# Patent

## Title
Recessed resin tips used in a connecting method

## Abstract

A connecting method of connecting covered wires with each other and recessed resinous tips used in the method are provided. In the method, it is executed at the first step to put a connecting part constituted by a shield wire and a ground wire between a first resin tip and a second resin tip. The first resin tips has, around the connecting part, first recessed parts for accommodating the molten cover of the shield wire and second recessed parts for accommodating the molten cover of the ground wire. The second resin tip has second recessed parts formed for accommodating the molten cover of the ground wire.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a division of application Ser. No. 09/575,676, filed Jun. 22, 2000, now U.S. Pat. No. 6,598,293 which is incorporated herein by reference.


STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
Not Applicable
REFERENCE TO A MICROFICHE APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
Description of Related Art
Japanese Patent Publication No. 7-320842 discloses a connecting method of two different covered wires as shown in FIGS. 1A and 1B. The shown method is related to a connection between a shield wire W1 and a ground wire W2. The shield wire W1 has a core line 14 as a conductive part covered with a resinous cover 8 and a shielding braided wire 13 as another conductive part which covers the resinous cover 8 and is also covered with another resinous cover 7. While, the ground wire W2 has a core line 15 as a conductive part covered with a resinous cover 9.
In order to connect the shield wire W1 with the ground wire W2, it is executed at the first step to put the connecting (overlapping) part defined by the wire W1 and the wire W2 between a pair of resinous tips 1, 3. In detail, the resinous tip 3 is inserted into an anvil 5 and subsequently, the shield wire W1 is inserted into the anvil 5 and put on the resinous tip 3. Further, the ground wire W2 is inserted and put on the inserted shield wire W1 and finally, the other resinous tip 1 is laid on the ground wire W2.
At the second step, it is carried out to partially remove the resinous covers 7, 9 of the wires W1, W2 by heating the connecting part defined by the wires W1, W2 under pressure and further seal the resulting connecting part by welding the resinous tips 1, 3 each other. In detail, a horn 11 is inserted from the upside of the resinous tip 1 and continuously, the tips 1, 3 are heated due to ultrasonic oscillations between the horn 11 and the anvil 5 under pressure. Owing to the generation of heat by the ultrasonic oscillations, the covers 7, 9 are molten at the connecting part, so that the braided wire 13 of the shield wire W1 and the core line 15 of the ground wire W2 are exposed together.
While, the so-molten covers 7, 9 are pushed out of the resinous tips 1, 3 through a clearance therebetween, so that the braided wire 13 comes into electrical contact with the core line 15. With further continuation to both oscillate and pressurize, the resinous tips 1, 3 are molten for their integration, so that the connecting part can be sealed as shown in FIG. 1B.
In the above-mentioned connecting method, however, there is a possibility that the shield wire's portion close to the resinous tips 1, 3, i.e., a part 17, is influenced by the heat of the resinous covers 7, 9 pushed out of the resin tips 1, 3 (see FIG. 1B), thereby causing the deterioration of insulation effect, the disconnection of conductive wire, the deterioration of bending, etc.
FIG. 2 shows respective sections of the shield wire W1 and the ground wire W2 in their sealed connection which is somewhat different from the previously-mentioned connecting structure. Shown in the figure is a condition where a resin 19 resulting from the melting of the ground wire W2 is pushed out from the clearance between the resinous tips 1, 3, so that the ground wire W2 is damaged at its part 21 close to the tips 1, 3 by the heat of the so-pushed resin 19, causing the exposure of the core line 15.
Therefore, also in this case, there may be caused problems of the deterioration of insulation effect of the cover 9 at a part of the ground wire W2, the disconnection of the core line 15 and the deterioration of bending, too.
FIELD OF THE INVENTION
The present invention relates to a connecting method of connecting two different wires to each other, for example, an electrical connection between a shield wire and a ground wire, and also relates to a pair of recessed resin tips which are appropriate in the connecting method.
BRIEF SUMMARY OF THE INVENTION
Under the circumstances, it is therefore an object of the present invention to provide a connecting method of connecting covered wires with each other, by which it is possible to prevent the molten insulating covers from being pushed out of the resin tips. Further, it is another object of the invention to provide resin tips which are appropriate in connecting the covered wires in accordance with the above method.
The former object of the present invention described above can be accomplished by a connecting method of connecting a first wire with a second wire, the first wire having a first conductive wire covered with a first insulating cover, the second wire having a second conductive wire covered with a second insulating cover, the connecting method comprising:

    
    
        a first step of putting a connecting part constituted by both of the first and second wires, between a first resin tip and a second resin tip; and
        a second step of heating the connecting part through the first and second resin tips under pressure thereby to remove the first and second insulating covers from the connecting part while welding the first and second resin tips together thereby to sealing the connecting part. In the method, at least either one of the first and second resin tips is provided, on both sides of the connecting part, with first recessed parts. While, at least either one of the first and second resin tips is provided, on both sides of the connecting part, with second recessed parts. Thus, the molten first insulating cover of the first wire is accommodated in the first recessed parts at the second step, while the molten second insulating cover of the second wire is accommodated in the second recessed parts at the second step.
    
    


In this way, it is possible to restrict the first and second covers of the first and second wires from being pushed out of the integrated resin tips, thereby avoiding the damage on the first and second wires due to heat of the so-pushed covers.
In this way, the exposure of the first and second conductive wires outside the first and second resin tips is restricted, so that the bending capabilities of the first and second wires can be maintained without causing the deterioration of insulation effect and the disconnection of the first and second conductive wires, etc.
Additionally, since the molten and removed first and second insulating covers are accommodated in the first recessed parts and the second recessed parts smoothly, it is possible to accomplish the shortage of welding time and the reduction in the number of working processes.
According to the present invention, the latter object of the invention can be accomplished by a combination of first and second resin tips which are usable in a connecting method of connecting a first wire with a second wire, the first wire having a first conductive wire covered with a first insulating cover, the second wire having a second conductive wire covered with a second insulating cover, the connecting method comprising a first step of putting a connecting part constituted by both of the first and second wires, between a first resin tip and a second resin tip and a second step of heating the connecting part through the first and second resin tips under pressure thereby to remove the first and second insulating covers from the connecting part while welding the first and second resin tips together thereby to sealing the connecting part. In this invention, the combination comprises first recessed parts formed at least either one of the first and second resin tips and arranged on both sides of the connecting part, for accommodating the molten first insulating cover of the first wire therein and second recessed parts formed at least either one of the first and second resin tips and arranged on both sides of the connecting part, for accommodating the molten second insulating cover of the second wire.
In the above-mentioned combination, preferably, the first recessed parts and the second recessed parts are continuously formed in one of the first and second resin tips so as to surround the connecting part in annular.
In this case, the molten first insulating cover can flow from the first recessed parts into the second recessed parts or conversely, the molten second insulating cover part can flow from the second recessed parts into the first recessed parts, accomplishing the smooth accommodation of the molten covers.
In the above-mentioned combination, more preferably, the second recessed parts are formed in the other of the first and second resin tips.
In this case, it is possible to accommodate the molten second insulating cover of the second wire more smoothly.
According to the invention, there is also provided a combination of first and second resin tips which are usable in a connecting method of connecting a first wire with a second wire, the first wire having a first conductive wire covered with a first insulating cover, the second wire having a second conductive wire covered with a second insulating cover, the connecting method comprising a first step of putting a connecting part constituted by both of the first and second wires, between a first resin tip and a second resin tip; and a second step of heating the connecting part through the first and second resin tips under pressure thereby to remove the first and second insulating covers from the connecting part while welding the first and second resin tips together thereby to sealing the connecting part.
The above invention is characterized in that the first and second resin tips have respective drawing parts formed to accommodate the first wire to be drawn out of the first and second resin tips, the drawing parts have diameters gradually increased toward the outside ends of the drawing parts.
Then, even if the first wire shakes, the above-mentioned configurations of the first and second resin tips allow the first wire to come into surface contact with the drawing parts in their weakened “edge” effect. Therefore, it is possible to improve the tips' force to retain the first wire at the connecting part and also the bending capability of the first wire in relation to the first and second resin tips.
According to the invention, there is also provided a pair of resin tips used for connecting conductive parts of two different covered wires with each other while removing insulating covers of the wires. In the invention, the pair comprises a first resin tip having a welding part formed at an intermediate portion thereof, first recessed parts formed on both sides of the welding part and second recessed parts also formed on both sides of the welding part, the first and second recessed parts being continuously arranged around the welding part and a second resin tip having recessed parts formed corresponding to the second recessed parts of the first resin tip.
Also in this invention, the operation and effects brought by the pair of resin tips are similar to those brought by the above-mentioned combination of the first and second resin tips.
Also in this invention, preferably, the welding part of the first resin tip has a semicircular-shaped recessed part formed for accommodating one of the wires and semicircular-shaped stepped parts arranged on both sides of the recessed part and also formed deeper than the semicircular-shaped recessed part.
Then, it is possible to restrict the first and second covers of the first and second wires from being pushed out of the integrated resin tips, thereby avoiding the damage on the first and second wires due to heat of the so-pushed covers.
Also in this invention, more preferably, the first and second resin tips have respective drawing parts formed to accommodate one of the wires to be drawn out of the first and second resin tips, the drawing parts have diameters gradually increased toward the outside ends of the drawing parts.
Similarly, it is possible to improve the tips' force to retain the first wire at the connecting part and also the bending capability of the first wire in relation to the first and second resin tips.
These and other objects and features of the present invention will become more fully apparent from the following description and appended claims taken in conjunction with the accompany drawings.



BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are perspective views for explanation of the connecting method in the earlier art, in which FIG. 1A is a perspective view showing the first step of the method and FIG. 1B is a perspective view showing the resulting connecting structure;
FIG. 2 is a sectional view of the connecting structure for explanation of its problems;
FIG. 3A is a perspective view of an upper resinous tip in accordance with the first embodiment of the invention, showing a condition to arrange its recessed lower face upward;
FIG. 3B is a perspective view of a lower resinous tip in accordance with the first embodiment of the invention, showing a condition to arrange its recessed upper face upward;
FIG. 4 is a perspective view of the integrated upper and lower resinous tips under their sealed condition;
FIG. 5 is a sectional view of the integrated tips, taken along a line 5—5 of FIG. 4.
FIG. 6 is a sectional view of the integrated tips, taken along a line 6—6 of FIG. 4.
FIG. 7A is a perspective view of an upper resinous tip in accordance with the second embodiment of the invention, showing a condition to arrange its recessed lower face upward;
FIG. 7B is a sectional view of FIG. 7A;
FIG. 7C is a perspective view of a lower resinous tip in accordance with the second embodiment of the invention, showing a condition to arrange its recessed upper face upward; and
FIG. 8 is a sectional view of the integrated tips of the second embodiment, for explanation of the operation of the integrated tips.



DESCRIPTION OF THE PREFERRED EMBODIMENT
Embodiments of the present invention will be described with reference to the drawings.
FIGS. 3A and 3B shows upper and lower resin tips in accordance with the first embodiment. FIG. 3A is a perspective view of the upper resin tip showing its recessed face directing upward. FIG. 3B is a perspective view of the lower resin tip showing its recessed face directing upward.
The upper resin tip 31 has a welding part 33 formed at its intermediate portion. The welding part 33 includes a semicircular-shaped recessed part 33a for accommodating the connecting part of the shield wire W1 (FIG. 4) and the ground wire W2 (FIG. 4) and stepped parts 33b, 33b arranged on both sides of the recessed part 33a in a direction to draw out the shield wire W1. The stepped parts 33b, 33b are also semicircular-shaped in sections. The depth of each stepped part 33b is larger than that of the recessed part 33a. Around the welding part 33 of the upper resin tip 31, first recessed parts 35a, 35b are respectively defined on both sides of the welding part 33 in the direction to draw out the shield wire (first wire) W1. While, second recessed parts 37a, 37b are respectively defined on both sides of the welding part 33 in the direction to draw the ground wire (second wire) W2.
These first recessed parts 35a, 35b and the second recessed parts 37a, 37b are continuously formed so as to surround the welding part 33, providing an annular groove surrounding the connecting part between the shield wire W1 and the ground wire W2.
Adjacent to the recessed parts 35a, 35b, the upper resin tip 31 further includes recessed parts 39a, 39b formed for holding and drawing out the shield wire W1. The recessed parts 39a, 39b are shaped to have semicircular sections for accommodating the wire W1. Note that these recessed parts 39a, 39b may be referred “drawing parts 39a, 39b,” hereinafter. Similar to the upper resin tip 31, the lower resin tip 41 has a semicircular-shaped groove formed along the direction to draw out the shield wire W1. The straight groove consists of a recessed part 43a positioned at the center of the groove to accommodate the connecting part between the shield wire W1 and the ground wire W2, and recessed parts 45a, 45b interposing the recessed part 43a therebetween. Also note that these recessed parts 45a, 45b may be referred “drawing parts 45a, 45b,” hereinafter.
According to the embodiment, the lower resin tip 41 has two recesses 47a, 47b formed adjacently to the straight groove. The recesses 47a, 47b of the tip 41 are positioned so as to correspond to the second recessed parts 37a, 37b of the upper resin tip 31 when it is overlaid with the tip 41. For this reason, the recesses 47a, 47b will be called “second recessed parts 47a, 47b” after.
Also in this embodiment, the connecting part between the shield wire W1 and the ground wire W2 can be obtained and sealed by the tips 31, 41 in accordance with the first step and the second step previously described with reference to FIGS. 1A and 1B. FIG. 4 shows the resultant connecting structure as the completion of welding.
During the welding operation, the resultant molten cover part 9a of the ground wire W2 is accommodated in the second recessed parts 37a, 47a, 37b, 47b at the second step since they are all formed in the tips 31, 41 along a direction to arrange the ground wire W2. FIG. 5 shows the cover part 9a being accommodated in the second recessed parts 37a, 47a, 37b, 47b. While, as shown in FIG. 6, the resultant molten cover part 7a of the shield wire W1 is accommodated in an area from the stepped parts 33b to the first recessed parts 35a, 35b at the second step. In the embodiment, the recessed part 33a is formed to have a width generally equal to the width of the ground wire W2, while the stepped parts 33b, 33b are provided on both sides of the recessed part 33a. Therefore, the molten cover part 7a of the shield wire W1 can be easily removed away from the recessed part 33a. 
Therefore, it is possible to restrict the cover parts 9a, 7a of the wires W2, W1 from being pushed out of the resin tips 31, 41, thereby avoiding the damage on the wires W2, W1 due to heat of the so-pushed cover parts 9a, 7a. 
In this way, the exposure of the conductive parts (i.e. the braided wire 13 and the core line 15) outside the resin tips 31, 41 is restricted, so that the bending capabilities of the wires W1, W2 can be maintained without causing the deterioration of insulation effect and the disconnection of the braided wire 13, the core line 15, etc.
Additionally, since the molten and removed cover parts 9a, 7a are accommodated in the first recessed parts 35a, 35b and the second recessed parts 37a, 47a, 37b, 47b smoothly, it is possible to accomplish the shortage of welding time and the reduction in the number of working processes.
Further, since the upper resin tip 31 has the first recesses parts 35a, 35b and the second recessed parts 37a, 37b formed in annular, the molten cover part 7a can flow from the first recessed parts 35a, 35b into the second recessed parts 37a, 37b or conversely, the molten cover part 9a can flow from the second recessed parts 37a, 37b into the first recessed parts 35a, 35b, accomplishing the smooth accommodation of the molten resin.
Moreover, since the upper and lower resin tips 31, 41 of the embodiment are provided with the second recessed parts 37a, 47a, 37b, 47b as shown in FIG. 5, the molten cover part 9a of the ground wire W2 can be accommodated and maintained in the resin tips 31, 41 more smoothly. That is, it is possible to prevent the ground wire W2 from being damaged and also possible to shorten the welding time.
FIGS. 7A to 7C show another embodiment of the present invention. In the figures, FIG. 7A is a perspective view of an upper resin tip 51, FIG. 2 a sectional view of the FIG. 7A, and FIG. 7C is a perspective view of an lower resin tip 53.
Also in this embodiment, essential constituents of the upper and lower resin tips 51, 53 are similar to those of the above-mentioned resin tips 31, 41, respectively. Therefore, the respective parts of the tips 51, 53 are indicated with the same reference numerals of the corresponding part of the tips 31, 41, respectively, and their overlapping descriptions are omitted.
According to the embodiment, the drawing parts 39a, 39b of the upper resin tip 51 and the drawing parts 45a, 45b of the lower resin tip 53 are all tapered in section so as to have diameters gradually increased toward the outside ends of the parts 39a, 39b, 45a, 45b, that is, opposing ports for drawing out the shield wire W1.
Thus, even if the shield wire W1 shakes as shown in FIG. 8, the above-mentioned configurations of the tips 51, 53 allow the wire W1 to come into surface contact with the drawing parts 39b, 45b in their weakened “edge” effect. Therefore, it is possible to improve the tips' force to retain the shield wire W1 at the welding part 33 and also the bending capability of the wire W1 in relation to the tips 51, 53.
Although the first recessed parts 35a, 35b and the second recessed parts 37a, 37b are annular-formed in the upper resin tip 31(51) in common with the above-mentioned embodiments, these parts 35a, 35b, 37a, 37b may be provided in the lower resin tip 41(53) in the modification. Alternatively, they may be provided in both of the upper and lower resin tips.
In common with the embodiments, the second recessed parts 47a, 47b of the lower resin tip 41(53) may be eliminated in the modification. Similarly, in case of forming the first and second recessed parts 35a, 35b, 37a, 37b in the lower resin tip 41(53), the upper resin tip 31 (51) may be provided with-no recess.
Furthermore, either one of the upper and lower resin tips 31, 41(51, 53) may be provided with the first recessed parts 35a, 35b while the other of the tips is provided with the second recessed parts 37a, 37b, equally.
It will be understood by those skilled in the art that the foregoing description relates to embodiments of the disclosed connecting method and the resin tips used for the method. Various changes and modifications may be made to the present invention without departing from the scope of the invention.

## Claims

1. A resin tip assembly, comprising:
a first wire having a conductive member and a resinous cover; 
a second wire having a conductive member and a resinous cover; 
a first resin tip having a central weld part provided with a central semi-circular groove configured to support the first wire and also having a continuous recess formed so as to surround the central weld part; and 
a second resin tip having a semi-circular groove configured to support the first wire, 
wherein the continuous recess of the first resin tip is formed so as to define a continuous space around the central weld part during assembly between the first resin tip and the second resin tip while interposing the first wire therebetween.

2. The resin tip assembly of claim 1, wherein the first wire is longitudinally aligned with the central semi-circular groove and the second wire is assembled substantially perpendicular to the first wire.

3. The resin tip assembly of claim 1, wherein the continuous recess is a continuous groove having a single planar bottom surface.

4. The resin tip assembly of claim 1, wherein the continuous recess is configured to accommodate all of the portion of the resinous cover of the first wire and at least a portion of the resinous cover of the second wire that are melted during assembly.

5. The resin tip assembly of claim 1, wherein the central weld part includes a central recessed part and stepped parts arranged on both sides of the central recessed parts, the stepped parts configured to hold the first wire.

6. The resin tip assembly of claim 5, wherein the stepped parts are semi-circular and are longitudinally aligned with the central recessed part.

7. The resin tip assembly of claim 5, wherein the stepped parts have a depth greater than a depth of the central recessed part.

8. The resin tip wire assembly of claim 1, wherein the first resin tip further includes:
a first recessed part disposed on a side of the central weld part, outside of the continuous recess, and longitudinally aligned with the central semi-circular groove; and 
a second recessed part disposed on a side of the central weld part opposite to the first recessed part, outside of the continuous recess, and longitudinally aligned with the central semi-circular groove, 
wherein the first and second recessed parts are formed so as to draw out the resinous cover of the first wire melted by the central weld part during assembly.

9. The resin tip assembly of claim 8, wherein each of the first and second recessed parts have an outside end oriented away from the central weld part and each of the first and second recessed parts have gradually increasing diameters towards the outside end.

10. The resin tip assembly of claim 1, wherein the second resin tip has two recesses formed adjacently to the semi-circular groove.