Connecting method of covered wire

Details Connecting method of covered wire Connecting method of covered wire

2000-06-22

2003-07-29

Vo, Peter (Department: 3729)

Metal working

Method of mechanical manufacture

Electrical device making

C029S564400, C029S840000, C029S858000, C029S868000, C029S873000, C174S07400A, C174S07500C, C174S07500C, C361S780000, C361S803000, C228S110100, C228S175000, C228S180500

Reexamination Certificate

active

06598293

ABSTRACT:

CROSS-REFERENCE TO RELATED APPLICATIONS
Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
Not Applicable
REFERENCE TO A MECROFICHE APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
1. Description of Related Art
Japanese Patent Publication No. 7-320842 discloses a connecting method of two different covered wires as shown in
FIGS. 1A and 1B
. The shown method is related to a connection between a shield wire W
1
and a ground wire W
2
. The shield wire W
1
has a core line
14
as a conductive part covered with a resinous cover
8
and a shielding braided wire
13
as another conductive part which covers the resinous cover
8
and is also covered with another resinous cover
7
. While, the ground wire W
2
has a core line
15
as a conductive part covered with a resinous cover
9
.
In order to connect the shield wire W
1
with the ground wire W
2
, it is executed at the first step to put the connecting (overlapping) part defined by the wire W
1
and the wire W
2
between a pair of resinous tips
1
,
3
. In detail, the resinous tip
3
is inserted into an anvil
5
and subsequently, the shield wire W
1
is inserted into the anvil
5
and put on the resinous tip
3
. Further, the ground wire W
2
is inserted and put on the inserted shield wire W
1
and finally, the other resinous tip
1
is laid on the ground wire W
2
.
At the second step, it is carried out to partially remove the resinous covers
7
,
9
of the wires W
1
, W
2
by heating the connecting part defined by the wires W
1
, W
2
under pressure and further seal the resulting connecting part by welding the resinous tips
1
,
3
each other. In detail, a horn
11
is inserted from the upside of the resinous tip
1
and continuously, the tips
1
,
3
are heated due to ultrasonic oscillations between the horn
11
and the anvil
5
under pressure. Owing to the generation of heat by the ultrasonic oscillations, the covers
7
,
9
are molten at the connecting part, so that the braided wire
13
of the shield wire W
1
and the core line
15
of the ground wire W
2
are exposed together.
While, the so-molten covers
7
,
9
are pushed out of the resinous tips
1
,
3
through a clearance therebetween, so that the braided wire
13
comes into electrical contact with the core line
15
. With further continuation to both oscillate and pressurize, the resinous tips
1
,
3
are molten for their integration, so that the connecting part can be sealed as shown in FIG.
1
B.
In the above-mentioned connecting method, however, there is a possibility that the shield wire's portion close to the resinous tips
1
,
3
, i.e., a part
17
, is influenced by the heat of the resinous covers
7
,
9
pushed out of the resin tips
1
,
3
(see FIG.
1
B), thereby causing the deterioration of insulation effect, the disconnection of conductive wire, the deterioration of bending, etc.
FIG. 2
shows respective sections of the shield wire W
1
and the ground wire W
2
in their sealed connection which is somewhat different from the previously-mentioned connecting structure. Shown in the figure is a condition where a resin
19
resulting from the melting of the ground wire W
2
is pushed out from the clearance between the resinous tips
1
,
3
, so that the ground wire W
2
is damaged at its part
21
close to the tips
1
,
3
by the heat of the so-pushed resin
19
, causing the exposure of the core line
15
.
Therefore, also in this case, there may be caused problems of the deterioration of insulation effect of the cover
9
at a part of the ground wire W
2
, the disconnection of the core line
15
and the deterioration of bending, too.
2. Field of the Invention
The present invention relates to a connecting method of connecting two different wires to each other, for example, an electrical connection between a shield wire and a ground wire, and also relates to a pair of recessed resin tips which are appropriate in the connecting method.
BRIEF SUMMARY OF THE INVENTION
Under the circumstances, it is therefore an object of the present invention to provide a connecting method of connecting covered wires with each other, by which it is possible to prevent the molten insulating covers from being pushed out of the resin tips. Further, it is another object of the invention to provide resin tips which are appropriate in connecting the covered wires in accordance with the above method.
The former object of the present invention described above can be accomplished by a connecting method of connecting a first wire with a second wire, the first wire having a first conductive wire covered with a first insulating cover, the second wire having a second conductive wire covered with a second insulating cover, the connecting method comprising:
a first step of putting a connecting part constituted by both of the first and second wires, between a first resin tip and a second resin tip; and
a second step of heating the connecting part through the first and second resin tips under pressure thereby to remove the first and second insulating covers from the connecting part while welding the first and second resin tips together thereby to sealing the connecting part. In the method, at least either one of the first and second resin tips is provided, on both sides of the connecting part, with first recessed parts. While, at least either one of the first and second resin tips is provided, on both sides of the connecting part, with second recessed parts. Thus, the molten first insulating cover of the first wire is accommodated in the first recessed parts at the second step, while the molten second insulating cover of the second wire is accommodated in the second recessed parts at the second step.
In this way, it is possible to restrict the first and second covers of the first and second wires from being pushed out of the integrated resin tips, thereby avoiding the damage on the first and second wires due to heat of the so-pushed covers.
In this way, the exposure of the first and second conductive wires outside the first and second resin tips is restricted, so that the bending capabilities of the first and second wires can be maintained without causing the deterioration of insulation effect and the disconnection of the first and second conductive wires, etc.
Additionally, since the molten and removed first and second insulating covers are accommodated in the first recessed parts and the second recessed parts smoothly, it is possible to accomplish the shortage of welding time and the reduction in the number of working processes.
According to the present invention, the latter object of the invention can be accomplished by a combination of first and second resin tips which are usable in a connecting method of connecting a first wire with a second wire, the first wire having a first conductive wire covered with a first insulating cover, the second wire having a second conductive wire covered with a second insulating cover, the connecting method comprising a first step of putting a connecting part constituted by both of the first and second wires, between a first resin tip and a second resin tip and a second step of heating the connecting part through the first and second resin tips under pressure thereby to remove the first and second insulating covers from the connecting part while welding the first and second resin tips together thereby to sealing the connecting part. In this invention, the combination comprises first recessed parts formed at least either one of the first and second resin tips and arranged on both sides of the connecting part, for accommodating the molten first insulating cover of the first wire therein and second recessed parts formed at least either one of the first and second resin tips and arranged on both sides of the connecting part, for accommodating the molten second insulating cover of the second wire.
In the above-mentioned combination, preferably, the first recessed parts and the second recessed parts are continuously formed in one of the first and second resin tips so as to surround the connecting part in annular.
In this case, the m

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