JP7166781B2 - Conductor joining device and conductor joining method - Google Patents

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a conductor joining apparatus and a method for joining conductors, for example, to fuse and join conductors installed in a vehicle or the like so as to be electrically conductive.

In recent years, automobiles have been equipped with a variety of electrical devices that improve operability and comfort. Transmission and reception and power supply are performed.

A plurality of coated electric wires constituting this wire harness are made conductive by a joint conductor in which ends of conductors exposed from an insulating coating are jointed to each other, for example. Conventionally, there has been proposed a conductor joining apparatus for joining such conductors so as to be conductive.

For example, Patent Document 1 discloses a conductor arrangement space formed by a pair of restricting portions opposed to each other at a predetermined interval in the width direction, and an anvil and a horn vertically opposed to each other between the restricting portions. While regulating the movement of the conductors in the width direction by the regulation part, the horn is moved to the anvil side to compress the conductors, and the horn is ultrasonically vibrated along the conductor insertion direction. A conductor joining apparatus for fusing and joining conductors together is disclosed, and this apparatus is said to be capable of producing joined conductors in which the conductors can be electrically connected to each other.

JP 2011-198506 A

However, in the joint conductors manufactured by the conductor joining apparatus disclosed in Patent Document 1, the conductors arranged along the vertical direction have sufficient joint strength, but the conductors arranged along the width direction have sufficient joint strength. has a problem that it does not have sufficient bonding strength.

SUMMARY OF THE INVENTION In view of the above problems, an object of the present invention is to provide a conductor bonding apparatus and a conductor bonding method capable of improving the bonding strength between conductors.

The present invention relates to a conductor joining apparatus for joining a plurality of conductors by ultrasonic welding, comprising: a horn that has a contact surface that contacts the conductor and that is ultrasonically vibrated; A pair of regulating parts configured to be relatively movable along a surface, and an anvil configured separately from the horn and corresponding to the number and outer diameter of each of the plurality of conductors to be connected are provided. The regulating portion is fixed to the horn so as to be movable along the opposing direction of the regulating surfaces that face each other, and the anvil is configured to be arranged at a position facing the contact surface, and At a position facing the contact surface, it is configured to move relative to the contact surface in a direction of movement toward or away from the contact surface, and at least one of the regulating surfaces facing each other in the pair of regulating portions is configured to move at least one of the other regulating surfaces facing each other. A corrugated wavy regulation in which a convex portion protruding toward a regulating surface and a concave portion recessed in a direction opposite to the projection direction of the convex portion are continuous along an orthogonal direction orthogonal to the facing direction and the moving direction. a portion is formed, and a main surface of the anvil facing the opposite direction is provided with a fitting concave portion and a fitting convex portion that fit into the convex portion and the concave portion of the restricting portion along the orthogonal direction, The regulating portion is configured to move relative to the anvil so that the anvil is sandwiched between the regulating surfaces facing each other, and at least one of the pair of regulating portions moves toward the other ; The anvil arranged at a position facing the contact surface is characterized in that the contact surface and the pair of restricting portions form an arrangement space through which the plurality of conductors are inserted .

Further, according to the present invention, there is provided a contact surface that contacts a conductor, a horn that vibrates ultrasonically, and a pair of horns that are in contact with the contact surface and opposed to each other at a predetermined distance, and move relative to each other along the contact surface. a conductor arranging step of arranging a plurality of the conductors in the space formed by the regulating portion ; The horn and the regulating portion are moved relative to the anvil, which is arranged at a position facing the contact surface of the horn and spaced apart from the contact surface by a predetermined distance, and the pair of regulating portions is moved. At least one of the pair of regulating portions moves relative to the other so that the anvil is sandwiched between the regulating surfaces facing each other at the portion, and the regulating portion sandwiches the anvil, and the conductor is held by the anvil and the horn. and a welding step of ultrasonically welding the conductor compressed by the anvil and the horn by ultrasonically vibrating the horn. Each of the regulating surfaces has a convex portion protruding toward the opposing regulating portion, and a concave portion recessed in a direction opposite to the direction in which the convex portion protrudes. Further, a wave-shaped wave restricting portion is formed continuously along an orthogonal direction orthogonal to a movement direction in which the horn relatively moves with respect to the anvil, and the main surface of the anvil facing the opposite direction has the above-described The conductor joining method is characterized in that a convex portion, a fitting concave portion that fits into the concave portion, and a fitting convex portion are provided.

The conductor includes a stranded wire in which conductive wires are twisted, a conductor composed of a single wire, a conductor in which wires are bundled, and the like. and includes a copper-based conductor made of copper or a copper alloy, or an aluminum-based conductor made of aluminum or an aluminum alloy.

The conductor is, for example, an exposed conductor exposed by cutting off the insulating coating forming the outer layer at one end of a coated wire in which a bundle of stranded wires or wires is coated with an insulating insulating coating, or an insulating coating. Including uncoated stranded conductors and conductor bundles in which strands are bundled.

The plurality of conductors mentioned above includes conductors of the same or different types. Specifically, conductors having different outer diameters and materials may be used, and some may be stranded wires and some may be single wires.
Moreover, the plurality of conductors described above includes, for example, a configuration in which a joint portion is surrounded by a copper tube, copper foil, or the like.

The waveform restricting portion refers to a configuration in which at least one or more convex portions and one or more concave portions are continuous along the orthogonal direction. It should be noted that the number of protrusions and recesses need not be the same as long as one or more of the protrusions and recesses are continuous.
The waveform restricting portion may be formed on the entire restricting surface or may be formed on a part of the restricting surface.

The protrusion projecting toward the other opposing regulation surface and the recess recessed in a direction opposite to the projecting direction of the protrusion are such that the protrusion and the recess relatively protrude outward or inward relative to each other. Any recessed configuration is acceptable.

When the waveform formed by the convex portion and the concave portion is a sine wave, or when the waveform is a rectangular wave, the wave shape is formed by peaks and troughs in which the corners of the rectangular wave are chamfered. Including cases where it is a waveform.

According to this invention, the bonding strength between the conductors can be improved.
More specifically, the wavy wavy restricting portion is formed on the regulating surface, and the anvil is provided with a fitting convex portion and a fitting recess that are formed so as to be fittable with the wavy restricting portion. The plurality of conductors are compressed by the anvil and the horn by moving the horn relative to the anvil.

Further, since the restricting portion moves inward in the opposing direction in accordance with the relative movement of the horn, the restricting portion restricts the outward movement of the conductor in the opposing direction and moves the conductor in the orthogonal direction. It can be curved into a wave shape that oscillates in the opposite direction as it goes.

By bending the conductors in a wave shape that oscillates in the facing direction, the conductors arranged side by side along the facing direction are arranged along one side of the orthogonal direction to form the wave shape. Since the conductors can be brought into contact with each other along the direction crossing the orthogonal direction, the conductors can be reliably brought into contact with each other. Therefore, by joining the conductors together by ultrasonic welding, the joint strength between the conductors arranged along the facing direction can be increased, and the integrity of the joint conductors can be improved. .
Therefore, the electrical conductivity and bonding strength of the bonding conductor can be improved. Moreover, since the joint strength between the conductors is improved, the rigidity of the manufactured joint conductor as a whole can also be improved.

As an aspect of the present invention, the waveform restricting portion may be formed in a sinusoidal shape.
According to the present invention, since the ends of the space formed by the horn, the restricting portion, and the anvil in the opposing direction are formed in an arcuate shape, the conductor is curved in an arcuate shape along the orthogonal direction. can do. As a result, the conductors arranged in the facing direction can be brought into continuous contact with each other, the conductors can be brought into contact with each other reliably, and the bonding strength can be increased. In addition, it is possible to prevent the formation of a corner portion that weakens the joint in the joint conductor during compression and ultrasonic welding.

Furthermore, the corrugation regulating portion allows the conductor to be formed into a smooth corrugated shape along the orthogonal direction. It is possible to prevent the conductor from being cut by contact, and to reliably improve the conductivity between the conductors and the rigidity of the joint conductor.

Moreover, as a mode of this invention, the said waveform control part may be provided in multiple numbers along the said orthogonal direction.
According to the present invention, since the conductor can be curved in a wave shape whose amplitude is periodically repeated in the opposite direction as it goes toward one side of the orthogonal direction, the conductors arranged in the opposite direction can be curved. The conductors can be periodically brought into contact with each other in the direction crossing the orthogonal direction, and the conductors can be brought into contact with each other more reliably.

Accordingly, the bonding strength can be further improved by ultrasonically bonding the conductors. Therefore, it is possible to further improve the integrity of the joint portion of the conductor, and further improve the conductivity of the joint conductor.

Further, as an aspect of the present invention, the waveform restricting portion is formed on both of the restricting surfaces facing each other in the pair of restricting portions, and the waveform restricting portion formed on one of the restricting surfaces is the first waveform restricting portion. , the waveform restricting portion formed on the other side is defined as a second waveform restricting portion, the first waveform restricting portion and the second waveform restricting portion are configured with the same waveform, and the convex portion of the first waveform restricting portion is The concave portion of the first waveform restricting portion may face the convex portion of the second waveform restricting portion while facing the concave portion of the second waveform restricting portion.

According to this aspect of the invention, since the first waveform restricting portion and the second waveform restricting portion are configured to be shifted by half a wavelength, the bonding is curved by the first waveform restricting portion and the second waveform restricting portion. The conductor is formed in a wavy shape that oscillates in the opposing direction while having a predetermined width with respect to the opposing direction toward one side of the orthogonal direction. Therefore, the apparent section modulus of the ultrasonically welded joint conductor can be improved, and the rigidity of the joint conductor can be improved.

In addition, since the width of the side surfaces of the joint conductors along the facing direction is a predetermined value, it is possible to suppress imbalance in contact area and joint strength between the conductors in the orthogonal direction. Therefore, the conductivity and bonding strength of the bonding conductor can be stabilized.

Further, as an aspect of the present invention, a flat portion formed flat along the orthogonal direction may be provided on the front end side of the regulation surface of the regulation portion in the orthogonal direction.
The flatness described above includes the case of being formed parallel to the regulation surface and the case of being inclined with respect to the regulation surface. That is, on the tip side of the regulation surface, it means a shape in which the opposing surface is not intentionally uneven.

According to the present invention, the tip side of the joining conductor can be formed flat, and the joint between the conductors can be prevented from peeling off from the tip side.
More specifically, when an unintended external force acts in the direction opposite to the bending direction, the curved portion of the bonding conductor that is curved in a wavy shape is likely to separate from the bonding of the conductors. Moreover, when the tip side of the joint conductor is formed in a wave shape, there is a possibility that an unintended external force acts on the wave-like tip portion in the direction opposite to the bending direction.

On the other hand, by providing a flat portion on the front end side of the regulation surface in the orthogonal direction, the front end side of the joint conductor can be formed flat, and the curved portion of the joint conductor curved in a wave shape can be flattened. It is possible to prevent an unintended external force from acting directly on the opposite side of the bending direction. Moreover, even if an unintended external force acts on the tip portion of the joint conductor, the tip portion formed on the plane can absorb the external force, so that the peeling of the joint between the conductors can be suppressed.

Further, as an aspect of the present invention, the horn may be ultrasonically vibrated along a direction in which the pair of restricting portions face each other or in a direction crossing a direction in which the horn and the anvil face each other.
The crossing direction mentioned above is not limited to the facing direction in which the restricting portion faces and the orthogonal direction orthogonal to the moving direction in which the horn and the anvil relatively move, but also includes a direction crossing the orthogonal direction.

According to this invention, the conductors can be joined efficiently.
More specifically, by compressing the conductors arranged in the conductor arrangement space between the horn and the anvil, the contact surfaces of the conductors arranged in the moving direction are compressed along the moving direction (compressing direction). Since the external force acts, the oxide film or the like on the surface of the metal is reliably removed by the ultrasonic vibration, and the conductor is easily welded by the interatomic attractive force of the metal forming the conductor.

In addition, since the conductors are formed in a wave shape that oscillates in the opposite direction as the conductors are oriented in the orthogonal direction by the waveform restricting portion, the conductors arranged in the opposite direction are arranged in a direction intersecting the orthogonal direction. will come into contact with

Therefore, even the conductors arranged side by side in the opposing direction, which are in contact with each other in the direction intersecting the orthogonal direction, are reliably oxidized on the metal surfaces by the ultrasonic vibrations vibrating in the orthogonal direction or the opposing direction. The interatomic attraction of the metals that make up the conductor facilitates welding of the conductor. Thereby, the conductors arranged in the moving direction or the facing direction can be joined efficiently and reliably.

Further, as an aspect of the present invention, a control section may be provided that synchronizes the relative movement of the horn and the restricting section with respect to the anvil and the movement of at least one of the pair of restricting sections relative to the other.
According to this invention, by synchronizing the movement of the horn and the restricting portion in the compression direction with the movement of the restricting portion in the opposing direction, the anvil and the horn compress the conductor before the conductor is compressed. The anvil and the restricting portion can be brought into contact with each other, and the conductor can be reliably prevented from being caught in a gap formed between the anvil and the restricting portion.

Further, as an aspect of the present invention, a compression-side protrusion and a compression-side recess formed in the same shape as the protrusion and the recess are formed on at least one of the contact surface facing the contact surface of the anvil and the contact surface. However, a wavy compression-side wavy portion may be provided that is continuous along the facing direction.

According to the present invention, since the conductor can be curved in a wave shape that oscillates with respect to the moving direction as it moves toward one side of the orthogonal direction, the conductors can be more reliably connected to each other in the opposing direction and the moving direction. can be brought into contact with each other, and the bonding strength can be increased. Therefore, the integrity of the joint conductor can be further improved, and the electrical conductivity and joint strength of the joint conductor can be further improved.

ADVANTAGE OF THE INVENTION By this invention, the conductor joining apparatus and conductor joining method which can improve the joint strength of conductors can be provided.

4 is a schematic perspective view of a joint conductor; FIG. Explanatory drawing of a junction conductor. 1 is a schematic perspective view of a conductor connecting device; FIG. 1 is a schematic exploded perspective view of a conductor connecting device; FIG. Explanatory drawing of a horn. Explanatory drawing of a regulation part. Explanatory drawing of an anvil. Explanatory drawing of a conductor connection apparatus. A flow chart of a conductor connection method. Explanatory drawing of the joining method of a conductor. Explanatory drawing of the joining method of a conductor. The schematic perspective view of the conductor connecting device of other embodiment. Sectional drawing of the conductor connecting device of other embodiment. The schematic perspective view of the joining conductor of other embodiment. Explanatory drawing of the joint conductor of other embodiment. Explanatory drawing of the joint conductor of other embodiment.

An embodiment of a bonding conductor 100 and a conductor bonding apparatus 1 for manufacturing the bonding 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 joint conductor 100, and FIG. 2 shows an explanatory diagram of the joint conductor 100. As shown in FIG. Specifically, FIG. 2(a) shows an enlarged plan view of the joint portion 110 of the joint conductor 100, FIG. 2(b) shows a cross-sectional view along line AA in FIG. 2(a), and FIG. FIG. 2(a) 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 the horn 13 constituting the conductor joining device 1, and FIG. FIG. 7 shows an explanatory diagram of a restricting portion 21 that constitutes the conductor bonding apparatus 1, FIG. 7 shows an explanatory diagram of an anvil 30 that constitutes the conductor bonding apparatus 1, and FIG. .

Here, in FIG. 3, the longitudinal direction of the coated wire 200 is defined as a longitudinal direction X, the width direction of the coated wire 200 and a direction perpendicular to the longitudinal direction X is defined as a width direction Y, and along the longitudinal direction X of FIG. The left side is the +X direction and the right side is the -X direction, and the left side along the width direction Y is the -Y direction and the right side is the +Y direction.
In FIG. 3, the vertical direction is the vertical direction Z, the upper side of FIG. 3 is the +Z direction (upward), and the lower side is the -Z direction (downward).

5A shows an enlarged bottom view of the bottom surface of the horn 13, FIG. 5B shows an enlarged side view of the horn 13 viewed from the +Y side, and FIG. ) shows an enlarged front view of the horn 13 viewed from the +X side. 5(b) and 5(c), only a portion of the horn 13 is enlarged and displayed.

6 and 7 will be described in detail. 6A shows an enlarged plan view of the upper surface of the restricting portion 21, FIG. 6B shows an enlarged side view of the restricting portion 21 viewed from the +Y side, and FIG. is viewed from the +X side. 6(a) and 6(c), only a portion of the restricting portion 21 is enlarged and displayed.
FIG. 7(a) shows a plan view of the anvil 30, and FIG. 7(b) shows an enlarged side view of the anvil upper portion 32 erected on the anvil 30 as seen from the +Y side.

Also, FIG. 8 will be described in detail. FIG. 8(a) shows a schematic front view of the part where the exposed conductor portion 220 is joined in the conductor joining device 1, viewed from the +X direction, and FIG. 8(b) shows a CC sectional view in FIG. 8(a). .

The joint conductor 100 is an integrated conductor obtained by joining the exposed conductor portions 220, which are the tip portions of the plurality of covered electric wires 200, by ultrasonic welding. It is

The covered electric wire 200 is configured by covering a stranded wire conductor formed by twisting aluminum alloy strands with an insulating coating 210 made of an insulating resin. A conductor exposed portion 220 is provided in which the twisted wire conductor is exposed by stripping the length of the wire (see FIG. 3).

The stranded conductor may be made of any material as long as it has electrical conductivity. For example, strands of aluminum, copper, copper alloy, or the like may be twisted together. Further, the exposed conductor portion 220 does not necessarily have to be composed of a twisted wire conductor, and may be composed of a bundle of electrically conductive strands.

The joint conductor 100 bundles a plurality of (nine in this embodiment) covered wires 200 along the longitudinal direction X, and strips and exposes the insulating coating 210 on the tip side (−X side) of the covered wires 200. The joint conductor 100 has a junction 110 in which the exposed conductor portion 220 is fused and joined.

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 (a right side (Y side)) facing each other in the width direction Y. A third surface 131 (a surface formed on the lower side (−Z side)) and a fourth surface 132 (a surface formed on the upper side (+Z side)) facing each other in the vertical direction Z. ) and has a rectangular cross-section, and a flat portion 150 formed in a flat shape is provided at the +X side end and the −X side end of the joint portion 110. ing.

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

The height L1 of the top of the peak 141 relative to the bottom of the valley 142 is approximately 0.20 times the distance between the first surface 121 and the second surface 122, that is, the width L2 of the bonding conductor 100. It is

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

Also, the height L1 of the top of the peak 141 with respect to the bottom of the valley 142 is configured to be approximately 0.6 times the diameter L3, which is the minimum diameter of the exposed conductor portion 220 forming the joint 110. there is

In this embodiment, the height L1 is 0.6 times the diameter L3, but this value is not necessarily required and may be changed as appropriate. From the viewpoint of conductivity, it is preferably 0.5 times or more that of the wire, and more preferably 0.5 times or more that of 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, height L1 is preferably 0.5 times or more of diameter L3, which is the minimum diameter of exposed conductor portion 220 .

Among the waveform portions 140 configured in this manner, four waveform portions 140L provided on the first surface 121 are arranged so that the valley portions 142 and the peak portions 141 are alternately and continuously arranged from the +X side. is provided in

On the other hand, among the wave portions 140, four wave portions 140R provided on the second surface 122 are arranged 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 peak portion 141 arranged on the first surface 121 are arranged to face the peak portion 141 and the valley portion 142 arranged on the second surface 122 along the width direction Y. In other words, the waveform portion 140L and the waveform portion 140R are provided on the first surface 121 and the second surface 122, respectively, with sine waves of the same shape shifted along the longitudinal direction X by a half wavelength.

As shown in FIGS. 2B and 2C, the joint 110 configured in this way has a cross-sectional shape that protrudes from the -Y side to the +Y side as it goes from the -X side to the +X side. The state of protruding to the side is periodically repeated. Therefore, since the apparent section modulus of the joint 110 is improved, the rigidity of the joint 110 is improved.

In addition, as will be described later, the joint conductor 100 is ultrasonically welded by the conductor joining apparatus 1 , so an ultrasonic joint 160 is formed at the interface between the conductors in the cross section of the joint 110 .

Furthermore, the joining portion 110 is provided with a flat portion 150 between the wavy portion 140 disposed at the distal end and the distal end portion in the longitudinal direction X, and the wavy portion 140 disposed at the proximal end and the wavy portion 140 disposed at the proximal end in the longitudinal direction. A planar portion 150 is provided between the proximal ends of the X's.
More specifically, as shown in FIGS. 1 and 2(a), the planar portion 150 is formed to protrude in a planar fashion toward the −X side and the +X side. In other words, the corrugated portion 140 is arranged at a predetermined distance from the tip of the joining conductor 100 .

Next, a conductor joining apparatus 1 for joining the tip side of the exposed conductor portion 220 exposed from the coated wire 200 to manufacture the joining conductor 100 will be described with reference to FIGS. 3 to 8. FIG.
As shown in FIG. 3, the conductor joining device 1 is a device for ultrasonically welding (ultrasonic metal joining) conductor exposed portions 220 exposed from the tip side of a plurality of covered electric wires 200. A plurality of anvils 30 for compressing the exposed conductor portion 220 by the ultrasonic welding tool 10, the pair of width direction adjusting parts 20 fixed on the +X direction side of the ultrasonic welding tool 10, and the ultrasonic welding tool 10 descending. and a control section 40 for controlling the movement of the ultrasonic welding tool 10 and the width direction adjustment section 20 .

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

As shown in FIGS. 3 and 4 , the horn support portion 12 is configured to protrude in the +X direction from the central portion of the elevation portion 11 and support the horn 13 on the elevation portion 11 .
In this embodiment, the horn support portion 12 protrudes from the elevation portion 11 along the longitudinal direction X, but does not necessarily protrude along the longitudinal direction X. For example, the horn support portion 12 protrudes along the width direction Y. It may be configured as That is, in the present embodiment, the projection direction of the horn support portion 12 is configured to be orthogonal to the moving direction of the restricting portion 21, which will be described later. good.

The horn 13 extends downward from the +X direction side end surface of the horn support portion 12 and is configured to be ultrasonically vibrated along the longitudinal direction X by being connected to an ultrasonic oscillator (not shown).
As shown in FIG. 5(a), the horn-side lower surface 13a, which is the bottom surface of the horn 13, has a horn-side concave portion 14 formed to be depressed upward and a horn-side convex portion 15 formed to protrude downward. are provided in a grid pattern along the longitudinal direction X and the width direction Y. As shown in FIG. That is, the bottom surface of the horn 13 is formed 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 includes a horn-longitudinal valley 14a (see FIG. 5B) formed by recessing upward from the horn-side lower surface 13a, and a horn-side recess 14a (see FIG. 5B) formed by recessing upward from the horn-side lower surface 13a. 5(c)), and is formed at the crossing portion thereof.

Further, the horn-side convex portion 15 includes horn longitudinal-direction peak portions 15a (see FIG. 5B) projecting downward from the horn-side lower surface 13a between the horn longitudinal-direction valley portions 14a formed along the longitudinal direction X. ) and a horn width direction crest 15b (see FIG. 5(c)) projecting downward from the horn side lower surface 13a between the horn width direction valleys 14b formed along the width direction Y. and formed at their intersection.

The horn longitudinal troughs 14a and the horn longitudinal ridges 15a are arranged in five rows and six rows, respectively, at equal intervals along the width direction Y. They are arranged in 23 rows and 24 rows at equal intervals along X (see FIG. 5(a)). The horn-side concave portion 14 and the horn-side convex portion 15 arranged in this manner are formed to have a iris shape when viewed from the bottom.

On the +X direction side of the ultrasonic welding tool 10, a pair of width direction adjustment portions 20 arranged opposite to each other include a regulation portion 21 that regulates the movement of the coated wire 200 in the width direction Y, and a regulation portion 21 that is fixed and supported. a fixing portion 23 that indirectly fixes the restricting portion 21 to the lifting portion 11; and a connecting portion 24 that movably connects the fixing support portion 22 to the fixing portion 23. .

The restricting portions 21 are arranged at predetermined intervals along the width direction Y, and as shown in FIGS. The height along the direction Z is sufficiently long compared to three times the outer diameter of the exposed conductor portion 220, and the restricting surface 26 is provided so as to face the opposing restricting portion 21. ing.

In the present embodiment, the height of the restricting portion 21 is sufficiently long compared to three times the outer diameter of the exposed conductor portion 220, but it does not need to be three times the outer diameter of the exposed conductor portion 220. It is sufficient that the length is sufficiently longer than the total outer diameter of the electric wire bundle formed by the plurality of conductor exposed portions 220 to be ultrasonically welded.

A restriction movement assisting portion 25 that engages with the horn-side concave portion 14 and the horn-side convex portion 15 to assist movement of the restriction portion 21 in the width direction Y is formed on the upper end surface of the restriction portion 21 .

The restricting movement assisting portion 25 is composed of a movement assisting portion 251 that slightly protrudes upward from the upper end side of the restricting surface 26 and an upper recessed portion 252 that is recessed downward on the outer side of the movement assisting portion 251 in the width direction Y. It is configured. Further, the movement assisting portion 251 has a plurality of regulating portion-side convex portions 253 that protrude upward and are arranged along the longitudinal direction X. As shown in FIG.

The restricting portion-side convex portion 253 is about half the height of the horn longitudinal direction valley portion 14a and the horn longitudinal direction peak portion 15a, and the width formed by the three restricting portion side convex portions 253 is It is configured to be slightly smaller than the width of the horn longitudinal direction ridges 15a (horn longitudinal direction troughs 14a), and the width of the longitudinal direction is corresponding to the horn longitudinal direction troughs 14a and the horn longitudinal direction ridges 15a. 18 pieces are arranged at regular intervals along X.

The restricting portion-side convex portion 253 configured in this manner provides a slight gap between the horn longitudinal direction valley portion 14a and the horn longitudinal direction peak portion 15a in a state in which the horn 13 and the restricting portion 21 are engaged with each other. can absorb the amplitude in the longitudinal direction X direction due to ultrasonic vibration.

As shown in FIG. 6(a), on the regulating surface 26 provided at the opposing portion of the regulating portion 21 that forms a pair, there are a sinusoidal waveform regulating portion 27 in a plan view and a longitudinal direction X of the waveform regulating portion 27. Flat portions 28 are provided at both ends.

The waveform restricting portion 27 includes a restricting portion-side convex portion 271 protruding to a predetermined height toward the opposing restricting surface 26 side, and a restricting portion-side protruding portion 271 projecting in a direction opposite to the projecting direction of the restricting portion-side convex portion 271 . Restriction-side concave portions 272 recessed to the same depth as the height of the portion 271 are formed alternately and continuously in a smooth manner (see FIG. 6A). In addition, four waveform restricting portions 27 are alternately and continuously arranged along the longitudinal direction X. As shown in FIG.

In this way, the waveform restricting portions 27 provided on the opposing restricting surfaces 26 each have a restricting portion-side convex portion 271 and a restricting portion-side recessed portion 272 , and the restricting portion-side recessed portions 272 provided on the other restricting surface 26 facing each other. and the restricting portion-side convex portion 271 .

That is, the waveform formed by the restricting portion-side convex portion 271 and the restricting portion-side concave portion 272 on the +Y side restricting surface 26 (hereinafter referred to as the restricting surface 26R) and the −Y side restricting surface 26 (hereinafter referred to as the restricting surface 26L). ) are shifted from each other by a half wavelength.

In the present embodiment, there are four restricting-side protrusions 271 and four restricting-side recesses 272 formed on the restricting surface 26. However, the number is not limited to this, and the method of using the conductor bonding apparatus 1 and The number of shapes and sizes can be adjusted as appropriate.
The flat portions 28 are flat surfaces formed along the vertical direction Z and the longitudinal direction X on both end sides in the longitudinal direction X of the waveform restricting portion 27 .

As shown in FIGS. 3 and 4, the outer side of the restricting portion 21 configured in this manner 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 passes through the fixing portion 23 fixed to the lifting portion 11 along the width direction Y and has one end fixed to the fixing support portion 22. , and is movable in the width direction Y by a width direction movement motor (not shown) controlled by the control unit 40 .

That is, the connecting portion 24 connects the fixed support portion 22 and the fixed portion 23, and is configured to allow the fixed support portion 22 to which the restricting portion 21 is fixed to the fixed portion 23 to move along the width direction Y. there is
Since the fixing portion 23 is fixed to the lifting portion 11 , the restricting portion 21 and the fixed support portion 22 are indirectly fixed to the lifting portion 11 .

A control unit 40 for controlling an elevation motor and a width direction movement motor (not shown) is configured to synchronize and drive the elevation motor and the width direction movement motor. , the opposingly arranged restricting portions 21 can be moved along the width direction Y at the same time.
Note that the restricting portion 21 can also be independently moved along the width direction Y under the control of the control portion 40 .

The anvil 30 is a rectangular parallelepiped receiving jig provided on the substrate of the conductor bonding apparatus 1. The anvil 30 has a movable base 31 configured to be movable along a rail 50 described later, and a movable base 31 erected on the movable base 31. Anvil upper part 32 .

The anvil upper portion 32 is configured such that its length in the width direction Y is slightly longer than the length in the width direction Y of the wire bundle formed by the plurality of conductor exposed portions 220 to be ultrasonically welded, and The anvil main surface 321, which is the main surface of the upper anvil portion 32, faces the width direction Y and is erected at the upper portion of the movable base portion 31. As shown in FIG.

The anvil main surface 321 is formed with anvil-side corrugated portions 33 continuously arranged along the longitudinal direction X. As shown in FIG. The anvil-side corrugated portion 33 is composed of an anvil-side convex portion 331 that protrudes outward in the width direction Y from the anvil main surface 321 and an anvil-side concave portion 332 that is recessed inside the anvil main surface 321 . .

The anvil-side protrusion 331 is formed to fit with the restriction-side recess 272 , and the anvil-side recess 332 is formed to fit with the restriction-side protrusion 271 . That is, the amplitude of the anvil-side waveform portion 33 is formed to have a sine wave shape in a plan view in which the amplitude is equal to the amplitude of the waveform restricting portion 27 .

The anvil-side corrugated portion 33, in which the anvil-side convex portion 331 and the anvil-side concave portion 332 configured in this manner are continuously arranged, is formed in a sinusoidal shape in a plan view, as shown in FIG. 7(a). , and four of them are continuously arranged along the longitudinal direction X.

Further, the anvil-side waveform portion 33 is provided on both surfaces of the anvil main surface 321 facing the width direction Y, and the anvil-side waveform portion 33 (anvil-side waveform portion 33R) provided on the +Y side and the -Y side are provided. and the anvil-side waveform portion 33 (anvil-side waveform portion 33L) provided at . That is, the anvil-side waveform portion 33R is provided in the order of the anvil-side recess 332 and the anvil-side protrusion 331 from the +X side, and the anvil-side waveform portion 33L is provided in the order of the anvil-side protrusion 331 and the anvil-side recess 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 on the anvil-side waveform portion 33L are regulated with respect to the anvil 30 so as to face the regulating portion-side concave portion 272 and the regulating portion-side convex portion 271 provided on the regulating 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 arranged with the anvil 30 so as to face the restricting portion-side concave portion 272 and the restricting portion-side convex portion 271 provided on the restricting surface 26R. 21R of regulation parts are arranged.

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

In addition, flat portions 35 having a length of about half the wavelength of the sine wave formed by the anvil-side corrugated portion 33 are formed in a flat portion 35 on the front end side and the rear end side of the anvil-side uneven portion 34 in the longitudinal direction X. provided along.

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

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

As shown in FIGS. 3 and 8, in the ultrasonic welding tool 10 and the width direction adjusting portion 20 configured as described above, the restricting portion-side convex portion 253 is loosely fitted to the horn-side concave portion 14 and the horn-side convex portion 15. As a result, the restricting portion 21 can be moved along the horn-side lower surface 13a.

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

In this way, the conductor joining device 1 in which the width direction adjusting portion 20 is fixed to the ultrasonic welding tool 10 so that the restricting portion 21 can move along the width direction Y, and the anvil 30 is arranged below the horn 13. , the ultrasonic welding tool 10 and the width direction adjusting portion 20 can be moved downward by the lifting motor under the control of the control portion 40 in a state in which the exposed conductor portion 220 is inserted into the arrangement space S. The restricting portion 21 can be moved along the width direction Y by the motor.

A method for manufacturing the joint conductor 100 using the conductor joint apparatus 1 will be briefly described below with reference to FIGS. 9 to 11. FIG.
Here, FIG. 9 shows a flowchart of a conductor joining method for melting and joining the exposed conductor portions 220 of a plurality of (nine in this embodiment) covered electric wires 200, and FIG. ) is inserted into the arrangement space S, and the restricting portion 21 is moved along the width direction Y. FIG. The explanatory view explaining the conductor joining method which joins the exposed part 220 is shown.

10(a) is an enlarged plan view of the restricting portion 21 and the anvil 30 before the exposed conductor portion 220 is inserted, and FIG. 10(b) is an enlarged plan view of the restricting portion 21 after the exposed conductor portion 220 is inserted. FIG. 10(c) shows a schematic plan view of the exposed conductor portion 220 compressed in FIG. 10(b). .

FIG. 11(a) shows a DD cross-sectional view with the conductor exposed portion 220 inserted into the arrangement space S, and FIG. 11(b) shows the ultrasonic welding tool with the conductor exposed portion 220 inserted into the arrangement space S. 10 and the width direction adjusting portion 20 are lowered and the compressed exposed conductor portion 220 is ultrasonically welded to the DD sectional view.
11, illustration of the horn-side concave portion 14 and the horn-side convex portion 15 is omitted.

As shown in FIG. 9, the exposed conductor portion 220 provided at the terminal portion of the coated wire 200 is formed by a wire placement step s1 for placing the exposed conductor portion 220 in the placement space S, the ultrasonic welding tool 10 and the width direction adjustment portion. 20, a conductor compression step s3 for compressing the exposed conductor portion 220 with the horn 13 and the anvil 30, and an ultrasonic welding step s4 for melting and joining the compressed exposed conductor portion 220 by ultrasonic waves. and are performed in this order, they are electrically connected.
The conductor compression step s3 and the ultrasonic welding step s4 can be performed simultaneously.

Each step will be described in detail below with reference to FIGS. 10 and 11. FIG.
A plurality of (nine 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 wire 200 is cut off by a predetermined length, and the insulating coating 210 is removed. A conductor exposed portion 220 is formed by exposing the stranded conductor surrounded by .

Next, an anvil 30 suitable for the number and outer diameter of the exposed conductor portions 220 to be connected 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. position. The anvil 30a is arranged below the ultrasonic welding tool 10 here.
Subsequently, the regulating portion 21 is moved along the width direction Y until the regulating surface 26 reaches a predetermined distance, and the ultrasonic welding tool 10 is raised until the horn 13 reaches a predetermined height, thereby closing the arrangement space S. Form.

In this state, as shown in FIG. 10(a), the exposed conductor portions 220 are arranged in the arrangement space S formed by the regulating portion 21 and the horn 13 which are arranged to face each other with a predetermined interval therebetween. Insert from the direction side toward the -X direction side (wire arrangement step s1). In the present embodiment, a total of nine conductor exposed portions 220 are inserted into the arrangement space S, with three conductor exposed portions 220 arranged in the vertical direction Z and three conductor exposed portions 220 arranged in the width direction Y. Join.

Under the control of the control unit 40, the ultrasonic welding tool 10 is lowered, and in synchronism with the lowering of the ultrasonic welding tool 10, the restricting part 21 is moved along the width direction Y toward the exposed conductor part 220 side. As a result, as shown in FIGS. 10B and 11A, the restricting surface 26 abuts both side surfaces of the anvil upper portion 32 in the width direction Y, and the exposed conductor portion 220 extends from the horn-side lower surface 13a and the anvil. It is sandwiched between the side upper surface 322 and the exposed conductor portion 220 is pressed from above by the horn 13 . (Compression movement step s2).

More specifically, the compression movement step s2 will be described in detail. In a state in which the exposed conductor portion 220 is arranged in the arrangement space S formed between the horn-side lower surface 13a, the anvil-side upper surface 322, and the pair of restricting surfaces 26, the ultrasonic wave is By lowering the welding tool 10 and moving the restricting portion 21 along the horn-side lower surface 13 a toward the exposed conductor portion 220 , the waveform restricting portion 27 provided on the restricting surface 26 and the anvil main surface 321 provided on the main surface 321 are separated. The anvil-side corrugated portion 33 is fitted to each other.

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

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

Subsequently, by further lowering the ultrasonic welding tool 10 (conductor compressing step s3), the exposed conductor portion 220 is pressed by the horn 13 and deformed to expand in the width direction Y. 27 is fitted to the anvil upper portion 32, the exposed conductor portion 220 is brought into contact with the restricting surface 26. As shown in FIG.

Further, when the exposed conductor portion 220 is pressed against the horn 13, as shown in FIG. Waveforms are formed continuously along the longitudinal direction X at locations corresponding to the side surfaces of the electric wire 200 .

In this manner, by further lowering the horn 13 with the covered wires 200 arranged in the arrangement space S, the exposed conductor portion 220 can be compressed in the vertical direction Z (conductor compression step s3). The conductor exposed portions 220 arranged in Z can be brought into contact with each other more reliably. In addition, since the exposed conductor portion 220 is compressed while being in contact with the regulation surface 26, the exposed conductor portion 220 is formed in a wavy shape along the longitudinal direction X. As shown in FIG. As a result, the exposed conductor portions 220 arranged in parallel along the width direction Y can be brought into contact with each other in the direction crossing the longitudinal direction X (the width direction Y), and the compression ensures that the exposed conductor portions 220 are in contact with each other. can be made

It is an important issue in manufacturing the joint conductor 100 to ensure that the exposed conductor portions 220 are brought into contact with each other and joined together in this way to ensure reliable conductivity. Further, for example, in recent years, with the demand for weight reduction of vehicles, it has become necessary to join high-strength alloyed electric wires. These high-strength materials are difficult to deform, making it difficult to bring the exposed conductor portions 220 into contact with each other more reliably.

In order to ensure that the exposed conductor portions 220 are brought into contact with each other and joined, for example, as a manufacturing process in the present embodiment, in the conductor compression step s3, weaker ultrasonic vibration is performed than during welding in the ultrasonic welding step s4, which will be described later. Alternatively, the conductor compression step s3 may be performed while increasing the temperature of the material to reduce the strength. The same object can also be achieved, for example, by performing ultrasonic vibration weaker than that during welding immediately before the ultrasonic welding step s4 after the conductor compression step s3.

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

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

In this state, the horn 13 is ultrasonically vibrated along the longitudinal direction X intersecting the width direction Y, whereby 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 controller 40 may control to determine the bottom dead center (stop point) in the vertical direction Z during welding. As a result, a sudden rise in the temperature of the exposed conductor portion 220 during welding is suppressed, and adhesion to the horn 13 is suppressed.

Further, the ultrasonic vibration may be continued even after reaching the bottom dead center during 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 are kept in contact with each other and maintained at a high temperature. This further improves conductivity and rigidity. The height of the bottom dead center is preferably smaller than the height formed in the conductor compression step s3. Less than 100% height to be filled is desired. If it is 100% or less, the above object can be achieved, but 90% or less and 70% or more is preferable. More preferably between 85% and 80%. If the compression is too small, it is difficult to achieve the above object, and if the compression is too large, the cross-sectional area of the root portion of the wire becomes small and the strength becomes weak, which is not preferable.

As described in the present embodiment, even if the wavy restricting portion 27 is not formed on the regulating surface 26 of the regulating portion 21, that is, the side surface of the joint portion 110 of the joint conductor 100 to be manufactured is corrugated. Even if the shaped corrugated portion 140 is not formed, the exposed conductor portions can be reliably brought into contact with each other and joined, and the conductivity of the joint conductor can be ensured.

As a result, the nine exposed conductor portions 220 pressurized so as to form a wavy shape along the longitudinal direction X in the interior of the arrangement space S are adjacent to each other along the longitudinal direction X and the width direction Y. Ultrasonic welding is performed while the exposed portions 220 are securely brought into contact with each other, so that the joint conductor 100 with improved conductivity and rigidity can be manufactured (see FIG. 11(b)).

In this way, the conductor joining device 1 that joins a plurality of exposed conductor portions 220 by ultrasonic welding includes the ultrasonic welding tool 10 that has the horn-side lower surface 13a in contact with the exposed conductor portions 220 and vibrates ultrasonically; A pair of restricting portions 21 contacting the horn-side lower surface 13a and relatively movable along the horn-side lower surface 13a, and an anvil 30 relatively moving in the vertical direction Z to approach or separate from the horn-side lower surface 13a. are provided on each of the regulating surfaces 26 facing each other in the pair of regulating portions 21, the regulating portion-side convex portion 271 projecting toward the other regulating surface 26 facing each other, and the projecting direction of the regulating portion-side convex portion 271 The wavy wavy restricting portion 27 is formed in which the regulating portion side concave portion 272 recessed in the opposite direction is continuous along the longitudinal direction X orthogonal to the width direction Y and the vertical direction Z in which the pair of regulating surfaces 26 face each other. The anvil 30 is provided with an anvil-side projection 331 and an anvil-side recess 332 that fit into the restriction-side projection 271 and the restriction-side recess 272, and is sandwiched between the restriction portions 21 facing each other. By moving the welding tool 10 and the restricting portion 21 relative to the anvil 30 and at least one of the pair of restricting portions 21 moving toward the other, the bonding strength between the exposed conductor portions 220 can be improved. can.

More specifically, the restricting surface 26 is formed with a corrugated wave restricting portion 27, and the anvil 30 is provided with an anvil-side convex portion 331 and an anvil-side recessed portion 332 formed so as to be fittable with the corrugated restricting portion 27. As a result, the horn 13 moves relative to the anvil 30 , and the plurality of exposed conductor portions 220 are compressed by the anvil 30 and the horn 13 .

In addition, since the restricting portion 21 moves inward in the width direction Y in accordance with the relative movement of the horn 13, the restricting portion 21 restricts the movement of the conductor outward in the width direction Y, and moves the exposed conductor portion 220 in the longitudinal direction. It can be curved in a wavy shape that oscillates in the width direction Y along the X direction.

By curving the exposed conductor portions 220 in a wave shape that oscillates in the width direction Y in this way, the exposed conductor portions 220 arranged side by side along the width direction Y are bent along the direction intersecting the longitudinal direction X. The exposed conductor portions 220 can be reliably brought into contact with each other. Therefore, by joining the exposed conductor portions 220 by ultrasonic welding, the joint strength between the exposed conductor portions 220 arranged along the width direction Y can be increased, and the integrity of the joint conductor 100 can be improved. can be made

Therefore, the conductivity and bonding strength of the bonding conductor 100 can be improved. In addition, since the joint strength between the exposed conductor portions 220 is improved, the rigidity of the manufactured joint conductor 100 as a whole can also be improved.

Further, since the waveform restricting portion 27 is formed in a sinusoidal shape, the end portion in the width direction Y of the arrangement space S formed by the horn 13, the restricting portion 21, and the anvil 30 is formed in an arc shape, so that the conductor is exposed. The portion 220 can be curved along the longitudinal direction X to form a wave shape. As a result, the exposed conductor portions 220 arranged in the width direction Y can be brought into continuous contact with each other, and the exposed conductor portions 220 can be reliably brought into contact with each other, and the bonding strength can be increased. In addition, it is possible to prevent the formation of a corner portion that weakens the joint in the joint conductor 100 during compression and ultrasonic welding.

Furthermore, since the conductor exposed portion 220 can be formed in a smooth wave shape along the longitudinal direction X by the waveform restricting portion 27, the anvil side convex portion 331 can be formed in a rectangular shape as in the case where the anvil side convex portion 331 is formed in a rectangular shape. It is possible to prevent the exposed conductor portion 220 from being cut by the exposed conductor portion 220 caused by the corner 331 , thereby reliably improving the conductivity and rigidity of the joint conductor 100 .

Furthermore, since a plurality of waveform restricting portions 27 are provided along the longitudinal direction X, the conductor is formed in a waveform that periodically repeats its amplitude in the width direction Y as it moves toward one side of the longitudinal direction X. Since the exposed portions 220 can be curved, the exposed conductor portions 220 arranged in the width direction Y can be brought into contact with each other periodically in a direction intersecting the longitudinal direction X, and the exposed conductor portions 220 can be brought into contact with each other. more reliable contact.

Accordingly, the bonding strength can be further improved by ultrasonically bonding the exposed conductor portion 220 . Therefore, the integrity of the joint portion of the exposed conductor portion 220 can be further improved, and the conductivity of the joint conductor 100 can be further improved.

Further, the waveform regulating portion 27 is formed on both of the regulating surfaces 26 (regulating surfaces 26R and 26L) facing each other in the pair of regulating portions 21, and the waveform regulating portion 27 formed on the regulating surface 26L is referred to as a waveform regulating portion 27L. , the waveform restricting portion 27 formed on the restricting surface 26R is referred to as a waveform restricting portion 27R, the waveform restricting portion 27L and the waveform restricting portion 27R are configured with the same waveform, and the restricting portion-side convex portion 271 of the waveform restricting portion 27L is a waveform restricting portion 27R. By facing the restricting portion-side recessed portion 272 of the restricting portion 27R and facing the restricting portion-side convex portion 271 of the waveform restricting portion 27R, the restricting portion-side recessed portion 272 of the waveform restricting portion 27L faces the restricting portion-side convex portion 271 of the waveform restricting portion 27R. Since the formed waveform regulating portion 27L and the waveform regulating portion 27R formed on the regulating surface 26R are configured to be shifted by half a wavelength, the joint conductor 100 curved by the waveform regulating portion 27L and the waveform regulating portion 27R has a longitudinal direction. It is formed in a wave shape that oscillates in the width direction Y while having a predetermined width with respect to the width direction Y as it goes to one side in the direction X. As shown in FIG. Therefore, the apparent section modulus of the ultrasonically welded joint conductor 100 can be improved, and the rigidity of the joint conductor 100 can be improved.

In addition, since the width length (length L2) between the side surfaces (the first surface 121 and the second surface 122) of the joining conductor 100 along the width direction Y is a predetermined value, the exposed conductor portion in the longitudinal direction X Imbalance in contact area and bonding strength between 220 can be suppressed. Therefore, the conductivity and bonding strength of the bonding conductor 100 can be stabilized.

A flat portion 28 formed flat along the longitudinal direction X is provided on the tip side of the restricting surface 26 of the restricting portion 21 in the longitudinal direction X, so that the tip side of the joining conductor 100 is formed in a planar shape. Therefore, it is possible to prevent the bonding between the exposed conductor portions 220 from being peeled off from the tip side.

More specifically, when an unintended external force acts in the direction opposite to the bending direction, the curved portion of the bonding conductor 100 that is curved in a wave shape is likely to separate the exposed conductor portions 220 from each other. Moreover, when the tip side of the joining conductor 100 is formed in a wave shape, there is a possibility that an unintended external force acts on the wave-like tip portion in the opposite direction to the bending direction.

On the other hand, by providing the flat portion 28 on the front end side of the longitudinal direction X of the regulating surface 26, the front end side of the joint conductor 100 can be formed flat, and the curved portion of the joint conductor 100 that is curved in a wavy shape can be formed. It is possible to prevent an unintended external force from acting directly on the side opposite to the bending direction. In addition, even if an unintended external force acts on the tip portion of the joint conductor 100, the tip portion formed on the plane can absorb the external force, so that peeling of the joint between the exposed conductor portions 220 can be suppressed.

In addition, the ultrasonic welding tool 10 is ultrasonically vibrated along a direction (longitudinal direction X) intersecting the direction in which the ultrasonic welding tool 10 and the anvil 30 face each other (vertical direction Z), thereby causing the exposed conductor portion 220 to move. can be joined efficiently.

More specifically, the exposed conductor portions 220 arranged in the arrangement space S are compressed by the ultrasonic welding tool 10 and the anvil 30, and the exposed conductor portions 220 arranged in the vertical direction Z are vertically compressed on the horn-side lower surface 13a. An external force acts along the direction Z (compressing direction).

In addition, since the ultrasonic welding tool 10 and the anvil 30 compress the exposed conductor portion 220, the exposed conductor portion 220 tries to expand in the width direction Y, but the waveform restricting portion 27 prevents the exposed conductor portion 220 from expanding in the width direction. Movement in the Y direction is restricted, and it is arranged so as to curve in the width direction Y as it goes in the longitudinal direction X. As shown in FIG. As a result, the exposed conductor portions 220 aligned in the width direction Y are brought into contact with each other more reliably, and the horn-side lower surface 13a is formed along the direction intersecting the longitudinal direction X. As shown in FIG.

In this state, by ultrasonically vibrating the ultrasonic welding tool 10 in the longitudinal direction X, the exposed conductor portions 220 arranged in the vertical direction Z where the external force acts on the exposed conductor portions 220 are vibrated by ultrasonic vibration. The oxide film or the like on the metal surface of the exposed conductor portion 220 to which the external force is acting is reliably removed, and the exposed conductor portion 220 is easily welded by the interatomic attractive force of the metal forming the exposed conductor portion 220 .

In addition, since the exposed conductor portions 220 arranged in the width direction Y are also curved to form the horn-side lower surface 13a along the direction intersecting with the longitudinal direction X, the exposed conductor portions 220 are moved by ultrasonic vibration. The oxide film or the like on the surface of the metal is reliably removed, and the exposed conductor portion 220 is easily welded due to the interatomic attractive force of the metal forming the exposed conductor portion 220 . As a result, the exposed conductor portions 220 aligned in the vertical direction Z or the width direction Y can be joined efficiently and reliably.

In the present embodiment, the horn 13 is configured to ultrasonically vibrate along the longitudinal direction X. However, it is configured to ultrasonically vibrate not only in the longitudinal direction X, but also in the width direction Y or a direction intersecting the longitudinal direction X. good too.
Further, in the present embodiment, the anvil main surface 321 faces the width direction Y and the restricting portion 21 is configured to move along the width direction Y, but this configuration is not necessarily required. The main surface 321 may face the longitudinal direction X orthogonal to the width direction Y, and the restricting portion 21 may be configured to move along the longitudinal direction X orthogonal to the width direction Y. Furthermore, the anvil main surface 321 may face in the direction intersecting the width direction Y, and the restricting portion 21 may be configured to move along the direction in which the anvil main surface 321 faces. That is, the direction of ultrasonic vibration of the horn 13 and the longitudinal direction of the coated wire 200 may coincide or may cross each other.

In addition, by providing the control unit 40 for synchronizing the relative movement of the ultrasonic welding tool 10 and the restricting part 21 with respect to the anvil 30 and the movement of at least one of the pair of restricting parts 21 with respect to the other, that is, the ultrasonic welding tool 10 And by synchronizing the movement of the restricting portion 21 in the compression direction and the movement of the restricting portion 21 in the width direction Y, before the anvil 30 and the ultrasonic welding tool 10 compress the exposed conductor portion 220 The anvil 30 and the restricting portion 21 can be brought into contact with each other, and the exposed conductor portion 220 can be reliably prevented from being caught in the gap formed between the anvil 30 and the restricting portion 21 .

In correspondence with the configuration of this invention and the above-described embodiments,
The conductor corresponds to the exposed conductor portion 220,
The contact surface corresponds to the horn-side lower surface 13a,
The facing direction corresponds to the width direction Y,
the orthogonal direction corresponds to the longitudinal direction X,
The convex portion corresponds to the regulating portion side convex portion 271,
The concave portion corresponds to the restricting portion side concave portion 272,
The fitting projection corresponds to the anvil-side projection 331,
The fitting recess is the anvil-side recess 332
The first waveform regulation portion corresponds to the waveform regulation portion 27R,
The second waveform regulation portion corresponds to the waveform regulation portion 27L,
The opposing contact surface corresponds to the anvil-side upper surface 322,
The conductor placement step corresponds to the wire placement step s1,
The moving compression step corresponds to the compression moving step s2, but
The present invention is not limited to the configurations of the above-described embodiments, and many embodiments can be obtained.

For example, in the present embodiment, the exposed conductor portion 220 is a stranded conductor formed by twisting conductive strands, but is not limited to this form. may be bundled. Moreover, the exposed conductor portion 220 is not limited to an aluminum-based material made of aluminum, an aluminum alloy, or the like, and may be made of, for example, copper or a copper alloy. In other words, any material may be used as long as it has conductivity.

In addition, the conductor exposed portion 220 is exposed by cutting off the insulating coating 210 forming the outer layer at one end of the covered wire 200 covered with the insulating insulating coating 210, but is not covered with the insulating coating 210. A conductor or a conductor that is simply a bundle of wires may be used.

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

Moreover, the waveform restricting portion 27 may be formed on only one of the paired restricting surfaces 26 instead of being present on both of the restricting surfaces 26 . In addition to the case where it is formed on the entire surface of the regulation surface 26, it may be formed on a part of it.
Furthermore, the corrugated portion 140 may have at least one ridge 141 and one or more troughs 142 continuous along the longitudinal direction X. For example, at least one ridge 141 and at least one trough 142 may be continuous. If so, the numbers of peaks 141 and valleys 142 need not match.

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

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

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

The compression-side corrugated portion 37 is composed of a compression-side convex portion 371 that protrudes upward compared to the flat portion 35 and a compression-side concave portion 372 that is recessed downward. 4 are arranged in a row. In other words, the compression-side protrusions 371 and the compression-side recesses 372 are continuously arranged alternately along the longitudinal direction X. As shown in FIG.

On the other hand, as shown in FIG. 13, the bottom surface of the horn 13 is provided with a wavy bottom portion 13b projecting downward. and a horn width direction crest 15c protruding downward in an arc.

Further, instead of the restricting movement assisting portion 25, a moving waveform portion 29 is formed in the restricting portion 21 formed so as to be movable in the width direction Y along the waved bottom surface portion 13b. The movement-assisting wavy portion 29 is composed of a movement-assisting convex portion 291 that can be loosely fitted to the horn width-direction trough portion 14c, and a movement-assisting recessed portion 292 that can be loosely fitted to the horn width-direction peak portion 15c. there is The movement-assisting convex portion 291 and the movement-assisting recessed portion 292 are formed in a continuous substantially sine wave shape in a side view.

With the conductor bonding apparatus 1x configured in this way, ultrasonic bonding can be performed not only in the width direction Y but also along the vertical direction Z while the exposed conductor portion 220 is formed in a wavy shape. It is possible to manufacture the bonding conductor 100x in which not only the first surface 121 and the second surface 122 along, but also the third surface 131 and the fourth surface 132 along the vertical direction Z are formed for corrugation.

The junction conductor 100x will be briefly described below with reference to FIGS. 14 to 16. FIG.
14 shows a schematic perspective view of the joint conductor 100x, and FIG. 15 shows a plan view (FIG. 15(a)) and a side view (FIG. 15(b)) of the joint conductor 100x. 16 is a plan view of the EE cross section (FIG. 16(a)), a plan view of the FF cross section (FIG. 16(b)), and a plan view of the GG cross section (FIG. FIG. 16(c)) and a plan view of the HH cross section (FIG. 16(d)).

As shown in FIGS. 14 and 15, the joining conductor 100x has a wavy shape not only on the first surface 121 and the second surface 122 but also on the third surface 131 and the fourth surface 132 (the third surface 131 and the fourth surface 132). Four other-side waveform portions 170 are continuously provided along the longitudinal direction X, and are formed in a sine wave shape when viewed from the side.
More specifically, the other-side waveform portion 170 includes the other-side peak portion 171 that protrudes outward in the vertical direction Z with respect to the third surface 131 and the fourth surface 132, and the third surface 131 and the fourth surface 132. and the other-side troughs 172 recessed inward in the vertical direction Z, and the other-side ridges 171 and the other-side troughs 172 are continuously and alternately arranged.

As shown in FIG. 16, the bonding conductor 100x configured in this manner moves from −X to +X along the longitudinal direction X from a state in which the peak portion 141 protrudes toward the −Y side in the width direction Y. (See FIG. 16(a)), the peak portion 141 does not protrude (see FIG. 16(b)), and then the peak portion 141 protrudes toward the +Y side (see FIG. 16(c)). , the peak portion 141 does not protrude (see FIG. 16(d)).

Similarly, along the longitudinal direction X from -X to +X with respect to the vertical direction Z, from the state in which the other-side peak portion 171 protrudes to the side (see FIG. 16B), the other-side peak portion 171 protrudes upward (+Z side) (see FIG. 16(b)), the other-side peak 171 does not protrude (see FIG. 16(c)), and the other-side peak 171 protrudes downward ( -Z side) (see FIG. 16(d)).

That is, along the longitudinal direction X from -X to +X, the peak portion 141 and the other-side peak portion 171 protrude spirally. The section modulus is improved, and the rigidity can be improved.
The horn width direction valley portion 14c, the horn width direction peak portion 15c, and the compression side waveform portion 37 are provided on the waved bottom portion 13b, which is the bottom portion of the horn 13, and on the anvil side upper surface 322, respectively. , the compression-side corrugated portion 37 may be provided only on one of the anvil-side upper surfaces 322 .

In this way, in the third surface 131 and the fourth surface 132 facing each other in the orthogonal cross section, the other-side peak portion 171 projecting outward and the restricting portion side recessed inward are formed on the third surface 131 and the fourth surface 132 . The concave portion 272 is continuous along the longitudinal direction X, and the corrugated other side corrugated portion 170 is formed. The conductor exposed portions 220 on the surface 131 and the fourth surface 132 can be reliably brought into contact with each other. Thereby, the integrity of the joint conductor 100 can be further improved, and the conductivity and joint strength of the joint conductor 100 can be further improved.

13a Horn-side lower surface 121 First surface 122 Second surface 131 Third surface 132 Fourth surface 271 Regulating portion-side convex portion 272 Regulating portion-side concave portion 27r Waveform-regulating portion 27l Waveform-regulating portion 220 Conductor exposed portion 322 Anvil-side upper surface s1 Wire arrangement Configuration s2 Compression moving step s3 Conductor compression step s4 Ultrasonic welding step

Claims (9)

A conductor joining device for joining a plurality of conductors by ultrasonic welding,
a horn having a contact surface in contact with the conductor and vibrating ultrasonically;
a pair of restricting portions that abut against the contact surface and are configured to be relatively movable along the contact surface;
An anvil configured separately from the horn and corresponding to the number and outer diameter of each of the plurality of conductors to be connected is provided,
a pair of the regulating portions fixed to the horn so as to be movable along the opposing direction of the regulating surfaces facing each other;
The anvil is configured to be arranged at a position facing the contact surface, and is configured to move relative to the contact surface in a moving direction toward or away from the contact surface at a position facing the contact surface. ,
On at least one of the regulating surfaces facing each other in the pair of regulating portions,
a convex portion protruding toward the other opposing regulation surface and a concave portion recessed in a direction opposite to the projection direction of the convex portion are continuous along an orthogonal direction orthogonal to the facing direction and the moving direction; A wave-shaped wave restricting portion is formed,
On the main surface of the anvil facing the opposite direction,
A fitting concave portion and a fitting convex portion that fit into the convex portion and the concave portion of the restricting portion are provided along the orthogonal direction,
The restricting portion is configured to move relative to the anvil so that the anvil is sandwiched between the restricting surfaces facing each other, and at least one of the pair of restricting portions moves toward the other ;
The anvil arranged at a position facing the contact surface forms an arrangement space through which the plurality of conductors are inserted by the contact surface and the pair of restricting portions.
Conductor splicing equipment. 2. The conductor joining apparatus according to claim 1, wherein said waveform restricting portion is formed in a sinusoidal shape. 3. The conductor joining device according to claim 1, wherein a plurality of said waveform restricting portions are provided along said orthogonal direction. the waveform restricting portions are formed on both opposing restricting surfaces of the pair of restricting portions;
The waveform restricting portion formed on one of the restricting surfaces is defined as a first waveform restricting portion,
The waveform restricting portion formed on the other side is defined as a second waveform restricting portion,
The first waveform regulating portion and the second waveform regulating portion are configured with the same waveform,
A convex portion of the first waveform restricting portion faces a concave portion of the second waveform restricting portion, and a concave portion of the first waveform restricting portion faces a convex portion of the second waveform restricting portion. 4. The conductor joining device according to claim 3. 5. The conductor joint according to any one of claims 1 to 4, wherein a flat portion formed flat along the orthogonal direction is provided on the tip end side of the regulation surface of the regulation portion in the orthogonal direction. Device. The horn
6. The conductor joint according to any one of claims 1 to 5, wherein the ultrasonic vibration is performed in a direction in which the pair of restricting portions face each other or in a direction crossing the direction in which the horn and the anvil face each other. Device. 7. The apparatus according to any one of claims 1 to 6, further comprising a control section for synchronizing relative movement of said horn and said restricting section with respect to said anvil and movement of at least one of said pair of restricting sections with respect to the other. conductor splicing equipment. On at least one of the contact surface facing the contact surface of the anvil and the contact surface, a compression-side protrusion and a compression-side recess formed in the same shape as the protrusion and the recess are formed along the facing direction. 8. The conductor joining device according to claim 1, further comprising a wavy compression side wavy portion that is continuous with the wavy portion. A horn that has a contact surface that contacts a conductor and that vibrates ultrasonically, and a pair of restrictors that are in contact with the contact surface and opposed to each other at a predetermined interval and move relatively along the contact surface, a conductor arranging step of arranging the plurality of conductors in the formed space;
An anvil that is separate from the horn and that corresponds to the number and outer diameter of each of the plurality of conductors to be connected is arranged at a position facing the contact surface of the horn and is spaced from the contact surface by a predetermined distance. At least one of the pair of regulating portions such that the horn and the regulating portion move relative to the anvils that are separated from each other, and the anvil is sandwiched between the mutually facing regulating surfaces of the pair of regulating portions. a moving compression step in which one of the conductors moves relative to the other, and the restricting portion sandwiches the anvil and compresses the conductor with the anvil and the horn;
a welding step of ultrasonically vibrating the horn to ultrasonically weld the conductor compressed by the anvil and the horn;
Each of the regulating surfaces facing each other in the pair of regulating portions has a pair of protrusions projecting toward the other opposing regulating portion and recesses recessed in a direction opposite to the projecting direction of the protrusions. a wavy wave-shaped regulating portion that is continuous along the opposing direction in which the regulating surfaces of and the orthogonal direction orthogonal to the movement direction in which the horn relatively moves with respect to the anvil,
A conductor joining method, wherein a main surface of the anvil facing the opposite direction is provided with the projection, a fitting recess that fits into the recess, and a fitting projection.

Images