Electricity: conductors and insulators – Conduits – cables or conductors – Combined
Reexamination Certificate
1998-01-08
2001-05-29
Reichard, Dean A. (Department: 2831)
Electricity: conductors and insulators
Conduits, cables or conductors
Combined
Reexamination Certificate
active
06239375
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a terminal for connection by ultrasonic wave, which is to be conductively connected to a covered wire by ultrasonic wave energy, and a structure therefor, wherein a covered wire is to be connected to a terminal by ultrasonic wave energy.
2. Description of Relevant Art
This kind of art has been disclosed in, for example, Japanese Patent Publication No. 7-70345.
FIGS. 1A-1D
illustrate the art.
FIG. 1A
shows a first member
1
and a second member
2
. Both the members
1
,
2
are formed of material (plastic) which can be fused by ultrasonic vibration. The first member
1
contains groove portions
3
and the second member
2
includes protrusions
4
which engage the groove portions
3
.
FIG. 1B
shows a terminal
7
contained in a groove portion
3
and a covered wire
8
placed on the terminal
7
. On a bottom face of the groove portion
3
are small concave portions
3
a
and on a top face of the corresponding protrusion
4
are provided small protrusions
4
a
which engage the small concave portions
3
a.
According to this art, as shown in
FIG. 1C
, the terminal
7
is contained in the groove portion
3
and the covered wire
8
is placed thereon. After that, the second member
2
is mounted on a top face of the first member
1
so that the protrusions
4
are inserted into the groove portions
3
. Then, ultrasonic vibration is applied while a pressing force is applied between the first and second members
1
,
2
, so that a cover portion of the covered wire
8
nipped between the protrusion
4
and the groove portion
3
is melted thereby making the core elements of the covered wire
8
into conductive contact with the terminal
7
. At the same time, the first and second members
1
,
2
are welded to each other by ultrasonic fusion so that an integrated connection structure as shown in
FIG. 1D
is obtained, whereby core elements of the covered wire
8
are connected to the terminal
7
.
However, according to the aforementioned art, as shown in
FIG. 2
, the melted cover portion
8
b
escapes into gaps between the groove portion
3
and side faces of the protrusion
4
. At this time, some of the core elements
8
a
escape sideways together with the melted cover portion
8
b,
so that excellent conductive contact between the core elements
8
a
and terminal
7
is lost.
As a countermeasure, as shown in
FIG. 3
, a method of eliminating the gap between the groove portion
3
and the protrusion
4
can be considered. However, if the side faces of both the groove portion
3
and protrusion
4
are in contact with each other, ultrasonic wave is not transmitted excellent to a target position (covered wire
8
on the terminal
3
) so that processing efficiency may drop. Further, because escape place of the melted cover portion
8
b
exists only in the length direction of the groove portion
3
, engagement between the first and second members
1
,
2
becomes incomplete, so that excellent conductive contact between the core elements
8
a
and terminal
7
may be lost.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a terminal for connection by ultrasonic wave, wherein an excellent connection with core elements can be obtained securely without decreasing processing efficiency, and a structure therefor.
To achieve the object, a first aspect of the invention provides a terminal for ultrasonic wave connection, which is to be nipped between a first member and a second member while a covered wire comprising core elements and a cover portion covering external circumference thereof being stacked on the terminal, wherein the cover portion is melted by applying ultrasonic vibration while the first and second members being pressed, so that the terminal and core elements are conductively contacted with each other, the terminal including a relief portion for releasing the melted cover portion, the relief portion being provided at a portion to which the covered wire is to be connected.
According to the first aspect, the cover portion melted by ultrasonic vibration escapes into the relief portion formed in the terminal positively. Therefore, an excellent contact between the terminal and core elements can be obtained.
To achieve the object, a second aspect of the invention provides a terminal for ultrasonic wave connection according to the first aspect wherein concave portions and convex portions are formed on a sheet surface on which a covered wire is to be stacked, of a portion to which the covered wire is to be connected, the relief portion being the concave portion.
According to the second aspect, relief portions are formed on a sheet surface on which the covered wire is to be stacked. Thus the core elements become difficult to be turned together with the melted cover portion into the gaps between the groove portion of the first member and side faces of the second member. Further, because the melted cover portion gathers in the relief portions, the top face of the concave portion becomes more likely to contact the core elements. Further, because ultrasonic wave energy is concentrated on the concave portion of the terminal, the cover portion becomes easier to melt. Because the concave portion and convex portion can be formed easily by serration processing, this structure can be realized easily.
To achieve the object, a third aspect of the invention provides a terminal for ultrasonic wave connection according to the second aspect wherein a plurality of concave portions and convex portions are formed in parallel to each other in a direction perpendicular to a direction in which the covered wire extends.
According to the third aspect, the terminal is in contact with a top face of the convex portion while crossing over the concave portion. Thus, an excellent conductive contact between the core elements and terminal can be obtained without being obstructed by the melted cover portion.
To achieve the object, a fourth aspect of the invention provides a terminal for ultrasonic wave connection according to the first aspect wherein a portion to which the covered wire is to be connected comprises a bottom wall on which the covered wire is to be placed and vertical walls raised from side edges of the bottom wall, having a cutout portion, the relief portion being the cutout portion.
According to the fourth aspect, the cover portion melted by ultrasonic vibration escapes through the cutout portions so that it is displaced from above the terminal. That is, when ultrasonic vibration is applied between the groove portion of the first member and the protrusion of the second member with the terminal and covered wire being nipped therebetween, a space inside the terminal and a space outside the terminal (the gap between the groove portion and the terminal) is separated by the terminal having the vertical walls. However, those spaces communicate with each other through the cutout portions provided in the vertical walls. Therefore, the cover portion melted inside the terminal is displaced into a space outside the terminal also through the cutout portions. Consequently, there is provided a space to which the melted cover portion is to be released. Further, due to the presence of the vertical walls, when melted cover portion escapes sideways with a tendency to carry core elements, the core elements are brought into abutment with the vertical walls, whereby they are prevented from being laterally deformed over there. Further, because of invasion of the melted cover portion into space sideways, a possibility of looseness between the terminal and groove portion (first member) is eliminated.
To achieve the object, a fifth aspect of the invention provides a terminal for ultrasonic wave connection according to the fourth aspect wherein a plurality of terminals are formed in an extending direction of the covered wire.
According to the fifth aspect, because a plurality of cutout portions are formed in an extending direction of the covered wire, the melted cover portion escapes smoothly into the cut
Finnegan Henderson Farabow Garrett & Dunner L.L.P.
Nguyen Chau N.
Reichard Dean A.
Yazaki -Corporation
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