JP7042678B2 - Joint conductor and manufacturing method of joint conductor - Google Patents

Description

The present invention relates to, for example, a bonded conductor in which a conductor is melt-bonded and a method for manufacturing a bonded conductor in which the conductor is melt-bonded.

In recent years, automobiles are equipped with various electric devices that improve operability and comfort, and such electric devices are electrically connected to each other by wire harnesses or the like distributed to the automobiles to provide signals. Transmission / reception and power supply are performed.

The plurality of covered electric wires constituting this wire harness are made conductive by exposing the conductors covered with the insulating coating and joining them to each other.
Such a bonded conductor is manufactured, for example, by ultrasonically bonding a plurality of conductors with a predetermined width regulated while pressurizing from the thickness direction (vertical direction) (see Patent Document 1).

Japanese Unexamined Patent Publication No. 2011-198506

However, in the bonded conductor disclosed in Patent Document 1, although the conductors adjacent to each other in the vertical direction are bonded to each other with sufficient strength, the bonding strength between the conductors adjacent to each other in the horizontal direction is higher than the bonding strength in the vertical direction. Tends to be weak.

In view of the above problems, it is an object of the present invention to provide a bonded conductor and a method for manufacturing the bonded conductor, which can improve the bonding strength between conductors and improve the conductivity.

In the present invention, a plurality of conductors arranged along the longitudinal direction are joined conductors having a melt-bonded joint portion, and the joint portion is provided with two surfaces facing each other along the longitudinal direction. A mountain portion, which is one of the facing surfaces, and a mountain portion where the two surfaces project outward in the facing direction on both the first surface facing the first surface and the second surface facing the first surface . A plurality of sinusoidal corrugated portions having a valley portion recessed inward in the facing direction and continuous along the longitudinal direction are provided along the longitudinal direction, and the corrugated portion formed on the first surface thereof. Is the first corrugated portion, the corrugated portion formed on the second surface is the second corrugated portion, and the first corrugated portion and the second corrugated portion are configured to have the same shape and the first corrugated portion. The crossing direction in which the mountain portion in the corrugated portion faces the valley portion in the second corrugated portion and the valley portion in the first corrugated portion faces the mountain portion in the second corrugated portion and intersects the facing direction. On at least one third surface of the surfaces facing each other, the crossing-side mountain portion protruding outward in the crossing direction and the crossing-side valley portion recessed inward in the crossing direction are formed in the longitudinal direction. A wave-shaped crossing-side corrugated portion is provided along the line, and the crossing-side corrugated portion is composed of a waveform having a different wave shape and pitch from the first corrugated portion and the second corrugated portion. It is a feature.

Further, the present invention is a method for manufacturing a bonded conductor in which a plurality of conductors arranged along the longitudinal direction are melt-bonded, wherein the conductor is compressed along a first direction orthogonal to the longitudinal direction and the longitudinal is described. A compression step for restricting the movement of the conductor in a direction and a second direction orthogonal to the first direction, and a welding step for performing ultrasonic welding by ultrasonic vibration to the conductor compressed in the first direction are performed. In the compression step, among the conductor bundles composed of the plurality of the conductors arranged, the mountain portion protruding outward in the second direction on the first surface formed in the second direction, and the above. The movement of the conductor in the second direction so that a plurality of sinusoidal first corrugated portions having continuous inwardly recessed valleys in the second direction are formed along the longitudinal direction. On the second surface facing the first surface, a mountain portion protruding outward in the second direction and a valley portion recessed inward in the second direction are continuously provided. At the same time, a plurality of sinusoidal second corrugated portions having a mountain portion facing the valley portion in the first corrugated portion and the valley portion facing the mountain portion in the first corrugated portion are formed along the longitudinal direction. As such, the movement of the conductor in the second direction is restricted, and the crossing side mountain portion and the first one projecting outward in the first direction on the third surface formed in the first direction. The crossing side valley portion recessed inward in the direction and the crossing side corrugated portion having a continuous wave shape along the longitudinal direction are of the wave shape, pitch, and phase of the first corrugated portion and the second corrugated portion. It is characterized by compressing the conductor along the first direction so that either is formed with a different waveform .

The conductor includes a stranded wire obtained by twisting a conductive wire, a conductor composed of a single wire, a conductor in which the conductor is bundled, and the like, and the conductor is made of any material as long as it has conductivity. It may be composed of, and includes a copper-based conductor composed of copper or a copper alloy, or an aluminum-based conductor composed of aluminum or an aluminum alloy.

The conductor may be an exposed conductor or an insulating coating obtained by stripping and exposing the insulating coating forming an outer layer at one end of a coated electric wire in which a bundle of twisted wires or strands is coated with an insulating insulating coating. Includes uncoated stranded conductors and conductors that bundle strands.

The plurality of conductors described above include those composed of the same or different types of conductors. Specifically, conductors having different outer diameters and materials may be used, and some may be stranded wires and some may be single wires.
The above-mentioned provisions of a plurality of corrugated portions along the longitudinal direction may mean that a plurality of the corrugated portions are continuously provided, or a portion formed in a plane may be sandwiched between them.

The mountain portion that protrudes outward in the facing direction may be the mountain portion that protrudes outward in the facing direction relative to the valley portion, and similarly, the above-mentioned facing direction. The dented inside may be a configuration in which the valley portion is recessed inward in the direction opposite to the mountain portion.

The corrugated portion includes a case where it is formed on the entire surface of the side surface and a case where it is formed on a part of the side surface.
Further, the corrugated portion refers to a configuration in which at least one or more of the peaks and valleys are continuous along the longitudinal direction, and if the peaks and valleys are continuous, the peaks and valleys are continuous. , The numbers of mountains and valleys do not have to match.

According to the present invention, the bonding strength between conductors can be improved and the conductivity can be improved.
More specifically, since the corrugated portion is formed on at least the first surface of the facing surfaces, the conductors arranged side by side in the facing direction among the plurality of conductors constituting the joint portion. Is joined in a state of being in contact with another conductor adjacent in the opposite direction along the direction intersecting the longitudinal direction. Therefore, in the joint portion, the joint strength between the conductors arranged in the opposite direction is improved.

Therefore, the integrity of the joint can be improved, the conductivity of the conductor constituting the joint conductor can be improved, and the rigidity of the joint conductor can also be improved.

Further, since the first corrugated portion formed on the first surface and the second corrugated portion formed on the second surface are configured to be offset by a half wavelength, the joint portion is formed in the opposite direction. Conductors arranged side by side along the line are joined in a state of having a certain width and oscillating in the opposite direction. Therefore, the apparent cross-sectional coefficient of the entire joint portion can be improved, and the rigidity of the joint conductor can be improved.

Further, since the width of the first surface and the second surface with respect to the facing direction is constant in the longitudinal direction, that is, the cross-sectional area of the conductors in the longitudinal direction is constant, the joint portion of the joint portion. Non-uniformity of rigidity can be suppressed, and variation in the quality of the joined conductor can be suppressed.

Furthermore, at the joint portion to which the conductors arranged periodically arranged in the intersecting direction intersecting the longitudinal direction are joined, it is possible to improve the bonding strength between the conductors arranged side by side in the intersecting direction. At the same time, the contact area between the conductors can be increased. Therefore, the integrity of the joint can be further improved, and the conductivity and rigidity of the conductor can be further improved.

Further, not only the contact area between the conductors arranged along the facing direction can be increased and the bonding strength can be improved, but also the contact area between the conductors arranged along the intersecting direction can be increased. Therefore, the joint strength of the joint conductor can be further improved. Further, since the integrity of the bonded conductor can be further improved, the conductivity of the bonded conductor can be further improved.

As an aspect of the present invention, the height in the orthogonal cross-sectional direction orthogonal to the longitudinal direction from the bottom of the valley to the apex of the mountain is the second surface facing the first surface and the first surface. It may be composed of 0.5 times or less of the interval in the opposite direction.
According to the present invention, the conductivity of the bonded conductor can be improved and the rigidity can be reliably improved.

More specifically, when the height of the mountain portion with respect to the valley portion is higher than 0.5 times the distance between the first surface and the second surface in the facing direction, the amplitude of the waveform at the joint portion is large. Therefore, the load applied to the conductor becomes large. Therefore, the conductor may be partially torn or damaged, the conductivity of the joined conductor may not be sufficiently ensured, and the rigidity may be lowered.

On the other hand, the height of the mountain portion with respect to the valley portion in the facing direction is 0.5 times or less the distance between the first surface and the second surface in the facing direction. Since the load on the conductors constituting the joint portion can be reduced and the conductors arranged in the facing direction can be oscillated in the facing direction, the bonding strength between the conductors due to bending can be surely improved. At the same time, the contact area between the conductors can be increased.

As a result, the integrity of the joint can be improved, the possibility that the conductor is partially torn or damaged can be reduced, the conductivity of the joint conductor can be sufficiently improved, and the rigidity can be sufficiently improved. Can be reliably improved.

Further, as an aspect of the present invention, the height from the bottom of the valley to the apex of the mountain in the orthogonal cross-sectional direction is 0.5 times or more the minimum diameter of the plurality of arranged conductors. It may be configured.
According to the present invention, the conductivity of the bonded conductor can be improved.

More specifically, when the height of the mountain portion with respect to the valley portion in the facing direction is lower than 0.5 times the minimum diameter of the plurality of arranged conductors, the mountain portion and the valley at the joint portion. Since the amount of amplitude of the waveform formed by the portions is small and the conductors arranged along the opposite directions are not arranged so as to intersect with each other in the longitudinal direction, the integrity of the joint portion is sufficiently improved. It is not possible to sufficiently improve the conductivity of the bonded conductor.

On the other hand, by setting the height of the mountain portion with respect to the valley portion in the facing direction to 0.5 times or more the minimum diameter of the plurality of arranged conductors, the joint portion is made into the mountain portion. Since the conductors can be reliably curved along the valley portion, the conductors arranged along the facing direction are arranged so as to intersect with each other in the longitudinal direction. As a result, the bonding strength between the conductors can be reliably improved, the contact area between the conductors can be increased, and the conductivity of the bonded conductors can be improved.

Further, as an aspect of the present invention, the joint portion may have a flat surface portion formed in a planar shape along the longitudinal direction between the tip and the corrugated portion.
The above-mentioned planar formation includes a case where it is formed parallel to the one side surface and a case where it is inclined with respect to the side surface. That is, it refers to a shape in which an intentional uneven shape is not provided on the side surface between the tip of the joint portion and the corrugated portion.

INDUSTRIAL APPLICABILITY According to the present invention, it is possible to prevent the joint between the conductors from being peeled off from the tip end side of the joint portion.
More specifically, since the mountain portion and the valley portion constituting the corrugated portion are configured by bending the conductor, when an external force acts on the side opposite to the bending direction, the conductors are joined to each other. It becomes easy to peel off.

However, since the joint portion has the flat surface portion between the tip and the corrugated portion, an unintended external force acting directly on the peak portion and the valley portion on the side opposite to the bending direction. In addition to being able to prevent it, even if an unintended external force acts, the flat surface portion can absorb the external force, so that peeling of the joint between the conductors can be suppressed.

Further, as an aspect of the present invention, the bonding portion may be formed by an ultrasonic bonding portion formed by ultrasonic welding.
According to the present invention, since the interface between conductors in the joint can be joined by ultrasonic welding, it can be sufficiently joined even inside the joined conductor. Thereby, the joint strength of the joint conductor can be stabilized. Further, since the change in physical properties due to the application of excessive heat is suppressed, it is possible to prevent the mixing of foreign substances. Therefore, the conductivity and rigidity of the bonded conductor can be stabilized.

Further, as an aspect of the present invention, the conductor may be made of aluminum or an aluminum alloy.
According to the present invention, the weight of the bonded conductor can be reduced.

INDUSTRIAL APPLICABILITY According to the present invention, it is possible to provide a bonded conductor and a method for manufacturing the bonded conductor, which can improve the bonding strength between conductors and improve the conductivity.

Schematic perspective view of the joined conductor. Explanatory drawing of a bonded conductor. Schematic perspective view of the conductor connecting device. Schematic exploded perspective view of the conductor connecting device. Explanatory drawing of the horn. Explanatory drawing of the regulation department. Explanatory drawing of the anvil. Explanatory drawing of the conductor connecting device. Flowchart of conductor connection method. Explanatory drawing of the method of joining a conductor. Explanatory drawing of the method of joining a conductor. Schematic perspective view of the conductor connecting device of another embodiment. Sectional drawing of the conductor connecting apparatus of another embodiment. Schematic perspective view of the joined conductors of other embodiments. Explanatory drawing of the bonded conductor of another embodiment. Explanatory drawing of the bonded conductor of another embodiment.

An embodiment of the conductor joining device 1 for manufacturing the joined conductor 100 and the joined conductor 100 according to the present invention will be described below with reference to the drawings.
FIG. 1 shows a schematic perspective view of the joined conductor 100, and FIG. 2 shows an explanatory view of the joined conductor 100. Specifically, FIG. 2A shows an enlarged plan view of the joint portion 110 of the joint conductor 100, FIG. 2B shows a cross-sectional view taken along the line AA in FIG. 2A, and FIG. 2C shows a cross-sectional view taken along the line AA. FIG. 2A shows a cross-sectional view taken along the line BB.

3 shows a schematic perspective view of the conductor joining device 1, FIG. 4 shows a schematic exploded perspective view of the conductor joining device 1, FIG. 5 shows an explanatory view of a horn 13 constituting the conductor joining device 1, and FIG. 6 shows an explanatory view. An explanatory diagram of the regulation unit 21 constituting the conductor bonding device 1 is shown, FIG. 7 shows an explanatory diagram of the anvil 30 constituting the conductor bonding device 1, and FIG. 8 shows an explanatory diagram explaining the configuration of the conductor bonding device 1. ..

Here, in FIG. 3, the longitudinal direction of the coated electric wire 200 is defined as the longitudinal direction X, the lateral width direction of the coated electric wire 200 and the direction orthogonal to the longitudinal direction X is defined as the width direction Y, and along the longitudinal direction X of FIG. The left side is in the + X direction, the right side is in the −X direction, the left side is in the −Y direction along the width direction Y, and the right side is in the + Y direction.
Further, in FIG. 3, the vertical direction is the vertical direction Z, the upper side of FIG. 3 is the + Z direction (upper side), and the lower side is the −Z direction (lower side).

In detail, FIG. 5 (a) shows an enlarged bottom view of the bottom surface of the horn 13, and FIG. 5 (b) shows an enlarged side view of the horn 13 as viewed from the + Y side, and FIG. 5 (c). ) Shows an enlarged front view of the horn 13 as viewed from the + X side. In FIGS. 5 (b) and 5 (c), only a part of the horn 13 is enlarged and displayed.

6 and 7 will be described in detail. FIG. 6A shows an enlarged plan view of the upper surface of the regulation unit 21, FIG. 6B shows an enlarged side view of the regulation unit 21 as viewed from the + Y side, and FIG. 6C shows the regulation unit 21. Is shown in an enlarged front view as viewed from the + X side. In FIGS. 6 (a) and 6 (c), only a part of the regulation unit 21 is enlarged and displayed.
FIG. 7A shows a plan view of the anvil 30 and FIG. 7B shows an enlarged side view of the anvil upper portion 32 erected on the anvil 30 as viewed from the + Y side.

Further, FIG. 8 will be described in detail. FIG. 8A shows a schematic front view of a portion of the conductor joining device 1 to which the exposed conductor portion 220 is joined as viewed from the + X direction, and FIG. 8B shows a sectional view taken along the line CC in FIG. 8A. ..

The bonded conductor 100 is a conductor in which a conductor exposed portion 220, which is a tip portion of a plurality of coated electric wires 200, is joined by ultrasonic welding and integrated, and is used for electrically connecting electric devices such as batteries. Has been done.

The coated electric wire 200 is configured by coating a stranded conductor formed by twisting aluminum alloy strands with an insulating coating 210 made of an insulating resin, and an insulating coating 210 is predetermined on the tip end side of the coated electric wire 200. A conductor exposed portion 220 is provided in which the stranded conductor is exposed by stripping for the length of the above (see FIG. 3).

The stranded conductor may be made of any material as long as it has conductivity, and for example, strands such as aluminum, copper, and a copper alloy may be twisted together. Further, the conductor exposed portion 220 does not necessarily have to be composed of a stranded conductor, and may be configured by bundling conductive strands.

The bonded conductor 100 bundles a plurality of (9 in this embodiment) coated electric wires 200 along the longitudinal direction X, and strips and exposes the insulating coating 210 on the tip end side (−X side) of the coated electric wires 200. It has a configuration in which a plurality of exposed conductor portions 220 are melt-bonded as a bundle of conductors, and the tip portion of the bonded conductor 100 has a joint portion 110 to which the exposed conductor portions 220 are melt-bonded.

As shown in FIGS. 1 and 2, the joint portion 110 has a first surface 121 (a surface formed on the left side (−Y side)) and a second surface 122 (right side (Y)) facing each other in the width direction Y. The surface formed on the side), the third surface 131 facing each other in the vertical direction Z (the surface formed on the lower side (-Z side)), and the fourth surface 132 (upper side (+ Z side)). The surface is formed in a rectangular shape in cross section, and a flat surface portion 150 formed in a flat shape is provided at the + X side end portion and the −X side end portion of the joint portion 110. ing.

On the first surface 121 and the second surface 122, a corrugated portion 140 formed in a sinusoidal shape along the longitudinal direction X in a plan view is formed (see FIG. 2A).
The corrugated portion 140 is continuously composed of a mountain portion 141 protruding outward along the width direction Y and a valley portion 142 recessed inward along the width direction Y.

The height L1 of the top of the mountain portion 141 with respect to the bottom of the valley portion 142 is configured to be about 0.20 times the distance between the first surface 121 and the second surface 122, that is, the length L2 of the width of the joined conductor 100. Has been done.

In the present embodiment, the height L1 is 0.20 times the length L2, but it does not necessarily have to be this value and may be changed as appropriate. From the viewpoint of conductivity and rigidity, it is preferably 0.5 times or less.

Further, the height L1 of the top of the mountain portion 141 with respect to the bottom of the valley portion 142 is configured to be about 0.6 times the diameter L3 which is the minimum diameter of the conductor exposed portion 220 constituting the joint portion 110. There is.

In the present embodiment, the height L1 is 0.6 times the diameter L3, but it does not necessarily have to be this value and may be changed as appropriate. From the viewpoint of conductivity, it is preferably 0.5 times or more the wire, and more preferably 0.5 times or more the outer diameter of the stranded conductor. Further, in the present embodiment, all nine conductor exposed portions 220 have the same diameter, but some or all of the conductor exposed portions 220 may have different diameters. In this case, the height L1 is preferably 0.5 times or more the diameter L3, which is the minimum diameter of the exposed conductor portion 220.

Of the corrugated portions 140 configured in this way, four corrugated portions 140L provided on the first surface 121 are arranged so that the valley portions 142 and the mountain portions 141 are alternately and continuously arranged from the + X side. It is provided in.

On the other hand, of the waveform portions 140, the waveform portions 140R provided on the second surface 122 are provided side by side so that the peak portions 141 and the valley portions 142 are alternately and continuously arranged from the + X side. ing.

In other words, the valley portion 142 and the mountain portion 141 arranged on the first surface 121 are arranged to face the mountain portion 141 and the valley portion 142 arranged on the second surface 122 along the width direction Y. That is, the corrugated portion 140L and the corrugated portion 140R are provided on the first surface 121 and the second surface 122, respectively, in which a sine wave having the same shape is displaced along the longitudinal direction X by half a wavelength.

As shown in FIGS. 2 (b) and 2 (c), the joint portion 110 configured in this way has a cross-sectional shape protruding from the −Y side to the + Y side as it goes from the −X side to the + X side. It will repeat periodically to the state of protruding to the side. Therefore, the apparent cross-sectional coefficient of the joint portion 110 is improved, so that the rigidity of the joint portion 110 is improved.

Further, as described later, since the bonded conductor 100 is ultrasonically welded by the conductor bonding device 1, the ultrasonic bonding portion 160 is formed at the interface between the conductors in the cross section of the bonding portion 110.

Furthermore, the joint portion 110 is provided with a flat surface portion 150 between the corrugated portion 140 arranged at the tip and the distal end side end portion in the longitudinal direction X, and is provided with the corrugated portion 140 arranged at the proximal end in the longitudinal direction. A flat surface portion 150 is provided between the proximal end side ends of the X.
More specifically, as shown in FIGS. 1 and 2A, the flat surface portion 150 is formed so as to project in a plane toward the −X side and the + X side. In other words, the corrugated portion 140 is arranged at a position separated from the tip of the bonded conductor 100 by a predetermined distance.

Next, a conductor joining device 1 for manufacturing a joined conductor 100 by joining the tip side of the exposed conductor portion 220 exposed from the coated electric wire 200 will be described with reference to FIGS. 3 to 8.
As shown in FIG. 3, the conductor joining device 1 is a device that ultrasonically welds (ultrasonic metal joining) the exposed conductor portions 220 exposed from the tip side of a plurality of covered electric wires 200, and moves up and down in the vertical direction Z. A plurality of anvils 30 for compressing the conductor exposed portion 220 by the ultrasonic welding tool 10 to be performed, the pair of width direction adjusting portions 20 fixed to the + X direction side of the ultrasonic welding tool 10, and the descending ultrasonic welding tool 10. And a control unit 40 that controls the movement of the ultrasonic welding tool 10 and the width direction adjusting unit 20.

The ultrasonic welding tool 10 includes an elevating portion 11 that moves up and down along the vertical direction Z by an elevating motor (not shown), a horn support portion 12 that protrudes from the central portion of the elevating portion 11 in the + X direction, and a horn support portion 12. It is composed of a horn 13 extending downward from the end face on the + X direction side.
The elevating motor is controlled by the control unit 40.

As shown in FIGS. 3 and 4, the horn support portion 12 is configured to project from the central portion of the elevating portion 11 toward the + X direction and to support the horn 13 on the elevating portion 11.
In the present embodiment, the horn support portion 12 protrudes from the elevating portion 11 along the longitudinal direction X, but does not necessarily have to protrude along the longitudinal direction X, and protrudes, for example, along the width direction Y. It may be configured as follows. That is, in the present embodiment, the protruding direction of the horn support portion 12 is configured to be orthogonal to the moving direction of the regulating portion 21, which will be described later, but even if it is configured to follow the moving direction of the regulating portion 21. good.

The horn 13 extends downward from the + X direction end surface of the horn support portion 12, and is configured to vibrate ultrasonically along the longitudinal direction X by being connected to an ultrasonic oscillator (not shown).
Further, as shown in FIG. 5A, the lower surface 13a on the horn side, which is the bottom surface of the horn 13, has a concave portion 14 on the horn side formed by being recessed upward and a convex portion 15 on the horn side formed by projecting downward. Are provided in a grid pattern along the longitudinal direction X and the width direction Y. That is, the bottom surface of the horn 13 is formed so as to have an uneven shape when viewed from the longitudinal direction X and the width direction Y (see FIGS. 5 (b) and 5 (c)).

More specifically, the horn-side recess 14 is formed by recessing upward from the horn-side lower surface 13a to form a horn longitudinal valley portion 14a (see FIG. 5B) and recessing upward from the horn-side lower surface 13a. It is composed of a valley portion 14b in the width direction of the horn (see FIG. 5C), and is formed at an intersection thereof.

Further, the horn-side convex portion 15 is a horn longitudinal direction mountain portion 15a (see FIG. 5B) that protrudes downward from the horn-side lower surface 13a between the horn longitudinal direction valley portions 14a formed along the longitudinal direction X. ) And the horn width direction mountain portion 15b (see FIG. 5 (c)) protruding downward from the horn side lower surface 13a between the horn width direction valley portions 14b formed along the width direction Y. It is formed at the intersection of these.

The horn longitudinal valley portion 14a and the horn longitudinal valley portion 15a are arranged in 5 rows and 6 rows at equal intervals along the width direction Y, respectively, and the horn width direction mountain portion 15b and the horn width direction valley portion 14b are arranged in the longitudinal direction. 23 rows and 24 rows are arranged at equal intervals along X (see FIG. 5A). The horn-side concave portion 14 and the horn-side convex portion 15 arranged in this way are formed so as to have an iris shape in the bottom view.

On the + X direction side of the ultrasonic welder 10, the pair of widthwise adjusting portions 20 arranged to face each other fix and support the regulating portion 21 that regulates the movement of the covered electric wire 200 in the width direction Y and the regulating portion 21. The fixed support portion 22 is composed of a fixed support portion 22 that indirectly fixes the regulating portion 21 to the elevating portion 11, and a connecting portion 24 that movably connects the fixed support portion 22 to the fixed portion 23. ..

The restricting portions 21 are arranged at predetermined intervals along the width direction Y, and as shown in FIGS. 3 and 4, the length along the longitudinal direction X is equal to the length of the corresponding horn 13, and is vertically and vertically. The height along the direction Z is configured to be sufficiently longer than three times the outer diameter of the exposed conductor portion 220, and the regulating surface 26 is provided so as to face the other regulating portions 21 facing each other. ing.

In the present embodiment, the height of the restricting portion 21 is sufficiently longer than the outer diameter of the exposed conductor portion 220, but it is necessary to be three times the outer diameter of the exposed conductor portion 220. It suffices that the conductors are formed sufficiently longer than the total outer diameter of the electric wire bundle formed by the plurality of exposed conductor portions 220 to be ultrasonically welded.

On the upper end surface of the restricting portion 21, a regulated movement assisting portion 25 that meshes with the horn-side concave portion 14 and the horn-side convex portion 15 to assist the movement of the restricting portion 21 in the width direction Y is formed.

The regulation movement assisting portion 25 is composed of a movement assisting portion 251 slightly protruding upward from the upper end side of the regulating surface 26 and an upper surface recess 252 formed by being recessed downward on the outside of the movement assisting portion 251 in the width direction Y. It is configured. Further, in the movement assisting portion 251, a plurality of restricting portion-side convex portions 253 projecting upward are arranged along the longitudinal direction X.

The height of the restricting portion side convex portion 253 is about half that of the horn longitudinal valley portion 14a and the horn longitudinal direction mountain portion 15a, and the width formed by the three restricting portion side convex portions 253 is large. It is configured to be slightly smaller than the width of the horn longitudinal mountain portion 15a (horn longitudinal valley portion 14a), and corresponds to the horn longitudinal valley portion 14a and the horn longitudinal valley portion 15a in the longitudinal direction. Eighteen pieces are lined up at equal intervals along X.

The restricting portion side convex portion 253 configured in this way is provided with a slight gap between the horn longitudinal direction valley portion 14a and the horn longitudinal direction mountain portion 15a in a state where the horn 13 and the restricting portion 21 are in mesh with each other. Therefore, it is possible to absorb the amplitude in the longitudinal direction X direction due to the ultrasonic vibration.

As shown in FIG. 6A, the regulation surface 26 provided on the opposite portion of the pair of regulation portions 21 has a sinusoidal waveform regulation portion 27 in a plan view and a longitudinal direction X of the waveform regulation portion 27. Flat portions 28 formed flat at both ends are provided.

The waveform regulating portion 27 has a regulating portion-side convex portion 271 projecting at a predetermined height toward the facing regulating surface 26 side and a regulating portion-side convex portion 271 in a direction opposite to the protruding direction of the regulating portion-side convex portion 271. The regulating portion-side recesses 272, which are recessed so as to have the same depth as the height of the portion 271, are alternately and smoothly and continuously configured (see FIG. 6A). It should be noted that the waveform regulating portions 27 are continuously arranged alternately by four along the longitudinal direction X.

In the waveform regulating portion 27 provided on each of the regulating surfaces 26 facing each other in this way, the regulating portion side convex portion 271 and the regulating portion side concave portion 272, respectively, are provided on the other regulating surface 26 facing the regulating portion side concave portion 272. And, it is arranged so as to face the convex portion 271 on the regulation portion side.

That is, the waveform formed by the regulation portion side convex portion 271 and the regulation portion side concave portion 272 on the regulation surface 26 on the + Y side (hereinafter referred to as the regulation surface 26R) and the regulation surface 26 on the −Y side (hereinafter referred to as the regulation surface 26L). The waveforms formed by the regulation portion-side convex portion 271 and the regulation portion-side concave portion 272 in the above) are formed with a deviation of half a wavelength from each other.

In the present embodiment, the number of the regulation portion side convex portion 271 and the regulation portion side concave portion 272 formed on the regulation surface 26 is four each, but the number is not limited to this, and the method of using the conductor joining device 1 and the like. The number of shapes and sizes can be adjusted as appropriate.
The flat portion 28 is a flat surface formed flat along the vertical direction Z and the longitudinal direction X on both ends of the waveform regulating portion 27 in the longitudinal direction X.

As shown in FIGS. 3 and 4, the outside of the restricting portion 21 configured in this way is fitted and fixed to the fixed support portion 22.
As shown in FIGS. 3 and 4, the connecting portion 24 is a rod-shaped body that penetrates the fixed portion 23 fixed to the elevating portion 11 along the width direction Y and has one end fixed to the fixed support portion 22. , A motor for moving in the width direction (not shown) controlled by the control unit 40 is configured to be movable along the width direction Y.

That is, the connecting portion 24 is configured to connect the fixed support portion 22 and the fixed portion 23, and to move the fixed support portion 22 in which the restricting portion 21 is fixed to the fixed portion 23 along the width direction Y. There is.
Since the fixed portion 23 is fixed to the elevating portion 11, the regulating portion 21 and the fixed support portion 22 are indirectly fixed to the elevating portion 11.

The control unit 40 that controls the elevating motor and the width direction moving motor (not shown) has a configuration in which the elevating motor and the width direction moving motor can be driven in synchronization with each other, and the ultrasonic welding tool 10 is lowered. , The restricting portions 21 arranged to face each other can be simultaneously moved along the width direction Y.
It should be noted that, under the control of the control unit 40, the regulation unit 21 can be independently moved along the width direction Y.

The anvil 30 is a rectangular parallelepiped receiving jig provided on the substrate of the conductor joining device 1, and is erected on a movable base portion 31 configured to be movable along a rail 50 described later and a movable base portion 31. It is composed of an anvil upper part 32.

The anvil upper portion 32 is configured so that its length with respect to the width direction Y is slightly longer than the length with respect to the width direction Y of the electric wire bundle formed by the plurality of conductor exposed portions 220 to be ultrasonically welded. The height is configured to be higher than the height of the regulating portion 21, and the anvil main surface 321 which is the main surface of the anvil upper portion 32 is erected on the upper portion of the movable base portion 31 so as to face the width direction Y.

Anvil-side corrugated portions 33 continuously arranged along the longitudinal direction X are formed on the anvil main surface 321. The anvil-side corrugated portion 33 is composed of an anvil-side convex portion 331 protruding outward in the width direction Y from the anvil main surface 321 and an anvil-side concave portion 332 recessed inside the anvil main surface 321. ..

The anvil-side convex portion 331 is formed so as to be fitted with the regulation portion-side concave portion 272, and the anvil-side concave portion 332 is formed so as to be fitted with the regulation portion-side convex portion 271. That is, it is formed in a sine and cosine shape in a plan view in which the amplitude of the waveform portion 33 on the anvil side is equal to the amplitude of the waveform regulating portion 27.

As shown in FIG. 7A, the anvil-side corrugated portion 33 in which the anvil-side convex portion 331 and the anvil-side concave portion 332 are continuously arranged is formed in a sinusoidal shape in a plan view. Four of them are lined up in succession along the longitudinal direction X.

Further, the anvil side waveform unit 33 is provided on both sides of the anvil main surface 321 facing the width direction Y, but the anvil side waveform unit 33 (anvil side waveform unit 33R) and the −Y side provided on the + Y side. The anvil-side corrugated portion 33 (anvil-side corrugated portion 33L) provided in the above is arranged half a wavelength apart from each other. That is, the anvil-side corrugated portion 33R is provided in the order of the anvil-side concave portion 332 and the anvil-side convex portion 331 from the + X side, and the anvil-side corrugated portion 33L is provided in the order of the anvil-side convex portion 331 and the anvil-side concave portion 332 from the + X side. In the anvil-side corrugated portion 33R and the anvil-side corrugated portion 33L, the anvil-side convex portion 331 and the anvil-side concave portion 332 are formed so as to face each other.

Further, the anvil-side convex portion 331 and the anvil-side concave portion 332 provided in the anvil-side corrugated portion 33L are regulated with the anvil 30 so as to face the regulation portion-side concave portion 272 and the regulation portion-side convex portion 271 provided in the regulation surface 26L. A portion 21L is arranged. Similarly, the anvil-side convex portion 331 and the anvil-side concave portion 332 provided on the anvil-side corrugated portion 33R are opposed to the regulatory portion-side concave portion 272 and the regulatory portion-side convex portion 271 provided on the regulation surface 26R with the anvil 30. The regulation unit 21R is arranged.

The anvil-side upper surface 322, which is the upper surface of the anvil upper portion 32, is a surface that compresses the conductor exposed portion 220 with the horn-side lower surface 13a when the ultrasonic welding tool 10 is lowered, and is formed along the vertical direction Z. The uneven portion 34 on the anvil side of the unevenness is provided.

Further, on the front end side and the rear end side of the anvil side uneven portion 34, a flat portion 35 formed in a plane shape having a length of about half a wavelength of the sine wave formed by the anvil side corrugated portion 33 is formed in the longitudinal direction X. It is provided along.

In addition, in this embodiment, three anvils 30 configured so that the width of the anvil upper portion 32 in the width direction Y is different (anvils 30a, 30b, 30c) are provided. The width in the width direction Y is formed so that the anvil 30a is the smallest and the anvil 30c is the largest.
The plurality of anvils 30 (anvils 30a, 30b, 30c) provided in this way are configured to be movable along the rail 50, and the desired anvil 30 can be arranged below the ultrasonic welder 10.

Further, in the present embodiment, three anvils 30 are provided, but the number of anvils 30 provided can be appropriately adjusted according to the connected covered electric wires 200, and the width of the anvil upper portion 32 in each anvil 30 can also be appropriately adjusted.

In the ultrasonic welding tool 10 and the width direction adjusting portion 20 configured in this way, as shown in FIGS. 3 and 8, the regulation portion side convex portion 253 is loosely fitted to the horn side concave portion 14 and the horn side convex portion 15. By doing so, the regulating portion 21 can be moved along the lower surface 13a on the horn side.

Further, the anvil 30 can be arranged so that the lower surface 13a on the horn side and the upper surface 322 on the anvil side face each other by moving along the rail 50 (see FIG. 8B). As a result, an arrangement space S through which a plurality of exposed conductor portions 220 can be inserted can be formed by the lower surface 13a on the horn side, the upper surface 322 on the anvil side, and the pair of restricting surfaces 26 (see FIG. 8A).

In this way, the conductor joining device 1 in which the regulating portion 21 fixes the width direction adjusting portion 20 so as to be movable along the width direction Y and the anvil 30 is arranged below the horn 13 with respect to the ultrasonic welding tool 10. With the conductor exposed portion 220 inserted through the arrangement space S, the ultrasonic welding tool 10 and the width direction adjusting portion 20 can be moved downward by the elevating motor under the control of the control unit 40, and for movement in the width direction. The regulating portion 21 can be moved along the width direction Y by the motor.

Hereinafter, a method for manufacturing the bonded conductor 100 using the conductor bonding device 1 will be briefly described with reference to FIGS. 9 to 11.
Here, FIG. 9 shows a flowchart of a conductor joining method in which the conductor exposed portions 220 of a plurality of (nine in the present embodiment) coated electric wires 200 are melt-bonded, and FIG. 10 shows a conductor exposed portion 220 (conductor exposed portion 220). ) Is inserted into the arrangement space S, and an explanatory diagram illustrating a state in which the restricting portion 21 is moved along the width direction Y is shown. FIG. 11 shows a conductor using the DD cross-sectional view of the α portion in FIG. An explanatory diagram illustrating a conductor joining method for joining the exposed portions 220 is shown.

More specifically, FIG. 10A shows an enlarged plan view of the restricting portion 21 and the anvil 30 before the conductor exposed portion 220 is inserted, and FIG. 10B shows the restricting portion 21 being inserted through the conductor exposed portion 220. An enlarged plan view of the regulating portion 21 and the anvil 30 in a state of being moved toward the conductor exposed portion 220 is shown, and FIG. 10 (c) shows a schematic plan view of the compressed conductor exposed portion 220 in FIG. 10 (b). ..

FIG. 11A shows a cross-sectional view taken along the line DD in a state where the conductor exposed portion 220 is inserted in the arrangement space S, and FIG. 11B shows an ultrasonic welding tool in a state where the conductor exposed portion 220 is inserted in the arrangement space S. 10 is a cross-sectional view taken along the line DD in a state where the conductor exposed portion 220 compressed by lowering the width direction adjusting portion 20 and the width direction adjusting portion 20 is ultrasonically welded.
In FIG. 11, the horn-side concave portion 14 and the horn-side convex portion 15 are not shown.

As shown in FIG. 9, the conductor exposed portion 220 provided at the terminal portion of the covered electric wire 200 includes the electric wire arrangement step s1 for arranging the conductor exposed portion 220 in the arrangement space S, the ultrasonic welding tool 10, and the width direction adjusting portion. The compression transfer step s2 that descends from 20 and the conductor compression step s3 that compresses the conductor exposed portion 220 by the horn 13 and the anvil 30, and the ultrasonic welding step s4 that melt-bonds the compressed conductor exposed portion 220 by ultrasonic waves. By performing and in this order, the connection can be made conductive.
The conductor compression step s3 and the ultrasonic welding step s4 can be performed at the same time.

Hereinafter, each step will be described in detail with reference to FIGS. 10 and 11.
A plurality of (9 in this embodiment) coated electric wires 200 are prepared in advance, and the insulating coating 210 on one end side (-X direction side) of the coated electric wires 200 is cut off by a predetermined length to obtain the insulating coating 210. The stranded conductor surrounded by the wire is exposed to form a conductor exposed portion 220.

Next, an anvil 30 suitable for the number of exposed conductor portions 220 to be connected and the outer diameter is selected, and the anvil 30 is moved along the rail 50 so that the anvil side upper surface 322 faces the horn side lower surface 13a, and the anvil 30 is designated. Place in the position of. Here, the anvil 30a is arranged on the lower side of the ultrasonic welder 10.
Subsequently, the regulating portion 21 is moved along the width direction Y until the regulating surface 26 reaches a predetermined interval, and the ultrasonic welding tool 10 is raised until the horn 13 reaches a predetermined height to create an arrangement space S. Form.

In this state, as shown in FIG. 10A, the conductor exposed portions 220 are arranged in the arrangement space S formed by the restricting portions 21 and the horns 13 which are arranged to face each other at a predetermined interval, and + X. Insert from the direction side toward the −X direction side (electric wire arrangement step s1). In the present embodiment, a total of nine conductor exposed portions 220, in which three conductor exposed portions 220 are arranged along the vertical direction Z and three conductors are arranged along the width direction Y, are inserted into the arrangement space S. Join.

Then, under the control of the control unit 40, the ultrasonic welding tool 10 is lowered, and the regulating unit 21 is moved to the conductor exposed portion 220 side along the width direction Y in synchronization with the lowering of the ultrasonic welding tool 10. As a result, as shown in FIGS. 10 (b) and 11 (a), the regulation surface 26 comes into contact with both side surfaces of the anvil upper portion 32 on the width direction Y side, and the conductor exposed portion 220 abuts on the horn side lower surface 13a and the anvil. It is sandwiched between the side upper surface 322 and the conductor exposed portion 220 is pressed from above by the horn 13. (Compression transfer step s2).

The compression transfer step s2 will be described in detail. In a state where the conductor exposed portion 220 is arranged in the arrangement space S formed between the lower surface 13a on the horn side, the upper surface 322 on the anvil side, and the regulation surface 26 paired with each other, ultrasonic waves are emitted. By lowering the welding tool 10 and moving the regulating portion 21 toward the conductor exposed portion 220 along the lower surface 13a on the horn side, the waveform regulating portion 27 provided on the regulating surface 26 and the anvil main surface 321 are provided. The anvil-side corrugated portion 33 and the corrugated portion 33 on the anvil side are fitted to each other.

Here, since the width of the anvil main surface 321 with respect to the width direction Y is configured to be slightly longer than the width formed by the wire bundle of the conductor exposed portion 220, the waveform regulating portion 27 and the anvil side waveform portion 33 are configured. It is also possible to prevent the conductor exposed portion 220 from being bitten between the regulating portion 21 and the anvil upper portion 32 in the state of being fitted with.

Further, even if the conductor exposed portion 220 is pushed from above and moved in the width direction Y by further lowering the ultrasonic welding tool 10 in the state where the conductor exposed portion 220 is arranged in the arrangement space S, the regulation surface. 26 can restrict the movement of the exposed conductor 220 in the width direction Y direction.

Subsequently, by further lowering the ultrasonic welding tool 10 (conductor compression step s3), the conductor exposed portion 220 is pressed by the horn 13 to be deformed and spread in the width direction Y, but the waveform regulating portion Since 27 is fitted to the anvil upper portion 32, the conductor exposed portion 220 comes into contact with the regulation surface 26.

Further, when the conductor exposed portion 220 is further pressed against the horn 13, the conductor exposed portion 220 is pressed against the waveform regulating portion 27 provided on the regulation surface 26 as shown in FIG. 10 (b), and the coating is covered. A continuous waveform is formed along the longitudinal direction X at a location corresponding to the side surface of the electric wire 200.

In this way, the conductor exposed portion 220 can be compressed from the vertical direction Z by further lowering the horn 13 while the covered electric wires 200 are arranged in the arrangement space S (conductor compression step s3), and the conductor is compressed in the vertical direction. The conductor exposed portions 220 arranged in Z can be brought into contact with each other more reliably. Further, since the conductor exposed portion 220 is compressed in a state of being in contact with the regulation surface 26, the conductor exposed portion 220 is formed in a wavy shape along the longitudinal direction X. As a result, the conductor exposed portions 220 arranged in parallel along the width direction Y can be brought into contact with each other in the direction intersecting the longitudinal direction X (width direction Y), and the conductor exposed portions 220 can be reliably contacted with each other by compression. Can be made to.

In this way, it is an important issue in the manufacture of the bonded conductor 100 to ensure that the exposed conductor portions 220 are brought into contact with each other and joined to each other to ensure reliable conductivity. Further, for example, in recent years, with the demand for weight reduction of vehicles, it has become necessary to join alloyed high-strength electric wires. These high-strength materials are not easily deformed, and it is difficult to make the conductor exposed portions 220 contact each other more reliably.

In order to ensure that the exposed conductor portions 220 are in contact with each other and joined to each other, for example, as a manufacturing process in the present embodiment, in the conductor compression step s3, weaker ultrasonic vibration is performed than in the ultrasonic welding step s4 described later. , The conductor compression step s3 may be carried out while raising the temperature of the material and lowering the strength. Further, for example, the same purpose can be achieved by performing ultrasonic vibration weaker than that at the time of welding after the completion of the conductor compression step s3 and immediately before the ultrasonic welding step s4.

Assuming that the thickness in which the inside of the mold is 100% filled with the conductor, which is calculated by dividing the total cross-sectional area of the conductor of the conductor exposed portion 220 by the anvil surface width, is 100% height, when the conductor compression step s3 is performed, , It is desirable to compress to a height lower than 100% height.

As a result, the conductor exposed portion 220 filled in the mold is stretched in the longitudinal direction X, the oxide film formed on the surface of the conductor exposed portion 220 is broken, and the oxide film is formed during subsequent welding. Removal is done efficiently. If it is 100% or less, the above object is achieved, but 95% or less and 70% or more are preferable. More preferably, it is carried out between 90% and 80%. If the compression is small, it is difficult to achieve the above object, and if the compression is too large, the cross-sectional area at the root of the electric wire becomes small and the strength becomes weak, which is not preferable.

In this state, by ultrasonically vibrating the horn 13 along the longitudinal direction X intersecting the width direction Y, the exposed conductor portions 220 are ultrasonically metal-bonded to each other by ultrasonic welding (ultrasonic welding step s4). .. In the ultrasonic welding step s4, the control unit 40 may control and determine the bottom dead center (stop point) in the vertical direction Z during welding. As a result, the rapid rise in temperature of the exposed conductor portion 220 during welding is suppressed, and sticking to the horn 13 is suppressed.

Further, the ultrasonic vibration may be continued even after reaching the bottom dead center at the time of welding. As a result, the oxide film is removed from the welded portion, and the atoms on the surface of the exposed conductor portion 220 remain in contact with each other and are maintained at a high temperature. This further improves conductivity and rigidity. It is desired that the height of the bottom dead center is smaller than the height formed in the conductor compression step s3, and the total cross-sectional area of the conductor exposed portion 220 is calculated from the anvil surface width. It is desired that it is smaller than the 100% height to be filled. If it is 100% or less, the above object is achieved, but 90% or less and 70% or more are preferable. More preferably, it is carried out between 85% and 80%. If the compression is small, it is difficult to achieve the above object, and if the compression is too large, the cross-sectional area at the root of the electric wire becomes small and the strength becomes weak, which is not preferable.

As described in the present embodiment, even when the waveform regulating portion 27 is not formed on the regulating surface 26 of the regulating portion 21, that is, a wave is formed on the side surface of the joint portion 110 in the joint conductor 100 to be manufactured. Even when the corrugated portion 140 having a shape is not formed, the exposed conductor portions can be reliably brought into contact with each other for joining, and the conductivity of the joined conductor can be reliably ensured.

As a result, inside the arrangement space S, the nine conductor exposed portions 220 pressurized so as to form a wave shape along the longitudinal direction X are adjacent conductors along the longitudinal direction X and the width direction Y. With the exposed portions 220 in contact with each other reliably, ultrasonic welding is performed, and the bonded conductor 100 with improved conductivity and rigidity can be manufactured (see FIG. 11B).

As described above, the plurality of exposed conductor portions 220 arranged along the longitudinal direction X are the joint conductors 100 having the joint portions 110 melt-bonded, and the joint portions 110 face each other along the longitudinal direction X. The first surface 121 and the second surface 122 are provided, and both of the first surface 121 and the second surface 122 facing each other are provided with the two surfaces facing each other toward the outside in the width direction Y. The protruding mountain portion 141 and the valley portion 142 recessed inward in the width direction Y are continuous along the longitudinal direction X, and the corrugated portion 140 is provided, so that the conductor exposed portions 220 are joined to each other. The strength can be improved and the conductivity can be improved.

More specifically, since the corrugated portion 140 is formed on at least the first surface 121 of the first surface 121 and the second surface 122 which are facing surfaces, the plurality of conductor exposed portions 220 constituting the joint portion 110 Among them, the conductor exposed portions 220 arranged side by side in the width direction Y are joined in a state of being in contact with other conductor exposed portions 220 adjacent in the width direction Y along the direction intersecting the longitudinal direction X (FIG. 10 (c)). Therefore, in the joint portion 110, the joint strength between the conductor exposed portions 220 arranged in the width direction Y is improved.

Therefore, the integrity of the joint portion 110 can be improved, the conductivity of the exposed conductor portion 220 constituting the joint conductor 100 can be improved, and the rigidity of the joint conductor 100 can also be improved.

Further, the corrugated portion 140 is provided on both the first surface 121 and the second surface 122 facing the first surface 121, and the corrugated portion 140 formed on the first surface 121 is referred to as the corrugated portion 140L, and the second surface 122 is used. The corrugated portion 140 formed in the above is referred to as a corrugated portion 140R, and the corrugated portion 140L and the corrugated portion 140R are composed of the same waveform, and the mountain portion 141 in the corrugated portion 140L faces the valley portion 142 in the corrugated portion 140R. The valley portion 142 in the corrugated portion 140L faces the mountain portion 141 in the corrugated portion 140R, in other words, the corrugated portion 140L formed on the first surface 121 and the corrugated portion 140R formed on the second surface 122. However, since they are configured with a half-waveform shift along the longitudinal direction X, the exposed conductor portions 220 arranged side by side along the width direction Y oscillate in the width direction Y with a constant width. Therefore, the apparent cross-sectional coefficient of the entire joint portion 110 can be improved, and the rigidity of the joint conductor 100 can be improved.

Further, since the width of the first surface 121 and the second surface 122 with respect to the width direction Y is constant in the longitudinal direction X, that is, the cross-sectional area of the exposed conductor portions 220 in the longitudinal direction X is constant, the joint portion. The non-uniformity of the rigidity of the 110 can be suppressed, and the variation in the quality of the bonded conductor 100 can be suppressed.

Furthermore, since a plurality of corrugated portions 140 are provided along the longitudinal direction X, the conductor exposed portions 220 that are periodically arranged side by side in the intersecting direction intersecting the longitudinal direction X are joined to the joint portion 110. (See FIG. 10 (c)), the bonding strength between the exposed conductor portions 220 arranged side by side in the crossing direction can be improved, and the contact area between the exposed conductor portions 220 can be increased. Therefore, the integrity of the joint portion 110 can be further improved, and the conductivity and rigidity of the conductor exposed portion 220 can be further improved.

Further, the height L1 in the orthogonal cross-sectional direction from the bottom of the valley portion 142 to the apex of the mountain portion 141 is 0.5 times or less the distance L2 in the width direction Y between the first surface 121 and the second surface 122. As a result, the conductivity of the bonded conductor 100 can be improved, and the rigidity can be reliably improved.

More specifically, when the height of the mountain portion 141 with respect to the valley portion 142 is higher than 0.5 times the distance between the first surface 121 and the second surface 122 in the width direction Y, the amplitude of the waveform at the joint portion 110 is large. Therefore, the load applied to the exposed conductor portion 220 becomes large, the exposed conductor portion 220 may be partially torn or damaged, the conductivity of the bonded conductor 100 may not be sufficiently ensured, and the rigidity may be lowered. ..

However, the height L1 of the mountain portion 141 with respect to the valley portion 142 in the width direction Y is 0.5 times or less the distance L2 in the width direction Y between the first surface 121 and the second surface 122, thereby joining. Since the load on the conductor exposed portions 220 constituting the portion 110 can be reduced and the conductor exposed portions 220 arranged in the width direction Y can be oscillated in the width direction Y, the bonding strength between the conductor exposed portions 220 due to bending can be ensured. It is possible to increase the contact area between the exposed conductor portions 220.

As a result, the integrity of the joint portion 110 can be improved, the possibility that the exposed conductor portion 220 is partially torn or damaged can be reduced, and the conductivity of the joint conductor 100 can be sufficiently improved. , The rigidity can be surely improved.

Furthermore, the height L1 in the orthogonal cross-sectional direction from the bottom of the valley portion 142 to the apex of the mountain portion 141 is 0.5 times or more the diameter L3 which is the minimum diameter of the plurality of arranged conductor exposed portions 220. By being configured as such, the conductivity of the bonded conductor 100 can be improved.

More specifically, when the height L1 of the mountain portion 141 with respect to the valley portion 142 in the width direction Y is lower than 0.5 times the minimum diameter of the plurality of arranged conductor exposed portions 220, the mountain portion in the joint portion 110 Since the amplitude of the waveform formed by 141 and the valley 142 is small and the conductor exposed portions 220 arranged along the width direction Y are not arranged so as to intersect with each other in the longitudinal direction X, the joint portion 110 is integrated. Cannot be sufficiently improved, and the conductivity of the bonded conductor 100 cannot be sufficiently improved.

On the other hand, by setting the height of the mountain portion 141 with respect to the valley portion 142 in the width direction Y to 0.5 times or more the minimum diameter of the plurality of arranged conductor exposed portions 220, the joint portion 110 is formed into a mountain portion 110. Since the conductors 141 and the valleys 142 can be reliably curved, the exposed conductors 220 arranged along the width direction Y are arranged so as to intersect each other with respect to the longitudinal direction X. As a result, the bonding strength between the exposed conductor portions 220 can be reliably improved, the contact area between the exposed conductor portions 220 can be increased, and the conductivity of the bonded conductor 100 can be improved.

Further, the joint portion 110 may have a flat surface portion 150 formed in a planar shape along the longitudinal direction X between the tip end and the corrugated portion 140. As a result, it is possible to prevent the joint between the exposed conductor portions 220 from being peeled off from the tip end side of the joint portion 110.

More specifically, since the mountain portion 141 and the valley portion 142 constituting the corrugated portion 140 are configured by bending the conductor exposed portion 220, the conductor exposed portion 220 is formed when an external force acts on the side opposite to the bending direction. The joints between them are easily peeled off.

However, since the joint portion 110 has the flat surface portion 150 between the tip and the corrugated portion 140, an unintended external force acting directly on the peak portion 141 and the valley portion 142 in the direction opposite to the bending direction. Even if an unintended external force acts, the flat surface portion 150 can absorb the external force, so that the peeling of the joint between the exposed conductor portions 220 can be suppressed.

Further, since the joint portion 110 is composed of the joint portion 110 formed by ultrasonic welding, the interface between the exposed conductor portions 220 in the joint portion 110 can be joined by ultrasonic welding, so that the joint conductor can be joined. It can be sufficiently joined even inside the 100. Thereby, the joint strength of the joint conductor 100 can be stabilized. Further, since the change in physical properties due to the application of excessive heat is suppressed, it is possible to prevent the mixing of foreign substances. Therefore, the conductivity and rigidity of the bonded conductor 100 can be stabilized.

Further, in the cross section of the joint portion 110, the conductor exposed portion 220 is deformed, and the interface between the conductor exposed portions 220 is closely joined by the ultrasonic joint portion 160. As shown in 2 (b) and FIG. 2 (c), since the conductor exposed portion 220 is deformed from, for example, a perfect circle to an elliptical shape in the orthogonal cross section orthogonal to the longitudinal direction X, the conductor exposed portions 220 are deformed to each other. Since the contact area is increased and the joint strength between the exposed conductor portions 220 is increased, the integrity of the joint portions 110 is further improved, and the conductivity and rigidity of the joint conductor 100 can be further improved.
Furthermore, since the conductor exposed portion 220 is also made of aluminum or an aluminum alloy, the weight of the bonded conductor 100 can be reduced.

In the correspondence between the configuration of the present invention and the above-described embodiment,
The conductor corresponds to the exposed conductor 220 and
The joint corresponds to the joint 110 and
The joint conductor corresponds to the joint conductor 100,
The first corrugated portion corresponds to the corrugated portion 140L and corresponds to the corrugated portion 140L.
The second waveform section corresponds to the waveform section 140R.
The facing direction corresponds to the width direction Y,
The ultrasonic bond corresponds to the bond 110 and
The ultrasonic weld corresponds to the ultrasonic bond 160,
The first direction corresponds to the vertical direction Z,
Although the second direction corresponds to the width direction Y, the present invention is not limited to the configuration of the above-described embodiment, and many embodiments can be obtained.

For example, in the present embodiment, the exposed conductor portion 220 is a twisted wire conductor obtained by twisting a wire having conductivity, but the present invention is not limited to this form, and for example, a hand made of a single wire may be used, or the wire may be a wire. May be bundled. Further, the conductor exposed portion 220 is not limited to the aluminum system made of aluminum or an aluminum alloy, and may be made of copper or a copper alloy, for example. That is, any material may be used as long as it has conductivity.

Further, the conductor exposed portion 220 is exposed by cutting off the insulating coating 210 forming the outer layer at one end of the coated electric wire 200 coated with the insulating insulating coating 210, but is not covered with the insulating coating 210. It may be a conductor or a conductor in which wires are simply bundled.

Furthermore, although the conductor exposed portion 220 is the same conductor, a plurality of different types of conductors may be used. Furthermore, for the plurality of conductor exposed portions 220 described above, a configuration in which the joint portion is surrounded by, for example, a copper tube or a copper foil may be used.

Further, the corrugated portion 140 may be formed not only on both the first surface 121 and the second surface 122, but also on only one of the first surface 121 and the second surface 122. Further, in addition to the case where it is formed on the entire surface of the first surface 121 or the second surface 122, it may be formed on a part thereof.
Further, in the corrugated portion 140, at least one mountain portion 141 and one or more valley portions 142 may be continuous along the longitudinal direction X, and for example, at least one or more peak portions 141 and valley portions 142 are continuous. If so, it is not necessary that the numbers of the mountain part 141 and the valley part 142 match.

Further, in the present embodiment, of the horn side lower surface 13a forming the arrangement space S for inserting the conductor exposed portion 220, the anvil side upper surface 322, and the pair of regulation surfaces 26, the wave-shaped waveform regulation is performed only on the regulation surface 26. Although the portion 27 is provided, for example, as shown in FIGS. 12 and 13, the bottom surface portion (referred to as a wavy bottom surface portion 13b) of the horn 13 and the anvil-side upper surface portion 322 may be formed in a wavy shape.

Hereinafter, the conductor joining device 1x in which the wavy bottom surface portion 13b and the anvil side upper surface surface 322 are formed in a wavy shape will be briefly described with reference to FIGS. 12 and 13.
Here, FIG. 12 shows a schematic perspective view of the conductor joining device 1x, and the horn 13 is a wavy bottom portion 13b and an anvil in the cross-sectional view corresponding to the CC cross-sectional view of FIG. 8A in the conductor joining device 1x. The side upper surface 322 is enlarged and shown.

As shown in FIGS. 12 and 13, the upper surface 322 on the anvil side is provided with a corrugated portion 37 on the compression side instead of the uneven portion 34 on the anvil side.
The anvil 30 in which the compression side waveform portion 37 is configured is referred to as an anvil 30d, an anvil 30e, and an anvil 30f, respectively (see FIG. 12).

The compression side corrugated portion 37 corresponds to the crossing side corrugated portion, and is composed of a compression side convex portion 371 that protrudes upward with respect to the flat portion 35 and a compression side concave portion 372 that is recessed downward. And four are arranged side by side in succession along the longitudinal direction X. That is, the compression side convex portion 371 corresponds to the intersection side mountain portion, and the compression side concave portion 372 corresponds to the intersection side valley portion, and each of them is continuously arranged along the longitudinal direction X.

On the other hand, as shown in FIG. 13, a wavy bottom surface portion 13b protruding downward is provided on the bottom surface side of the horn 13, and the wavy bottom surface portion 13b has a valley recessed in an arc shape toward the upper side. A valley portion 14c in the horn width direction and a mountain portion 15c in the horn width direction protruding downward on an arc are provided.

Further, in the restricting portion 21 formed so as to be movable in the width direction Y along the wavy bottom surface portion 13b, a moving corrugated portion 29 is formed instead of the regulated movement assisting portion 25. The moving corrugated portion 29 is composed of a moving assisting convex portion 291 that can be loosely fitted to the horn width direction valley portion 14c and a moving assisting concave portion 292 that can be loosely fitted to the horn width direction mountain portion 15c. There is. The movement assisting convex portion 291 and the moving assisting concave portion 292 are formed in a continuous side view substantially sinusoidal shape.

The conductor bonding device 1x configured in this way can ultrasonically bond the conductor exposed portion 220 in a wavy shape not only in the width direction Y but also along the vertical direction Z, so that the conductor bonding device 1x can be ultrasonically bonded in the width direction Y. Not only the corrugated portions 140 are formed on the first surface 121 and the second surface 122 facing each other along the vertical direction Z, but also the upper and lower corrugated portions 170 are formed on the third surface 131 and the fourth surface 132 facing each other along the vertical direction Z. It is possible to manufacture a bonded conductor 100x formed by the above.

Hereinafter, the bonded conductor 100x will be briefly described with reference to FIGS. 14 to 16.
Here, FIG. 14 shows a schematic perspective view of the joined conductor 100x, and FIG. 15 shows a plan view (FIG. 15 (a)) and a side view (FIG. 15 (b)) of the joined conductor 100x. Further, FIG. 16 is a plan view of the EE cross-sectional view (FIG. 16 (a)), a plan view of the FF cross-sectional view (FIG. 16 (b)), and a plan view of the GG cross-sectional view in FIG. 15 (a). 16 (c)) and a plan view of a cross-sectional view taken along the line HH (FIG. 16 (d)) are shown.

As shown in FIGS. 14 and 15, in the bonded conductor 100x, not only the corrugated portion 140 is formed on the first surface 121 and the second surface 122, but also the upper and lower wave shapes are formed on the third surface 131 and the fourth surface 132. Four side corrugated portions 170 are continuously provided along the longitudinal direction X, and are formed in a sinusoidal shape in a side view.
More specifically, the upper and lower corrugated portions 170 have an upper and lower mountain portion 171 protruding outward in the vertical direction Z with respect to the third surface 131, and an upper and lower recessed inward in the vertical direction Z with respect to the third surface 131. It is composed of side valley portions 172, and upper and lower side mountain portions 171 and upper and lower side valley portions 172 are continuously and alternately arranged.

As shown in FIG. 16, the bonded conductor 100x thus configured has a mountain portion 141 protruding toward the −Y side in the width direction Y as the joint conductor 100x is directed from −X to + X along the longitudinal direction X. (See FIG. 16 (a)), the mountain portion 141 does not protrude (see FIG. 16 (b)), and then the mountain portion 141 protrudes to the + Y side (see FIG. 16 (c)). , The mountain portion 141 is in a non-protruding state (see FIG. 16D).

Similarly, with respect to the vertical direction Z, from the state where the upper and lower mountain portions 171 project sideways along the longitudinal direction X from -X to + X (see FIG. 16B), the upper and lower mountain portions The 171 is in a state of protruding upward (+ Z side) (see FIG. 16 (b)), the upper and lower mountain portions 171 are not protruding (see FIG. 16 (c)), and the upper and lower mountain portions 171 are in a downward position (see FIG. 16 (c)). It is in a state of protruding toward the −Z side) (see FIG. 16 (d)).

That is, the mountainous portions 141 and the upper and lower mountainous portions 171 which are the protruding portions protrude in a spiral shape from −X to + X along the longitudinal direction X, so that they are more apparent than the bonded conductor 100. The section modulus can be improved and the rigidity can be improved. The wavy bottom surface portion 13b, which is the bottom surface portion of the horn 13, and the anvil side upper surface portion 322 are provided with a horn width direction valley portion 14c, a horn width direction mountain portion 15c, and a compression side waveform portion 37, respectively. The compression side waveform portion 37 may be provided only on one of the anvil side upper surface 322.

In this way, the upper and lower mountain portions 171 protruding outward and the restricting portion side concave 272 recessed inward are formed on the third surface 131 and the fourth surface 132 of the vertically facing side assembly 130 facing each other in the orthogonal cross section. By configuring the wave-shaped upper and lower corrugated portions 170 that are continuous along the longitudinal direction X, the contact area and the bonding strength between the exposed conductor portions 220 arranged side by side in the width direction Y and the vertical direction Z are increased. Will be increased. That is, since the contact area and the joint strength between the exposed conductor portions 220 are further increased, the integrity of the joint conductor 100 can be further improved, and the conductivity of the joint conductor 100 can be further improved.

100 Welding conductor 110 Welding part 121 First side 122 Second side 131 Third side 140 Waveform part 140L Waveform part 140R Waveform part 141 Mountain part 142 Valley part 170 Upper and lower side waveform part 171 Upper and lower side mountain part 172 Upper and lower side valley part 220 Conductor Exposed part s3 Conductor compression process s4 Ultrasonic welding process X Longitudinal direction Y Width direction Z Vertical direction

Claims (9)

A plurality of conductors arranged along the longitudinal direction are joint conductors having a melt-bonded joint portion.
The joint is
Two surfaces facing each other along the longitudinal direction are provided.
On both the first surface, which is one of the facing surfaces, and the second surface, which faces the first surface ,
A sinusoidal corrugated portion in which a mountain portion in which the two surfaces face each other and protrudes outward in the facing direction and a valley portion recessed inward in the facing direction are continuous along the longitudinal direction is described . Multiple are provided along the longitudinal direction ,
The corrugated portion formed on the first surface is used as the first corrugated portion.
The corrugated portion formed on the second surface is referred to as a second corrugated portion.
The first corrugated portion and the second corrugated portion have the same shape, and the first corrugated portion and the second corrugated portion have the same shape.
The mountain portion in the first waveform portion faces the valley portion in the second waveform portion, and the valley portion in the first waveform portion faces the mountain portion in the second waveform portion.
On at least one third surface of the surfaces facing each other in the crossing direction intersecting the facing direction,
A wave-shaped crossing-side corrugated portion is provided in which a crossing-side mountain portion protruding outward in the crossing direction and a crossing-side valley portion recessed inward in the crossing direction are continuous along the longitudinal direction. ,
The crossing side waveform portion is composed of a waveform having a wave shape, pitch, or phase different from that of the first waveform portion and the second waveform portion.
Joined conductor. The crossing side waveform portion is composed of a waveform having a different wave shape and pitch from the first waveform portion and the second waveform portion.
The joint conductor according to claim 1. The crossing side corrugated portion is composed of a sine wave having the same shape as the first corrugated portion.
The crossing side mountain portion in the crossing side corrugated portion is arranged in the central portion of the mountain portion and the valley portion in the first corrugated portion.
The joint conductor according to claim 1 , wherein an intersecting side valley portion is arranged at a central portion between a valley portion and a mountain portion in the adjacent first corrugated portion . The height in the orthogonal cross-sectional direction orthogonal to the longitudinal direction from the bottom of the valley to the apex of the mountain is the distance between the second surface facing the first surface and the first surface in the opposite direction. Consists of 0.5 times or less
The bonded conductor according to any one of claims 1 to 3 . The height from the bottom of the valley to the apex of the mountain in the facing direction is configured to be 0.5 times or more the minimum diameter of the plurality of arranged conductors.
The bonded conductor according to any one of claims 1 to 4 . The joint is
A flat surface portion formed in a planar shape along the longitudinal direction is provided between the tip and the corrugated portion.
The bonded conductor according to any one of claims 1 to 5 . The joint is
An ultrasonic bond formed by ultrasonic welding was constructed.
The bonded conductor according to any one of claims 1 to 6 . The conductor is made of aluminum or an aluminum alloy.
The bonded conductor according to any one of claims 1 to 7 . A method for manufacturing a bonded conductor in which a plurality of conductors arranged along the longitudinal direction are melt-bonded.
A compression step of compressing the conductor along a first direction orthogonal to the longitudinal direction and restricting the movement of the conductor in the longitudinal direction and the second direction orthogonal to the first direction.
A welding step of performing ultrasonic welding by ultrasonic vibration to the conductor compressed in the first direction is performed.
In the compression step
Of the conductor bundles composed of the plurality of conductors arranged, the first surface formed in the second direction has a mountain portion protruding outward in the second direction and the inside in the second direction. While restricting the movement of the conductor in the second direction, a plurality of sinusoidal first corrugated portions having continuous recessed valley portions are formed along the longitudinal direction .
On the second surface facing the first surface, a mountain portion protruding outward in the second direction and a valley portion recessed inward in the second direction are continuously provided, and the first surface is provided. The above-mentioned so as to form a plurality of sinusoidal second waveform portions along the longitudinal direction in which the peak portion in the corrugated portion faces the valley portion and the valley portion in the first waveform portion faces the peak portion. Regulate the movement of the conductor in the second direction,
On the third surface formed in the first direction, a crossing-side mountain portion protruding outward in the first direction and a crossing-side valley portion recessed inward in the first direction are formed along the longitudinal direction. Along the first direction, the crossing side waveform portions of the continuous wave shape are formed with waveforms having different wave shapes, pitches, and phases of the first waveform portion and the second waveform portion. A method for manufacturing a bonded conductor that compresses the conductor.

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