Method of lead wire connection

• US 6,671,952 B2
• Filed: 02/25/2002
• Issued: 01/06/2004
• Est. Priority Date: 02/28/2001
• Status: Expired due to Fees

• Current Assignee: Star Micronics Company Limited
• Original Assignee: Star Micronics Company Limited
• Inventors: Ono, Kazuyasu
• Primary Examiner(s): Tugbang, A. Dexter
• Assistant Examiner(s): NGUYEN, TAI V
• Application Number:
  US10/080,680
• Publication Number:
  US 20020117327A1
• Time in Patent Office: 680 Days
• Field of Search: 298/68, 298/30, 298/32, 298/40, 298/42, 298/43, 298/54, 298/60, 298/61, 298/59, 29D/IG.48, 219/56.21, 219/56.22, 219/92, 219/110
• US Class Current: 29/860
• CPC Class Codes: H01R 43/0228 without preliminary removing of insulation before soldering or welding
• CPC Class Codes: H04R 1/06 Arranging circuit leads; Relieving strain on circuit leads
• CPC Class Codes: H04R 13/00 Transducers having an acoustic diaphragm of magnetisable material directly co-acting with electromagnet
• CPC Class Codes: Y10T 29/49126 Assembling bases
• CPC Class Codes: Y10T 29/4913 Assembling to base an electrical component, e.g., capacitor, etc.
• CPC Class Codes: Y10T 29/49144 by metal fusion
• CPC Class Codes: Y10T 29/49149 by metal fusion bonding
• CPC Class Codes: Y10T 29/49179 by metal fusion bonding

Abstract

A method of lead wire connection includes mounting a lead wire onto an uppre surface of a land portion, supplying a cover member onto the lead wire, pressing the lead wire via the cover member against the upper surface of the land portion by a first electrode tool, heating the first electrode tool to expose a part of the lead wire, and applying an electric current between the first electrode and a second electrode tool so that resistance welding is effected between the cover member and the lead wire and between the lead wire and the land portion.

Claims

1. A method of lead wire connection comprising:

mounting a lead wire covered with an electrical insulating coating onto an upper surface of a land portion;

supplying a cover member onto the lead wire, the cover member made of a metal material and separately formed from the lead wire and the land portion;

pressing the lead wire via the cover member against the upper surface of the land portion by a first electrode tool having a heater mechanism while supporting a lower surface of the land portion by a second electrode tool;

heating the first electrode tool by the heater mechanism to make the lead wire exposed partially; and

applying an electric current between the first and second electrode tools so that resistance welding is effected between the cover member and the lead wire and between the lead wire and the land portion, simultaneously.

2. A method of lead wire connection comprising:

mounting a lead wire covered with an electrical insulating coating onto an upper surface of a land portion;

supplying a cover member onto the lead wire, the cover member formed separately from the lead wire and the land portion;

pressing the lead wire via the cover member against the upper surface of the land portion by a pressure welding tool having a heater mechanism;

heating the pressure welding tool by the heater mechanism at a first temperature to make the lead wire exposed partially; and

heating the pressure welding tool by the heater mechanism at a second temperature higher than the first temperature to supply a melted portion of the cover member around the lead wire and the land portion.

3. The method of lead wire connection according to claim 2, wherein the cover member comprises a laminate of a plurality of metal materials having different melting points;

and

the metal material brought into contact with the lead wire has a melting point lower than a melting point of the metal material brought into contact with the pressure welding tool.

4. A method of lead wire connection comprising:

mounting a lead wire covered with an electrical insulating coating onto an upper surface of a land portion;

heating the electrical insulating coating at a first temperature by a pressure welding tool having a heater mechanism to melt the electrical insulating coating on the upper surface of the land portion;

supplying a cover member onto the lead wire on the upper surface of the land portion, the cover member formed separately from the lead wire and the land portion; and

heating a portion of the cover member by the heater mechanism at a second temperature higher than the first temperature and lower than the melting point of the land portion to melt the portion to supply the melted portion around the lead wire and the land portion.

5. A method of lead wire connection comprising:

mounting a lead wire covered with an electrical insulating coating onto an upper surface of a land portion;

supplying a cover member onto the lead wire on the upper surface of the land portion, the cover member formed separately from the lead wire and the land portion;

pressing the lead wire via the cover member against the upper surface of the land portion by a pressure welding tool having a heater mechanism;

bringing a non-melting portion of the cover member in contact with the pressure welding tool;

supplying a melting portion of the cover member onto the lead wire on the upper surface of the land portion; and

heating a portion of the cover member by the heater mechanism at a predetermined temperature to melt and supply the melting portion around the lead wire and the land portion.