Method for connecting film-coated wire to subject member

• US 20030213775A1
• Filed: 05/15/2003
• Published: 11/20/2003
• Est. Priority Date: 05/16/2002
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Kanamori, Hiroyasu, Urushizaki, Mamoru, Kikuchi, Atsuo
• Granted Patent: US 7,053,328 B2
• Time in Patent Office: Days
• US Class Current: 219/56.22
• CPC Class Codes: B23K 11/002 specially adapted for particular articles or work
• CPC Class Codes: B23K 11/163 Welding of coated materials
• CPC Class Codes: B23K 11/34 Preliminary treatment
• CPC Class Codes: B23K 2103/12 Copper or alloys thereof
• CPC Class Codes: H01R 43/0214 Resistance welding H01R43/0228 takes precedence
• CPC Class Codes: H01R 43/0228 without preliminary removing of insulation before soldering or welding

Abstract

A film-coated wire is wound around a terminal at least one turn and pressed by an upper electrode of a resistance welding machine. A current is passed through the upper electrode when the wire is pressed, and heat is produced. The heat melts a film on the wire. The current is passed between the upper electrode and the lower electrode via the wire and the terminal to connect the wire with the terminal by resistance welding. A contact area between the wire and the terminal is increased by winding the wire around the terminal. Therefore, the wire is less likely to shift its position when a force is applied by the upper electrode. This increases reliability of the connection. Moreover, the terminal is reduced in size because it is not required to be formed in a U-shape.

Claims

1. A method for connecting a film-coated wire to a subject member comprising:

winding the film-coated wire around the subject member at least one turn;

applying a force to the subject member via at least one of first and second electrodes of a resistance welding machine;

passing a current between the first and the second electrodes to produce heat;

removing a film on the film-coated wire by the heat;

passing a current between the first and the second electrodes via the film-coated wire and the subject member; and

connecting the film-coated wire to the subject member by welding.

2. The method according to claim 1, wherein the force is applied to the subject member via the first electrode.

3. The method according to claim 2, wherein:

the second electrode has a dent portion for housing a part of the film-coated wire so that the film-coated wire is not pressed between the second electrode and the subject member; and

the second electrode has a contact surface that contacts with the subject member.

4. The method according to claim 2, wherein:

the resistance welding machine comprises a pressure bearing jig for supporting the subject member when the first electrode is pressed against the film-coated wire; and

the second electrode is held at a position to maintain contact with the subject member during the film removing step and the connecting step.

5. The method according to claim 1, wherein:

the first and the second electrodes are arranged on opposed sides of the subject member;

the force is applied to the film-coated wire via the first and the second electrodes;

the current is passed through each electrode; and

each electrode produces heat when the current is passed through each electrode.

6. The method according to claim 1, wherein the subject member is formed in a rod shape.