The present application claims priority to Japanese Patent Application No. 2018-173638 filed on Sep. 18, 2018, the entire contents of which are incorporated by reference herein.
The present invention relates to a terminal-wire (terminal wire) bonding method of ultrasonically connecting exposed cores of a plurality of wires together and a bonded terminal-wire (terminal wire).
An example of this type of wire connecting method is disclosed in JP 2013-118196 A. As illustrated in
The ultrafine wire 2 close to the anvil 8 at the ultrasonic bonding during the bonding, is less likely to break due to contact with the horn 6, so that the ultrafine wire 2 can be ultrasonically bonded with the possibility of cutting reduced.
However, the conventional wire connecting method requires the temporary bonding after the preparing but before the bonding, resulting in a rise in the number of steps and a rise in cost. In addition, the core 2a that bonds to the core 1a of the other wire 1, is likely to be damaged, such as breaking.
Thus, the present invention has been made in order to solve the problem, and an object of the present invention is to provide a terminal-wire bonding method capable of bonding cores of a plurality of wires together simply at low cost without breaking, the terminal-wire bonding method enabling inhibition of a terminal connected with an end of each wire, from being damaged, such as breaking, and a bonded terminal-wire.
According to an aspect of the present invention, provided is a terminal-wire bonding method with a first terminal-wire and a second terminal-wire, the first terminal-wire having a first terminal connected with a first core exposed from an insulating sheath at a first end, the first core being exposed from the insulating sheath at a second end of the first terminal-wire, the second terminal-wire having a second terminal connected with a second core exposed, at a first end, from an insulating sheath longer than the insulating sheath of the first terminal-wire, the second core being exposed from the insulating sheath longer than the insulating sheath of the first terminal-wire, at a second end of the second terminal-wire, the terminal-wire bonding method including: arranging the second core at the second end onto a side of a horn for ultrasonic bonding and the first core at the second end onto a side of an anvil for ultrasonic bonding; and bonding the first core at the second end and the second core at the second end together by ultrasonic bonding between the horn and the anvil.
According to an aspect of the present invention, provided is a bonded terminal-wire including: a first terminal-wire having a first terminal connected with a first core including a plurality of strands exposed from an insulating sheath at a first end, the first core being exposed from the insulating sheath at a second end of the first terminal-wire; and a second terminal-wire having a second terminal connected with a second core including a plurality of strands exposed, at a first end, from an insulating sheath longer than the insulating sheath of the first terminal-wire, the plurality of strands each being identical in thickness to each strand of the first core, the second core being exposed from the insulating sheath longer than the insulating sheath of the first terminal-wire, at a second end of the second terminal-wire, in which the first core at the second end and the second core at the second end are bonded together by ultrasonic bonding between a horn and an anvil for ultrasonic bonding with the second core at the second end arranged on a side of the horn and the first core at the second end arranged on a side of the anvil, and the plurality of strands of the second core at the second end on the side of the horn is bonded with collapse stronger than collapse of the plurality of strands of the first core at the second end on the side of the anvil.
According to the present invention, the number of steps can be reduced in comparison to the conventional method, and the first core at the second end of the first terminal-wire and the second core at the second end of the second terminal-wire can be bonded together simply at low cost. In addition, the first end of each wire can receive weak vibration at ultrasonic bonding, so that the first terminal at the first end of the first terminal-wire can be inhibited from being damaged, such as breaking.
Embodiments of the present invention will be described below on the basis of the drawings.
As illustrated in
The respective cores 12 and 22 of the first terminal-wire 10 and the second terminal-wire 20 that bond together are identical in material and in sectional area. Examples of the material of the cores 12 and 22 include aluminum, aluminum alloy, copper, copper alloy, a tinned copper, and aluminum doped with carbon nanotubes. The cores 12 and 22 each may be a stranded conductor or a single core.
As illustrated in
Next, the terminal-wire bonding method according to the first embodiment will be described. As illustrated in
Next, as illustrated in
At this time, the ultrasonic vibration oscillated from the horn 6 travels from the second end 20b to the second terminal-wire 20 and then propagates to the first end 20a while damping in the second terminal-wire 20. The vibration of the horn 6 propagates to the anvil 8 while damping. The first terminal-wire 10 shorter in wire length arranged on the side of the anvil 8, receives the vibration damped more than that of the second terminal-wire 20 longer in wire length on the side of the horn 6, and thus the vibration that travels to the first end 10a weakens. Thus, the first core 12 exposed from the insulating sheath 11 of the first terminal-wire 10 shorter in wire length, receive less damage, such as breaking. The second terminal-wire 20 longer in wire length arranged on the side of horn 6, causes the vibration received from the horn 6, to damp in the second terminal-wire 20, so that the vibration that travels to the first end 20a weakens.
That is, as the comparative example illustrated in
As illustrated in
As described above, the arrangement and bonding of the first core 12 at the second end 10b of the first terminal-wire 10 shorter in wire length, on the side of the anvil 8, enables the cores 12 and 22 at the first ends 10a and 20a of the wires 10 and 20 (crimp terminals 13 and 23) to receive less vibration. In addition, the first terminal-wire 10 and the second terminal-wire 20 can be bonded together with the first terminal-wire 10 shorter in wire length, inhibited from being damaged, as much as possible.
A terminal-wire bonding method according to the second embodiment is different from that according to the first embodiment in that a second core 22 exposed by peeling of an intermediate 20c of an insulating sheath 21 of a second terminal-wire 20 longer in wire length and a first core 12 exposed from an insulating sheath 11 at a second end 10b of a first terminal-wire 10 shorter in wire length are ultrasonically bonded together. Note that the other configurations are similar to those according to the first embodiment. Thus, the same constituent elements are denoted with the same reference signs, and the detailed descriptions thereof will be omitted.
The terminal-wire bonding method according to the second embodiment will be described. At setting, the second core 22 exposed by intermediate peeling of the insulating sheath 21 of the second terminal-wire 20 longer in wire length is arranged on the side of a horn 6, and the first core 12 exposed from the insulating sheath 11 at the second end 10b of the first terminal-wire 10 shorter in wire length is arranged on the side of an anvil 8. At bonding, the second core 22 exposed by the intermediate peeling of the insulating sheath 21 of the second terminal-wire 20 longer in wire length and the first core 12 exposed from the insulating sheath 11 at the second end 10b of the first terminal-wire 10 shorter in wire length, are bonded together by ultrasonic bonding between the horn 6 and the anvil 8. Thus, a bonded terminal-wire 31 illustrated in
The terminal-wire bonding method according to the third embodiment is different from that according to the first embodiment in that a core 27 including a plurality of strands 27a exposed from an insulating sheath 26 at a second end 25b of the dummy wire 25 for damping ultrasonic vibration from the horn 6 to the first terminal-wire 10 and the second terminal-wire 20, is arranged on the side of the horn 6 with respect to a second core 22 at a second end 20b, for ultrasonic bonding. Note that the other configurations are similar to those according to the first embodiment. Thus, the same constituent elements are denoted with the same reference signs, and the detailed descriptions thereof will be omitted.
The terminal-wire bonding method according to the third embodiment will be described. At setting, the core 27 exposed from the insulating sheath 26 of the dummy wire 25 for damping propagation of ultrasonic vibration from the horn 6 to the first terminal-wire 10 shorter in wire length and the second terminal-wire 20 longer in wire length, is arranged intermixedly on the side of the horn 6 with respect to the second core 22 at the second end 20b of the second terminal-wire 20 longer in wire length. At bonding, a first core 12 at a second end 10b, the second core 22 at the second end 20b, and the core 27 of the dummy wire 25 are bonded together by ultrasonic bonding between the horn 6 and the anvil 8. Thus, a bonded terminal-wire 32 illustrated in
Note that, according to each embodiment, the core exposed from the insulating sheath at the first end of each wire is connected with the terminal by crimping. However, the core and the terminal may be connected together by, for example, ultrasonic bonding, laser bonding, resistance bonding, or electromagnetic welding.
According to each embodiment, after connecting the terminal with the core exposed from the insulating sheath at the first end of each wire, the cores at the second ends of the two different-length wires are boned together by ultrasonic bonding. However, after bonding the cores at the second ends of the two different-length wires together by ultrasonic bonding, the core exposed from the insulating sheath at the first end of each of the two different-length wires may be connected with the terminal by, for example, crimping.
Furthermore, according to each embodiment, the wires having the respective cores identical in material are bonded together, but the wires having the respective cores different in material may be bonded together. For example, in a case where a copper (Cu) wire and an aluminum (Al) wire are bonded together, the Cu wire is arranged on the side of the horn for bonding. Furthermore, the number of wires is not limited to two. For example, in a case where three wires of two thin Cu wires and one thick Al wire are bonded together, each thin Cu wire is arranged on the side of the horn for bonding.
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JP2018-173638 | Sep 2018 | JP | national |
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