JP2009137357A - Welded structure, its manufacturing method, and grip heater equipped with the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a welded structure capable of obtaining a stable weld strength. <P>SOLUTION: The welded structure 30, in which an electric wire 20 is welded at an end portion 18 with thickness of 20-80 μm, is equipped with a welding heat holding means 31 at the end portion 18. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a welded structure in which an electric wire is welded to a terminal portion having a thickness of 20 to 80 μm, a manufacturing method thereof, and a grip heater for a motorcycle handle equipped with the welded structure.

  Grip heaters have been proposed that are used to warm a hand that grips a motorcycle handle during cold weather (for example, Patent Documents 1 to 4). Such a grip heater is constituted by an electric wire connected to a heating element including a thin metal foil by soldering or welding.

  However, when soldering an electric wire to a heating element, it is not preferable to use solder that contains lead, which is an environmentally hazardous substance. Also, if solder that does not contain lead is used, the melting point is high, so the influence of heat during connection There is a problem that there is a possibility of extending to the surroundings.

Further, when the electric wire is welded to the heating element, there is a problem that the reliability is low due to large variation in welding strength. On the other hand, in Patent Document 5, when the electric wire is composed of a twisted wire in which a plurality of wires are bundled, the upper and lower electrode rods press the upper and lower electrode rods in a pressurized state by pressing the stranded wires on the conductive base material. In the method of spot welding of electric wires that are energized and welded, the conductive thin wire is wound before the spot welding is performed on the portion corresponding to the stranded wire welding, and the stranded wire is formed through the portion wound with the thin wire. Welding is disclosed.
Japanese Patent Laid-Open No. 2005-199913 Japanese Patent Laid-Open No. 2005-199914 Japanese Patent Laid-Open No. 2005-199915 JP 2006-168519 A Japanese Patent Laid-Open No. 10-172710

  An object of this invention is to provide the welding structure which can obtain the stable welding strength, its manufacturing method, and a grip heater provided with the same.

The welded structure of the present invention is obtained by welding an electric wire to a terminal portion having a thickness of 20 to 80 μm,
The terminal portion is provided with welding heat holding means.

  The method for manufacturing a welded structure according to the present invention is characterized in that a welding heat retaining material is provided in contact with the side of the terminal portion opposite to the wire welding side so as to correspond to the wire welding portion.

A grip heater for a motorcycle handle according to the present invention comprises the welded structure according to the present invention,
The terminal portion is provided on a narrow metal resistor included in the heating element.

  According to the present invention, although the terminal portion is very thin as 20 to 80 μm, it is possible to suppress scattering of welding heat at the time of welding by providing the welding heat holding means, and therefore the range of welding conditions is wide. As a result, stable welding strength can be obtained.

  Hereinafter, embodiments will be described in detail based on the drawings.

(Embodiment 1)
1 and 2 show a grip heater 10 according to the first embodiment. The grip heater 10 is of a type that is attached to a two-wheeled vehicle handle such as a bicycle or a motorcycle and warms a grip half circumference.

  The grip heater 10 has a sheet-like heating element 12 attached so as to cover approximately half of the outer peripheral surface of the cylindrical cylindrical main body 11, and a power supply wiring extending from a power source (not shown) to the heating element 12. 14 is connected.

  The cylindrical main body 11 is made of, for example, flexible rubber or resin. The cylindrical main body 11 is provided at one end so that a wiring holding portion 15 formed with a U-shaped wiring holding groove protrudes outward. The cylindrical main body 11 has a length of 110 to 150 mm, an outer diameter of 25 to 40 mm, and an inner diameter of 22 to 30 mm, for example.

  The heating element 12 has a configuration in which a thin metal resistor 17 is provided on a flexible electrical insulating plate 16. Such a heating element 12 can be obtained, for example, by punching a metal foil uniformly attached on the electrical insulating plate 16 into a desired shape by half-cutting and peeling off an unnecessary metal foil portion. it can.

  The electrical insulating plate 16 is made of, for example, flexible rubber or resin. For example, the electrical insulating plate 16 has a vertical length of 40 to 80 mm corresponding to the circumferential direction of the cylindrical main body 11, a horizontal length of 100 to 120 mm corresponding to the axial direction of the cylindrical main body 11, and a thickness of 70 to 70 mm. Each is formed to 150 μm.

  The metal resistor 17 is made of, for example, a stainless steel foil such as SUS, a copper foil, or the like. The metal resistor 17 is provided with a pair of terminal portions 18 at substantially the center in the vertical direction on the electrical insulating plate 16, extending in the horizontal direction starting from each of the pair of terminal portions 18, and then outwardly. It folds back and extends in the horizontal direction, then folds outward again and extends in the horizontal direction, then bends inward, and finally laid so as to have a meandering track in which the ones extending from the pair of terminal portions 18 are connected to each other Yes. The width of the terminal portion 18 is, for example, 5 to 7 mm. The thickness of the terminal portion 18 is 20 to 80 μm (preferably 60 to 70 μm).

  The heating element 12 may be provided so that the metal resistor 17 faces the outer side with respect to the cylindrical main body part 11, and faces the inner side if the cylindrical main body part 11 has an insulating property. It may be provided (the former in FIG. 1). The heating element 12 is affixed to the cylindrical main body 11 with a rubber or resin adhesive.

  The power supply wiring 14 has a configuration in which a pair of electric wires 20 are inserted into the covering tube 19 and integrated. The power supply wiring 14 is fitted into the wiring holding portion 15 of the cylindrical main body portion 11, and the covering tube 19 is removed from the distal end portion so that the pair of electric wires 20 are exposed and extend. The exposed length of the electric wire 20 protruding from the covering tube 19 is, for example, 10 to 30 mm.

  The covering tube 19 is made of, for example, flexible rubber or resin. The coated tube 19 has an inner diameter of 0.8 to 1.5 mm and a thickness of 0.15 to 0.30 mm, for example.

  Each of the pair of electric wires 20 has a configuration in which a metal wire 21 is covered with an insulating coating layer 22. In the pair of electric wires 20, the insulating coating layer 22 is peeled off at the tip portion to expose the metal wire 21, and one metal wire 21 is connected to one end portion 18 of the heating element 12 and the other metal. The wire | line 21 is connected to the other terminal part 18 of the heat generating body 12, respectively by welding. The exposed length of the metal wire 21 protruding from the insulating coating layer 22 is, for example, 5 to 7 mm.

  The metal wire 21 is made of, for example, copper, tin-plated annealed copper, or the like. The metal wire 21 may be composed of a single wire wire or may be composed of a bundle of a plurality of wire wires. In the latter case, the number of wire lines is, for example, 1 to 100. The metal wire 21 has an outer diameter of, for example, 0.8 to 1.5 mm. When the metal wire 21 is composed of a bundle of a plurality of wire wires, the outer diameter of each wire wire is formed to 0.05 to 0.10 mm, for example, from the viewpoint of preventing the occurrence of sparks during welding, The portion protruding from the insulating coating layer 22 is preferably twisted in one direction.

  The insulating coating layer 22 is made of, for example, flexible rubber or resin.

  Such a grip heater 10 is used by being attached to a two-wheeled vehicle handle such as a bicycle or a motorcycle, and generates heat by flowing an electric current through the metal resistor 17 through the electric wire 20, thereby warming a user's hand.

  Next, each example of the 1st and 2nd welding structure from which a structure mutually differs is demonstrated about the welding structure of the electric wire 20 to the terminal part 18 of the heat generating body 12. FIG.

<First welding structure>
FIG. 3 shows the first welded structure 30 in the first embodiment.

  The first welded structure 30 has a folded overlapping structure 31 in which the terminal portion 18 is folded and overlapped so as to correspond to the wire welded portion.

  In this folded overlapping structure 31, the folded direction of the terminal portion 18 may be on the wire welding side, or may be on the opposite side to the wire welding side (the latter in FIG. 3). In the folded overlap structure 31, the number of folded overlap layers of the terminal unit 18 is, for example, two. In the folded overlapping structure 31, the overlapping thickness of the terminal portion 18 is preferably 40 to 160 μm, and more preferably 120 to 140 μm.

  Such a first welding structure 30 is configured by folding the terminal portion 18 to form a folded overlapping structure 31, on which the side surface of the metal wire 21 protruding from the insulating coating layer 22 of the electric wire 20 is brought into contact, And it can obtain by welding these.

  Examples of the welding method include resistance welding, laser welding, ultrasonic welding, and the like.

  When an electric wire is welded to a terminal portion having a thickness of 20 to 80 μm, sparks are easily generated, and in the case of resistance welding, it is necessary to polish or replace the electrode. Therefore, the range of welding conditions is very narrow, and it becomes very difficult to obtain stable welding strength. Moreover, if the thickness of the terminal portion is increased, a large-scale device is required for attaching the heating element to the cylindrical main body portion, and an adhesive for that is required, which increases costs and labor. It will be. However, in such 1st welding structure 30, although the terminal part 18 is very thin with 20-80 micrometers, the folding superimposition structure 31 is comprised, Therefore The welding heat at the time of welding is stored in the folding superimposition structure 31, As a result, the range of welding conditions can be widened, and as a result, stable welding strength can be obtained, and the welding strength can be improved as compared to the conventional method (specifically, the tensile direction). Improvement of about 20%). Accordingly, the folded superposed structure 31 constitutes a welding heat retaining means, and the folded lower end portion 18 constitutes a welding heat retaining material.

  Further, without forming the folded overlapping structure 31 of the terminal portion 18, the metal welding is separated from the terminal portion 18 so as to correspond to the wire welding portion on the side opposite to the wire welding side of the terminal portion 18. The same stable welding strength can be obtained even if welding is performed in a state where the heat retaining material is provided in contact.

<Second welded structure>
FIG. 4 shows the second welded structure 40 in the first embodiment.

  This second welded structure 40 has a folded holding structure 41 that holds the metal wire 21 of the electric wire 20 while the terminal portion 18 is turned back, on both sides of the metal wire 21 of the electric wire 20 held by the terminal portion 18. Welded.

  The folded holding structure 41 may be combined with the first welding structure 30 so that the terminal portion 18 is superimposed and the metal wire 21 of the electric wire 20 is held therebetween.

  Such a second welding structure 40 can be obtained by sandwiching the metal wire 21 of the electric wire 20 while the terminal portion 18 is folded to form the folded clamping structure 41 and welding from both sides.

  Examples of the welding method include resistance welding, laser welding, ultrasonic welding, and the like.

  In such a second welding structure 40, although the terminal portion 18 is very thin as 20 to 80 μm, the folded holding structure 41 is configured, so that a wide contact area of the electric wire 20 to the terminal portion 18 can be secured. In addition, the welding heat at the time of welding of the metal wire 21 can be stored in the folded holding structure 41 and the scattering thereof can be suppressed, so that the range of welding conditions is widened, and as a result, stable welding strength can be obtained, and The welding strength can be improved as compared with the conventional case (specifically, about 20% improvement in the tensile direction). Therefore, the folded holding structure 41 constitutes a welding heat holding means.

(Embodiment 2)
FIG. 5 shows a grip heater 10 according to the second embodiment. In addition, the part of the same name as Embodiment 1 is shown with the same code | symbol as Embodiment 1. FIG. The grip heater 10 is of a type that is attached to a motorcycle handle such as a bicycle or a motorcycle to warm the entire circumference of the grip.

  In the grip heater 10, a narrow belt-like heating element 12 is provided in a spiral shape on the outer peripheral surface of a cylindrical tubular main body 11, and a power supply wiring 14 extending from a power source (not shown) is connected to the heating element 12. Have a configuration.

  The cylindrical main body 11 is made of, for example, flexible rubber or resin. The cylindrical main body 11 is provided at one end so that a wiring holding portion 15 formed with a U-shaped wiring holding groove protrudes outward, and on the outer peripheral surface from one end to the other end. A spiral groove 23 extending in a spiral shape is provided, and an electric wire holding groove 24 extending in the axial direction from the base end of the wiring holding portion 15 is provided at a deeper position than the spiral groove 23 on the outer peripheral surface.

  The heat generating body 12 is comprised by the metal foil of the narrow strip | belt shape formed, for example with stainless steel foil, such as SUS, copper foil. The heating element 12 is provided so as to be fitted into the spiral groove 23 of the cylindrical main body portion 11, and both ends located on one end side and the other end side of the cylindrical main body portion 11 are respectively configured in the terminal portion 18. Yes. The heating element 12 is fixed in the spiral groove 23 by, for example, inserting a pin formed at the bottom of the spiral groove 23 and melting the tip of the pin. The heating element 12 including the terminal portion 18 is formed to have a total length of 900 to 1000 mm, a width of 5 to 7 mm, and a thickness of 20 to 80 μm, for example. The thickness of the terminal portion 18 is 20 to 80 μm (preferably 60 to 70 μm).

  The power supply wiring 14 has a configuration in which a pair of electric wires 20 are inserted into the covering tube 19 and integrated. The power supply wiring 14 is fitted into the wiring holding portion 15 of the cylindrical main body portion 11, and the covering tube 19 is removed from the distal end portion so that the pair of electric wires 20 are exposed and extend. The exposed length of the electric wire 20 protruding from the coated tube 19 is, for example, 20-40 mm for one electric wire 20 and 100-120 mm for the other electric wire 20.

  Each of the pair of electric wires 20 has a configuration in which a metal wire 21 is covered with an insulating coating layer 22. In the pair of electric wires 20, the insulating coating layer 22 is peeled off at the tip portions to expose the metal wires 21, and the metal wires 21 of the one electric wires 20 are located on one end side of the cylindrical main body portion 11. The other end of the cylindrical main body 11 is drawn around one end portion 18 of the body 12 and the wire holding groove 24 below the heating element 12 in which the metal wire 21 of the other electric wire 20 is spirally provided. Each is connected to the other terminal portion 18 of the heating element 12 located on the end side by welding.

  Also in the grip heater 10 according to the second embodiment, the welding structure in which the electric wire 20 is welded to the terminal portion 18 is configured by the first welding structure 30 or the second welding structure 40 in the first embodiment.

  Other configurations are the same as those of the first embodiment.

  Such a grip heater 10 is used by being attached to a two-wheeled vehicle handle such as a bicycle or a motorcycle, and generates heat by flowing an electric current to the heating element 12 through the electric wire 20, thereby warming the user's hand.

(Other embodiments)
In the said Embodiment 1 and 2, although it was set as the welded structure of the grip heater 10, it is not limited to this in particular, The welded structure which welded the electric wire to the other terminal part of thickness 20-80 micrometers may be sufficient. .

  INDUSTRIAL APPLICABILITY The present invention is useful for a welded structure in which an electric wire is welded to a terminal portion having a thickness of 20 to 80 μm, a manufacturing method thereof, and a grip heater for a two-wheeled vehicle handle equipped with the welded structure.

3 is a perspective view of a grip heater according to Embodiment 1. FIG. FIG. 3 is an enlarged perspective view of a main part of the grip heater according to the first embodiment. It is a perspective view which shows the 1st welding structure in Embodiment 1. FIG. It is a perspective view which shows the 2nd welding structure in Embodiment 1. FIG. 6 is a perspective view of a grip heater according to Embodiment 2. FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Grip heater 12 Heating element 16 Electrical insulation board 17 Metal resistor 18 Terminal part 20 Electric wire 30 1st welding structure 31 Folding overlapping structure (welding heat retention means)
40 Second welding structure 41 Folding clamping structure (welding heat retaining means)

Claims (6)

A welding structure in which an electric wire is welded to a terminal portion having a thickness of 20 to 80 μm,
A welding structure characterized in that welding heat holding means is provided at the terminal portion. The welded structure according to claim 1,
The welding heat holding means has a folded overlapping structure in which the terminal portion is folded and overlapped so as to correspond to the wire welded portion. The welded structure according to claim 1,
The welding heat retaining means is a folded holding structure that holds the electric wire while the terminal portion is folded,
The said electric wire is welded by the both sides clamped by the said terminal part, The welding structure characterized by the above-mentioned. A grip heater for a two-wheeled vehicle handle provided with the welded structure according to any one of claims 1 to 3,
A grip heater, wherein the terminal portion is provided on a narrow metal resistor included in a heating element. In the grip heater according to claim 4,
A grip heater, wherein the narrow metal resistor is provided on a flexible electrical insulating plate. A method for manufacturing a welded structure in which an electric wire is welded to a terminal portion having a thickness of 20 to 80 μm,
A method for manufacturing a welded structure, characterized in that a welding heat retaining material is provided in contact with a wire welding portion on the side opposite to the wire welding side of the terminal portion.

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