JPH0646585B2 - How to connect insulation-coated wires and terminals - Google Patents

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for electrically and mechanically connecting an insulated wire and a metal terminal by a fusing method.

2. Description of the Related Art In manufacturing a ballast, for example, there is a step of connecting a winding start end and a winding end end of a winding wound around a bobbin to terminals mounted on the bobbin. The winding of this ballast is an insulation-coated wire in which the surface of the copper wire is coated with an insulation coating of resin such as polyester.To connect to the terminals of this winding, the insulation coating on the winding surface is partially removed to remove copper. This is done by electromechanically connecting the wires to the terminals.

The fusing method is one of the methods of connecting the winding and the terminal in such a ballast. In this fusing method, a part of the winding is sandwiched between the terminals and pressurized, and the heat generated by applying an electric current to the sandwiched part melts the insulating film of the winding sandwiched between the terminals, so that the copper wire and the terminal are It is a method of joining and unifying, and this method has advantages such as higher working speed, higher efficiency, and suitability for automation compared with the normal soldering method, but it is more reliable than the soldering method as described later. There was a chipping problem.

That is, a method of connecting the winding (1) and the terminal (2) in the ballast by the conventional fusing method will be described with reference to FIGS. 3 to 5. In the figure, (3) is a flanged bobbin of the ballast, and terminal fitting portions (3b) (3b) are formed at two positions of the flange portion (3a), and the terminal fitting portion (3b) ( Three
Two terminals (2) and (2) are fitted and fixed to b). The winding wire (1) is, for example, an insulating coated electric wire in which the surface of a copper wire (1a) is coated with an insulating coating (1b) such as polyester. The two terminals (2) and (2) are metal plates such as copper alloys, and have cut and raised pieces (2b) and (2b) in a part of the flat plate portions (2a) and (2a). Further, (4) and (5) are a pair of fusing electrodes facing each other vertically.

The winding (1) has a winding starting end having a flat plate portion (2
a) and the cut-and-raised piece (2b) are caulked between the bobbin (3) by fusing connection as described later, and the winding end is fused to the remaining terminal (2) as follows. Connected. First, connect the end of the winding (1) to the terminal (2).
The cut-and-raised piece (2b) and the flat plate portion (2a) are engaged with each other. Next, as shown in FIG. 5, the electrodes (4) and (5) are lowered and raised above and below the terminal (2) to lower the lower surface of the flat plate portion (2a) of the terminal (2) with the lower electrode (5). Support,
The upper electrode (4) is cut and raised, and the piece (2b) is pressed and deformed and pressed against the winding (1). The upper and lower electrodes (4) in this state
A fusing current I _{1 is} passed between (5). This current I ₁
First flows through the cut-and-raised piece (2b), and the heat generated by the current I ₁ during this time melts the portion of the insulating coating (1b) of the winding (1) sandwiched by the cut-and-raised piece (2b), Copper wire (1a)
Is exposed and pressure-bonded to the terminal (2).

DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention By the way, in the connection of the terminal (2) and the winding fuel (1) by the upper fusing method, the engaging portion of the terminal (2) and the winding (1) is the winding (1). A fusing current I ₁ is applied to generate heat (about 1100 ° C.) to such an extent that a part of the copper wire (1a) is melted together with the insulating coating (1b), and the copper wire (1a) is partially welded to the terminal (2). I'm going to be close to being done. Such a fusing connection close to welding improves the electromechanical connection of the winding (1) to the terminal (2), but if the winding (1) has a small wire diameter, the copper wire is The terminal (2) of the winding (1) is melted because a part of (1a) is melted and the cross section of the portion pressed and clamped by the terminal (2) of the copper wire (1a) is deformed nearly flat. In some cases, the mechanical strength of the part connected by was extremely reduced, and the wire was disconnected from this part.

Therefore, in order to prevent the above-mentioned disconnection, it is conceivable to control the fusing current I ₁ to such an extent that only the insulating coating (1b) of the winding (1) melts and pressurize the copper wire so that it does not deform. However, in this case, the contact between the terminal (2) and the exposed copper wire (1a) of the winding (1) is close to point contact, and a large gap can be formed between the terminal (2) and the copper wire (1a). Therefore, there is a high possibility that the electromechanical connection between the terminal (2) and the winding (1) will be defective. Further, if there is a large gap between the terminal (2) and the copper wire (1a), the varnish will penetrate into the gap when the ballast is subjected to the varnish impregnation process later, and the terminal (2) and the copper wire (1a).
The electrical connection state of a) was sometimes worsened.

Therefore, it is an object of the present invention to provide a method of sufficiently satisfactory fusing connection of an insulation-coated electric wire, even if the insulation-coated electric wire has a small diameter.

Means for Solving the Problems The present invention is a method for connecting an insulating coated electric wire having an insulating coating on the surface of a conductor and a terminal by a fusing method, wherein the surface of the terminal has a melting point lower than that of the insulating coating of the insulating coated electric wire. A metal film is formed, and a fusing current is applied to the part where the insulation-coated wire is sandwiched between the terminals by melting the insulation coating of the insulation-coated wire and not melting the conductor wire and the metal film with a low melting point. The above-mentioned object is achieved by connecting the lead wire and the lead wire.

Action In the method of the present invention, the insulation-coated electric wire is sandwiched between terminals whose surface is treated with a low melting point metal, and a predetermined fusing current is applied to the extent that the metal film does not scatter, and the insulation coating of the insulation-coated electric wire is melted, The metal film on the surface of the terminal, which has a lower melting point than this insulating film, is also melted, and this molten metal fills the gap between the exposed conductor wire of the terminal and the insulation-coated wire, and improves the electromechanical connection between the terminal and the conductor wire. In addition, the fusing current can be set to such a small value that the conductor wire of the insulation-coated electric wire is not melted by this operation, and there is no fear of breaking even if the insulation-coated electric wire is thin.

EXAMPLE A specific example applied to the method for connecting the winding (1) and the terminal (2) of the ballast of the method of the present invention will be described below with reference to FIGS. 1 and 2.

First, prior to carrying out the method of the present invention, a metal film (6) such as tin or solder having a melting point lower than that of the insulating coating (1b) of the winding (1) is formed on the surface of the terminal (2) by a plating method or the like. It is adhered and formed. The surface treatment of the terminal (2) with the low melting point metal can be mass-produced, and can be performed without any problems in terms of productivity and technology.

Then, as shown in FIG. 1, the cut-and-raised piece (2) of the terminal (2) is
Insert part of the winding (1) between b) and the flat plate part (2a),
Next, as shown in FIG. 2, the terminal (2) is sandwiched between the electrodes (4) and (5) from above and below, and the cut and raised piece (2b) is used as the winding (1) without crushing the copper wire (1a). The fusing current I _{2 is made} to flow between both electrodes (4) and (5) by pressing them with a force of a certain degree. Here, the melting point of the copper wire (1a) of the winding wire (1) is a little over 1000 ° C, and the insulating coating (1b) is usually made of resin and its melting point is several hundreds.
Since the fusing current I ₂ is about ℃, the winding (1)
The insulating film (1b) is melted at the joint between the terminal (2) and the terminal (2), and the copper wire (1a) is not melted. Then, the portion of the winding (1) sandwiched between the insulating coating (1b) and the terminal (2) is melted by the fusing current I ₂ , and the copper wire (1a) thereunder is melted.
Is exposed. At the same time, the metal film (6) having a melting point lower than that of the insulating coating (1b) also melts, and most of this molten metal flows into the gap between the terminal (2) and the copper wire (1a) to fill the gap.

Therefore, the fusing current I ₂ is supplied for a suitable time to stop,
When the electrodes (4) and (5) are removed from the terminals (2), the winding (1)
The exposed copper wire (1a) is directly connected to the terminal (2) by crimping, and the metal film (6) is melted and then hardened (6 ') to be indirectly connected. Is electrically and mechanically connected to. In addition, the copper wire (1a) in the portion sandwiched by the terminals (2) of the winding (1) is slightly deformed by the pressure applied from the terminal (2), but since it does not melt even in part, its cross-sectional area is Is almost unchanged, and therefore there is no concern that the winding (1) will be disconnected from the connection portion with the terminal (2) after connection. Also, the terminal (2) and the copper wire (1a)
The metal (6 ') filling the gap between the terminals (2) and the copper wire (1)
In addition to improving the electromechanical connection of a), the varnish between the terminal (2) and the copper wire (2a) and the oxidation of the varnish are prevented, so that the connection between the terminal (2) and the copper wire (2a) can be improved over time. Prevent deterioration.

The present invention is not limited to the method of connecting the winding of the ballast and the terminal, but can be sufficiently applied to the method of connecting the terminal and the lead wire of the high frequency electric device.

EFFECTS OF THE INVENTION According to the present invention, the insulation-coated electric wire for the terminal is partially melted, and since the melted metal film on the terminal surface is buried between the conductive wire and the terminal for fusing connection, Even if the insulation-coated electric wire is thin, there is no fear of disconnection, and it is always connected well to the terminal, and it is possible to provide a highly reliable connection method by the fusing method.

[Brief description of drawings]

1 and 2 are cross-sectional views at the time of each operation showing an example of a concrete apparatus for carrying out the method of the present invention. FIG. 3 is a view for explaining a conventional method of fusing connection between a winding and a terminal of a ballast, FIG. 3 is a partial perspective view of the ballast, and FIGS. 4 and 5 are terminals in FIG. FIG. 3 is each enlarged cross-sectional view before and after the connection of the coil and the winding. (1) ... Insulated coated electric wire [winding], (1a) ... Conductor wire [copper wire], (1b) ... Insulating coating, (2) ... Terminal,
(6) ... Metal film, I ₂ ... Fusing current.

Claims (1)

[Claims] 1. A method of connecting an insulating coated electric wire having an insulating coating on the surface of a conductor and a terminal by a fusing method, wherein a metal film having a melting point lower than that of the insulating coating of the insulating coated electric wire is formed on the surface of the terminal, Connect the terminal and the conductor by applying a fusing current that melts the insulation coating of the insulation-coated wire to the part where the insulation-coated wire is sandwiched by this terminal and does not melt the conductor and does not scatter the metal film with a low melting point. A method of connecting an insulated coated electric wire and a terminal, which is characterized by: