Method of manufacturing a wiring material

• US 8,769,813 B2
• Filed: 07/23/2010
• Issued: 07/08/2014
• Est. Priority Date: 12/10/2004
• Status: Active Grant

• Current Assignee: Hitachi Metals Limited (Hitachi Metals (Thailand) Ltd.)
• Original Assignee: Hitachi Metals Limited (Hitachi Metals (Thailand) Ltd.)
• Inventors: Sumi, Toru, Iwasita, Tsukasa, Egami, Kenichi, Watanabe, Kazuyuki, Okikawa, Hiroshi
• Primary Examiner(s): Nguyen, Donghai D
• Application Number:
  US12/842,671
• Publication Number:
  US 20100281686A1
• Time in Patent Office: 1,446 Days
• Field of Search: 298/40, 298/87, 29860-863, 174/84.R, 219/56.1, 219/56.22, 219/85.16, 228/228, 310/77, 439/877, 439/879
• US Class Current: 29/862
• CPC Class Codes: H01R 4/023 between cables or wires and terminals
• CPC Class Codes: Y10T 29/49172 by molding of insulating material
• CPC Class Codes: Y10T 29/49176 with molding of electrically insulating material
• CPC Class Codes: Y10T 29/49179 by metal fusion bonding
• CPC Class Codes: Y10T 29/49181 by deforming
• CPC Class Codes: Y10T 29/49183 of ferrule about conductor and terminal
• CPC Class Codes: Y10T 29/4919 Through insulation
• CPC Class Codes: Y10T 29/49227 Insulator making

Abstract

A wiring material is provided by electrically connecting a connecting terminal with two single line conductors arranged in parallel. The connecting terminal is provided with a tube-shaped section for storing two single line conductors, the two single line conductors are inserted into the tube-shaped section, resistance welding is performed by carrying electricity from the external of the tube-shaped section in a status where the tube-shaped section and the single line conductors are mutually brought into contact, and the connecting terminal is electrically connected with the two single line conductors.

Claims

1. A method of manufacturing a wiring material having a connecting terminal electrically connected to a circular shaped single line conductor, comprising the steps of:

bending a single line conductor to have a circular shape;

extending both ends of the single line conductor that is bent in parallel;

forming a tube-shaped section having a circular cross section at the connecting terminal for accommodating the both ends of the single line conductor;

inserting the both ends of the single line conductor into the tube-shaped section; and

conducting a resistance welding by energizing welding electrodes from the outer periphery of the tube-shaped section, in a state where a portion of the tube-shaped section between the ends of the single line conductor is pushed by the welding electrode into a space formed between the ends of the single line conductor and an inner periphery surface of the tube-shaped section contacts with the both ends of the single line conductor to electrically connect the connecting terminal with the both ends of the single line conductor.

2. The method of manufacturing a wiring material according to claim 1, wherein:

the resistance welding is conducted by energizing by a pair of electrodes from the outer periphery of the tube-shaped section, and a tip angle of any one or both of the pair of the electrodes is from 60°

to 90°

.

3. The method of manufacturing a wiring material according to claim 2, wherein:

a round-shape at a tip portion of any one or both of the pair of the electrodes is from 1.25 mm to 3 mm.

4. The method of manufacturing a wiring material according to claim 1, further comprising the step of:

conducting a crush process on the tube-shaped section of the connecting terminal, to contact an inner periphery of the tube-shaped section and the both ends of the single line conductor with each other.

5. The method of manufacturing a wiring material according to claim 4, wherein:

the crush process is conducted such that an upper portion of the tube-shaped section of the connecting terminal contacts with a concave portion formed between the both ends of the two single line conductors and contacts along a longitudinal direction of the two single line conductors.

6. The method of manufacturing a wiring material according to claim 4, further comprising the step of:

conducting a crush process to press the tube-shaped section of the connecting terminal along a direction perpendicular to the longitudinal direction of the two single line conductors.