Connection structure for electric wire, manufacturing method therefor, and electric

Abstract

The invention provides a connection structure of electric wires, a manufacturing method of the connection structure, and an electric wire assembly, wherein the terminal of a core wire exposed at the end part area of the electric wires formed by electric wires, cables and the like can be electrically connected with a terminal of a connection object in a high density. An electric wire connection structure (10) for electrically connecting terminals of a plurality of core wires, which are exposed by peeling off a coating in an end region of each of a plurality of insulated electric wires (1A) arranged side by side, to a plurality of corresponding terminals, is provided with a fixing member (3) that is formed so as to fix the core wires in the vicinity of the end region, in a state in which the plurality of insulated wires (1A) are entirely parallel to each other, the plurality of insulated wires (1A) are in contact with the outer peripheral surfaces in the vicinity of the end regions of the plurality of insulated wires (1A), thereby fixing the relative positions of the insulated wires (1A).

Description

Technical Field

[0001] This invention relates to connection structures for electrical wires, methods for manufacturing them, and electrical wire assemblies. Background Technology

[0002] In recent years, a method for manufacturing transmission cables with connectors has been proposed, which solves the problems of skewness and spacing offset caused by the offset of the core wire in the length direction during the processing of the transmission cable terminal (for example, see Patent Document 1).

[0003] In the method for manufacturing a transmission cable with a connector described in Patent Document 1, a circular transmission cable, formed by covering multiple insulating wires with an outer sheath, is cut to a predetermined length. At the end region of the transmission cable, the outer sheath is removed by a predetermined length, so that the exposed ends of the multiple insulating wires abut against the abutment portion of a cable-aligning clamp. The insulating wires are then aligned by embedding them into the recess of the cable-aligning clamp. Near the cable-aligning clamp, the insulating wires are fixed using a fixing unit (adhesive tape with adhesive, adhesive, or a material cured by resin molding). The cable-aligning clamp is removed, and the front ends of the core wires are soldered to corresponding cable connection terminals on the connector wiring board. The fixing unit is then removed. Thus, the transmission cable and the connector wiring board are electrically connected.

[0004] Patent Document 1: Japanese Patent Application Publication No. 2007-317676

[0005] According to the aforementioned existing example, since the insulated wires leading from a circular cable are fixed using a fixing unit, each insulated wire is fixed in an inclined state (a state of residual bending stress) within the fixing unit. Therefore, if the wire clamp is removed, the position of the front end of the core wire may shift due to bending stress, making high-density electrical connections at the ends of the core wire difficult. Furthermore, in recent years, with the increasing integration and multifunctionality of semiconductors assembled in electronic components and electronic devices, there is a growing demand for high-density connectors and substrate terminals (also called pads) used for communication between semiconductors and external systems, as well as communication using various wires with different applications and outer diameters. Summary of the Invention

[0006] The objective of this invention is to provide a connection structure for a type of wire, a method for manufacturing the same, and a wire assembly that enables high-density electrical connection between the end of the core wire exposed in the end region of a wire or cable and the terminal of the object to be connected.

[0007] [1] A connection structure for electrical wires, used to electrically connect the terminals of multiple core wires exposed by stripping the covering of the end regions of multiple wires arranged side by side to corresponding terminals. The connection structure of the aforementioned wires includes a fixing member, which is formed to contact the outer peripheral surface of the aforementioned end region of the aforementioned multiple wires when the multiple wires are aligned parallel to each other, thereby fixing the relative position between the aforementioned wires. [2] Based on the connection structure of the wires described in [1] above, The aforementioned types of electrical wires are arranged side by side in multiple layers, and the aforementioned fixing components are provided for each layer. [3] Based on the connection structure of the wires described in [2] above, The external dimensions of the fixing components provided for each of the aforementioned layers are the same. [4] Based on the connection structure of the wires described in [1] above, It also includes a sealing component that covers the fixing component and watertightly seals the connection portions of the plurality of terminals and the terminals of the plurality of core wires. [5] Based on the connection structure of the wires described in [3] above, It also includes a sealing component that covers the aforementioned fixing components provided for each layer and watertightly seals the connection portions of the plurality of terminals and the terminals of the plurality of core wires. [6] According to the connection structure of the wires described in any of [1] to [5] above, The aforementioned types of electrical wires include cables, which comprise: two insulated wires; a shielding wire; a shielding layer covering the outer periphery of the two insulated wires and the shielding wire; and an outer sheath covering the outer periphery of the shielding layer and formed of an insulating material. The two insulated wires and the shielded wire are arranged in the same direction as the plurality of wires arranged side by side, and the shielded wire is arranged next to the two insulated wires. [7] Based on the connection structure of the wires described in [1] above, The aforementioned terminals are arranged at a specified spacing on the same line along the direction in which the aforementioned types of wires are arranged side by side. The aforementioned multiple types of wires are divided into at least two groups of wires with the spacing between the wires being wider than the specified spacing between the terminals. The aforementioned fixing component is at least divided into a first component and a second component that respectively fix the relative positions between the wires constituting the at least two wire groups. [8] A method for manufacturing a connection structure for electrical wires, wherein the connection structure is used to electrically connect the terminals of multiple core wires exposed by stripping the covering of the end regions of multiple electrical wires arranged side by side to corresponding terminals. In the manufacturing method of the above-mentioned wire connection structure, A pair of wire clamps with multiple wire slots are arranged at a specified distance, the multiple wire slots being formed to correspond to the outer diameter of each of the multiple types of wires; The plurality of wires are arranged in the corresponding wire trays such that the vicinity of the aforementioned end region is located between the aforementioned pair of wire clamps, and the plurality of wires are wired parallel to each other in the aforementioned end region; A fixing member is formed between the pair of wire clamps in such a way that it contacts the outer peripheral surface near the end region of the plurality of wires to fix the relative position between the wires. Remove the pair of cable clamps from the aforementioned multiple types of wires; and Before or after forming the aforementioned fixing component, the following steps are performed: the plurality of wires are cut at a specified length from the aforementioned fixing component; the wrapping of the end regions of the plurality of wires on the cut side is stripped off to expose the plurality of core wires; and the ends of the exposed plurality of core wires are connected to the corresponding plurality of terminals. [9] The manufacturing method of the connection structure of the wires described in [8] above, The mold for injection molding, which has a cavity corresponding to the aforementioned fixed component, is used as the master mold, and the pair of line clamps are used as inserts to be embedded in the master mold. The aforementioned fixed component is formed by injection molding.

[10] A wire assembly, comprising: Multiple types of electrical wires arranged side by side; A connection object having multiple terminals, wherein the multiple terminals are electrically connected to the terminals of multiple core wires exposed by stripping the covering from the end regions of the respective multiple types of wires; and The fixing component is formed to contact the outer peripheral surface of the end region of the plurality of wires near the end region when the plurality of wires are aligned parallel to each other, thereby fixing the relative position between the wires.

[0008] According to the present invention, it is possible to make a high-density electrical connection between the end of the core wire exposed in the end region of an electric wire or cable and the terminal of the object to be connected. Attached Figure Description

[0009] Figure 1 This is a top view showing the connection structure of the wires according to the first embodiment of the present invention. Figure 2 yes Figure 1 A sectional view along line AA. Figure 3 yes Figure 2BB line section view. Figure 4 It is a top view showing the state of multiple insulated wires being aligned using a pair of wire clamps. Figure 5 (a) is a front view showing an example of a wire clamp. Figure 5 (b) is Figure 5 Detailed diagram of part C of (a), Figure 5 (c) indicates that in Figure 5 The diagram shown in (b) depicts the state in which insulated wires are arranged in the wire slot of the wire clamp. Figure 6 An example of a mold for fixing a component is shown below: (a) is a sectional view of (b) along line DD, (b) is a sectional view along the X direction, and (c) is a sectional view of (b) along line EE. Figure 7 It is a top view of the fixed components formed between the clamps of the entire line. Figure 8 This is a top view showing the cutting process of multiple insulated wires. Figure 9 This is a top view showing the stripping process of multiple insulated wires. Figure 10 This is a front view of the main part of the assembly line fixture involved in variations 1 to 4. Figure 11 This is a perspective view showing an example of an insulated wire used in the connection structure of an electrical wire according to the second embodiment of the present invention. Figure 12 (a) and (b) are front views of the wire clamp used in the second embodiment, viewed from the front end side of the insulated wire. Figure 12 (c) is the front view of the rigging fixture involved in Variation Example 5. Figure 13 This is a cross-sectional view along the Y direction of the fixing component according to the second embodiment. Figure 14 This is a top view showing the connection structure of the wires according to the third embodiment of the present invention. Figure 15 Is with Figure 3 The corresponding sectional view. Figure 16 This is a top view showing the connection structure of the wires according to the fourth embodiment of the present invention. Figure 17 Is with Figure 3 The corresponding sectional view of the main part. Figure 18 This is a cross-sectional view of the type of electrical wire according to the fifth embodiment of the present invention. Explanation of reference numerals in the attached figures 1A~1E…Insulated wire; 1a~1e…Center wire; 2…Edge base plate; 2a…Edge portion; 3, 3A~3D…Fixing component; 3a…First component; 3b…Second component; 4…Sealing component; 10…Wire connection structure; 10a…First layer; 10b…Second layer; 10c…Third layer; 10ca…First layer of the third layer; 10cb…Second layer of the third layer; 10d…Fourth layer; 11a~11e…Core wire; 12a, 12e…Insulation layer; 13a…Shielding conductor; 14a~14d…Outer sheath; 15…Cable; 16…Shielded wire; 16a…Center wire; 17…Shielding tape; 18…Outer sheath; 21…Base material; 21a…Surface; 23A, 23B…Edge terminals; 3 0…Contact surface; 31…Thin-walled portion; 100A, 100B…Wire clamp; 100Aa, 100Ba…First clamp; 100Ab, 100Bb…Second clamp; 100a…Protrusion; 101a~101d…Wire groove; 102a…Wire groove center; 103, 103a~103d…Base line; 104…Bolt; 110…Mold for fixing components; 111…First mold; 112…Second mold; 113…Cavity; 221…First terminal; 222…First grounding terminal; 223…Second terminal; 224…Second grounding terminal; 225…Third terminal; 226…Third grounding terminal; 227…Fourth terminal; 228…Fourth grounding terminal; d…Interval; W…Width. Detailed Implementation

[0010] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. Furthermore, in each drawing, constituent elements having substantially the same function are labeled with the same reference numerals, and repeated descriptions thereof are omitted.

[0011] [First Implementation Method] Figure 1 This is a top view showing the connection structure of the wires according to the first embodiment of the present invention. Figure 2 yes Figure 1 AA-line sectional view, Figure 3 yes Figure 2 BB line section view.

[0012] In addition, Figure 1 , Figure 2This refers to a situation where a connector is used to connect multiple wires to one end. The connection object is not limited to connectors; it can also be a substrate or other connection objects. Examples of connectors that are connection objects include connectors that connect wires to a card edge substrate, connectors that connect wires to a substrate with a plug or socket connector, and connectors that directly connect wires to the terminals (pin headers, socket terminals, cup terminals, etc.) of the connector. The mounting types of plug or socket connectors to the substrate include SMT (Surface Mount Technology), DIP (Dual In-line Package), and press-fit (press-in to a through-hole in the substrate). Examples of substrates that are connection objects include substrates that directly connect wires to PCBs (Printed Circuit Boards), FPCs (Flexible Printed Circuit Boards), circuit boards, control boards, relay boards, etc. Furthermore, connectors can be used to connect to both ends of multiple wires, substrates can be used to connect to both ends, or connectors can be used to connect to one end and substrates to the other end. Figure 1 , Figure 2 The diagrams of solder used to electrically connect the core wires and shielding terminals to the terminals (also called pads) are omitted. Furthermore, in this specification and accompanying drawings, the length direction of the wire type is designated as the X direction, the direction in which multiple wire types are arranged side-by-side is designated as the Y direction, and the direction orthogonal to the X and Y directions is designated as the Z direction.

[0013] Furthermore, in this specification, "wire type" includes both wires and cables, encompassing wires consisting of a single wire (also known as an insulated wire) and cables formed by bundling multiple wires and covering their outer perimeter with an insulating sheath. Additionally, in this specification, "end area" refers to the area of ​​the wire type where the insulation has been stripped for connection to terminals on a connecting object (connector, substrate, etc.). A wire type assembly is constructed by connecting connectors or substrates to one or both ends of multiple wire types.

[0014] The connection structure 10 for electrical wires includes: multiple insulated wires 1A (in... Figure 1 In the diagram, only the third layer (10c) is shown; in the multi-layer diagram (four layers in this diagram) (see reference...) Figure 2 The insulated wires 1A are arranged side-by-side along the Y direction; the edge substrate 2 connects the terminals of multiple insulated wires 1A by solder (not shown), and the front edge 2a becomes an edge connector; multiple (e.g., four) fixing parts 3A to 3D (also referred to as "fixing parts 3" when collectively referred to) fix the relative positions of the insulated wires 1A for each layer; and the sealing part 4 (in Figure 1(Illustrated with imaginary lines) The fixing components 3A to 3D are covered, and the connection portions of the core wires 11a of the plurality of insulated wires 1A to the corresponding plurality of terminals 221 to 228 are watertightly covered. Here, the insulated wire 1A is an example of a wire.

[0015] As a method for fixing multiple cables (insulated wires) arranged side-by-side near their end areas, methods are known such as clamping multiple cables (insulated wires) with two grounding rods (e.g., Japanese Patent Application Laid-Open No. 2008-181817) and clamping multiple cables (insulated wires) with two adhesive tapes (e.g., Japanese Patent Application Laid-Open No. 2019-67519). The method using grounding rods involves embedding solder between the grounding rods and the cables; therefore, if the outer diameters of the cables are different, the gaps between the cables and the grounding rods are inconsistent, resulting in a lack of uniform bonding force between the cables. In the method using adhesive tapes, if the outer diameters of the cables are different, the contact area between the smaller outer diameter cable and the tape is smaller, and combined with the weight difference of the cables, a uniform bonding force cannot be obtained between the cables. Furthermore, in the aforementioned method of fixing an insulated wire drawn from a circular cable using a fixing unit (Japanese Patent Application Publication No. 2073-317676), since each insulated wire is fixed in an inclined state (a state of residual bending stress) within the fixing unit, if the wire clamp is removed, the position of the front end of the core wire may shift due to bending stress.

[0016] As described below, in this embodiment, the fixing member 3 is used to align multiple insulated wires 1A into parallel positions using a pair of wire clamps (see reference). Figure 6 The fixing member 3 is formed by resin molding to contact the outer peripheral surfaces of multiple insulated wires 1A, thereby fixing the relative positions of the insulated wires 1A. By forming such a fixing member 3, no bending stress remains on the insulated wires 1A, thus suppressing the positional displacement of the front end of the core wire 11a after the wire clamp is removed. In addition, since the fixing member 3 is formed to contact the outer peripheral surfaces of the insulated wires 1A, insulated wires 1A with different outer diameters can be fixed at arbitrary intervals.

[0017] Furthermore, in this embodiment, only one end of the plurality of insulated wires 1A is shown, but it could also be a structure where both ends are connected to the connector, for example, a structure connected to the retaining plate 2. Alternatively, the plurality of insulated wires 1A could be arranged side-by-side along the Y direction in any one, two, or three, or five or more of the four layers from the first layer 10a to the fourth layer 10d. Additionally, in this embodiment, terminals 221 to 228 of the retaining plate 2 of the connector, which serve as an example of the connection object for the core wires 11a of the insulated wires 1A, are shown (see reference). Figure 2However, it can also be a terminal on a substrate other than a connector. Furthermore, the sealing member 4 does not cover the entirety of the fixing members 3A to 3D, but it can also cover the entirety. Additionally, if it is not necessary to use the sealing member 4 to watertightly cover the connection portion between the core wire 11a and the shielding conductor 13a and the terminals 221 to 228, the sealing member 4 may not be provided.

[0018] (Structure of insulated wires) Multiple insulated wires 1A have the same outer diameter and are arranged side-by-side at equal intervals along the Y direction in the fixing member 3. The insulated wires 1A are, for example, coaxial wires, comprising a core wire 11a formed of a conductor, an insulating layer 12a covering the outer periphery of the core wire 11a, a shielding conductor 13a formed on the outer periphery of the insulating layer 12a, and an outer sheath 14a covering the outer periphery of the shielding conductor 13a and formed of insulating material. The core wire 11a can be a single wire or formed by twisting multiple bare wires together. The insulating layer 12a can be formed, for example, of polyethylene resin (low-density polyethylene, high-density polyethylene, etc.), fluoropolymer resin, etc. The shielding conductor 13a can be formed by spirally winding conductive strip transversely around the outer periphery of the insulating layer 12a, or it can be arranged longitudinally along the length of the insulated wire 1A, or it can be formed by transversely winding or braiding bare wires. The outer sheath 14a can also be formed, for example, of fluoropolymer resin, polyvinyl chloride (PVC), polyester resin, etc.

[0019] Furthermore, the multiple insulated wires 1A can also have different outer diameters. Additionally, in the fixing member 3, the multiple insulated wires 1A can be arranged side-by-side in the Y direction at different spacings depending on their outer diameters, or the outer sheaths 14a of adjacent insulated wires 1A can be arranged in contact with each other. Furthermore, the insulated wires 1A can also be single-wire or other types of insulated wires. Furthermore, the type of wire fixed by one fixing member 3 can be composed only of insulated wires as in this embodiment, but it can also be composed of a mixture of insulated wires and cables, or only of cables, or it can include other linear components such as shielded wires in addition to insulated wires and cables. Furthermore, in Figure 1 , Figure 2 In this case, multiple insulated wires 1A can also be arranged side by side along the Y direction near the fixing component 3, but not in the Y direction at the location away from the fixing component 3. For example, they can be bundled into an elliptical or circular shape using a cable tie or the like.

[0020] The front end of the core wire 11a of the insulated wire 1A configured in the first layer 10a and the second layer 10b is located at a distance L1 from the fixing component 3, and the front end of the core wire 11a of the insulated wire 1A configured in the third layer 10c and the fourth layer 10d is located at a distance L2 from the fixing component 3 (where L2 > L1).

[0021] (Structure of the card edge substrate) The card edge substrate 2 includes: a substrate 21 formed of an insulating material; a plurality of first terminals 221, a first ground terminal 222, a plurality of second terminals 223 and a second ground terminal 224 formed on the surface 21a of the substrate 21; and a plurality of third terminals 225, a third ground terminal 226, a plurality of fourth terminals 227 and a fourth ground terminal 228 formed on the back side 21b of the substrate 21.

[0022] A plurality of first terminals 221 and first grounding terminals 222 formed on surface 21a correspond to a plurality of insulated wires 1A disposed on first layer 10a. A plurality of second terminals 223 and second grounding terminals 224 formed on back surface 21b correspond to a plurality of insulated wires 1A disposed on second layer 10b. A plurality of third terminals 225 and third grounding terminals 226 formed on surface 21a correspond to a plurality of insulated wires 1A disposed on third layer 10c. A plurality of fourth terminals 227 and fourth grounding terminals 228 formed on back surface 21b correspond to a plurality of insulated wires 1A disposed on fourth layer 10d. The number of first terminals 221 and the number of third terminals 225 are the same in this embodiment, but may be different. The Y-direction positions of the first terminals 221 and the third terminals 225 are the same in this embodiment, but may be different. The number of second terminals 223 and the number of fourth terminals 227 are the same in this embodiment, but may be different. The Y-direction positions of the second terminals 223 and the fourth terminals 227 are the same in this embodiment, but may be different.

[0023] In addition, the card edge substrate 2 has an edge portion 2a that serves as a front-end insertion into a female connector (not shown). Multiple edge terminals 23A are formed on the surface 21a of the substrate 21 of the edge portion 2a, and multiple edge terminals 23B are formed on the back side 21b of the substrate 21 of the edge portion 2a.

[0024] For the card edge substrate 2, the terminals 221 to 228 formed on the surface 21a and the back surface 21b of the substrate 21 are connected to the edge terminals 23A and 23B formed on the surface 21a and the back surface 21b of the edge portion 2a via the wiring pattern (not shown) formed on the surface 21a and the back surface 21b of the substrate 21.

[0025] (Structure of the fixed component) The fixing component 3 has a cuboid with a width W extending in the X direction along the Y direction. The fixing component 3 is formed, for example, from a resin material (e.g., polyamide resin, ABS, etc.) through resin molding (e.g., injection molding, compression molding, extrusion molding, calendering, transfer molding, lamination molding, etc.). Furthermore, the resin constituting the fixing component 3 is not limited to injection molding resin; heat-sensitive adhesives (hot melt adhesives, etc.), moisture-curing adhesives (reactive hot melt adhesives, etc.), light-curing resins (ultraviolet-curing resins, visible-light-curing resins, etc.), two-component reactive adhesives, etc., can also be used, and the fixing component 3 can be formed by coating and curing these adhesives. Additionally, portions divided along reference lines 103a to 103d can be formed separately by resin molding or machining, and these portions can clamp the insulated wire 1A and be joined by bonding or welding. When using polyamide resin as the injection molding resin, because polyamide resin has a low melt viscosity, low-pressure and low-temperature (e.g., around 200°C) low-pressure injection molding can be performed.

[0026] The width W in the X direction is preferably a certain width so that the center lines 1a of the insulated wires 1A remain parallel to each other after the wire clamp 100A is removed. Specifically, when the maximum outer diameter of the wire is set to Dmax, it is preferable, for example, that Dmax ≤ W, 1.5Dmax ≤ W, 2Dmax ≤ W, etc. In addition, the thickness in the Z direction is preferably greater than the maximum outer diameter of the wire, but it is also permissible for a portion of the wire sheath to be exposed.

[0027] like Figure 3 As shown, the fixing component 3A corresponding to the first layer 10a and the fixing component 3B corresponding to the second layer 10b have the same external dimensions, and the reference lines 103a and 103b are positioned off-center from the center of the thickness in the Z direction. The fixing component 3C corresponding to the third layer 10c and the fixing component 3D corresponding to the fourth layer 10d have the same external dimensions, and the reference lines 103c and 103d are positioned at the center of the thickness in the Z direction. Furthermore, the fixing components 3A and 3B corresponding to the first layer 10a and the second layer 10b may also have the same external dimensions as the fixing components 3C and 3D corresponding to the third layer 10c and the fourth layer 10d. Thus, the mold used to form the fixing component 3 can be shared.

[0028] (Structure of the sealing component) The sealing component 4 is cuboid in shape to cover the area including the four fixing components 3A to 3D, the connection portion between the core wire 11a of the insulated wire 1A and the terminals 221, 223, 225, and 227 of the card edge substrate 2, and the connection portion between the shielding conductor 13a of the insulated wire 1A and the grounding terminals 222, 224, 226, and 228 of the card edge substrate 2. The sealing component 4 can be formed in the same manner as the fixing component 3. That is, the sealing component 4 can be formed, for example, from a resin material (e.g., polyamide resin, ABS, etc.) by resin molding (e.g., injection molding, compression molding, extrusion molding, calendering, transfer molding, lamination molding, etc.). Furthermore, the resin constituting the sealing component 4 is not limited to injection molding resin; heat-sensitive adhesives (hot melt adhesives, etc.), moisture-curing adhesives (reactive hot melt adhesives, etc.), light-curing resins (ultraviolet-curing resins, visible light-curing resins, etc.), two-component reactive adhesives, etc., can also be used, and the sealing component 4 can be formed by coating and curing them. Alternatively, portions can be formed separately by resin molding or machining, with the portions corresponding to the center of the thickness of the card edge substrate 2. These portions can be used to clamp and fix the components 3A to 3D and joined by bonding or welding. When polyamide resin is used as the resin for injection molding, since polyamide resin has a low melt viscosity, low-pressure injection molding (e.g., around 200°C) can be performed.

[0029] (Methods for connecting the ends of insulated wires) Next, refer to Figures 4-9 An example of a method for connecting the terminals of an insulated wire is illustrated. Figure 4 It is a top view showing the state of multiple insulated wires being aligned using a pair of wire clamps. Figure 5 (a) is a front view showing an example of a wire clamp. Figure 5 (b) is Figure 5 Detailed diagram of part C of (a), Figure 5 (c) indicates that in Figure 5 The diagram shown in (b) depicts the state in which insulated wires are arranged in the wire slot of the wire clamp. Figure 6 An example of a mold for fixing a component is shown below: (a) is a sectional view of (b) along line DD, (b) is a sectional view along the X direction, and (c) is a sectional view of (b) along line EE. Figure 7 It is a top view of the fixed components formed between the clamps of the entire line. Figure 8 This is a top view showing the cutting process of multiple insulated wires. Figure 9This is a top view showing the stripping process of multiple insulated wires. The following description explains the case where the insulated wires are cut and stripped after the fixing member 3 is formed; however, the fixing member 3 can also be formed after the insulated wire 1A is cut and stripped. When the spacing of the insulated wires in the Y direction is relatively small, forming the fixing member 3 after the insulated wires are cut and stripped allows for more accurate cutting and stripping.

[0030] (1) Configuration of the entire line clamp like Figure 4 As shown, the first clamp 100Aa of a pair of wire clamps 100A (refer to...) Figure 5 (a) is arranged along the X direction at intervals d equal to the width W. For example... Figure 5 As shown in (a), the wire clamp 100A includes a first clamp 100Aa with a plurality of wire aligning grooves 101a and a second clamp 100Ab that is a flat rod without wire aligning grooves. Figure 5 As shown in (b), the grooving channel 101a has a generally U-shaped form, with a depth (Z direction) and width (Y direction) equal to the outer diameter of the insulated wire 1A. Its bottom surface is formed as a semi-circle centered on the grooving channel center 102a. The radius of the bottom surface of the grooving channel 101a is half the outer diameter of the insulated wire 1A. Furthermore, the center of each grooving channel 102a is set on a reference line 103 extending along the Y direction. Thus, the centerline 1a of each insulated wire 1A after grooving coincides with the center of the grooving channel 102a. The interval d is an example of a specified distance.

[0031] Furthermore, the center line 1a of the insulated wire 1A may not be aligned with the reference line 103. For example, the wire groove 101a may be formed such that the tangent line tangent to the outer peripheral surface of the core wire 11a and opposite to the retaining plate 2 is aligned between the insulated wires 1A. As a result, since the tangent line tangent to the outer peripheral surface of the core wire 11a and opposite to the retaining plate 2 is aligned between the insulated wires 1A, the electrical connection of the core wire 11a to the terminals 221, 223, 225, and 227 becomes easier.

[0032] (2) Configuration of insulated wires Next, the insulated wires 1A are respectively placed in the wire-aligning slots 101a of the first clamp 100Aa of the pair of wire-aligning clamps 100A. The insulated wires 1A are pressed down from above using the second clamp 100Ab, and fastening components (e.g., bolts) 104 (see reference) are used. Figure 7 The second clamp 100Ab is installed on the first clamp 100Aa. At this stage, the end of the insulated wire 1A is not yet exposed. Alternatively, pressure from above or below or to the left or right for mounting the mold to the molding machine, or pressure using a vise or toggle clamp mechanism, can be used instead of the fastening component 104.

[0033] (3) Formation of fixed components Next, as Figure 6 As shown, a fixing member mold 110 with a cavity 113 (first space) corresponding to the fixing member 3 is arranged around the insulated wire 1A between a pair of wire clamps 100A. The fixing member mold 110 serves as a master mold, and the wire clamps 100A serve as inserts embedded into the master mold. The fixing member mold 110 has a first mold 111 and a second mold 112 with a structure divided into two parts. In addition, the diagram of the fixing member mold 110 omits the gate, etc., which serve as the injection port for molten resin. A pair of wire clamps 100A that have been wired together with multiple insulated wires 1A are arranged in the first mold 111, and the second mold 112 is installed in the first mold 111.

[0034] Next, molten first resin (e.g., polyamide resin) is injected into the cavity 113 (first space). After the first resin cools and solidifies, the solidified molded article is demolded from the fixing member mold 110. At this time, the wire clamp 100A is removed from the insulated wire 1A. Thus, for example, a fixing member 3C for the third layer 10c is formed. Furthermore, a fixing member 3D for the fourth layer 10d can also be used. Figure 6 The fixing components shown are formed using mold 110, but the fixing component 3A for the first layer 10a and the fixing component 3B for the second layer 10b use fixing component molds whose shapes correspond to their shapes. Additionally, as... Figure 5 As shown in (c), there is a gap between the duct 101a and the insulated wire 1A. Sometimes molten resin may enter this gap, but this part can be removed by cutting or the like after the fixing part 3C is formed.

[0035] (4) Cutting of insulated wires Next, as Figure 8 As shown, the insulated wire 1A is cut at a distance L2 from the fixing member 3C to prepare the insulated wire 1A before stripping for the third layer 10c. Similarly, the insulated wire 1A is arranged and the fixing member 3D is formed, and the insulated wire 1A is cut at a distance L2 from the fixing member 3D to prepare the insulated wire 1A before stripping for the fourth layer 10d. Similarly, the insulated wire 1A is arranged and the fixing member 3A is formed, and the insulated wire 1A is cut at a distance L1 from the fixing member 3A to prepare the insulated wire 1A before stripping for the first layer 10a. Similarly, the insulated wire 1A is arranged and the fixing member 3B is formed, and the insulated wire 1A is cut at a distance L1 from the fixing member 3B to prepare the insulated wire 1A before stripping for the second layer 10b.

[0036] (5) Stripping of insulated wires Next, the insulation of wire 1A is stripped, such as... Figure 9 As shown, the shielding conductor 13a, insulation layer 12a, and core wire 11a are sequentially exposed from the outer sheath 14a. Thus, for example, an insulated wire 1A for the third layer 10c is manufactured. Similarly, insulated wires 1A for the first layer 10a, second layer 10b, and fourth layer 10d are also stripped to manufacture insulated wires 1A for the first layer 10a, second layer 10b, and fourth layer 10d.

[0037] (6) Connection of core wires, etc. Next, the core wire 11a of the insulated wire 1A of the first layer 10a is soldered to the first terminal 221, and the shielding conductor 13a is soldered to the first grounding terminal 222. The core wire 11a of the insulated wire 1A of the second layer 10b is soldered to the second terminal 223, and the shielding conductor 13a is soldered to the second grounding terminal 224. The core wire 11a of the insulated wire 1A of the third layer 10c is soldered to the third terminal 225, and the shielding conductor 13a is soldered to the third grounding terminal 226. The core wire 11a of the insulated wire 1A of the fourth layer 10d is soldered to the fourth terminal 227, and the shielding conductor 13a is soldered to the fourth grounding terminal 228.

[0038] (7) Formation of sealing components Next, a mold for sealing components (not shown) having a second space corresponding to the sealing component 4 is arranged around the edge substrate 2 and the fixing component 3. Then, molten second resin (e.g., polyamide resin) is injected into the second space. After the second resin cools and solidifies, the mold for sealing components is demolded. Thus, a sealing component 4 made of the second resin is formed.

[0039] (Effects of the first implementation method) According to this embodiment, the following effects are achieved. (a) Since the end regions of the multiple insulated wires 1A are fixed to be parallel to each other by the fixing member 3, even if the outer diameters of the insulated wires 1A are different, the terminals of the core wires 11a exposed in the end regions of the insulated wires 1A can be electrically connected to the terminals of the connecting object (connector, substrate, etc.) with high density. (b) After multiple insulated wires 1A are fixed by the fixing component 3, the cutting, stripping and connecting of the front end can be performed with high precision and simplicity. (c) By changing the size and position of the aligning groove 101a of the aligning clamp 100A, while keeping the external dimensions of the fixing components 3 the same, it is possible to accommodate changes in the type of wire with different structures and outer diameters, variations in the number of wires, and variations in the spacing between wires, by changing the size and position of the aligning groove 101a of the aligning clamp 100A. In addition, when forming the sealing component 4, the total external diameter of the four fixing components 3A to 3D can be made the same, so that the injection molding mold for the sealing component 4 can be shared regardless of the structure of the wire.

[0040] (Variations 1 to 4) Figure 10 (a) to (d) are the main front views of the main parts of the line clamp 100A involved in variations 1 to 4, respectively. Figure 10 In Modification 1 shown in (a), the straightening groove 101a formed in the first fixture 100Aa is rectangular. According to Modification 1, the machining of the straightening groove 101a becomes easier. Figure 10 In Modification 2 shown in (b), semi-circular wire grooves 101a with radii equal to half the outer diameter of the insulated wire 1A are formed in both the first clamp 100Aa and the second clamp 100Ab. According to Modification 2, even when the outer diameters of the wires are different, the wire grooves can be made to fit tightly against the wires. Figure 10 In variation example 3 shown in (c), the following is made Figure 10 The straightening groove 101a shown in (b) is rectangular in shape. According to variation 3, the machining of the straightening groove 101a becomes easier. Figure 10 In variation example 4 shown in (d), the following is made Figure 10 In (a), a portion of the wire groove 101a in the first clamp 100Aa becomes deeper. A protrusion 100a is formed in the second clamp 100Ab at the location corresponding to the deepened wire groove 101a. According to Modification 4, by changing the depth of the wire groove 101a, the center line 1a of the insulated wire 1A can be deviated from the reference line 103 depending on the object being connected.

[0041] [Second Implementation] Figure 11 This is a perspective view showing an example of an insulated wire used in the connection structure of the wires according to the second embodiment of the present invention. In the first embodiment, the case where multiple insulated wires 1A with the same outer diameter were used as multiple wires arranged in the first layer 10a to the fourth layer 10d was described. However, in this embodiment, multiple insulated wires 1A to 1D with different outer diameters and structures are used in any one or all of the first layer 10a to the fourth layer 10d. Hereinafter, this embodiment will be described focusing on the differences from the first embodiment.

[0042] Similar to the first embodiment, insulated wire 1A is coaxial. Insulated wires 1B, 1C, and 1D are single wires with different structures and outer diameters. Insulated wire 1B, for example, is a single wire with a relatively thin outer diameter, and has a core wire 11b formed of a conductor and an outer sheath 12b formed of insulating material covering the outer periphery of the core wire 11b. Insulated wire 1C, for example, is a single wire with a medium outer diameter, and has a core wire 11c formed of a conductor and an outer sheath 12c formed of insulating material covering the outer periphery of the core wire 11c. Insulated wire 1D, for example, is a single wire with a relatively thick outer diameter, and has a core wire 11d formed of a conductor and an outer sheath 12d formed of insulating material covering the outer periphery of the core wire 11d. The core wires 11b, 11c, and 11d also become thicker according to the outer diameter of the outer sheaths 14b, 14c, and 14d.

[0043] Figure 12 This is a front view of the wire clamp used in the second embodiment, viewed from the front end of the insulated wire. (Example) Figure 12 As shown in (a), the wire straightening clamp 100B according to the second embodiment includes a first clamp 100Ba and a second clamp 100Bb, each having a semi-circular wire straightening groove 101a-101d with a radius equal to half the outer diameter of the disposed insulated wires 1A-1D. The wire straightening grooves 101a-101d are formed as semi-circles centered on the center 102a-102d of the wire straightening groove. Furthermore, the center 102a-102d of each wire straightening groove is set on a reference line 103 extending in the Y direction. Thus, as... Figure 12 As shown in (b), the center lines 1a to 1d of each insulated wire 1A to 1D after the entire line is assembled are aligned with the center lines 102a to 102d of the entire line trough.

[0044] Furthermore, the center lines 1a to 1d of the insulated wires 1A to 1D may not coincide with the reference line 103. For example, the wire grooves 101a to 101d may be formed such that the tangent lines tangent to the outer peripheral surfaces of the core wires 11a to 11d and opposite to the retaining plate 2 are aligned between the insulated wires 1A to 1D. In this case, such as Figure 10 As shown in (d), a rectangular wire-aligning groove is formed in the first clamp 100Ba, and a protrusion is formed at a necessary location in the second clamp 100Bb, thereby enabling the preparation of the wire-aligning clamp 100B. As a result, since the tangent lines tangent to the outer peripheral surfaces of the core wires 11a-11d and opposite to the card edge substrate 2 coincide between the insulated wires 1A-1D, electrical connection of the core wires 11a-11d to the terminals 221, 223, 225, and 227 becomes easier.

[0045] (Variation Example 5) Figure 12Figure (c) is a front view of the main part of the wire straightening clamp 100B according to Modification 5. The wire straightening clamp 100B of Modification 5 shown in this figure includes a first clamp 100Ba with rectangular wire straightening grooves 101a-101d corresponding to the outer diameter of the insulated wires 1A-1D, and a flat, rod-shaped second clamp 100Bb without wire straightening grooves. The wire straightening grooves 101a are formed with the same depth (Z direction) and width (Y direction) as the outer diameter of the insulated wires 1A-1D. According to Modification 5, the processing of the wire straightening grooves 101a-101d becomes easier. In the case of Modification 5, the Z-direction position of the center lines 1a-1d of the insulated wires 1A-1D varies depending on the outer diameter of the insulated wires.

[0046] Figure 13 This is a cross-sectional view along the Y direction of the fixing member 3 according to the second embodiment. Furthermore, the insulated wires 1A to 1D are simplified in this figure. The fixing member 3 is formed as follows: that is, […]. Figure 12 The pair of wire clamps 100B shown are arranged along the X direction at a distance d equal to the width W, similar to the first embodiment, and insulated wires 1A to 1D corresponding to the wire aligning grooves 101a to 101d are arranged thereon. Next, a mold for fixing members, having cavities (first spaces) corresponding to fixing members 3, is arranged around the insulated wires 1A to 1D between the pair of wire clamps 100B. As described in the first embodiment, the mold for fixing members uses a mold with a two-part structure as a master mold, and the wire clamps 100B are used as inserts embedded into the master mold. Next, molten first resin (e.g., polyamide resin) is injected into the cavity (first space), and after the first resin cools and solidifies, the first mold is demolded. Thus, a [structure / form] is formed. Figure 13 The fixed component 3 shown.

[0047] According to the second embodiment, it achieves the same effect as the first embodiment, and even when the outer diameter and arrangement spacing of the insulated wires are different, the insulated wires 1A to 1D can be fixed in parallel using the fixing member 3 in the same way as the first embodiment. Therefore, the terminals of the core wires 11a to 11d can be electrically connected to the terminals 221, 223, 225, and 227 of the connected object with high density.

[0048] [Third Implementation Method] Figure 14 This is a top view showing the connection structure of the wires according to the third embodiment of the present invention. Figure 15 Is with Figure 3 The corresponding sectional view. In the first embodiment, as... Figure 3 As shown, the insulated wires 1A of the first layer 10a to the fourth layer 10d are arranged at the same position in the Y direction, but in this embodiment, as... Figure 15As shown, the insulated wires 1A of the first layer 10a and the second layer 10b are arranged between the insulated wires 1A of the third layer 10c and the fourth layer 10d. Hereinafter, this embodiment will be described focusing on the differences from the first embodiment.

[0049] Similar to the first embodiment, the card edge substrate 2 includes a first terminal 221, a first ground terminal 222, a second terminal 223, a second ground terminal 224, a third terminal 225, a third ground terminal 226, a fourth terminal 227, and a fourth ground terminal 228. However, the first terminal 221 is positioned between the third terminals 225 in the Y direction, and the second terminal 223 is positioned between the fourth terminals 227 in the Y direction. Furthermore, in this figure, the number of first terminals 221 and second terminals 223 is one less than the number of third terminals 225 and fourth terminals 227, but they can also be the same number.

[0050] According to the third embodiment, the first terminal 221 is positioned between the third terminals 225 and the second terminal 223 is positioned between the fourth terminals 227 in the Y direction, thus making the connection operation of the insulated wire 1A easier.

[0051] [Fourth Implementation Method] Figure 16 This is a top view showing the connection structure of the wires according to the fourth embodiment of the present invention. Figure 17 Is with Figure 3 The corresponding sectional view of the main parts. In addition... Figure 16 This refers to the insulated wire 1A of the third layer 10c. In this embodiment, the number of insulated wires 1A is greater than in the first embodiment. Hereinafter, this embodiment will be described focusing on the differences from the first embodiment.

[0052] like Figure 16 As shown, the third terminal 225 formed on the surface 21a of the card edge substrate 2 is arranged at a predetermined spacing on the same line along the Y direction.

[0053] The plurality of insulated wires 1A constituting the third layer 10c are divided into a plurality of insulated wires 1A constituting the first layer 10ca and a plurality of insulated wires 1A constituting the second layer 10cb in the third layer, such that the spacing between the insulated wires 1A is wider than the spacing between the third terminals 225 (for example, twice as wide). Furthermore, the number of divisions is not limited to two, but may be three or more. The plurality of insulated wires 1A constituting the first layer 10ca and the plurality of insulated wires 1A constituting the second layer 10cb in the third layer are examples of wire class groups.

[0054] like Figure 17As shown, the fixing member 3C for the third layer 10c is divided into a first member 3a corresponding to the first layer 10ca in the third layer and a second member 3b corresponding to the second layer 10cb in the third layer. The number of divisions of the fixing member 3C is the same as that of the plurality of insulated wires 1A constituting the third layer 10c, and is not limited to two, but may be three or more. The first member 3a and the second member 3b have contact surfaces 30 that contact each other. The first member 3a fixes the plurality of insulated wires 1A constituting the first layer 10ca in the third layer at a position close to its own contact surface 30. The second member 3b fixes the plurality of insulated wires 1A constituting the second layer 10cb in the third layer at a position close to its own contact surface 30. The portion of the insulated wire 1A close to the contact surface 30 of the first member 3a and the second member 3b is called a thin-walled portion 31. The thickness of the thin-walled portion 31 is not particularly limited, and may be less than 1 mm or less than 0.1 mm, or even 0 mm.

[0055] The first component 3a and the second component 3b are formed in the same manner as the fixing component 3C in the first embodiment. With the contact surfaces 30 of the first component 3a and the second component 3b in contact with each other, a sealing component 4 is formed in the same manner as in the first embodiment.

[0056] According to the fourth embodiment, since the core wires 11a of the plurality of insulated wires 1A constituting the first layer 10ca in the third layer can be soldered to the corresponding third terminal 225, the core wires 11a of the plurality of insulated wires 1A constituting the second layer 10cb in the third layer can be soldered to the corresponding third terminal 225, the installation density of terminals arranged on the same line along the Y direction can be increased.

[0057] Furthermore, the fourth embodiment describes the third layer 10c, but the same structure as the third layer 10c can also be applied to the fourth layer 10d, or to the first layer 10a and the second layer 10b.

[0058] [Fifth Implementation] Figure 18 This is a cross-sectional view of the wire type according to the fifth embodiment of the present invention. In the first to fourth embodiments, only insulated wires were used as the wire type, but in the fifth embodiment, multiple insulated wires and... Figure 18 The cable shown.

[0059] The cable 15 used in the fifth embodiment includes a plurality of (e.g., two) insulated wires 11E, a shielding wire 16, a shielding strip 17 that covers the outer periphery of the plurality of insulated wires 11E and the shielding wire 16, and an outer sheath 18 formed of insulating material that covers the outer periphery of the shielding strip 17. The insulated wires 11E include core wires 11e formed of conductors and an insulating layer 12e covering the outer periphery of the core wires 11e. The shielding strip 17 is, for example, formed by laterally winding conductive strip in a spiral shape. The shielding strip 17 is an example of a shielding layer.

[0060] The fixing component 3 is formed by resin molding such that the center line 1e of the two insulated wires 11E and the center line 16a of the shielded wire 16 are located on the reference line 103 along the Y direction and are in contact with the outer peripheral surface of the outer sheath 18 of other insulated wires and cables 15, thereby fixing the relative position between the wires.

[0061] According to the fifth embodiment, the cable 15 is a side-shielded type where the shielded wire 16 is disposed beside the two insulated wires 11E. Therefore, compared to the center-shielded type where the shielded wire 16 is disposed in contact with the outer peripheral surfaces of both insulated wires 11E, the cross-sectional shape of the cable 15 can be made into an elongated oval shape that is longer in the Y direction, thus allowing the thickness of the fixing member 3 in the Z direction to be reduced. In addition, the shielded wire 16 can be electrically connected to the terminal without bending in the Y direction.

[0062] The embodiments of the present invention have been described above, but the embodiments of the present invention are not limited to the above embodiments and can be modified and implemented in various ways.

Claims

1. A connection structure for electrically connecting the terminals of multiple core wires exposed after the end covering of each of a plurality of parallelly arranged electrical wires has been stripped to corresponding terminals, wherein, The connection structure of the wires includes a fixing member that is formed near the end region and contacts the outer peripheral surface of the multiple wires near the end region when the multiple wires are aligned parallel to each other, thereby fixing the relative position between the wires.

2. The connection structure for electrical wires according to claim 1, wherein, The various types of electrical wires are arranged side by side in multiple layers. The fixing components are provided for each layer.

3. The connection structure for electrical wires according to claim 2, wherein, The external dimensions of the fixing components provided for each of the layers are the same.

4. The connection structure for electrical wires according to claim 1, wherein, It also includes a sealing component that covers the fixing component and watertightly seals the connection portions of the plurality of terminals to the terminals of the plurality of core wires.

5. The connection structure for electrical wires according to claim 3, wherein, It also includes a sealing component that covers the fixing component provided for each layer and watertightly seals the connection between the plurality of terminals and the terminals of the plurality of core wires.

6. The connection structure for electrical wires according to any one of claims 1 to 5, wherein, The plurality of wire types include cables comprising: two insulated wires; a shielding wire; a shielding layer covering the outer periphery of the two insulated wires and the shielding wire; and an outer sheath covering the outer periphery of the shielding layer and formed of an insulating material. The two insulated wires and the shielded wire are arranged in the same direction as the plurality of wires arranged side by side, and the shielded wire is arranged next to the two insulated wires.

7. The connection structure for electrical wires according to claim 1, wherein, The plurality of terminals are arranged at a predetermined spacing on the same line along the direction in which the plurality of wires are arranged side by side. The plurality of wire types are divided into at least two wire type groups in such a way that the spacing between the wire types is wider than the spacing between the terminals. The fixing component is at least divided into a first component and a second component that respectively fix the relative positions between the wires constituting the at least two wire groups.

8. A method for manufacturing a connection structure for electrical wires, wherein the connection structure is used to electrically connect the terminals of multiple core wires exposed after stripping the covering from the end regions of multiple electrical wires arranged side by side to corresponding terminals, wherein... In the manufacturing method of the aforementioned wire-type connection structure, A pair of wire clamps with multiple wire slots are arranged at a specified distance, the multiple wire slots being formed to correspond to the outer diameter of each of the multiple types of wires; The plurality of wires are arranged in the corresponding wire slots in such a way that they are located near the end region between the pair of wire clamps, and the plurality of wires are wired parallel to each other in the end region. A fixing member is formed between the pair of wire clamps in such a way that it contacts the outer peripheral surface near the end region of the plurality of wires to fix the relative position between the wires; Remove the pair of wire clamps from the plurality of wires; and Before or after forming the fixing component, the following steps are performed: the plurality of wires are cut at a specified length from the fixing component, the wrapping of the end regions of the plurality of wires on the cut side is stripped off to expose the plurality of core wires, and the ends of the exposed plurality of core wires are connected to the corresponding plurality of terminals.

9. The method for manufacturing the wire connection structure according to claim 8, wherein, A mold for injection molding with a cavity having a space corresponding to the fixed component is used as a master mold, and the pair of line clamps are used as inserts embedded in the master mold, and the fixed component is formed by injection molding.

10. A wire assembly, wherein, have: Multiple types of electrical wires arranged side by side; A connection object having multiple terminals, the multiple terminals being electrically connected to the terminals of multiple core wires exposed by stripping the covering of the end regions of each of the multiple types of wires; as well as A fixing component is formed near the end region, in which the plurality of wires are aligned parallel to each other, and contacts the outer peripheral surface near the end region of the plurality of wires, thereby fixing the relative position between the wires.

Images