JP4514728B2 - Welding method for electric wire with terminal - Google Patents

Description

  The present invention relates to a method for ultrasonic welding a terminal-attached electric wire having a terminal such as a connector at one end to another electric wire or the like.

  When connecting an electric wire with a terminal having a terminal such as a connector at one end to a wire harness or the like of an automobile, to an end portion or an intermediate portion of another electric wire, for example, as shown in Patent Document 1, an insulating coating at a connection site is provided. A method is often used in which the exposed core wires are superposed and the core wires are joined in this state by applying ultrasonic vibration with an ultrasonic welding machine. Patent Document 2 discloses a form in which an electric wire and a terminal fitting are joined by ultrasonic welding.

JP 2000-188018 A JP 2005-319497 A

  When performing such ultrasonic welding, vibration during welding is transmitted to the terminal through the electric wire, and there is a risk of causing breakage or the like at a relatively weak portion such as a bent portion of the terminal. For example, as shown in FIG. 4, a contact 18 with a male terminal fixed in a female terminal serving as a terminal is formed between a pair of upper and lower contact plates 18a and 18b having a rectangular shape, and edges between both contact plates 18a and 18b. In the case where the contact plate 18a and 18b are connected to each other so as to connect the contact plates 18a and 18b so as to maintain a predetermined distance, the connection portion 18c is easily damaged during welding. This terminal breakage is particularly likely to occur when the length of the wire is short. As measures against this, attempts have been made to damp vibrations by holding the wires with vibration-proofing materials such as rubber materials and jigs, but only holding the outer insulation coating and actually transmitting vibrations. Since the core wire cannot be directly held, the vibration cannot be completely absorbed, and the damage prevention effect is not sufficient. Further, in order to obtain a vibration damping effect, it is necessary to secure a certain holding length, and there is a problem that it cannot be applied to a short electric wire. In addition, using such a vibration isolating material leads to an increase in cost.

  Accordingly, the present invention provides a method for welding a terminal-attached electric wire that can effectively attenuate vibration to the terminal with a simple configuration regardless of the length of the electric wire, and can obtain a higher effect of preventing damage to the terminal. It is intended to do.

In order to achieve the above object, the invention according to claim 1 is a winding in which the electric wire itself is wound around another member at least once in a contact state between the terminal and the welded portion in the electric wire with terminal . The ultrasonic welding is performed in a state where the portion is formed and the shape of the wound portion is maintained using a jig .
The invention according to claim 2, in addition to the purpose of claim 1, in order to obtain a more effective vibration damping, the winding portion are obtained by a multi-turn electric wire contact each other.

In addition to the object of the first or second aspect , the invention according to the third aspect is provided with at least a winding part in another member and / or jig in order to enhance the vibration damping effect by the other member or jig. The contact portion is made of an elastic material.
According to a fourth aspect of the present invention, in the configuration according to any one of the first to third aspects, the terminal provided on the electric wire is provided between the pair of contact plates and the edges of the contact plates, so that the contact plates are predetermined. And a connection portion that is connected so as to maintain the interval.

According to the first aspect of the present invention, it is possible to effectively attenuate the vibration to the terminal, and it is possible to suitably prevent the terminal from being damaged. In particular, since it is sufficient to form the winding portion with the terminal-attached electric wire itself, it is possible to cope with the length of the electric wire with the terminal, and there is no increase in cost related to vibration attenuation.
Further , the vibration damping part can be easily obtained by a simple operation of forming the winding part, and the workability is not impaired. Furthermore, vibration attenuation is achieved by other members that come into contact, and the effect of preventing damage to the terminals is enhanced.
According to the second aspect of the present invention, in addition to the effect of the first aspect , the multiple-winding electric wires are brought into contact with each other to more effectively attenuate the vibration, thereby improving the effect of preventing damage to the terminals.
According to the third aspect of the present invention, in addition to the effect of the first or second aspect , the vibration damping effect by other members or jigs can be enhanced by employing an elastic material. In particular, if an elastic material is used for the jig, there is no risk of damaging the electric wire when the jig is held.
According to the fourth aspect of the invention, in addition to the effect of any one of the first to third aspects, even a terminal having a connection portion that has been easily damaged during conventional welding is suitably prevented from being damaged.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
Drawing 1 is an explanatory view showing an example of a welding unit which enforces a welding method of an electric wire with a terminal of the present invention, (A) expresses a plane and (B) expresses the front, respectively. The welding unit 1 includes an electric wire support 2 installed on a work table and an ultrasonic welder 3 installed on the right side (right side in FIG. 1) of the electric wire support 2. Is made of stainless steel columns 4, 4 erected at a predetermined interval in the front-rear direction on the ultrasonic welder 3 side, a clamp 5 arranged on the left side of the columns 4, 4, It is composed of a winding column 8 made of urethane and having a circular cross section. The clamp 5 corresponds to the jig in the present invention, and the winding column 8 corresponds to another member in the present invention.

  The ultrasonic welding machine 3 places a work piece on an anvil and applies an ultrasonic vibration from a welding tip (not shown) in a state where static pressure is applied to a joint surface to cause a sudden plastic flow in the work piece. It is a well-known welding machine that joins together. The clamp 5 is also provided with a receiving base 6 disposed below, a pressing plate 7 disposed above it, and a feed mechanism (not shown) such as a screw feed or an air cylinder for moving the pressing plate 7 up and down. It has a known structure for holding an object between the base 6 and the pressing plate 7.

The procedure for welding using the welding unit 1 configured as described above will be described by taking as an example the case of welding another electric wire to the electric wire with terminal.
First, as shown in FIG. 2A, a terminal-attached electric wire (hereinafter referred to as “target electric wire”) 9 provided with a terminal 10 (for example, a female terminal having a contact 18 as shown in FIG. 4) at one end and other terminals The end of the welding side with the electric wire 11 is aligned and set in the ultrasonic welding machine 3, the target electric wire 9 is located behind the columns 4, 4, and the other electric wire 11 is located nearer than the columns 4, 4. Pull out. The reason why the other electric wires 11 are pulled out in this way is to prevent the wire 5 from being caught on the clamp 5 side.
Next, the target electric wire 9 drawn to the left side is wound around the winding column 8 once as shown in FIG. 5B, and a winding that becomes a vibration damping portion between the terminal 10 and the end portion on the welding side is wound. Part 12 is formed. At this time, the winding part 12 is brought into contact with the winding column 8.

And the range including the cross | intersection part 13 of the winding part 12 is hold | maintained with the clamp 5, and the edge parts of the object electric wire 9 and the other electric wire 11 are joined with the ultrasonic welding machine 3. FIG. Here, since the winding portion 12 is formed between the terminal 10 and the end portion on the welding side of the target electric wire 9, vibration generated during welding is effectively attenuated by the winding portion 12, and the terminal 10 Is hardly transmitted.
After completion of the joining, the holding by the clamp 5 is released, the target electric wire 9 is removed from the winding column 8 and taken out from the ultrasonic welding machine 3 together with the other electric wires 11 joined.

Thus, according to the welding method of the electric wire with a terminal of the above-mentioned form, the winding part 12 formed by deforming the electric wire itself into a predetermined shape is formed between the terminal 10 in the target electric wire 9 and the welding part, By performing ultrasonic welding in the state, vibration attenuation to the terminal 10 can be effectively performed, and damage to the terminal 10 can be suitably prevented. In particular, since it is sufficient to form the winding portion 12 with the target electric wire 9 itself, it is possible to cope with the length of the target electric wire 9 and no cost increase related to vibration attenuation occurs.
Moreover, by adopting the winding part 12 as the vibration attenuating part, the vibration attenuating part can be easily formed by a simple operation of winding the target electric wire 9, and workability is not impaired.
Furthermore, since the winding part 12 is wound in the contact state by using the winding column 8 here, vibration attenuation is also achieved by the winding column 8 and the effect of preventing damage to the terminal 10 is enhanced.
In addition, since the winding part 12 is held by the clamp 5 at the time of welding, the shape of the winding part 12 is maintained and the vibration damping effect is reliably exhibited.

In addition, in the welding method of the said form, although the winding part is made into 1 turn, it does not interfere even if it is multiple winding of 2 or more turns which electric wires contact. When such multiple winding is used, vibrations are more effectively attenuated by the contact between the electric wires, and the effect of preventing damage to the terminals is improved.
Further, in the welding unit, the winding column is not limited to urethane, and other materials such as silicon rubber may be used. Furthermore, it is desirable to use an elastic material such as rubber or synthetic resin for the contact portion of the clamp with the target electric wire (here, the surface facing the receiving table and the pressing table). Thereby, effective vibration damping can be expected even in the clamp, and there is no possibility of damaging the held target electric wire.
However, if sufficient vibration damping is possible with only the winding part, the winding column and the clamp can be omitted. Installation of pillars is also optional.

And as a vibration damping part, it is not restricted to the winding part of the said form, U-shaped bending part 14 shown to FIG. 3 (A), and the two right-angle bending parts 15 and 15 shown to the same figure (B). If the total bending angle is 180 ° or more, the vibration damping effect can be obtained.
Further, even when the folding directions are reversed as in the bent portions 16 and 16 shown in FIG. 10C, the total bending angle may be 180 ° or more. In this case, the respective angles may be different as in the bent portions 17 and 17 in FIG. Of course, three or more bent portions may be provided, or a wound portion and a bent portion may be used in combination. Even in these cases, the vibration damping portion can be easily obtained by a simple operation of forming the bent portion without impairing workability.

As these other bent parts, the bent parts can be formed in contact with each other by using a column having a circular cross section or a square as in the above-mentioned form, or the bent parts can be held using a jig such as a clamp. If so, an improvement in vibration damping effect can be expected.
However, the bent portion does not need to be clearly formed as illustrated in FIG. 3, and depending on the diameter and hardness of the electric wire itself, and the shape of other members used as a guide, etc. Even at the corners, the vibration damping effect does not change.

In addition, although the said form has demonstrated the case where there is one object electric wire and another electric wire one by one, when there are a plurality of the electric wires, a plurality of other electric wires may be formed together by forming a winding portion. If this is the case, you can pull them all together.
Moreover, it is not restricted to the form in which another electric wire is joined to the end portion of the target electric wire, or when another electric wire is joined to the intermediate portion of the target electric wire, or the intermediate portion of the other electric wire is joined to the end portion of the target electric wire. In the case where the target electric wire and the other electric wires are joined to each other, the present invention is similarly applicable even when the target electric wire and the terminal fitting are joined.
The vibration damping effect can be obtained even if the operator performs welding while holding the vibration damping part such as a winding part by hand without using the other members and jigs.

It is explanatory drawing which shows an example of a welding unit, (A) represents a plane and (B) represents the front, respectively. (A) (B) is explanatory drawing which shows the procedure of the welding method. (A)-(D) is explanatory drawing which shows the example of a bending part, respectively. It is a perspective view which shows an example of a terminal.

Explanation of symbols

1 .... Welding unit 2 .... Wire support stand 3 .... Ultrasonic welding machine 4 .... Pole 5 .... Clamp, 8 .... Wound pillar, 9 .... Target wire 10 .... Terminal 11, ... -Other electric wires, 12 ... winding part, 14-17 ... bending part.

Claims (4)

A welding method for a terminal-attached wire for ultrasonic welding a terminal-attached wire having a terminal at least at one end,
Between the terminal and the welded portion of the terminal-attached electric wire , a winding portion is formed by winding the electric wire itself on another member in a contact state at least once, and the shape of the winding portion is a jig. A welding method for an electric wire with a terminal, wherein ultrasonic welding is performed in a state where the electric wire is maintained . The welding method for an electric wire with a terminal according to claim 1 , wherein the winding portion is a multiple winding in which the electric wires come into contact with each other. The welding method of the electric wire with a terminal of Claim 1 or 2 which has formed the contact part with the winding part at least in another member and / or a jig | tool with the elastic material. Terminal with the electric wire, any one of claims 1 to 3 and a connecting portion connecting a pair of contact plates, the contact plates are being extended between the end edge of the contact plate so as to maintain a predetermined distance The welding method of the electric wire with a terminal as described in 2.

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