Connection structure for connecting a covered wire and...

Details Connection structure for connecting a covered wire and... Connection structure for connecting a covered wire and...

1998-01-08

2001-07-17

Bradley, P. (Department: 2833)

Electrical connectors

Metallic connector or contact having part permanently...

C439S700000

Reexamination Certificate

active

06261135

ABSTRACT:

BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a connection structure for connecting a covered wire and a terminal, wherein a covered wire is placed on a terminal and a cover portion thereof is melted and removed by pressing and applying ultrasonic vibration, so that the core elements of the covered wire and in terminal are conductive contact with each other, and a connection method thereof.
2. Description of Relevant Art
This kind of art has been disclosed in, for example, Japanese Patent Publication No.7-70345.
FIGS. 1
show that invention.
FIG. 1A
shows a first member
1
and a second member
2
. The members
1
,
2
are made of material (plastic) which can be fused by ultrasonic vibration. The first member
1
contains groove portions
3
, and the second member
2
has convex portions
4
which engage the groove portions
3
.
FIGS. 1B
,
1
C show a state in which a terminal
7
is contained in the groove portion
3
and a covered wire
8
is placed thereon. On a bottom face of the groove portion
3
are provided small concave portions
3
a
and a top face of a convex portion
4
has small protrusions
4
a
which engage the small concave portions
3
a
.
According to this art, as shown in
FIGS. 1B
,
1
C, the terminal
7
is incorporated in the groove portion
3
and a covered wire
8
is placed thereon. The second member
2
is placed on the top face of the first member
1
so that the protrusions
4
are inserted into the groove portions
3
. While applying a pressing force between the first and second members
1
,
2
, ultrasonic vibration is applied so as to melt the cover portion of the covered wire
8
nipped between the protrusion
4
and the groove portion
3
. Consequently, the core elements of the covered wire
8
and terminal
7
come into conductive contact contact with each other. At the same time, the first and second members
1
,
2
are fit to each other by fusion so as to obtain an integrated connection structure as shown in FIG.
1
D.
However, according to the aforementioned prior art, and as shown in
FIG. 2
, the core elements
8
a
retreat together with the melted cover portion
8
b
into a gap provided between the groove portion
3
and a side face of the protrusion
4
, so that sometimes, it is not possible obtain excellent conductive contact between the core elements
8
a
and the terminal
7
.
As a countermeasure for solving that problem, a method of eliminating a gap between the groove portion
3
and the side face of the protrusion
4
as shown in
FIG. 3
can be considered. However, if the groove portion
3
and the side face of the protrusion
4
are in contact with each other, ultrasonic wave is not transmitted properly to target positions (covered wire
8
on the terminal
3
) so that processing efficiency deteriorates. Further, because escape of the melted cover portion
8
b
is limited to the length direction of the groove portion
3
, the engagement between the first and second members
1
,
2
becomes incomplete, so that there is a fear that excellent conductive contact between the core elements
8
a
and terminal
7
cannot be obtained.
SUMMARY OF THE INVENTION
The present invention has been achieved with such points in view.
It therefore is an object of the invention to provide a connection structure for connecting a covered wire and terminal, in order to obtain an excellent conductive contact between core elements of the covered and of the terminal without deterioration processing efficiency, and a connection method thereof.
To achieve the object, a first aspect of the invention provides a connection structure for connecting a covered wire and terminal comprising, a first member having groove portion; a terminal to be incorporated in the groove portion, a covered wire to be placed on the terminal, and a second member having a convex portion for clogging the groove portion, wherein, while pressing the covered wire by the second member, ultrasonic vibration is applied thereto so as to melt a cover portion of the covered wire thereby making the covered wire and core elements into conductive contact with each other, the terminal having a wire connecting portion comprising a bottom wall on which the covered wire is to be placed and vertical walls raised from side edges of the bottom wall, the vertical wall having a gap relative to the convex portion.
According to the first aspect, even in a case when the core elements of the covered wire move to the gap between the groove portion and convex portion together with the melted cover portion, the core elements make contact with the vertical walls of the terminal. Further, because there is a gap secured between the vertical wall and the convex portion, ultrasonic wave can be transmitted excellently to a target position and the melted cover portion can be allowed to escape into that gap, thereby placing the core elements and terminal into a secure contact with each other.
Accordingly, an excellent conductive contact performance can be obtained.
To achieve the object, a second aspect of the invention provides a connection structure for connecting a covered wire and terminal according to the first aspect wherein the first member is a terminal holding portion formed so as to protrude at an end of a connector housing body and the second member is a cover body for clogging the terminal holding portion.
According to the second aspect, the covered wire and terminal come into contact with each other by ultrasonic vibration and simultaneously an integrated connector can be formed.
To achieve the object, a third aspect of the invention provides a connection structure for connecting a covered wire and terminal according to the first or second aspect wherein a gap for allowing an escape of the melted cover portion of the covered wire is formed between a front end of the vertical wall and a root portion of the convex portion of the second member.
According to the third aspect, the melted cover portion escapes into a gap secured between a front end of the vertical wall of the terminal and a root portion of the convex portion of the second member.
Accordingly, there is produced such an effect that secure conductive contact between the core elements and terminal can be attained.
To achieve the object, a fourth aspect of the invention provides a connection structure for connecting a covered wire and terminal according to any one of the first - third aspect wherein the wire connecting portion has a U-shaped cross section having a pair of vertical walls facing each other.
According to the fourth aspect, because a pair of the vertical wall are provided, even when the core elements escape to both sides of the convex portion, the core elements can be brought into contact with the terminal securely.
To achieve the object, a fifth aspect of the invention provides a connection structure for connecting a covered wire and terminal according to any one of the first—third aspect wherein the wire connecting portion has a L-shaped cross section having a vertical wall on only one side thereof.
According to the fifth aspect, the vertical wall is provided on only one side, and therefore the shape of the terminal is simple and easy to produce.


REFERENCES:
patent: 4648679 (1987-03-01), Pelczarski
patent: 5759052 (1998-06-01), Seki
patent: 5849424 (1998-12-01), Sugawara et al.
patent: 7-70345 (1995-07-01), None

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