JP2536765B2 - Method for manufacturing brush assembly-substrate and brush assembly- - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a brush assembly widely used as a potentiometer, a trimmer, an encoder, etc. for transmitting an electric signal in combination with a resistor, a slip ring, or the like. And a method for manufacturing a brush assembly.

[Conventional technology]

A method of manufacturing a brush assembly by horizontally aligning a plurality of fine wires in a horizontal state and welding them to a substrate is already known, as described in, for example, Japanese Patent Publication No. 60-16718. In this method, since the wire is directly welded to the bar connecting the two suspension belts, the bar is distorted by the heat applied during welding and the frame is slightly deformed. However, there is a problem that the cross section is distorted, the entire frame is deformed, or the wire rod hits the projection wrongly, resulting in poor accuracy or poor welding. Further, after welding the wire rod to the cross section connecting the two suspension bands, the both ends of the cross section are cut, so that a secondary force is inevitably applied to the welded portion, especially in the vicinity of the cut portion, and the welding strength is reduced or the distortion is generated. There is a problem that the welded part is adversely affected, for example, remains.

[Problems to be solved by the invention]

Therefore, in the present invention, when welding a wire rod, distortion during welding is unlikely to affect the next welded portion, and a secondary force is less likely to be applied to the welded portion even during cutting, resulting in reduced welding strength or strain. It is an object of the present invention to provide a substrate for a brush assembly that does not adversely affect the welded part, such as residual metal, to increase the yield and reduce material loss.
Another object of the present invention is to provide a method for efficiently manufacturing a brush assembly using the above substrate.

[Means for solving problems]

According to the present invention, a plurality of square frames are formed by connecting side portions of two suspension parts arranged in parallel with a plurality of joint pieces at substantially equal intervals.
A brush assembly in which at least two tongue pieces are provided in each frame and extend from the respective suspension parts toward other suspension parts to the middle of the frame, and at least one row of projections is provided on the tongue parts. This is based on the finding that the above problems can be efficiently solved by using a substrate for a battery.
Further, while using the substrate for the brush assembly, the wire rod and the substrate are transferred in synchronism with each other, and the wire rod is aligned in a plane substantially parallel to the projection provided on the tongue portion, and then the wire rod is welded to the projection. It was made based on the finding that it is possible to efficiently manufacture a brush assembly formed by welding a wire rod made up of a large number of thin wires to the tongue portion.

Next, a method for manufacturing a substrate for a brush assembly and a brush assembly according to the present invention will be described with reference to an embodiment. FIG. 1 is an enlarged schematic view of a brush assembly substrate 1 used in the present invention, in which a side portion 3 of two suspension portions 2 and 2'is connected by a plurality of joint pieces 4 to form a square shape. A large number of frames are formed. Incidentally, in order to make the welding position and the like accurate, pilot holes 5 for positioning can be provided at predetermined intervals in the suspension belts 2 and 2 '.

Then, in the frame, the tongue portion 6 extending from the suspension part 2 toward the suspension part 2 ′ to the middle of the frame and the suspension part 2 ′ toward the suspension part 2 within the frame. Tongue piece 7 extending to the middle
Are formed. Here, the tongue pieces 6 and 7 are the suspension portions 2,
Vertical portions 8 and 9 which are connected to 2'and extend in a direction perpendicular to the suspension portions 2 and 2 '(see FIGS. 1 and 2) or at an obtuse angle (see FIG. 4) and suspensions at the tips of the vertical portions. It consists of strips 2 and 2'and protrusions 10 and 11 provided in parallel, and two rows of projections 12 and 13 are provided at the tips of the protrusions, respectively. As will be described later, the two-row projection is for welding the wire rod 15 consisting of the thin wire 14. However, in the case of one row as in the conventional case, the number of the wire rods can be increased due to the multi-use of the brushes. The higher the number, the higher the probability of welding failure, so there is a problem for this type of component that requires high reliability. However, in the case of 2 rows, 2 wires per wire
Since the welding is performed at each of the two places, the probability of defective welding at the two places is 1 / square of the case of the one place, which contributes to a remarkable improvement in reliability. Regarding the shape of the projection 12 or 13, the surface thereof may be flat and have a uniform height, but the diameter is 120 μm in FIG. 2 as the AA cross section of FIG.
As shown in the cross-sectional view of the wire rod 15 made up of the six thin wires 14, the projection 12 or 13 is placed on the protrusion 10.
The height of the recesses is preferably about 30 to 50 μm, the recesses 16 have an angle of 120 °, the pitch intervals are substantially the same as the diameter of the fine wires 14, and the height of the recesses is about 30 μm. In the present invention, as shown in FIG. 2, it is desirable that the concave portion 16 is provided on the surface of the projection in such a shape that the concave portion 16 comes into contact with each thin wire 14 at least at two points in the state where almost no pressure is applied during welding. That is, in this way, it is possible to perform extremely close contact welding without deviation of the thin wire during welding, and to obtain stable welding strength for each wire. The concave portion provided on the projection is not limited to the one shown in FIG. 2, and may have various shapes such as a semicircle that matches the shape of the fine line. The formation of the concave portion on the projection can be easily performed by a known method, for example, by pressing.

As a substrate for a brush assembly of the present invention, as shown in FIG. 3, a protrusion 17 of a tongue piece is formed by extending a vertical portion 18, and as shown in FIG. The base portions 8 and 9 extend from the suspension portions 2 and 2'to an intermediate portion in the frame at an obtuse angle to form three tongue portions, and the tip portions thereof are parallel to the suspension portion and projecting portions 19 on both sides. , 20 can also be used in the present invention. Further, in the present invention, by providing three or more, for example, 3 to 5, tongue pieces in the frame, the loss of expensive wire rod can be remarkably improved by this method, especially when a precious metal wire rod is used.

Using the above-described substrate for a brush assembly, a brush assembly can be manufactured by various methods. As a specific example, FIG. 5 shows a schematic view of a method for manufacturing the brush assembly of the present invention. According to this method, the diameter 120
The wire 15 consisting of seven thin wires of μm is supported by the guide 31 and is transferred to the close contact alignment device 32 in a cycle of constant speed feeding and temporary stop. In the close contact aligning device 32, a plurality of thin wires are closely contacted and aligned so that they are firmly aligned in the recesses of the projection when they are stacked on the substrate in the next step. On the other hand, the continuous substrate 1 separately from the wire 15 passes through the substrate guide 33,
The wire rods 15 are sequentially sent out in parallel with the aligned surface of the wire rods 15 arranged in close parallel to each other and in conjunction with the cycle movement of the wire rods 15 being sent out. The wire material 15 and the substrate 1 which are sent out in an interlocking manner are overlapped with each other during the transfer to be integrated, and for example, as shown in FIG. 2, a fine wire 14 which constitutes the wire material 15 is provided on the tongue portion 6. It is inserted between the recesses 16 of the projection 12. Therefore, according to this method, the thin wires can be easily brought into close contact with each other so that there is no gap between the thin wires. Then, it passes through the substrate feed roller 34 and reaches the welding device 35. In addition, after the wire material 15 and the substrate 1 which are sent out in conjunction with each other are temporarily stopped,
It is advisable to enter the welding device 35. As shown in FIG. 6, the welding device 35 is installed such that the upper electrode 36 and the lower electrode 37 are parallel to the surface of the wire. When the projections 12, 13 of the substrate 1 stop below the upper electrode 36 of the welding device 35, the welding of the wire 15 to the substrate 1 lowers the upper electrode 36 and presses the substrate 1 to lower the electrode 37. The upper closely aligned wire 15 is welded to the projection parts 12 and 13. At this time, according to the present invention, the thin wires are closely attached to each other, and even if pressed by the lowering of the upper electrode 36, the thin wires are firmly fixed in the recesses, so that the thin wires do not shift and are extremely efficient. It has the advantage that it can be welded. Then wire
Substrate 1 on which 15 is welded is sequentially transferred to take-up roll
Roll it up to 38.

In the above-mentioned embodiment, the continuous substrate 1 is sent out to the upper side of the closely-aligned parallel aligned wire rod 15. However, in some cases, it is sent to the lower side of the aligned wire rod 15 and the upper electrode 36 descends, so that the aligned wire rod 15 is projected onto the substrate 12. Alternatively, they may be welded by being pressed against the recessed portion 16 provided in the groove 13.

In addition, in the present invention, as the fine wire constituting the wire material 15, various diameters, for example, those having a diameter of 60 to 150 μm can be used, and the number of aligned lines is not limited to 7, and, for example, 10
, 80 or the like.

In the present invention, a wire rod made up of a large number of fine wires can be aligned substantially horizontally and welded to a substrate. However, a wire rod made up of a large number of fine wires is aligned substantially in parallel on one plane and the planes are orthogonal to the feed direction of the wire rod. The axis is inclined at an angle of 15 to 90 ° with respect to the horizontal plane, preferably 30 to 45 °, and the thin wire is closely attached,
It can also be welded to a substrate that is transferred in synchronization with the wire.
Thereby, the adhesion can be further improved.

In the brush assembly manufactured in this way, as shown in FIG. 7, after cutting the wire 15, the tip of the cut wire is bent if necessary, and then the vertical portion 8 of the tongue piece 8 is cut. It can be used as a sliding brush, for example, by cutting the boundary between the protrusion 10 and the protrusion 10.

〔The invention's effect〕

ADVANTAGE OF THE INVENTION According to this invention, a secondary force is hard to be applied to a welding part at the time of cutting, welding strength will fall, distortion will remain, and a brush assembly can be manufactured, without having a bad influence on a welding part. it can.

In addition, when a projection having a concave portion is employed, the fine wires constituting the wire can be easily adhered to each other and can be easily welded to the substrate without any gap between the fine wires without using a special device. At the same time, since the thin wire does not deviate from a predetermined position on the projection during welding, the fine wire can be accurately welded on the projection.

Therefore, it is possible to efficiently prevent the brush from becoming loose and unnecessary adhesion of welding objects. Also, in this method, 2 in 1 frame
Since more than one tongue piece is provided, for example, the eighth of one tongue piece in one frame
Comparing the figure with the first figure of the two tongue pieces in one frame, the yield is improved by 33% because three products are obtained in the former and four products are obtained in the latter for the substrate having the same length l. This is a marked improvement in productivity when considered as a mass-produced product. Furthermore, if the Teflon coating is applied to the wire contact surface of the close alignment device, the wire and the substrate can be prevented from being damaged, and smooth transfer can be achieved.

[Brief description of drawings]

FIG. 1 is an enlarged schematic view of a substrate for a brush assembly used in the present invention, in which fine wires constituting a wire material are welded, FIG. 2 is a sectional view taken along the line AA of FIG. 1, and FIGS. Another schematic view of a substrate for a brush assembly used in the present invention, FIG. 5 is a schematic view showing a manufacturing process of the brush assembly of the present invention,
FIG. 7 is a schematic cross-sectional view of a welding apparatus, FIG. 7 is a view showing the manufacture of a sliding brush, and FIG. 8 is a schematic view of a brush assembly substrate of a comparative example. In the figure, 1 is a substrate, 2'is a suspension, 4 is a joint piece part, 6, 7
Is a tongue piece, 10 and 11 are protrusions, 12 and 13 are projections, 15 is a wire rod, 15 is a recess, 16 is a concave alignment device, 32 is a close contact aligning device, 35 is a welding device, 36 is an upper electrode, 37 is a lower electrode, and 39 is a detached part. It is a single brush.

Claims (6)

(57) [Claims] 1. A plurality of rectangular frames are formed by connecting side parts of two suspension parts arranged in parallel with a plurality of joint pieces at substantially equal intervals.
Providing in each frame at least two tongues extending from their respective suspensions towards the other suspension to the middle of the frame, and providing at least one row of projections on the tongues. Substrate for brush assembly. 2. The board according to claim 1, wherein the tongue piece has a protrusion provided on one side or both sides of the tip in parallel to the suspension portion. 3. The substrate according to claim 1, wherein the projections are provided in one row or in two or more rows in a direction substantially perpendicular to the suspension band. 4. The substrate according to claim 1, wherein the projection is provided with a recess. 5. A method for manufacturing a brush assembly, which comprises welding a wire rod made up of a large number of thin wires to a substrate, wherein the side portions of two suspension parts provided in parallel as the substrate are formed by a plurality of joint pieces. A large number of square frames are formed so as to be connected at equal intervals, and at least two tongue pieces extending from each suspension part toward other suspension parts to the middle of the frame are provided in each frame. Using a brush assembly substrate provided with at least one row of projections on its part, the wire rod and the substrate were transferred in synchronism, and the wire rods were aligned in a plane substantially parallel to the projection provided on the tongue portion. After that, the wire rod is welded to the projection to produce a brush assembly. 6. A method according to claim 5, wherein the projection is provided with a recess, and the recess is shaped so as to make contact with each thin wire at at least two points.