Apparatus and method for connecting coated wires

• US 20060208033A1
• Filed: 03/21/2005
• Published: 09/21/2006
• Est. Priority Date: 03/21/2005
• Status: Abandoned Application

• Current Assignee: Curtis L. Welter
• Original Assignee: Curtis L. Welter
• Inventors: Welter, Curtis L.
• Application Number:
  US11/085,283
• Publication Number:
  US 20060208033A1
• Time in Patent Office: Days
• US Class Current: 228/110.100
• CPC Class Codes: B23K 11/002 specially adapted for particular articles or work
• CPC Class Codes: B23K 20/10 making use of vibrations, e.g. ultrasonic welding
• CPC Class Codes: B23K 2101/38 Conductors
• CPC Class Codes: B23K 28/02 Combined welding or cutting procedures or apparatus

Abstract

An apparatus and method of connecting a covered wire to a wire terminal which incorporates ultrasonic and resistance welding in sequence. The method includes (a) positioning the wire terminal against an anvil; (b) positioning the covered wire against the terminal; (c) positioning a tip of an ultrasonic welder in clamped engagement with the wire terminal and the covered wire together against the anvil; (d) ultrasonically vibrating the tip for a time sufficient for the covering against the terminal to be displaced and electrical contact established between the tip and the anvil through the wire and the terminal; and (e) applying sufficient electric current between the tip and the anvil to resistance weld the wire and the terminal together.

Claims

1. A method of connecting a covered wire to a conductive wire terminal comprising the steps of:

positioning the wire terminal against an anvil;

positioning the covered wire against the terminal;

positioning a tip of an ultrasonic welder in clamped engagement with the wire terminal and covered wire together against the anvil;

actuating the ultrasonic welder for a time sufficient for a covering of the wire to be displaced and electrical contact established between the tip and the anvil through the wire and the terminal;

stopping the ultrasonic welder;

applying sufficient electrical energy between the tip and the anvil to resistance weld the wire and the terminal together.

2. A method of connecting a covered wire to a conductive wire terminal, the wire having an outer non-conductive cover and an inner conductive wire, comprising the steps of:

positioning the wire terminal against an anvil;

positioning the covered wire against the terminal;

positioning a tip of an ultrasonic welder in clamped engagement with the wire terminal and covered wire together against the anvil;

actuating the ultrasonic welder to vibrate the tip ultrasonically for a time sufficient for a covering of the wire to be displaced and electrical contact established between the tip and the anvil through the wire and the terminal;

stopping the tip vibration;

applying sufficient electric current between the tip and the anvil to resistance weld the wire and the terminal together.

3. A method of connecting a covered wire to a conductive wire terminal comprising the steps of:

clamping the wire terminal onto an anvil;

positioning the covered wire against the terminal;

clamping a tip of an ultrasonic welder against the wire terminal and covered wire together and against the anvil;

ultrasonically vibrating the tip only for a time sufficient for a covering of the wire to be displaced and electrical contact established between the tip and the anvil through a conductor in the wire and the terminal;

after the ultrasonic welder is stopped, applying electric power between the tip and the anvil to resistance weld the wire conductor and the terminal together.

4. An apparatus for connecting a covered wire to a conductive wire terminal comprising:

an ultrasonic welder including a movable tip and an anvil adapted for supporting the wire terminal positioned thereagainst;

said tip clampingly engagable against a portion of a covered wire and the wire terminal together against the anvil;

a control for actuating the ultrasonic welder to vibrate the tip ultrasonically only for a time sufficient for a covering of the wire against the terminal to be displaced and electrical contact established between the tip and the anvil through a conductor of the wire and the terminal;

said control also actuating an electric power source between the tip and the anvil sufficient to resistance weld the wire conductor and the terminal together.

5. A process of ultrasonic-resistance welding a covered wire and a conductive wire terminal together comprising the steps of:

positioning the wire terminal against an anvil;

positioning the covered wire against the terminal;

positioning a tip of an ultrasonic welder in clamped engagement with the wire terminal and covered wire together against the anvil;

actuating the ultrasonic welder for a time sufficient for a covering of the wire to be displaced and electrical contact established between the tip and the anvil through the wire and the terminal;

stopping the ultrasonic welder;

applying sufficient electrical energy between the tip and the anvil to resistance weld the wire and the terminal together.