WO2006062203A1 - 配線材およびその製造方法、並びにその製造に用いる抵抗溶接機 - Google Patents
配線材およびその製造方法、並びにその製造に用いる抵抗溶接機 Download PDFInfo
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- WO2006062203A1 WO2006062203A1 PCT/JP2005/022693 JP2005022693W WO2006062203A1 WO 2006062203 A1 WO2006062203 A1 WO 2006062203A1 JP 2005022693 W JP2005022693 W JP 2005022693W WO 2006062203 A1 WO2006062203 A1 WO 2006062203A1
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- WIPO (PCT)
- Prior art keywords
- single wire
- tubular portion
- connection terminal
- wiring material
- manufacturing
- Prior art date
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/02—Soldered or welded connections
- H01R4/023—Soldered or welded connections between cables or wires and terminals
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49169—Assembling electrical component directly to terminal or elongated conductor
- Y10T29/49171—Assembling electrical component directly to terminal or elongated conductor with encapsulating
- Y10T29/49172—Assembling electrical component directly to terminal or elongated conductor with encapsulating by molding of insulating material
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49174—Assembling terminal to elongated conductor
- Y10T29/49176—Assembling terminal to elongated conductor with molding of electrically insulating material
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49174—Assembling terminal to elongated conductor
- Y10T29/49179—Assembling terminal to elongated conductor by metal fusion bonding
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49174—Assembling terminal to elongated conductor
- Y10T29/49181—Assembling terminal to elongated conductor by deforming
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49174—Assembling terminal to elongated conductor
- Y10T29/49181—Assembling terminal to elongated conductor by deforming
- Y10T29/49183—Assembling terminal to elongated conductor by deforming of ferrule about conductor and terminal
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49174—Assembling terminal to elongated conductor
- Y10T29/49181—Assembling terminal to elongated conductor by deforming
- Y10T29/49185—Assembling terminal to elongated conductor by deforming of terminal
- Y10T29/49188—Assembling terminal to elongated conductor by deforming of terminal with penetrating portion
- Y10T29/4919—Through insulation
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49227—Insulator making
Definitions
- the present invention relates to a wiring material used for automobile equipment and the like, a method for manufacturing the same, and a resistance welding machine used for manufacturing the wiring material, and in particular, a wiring material using a single-wire conductor coated with insulation, a method for manufacturing the same,
- the present invention relates to a resistance welding machine used for manufacturing the same.
- the wiring material for distributing power to a stator coil of a motor.
- the wiring material has been configured by extending enameled wire wound around the stator core to the power supply unit, bundling it, and connecting to the power supply unit by TIG (Tungsten Inert Gas) welding or soldering .
- a method is used in which a stator coil in which an enamel wire is wound around a stator core is assembled to a stator housing, and then the enamel wire and a wiring material are connected (for example, refer to Patent Document 1 and Patent Document 2).
- a wiring material a copper plate is punched and formed into a predetermined shape (annular), and two or three copper plates formed into the predetermined shape are integrally formed by a resin mold as a set, and insulated.
- There are coated wiring materials see Patent Document 3, for example). According to this, it is possible to save space in wiring material handling, etc., mechanization, and improve workability during assembly.
- a power supply terminal in the method of manufacturing a wiring material by punching a copper plate, can be stamped and formed in a process of punching into an annular shape, but a wire coated with an insulating material can be used.
- a wire coated with an insulating material In the method of manufacturing a wiring material by bending a wire, it is necessary to prepare a power supply terminal separately and to electrically connect the power supply terminal and the tip of the wire conductor by crimping or the like.
- Patent Document 1 JP-A-11 299159
- Patent Document 2 Japanese Patent Laid-Open No. 2001-25198
- Patent Document 3 JP 2003-134724
- Patent Document 4 Japanese Unexamined Patent Application Publication No. 2004 96841
- Patent Document 5 JP-A-5-114450
- Patent Document 6 Japanese Patent Laid-Open No. 2002-75481
- soldering and brazing must be performed manually, which is difficult to automate. In manual work, it is difficult to make the amount of solder and solder adhesion and the connection work time constant, and it is difficult to make the connection reliability uniform. In addition, wiring materials are installed in automobiles, etc. In such a case, there is a concern that cracks may occur because thermal fatigue or vibration is applied to the connection.
- the wiring material is a motor wiring material as described above, and the single wire conductor of the wiring material is connected by soldering, the above-described problem occurs.
- the single wire conductor of the wiring material is connected by TIG welding, there is a possibility that a failure may occur due to the thermal effect of the connection part and the problem of hydrogen embrittlement of the molten part.
- connection method described in Patent Document 5 is a method that requires a joining auxiliary material, and the connection method described in Patent Document 6 does not disclose a terminal connection method of a single-wire conductor! / ⁇ .
- an object of the present invention is to provide a wiring material having a uniform connection property of a connection portion between a single wire conductor and a connection terminal and having high connection reliability.
- the present invention provides a wiring material in which a connection terminal is electrically connected to two single wire conductors provided in parallel, and the two single wires are connected to the connection terminal.
- the two single wire conductors are inserted into the tubular portion, and electricity is applied from the outside of the tubular portion in a state where the tubular portion and the single wire conductor are in contact with each other.
- the connection terminal is electrically connected to the two single wire conductors.
- the present invention provides a wiring member in which a connection terminal is electrically connected to two single wire conductors provided in parallel, wherein the connection terminal has a tubular portion, and A wiring member characterized in that the two single wire conductors are inserted and arranged in an inner peripheral portion of the tubular portion, and the connection terminal and the two single wire conductors are electrically connected via a resistance welding portion.
- the present invention provides a wiring member in which an annular single wire conductor and a connection terminal are electrically connected, wherein both ends of the annular single wire conductor are extended in parallel.
- the connecting terminal has a tubular portion, both end portions of the single wire conductor are inserted and arranged in an inner peripheral portion of the tubular portion, and both end portions of the connecting terminal and the single wire conductor are interposed through resistance welding portions.
- a wiring material characterized by being electrically connected.
- the tubular portion of the connection terminal has a crushed portion on at least a part of the outer peripheral surface thereof.
- the crushing portion may be a concave portion having a cylindrical shape.
- the crushing portion may be a concave portion having a rectangular shape! /.
- the crushing force portion may be a concave portion having a substantially long cylindrical shape.
- the recess may be extended in the longitudinal direction of the single wire conductor.
- the recess may be extended in a direction orthogonal to the longitudinal direction of the single-wire conductor.
- the tubular portion of the connection terminal has a substantially elliptical shape, and the length in the minor axis direction of the inner peripheral portion thereof is formed to be substantially the same as the outer diameter of the single wire conductor. It is.
- the single wire conductor is made of copper or a copper alloy, and has a sparrow layer on the outer periphery thereof.
- the tubular portion of the connection terminal is made of copper or a copper alloy and has a splice layer on the inner peripheral surface thereof.
- the resistance welded portion is formed by a melted portion of the splicing layer of the connection terminal and the splicing layer of each single wire conductor.
- the resistance welded portion is formed by a melted portion of the splicing layer of the connection terminal and the splicing layers of the both end portions.
- the present invention provides a wiring material manufacturing method in which a connection terminal is electrically connected to two single wire conductors provided in parallel.
- providing a resistance welding process by energizing from the outer periphery of the tubular portion and electrically connecting the connection terminal to the two single wire conductors. .
- the resistance welding is performed by energizing a pair of electrodes from the outer periphery of the tubular portion, and a tip angle of either or both of the pair of electrodes is 60 ° to 90 °. It is.
- the tip R shape of either or both of the pair of electrodes is 1.25mn! ⁇ 3mm.
- the method includes a step of crushing the tubular portion of the connection terminal and causing the inner peripheral portion of the tubular portion and the two single wire conductors to contact each other during resistance welding.
- an upper surface of the tubular portion of the connection terminal located between the two single wire conductors is in contact with a recess formed between the two single wire conductors. And it is made to contact
- the method includes a step of crushing and crushing the tubular portion of the connection terminal along a direction orthogonal to the longitudinal direction of the two single wire conductors.
- the present invention provides a method for manufacturing a wiring member in which a connection terminal is electrically connected to an annular single wire conductor, and a step of bending the single wire conductor into an annular shape, A step of extending both ends of the bent single wire conductor in parallel and a tubular portion that accommodates the both ends of the single wire conductor are formed at the connection terminal, and the both ends of the single wire conductor are formed at the tubular portion.
- resistance welding is performed by energizing from the outer periphery of the tubular portion, and the both ends of the single wire conductor are And a step of electrically connecting the connection terminals.
- a method of manufacturing a wiring material is provided.
- the resistance welding is performed by energizing the pair of electrodes from the outer periphery of the tubular portion, and the tip angle of either or both of the pair of electrodes is 60 ° to 90 °.
- the tip R shape of either or both of the pair of electrodes is 1.25mn! ⁇ 3mm.
- the method includes a step of crushing the tubular portion of the connection terminal and causing the inner peripheral portion of the tubular portion and both ends of the single wire conductor to contact each other during resistance welding.
- the method includes a step of crushing and crushing the tubular portion of the connection terminal along a direction orthogonal to the longitudinal direction of the single wire conductor.
- the present invention is a resistance welding machine including a pair of welding electrodes, and the tip angle of either or both of the pair of welding electrodes is 60 ° to 90 °.
- tip R shape 1.25mn! Providing a resistance welding machine characterized in that it is ⁇ 3mm
- FIG. 1 is a plan view of a wiring material according to a first embodiment of the present invention.
- FIG. 2 is a cross-sectional view taken along line 2-2A in FIG. 1 (only a cross section is shown).
- FIG. 3 is a cross-sectional view of a connection terminal constituting the wiring member according to the first embodiment, showing a tubular portion before press forming.
- FIG. 4 is a cross-sectional view of a connection terminal constituting the wiring material according to the first embodiment, showing a tubular portion after press forming.
- FIG. 5 is a cross-sectional view of a connection terminal and a single wire conductor constituting the wiring material according to the first embodiment.
- FIG. 6 is a cross-sectional view of a connection terminal and a single wire conductor constituting the wiring material according to the first embodiment.
- FIG. 7 is a front view of a resistance welder used for manufacturing the wiring material according to the first embodiment.
- FIG. 8 is a side view of the resistance welder of FIG.
- FIG. 9 is a plan view of a wiring material according to a second embodiment of the present invention.
- FIG. 10 is a cross-sectional view (only a cross section is shown) taken along the line 10A-10A in FIG.
- FIG. 11 is a front view of a resistance welder used for manufacturing a wiring material according to a second embodiment.
- FIG. 12 is a side view of the resistance welder of FIG. 11.
- FIG. 13 is a side view of a resistance welder used for manufacturing a wiring material according to a third embodiment of the present invention.
- FIG. 14 is a plan view of a wiring material according to a fourth embodiment of the present invention.
- FIG. 15 is a cross-sectional view (only a cross section is shown) taken along line 15A-15A in FIG.
- FIG. 16 is a front view of a resistance welder used for manufacturing a wiring material according to a fourth embodiment.
- FIG. 17 is a side view of the resistance welder of FIG.
- FIG. 18 is a plan view of a wiring material according to a fifth embodiment of the present invention.
- FIG. 19 is a cross-sectional view of the upper welding electrode 15A-15A line in FIG. 14 (only the cross section is shown) when the tip R shape is 1.25 mm and the tip electrode angle is 60 °.
- FIG. 20 is a cross-sectional view (only a cross section is shown) taken along the line 15A-15A in FIG. 14 when the tip R shape of the upper welding electrode is 3. Omm and the tip electrode angle is 90 °.
- FIG. 1 is a plan view of a wiring material according to the first embodiment of the present invention.
- 2 is a cross-sectional view (only a cross section is shown) taken along line 2A 2A in FIG.
- the wiring member 1 includes two single wire conductors 2 and 2 provided in parallel and a connection terminal 4 electrically connected to the single wire conductors 2 and 2.
- Each single-wire conductor 2, 2 is a metal single-wire force. More specifically, for example, a single wire of copper or copper alloy to which sparrow is applied.
- the copper alloy is, for example, a copper monotin alloy.
- the single wire conductors 2 and 2 of this embodiment are covered with the insulator 9, they may not be covered.
- connection terminal 4 is made of, for example, copper or a copper alloy, and includes a tubular portion 5 connected to the single wire conductors 2 and 2, and a connector portion 6 connected to the power feeding side.
- the copper alloy for example, a copper monotin alloy can be used.
- the inner peripheral portion of the tubular portion 5 is preferably provided with a sparrow.
- tubular portion 5 two single wire conductors 2 and 2 are inserted and arranged on the inner peripheral portion thereof.
- the two single wire conductors 2 and 2 are joined to each other by melting the sparrow by resistance welding.
- the tubular portion 5 and the single wire conductors 2 and 2 are joined by resistance welding and the melted sparrows of the single wire conductors 2 and 2.
- the connection terminal 4 (tubular portion 5) and each single wire conductor 2 are electrically connected.
- a crimp mark (crushing portion) 8 is formed by crushing.
- the crimp mark 8 is a substantially circular recess having a cylindrical shape in plan view. It should be noted that the crimp mark 8 of this embodiment is slightly recessed, but the degree of depression of the force crimp mark is not limited to this.
- connection terminal 4 of this embodiment also functions as a crimp terminal.
- the tubular terminal 5 that accommodates the two single wire conductors 2 and 2 is formed in the connection terminal 4, and the two single wire conductors are formed in the tubular portion 5. 2 and 2, and in the state where the inner peripheral surface of the tubular portion 5 and the two single-wire conductors 2 and 2 are in contact with each other, current is applied from the outer periphery of the tubular portion 5 and resistance welding is performed. And a step of electrically connecting the connection terminal 4 to the single wire conductors 2 and 2.
- FIG. 3 is a cross-sectional view of the connection terminal constituting the wiring member according to the first embodiment, and shows the tubular portion before press molding.
- FIG. 4 is a cross-sectional view of the connection terminal constituting the wiring member according to the first embodiment, and shows the tubular portion after press molding.
- FIG. 5 and FIG. 6 are cross-sectional views of the connection terminal and the single wire conductor constituting the wiring material according to the first embodiment.
- a copper or copper alloy wire is prepared, and the single wire conductor 2 is formed by applying a sparrow to the copper or copper alloy wire.
- the diameter of a copper or copper alloy wire is 2.6 mm, and a tin plating layer is formed with a thickness of 0.5 ⁇ m.
- the insulator 9 is coated on the splice layer of the copper or copper alloy wire.
- PFA perfluoroalkoxy
- the insulator (insulating material) 9 is 0.3 m. Insulate with a thickness of m.
- the insulator 9 at the tip of the insulation-coated copper or copper alloy wire is peeled off to expose the conductor.
- the end of the insulator 9 is stripped to a length of about 13 mm.
- a pipe member having a perfectly circular cross section with copper or copper alloy force is prepared.
- the tubular member 5 of the connection terminal 4 is formed by the pipe member.
- the diameter of the opening of the pipe member is 3.4 mm.
- the tubular portion 5 of the connection terminal 4 is press-molded.
- the press-molded tubular portion 5 has a substantially elliptical cross section, and the length of the inner peripheral portion in the minor axis direction is formed to be substantially the same as the outer diameter of the single wire conductor 2.
- the tubular portion 5 is formed in a substantially oval cross section so that the upper surface and the lower surface are flat and parallel to each other.
- the two single wire conductors 2 and 2 are arranged in parallel and inserted into the inside of the tubular portion 5 from the opening of the tubular portion 5.
- the single wire conductors 2 and 2 are preferably flattened slightly.
- FIG. 7 is a front view of a resistance welder used for manufacturing the wiring material according to the first embodiment
- FIG. 8 is a side view thereof.
- the resistance welding machine used for resistance welding includes a pair of upper and lower welding electrodes (hereinafter referred to as electrodes) 11 and 11.
- Each electrode 11 has a cylindrical shape extending in the vertical direction For example, the diameter is 10 mm and the length is 25 mm.
- a tungsten electrode may be used.
- the tanta- sten electrode is difficult to weld by heating only the contact resistance between the electrode and the work piece and the work piece when energized, the electrode itself generates heat and assists welding.
- an electrode 11 in which a tungsten electrode 1 la is integrated by embedding a chromium copper electrode 1 lb is used.
- the integrated electrode 11 has a structure in which cooling water is supplied to 1 lb of the chromium copper electrode to cool the tungsten electrode 11a so that the temperature becomes excessively high when the tungsten electrode 11a generates heat.
- connection terminal 4 into which the single wire conductors 2 and 2 are inserted is positioned with respect to the electrodes 11 and 11 of the resistance welding machine 10. Thereafter, the tubular portion 5 is sandwiched between the vertical force electrodes 11, and energization is performed while pressurizing the tubular portion 5 with the electrodes 11, 11.
- energization the single wire conductors 2 and 2 and the tubular portion 5 generate heat, and the sprinkling of the surface of the single wire conductors 2 and 2 is melted.
- the single wire conductors 2 and 2, and the single wire conductors 2 and 2 and the tubular portion 5 are joined by the melted sparrow. This joint is a resistance weld.
- the energization current value and the energization time are appropriately set so that the metal (copper or copper alloy) itself of the single wire conductors 2 and 2 and the connection terminal 4 does not melt, but only the sparrow melts. .
- the tubular portion 5 of the connection terminal 4 is crushed by pressurization during resistance welding.
- the upper and lower electrodes 11 and 11 sandwich the tubular portion 5 from above and below, so that the upper and lower surfaces of the tubular portion 5 are plastically deformed, and the tubular portion 5 and the single wire conductor 2 are connected to each other as shown in FIG. From the contact state, the surface contact state as shown in FIG.
- a crushing part (crimp mark) 8 is formed, and the inner periphery of the tubular part 5 and the two single wire conductors 2 and 2 are in surface contact.
- the connecting terminal 4 and the single wire conductors 2 and 2 are plastically deformed by crushing and heat generation, so that they can be pressure-bonded.
- the wiring material according to the present embodiment is not limited to the force described in the case where the shape of the crimp mark 8 is a cylindrical recess (substantially circular in plan view).
- the shape of the electrode and the shape of the crimp mark may be different!
- FIG. 9 is a plan view of a wiring member according to the second embodiment of the present invention.
- FIG. 10 is a cross-sectional view (only a cross section is shown) taken along line 1 OA-10A in FIG.
- the wiring member 21 according to the present embodiment is rectangular in plan view in which the tubular portion 5 of the connection terminal 24 is crushed along a direction orthogonal to the longitudinal direction (axial direction) of the single wire conductors 2 and 2. It has a crimp mark (crushed part) 28 in the shape. More specifically, the crimp mark (crushing portion) 28 is a concave portion having a rectangular shape. The concave portion (crushing portion) 28 is extended in a direction orthogonal to the longitudinal direction of the single wire conductor 2 (or substantially orthogonal, for example, may be oblique). The crimp mark may be, for example, a recess having a substantially long cylindrical shape (substantially elliptical in plan view). Other configurations are the same as those of the wiring material according to the first embodiment.
- FIG. 11 is a front view of a resistance welder used for manufacturing the wiring material according to the second embodiment
- FIG. 12 is a side view thereof.
- the method for manufacturing the wiring member 21 according to the present embodiment is the same as the method for manufacturing the wiring member 1 according to the first embodiment, but there is a difference in the resistance welding machine used.
- a contact surface (hereinafter referred to as contact surface) 111 with the tubular portion 5 in the upper welding electrode 12 of the resistance welder 20 is formed in a substantially rectangular shape.
- the welding electrode 12 is formed by scraping the bottom of the cylindrical electrode 11 shown in FIGS. 7 and 8 from both sides.
- the longitudinal direction of the substantially rectangular contact surface 111 (the left-right direction in FIG. 11 and the direction perpendicular to the drawing in FIG. 12) is defined as the longitudinal direction of the electrode.
- the welding electrode 12 is arranged such that the longitudinal direction of the welding electrode 12 is aligned with the direction orthogonal to the longitudinal direction (axial direction) of the single-wire conductors 2 and 2.
- the electrode 12 is pressed against the tubular portion 5 and pressed, and the tubular portion 5 is crushed by crushing along the direction perpendicular to the longitudinal direction of the single wire conductors 2 and 2, and at the same time, the welding electrode 12 is energized. Then, the processed part is resistance welded.
- the contact area force S between the electrode 12 and the tubular portion 5 is reduced, and the contact resistance is increased. For this reason, heat is likely to occur between the electrode 12 and the tubular portion 5 even with a relatively small current.
- resistance welding can be performed even with a small current by reducing the contact area between the electrode 12 and the connection terminal 24 (tubular portion 5). Therefore, the manufacturing cost of the wiring material 1 can be reduced.
- resistance welding is performed with a small current and the resistance heat generation of the electrode 12 itself is used, the amount of heat generation can be suppressed, and melting of the insulation coating due to the heat generation can be prevented.
- the concave portion 102 formed in the single wire conductor 2 is tubular by crushing in a direction perpendicular to the longitudinal direction of the single wire conductors 2 and 2.
- the single wire conductors 2 and 2 are disconnected from the connection terminal 24 by being caught by the convex portion 105 formed in the portion 5.
- FIG. 13 is a side view of a resistance welder used for manufacturing a wiring material according to the third embodiment of the present invention.
- a welding electrode 14 having a rounded contact surface is used. Specifically, in the welding electrode 12 shown in FIGS. 11 and 12, corners of the portions that contact the connection terminals 24 are taken (that is, the sides of the substantially rectangular contact surface are rounded), and the tip of the welding electrode 14 is formed. The part 131 was formed in a round shape. As a result, the bottom of the crimp mark (not shown) has a curved shape with a corner removed.
- the contact area between the welding electrode 14 and the connection terminal 24 is smaller than in the second embodiment, and resistance welding can be performed with a smaller current value.
- FIG. 14 is a plan view of a wiring material according to a fourth embodiment of the present invention.
- FIG. 15 is a cross-sectional view (only a cross section is shown) taken along line 15A-15A in FIG.
- the upper surface of the tubular portion 5 of the connection terminal 44 positioned between the single wire conductors 2 and 2 is formed between the single wire conductors 2 and 2 in the crushing process.
- the crimp mark (crushing portion) 48 of the present modification is a recess extending in the longitudinal direction of the single wire conductor.
- the shape of the recess is not limited. Other configurations are the same as those of the wiring material according to the first embodiment.
- FIG. 16 is a front view of a resistance welder used for manufacturing the wiring material according to the fourth embodiment
- FIG. 17 is a side view thereof.
- the method for manufacturing the wiring member 41 according to the present embodiment includes the wiring member according to the first embodiment.
- the upper welding electrode is a rectangular tip electrode, and the orientation of the upper welding electrode in the resistance welding machine used for manufacturing the wiring material according to the third embodiment is changed (90 ° Use a rotating resistance welder.
- the welding electrode 14 is arranged so that the horizontal direction in Fig. 7 is aligned with the longitudinal direction of the single conductors 2 and 2.
- the connection terminal 44 is positioned so that the contact surface of the welding electrode 14 is located between the two single wire conductors 2 and 2.
- the upper surface of the tubular portion 5 of the connection terminal 44 located between the single wire conductors 2 and 2 is placed between the single wire conductors 2 and 2 by crushing cage. It is in contact with the upper concave portion (first space) 161a to be formed, and in contact with the single wire conductors 2 and 2 in the longitudinal direction. More specifically, the upper surface and the lower surface of the tubular portion 5 are plastically deformed and pushed into the first spaces 161a and 161b formed between the single wire conductors 2. Further, each single wire conductor 2 is pushed in the long axis direction (left and right direction in FIG. 16) of the tubular portion 5 by the pushed-in tubular portion 5, and each single wire conductor 2 is formed between the tubular portion 5. It is pushed into the second space 162a, 162b.
- the upper welding electrode has a tip angle of 60 ° to 90 ° and an R shape force of the tip of 1.25 mm to R3 mm. If the tip angle and tip R shape fall outside this range, excessive crushing and crushing will be reduced, and good connection will not be possible. If the tip angle is less than 60 ° or the tip R shape is less than Rl. 25mm, the terminal will be pushed too far. Also, if the tip angle of the electrode is greater than 90 °, or if the tip R-shaped force is greater than 3 mm, the terminal will not be crushed and the terminal will generate heat, causing the insulation coating material of the conductor to melt. . Only the shape of the lower welding electrode on the upper side may be the shape having the above angle and R shape, or the shape of the upper and lower welding electrodes may be the shape having the above angle and R shape.
- the contact area between the tubular portion 5 and the single wire conductors 2 and 2 can be increased as compared with the first to third embodiments.
- connection terminal 4 When the connection terminal 4 is deformed by crushing, the extension of the connection terminal 4 in the longitudinal direction of the single wire conductor 2 can be reduced. This is particularly advantageous when dimensional accuracy is required.
- FIG. 18 is a plan view of a wiring material according to the fifth embodiment of the present invention.
- This embodiment differs from the first to fourth embodiments in the configuration of the single wire conductor, and has the same configuration as that of the third embodiment. Accordingly, the same elements are designated by the same reference numerals in the drawings, and detailed description thereof is omitted.
- a plurality of (two) single wire conductors are used, but in this embodiment, a single single wire conductor is used.
- the wiring material of this embodiment is used as a wiring material for a motor having a plurality of stator coils arranged at intervals in the circumferential direction as described in the background art section.
- the wiring member 51 includes an annular single wire conductor 22 and a connection terminal 44 electrically connected to the annular single wire conductor 22.
- the annular single wire conductor 22 has both end portions 22a, 22a extending in parallel.
- the both end portions 22a and 22a are inserted and arranged in the inner peripheral portion of the tubular portion 5 of the connection terminal 44, and both ends 22a and 22a of the connection terminal 44 and the single wire conductor 22 are formed by resistance welding (via resistance welding portions). Are electrically connected.
- the single wire conductor 22 covered with the insulator 9 is formed in an annular shape, and both end portions 22a and 22a of the single wire conductor 22 extend outward in the radial direction.
- the single wire conductor 22 is provided with a bent portion 22b that is bent radially inward.
- a plurality of the bent portions 22b are provided at circumferential positions corresponding to the respective stator coils.
- the single wire conductor 22 has both end portions 22a, 22a and a bent portion 22
- the insulator 9 is peeled off at b and the conductor is exposed.
- both end portions 22a and 22a of the single wire conductor 22 are connected to a power feeding portion (not shown) via the connection terminal 44, and each bent portion 22b is connected to the enamel wire of each stator coil. Is done.
- the wiring material 51 supplies power to each enameled wire in addition to the power supply unit force.
- the method of manufacturing the wiring member 51 of the present embodiment includes the step of bending the single wire conductor 22 into an annular shape and extending both ends 22a, 22a of the bent single wire conductor 22 in parallel. Forming a tubular portion 5 that accommodates both end portions 22a, 22a of the single wire conductor 22 in the connection terminal 44, inserting the both end portions 22a, 22a of the single wire conductor 22 into the tubular portion 5, and a tubular portion.
- connection terminals 44 are connected to both ends 22a, 22a of the single wire conductor 22. And electrically connecting the two.
- a single-wire conductor 22 is prepared in which a copper or copper alloy wire is sprinkled and then further coated with an insulating coating.
- the insulator 9 at the portions corresponding to the both end portions 22a and 22a and the bent portion 22b of the single wire conductor 22 is peeled off.
- the single wire conductor 22 is bent into an annular shape. Further, a plurality of bent portions 22 b are formed in the single wire conductor 22. Further, both end portions 22a and 22a of the single wire conductor 22 are extended in parallel in the radially outward direction.
- the annular bending process, the formation of the bent part 22b, and the extension of the both end parts 22a and 22a may be performed individually or simultaneously.
- connection terminal 44 the connection terminal 44 and the single wire conductor 22 are connected by resistance welding in the same manner as in the method of manufacturing the wiring member 1 according to the first embodiment.
- the wiring member 51 manufactured in this way is integrated as a set of two or three in accordance with the phase of the motor, and is assembled to the motor.
- Zinc soldering, solder soldering, etc. are possible.
- the crushed portion is formed on the upper surface of the tubular portion.
- the present invention is not limited to this.
- the crushed portion is formed on both the lower surface and the upper and lower surfaces of the tubular portion. You may make it form in. Further, a plurality of crushing portions may be formed.
- the welding electrode used for resistance welding is not limited to a cylindrical electrode, and various shapes are possible.
- a quadrangular columnar electrode or a product obtained by covering the quadrangular columnar electrode may be used.
- the material of the welding electrode is not limited to tungsten, and for example, molybdenum may be used.
- the welding electrode is not limited to the structure in which the tungsten electrode is embedded in the chromium copper electrode, but may be a structure in which the tungsten electrode is directly fixed to the holder of the copper electrode.
- the PFA coating material is used as the insulator of the single wire conductor, the present invention is not limited to this.
- the tubular portion of the connection terminal is in contact with both end portions of the two single wire conductors or the annular single wire conductor when accommodating both end portions of the two single wire conductors or the annular single wire conductor. It may be formed in an oval shape.
- Examples and comparative examples of the wiring material according to the fourth embodiment will be described below.
- Wiring materials of Examples 1 to 8 and Comparative Examples 1 to 4 were prepared, and evaluations were made on whether the connection terminals were cut, whether the insulating coating was melted, and connection reliability.
- a copper wire having a diameter of 2.6 mm was plated with Sn of 0.5 m thickness, and further an insulating material (PFA) was coated with a thickness of 0.3 mm.
- PFA insulating material
- connection terminal 44 in which the Sn plated copper wire (single wire conductor) 2 was inserted was positioned with respect to the upper and lower electrodes of the resistance welding machine 40. At that time, the electrodes are arranged with the longitudinal direction of the upper welding electrode 14 aligned with the longitudinal direction of the Sn-plated copper wire (single wire conductor) 2, and the contact surface of the welding electrode 14 has two Sn-plated copper wires (single wire). The connection terminal 44 was positioned so that it was located between the conductors 2).
- the upper welding electrode 14 of the resistance welding machine 40 used has a circular bottom surface with a diameter of 10 mm, and a tungsten electrode 14a having a total thickness (height) of 9 mm (specifically, a cylinder with a thickness of 2 mm) Shape, 7mm thickness, R shape at the tip, 1.25, tip portion with electrode angle of 60 °) and cylindrical chrome copper electrode 14b.
- the lower welding electrode 11 is composed of a flat cylindrical tungsten electrode 1 la and a chromium copper electrode 1 lb.
- connection terminal 44 is sandwiched between the upper and lower electrodes, and the connection terminal 44 is connected by these electrodes. While pressurizing with a pressure of 4 kN, current was applied at a current of 5.8 kA and a time of 2 seconds. In this way, a wiring material having an indentation mark (crushing portion) extending in the longitudinal direction of the Sn-plated copper wire (single wire conductor) 2 on the upper surface of the connection terminal 44 was completed.
- the tip R shape of the upper welding electrode 14 is 1.25 mm, and the tip electrode angle is 60.
- FIG. 15 is a cross-sectional view taken along the line 15A-15A in FIG. 14 (only a cross section is shown).
- a wiring material was completed under the same conditions as in Example 1 except that the R shape of the tip of the upper welding electrode 14 was 1.5 mm and the electrode angle was 70 °.
- a wiring material was completed under the same conditions as in Example 1 except that the R shape of the tip of the upper welding electrode 14 was 1.75 mm and the electrode angle was 75 °.
- a wiring material was completed under the same conditions as in Example 1 except that the R shape of the tip of the upper welding electrode 14 was 2. Omm and the electrode angle was 80 °.
- a wiring material was completed under the same conditions as in Example 1 except that the R shape of the tip of the upper welding electrode 14 was 2.5 mm and the electrode angle was 85 °.
- FIG. 20 is a cross-sectional view of the upper welding electrode 14 taken along line 15A-15A in FIG. 14 (only the cross section is shown) when the tip R shape is 3. Omm and the tip electrode angle is 90 °.
- a wiring material was completed under the same conditions as in Example 1 except that the R shape at the tip of the upper welding electrode 14 was 3. Omm and the electrode angle was 60 °.
- a wiring material was completed under the same conditions as in Example 1 except that the R shape of the tip of the upper welding electrode 14 was 1.25 mm and the electrode angle was 90 °. [0134] (Comparative Example 1)
- a wiring material was completed under the same conditions as in Example 1 except that the R shape of the tip of the upper welding electrode 14 was 1. Omm and the electrode angle was 60 °.
- a wiring material was completed under the same conditions as in Example 1 except that the R shape of the tip of the upper welding electrode 14 was 3.25 mm and the electrode angle was 60 °.
- a wiring material was completed under the same conditions as in Example 1 except that the R shape at the tip of the upper welding electrode 14 was 1.5 mm and the electrode angle was 55 °.
- a wiring material was completed under the same conditions as in Example 1 except that the R shape of the tip of the upper welding electrode 14 was 1.5 mm and the electrode angle was 95 °.
- connection terminal is made of a copper plate by press molding to produce a terminal expansion shape, bent so that it becomes a part (tubular part) that holds a single wire conductor, and the butted part is brazed to have a true circular cross section.
- the terminal barrel part is manufactured.
- connection terminal tubular part
- the tip angle is in the range of 60 ° to 90 ° and the tip R shape is 1.25mm to R3mm, the insulating coating that does not cut the electrode terminals will not melt. The fact that a good connection is possible is a major factor.
- a wiring material that is used for automobile equipment and the like, and has a uniform bonding property at a connection portion between a single wire conductor and a connection terminal, and has high connection reliability.
Landscapes
- Manufacturing Of Electrical Connectors (AREA)
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
- Processing Of Terminals (AREA)
- Manufacture Of Motors, Generators (AREA)
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/792,839 US7832099B2 (en) | 2004-12-10 | 2005-12-09 | Method of manufacturing a wiring material |
US12/842,671 US8769813B2 (en) | 2004-12-10 | 2010-07-23 | Method of manufacturing a wiring material |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
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JP2004-358648 | 2004-12-10 | ||
JP2004358648 | 2004-12-10 | ||
JP2005-355237 | 2005-12-08 | ||
JP2005355237A JP2006190662A (ja) | 2004-12-10 | 2005-12-08 | 配線材およびその製造方法、並びにその製造に用いる抵抗溶接機 |
Related Child Applications (2)
Application Number | Title | Priority Date | Filing Date |
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US11/792,839 A-371-Of-International US7832099B2 (en) | 2004-12-10 | 2005-12-09 | Method of manufacturing a wiring material |
US12/842,671 Division US8769813B2 (en) | 2004-12-10 | 2010-07-23 | Method of manufacturing a wiring material |
Publications (1)
Publication Number | Publication Date |
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WO2006062203A1 true WO2006062203A1 (ja) | 2006-06-15 |
Family
ID=36578023
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PCT/JP2005/022693 WO2006062203A1 (ja) | 2004-12-10 | 2005-12-09 | 配線材およびその製造方法、並びにその製造に用いる抵抗溶接機 |
Country Status (3)
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US (2) | US7832099B2 (ja) |
JP (1) | JP2006190662A (ja) |
WO (1) | WO2006062203A1 (ja) |
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JP2014107370A (ja) * | 2012-11-27 | 2014-06-09 | Sumiden Asahi Industries Ltd | グリーン電力システムの送電線路 |
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JP2015041509A (ja) * | 2013-08-22 | 2015-03-02 | 住友電装株式会社 | 導電路及び電線 |
DE102013020082A1 (de) | 2013-11-29 | 2015-06-03 | Böllhoff Verbindungstechnik GmbH | Schweißhilfsfügeteil, Matrize zum Setzen des Schweißhilfsfügeteils, ein Verbindungsverfahren für das Schweißhilfsfügeteil sowie Herstellungsverfahren für das Schweißhilfsfügeteil und die Matrize |
US9937583B2 (en) * | 2013-12-24 | 2018-04-10 | Innovative Weld Solutions Ltd. | Welding assembly and method |
WO2015148155A1 (en) * | 2014-03-28 | 2015-10-01 | Dow Global Technologies Llc | Device and method for forming highly reliable connections in a photovoltaic components |
CN103944033A (zh) * | 2014-04-04 | 2014-07-23 | 昆山达功电子有限公司 | 铜线焊接夹具 |
CN107430908B (zh) * | 2015-04-21 | 2020-03-10 | 住友电装株式会社 | 导电部件 |
JP6569345B2 (ja) * | 2015-07-15 | 2019-09-04 | 株式会社オートネットワーク技術研究所 | 抵抗溶接用の電極および端子付き電線 |
DE102017215970B3 (de) | 2017-09-11 | 2018-07-26 | Strunk Connect automated solutions GmbH & Co. KG | Verfahren zum Verbinden einer elektrischen Aluminiumleitung mit einem Aluminiumrohr |
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Also Published As
Publication number | Publication date |
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US20100281686A1 (en) | 2010-11-11 |
JP2006190662A (ja) | 2006-07-20 |
US8769813B2 (en) | 2014-07-08 |
US20080081499A1 (en) | 2008-04-03 |
US7832099B2 (en) | 2010-11-16 |
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