JP5581413B2 - Wire connection method - Google Patents

Description

  The present invention relates to a method for connecting electric wires.

2. Description of the Related Art Conventionally, a method for connecting electric wires is known in which a plurality of insulated wires are stripped to expose conductors, and the exposed conductors are welded together by ultrasonic welding (for example, Patent Document 1). In this electric wire connection method, since the conductors of a plurality of insulated electric wires are twisted in the same direction and then ultrasonically welded, the connection strength can be increased.
JP 2005-322544 A

  However, in the conventional wire connection method, when an ultrafine wire having a smaller cross-sectional area than that of a normal wire is ultrasonically welded, the ultrasonic welder is extremely fine at a location where damage to the wire is large (for example, a location in contact with the horn). Electric wires may be located. In such a case, the ultrafine electric wire may be disconnected due to the small cross-sectional area, and the tensile strength after welding may be reduced without disconnection.

  The present invention has been made in order to solve such a conventional problem, and the object of the present invention is to reduce the possibility of disconnection and suppress the decrease in tensile strength when ultrasonic welding is performed on an ultrafine wire. An object of the present invention is to provide a method for connecting electric wires.

  The method for connecting electric wires according to the present invention includes a preparation step of removing a coating between an electric wire and an extra fine wire having a smaller cross-sectional area than the electric wire to expose the conductor, and the conductors exposed in the preparation step are ultrasonic welders. A welding process in which the horn is vibrated and ultrasonically welded by vibrating the horn, and after the preparation process and before the welding process, in the welding process It has a temporary joining step of obtaining a temporary joined body by ultrasonic welding of conductors of an electric wire and the ultrafine wire with ultrasonic vibration energy smaller than the ultrasonic vibration energy. In the welding step, In the state where the ultrafine electric wire of the obtained temporary joined body is disposed on the side closer to the anvil side than the horn side, the conductors are ultrasonically welded, and in the temporary joining step, the ultrafine electric wire is larger than the electric wire. sound In a state of being disposed on the horn side of the welding machine, characterized in that it is ultrasonic welding.

  According to the wire connection method of the present invention, after the preparation process and before the welding process, the conductors of the wire and the ultrafine wire are ultrasonically welded with ultrasonic vibration energy smaller than the ultrasonic vibration energy in the welding process. A temporary bonding step of obtaining a temporary bonded body; For this reason, an ultrafine electric wire will be temporarily joined to an electric wire in a temporary joining process. When ultrasonic welding is performed in the welding process, since the ultrafine electric wire is in a temporarily joined state, the position does not shift and the horn side or the like does not move. Accordingly, it is possible to reduce the possibility of disconnection in ultrasonic welding of the ultrafine electric wire and to suppress the decrease in tensile strength. Also, in the welding process, the conductors are ultrasonically welded in a state where the ultrafine wire of the temporary joined body is closer to the anvil side than the horn side. The extra fine wire is not positioned, and the possibility of disconnection can be further reduced and the decrease in tensile strength can be suppressed. Furthermore, since the ultrafine wire is disposed closer to the horn side of the ultrasonic welding machine than the wire in the temporary joining process, the damage is not increased depending on the magnitude of the ultrasonic vibration energy in the temporary joining process. Vibrations are easy to be transmitted and the ultrafine electric wires are firmly joined temporarily. Thereby, it can contribute to the improvement of the tensile strength of a very fine electric wire.

  According to the electric wire connection method of the present invention, it is possible to reduce the possibility of disconnection and to suppress a decrease in tensile strength when ultrasonically welding an extra fine electric wire.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, preferred embodiments of the invention will be described with reference to the drawings. FIG. 1 is a schematic view showing an example of an ultrasonic welding machine. The ultrasonic welding machine 1 shown in FIG. 1 is roughly composed of a power source 10, a vibrator 20, and an ultrasonic welding part 30. The power source 10 is an AC power source for performing ultrasonic welding in the ultrasonic welding part 30. The vibrator 20 is vibrated by an alternating current from the power source 10. The ultrasonic weld 30 includes a horn 31 and an anvil 32. A plurality of members are sandwiched between the horn 31 and the anvil 32, and the horn 31 is vibrated by the vibrator 20, so that ultrasonic waves are generated between the plurality of members. Welding is performed by propagating vibration energy and destroying or removing the oxide film on the surface of the member.

  FIG. 2 is an enlarged perspective view showing a state of general ultrasonic welding. The ultrasonic weld 30 includes a gather 33 in addition to the horn 31 and the anvil 32.

  When performing ultrasonic welding, an operator first strips the coating of the plurality of electric wires to expose the conductor. Thereafter, with the conductors adjacent to each other, the conductor portion is inserted into a space 40 sandwiched between the horn 31, the anvil 32, and the gather 33 (see FIG. 2A).

  Next, the operator operates the ultrasonic welding machine 1. The ultrasonic welding machine 1 performs the following operations in accordance with operations from the operator. First, the ultrasonic welder 1 moves the gather 33 to the anvil 32 side (see FIG. 2B). Thereby, the conductor is in a state in which movement in the left-right direction (X-axis direction shown in FIG. 2) is restricted. Next, the ultrasonic welder 1 moves the pressurizing part 32a of the anvil 32 to keep the conductor closed in the vertical direction (Y-axis direction shown in FIG. 2).

  Thereafter, the ultrasonic welder 1 lowers the entire anvil 32 (moves it in the negative direction of the Y axis shown in FIG. 2), and sandwiches the conductor in the vertical direction by the pressurizing portion 32a and the horn 31 (FIG. 2C). )reference). The ultrasonic welding machine 1 transmits the vibration from the vibrator 20 to the horn 31 to vibrate the horn 31 in the depth direction (Z-axis direction shown in FIG. 2). As a result, the conductors of the plurality of electric wires are welded together by destroying and removing the oxide film on the conductor surface with ultrasonic vibration energy.

  Thereafter, the anvil 32 and the gathers 33 return to the initial positions, and the operator takes out the ultrasonically welded electric wire (see FIG. 2D).

  However, in recent years, ultra-fine wires (for example, wires of less than 0.3 sq) whose cross-section machine is smaller than wires have been used, and if such wires are ultrasonically welded, there is a possibility that the ultra-fine wires may be disconnected. There is. If it demonstrates concretely, the conductor part of an ultrafine electric wire may deform | transform by ultrasonic welding, and a cross-sectional area may reduce. In such a case, the possibility that the extra fine electric wire originally having a small cross-sectional area will be increased. Moreover, even if it does not disconnect, the fall of tensile strength will be caused.

Therefore, in the wire connection method according to this embodiment, the ultrafine wire is ultrasonically welded by the method shown in FIG . FIG. 3 is a main part schematic diagram showing the electric wire connection method according to the present embodiment. In the electric wire connection method according to the present embodiment, after the ultrafine electric wire is temporarily joined in the temporary joining step shown in FIG. 3A (reference example) , the original ultrasonic welding is performed by the welding step shown in FIG. This is done to reduce the possibility of disconnection of ultrafine wires. In addition, in FIG. 3, the example which ultrasonically welds the 5 sq electric wire 51 and the 0.13 sq extra fine electric wire 52 is demonstrated. Further, the number of the electric wires 51 and the extra fine electric wires 52 is one.

  First, the worker peels off the covering of the electric wire 51 and the extra fine electric wire 52 to expose the conductors 51a and 52a (preparation step). Then, as shown in FIG. 3A, the exposed conductors 51 a and 52 a are sandwiched between the horn 31 and the anvil 32.

  Next, the operator vibrates the horn 31. At this time, the operator performs ultrasonic welding with energy about 1/4 of the original ultrasonic vibration energy (ultrasonic vibration energy in the welding process). Thereby, as shown in FIG.3 (b), the temporary joining body 60 to which the conductors 51a and 52a were temporarily joined is obtained. Here, the ultrasonic vibration energy is determined by the pressure and width of the anvil 32 (that is, the distance between the anvil 32 and the gather 33), the amplitude of the horn 31, and the oscillation energy. In the temporary joining step for obtaining the temporary joined body 60, the operator sets the above four conditions and sets the ultrasonic vibration energy to about 1/4.

  Thus, the temporary joining process is completed. The extra fine electric wire 52 is temporarily joined to the electric wire 51 by this temporary joining step. Further, since the ultrasonic vibration energy is about ¼, the fine electric wire 52 is less damaged and the possibility of disconnection or the like is reduced.

  Next, as shown in FIG. 3B, the temporary joined body 60 obtained in the temporary joining step is ultrasonically welded again. At this time, the operator arranges the ultrafine electric wire 52 closer to the anvil 32 side than the horn 31 side, and performs ultrasonic welding. In addition, the operator performs ultrasonic welding by increasing the ultrasonic vibration energy to about four times that of the temporary bonding process.

  This completes the welding process. By this welding process, ultrasonic welding of the electric wire 51 and the ultrafine electric wire 52 is completed. Here, when ultrasonic welding is performed in the welding process, the ultrafine wire 52 is close to the anvil side and is not located at a place where the damage such as contact with the horn 31 is large. Moreover, the ultrafine wire 52 is temporarily joined to the wire 51. For this reason, the extra fine electric wire 52 does not move to a position where the damage is large, such as the horn 31 side, without causing displacement. Therefore, even in the welding process, the ultrafine electric wire 52 is not significantly damaged, and the ultrafine electric wire 52 can be ultrasonically welded after reducing the possibility of disconnection or the like by the temporary joining process and the welding process.

FIG. 4 is a main part schematic diagram showing a first connection method of electric wires according to a reference example . In the first connection method of the electric wire according to the reference example, similarly to the electric wire connection method according to the present embodiment , after the ultrafine electric wire 52 is temporarily joined in the temporary joining step, the original ultrasonic welding is performed by the welding step. The possibility of disconnection of the ultrafine wire 52 is reduced. In addition, in FIG. 4, the example which ultrasonically welds the 5sq electric wires 53 and 54 and the 0.13 sq extra fine electric wire 52 is demonstrated. In addition, the number of the electric wires 53 and 54 is plural (specifically, three), and the number of the ultrafine electric wires 52 is one.

  First, an operator peels off the covering of the plurality of electric wires 53 and 54 and the extra fine electric wire 52 to expose the conductors 53a, 54a and 52a (preparation step). Next, as shown in FIG. 4A, the conductors 53 a and 52 a of a part of the plurality of wires 53 and 54 and the ultrafine wire 52 are sandwiched between the horn 31 and the anvil 32. At this time, the worker arranges the ultrafine electric wires 52 closer to the anvil 32 side than to the horn 31 side.

  Next, the operator vibrates the horn 31. At this time, the operator performs ultrasonic welding with energy about 1/4 of the ultrasonic vibration energy in the welding process. Thereby, the temporary joined body 60 shown in FIG.4 (b) is obtained.

  Thus, the temporary joining process is completed. The extra fine electric wires 52 are temporarily joined to some of the electric wires 53 by this temporary joining step. Further, since the ultrasonic vibration energy is about ¼, the fine electric wire 52 is less damaged and the possibility of disconnection or the like is reduced.

  Next, as shown in FIG. 4B, the temporary joined body 60 obtained in the temporary joining step is ultrasonically welded again. At this time, the operator performs ultrasonic welding after arranging the fine wires 52 to be sandwiched between some of the wires 53 and the remaining wires 54. In addition, the operator performs ultrasonic welding by increasing the ultrasonic vibration energy to about four times that of the temporary bonding process.

  This completes the welding process. By this welding process, ultrasonic welding of the plurality of electric wires 53 and 54 and the ultrafine electric wire 52 is completed. Here, when ultrasonic welding is performed in the welding process, the ultrafine electric wire 52 is sandwiched between a part of the electric wires 53 and the remaining electric wires 54, and is not located at a place where the damage such as contact with the horn 31 is large. In addition, when ultrasonic welding is performed in the welding process, the ultrafine wires 52 are temporarily joined to some of the wires 53. For this reason, the extra fine electric wire 52 does not move to a highly damaged part such as the horn 31 side without causing a positional shift. Therefore, even in the welding process, the ultrafine electric wire 52 is not significantly damaged, and the ultrafine electric wire 52 can be ultrasonically welded after reducing the possibility of disconnection or the like by the temporary joining process and the welding process.

The joined body obtained by the first connection method of the electric wires according to the reference example has an average tensile strength (n = 30) of the ultrafine electric wires 52 of 89 N (base material strength ratio of about 80%), and variations ( -3σ) was taken into consideration, the strength of 69.3N (base material strength ratio of about 62%) was secured.

FIG. 5 is a main part schematic diagram illustrating a second connection method of electric wires according to a reference example . In the second connection method of the electric wire according to the reference example, similarly to the electric wire connection method according to the present embodiment , after the ultrafine wire 52 is temporarily joined in the temporary joining step, the original ultrasonic welding is performed by the welding step. The possibility of disconnection of the ultrafine wire 52 is reduced. In addition, in FIG. 5, the example which ultrasonically welds the 5 sq electric wires 53 and 54 and the 0.13 sq extra fine electric wire 52 is demonstrated. In addition, the number of the electric wires 53 and 54 is plural (specifically, three), and the number of the ultrafine electric wires 52 is one.

  First, an operator peels off the coverings of the electric wires 53 and 54 and the extra fine electric wire 52 to expose the conductors 53a, 54a and 52a (preparation process). Next, as shown in FIG. 5A, the conductors 53 a and 52 a of a part of the plurality of wires 53 and 54 and the ultrafine wire 52 are sandwiched between the horn 31 and the anvil 32. At this time, the worker arranges the ultrafine electric wires 52 closer to the horn 31 side than to the anvil 32 side.

  Thereafter, the operator vibrates the horn 31. At this time, the operator performs ultrasonic welding with energy about 1/4 of the ultrasonic vibration energy in the welding process. Thereby, the temporary joined body 60 shown in FIG.5 (b) is obtained.

  Then, about a welding process, it is performed like the method demonstrated with reference to FIG.4 (b). Also by this third connection method, the ultrafine wire 52 can be ultrasonically welded after reducing the possibility of disconnection or the like.

In the joined body obtained by the second connection method of the electric wires according to the reference example, the tensile strength (n = 30) of the ultrafine electric wires 52 is 91 N (base material strength ratio of about 81%) on average. It was.

Thus, according to the connection method of the electric wire which concerns on this embodiment, after the preparation process and before the welding process, with the ultrasonic vibration energy smaller than the ultrasonic vibration energy in the welding process, the electric wire 51 and the extra fine electric wire 52 A temporary joining step of obtaining a temporary joined body 60 by ultrasonic welding of the two conductors. For this reason, the extra fine electric wire 52 is temporarily joined to the electric wire 51 in the temporary joining step. When ultrasonic welding is performed in the welding process, the ultrafine electric wire 52 is in a temporarily joined state, and therefore does not move to a highly damaged part such as the horn 31 side without causing a positional shift. Therefore, it is possible to reduce the possibility of disconnection in ultrasonic welding of the ultrafine wire 42 and to suppress a decrease in tensile strength.

  Further, in the welding process, the conductors are ultrasonically welded in a state in which the ultrafine wire 52 of the temporary joined body 60 is disposed closer to the anvil 32 side than the horn 31 side, and thus damage is increased in the welding process. The ultrafine electric wire 52 is not positioned on the horn 31 side, which can easily reduce the possibility of disconnection and suppress the decrease in tensile strength.

  Further, in the temporary joining step, the ultrafine electric wire 52 is disposed closer to the horn 31 of the ultrasonic welding machine than the electric wire 51. Therefore, depending on the magnitude of the ultrasonic vibration energy in the temporary joining step, the damage is not increased, and conversely Thus, the ultrasonic vibration is easily transmitted, and the ultrafine wire 52 is firmly temporarily joined. Thereby, it can contribute to the improvement of the tensile strength of the extra fine wire 52.

In addition, according to the first and second connection methods of the electric wire according to the reference example , the possibility of disconnection is reduced and the tension is reduced in ultrasonic welding of the ultrafine electric wire 42 as in the electric wire connection method according to the present embodiment. A decrease in strength can be suppressed.

  Moreover, there are a plurality of electric wires 53 and 54, and in the temporary bonding step, the conductors of some of the electric wires 53 and the ultrafine electric wires 52 are ultrasonically welded to obtain a temporary bonded body 60. At the same time, in the welding process, the ultrafine electric wires 52 of the temporary bonded body 60 obtained in the temporary bonding process are arranged to be sandwiched between a part of the electric wires 53 and the remaining electric wires 54 and then ultrasonically welded. For this reason, the extra fine electric wire 52 is enclosed by some electric wires 53 and the remaining electric wires 54 among the plurality of electric wires 53 and 54, and it becomes difficult to move to a place where damage is much greater. Therefore, the possibility of disconnection can be further reduced and the decrease in tensile strength can be suppressed.

Further, in the temporary joining step of the first electric wire connecting method according to the reference example , the extra fine wires 52 are arranged closer to the anvil 32 side of the ultrasonic welding machine than some of the electric wires 53. It is difficult to receive damage due to the vibration of the wire, and it is possible to suppress a situation in which the fine wire 52 is greatly damaged.

Further, in the temporary joining step of the second connection method of electric wires according to the reference example , the ultrafine wires 52 are arranged closer to the horn 31 side of the ultrasonic welding machine than some of the wires, so that the ultrasonic vibration in the temporary joining step Depending on the magnitude of the energy, the damage does not become large, and on the contrary, the ultrasonic vibration is easily transmitted, and the ultrafine electric wire 52 is firmly temporarily joined. Thereby, it can contribute to the improvement of the tensile strength of a very fine electric wire.

Furthermore, according to the connection method, ultrasonic welding can be performed more easily than the connection method described in Patent Document 1 . Furthermore, according to the connection method described in Patent Document 1, the amount of stripping of the coating must be made appropriate in order to twist the electric wire, and the stripping operation of the coating becomes troublesome. Such a problem does not occur.

  In addition, when mass producing ultrasonically welded electric wires by the connection method described in Patent Document 1, equipment for twisting the electric wires by about 1/4 turn is required, and new incidental equipment is required. According to the above connection method, since only the ultrasonic welding machine 1 is used, no incidental equipment for twisting the electric wire is required.

As described above, the present invention has been described based on the embodiment, but the present invention is not limited to the above embodiment, and may be modified without departing from the gist of the present invention. Here, in the reference example , the number of the electric wires 53 and 54 is not limited to three, and may be four or more. Similarly, the number of the electric wires 53 is not limited to one and may be two or more, and the remaining electric wires 54 are not limited to two and may be one or three or more. Furthermore, the number of the ultrafine wires 52 is not limited to one and may be two or more.

  When the second connecting method is performed by using the three partial wires 53 in the temporary joining step and adding the remaining three wires 54 in the welding step, the obtained joined body is an extra fine wire. The tensile strength (n = 30) of 52 was 102 N (base material strength ratio of about 91%) on average. In addition, when the third connection method is performed with the above number, the obtained joined body has an average tensile strength (n = 30) of the ultrafine wire 52 of 102 N (base material strength ratio of about 91%). Secured. Thus, in the electric wire connection method according to the present embodiment, the possibility of disconnection of the ultrafine electric wires 52 is reduced and the decrease in tensile strength can be suppressed without being limited to the number of wires.

Furthermore, in the first and second electric wire connection methods according to the reference example , as shown in FIGS. 4 and 5, the total number of ultrasonic welding wires in the temporary joining step (one ultrafine electric wire 52 is partly included). And the total number of wires of the second ultrasonic welding (one ultrafine wire 52, one partial wire 53, and the remaining two wires 54). 4), the width when the electric wire is sandwiched between the anvil 32 and the gather 33 (that is, the distance in the X-axis direction in FIG. 2) is the same in the temporary joining process and the welding process. Is desirable. This is because it is possible to further suppress the positional shift of the temporarily bonded extra fine electric wire 52.

In addition, when the width | variety is not made the same at a temporary joining process and a welding process, as for the joined body obtained by the 1st connection method of the electric wire which concerns on a reference example, the tensile strength (n = 30) of the ultrafine electric wire 52 is an average. The strength was 82N (base material strength ratio: approximately 73%). On the other hand, when the width is the same in the temporary joining process and the welding process, the joined body obtained by the first connection method of the electric wire according to the reference example has an average tensile strength (n = 30) of the ultrafine electric wire 52 of 89 N. The strength of the base material strength ratio was about 80%.

It is the schematic which shows an example of an ultrasonic welding machine. It is an expansion perspective view which shows the mode of general ultrasonic welding, (a) shows a 1st process, (b) shows a 2nd process, (c) shows a 3rd process, ( d) shows the fourth step. It is a principal part schematic diagram which shows the connection method of the electric wire which concerns on this embodiment, (a) shows the temporary joining process (reference example) , (b) has shown the welding process. It is the principal part schematic which shows the 1st connection method of the electric wire which concerns on a reference example , (a) shows the temporary joining process, (b) has shown the welding process. It is a principal part schematic diagram which shows the 2nd connection method of the electric wire which concerns on a reference example , (a) shows the temporary joining process, (b) has shown the welding process.

DESCRIPTION OF SYMBOLS 1 ... Ultrasonic welding machine 10 ... Power source 20 ... Vibrator 30 ... Ultrasonic welding part 31 ... Horn 32 ... Anvil 32a ... Pressurization part 33 ... Gather 40 ... Space 51, 53, 54 ... Electric wire 52 ... Extra fine electric wire 60 ... Temporary Joining

Claims (1)

The preparatory step of removing the coating between the electric wire and the ultrafine electric wire having a smaller cross-sectional area than the electric wire to expose the conductor, and the conductors exposed by the preparatory step were pressurized with a horn and an anvil of an ultrasonic welder On the other hand, a welding process for ultrasonic welding by vibrating the horn,
After the preparation step and before the welding step, the temporary joining is obtained by ultrasonic welding the conductors of the electric wire and the ultrafine wire with ultrasonic vibration energy smaller than the ultrasonic vibration energy in the welding step. Having a process,
In the welding step, the conductors obtained by the temporary joining step are ultrasonically welded to each other in a state where the ultrafine electric wire of the temporary joined body is disposed closer to the anvil side than the horn side,
In the temporary joining step, the ultrafine wire is ultrasonically welded in a state where it is in contact with the horn and disposed on the horn side of the ultrasonic welder with respect to the wire in a state where the wire is interposed between the ultrafine wire and the anvil. A method for connecting electric wires, characterized in that:

Images