# US 11,114,825 B2 · Joining method of electric wires > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,114,825 B2 - Document ID: US11114825B2 - Status: Granted - Kind: B2 - Application number: 15/726,111 - Filed: 2017-10-05 - Published: 2018-05-10 - Granted: 2021-09-07 - Earliest claimed: 2016-11-10 - Assignees: Yazaki Corporation - Applicants: Yazaki Corporation - Inventors: Shigeru Tanaka; Masayuki Kataoka - Web page: https://patentgrep.com/patent/US11114825B2 ## CPC - H02G 1/145: {Moulds} - H01B 7/02: Disposition of insulation - H01R 4/021: {between two or more cables or wires} - H01R 4/029: {Welded connections (H01R4/021 - H01R4/028 take precedence)} - H01R 43/0214: {Resistance welding (H01R43/0228 takes precedence)} - H01R 4/10: effected solely by twisting, wrapping, bending, crimping, or other permanent deformation - H01R 4/70: Insulation of connections (end caps H01R4/22) - H02G: INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES - H01B: CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES (selection for magnetic properties H01F1/00; waveguides H01P {; printed circuits H05K}) - H01R: ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS ## Abstract In a joining method of an electric wire, an end of a first conductor is held by a holding surface of a first jig electrode from an outer circumference side and an end of a second conductor is held by a holding surface of a second jig electrode from an outer circumference side to butt and join the ends of the first conductor and the second conductor in the axial direction while heating the ends. Then, a melted material is bulged outward from an outer circumferential surface of a joining portion to a bulge molding portion formed to surround a joining portion of the ends of the first conductor and the second conductor. ## Claims ### Claim 1 A joining method of electric wires comprising: a holding step of arranging a conductive first conductor formed by a plurality of element wires and a conductive second conductor formed in a bar shape to be opposed to each other in an axial direction, holding an end of the first conductor by a first holding surface of a first jig electrode from an outer circumference side, and holding an end of the second conductor by a second holding surface of a second jig electrode from an outer circumference side; an approaching step of relatively moving the first jig electrode and the second jig electrode to be opposed to each other in the axial direction and moving the end of the first conductor and the end of the second conductor to be closer to each other; and a joining and molding step of abutting and joining the end of the first conductor and the end of the second conductor while heating the ends by energizing the first jig electrode and the second jig electrode and bulging a melted material outward from an outer circumferential surface of a joining portion to a bulge molding portion formed to surround the joining portion of the end of the first conductor and the end of the second conductor, wherein the bulge molding portion has molding surfaces on the first jig electrode and the second jig electrode to mold the melted material and is formed so that widths of opposing portions of the molding surfaces opposed to each other so as to sandwich the joining portion in an orthogonal direction orthogonal to the axial direction are larger than a larger one of the widths of opposing portions of the first holding surface opposed to each other so as to sandwich the first conductor in the orthogonal direction and the widths of opposing portions of the second holding surface opposed to each other so as to sandwich the second conductor in the orthogonal direction. ### Claim 2 (depends on 1) The joining method of the electric wires according to claim 1, wherein the molding surfaces form a smooth surface around an axial direction of the melted material. ### Claim 3 (depends on 2) The joining method of the electric wires according to claim 2, wherein the molding surfaces form the smooth surface in parallel to the axial direction and around the axial direction. ### Claim 4 (depends on 3) The joining method of the electric wires according to claim 3, wherein the molding surfaces form the smooth surface as a columnar outer surface having a central axis in the axial direction. ### Claim 5 (depends on 4) The joining method of the electric wires according to claim 4, wherein the molding surfaces form the smooth surface as tapered surfaces to be tapered from both ends of the outer surface in the axial direction toward the respective outer surfaces of the first conductor and the second conductor. ### Claim 6 (depends on 5) The joining method of the electric wires according to claim 5, wherein the molding surfaces are divided into a first molding surface and a second molding surface in the axial direction, the first jig electrode is formed integrally with the first molding surface in the axial direction, and the second jig electrode is formed integrally with the second molding surface in the axial direction. ### Claim 7 (depends on 4) The joining method of the electric wires according to claim 4, wherein the molding surfaces are divided into a first molding surface and a second molding surface in the axial direction, the first jig electrode is formed integrally with the first molding surface in the axial direction, and the second jig electrode is formed integrally with the second molding surface in the axial direction. ### Claim 8 (depends on 3) The joining method of the electric wires according to claim 3, wherein the molding surfaces are divided into a first molding surface and a second molding surface in the axial direction, the first jig electrode is formed integrally with the first molding surface in the axial direction, and the second jig electrode is formed integrally with the second molding surface in the axial direction. ### Claim 9 (depends on 3) The joining method of the electric wires according to claim 3, wherein the width of the molding surfaces are formed to be smaller than the smaller one of a width in the orthogonal direction of a first wiring member including the first conductor and an insulating first insulating cover portion covering a side of an outer circumference of the first conductor and a width in the orthogonal direction of a second wiring member including the second conductor and an insulating second insulating cover portion covering a side of an outer circumference of the second conductor, and a length of the molding surfaces in the axial direction is formed to be shorter than the shorter one of the width of the first wiring member in the orthogonal direction and the width of the second wiring member in the orthogonal direction. ### Claim 10 (depends on 2) The joining method of the electric wires according to claim 2, wherein the molding surfaces form the smooth surface as a columnar outer surface having a central axis in the axial direction. ### Claim 11 (depends on 10) The joining method of the electric wires according to claim 10, wherein the molding surfaces form the smooth surfaces as tapered surfaces to be tapered from both ends of the outer surface in the axial direction toward the respective outer surfaces of the first conductor and the second conductor. ### Claim 12 (depends on 11) The joining method of the electric wires according to claim 11, wherein the molding surfaces are divided into a first molding surface and a second molding surface in the axial direction, the first jig electrode is formed integrally with the first molding surface in the axial direction, and the second jig electrode is formed integrally with the second molding surface in the axial direction. ### Claim 13 (depends on 11) The joining method of the electric wires according to claim 11, wherein the width of the molding surfaces are formed to be smaller than the smaller one of a width in the orthogonal direction of a first wiring member including the first conductor and an insulating first insulating cover portion covering a side of an outer circumference of the first conductor and a width in the orthogonal direction of a second wiring member including the second conductor and an insulating second insulating cover portion covering a side of an outer circumference of the second conductor, and a length of the molding surfaces in the axial direction is formed to be shorter than the shorter one of the width of the first wiring member in the orthogonal direction and the width of the second wiring member in the orthogonal direction. ### Claim 14 (depends on 10) The joining method of the electric wires according to claim 10, wherein the molding surfaces are divided into a first molding surface and a second molding surface in the axial direction, the first jig electrode is formed integrally with the first molding surface in the axial direction, and the second jig electrode is formed integrally with the second molding surface in the axial direction. ### Claim 15 (depends on 10) The joining method of the electric wires according to claim 10, wherein the width of the molding surfaces are formed to be smaller than the smaller one of a width in the orthogonal direction of a first wiring member including the first conductor and an insulating first insulating cover portion covering a side of an outer circumference of the first conductor and a width in the orthogonal direction of a second wiring member including the second conductor and an insulating second insulating cover portion covering a side of an outer circumference of the second conductor, and a length of the molding surfaces in the axial direction is formed to be shorter than the shorter one of the width of the first wiring member in the orthogonal direction and the width of the second wiring member in the orthogonal direction. ### Claim 16 (depends on 2) The joining method of the electric wires according to claim 2, wherein the molding surfaces are divided into a first molding surface and a second molding surface in the axial direction, the first jig electrode is formed integrally with the first molding surface in the axial direction, and the second jig electrode is formed integrally with the second molding surface in the axial direction. ### Claim 17 (depends on 2) The joining method of the electric wires according to claim 2, wherein the width of the molding surfaces are formed to be smaller than the smaller one of a width in the orthogonal direction of a first wiring member including the first conductor and an insulating first insulating cover portion covering a side of an outer circumference of the first conductor and a width in the orthogonal direction of a second wiring member including the second conductor and an insulating second insulating cover portion covering a side of an outer circumference of the second conductor, and a length of the molding surfaces in the axial direction is formed to be shorter than the shorter one of the width of the first wiring member in the orthogonal direction and the width of the second wiring member in the orthogonal direction. ### Claim 18 (depends on 1) The joining method of the electric wires according to claim 1, wherein the molding surfaces are divided into a first molding surface and a second molding surface in the axial direction, the first jig electrode is formed integrally with the first molding surface in the axial direction, and the second jig electrode is formed integrally with the second molding surface in the axial direction. ### Claim 19 (depends on 18) The joining method of the electric wires according to claim 18, wherein the width of the molding surfaces are formed to be smaller than the smaller one of a width in the orthogonal direction of a first wiring member including the first conductor and an insulating first insulating cover portion covering a side of an outer circumference of the first conductor and a width in the orthogonal direction of a second wiring member including the second conductor and an insulating second insulating cover portion covering a side of an outer circumference of the second conductor, and a length of the molding surfaces in the axial direction is formed to be shorter than the shorter one of the width of the first wiring member in the orthogonal direction and the width of the second wiring member in the orthogonal direction. ### Claim 20 (depends on 1) The joining method of the electric wires according to claim 1, wherein the width of the molding surfaces are formed to be smaller than the smaller one of a width in the orthogonal direction of a first wiring member including the first conductor and an insulating first insulating cover portion covering a side of an outer circumference of the first conductor and a width in the orthogonal direction of a second wiring member including the second conductor and an insulating second insulating cover portion covering a side of an outer circumference of the second conductor, and a length of the molding surfaces in the axial direction is formed to be shorter than the shorter one of the width of the first wiring member in the orthogonal direction and the width of the second wiring member in the orthogonal direction. ### Claim 21 A joining method of electric wires comprising: a holding step of arranging a conductive first conductor formed by a plurality of element wires and a conductive second conductor formed in a bar shape to be opposed to each other in an axial direction, holding an end of the first conductor by a first holding surface of a first jig electrode from an outer circumference side, and holding an end of the second conductor by a second holding surface of a second jig electrode from an outer circumference side; an approaching step of relatively moving the first jig electrode and the second jig electrode to be opposed to each other in the axial direction and moving the end of the first conductor and the end of the second conductor to be closer to each other; and a joining and molding step of abutting and joining the end of the first conductor and the end of the second conductor while heating the ends by energizing the first jig electrode and the second jig electrode and bulging a melted material outward from an outer circumferential surface of a joining portion to a bulge molding portion formed to surround the joining portion of the end of the first conductor and the end of the second conductor, wherein in the joining and molding step, until the end of the first jig electrode in the axial direction and the end of the second jig electrode in the axial direction have contact with each other, the end of the first conductor and the end of the second conductor are pressurized to be butted to each other in the axial direction, and the bulge molding portion has molding surfaces on the first jig electrode and the second jig electrode to mold the melted material and is formed so that widths of opposing portions of the molding surfaces opposed to each other so as to sandwich the joining portion in an orthogonal direction orthogonal to the axial direction are larger than a larger one of the widths of opposing portions of the first holding surface opposed to each other so as to sandwich the first conductor in the orthogonal direction and the widths of opposing portions of the second holding surface opposed to each other so as to sandwich the second conductor in the orthogonal direction.