JPH0927377A - Connection method for wire and connection device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a connection method for wires and its connection device by which sufficient mechanical strength is obtained and connected wires can be manufactured at a low cost. SOLUTION: Core portions 21a, 22a, whose diameters are D1, D2 (D1>D2), of two wires 21, 22 are crossed, the cross section is sandwiched between electrode chips 11, 12 having flat sandwiching faces in a pressurizing state, and a current is caused to flow between both electrode chips 11, 12 so that the two wires 21, 22 are welded by fusing the cross section by resistance heating. At this time, the minimum gap S between the electrode chip 11, 12 are previously set so as to be S=D1, and more than required pressurizing of the cross section by the electrode chips 11, 12 is to be avoided.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electric wire connecting method used for connecting two electric wires to each other to form a branch portion.

[0002]

2. Description of the Related Art When a branch line is formed by connecting a branch line to a trunk line, as shown in FIG. 11, the coatings 51b, 52b on the middle part of the trunk line 51 and the terminal part of the branch line 52 are stripped off to remove the core wire 5.
After exposing 1a and 52a, the core wire 51a portion of the trunk wire 51 is overlapped with the core wire 52a portion of the branch wire 52 along the core wire 51a, and the core wires 51a and 52a are melted by resistance welding or ultrasonic welding. There is a method in which the main line 51 and the branch line 52 are connected by such a method, but as shown in FIG.
It is necessary to bend the branch line 52 in a desired direction at a position distant from the connecting portion of the above, and a space for bending the branch line 52 is required in addition to the connecting portion.

For this reason, as shown in FIG.
Of the branch line 52 by welding the trunk line 51 and the branch line 52 in a state where the core line 52a part of the branch line 52 is overlapped with the core line 51a part of the above so as to intersect in a desired direction in advance. A method of eliminating the bending space can be considered.

By the way, when two electric wires are connected by the above resistance welding or ultrasonic welding, the overlapped portions of the two electric wires are pressurized with a pair of electrode tips, a vibrator and an anvil. By sandwiching and applying a large current or ultrasonic energy to it, the sandwiched portions of the electric wires are melted and welded to each other.

[0005]

However, as described above, when resistance welding or the like is performed with the electric wires 51 and 52 crossing each other, as shown in FIG. 14, the electrode tip 61 of the resistance welding machine 60 becomes In order to pressurize the intersecting portion more than necessary, the welded portion becomes a thin flat plate shape as shown in FIG.
Moreover, since the area of the connecting portion of the electric wires 51 and 52 is small,
There are drawbacks such as reduced mechanical strength and lack of reliability.

Further, in order to solve such a drawback, as shown in FIG. 16, a groove 7 having a V-shaped cross section in which each wire is housed in the wire holding surface of the electrode tip 71 of the resistance welding machine.
It is conceivable that a method of forming the wire 2 to prevent the welded portions of the electric wires 51 and 52 from being pressed more than necessary (Japanese Patent Laid-Open No. 7-
22149), it is necessary to prepare an electrode tip 71 having grooves 72 having different sizes according to the wire diameters of the electric wires 51 and 52 to be connected, resulting in a high processing cost of the electrode tip 71 and the like. However, there is a problem that the product cost rises.

SUMMARY OF THE INVENTION An object of the present invention is to provide a wire connecting method and a wire connecting device which can obtain sufficient mechanical strength and can be manufactured at low cost.

[0008]

In order to solve the above-mentioned problems, the present invention crosses two electric wires having a wire diameter D and places the intersecting portions in a pressurized state by a holding body having a flat holding surface. In a method of connecting electric wires in which the two electric wires are welded while being sandwiched and heated to melt the intersecting portions, a minimum gap S between the holding bodies is D ≦ S ≦ 2D.
It is set so that the sandwiching body does not pressurize the intersecting portion more than necessary. Particularly, it is preferable to set the minimum gap S such that S = D.

Further, different wire diameters D1 and D2 (D1> D)
When connecting the two wires in 2), the minimum gap S
Is preferably set to satisfy D1 ≦ S ≦ D1 + D2, and particularly, the minimum gap S is more preferably set to S = D.

The sandwiching body may be composed of a pair of electrodes, and the intersecting portion may be melted by resistance heating generated by supplying a current to the intersecting portion. The intersecting portion may be melted by vibrating and generating heat by supplying.

Further, as a connecting device for carrying out the method for producing the electric wire, two electric wires are crossed, and the crossing portion is sandwiched by a sandwiching body having a flat sandwiching surface in a pressurized state and heated. Thus, in the electric wire connecting device for welding the two electric wires while melting the intersecting portion, the minimum gap between the holding bodies is equal to or more than the wire diameter of one of the electric wires and the wire diameter of the two electric wires. It suffices to provide an adjusting means for adjusting the sandwiching body so that the minimum gap becomes substantially the same length as the wire diameter of one of the electric wires, so that the sandwiching body is adjusted by the adjusting means. It is desirable to adjust the amount of movement.

[0012]

Embodiments will be described below with reference to the drawings. As shown in FIG. 1A, the electric wire connecting device 10 is a resistance welding machine including a pair of electrode tips 11 and 12 having flat holding surfaces 11a and 12a, and one electrode tip 11 is supported. The electrode chip 12 is fixedly installed on the base body 13 via the member 14, and the other electrode chip 12 is mounted on the base body 13 via the support member 15 so as to be freely attached to and detached from the electrode chip 11.

Further, in the wire connecting device 10, the electrode chip 1 is formed by driving the supporting member 15.
Drive means (not shown) for moving the electrode 2 toward and away from the electrode chip 11 is provided, and the electric wire to be connected can be sandwiched in a pressurized state by this drive means.

The electrode tip 12 is shown in FIG.
As shown in FIG. 3, the electrode chip 12 is slidably attached to the support member 15, and the electrode tip 12 can be fixed to the support member 15 with a screw 16 at an arbitrary position within the sliding range.

A wire connecting device 1 constructed as described above.
0 to use the core wire portion 2 as shown in FIGS. 2 (a) and 2 (b).
Two electric wires with diameters D1 and D2 of 1a and 22a (D1> D
2) Connect 21 and 22 as follows. First, as shown in FIG. 3, the driving means is operated to bring the electrode tip 12 closest to the electrode tip 11. Then, as shown in FIG. 4, loosen the screw 16 that fixes the electrode tip 12 to the support member 15,
The electrode tip 12 is slidable with respect to the support member 15, and the sandwiching surfaces 11a of the electrode tips 11 and 12,
A spacer a having the same thickness as the wire diameter D1 of the electric wire 21 is sandwiched between the two 12a, and in this state, the electrode chip 12 is fixed to the supporting member 15 with a screw 16 so that both electrode chips 1
The minimum gap between 1 and 12 is set.

Next, after the electrode chips 11 and 12 are once separated from each other, as shown in FIG.
The coatings 21b and 22b of the portions to be connected are stripped off to expose the core wire portions 21a and 22a.
Superimpose so that a and 22a intersect. And
As shown in FIG. 6, this intersection is sandwiched between the electrode chips 11 and 12 of the connection device 10, and the driving means is operated to pressurize the intersection.

In this state, an electric current is passed between the two electrode chips 11 and 12 to melt the intersecting portions of the core wire portions 21a and 22a by resistance heating at the intersecting portions of the core wire portions 21a and 22a.
When 2 is welded, as shown in FIG. 8, two electric wires 21,
22 is connected. At this time, the electrode chips 11 and 12
As shown in FIG. 7, the intersecting portion is pressed until the gap between the sandwiching surfaces 11a and 12a becomes the minimum gap that is the same as the thickness of the spacer a, but the gap between the sandwiching surfaces 11a and 12a is reduced. Since it will not be smaller than the minimum gap,
The thickness of the welded portion of the two electric wires 21 and 22 is D1 which is the wire diameter of the electric wire 21, as shown in FIG. As described above, the welded portions of the electric wires 21 and 22 do not have an extremely thin flat plate shape, and the thickness thereof is approximately the same as the wire diameter of the electric wire 21, so that sufficient mechanical strength is ensured and the external appearance is improved. Can be said to be flat and have a preferable shape.

In this case, the minimum gap S between the electrode tips 11 and 12 is adjusted to be the same as the wire diameter D1 of the thicker electric wire 21, but it is not particularly limited to this and is generally There is no problem if adjustment is made within the range of D1 ≦ S ≦ D1 + D2. Also, the diameter D of the thinner electric wire 22
If 2 is not extremely smaller than the wire diameter D1 of the thicker electric wire 21, the minimum gap S between the electrode chips 11 and 12 can be adjusted within a range of approximately D2 ≦ S ≦ D1 + D2.

When the two wires have the same wire diameter D, the minimum gap S between the electrode chips 11 and 12 may be adjusted within the range of D≤S≤2D, and especially S It is desirable to adjust it to about = D.

In this embodiment, the resistance welding machine is used as the electric wire connecting device, but the present invention is not limited to this. For example, the connecting portion of the electric wire is applied by the anvil and the exciter. It is also possible to use an ultrasonic welding machine which sandwiches the wire in a pressure state, supplies ultrasonic energy to the connecting portion by a vibrating element, and melts the connecting portion of the electric wire by vibrating and generating heat to weld the electric wires to each other.
However, when an ultrasonic welding machine is used as a wire connecting device, an adjusting means for adjusting the minimum gap between the anvil and the vibrator as a holding body for sandwiching the connecting portion of the wire is provided, and the adjusting means of the embodiment is used. Electrode tip 11, 12
It is necessary to adjust the minimum gap in advance as in the case of.

The electric wire connection method as described above is, for example, as follows.
It can be used when manufacturing a wiring member 30 having a large number of branch portions as shown in FIG. That is, FIG. 10 (a)
As shown in Fig. 2, two sets of electric wire groups in which a plurality of bare electric wires 31 are arranged at regular intervals are crossed at an angle of 90 degrees, and the crossing portion of the corresponding bare electric wires 31 of the two electric wire groups is described above. When the unnecessary portion of the bare wire 31 is cut off after connecting by the above-mentioned wire connection method, the two bare wires 31 are connected while maintaining sufficient mechanical strength, as shown in FIG. As a result, an electric wire group having a large number of branch portions formed is completed. Therefore, the synthetic resin film 3 is formed from the upper surface side and the lower surface side of the electric wire group via an adhesive.
When sandwiched by the two, the wiring member 30 as shown in FIG. 9 is completed.

[0022]

As described above, according to the method and apparatus for manufacturing an electric wire of the present invention, the minimum gap between the holding bodies is set within a predetermined range, and the holding body presses the intersection of the electric wires more than necessary. Since this is not done, the welded portion of the electric wire does not become thinner than necessary, and sufficient mechanical strength of the welded portion is secured.

Further, since it is not necessary to make a work such as forming a groove in the holding body itself, there is versatility that it can be applied to electric wires having different wire diameters, and the product cost does not increase.

[Brief description of drawings]

FIG. 1 is a schematic view showing an embodiment of an electric wire connecting device of the present invention.

FIG. 2 is a sectional view showing an electric wire to be connected.

FIG. 3 is a process drawing showing a method of connecting the electric wires of the above.

FIG. 4 is a process drawing showing the method of connecting the electric wires of the above.

FIG. 5 is a process drawing showing the method of connecting the electric wires of the above.

FIG. 6 is a process drawing showing the method of connecting the electric wires of the above.

FIG. 7 is a process drawing showing the method of connecting the electric wires of the above.

FIG. 8 is a process drawing showing the method of connecting the electric wires of the above.

FIG. 9 is a plan view showing a wiring member manufactured by using the above electric wire connecting method.

FIG. 10 is a process drawing showing the specific method for manufacturing the above wiring member.

FIG. 11 is a plan view showing the background art.

FIG. 12 is a plan view showing the background art.

FIG. 13 is a process diagram showing a conventional electric wire connecting method.

FIG. 14 is a process chart showing a conventional electric wire connection method.

FIG. 15 is a perspective view showing electric wires connected by the above connecting method.

FIG. 16 is a perspective view showing a conventional electric wire manufacturing apparatus.

[Explanation of symbols]

 10 Electric Wire Connecting Device 11, 12 Electrode Chip 13 Base 14, 15 Supporting Member 16 Screw 21, 22 Electric Wire 21a, 22a Core Wire Part a Spacer 30 Wiring Material 31 Bare Electric Wire 32 Synthetic Resin Film

Claims (8)

[Claims] 1. An electric wire having a wire diameter D is crossed, and the crossing portion is sandwiched by a sandwiching body having a flat sandwiching surface in a pressurized state and heated to melt the crossing portion, In a method for connecting electric wires by welding two electric wires, a minimum gap S between the holding bodies is set so that D ≦ S ≦ 2D, and the holding body does not pressurize the intersecting portion more than necessary. A method of connecting electric wires characterized in that 2. The electric wire connecting method according to claim 1, wherein the minimum gap S is set so that S = D. 3. An electric wire having a wire diameter D1 and a wire diameter D2 (D1> D)
2) Connecting electric wires that intersect the electric wires and sandwich the intersecting parts in a pressurized state with a sandwiching body having a flat sandwiching surface to heat them to melt the intersecting parts while welding the two electric wires. In the method, the minimum gap S between the holding bodies is set so that D1 ≦ S ≦ D1 + D2, and the holding body does not pressurize the intersecting portion more than necessary. Method. 4. The method for connecting electric wires according to claim 3, wherein the minimum gap S is set so that S = D1. 5. The sandwiching body is constituted by a pair of electrodes, and the intersecting portion is melted by resistance heating generated by supplying a current to the intersecting portion. How to connect electric wires. 6. The method of connecting an electric wire according to claim 1, wherein the crossing portion is melted by vibrating heat generated by supplying ultrasonic vibration energy to the holding body. 7. The two electric wires are crossed, and the crossed parts are sandwiched by a sandwiching body having a flat sandwiching surface in a pressurized state and heated to melt the crossing parts, and thereby the two electric wires are melted. In the device for connecting electric wires to be welded, adjusting means is provided for adjusting the minimum gap between the holding bodies to a range not less than the wire diameter of one of the electric wires and not more than the sum of the wire diameters of the two electric wires. Wire connection device. 8. The wire connecting device according to claim 7, wherein the minimum gap is adjusted by the adjusting means so that the minimum gap has a length substantially the same as the wire diameter of one of the wires.