JP6990858B2 - Terminal and terminal joining method - Google Patents

Description

The present disclosure relates to terminals and a method of joining terminals.

Conventionally, Patent Document 1 discloses a terminal to which a coil terminal is connected by winding a coil terminal around a terminal. At this terminal, the coil terminal is sandwiched by the holding portion in order to secure the strength of the coil terminal.

Japanese Unexamined Patent Publication No. 11-186023

However, in the conventional terminal, the coil terminal may be separated from the sandwiching portion, and in this case, it is difficult to sufficiently secure the joint strength between the coil terminal and the terminal. For this reason, there is a demand for ensuring the joint strength between the coil terminal and the terminal.

Therefore, an object of the present disclosure is to provide a terminal and a terminal joining method capable of ensuring the joining strength between the columnar metal terminal and the metal wire.

In order to achieve the above object, the terminal according to one embodiment of the present disclosure includes a columnar metal terminal and a metal wire, and the electric resistance value of the metal wire is larger than the electric resistance value of the columnar metal terminal. The metal wire is wound around the columnar metal terminal, the metal wire and the columnar metal terminal are metal-bonded , and the columnar metal terminal has a polygonal column shape having a plurality of terminal surfaces, and the columnar metal terminal is formed. In the vicinity of the metal terminal, the metal wires have intersections where the columnar metal terminals overlap each other in the circumferential direction, and some of the terminal surfaces of the plurality of terminal surfaces are joint terminal surfaces on which the intersections are not arranged. On the joint terminal surface, the columnar metal terminal and the metal wire are metal-bonded .

Further, the terminal joining method according to one embodiment of the present disclosure includes a first step of winding a metal wire having an electric resistance value larger than the electric resistance value of the columnar metal terminal around the columnar metal terminal, and the first step. Later, a pair of opposing weld electrodes are brought into contact with the metal wire, a current is passed from the pair of weld electrodes to the metal wire and the columnar metal terminal, and Joule heat of the metal wire and the columnar metal terminal causes the said. In the second step of metal-bonding the metal wire and the columnar metal terminal, and in the first step, the metal wires are placed in the circumferential direction of the columnar metal terminal at a portion where the metal wire starts to be wound around the columnar metal terminal. The metal wire is wound around the columnar metal terminal so as to form an overlapping intersection, and in the second step, the pair of weld electrodes facing each other and the intersection of the metal wire are avoided from contacting each other. The columnar metal terminal around which the metal wire is wound is arranged, and the metal wire and the columnar metal terminal are metal-bonded .
Further, the terminal joining method according to one embodiment of the present disclosure includes a first step of winding a metal wire having an electric resistance value larger than the electric resistance value of the columnar metal terminal around the columnar metal terminal, and the first step. Later, a pair of opposing weld electrodes are brought into contact with the metal wire, a current is passed from the pair of weld electrodes to the metal wire and the columnar metal terminal, and Joule heat of the metal wire and the columnar metal terminal causes the said. A second step of metal-bonding the metal wire and the columnar metal terminal is included. In the first step, a plurality of the metal wires are wound around one columnar metal terminal, and each of the metal wires is connected to the columnar metal. The metal wires are formed so as to form overlapping portions in the circumferential direction of the terminals, and in the second step, the metal wires are arranged so as to avoid contact between the pair of weld electrodes facing each other and the respective intersections of the plurality of the metal wires. The columnar metal terminal around which the metal is wound is arranged, and the metal wire and the columnar metal terminal are metal-bonded.

According to the present disclosure, it is possible to secure the bonding strength between the columnar metal terminal and the metal wire.

FIG. 1 is a schematic view showing terminals according to an embodiment. FIG. 2 is a cross-sectional view showing a terminal according to an embodiment of the line II-II of FIG. FIG. 3 is a diagram showing a state in which a metal wire is entwined with a columnar metal terminal according to an embodiment. FIG. 4 is a flow chart showing a process of entwining a metal wire around a columnar metal terminal according to an embodiment. FIG. 5 is a diagram showing a process of making an assembly, thermocompression bonding, and metal joining according to an embodiment. FIG. 6 is a flow chart showing a process of metal-bonding an assembly according to an embodiment. FIG. 7 is an explanatory diagram showing a pressing amount at the time of thermocompression bonding when the diameters of the metal wires are the same according to the embodiment. FIG. 8 is an explanatory diagram illustrating a conduction path when metal bonding is performed according to the embodiment. FIG. 9 is a schematic view showing a columnar metal terminal around which a plurality of metal wires are wound according to an embodiment. FIG. 10 is an explanatory diagram showing a pushing amount at the time of thermocompression bonding when the diameters of the metal wires are different according to the embodiment.

Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. Each of the embodiments described below is a comprehensive or specific example. The numerical values, shapes, materials, components, arrangement positions and connection forms of the components, steps, the order of steps, etc. shown in the following embodiments are examples, and are not intended to limit the present disclosure. Further, among the components in the following embodiments, the components not described in the independent claim indicating the highest level concept are described as arbitrary components.

It should be noted that each figure is a schematic view and is not necessarily exactly illustrated. Further, in each figure, the same reference numerals are given to substantially the same configurations, and duplicate explanations will be omitted or simplified.

Hereinafter, the terminal and the method of joining the terminal according to the embodiment of the present disclosure will be described.

(Embodiment)
[Constitution]
FIG. 1 is a schematic view showing a terminal 1 according to an embodiment.

As shown in FIG. 1, the terminal 1 is provided in each of a plurality of coils constituting a stator that constitutes a part of a motor mounted on the device. The terminal 1 supplies electric power to the coil from the circuit board mounted on the power supply unit of the apparatus. The terminal 1 has a columnar metal terminal 10 and a metal wire 20.

FIG. 2 is a cross-sectional view showing a terminal 1 according to an embodiment of the line II-II of FIG.

As shown in FIG. 2, the columnar metal terminal 10 is a columnar metal member electrically connected to a coil. The columnar metal terminal 10 is electrically connected to a metal wire 21 that constitutes a part of the metal wire 20. Specifically, the columnar metal terminal 10 is welded to the metal wire 21 in a state where the metal wire 21 is wound, that is, the metal wire 21 is metal-bonded. The columnar metal terminal 10 is, for example, a member in which the periphery of iron (Fe) is composed of a copper (Cu) layer, and the periphery of copper is coated with tin (Sn). In the present embodiment, the metal wire 21 and the columnar metal terminal 10 are metal-bonded in a state where the metal wire 21 is entwined with the columnar metal terminal 10. Tangled means that they are tied in a wound state, and that there is a portion where the metal wires 21 overlap. In the present embodiment, the metal wire 21 is singly wound around the columnar metal terminal 10 except for the intersection.

The term "metal bonding" as used herein means to include thermocompression bonding, ultrasonic bonding, solid phase bonding such as fusing, diffusion bonding, and melt bonding such as resistance welding. In this embodiment, resistance welding, which is an example of welding, will be mainly described, but the metal wire 21 and the columnar metal terminal 10 are connected by thermal bonding, ultrasonic bonding, solid bonding such as fusing, and diffusion bonding. It may be joined.

In the present embodiment, the columnar metal terminal 10 is a rectangle having a short side of about 0.4 mm and a long side of about 0.6 mm, the thickness of the copper layer is about 25 μm, and the thickness of the tin layer is about 3 to 6 μm. Further, in the metal wire 20, the diameter of the metal wire 21 is about 0.15 mm.

The columnar metal terminal 10 may be made of a material containing copper as a main component, or a member in which a tin layer is laminated on the surface of copper may be used. Therefore, iron and tin are not essential constituents of the columnar metal terminal 10.

The columnar metal terminal 10 has a polygonal column shape. In the present embodiment, the columnar metal terminal 10 is a quadrangle when viewed from the longitudinal direction. The columnar metal terminal 10 is not limited to a quadrangle when viewed from the longitudinal direction, and may have a polygonal shape, a circular shape, or a combination thereof.

The columnar metal terminal 10 has a rectangular cross section in a direction intersecting the longitudinal direction of the columnar metal terminal 10, and has a pair of long side surfaces and a pair of short side surfaces. The long side surface is a surface whose cross section constitutes the long side of a rectangle, and the short side surface is a surface whose cross section constitutes the short side of a rectangle. The short side surface and the long side surface are terminal surfaces 11 which will be described later. The long side surface is a joint terminal surface 11a, which will be described later.

The metal wire 21 is a wire that forms a part of the metal wire 20 and has an insulating coating formed therein. The metal wire 21 is metal-bonded to a pair of long side faces.

The metal wire 21 forms an intersection 23 in which the metal wires 21 overlap each other in the circumferential direction of the columnar metal terminal 10 in the vicinity of the columnar metal terminal 10. The intersection 23 is formed so as to be in contact with either short side surface.

The cross section in the direction intersecting the longitudinal direction of the columnar metal terminal 10 may be a square, that is, there is no distinction between a long side and a short side. In this case, the terminal surface 11 and the terminal surface 11a described above are long sides. Identification that does not originate from the shape such as a surface or a short side surface is performed.

[Terminal joining method]
A method of winding the metal wire 20 around the columnar metal terminal 10 will be described.

First, the columnar metal terminal 10 and the metal wire 20 before joining will be described.

The columnar metal terminal 10 has a plurality of terminal surfaces 11. A part of the terminal surfaces 11 among the plurality of terminal surfaces 11 is a joint terminal surface 11a on which the intersection 23 is not arranged. The joining terminal surface 11a is a surface on which the columnar metal terminal 10 and the metal wire 20 are joined. The columnar metal terminal 10 used in this joining method is a square columnar as described above.

Further, the metal wire 20 is a wire having an insulating coating formed on the metal wire 21, and is, for example, an enamel wire, a lead wire, or the like. The metal wire 21 is made of, for example, a material containing aluminum as a main component. The insulating coating is made of a resin material such as urethane, polyester, polyesterimide, or polyamideimide. Further, the electric resistance value of the metal wire 20 is larger than the electric resistance value of the copper layer of the columnar metal terminal 10.

FIG. 3 shows a state in which the metal wire 20 is entwined with the columnar metal terminal 10 according to the embodiment. FIG. 3A shows a state in which the metal wire 20 is entwined with the columnar metal terminal 10 when viewed from a direction intersecting the longitudinal direction of the columnar metal terminal 10. FIG. 3B shows a state in which the metal wire 20 is entwined with the columnar metal terminal 10 when viewed from the longitudinal direction of the columnar metal terminal 10. Further, FIG. 4 is a flow chart showing a process of entwining the metal wire 20 with the columnar metal terminal 10 according to the embodiment.

As shown in FIGS. 3 and 4, first, the columnar metal terminal 10 is fixed so that the metal wire 20 can be wound around (S111). The portion where the metal wire 20 starts to be wound is arranged in contact with the terminal surface 11 of the columnar metal terminal 10, and the portion where the metal wire 20 starts to be wound is pulled and wound around the columnar metal terminal 10.

Next, when winding the first and second turns around the winding starting portion, the metal wire 20 is wound in a coil shape so as to overlap and intersect the winding starting portion (S112). As a result, the metal wire 20 has an intersection 23 formed on one surface of the columnar metal terminal 10. Specifically, when the metal wire 20 is wound around the columnar metal terminal 10, the intersection 23 is the metal wire to be wound around the winding start portion of the metal wire 20 when the metal wire 20 and the columnar metal terminal 10 are viewed in a plan view. By crossing the 20, it is a portion where the single metal wires 20 overlap each other. In the present embodiment, the intersection 23 is configured at a position facing the terminal surface 11. Step S112 is an example of the first step.

Further, the metal wire 20 is wound around the columnar metal terminal 10 for several turns (S113). In this way, by cutting the portion where the metal wire 20 starts to be wound with nippers or the like to prepare the metal wire 20, the assembly shown in FIG. 5 in which the metal wire 20 is wound around the columnar metal terminal 10 can be obtained. FIG. 5 is a diagram showing steps of assembling, thermocompression bonding, and joining according to an embodiment.

Next, the metal wire 20 and the columnar metal terminal 10 are joined. In the present embodiment, the metal wire 20 is realized by thermocompression bonding and resistance welding to the columnar metal terminal 10.

FIG. 6 is a flow chart showing a process of joining an assembly according to an embodiment.

As shown in FIGS. 5 and 6, first, the above-mentioned assembly is placed between a pair of welding electrodes 30 included in the resistance welder (S121). Specifically, the assembly is arranged between the pair of welding electrodes 30 so that the pair of bonding terminal surfaces 11a of the columnar metal terminal 10 and the pair of welding electrodes 30 oppose each other on a one-to-one basis.

Next, the assembly is thermocompression bonded by a pair of welding electrodes 30 (S122). At this time, the resistance welder passes a current through the pair of welding electrodes 30 as shown by the broken line arrow in FIG. At this time, a load is applied to the metal wire 21 by the pair of welding electrodes 30 so that the metal wire 21 is naturally crushed. Then, the pair of welding electrodes 30 generate heat and heat the metal wire 20, so that the insulating coating 22 of the metal wire 20 is peeled off from the metal wire 21 of the metal wire 20 and melted and removed. The pair of welding electrodes 30 pushes the metal wire 21 by a predetermined pushing amount. Further, since the metal wire 21 and the columnar metal terminal 10 are crimped by the pair of welding electrodes 30, the metal wire 21 and the columnar metal terminal 10 come into contact with each other. The pushing amount will be described later. Step S122 is an example of the second step.

Next, the resistance welder causes the metal wire 21 and the metal wire 21 to flow due to the electric resistance between the columnar metal terminal 10 and the metal wire 21 by passing an electric current through the pair of welding electrodes 30 as shown by the broken arrow in FIG. Joule heat is generated in the columnar metal terminal 10. As a result, the metal wire 21 is melted, and the metal wire 21 is resistance welded to the columnar metal terminal 10 (S123). Step S123 is an example of the second step.

Then, the resistance welder releases the load applied to the assembly by the pair of welding electrodes 30. In this way, the terminal 1 in which the metal wire 21 is electrically connected to the columnar metal terminal 10 can be obtained.

FIG. 2 illustrates a state in which the metal wire 21 is metal-bonded to the columnar metal terminal 10. Since the melting point of the tin layer of the columnar metal terminal 10 is lower than the melting point of the aluminum forming the metal wire 21, the tin layer is pushed left and right by the metal wire 21, and the metal wire 21 is melt-bonded to the copper layer of the columnar metal terminal 10. At the interface between the metal wire 21 and the copper layer, the metal wire 21 and the copper layer are melted and metal-bonded. The displaced tin forms a metal compound with the alumnium forming the metal wire 21 and the copper of the columnar metal terminal 10, and contributes to the reinforcement of the bond between the metal wire 21 and the columnar metal terminal 10.

Next, the pushing amount at the time of thermocompression bonding performed in step S122 of FIG. 6 will be specifically described.

FIG. 7 is an explanatory diagram showing a pressing amount at the time of thermocompression bonding according to the embodiment. FIG. 7 describes joining by the welding electrode 30a on one side. Here, a metal wire 20 having the same diameter is wound around the columnar metal terminal 10.

The resistance welder pushes the metal wire 21 in the direction in which the pair of welding electrodes 30 approach each other. Specifically, the resistance welder pushes the metal wire 20 by applying a load to the metal wire 20 by a pair of welding electrodes 30 with a specified load calculated by using the diameter, the number of turns, and the withstand force of the metal wire 20 or more. , Transform. The position obtained by subtracting the pushing amount of the metal wire 20 from the diameter of the metal wire 20 is the height of the metal wire 20 from the columnar metal terminal 10. The same applies to the other weld electrode 30b.

Further, in order to specify the pair of welding electrodes 30, the metal wire 21 and the pair of welding electrodes 30 are in contact with each other by using a load cell in order to appropriately heat-press the metal wire 20 by the pair of welding electrodes 30. Is detected. As a result, the resistance welder can push the metal wire with the pushing amount from the point of contact with the metal wire 21.

When the metal wire 21 is pushed into the welding electrode 30 on one side by a predetermined pushing amount, the metal wire 21 is deformed according to the pushing amount. In the metal wire 21 of FIG. 7, the height of the metal wire 21 after joining is indicated by (d0-pushing amount). In this way, the surface of the metal wire 21 on the outer peripheral side of the terminal 1 is flattened, the metal wire 21 wound for several turns and the plurality of contact surfaces of the welding electrode 30 are evenly contacted, and electricity is supplied through all the contact surfaces. It will be possible.

Next, the joining in step S123 of FIG. 6 will be specifically described.

First, when the metal wire 20 is resistance welded to the columnar metal terminal 10, if the temperature of the metal wire 21 rises too much, the metal wire 21 may be crushed and broken or melted. Therefore, the resistance welder controls the current flowing through the pair of welding electrodes 30 so that the metal wire 21 does not collapse and break or melt.

An assembly arranged between the pair of welding electrodes 30 is illustrated in FIG. FIG. 8 is an explanatory diagram illustrating a conduction path at the time of joining according to the embodiment. FIG. 8 shows a view of the assembly in the longitudinal direction of the columnar metal terminal 10, as in FIG.

As shown in FIG. 8, the path through which the current flows from one welding electrode 30a to the other welding electrode 30b via the assembly is defined as the conduction path D1, and the columnar metal terminal 10 from one welding electrode 30a to the other welding electrode 30b. The paths of the current flowing through the metal wire 21 are the conduction paths D2 and D3.

Here, when a current is passed from one welding electrode 30a to the other welding electrode 30b, the electric resistance value _RB1 between the metal wire 21 of the metal wire 20 on one side and the columnar metal terminal 10 and the metal on the other side are obtained. Due to the electric resistance value _RB2 between the metal wire 21 of the wire 20 and the columnar metal terminal 10, Joule heat is generated in the metal wire 21 and the columnar metal terminal 10 of the metal wire 20. In addition, Joule heat is generated due to the electric resistance value of each element constituting the metal wire 21 and the columnar metal terminal 10. Gradually, Joule heat generated in iron, which is the core material of the columnar metal terminal 10, propagates to the copper layer of the columnar metal terminal 10 and the metal wire 21. As a result, on the contact surface between the metal wire 21 of the metal wire 20 and the columnar metal terminal 10, the metal of the metal wire 20 having the lowest melting point except for the copper layer of the columnar metal terminal 10 and the tin layer of the elements constituting the metal wire 21. The wire 21 begins to melt locally.

In the present embodiment, the columnar metal terminal 10 is a three-layered structure of an iron layer, a copper layer, and a tin layer. The structure in which an iron layer having a high resistivity is thinly coated with a copper layer having a low resistivity causes Joule heat to be generated at the peripheral edge of the columnar metal terminal 10 in contact with the metal wire 21, and heat is transferred to the metal wire 21. It increases the speed and contributes to the promotion of melting.

If an excessive current flows through the conduction paths D2 and D3, the metal wire 21 of the metal wire 20 is melted by Joule heat caused by the electric resistance value _RA3 with the metal wire 21 of the metal wire 20. From this point of view, it is preferable that no current flows through the conduction paths D2 and D3 as much as possible. Therefore, it is considered that the electric resistance value of the copper layer of the conduction path D1 needs to be smaller than the electric resistance value of each of the conduction paths D2 and D3.

By the way, the electric resistance values of the conduction paths D1 to D3 will be expressed by the following equations (1) and (2).

Electrical resistance value R ₁ = R _D1 + R _A1 + R _B1 + _RC + R _B2 + R _A2 + R _D2 equation (1)

Electrical resistance value of conduction path D2 R ₂ = Electrical resistance value of conduction path D3 R ₃ = R _D1 + R _A3 + R _D2 equation (2)

_R1 is the electric resistance value of the conduction path D1. _R2 is the electric resistance value of the conduction path D2. R ₃ is the electric resistance value of the conduction path D3. _RD1 is a contact resistance value between one welding electrode 30a and the metal wire 21 of the metal wire 20. _RA1 is the electric resistance value of the metal wire 21 of the metal wire 20 between one of the welding electrodes 30a and the columnar metal terminal 10. _RC is the electric resistance value of the columnar metal terminal 10. _RA2 is the electric resistance value of the metal wire 21 of the metal wire 20 between the other welding electrode 30b and the columnar metal terminal 10. _RD2 is a contact resistance value between the other welding electrode 30b and the metal wire 21 of the metal wire 20. _RA3 is an electric resistance value of the conduction paths D2 and D3.

Comparing the equations (1) and (2), the difference in the electrical resistance values between the conduction path D1 and the conduction paths D2 and D3 is that in the conduction path D1, _RA1 + _RB1 + _RC + _RB2 + R _A2 , the conduction path D2. , D3 is _RA3 . Therefore, it can be seen that it is necessary to set ( _RA1 + R _B1 + _RC + R _B2 + R _A2 ) < _RA3 . On the other hand, it is necessary to melt the metal wire 21 of the metal wire 20 by increasing the electric resistance value _RB1 and the electric resistance value _RB2 .

Therefore, in order to satisfy ( _{RA1 + R B1 + RC} + R _B2 + _RA2 ) < _RA3 , it is necessary to satisfy ( _RA1 + _RA2 ) < _RA3 and reduce the electric resistance value of the columnar metal terminal 10. It is believed that there is.

Since the length of the conduction path D2 and D3 is larger than the thickness of the metal wire 21, the conduction path D2 and D3 should be made as long as possible, that is, the metal wire 21 of the metal wire 20 in the portion of the conduction path D2 and D3 should be bent. The electric resistance value _RA3 can be increased. For example, by making the sum of the thickness S1 of the metal wire 21 having the electric resistance value _RA1 and the thickness S2 of the metal wire 21 having the electric resistance value _RA2 smaller than the length of the conduction path D2 or the conduction path D3. ( _RA1 + _RA2 ) < _RA3 can be satisfied.

Further, by thinning the metal wire 21 of the metal wire 20, the electric resistance values _RA3 of the conduction paths D2 and D3 become large, and ( _RA1 + _RA2 ) < _RA3 is satisfied.

Further, the electrical resistivity of the copper layer of the columnar metal terminal 10 is smaller than the electrical resistivity of the metal wire 21 of the metal wire 20. As described above, the material of the columnar metal terminal 10 may be a material having a lower electrical resistivity than the material of the metal wire 21 of the metal wire 20, or the thickness of the columnar metal terminal 10 on the conduction path D1 may be further reduced. Further, in the present embodiment, the thickness of the columnar metal terminal 10 on the conduction path D1 is larger than, for example, the diameter of the metal wire 21 of the metal wire 20, but is thinner than the diameter of the metal wire 21 of the metal wire 20. May be good.

Next, in order to increase the electric resistance value _RB1 and the electric resistance value _RB2 , the contact area between the metal wire 21 of the metal wire 20 on one side and the columnar metal terminal 10 can be reduced, or the metal on the other side can be increased. This is realized by reducing the contact area between the metal wire 21 of the wire 20 and the columnar metal terminal 10. At this time, the load on the assembly by the pair of welding electrodes 30 is further reduced so as not to crush the metal wire 21 of the metal wire 20.

As described above, by considering the above points, the electric resistance value of the conduction path D1 is made smaller than the electric resistance value of each of the conduction paths D2 and D3.

FIG. 9 is a schematic view showing a columnar metal terminal 10 around which a plurality of metal wires 20 are wound according to an embodiment.

Next, a case where a plurality of types of metal wires 20 are wound around the columnar metal terminals 10 will be described. Here, it is assumed that the first metal wire 20a of the main coil and the second metal wire 20b of the sub coil are wound around the columnar metal terminal 10.

First, as shown in FIG. 9, the first metal wire 20a is wound around the columnar metal terminal 10. At this time, the first metal wire 20a is wound around the columnar metal terminal 10 with the first metal wires 20a spaced apart from each other.

Further, the second metal wire 20b is wound around the columnar metal terminal 10 so as not to overlap with the first metal wire 20a. The second metal wire 20b is singly wound around the columnar metal terminal 10 so as to be alternately arranged so as not to overlap with the first metal wire 20a.

In this way, the first metal wire 20a and the second metal wire 20b are wound around the columnar metal terminal 10 in a double spiral. Here, the intersection 23 of the first metal wire 20a and the intersection 23 of the second metal wire 20b are arranged so as to face the joint terminal surface 11a. These intersecting portions 23 may be arranged on the same joint terminal surface 11a side, but may be arranged so as to be paired with the columnar metal terminal 10 interposed therebetween.

Next, a case where a plurality of metal wires 20 having different diameters are joined to the columnar metal terminal 10 will be described.

FIG. 10 is an explanatory diagram showing a pressing amount at the time of thermocompression bonding when the diameters of the metal wires 20 are different according to the embodiment. In FIG. 10, joining by the welding electrode 30 on one side will be described. Here, a plurality of metal wires 20 having different diameters are wound around the columnar metal terminal 10. The plurality of metal wires 20 are, for example, a first metal wire 20a and a second metal wire 20b, and the diameter of the first metal wire 20a is larger than the diameter of the second metal wire 20b.

As shown in FIG. 10, in a state where the first metal wire 20a and the second metal wire 20b are wound around the columnar metal terminal 10, the diameter of the first metal wire 20a and the diameter of the second metal wire 20b are different.

At this time, the metal wire 20 and the columnar metal terminal 10 are joined so as to match the metal wire 20 having the smallest diameter among the plurality of metal wires 20. Specifically, the resistance welder pushes the metal wire 20 having the smallest diameter by one of the welding electrodes 30a of the pair of welding electrodes 30 to push the metal wire 20 from the diameter of the metal wire 20 having the smallest diameter. The position where the pushed-in amount is subtracted is the height of the metal wire 20 from the columnar metal terminal 10. The same applies to the other weld electrode 30b.

Further, the load cell is used to detect that the metal wire 20 having the largest diameter among the plurality of metal wires 20 and the pair of welding electrodes 30 are in contact with each other. As a result, the resistance welder can push the metal wire 20 with the pushing amount from the point of contact with the metal wire 21 having the largest diameter among the plurality of metal wires 20.

As a result, in the present embodiment, since the diameter d1 of the first metal wire 21a of the metal wire 20 is larger than the diameter d2 of the second metal wire 21b of the metal wire 20, the terminal 1 has the diameter of the second metal wire 21b. It is flattened at a position that matches d2.

The second metal wire 21b is pushed by a predetermined pushing amount with respect to the diameter d2 of the second metal wire 21b. Therefore, the first metal wire 21a is pushed in by the calculated value (diameter d1 of the first metal wire 21a + diameter d2 of the second metal wire + predetermined pushing amount).

When the second metal wire 21b is pushed into the welding electrode 30 on one side by a predetermined pushing amount with respect to the diameter d2, the second metal wire 21b is deformed according to the pushing amount. In the second metal wire 21b of FIG. 10, the height of the metal wire 21 after joining is indicated by (d2-pushing amount).

Further, when the metal wire 21 of the first metal wire 20a is pushed into the welding electrode 30 on one side (d1-d2 + a predetermined pushing amount) with respect to the diameter d1, the metal wire 21 of the first metal wire 20a becomes. It is deformed according to (d1-d2 + predetermined pushing amount).

In this way, the surface of the metal wire 21 on the outer peripheral side of the terminal 1 is flattened, and even if a plurality of metal wires 21 having different wire diameters are wound for several turns, the plurality of contact surfaces of the metal wire 21 and the welding electrode 30 are even. It comes into contact with the wire and can be energized through all the contact surfaces.

The same applies to the case where a plurality of metal wires 20 having different wire diameters are joined to the columnar metal terminal 10, so the description thereof will be omitted.

In this way, even if metal wires 20 having different diameters are wound around the columnar metal terminal 10, the terminal 1 can be manufactured by flattening the metal wire 20 so as to match the metal wire 20 having the smallest diameter.

[Action effect]
Next, the operation and effect of the terminal 1 and the method of joining the terminal 1 in the present embodiment will be described.

As described above, the terminal 1 according to the present embodiment includes a columnar metal terminal 10 and a metal wire 20. Further, the electric resistance value of the metal wire 20 is larger than the electric resistance value of the columnar metal terminal 10. Further, the metal wire 20 is wound around the columnar metal terminal 10. The metal wire 20 and the columnar metal terminal 10 are metal-bonded.

According to this, since the metal wire 20 is wound around the columnar metal terminal 10 and the metal wire 20 and the columnar metal terminal 10 are metal-bonded, the metal wire 20 and the columnar metal terminal 10 are firmly bonded. ..

Therefore, the bonding strength between the columnar metal terminal 10 and the metal wire 20 can be ensured.

In particular, in order to reinforce the joint between the metal wire 20 and the columnar metal terminal 10, it is not necessary to fix the metal wire 20 with a reinforcing member, so that the terminal 1 can suppress the manufacturing cost.

Further, in the terminal 1 according to the present embodiment, the columnar metal terminal 10 has a polygonal column shape having a plurality of terminal surfaces 11. The terminal 1 has an intersection 23 in which the metal wires 20 overlap each other in the circumferential direction of the columnar metal terminal 10 in the vicinity of the columnar metal terminal 10. The terminal surface 11 of a part of the plurality of terminal surfaces 11 is a joint terminal surface 11a on which the intersection 23 is not arranged. Then, on the joint terminal surface 11a, the columnar metal terminal 10 and the metal wire 20 are metal-bonded.

For example, when the crossing portion 23 is joined to the joining terminal surface 11a, the metal wires 20 overlap at the crossing portion 23, and the height of the metal wire 20 from the columnar metal terminal 10 is approximately doubled. Even if it is detected that the metal wire 21 of the metal wire 20 and the pair of welding electrodes 30 are in contact with each other, the pushing amount of the pair of welding electrodes 30 cannot be appropriately controlled. As a result, not only the columnar metal terminal 10 and the metal wire 20 may not be properly joined, but also the metal wire 21 may be broken. However, in this terminal 1, the intersection 23 in which the metal wires 20 overlap each other in the circumferential direction of the columnar metal terminal 10 is arranged on the side surface side of the columnar metal terminal 10 different from the pair of joint terminal surfaces 11a, and the metal wire 21 is provided. Since the metal wire 20 and the columnar metal terminal 10 are metal-bonded on the joint terminal surface 11a without breaking, the strength between the metal wire 20 and the columnar metal terminal 10 can be ensured.

Further, in the terminal 1 according to the present embodiment, a plurality of metal wires 20 having different diameters are wound around one columnar metal terminal 10.

According to this, since the plurality of metal wires 20 are wound around one columnar metal terminal 10, the plurality of metal wires 20 can be shared with one columnar metal terminal 10. Therefore, it is not necessary to individually prepare the columnar metal terminals 10, so that the manufacturing cost of the terminals 1 can be suppressed.

Further, in the method of joining the terminal 1 according to the present embodiment, a first step of winding a metal wire 20 having an electric resistance value larger than the electric resistance value of the columnar metal terminal 10 around the columnar metal terminal 10 and a first step. After that, the pair of opposed welding electrodes 30 are brought into contact with the metal wire 20, a current is passed from the pair of welding electrodes 30 to the metal wire 20 and the columnar metal terminal 10, and the Joule heat of the metal wire 20 and the columnar metal terminal 10 is used. , A second step of metal bonding the metal wire 20 and the columnar metal terminal 10 is included.

According to this, since the electric resistance value of the metal wire 20 is larger than the electric resistance value of the columnar metal terminal 10, the metal wire 20 and the columnar metal terminal are connected to the metal wire 20 from the weld electrode 30 in a state where the metal wire 20 is wound around the columnar metal terminal 10. When a current is passed through the columnar metal terminal 10, the current flowing through the metal wire 21 of the metal wire 20 is suppressed by bypassing the columnar metal terminal 10, and the current can be efficiently passed through the columnar metal terminal 10. Therefore, the metal wire 21 is prevented from being blown, and the Joule heat caused by the electric resistance of the columnar metal terminal 10 and the Joule heat caused by the contact resistance between the columnar metal terminal 10 and the metal wire 21 are efficiently used. , The metal wire 20 and the columnar metal terminal 10 can be metal-bonded.

Therefore, the bonding strength between the columnar metal terminal 10 and the metal wire 20 can be ensured.

In particular, in order to reinforce the joint between the metal wire 20 and the columnar metal terminal 10, it is not necessary to fix the metal wire 20 with a reinforcing member. Therefore, this joining method improves the work efficiency of manufacturing the terminal 1.

Further, in the method of joining the terminal 1 according to the present embodiment, in the first step, the metal wire is formed at the portion where the metal wire 20 starts to be wound around the columnar metal terminal 10 so that the metal wire 20 overlaps with each other. 20 is wound around the columnar metal terminal 10. Then, in the second step, the columnar metal terminal 10 around which the metal wire 20 is wound is arranged so as to avoid contact between the pair of welding electrodes 30 facing each other and the intersection 23 of the metal wire 20, and the metal wire 20 and the columnar metal are arranged. Join the terminal 10.

For example, when the crossing portion 23 is joined to the joining terminal surface 11a, the metal wires 20 overlap at the crossing portion 23, and the height of the metal wire 20 from the columnar metal terminal 10 is approximately doubled. Even if it is detected that the metal wire 21 of the metal wire 20 and the pair of welding electrodes 30 are in contact with each other, the pushing amount of the pair of welding electrodes 30 cannot be appropriately controlled. As a result, not only the columnar metal terminal 10 and the metal wire 20 may not be properly metal-bonded, but also the metal wire 21 may be broken. However, in this joining method, the intersection 23 is arranged on the side surface side of the columnar metal terminal 10 different from the pair of joining terminal surfaces 11a, and the metal wire 20 and the columnar metal are arranged on the joining terminal surface 11a without breaking the metal wire 21. Since the terminal 10 is metal-bonded, it is possible to manufacture the terminal 1 in which the strength between the metal wire 20 and the columnar metal terminal 10 is ensured.

Further, in the method of joining the terminals 1 according to the present embodiment, in the first step, a plurality of metal wires 20 are wound around one columnar metal terminal 10, and the metal wires 20 are connected to each other in the circumferential direction of the columnar metal terminal 10. The overlapping intersections 23 are formed respectively. Then, in the second step, a columnar metal terminal 10 around which the metal wire 20 is wound is arranged so as to avoid contact between the pair of welding electrodes 30 facing each other and the intersections 23 of the plurality of metal wires 20. 20 and the columnar metal terminal 10 are joined.

According to this, it is not necessary to prepare a plurality of columnar metal terminals 10, and by winding a plurality of metal wires 20 around one columnar metal terminal 10, the plurality of metal wires 20 and the columnar metal terminals 10 are metal-bonded. be able to. Therefore, according to this method, the manufacturing cost of the terminal 1 can be suppressed.

Further, in the method of joining the terminal 1 according to the present embodiment, in the second step, the metal wire 20 is pushed in by the welding electrode 30a of one of the pair of welding electrodes 30, so that the metal is formed from the diameter of the metal wire 20. The position where the pushed amount of the wire 20 is subtracted is the height of the metal wire 20 from the columnar metal terminal 10.

According to this, the metal wire 20 wound around the columnar metal terminal 10 is pushed or sandwiched by the pair of welding electrodes 30 from both sides, so that the outer peripheral side of the metal wire 20 is flat at the position of the pair of welding electrodes 30. The metal wire 21 of the metal wire 20 wound around the metal wire 20 for several turns and the plurality of contact surfaces of the welding electrode 30 are evenly contacted with each other, and electricity can be supplied through all the contact surfaces. As a result, the metal wire 20 and the columnar metal terminal 10 are reliably metal-bonded, and the terminal 1 having the outer peripheral side of the metal wire 20 flattened can be manufactured.

Further, in the method of joining the terminals 1 according to the present embodiment, when a plurality of metal wires 20 having different diameters are wound around the columnar metal terminals 10, in the second step, one of the pair of welding electrodes 30 is wound. By pushing the metal wire 20 having the smallest diameter with the welding electrode 30a, the position obtained by subtracting the pushing amount of the metal wire 20 from the diameter of the metal wire 20 having the smallest diameter is the position of the metal wire from the columnar metal terminal 10. It will be 20 heights.

According to this, the metal wire 20 wound around the columnar metal terminal 10 by the pair of welding electrodes 30 is pushed in from both sides, that is, sandwiched. By pushing the metal wire 20 from both sides so that the pair of welding electrodes 30 match the diameter of the metal wire 20 having the smallest diameter, the outer peripheral side of the metal wire 20 is flattened at the position of the pair of welding electrodes 30 and the wire is formed. Even if the metal wires 21 of the plurality of metal wires 20 having different diameters are wound for several turns, the metal wires 21 and the plurality of contact surfaces of the welding electrode 30 are evenly contacted, and electricity can be supplied through all the contact surfaces. Become. As a result, the metal wire 20 and the columnar metal terminal 10 are surely metal-bonded, and the terminal 1 whose outer peripheral side of the metal wire 20 is flattened can be manufactured.

Further, in the method of joining the terminal 1 according to the present embodiment, in the second step, the metal wire is formed by a pair of welding electrodes 30 at a specified load calculated by using the diameter, the number of turns, and the withstand force of the metal wire 20. A load is applied to 20 to control the amount of pushing in the direction in which the metal wire 20 is pushed.

In this way, by controlling the pushing amount of the pair of welding electrodes 30 based on the load, the metal wire 20 is deformed by the pushing amount according to the diameter, the number of turns, and the withstand force of the metal wire 20. .. As a result, problems such as disconnection due to the metal wire 20 being pushed in too much are suppressed. Therefore, in this joining method, the metal wire 20 and the columnar metal are secured while ensuring the joining strength between the columnar metal terminal 10 and the metal wire 20. The terminal 10 can be reliably metal-bonded.

Further, in the method of joining the terminal 1 according to the present embodiment, the metal material of the metal wire 20 contains aluminum as a main component.

According to this, the manufacturing cost can be suppressed by adopting aluminum, which is cheaper than copper.

(Other modifications, etc.)
Although the present invention has been described above based on the embodiments, the present invention is not limited to the above embodiments. In the following description, in the same parts as those in the above embodiment, the same reference numerals may be given and the description thereof may be omitted.

For example, in the terminal and terminal joining method of the present embodiment, the columnar metal terminal and the metal wire are metal-bonded in a state where the metal wire is not entwined with the columnar metal terminal, that is, in a state where the metal wire is simply wound in a single layer. You may.

Further, regarding the terminal and the terminal joining method of the present embodiment, the metal wire 20 having an electric resistance value larger than the electric resistance value of the columnar metal terminal 10 is wound around the columnar metal terminal 10 in step S113 of FIG. However, the metal wire 20 having an electric resistance larger than the electric resistance of the columnar metal terminal 10 may be wound around the columnar metal terminal 10.

Further, regarding the terminal and the terminal joining method of the present embodiment, since the electric resistance value of the metal wire may be larger than the electric resistance value of the columnar metal terminal, the electric resistance value of a part of the metal wire is used in a part of the terminal. However, it may be smaller than the electric resistance value of a part of the columnar metal terminal.

In addition, there are also forms obtained by subjecting various modifications to the embodiments that can be conceived by those skilled in the art, and embodiments realized by arbitrarily combining the components and functions of the embodiments without departing from the spirit of the present invention. Included in the present invention.

1 Terminal 10 Columnar metal terminal 11 Terminal surface 11a Joint terminal surface 20, 20a, 20b Metal wire 23, 23a, 23b Intersection 30, 30a, 30b Welded electrode

Claims (9)

Columnar metal terminals and
Equipped with metal wire,
The electric resistance value of the metal wire is larger than the electric resistance value of the columnar metal terminal.
The metal wire is wound around the columnar metal terminal and is wound around the columnar metal terminal.
The metal wire and the columnar metal terminal are metal-bonded to each other .
The columnar metal terminal has a polygonal column shape having a plurality of terminal surfaces.
In the vicinity of the columnar metal terminal, the metal wires have an intersection where the columnar metal terminals overlap each other in the circumferential direction.
Some of the terminal surfaces of the plurality of terminal surfaces are joint terminal surfaces on which the intersections are not arranged.
On the joint terminal surface, the columnar metal terminal and the metal wire are metal-bonded.
Terminal. The terminal according to claim 1, wherein the plurality of metal wires having different diameters are wound around one columnar metal terminal. The first step of winding a metal wire having an electric resistance value larger than the electric resistance value of the columnar metal terminal around the columnar metal terminal,
After the first step, a pair of opposed welding electrodes are brought into contact with the metal wire, and a current is passed from the pair of welding electrodes to the metal wire and the columnar metal terminal to cause the metal wire and the columnar metal terminal to flow. The second step of metal welding the metal wire and the columnar metal terminal with Joule heat ,
In the first step, the metal wire is attached to the columnar metal terminal so that an intersection is formed at a portion where the metal wire starts to be wound around the columnar metal terminal so that the metal wires overlap each other in the circumferential direction of the columnar metal terminal. Wrap around,
In the second step, the columnar metal terminal around which the metal wire is wound is arranged so as to avoid contact between the pair of welding electrodes facing each other and the intersection of the metal wire, and the metal wire and the columnar metal are arranged. A method of joining terminals, including joining terminals with metal . The first step of winding a metal wire having an electric resistance value larger than the electric resistance value of the columnar metal terminal around the columnar metal terminal,
After the first step, a pair of opposed welding electrodes are brought into contact with the metal wire, and a current is passed from the pair of welding electrodes to the metal wire and the columnar metal terminal to cause the metal wire and the columnar metal terminal to flow. It comprises a second step of metal joining the metal wire and the columnar metal terminal with Joule heat.
In the first step, a plurality of the metal wires are wound around one columnar metal terminal to form an intersection in which the metal wires overlap each other in the circumferential direction of the columnar metal terminal.
In the second step, the columnar metal terminal around which the metal wire is wound is arranged so as to avoid contact between the pair of welding electrodes facing each other and the intersection of each of the plurality of metal wires, and the metal wire is arranged. And the columnar metal terminal are metal-bonded.
How to join terminals. In the first step, the metal wire is attached to the columnar metal terminal so that an intersection is formed at a portion where the metal wire starts to be wound around the columnar metal terminal so that the metal wires overlap each other in the circumferential direction of the columnar metal terminal. Wrap around,
In the second step, the columnar metal terminal around which the metal wire is wound is arranged so as to avoid contact between the pair of welding electrodes facing each other and the intersection of the metal wire, and the metal wire and the columnar metal are arranged. The method for joining terminals according to claim 4, wherein the terminals are metal-bonded. In the second step, the metal wire is pushed by one of the pair of welding electrodes, and the position where the pushing amount of the metal wire is subtracted from the diameter of the metal wire is the position. The terminal joining method according to any one of claims 3 to 5 , which is the height of the metal wire from the columnar metal terminal. When a plurality of metal wires having different diameters are wound around the columnar metal terminals, in the second step, the metal wire having the smallest diameter is pushed by one of the pair of welding electrodes. The terminal according to claim 4 or 5 , wherein the position obtained by subtracting the pushing amount of the metal wire from the diameter of the metal wire having the smallest diameter is the height of the metal wire from the columnar metal terminal. Joining method. In the second step, a load is applied to the metal wire by the pair of welding electrodes with a specified load calculated using the diameter, the number of turns, and the withstand force of the metal wire, and the metal wire is pushed in. The terminal joining method according to any one of claims 3 to 7 , wherein the pushing amount of the metal is controlled. The terminal joining method according to any one of claims 3 to 8 , wherein the metal material of the metal wire is mainly composed of aluminum.

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