While pressing in the electric wire radial direction, ultrasonic vibration is performed in the front-rear direction (electrical wire longitudinal direction) to temporarily weld (temporarily connect) the core wire portions 2 to each other. Temporary welding is to weakly weld each wire 1 to such an extent that it cannot be removed by lightly pulling. The vibration time or pressurizing force of the ultrasonic horn 8 required for the temporary welding may be, for example, about half that when the divided electric wires 1 are actually welded. It is also possible to temporarily weld each core wire portion 2 to the same extent as the main welding.

  The plurality of temporary connection wires 4 shown in FIGS. 2 and 5B are formed by the temporary welding step shown in FIG. Since the temporary connection electric wire 4 is composed of a small number (at least two or more) of electric wires 1, each core wire portion 2 is constituted between the temporary welding core wire portion 5 of each electric wire 1 and the tip 3 a of each insulating coating 3. A large number of thin strands are not pulled strongly, and each core wire portion 2 continues in a gentle curve from the tip 3a of the insulating coating 3 to the temporary welding core wire portion 5 as shown in FIG. The temporary welding core wire portion 5 of the temporary connection wire 4 is compressed into a rectangular cross section between the receiving member 12 and the tip 9 of the ultrasonic horn 8.

  Next, as shown in FIG. 3, with the plurality of temporary connection wires 4 supported by the main connection receivers 16, 17, the temporary welding core wire portions 5 of the temporary connection wires 4 are connected by the ultrasonic horn 10 for main connection. Weld together.

  The main connection receivers 16 and 17 are formed to be slightly larger than the temporary connection receivers 12 and 13. With the tips of the temporary welding core wire portions 5 of the temporary connection wires 4 aligned, the temporary welding core wire portions 5 are accommodated in the receiving groove 18 of the metal receiver (anvil) 16 from above through the guide inclined surface 18c. The receiving groove 18 is stably supported by the bottom surface 18a and both side surfaces 18b without spreading laterally. The insulation covering portion 3 at the intermediate portion in the longitudinal direction of each temporary connection wire 4 is smoothly inserted into a vertical receiving groove 19 of a metal or synthetic resin receiving member 17 through a guide inclined surface 19c and supported vertically. Each insulation coating portion 3 is stably supported by the bottom surface 19a and both side surfaces 19b of the receiving groove 19 without spreading laterally. Since the temporary welding core wire part 5 of the temporary connection electric wire 4 has a rectangular cross section, the temporary welding core wire parts 5 come into stable contact with each other in a plane.

  In this state, the ultrasonic horn 10 for main connection is lowered from the upper side of the receiving tool 16 to enter the vertical receiving groove 18, and each temporary welding core wire portion 5 is moved downward (to the bottom surface 18 a of the receiving groove 18 ( The ultrasonic horn 10 is ultrasonically vibrated in the front-rear direction (longitudinal direction of the electric wire) while pressing in the electric wire radial direction), and the temporary welding core wire portions 5 are finally welded (mainly connected) to each other. The main welding means that the electric wires 1 are strongly welded so as not to be detached even if they are pulled strongly. Ultrasonic vibration is performed in a state where the temporarily welded core wire portions 5 having a rectangular cross section are in surface contact with each other, so that the temporary welded core wire portions 5 are reliably permanently welded.

  A pair of main connection wires 6 in FIGS. 4 and 5C is formed by the main welding step in FIG. The main welding core wire portion 7 of the main connecting wire 6 is formed in a rectangular cross section. The main connection wire 6 is formed by joining the temporary welding core wire portions 5 of a plurality of sets of the temporary connection wires 4 to each other. As described above, each temporary connection wire 4 includes a small number (at least two or more) of wires 1. Each core wire portion 2 is not pulled strongly between the temporary welding core wire portion 5 of each electric wire 1 and the tip 3a of each insulating coating 3, and gently from the tip 3a of the insulating coating 3 to the temporary welding core wire portion 5. (For example, in a curved shape with a large radius curve), even when the temporary welding core wire portions 5 of the temporary connection wires 4 are finally welded to each other, each temporary welding core wire portion 5 and the tip of each insulating coating 3 Each core wire portion 2 is not strongly pulled inward in the radial direction of the electric wire between the wire 3a and the thin strands of each core wire portion 2 are not frayed or cut. Pull-in does not occur and the position of the tip of each temporary welding core wire portion 5 is misaligned. Made it) is prevented.

  By temporarily connecting the temporary welding core wire portions 5 of the terminals of the plurality of sets of temporary connection wires 4, the plurality of wires 1 are jointed to each other. For example, the power supply current is transferred from one wire 1 to another plurality of wires 1. It is possible to supply or ground the plurality of electric wires 1 to the vehicle body or the like with one electric wire 1.

  The main welding core wire portion 7 of the main connecting wire 6 is wound with an insulating tape (not shown) or inserted into an insulating cap to be insulated. Waterproofing can be imparted by injecting an insulating resin material into the insulating cap and solidifying it.

  Although the example which connects the core wire part 2 of the terminal of the electric wire 1 was shown in the said FIGS. 1-5, it is also possible to connect the intermediate core wire part 2 of the electric wire 1 as shown in FIGS. . The same components as those in the previous example are denoted by the same reference numerals, and detailed description thereof is omitted.

  That is, as shown in FIG. 6, the insulation coating 3 in the middle portion in the longitudinal direction of the plurality of electric wires 1 is peeled off to expose the core wire portion 2, and the core wire portion 2 is received in the receiving groove of the intermediate receiving tool 12 for temporary connection. At the same time, the insulation covering portions 3 on both the front and rear sides of the core wire portion 2 are supported by the receiving grooves 15 of the front and rear receiving devices 13, and an ultrasonic horn 8 for temporary connection is added to the core wire portion 2 as in the previous example. The core wire portions 2 are temporarily welded by applying pressure to obtain a plurality of sets of temporary connection wires 4 in FIG.

  As shown in FIG. 7, the temporary welding core wire portion 5 of the temporary connection wire 4 is formed at the center portion of the exposed core wire 2, and both the front and rear sides of the temporary welding core wire portion 5 are the core wire portions (multiple strands) 2 and the insulation coating portion. 3 to the tip 3a side. Since the temporary connection wire 4 is composed of a small number of wires 1, the wire of each core wire portion 2 is gently pulled from the temporary welding core wire portion 5 to the tip 3 a of the insulating coating portion 3 as in FIG. 5B. It continues in a curve. The temporary welding core wire part 5 is compressed into a rectangular cross section between the support 12 and the ultrasonic horn 8.

As shown in FIG. 8, a plurality of sets of temporary connection wires 4 are accommodated and set in the receiving grooves 18 of the intermediate connection 16 for the main connection, and at the same time, the insulation covering portions 3 on both the front and rear sides of the temporary welding core wire portion 5 are respectively received by 17, the ultrasonic horn 10 for main connection is pressure-excited to the temporary welding core wire part 5 and the temporary welding core wire parts 5 are finally welded to each other. An electric wire 6 is obtained. Since the temporary welding core wire portion 5 of the temporary connection electric wire 4 has a rectangular cross section, the temporary welding core wire portions 5 are in stable contact with each other in a planar manner, and the temporary welding core wire portions 5 having a rectangular cross section are in surface contact with each other. By sonic vibration, the temporary welding core wire portions 5 are securely welded together.

  As shown in FIG. 9, the main welding core wire portion 7 of the main connecting wire 6 is formed at the exposed central portion of the core wire 2, and the front and rear sides of the main welding core wire portion 7 are the core wire portions (multiple strands) 2 and the insulation coating portion. 3 to the tip 3a side. The main connection wire 6 is formed by joining the temporary welding core wire portions 5 of a plurality of sets of the temporary connection wires 4 to each other. As described above, each temporary connection wire 4 includes a small number (at least two or more) of wires 1. Each core wire portion 2 is not pulled strongly between the temporary welding core wire portion 5 of each electric wire 1 and the distal end 3a of each insulating coating portion 3, and gently from the distal end 3a of the insulating coating portion 3 to the temporary welding core wire portion 5. Each of the core wires between the temporary welding core wire portions 5 and the distal ends 3a of the insulating coating portions 3 even when the temporary welding core wire portions 5 of the temporary connection wires 4 are welded to each other. The portion 2 is not strongly pulled inward in the radial direction of the wire, the thin strands of the core wire portion 2 are not frayed or cut, and the temporary welding core wire portion 5 is not pulled in. The misalignment (unevenness) of the welding core wire part 5 is prevented.

  A plurality of wires 1 are jointed to each other by main welding the intermediate welding core wire portions 5 in the middle of the plurality of sets of temporary connection wires 4. For example, the power supply current is changed from one wire 1 to another plurality of wires 1. Or the ground of a plurality of electric wires 1 can be connected to the vehicle body or the like with a single electric wire 1.

  The welding core wire portion 7 of the connecting wire 6 is wound with an insulating tape, an insulating tube is attached, or an insulating resin material is attached in a molding die to provide insulation and waterproofness. Can do.

  10 to 12 show another embodiment of the electric wire connection method according to the present invention.

  This electric wire connection method is the above-mentioned figure in a state where the core wire portion 2 of a plurality of sets of a small number of electric wires 1 or the temporary connection core wire portions 5 of a plurality of sets of temporary connection wires 4 ′ are bent at the base side so as to be close to each other. It aims at relieving the tensile force which acts on the core part 2 of each electric wire 1 at the time of this connection (FIG. 3, FIG.5 (c)) by performing this connection of embodiment of 1-5. The same components as those in FIGS. 1 to 5 are denoted by the same reference numerals, and detailed description thereof is omitted.

  As an example, as shown in FIG. 10, when the core part 2 of each electric wire 1 is temporarily connected with the tip 9 of the ultrasonic horn 8 for temporary connection, an inclined surface 14a ′ is formed on the bottom surface 14a of the receiving groove 14 of the receiving tool 12 ′. By forming, the core wire portion 2 ′ is formed in an inclined shape between the temporary welding core wire portion (temporary connection core wire portion) 5 of each of the upper and lower temporary connection wires 4 in FIG. 11 and the tip 3 a of the insulating coating 3. The upper and lower temporary welding core wire portions 5 are arranged eccentric to the intermediate temporary welding core wire portion 5.

  The inclined surface 14a ′ of the receiving tool 12 ′ in FIG. 10 is inclined downward from the rear end 14b of the receiving groove 14 to the intermediate portion, and is in front of the temporary welding core wire portion 5 of the upper temporary connection wire 4 ′ in FIG. An inclined core wire portion 2 'is formed on the substrate. The temporary welding core wire portion 5 of the lower temporary connection wire 4 ′ in FIG. 11 can be obtained by turning the upper temporary connection wire 4 ′ upside down.

  12 (a) to 12 (d), the wire connection method of this embodiment is shown in the order of steps. First, in FIG. 12 (a), a plurality of sets (three in this example) of wires 1 are combined ( In this example, three sets of temporary connection wire groups 20 are formed. The electric wires 1 constituting each electric wire group 20 are appropriately divided in consideration of the number of electric wires at the time of main connection.

Next, the upper and lower electric wire groups 20 are set to the receivers 12 ′ and 13 of FIG. 10 for each set, and the core wire portion 2 is temporarily connected by the ultrasonic horn 8. The wire group 4 in the middle in the height direction temporarily connects the core wire portion 2 by using the ordinary receiving tool shown in FIG. 1, and the temporary welding core wire portion 5 and the remaining core wire portion 2 are positioned substantially straight. In addition, each core wire part 2 of many sets of electric wire groups 20 is temporarily connected in an inclined shape or a straight line in advance using the temporary connectors 12 'and 8 in FIG. 10 and the temporary connectors 12 and 8 in FIG. Of these, the temporary connection wires 4 and 4 ′ arranged at the upper, middle, and lower positions may be appropriately selected.

  As shown in FIG. 12B, simultaneously with the temporary connection, the temporary welding core wire portion 5 of the upper and lower temporary connection wires 4 ′ is directed toward the temporary welding core wire portion 5 of the intermediate temporary connection wire 4 via the inclined core wire portion 2 ′. The upper temporary welding core wire portion 5 protrudes below the lower end surface 3b of the insulating coating 3 of the upper temporary connection wire 4 ′, and the lower temporary welding core wire portion 5 extends downward. The distance S between the upper and lower temporary welding core wire portions 5 and the intermediate temporary welding core wire portion 5 protruding below the upper end surface 3c of the insulating coating 3 of the connecting wire 4 ′ is the form shown in FIG. 5B. The temporary welding core wire portions 5 are arranged in parallel with each other and narrower than in FIG.

  From the state of FIG. 12 (b), as shown in FIG. 12 (c), the insulation coatings 3 of the temporary connection wires 4 and 4 ′ are overlapped vertically, so that the temporary connection welds 5 are overlapped with each other without difficulty. Makes surface contact with no gap. In this state, using the receivers 16 and 17 of the embodiment of FIG. 3 and the ultrasonic horn 10, the temporary welding core wire portions 5 of the temporary connection wires 4 and 4 ′ are permanently connected as shown in FIG. The welding core wire portion 7 is formed by welding. Thereby, a set of thick main connection electric wires 6 is completed.

  In FIG. 12B, the temporary welding core wires 5 of the temporary connection wires 4 and 4 ′ are made to approach each other in parallel before the main connection, so that the upper and lower temporary welding core wires at the time of the main connection in FIG. The portion 5 is no longer pulled toward the intermediate temporary welding core wire portion 5, and a large tensile force may act on the core wire portion 2 ′ between the upper and lower temporary welding core wire portions 5 and the tip 3 a of the insulating coating 3. In addition, each of the strands constituting the core wire portion 2 ′ is reliably prevented from being cut off, and the parallel temporarily welded core wire portions 5 at the time of main connection in FIG. Connection (main welding) is performed more reliably.

  In the embodiment of FIG. 10, the temporary welding core wire portion 5 is formed (eccentric forming) simultaneously with the temporary connection. For example, before the temporary connection, the electric wire group including the plurality of electric wires 1 of FIG. It is also possible to eccentrically mold the core wire portion 2 into the shape of FIG. 12B at 20, and then temporarily weld the upper and lower eccentric core wire portions 2 ′ and the intermediate straight core wire portion 2 to each other.

  Moreover, although the core wire part 2 of the terminal of the electric wire 1 was temporarily welded or main welded in the embodiment of FIGS. 10-12, in the longitudinal direction intermediate part of the electric wire 1 like the said embodiment of FIGS. The core wire part 2 can also be temporarily welded or permanently welded.

  10 to 12, the upper, middle, and lower temporary connection wires 4 ′, 4, 4 ′ are overlapped for main connection, but the upper and lower temporary connection wires 4 ′, 4 ′ are overlapped for main connection. In FIG. 12B, the upper and middle temporary connection wires 4 ′ and 4 can be overlapped and finally connected, or the middle and lower temporary connection wires 4 and 4 ′ can be overlapped and finally connected.

  Moreover, in each said embodiment, if the method (division | combination of the electric wire 1) of the division | segmentation of the electric wire 1 in FIG.1, FIG.5 (a), FIG.6 is all the electric wires 1 of the same kind (shape size), The same type of electric wire 1 can be divided into several to obtain a plurality of sets of temporary connection electric wires 4, 4 ′ having the same shape in FIGS. 2, 5 (b), 7 and 12 (b). For example, when different types of different electric wires 1 are used, it is possible to obtain temporary connection wires 4 and 4 ′ composed of the same type of electric wires 1 by dividing the electric wires 1 for each type. It is preferable for facilitating the treatment.

Moreover, in each said embodiment, although the holders 12, 13, 16, and 17 and the ultrasonic horns 8 and 10 which are respectively different by the temporary connection of the electric wire 1 and this connection were used, the holder 16 for this connection, It is also possible to make a temporary connection using 17 and the ultrasonic horn 10. In this case, when the electric wire 1 is temporarily connected, each core wire portion 2 expands in the horizontal direction and the temporary welding core wire portion 5 tends to have a flat shape. However, each flat temporary welding core wire portion 5 is permanently welded in the thickness direction. Thus, a relatively thick main welding core wire portion 7 can be obtained.

  Moreover, in each said embodiment, although the electric wire group 20 and temporary connection electric wires 4 and 4 'were piled up in the up-down direction (height direction), temporary connection and this connection were performed, For example, it is an electric wire in the left-right direction (lateral direction) The group 20 and the temporary connection wires 4 and 4 ′ can be overlapped to perform temporary connection or main connection.

  In each of the above embodiments, the temporary connection and the main connection are performed by ultrasonic welding, but the temporary connection and the main connection are performed by resistance welding or pressure soldering (adhesion) instead of the ultrasonic welding, Alternatively, after temporary connection by ultrasonic welding, it is possible to make a main connection by resistance welding or pressure soldering, or after making a temporary connection by resistance welding or pressure soldering, and then make a main connection by ultrasonic welding. is there.

  In resistance welding, a current is passed between both electrodes in a state where the core wire portion 2 of each electric wire 1 and the temporary welding core wire portion 5 of the temporary connection electric wire 4 are pressurized between upper and lower electrodes (not shown). Done. For example, as for the lower electrode, each core wire part 2 and the temporary welding core wire part 5 are positioned and set in the grooves shallower than the receiving grooves 14 and 18 of the receivers 12 and 16 in FIGS. The upper electrodes instead of the ultrasonic horns 8 and 10 are pressed against the respective core wire portions 2 and the temporary welding core wire portions 5 without touching the lower electrodes, and are energized.

  Moreover, the receptacles 13 and 17 which support the insulation coating part 3 of each electric wire 1 and the insulation coating part 3 of each temporary connection electric wire 4 and 4 'are not necessarily required. With each temporary connection wire 4, 4 ′ held, temporary connection or main connection can be performed, or each wire 1 or each temporary connection wire 4, 4 ′ can be held with an openable / closable chuck (not shown), It is also possible to perform temporary connection or main connection in a state where each wire 1 or each temporarily connected wire 4, 4 ′ is supported only by the core wire portion 2 or the temporarily welded core wire portion 5.

  Moreover, as the receiving tools 12 and 16 which support the core wire part 2 of each electric wire 1 and the temporary welding core wire part 5 of temporary connection electric wires 4 and 4 ', the receiving groove 14, rather than FIG. 1, FIG. 6, FIG. It is also possible to use 18 shallow ones or to use a flat receiving member without the receiving grooves 14 and 18.

  Further, as each of the receiving tools 12, 13, 16, and 17, a tool that can variably adjust the width of the receiving grooves 14, 15, 18, and 19 is used, and the temporary connection of the electric wire 1 and the main connection are shared by one kind. It is also possible to carry out with the receiving device.

  13 to 15 show other embodiments of the electric wire connection method according to the present invention.

This electric wire connection method pays attention to the diameter of the strand 22 (22 _{1 to} 22 ₄ ) constituting the conductive metal core portion 23 (23 ₁ to 23 ₄ ) of the electric wire 21 (21 _{1 to} 21 ₄ ). the wire 21 together close to no same diameter and temporarily connected primary temporary connection wire 26 (26 ₁ to 26 ₄₎ (FIG. 13) is formed, the temporary connection wires 26 to each other and further temporarily connected to the secondary temporary connection wire 29 (29 _{1 to} 29 ₄ ) (FIG. 14), and then the secondary temporary connection wires 29 are finally connected to form the main connection wires 32 (FIG. 15).

  The combinations and the number of the electric wires 21 shown in FIGS. 13 to 15 are merely examples, and the diameter of the strands 22, the number of the electric wires 21 in FIG. 13, the combination of the primary temporary connection electric wires 26 in FIG. . In short, the primary temporary connection is basically made by combining the same or similar diameters of the strands 22 (it goes without saying that the same one is the best).

FIG. 13A shows a state where the wires 21 ₁ having the smallest wire diameter in FIG. 13 are temporarily connected to each other, and FIG. 13B shows the wires 21 ₂ having the second smallest wire diameter connected to each other. primary temporary connection state, FIG. 13 (c), while another primary temporary connection wires 21 ₃ moderate wire diameter, FIG. 13 (d) is a large wire 21 ₄ of wire diameter mutually The state of primary temporary connection is shown.

In FIG. 13 (a), reference numeral 23 ₁ is a core wire portion composed of a plurality of strands 22 ₁ , 24 ₁ is a primary temporary welded (temporary connection) core wire portion in which the core wire portion 23 ₁ is temporarily connected by ultrasonic waves, thermocompression bonding, etc. In FIG. 13B, reference numeral 23 ₂ denotes a core wire portion, 24 ₂ denotes a primary temporary welding (temporary connection) core wire portion, FIG. 13C shows reference numeral 23 ₃ to a core wire portion, and 24 ₃ denotes primary temporary welding (temporary connection) core wire. 13D in FIG. 13D, the core wire portion 23 ₄ , 24 ₄ is the primary temporary welding (temporary connection) core wire portion, and FIGS. 13A to 13D, 25 _{1 to} 25 ₄ are the insulation coating portions, respectively. ing.

For reference, for example, in a JIS C3105 hard copper stranded wire, the number of strands is set to 7 in the range of strand diameters of 0.4 mm to 2.6 mm (for example, 0.4 mm strands). 7 wires, 7 wires of 0.5mm). In this case, it goes without saying that the nominal cross-sectional area mm ² of the core wire portion increases or decreases according to the strand diameter.

  In the example of FIGS. 13A to 13D, the number of strands decreases as the strand diameter increases, and the cross-sectional area of the core portion 23 is almost the same. However, as in JISC3105, Even if the strand diameter increases, the number of strands is the same, and even when the cross-sectional area of the core portion 23 increases in accordance with the strand diameter, the wires having the same strand diameter are temporarily connected temporarily, and the primary temporarily connected wires 26 can be temporarily provisionally connected to each other.

  In short, not the diameter of the core wire portion 23 but the same or close diameters of the strands 22 are targeted for primary temporary connection. The wire 22 having a close diameter is, for example, in the above-mentioned JISC3105 where the wire diameter is in the range of about 0.4 to 0.6 mm (if the wire diameter is 0.5 mm, it is about plus or minus 0.1 mm) ) Is preferred. In the case of the primary temporary connection in FIG. 13, when the wire diameters of the two electric wires 21 are the same and the number of wires is different (large), it is the same as the case where three wires having a small number of wires are simultaneously temporarily temporarily connected. There is no problem with temporary connection.

  Temporary connection between wires with the same or similar wire diameter enables stable temporary connection, and more reliable wire breakage and fraying or pulling in of the core wire up to the main connection. Is prevented. In addition, since energy efficiency in ultrasonic welding, heat welding, or the like is achieved at the time of the primary temporary connection, the power consumption is reduced in total even if the secondary temporary connection or the main connection is performed, which is good for the natural environment.

Figure 14 (a), the 13 primary temporary connection wires 26 ₁ of the minimum diameter of the strands 22 ₁ (a), FIG. 13 (b) of the second foremost small strands 22 _secondary temporary connection wire 26 ₂ Are temporarily connected to each other. 14B, the primary temporary connection electric wire 26 ₃ of the medium diameter wire 22 ₃ in FIG. 13C and the primary temporary connection of the large diameter wire 22 ₄ in FIG. 13D. are secondary provisionally connecting the electric wire 26 ₄ to each other. In FIG. 14, reference numerals 27 ₁ and 27 ₂ denote core wire portions, and 28 ₁ and 28 ₂ denote secondary temporary welding (temporary connection) core wire portions, respectively.

In the secondary temporary connection of FIG. 14, for example, FIG. 13 and the first pre-connected wires 26 ₁ of the minimum diameter of the strands 22 ₁ (a), primary provisional 13 strands 22 ₃ of the diameter of the moderate (c) The secondary temporary connection between the connection wire 26 ₃ and the primary temporary connection wire 26 _{2 of the second} smallest strand 22 ₂ of FIG. 13B and the large-diameter strand 22 ₄ of FIG. Secondary temporary connection to the primary temporary connection electric wire 26 ₄ , or the primary temporary connection electric wire 26 ₁ of the minimum diameter strand 22 ₁ of FIG. 13A and the large diameter strand of FIG. 13D 22 ₄ primary temporary connection electric wire 26 ₄ is secondarily temporarily connected, or primary temporary connection electric wire 26 _{2 of the second} smallest strand 22 ₂ in FIG. it is also possible to a primary temporary connection wire 26 ₃ of the strand 22 ₃ diameters or secondary temporary connection.

  That is, in the secondary temporary connection, since each primary temporary welding core wire portion 24 is solidified in a rectangular cross section in the primary temporary connection in FIG. 13, the secondary connection between the primary temporary welding core wire portions 24 having a rectangular cross section is provided. Can be performed satisfactorily irrespective of the diameter of the strand 22 (without strand breakage, fraying or drawing of the core portion).

  Similarly, in the main connection in FIG. 15, the primary temporary welding (temporary connection) core wire portions 28 that are solidified in a rectangular cross section of each secondary temporary connection electric wire 29 in FIGS. 14A and 14B are connected to each other. For this reason, the wires 21 having the respective wire diameters can be properly connected (without breakage of the strands, fraying or drawing of the core portion, etc.) regardless of the diameter of the strands 22.

  In the embodiment of FIGS. 13 to 15, the ultrasonic horns 8 and 10 and the receivers 12, 13, 16, and 17 of FIGS. 6 and 8 can be used for temporary connection and main connection of the intermediate portion of the electric wire using the ultrasonic horns 8 and 10 and the receivers 12, 13, 16 and 17.

  Further, in the primary temporary connection in FIG. 13, the secondary temporary connection in FIG. 14, and the main connection in FIG. 15, as in the examples of FIGS. It is also possible to perform the next welding (connection) in a state in which the welding core wire portions 24 and 28 are close to each other in parallel by bending the strands 23 and 27 in an inclined manner.

  Further, when the number of types of wire diameters in the primary temporary connection in FIG. 13 is small (for example, two types), the secondary temporary connection in FIG. 14 is omitted after the primary temporary connection and the main connection in FIG. 15 is performed. It is possible.

It is a perspective view which shows one Embodiment of the temporary connection process of the electric wire connection method which concerns on this invention. It is a perspective view which shows the multiple sets of temporarily connected electric wires temporarily connected. It is a perspective view which shows one Embodiment of this connection process of an electric wire connection method. It is a perspective view which shows a set of this connection electric wire by which this connection was carried out. (A) is the state which divided | segmented the some electric wire, (b) is the state which temporarily connected the divided | segmented electric wire, (c) is a side view which respectively shows the state which carried out the main connection of several sets of temporary connection electric wires. It is a perspective view which shows other embodiment of the temporary connection process of the electric wire connection method which concerns on this invention. It is a perspective view which shows the multiple sets of temporarily connected electric wires temporarily connected. It is a perspective view which shows other embodiment of this connection process of an electric wire connection method. It is a perspective view which shows a set of this connection electric wire by which this connection was carried out. It is a perspective view which shows other embodiment of the temporary connection process of the electric wire connection method which concerns on this invention. It is a perspective view which shows the multiple sets of temporarily connected electric wires temporarily connected. (A) is a state in which a plurality of electric wires are divided, (b) is a state in which the divided electric wires are temporarily connected, (c) is a state in which a plurality of sets of temporary connection wires are overlapped, and (d) is a plurality of sets of temporary wires. It is a side view which shows the state which connected the connection electric wire. (A)-(d) is a perspective view which shows the primary temporary connection electric wire in the electric wire connection method of this invention. (A) (b) is a perspective view which similarly shows a secondary temporary connection electric wire. It is a perspective view which similarly shows this connection electric wire. (A) is one form of the conventional electric wire connection method, (b) is a side view which respectively shows the electric wire connected similarly. (A) is a perspective view which shows the other form of the conventional electric wire connection method, (b) is a side view which similarly shows the connected electric wire. It is a perspective view which shows the other form of the conventional electric wire connection method. It is a perspective view which shows the electric wire similarly connected. (A) is the side view which shows the several electric wire before a connection, (b) respectively shows the connected electric wire.

Explanation of symbols

1,21 Electric wire 2,23 Core wire portion 3,25 Insulation coating portion 4,4 'Temporary connection electric wire 5,24,28 Temporary welding core wire portion (temporary connection core wire portion)
6,32 connecting wires 7,30 welding core wires (main connecting core wires)
8,10 Ultrasonic horn 12,16 Receptor 13,17 Receiver 14,18 Receiving groove 22 Wire 26 Primary temporary connection wire 29 Secondary temporary connection wire

Claims (6)

  In the wire connection method in which the core portions of a plurality of wires are pressurized and connected to each other by welding or adhesion, the plurality of wires are divided into a plurality of sets of a small number of wires, and the small number of wires for each set A plurality of sets of temporary connection wires are temporarily connected to form a set of main connection wires by mutually connecting the temporary connection core wires of the plurality of sets of temporary connection wires. Electric wire connection method.   The main connection is performed in a state in which the core wire portions of the plurality of sets of small number of electric wires or the temporary connection core wire portions of the plurality of sets of temporary connection wires are bent at the base side so as to be close to each other in parallel. The electric wire connection method according to claim 1.   The wire connection method according to claim 1 or 2, wherein the temporary connection is performed by setting the diameters of the strands of the small number of wires to be the same or close to each other.   The primary temporary connection is performed by setting the diameters of the strands of the small number of electric wires to be the same or close to each pair, and the primary temporary connection wires are secondarily temporarily connected to obtain the plurality of sets of temporary connection wires. The electric wire connection method according to claim 3.   The core wires of the small number of electric wires are received in a receiving groove of a receiving tool, an ultrasonic horn is inserted into the receiving groove, the core wires are temporarily welded with the ultrasonic horn, and the plurality of sets The temporary connection core wire portion of the temporary connection electric wire is accommodated in a receiving groove of a receiving tool, an ultrasonic horn is entered into the receiving groove, and the temporary connection core wire portions are permanently welded with the ultrasonic horn. The electric wire connection method according to any one of claims 1 to 4.   6. The electric wire connection method according to claim 5, wherein the insulation coating portions of the small number of electric wires and the insulation coating portions of the plurality of sets of temporarily connected electric wires are supported by receiving members, respectively.

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