Wire connection structure, manufacturing method for the same, and wire assembly

Abstract

To provide a wire connection structure that enables a high-density electrical connection between the exposed terminal of a core wire in the end region of wires, cables, etc., and a terminal of a connection target, a manufacturing method for the same, and a wire assembly.SOLUTION: A wire connection structure 10 is a wire connection structure for electrically connecting multiple exposed core wire terminals, obtained by stripping the insulation from the end regions of multiple parallel insulated wires 1A, to corresponding multiple terminals. The wire connection structure includes a fixing member 3 formed to contact the outer peripheral surface near the end regions of the multiple insulated wires 1A while the multiple insulated wires 1A are arranged parallel to each other near the end regions, thereby fixing the relative positions between the insulated wires 1A.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a connection structure for electric wires, a manufacturing method thereof, and an electric wire assembly. [Background technology]

[0002] In recent years, a method for manufacturing a connectorized transmission cable has been proposed that solves the problems of skew and pitch deviation caused by longitudinal deviation of core wires during terminal processing of the transmission cable (see, for example, Patent Document 1).

[0003] The method for manufacturing a connector-equipped transmission cable described in Patent Document 1 involves cutting a round transmission cable, in which multiple insulating coated wires are coated with an outer coating layer, to a predetermined length, removing a predetermined length of the outer coating layer from an end region of the transmission cable, butting the exposed end tips of the multiple insulating coated wires against the butting portion of a wiring jig, and fitting the insulating coated wires into the recesses of the wiring jig to perform wiring arrangement, fixing the insulating coated wires with fixing means (adhesive tape, or a hardening material made of adhesive or resin mold) near the wiring jig, removing the wiring jig, soldering the tips of the core wires to corresponding cable connection terminals on the connector wiring board, and then removing the fixing means, thereby electrically connecting the transmission cable to the connector wiring board. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2007-317676 Summary of the Invention [Problem to be solved by the invention]

[0005] In the above-mentioned conventional example, since the insulating coated wires pulled out from one round cable are fixed by a fixing means, each insulating coated wire is fixed in an inclined state (state in which bending stress remains) within the fixing means, and therefore when the wire arrangement jig is removed, the bending stress may cause the position of the tip of the core wire to shift, making it difficult to achieve high-density electrical connection of the terminal of the core wire. Furthermore, in recent years, with the high integration and multi-functionality of semiconductors incorporated into electronic components and electronic devices, there has been a demand for higher density of terminals (also called pads) on connectors and boards for communication between semiconductors and the outside, and for communication using various types of electric wires with different uses and outer diameters.

[0006] The object of the present invention is to provide a connection structure for electric wires that enables high-density electrical connection between the end of an exposed core wire in the end region of an electric wire made of an electric wire, cable, etc. and a terminal of the object to be connected, a manufacturing method thereof, and an electric wire assembly. [Means for solving the problem]

[0007] [1] A connecting structure for electric wires for electrically connecting the ends of a plurality of core wires exposed by stripping the coating of the end regions of a plurality of electric wires arranged in parallel to a plurality of corresponding terminals, a fixing member formed to contact outer peripheral surfaces of the plurality of electric wires in the vicinity of the end region while the plurality of electric wires are arranged parallel to one another in the vicinity of the end region, and to fix the relative positions of the electric wires; A connection structure for electric wires comprising: [2] The plurality of electric wires are arranged in parallel in a plurality of layers, The electric wire connection structure according to [1], wherein the fixing member is provided for each layer. [3] The electric wire connection structure according to [2], wherein the fixing members provided for each layer have the same outer size. [4] The electric wire connection structure described in [1], further comprising a sealing member that covers the fixing member and watertightly seals the connection portions between the plurality of terminals and the ends of the plurality of core wires. [5] The connection structure of electric wires described in [3] above, further comprising a sealing member that covers the fixing members provided for each layer collectively and watertightly seals the connection portions between the plurality of terminals and the ends of the plurality of core wires. [6] The plurality of electric wires includes a cable including two insulated electric wires, a drain wire, a shielding layer that collectively covers the outer peripheries of the two insulated electric wires and the drain wire, and an outer jacket formed of an insulating material that covers the outer periphery of the shielding layer, [5] The electric wire connection structure according to any one of [1] to [5], wherein the two insulated electric wires and the drain wire are arranged in the same direction as the direction in which the plurality of electric wires are arranged in parallel, and the drain wire is arranged next to the two insulated electric wires. [7] The plurality of terminals are arranged at a predetermined pitch on the same line along the direction in which the plurality of electric wires are arranged in parallel, the plurality of electric wires are divided into at least two groups of electric wires such that the pitch of the electric wires is wider than the predetermined pitch of the terminals; The connection structure for electric wires described in [1], wherein the fixing member is divided into at least a first member and a second member that respectively fix the relative positions of the electric wires that make up the at least two groups of electric wires. [8] A method for manufacturing a connection structure for electric wires for electrically connecting terminals of a plurality of core wires, which are exposed by stripping off the coating from the end regions of a plurality of electric wires arranged in parallel, to a plurality of corresponding terminals, comprising: a pair of wire-arranging jigs each having a plurality of wire-arranging grooves formed to correspond to the outer diameters of the plurality of electric wires, the pair of wire-arranging jigs being arranged at a predetermined distance from each other; The plurality of electric wires are arranged in the corresponding wire-arranging grooves so that the vicinity of the end region is located between the pair of wire-arranging jigs, and the plurality of electric wires are arranged parallel to each other in the end region; a fixing member is formed between the pair of wire dressing jigs so as to contact outer peripheral surfaces of the plurality of electric wires in the vicinity of the end regions, thereby fixing the relative positions of the electric wires; Remove the pair of wire-arranging jigs from the plurality of electric wires, A method for manufacturing a connection structure for electric wires, the method comprising the steps of cutting the plurality of electric wires at a predetermined length from the fixing member, stripping the coating of the end regions of the plurality of electric wires on the cut side to expose the plurality of core wires, and connecting the ends of the exposed plurality of core wires to the corresponding plurality of terminals, before or after forming the fixing member. [9] A method for manufacturing a connection structure for electric wires described in [8], in which an injection molding die having a cavity corresponding to the fixing member is used as a mother mold, and the pair of wire arrangement jigs are used as nests to be fitted into the mother mold, and the fixing member is formed by injection molding.

[10] Multiple electric wires arranged in parallel; a connection target having a plurality of terminals to which ends of a plurality of core wires exposed by stripping off the coatings from end regions of the plurality of electric wires are electrically connected; and a fixing member formed to contact the outer peripheral surfaces of the plurality of electric wires near the end regions and fix the relative positions of the electric wires while the plurality of electric wires are arranged parallel to each other near the end regions. [Effects of the Invention]

[0008] According to the present invention, it is possible to achieve high-density electrical connection between the ends of core wires exposed in the end region of electric wires such as electric wires and cables and the terminals of the connection targets. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a plan view showing a connection structure for electric wires according to a first embodiment of the present invention. [Figure 2] FIG. 2 is a cross-sectional view taken along line AA in FIG. [Figure 3] FIG. 3 is a cross-sectional view taken along line BB in FIG. [Figure 4] FIG. 4 is a plan view showing a state in which a plurality of insulated wires are arranged by a pair of wire-arranging jigs. [Figure 5]FIG. 5(a) is a front view showing an example of a wire arranging jig, FIG. 5(b) is a detailed view of part C in FIG. 5(a), and FIG. 5(c) is a view showing the state in which an insulated electric wire is placed in the wire arranging groove of the wire arranging jig shown in FIG. 5(b). [Figure 6] FIG. 6 shows an example of a mold for a fixing member, where (a) is a cross-sectional view taken along line DD in (b), (b) is a cross-sectional view taken along the X direction, and (c) is a cross-sectional view taken along line EE in (b). [Figure 7] FIG. 7 is a plan view of a fixing member formed between the wire dressing jigs. [Figure 8] FIG. 8 is a plan view showing a step of cutting a plurality of insulated wires. [Figure 9] FIG. 9 is a plan view showing the stripping process of a plurality of insulated wires. [Figure 10] FIG. 10 is a front view of a main part of the wire arrangement jig according to the first to fourth modifications. [Figure 11] FIG. 11 is a perspective view showing an example of an insulated wire used in the electric wire connecting structure according to the second embodiment of the present invention. [Figure 12] 12(a) and 12(b) are front views of the wire arranging jig used in the second embodiment as seen from the tip end side of the insulated wire, and FIG. 12(c) is a front view of the wire arranging jig according to Modification 5. [Figure 13] FIG. 13 is a cross-sectional view of the fixing member according to the second embodiment taken along the Y direction. [Figure 14] FIG. 14 is a plan view showing a connection structure for electric wires according to the third embodiment of the present invention. [Figure 15] FIG. 15 is a cross-sectional view corresponding to FIG. [Figure 16] FIG. 16 is a plan view showing a wire connection structure according to the fourth embodiment of the present invention. [Figure 17] FIG. 17 is a cross-sectional view of a main part corresponding to FIG. [Figure 18] FIG. 18 is a cross-sectional view of an electric wire according to the fifth embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the drawings, components having substantially the same functions are designated by the same reference numerals, and redundant description thereof will be omitted.

[0011] [First embodiment] FIG. 1 is a plan view showing an electric wire connection structure according to a first embodiment of the present invention, FIG. 2 is a cross-sectional view taken along line AA in FIG. 1, and FIG. 3 is a cross-sectional view taken along line BB in FIG.

[0012] 1 and 2 show a case where a connector to be connected is connected to one end of a plurality of electric wires. The connection object is not limited to a connector, but may be a circuit board or other connection object. Examples of the connector to be connected include a connector that connects electric wires to a card edge board, a connector that connects electric wires to a board on which a plug connector or receptacle connector is mounted, and a connector that directly connects electric wires to a connector terminal (e.g., pin header, socket terminal, or cup terminal). Mounting types of plug connectors and receptacle connectors to boards include SMT (surface mount), DIP (soldering component leads through through holes in the board), and press-fit (press-fitting into through holes in the board). Examples of the connection object board include a PCB (printed circuit board), FPC (flexible printed circuit board), circuit board, control board, relay board, etc., to which electric wires are directly connected. Connectors may be connected to both ends of a plurality of electric wires, a board may be connected to both ends, or a connector may be connected to one end and a board to the other end. 1 and 2, solder for electrically connecting the core wire and shield terminal to the terminal (also called a pad) is omitted. In this specification and drawings, the longitudinal direction of the electric wires is defined as the X direction, the direction in which the electric wires are arranged in parallel is defined as the Y direction, and the direction perpendicular to the X direction and the Y direction is defined as the Z direction.

[0013] In this specification, "electric wires" is a concept that encompasses electric wires and cables, and includes those consisting of a single electric wire (also called an insulated electric wire) and cables in which multiple electric wires are bundled and covered with an insulating outer jacket. In this specification, "end region" refers to the region where the wires are stripped in order to connect to a terminal on an object to which the electric wires are connected (such as a connector or a board). A configuration in which a connector or a board is connected to one or both ends of multiple electric wires constitutes an electric wire assembly.

[0014] The electric wire connection structure 10 includes a plurality (four in the figure) of insulated electric wires 1A (see FIG. 2) arranged in parallel in the Y direction (only the third layer 10c is shown in FIG. 1), a card edge substrate 2 to which the terminals of the insulated electric wires 1A are connected with solder (not shown) and whose leading edge portions 2a form a card edge connector, a plurality (e.g., four) of fixing members 3A-3D (collectively referred to as "fixing members 3") that fix the relative positions of the insulated electric wires 1A for each layer, and a sealing member 4 (shown by phantom lines in FIG. 1) that covers the fixing members 3A-3D and watertightly covers the connection portions between the core wires 11a of the insulated electric wires 1A and the corresponding terminals 221-228. Here, the insulated electric wire 1A is an example of an electric wire.

[0015] Known methods for securing the end regions of multiple parallel-arranged electric wires include sandwiching multiple cables (insulated electric wires) between two ground bars (e.g., JP 2008-181817 A) and sandwiching them between two tapes (e.g., JP 2019-67519 A). The method of sandwiching the cables between the ground bars involves filling the gap between the ground bar and the cables with solder, which means that if the outer diameters of the cables differ, the gap between the cables and the ground bar becomes uneven, making it impossible to achieve a uniform joining force between the cables. The method of sandwiching the cables with tape means that if the outer diameters of the cables differ, the contact area between the tape and the cable with a smaller outer diameter becomes smaller, and this, combined with the difference in cable weight, makes it impossible to achieve a uniform joining force between the cables. Furthermore, in the method of fixing the insulated wires pulled out from one round cable using a fixing means (Patent Publication No. 2073-317676), each insulated wire is fixed in an inclined state (a state in which bending stress remains) within the fixing means, so when the wire arrangement jig is removed, the bending stress may cause the tip of the core wire to shift position.

[0016] The fixing member 3 of this embodiment is formed by resin molding so as to contact the outer peripheral surfaces of the insulated electric wires 1A when the insulated electric wires 1A are arranged parallel to one another using a pair of wire-arranging jigs (see FIG. 6), as will be described later. By forming such fixing member 3, no bending stress remains in the insulated electric wires 1A, which makes it possible to prevent the tip of the core wire 11a from shifting position after the wire-arranging jig is removed. Furthermore, because the fixing member 3 is formed so as to contact the outer peripheral surfaces of the insulated electric wires 1A, it is possible to fix insulated electric wires 1A with different outer diameters at any pitch.

[0017] Although this embodiment shows one end of a plurality of insulated wires 1A, both ends may be connected to a connector, for example, to a card edge substrate 2. Furthermore, a plurality of insulated wires 1A may be arranged in parallel in the Y direction in one, two, or three of the four first through fourth layers 10a-10d, or in five or more layers. Furthermore, this embodiment shows terminals 221-228 (see FIG. 2) of a card edge substrate 2 of a connector as an example of a connection target for the core wire 11a of the insulated wire 1A, but terminals of a substrate other than a connector may also be used. Furthermore, although the sealing member 4 does not entirely cover the fixing members 3A-3D, it may entirely cover them. Furthermore, if there is no need to watertightly cover the connection portions between the core wire 11a and the shield conductor 13a and the terminals 221-228 with the sealing member 4, the sealing member 4 may not be provided.

[0018] (Insulated wire structure) The multiple insulated wires 1A have the same outer diameter and are arranged in parallel at the same pitch in the Y direction on the fixing member 3. The insulated wires 1A are, for example, coaxial wires and include a core wire 11a made of a conductor, an insulating layer 12a covering the outer periphery of the core wire 11a, a shield conductor 13a formed on the outer periphery of the insulating layer 12a, and an outer sheath 14a made of an insulating material covering the outer periphery of the shield conductor 13a. The core wire 11a may be a solid wire or may be formed by twisting together multiple strands. The insulating layer 12a may be formed, for example, from a polyethylene-based resin (such as low-density polyethylene or high-density polyethylene) or a fluorine-based resin. The shield conductor 13a may be formed by spirally winding a conductive tape around the outer periphery of the insulating layer 12a, or by attaching the conductive tape longitudinally along the longitudinal direction of the insulated wire 1A, or by horizontally winding or braiding strands of strands. The outer sheath 14a may be formed, for example, from a fluorine-based resin, polyvinyl chloride (PVC), polyester resin, or the like.

[0019] The multiple insulated wires 1A may have different outer diameters. In the fixing member 3, the multiple insulated wires 1A may be arranged in parallel in the Y direction at different pitches depending on the outer diameters of the insulated wires, or the outer sheaths 14a of adjacent insulated wires 1A may be arranged so that they are in contact with each other. The insulated wires 1A may also be other insulated wires, such as solid wires. The wires fixed by one fixing member 3 may consist of only insulated wires, as in the present embodiment, or may be a mixture of insulated wires and cables, or may consist of only cables, or may include other linear components, such as drain wires, in addition to insulated wires and cables. In FIGS. 1 and 2 , the multiple insulated wires 1A are arranged parallel to each other in the Y direction near the fixing member 3. However, at locations away from the fixing member 3, they do not have to be arranged parallel to each other in the Y direction. For example, they may be bundled into an oval or circular shape using a cable tie or the like.

[0020] The core wires 11a of the insulated electric wires 1A arranged in the first layer 10a and the second layer 10b have their tips positioned at a distance L1 from the fixing member 3, and the core wires 11a of the insulated electric wires 1A arranged in the third layer 10c and the fourth layer 10d have their tips positioned at a distance L2 (where L2 > L1) from the fixing member 3.

[0021] (Card edge board configuration) The card edge substrate 2 comprises a base material 21 formed from 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 front surface 21a of the base material 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 surface 21b of the base material 21.

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

[0023] In addition, the card edge substrate 2 has an edge portion 2a whose tip side serves as a card edge connector to be inserted into a female connector (not shown), and a plurality of edge terminals 23A are formed on the surface 21a of the base material 21 of the edge portion 2a, and a plurality of edge terminals 23B are formed on the back surface 21b of the base material 21 of the edge portion 2a.

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

[0025] (Configuration of fixing member) The fixing member 3 has a rectangular parallelepiped shape with a width W in the X direction and extending in the Y direction. The fixing member 3 is formed, for example, from a resin material (e.g., polyamide resin, ABS, etc.) by resin molding (e.g., injection molding, compression molding, extrusion molding, calendar molding, transfer molding, laminate molding, etc.). The resin constituting the fixing member 3 is not limited to resin for injection molding. Heat-sensitive adhesives (e.g., hot-melt adhesives), moisture-curable adhesives (e.g., reactive hot-melt adhesives), photo-curable resins (e.g., ultraviolet-curable resins, visible-light-curable resins), two-component reactive adhesives, etc. may be used, and the fixing member 3 may be formed by applying and curing these. Alternatively, the sections divided by the reference lines 103a to 103d may be formed by resin molding or machining, and then joined by gluing or fusion bonding with the insulated electric wire 1A sandwiched between them. When polyamide resin is used as the resin for injection molding, its low melt viscosity allows for low-pressure injection molding at low temperatures (e.g., about 200°C).

[0026] The width W in the X direction is preferably a certain width so that the center lines 1a of the insulated electric wires 1A remain parallel to one another after the wire dressing jig 100A is removed. Specifically, when the maximum outer diameter of the electric wire is Dmax, for example, Dmax≦W, 1.5Dmax≦W, 2Dmax≦W, etc. are preferred. The thickness in the Z direction is preferably equal to or greater than the maximum outer diameter of the electric wire, but the outer sheath of the electric wire may be partially exposed.

[0027] As shown in FIG. 3, fixing member 3A corresponding to first layer 10a and fixing member 3B corresponding to second layer 10b have the same outer size and are formed so that reference lines 103a and 103b are eccentric with respect to the center of the thickness in the Z direction. Fixing member 3C corresponding to third layer 10c and fixing member 3D corresponding to fourth layer 10d have the same outer size and are formed so that reference lines 103c and 103d are positioned at the center of the thickness in the Z direction. Fixing members 3A and 3B corresponding to first layer 10a and second layer 10b may have the same outer size as fixing members 3C and 3D corresponding to third layer 10c and fourth layer 10d. This allows the same mold for forming fixing member 3.

[0028] (Configuration of sealing member) The sealing member 4 has a rectangular parallelepiped shape that covers an area including the four fixing members 3A to 3D, the connection portions between the core wire 11a of the insulated electric wire 1A and the terminals 221, 223, 225, and 227 of the card edge substrate 2, and the connection portions between the shield conductor 13a of the insulated electric wire 1A and the ground terminals 222, 224, 226, and 228 of the card edge substrate 2. The sealing member 4 can be formed in the same manner as the fixing member 3. That is, the sealing member 4 is formed, for example, by resin molding (e.g., injection molding, compression molding, extrusion molding, calendar molding, transfer molding, laminate molding, etc.) from a resin material (e.g., polyamide resin, ABS, etc.). Note that the resin constituting the sealing member 4 is not limited to resin for injection molding. For example, a heat-sensitive adhesive (e.g., a hot-melt adhesive), a moisture-curing adhesive (e.g., a reactive hot-melt adhesive), a light-curing resin (e.g., an ultraviolet-curing resin, a visible-light-curing resin), a two-component reactive adhesive, etc. may be used, and the sealing member 4 may be formed by applying and curing these. Alternatively, the card edge substrate 2 may be divided into sections at a position corresponding to the center of its thickness, each section formed by resin molding or machining, and then the fixing members 3A to 3D may be sandwiched between these sections and joined by adhesion or fusion. When polyamide resin is used as the resin for injection molding, low-pressure injection molding at low pressure and low temperature (for example, about 200°C) is possible because polyamide resin has a low melt viscosity.

[0029] (Method of connecting the ends of insulated wires) Next, an example of a method for connecting the ends of insulated electric wires will be described with reference to FIGS. 4 to 9. FIG. 4 is a plan view showing a state in which multiple insulated electric wires have been arranged using a pair of wire-arranging jigs. FIG. 5(a) is a front view showing an example of the wire-arranging jig, FIG. 5(b) is a detailed view of portion C in FIG. 5(a), and FIG. 5(c) is a view showing a state in which insulated electric wires have been placed in the wire-arranging groove of the wire-arranging jig shown in FIG. 5(b). FIG. 6 shows an example of a mold for a fixing member, where (a) is a cross-sectional view taken along line DD in (b), (b) is a cross-sectional view taken along direction X, and (c) is a cross-sectional view taken along line EE in (b). FIG. 7 is a plan view of a fixing member formed between the wire-arranging jigs. FIG. 8 is a plan view showing a step of cutting multiple insulated electric wires. FIG. 9 is a plan view showing a stripping process for multiple insulated electric wires. Hereinafter, a case in which cutting and stripping of insulated electric wires are performed after forming the fixing member 3 will be described. However, the fixing member 3 may be formed after cutting and stripping the insulated electric wire 1A. When the pitch of the insulated wires in the Y direction is relatively small, the insulated wires can be cut and stripped more accurately by forming the fixing member 3 after cutting and stripping the insulated wires.

[0030] (1) Wire arrangement jig placement As shown in FIG. 4, first jigs 100Aa (see FIG. 5(a)) of a pair of wire arranging jigs 100A are arranged in the X direction at a distance d equal to the width W. As shown in FIG. 5(a), the wire arranging jig 100A includes a first jig 100Aa having a plurality of wire arranging grooves 101a formed therein and a second jig 100Ab having a rectangular rod shape and no wire arranging grooves formed therein. As shown in FIG. 5(b), each wire arranging groove 101a is substantially U-shaped, with its depth (Z direction) and width (Y direction) equal to the outer diameter of the insulated electric wire 1A, and its bottom surface formed in a semicircular shape centered on a wire arranging groove center 102a. The radius of the bottom surface of the wire arranging groove 101a is half the outer diameter of the insulated electric wire 1A. Each wire arranging groove center 102a is set on a reference line 103 extending in the Y direction. As a result, the center line 1a of each insulated wire 1A after wire arrangement coincides with the center 102a of the wire arrangement groove. The interval d is an example of a predetermined distance.

[0031] Note that the center line 1a of the insulated wire 1A does not have to coincide with the reference line 103. For example, the wiring arrangement groove 101a may be formed so that the tangents that contact the outer peripheral surface of the core wire 11a and face the card edge substrate 2 coincide between the insulated wires 1A. This allows the tangents that contact the outer peripheral surface of the core wire 11a and face the card edge substrate 2 to coincide between the insulated wires 1A, facilitating electrical connection of the core wire 11a to the terminals 221, 223, 225, and 227.

[0032] (2) Arrangement of insulated wires Next, the insulated wire 1A is placed in each of the wire dressing grooves 101a of the first jig 100Aa of the pair of wire dressing jigs 100A, and the insulated wire 1A is pressed down from above by the second jig 100Ab, while the second jig 100Ab is attached to the first jig 100Aa with fastening members (e.g., bolts) 104 (see FIG. 7). At this stage, the end of the insulated wire 1A is not yet exposed. Note that instead of the fastening members 104, a press for attaching a mold to a molding machine from above or below or from the left or right, or a press with a vice or toggle clamp mechanism may be used.

[0033] (3) Formation of fixing members Next, as shown in FIG. 6 , a fixing member mold 110 having a cavity 113 (first space) corresponding to the fixing member 3 is placed around the insulated electric wire 1A between the pair of wire dressing jigs 100A. The fixing member mold 110 is used as a matrix, and the wire dressing jig 100A is used as a nest to be fitted into the matrix. The fixing member mold 110 has a two-piece structure consisting of a first mold 111 and a second mold 112. Note that the illustration of the fixing member mold 110 includes a sprue, which is an injection port for molten resin. The pair of wire dressing jigs 100A with the multiple insulated electric wires 1A arranged therein, is placed in the first mold 111, and the second mold 112 is attached to the first mold 111.

[0034] Next, a 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 product is released from the fixing member mold 110. At this time, the wire arranging jig 100A is removed from the insulated wire 1A. This results in, for example, a fixing member 3C for the third layer 10c being formed. The fixing member 3D for the fourth layer 10d can also be formed using the fixing member mold 110 shown in FIG. 6, but fixing member molds corresponding to the shapes of the fixing member 3A for the first layer 10a and the fixing member 3B for the second layer 10b are used. Furthermore, as shown in FIG. 5(c), there is a gap between the wire arranging groove 101a and the insulated wire 1A, and molten resin may get into this gap. However, this gap can be removed by cutting or the like after the fixing member 3C is formed.

[0035] (4) Cutting insulated wires Next, as shown in FIG. 8 , the insulated wire 1A is cut at a position distance L2 from the fixing member 3C to prepare an unsheathed insulated wire 1A 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 position distance L2 from the fixing member 3D to prepare an unsheathed insulated wire 1A 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 position distance L1 from the fixing member 3A to prepare an unsheathed insulated wire 1A 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 position distance L1 from the fixing member 3B to prepare an unsheathed insulated wire 1A for the second layer 10b.

[0036] (5) Stripping of insulated wires Next, the insulated wire 1A is stripped to sequentially expose the shield conductor 13a, the insulating layer 12a, and the core wire 11a from the outer sheath 14a, as shown in Fig. 9. This results in, for example, an insulated wire 1A for the third layer 10c. Similarly, the insulated wires 1A for the first layer 10a, the second layer 10b, and the fourth layer 10d are also stripped to produce insulated wires 1A for the first layer 10a, the second layer 10b, and the fourth layer 10d.

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

[0038] (7) Formation of sealing material Next, a mold for sealing member (not shown) having a second space corresponding to the sealing member 4 is placed around the card edge substrate 2 and the fixing member 3. Next, a molten second resin (e.g., polyamide resin) is injected into the second space, and after the second resin cools and solidifies, the mold for sealing member is released. This forms the sealing member 4 made of the second resin.

[0039] (Effects of the first embodiment) According to this embodiment, the following effects are achieved. (a) The vicinity of the end regions of the multiple insulated electric wires 1A are fixed in parallel with each other by the fixing member 3. Therefore, even if the outer diameters of the insulated electric wires 1A are different, high-density electrical connection can be achieved between the ends of the core wires 11a exposed in the end regions of the insulated electric wires 1A and the terminals of the connection object (connector, board, etc.). (b) After a plurality of insulated wires 1A are fixed by the fixing member 3, cutting of the ends, stripping, splicing, and other processes can be performed all at once with high accuracy and ease. (c) When the outer size of the fixing members 3 is the same, by changing the size and position of the wire arrangement groove 101a of the wire arrangement jig 100A, it is possible to accommodate electric wires with different structures and outer diameters, variations in the number of wires, variations in the inter-wire pitch, etc. Furthermore, when forming the sealing member 4, the combined outer diameter size of the four fixing members 3A to 3D can be made the same, so that the injection molding die for the sealing member 4 can be shared regardless of the configuration of the electric wires.

[0040] (Variations 1 to 4) 10(a) to 10(d) are front views of essential parts of the wire arranging jig 100A according to Modifications 1 to 4, respectively. In Modification 1 shown in FIG. 10(a), the wire arranging groove 101a formed in the first jig 100Aa is rectangular. Modification 1 facilitates the processing of the wire arranging groove 101a. In Modification 2 shown in FIG. 10(b), semicircular wire arranging grooves 101a with a radius half the outer diameter of the insulated electric wire 1A are formed in each of the first jig 100Aa and the second jig 100Ab. Modification 2 allows the wire arranging groove to be tightly attached to the electric wires even when the outer diameters of the electric wires are different. In Modification 3 shown in FIG. 10(c), the wire arranging groove 101a shown in FIG. 10(b) is rectangular. Modification 3 facilitates the processing of the wire arranging groove 101a. In Modification 4 shown in Fig. 10(d), some of the wire arranging grooves 101a in the first jig 100Aa in Fig. 10(a) are deepened. Convex portions 100a are formed in the second jig 100Ab at locations corresponding to the deepened wire arranging grooves 101a. According to Modification 4, by changing the depth of the wire arranging grooves 101a, the center line 1a of the insulated electric wire 1A can be shifted from the reference line 103 depending on the connection target.

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

[0042] The insulated wire 1A is a coaxial wire, as in the first embodiment. The insulated wires 1B, 1C, and 1D are solid wires with different structures and outer diameters. The insulated wire 1B is, for example, a solid wire with a relatively small outer diameter and includes a core wire 11b made of a conductor and an outer sheath 12b made of an insulating material and covering the outer periphery of the core wire 11b. The insulated wire 1C is, for example, a solid wire with a medium outer diameter and includes a core wire 11c made of a conductor and an outer sheath 12c made of an insulating material and covering the outer periphery of the core wire 11c. The insulated wire 1D is, for example, a solid wire with a relatively large outer diameter and includes a core wire 11d made of a conductor and an outer sheath 12d made of an insulating material and covering the outer periphery of the core wire 11d. The core wires 11b, 11c, and 11d also have thicknesses corresponding to the outer diameters of the outer sheaths 14b, 14c, and 14d.

[0043] Fig. 12 is a front view of a wire arranging jig used in a second embodiment, as seen from the tip end side of the insulated electric wires. As shown in Fig. 12(a), a wire arranging jig 100B according to the second embodiment includes a first jig 100Ba and a second jig 100Bb, in which semicircular wire arranging grooves 101a-101d having radii half the outer diameters of the insulated electric wires 1A-1D to be placed are formed, respectively. The wire arranging grooves 101a-101d are formed in semicircular shapes with wire arranging groove centers 102a-102d as centers. Furthermore, each of the wire arranging groove centers 102a-102d is set on a reference line 103 extending in the Y direction. As a result, as shown in Fig. 12(b), the center lines 1a-1d of each insulated electric wire 1A-1D after wire arranging coincide with the wire arranging groove centers 102a-102d.

[0044] The center lines 1a to 1d of the insulated wires 1A to 1D do not have to be aligned with the reference line 103. For example, the wire-arranging grooves 101a to 101d may be formed so that the tangents that contact the outer peripheral surfaces of the core wires 11a to 11d and face the card edge substrate 2 are aligned among the insulated wires 1A to 1D. In this case, as shown in FIG. 10(d), a wire-arranging jig 100B can be prepared by forming rectangular wire-arranging grooves in a first jig 100Ba and forming protrusions at necessary locations on a second jig 100Bb. This ensures that the tangents that contact the outer peripheral surfaces of the core wires 11a to 11d and face the card edge substrate 2 are aligned among the insulated wires 1A to 1D, facilitating electrical connection of the core wires 11a to 11d to the terminals 221, 223, 225, and 227.

[0045] (Variation 5) FIG. 12(c) is a front view of a main portion of a wire arranging jig 100B according to Modification 5. The wire arranging jig 100B of Modification 5 shown in the figure includes a first jig 100Ba in which rectangular wire arranging grooves 101a-101d corresponding to the outer diameters of the insulated electric wires 1A-1D are formed, and a second jig 100Bb in the shape of a rectangular bar in which no wire arranging grooves are formed. The wire arranging groove 101a is formed with the same depth (Z direction) and width (Y direction) as the outer diameters of the insulated electric wires 1A-1D to be placed. Modification 5 makes it easy to process the wire arranging grooves 101a-101d. In Modification 5, the positions in the Z direction of the center lines 1a-1d of the insulated electric wires 1A-1D differ depending on the outer diameters of the insulated electric wires.

[0046] FIG. 13 is a cross-sectional view of a fixing member 3 according to the second embodiment, taken along the Y direction. Note that in this figure, the insulated wires 1A to 1D are shown in a simplified form. The fixing member 3 is formed as follows. A pair of wire arranging jigs 100B shown in FIG. 12 are arranged in the X direction at a distance d equal to the width W, as in the first embodiment, and the insulated wires 1A to 1D are arranged in the wire arranging grooves 101a to 101d. Next, a fixing member mold having a cavity (first space) corresponding to the fixing member 3 is placed around the insulated wires 1A to 1D between the pair of wire arranging jigs 100B. As described in the first embodiment, a fixing member mold having a two-piece structure is used as a matrix, and the wire arranging jig 100B is used as a nest to be fitted into the matrix. Next, a molten first resin (e.g., polyamide resin) is injected into the cavity (first space). After the first resin cools and solidifies, the first mold is released. As a result, the fixing member 3 shown in FIG. 13 is formed.

[0047] According to the second embodiment, the same effects as those of the first embodiment can be achieved, and even if the outer diameters or arrangement pitches of the insulated electric wires are different, the fixing member 3 can fix the insulated electric wires 1A to 11d in parallel, as in the first embodiment, thereby enabling high-density electrical connection between the ends of the core wires 11a to 11d and the terminals 221, 223, 225, 227 of the connection object.

[0048] [Third embodiment] Fig. 14 is a plan view showing a connection structure for electric wires according to a third embodiment of the present invention. Fig. 15 is a cross-sectional view corresponding to Fig. 3. In the first embodiment, the insulated electric wires 1A in the first to fourth layers 10a to 10d are arranged at the same position in the Y direction as shown in Fig. 3. However, in this embodiment, the insulated electric wires 1A in the first layer 10a and the second layer 10b are arranged between the insulated electric wires 1A in the third layer 10c and the fourth layer 10d as shown in Fig. 15. The following describes this embodiment, focusing on the differences from the first embodiment.

[0049] As in 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, but 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. Note that, although the number of first terminals 221 and second terminals 223 is one less than the number of third terminals 225 and fourth terminals 227 in the drawing, they may 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, which makes it easier to connect the insulated wire 1A.

[0051] [Fourth embodiment] Fig. 16 is a plan view showing a connection structure for electric wires according to a fourth embodiment of the present invention. Fig. 17 is a cross-sectional view of a main part corresponding to Fig. 3. Fig. 16 shows an insulated electric wire 1A in the third layer 10c. In this embodiment, the number of insulated electric wires 1A is increased compared to the first embodiment. Below, this embodiment will be described, focusing on the differences from the first embodiment.

[0052] As shown in FIG. 16, the third terminals 225 formed on the surface 21a of the card edge substrate 2 are arranged at a predetermined pitch on the same line along the Y direction.

[0053] The plurality of insulated electric wires 1A constituting the third layer 10c are divided into a plurality of insulated electric wires 1A constituting the third one layer 10ca and a plurality of insulated electric wires 1A constituting the third two layer 10cb so that the pitch of the insulated electric wires 1A is wider (for example, twice) than the pitch of the third terminals 225. The number of divisions is not limited to two and may be three or more. The plurality of insulated electric wires 1A constituting the third one layer 10ca and the plurality of insulated electric wires 1A constituting the third two layer 10cb are each an example of an electric wire group.

[0054] As shown in FIG. 17 , the fixing member 3C for the third layer 10c is divided into a first member 3a corresponding to the third layer 10ca and a second member 3b corresponding to the third layer 20cb. The number of divisions of the fixing member 3C is not limited to two, as with the plurality of insulated electric wires 1A constituting the third layer 10c, and may be three or more. The first member 3a and the second member 3b have contact surfaces 30 that come into contact with each other. The first member 3a fixes the plurality of insulated electric wires 1A constituting the third layer 10ca at positions close to its contact surface 30. The second member 3b fixes the plurality of insulated electric wires 1A constituting the third layer 20cb at positions close to its contact surface 30. The portions of the insulated electric wires 1A close to the contact surfaces 30 of the first member 3a and the second member 3b are thin-walled portions 31. The thickness of the thin portion 31 is not particularly limited, but may be 1 mm or less, 0.1 mm or less, or even 0 mm.

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

[0056] According to the fourth embodiment, the core wires 11a of the multiple insulated electric wires 1A constituting the third 1st layer 10ca can be soldered to the corresponding third terminals 225, and then the core wires 11a of the multiple insulated electric wires 1A constituting the third 2nd layer 10cb can be soldered to the corresponding third terminals 225, thereby increasing the mounting density of terminals arranged on the same line in the Y direction.

[0057] Although the fourth embodiment has been described with reference to the third layer 10c, a configuration similar to that of the third layer 10c may be applied to the fourth layer 10d, or may be applied to the first layer 10a and the second layer 10b.

[0058] [Fifth embodiment] Fig. 18 is a cross-sectional view of an electric wire according to a fifth embodiment of the present invention. In the first to fourth embodiments, only an insulated electric wire is used as the electric wire, but in the fifth embodiment, a plurality of insulated electric wires and the cable shown in Fig. 18 are used as the electric wire.

[0059] The cable 15 used in the fifth embodiment includes a plurality of (e.g., two) insulated wires 11E, a drain wire 16, a tape shield 17 collectively covering the outer peripheries of the plurality of insulated wires 11E and the drain wires 16, and an outer sheath 18 made of an insulating material covering the outer periphery of the tape shield 17. The insulated wire 11E includes a core wire 11e made of a conductor and an insulating layer 12e covering the outer periphery of the core wire 11e. The tape shield 17 is, for example, a conductive tape wound laterally in a spiral shape. The tape shield 17 is an example of a shielding layer.

[0060] The fixing member 3 is formed by resin molding so that the center lines 1e of the two insulated wires 11E and the center line 16a of the drain wire 16 are positioned on a reference line 103 along the Y direction, and contacts the outer surface of the other insulated wires and the outer jacket 18 of the cable 15, thereby fixing the relative positions of the wires.

[0061] According to the fifth embodiment, cable 15 is a side-drain type in which drain wire 16 is arranged on the side of two insulated wires 11E, and therefore, compared to a center-drain type in which drain wire 16 is arranged so as to contact the outer peripheral surfaces of both insulated wires 11E, the cross-sectional shape of cable 15 can be an ellipse that is long in the Y direction, and therefore the thickness in the Z direction of fixing member 3 can be made thinner. In addition, drain wire 16 can be electrically connected to a terminal without being bent in the Y direction.

[0062] Although the embodiments of the present invention have been described above, the embodiments of the present invention are not limited to the above-described embodiments, and various modifications and implementations are possible. [Explanation of symbols]

[0063] 1A to 1E...insulated wire, 1a to 1e...center wire, 2...card edge board, 2a...edge portion, 3, 3A to 3D...fixing member, 3a...first member, 3b...second member, 4...sealing member, 10...connection structure for electric wires, 10a...first layer, 10b...second layer, 10c...third layer, 10ca...third-first layer, 10cb...third-second layer, 10d...fourth layer, 11a to 11e...core wire, 12a, 12e...insulating layer, 13a...shield conductor, 14a to 14d...outer sheath, 15...cable, 16...drain wire, 16a...center wire, 17...tape shield, 18...outer sheath, 21...substrate, 21a...surface, 23A, 23B...edge terminal, 30...contact surface, 31...thin portion, 100A, 100B...wire arrangement jig, 100Aa, 100Ba...first jig, 100Ab, 100Bb...second jig, 100a...protrusion, 101a to 101d...wire arrangement groove, 102a...wire arrangement groove center, 103, 103a to 103d...reference line, 104...bolt, 110...mold for fixing member, 111...first mold, 112...second mold, 113...cavity, 221...first terminal, 222...first ground terminal, 223...second terminal, 224...second ground terminal, 225...third terminal, 226...third ground terminal, 227...fourth terminal, 228...fourth ground terminal, d...spacing, W...width

Claims

1. A connecting structure for electric wires for electrically connecting terminals of a plurality of core wires exposed by stripping off the coating of end regions of a plurality of electric wires arranged in parallel to a plurality of corresponding terminals, a fixing member formed to contact outer peripheral surfaces of the plurality of electric wires in the vicinity of the end region while the plurality of electric wires are arranged parallel to one another in the vicinity of the end region, and to fix the relative positions of the electric wires; A connection structure for electric wires comprising:

2. The plurality of electric wires are arranged in parallel in a plurality of layers, The fixing member is provided for each layer. The electric wire connection structure according to claim 1 .

3. The fixing members provided for each layer have the same outer size. The electric wire connection structure according to claim 2 .

4. a sealing member that covers the fixing member and watertightly seals the connection portions between the plurality of terminals and the ends of the plurality of core wires; The electric wire connection structure according to claim 1 , further comprising:

5. a sealing member that collectively covers the fixing members provided for each layer and watertightly seals the connection portions between the plurality of terminals and the ends of the plurality of core wires; The electric wire connection structure according to claim 3, further comprising:

6. the plurality of electric wires includes a cable including two insulated electric wires, a drain wire, a shielding layer collectively covering the outer peripheries of the two insulated electric wires and the drain wire, and an outer jacket formed of an insulating material and covering the outer periphery of the shielding layer; the two insulated wires and the drain wire are arranged in the same direction as the direction in which the plurality of electric wires are arranged in parallel, and the drain wire is arranged next to the two insulated wires; The electric wire connection structure according to any one of claims 1 to 5.

7. The plurality of terminals are arranged at a predetermined pitch on the same line along the direction in which the plurality of electric wires are arranged in parallel, The plurality of electric wires are divided into at least two groups of electric wires such that the pitch of the electric wires is wider than the pitch of the terminals; the fixing member is divided into at least a first member and a second member, each of which fixes the relative positions of the electric wires constituting the at least two electric wire groups; The electric wire connection structure according to claim 1 .

8. A method for manufacturing a connection structure for electric wires for electrically connecting terminals of a plurality of core wires, which are exposed by stripping off coatings from end regions of a plurality of electric wires arranged in parallel, to a plurality of corresponding terminals, comprising: a pair of wire-arranging jigs each having a plurality of wire-arranging grooves formed to correspond to the outer diameters of the plurality of electric wires, the pair of wire-arranging jigs being arranged at a predetermined distance from each other; The plurality of electric wires are arranged in the corresponding wire-arranging grooves so that the vicinity of the end region is located between the pair of wire-arranging jigs, and the plurality of electric wires are arranged parallel to each other in the end region; a fixing member is formed between the pair of wire dressing jigs so as to contact outer peripheral surfaces of the plurality of electric wires in the vicinity of the end regions, thereby fixing the relative positions of the electric wires; Remove the pair of wire-arranging jigs from the plurality of electric wires, a step of cutting the plurality of electric wires at a predetermined length from the fixing member, stripping off the coating of the end region of the plurality of electric wires on the cut side to expose the plurality of core wires, and connecting the ends of the exposed plurality of core wires to the corresponding plurality of terminals, the step being performed before or after forming the fixing member; A method for manufacturing a connection structure for electric wires.

9. a mold for injection molding having a cavity corresponding to the fixing member is used as a mother mold, and the pair of wire arranging jigs are used as nests to be fitted into the mother mold, thereby forming the fixing member by injection molding; A method for manufacturing the electric wire connection structure according to claim 8.

10. A plurality of electric wires arranged in parallel; a connection target having a plurality of terminals to which ends of a plurality of core wires exposed by stripping off the coatings from end regions of the plurality of electric wires are electrically connected; and a fixing member formed to contact the outer peripheral surfaces of the plurality of electric wires near the end regions and fix the relative positions of the electric wires while the plurality of electric wires are arranged parallel to each other near the end regions.

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