JP4610263B2 - Manufacturing method of LED wiring unit - Google Patents

Description

  In the present invention, the tip of the protruding pin on the synthetic resin insulating base side that is engaged with the opening on the metal bus bar side that is the power supply path on which the LED is mounted is fixed to the periphery of the opening by ultrasonic caulking. The present invention also relates to a method for manufacturing an LED wiring unit including an ultrasonic caulking process in which an LED-mounted bus bar is laminated and integrated on an insulating base.

  2. Description of the Related Art As a vehicular lamp using an LED as a light source, there is known a lamp structure in which an LED wiring unit in which an LED is mounted and integrated on a metal bus bar fixed to an insulating base is accommodated in a lamp chamber. The bus bar that constitutes this LED wiring unit has a structure in which a plurality of power feeding paths are connected in advance by a strip-shaped connecting portion, and after fixing the bus bar to the base, the bus bar cuts the connecting portion of the bus bar, so that the bus bar has a power feeding path to the LED. It is configured.

  And in the development process of this kind of lamp, the inventors considered as follows. First, as a procedure for assembling the LED wiring unit, it is desirable to mount the LED on the bus bar (caulking or welding between the LED leg and the bus bar) and then fix the LED mounting bus bar to the base. This is because when the bus bar is mounted on the base and the LED is mounted on the bus bar, the base becomes in the way and the workability is poor. Further, as a method of fixing between the bus bar and the base, it is desirable to engage the protruding pin provided on the base side with the hole on the bus bar side and caulk the tip end portion of the protruding pin protruding from the hole by ultrasonic caulking. This is because ultrasonic caulking is faster than the usual thermal caulking, and the melting and softening of the resin is extremely fast, so that the time required for the caulking process can be remarkably shortened and the risk of thermal damage to the LED is considered to be small.

Further, as this type of prior art, there is the following Patent Document 1, in which a projecting pin 2 is provided on the bottom surface of the recess 1a of the transparent resin outer case 1, as shown in FIG. A hole 4a for engaging the projecting pin 2 is provided at a portion facing the recess 1a on the outer case 1 side in the metal inner case 4 on which the LED and the PD arranged opposite to each other with the recess 1a interposed therebetween. The outer case 1 and the inner case 4 are assembled so that the hole 2 and the hole 4a are engaged with each other, the protruding pin 2 protruding from the hole 4a is crushed by ultrasonic caulking, and the outer case 1 and the inner case 4 are fixed and integrated as a rain sensor. A technique for realizing the above is disclosed.
Noto 2558550 (paragraphs 0014, 0015, FIGS. 1 and 2)

  However, when assembling the LED wiring unit, ultrasonic caulking was used in the process of caulking and fixing the bus bar to the base. As a result, the LED could be damaged by ultrasonic vibration. When the inventors considered the cause, the pin tip (resin) protruding from the hole of the bus bar was melted and softened by being pressurized while ultrasonic vibration was transmitted through the horn, and was crushed. It becomes a crimped part that covers the peripheral edge of the hole, but it is understood that the vibrating horn contacts the bus bar in the process of crushing the tip of the pin, and ultrasonic vibration is transmitted to the LED through the bus bar. It was.

  The ultrasonic caulking method disclosed in Patent Document 1 has the same problem.

  The present invention has been made in view of the above-described problems of the prior art, and an object thereof is to provide a method for manufacturing an LED wiring unit including an ultrasonic caulking process that does not damage an LED due to transmission of ultrasonic vibration. There is.

In order to achieve the object, in the method for manufacturing an LED wiring unit according to claim 1, a pin protruding from an insulating base made of synthetic resin is made of a metal power supply path constituting member on which an LED is mounted. A process of stacking and placing an insulating base and a bus bar on a receiving portion by engaging with an opening provided in a certain bus bar;
An ultrasonic caulking step in which a horn that is an ultrasonic vibration transmitting member is pressed against the tip of the pin protruding from the opening of the bus bar, and the tip of the pin melted and softened by ultrasonic vibration is caulked. In the manufacturing method of the wiring unit,
In the ultrasonic caulking step, the insulating base is laminated by a flat plate-shaped pressing portion opened around the opening of the bus bar so as not to interfere with the horn at least while the horn and the pin are in contact with each other. The LED-mounted bus bar is pressed and held on the receiving portion, and the pin is pressed and crushed while applying ultrasonic vibration through the horn, and the ultrasonic vibration is stopped after the horn approaches the bus bar. Thus, the pin is pressed and crushed.
(Function) In the ultrasonic caulking process, the tip end portion of the insulating base whose back side is supported by the receiving portion is pressed in the axial direction by a horn that vibrates ultrasonically, and therefore melts by the transmitted ultrasonic vibration. The softened pin tip (resin) is crushed in the axial direction and spreads around the periphery of the opening, and is held in a state where the ultrasonic vibration is stopped, so that it cools and becomes a crimped portion.

  The horn melts and softens the tip of the pin until it reaches the position where it abuts the bus bar, but when the horn approaches the bus bar to a predetermined position, the ultrasonic vibration of the horn stops and the horn is in a non-vibrating state. Therefore, the ultrasonic vibration is not transmitted to the LED through the bus bar.

Even if the ultrasonic vibration stops at the position where the horn is close to the bus bar, the pin tip (melt softening resin) immediately after the ultrasonic vibration stops is sufficiently soft so that it is crushed by the horn, spreads, cools and caulked. There is no change in the effect of becoming a part.
Further, in the ultrasonic caulking process, the bus bar is held by the pressing portion in the form of being pressed and held by the receiving portion together with the insulating base. For example, even if the bus bar is warped, it is corrected by the pressing portion. Hard to touch.

According to a second aspect of the present invention, in the method for manufacturing the LED wiring unit according to the first aspect, a concave portion having a cross-sectional area larger than the cross-sectional area of the pin is formed on the end face of the horn tip.
(Function) The crimped portion formed by melting and softening and crushing the pin tip portion is a convex shape that is a transfer of the concave portion of the horn tip, and its outer periphery extends to the peripheral edge of the opening of the bus bar with which the pin is engaged. , To reliably prevent the deviation of the pin from the opening.

According to a third aspect of the present invention, in the LED wiring unit manufacturing method according to the second aspect of the present invention, the volume of the concave portion at the end face of the horn tip is configured to be smaller than the volume of the melt softening portion of the pin.
(Operation) A part of the melt-softening resin that does not fit in the concave portion of the horn tip is pushed out of the concave portion and extends in a film shape between the end surface of the horn tip and the bus bar to ensure contact between the horn and the bus bar. To prevent.

According to a fourth aspect of the present invention, in the method for manufacturing an LED wiring unit according to any one of the first to third aspects, a fine concave groove is provided at least in a portion of the horn tip that contacts the pin.
(Operation) Relative sliding at the contact portion between the horn and the pin is suppressed and the ultrasonic vibration of the horn is efficiently transmitted to the pin as compared with the case where the portion in contact with the pin at the tip of the horn is a smooth surface.

  In addition, compared with the case where the portion of the horn tip that contacts the pin is a smooth surface, the melt softening resin is prevented from flowing out of the portion where the horn contacts, and the pin tip is properly crushed in the axial direction. The crimped portion is formed.

According to the manufacturing method of the LED wiring unit according to claim 1, in the ultrasonic caulking process for fixing the base and the bus bar, the damage of the LED due to the transmission of the ultrasonic vibration is avoided, and the yield of the LED wiring unit to be manufactured. Will improve.
Also, in the ultrasonic caulking process for fixing the base and bus bar, the contact between the horn and the bus bar is more reliably prevented, so that LED damage caused by transmission of ultrasonic vibration is further avoided, and the LED wiring to be manufactured Unit yield is further improved.

  According to the second aspect, since the periphery of the opening of the bus bar is individually determined by the caulking portion that extends to the periphery of the opening, it is possible to manufacture an LED wiring unit that is securely fixed between the bus bar and the base.

  According to claim 3, since the contact between the horn and the bus bar is reliably prevented in the ultrasonic caulking process for fixing the base and the bus bar, damage to the LED due to the transmission of the ultrasonic vibration is further avoided. The yield of the LED wiring unit to be manufactured is further improved.

  According to the fourth aspect, since the transmission efficiency of ultrasonic vibration to the pin is good, the melting and softening speed of the pin is high, and the time required for the ultrasonic caulking process is shortened accordingly.

  Further, a caulking portion having an appropriate size is formed at the tip of the pin, and an LED wiring unit can be manufactured in which the bus bar and the base are more reliably fixed.

  Next, embodiments of the present invention will be described based on examples.

  1 to 6 show an embodiment of the present invention. FIG. 1 is a longitudinal sectional view of an automotive marker lamp (tail and stop lamp) according to a first embodiment of the present invention. FIG. FIG. 3 is a front view of the LED wiring unit housed in the LED wiring unit (plan view of the LED wiring unit horizontally disposed in FIG. 1 as viewed from above the lamp rear side), and FIG. 4 is an enlarged sectional view of a caulking fixing portion between the base and the bus bar, FIG. 5 is a schematic diagram of an ultrasonic caulking device, and FIG. 6 is a diagram for explaining an ultrasonic caulking process. ) Is a diagram showing the position of the horn and the shape of the pin immediately before the start of ultrasonic caulking, (b) is a diagram showing a state in which the horn pressurizes the tip of the pin, and (c) is a state in which the caulking portion is being cooled. FIG.

  In FIG. 1, reference numeral 10 denotes a lamp lamp body of a container-like tail-and-stop lamp in which an upper tail lamp A and a lower stop lamp B are integrated, and the front side is open. The lamp body 10 extends left and right. The partition wall 10a separates the lamp lamp body 10A of the tail lamp A and the lamp lamp body 10B of the stop lamp B. A red front lens 16 is assembled and integrated in the front opening of the lamp lamp body 10 to define lamp chambers SA and SB for the respective lamps A and B.

  A parabolic reflector 12A is integrally provided inside the lamp lamp body 10A, and a bulb 14 as a light source is fitted in the bulb mounting hole 11 of the lamp lamp body 10A. When the tail lamp A is lit, the bulb 14 is turned on. Is reflected by the reflector 12A, and the area corresponding to the lamp chamber SA of the front lens 16 emits red light.

  On the other hand, inside the lamp lamp body 10B, an LED wiring unit U in which a bus bar 30 on which an LED 34 as a light source is mounted is integrated with an insulating base 20 is provided in parallel in two upper and lower stages. Below the light emitting side, a reflector 36 is provided, and when the stop lamp B is lit, the light emitted from the LED 34 is reflected by the reflector 36 and the area corresponding to the lamp chamber SB of the front lens 16 emits red light.

  As shown in FIGS. 2 and 3, the LED wiring unit U has four metal contacts 30a constituting a power supply path on the upper surface of a flat synthetic resin insulating base 20 formed in a rectangular shape in plan view. , 30b, 30c, 30d, for example, a bus bar 30 having a thickness of 0.4 mm is fixed and integrated by ultrasonic caulking, and each LED 34 mounted between the contacts 30a, 30b, 30c, 30d is provided. The base 20 has a structure exposed to the lower surface side from the rectangular opening 21. Reference numeral 24a denotes an ultrasonic caulking portion formed at the tip of the pin 24 on the base 20 side protruding from the hole 32 of the bus bar 30 by a dish-shaped recess 46a provided at the tip of the horn 46 of the ultrasonic caulking device shown in FIG. As shown in FIG. 4, the caulking portion 24a has a dish-shaped convex portion to which the dish-shaped concave portion 46a of the horn 46 is transferred, and the surface thereof is finely formed on the inner surface of the dish-shaped concave portion 46a. A fine unevenness 24a1 to which the concave groove 46a1 is transferred is formed. A ring-shaped thin film 24b that is in close contact with the bus bar 30 is formed around the crimped portion 24a. In addition, the opening 21 is formed in a size that allows the whole including the legs of the LED 34 to be sufficiently accommodated, and the base 20 and the bus bar 30 (contacts 30a, 30b, 30c, 30d) are in close contact with each other.

Each contact 30a, 30b, 30c, 30d constituting the bus bar 30 is configured as a flat plate-like integrated body connected to each other by a narrow strip-shaped connecting portion 31 formed by, for example, sheet metal cutting press processing. And after LED34 is mounted so that it may straddle between each contact 30a, 30b, 30c, 30d (for example, the spot part of LED34 is spot-welded to each contact), the bus bar 30 carrying LED34 is laminated and integrated with the base 20, Thereafter, by cutting the connecting portion 31, each contact 30a, 30b, 30c, 30d is configured to function as a power supply path to the LED 34. Reference numerals 33 and 33 in FIG. 2 are terminals for connecting a lighting control circuit (not shown) for controlling the lighting of the LED 34 provided on the contacts 30a and 30d, and reference numeral 22 is provided at a position corresponding to the connecting portion 31. It is an opening part with which the blade for cutting of the connection part 31 which was made was engaged. Reference numeral 26 denotes a bracket provided near the side edge of the base 20, which is a part for attaching the LED wiring unit U (base 20) to the lamp body 10B.

  The bus bar 30 (contacts 30a, 30b, 30c, 30d) is provided with a plurality of holes 32 (see FIGS. 4 and 5) that are fixed to the base 20 by caulking. For example, a pin 24 (see FIG. 5) having a height of 3.5 mm is formed so as to be engaged with the hole 32 on the 30 (contact 30a, 30b, 30c, 30d) side, and the pin 24 on the base 20 side is connected to the bus bar 30 side. The base 20 and the bus bar 30 are stacked to engage with each other, and the tip of the pin 24 protruding from the hole 32 is subjected to ultrasonic caulking using the apparatus shown in FIG. A caulking portion 24a is formed at the tip of the pin protruding from the hole 32, and the base 20 and the bus bar 30 are firmly integrated.

As shown in FIG. 5, the ultrasonic caulking device that caulks and fixes the bus bar 30 on which the LED 34 is mounted to the base 20 includes a receiving portion 40 that supports the base 20, and the base 20 and the bus bar 30 that are placed on the receiving portion 40. A pressing portion 44 that presses and a horn 46 that is a vibration transmitting member that moves up and down above the receiving portion 40 are configured.

  The holding portion 44 is formed to be substantially the same size as the bus bar 30 and has a flat plate shape with a thickness of, for example, 3.5 mm and opened around the hole 32 of the bus bar 30 so as not to interfere with the horn 46 that moves up and down. It is configured. Further, one side edge portion of the pressing portion 44 is connected to the receiving portion 40 via a hinge (not shown), and the other side edge portion is swung up and down with respect to the receiving portion 40 around the hinge. Thus, the base 20 and the bus bar 30 are configured to be in two forms: a closed state in which the base 20 and the bus bar 30 are pressed, and an open state in which the base 20 and the bus bar 30 spring upward.

  The bus bar 30 is held in a form pressed and held by the holding portion 40 together with the base 20 by the holding portion 44. For example, even if the bus bar 30 is warped, the bus bar 30 is held in a corrected state by the holding portion 44. In the caulking process, the horn 46 is difficult to come into contact with the bus bar 30.

  The horn 46 is connected to a vibrator 47 that is ultrasonically vibrated by the operation of a transmitter (not shown), and the ultrasonic vibration of the vibrator 47 is transmitted to the pin 24 that contacts the horn 46 via the horn 46. It has become. The vibrator 47 can be slid up and down by an air cylinder 48, and the air cylinder 48 is assembled to a vertical sliding slider 49 a of the servo unit 49 and can slide greatly up and down. The servo unit 49 is supported by, for example, a robot arm (not shown) that can move in three orthogonal axes.

  The tip of the horn 46 is provided with a dish-shaped recess 46a that contacts the tip of the pin 24, and the tip 24 (resin) of the pin 24 that is pressurized in the axial direction by the recess 46a of the horn 46 that vibrates ultrasonically is provided. Then, it is melted and softened by the transmitted ultrasonic vibration, is crushed in the axial direction, spreads around the periphery of the hole 32, is cooled while being held in a state where the ultrasonic vibration is stopped, and becomes a crimped portion 24a.

  Further, a fine concave groove 46a1 (see FIG. 4) is provided on the inner surface of the dish-shaped concave portion 46a at the tip of the horn 46, and relative sliding at the contact portion between the horn 46 and the pin 24 is suppressed. The sound wave vibration is efficiently transmitted to the pin 24. For this reason, the ultrasonic vibration transmitted through the horn 46 increases the melting and softening speed of the resin at the tip of the pin 24, and the time required for the caulking process is reduced accordingly.

  Further, the minute concave groove 46a1 on the inner surface of the dish-shaped concave portion suppresses the outflow of the melt softening resin to the outside of the concave portion 46a at the portion in contact with the horn 46, and the tip end portion of the pin 24 is properly crushed in the axial direction. The crimped portion 24a is formed.

  Further, since the cross-sectional area of the dish-shaped recess 46a at the horn tip is formed to be larger than the cross-sectional area of the pin 24, the softened pin tip (melt softening resin) is the dish-shaped recess 46a at the horn tip. The caulking portion 24a formed by being crushed is a dish-shaped convex portion to which the dish-shaped concave portion 46a is transferred. The outer circumference of the bus bar 30 extends to the peripheral edge of the hole 32, so that the pin 24 is surely deviated from the hole 32. To be prevented.

  Further, since the volume of the dish-shaped recess 46a at the tip of the horn is formed to be smaller than the volume of the melt softening resin at the tip of the pin 24, the melt does not fit in the dish-shaped recess 46a at the tip of the horn. A part of the softened resin is pushed out from the dish-shaped recess 46a and extends as a resin thin film 24b (see FIGS. 4 and 6C) between the end face of the horn 46 and the bus bar 30, and the horn 46 and the bus bar. 30 contacts are reliably prevented.

  The operation of the ultrasonic transmitter (start and stop of ultrasonic vibration) is set to operate in conjunction with the operation of the air cylinder 48. That is, the horn 46 descends at a predetermined speed by sliding the air cylinder 48 downward, but as shown in FIG. 6A, the tip of the horn 46 is at a position 3.5 mm from the bus bar 30. When the air cylinder 48 (horn 46) starts to descend, the ultrasonic transmitter is activated (the horn 46 starts ultrasonic vibration). Then, as shown in FIG. 6B, when the tip of the horn 46 is 0.7 mm from the bus bar 30, the ultrasonic transmitter stops operating (the ultrasonic vibration of the horn 46 stops). Furthermore, as shown in FIG. 6C, the horn 46 is lowered to the lower end position of the air cylinder 48 where the tip of the horn 46 is located at a position of 0.2 mm from the bus bar 30. The horn 46 is held at the lowermost position for a predetermined time (for example, 0.5 seconds), and then moved upward to the air cylinder 48 and the vertical sliding slider 49a to the original standby position shown in FIG. Configured to go back.

  Next, a method for manufacturing the LED wiring unit U will be described.

  First, by using a spot welder (not shown), the legs of the LED 34 are welded to predetermined positions of the bus bar 30 where the contacts 30a, 30b, 30c, 30d are connected to each other by the strip-shaped connecting portion 31, thereby the contacts 30a, 30b, 30c. , 30d, the LED 34 mounted bus bar 30 on which the LED 34 is mounted is manufactured in advance. In addition, as a fixing method of the leg part of LED34 and the bus-bar 30, it may replace with welding and a crimping may be sufficient.

  Next, as shown in FIG. 5, the base 20 is placed on the receiving portion 40 of the ultrasonic welding apparatus, and the base 20 is positioned in the horizontal direction with respect to the receiving portion 40. Further, the LED 34 mounted bus bar 30 is stacked on the base 20 so that the pin 24 on the base 20 side and the hole 32 on the bus bar 30 side engage with each other. Since the pin 24 on the base 20 side and the hole 32 on the bus bar 30 side are configured so that they can be engaged (fitted) with almost no gap at a plurality of locations, the pin 24 and the hole 32 can be smoothly engaged. In addition, the bus bar 30 with the LED 34 can be positioned in the horizontal direction with respect to the receiving portion 40. Then, the holding portion 44 that is bounced upward is swung downward so that the bus bar 30 and the base 20 are pressed onto the receiving portion 40 to receive the peripheral portion of the hole 32 with which the pin 24 engages. A plane parallel to the portion 40 is used.

  When the ultrasonic welding apparatus is driven, the robot arm moves the servo unit 49, and the horn 46 integrated with the servo unit 49 is directly above the first pin 24 as shown in FIG. come. Then, the slider 49a of the servo unit 49 at the rising end is located at a position of 3.5 mm between the standby position shown in FIG. 5 and the caulking preparation position shown in FIG. 6A (the distance between the tip of the horn 46 and the bus bar 30). Ascend end position of the air cylinder 48, the position immediately before the horn 46 contacts the pin 24). Up to this point, the ultrasonic transmitter has not yet operated (the ultrasonic transducer 47 vibrates), but when the air cylinder 48 (horn 46) starts to descend at the caulking preparation position shown in FIG. At the same time, the ultrasonic transmitter is activated (the horn 46 starts ultrasonic vibration). 6B, the horn 46 pressurizes the tip of the pin 24 while vibrating until the tip of the horn 46 is 0.7 mm from the bus bar 30 (0.5 mm before the air cylinder lowering end). Therefore, the ultrasonic vibration transmitted through the horn 46 melts and softens the resin at the tip of the pin and enters a heat caulking state.

  Also, as shown in FIG. 6B, the ultrasonic vibration of the horn 46 stops at the position where the horn tip is 0.7 mm from the bus bar 30 (0.5 mm before the air cylinder descending end). As shown in (c), until the horn 46 reaches a position of 0.2 mm from the bus bar 30 (air cylinder descending end position), the horn 46 that has stopped ultrasonic vibration pressurizes the melted and softened resin. Even if the ultrasonic vibration of the horn 46 is stopped, the pin tip (melt softening resin) immediately after the ultrasonic vibration is stopped is sufficiently soft, so that the action of being crushed and expanded by the horn 46 does not change.

  Then, as shown in FIG. 6 (c), when the horn 46 is 0.2 mm from the bus bar 30 (air cylinder descending end position), the descent of the horn 46 stops and the caulking portion 24a cools down for a predetermined time (for example, 0 5 seconds), the air cylinder 48 and the vertical sliding slider 49a slide upward, and the horn 46 returns to the original standby position shown in FIG.

  Then, the robot arm moves the servo unit 49 again, and the horn 46 comes directly above the second pin 24. Then, the horn 46 is lowered to perform the same step as the step of caulking the first pin 24 with ultrasonic vibration, and the ultrasonic caulking step is repeated for the second and third pins 24. .

  In this way, by caulking all the pins 24 with ultrasonic vibration, a unit in which the LED 34 mounted bus bar 30 is caulked and fixed to the base 20 can be configured. After that, a unit in which the LED 34 mounted bus bar 30 is caulked and fixed to the base 20 in a form in which the holding portion 44 is flipped up with respect to the receiving portion 40 is taken out from the receiving portion 40, and the bus bar is removed by a cutting device equipped with a cutting punch or the like. If the connection part 31 is cut, the LED wiring unit U is completed.

  In the embodiment described above, the horn 46 is moved in the horizontal direction with respect to the lower receiving portion 40 fixed in the horizontal direction in order to align the pin 24 and the horn 46 in the vertical direction. The receiving unit 40 may be configured by an XY table, for example, so that the receiving unit 40 is moved in the horizontal direction with respect to the horn 46 fixed in the horizontal direction.

  In the above-described embodiment, the single horn 46 is moved up and down by the air cylinder 48, and the plurality of pins 24 protruding from the holes 32 of the bus bar 30 are caulked one by one by ultrasonic vibration. However, for example, as shown in FIG. 7, when the pins 24 'are arranged as a group of a plurality of pins provided at a constant interval L1, the arrangement of the plurality of pins 24' constituting the group is changed. Correspondingly, a plurality of horns 46 ′ are arranged and integrated at intervals L 2 (= L 1), and a plurality of horns 46 ′ can be moved up and down integrally by the air cylinder 48. Since the pins 24 'can be caulked simultaneously, the time required for the ultrasonic caulking process, and thus the time required for manufacturing the LED wiring unit U can be shortened. The pin 24 ′ is the same as the pin 24, and the horn 46 ′ having a dish-shaped recess 46 a ′ at the tip is formed in the same shape as the horn 46.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a longitudinal sectional view of an automotive marker lamp (tail and stop lamp) according to a first embodiment of the present invention. FIG. 2 is a plan view of an LED wiring unit housed in the marker lamp (a plan view of the LED wiring unit disposed horizontally in FIG. 1 as viewed from the upper rear side of the lamp). It is a front view (front view seen from the lower side of FIG. 2) of the LED wiring unit. It is an expanded sectional view of the caulking fixed part between a base and a bus bar. It is a schematic diagram of an ultrasonic caulking device. It is a figure explaining an ultrasonic caulking process, (a) is a figure showing the position of a horn and the shape of a pin immediately before ultrasonic caulking, (b) is a figure showing a state where the horn pressurizes the pin tip, (C) is a figure which shows the state which has cooled the crimping | crimped part. It is a schematic diagram of other examples of an ultrasonic caulking device. It is a schematic diagram of a prior art (patent document 1).

Explanation of symbols

A Tail lamp B Stop lamp 10 Lamp body of tail and stop lamp 10A Lamp lamp body of tail lamp 10B Lamp lamp body of stop lamp 16 Front lens U LED wiring unit 20 Insulating base made of synthetic resin 24, 24 'Pin 24a Caulking portion 24a1 Fine irregularities on the caulking portion surface 24b Thin film of resin 30 Bus bars 30a, 30b, 30c, 30d as power supply path constituent members 31 Connection portions 32 Holes as openings 34 LEDs
36 reflector 40 receiving part 44 holding part 46, 46 'horn 46a which is a vibration transmission member 46a dish-shaped concave part 46a1 minute concave groove 47 ultrasonic vibrator 48 air cylinder which is pin pressurizing means

Claims (4)

A pin projecting from an insulating base made of synthetic resin is engaged with an opening provided in a bus bar which is a metal power supply path constituting member mounted with an LED, and an insulating base and A step of stacking bus bars;
An ultrasonic caulking step in which a horn that is an ultrasonic vibration transmitting member is pressed against the tip of the pin protruding from the opening of the bus bar, and the tip of the pin melted and softened by ultrasonic vibration is caulked. In the manufacturing method of the wiring unit,
In the ultrasonic caulking step, the insulating base is laminated by a flat plate-shaped pressing portion opened around the opening of the bus bar so as not to interfere with the horn at least while the horn and the pin are in contact with each other. The LED-mounted bus bar is pressed and held on the receiving portion, and the pin is pressed and crushed while applying ultrasonic vibration through the horn, and the ultrasonic vibration is stopped after the horn approaches the bus bar. Then, the method for manufacturing the LED wiring unit is characterized in that the pin is pressed and crushed.   2. The method of manufacturing an LED wiring unit according to claim 1, wherein a recess having a cross-sectional area larger than a cross-sectional area of the pin is formed on an end face of the horn tip.   3. The method of manufacturing an LED wiring unit according to claim 2, wherein the volume of the concave portion at the end surface of the horn tip is smaller than the volume of the melt-softening portion of the pin.   The method for manufacturing an LED wiring unit according to claim 1, wherein a minute concave groove is provided at least in a portion of the horn tip that contacts the pin.

Images