Cable, cable connection method and cable welder

• US 7,339,114 B2
• Filed: 04/02/2003
• Issued: 03/04/2008
• Est. Priority Date: 04/04/2002
• Status: Expired due to Fees

• Current Assignee: Fujikura Limited
• Original Assignee: Fujikura Limited
• Inventors: Tachibana, Yuko, Akashi, Kazuya, Ashida, Shigeru
• Primary Examiner(s): Mayo, III; William H.
• Application Number:
  US10/510,031
• Publication Number:
  US 20050087359A1
• Time in Patent Office: 1,798 Days
• Field of Search: 174/74.R, 174/77.R, 174/84.R, 174/88.R, 439/492, 439/494
• US Class Current: 174/84.00R
• CPC Class Codes: B23K 11/0033 Welding locally a thin plate to a large piece
• CPC Class Codes: B23K 11/11 Spot welding
• CPC Class Codes: B23K 2101/32 Wires
• CPC Class Codes: B23K 2101/36 Electric or electronic devices
• CPC Class Codes: B23K 2101/38 Conductors
• CPC Class Codes: H01L 2224/78282 in the upper part of the bonding apparatus, e.g. in the capillary or wedge
• CPC Class Codes: H01L 2224/78313 Wedge
• CPC Class Codes: H01R 43/0214 Resistance welding H01R43/0228 takes precedence

Abstract

A connection method for connecting an end of a signal wire (53) of a cable (51) to the connecting face of a contact (59) of a connector (52). The lengthwise direction of the connecting face of the contact (59) and the lengthwise direction of the signal wire (53) are mutually matched in connection. The end of the signal wire (53) is pressured against the connecting part by a pair of electrodes (69A, 69B) disposed in mutual separation in the lengthwise direction of the signal wire (53), and an electric current is passed between the pair of electrodes (69A, 69B). Thereby, the end of the cable (51) and the connecting part are mutually welded.

Claims

1. A method for connecting a round conductive wire of a cable to a flat contact of a connector or substrate, the method comprising:

pressing an end portion of a round conductive wire to form a pair of opposing flat surfaces in the end portion;

setting the end portion of the round conductive wire on a flat contact of a connector such that one of the flat surfaces of the round conductive wire comes in contact with the flat contact;

setting a pair of electrodes on the other of the flat surfaces of the round conductive wire on a side opposite to the flat contact, the pair of electrodes being mutually spaced apart in a longitudinal direction of the round conductive wire; and

welding the one of the flat surfaces of the round conductive wire to the flat contact by passing an electric current between the pair of electrodes.

2. A cable comprising:

a connector including a base having a plurality of flat contacts; and

a cable main body including a plurality of round conducting wires, each of the round conducting wires having a pair of opposing flat surface formed in the end portion thereof, each of the round conducting wires is electrically connected to each of the flat contacts at a part of one of the flat surfaces by welding.

3. The cable according to claim 2, wherein:

a long elongated welded part is formed along the lengthwise direction of each of the round conducting wires in each connecting part between the flat contacts and the round conducting wires,

the state of the welding in the welded part is within the scope from the condition in which the depth at the top of a color changed part forming an arc on the signal contact is above 0.1 mm to the condition immediately prior to the condition of blasting of the signal contact.

4. The cable according to claim 2, wherein:

a welded part is formed in each connecting part between the flat contacts and the round conducting wires,

the state of welding in the welded part is within the scope from the condition in which the dispersion of a layer of precious metal thinly covering the surface of the signal wire forms an alloy layer of that precious metal in the signal contact that is of a depth of 5 μ

m to the condition in which the alloy layer is half the thickness of the signal contact.

5. A cable comprising:

a connector including;

a plurality of ground contacts each having a hexahedron shape and having an opening in the center thereof,

a flat plate formed of a material having a heat resistance and insulating properties, said flat plate passing through the openings to secure the ground contacts so that the ground contacts are disposed apart from each other,

a plurality of first signal contacts each disposed between the adjacent ground contacts at one side of the flat plate in the thickness direction, and

a plurality of second signal contacts each disposed between the adjacent ground contacts at the other side of the flat plate in the thickness direction, and

a cable main body including a plurality of first signal wires, a plurality of second signal wires, and a plurality of drain wires,

wherein ends of the first signal wires are separately connected to the respective first signal contacts, ends of the second signal wires are separately connected to the respective second signal contacts, and ends of the drain wires are separately connected to the respective ground contacts,

the first and second signal contacts are located inside the ground contacts when viewed from the passing direction of the flat plate through the ground contacts, and the ends of the drain wires are located on the same side of the respective ground contacts.

6. The cable according to claim 5, wherein:

exposed portions of the signal wires are located inside the ground contacts in the thickness direction when viewed from the passing direction of the flat plate through the ground contacts.

7. The cable according to claim 5, wherein:

a long elongated welded part is formed along the lengthwise direction of each of the signal wires in each connecting part between the signal contacts and the signal wires,

the state of the welding in the welded part is within the scope from the condition in which the depth at the top or a color changed part forming an arc on the signal contact is above 0.1 mm to the condition immediately prior to the condition of blasting of the signal contact.

8. The cable according to claim 5, wherein:

a welded part is formed in each connecting part between the signal contacts and the signal wires,

the state of welding in the welded part is within the scope from the condition in which the dispersion of a layer of precious metal thinly covering the surface of the signal wire forms an alloy layer of that precious metal in the signal contact that is of a depth of 5 μ

m to the condition in which the alloy layer is half the thickness of the signal contact.