JP2019186070A - Bonded conductor and manufacturing method thereof - Google Patents

Abstract

To provide a bonded conductor and a manufacturing method thereof that can improve the conductivity between conductors.SOLUTION: In a joint conductor 100 having a joint portion 110 in which a plurality of conductor exposed portions 220 arranged along the longitudinal direction X are melt-joined, the joint portion 110 has a substantially rectangular shape in the cross section orthogonal to the longitudinal direction X, and a wave-shaped corrugated portion 140 is formed in which a peak portion 141 protruding outward and a valley portion 142 recessed inward are alternately continued along the longitudinal direction X for each of a first surface 121 and a second surface 122 in at least one width direction side group 120 from among the width direction side surface group 120 and a vertical direction side surface group 130 in which the first surface 121 and the second surface 122 and horns 131 and 132 that face each other in the orthogonal cross section are configured as a pair.SELECTED DRAWING: Figure 1

Description

  The present invention relates to, for example, a bonded conductor obtained by melting and bonding a conductor, and a method for manufacturing a bonded conductor by melting and bonding the conductor.

  In recent years, automobiles are equipped with various electric devices that improve operability and comfort. Such electric devices are electrically connected to each other by a wire harness or the like routed in the automobile, and signal Transmission / reception and power supply are performed.

The plurality of covered electric wires constituting the wire harness can be made conductive by the bonding conductors that are bonded to each other by exposing the conductors covered with the insulating coating.
Such a bonded conductor is manufactured, for example, by ultrasonic bonding while pressing from the thickness direction (vertical direction) in a state where a plurality of conductors are regulated to a predetermined width (see Patent Document 1).

JP 2011-198506 A

  However, in the bonding conductor disclosed in Patent Document 1, the conductors adjacent in the vertical direction are bonded with sufficient strength, but the bonding strength between the conductors adjacent in the horizontal direction is higher than the bonding strength in the vertical direction. Tend to be weak.

  An object of this invention is to provide the manufacturing method of the joining conductor which can improve the joint strength of conductors, and can improve electroconductivity in view of the above-mentioned problem.

  The present invention is a bonded conductor having a bonded portion in which a plurality of conductors arranged along the longitudinal direction are melt-bonded, and the bonded portion is provided with two surfaces facing each other along the longitudinal direction. The first surface, which is at least one of the opposing surfaces, has a peak portion projecting toward the outside in the opposing direction where the two surfaces oppose each other, and a valley portion recessed inward in the opposing direction. A wave-shaped corrugated portion continuous along the longitudinal direction is provided.

  Further, the present invention is a method for manufacturing a bonded conductor for melting and bonding a plurality of conductors arranged along a longitudinal direction, the conductor being compressed along a first direction orthogonal to the longitudinal direction, and the longitudinal direction A compression step for restricting movement of the conductor in a second direction orthogonal to the direction and the first direction, and a welding step for performing ultrasonic welding by ultrasonic vibration on the conductor compressed in the first direction. In the compression step, among the conductor bundles composed of a plurality of the conductors arranged, a peak portion protruding toward the outside in the second direction on the first surface formed in at least one of the second directions And a trough recessed inward in the second direction, and the movement of the conductor in the second direction so that a corrugated corrugated portion is formed along the longitudinal direction. It is characterized by regulating .

  The conductor includes a stranded wire formed by twisting a conductive wire, or a conductor composed of a single wire, a conductor bundled with a strand, and the conductor is made of any material as long as it has conductivity. It may be comprised by, and the thing comprised by the copper-type conductor comprised by copper and a copper alloy, and the aluminum-type conductor comprised by aluminum, aluminum alloy, etc. is included.

  The conductor is, for example, an exposed conductor obtained by cutting off and exposing the insulating coating forming the outer layer at one end of a covered electric wire obtained by coating a bundle of stranded wires or strands with an insulating insulating coating, or an insulating coating. Includes uncoated stranded conductors and conductors bundled with strands.

  The above-mentioned plurality of conductors include those composed of the same or different types of conductors. Specifically, conductors having different outer diameters and materials may be used, or some may be stranded and some may be a single wire.

  The peak portion protruding toward the outside in the facing direction is only required that the peak portion protrudes outward in the facing direction relative to the valley portion. Similarly, the peak direction described above. It should just be the structure which the said trough part recessed in the said opposing direction inner side relatively with respect to the said peak part.

The corrugated portion includes a case where the corrugated portion is formed on the entire side surface or a case where the corrugated portion is formed on a part of the side surface.
Further, the corrugated portion indicates a configuration in which at least one or more of the crests and the troughs are continuous along the longitudinal direction, respectively, provided that the crests and troughs are continuous. The number of peaks and valleys need not match.

According to the present invention, the bonding strength between the conductors can be improved and the conductivity can be improved.
Specifically, since the corrugated portion is formed on at least the first surface of the opposing surfaces, the conductors arranged side by side in the opposing direction among the plurality of conductors constituting the joint portion. Are joined in contact with another conductor adjacent in the opposing direction along a direction intersecting the longitudinal direction. For this reason, in the said junction part, the joint strength of the said conductors arrange | positioned in the said opposing direction is improving.

  Therefore, the integrity of the joint portion can be improved, the conductivity of the conductor constituting the joint conductor can be improved, and the rigidity of the joint conductor can also be improved.

  As an aspect of the present invention, the corrugated portion is provided on both the first surface and the second surface facing the first surface, and the corrugated portion formed on the first surface is defined as a first corrugated portion. The waveform portion formed on the second surface is a second waveform portion, the first waveform portion and the second waveform portion are configured with the same waveform, and the peak portion in the first waveform portion is While facing the trough part in the second corrugated part, the trough part in the first corrugated part may face the peak part in the second corrugated part.

  According to this invention, since the first corrugated portion formed on the first surface and the second corrugated portion formed on the second surface are configured to be shifted by a half wavelength, the joint portion is The conductors arranged side by side along the facing direction are joined with a certain width and an amplitude in the facing direction. For this reason, it is possible to improve the apparent section modulus of the entire joint, and to improve the rigidity of the joint conductor.

  In addition, since the width of the first surface and the second surface with respect to the facing direction is constant in the longitudinal direction, that is, the cross-sectional area of the conductors in the longitudinal direction is constant, Rigidity nonuniformity can be suppressed, and variations in the quality of the bonded conductor can be suppressed.

As an aspect of the present invention, a plurality of the corrugated portions may be provided along the longitudinal direction.
The phrase “provided in plural along the longitudinal direction” described above may mean that a plurality of corrugated portions are provided continuously, or a portion formed in a planar shape is sandwiched therebetween.

  According to the present invention, in the joint portion in which the conductors arranged periodically in the intersecting direction intersecting the longitudinal direction are joined, the joint strength between the conductors arranged in the intersecting direction is improved. And the contact area between the conductors can be increased. Therefore, the integrity of the joint portion can be further improved, and the conductivity and rigidity of the conductor can be further improved.

Further, as an aspect of the present invention, the height in the cross-sectional direction orthogonal to the longitudinal direction from the bottom of the valley to the top of the peak is a second surface facing the first surface and the first surface. The distance in the facing direction may be 0.5 times or less.
According to the present invention, the conductivity of the bonding conductor can be improved and the rigidity can be reliably improved.

  More specifically, when the height of the crest relative to the trough is higher than 0.5 times the distance between the first surface and the second surface in the facing direction, the amplitude of the waveform at the joint is large. Thus, the load on the conductor increases. For this reason, there exists a possibility that the said conductor may be partially torn or damaged, there exists a possibility that the electroconductivity of the said joining conductor cannot fully be ensured, and rigidity may also fall.

  On the other hand, the height of the peak portion with respect to the valley portion in the facing direction is configured to be 0.5 times or less of the interval in the facing direction between the first surface and the second surface. Since the load of the conductors constituting the joint portion can be reduced and the conductors arranged in the facing direction can be made to swing in the facing direction, the joint strength between the conductors due to bending can be reliably improved. In addition, the contact area between the conductors can be increased.

  As a result, the integrity of the joint portion can be improved, the possibility that the conductor is partially broken or damaged can be reduced, the conductivity of the joint conductor can be sufficiently improved, and the rigidity can be improved. Can be reliably improved.

As an aspect of the present invention, the height in the orthogonal cross-section direction from the bottom of the valley to the apex of the peak is 0.5 times or more the minimum diameter of the plurality of conductors arranged. It may be configured.
According to the present invention, the conductivity of the bonding conductor can be improved.

  Specifically, when the height of the crest relative to the trough in the facing direction is lower than 0.5 times the minimum diameter of the plurality of conductors arranged, the crest and trough in the junction Since the amount of amplitude of the waveform formed by the portion is small and the conductors arranged along the opposing direction are not arranged in a state of intersecting the longitudinal direction, the integrity of the joint portion is sufficiently improved. The electrical conductivity of the joint conductor cannot be sufficiently improved.

  On the other hand, the height of the crest relative to the trough in the facing direction is 0.5 times or more the minimum diameter of the plurality of conductors arranged, whereby the junction is the crest And since it can bend | curved reliably along a trough part, the said conductors arrange | positioned along the said opposing direction will be arrange | positioned in the state which cross | intersected with respect to the said longitudinal direction. Thereby, while being able to improve the joining strength of the said conductors reliably, the contact area of the said conductors can be increased, and the electroconductivity of the said joining conductor can be improved.

Moreover, as an aspect of the present invention, the joint portion may have a flat portion formed in a planar shape along the longitudinal direction between the tip and the corrugated portion.
Forming in the above-mentioned planar shape includes the case where it is formed parallel to the one side surface and the case where it is inclined with respect to the side surface. That is, it refers to a shape in which no intentional uneven shape is provided on the side surface between the tip of the joint and the corrugated portion.

By this invention, it can suppress that joining of the said conductors peels from the front end side of the said junction part.
More specifically, since the crest and the trough constituting the corrugated part are configured by curving the conductor, when an external force acts on the side opposite to the curving direction, the conductors are joined to each other. Easy to peel.

  However, since the joint portion has the flat portion between the tip and the corrugated portion, an unintended external force on the opposite side to the bending direction directly acts on the peak portion and the valley portion. In addition to being able to prevent, even if an unintended external force is applied, the external force can be absorbed by the flat surface portion, so that it is possible to suppress separation of the joints between the conductors.

As an aspect of the present invention, the joint may be an ultrasonic joint formed by ultrasonic welding.
According to this invention, since the interface between the conductors in the joint can be joined by ultrasonic welding, the joint can be sufficiently joined even inside the joint conductor. Thereby, the joint strength of the joint conductor can be stabilized. Moreover, since the physical property change by the application | coating of excess heat is suppressed, mixing of a foreign material can be prevented. Therefore, the conductivity and rigidity of the joint conductor can be stabilized.

As an aspect of the present invention, the conductor may be made of aluminum or an aluminum alloy.
According to this invention, the weight of the joining conductor can be reduced.

  Further, as an aspect of the present invention, an intersection-side ridge that protrudes outward in the intersecting direction on a third surface that is at least one of the surfaces facing each other in the intersecting direction intersecting the facing direction, and the intersecting A wave-shaped cross-side corrugated portion in which a cross-side trough depressed inward in the direction continues along the longitudinal direction may be provided.

  According to the present invention, not only the contact area between the conductors arranged along the facing direction is increased and the bonding strength is improved, but also the contact area between the conductors arranged along the intersecting direction is increased. it can. For this reason, the joint strength of the joint conductor can be further improved. Moreover, since the integrity of the joining conductor can be further improved, the conductivity of the joining conductor can be further improved.

  According to the present invention, it is possible to provide a bonded conductor and a method of manufacturing the bonded conductor that can improve the bonding strength between the conductors and improve the conductivity.

The schematic perspective view of a joining conductor. Explanatory drawing of a joining conductor. The schematic perspective view of a conductor connection apparatus. The schematic exploded perspective view of a conductor connection device. Explanatory drawing of a horn. Explanatory drawing of a control part. Explanatory drawing of an anvil. Explanatory drawing of a conductor connection apparatus. The flowchart of the conductor connection method. Explanatory drawing of the joining method of a conductor. Explanatory drawing of the joining method of a conductor. The schematic perspective view of the conductor connection apparatus of other embodiment. Sectional drawing of the conductor connection apparatus of other embodiment. The schematic perspective view of the joining conductor of other embodiment. Explanatory drawing of the joining conductor of other embodiment. Explanatory drawing of the joining conductor of other embodiment.

DESCRIPTION OF EMBODIMENTS An embodiment of a conductor bonding apparatus 100 that manufactures a bonding conductor 100 and a bonding conductor 100 according to the present invention will be described with reference to the drawings.
FIG. 1 is a schematic perspective view of the bonding conductor 100, and FIG. 2 is an explanatory diagram of the bonding conductor 100. Specifically, FIG. 2A shows an enlarged plan view of the joint 110 in the joint conductor 100, FIG. 2B shows an AA cross-sectional view in FIG. 2A, and FIG. The BB sectional view in Drawing 2 (a) is shown.

  3 shows a schematic perspective view of the conductor joining apparatus 1, FIG. 4 shows a schematic exploded perspective view of the conductor joining apparatus 1, FIG. 5 shows an explanatory view of the horn 13 constituting the conductor joining apparatus 1, and FIG. FIG. 7 shows an explanatory view of the anvil 30 constituting the conductor joining device 1, and FIG. 8 shows an explanatory view explaining the configuration of the conductor joining device 1. .

Here, in FIG. 3, the longitudinal direction of the covered electric wire 200 is defined as the longitudinal direction X, the lateral width direction of the covered electric wire 200 and the direction orthogonal to the longitudinal direction X is defined as the width direction Y, and along the longitudinal direction X of FIG. The left side is the + X direction, the right side is the -X direction, the left side along the width direction Y is the -Y direction, and the right side is the + Y direction.
In FIG. 3, the vertical direction is the vertical direction Z, the upper side of FIG. 3 is the + Z direction (upward), and the lower side is the −Z direction (downward).

  5A is an enlarged bottom view in which the bottom surface of the horn 13 is enlarged, FIG. 5B is an enlarged side view of the horn 13 viewed from the + Y side, and FIG. ) Shows an enlarged front view of the horn 13 viewed from the + X side. 5B and 5C, only a part of the horn 13 is enlarged and displayed.

6 and 7 will be described in detail. 6A shows an enlarged plan view in which the upper surface of the restricting portion 21 is enlarged, FIG. 6B shows an enlarged side view of the restricting portion 21 viewed from the + Y side, and FIG. 6C shows the restricting portion 21. The enlarged front view which looked at from the + X side is shown. 6A and 6C, only a part of the restricting portion 21 is enlarged and displayed.
FIG. 7A shows a plan view of the anvil 30, and FIG. 7B shows an enlarged side view of the anvil upper portion 32 erected on the anvil 30 as viewed from the + Y side.

  Further, FIG. 8 will be described in detail. FIG. 8A shows a schematic front view of a portion where the conductor exposed portion 220 is joined in the conductor joining apparatus 1 as viewed from the + X direction, and FIG. 8B shows a CC cross-sectional view in FIG. 8A. .

  The joint conductor 100 is an integrated conductor obtained by joining conductor exposed portions 220, which are tip portions of the plurality of covered electric wires 200, by ultrasonic welding, and is used to electrically connect electric devices such as batteries, for example. It has been.

  The covered electric wire 200 is formed by coating a stranded conductor formed by twisting strands of an aluminum alloy with an insulating coating 210 made of an insulating resin. A conductor exposed portion 220 is provided in which the stranded wire conductor is exposed by stripping the length of (see FIG. 3).

  The stranded wire conductor may be any material as long as it has conductivity. For example, strands such as aluminum, copper, and copper alloy may be twisted together. Moreover, the conductor exposed part 220 does not necessarily need to be comprised by the strand wire conductor, and may be comprised by bundling the strand which has electroconductivity.

  The bonding conductor 100 bundles a plurality (9 in the present embodiment) of the covered electric wires 200 along the longitudinal direction X, and peels and exposes the insulating coating 210 on the tip side (−X side) of the covered electric wires 200. The conductor exposed portion 220 is melted and joined as a bundle of conductors, and a joint 110 is formed at the tip of the joined conductor 100 by melting and joining the conductor exposed portion 220.

  As shown in FIGS. 1 and 2, the joint portion 110 includes a first surface 121 (surface formed on the left side (−Y side)) and a second surface 122 (right side (Y) that face each other in the width direction Y. A third surface 131 (referred to as a surface formed on the lower side (−Z side)) and a fourth surface 132 (upper side (+ Z side)). Are formed in a rectangular shape in cross section, and a planar portion 150 formed in a planar shape is provided at the + X side end portion and the −X side end portion of the joint portion 110. ing.

On the first surface 121 and the second surface 122, a corrugated portion 140 formed in a sinusoidal shape along the longitudinal direction X in plan view is formed (see FIG. 2A).
The corrugated portion 140 includes a peak portion 141 that protrudes outward along the width direction Y and a trough portion 142 that is recessed inward along the width direction Y.

  The height L1 of the top portion of the peak portion 141 with respect to the bottom portion of the valley portion 142 is configured to be about 0.20 times the distance between the first surface 121 and the second surface 122, that is, the length L2 of the width of the bonded conductor 100. Has been.

  In the present embodiment, the height L1 is 0.20 times the length L2, but it does not necessarily have to be this value and may be changed as appropriate. In addition, from a viewpoint of electroconductivity and rigidity, it is preferable that it is 0.5 times or less.

  Further, the height L1 of the top of the peak 141 with respect to the bottom of the valley 142 is configured to be about 0.6 times the diameter L3 that is the minimum diameter of the conductor exposed part 220 constituting the joint 110. Yes.

  In the present embodiment, the height L1 is 0.6 times the diameter L3. However, the height L1 does not necessarily have to be this value, and may be changed as appropriate. From the viewpoint of conductivity, it is preferably 0.5 times or more of the strand, more preferably 0.5 times or more of the outer diameter of the stranded conductor. In the present embodiment, all nine conductor exposed portions 220 have the same diameter, but some or all of the conductor exposed portions 220 may have different diameters. In this case, the height L1 is preferably not less than 0.5 times the diameter L3 that is the minimum diameter of the exposed conductor 220.

  Among the corrugated portions 140 configured as described above, four corrugated portions 140L provided on the first surface 121 are arranged so that valley portions 142 and mountain portions 141 are alternately and continuously arranged from the + X side. Is provided.

  On the other hand, among the corrugated parts 140, four corrugated parts 140R provided on the second surface 122 are provided side by side so that the peak parts 141 and the valley parts 142 are alternately arranged from the + X side. ing.

  In other words, the troughs 142 and the crests 141 arranged on the first surface 121 are arranged to face the crests 141 and the troughs 142 arranged on the second surface 122 along the width direction Y. That is, the corrugated part 140L and the corrugated part 140R are provided on the first surface 121 and the second surface 122, respectively, by shifting a sine wave having the same shape along the longitudinal direction X by a half wavelength.

  As shown in FIG. 2B and FIG. 2C, the junction 110 configured in this way is + Y from a state in which the cross-sectional shape protrudes to the −Y side as it goes from the −X side to the + X side. It will repeat periodically to the state which protrudes to the side. For this reason, since the apparent sectional modulus of the joint part 110 is improved, the rigidity of the joint part 110 is improved.

  In addition, since the bonding conductor 100 is ultrasonically welded by the conductor bonding apparatus 1 as described later, an ultrasonic bonding portion 160 is formed at the interface between the conductors in the cross section of the bonding portion 110.

Furthermore, the joint portion 110 includes a flat portion 150 between the corrugated portion 140 disposed at the distal end and the distal end side end portion in the longitudinal direction X, and the longitudinal direction of the corrugated portion 140 disposed at the proximal end. A flat surface portion 150 is provided between the proximal end portions of X.
More specifically, as shown in FIGS. 1 and 2A, the flat portion 150 is formed to project in a planar shape toward the −X side and the + X side. In other words, the corrugated portion 140 is disposed at a position spaced a predetermined distance from the tip of the bonding conductor 100.

Next, the conductor joining apparatus 1 that joins the leading ends of the conductor exposed portions 220 exposed from the covered electric wire 200 to manufacture the joined conductor 100 will be described with reference to FIGS. 3 to 8.
As shown in FIG. 3, the conductor bonding apparatus 1 is an apparatus for ultrasonic welding (ultrasonic metal bonding) between exposed conductors 220 exposed from the distal end side of a plurality of covered electric wires 200, and is moved up and down in the vertical direction Z. A plurality of anvils 30 that compress the conductor exposed portion 220 with the ultrasonic welding tool 10 to be performed, the pair of width direction adjusting parts 20 fixed to the + X direction side of the ultrasonic welding tool 10, and the ultrasonic welding tool 10 to be lowered. And a control unit 40 that controls the movement of the ultrasonic welding tool 10 and the width direction adjusting unit 20.

The ultrasonic welding tool 10 includes an elevating part 11 that elevates in the vertical direction Z by an elevating motor (not shown), a horn support part 12 that protrudes from the central part of the elevating part 11 to the + X direction side, and a horn support part 12 The horn 13 extends downward from the + X direction side end face.
The lifting motor is controlled by the control unit 40.

As shown in FIGS. 3 and 4, the horn support portion 12 protrudes from the central portion of the elevating portion 11 toward the + X direction side and is configured to support the horn 13 on the elevating portion 11.
In the present embodiment, the horn support portion 12 protrudes from the lifting / lowering portion 11 along the longitudinal direction X, but does not necessarily protrude along the longitudinal direction X, for example, protrudes along the width direction Y. It may be configured as follows. That is, in the present embodiment, the protruding direction of the horn support 12 is configured to be orthogonal to the moving direction of the restricting portion 21 described later, but may be configured to follow the moving direction of the restricting portion 21. Good.

The horn 13 extends downward from the + X direction side end face of the horn support 12 and is configured to vibrate ultrasonically along the longitudinal direction X by being connected to an ultrasonic oscillator (not shown).
Further, on the horn side lower surface 13a which is the bottom surface of the horn 13, as shown in FIG. 5A, a horn side concave portion 14 formed by being depressed upward and a horn side convex portion 15 formed by projecting downward are formed. Are provided in a lattice shape along the longitudinal direction X and the width direction Y. That is, the bottom surface of the horn 13 is formed so as to have an uneven shape when viewed from the longitudinal direction X and the width direction Y (see FIGS. 5B and 5C).

  Specifically, the horn-side recess 14 is formed by recessing upward from the horn-side lower surface 13a (see FIG. 5 (b)), and by recessing upward from the horn-side lower surface 13a. The horn width direction trough part 14b (refer FIG.5 (c)) was comprised, and it forms in these crossing parts.

  Further, the horn-side convex portion 15 is formed between the horn longitudinal valleys 14a formed along the longitudinal direction X, and the horn longitudinal peak 15a projecting downward from the horn-side lower surface 13a (see FIG. 5B). ) And a horn width direction peak 15b (see FIG. 5C) protruding downward from the horn side lower surface 13a between the horn width direction valleys 14b formed along the width direction Y. And formed at these intersections.

  The horn longitudinal troughs 14a and the horn longitudinal troughs 15a are arranged at equal intervals along the width direction Y in 5 and 6 rows, respectively. The horn width troughs 15b and the horn width troughs 14b are longitudinal. 23 rows and 24 rows are arranged at equal intervals along X (see FIG. 5A). The horn side concave portion 14 and the horn side convex portion 15 arranged in this way are formed so as to have an iris shape when viewed from the bottom.

  On the + X direction side of the ultrasonic welding tool 10, the pair of width direction adjustment portions 20 arranged to face each other fixes and supports the restriction portion 21 that restricts the movement of the covered electric wire 200 in the width direction Y and the restriction portion 21. The fixing support portion 22 is configured to include a fixing portion 23 that indirectly fixes the restricting portion 21 to the elevating portion 11, and a connecting portion 24 that movably connects the fixing support portion 22 to the fixing portion 23. .

  The restricting portions 21 are arranged at predetermined intervals along the width direction Y. As shown in FIGS. 3 and 4, the length along the longitudinal direction X is equal to the length of the corresponding horn 13 and The height along the direction Z is configured to be sufficiently longer than three times the outer diameter of the conductor exposed portion 220, and a regulating surface 26 is provided so as to face another opposing regulating portion 21. ing.

  In the present embodiment, the height of the restricting portion 21 is sufficiently long compared to three times the outer diameter of the conductor exposed portion 220. However, the height of the restricting portion 21 needs to be three times the outer diameter of the conductor exposed portion 220. However, it should just be formed sufficiently longer than the total outer diameter of the wire bundle formed by the plurality of exposed conductors 220 to be ultrasonically welded.

  On the upper end surface of the restricting portion 21, a restricting movement assisting portion 25 is formed that meshes with the horn side recessed portion 14 and the horn side protruding portion 15 to assist the movement of the restricting portion 21 in the width direction Y.

  The restriction movement assisting portion 25 includes a movement assisting portion 251 that slightly protrudes upward from the upper end side of the restriction surface 26, and an upper surface recess 252 that is recessed downward on the outside in the width direction Y of the movement assisting portion 251. It is configured. In addition, the movement assisting portion 251 has a plurality of restricting portion side convex portions 253 protruding upward along the longitudinal direction X.

  The restriction portion-side convex portion 253 has a height that is about a half of that of the horn longitudinal direction valley portion 14a and the horn longitudinal direction peak portion 15a, and the width formed by the three restriction portion side convex portions 253 is small. It is comprised so that it may become slightly smaller than the width | variety of the horn longitudinal direction peak part 15a (horn longitudinal direction trough part 14a), and a longitudinal direction may be corresponded to the horn longitudinal direction trough part 14a and the horn longitudinal direction peak part 15a. 18 are arranged at equal intervals along X.

  The restricting portion-side convex portion 253 configured as described above provides a slight gap between the horn longitudinal valley 14a and the horn longitudinal ridge 15a in a state where the horn 13 and the restricting portion 21 are engaged with each other. Thus, the amplitude in the longitudinal direction X due to ultrasonic vibration can be absorbed.

  As shown in FIG. 6A, a sine wave-shaped waveform regulating portion 27 in a plan view and a longitudinal direction X of the waveform regulating portion 27 are provided on the regulating surface 26 provided at the opposing portion of the regulating portion 21 that is a pair. Flat portions 28 formed flat at both ends are provided.

  The waveform restricting portion 27 has a restricting portion side convex portion 271 in a direction opposite to a protruding direction of the restricting portion side protruding portion 271 and a restricting portion side protruding portion 271 protruding to a predetermined height toward the opposing restricting surface 26 side. The restricting portion side recesses 272 that are recessed so as to have the same depth as the height of the portion 271 are alternately and smoothly configured (see FIG. 6A). It should be noted that the waveform restricting portions 27 are alternately arranged four by four along the longitudinal direction X.

  In this way, the waveform restricting portions 27 provided on the opposing restricting surfaces 26 are respectively provided with restricting portion-side convex portions 271 and restricting portion-side concave portions 272 provided on the other restricting face 26 facing each other. And it arrange | positions so that the control part side convex part 271 may be opposed.

  That is, the waveform formed by the restriction portion side convex portion 271 and the restriction portion side concave portion 272 on the + Y side restriction surface 26 (hereinafter referred to as the restriction surface 26R), and the −Y side restriction surface 26 (hereinafter referred to as the restriction surface 26L). The waveform formed by the restriction portion side convex portion 271 and the restriction portion side concave portion 272 is shifted by half a wavelength from each other.

In the present embodiment, there are four restricting portion side convex portions 271 and four restricting portion side recessed portions 272 formed on the restricting surface 26, but the number is not limited to this number. The number of shapes and sizes can be adjusted as appropriate.
The flat portion 28 is a flat surface formed along the vertical direction Z and the longitudinal direction X on both end sides in the longitudinal direction X of the waveform restricting portion 27.

As shown in FIGS. 3 and 4, the outside of the restriction portion 21 configured in this manner is fitted and fixed to the fixed support portion 22.
As shown in FIGS. 3 and 4, the connecting portion 24 is a rod-like body that penetrates the fixing portion 23 fixed to the elevating portion 11 along the width direction Y and has one end fixed to the fixing support portion 22. In addition, it is configured to be movable along the width direction Y by a width direction moving motor (not shown) controlled by the control unit 40.

That is, the connecting portion 24 is configured to connect the fixed support portion 22 and the fixed portion 23, and to move the fixed support portion 22 in which the restricting portion 21 is fixed to the fixed portion 23 along the width direction Y. Yes.
Since the fixing part 23 is fixed to the elevating part 11, the regulating part 21 and the fixing support part 22 are indirectly fixed to the elevating part 11.

The controller 40 that controls the lifting motor and the width direction movement motor (not shown) is configured to drive the lifting motor and the width direction movement motor in synchronization with each other, and lowers the ultrasonic welding tool 10. The restricting portions 21 arranged opposite to each other can be simultaneously moved along the width direction Y.
In addition, the control part 40 can also be independently moved along the width direction Y by control of the control part 40.

  The anvil 30 is a rectangular parallelepiped receiving jig provided on the substrate of the conductor bonding apparatus 1. The anvil 30 is erected on the movable base 31 and a movable base 31 configured to be movable along a rail 50 described later. The anvil upper part 32 is comprised.

  The anvil upper portion 32 is configured such that the length in the width direction Y is slightly longer than the length in the width direction Y of the bundle of wires formed by the plurality of conductor exposed portions 220 to be ultrasonically welded, and The anvil main surface 321, which is the main surface of the anvil upper portion 32, is erected on the upper portion of the movable base portion 31 so as to face the width direction Y.

  On the anvil main surface 321, an anvil side corrugated portion 33 that is continuously arranged along the longitudinal direction X is formed. The anvil-side corrugated portion 33 includes an anvil-side convex portion 331 that protrudes outward from the anvil main surface 321 in the width direction Y, and an anvil-side concave portion 332 that is recessed inside the anvil main surface 321. .

  The anvil side convex portion 331 is formed so as to be fitted with the restriction portion side concave portion 272, and the anvil side concave portion 332 is formed so as to be fitted with the restriction portion side convex portion 271. That is, it is formed in a sine wave shape in plan view in which the amplitude of the anvil side waveform portion 33 is equal to the amplitude of the waveform restriction portion 27.

  The anvil-side corrugated portion 33 in which the anvil-side convex portion 331 and the anvil-side concave portion 332 thus configured are continuously arranged is formed in a sine wave shape in plan view as shown in FIG. The four are arranged along the longitudinal direction X continuously.

  The anvil-side corrugated portion 33 is provided on both surfaces of the anvil main surface 321 facing the width direction Y. The anvil-side corrugated portion 33 (anvil-side corrugated portion 33R) provided on the + Y side and the −Y side are provided. The anvil-side corrugated portion 33 (anvil-side corrugated portion 33L) provided on the side is shifted by a half wavelength. That is, the anvil-side corrugated portion 33R is provided in the order of the anvil-side concave portion 332 and the anvil-side convex portion 331 from the + X side, and the anvil-side corrugated portion 33L is the order of the anvil-side convex portion 331 and the anvil-side concave portion 332 from the + X side. The anvil-side corrugated portion 33R and the anvil-side corrugated portion 33L are formed such that the anvil-side convex portion 331 and the anvil-side concave portion 332 face each other.

  Further, the anvil-side convex portion 331 and the anvil-side concave portion 332 provided on the anvil-side corrugated portion 33L are regulated with the anvil 30 so as to face the regulating-unit-side concave portion 272 and the regulating-unit-side convex portion 271 provided on the regulating surface 26L. The part 21L is arranged. Similarly, the anvil-side convex portion 331 and the anvil-side concave portion 332 provided in the anvil-side corrugated portion 33R and the anvil 30 so as to face the regulating-unit-side concave portion 272 and the regulating-unit-side convex portion 271 provided in the regulating surface 26R. A restricting portion 21R is arranged.

  An anvil-side upper surface 322 that is the upper surface of the anvil upper portion 32 is a surface that compresses the conductor exposed portion 220 with the horn-side lower surface 13a when the ultrasonic welding tool 10 is lowered, and is formed along the vertical direction Z. An uneven anvil side uneven portion 34 is provided.

  In addition, on the front end side and the rear end side of the anvil side uneven portion 34, a flat portion 35 formed in a planar shape having a length of about half a wavelength of the sine wave formed by the anvil side corrugated portion 33 is formed in the longitudinal direction X. Are provided along.

In the present embodiment, three anvils 30 configured so that the widths in the width direction Y of the anvil upper portion 32 are different are provided (anvils 30a, 30b, and 30c). The width in the width direction Y is formed such that the anvil 30a is the smallest and the anvil 30c is the largest.
The plurality of anvils 30 (anvils 30 a, 30 b, 30 c) provided in this way are configured to be movable along the rails 50, and the desired anvil 30 can be disposed below the ultrasonic welding tool 10.

  Moreover, in this embodiment, although the three anvils 30 are provided, the number provided according to the covered electric wire 200 to connect can be adjusted suitably, and the width | variety of the anvil upper part 32 in each anvil 30 can also be adjusted suitably.

  As shown in FIGS. 3 and 8, the ultrasonic welding tool 10 and the width direction adjustment unit 20 configured in this way are loosely fitted into the horn side concave portion 14 and the horn side convex portion 15 with the restricting portion side convex portion 253. By doing so, the restricting portion 21 can be moved along the horn side lower surface 13a.

  Moreover, the anvil 30 can be arrange | positioned so that the horn side lower surface 13a and the anvil side upper surface 322 may oppose by moving along the rail 50 (refer FIG.8 (b)). As a result, the horn-side lower surface 13a, the anvil-side upper surface 322, and the pair of regulating surfaces 26 can form an arrangement space S through which the plurality of exposed conductors 220 are inserted (see FIG. 8A).

  In this way, the conductor joining apparatus 1 in which the regulating portion 21 is fixed to the ultrasonic welding tool 10 so that the regulating portion 21 can move along the width direction Y and the anvil 30 is disposed below the horn 13. Can move the ultrasonic welding tool 10 and the width direction adjustment unit 20 downward by a lifting motor under the control of the control unit 40 while the conductor exposed portion 220 is inserted into the arrangement space S, and can move in the width direction. The restriction portion 21 can be moved along the width direction Y by the motor.

Hereinafter, the manufacturing method of the joining conductor 100 using the conductor joining apparatus 1 is demonstrated easily based on FIG. 9 thru | or FIG.
Here, FIG. 9 shows a flowchart of a conductor joining method for melting and joining the conductor exposed portions 220 in a plurality (9 in this embodiment) of the covered electric wires 200, and FIG. 10 shows a conductor exposed portion 220 (conductor exposed portion 220). ) Is inserted through the arrangement space S, and an explanatory view illustrating a state in which the restricting portion 21 is moved along the width direction Y is shown. FIG. 11 is a conductor using a DD cross-sectional view of the α portion in FIG. Explanatory drawing explaining the conductor joining method which joins the exposed part 220 is shown.

  More specifically, FIG. 10A shows an enlarged plan view of the restricting portion 21 and the anvil 30 before the conductor exposed portion 220 is inserted, and FIG. 10B shows the restricting portion 21 inserted through the conductor exposed portion 220. FIG. 10C is an enlarged plan view of the regulating portion 21 and the anvil 30 in a state where the conductor exposed portion 220 is moved toward the conductor exposed portion 220, and FIG. 10C is a schematic plan view of the conductor exposed portion 220 compressed in FIG. .

11A shows a DD cross-sectional view with the conductor exposed portion 220 inserted into the arrangement space S, and FIG. 11B shows the ultrasonic welding tool with the conductor exposed portion 220 inserted into the arrangement space S. 10 and DD sectional view in a state where ultrasonic welding is performed on the conductor exposed portion 220 compressed by lowering the width direction adjusting portion 20 and the width direction adjusting portion 20 are shown.
In addition, in FIG. 11, illustration of the horn side recessed part 14 and the horn side convex part 15 is abbreviate | omitted.

As shown in FIG. 9, the conductor exposed portion 220 provided at the terminal portion of the covered electric wire 200 includes an electric wire arranging step s1 in which the conductor exposed portion 220 is arranged in the arrangement space S, the ultrasonic welding tool 10 and the width direction adjusting portion. 20, a conductor moving step s3 for compressing the conductor exposed portion 220 with the horn 13 and the anvil 30, and an ultrasonic welding step s4 for melting and bonding the compressed conductor exposed portion 220 with ultrasonic waves. Are connected in such a manner that conduction is possible.
The conductor compression step s3 and the ultrasonic welding step s4 can be performed simultaneously.

Hereafter, each process is explained in full detail based on FIG.10 and FIG.11.
A plurality (9 in this embodiment) of the covered electric wire 200 is prepared in advance, and the insulating coating 210 on one end side (the −X direction side) of the covered electric wire 200 is cut off by a predetermined length, and the insulating coating 210 is cut off. The exposed conductor 220 is formed by exposing the stranded wire conductor surrounded by the conductor.

Next, the anvil 30 suitable for the number of exposed conductors 220 to be connected and the outer diameter is selected, and the anvil 30 is moved along the rail 50 so that the anvil-side upper surface 322 faces the horn-side lower surface 13a. Place at the position. Here, the anvil 30a is arranged on the lower side of the ultrasonic welding tool 10.
Subsequently, the restricting portion 21 is moved along the width direction Y until the restricting surface 26 reaches a predetermined interval, and the ultrasonic welding tool 10 is raised until the horn 13 reaches a predetermined height, so that the arrangement space S is increased. Form.

  In this state, as shown in FIG. 10 (a), the conductor exposed portion 220 is arranged in the arrangement space S formed by the restricting portion 21 and the horn 13 that are opposed to each other at a predetermined interval, and + X It inserts toward the -X direction side from a direction side (electric wire arrangement process s1). In the present embodiment, a total of nine conductor exposed portions 220 in which three conductor exposed portions 220 are arranged along the vertical direction Z and three conductor exposed portions 220 along the width direction Y are inserted into the arrangement space S. Join.

  Then, under the control of the control unit 40, the ultrasonic welding tool 10 is lowered, and the regulating part 21 is moved along the width direction Y toward the conductor exposed part 220 in synchronization with the lowering of the ultrasonic welding tool 10. As a result, as shown in FIGS. 10B and 11A, the regulating surface 26 comes into contact with both side surfaces of the anvil upper portion 32 in the width direction Y, and the conductor exposed portion 220 is connected to the horn side lower surface 13a and the anvil. The conductor exposed portion 220 is pressed by the horn 13 from above by being sandwiched between the side upper surfaces 322. (Compression movement process s2).

  The compression moving step s2 will be described in detail. In the state where the conductor exposed portion 220 is arranged in the arrangement space S formed between the horn side lower surface 13a, the anvil side upper surface 322, and the pair of regulating surfaces 26, ultrasonic waves While lowering the welding tool 10 and moving the restricting portion 21 along the horn side lower surface 13a toward the conductor exposed portion 220, the wave restricting portion 27 provided on the restricting surface 26 and the anvil main surface 321 are provided. The anvil side corrugated portion 33 is fitted to each other.

  Here, since the width with respect to the width direction Y of the anvil main surface 321 is configured to be slightly longer than the width formed by the wire bundle of the conductor exposed portion 220, the waveform regulating portion 27 and the anvil-side waveform portion 33 are configured. It is also possible to prevent the conductor exposed portion 220 from being caught between the restricting portion 21 and the anvil upper portion 32 in the fitted state.

  Even when the conductor exposed portion 220 is pushed from above and moved in the width direction Y by further lowering the ultrasonic welding tool 10 in the state where the conductor exposed portion 220 is disposed in the arrangement space S, the regulating surface 26 can restrict the movement of the conductor exposed portion 220 in the width direction Y direction.

  Subsequently, by lowering the ultrasonic welding tool 10 further downward (conductor compression step s3), the conductor exposed portion 220 is pressurized and deformed by the horn 13 and spreads in the width direction Y. By engaging 27 with the anvil upper part 32, the conductor exposed portion 220 comes into contact with the regulating surface 26.

  Further, when the conductor exposed portion 220 is further pressed against the horn 13, the conductor exposed portion 220 is pressed against the waveform restricting portion 27 provided on the restricting surface 26 as shown in FIG. A continuous waveform along the longitudinal direction X is formed at a location corresponding to the side surface of the electric wire 200.

  Thus, by further lowering the horn 13 with the covered electric wires 200 arranged in the arrangement space S, the conductor exposed portion 220 can be compressed from the vertical direction Z (conductor compression step s3), and the vertical direction. The conductor exposed portions 220 arranged in Z can be brought into contact with each other more reliably. In addition, since the conductor exposed portion 220 is compressed while being in contact with the regulation surface 26, the conductor exposed portion 220 is formed in a wave shape along the longitudinal direction X. As a result, the exposed conductors 220 arranged in parallel along the width direction Y can be brought into contact with each other in the direction intersecting the longitudinal direction X (width direction Y), and the exposed conductors 220 can be reliably contacted by compression. Can be made.

  In this way, it is an important issue in the manufacture of the bonded conductor 100 that the conductor exposed portions 220 are reliably brought into contact with each other and bonded to ensure reliable conductivity. In addition, for example, with the recent demand for weight reduction of vehicles, it has become necessary to join alloyed high-strength electric wires. These high-strength materials are not easily deformed, and it is difficult to contact the exposed conductors 220 more reliably.

  Thus, in order to reliably contact and bond the exposed conductors 220 to each other, for example, as a manufacturing process in the present embodiment, in the conductor compression step s3, weaker ultrasonic vibration is performed than in welding in an ultrasonic welding step s4 described later. The conductor compression step s3 may be performed while increasing the temperature of the material and decreasing the strength. Further, for example, the same purpose can be achieved by performing weaker ultrasonic vibrations after welding after the conductor compression step s3 and immediately before the ultrasonic welding step s4.

  When the conductor filling step s3 is performed when the total filling area of the conductor of the conductor exposed portion 220 is divided by the anvil surface width and the thickness in which the inside of the mold is 100% filled with the conductor is 100% height. It is desirable to compress to a height lower than 100%.

  As a result, the conductor exposed portion 220 filled in the mold is elongated in the longitudinal direction X, the oxide film formed on the surface of the conductor exposed portion 220 is broken, and the oxide film formed during the subsequent welding is broken. Removal is performed efficiently. If the amount is 100% or less, the above object is achieved, but 95% or less and 70% or more are preferable. More preferably, it is performed between 90% and 80%. If the compression is small, the above-mentioned object is difficult to achieve, and if the compression is too large, the cross-sectional area becomes small and the strength becomes weak at the base portion of the electric wire, which is not preferable.

  In this state, the horn 13 is ultrasonically vibrated along the longitudinal direction X intersecting the width direction Y, so that the conductor exposed portions 220 are ultrasonically bonded to each other by ultrasonic welding (ultrasonic welding step s4). . In the ultrasonic welding process s4, control may be performed by the control unit 40 to determine the bottom dead center (stop point) in the vertical direction Z during welding. Thereby, the rapid increase of the temperature at the time of welding of the conductor exposure part 220 is suppressed, and the adhering to the horn 13 is suppressed.

  Further, the ultrasonic vibration may be continued even after reaching the bottom dead center at the time of welding. Accordingly, the oxide film is removed from the welded portion, and the surface of the conductor exposed portion 220 is maintained at a high temperature while the atoms are in contact with each other. Thereby, continuity and rigidity are further improved. The height of the bottom dead center is desired to be smaller than the height formed in the conductor compression step s3, and the total cross-sectional area of the conductor exposed portion 220 is 100% in the die calculated from the anvil surface width. It is desirable to be less than the 100% height to be filled. If the amount is 100% or less, the above object is achieved, but 90% or less and 70% or more are preferable. More preferably, it is performed between 85% and 80%. If the compression is small, the above-mentioned object is difficult to be achieved, and if the compression is too large, the cross-sectional area becomes small at the base portion of the electric wire, which is not preferable.

  Note that, as described in the present embodiment, even when the wave restricting portion 27 is not formed on the restricting surface 26 of the restricting portion 21, that is, the wave is generated on the side surface of the joint 110 in the joint conductor 100 to be manufactured. Even when the corrugated portion 140 is not formed, the conductor exposed portions can be reliably brought into contact with each other and bonded, and the conductivity of the bonded conductor can be reliably ensured.

  As a result, the nine conductor exposed portions 220 pressed so as to form a wave shape along the longitudinal direction X in the arrangement space S are adjacent conductors along the longitudinal direction X and the width direction Y. Ultrasonic welding is performed in a state where the exposed portions 220 are in contact with each other reliably, and the joined conductor 100 with improved conductivity and rigidity can be manufactured (see FIG. 11B).

  In this way, the plurality of exposed conductors 220 arranged along the longitudinal direction X is the joined conductor 100 having the joined part 110 that is melt-joined, and the joined parts 110 face each other along the longitudinal direction X. The first surface 121 and the second surface 122 which are two surfaces are provided, and both of the first surface 121 and the second surface 122 facing each other are directed toward the outside in the width direction Y where the two surfaces are opposed. Since the protruding peak portion 141 and the trough portion 142 recessed in the width direction Y are continuous along the longitudinal direction X, the corrugated waveform portion 140 is provided, so that the conductor exposed portions 220 are joined to each other. Strength can be improved and conductivity can be improved.

  More specifically, since the corrugated portion 140 is formed on at least the first surface 121 of the first surface 121 and the second surface 122 which are the opposing surfaces, the plurality of conductor exposed portions 220 constituting the joint portion 110 are formed. Among them, the conductor exposed portions 220 arranged side by side in the width direction Y are joined in contact with another conductor exposed portion 220 adjacent in the width direction Y along the direction intersecting the longitudinal direction X (see FIG. 10 (c)). For this reason, in the junction part 110, the joining strength of the conductor exposed parts 220 arrange | positioned in the width direction Y is improving.

  Therefore, the integrity of the joint portion 110 can be improved, the conductivity of the conductor exposed portion 220 constituting the joint conductor 100 can be improved, and the rigidity of the joint conductor 100 can also be improved.

  In addition, the corrugated portion 140 is provided on both the first surface 121 and the second surface 122 facing the first surface 121, the corrugated portion 140 formed on the first surface 121 is defined as a corrugated portion 140 </ b> L, and the second surface 122. The corrugated part 140 formed on the corrugated part 140R is a corrugated part 140R, and the corrugated part 140L and the corrugated part 140R are configured with the same waveform, and the peak 141 in the corrugated part 140L is opposed to the valley 142 in the corrugated part 140R. The trough portion 142 in the corrugated portion 140L is opposed to the peak portion 141 in the corrugated portion 140R, in other words, the corrugated portion 140L formed on the first surface 121 and the corrugated portion 140R formed on the second surface 122. However, the conductor exposed portions 220 arranged side by side along the width direction Y have a constant width and an amplitude in the width direction Y. To have. For this reason, the apparent sectional modulus of the entire joint 110 can be improved, and the rigidity of the joint conductor 100 can be improved.

  Further, since the width of the first surface 121 and the second surface 122 with respect to the width direction Y is constant in the longitudinal direction X, that is, the cross-sectional area of the conductor exposed portions 220 in the longitudinal direction X is constant, 110, the unevenness of the rigidity of the joint conductor 100 can be suppressed, and variations in the quality of the bonded conductor 100 can be suppressed.

  Furthermore, by providing a plurality of corrugated portions 140 along the longitudinal direction X, the joint portion 110 where the conductor exposed portions 220 that are periodically arranged in the intersecting direction intersecting the longitudinal direction X are joined. Then (see FIG. 10C), the bonding strength between the conductor exposed portions 220 arranged in the crossing direction can be improved, and the contact area between the conductor exposed portions 220 can be increased. Therefore, the integrity of the joint 110 can be further improved, and the conductivity and rigidity of the conductor exposed portion 220 can be further improved.

  Further, the height L1 in the orthogonal cross-section direction from the bottom of the valley 142 to the apex of the peak 141 is configured to be 0.5 times or less of the interval L2 in the width direction Y between the first surface 121 and the second surface 122. As a result, the conductivity of the bonded conductor 100 can be improved, and the rigidity can be reliably improved.

  More specifically, when the height of the crest 141 relative to the trough 142 is higher than 0.5 times the interval in the width direction Y between the first surface 121 and the second surface 122, the waveform amplitude at the joint 110 is large. Therefore, the load applied to the conductor exposed portion 220 is increased, and the conductor exposed portion 220 may be partially broken or damaged, and the conductivity of the bonded conductor 100 cannot be sufficiently ensured, and the rigidity may be lowered. .

  However, the height L1 of the peak portion 141 with respect to the valley portion 142 in the width direction Y is configured to be 0.5 times or less of the interval L2 in the width direction Y between the first surface 121 and the second surface 122. The load on the conductor exposed portions 220 constituting the portion 110 can be reduced, and the conductor exposed portions 220 arranged in the width direction Y can be made to swing in the width direction Y, so that the bonding strength between the conductor exposed portions 220 due to bending is ensured. And the contact area between the conductor exposed portions 220 can be increased.

  Thereby, while being able to improve the integrity of the joining part 110, the possibility that the conductor exposed part 220 is partially broken or damaged can be reduced, and the conductivity of the joining conductor 100 can be sufficiently improved. The rigidity can be improved reliably.

  Furthermore, the height L1 in the orthogonal cross-section direction from the bottom of the valley 142 to the apex of the peak 141 is 0.5 times or more the diameter L3, which is the minimum diameter among the plurality of exposed conductor portions 220. By being configured in this manner, the conductivity of the bonding conductor 100 can be improved.

  More specifically, when the height L1 of the peak 141 with respect to the valley 142 in the width direction Y is lower than 0.5 times the minimum diameter of the plurality of exposed conductors 220, the peak at the joint 110 141 and the valley portion 142 are small in amplitude, and the conductor exposed portions 220 arranged along the width direction Y are not arranged in a state of intersecting the longitudinal direction X. Cannot be sufficiently improved, and the conductivity of the bonding conductor 100 cannot be sufficiently improved.

  On the other hand, the height of the crest 141 with respect to the trough 142 in the width direction Y is 0.5 times or more the minimum diameter of the plurality of conductor exposed portions 220, whereby the joint 110 is crested. Since it can be surely bent along the part 141 and the valley part 142, the conductor exposed parts 220 arranged along the width direction Y are arranged in a state intersecting with the longitudinal direction X. Accordingly, the bonding strength between the exposed conductors 220 can be reliably improved, the contact area between the exposed conductors 220 can be increased, and the conductivity of the bonded conductor 100 can be improved.

  Further, the joint portion 110 may have a flat portion 150 formed in a planar shape along the longitudinal direction X between the tip and the corrugated portion 140. Thereby, it can suppress that joining of the conductor exposed parts 220 peels from the front end side of the junction part 110. FIG.

  More specifically, the crest portion 141 and the trough portion 142 constituting the corrugated portion 140 are configured by curving the conductor exposed portion 220. Therefore, when an external force acts on the side opposite to the bending direction, the conductor exposed portion 220 is formed. Bonding between each other is easy to peel off.

  However, since the joining part 110 has the flat part 150 between the front-end | tip and the waveform part 140, the unintended external force to the opposite side to a curving direction acts directly on the peak part 141 or the trough part 142. Even when an unintended external force is applied, the flat portion 150 can absorb the external force, and therefore, the peeling of the joint between the conductor exposed portions 220 can be suppressed.

  Moreover, since the junction part 110 can comprise the interface of the conductor exposed parts 220 in the junction part 110 by ultrasonic welding because the junction part 110 formed by the ultrasonic welding is comprised, the junction conductor is joined. Even in the interior of 100, it can be sufficiently joined. Thereby, the joining strength of the joining conductor 100 can be stabilized. Moreover, since the physical property change by the application | coating of excess heat is suppressed, mixing of a foreign material can be prevented. Therefore, the conductivity and rigidity of the bonding conductor 100 can be stabilized.

Further, in the cross section of the joint portion 110, the conductor exposed portion 220 is deformed and the interface between the conductor exposed portions 220 is more closely joined by the ultrasonic joint portion 160. 2 (b) and FIG. 2 (c), the conductor exposed portions 220 are deformed from, for example, a perfect circle to an ellipse in an orthogonal cross section orthogonal to the longitudinal direction X. As the contact area increases and the bonding strength between the conductor exposed portions 220 increases, the integrity of the bonding portion 110 is further improved, and the conductivity and rigidity of the bonding conductor 100 can be further improved.
Furthermore, since the conductor exposed portion 220 is made of aluminum or an aluminum alloy, the weight of the bonded conductor 100 can be reduced.

In correspondence between the configuration of the present invention and the above-described embodiment,
The conductor corresponds to the conductor exposed portion 220,
The joint corresponds to the joint 110,
The bonding conductor corresponds to the bonding conductor 100,
The first waveform portion corresponds to the waveform portion 140L,
The second waveform portion corresponds to the waveform portion 140R,
The facing direction corresponds to the width direction Y,
The ultrasonic bonding part corresponds to the bonding part 110,
The ultrasonic weld corresponds to the ultrasonic joint 160,
The first direction corresponds to the vertical direction Z,
The second direction corresponds to the width direction Y, but the present invention is not limited to the configuration of the above-described embodiment, and many embodiments can be obtained.

  For example, in the present embodiment, the conductor exposed portion 220 is a stranded wire conductor obtained by twisting a conductive strand. However, the present invention is not limited to this configuration. For example, a hand composed of a single wire may be used. May be bundled. Moreover, the conductor exposed part 220 is not limited to the aluminum type | system | group comprised with aluminum, aluminum alloy, etc. For example, you may comprise with copper or copper alloy. In other words, any material may be used as long as it has conductivity.

  The conductor exposed portion 220 is exposed by cutting off the insulating coating 210 forming the outer layer at one end of the covered electric wire 200 covered with the insulating insulating coating 210, but is not covered with the insulating coating 210. The conductor which just bundled the conductor and the strand may be sufficient.

  Furthermore, although the conductor exposed portion 220 is the same conductor, a plurality of different types of conductors may be used. Furthermore, for example, a configuration in which a joint portion is surrounded by, for example, a copper tube or a copper foil may be used for the plurality of conductor exposed portions 220 described above.

Moreover, the waveform part 140 may be formed not only in the case where it is formed in both the 1st surface 121 or the 2nd surface 122 but in only one side. Moreover, in addition to the case where it is formed on the entire surface of the first surface 121 or the second surface 122, it may be formed on a part.
Further, the corrugated portion 140 only needs to have at least one peak portion 141 and one valley portion 142 continuous along the longitudinal direction X. For example, at least one peak portion 141 and the valley portion 142 are continuous. If it does, it is not necessary for the number of peak parts 141 and trough parts 142 to correspond.

  Further, in the present embodiment, only the restricting surface 26 among the horn-side lower surface 13a, the anvil-side upper surface 322, and the pair of restricting surfaces 26 forming the arrangement space S for inserting the conductor exposed portion 220 is a wave-shaped waveform restriction. Although the portion 27 is provided, for example, as shown in FIGS. 12 and 13, the bottom surface portion of the horn 13 (referred to as the wavy bottom surface portion 13 b) and the anvil side upper surface 322 may be formed in a wave shape.

Hereinafter, the conductor joining apparatus 1x in which the waved bottom surface portion 13b and the anvil side upper surface 322 are formed in a wave shape will be briefly described with reference to FIGS.
Here, FIG. 12 shows a schematic perspective view of the conductor joining device 1x, and the horn 13 is a corrugated bottom surface portion 13b and an anvil among the sectional views corresponding to the CC sectional view in FIG. 8A of the conductor joining device 1x. The side upper surface 322 is enlarged and shown.

As shown in FIGS. 12 and 13, a compression-side corrugated portion 37 is provided on the anvil-side upper surface 322 instead of the anvil-side uneven portion 34.
In addition, the anvil 30 in which the compression side waveform part 37 was comprised is each set as the anvil 30d, the anvil 30e, and the anvil 30f (refer FIG. 12).

  The compression-side corrugated portion 37 corresponds to the intersecting-side corrugated portion, and includes a compression-side convex portion 371 that protrudes upward as compared with the flat portion 35 and a compression-side concave portion 372 that is recessed downward. The four are arranged in a row along the longitudinal direction X. That is, the compression-side convex portion 371 corresponds to the crossing-side peak portion, and the compression-side concave portion 372 corresponds to the crossing-side valley portion, and each is continuously arranged along the longitudinal direction X.

  On the other hand, as shown in FIG. 13, the bottom surface side of the horn 13 is provided with a waved bottom surface portion 13 b that protrudes downward, and the waved bottom surface portion 13 b has a valley that is recessed in an arc shape toward the upper side. The horn width direction trough part 14c which forms horn, and the horn width direction peak part 15c which protrudes on a circular arc on the downward side are provided.

  In addition, a movement corrugated portion 29 is formed in place of the restricting movement assisting portion 25 in the restricting portion 21 formed to be movable in the width direction Y along the waved bottom surface portion 13b. This waveform part 29 for movement is comprised by the convex part 291 for movement assistance which can be loosely fitted with respect to the horn width direction trough part 14c, and the movement assistance recessed part 292 which can be loosely fitted with the horn width direction peak part 15c. Yes. The movement assisting convex portion 291 and the movement assisting concave portion 292 are formed in a continuous sine wave shape in a side view.

  The conductor bonding apparatus 1x configured in this way can be ultrasonically bonded with the conductor exposed portion 220 formed in a wave shape not only in the width direction Y but also in the vertical direction Z. The corrugated portion 140 is formed not only on the first surface 121 and the second surface 122 opposed along the vertical direction, but also on the third surface 131 and the fourth surface 132 opposed along the vertical direction Z. The junction conductor 100x in which is formed can be manufactured.

Hereinafter, the bonding conductor 100x will be briefly described with reference to FIGS.
FIG. 14 is a schematic perspective view of the bonding conductor 100x, and FIG. 15 is a plan view (FIG. 15A) and a side view (FIG. 15B) of the bonding conductor 100x. 16 is a cross-sectional plan view taken along the line EE in FIG. 15A (FIG. 16A), a cross-sectional plan view taken along the line FF (FIG. 16B), and a plan view taken along the line GG. FIG. 16 (c)) and HH sectional view plan view (FIG. 16 (d)) are shown.

As shown in FIGS. 14 and 15, the bonding conductor 100 x has not only the corrugated portion 140 formed on the first surface 121 and the second surface 122, but also the upper and lower portions of the corrugated shape on the third surface 131 and the fourth surface 132. Four side corrugations 170 are continuously provided along the longitudinal direction X, and are formed in a sine wave shape in a side view.
More specifically, the upper and lower corrugated portions 170 include an upper and lower peak portion 171 that protrudes outward in the vertical direction Z with respect to the third surface 131, and an upper and lower portion that is recessed inward in the vertical direction Z with respect to the third surface 131. It is comprised by the side trough part 172, and the up-and-down side peak part 171 and the up-and-down side trough part 172 are arrange | positioned alternately continuously.

  As shown in FIG. 16, the joining conductor 100 x configured in this way is from a state in which the peak portion 141 protrudes to the −Y side in the width direction Y as it goes from −X to + X along the longitudinal direction X. (See FIG. 16 (a)), and the peak portion 141 does not protrude (see FIG. 16 (b)), and then the peak portion 141 protrudes to the + Y side (see FIG. 16 (c)). Then, the mountain portion 141 is not projected (see FIG. 16D).

  Similarly, with respect to the up-down direction Z, from the state in which the up-down side peak 171 protrudes to the side along the longitudinal direction X from −X to + X (see FIG. 16B), the up-down side peak 171 protrudes upward (+ Z side) (see FIG. 16B), and after passing through the state where the upper and lower ridges 171 do not protrude (see FIG. 16C), the upper and lower ridges 171 move downward (see FIG. -Z side) (see FIG. 16D).

That is, as it goes from -X to + X along the longitudinal direction X, the peak portion 141 and the upper and lower side peak portions 171 that are protruding portions protrude in a spiral shape, so that it looks more apparent than the bonding conductor 100. The section modulus is improved and the rigidity can be improved.
In addition, although it is set as the structure which provided the horn width direction trough part 14c, the horn width direction peak part 15c, and the compression side waveform part 37 in the wavy bottom face part 13b which is a bottom face part of the horn 13, and the anvil side upper surface 322, respectively, The compression-side corrugated portion 37 may be provided only on one of the anvil-side top surfaces 322.

  As described above, the third surface 131 and the fourth surface 132 of the vertical side surface set 130 facing each other in the orthogonal cross section have the upper and lower side mountain portions 171 protruding outward and the restriction portion side concave portion 272 recessed inward. By forming the wavy upper and lower corrugated portions 170 that are continuous along the longitudinal direction X, the contact area and bonding strength between the conductor exposed portions 220 arranged in the width direction Y and the vertical direction Z can be reduced. Will be increased. That is, since the contact area and bonding strength between the conductor exposed portions 220 are further increased, the integrity of the bonding conductor 100 can be further improved, and the conductivity of the bonding conductor 100 can be further improved.

100 Joined conductor 110 Joined part 121 First surface 122 Second surface 131 Third surface 140 Corrugated part 140L Corrugated part 140R Corrugated part 141 Peak part 142 Valley part 170 Upper and lower side corrugated part 171 Upper and lower side peak part 172 Upper and lower side valley part 220 Conductor Exposed part s3 Conductor compression process s4 Ultrasonic welding process X Longitudinal direction Y Width direction Z Vertical direction

Claims (10)

A plurality of conductors arranged along the longitudinal direction are bonded conductors having a fusion bonded joint,
The joint is
Two surfaces facing each other along the longitudinal direction are provided,
On the first surface of at least one of the facing surfaces,
A wave-shaped corrugated portion is provided in which a crest projecting outward in the facing direction where the two surfaces face each other and a trough depressed inward in the facing direction are continuous along the longitudinal direction. Bonded conductor. The corrugated portion is provided on both the first surface and the second surface facing the first surface,
The corrugated portion formed on the first surface is a first corrugated portion,
The corrugated portion formed on the second surface is a second corrugated portion,
The first waveform portion and the second waveform portion are configured with the same waveform,
The peak portion in the first corrugated portion is opposed to the trough portion in the second corrugated portion, and the trough portion in the first corrugated portion is opposed to the peak portion in the second corrugated portion. Junction conductor. The joint conductor according to claim 1, wherein a plurality of the corrugated portions are provided along the longitudinal direction. The height in the cross-sectional direction orthogonal to the longitudinal direction from the bottom of the valley to the apex of the peak is the interval in the facing direction between the second surface facing the first surface and the first surface. The joining conductor according to any one of claims 1 to 3, wherein the joining conductor is configured to be 0.5 times or less. The height in the opposing direction from the bottom part of the said trough part to the vertex of the said peak part is comprised so that it may become 0.5 times or more of the minimum diameter among the said several conductors arrange | positioned. Item 5. The bonded conductor according to any one of Items 4 to 5. The joint is
The junction conductor according to any one of claims 1 to 5, wherein a flat portion formed in a planar shape along the longitudinal direction is provided between a tip and the corrugated portion. The joint is
The bonding conductor according to claim 1, wherein an ultrasonic bonding portion formed by ultrasonic welding is configured. The joint conductor according to claim 1, wherein the conductor is made of aluminum or an aluminum alloy. At least one third surface among the surfaces facing each other in the intersecting direction intersecting the facing direction,
A wave-shaped cross-side corrugated portion is provided in which a cross-side peak projecting outward in the cross direction and a cross-side valley recessed inward in the cross direction are continuous along the longitudinal direction. The bonded conductor according to any one of claims 1 to 8. A method of manufacturing a bonded conductor for melting and bonding a plurality of conductors arranged along a longitudinal direction,
A compressing step of compressing the conductor along a first direction orthogonal to the longitudinal direction and restricting movement of the conductor in the longitudinal direction and a second direction orthogonal to the first direction;
Performing a welding process of performing ultrasonic welding by ultrasonic vibration on the conductor compressed in the first direction;
In the compression step,
Of the conductor bundle composed of a plurality of the conductors arranged, the first surface formed on at least one side in the second direction has a peak portion protruding outward in the second direction, and the second direction. Of a conductor that restricts movement of the conductor in the second direction so that a corrugated corrugated portion continuously provided with a valley recessed inward is formed along the longitudinal direction. Method.

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