U.S. patent application number 16/988856 was filed with the patent office on 2020-11-26 for bonding method for conductor of electric wire and electric wire.
This patent application is currently assigned to Yazaki Corporation. The applicant listed for this patent is Yazaki Corporation. Invention is credited to Naoki Ito, Yasunori Nabeta, Tomoya SATO, Kazuhide Takahashi.
Application Number | 20200373720 16/988856 |
Document ID | / |
Family ID | 1000005019718 |
Filed Date | 2020-11-26 |
View All Diagrams
United States Patent
Application |
20200373720 |
Kind Code |
A1 |
SATO; Tomoya ; et
al. |
November 26, 2020 |
BONDING METHOD FOR CONDUCTOR OF ELECTRIC WIRE AND ELECTRIC WIRE
Abstract
A bonding method for a conductor of an electric wire includes a
conductor formed of a plurality of strands and a sheath covering
the conductor such that the conductor is exposed to a predetermined
length. The bonding method ultrasonically bonds the plurality of
strands of the electric wire to each other using an anvil and a
horn. When the strands are ultrasonically bonded to each other by
clamping a part of the conductor exposed from the sheath between
the anvil and the horn throughout a predetermined length and
ultrasonically vibrating the horn, a distance from the anvil or the
horn to the sheath of the electric wire is shorter than a length of
the strands when the strand vibrates in a primary mode by
ultrasonic vibration.
Inventors: |
SATO; Tomoya; (Shizuoka,
JP) ; Takahashi; Kazuhide; (Shizuoka, JP) ;
Ito; Naoki; (Shizuoka, JP) ; Nabeta; Yasunori;
(Shizuoka, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Yazaki Corporation |
Tokyo |
|
JP |
|
|
Assignee: |
Yazaki Corporation
Tokyo
JP
|
Family ID: |
1000005019718 |
Appl. No.: |
16/988856 |
Filed: |
August 10, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
16288428 |
Feb 28, 2019 |
10797457 |
|
|
16988856 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01R 43/28 20130101;
H01R 43/0207 20130101; B23K 20/22 20130101; B23K 20/10 20130101;
H01R 43/0263 20130101; H01R 4/029 20130101; B23K 2101/32 20180801;
H01R 4/021 20130101; B23K 2101/38 20180801 |
International
Class: |
H01R 43/02 20060101
H01R043/02; H01R 4/02 20060101 H01R004/02; B23K 20/10 20060101
B23K020/10; B23K 20/22 20060101 B23K020/22; H01R 43/28 20060101
H01R043/28 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 1, 2018 |
JP |
2018-036338 |
Claims
1. A bonding method for a conductor of an electric wire including a
conductor formed of a plurality of strands and a sheath covering
the conductor such that the conductor is exposed to a predetermined
length, the bonding method ultrasonically bonding the plurality of
strands of the electric wire to each other using an anvil and a
horn, wherein when the strands are ultrasonically bonded to each
other by clamping a part of the conductor exposed from the sheath
between the anvil and the horn throughout a predetermined length
and ultrasonically vibrating the horn, a distance from the anvil or
the horn to the sheath of the electric wire is shorter than a
length of the strands when the strand vibrates in a primary mode by
ultrasonic vibration.
2. The bonding method for a conductor of an electric wire according
to claim 1, wherein an outer diameter of a middle portion of the
conductor, positioned between the bonded portion formed by the
ultrasonic bonding and a portion covered with the sheath, gradually
decreases toward the bonded portion from the portion of the
conductor covered with the sheath, a maximum value of an
intersection angle between an upper surface of the bonded portion
or a longitudinal direction of the electric wire and the strands of
the middle portion of the conductor is smaller than a predetermined
angle, and the predetermined angle is an angle at which breakage of
the strands is prevented when the ultrasonic bonding is
performed.
3. The bonding method for a conductor of an electric wire according
to claim 2, wherein the anvil and the horn are provided with an
inclined surface contacting a portion of the middle portion of the
conductor on a side of the bonded portion throughout a
predetermined length.
4. The bonding method for a conductor of an electric wire according
to claim 1, wherein, after the bonded portion is formed, a bonding
state of the bonded portion is inspected by performing at least one
of allowing a fluid having a flow rate exceeding a predetermined
speed to flow to the bonded portion and applying an acceleration
exceeding a predetermined magnitude to the bonded portion.
5. The bonding method for a conductor of an electric wire according
to claim 1, wherein a part of the sheath is held when the strands
are ultrasonically bonded to each other.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a Divisional application of U.S.
application Ser. No. 16/288,428 filed Feb. 28, 2019, which is based
upon and claims the benefit of priority from the prior Japanese
Patent Application No. 2018-036338 (filing date: Mar. 1, 2018), the
entire contents of each of which are incorporated herein by
reference.
BACKGROUND
Technical Field
[0002] The present invention relates to a bonding method for a
conductor of an electric wire and an electric wire, and in
particular, to a method for bonding a plurality of strands to each
other in a part of a conductor of an electric wire.
Related Art
[0003] Conventionally, technology has been known in which a part of
a conductor of an electric wire is clamped between an anvil and a
horn and a plurality of strands constituting the conductor are
bonded to each other by ultrasonically vibrating the horn in a
longitudinal direction of the electric wire (front rear direction)
(see JP 2015-135742 A).
[0004] On the other hand, when the strands are bonded to each other
by ultrasonic bonding using the anvil and the horn, in a middle
portion of the conductor existing between a part of the conductor
covered with the sheath and a part of the conductor clamped between
the anvil and the horn, the strands constituting the conductor is
ultrasonically vibrated, for example, in the front rear
direction.
[0005] In a case in which such an ultrasonic vibration is performed
on the conductor and when the middle portion has a large value of
the dimension, the strands in the middle portion of the conductor
are resonantly vibrated in the primary mode, the secondary mode, or
the like by being held by part of the conductor sandwiched between
the anvil and the horn and the part of the conductor covered with
the sheath.
[0006] Thus, it is apprehended that, when the strands constituting
the middle portion of the conductor are repeatedly subjected to
stress, for example, strand breakage occurs due to fatigue fracture
in a portion in which a value of the repeated stress is large.
[0007] In the present invention, the fatigue fracture caused by the
repeated stress occurring in the strands due to the ultrasonic
vibration is considered as the vibration of the primary mode.
SUMMARY
[0008] The present invention has been made in view of the above
problems, and it is an object of the present invention to provide a
bonding method for a conductor of an electric wire and the electric
wire, which ultrasonically bond a plurality of strands of an
electric wire to each other using an anvil and a horn to prevent
occurrence of strand breakage at the time of performing ultrasonic
bonding.
[0009] A bonding method for a conductor of an electric wire
according to first aspect of the present invention includes a
conductor formed of a plurality of strands and a sheath covering
the conductor such that the conductor is exposed to a predetermined
length. The bonding method ultrasonically bonds the plurality of
strands of the electric wire to each other using an anvil and a
horn. When the strands are ultrasonically bonded to each other by
clamping a part of the conductor exposed from the sheath between
the anvil and the horn throughout a predetermined length and
ultrasonically vibrating the horn, a distance from the anvil or the
horn to the sheath of the electric wire is shorter than a length of
the strands when the strand vibrates in a primary mode by
ultrasonic vibration.
[0010] An outer diameter of a middle portion of the conductor,
positioned between the bonded portion formed by the ultrasonic
bonding and a portion covered with the sheath, may gradually
decrease toward the bonded portion from the portion of the
conductor covered with the sheath. A maximum value of an
intersection angle between an upper surface of the bonded portion
or a longitudinal direction of the electric wire and the strands of
the middle portion of the conductor may be smaller than a
predetermined angle. The predetermined angle may be an angle at
which breakage of the strands is prevented when the ultrasonic
bonding is performed.
[0011] The anvil and the horn may be provided with an inclined
surface contacting a portion of the middle portion of the conductor
on a side of the bonded portion throughout a predetermined
length.
[0012] After the bonded portion is formed, a bonding state of the
bonded portion may be inspected by performing at least one of
allowing a fluid having a flow rate exceeding a predetermined speed
to flow to the bonded portion and applying an acceleration
exceeding a predetermined magnitude to the bonded portion.
[0013] A part of the sheath may be held when the strands are
ultrasonically bonded to each other.
[0014] An electric wire according to second aspect of the present
invention includes a conductor formed of a plurality of strands and
a sheath covering the conductor such that the conductor is exposed
to a predetermined length. The electric wire includes a bonded
portion spaced apart from the sheath by a predetermined distance,
in which the strands of the conductor exposed from the sheath are
bonded to each other, and a middle portion of the conductor formed
between the bonded portion and the sheath. A value of a length
dimension of the middle portion is smaller than a value of a length
dimension with which the strands are vibrated in the primary mode
by ultrasonic vibration when the bonded portion is formed.
[0015] An outer diameter of the middle portion of the conductor
positioned between the bonded portion and a portion covered with
the sheath may gradually decrease toward the bonded portion from
the portion covered with the sheath. A maximum value of an
intersection angle between an upper surface of the bonded portion
or a longitudinal direction of the electric wire and the strands of
the middle portion of the conductor may be smaller than a
predetermined angle. The predetermined angle may be an angle at
which breakage of the strands is prevented when the ultrasonic
bonding is performed.
[0016] A bonding method for a conductor of an electric wire and the
electric wire, which ultrasonically bond a plurality of strands of
an electric wire to each other using an anvil and a horn according
to the aspects of the present invention prevents occurrence of
strand breakage at the time of performing ultrasonic bonding.
BRIEF DESCRIPTION OF DRAWINGS
[0017] FIG. 1 is a perspective view illustrating an electric wire
obtained by a bonding method for a conductor of an electric wire
according to an embodiment of the present invention;
[0018] FIG. 2 is a diagram illustrating a bonding method for a
conductor of an electric wire according to an embodiment of the
present invention;
[0019] FIG. 3A is a diagram illustrating a bonding method for a
conductor of an electric wire according to an embodiment of the
present invention;
[0020] FIG. 3B is a diagram viewed along arrow IIIB of FIG. 3A;
[0021] FIG. 3C is a cross-sectional view taken along IIIC-IIIC of
FIG. 3A;
[0022] FIG. 4 is a diagram illustrating an electric wire with a
terminal in which a terminal is fixed in an electric wire obtained
by a bonding method for a conductor of an electric wire according
to an embodiment of the present invention;
[0023] FIG. 5 is a diagram illustrating a bonding method for a
conductor of an electric wire according to a modification;
[0024] FIG. 6 is a perspective view illustrating an electric wire
obtained by a bonding method for a conductor of an electric wire
according to a modification;
[0025] FIG. 7A is a diagram illustrating a bonding method for a
conductor of an electric wire according to a modification;
[0026] FIG. 7B is a diagram illustrating a bonding method for a
conductor of an electric wire according to a modification;
[0027] FIG. 8A is a diagram illustrating a bonding method for a
conductor of an electric wire according to a modification;
[0028] FIG. 8B is a diagram illustrating a bonding method for a
conductor of an electric wire according to a modification;
[0029] FIG. 9A is a diagram illustrating a bonding method for a
conductor of an electric wire according to a modification;
[0030] FIG. 9B is a diagram illustrating a bonding method for a
conductor of an electric wire according to a modification;
[0031] FIG. 10A is a diagram illustrating a bonding method for a
conductor of an electric wire according to a modification;
[0032] FIG. 10B is a diagram illustrating a bonding method for a
conductor of an electric wire according to a modification;
[0033] FIG. 11A is a diagram illustrating an electric wire in which
some of strands are not bonded to a bonded portion and a state in
which strands that are not bonded to the bonded portion (straggling
strands) extend along the bonded portion;
[0034] FIG. 11B is a diagram illustrating an electric wire in which
some of strands are not bonded to a bonded portion and a state in
which strands that are not bonded to the bonded portion are
separated from the bonded portion and stretch out;
[0035] FIG. 12A is a diagram illustrating an electric wire in which
some of strands are not bonded to a bonded portion and a state in
which strands that are not bonded to the bonded portion are
separated from the bonded portion and stretch out;
[0036] FIG. 12B is a side view of FIG. 12A;
[0037] FIG. 13A is a diagram illustrating an electric wire in which
some of strands are not bonded to a bonded portion and a state in
which strands that are not bonded to the bonded portion are
separated from the bonded portion and stretch out;
[0038] FIG. 13B is a side view of FIG. 13A;
[0039] FIG. 14A is a diagram illustrating an electric wire in which
some of strands are not bonded to a bonded portion and a state in
which strands that are not bonded to the bonded portion are
separated from the bonded portion and stretch out;
[0040] FIG. 14B is a side view of FIG. 14A;
[0041] FIG. 15 is a diagram illustrating a modification of FIGS.
11A to 14B;
[0042] FIG. 16 is a diagram illustrating a modification of FIGS.
11A to 14B; and
[0043] FIG. 17 is a diagram illustrating a modification of FIGS.
11A to 14B.
DETAILED DESCRIPTION
[0044] An electric wire 1 manufactured by a bonding method for a
conductor of an electric wire according to an embodiment of the
present invention will be described below with reference to FIGS. 1
and 2.
[0045] For convenience of description, the longitudinal direction
of the electric wire 1 is defined as the front-rear direction, one
predetermined direction orthogonal to the front rear direction is
defined as the vertical direction, and a direction orthogonal to
the longitudinal direction and the vertical direction is defined as
a width direction.
[0046] The electric wire 1 includes a conductor 3 and a sheath 5.
The conductor 3 is formed of a plurality of strands 7. The sheath 5
covers the conductor 3 such that the conductor 3 is exposed to a
predetermined length. The conductor 3 is exposed to the
predetermined length in, for example, a front end of the electric
wire 1.
[0047] A bonded portion 9 is formed in the electric wire 1. The
bonded portion 9 is spaced apart from the sheath 5 by a
predetermined distance in the front rear direction and is formed to
have a predetermined length in the front rear direction. In the
bonded portion 9, the strands 7 of the conductor 3A which is
exposed (exposed conductor) (see FIGS. 3A to 3C; separate strands
are not illustrated in FIGS. 1 and 2) are bonded to each other by
ultrasonic bonding (ultrasonic treatment) using an anvil 11 and a
horn 13. The conductor 3 becomes, for example, a single wire in the
bonded portion 9, for example.
[0048] In addition, a middle portion 15 is formed in the electric
wire 1. The middle portion 15 is formed between the bonded portion
9 and the sheath 5 in the front rear direction. In the middle
portion 15, the strands 7 of the exposed conductor 3A are not
bonded to each other, but in the vicinity of the bonded portion 9,
the strands 7 may be bonded to each other due to the influence of
the ultrasonic bonding using the anvil 11 and the horn 13.
[0049] The bonded portion 9 is formed in a rectangular
parallelepiped shape (a square column shape), and the dimension
thereof in the width direction is greater than the dimension in the
vertical direction. In addition, when viewed in the front rear
direction, a portion of the conductor 3 covered with the sheath 5
has a circular shape (see FIG. 3C).
[0050] The cross-sectional shape of the bonded portion 9 (the
cross-sectional shape taken along the plane orthogonal to the front
rear direction) is smaller than the cross-sectional shape of the
portion of the conductor 3 covered with the sheath 5. The
cross-sectional shape of the middle portion 15 gradually changes
from the circular shape of the portion covered by the sheath 5 to
the rectangular shape of the bonded portion 9.
[0051] When seen in the front-rear direction, the
rectangular-shaped bonded portion 9 is positioned inside the
circular-shaped conductor 3 covered with the sheath 5, and the
center of the conductor 3 covered with the sheath 5 and the center
of the bonded portion 9 coincide with each other. In addition, the
center of the conductor 3 covered with the sheath 5 and the center
of the bonded portion 9 may be deviated from each other.
[0052] The outer diameter (the maximum outer diameter d1
illustrated in FIG. 1 and the minimum outer diameter d2 illustrated
in FIG. 2) of the bonded portion 9 is smaller than the outer
diameter d3 (see FIG. 2) of the portion of the conductor 3 covered
with the sheath 5 (more precisely, the portion of the conductor 3
at an end of the sheath 5 at a position at which the conductor 3
starts to be exposed).
[0053] The outer diameter of the middle portion 15 of the conductor
3 gradually decreases toward the bonded portion 9 from the portion
of the conductor 3 covered with the sheath 5 (toward the front side
from the rear side).
[0054] In the electric wire 1, the value x (see FIG. 2) of a length
dimension (a dimension in the front rear direction) of the middle
portion 15 is less than a value of a length dimension L (see
formula "f1" described below) required for the strands 7 to
resonantly vibrate in the primary mode between the anvil 11 (or the
horn 13) and the sheath 5 by ultrasonic vibration, the ultrasonic
vibration performed on the strands 7 to form the bonded portion 9.
The length dimension L will be described below.
[0055] In addition, in the electric wire 1, the maximum value
.theta. of the intersection angle between an upper surface of the
bonded portion 9 or the front and rear direction and the strands 7
of the middle portion 15 of the conductor 3 is smaller than a
predetermined angle .theta.a. The upper surface of the bonded
portion 9 may be a lower surface of the bonded portion 9.
[0056] The intersection angle between the front-rear direction (the
central axis C1 of the electric wire 1) and the outer peripheral
surface 15A of the middle portion 15 may be adopted as the maximum
value .theta. of the intersection angle (see FIG. 2).
[0057] The maximum value .theta. of the intersection angle may be
an angle at which the breakage of all the strands 7 of the middle
portion 15 due to ultrasonic bonding can be prevented. More
specifically, the maximum value .theta. of the intersection angle
is an angle at which a strand 7 intersecting at the angle of
maximum value .theta. with respect to the front rear direction
among the strands 7 of the middle portion 15 does not cause fatigue
fracture even due to compression of the strands 7 at the bonded
portion 9 and ultrasonic vibration during ultrasonic bonding. The
maximum value .theta. of the intersection angle and the
predetermined angle .theta.a will be described below.
[0058] As illustrated in FIG. 4, a terminal 17 is fixed in the
electric wire 1 illustrated in FIG. 1 or 2 and therefore, an
electric wire 19 with a terminal is obtained.
[0059] The terminal 17 is provided with a wire barrel portion 21
and an insulation barrel portion 23. In the electric wire 19 with
the terminal, since the wire barrel portion 21 is crimped, the wire
barrel portion 21 and the bonded portion 9 are integrated together,
and since the insulation barrel portion 23 is crimped, the
insulation barrel portion 23 and a front end of the sheath 5 are
integrated together.
[0060] A bonding method for a conductor of an electric wire
according to an embodiment of the present invention will be
described below.
[0061] The bonding method for a conductor of an electric wire
according to an embodiment of the present invention is, as
illustrated in FIGS. 2 to 3C, a method of ultrasonically bonding a
plurality of strands 7 of an electric wire 1 to each other using an
anvil 11 and a horn 13, the electric wire 1 including a conductor 3
formed of the plurality of strands 7 and a sheath 5 covering the
conductor 3 such that the conductor 3 is exposed to a predetermined
length.
[0062] In the bonding method for a conductor of an electric wire
according to an embodiment of the present invention, a part of the
conductor (exposed conductor) 3A that is exposed is clamped between
the anvil 11 and the horn 13 throughout a predetermined length and
the horn 13 is ultrasonically vibrated in the longitudinal
direction (in the front rear direction) of the strands 7 (conductor
3) to ultrasonically bond the strands 7 to each other.
[0063] The ultrasonic bonding will be described in detail
below.
[0064] The electric wire 1 includes, as described above, a
conductor (core wire) 3 formed by gathering a plurality of strands
7 and a sheath (insulator) 5 covering (coating) the conductor
3.
[0065] In addition, in the electric wire 1 before the strands 7 are
ultrasonically bonded to each other, since the sheath 5 is not
present (the sheath 5 is eliminated) in a part of the electric wire
1 in the longitudinal direction (for example, one end), the
conductor 3 is exposed to a predetermined length (an exposed
conductor 3A is formed).
[0066] The strands 7 of the conductor 3 are made of metal such as
copper, aluminum, or aluminum alloy, and are formed in an elongated
cylindrical shape. The conductor 3 is formed in a form in which a
plurality of strands 7 are twisted, or a form in which a plurality
of strands 7 are arranged and extend linearly.
[0067] In addition, the cross-section of the portion of the
electric wire 1 where the sheath 5 is present (cross-section taken
along a plane orthogonal to the longitudinal direction) is formed
in a predetermined shape such as a circular shape.
[0068] Although the electric wire 1 is flexible, for convenience of
description, it is assumed that the electric wire 1 extends
linearly.
[0069] The cross section of the conductor 3 at the portion of the
electric wire 1 where the sheath 5 is present is formed in a
generally circular shape because a plurality of the strands 7 are
bundled in a state of almost no gap therebetween. The cross section
of the sheath 5 at the portion of the electric wire 1 where the
sheath 5 is present is formed in an annular shape with a
predetermined width (thickness). The entire of the inner
circumference of the sheath 5 is in contact with the entire of the
outer circumference of the conductor 3.
[0070] Further, in the portion of the electric wire 1 where the
sheath 5 is present, the strands 7 are tightened by the sheath 5
(the strands 7 receives an urging force from the sheath 5 such that
the cross-section of the conductor 3 becomes smaller). Therefore,
the strands 7 are gathered and are integrated together in the
portion of the electric wire 1 where the sheath 5 is present, and
vibration at each of the strands 7 is rapidly reduced. The urging
force by the sheath 5 almost does not exist in a middle portion
15.
[0071] The ultrasonic bonding of the strands 7 is, as illustrated
in FIG. 2 and FIGS. 3A and 3B, performed by using, for example, a
grinding jaw 25, an anvil plate 27, a horn 13, and an anvil 11.
[0072] In each of the anvil 11, the grinding jaw 25, the anvil
plate 27, and the horn 13, planes or planar portions (for example,
planar portions having fine irregularities) 29, 31, 33, 35 are
formed in the anvil 11, the grinding jaw 25, the anvil plate 27,
and the horn 13, respectively.
[0073] The planar portion 31 of the grinding jaw 25 and the planar
portion 33 of the anvil plate 27 are orthogonal to each other in
the width direction and face each other in parallel. The distance
between the planar portion 31 of the grinding jaw 25 and the planar
portion 33 of the anvil plate 27 is adjustable through position
determination by moving at least one of the grinding jaw 25 and the
anvil plate 27 in the width direction.
[0074] The planar portion 35 of the horn 13 and the planar portion
29 of the anvil 11 are orthogonal to each other in the vertical
direction and face each other in parallel. As understood above, the
planar portion 31 of the grinding jaw 25 and the planar portion 33
of the anvil plate 27, and the planar portion 35 of the horn 13 and
the planar portion 29 of the anvil 11 are orthogonal to each
other.
[0075] The distance between the planar portion 35 of the horn 13
and the planar portion 29 of the anvil 11 is changed by moving at
least one of the horn 13 and the anvil 11 in the vertical
direction. For example, the distance between the planar portion 35
of the horn 13 and the planar portion 29 of the anvil 11 can be
changed by moving the anvil 11 with specified force using an
actuator such as an air pressure cylinder with respect to the horn
13.
[0076] In addition, a quadrangular prism shaped space 37, both ends
of which are open in the front rear direction, is formed by the
grinding jaw 25, the anvil plate 27, the horn 13, and the anvil 11.
The quadrangular prism shaped space 37 is surrounded by the planar
portion 31 of the grinding jaw 25, the planar portion 33 of the
anvil plate 27, the planar portion 35 of the horn 13, and the
planar portion 29 of the anvil 11.
[0077] When ultrasonic bonding is performed, a conductor 3A which
is exposed (exposed conductor) is inserted into the quadrangular
prism shaped space 37 such that the longitudinal direction of the
strands 7 coincides with the front rear direction of the
quadrangular prism shaped space 37.
[0078] That is, when ultrasonic bonding is performed, the exposed
conductor 3A is inserted into the quadrangular prism shaped space
37 such that the longitudinal direction of the strands 7 is
parallel with the planar portion 31 of the grinding jaw 25, the
planar portion 33 of the anvil plate 27, the planar portion 35 of
the horn 13, and the planar portion 29 of the anvil 11 (becomes the
front rear direction).
[0079] In a state where the strands 7 of the exposed conductor 3A
are inserted into the quadrangular prism shaped space 37, the
ultrasonic bonding of the strands 7 is made by moving the anvil 11
toward the horn 13 to press the strands 7 with the anvil 11 and the
horn 13 and at the same time, ultrasonically vibrating the horn 13.
By ultrasonically bonding the strands 7, inserted into the
quadrangular prism shaped space 37, to each other, a bonded portion
9 with a predetermined length is formed in a part of the exposed
conductor 3A in the longitudinal direction.
[0080] The vibration direction of the horn 13 at the time of
ultrasonic bonding is, for example, the front rear direction (the
longitudinal direction of the strands 7). Furthermore, since the
strands 7 are pressed with the anvil 11 and the horn 13, the planar
portion 31 of the grinding jaw 25 and the planar portion 33 of the
anvil plate 27 receive the pressing force from the strands 7.
[0081] In the case of ultrasonic bonding, the distance x between
the anvil 11 and the horn 13 (more precisely, an end of the exposed
conductor 3A, clamped between the anvil 11 and the horn 13, on the
side of the sheath 5) and the sheath 5 of the electric wire 1 (see
FIG. 2) is shorter than a length L in a case where the strand 7 is
vibrated in the primary mode (a length in a case where vibration is
generated in the primary mode at a single strand 7 due to the
ultrasonic vibration of the horn 13) (x<L).
[0082] The above-mentioned length L may be expressed by the formula
f1 described below.
L = m ( 1 2 .pi. f ) 1 2 ( EI .rho. A ) 3 4 ( f 1 )
##EQU00001##
The formula f1 is a formula showing a primary vibration mode of a
strand in a middle portion of a conductor of an electric wire
according to an embodiment of the present invention; In the formula
f1, "m" is a constant, and a value thereof is "4.730". In the
formula f1, "f" is an ultrasonic frequency (the frequency of the
horn 13), and its unit is "Hz".
[0083] In the formula f1, ".rho." is the density of the strands 7,
and its unit is "kg/m.sup.3". In the formula f1, "A" is the
cross-sectional area of a single strand 7 (the area of a
cross-section taken along a plane orthogonal to the longitudinal
direction), and its unit is "m.sup.2". In the formula f1, "E" is
the Young's modulus of the strand 7 (longitudinal elastic modulus),
and its unit is "N/m.sup.2". In the formula f1, "I" is the
cross-sectional secondary moment of a single strand 7, and its unit
is "m.sup.4".
[0084] On the other hand, in the electric wire 1 illustrated in
FIG. 1 or 2, the outer diameter of a middle portion 15 of the
conductor 3 positioned between the bonded portion 9 formed by
ultrasonic bonding and a portion covered by the sheath 5 (a portion
of the conductor 3 positioned between the bonded portion 9 and the
sheath 5 in the front rear direction) gradually decreases from the
portion covered by the sheath 5 toward the bonded portion 9 (from
the rear side toward the front side), as described above.
[0085] In addition, in the electric wire 1, the maximum value
.theta. of the intersection angle between the longitudinal
direction (the front rear direction) of the electric wire 1 and the
strands 7 of the middle portion 15 of the conductor 3 is smaller
than a predetermined angle .theta.a (.theta.<.theta.a).
[0086] The predetermined angle (breakage prevention angle) .theta.a
is an angle at which breakage of all the strands 7 in the middle
portion 15 can be prevented when the ultrasonic bonding is
performed (when the ultrasonic bonding is performed or when the
ultrasonic bonding is completed).
[0087] In addition, the predetermined angle .theta.a is an angle at
which all the strands 7 in the middle portion 15 does not cause
fatigue fracture by a load applied to the strands 7 due to
compression of the strands 7 at the bonded portion 9 and ultrasonic
vibration when the ultrasonic bonding is performed or when the
ultrasonic bonding is completed.
[0088] The fatigue fracture is caused by the fluctuation load
(repeated load) applied to the strands 7 of the middle portion 15
and a static load applied to the strands 7 of the middle portion 15
and is, for example, fracture of the strands 7 in the middle
portion 15.
[0089] The fluctuation load is a load (for example, a vibration
load) applied to the strands 7 of the middle portion 15 due to the
vibration of the horn 13 at the time of ultrasonic bonding. The
repeated stress is caused in the strands 7 of the middle portion 15
due to the fluctuation load.
[0090] Since the strands 7 are vibrated similarly by the vibration
of the horn 13, values of the repeated stress occurring in the
respective strands 7 are almost equal to each other.
[0091] When the fracture of the strands 7 due to only the
fluctuation load is defined as pure fatigue fracture, it is
determined whether or not pure fatigue fracture occurs depending on
forms of repeated stress occurring in the strands 7 by ultrasonic
bonding (a force for clamping a plurality of strands 7 between the
anvil 11 and the horn 13, a vibration frequency of the horn 13, an
amplitude of the horn 13, etc.), a time during which the repeated
stress occurs in the strands 7 due to the ultrasonic bonding, a
material of the strands 7, and the like.
[0092] The static load is a load applied to the strands 7 of the
middle portion 15 as the outer diameter of the middle portion 15 of
the conductor 3 gradually decreases from the rear side toward the
front side. The static load is not generated in a state before the
strands 7 (conductor 3) are clamped between the anvil 11 and the
horn 13 (for example, see FIG. 3A).
[0093] In the state before the strands 7 are clamped between the
anvil 11 and the horn 13 (for example, see FIG. 2), and the horn 13
starts to be vibrated, a distance between the anvil 11 and the horn
13 (a distance in the vertical direction) is smaller than the outer
diameter d3 of the portion covered with the sheath 5 of the
conductor 3.
[0094] Therefore, most of the strands 7 of the middle portion 15
stretches out obliquely. Each of the strands 7 extends except a
part (except a part extending along the central axis C1), and
distortion in each of the strands 7 occurs, resulting in occurrence
of static stress in most of the strands 7.
[0095] Thereafter, when ultrasonic vibration is performed on the
horn 13, bonding of the strands 7 is made and the bonded portion 9
is then formed. In this case, the distance between the anvil 11 and
the horn 13 (the distance in the vertical direction) gradually
decreases and the shape of the middle portion 15 is gradually
changed.
[0096] As a result, the values of the static stress in the
respective strands 7 gradually increase, and as illustrated in FIG.
2, a height dimension of the bonded portion 9 becomes "d2" and,
when the ultrasonic bonding is completed, the height dimension
reaches the maximum.
[0097] Although the values of the above-mentioned repeated stress
are almost the same with respect to the respective strands 7 in the
middle portion 15, the values of the static stress are different
depending on the positions of the strands 7 in the middle portion
15.
[0098] For example, the value of the repeated stress of the strands
7 positioned at the central axis C1 and the value of the repeated
stress of the strands 7 positioned in an outer peripheral surface
15A are almost equal to each other. In contrast, the value of the
static stress of the strands 7 positioned at the central axis C1 is
almost "0", and static stress occurs in the strands 7 positioned in
the outer peripheral surface 15A. The value of the static stress
increases as the value of the intersection angle of the strand 7
with respect to the front rear direction increases.
[0099] Therefore, the static stress occurring in the strand 7
varies depending on a shape of the middle portion 15, diameters of
the strands 7, positions of the strands 7 constituting the middle
portion 15, and the like.
[0100] When the fracture of the strand 7 due to the static load
alone is considered in the formation of the bonded portion 9 using
the anvil 11 and the horn 13, only an intersection angle .theta.b
of a strand 7 in which the value of the intersection angle with
respect to the front rear direction is the maximum can be
considered after the formation of the bonded portion 9.
[0101] The intersection angle .theta.b can be calculated by the
formula f2; .theta.b=cos-1 (1/(1+.epsilon.)). Here, ".epsilon."
indicates a distortion of the strand 7 having the maximum value of
the intersection angle with respect to the front rear direction
(for example, the strand positioned in the outer peripheral surface
15A of the middle portion 15 illustrated in FIG. 2).
[0102] Also, ".epsilon." can also be expressed by the dimension a,
shown in FIG. 2 or 3, and the dimension b shown in FIG. 2. That is,
.epsilon.=(b-a)/a.
[0103] In FIG. 2, the static stress as of the strand 7 positioned
in the outer peripheral surface 15A is given by the formula f3;
.sigma.s=.epsilon.E. "E" is the longitudinal elastic modulus of the
strand 7.
[0104] Since the fatigue fracture of the strand 7 needs to be
considered in conjunction with the pure fatigue fracture of the
strand 7 and the fracture due to the static load of the strand 7,
the above-mentioned predetermined intersection angle .theta.a is
smaller than the intersection angle .theta.b for avoiding fracture
caused by the static load alone.
[0105] Therefore, a relationship of the maximum value of the
intersection angle .theta. illustrated in FIG. 2<the
predetermined intersection angle .theta.a<the intersection angle
.theta.b for avoiding fracture caused by the static load alone is
established.
[0106] The difference between the intersection angle .theta.b and
the intersection angle .theta.a is determined by a type of the
ultrasonic bonding, such as the vibration frequency of the horn 13,
as understood already.
[0107] The intersection angle between the front rear direction and
the strand 7 will be further described below.
[0108] When the bonded portion 9, the middle portion 15 and the
portion covered with sheath 5 in electric wire 1 illustrated in
FIG. 1 or 2 is viewed from a direction (a vertical direction, a
width direction, or an oblique direction with respect to the
vertical direction and the width direction) orthogonal to an
extending direction (the longitudinal direction of the electric
wire 1) of the central axis C1 of the electric wire 1, most of a
plurality of strands 7 intersect at predetermined angles with
respect to the longitudinal direction of the electric wire 1 (the
front rear direction) in the middle portions 15 as described above.
As described above, the values of the intersection angles of the
plurality of strands 7 are different from each other.
[0109] Here, the intersection angle will be described for sure.
Generally, there are two intersection angles as the intersection
angle of two straight lines on the plane. The sum of these two
intersection angles is 180.degree.. One angle of the two
intersection angles is an acute angle and the other intersection
angle is an obtuse angle. The intersection angle .theta. (.theta.a,
.theta.b) in the present specification is the smaller one of the
two intersection angles (acute angle) as already understood.
[0110] The intersection angle varies depending on the angle at
which the electric wire 1 is viewed. For example, when the strands
7 positioned in the outer peripheral surface 15A of the middle
portion 15 are viewed in the width direction, the intersection
angle becomes ".theta." as illustrated in FIG. 2, and, when the
strands 7 positioned in the outer peripheral surface 15A of the
middle portion 15 are viewed in the vertical direction, the
intersection angle becomes "0.degree.".
[0111] In the case where the strands 7 are not twisted, the strands
7 are parallel to each other and extend in the longitudinal
direction of the electric wire 1 in the portion of the conductor 3
covered with the sheath 5. In addition, when the strands 7 are not
twisted, the maximum of the intersection angle is indicated by
reference symbol ".theta." in FIG. 2.
[0112] Although the intersection angle of the strands 7 position in
the outer peripheral surface 15A of the middle portion 15 is
largest in the above description, the intersection angle of the
strands 7 positioned in ridge lines 15B of the middle portion 15
illustrated in FIG. 1 or other strands may be the largest.
[0113] In the above description, the strands 7 are not twisted, and
therefore, the intersection angle is caught two-dimensionally, but,
in a case where the strands 7 are twisted, the intersection angle
may be caught three-dimensionally by considering the twisting of
the strands 7.
[0114] Although the bonded portion 9 is formed in a rectangular
shape in the above description, the bonded portion 9 may be formed
in a cylindrical shape as illustrated in FIG. 6. In addition, the
cross-sectional shape of the portion of the conductor 3 covered
with the sheath 5 may have another shape such as a rectangular
shape.
[0115] Furthermore, in the above description, although, when
ultrasonic bonding is performed, as illustrated in FIG. 2, the
position of the front end of the conductor 3 of the electric wire 1
and the position of the front end of the anvil 11 and the horn 13
coincide with each other in the front-rear direction, the front end
of the conductor 3 of the electric wire 1 may be positioned on the
front side than the front ends of the anvil 11 and the horn 13, or
may be positioned on the rear side, as illustrated in FIG. 5.
[0116] On the other hand, when ultrasonic bonding of the conductor
3 of the electric wire 1 is performed using the anvil 11 and the
horn 13, as illustrated in FIGS. 2, 3A and 3C, the sheath 5 of the
electric wire 1 is clamped by a sheath holding part 39 having a
pair of dampers 41.
[0117] In this case, the distance L1 between the pair of clampers
41 and the front end of the sheath 5 is appropriately determined.
The distance L1 may be set to "0", or the value of the distance L1
may be smaller or larger than the value of the outer diameter d4 of
the electric wire 1 (the sheath 5).
[0118] Furthermore, as illustrated in FIGS. 10A and 10B, the anvil
11 and the horn 13 may be provided with an inclined surface 43. The
inclined surface 43 is formed in such a manner that the
above-mentioned angle .theta. is formed at a portion of the middle
portion 15 of the conductor 3 of the electric wire 1 on the side of
the bonded portion 9 and is in contact with the conductor 3 over a
predetermined length.
[0119] Although the bonded portion 9 is formed at one end in the
longitudinal direction of one electric wire 1 in the above
description, as illustrated in FIGS. 9A and 9B, the bonded portion
9 is formed at the middle portion of one electric wire 1 in the
longitudinal direction.
[0120] As illustrated in FIGS. 7A to 8B, strands 7 of conductors 3
of a plurality of electric wires (for example, two electric wires)
1 may be ultrasonically bonded to each other to form one bonded
portion 9.
[0121] In the embodiment illustrated in FIGS. 7A and 7B, by forming
the bonded portion 9 at an end of one electric wire 1 (1a) and an
end of the other electric wire 1 (1b), the electric wire 1a and the
electric wire 1b are connected in series, so that the electric wire
1b is connected to the electric wire 1a at the bonded portion 9,
and the electric wire 1a and the electric wire 1b extends in a
single straight line.
[0122] In the embodiment illustrated in FIGS. 8A and 8B, by forming
the bonded portion 9 at an end of one electric wire 1 (1a) and an
end of the other electric wire 1(1b), the electric wire 1a and the
electric wire 1b are connected in parallel so that the electric
wire 1a and the electric wire 1b extends in parallel from the
bonded portion 9.
[0123] On the other hand, in the ultrasonic bonding of the
conductor 3 of the electric wire 1, the bonding state of the bonded
portion 9 may be inspected after the bonded portion 9 has been
formed.
[0124] The inspection for the bonding state of the bonded portion 9
is performed in other to determine whether or not a strand
(straggling strand) 7A that is not bonded to the bonded portion 9
exists, and as illustrated in FIGS. 11A to 14, the inspection is
made by allowing a fluid (for example, air) to flow to the bonded
portion 9 at a flow rate exceeding a predetermined speed.
[0125] More specifically, the inspection for the bonding state of
the bonded portion 9 is performed, as illustrated in FIGS. 11A and
11B, and FIGS. 12A and 12B, by blowing compressed air of a
predetermined pressure toward the bonded portion (see the arrow)
from an ejection port (an ejection port with a predetermined inner
diameter) of a jet nozzle (not illustrated) spaced apart from the
bonded portion 9 by a predetermined distance.
[0126] In the embodiment illustrated in FIGS. 11A and 11B, the jet
nozzle is arranged on the front side than the front end of the
bonded portion 9 of the electric wire 1, and the compressed air is
jetted to the rear side from the jet nozzle for a predetermined
time and is then brown to the bonded portion 9 positioned on the
rear side of the jet nozzle.
[0127] FIG. 11A illustrates a state before compressed air is blown,
and FIG. 11B illustrates a state after compressed air is blown.
[0128] In FIG. 11A, a strand 7A that is not bonded to the bonded
portion 9 substantially sticks to the bonded portion 9, and it is
difficult to determine whether or not the strand 7A that is not
bonded to the bonded portion 9 exist with the naked eye (visual
inspection by visual observation).
[0129] In this regard, in FIG. 11B, the strand 7A that is not
bonded to the bonded portion 9 is deformed by the compressed air
and is separated from the bonded portion 9 so that it is possible
to easily determine whether or not the strand 7A that is not bonded
to the bonded portion 9 exist even with the naked eye.
[0130] In the embodiment illustrated in FIGS. 12A and 12B, the jet
nozzle is arranged on the lateral side of the bonded portion 9, and
the compressed air is blown toward the bonded portion 9 from the
direction (for example, width direction) orthogonal to the
longitudinal direction (the front rear direction) of the electric
wire 1 for a predetermined time.
[0131] FIGS. 12A and 12B illustrate a state after compressed air is
blown, and in FIGS. 12A and 12B, the strand 7A that is not bonded
to the bonded portion 9 is deformed by the compressed air and is
separated from the bonded portion 9 so that it is possible to
easily determine whether or not the strand 7A that is not bonded to
the bonded portion 9 exist even with the naked eye.
[0132] In addition, the inspection for the bonding state of the
bonded portion 9 may be performed, as illustrated in FIGS. 13A and
13B, by sucking air by a suction port (a suction port with a
predetermined inner diameter) of a suction nozzle (not illustrated)
spaced apart from the bonded portion 9 by a predetermined distance
at a predetermined flow rate (see the arrow).
[0133] In the embodiment illustrated in FIGS. 13A and 13B, suction
nozzles are arranged on the lower side and the upper side of the
bonded portion 9 to suck air from the lower side and the upper side
of the bonded portion 9. In FIGS. 13A and 13B, what are indicated
by reference numeral 7A are the strands 7A that are not bonded to
the bonded portion 9 and are separated from the bonded portion
9.
[0134] In the embodiments illustrated in FIGS. 12 to 14, in order
to inspect the whole of the bonded portion 9 all over, it may be
possible that the jet nozzle and the suction nozzle is relatively
moved or rotated (rotation in the case of the bonded portion 9,
revolution in the case of the nozzle) with respect to the bonded
portion 9 (electric wire 1), and the compressed air is blown or the
air is sucked.
[0135] In addition, air may be blown or sucked by the nozzle
intermittently. For example, the flow of air may be turned on and
off every second.
[0136] Further, the bonding state of the bonded portion 9 may be
inspected by applying an acceleration exceeding a predetermined
magnitude to the bonded portion 9 as illustrated in FIGS. 14A and
14B.
[0137] In the embodiment illustrated in FIGS. 14A and 14B, the
strand 7A that is not bonded to the bonded portion 9 is separated
from the bonded portion 9 by centrifugal force generated when the
bonded portion 9 is rotated around the central axis C1 at a speed
equal to or higher than a predetermined rotation speed.
[0138] Instead of or in addition to rotating of the bonded portion
9, by performing shaking of the bonded portion 9 or the like, the
strands 7 may be separated from the bonded portion 9 by inertial
force of the strand 7A that are not bonded to the bonded portion
9.
[0139] Further, after the bonded portion 9 is formed, by performing
at least one (for example both) of: allowing a fluid having a flow
rate exceeding a predetermined speed to flow to the bonded portion
9; and applying an acceleration exceeding a predetermined magnitude
to the bonded portion 9, the bonding state of the bonded portion 9
may be inspected.
[0140] Further, after the strand 7A that is not bonded to the
bonded portion 9 is separated from the bonded portion 9, inspection
may be performed not by visual inspection but by an inspection
apparatus having an imaging part, an image processing part, a
memory, or a CPU. That is, after the strand 7A that is not bonded
to the bonded portion 9 is separated from the bonded portion 9, the
bonded portion 9 and the strand 7A are photographed by the imaging
part, and the photographed image data is processed by the image
processing part, and the strand 7A that is not bonded to the bonded
portion 9 may be detected.
[0141] In addition, by allowing a fluid having a flow rate
exceeding a predetermined speed to flow to the middle portion 15 or
applying an acceleration exceeding a predetermined magnitude to the
middle portion 15, the strand breakage occurring in the middle
portion 15 may be inspected.
[0142] According to the electric wire 1, since a distance from the
anvil 11 or the horn 13 to the sheath 5 of the electric wire 1 is
shorter than a length of the strands 7 when the strand 7 vibrates
in the primary mode by ultrasonic vibration, the vibration of the
strand 7 is effectively suppressed and a specific portion cannot be
subjected to repeated stress, thereby preventing occurrence of
strand breakage when ultrasonic bonding is performed.
[0143] Further, according to the electric wire 1, the maximum value
.theta. of the intersection angle between the longitudinal
direction of the electric wire 1 and the strand 7 in the middle
portion 15 of the conductor 3 is smaller than the predetermined
angle .theta.a, and the predetermined angle .theta.a is an angle at
which all of the strands 7 of the middle portion 15 can be
prevented from being broken at the time of ultrasonic bonding,
thereby preventing occurrence of strand breakage when ultrasonic
bonding is performed.
[0144] Further, according to the electric wire 1, the maximum value
.theta. of the intersection angle between the longitudinal
direction of the electric wire 1 and the strand 7 in the middle
portion 15 of the conductor 3 is smaller than the predetermined
angle .theta.a, and the predetermined angle .theta.a is an angle at
which fatigue fracture cannot be caused in all of the strands 7 of
the middle portion 15 at the time of ultrasonic bonding, thereby
more reliably preventing occurrence of strand breakage at the time
of ultrasonic bonding.
[0145] Further, according to the electric wire 1, since the
inclined surface 43 is formed on the anvil 11 and the horn 13, a
portion of the middle portion 15 on the side of the bonded portion
9 is also clamped between the anvil 11 and the horn 13
appropriately when ultrasonic bonding is performed. As a result, it
is possible to accurately hold the boundary between the bonded
portion 9 and the middle portion 15 and the vicinity thereof and to
suppress occurrence of stress concentration in the strand 7 in the
boundary between the bonded portion 9 and the middle portion
15.
[0146] Further, according to the electric wire 1, after the bonded
portion 9 is formed, by allowing a fluid having a flow rate
exceeding a predetermined speed to flow into the bonded portion 9
or applying an acceleration exceeding a predetermined magnitude to
the bonded portion 9, it is possible to easily discover a strand 7
that does not form the bonded portion 9 with the naked eye.
[0147] That is, only when the bonded portion 9 is simply formed, it
seems like that the strand 7 that is not bonded to the bonded
portion 9 also extend in the front rear direction in a manner that
it sticks to the bonded portion 9 and is integrated with the bonded
portion 9.
[0148] However, by allowing a fluid having a flow rate exceeding a
certain speed to flow to the bonded portion 9 or applying an
acceleration exceeding a predetermined magnitude to the bonded
portion 9, a strand (for example, one strand which exists alone) 7A
that does not form the bonded portion 9 is separated from the
bonded portion 9 and stretches out. As a result, the strand 7A that
is not bonded to the bonded portion 9 can be easily found with the
naked eye, and defective products can be eliminated.
[0149] Further, according to the electric wire 1, since a part of
the sheath 5 is held when ultrasonic bonding of the strands 7 is
performed, it is possible to reliably prevent the strands 7 from
being vibrated in the portion of the conductor 3 covered with the
sheath 5 and to precisely secure the length x of the middle portion
15, thereby more reliably preventing occurrence of strand breakage
at the time of ultrasonic bonding.
[0150] Although the bonded portion 9 is formed by ultrasonic
bonding in the above description, the bonded portion 9 may be
formed by other treatments than the ultrasonic treatment, such as
cold welding, friction stir welding, friction welding,
electromagnetic welding, diffusion welding, brazing, soldering,
resistance welding, electron beam welding, laser welding, and light
beam welding.
* * * * *