# US 8,769,813 B2 · Method of manufacturing a wiring material

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- Number: US 8,769,813 B2
- Document ID: US8769813B2
- Status: Granted
- Kind: B2
- Application number: 12/842,671
- Filed: 2010-07-23
- Published: 2010-11-11
- Granted: 2014-07-08
- Earliest claimed: 2004-12-10
- Assignees: Hitachi Metals, Ltd.
- Applicants: Toru Sumi; Tsukasa Iwasita; Kenichi Egami; Kazuyuki Watanabe; Hiroshi Okikawa
- Inventors: Toru Sumi; Tsukasa Iwasita; Kenichi Egami; Kazuyuki Watanabe; Hiroshi Okikawa
- Web page: https://patentgrep.com/patent/US8769813B2

## CPC

- H01R 4/023: {between cables or wires and terminals}
- Y10T 29/49172: by molding of insulating material
- Y10T 29/49176: with molding of electrically insulating material
- Y10T 29/49179: by metal fusion bonding
- Y10T 29/49181: by deforming
- Y10T 29/49183: of ferrule about conductor and terminal
- Y10T 29/4919: Through insulation
- Y10T 29/49227: Insulator making
- H01R: ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

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

## Claims

### Claim 1

A method of manufacturing a wiring material having a connecting terminal electrically connected to a circular shaped single line conductor, comprising the steps of:
bending a single line conductor to have a circular shape;
extending both ends of the single line conductor that is bent in parallel;
forming a tube-shaped section having a circular cross section at the connecting terminal for accommodating the both ends of the single line conductor;
inserting the both ends of the single line conductor into the tube-shaped section; and
conducting a resistance welding by energizing welding electrodes from the outer periphery of the tube-shaped section, in a state where a portion of the tube-shaped section between the ends of the single line conductor is pushed by the welding electrode into a space formed between the ends of the single line conductor and an inner periphery surface of the tube-shaped section contacts with the both ends of the single line conductor to electrically connect the connecting terminal with the both ends of the single line conductor.

### Claim 2 (depends on 1)

The method of manufacturing a wiring material according to claim 1, wherein:
the resistance welding is conducted by energizing by a pair of electrodes from the outer periphery of the tube-shaped section, and a tip angle of any one or both of the pair of the electrodes is from 60° to 90°.

### Claim 3 (depends on 2)

The method of manufacturing a wiring material according to claim 2, wherein:
a round-shape at a tip portion of any one or both of the pair of the electrodes is from 1.25 mm to 3 mm.

### Claim 4 (depends on 1)

The method of manufacturing a wiring material according to claim 1, further comprising the step of:
conducting a crush process on the tube-shaped section of the connecting terminal, to contact an inner periphery of the tube-shaped section and the both ends of the single line conductor with each other.

### Claim 5 (depends on 4)

The method of manufacturing a wiring material according to claim 4, wherein:
the crush process is conducted such that an upper portion of the tube-shaped section of the connecting terminal contacts with a concave portion formed between the both ends of the two single line conductors and contacts along a longitudinal direction of the two single line conductors.

### Claim 6 (depends on 4)

The method of manufacturing a wiring material according to claim 4, further comprising the step of:
conducting a crush process to press the tube-shaped section of the connecting terminal along a direction perpendicular to the longitudinal direction of the two single line conductors.