JPH0562754A - Connecting method for conductor - Google Patents

Abstract

PURPOSE:To improve the reliability of connection and reduce the cost in the connecting method of a flat cable and lead wires with bus bars. CONSTITUTION:A flat cable 2 and conductors 2a, 3a of lead wires 3 are directly connected on terminals 1a of bus bars 1 with multiple terminals 1a connected to each other at the middle position. This connection section including the bus bars 1 is insert-molded, then mutual connection sections 1b of the terminals 1a of the bus bars 1 are trimmed through an insert molding 4.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a conductor connecting method for connecting a flat cable and a lead wire to each other using a bus bar.

[0002]

2. Description of the Related Art Conventionally, for example, in a steering apparatus of an automobile, a roll connector in which a flat cable wound in a spiral shape is housed in a case in order to constantly electrically connect a rotating steering wheel to a steering column. The lead wires of the steering column side and the steering wheel side are respectively connected to both ends of the flat cable by using. A flat cable consists of several thin copper foils covered on both sides with a flexible thin resin film and is extremely weak against external force, so it is difficult to connect it directly to an external lead wire. As such, the connection is typically made via a bus bar.

An example of this connection method is shown in FIG.
In the conventional method, first, several bus bars 10 are lined up and insert-molded with resin, and each bus bar 10 is positioned by the primary molding 11. Next, after the copper foil 12a of the flat cable 12 is connected to one end of each bus bar 10 and the core wire 13a of the lead wire 13 is connected to the other end by a method such as soldering, each bus bar is fixed by the primary molded body 11. The entire connecting portion including 10 is insert-molded again, and the joint portion is protected by the secondary molded body 14 shown by a virtual line.

[0004]

As described above, since it is difficult to directly connect the flat cable 12 and the lead wire 13 to each other, the connection is made by such a method. However, since it is necessary to join the flat cable 12 and the bus bar 10 and the bus bar 10 and the lead wire 13 at two locations, an increase in the joining man-hour and a decrease in joining reliability cannot be avoided. Also, regarding the molding performed twice, there is a problem in that the cost is increased due to an increase in the number of steps as compared with the case of directly connecting.

Therefore, the technical problem to be solved by the present invention is to provide a connection method that enables a direct connection between a flat cable and a lead wire and that requires only one molding process to improve the reliability of the connection. It is to improve man-hours and reduce costs.

[0006]

In order to solve the above-mentioned technical problems, the method of connecting conductors according to the present invention is directed to a bus bar in which a plurality of terminals are connected to each other at their intermediate positions. Directly connecting the flat cable and each lead wire on the terminal, insert molding this connecting part including the bus bar, and insert the interconnected part of the terminal in the bus bar by insert molding with a method such as pressing. And a trimming process.

According to this method, since the flat cable and the lead wire are directly joined by soldering or the like on the bus bar in which several terminals are integrally formed, the number of joints and the number of steps are not increased, and the reliability is improved. Can also be prevented. Further, since insert molding only has to be performed once, it is possible to prevent an increase in cost due to an increase in the number of steps.

Further, according to the present invention, a bus bar in which a plurality of terminals are connected to each other at an intermediate position is provided.
The step of directly connecting the flat cable and each lead wire to the plurality of arbitrary terminals of the terminal on the terminal, and connecting only the flat cable wire to the remaining terminals, and the connection. It is composed of a step of insert-molding a part including the bus bar, and a step of trimming the connecting part of the terminal in the bus bar through the insert-molded body so that one lead wire corresponds to a plurality of flat cable conductors. A method of connecting a conductive wire is provided.

When the conductors are connected by this method, a plurality of core wires of the flat cable correspond to one lead wire. Therefore, the conductor wire is different from the case where the lead wire and the conductor wire of the flat cable are connected one by one. The resistance value as a whole is substantially reduced. Therefore, it is possible to connect the flat cable and the lead wire in a circuit that allows a relatively large current to flow with high reliability and at low cost.
If it is only intended to reduce the resistance value of the conductor as a whole, it is possible to connect the lead wire and the corresponding flat cable conductor separately to both ends of the bus bar without overlapping. Is.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A conductor connecting method according to a first embodiment of the present invention will be described below in detail with reference to FIG. 1 which is a plan view and FIG. 2 which is a side view. In the figure, 1 is a bus bar, 2 is a flat cable, and 3 is a lead wire. Bus bar 1
As shown in the figure, four thin terminals 1a and a connecting portion 1b located in the middle thereof are integrally formed, and the terminals 1a are fixed in parallel at regular intervals.

In the method of this embodiment, first, the copper foil 2a of the flat cable 2 is provided on each terminal 1a of the bus bar 1.
And the core wire 3a of the lead wire 3 is overlapped, and these are joined at once by soldering or the like. Then, from the end of the resin film 2b of the flat cable 2 to the end of the coating 3b of the lead wire 3, the bus bar 1 and the like are covered with an insert-molded body 4 made of resin as shown by a virtual line. Although not shown, the insert molded body 4 exposes the connecting portion 1b of the bus bar 1, so that the connecting portion 1b is not exposed.
The window is formed in the portion corresponding to. After protecting the joint in this way, the terminal 1 in the busbar 1
The connecting portion 1b of a is pulled out through the window of the insert molded body 4 by a method such as pressing. Therefore, since the copper foil 2a of the flat cable 2 and the lead wire 3 are conducted one by one, it is possible to cope with an arbitrary number of electric circuits.

As described above, in the method of this embodiment, the copper foil 2a of the flat cable 2 and the core wire 3a of the lead wire 3 are soldered on the bus bar 1 in which four terminals are integrally formed in advance. Since the joining is directly performed, the number of joining points and the number of steps are smaller than those where the flat cable and the lead wire are joined separately at both ends of the bus bar, and the reliability of the joining portion can be prevented from lowering. Also,
Since the insert molding only has to be performed once, the cost increase due to the increase in the number of steps can be prevented.

Next, a method of connecting conductors according to the second embodiment of the present invention will be described with reference to FIG. 3 which is a plan view. In addition,
In this figure, the same parts as those in the first embodiment are designated by the same reference numerals as those in FIG.

This embodiment has the same structure as that of the first embodiment except that two copper foils 2a of the flat cable 2 are connected to one lead wire 3. In particular,
The copper foil 2a of the flat cable 2 is laid on each terminal 1a of the bus bar 1 in which the four thin terminals 1a and the connecting portion 1b located in the middle are integrally formed. The core wire 3a of the lead wire 3 is superposed on the first and third terminals 1a, and they are joined by soldering or the like. Then, from the end of the resin film 2b of the flat cable 2 to the lead wire 3
The cover 3b up to the end is covered with the insert molding 4 as in the first embodiment, and the terminal 1a of the bus bar 1 is covered.
The connecting portion 1b of 1 is removed by a method such as pressing at only one place.

According to this embodiment, two copper foils 2a of the flat cable 2 are electrically connected to one lead wire 3, so that the core wire 3a of the lead wire 3 and the copper foil 2a of the flat cable 2 are connected to each other. The electric resistance value of the entire conductor can be suppressed to be small as compared with the case where the wires are connected one by one on the terminal 1a of the bus bar 1. In order to suppress the resistance value, it is possible to shorten the length of the flat cable 2 or the lead wire 3 or thicken the core wire 3a of the lead wire 3, but these methods have space limitations. Large and difficult to realize. It is also possible to increase the cross-sectional area of the copper foil 2a of the flat cable 2, but this method leads to an increase in the cost of the flat cable 2. Therefore,
The present embodiment is extremely effective in connecting the flat cable 2 and the lead wire 3 in a circuit that allows a relatively large current to flow while preventing a decrease in reliability and an increase in cost. In the present embodiment, two copper foils 2a of the flat cable 2 are connected to one lead wire 3, but the number of the copper foils 2a of the flat cable 2 corresponding to one lead wire can be changed. By properly setting, the resistance value can be arbitrarily changed.

[Brief description of drawings]

FIG. 1 is a plan view showing a method of connecting conductors according to a first embodiment of the present invention.

FIG. 2 is a side view showing this method.

FIG. 3 is a plan view showing a method of connecting conductors according to a second embodiment of the present invention.

FIG. 4 is a plan view showing a method for connecting conductors according to a conventional example.

[Explanation of symbols]

 1 Bus bar 1a Terminal 1b Connection part 2 Flat cable 2a Copper foil 2b Resin film 3 Lead wire 3a Core wire 3b Coating 4 Insert molding

Claims (2)

[Claims] 1. A method of connecting conductors, wherein a flat cable (2) and a lead wire (3) are connected using a bus bar (1), wherein a plurality of terminals (1a) are connected to each other at an intermediate position thereof. Directly connecting the flat cable (2) and each lead wire (3a) of the lead wire (3) on each terminal (1a) of the bus bar (1), including this connection part including the bus bar (1) Insert molding process, and the connecting part (1b) of the terminal (1a) in the bus bar (1)
And a step of trimming the product through the insert molded body (4). 2. In a method of connecting a conductor for connecting a flat cable (2) and a lead wire (3) using a bus bar (1), a plurality of terminals (1a) are connected to each other at an intermediate position. Flat cable (2) and lead wire (3) at a ratio of one to any arbitrary number of terminals (1a) to the bus bar (1)
Directly connect each conductor (2a, 3a) on the terminal (1a) and connect only the conductor (2a) of the flat cable (2) to the remaining terminal (1a), and this connection part A step of insert molding including the bus bar (1), and a connecting portion of the terminal (1a) in the bus bar (1),
Multiple conductors of flat cable (2) on one lead (3)
A method of connecting a conductor, comprising the step of trimming through the insert molded body (4) so that (2a) corresponds.