JP2005118805A - Welded metal wire, and manufacturing method therefor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a welded metal wire manufacturing method by which a welded portion can be sufficiently insulated and electric characteristics such as electric resistance are not impaired when ends of two metal wire parts are welded. <P>SOLUTION: Ends 41T and 42T of a first metal wire part 41 and a second metal wire part 42 are overlapped each other at side surface parts thereof, the first metal wire part 41 of larger sectional area is irradiated with laser beams from a welding laser irradiation apparatus 43 to weld the ends 41T and 42T. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

    The present invention relates to a welded metal wire and a method for manufacturing the same, and in particular, in welding of the ends of two metal wire portions, it is possible to obtain an excellent effect in preventing damage such as insulation of the welded portion, electrical characteristics, and disconnection. The present invention relates to a welded metal wire and a manufacturing method thereof.

  As a means for integrally joining a thin metal wire such as a signal wire or a lead wire derived from an electronic component to another metal wire, a soldering method, a resistance welding method, or the like has been conventionally used. However, solder is an alloy containing harmful lead and has a problem with a large environmental load after disposal. In addition, the resistance welding method has a limit on the miniaturization of the welding range, and the influence of heat extends over a wide range, so that it is not suitable for high-precision joining applications in recent years. Under these circumstances, in recent years, various metal joining technologies such as lead-free solder, friction welding, ultrasonic joining, and welding with high-density energy such as laser have progressed, and joining methods according to the shape, material and quality of materials have been developed. It has become possible to select as appropriate. However, lead-free solder is expensive and has poor workability due to the fact that the construction temperature is higher than that of conventional solder. To apply friction welding and ultrasonic welding to thin wires, workability and production efficiency are still important. It is difficult to apply with. In particular, laser welding, electron beam or finely squeezed arc welding capable of melting and joining small metal parts with high precision and efficiency are promising means for joining thin metal wires, and are harmful. There is no problem.

  Laser welding is a welding method in which a laser beam is focused on a portion to be welded and irradiated, and the portion to be welded is instantaneously melted and joined by the energy of the laser beam. On the other hand, electron beam welding is a welding method in which the welding target parts are melted and joined by the energy of the electron beam.

  However, in the case of laser welding or electron beam welding of the first metal wire portion made of a plurality of metal wires and other metal wire portions, incomplete welding such as generation of unwelded metal wires, fusing, etc. Likely to happen. For this reason, there are problems such as insufficient welding strength, risk of disconnection, uneven quality of the welded portion for each treatment, and instability of electrical characteristics such as current and resistance. In order to solve such a problem, the applicants of the present application firstly conducted a weld metal wire that efficiently conducts heat for welding to the entire site to be welded to improve the quality and strength of the welded portion, and a method for manufacturing the same. (Patent Document 1).

  That is, the method is to converge a plurality of metal strands in the first metal wire portion into a closely contacted state by twisting or other methods, and the convergence portion of the first metal wire portion and other metal wires Are overlapped in the vertical direction, and the overlapped portion is irradiated with laser light or an electron beam from above to weld them. With this method, the heat of welding is quickly conducted from the irradiated position to all the metal wires and other metal wires constituting the first metal wire portion, so that a good welding state is obtained. The purpose of the period can be achieved.

Japanese Patent Application Laid-Open No. 2003-80334, “Welding metal wire and manufacturing method thereof”. Description, detailed description of invention, paragraphs 0005-0037, 0051-0054. Drawing, FIG. 1, FIG. 2, FIG. 7, FIG.

As described above, in the previous proposal, the first metal wire portion and the other metal wire portion are welded to each other, and the first metal wire portion is a non-welded portion in the vicinity of the welded portion with the other metal wire portion. A weld metal wire composed of a plurality of metal strands converged in close contact with each other and a manufacturing method thereof have been disclosed. However, the method specifically disclosed by this proposal has the following problems.
(A) Since these two metal wire portions are welded in the vertical direction, and both outer sides on the axis of each welding target part are fixed and irradiated with a laser or the like from above, The end portions of both the metal wire portions are formed with the weld metal wires protruding from the welded portion without being subjected to the welding process, or with the cut end faces exposed in addition thereto.

(B) When the cut end face is exposed, the welded part and the surrounding metal part are resin-coated. For example, when manufacturing this as a sensor application, the exposed part protrudes from the coated part, and current flows to the outside. Since it becomes easy, the exact electric resistance value required cannot be obtained.
(C) Even in cases other than sensor applications, various electrical properties cannot be obtained due to poor insulation as in (b).
(D) A short circuit caused by contact with a conductive material other than a weld metal wire, generation of defective heat due to adhesion of dust or the like, deterioration of electrical characteristics, and shortening of the product life due to any of these may occur.

(E) The protrusion at the end is likely to be caught between other substances, and is likely to be broken or disconnected.
(F) Due to the protrusions at the ends, it is necessary to be cautious in handling, which is complicated in the manufacturing process and other handling.

These problems will be described with reference to the drawings.
FIG. 12 is an explanatory view showing a configuration of a weld metal wire formed by welding a metal single wire connected to a sensor and another metal wire bundle using the method disclosed in Patent Document 1. In the figure, the weld metal wires are welded to metal wire bundles 91A and 91B by metal single wires 92A and 92B connected to the sensor 98 to form welds WdA and WdB. In this method, a bundle of metal wires 91A and the like and a single metal wire 92A and the like are vertically overlapped, and a laser beam or the like is irradiated from above on the overlapping portions that are separated from the respective end portions 91TA and 92TA by a required distance. Therefore, the respective end portions 91TA, 92TA and the like remain without being welded, that is, the form exposed from the welded portions WdA, WdB is inevitably formed, and the above-described problems occur.

  The object of the present invention is to solve these problems of the prior art, and in the welding of the ends of the two metal wire parts, the insulation of the welded part can be sufficiently obtained, and the electrical characteristics such as the electric resistance value can be impaired. It is another object of the present invention to provide a welded metal wire that is excellent in preventing breakage such as disconnection, and is excellent in maintainability and handleability, and a method for manufacturing the same.

The inventor of the present application has intensively studied to solve the above problems, and found that the above problems can be solved by defining the arrangement method of the two metal wire portions and the irradiation direction of the laser or the like with respect to these methods, leading to the present invention. It was. That is, the invention claimed or disclosed in the present application is as follows.
(1) A first metal wire portion made of one or more metal strands, a second metal wire portion made of one or more metal strands, and the end portions thereof are welded to each other. A welded metal wire comprising: a welded metal wire, wherein both end portions of both metal wire portions are included in the welded portion.
(2) A substantially orthogonal cross section in the axial direction at the boundary between the welded portion and the non-welded portion of the first metal wire portion, and the axial direction at the boundary between the welded portion and the non-welded portion of the second metal wire portion The welded metal wire according to (1), characterized in that the substantially orthogonal cross sections deviate from each other or are substantially circumscribed.
(3) The first metal wire portion made of one or more metal wires, the second metal wire portion made of one or more metal wires, and the welded end portions thereof were welded to each other. A welded metal wire comprising an exposed end that can be formed when the weld end remains unwelded on the distal side thereof A welded metal wire, characterized in that there are no protrusions made of excess metal wire.
(4) The welding according to any one of (1) to (3), wherein at least one of the two metal wire portions is a metal wire bundle in a state where a plurality of metal wires are in close contact with each other. Metal wire.

(5) The first metal wire portion made of one or more metal strands and the end portions of the second metal wire portion made of one or more metal strands are overlapped with each other, and laser welding is performed thereon. Is a method of manufacturing a welded metal wire formed by welding these workpieces, forming an overlapping region in the side direction in which both side portions are juxtaposed so that the side portions are in contact with each other, Production of a welded metal wire, characterized in that a welded metal wire is obtained by irradiating a laser to the overlap region from outside the plane including the overlap region and welding the both ends. Method.
(6) The first metal wire portion is a metal wire bundle in a state where a plurality of metal strands are in close contact, and the second metal wire portion is another metal single wire or a metal wire bundle, and the first metal wire portion Is a method of manufacturing a welded metal wire in which the workpieces are welded by superimposing the end portions of the portion and the second metal wire portion and performing laser welding on the end portions, Is a superposition performed by bringing the side surface portions into contact with each other, and the angle between the line segment connecting the centers of the substantially orthogonal cross sections of the workpieces and the laser irradiation direction is within a range of 10 ° to 170 °. A method for producing a welded metal wire, characterized in that:
(6-2) An angle formed by a line segment that connects substantially orthogonal cross-sectional centers in the axial direction of the respective workpieces and a laser irradiation direction is in a range of 45 ° to 135 °, (6) A method for producing a welded metal wire according to claim 1.
(7) The welded metal wire according to (5) or (6), wherein the laser welding is performed to form a welded portion in which end surfaces of both the metal wire portions are included. Production method.

(8) The welded metal wire according to any one of (5) to (7), wherein the laser irradiation is performed on the larger one of the two workpieces to be welded. Manufacturing method.
(9) The laser irradiation is performed so that the center of the irradiation diameter hits somewhere in the inter-axis region including on each axis of both workpieces, (5) to ( 7) The method for producing a welded metal wire according to any one of 7).
(10) The method for manufacturing a welded metal wire according to any one of (5) to (9), wherein the welding method uses an electron beam or an arc instead of a laser.

  Since the welded metal wire and the manufacturing method thereof according to the present invention are configured as described above, it is possible to sufficiently obtain insulation of the welded portion in the welding between the ends of the two metal wire portions, and the electric resistance value. The electrical characteristics such as can be maintained at a high level. Further, breakage such as disconnection can be effectively prevented. In addition, these can be improved in terms of maintainability and handling.

Hereinafter, the present invention will be described in more detail using appropriate drawings. Hereinafter, “welded metal wire” is also referred to as “welded metal wire” as appropriate.
FIG. 1A and FIG. 1B are explanatory views showing a basic configuration of a welded metal wire of the present invention. Among these, FIG. 1A is a plan view showing a main part configuration of a welded metal wire, and FIG. 1B is a double metal wire before welding observed from the configuration shown in FIG. It is a top view which shows the arrangement | positioning state of a part. In these drawings, the welded metal wire includes a first metal wire portion 1 made of one or more metal wires, a second metal wire portion 2 made of one or more metal wires, and their The end portions 1T and 2T are welded to each other, and the end portions 1T and 2T of both metal wire portions are both included in the welded portion Wd. This is the main configuration (the invention of (1) above).

  Here, the metal wire portion is a concept including both a single metal wire, a plurality of the same kind of single metal wires (metal strands), and both. The former is appropriately referred to as a metal single wire, and the latter is also referred to as a metal wire bundle as appropriate. As will be described later, examples of the metal constituting these metal wire portions include Fe alloy and Cu, but the present invention is not limited by the type of metal. That is, the present invention is applicable to any metal as long as it is used for the second metal wire portion to be welded.

The end portion includes the end face of the metal wire portion and a portion of a certain length from the end surface, but is not essentially defined by the length, in short, between the metal wire portion to be joined. Thus, it suffices if the portion is sufficient to be subjected to welding so as not to leave the exposed portion described above. Examples of welding methods include lasers, electron beams, and arcs as will be described later, but the present invention is not limited by such specific welding methods. For example, the present invention can also be applied to bonding methods such as ultrasonic bonding, diffusion bonding, friction welding, electric resistance heating fusion, and pressure bonding.

  In the figure, the weld metal wire of the present invention has such a configuration, that is, the first metal wire portion 1 and the second metal wire portion 2 have both end portions 1T and 2T included in the weld portion Wd, The end portions of both metal wire portions 1 and 2 do not protrude from the welded portion Wd, and the cut end surfaces are not exposed. As a result, even if the welded portion Wd and the surrounding metal portion are coated with a resin and used, for example, as a sensor, the exposed portion does not protrude from the coated portion. The problem of a decrease in electrical resistance value accuracy due to is not caused. Even in cases other than sensor applications, sufficient insulation can be obtained, so that various electrical characteristics can be obtained.

  Furthermore, according to the configuration of the weld metal wire of the present invention, short circuit due to contact with other conductive substances, generation of trouble heat due to adhesion of dust, etc. and reduction of electrical characteristics, and further shortening of product life due to these, Can be prevented. In addition, since there is no protrusion of the end portions 1T and 2T of both metal wire portions 1 and 2, there is no occurrence of hooking between other materials, and damage and disconnection are less likely to occur than in the prior art. The complexity of the process and other handling can be eliminated.

2 (a) and 2 (b) are side views showing the side configuration of the main part of the welded metal wire of the present invention. Among these, Fig.2 (a) is a figure which shows the principal part side surface structure of the welded metal wire of this invention, and is a side view including the IIa-IIa 'arrow cut surface in FIG.1 (a). The hatched Cs1 is a substantially orthogonal cross section in the axial direction at the boundary between the welded portion and the non-welded portion of the first metal wire portion, and is a non-welded portion. Wd is a welded portion, and its side surface portion is illustrated. Moreover, FIG.2 (b) is a figure which shows the principal part side surface structure of the welded metal wire of this invention, and is a side view including the IIb-IIb 'arrow cut surface in FIG.1 (a). The hatched Cs2 is a substantially orthogonal cross section in the axial direction at the boundary between the welded portion and the non-welded portion of the second metal wire portion, and is a non-welded portion. Wd is a welded portion, and its side surface portion is illustrated.
In these drawings, the present weld metal wire is in the axial direction at the boundary between the welded portion Wd and the non-welded portion of the first metal wire portion 1 in addition to the configuration described in FIGS. 1 (a) and 1 (b). A configuration in which the substantially orthogonal cross section Cs1 and the substantially orthogonal cross section Cs2 in the axial direction at the boundary between the welded portion Wd and the non-welded portion of the second metal wire portion 2 are offset from each other or are substantially circumscribed. (Invention (2) above).

  Here, the boundary between the welded portion and the non-welded portion refers to a portion in the non-welded portion that is close to the boundary between the two. Further, “the cross sections are shifted from each other” means that the cross-sectional shapes of the first metal wire portion 1 and the second metal wire portion 2 are completely inside one other shape, for example, as in butt welding. It is said that there is a part protruding from the inside to some extent rather than being overlapped, and this includes the case where there is no overlapping part of both cross-sectional shapes and just circumscribed.

  In the drawing, the present weld metal wire has such a configuration, and therefore, at least in the welded portion Wd or in the vicinity of the welded portion Wd, both metal wire portions are arranged so that the axis thereof is non-coaxial. I can say that. Particularly, in the case of a configuration in which both cross sections are substantially circumscribed, at least in the welded portion Wd or in the vicinity of the welded portion Wd, both metal wire portions are arranged and welded so that the side surfaces thereof are in contact with each other. It can be said.

  As shown in FIG. 1A, the present weld metal wire includes a first metal wire portion 1 made of one or more metal wires and a second metal wire portion 2 made of one or more metal wires. And a welded portion Wd formed by welding the welded end portions (1T, 2T) to each other, and the welded end portion (1T, 2T) includes the welded end portion (1T, 2T). A characteristic configuration is that there is no projecting portion made of an excess metal wire including an exposed end portion that can be formed when the end portion remains without being subjected to the welding process (the invention of (3) above). That is, there is no formation of protrusions such as the exposed end portions (91TA, 91TB, 92TA, and 92TB) shown in FIG. 12, and the above-described functions and effects can be obtained.

  FIG. 3 is a perspective view of a main part showing a configuration example of a metal wire portion according to the weld metal wire of the present invention. In the figure, as at least one of the two metal wire portions 31, a metal wire bundle in which a plurality of metal strands 311 and 312 are in close contact with each other can be used (invention (4) above). That is, one of the two metal wire portions constituting the weld metal wire may be the metal wire bundle 31, or both may be the metal wire bundle 31. When both are the metal wire bundles 31, the types of the metal strands 311 constituting these may be different or the same. The metal wire bundle 311 and the like are in close contact with each other as disclosed in Patent Document 1 (Japanese Patent Laid-Open No. 2003-80334), such as twisting, knitting, ultrasonic vibration, arc, laser, electron beam, and electricity. It can be formed by converging the plurality of metal strands 311 and the like by resistance heating, pressure bonding, heat fusion, or other appropriate methods.

  In the figure, the seven metal strands 311, 312, 313, 314, 315, 316 and 317 are illustrated in a state where the cross-sectional shape is twisted into a substantially circular shape and is in close contact, but the metal strand used The shape of the cross section formed by the close contact (that is, the aggregate form of the metal strands) and the close contact method are not limited to the examples in the figure. That is, the number of metal strands may be less than 7, such as 2, 3, etc., or may be as large as 9, 12, 19, etc. The cross-sectional shape may be a substantially elliptical shape. Further, the close contact may be obtained using any of the methods disclosed in Patent Document 1 or may be obtained using other known methods.

  For example, when a metal single wire coupled to a sensor is joined to a lead wire, the metal wire portion related to the weld metal wire is a combination of a metal single wire and a metal wire bundle.

  4 (a) to 4 (c) are explanatory views showing a method for producing a welded metal wire according to the present invention, in which FIG. 4 (a) is a plan view showing the previous stage of the method, and FIG. 4 (b). Is a side view, and FIG. 4C is a plan view showing a state after using the method. In these drawings, in the present manufacturing method, the end portions 41T and 42T of the first metal wire portion 41 made of one or more metal strands and the second metal wire portion 42 made of one or more metal strands. The welded metal wire 40 is manufactured by welding the workpieces 41 and 42 by superimposing them and applying laser welding thereto. In particular, the side portions of the end portions 41T and 42T are in contact with each other. To form the overlapping region S in the side surface direction (FIG. 4A), and for welding the overlapping region S from the outside of the plane P including the overlapping region S. The two metal wire portions 41 and 42 are welded to each other through a process of welding the both end portions 41T and 42T by irradiating a laser using a laser emitting device 43 or the like (FIG. 4B), and a welded portion Wd4. Formed welded Genus line 40 is obtained (FIG. 4 (c), the invention described in (5)).

  The main welding metal wire 40 manufactured in this way is provided with the configuration and operational effects of the present welding metal wire described with reference to FIGS. 1 (a) and 1 (b) and FIGS. 2 (a) and 2 (b). It becomes. The first metal wire portion 41 in the illustrated example has a configuration of a metal wire bundle in which seven metal wires 411, 412, 413, 414, 415, 416 and 417 are in close contact with each other. Needless to say, the configuration is not limited to this.

  In FIG. 4B, reference numeral 43 denotes a welding laser emitting device. However, as will be described later, when welding is performed using an electron beam or an arc instead of a laser, the welding electron beam emitting device and the welding arc are respectively used. An emission device is used.

  Fig.5 (a) is explanatory drawing explaining another structure of this welding metal wire manufacturing method from a cross-sectional direction. FIG. 5B is an explanatory diagram for explaining the effect of setting the laser irradiation angle. In these drawings, the present method is such that the first metal wire portion 51 is a metal wire bundle in which a plurality of metal strands 511, 512, etc. are in close contact, and the second metal wire portion 52 is another metal single wire or It is a metal wire bundle, and the workpieces 51 and 52 are welded by overlapping the end portions 51T and 52T of the first metal wire portion 51 and the second metal wire portion 52 and performing laser welding on them. However, the end portions 51T and 52T are overlapped by bringing their side portions into contact with each other, and the axial direction of each of the workpieces 51 and 52 is substantially the same. The laser L is irradiated so that the angle θ formed by the line segment C1C2 connecting the orthogonal cross-sectional centers C1 and C2 and the irradiation direction of the laser L is within a range of 10 ° to 170 ° ((6 ) Invention). The metal wire bundle 51 in the illustrated example has a configuration in which seven metal strands 511, 512, 513, 514, 515, 516 and 517 are in close contact, but the configuration of the metal wire bundle is not limited to this. This is the same as described with reference to FIG.

  The method of irradiating the laser L as described above in FIGS. 5A and 5B will be further described. When the angle between the line segment C1C2 connecting the center of the cross section and the laser L irradiation direction is less than 10 ° or more than 170 °, the laser L is irradiated from an extremely shallow angle. The probability of hitting the surface on the side opposite to the part CT in contact with the contact CT increases. This is because the cross-sectional shapes of both metal line portions 51 and 52 are both substantially circular or oval, that is, a solid shape having a raised central portion, and laser L irradiation at a too shallow angle. This is because it can be a barrier against irradiation of the contact site CT. If it does so, the heat transfer efficiency in this contact part CT of both the metal wire parts 51 and 52 will worsen, and it will cause the fall of welding efficiency and workability | operativity (refer the comparative examples 5 and 6 in a postscript Example).

  On the other hand, by setting the angle within the range of 10 ° to 170 °, the excessive shallowness of the angle in the irradiation of the laser L is eliminated or reduced. The probability that 51 and 52 hit the surface on the opposite side to the contact part CT is low. That is, the obstacle to the irradiation to the contact part CT is eliminated or reduced. If it does so, the heat transfer efficiency in this contact part CT of both the metal wire parts 51 and 52 will become good, and the fall of welding efficiency and the fall of workability | operativity will be eliminated or reduced.

  As shown in FIG. 5B, the angle formed between the line segment C1C2 connecting the centers of the substantially orthogonal cross sections in the axial direction of the respective workpieces and the irradiation direction of the laser L is 45 ° or more and 135 ° regardless of the above description. (Invention (6-2) above). By adopting such an angle range, the excessive shallowness of the angle in the irradiation of the laser L is further eliminated, so that the laser L hits the surface opposite to the contact part CT with both the metal line portions 51 and 52. The probability is substantially zero. That is, the obstacle to the irradiation to the contact part CT is eliminated. If it does so, the heat transfer efficiency in this contact part CT of both the metal wire parts 51 and 52 will become good, and the fall of welding efficiency and the fall of workability | operativity will be further eliminated.

  According to the weld metal wire manufacturing method of the present invention described above, a welded portion in which end surfaces of both metal wire portions are included is formed by the laser welding process (the invention of (7) above). That is, the laser welding process is performed so that the end faces of the two metal wire portions are included in the welded portion and no exposed end portion is generated.

  5 (a) and 5 (b), L represents laser irradiation. However, as will be described later, the description of the case of welding using an electron beam or an arc instead of a laser will be described with respect to electron beam irradiation and arc irradiation, respectively. These figures can be used by replacing

  FIG. 6 is an explanatory view explaining the laser irradiation method in the weld metal wire manufacturing method of the present invention from the cross-sectional direction. In the figure, in this method, laser irradiation by the welding laser emitting device 63 or the like can be performed on the larger one of the cross-sectional areas of the two workpieces 61 and 62 ((8) above). Invention). In the example of the figure, the metal wire portion 61 has a larger cross-sectional area, and shows the state in which the angle and position of the welding laser emitting device are set so that the laser is irradiated to the metal wire portion 61. Yes.

  The reason for irradiating the larger cross-sectional area is as follows. That is, the molten volume by laser irradiation is larger in the metal wire portion having a larger cross-sectional area. Therefore, the laser irradiation on the metal wire portion generates a larger amount of molten metal, which can sufficiently wrap the end portion of the other small-diameter metal wire portion, and can realize sufficient bonding. In other words, in this case, the degree of welding becomes more complete when the amount of molten metal provided for welding with respect to the amount of the portion to be welded is large, and this is also related to the strength of the welded portion. By irradiating the large-diameter metal wire portion with laser, the welding effect can be enhanced and the strength of the welded portion can be increased.

  As shown in FIG. 6, in the weld metal wire manufacturing method of the present invention, the center of the laser irradiation diameter hits anywhere in the inter-axis region D including the respective axes of the workpieces 61 and 62. Thus, laser irradiation can be performed using the laser emitting device 63 for welding or the like (the invention of (9) above). When comparing the inter-axis region D with the outer regions E1 and E2 of D, the region where the metal wire portions 61 and 62 are welded is of course D. And heat transfer in welding is performed more efficiently as the transfer distance is shorter. Therefore, by performing laser irradiation so that the center of the irradiation diameter hits in the inter-axis region D, the laser is irradiated to D which is a region where both the metal wire portions 61 and 62 are in contact with each other. Heat transfer is efficiently performed at the contact portion CT, and both the metal wire portions 61 and 62 can be melted and melted together, so that the welding effect and efficiency are increased, and the strength of the welded portion can be increased.

  In FIG. 6, reference numeral 63 denotes a welding laser emission device. However, as will be described later, when welding is performed using an electron beam or an arc instead of a laser, a welding electron beam emission device and a welding arc emission device are provided. Used.

  As mentioned above, although the welding metal wire manufacturing method of this invention using laser welding was demonstrated, the welding method which can be used in this invention is not limited to laser welding. That is, it is possible to use an electron beam or arc welding instead of the laser, or any other appropriate welding method (the invention of (10) above). For example, ultrasonic bonding, diffusion bonding, friction welding, electric resistance heating fusion, pressure bonding, and the like.

FIGS. 7A to 7C are plan views showing examples other than those described above with respect to the contact method of the second metal wire portion in the weld metal wire manufacturing method of the present invention.
In FIG. 7A, a convex portion 724 is provided at a welding target portion (end portion) of one metal wire portion 72A, this is placed in contact with the end portion of another metal wire portion 71B, and a welding process is performed. It is an example. In the figure, the convex portion 724 is provided on the metal wire portion 72A having a relatively small diameter. However, when the cross-sectional areas of the two metal wire portions are different, the metal wire portion 71A having a large diameter may be provided.

FIG. 7B is an example in which one metal wire portion 72B is bent and its end portion is placed side by side in contact with the end portion of the other metal wire portion 72A to perform a welding process. When the cross-sectional areas of the two metal wire portions are different, the large-diameter metal wire portion 71B may be bent in the opposite direction to the example shown in the drawing.
FIG. 7C is an example in which both metal wire portions 71C and 72C are bent, the respective end portions are brought into contact with each other, and the welding process is performed.
In this way, at the overlapping part where the welded part is melted, it is necessary to place it in parallel or at least a contact point, but in a place away from the overlapping part, the line and the bundle are processed in any form. It does not matter if it has been done.

EXAMPLES Hereinafter, although an Example demonstrates this invention further in detail, this invention is not limited to these Examples.
Example 1 Welded metal wire by YAG laser welding (part 1)
Preparation of welded metal wire After removing the covering tube for a length of about 5 mm from the end of a metal wire bundle consisting of seven copper wire strands having a wire diameter of 0.2 mm inserted into an insulation-coated tube, the metal wire bundle Each wire was closely twisted, and an Fe alloy single wire having a wire diameter of 0.2 mm and a tip portion were overlapped, and a welding test using a pulsed YAG laser was performed. The overlapping length was 1 mm. The angle formed between the line segment connecting the cross-sectional center of the metal wire bundle and the cross-sectional center of the Fe alloy single wire and the YAG laser irradiation direction was changed. The YAG laser was a single shot with a pulse width of 8 ms, and irradiation was performed by changing the pulse energy with just focus.

Strength evaluation The strength evaluation of the welded part was performed based on whether or not the base metal was broken by a tensile test.

Insulation performance evaluation The welded part and the surrounding metal part were subjected to resin coating treatment, and then the part was submerged, and the insulation resistance value was measured in a state where DC 500 V was applied between the metal wire bundle and water. If the end of the weld is exposed, it is measured that the current flows in water and insulation is insufficient. Therefore, the insulation resistance value of less than 100 MΩ is rejected, and the value higher than that is acceptable. did.
Table 1 summarizes the weld metal wire production conditions of Example 1 and the evaluation results thereof.

  FIG. 8 is a photomicrograph showing the state before welding of the weld metal wire of Example 1-1, and FIG. 9 is after welding as seen from the laser irradiation side (front side) of the weld metal wire of Example 1-1. FIG. 10 is a photomicrograph showing the state after welding as seen from the back side. As shown in these figures, it was confirmed by microscopic observation that the metal wire bundle and the alloy single wire were welded with the formation of a complete weld by laser welding under the conditions of Example 1-1. Moreover, exposure of the end portions of the metal wire bundle and the alloy single wire was not recognized at all, and both ends were welded in the welded portion. Although the photographic diagram relates to Example 1-1, the same results were obtained in each of Examples 1-2, 1-3, 1-4, 1-5, and 1-6. Also in this example, it was shown that there is no end portion exposure and welding is performed in which a complete weld is formed.

  As shown in Table 1, it was possible to obtain a weld metal wire that gave good results in both welding strength and insulation resistance value in a wide angle range of laser irradiation angles of 15 ° to 165 °. In other words, if the laser irradiation angle is set within the above range and the laser irradiation center position is set within the inter-axis region between the metal wire bundle and the alloy single wire, the weld will not break in the tensile test, and insulation A weld metal wire having a good resistance value of 100 MΩ or more was obtained.

  On the other hand, in all of Comparative Examples 1-1 to 1-6, the welded portion was broken in the tensile test, and the insulation resistance value was also less than 100 MΩ, and good results were obtained in both the welding strength and the insulation resistance value. The given weld metal wire could not be obtained. Considering conditions different from those of Example 1-1 and the like in these comparative examples, Comparative Examples 1-1, 1-2, 1-5, and 1-6 have laser irradiation angles of less than 10 ° or 170 ° or more. It was set. In Comparative Examples 1-3 and 1-4, the laser irradiation center position was set outside the inter-axis region.

  In these comparative examples, good evaluation was not obtained because, under such conditions, the molten volume of the molten metal generated by laser irradiation was small, so that the area to be welded was small, and the strength of the welded portion was small. This is thought to be due to a decline. Moreover, both ends were not completely melted and remained, resulting in a welding finish in which the ends were exposed from the weld after the resin coating. For this reason, it is considered that the measured insulation resistance value showed a defect value of less than 100 MΩ.

<Example 2 Welded metal wire by electron beam welding>
A weld metal wire was prepared and evaluated under the same conditions as in Example 1 except that an electron beam was used instead of the YAG laser. The electron beam irradiation was performed by adjusting the voltage and current so that the energy was almost equal to that in the case of the laser of Example 1.
Table 2 summarizes the weld metal wire production conditions of Example 2 and the evaluation results thereof.

  In each of the specific examples 2-1, 2-2, 2-3, 2-4, 2-5, and 2-6 in the present example, the same results as in Example 1 were obtained. Also in the example, it was shown by microscope observation that there is no end exposure and a weld with a complete weld is formed.

  As shown in Table 2, it was possible to obtain a weld metal wire that gave good results in both the welding strength and the insulation resistance value in a wide angle range of an electron beam irradiation angle of 15 ° to 165 °. That is, when the electron beam irradiation angle is set within the above range, and the irradiation center position of the electron beam is set within the interaxial region of the metal wire bundle and the alloy single wire, the weld does not break in the tensile test, In addition, a weld metal wire having a good insulation resistance value of 100 MΩ or more was obtained.

  On the other hand, in all of Comparative Examples 2-1 to 2-6, the welded portion was broken in the tensile test, and the insulation resistance value was less than 100 MΩ, and good results were obtained in both the welding strength and the insulation resistance value. The given weld metal wire could not be obtained. Considering conditions different from those of Example 2-1 and the like in these comparative examples, Comparative Examples 2-1, 2-2, 2-5, and 2-6 have laser irradiation angles of less than 10 ° or 170 ° or more. It was set. In Comparative Examples 2-3 and 2-4, the irradiation center position of the electron beam was set outside the inter-axis region.

  The reason why good evaluation was not obtained in these comparative examples is considered to be the same reason as in Example 1 described above.

Example 3 Welded metal wire by arc welding
A weld metal wire was prepared and evaluated under the same conditions as in Example 1 except that an arc was used instead of the YAG laser. The arc irradiation was performed by adjusting the voltage and current so that the energy was almost equal to that in the case of the laser of Example 1.
Table 3 summarizes the weld metal wire production conditions of Example 3 and the evaluation results thereof.

  In each of the specific examples 3-1, 3-2, 3-3, 3-4, 3-5, and 3-6 in the present example, the same results as in the first and second examples were obtained. In any of the examples, it was shown by microscopic observation that the end portion was not exposed and a weld with a complete weld portion was formed.

  As shown in Table 3, a weld metal wire that gave good results in both welding strength and insulation resistance value could be obtained in a wide angle range of arc irradiation angles of 15 ° to 165 °. In other words, when the arc irradiation angle is set within the above range and the arc irradiation center position is set within the inter-axis region between the metal wire bundle and the alloy single wire, the weld will not break in the tensile test and insulation A weld metal wire having a good resistance value of 100 MΩ or more was obtained.

  On the other hand, in Comparative Examples 3-1 to 3-6, the welded part was broken in the tensile test, and the insulation resistance value was less than 100 MΩ, and good results were obtained in both the welding strength and the insulation resistance value. The given weld metal wire could not be obtained. Considering conditions different from those of Example 3-1 and the like in these comparative examples, Comparative Examples 3-1, 3-2, 3-5, and 3-6 have laser irradiation angles of less than 10 ° or 170 ° or more. It was set. In Comparative Examples 3-3 and 3-4, the irradiation center position of the arc was set outside the inter-axis region.

  The reason why good evaluation was not obtained in these comparative examples is considered to be the same reason as in Example 1 described above.

Example 4 Welded Metal Wire by YAG Laser Welding (Part 2)
Example 1 except that a metal wire bundle having 12 copper wires having a wire diameter of 0.2 mm inserted in an insulation-coated tube and a Fe alloy single wire having a wire diameter of 0.4 mm was used. Welded metal wires were prepared and evaluated under the conditions.
Table 4 summarizes the weld metal wire production conditions of Example 4 and the evaluation results thereof.

  Also in each of the concrete examples 4-1, 4-2, 4-3, 4-4, 4-5, 4-6 in the present embodiment, in which both the metal wire bundle and the alloy single wire are larger in size than the embodiment 1, The results similar to those of Example 1, Example 2, and Example 3 were obtained. In any of the examples, it was confirmed by microscopic observation that there was no end portion exposure and welding with which a complete weld was formed. Indicated.

  As shown in Table 4, it was possible to obtain a weld metal wire that gave good results in both welding strength and insulation resistance value in a wide angle range of laser irradiation angles of 15 ° to 165 °. In other words, if the laser irradiation angle is set within the above range and the laser irradiation center position is set within the inter-axis region between the metal wire bundle and the alloy single wire, the weld will not break in the tensile test, and insulation A weld metal wire having a good resistance value of 100 MΩ or more was obtained.

  On the other hand, in all of Comparative Examples 4-1 to 4-6, the welded portion was broken in the tensile test, and the insulation resistance value was less than 100 MΩ, and good results were obtained in both the welding strength and the insulation resistance value. The given weld metal wire could not be obtained. Considering conditions different from those of Example 4-1 and the like in these comparative examples, Comparative Examples 4-1, 4-2, 4-5, and 4-6 have laser irradiation angles of less than 10 ° or 170 ° or more. It was set. In Comparative Examples 4-3 and 4-4, the laser irradiation center position was set outside the inter-axis region.

  The reason why good evaluation was not obtained in these comparative examples is considered to be the same reason as in Example 1 described above.

<Example 5 Temperature sensor and lead wire welding>
FIG. 11 is a perspective view of a weld metal wire obtained by laser welding a temperature sensor and a lead wire under the same conditions as in Example 1-6. Good results were obtained in both welding strength and insulation resistance, and there was no exposed end as shown in the conventional example of FIG. 12, and a weld metal wire with excellent maintainability and handleability was obtained. It was.

  As described above, according to the welded metal wire and the manufacturing method thereof of the present invention, the insulation of the welded portion can be sufficiently obtained by a relatively simple technique without impairing the electrical characteristics such as the electrical resistance value. In addition, a weld metal wire having excellent welding strength can be obtained. The obtained welded metal wire is also excellent in preventing breakage such as disconnection, excellent in maintainability and handleability, and is an invention with extremely high industrial applicability.

It is a top view which shows the principal part structure of the welded metal wire. It is a top view which shows the arrangement | positioning state of the both metal wire parts before welding seen from the structure shown to Fig.1 (a). It is a figure which shows the principal part side surface structure of the welded metal wire of this invention, and is a side view containing the IIa-IIa 'arrow cut surface in Fig.1 (a). Cs1 to which hatching is given is a substantially orthogonal cross section in the axial direction at the boundary portion between the welded portion and the non-welded portion of the first metal wire portion, and is a non-welded portion. Wd is a welded portion, and its side surface portion is illustrated. It is a figure which shows the principal part side surface structure of the welded metal wire of this invention, and is a side view containing the IIb-IIb 'arrow cut surface in Fig.1 (a). The hatched Cs2 is a substantially orthogonal cross section in the axial direction at the boundary between the welded portion and the non-welded portion of the second metal wire portion, and is a non-welded portion. Wd is a welded portion, and its side surface portion is illustrated. It is a principal part perspective view which shows the structural example of the metal wire part concerning this invention weld metal wire. It is a top view which shows the manufacturing method of the welded metal wire of this invention which shows this method front stage. It is a side view which shows the manufacturing method of the welded metal wire of this invention. It is a top view which shows the state after using this method regarding the manufacturing method of the welded metal wire of this invention. It is explanatory drawing explaining another structure of this welding metal wire manufacturing method from a cross-sectional direction. It is explanatory drawing explaining the effect of a laser irradiation angle setting. It is explanatory drawing explaining the laser irradiation method in this invention weld metal wire manufacturing method from the cross-sectional direction. It is the top view which showed the example except having mentioned above about the contact method of the 2nd metal wire part in the weld metal wire manufacturing method of this invention. It is the top view which showed the other contact method of the same 2 metal wire part. It is the top view which showed the other contact method of the same 2 metal wire part. It is a microscope picture figure which shows the state before welding of the weld metal wire of Example 1-1. It is a microscope picture figure which shows the state after the welding seen from the laser irradiation side (front side) of the welding metal wire of Example 1-1. It is a microscope picture figure which shows the state after the welding seen from the laser irradiation opposite side (back side) of the welding metal wire of Example 1-1. It is a perspective view of the welding metal wire obtained by laser-welding a temperature sensor and a lead wire on the same conditions as Example 1-6. It is explanatory drawing which shows the structure of the welding metal wire by a prior art.

Explanation of symbols

1, 41, 51, 61 ... 1st metal wire part 2, 42, 52, 62 ... 2nd metal wire part Wd, Wd4 ... Welded part 1T, 2T, 41T, 42T, 51T, 52T ... of metal wire part End portion Cs1... Substantially orthogonal cross section Cs2 at the boundary between the welded portion and the non-welded portion of the first metal wire portion, approximately the axial direction at the boundary between the welded portion and the non-welded portion of the second metal wire portion Orthogonal cross section 31 ... Metal wire part (metal wire bundle)
311, 312, 313, 314, 315, 316, 317 ... metal wire 40 ... weld metal wire 43, 63 ... welding laser (electron beam, arc) emitting device 411, 412, 413, 414, 415, 416, 417 ... Metal wire S ... Superposition region P ... Plane L including superposition region ... Laser (electron beam, arc) irradiation,
CT ... contact part 511, 512, 513, 514, 515, 516, 517 ... metal element wire C1C2 ... line segment C1C2 (straight line C1C2)
D ... interaxial region E1, E2 ... interaxial region outside region 71A, 71B, 71C ... first metal wire portion 72A, 72B, 72C ... second metal wire portion 724 ... convex portion 80 ... sensors 81A, 81B ... metal Wire bundles 82A, 82B ... Metal single wires 85A, 85B ... Insulation coated tube 98 ... Sensors 91A, 91B ... Metal wire bundles 92A, 92B ... Metal single wires 95A, 95B ... Insulation coated tubes WdA, WdB ... Welds 91TA, 92TA, 91TB, 92TB ... End exposed from weld

Claims (10)

A first metal wire portion made of one or more metal strands, a second metal wire portion made of one or more metal strands, and a welded portion formed by welding the end portions thereof. A welded metal wire comprising: a welded metal wire, wherein both end portions of both metal wire portions are included in the weld portion. A substantially orthogonal cross section in the axial direction at the boundary portion between the welded portion and the non-welded portion of the first metal wire portion, and a substantially orthogonal cross section in the axial direction at the boundary portion between the welded portion and the non-welded portion of the second metal wire portion. The welded metal wires according to claim 1, characterized in that they are offset from each other or substantially circumscribed. A first metal wire portion made of one or more metal strands, a second metal wire portion made of one or more metal strands, and a weld portion formed by welding their weld ends to each other; A welded metal wire comprising an exposed end that can be formed when the weld end remains unwelded at the distal end thereof A welded metal wire, characterized in that there are no protrusions made of wire. The welded metal wire according to any one of claims 1 to 3, wherein at least one of the two metal wire portions is a metal wire bundle in a state where a plurality of metal wires are in close contact with each other. By superimposing the ends of the first metal wire portion made of one or more metal wires and the second metal wire portion made of one or more metal wires, and applying laser welding thereto, these A method of manufacturing a welded metal wire formed by welding an object to be welded, wherein both end portions are juxtaposed so that the side surface portions are in contact with each other to form an overlapping region in the side surface direction, and the overlapping A method for producing a welded metal wire, characterized in that a welded metal wire is obtained by irradiating a laser to the overlapping region from outside a plane including the region and welding the both ends. The first metal wire portion is a metal wire bundle in which a plurality of metal strands are in close contact, and the second metal wire portion is another metal single wire or a metal wire bundle, and the first metal wire portion and the first metal wire portion A method for producing a welded metal wire in which the welded objects are welded by superimposing ends of two metal wire portions and performing laser welding on the end portions, and superimposing the end portions Is a superposition performed by bringing the side surfaces into contact with each other, and the angle between the line connecting the centers of the substantially orthogonal cross sections of the workpieces and the laser irradiation direction is within the range of 10 ° to 170 °. A method for producing a welded metal wire, characterized by: The method for manufacturing a welded metal wire according to claim 5 or 6, wherein the laser welding is performed to form a welded portion in which end faces of both the metal wire portions are included. The method of manufacturing a welded metal wire according to any one of claims 5 to 7, wherein the laser irradiation is performed on one of the two workpieces having a larger cross-sectional area. The laser irradiation is performed so that the center of the irradiation diameter hits anywhere in an inter-axis region including on each axis of both workpieces. A method for producing a welded metal wire according to claim 1. 10. The method for producing a welded metal wire according to claim 5, wherein the welding method uses an electron beam or an arc instead of the laser.

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