阅读说明：本技术 磁线接合方法以及接合构造 (Magnet wire joining method and joining structure ) 是由 栉原弘 石桥和之 丸山裕史 新井真一 村松俊纪 原慎一 豊竹克年 于 2019-07-18 设计创作，主要内容包括：本发明涉及一种将磁线不缠绕地接合于端子销的磁线接合方法以及接合构造。本发明的磁线接合方法以及接合构造是如下的方法和构成：将具有设于销部(11a)的平板部(40)的端子销(11)用于端子销保持部(3),将磁线(13)不进行缠绕地按长条状载置于所述平板部(40)的平面(40a)上,利用超声波焊头(50)将所述磁线(13)的外周面(13E)超声波接合于所述平面(40a)上。(The present invention relates to a magnet wire joining method and a joining structure for joining a magnet wire to a terminal pin without winding the magnet wire. The magnetic wire joining method and joining structure of the present invention are the following methods and configurations: a terminal pin (11) having a flat plate portion (40) provided on a pin portion (11a) is used for a terminal pin holding portion (3), a magnetic wire (13) is placed in a long shape on a flat surface (40a) of the flat plate portion (40) without being wound, and an outer peripheral surface (13E) of the magnetic wire (13) is ultrasonically bonded to the flat surface (40a) by an ultrasonic horn (50).)

1. A method of joining magnet wires, characterized in that,

a terminal pin (11) having a flat plate portion (40) provided on a pin portion (11a) is used for a terminal pin holding portion (3), a magnetic wire (13) is placed in a long shape on a flat surface (40a) of the flat plate portion (40) without being wound, and an outer peripheral surface (13E) of the magnetic wire (13) is ultrasonically bonded to the flat surface (40a) by an ultrasonic horn (50).

2. The magnet wire joining method as claimed in claim 1,

the terminal pin (11) is insert-molded to a terminal pin holding portion (3) of a rotary transformer or inserted into a mounting hole of the rotary transformer, and a flat plate portion (40) of the terminal pin (11) is located inside a bottom surface (30a) of the terminal pin holding portion (3).

3. The magnet wire joining method as claimed in claim 1 or 2,

the magnetic wire (13) is in contact with the flat surface (40a) by the same length as the length (L) of the flat surface of the flat plate portion (40).

4. A method of joining magnet wires according to any of claims 1 to 3,

a guide pin or a loosening pin (20) is provided in a position near the flat plate portion (40) of the terminal pin holding portion (3), and the magnetic wire (13) ultrasonically bonded to the flat plate portion (40) uses an end wire (13) wound around a projecting magnetic pole (32) of a wheel-shaped stator (30) connected to the terminal pin holding portion (3).

5. The magnet wire joining method as claimed in any one of claims 1 to 4,

the magnetic wires (13) are bonded to the plane (40a) of the flat plate portion (40) in an elongated shape along a plane direction (M) of the plane (40 a).

6. A magnetic wire engagement construction, comprising:

a flat plate part (40) formed at the other end (11b) of the terminal pin (11) provided in the terminal pin holding part (3); a magnetic wire (13) that is placed on the flat plate portion (40) and has no wound portion; and a joining portion (60) that joins the magnet wire (13) to the flat plate portion (40) with an ultrasonic horn (50), the magnet wire (13) being joined in an elongated shape along a plane direction (M) of a plane (40a) of the flat plate portion (40) with respect to the plane (40 a).

7. The magnet wire engagement configuration of claim 6,

the terminal pin (11) is provided on a terminal pin holding portion (3), the terminal pin holding portion (3) is provided on one end (31a) of a wheel-shaped insulating cover (31) covering a wheel-shaped stator (30) having a plurality of projecting magnetic poles (32), and the terminal pin (11) includes a linear pin portion (11a) and the flat plate portion (40) provided integrally with or separately from the pin portion (11 a).

8. The magnet wire engagement configuration of claim 6 or 7,

the flat plate portion (40) is located inside a bottom surface (30a) of the terminal pin holding portion (3).

Technical Field

The present invention relates to a magnetic wire joining method and a joining structure, and more particularly, to a new improvement for ultrasonically joining an elongated outer peripheral surface of a magnetic wire having no wound portion to a flat surface of a flat plate portion of a terminal pin.

Background

As a conventional magnetic wire joining method and joining structure, a structure of patent document 1 shown in fig. 7 and 8 and a structure currently sold by the applicant (non-patent document and the like) shown in fig. 9 and 10 can be cited.

That is, a portion indicated by reference numeral 1 in fig. 7 is a magnetic sensor, and a plurality of lead terminals 9, 10, and 11 which are insert-molded are disposed in a state where a part of the lead terminal holders 3 of the magnetic sensor 1 is exposed.

The base portions 9a, 10a and 11a of the lead terminals 9, 10 and 11 protrude into the recesses 20 formed in the lead terminal holders 3.

A sensor element body 2 made of a substrate is provided above the recess 20, and a magnetic sensor layer 5 and conductive portions 7a, 7b, and 7c made of copper are provided in parallel with each other on the sensor element body 2.

The base portions 9a, 10a, and 11a and the conductive portions 7a, 7b, and 7c are connected to the magnetic sensors (not shown) of the magnetic sensor layer 5, and the conductive portions 7a, 7b, and 7c and the base portions 9a, 10a, and 11a are connected to each other by a lead 13 of copper, gold, or the like, using the same device (not shown) as a wire bonding machine (not shown) required for manufacturing a well-known semiconductor chip or the like.

A rotor 35 is rotatably disposed on the front side of the sensor element body 2 of the magnetic sensor 1, and the rotor 35 alternately magnetizes an N pole and an S pole in a state in which the rotor is close to the front side of the sensor element body 2 of the magnetic sensor 1.

Although fig. 8 shows the sensor element main body 2 of the lead terminal holder 3 in an enlarged manner, the leading ends or the trailing ends of the respective lead wires 13 are bonded to the respective conductive portions 7a, 7b, and 7c and to the respective base portions 9a, 10a, and 11a, and therefore the bonding state becomes the point bonding T.

As another conventional example, the structure shown in fig. 9 and 10, which is manufactured and sold by the applicant but is not disclosed in patent documents, etc., can be cited.

In the configuration of fig. 9 and 10, the same reference numerals are used for the same or equivalent portions as those of fig. 7 and 8.

A portion denoted by reference numeral 3 in fig. 9 is a terminal pin holding portion formed by integrally projecting a wheel-shaped insulating cover 31 of a wheel-shaped stator 30 of a resolver (resolver), for example, and a plurality of terminal pins 11 are linearly arranged at predetermined intervals at the outermost position of the terminal pin holding portion 3.

A plurality of guide pins or loosening pins 20 arranged linearly in parallel with the terminal pins 11 are provided in front of the terminal pins 11 provided on the one surface 3A of the terminal pin holding portion 3.

A pair of guide pins 21 are provided inside the guide pins or the loosening pins 20.

A plurality of projecting magnetic poles 32 projecting inward are provided at predetermined angular intervals inside the wheel-shaped stator 30, and a wheel-shaped insulating cover 31 integrated with the terminal pin holding portion 3 is provided on the outer periphery of each projecting magnetic pole 32.

The end wire 13 including the stator coil 13A for excitation and output wound around each of the projecting magnetic poles 32 is wound around and connected to the terminal pin 11 via each of the guide pins 21 and the guide pin or loosening pin 20.

Fig. 10 is a cross-sectional view showing a cross section a-a' of fig. 9, and the same portions as those described in fig. 9 are denoted by the same reference numerals, and the description thereof will be omitted.

The terminal pin 11 insert-molded in the terminal pin holding portion 3 formed at one end 31a of the wheel-shaped insulating cover 31 has a pin portion 11a formed at the tip thereof projecting into the space 3D of the connecting portion 3B of the terminal pin holding portion 3.

The other end 11b of the terminal pin 11 protrudes outside the bottom surface 3C of the terminal pin holding portion 3.

Disclosure of Invention

Problems to be solved by the invention

The conventional magnetic wire joining method and the joining structure thereof are configured as described above, and therefore have the following problems.

That is, in the first conventional configuration shown in fig. 7 and 8, in order to connect the lead wires 13 between the base portions 9a (10 a, 11a) and the conductive portions 7a (7 b, 7c), the connection state is poor in the process because the lead wires are in a state of point-to-point bonding T by any one of soldering (soldering), TIG welding, and brazing (brazing), which causes an increase in the process-state failure and a deterioration in productivity.

In the case of the second conventional configuration shown in fig. 9 and 10, the end wire 13 of the stator coil 13A wound around the projecting magnetic pole 32 must be wound around the terminal pin 11 via the guide pins 20 and 21, and therefore, the winding time is increased, and the number of devices to be loaded is increased.

Further, since the terminal wire is wound around the terminal pin via the plurality of pins as described above, the winding work is difficult and the layout of the components is also difficult in the resolver in which the terminal wire is short and has a small diameter.

Further, as shown in fig. 10, as a serious problem, the other end 11b of the terminal pin 11 protrudes outward from the bottom surface 3C of the terminal pin holding portion 3, and therefore, when the resolver shown in fig. 9 and 10 is connected to another device not shown, the other end 11b becomes an obstacle, and the connection configuration becomes difficult.

The present invention has been made to solve the above-described problems, and an object thereof is to provide a magnetic wire joining method and a joining structure for ultrasonically joining an outer peripheral surface of a long piece of end wire including a magnetic wire having no wound portion to a plane surface of a flat plate portion of a terminal pin.

Means for solving the problems

The method of joining magnet wires of the present invention is as follows: the terminal pin having a flat plate portion provided on a pin portion is used for a terminal pin holding portion, a magnetic wire is placed in a long shape on a flat surface of the flat plate portion without being wound, an outer peripheral surface of the magnetic wire is ultrasonically bonded to the flat surface by an ultrasonic horn, the terminal pin is insert-molded into a terminal pin holding portion of a resolver or inserted into a mounting hole of the resolver, the flat plate portion of the terminal pin is positioned inside a bottom surface of the terminal pin holding portion, the magnetic wire and the flat surface are in contact with each other by a length equal to a flat length of the flat plate portion, a guide pin or a loosening pin is provided at a position near the flat plate portion of the terminal pin holding portion, and the magnetic wire ultrasonically bonded to the flat plate portion uses an end wire wound around a projecting magnetic pole of a wheel-shaped stator connected to the terminal pin holding portion, further, the magnet wires are bonded to the plane of the flat plate portion in an elongated shape along a plane direction of the plane, and the magnet wire bonding structure of the present invention is configured as follows: the magnet wire engagement configuration includes: a flat plate portion formed at the other end of the terminal pin provided in the terminal pin holding portion; a magnetic wire placed on the flat plate portion and having no wound portion; and a joining portion for joining the magnetic wire portion to the flat plate portion by an ultrasonic horn, the magnetic wire portion being joined to the flat plate portion in a long shape along a planar direction of the flat plate portion, wherein the terminal pin is provided in a terminal pin holding portion provided at one end of a wheel-shaped insulating cover covering a wheel-shaped stator having a plurality of projecting magnetic poles, the terminal pin includes a linear pin portion and the flat plate portion integrally or separately provided with the pin portion, and the flat plate portion is located inside a bottom surface of the terminal pin holding portion.

Effects of the invention

The magnetic wire joining method and the joining structure of the present invention are configured as described above, and therefore the following effects can be obtained.

That is, the terminal pin having the flat plate portion provided on the pin portion is used as the terminal pin holding portion, the magnetic wire is placed on the flat surface of the flat plate portion in an elongated shape without being wound, and the outer peripheral surface of the magnetic wire is ultrasonically bonded to the flat surface by the ultrasonic horn, whereby the bonding between the magnetic wire and the terminal pin becomes strong, and the length of the terminal pin can be shortened. Therefore, as shown in fig. 6, the thickness of the resolver stator can be reduced and the diameter in the radial direction can also be reduced. As a result, the distance from the motor can be reduced. In addition, the number of input reels can be reduced by shortening the winding time for the terminal pins. Further, the terminal pin is insert-molded in the terminal pin holding portion of the resolver or inserted into the mounting hole of the resolver, and the flat plate portion of the terminal pin is positioned inside the bottom surface of the terminal pin holding portion, whereby the thickness reduction of the resolver stator can be greatly facilitated.

Further, the magnetic wire and the flat surface are in contact with each other by the same length as the flat surface of the flat plate portion, whereby the engagement of the end wire and the flat plate portion can be made reliable.

Further, since the guide pin or the loosening pin is provided at a position near the flat plate portion of the terminal pin holding portion, and the magnetic wire ultrasonically bonded to the flat plate portion uses the end wire wound around the projecting magnetic pole of the wheel-shaped stator connected to the terminal pin holding portion, the number of pins for guiding the end wire can be significantly reduced as compared with the conventional case.

Further, the magnetic wires are joined to the flat plate portion in an elongated shape along the planar direction of the flat plate portion, whereby the joint area of the end wires and the flat plate portion can be increased.

Drawings

Fig. 1 is a plan view showing a main part of a magnet wire joining method and a joining structure of the present invention.

Fig. 2 is a sectional view a-a' of fig. 1.

Fig. 3 is a view showing the structure of the joining of the magnet wire in the present invention.

Fig. 4 is a perspective view showing the terminal pin of fig. 3.

Fig. 5 is a top view of the bonded assembly of fig. 3.

Fig. 6 is a diagram showing a comparison of main parts of a conventional resolver stator and a resolver stator according to the present invention.

Fig. 7 is a diagram showing the configuration of a conventional magnetic sensor.

Fig. 8 is an enlarged view of a main portion of fig. 7.

Fig. 9 is a plan view showing a main part of a conventional resolver stator.

Fig. 10 is a sectional view a-a' of fig. 9.

Description of reference numerals:

3a terminal pin holding part;

3A, one side;

a 3D space;

a 3B connection part;

11a terminal pin;

11a pin portion;

11b, the other end;

13 magnet wires (end wires);

13A stator coil;

13E outer peripheral surface;

20 guide pins or slack pins;

a 30-wheel stator;

30a bottom surface;

31 wheel-shaped insulating covers;

31a one end;

32 projecting the magnetic pole;

40a flat plate portion;

40a plane;

50 ultrasonic welding heads;

60 a joint portion;

c, the vibration direction of the ultrasonic wave;

l plane length;

the M plane direction.

Detailed Description

The method and structure for joining magnetic wires according to the present invention ultrasonically join the outer peripheral surface of a long magnetic wire having no wound portion to the flat surface of a flat plate portion of a terminal pin.