JP2557259B2 - Substrate for brush assembly and method for manufacturing brush assembly - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial field of application] The present invention is used as a potentiometer, a trimmer, an encoder, etc., as a brush for sliding an electric signal or a micromotor in combination with a resistor, a slip ring, etc. The present invention relates to a widely used substrate for a brush assembly and a method for manufacturing the 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 welded to the bar connecting the two suspension bands, both ends of the bar are cut,
There is a problem that a secondary force is inevitably applied to the welded portion, the weld strength is reduced, and distortion remains, which adversely affects the welded portion.

Further, in the method of aligning and aligning a wire rod made up of a large number of thin wires with a suspension member and welding them to a substrate, it is not economical because it is necessary to cut unnecessary wire rods after welding, and it is difficult to visually check the welding process. There is.

[Problems to be Solved by the Invention]

Therefore, according to the present invention, a secondary force is hard to be applied to a welded portion at the time of cutting, the weld strength is not deteriorated, distortion remains, and the like, and the welded portion is not adversely affected and unnecessary wire rod loss is less likely to occur. An object is to provide a substrate for a brush assembly. It is another object of the present invention to provide a method of manufacturing the suspension part which is less likely to be distorted during manufacturing, can be transported securely, and allows the welded part to be visually observed.

[Means for solving the problem]

Unlike the conventional method, the present invention provides a substrate for a brush assembly in a form in which a pedestal is held in a rectangular frame and a wire can be supplied from a direction orthogonal to the transfer direction of the suspension to weld the wire to a projection. This was done based on the finding that the above problems can be solved efficiently by shaping.

Therefore, according to the present invention, the side parts of the two suspension parts provided in parallel are connected to each other at a substantially equal interval by a plurality of joint pieces to form a large number of square frames, and one frame is formed through the connecting part in each frame. There is provided a substrate for a brush assembly, which is provided with at least one pedestal in the direction from the suspension portion to the other suspension portion, and at least one row of projections is provided on the pedestal in parallel to the suspension portion.

The present invention also provides a method of manufacturing a brush assembly, comprising using the above substrate, introducing a wire from a direction perpendicular to a suspension band of the substrate, and welding the wire to a projection on the substrate.

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 substrate 1 for a brush assembly used in the present invention, in which two suspension straps arranged in parallel are shown.
The side portions of 31 and 32 are connected to each other by joint pieces 33 and 34 to form a rectangular frame, and a pedestal 4 is provided in each frame through a connecting portion 3 so as to project to the side of the suspension 31. A row of projections 6 is provided on the tip portion 5 substantially parallel to the suspension 31. The projection 6 is for welding a wire rod 8 made of a thin wire 7, as described later. The surface of the projection 6 may be flat, but for example has a diameter of 120.
A projection (for example, 30 to 30 mm) is used so that the wire rod 8 composed of six fine wires 6 (circular in cross section) of μm is firmly fixed.
A recess having a depth of, for example, about 30 μm can be formed on the height of 50 μm). That is, in this way, it is possible to perform extremely uniform close contact welding without shifting the fine wires during welding, and to obtain stable welding strength for each wire rod.

Although FIG. 1 shows an example in which projections are provided on a single-row pedestal, in the present invention, two or more rows of projections can be provided on a pedestal. In particular, it is preferable to provide projections in two or more rows because it is possible to reduce welding defects when welding wire rods.

The projection is provided as a protruding portion on the pedestal, and can be formed by a method by press processing. Also, the shape of the projection may be any as long as it projects onto the pedestal and can weld the wire rod, but a rectangular wire rod is used as the wire rod, and without close welding,
For example, when the wire rod is welded to the projection with an interval of 50 to 300 μm, if the projection is configured as shown in FIG. 2 (an enlarged view of the pedestal portion is shown), the melted unwanted material accumulates in the depression 9, Since it does not adhere to the welding electrode, it has the advantage of extending the life of the welding electrode.

The rectangular wire used here has a width of 150 to 300 μm and a thickness of 50 to 100 μm. Also as a projection, width (W) 150-300 μm, length (L) 150-3
It has a diameter of 00 μm and a height of 20 to 50 μm.

In the present invention, for example, as shown in FIG.
The pedestal 4 is connected to the side of the plate-like suspension 31 or 32 (thickness is optional, but generally 5 to 20 m is used) having a thickness of 100 to 500 μm via the connecting portion 3. However, the connecting portion may have various shapes other than that shown in FIG. For example, the pedestal may have the same width as that of the pedestal, or the pedestal may have a shape corresponding to a device to be used.
Further, two or more pedestals can be provided in one rectangular frame. 1 (a) is a perspective view of the brush assembly substrate before welding the wire rod, and FIG. 1 (b) is a brush assembly substrate to which the wire rod is welded, and FIG. ) Indicates that the pedestal is separated from the substrate for the brush assembly by the cutting line 10 and the end use form 15
It is a figure which shows what became.

In the present invention, in addition to the substrate shown in FIG.
It is also possible to use a substrate of the form shown. FIG. 5 (a) is a view in which the wire rod is welded, and FIG. 5 (b) is a view in which the wire is cut along the line 10 into the final use form 15.

As shown in FIG. 1 (c), in the present invention, the pedestal 4 has the shape of the brush assembly to be finally used. Therefore, when the substrate is sequentially punched along the cutting line indicated by 10, It has an excellent advantage that it can be used as it is. That is, in the conventional method, the wire rod was separated after welding to form a brush unit, and this brush unit had to be attached to the spring pedestal by secondary welding to form a brush assembly. In addition to saving labor, there is no room for intervention in the accuracy of the secondary welding, which improves workability and quality.

Incidentally, in order to facilitate the movement of the substrate, the suspension holes 31, 32 may be provided with positioning pilot holes 11 at predetermined intervals.

Using the above-described substrate for a brush assembly, a brush assembly can be manufactured by various methods. As a specific example, FIGS. 6 and 7 show schematic views of a method for manufacturing the brush assembly of the present invention. According to this method, a wire 8 composed of three rectangular wires 7 having a width of 200 μm and a thickness of 70 μm wound on a reel 20 passes through a width guide 21,
The rectangular wire feeder 22 intermittently feeds the wire to the projections from the direction orthogonal to the transport direction of the suspension belts 31 and 32 for welding to the projection. On the other hand, the continuous substrate 1 separate from the wire 8 passes through the substrate guide 23, and is sequentially sent out in a direction perpendicular to the alignment surface of the aligned wire 8 and in conjunction with the cycle movement in which the wire 8 is sent out. The wire rods 8 sent out in conjunction with each other are overlapped on the projection on the substrate 1 and welded by the welding device 24. In the welding device 24, the upper electrode 24a is lowered, the substrate 1 is pressed, and the alignment wire 8 on the lower electrode 24b is welded to the projection 6.

Then, after passing through the lower cutter / groove guide 25, the upper cutter 26 descends to simultaneously separate the plurality of rectangular wire rods 8. Next, the upper cutter 26 rises, the pedestal 4 is transferred by the pedestal feeding device 27 at regular intervals, and the next pedestal 4 is installed between the upper and lower electrodes 24. After that, a plurality of rectangular wires 8
Is fed to the fixed length by the flat wire feeder 22 and guided onto the projection 6 of the pedestal 4. Also, the pedestal 4 is synchronized with the pedestal feeding device 27 at a constant interval, and the cutter 29 for disconnecting the connecting portion descends to complete the brush.
15 is cut off. The final brush 15 is manufactured by repeating a series of operations in this manner, and can be used as a sliding brush, for example.

〔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 to these advantages, since the substrate used in the present invention has the suspensions on both sides in the longitudinal direction, the substrate can be transferred smoothly, and even if stress is applied during the transfer, the entire substrate for the brush assembly can be transferred. As a result, there is an advantage in that the influence of the stress is difficult to be transmitted to the pedestal. Further, since the wire rod is supplied from the direction perpendicular to the suspension band, there is a great advantage that it is easy to visually recognize a portion where the wire rod is welded to the projection and there is no wire rod loss.

Further, it can be efficiently manufactured when the entire thickness is thin or the pedestal has a complicated shape.

[Brief description of drawings]

FIG. 1 is an enlarged schematic view of a brush assembly substrate used in the present invention in which fine wires constituting a wire are welded, FIG. 2 is an enlarged view of another form of a pedestal used in the present invention, and FIGS. 5
The drawings are other schematic views of the substrate for the brush assembly used in the present invention, and FIGS. 6 and 7 are a schematic plan view and a schematic side view showing the manufacturing process of the brush assembly of the present invention, respectively. In the figure, 1 is a substrate, 31 and 32 are suspension belts, 33 and 34 are joint pieces, 3 is a connecting portion, 4 is a pedestal, 6 is a projection, 8 is a wire rod,
24 is a welding device, 24a is an upper electrode, 24b is a lower electrode, and 15 is a separated brush unit.

Claims (2)

(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.
At least one pedestal is provided in each frame in the direction from one suspension part to the other suspension part via a connecting part, and at least one row of projections is provided on the pedestal in parallel with the suspension. Substrate for brush assembly. 2. A method of manufacturing a brush assembly, wherein a wire rod made up of a large number of fine wires is welded to a projection on a substrate, wherein two side portions of two suspension parts provided in parallel as the substrate have a plurality of joint pieces. A plurality of square frames are connected to each other at substantially equal intervals, and at least one pedestal is provided in each frame in the direction from one suspension part to the other suspension part via a connecting part,
Using a brush assembly substrate in which at least one row of projections is provided on the pedestal in parallel with the suspension, and introducing the wire from a direction orthogonal to the suspension of the substrate to weld the wire to the projection on the substrate. A method for manufacturing a characteristic brush assembly.